Roll Casting of Aluminum Alloy Clad Strip

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

Nakamura, R.; Tsuge, H.; Haga, T.

2011-01-17

Casting of aluminum alloy three layers of clad strip was tried using the two sets of twin roll casters, and effects of the casting parameters on the cladding conditions were investigated. One twin roll caster was mounted on the other twin roll caster. Base strip was 8079 aluminum alloy and overlay strips were 6022 aluminum alloy. Effects of roll-load of upper and lower casters and melt temperature of the lower caster were investigated. When the roll-load of the upper and lower caster was large enough, the overlay strip could be solidified and be connected. The overlay strip could be connectedmore » when the melt of the overlay strip cast by the lower caster was low enough. Sound three layers of clad strip could be cast by proper conditions.« less

An Integrated Study on the Evolution of Inclusions in EH36 Shipbuilding Steel with Mg Addition: From Casting to Welding

NASA Astrophysics Data System (ADS)

Zou, Xiaodong; Zhao, Dapeng; Sun, Jincheng; Wang, Cong; Matsuura, Hiroyuki

2018-04-01

Inclusion evolution behaviors, in terms of composition, size, and number density, and associated influence on the microstructures of the as-cast slabs, rolled plates, and simulated welded samples of plain EH36 and EH36-Mg shipbuilding steels have been systematically investigated. The results indicate that the inclusions in the as-cast plain EH36 are almost Al-Ca-S-O-(Mn) complex oxides with sizes ranging from 1.0 to 2.0 μm. After Mg addition, a large amount of individually fine MnS precipitates and Mg-containing Ti-Al-Mg-O-(Mn-S) complex inclusions are generated, which significantly refine the microstructure and are conducive to the nucleation of acicular ferrite in the rolled and welded sample. Moreover, after rolling and welding thermal simulation, the number of individual MnS decreases gradually due to its precipitation on the surface of Ti-Al-Mg-O oxides.

[Comparison of texture distribution of cold rolled DC and CC AA 5052 aluminum alloy at different positions through thickness direction by XRD].

PubMed

Chen, Ming-biao; Ma, Min; Yang, Qing-xiang; Wang, Shan; Liu, Wen-chang; Zhao, Ying-mei

2013-09-01

To provide gist of DC AA 5052 and CC AA 5052 aluminum alloy to industry production and application, the texture variation of cold rolled sheets through thickness direction was studied by X-ray diffraction method, and the difference in texture at surface, quarter and center layer was analyzed. The hot plates of direct chill cast (DC) AA 5052 and continuous cast (CC) AA 5052 aluminum alloy were annealed at 454 degrees C for 4 hours and then cold rolled to different reductions. The strength and volume fraction of the fiber in CC AA 5052 aluminum alloy is larger than in DC AA 5052 aluminum alloy after same rolling reduction The volume fraction of the recrystallization texture cube in the CC AA 5052 aluminum alloy is less than in the DC AA 5052 aluminum alloy, which result in that CC AA 5052 aluminum alloy needs less cold rolling reduction than DC AA 5052 aluminum alloy for generating the texture with same intensity and volume fraction at surface layer, quarter layer and center layer. The manufacturability and performance of CC AA 5052 aluminum alloy is superior to DC AA 5052 aluminum alloy for use in stamping.

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.

Method of manufacturing metallic products such as sheet by cold working and flash anealing

DOEpatents

Hajaligol, Mohammad R.; Sikka, Vinod K.

2001-01-01

A metallic alloy composition is manufactured into products such as press formed or stamped products or rolled products such as sheet, strip, rod, wire or band by one or more cold working steps with intermediate or final flash annealing. The method can include cold rolling an iron, nickel or titanium aluminide alloy and annealing the cold worked product in a furnace by infrared heating. The flash annealing is preferably carried out by rapidly heating the cold worked product to an elevated temperature for less than one minute. The flash annealing is effective to reduce surface hardness of the cold worked product sufficiently to allow further cold working. The product to be cold worked can be prepared by casting the alloy or by a powder metallurgical technique such as tape casting a mixture of metal powder and a binder, roll compacting a mixture of the powder and a binder or plasma spraying the powder onto a substrate. In the case of tape casting or roll compaction, the initial powder product can be heated to a temperature sufficient to remove volatile components. The method can be used to form a cold rolled sheet which is formed into an electrical resistance heating element capable of heating to 900.degree. C. in less than 1 second when a voltage up to 10 volts and up to 6 amps is passed through the heating element.

Method of manufacturing metallic products such as sheet by cold working and flash annealing

DOEpatents

Hajaligol, Mohammad R.; Sikka, Vinod K.

2000-01-01

A metallic alloy composition is manufactured into products such as press formed or stamped products or rolled products such as sheet, strip, rod, wire or band by one or more cold working steps with intermediate or final flash annealing. The method can include cold rolling an iron, nickel or titanium aluminide alloy and annealing the cold worked product in a furnace by infrared heating. The flash annealing is preferably carried out by rapidly heating the cold worked product to an elevated temperature for less than one minute. The flash annealing is effective to reduce surface hardness of the cold worked product sufficiently to allow further cold working. The product to be cold worked can be prepared by casting the alloy or by a powder metallurgical technique such as tape casting a mixture of metal powder and a binder, roll compacting a mixture of the powder and a binder or plasma spraying the powder onto a substrate. In the case of tape casting or roll compaction, the initial powder product can be heated to a temperature sufficient to remove volatile components. The method can be used to form a cold rolled sheet which is formed into an electrical resistance heating element capable of heating to 900.degree. C. in less than 1 second when a voltage up to 10 volts and up to 6 amps is passed through the heating element.

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.

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.

Fabrication of thin bulk ceramics for microwave circulator applications

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

Ings, J.B.; Simmins, J.J.; May, J.L.

1995-09-01

Planer MMIC circulator applications require the production of thin, flat garnet, spinel, and hexagonal ferrite circulator elements. Fabrication of cira 250 {mu}m circulator elements was done by tape casting and roll compaction. For the garnet, tape cast gave equivalent results to roll compaction. For the spinel and hexaferrite materials, which undergo magnetic flocculation, roll compaction was found to be the preferred fabrication method. Roll compacted lithium ferrite resulted in higher densities and lower {triangle}H and tan{delta} than did the tape case material. Roll compacted barium hexaferrite resulted in higher densities and remanent magnetization than did the tape cast material.

Investigation of Wear and Friction Properties Under Sliding Conditions of Some Materials Suitable for Cages of Rolling-Contact Bearings

NASA Technical Reports Server (NTRS)

Johnson, Robert L; Swikert, Max A; Bisson, Edmond E

1952-01-01

An investigation of wear and friction properties of a number of materials sliding against SAE 52100 steel was conducted. These materials included brass, bronze, beryllium copper, monel, nichrome v, 24s-t aluminum, nodular iron, and gray cast iron. The metals investigated may be useful as possible cage (separator or retainer) materials for rolling-contact bearings of high-speed turbine engines. The ability of materials to form surface films that prevent welding is a most important factor in both dry friction and boundary lubrication. On the basis of wear and resistance to welding only, the cast irons were the most promising materials investigated; they showed the least wear and the least tendency to surface failure when run dry, and when boundary lubricated they showed the highest load capacity. On the basis of mechanical properties, nodular iron is superior to gray cast iron. Bronze had the lowest friction coefficient under dry sliding conditions. The results with brass, beryllium copper, and aluminum were poor and these materials do not appear, with regard to friction and wear, to be suitable for cages.

Rolling Contact Fatigue Failure Mechanisms of Plasma-Nitrided Ductile Cast Iron

NASA Astrophysics Data System (ADS)

Wollmann, D.; Soares, G. P. P. P.; Grabarski, M. I.; Weigert, N. B.; Escobar, J. A.; Pintaude, G.; Neves, J. C. K.

2017-05-01

Rolling contact fatigue (RCF) of a nitrided ductile cast iron was investigated. Flat washers machined from a pearlitic ductile cast iron bar were quenched and tempered to maximum hardness, ground, polished and divided into four groups: (1) specimens tested as quenched and tempered; (2) specimens plasma-nitrided for 8 h at 400 °C; (3) specimens plasma-nitrided and submitted to a diffusion process for 16 h at 400 °C; and (4) specimens submitted to a second tempering for 24 h at 400 °C. Hardness profiles, phase analyses and residual stress measurements by x-ray diffraction, surface roughness and scanning electron microscopy were applied to characterize the surfaces at each step of this work. Ball-on-flat washer tests were conducted with a maximum contact pressure of 3.6 GPa, under flood lubrication with a SAE 90 API GL-5 oil at 50 °C. Test ending criterion was the occurrence of a spalling. Weibull analysis was used to characterize RCF's lifetime data. Plasma-nitrided specimens exhibited a shorter RCF lifetime than those just quenched and tempered. The effects of nitriding on the mechanical properties and microstructure of the ductile cast iron are discussed in order to explain the shorter endurance of nitrided samples.

Computational Fluid Dynamics Modeling of Macrosegregation and Shrinkage in Large-Diameter Steel Roll Castings

NASA Astrophysics Data System (ADS)

Nastac, Laurentiu

2011-12-01

Minimizing macrosegregation and shrinkage in large cast steel mill rolls challenges the limits of commercial foundry technology. Processing improvements have been achieved by balancing the total heat input of casting with the rate of heat extraction from the surface of the roll in the mold. A submerged entry nozzle (SEN) technique that injects a dilute alloy addition through a nozzle into the partially solidified net-shaped roll ingot can mitigate both centerline segregation and midradius channel segregate conditions. The objective of this study is to optimize the melt chemistry, solidification, and SEN conditions to minimize centerline and midradius segregation, and then to improve the quality of the transition region between the outer shell and the diluted interior region. To accomplish this objective, a multiphase, multicomponent computational fluid dynamics (CFD) code was developed for studying the macrosegregation and shrinkage under various casting conditions for a 65-ton, 1.6-m-diameter steel roll. The developed CFD framework consists of solving for the volume fraction of phases (air and steel mixture), temperature, flow, and solute balance in multicomponent alloy systems. Thermal boundary conditions were determined by measuring the temperature in the mold at several radial depths and height locations. The thermophysical properties including viscosity of steel alloy used in the simulations are functions of temperature. The steel mixture in the species-transfer model consists of the following elements: Fe, Mn, Si, S, P, C, Cr, Mo, and V. Density and liquidus temperature of the steel mixture are locally affected by the segregation of these elements. The model predictions were validated against macrosegregation measured from pieces cut from the 65-ton roll. The effect of key processing parameters such as melt composition and superheat of both the shell and the dilute interior alloy are addressed. The influence of mold type and thickness on macrosegregation and shrinkage also are discussed.

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

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

Liu, Hai-Tao, E-mail: liuht@ral.neu.edu.cn; Institute of Research of Iron and Steel, Shasteel, Zhangjiagang 215625, Jiangsu; Yao, Sheng-Jie

2015-08-15

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

Multi-passes warm rolling of AZ31 magnesium alloy, effect on evaluation of texture, microstructure, grain size and hardness

NASA Astrophysics Data System (ADS)

Kamran, J.; Hasan, B. A.; Tariq, N. H.; Izhar, S.; Sarwar, M.

2014-06-01

In this study the effect of multi-passes warm rolling of AZ31 magnesium alloy on texture, microstructure, grain size variation and hardness of as cast sample (A) and two rolled samples (B & C) taken from different locations of the as-cast ingot was investigated. The purpose was to enhance the formability of AZ31 alloy in order to help manufacturability. It was observed that multi-passes warm rolling (250°C to 350°C) of samples B & C with initial thickness 7.76mm and 7.73 mm was successfully achieved up to 85% reduction without any edge or surface cracks in ten steps with a total of 26 passes. The step numbers 1 to 4 consist of 5, 2, 11 and 3 passes respectively, the remaining steps 5 to 10 were single pass rolls. In each discrete step a fixed roll gap is used in a way that true strain per step increases very slowly from 0.0067 in the first step to 0.7118 in the 26th step. Both samples B & C showed very similar behavior after 26th pass and were successfully rolled up to 85% thickness reduction. However, during 10th step (27th pass) with a true strain value of 0.772 the sample B experienced very severe surface as well as edge cracks. Sample C was therefore not rolled for the 10th step and retained after 26 passes. Both samples were studied in terms of their basal texture, microstructure, grain size and hardness. Sample C showed an equiaxed grain structure after 85% total reduction. The equiaxed grain structure of sample C may be due to the effective involvement of dynamic recrystallization (DRX) which led to formation of these grains with relatively low misorientations with respect to the parent as cast grains. The sample B on the other hand showed a microstructure in which all the grains were elongated along the rolling direction (RD) after 90 % total reduction and DRX could not effectively play its role due to heavy strain and lack of plastic deformation systems. The microstructure of as cast sample showed a near-random texture (mrd 4.3), with average grain size of 44 & micro-hardness of 52 Hv. The grain size of sample B and C was 14μm and 27μm respectively and mrd intensity of basal texture was 5.34 and 5.46 respectively. The hardness of sample B and C came out to be 91 and 66 Hv respectively due to reduction in grain size and followed the well known Hall-Petch relationship.

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.

Application of RNAMlet to surface defect identification of steels

NASA Astrophysics Data System (ADS)

Xu, Ke; Xu, Yang; Zhou, Peng; Wang, Lei

2018-06-01

As three main production lines of steels, continuous casting slabs, hot rolled steel plates and cold rolled steel strips have different surface appearances and are produced at different speeds of their production lines. Therefore, the algorithms for the surface defect identifications of the three steel products have different requirements for real-time and anti-interference. The existing algorithms cannot be adaptively applied to surface defect identification of the three steel products. A new method of adaptive multi-scale geometric analysis named RNAMlet was proposed. The idea of RNAMlet came from the non-symmetry anti-packing pattern representation model (NAM). The image is decomposed into a set of rectangular blocks asymmetrically according to gray value changes of image pixels. Then two-dimensional Haar wavelet transform is applied to all blocks. If the image background is complex, the number of blocks is large, and more details of the image are utilized. If the image background is simple, the number of blocks is small, and less computation time is needed. RNAMlet was tested with image samples of the three steel products, and compared with three classical methods of multi-scale geometric analysis, including Contourlet, Shearlet and Tetrolet. For the image samples with complicated backgrounds, such as continuous casting slabs and hot rolled steel plates, the defect identification rate obtained by RNAMlet was 1% higher than other three methods. For the image samples with simple backgrounds, such as cold rolled steel strips, the computation time of RNAMlet was one-tenth of the other three MGA methods, while the defect identification rates obtained by RNAMlet were higher than the other three methods.

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.

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

NASA Astrophysics Data System (ADS)

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

2015-05-01

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

A novel ultra-low carbon grain oriented silicon steel produced by twin-roll strip casting

NASA Astrophysics Data System (ADS)

Wang, Yang; Zhang, Yuan-Xiang; Lu, Xiang; Fang, Feng; Xu, Yun-Bo; Cao, Guang-Ming; Li, Cheng-Gang; Misra, R. D. K.; Wang, Guo-Dong

2016-12-01

A novel ultra-low carbon grain oriented silicon steel was successfully produced by strip casting and two-stage cold rolling method. The microstructure, texture and precipitate evolution under different first cold rolling reduction were investigated. It was shown that the as-cast strip was mainly composed of equiaxed grains and characterized by very weak Goss texture ({110}<001>) and λ-fiber (<001>//ND). The coarse sulfides of size 100 nm were precipitated at grain boundaries during strip casting, while nitrides remained in solution in the as-cast strip and the fine AlN particles of size 20-50 nm, which were used as grain growth inhibitors, were formed in intermediate annealed sheet after first cold rolling. In addition, the suitable Goss nuclei for secondary recrystallization were also formed during intermediate annealing, which is totally different from the conventional process that the Goss nuclei originated in the subsurface layer of the hot rolled sheet. Furthermore, the number of AlN inhibitors and the intensity of desirable Goss texture increased with increasing first cold rolling reduction. After secondary recrystallization annealing, very large grains of size 10-40 mm were formed and the final magnetic induction, B8, was as high as 1.9 T.

Real-time measurement system for tracking birefringence, weight, thickness, and surface temperature during drying of solution cast coatings and films

NASA Astrophysics Data System (ADS)

Unsal, E.; Drum, J.; Yucel, O.; Nugay, I. I.; Yalcin, B.; Cakmak, M.

2012-02-01

This paper describes the design and performance of a new instrument to track temporal changes in physical parameters during the drying behavior of solutions, as well as curing of monomers. This real-time instrument follows in-plane and out-of-plane birefringence, weight, thickness, and surface temperature during the course of solidification of coatings and films through solvent evaporation and thermal or photocuring in a controlled atmosphere. It is specifically designed to simulate behavior of polymer solutions inside an industrial size, continuous roll-to-roll solution casting line and other coating operations where resins are subjected to ultraviolet (UV) curing from monomer precursors. Controlled processing parameters include air speed, temperature, initial cast thickness, and solute concentration, while measured parameters are thickness, weight, film temperature, in-plane and out-of-plane birefringence. In this paper, we illustrate the utility of this instrument with solution cast and dried poly (amide-imide)/DMAc (Dimethylacetamide) solution, water based black paint, and organo-modified clay/NMP (N-Methylpyrrolidone) solution. In addition, the physical changes that take place during UV photo polymerization of a monomer are tracked. This instrument is designed to be generic and it can be used for tracking any drying/swelling/solidification systems including paper, foodstuffs such as; grains, milk as well as pharmaceutical thin paste and slurries.

3D analysis of macrosegregation in twin-roll cast AA3003 alloy

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

Šlapáková, Michaela, E-mail: slapakova@karlov.mff.

Twin-roll cast aluminium alloys have a high potential for industrial applications. However, one of the drawbacks of such materials is an inhomogeneous structure generated by macrosegregation, which appears under certain conditions in the center of sheets during solidification. Segregations in AA3003 alloy form as manganese, iron and silicon rich channels spread in the rolling direction. Their spatial distribution was successfully detected by X-ray computed tomography. Scanning electron microscopy was used for a detailed observation of microstructure, morphology and chemical analysis of the segregation. - Highlights: •Macrosegregations in twin-roll cast sheets stretch along the rolling direction. •X-ray computed tomography is anmore » effective tool for visualization of the segregation. •The segregations copy the shape of grain boundaries.« less

Ohno continuous casting

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

Soda, H.; McLean, A.; Motoyasu, G.

1995-04-01

Production of net-shape products directly from the liquid is an attractive manufacturing route for alloys that are difficult to process or that cannot be rolled, drawn, or extruded. Developed at the Chiba Institute of Technology in Japan, the Ohno Continuous Casting (OCC) approach not only provides significant cost savings, but also has the potential to create new products. OCC process equipment includes a melting furnace, crucible, mold level-control block, cooling device, and pinch rolls. OCC is currently used to produce copper rods and wires for audio and video cables, and aluminum alloy welding rods for hard-surfacing applications. For example, Mitsuimore » Engineering and Ship Building Co. has used OCC to produce copper tubing products with internal fins and partitions for applications such as heat exchanger tubes and induction coils.« less

Hydrogen transport behavior of beryllium

NASA Astrophysics Data System (ADS)

Anderl, R. A.; Hankins, M. R.; Longhurst, G. R.; Pawelko, R. J.; Macaulay-Newcombe, R. G.

1992-12-01

Beryllium is being evaluated for use as a plasma-facing material in the International Thermonuclear Experimental Reactor (ITER). One concern in the evaluation is the retention and permeation of tritium implanted into the plasma-facing surface. We performed laboratory-scale studies to investigate mechanisms that influence hydrogen transport and retention in beryllium foil specimens of rolled powder metallurgy product and rolled ingot cast beryllium. Specimen characterization was accomplished using scanning electron microscopy, Auger electron spectroscopy, and Rutherford backscattering spectrometry (RBS) techniques. Hydrogen transport was investigated using ion-beam permeation experiments and nuclear reaction analysis (NRA). Results indicate that trapping plays a significant role in permeation, re-emission, and retention, and that surface processes at both upstream and downstream surfaces are also important.

Phosphorus Segregation in Meta-Rapidly Solidified Carbon Steels

NASA Astrophysics Data System (ADS)

Li, Na; Qiao, Jun; Zhang, Junwei; Sha, Minghong; Li, Shengli

2017-09-01

Twin-roll strip casters for near-net-shape manufacture of steels have received increased attention in the steel industry. Although negative segregation of phosphorus occurred in twin-roll strip casting (TRSC) steels in our prior work, its mechanism is still unclear. In this work, V-shaped molds were designed and used to simulate a meta-rapid solidification process without roll separating force during twin roll casting of carbon steels. Experimental results show that no obvious phosphorus segregation exist in the V-shaped mold casting (VMC) steels. By comparing TRSC and the VMC, it is proposed that the negative phosphorus segregation during TRSC results from phosphorus redistribution driven by recirculating and vortex flow in the molten pool. Meanwhile, solute atoms near the advancing interface are overtaken and incorporated into the solid because of the high solidification speed. The high rolling force could promote the negative segregation of alloying elements in TRSC.

40 CFR 467.21 - Specialized definitions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... AND STANDARDS (CONTINUED) ALUMINUM FORMING POINT SOURCE CATEGORY Rolling With Emulsions Subcategory... emulsions subcategory shall include rolling using emulsions, roll grinding, stationary casting, homogenizing...

40 CFR 467.21 - Specialized definitions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... AND STANDARDS (CONTINUED) ALUMINUM FORMING POINT SOURCE CATEGORY Rolling With Emulsions Subcategory... emulsions subcategory shall include rolling using emulsions, roll grinding, stationary casting, homogenizing...

40 CFR 467.21 - Specialized definitions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... AND STANDARDS (CONTINUED) ALUMINUM FORMING POINT SOURCE CATEGORY Rolling With Emulsions Subcategory... emulsions subcategory shall include rolling using emulsions, roll grinding, stationary casting, homogenizing...

STANDBY TOP AND BOTTOM ROTARY MILLING CUTTERS FOR TORIN LINE. ...

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

STANDBY TOP AND BOTTOM ROTARY MILLING CUTTERS FOR TORIN LINE. SOME PRODUCT FROM THE #43 HOT ROLL IS PROCESSED ON THE TORIN LINE TO REMOVE OXIDIZED SURFACE MATERIAL. IN PRACTICE 15-20/1000 IS CUT FROM THE UPPER AND LOWER SURFACES OF THE STRIP AND RECYCLED TO THE CASTING SHOP. TORIN LINE ADDED AS PART OF 1981 EXPANSION PROGRAM. - American Brass Foundry, 70 Sayre Street, Buffalo, Erie County, NY

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

NASA Astrophysics Data System (ADS)

Park, Jong-Jin

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

A Scalable Route to Nanoporous Large-Area Atomically Thin Graphene Membranes by Roll-to-Roll Chemical Vapor Deposition and Polymer Support Casting.

PubMed

Kidambi, Piran R; Mariappan, Dhanushkodi D; Dee, Nicholas T; Vyatskikh, Andrey; Zhang, Sui; Karnik, Rohit; Hart, A John

2018-03-28

Scalable, cost-effective synthesis and integration of graphene is imperative to realize large-area applications such as nanoporous atomically thin membranes (NATMs). Here, we report a scalable route to the production of NATMs via high-speed, continuous synthesis of large-area graphene by roll-to-roll chemical vapor deposition (CVD), combined with casting of a hierarchically porous polymer support. To begin, we designed and built a two zone roll-to-roll graphene CVD reactor, which sequentially exposes the moving foil substrate to annealing and growth atmospheres, with a sharp, isothermal transition between the zones. The configurational flexibility of the reactor design allows for a detailed evaluation of key parameters affecting graphene quality and trade-offs to be considered for high-rate roll-to-roll graphene manufacturing. With this system, we achieve synthesis of uniform high-quality monolayer graphene ( I D / I G < 0.065) at speeds ≥5 cm/min. NATMs fabricated from the optimized graphene, via polymer casting and postprocessing, show size-selective molecular transport with performance comparable to that of membranes made from conventionally synthesized graphene. Therefore, this work establishes the feasibility of a scalable manufacturing process of NATMs, for applications including protein desalting and small-molecule separations.

Effects of MC-Type Carbide Forming and Graphitizing Elements on Thermal Fatigue Behavior of Indefinite Chilled Cast Iron Rolls

NASA Astrophysics Data System (ADS)

Ahiale, Godwin Kwame; Choi, Won-Doo; Suh, Yongchan; Lee, Young-Kook; Oh, Yong-Jun

2015-11-01

The thermal fatigue behavior of indefinite chilled cast iron rolls with various V+Nb contents and Si/Cr ratios was evaluated. Increasing the ratio of Si/Cr prolonged the life of the rolls by reducing brittle cementites. Higher V+Nb addition also increased the life through the formation of carbides that refined and toughened the martensite matrix and reduced the thermal expansion mismatch in the microstructure.

Structural Engineering. Loads. Design Manual 2.2.

DTIC Science & Technology

1981-11-01

cast, rolled 534 Locust 46 Bronze, 7.9 to 14% Sn 509 Maple, hard 43 Bronze, aluminum 481 Maple, white 33 Copper , cast, rolled 556 Oak, chestnut 54... Copper ore, pyrites 262 Oak, live 59 Gold, cast, hammered 1205 Oak, red, black 41 Gold, bars, stacked 1133 Oak, white 46 Gold, coin in bags 1084 Pine...Phosphate rock, apatite 200 Glass, crystal 184 Porphyry 172 Hay and straw - bales 20 Pumice, natural 40 Leather 59 Quartz, flint 165 Paper 58 Sandstone

Novel twin-roll-cast Ti/Al clad sheets with excellent tensile properties.

PubMed

Kim, Dae Woong; Lee, Dong Ho; Kim, Jung-Su; Sohn, Seok Su; Kim, Hyoung Seop; Lee, Sunghak

2017-08-14

Pure Ti or Ti alloys are recently spot-lighted in construction industries because they have excellent resistance to corrosions, chemicals, and climates as well as various coloring characteristics, but their wide applications are postponed by their expensiveness and poor formability. We present a new fabrication process of Ti/Al clad sheets by bonding a thin Ti sheet on to a 5052 Al alloy melt during vertical-twin-roll casting. This process has merits of reduced production costs as well as improved tensile properties. In the as-twin-roll-cast clad sheet, the homogeneously cast microstructure existed in the Al alloy substrate side, while the Ti/Al interface did not contain any reaction products, pores, cracks, or lateral delamination, which indicated the successful twin-roll casting. When this sheet was annealed at 350 °C~600 °C, the metallurgical bonding was expanded by interfacial diffusion, thereby leading to improvement in tensile properties over those calculated by a rule of mixtures. The ductility was also improved over that of 5052-O Al alloy (25%) or pure Ti (25%) by synergic effect of homogeneous deformation due to excellent Ti/Al bonding. This work provides new applications of Ti/Al clad sheets to lightweight-alloy clad sheets requiring excellent formability and corrosion resistance as well as alloy cost saving.

Microstructure, texture evolution and magnetic properties of strip-casting non-oriented 6.5 wt.% Si electrical steel doped with cerium

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

Li, Hao-Ze, E-mail: lhzqq83@163.com; Liu, Hai-Tao; Liu, Zhen-Yu, E-mail: zyliu@mail.neu.edu.cn

A 0.3 mm thick non-oriented 6.5 wt.% Si electrical steel sheet doped with cerium is produced by twin-roll strip casting, hot rolling, warm rolling and annealing. A detailed study of the cerium precipitates in the as-cast strip, microstructure and texture evolution at different processing stages is carried out by electron probe micro-analysis, optical microscopy, X-ray diffraction and electron backscattered diffraction analysis. Grain interior distributing precipitates identified as Ce-oxides, Ce-oxysulfides and Ce-phosphides, and boundary distributing Ce-oxides and Ce-phosphides are observed in the as-cast strip. The initial as-cast strip is characterized by a much finer solidification microstructure and dominated by obvious //ND texture through the strip thickness. After hot and warm rolling, inhomogeneous microstructure containing large amounts of in-grain shear bands is characterized by mixed < 110 >//RD and < 111 >//ND textures. The texture of the annealed sheet with a relatively large average grain size is far more optimized by the domination of the beneficial cube, rotated cube, (001)< 120 > to (001)< 130 > and Goss texture components, and the elimination of the detrimental γ-fiber texture, leading to a superior magnetic induction and improved iron loss. - Highlights: • An Fe–6.5 wt.% Si as-cast strip doped with cerium was produced. • A thin warm rolled sheet with limited edge cracks was obtained. • Microstructure and texture evolution at each stage were investigated. • Strong λ-fiber and Goss recrystallization textures were formed. • The magnetic properties of the annealed sheet were significantly improved.« less

Effect of intermediate annealing on the microstructure and mechanical property of ZK60 magnesium alloy produced by twin roll casting and hot rolling

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

Chen, Hongmei, E-mail: hmchen@just.edu.cn; Zang, Qianhao; Yu, Hui

2015-08-15

Twin roll cast (designated as TRC in short) ZK60 magnesium alloy strip with 3.5 mm thickness was used in this paper. The TRC ZK60 strip was multi-pass rolled at different temperatures, intermediate annealing heat treatment was performed when the thickness of the strip changed from 3.5 mm to 1 mm, and then continued to be rolled until the thickness reached to 0.5 mm. The effect of intermediate annealing during rolling process on microstructure, texture and room temperature mechanical properties of TRC ZK60 strip was studied by using OM, TEM, XRD and electronic universal testing machine. The introduction of intermediate annealingmore » can contribute to recrystallization in the ZK60 sheet which was greatly deformed, and help to reduce the stress concentration generated in the rolling process. Microstructure uniformity and mechanical properties of the ZK60 alloy sheet were also improved; in particular, the room temperature elongation was greatly improved. When the TRC ZK60 strip was rolled at 300 °C and 350 °C, the room temperature elongation of the rolled sheet with 0.5 mm thickness which was intermediate annealed during the rolling process was increased by 95% and 72% than that of no intermediate annealing, respectively. - Highlights: • Intermediate annealing was introduced during hot rolling process of twin roll cast ZK60 alloy. • Intermediate annealing can contribute to recrystallization and reduce the stress concentration in the deformed ZK60 sheet. • Microstructure uniformity and mechanical properties of the ZK60 sheet were improved, in particular, the room temperature elongation. • The elongation of the rolled ZK60 sheet after intermediate annealed was increased by 95% and 72% than that of no intermediate annealing.« less

40 CFR 467.21 - Specialized definitions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... AND STANDARDS ALUMINUM FORMING POINT SOURCE CATEGORY Rolling With Emulsions Subcategory § 467.21 Specialized definitions. For the purpose of this subpart: (a) The “core” of the rolling with emulsions subcategory shall include rolling using emulsions, roll grinding, stationary casting, homogenizing, artificial...

Microstructure, Tensile and Fatigue Properties of Al-5 wt.%Mg Alloy Manufactured by Twin Roll Strip Casting

NASA Astrophysics Data System (ADS)

Heo, Joon-Young; Baek, Min-Seok; Euh, Kwang-Jun; Lee, Kee-Ahn

2018-04-01

This study investigated the microstructure, tensile and fatigue properties of Al-5 wt.%Mg alloy manufactured by twin roll strip casting. Strips cast as a fabricated (F) specimen and a specimen heat treated (O) at 400 °C/5 h were produced and compared. In the F specimen, microstructural observation discovered clustered precipitates in the center area, while in the O specimen precipitates were relatively more evenly distributed. Al, Al6(Mn, Fe), Mg2Al3 and Mg2Si phases were observed. However, most of the Mg2Al3 phase in the heat-treated O specimen was dissolved. A room temperature tensile test measured yield strength of 177.7 MPa, ultimate tensile strength of 286.1 MPa and elongation of 11.1% in the F specimen and 167.7 MPa (YS), 301.5 MPa (UTS) and 24.6% (EL) in the O specimen. A high cycle fatigue test measured a fatigue limit of 145 MPa in the F specimen and 165 MPa in the O specimen, and the O specimen achieved greater fatigue properties in all fatigue stress conditions. The tensile and fatigue fracture surfaces of the above-mentioned specimens were observed, and this study attempted to investigate the tensile and fatigue deformation behavior of strip cast Al-5 wt.%Mg based on the findings.

Wrinkling Phenomena to Explain Vertical Fold Defects in DC-Cast Al-Mg4.5

NASA Astrophysics Data System (ADS)

Davis, J. Lee; Mendez, Patricio F.

Some aluminum ingots cast by the direct chill method are subject to surface defects on the molten ingot head during casting while others are not. These defects -commonly called "vertical folds" -are frozen into the casting and must be removed prior to rolling. Vertical folds are found on top of the molten ingot surface where areas of thin oxide are (a) bounded by physical constraints and (b) stretched. Physical constraints include (1) substantially thicker oxide or (2) a refractory skim ring adjacent to the thin oxide. The mechanism of wrinkling is suggested for the formation of vertical folds. Wrinkling behavior is described by physical expressions for an elastic sheet in tension whose behavior depends upon thickness h, length L, Young's modulus E, and Poisson's ratio v. The depth and frequency of folds in the thin, elastic sheet parallel to the tensile axis between the two "constraints" can be calculated from these parameters. The observed frequency (and amplitude) of vertical folds in DC-cast aluminum has been found to obey similar wrinkling laws. The frequency-dependence (λ) is examined and found to be related to classic wrinkling parameters but with significant scaling deviations. These deviations may be related to the pseudo-plasticity (self-healing behavior) of the oxide film on the molten surface. A wrinkling model coupled with pseudo-plasticity predicts subtle behaviors in DC casting of Al-Mg4.5 that are not explained by other theories.

Effect of minor chemistry elements on GTA weld fusion zone characteristics of a commercial grade titanium

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

Marya, S.K.

1996-06-01

Gas Tungsten Arc Welding (GTAW) is the most common technique employed in the fabrication of rolled thin tubes. One of the major manufacturing problems concerns the stability of weld fusion zone on materials from different casts, notwithstanding stringent monitoring of the process parameters -- current, voltage and travel speed. These parameters determine the theoretical weld heat and are expected to control the instantaneous mass of melt. According to the data compiled by Sahoo et al., oxygen is known to reduce the surface tension of most of the metals. However, investigations on the role of minor changes in concentrations of elementsmore » like sulphur, oxygen, selenium, bismuth, aluminium, and titanium in steels have very often attributed the cast to cast variations to different temperature gradients of surface tension over the weldpool. To the author`s knowledge, no reported work so far has revealed changing weld profiles in autogeneous mechanized GTA welds on titanium due to minor composition changes.« less

Raising the Reliability of Forming Rolls by Alloying Their Core with Copper

NASA Astrophysics Data System (ADS)

Zhizhkina, N. A.

2016-11-01

The mechanical properties and the structure of forming rolls from cast irons of different compositions are studied. A novel iron including a copper additive that lowers its chilling and raises the homogeneity of the structure is suggested for the roll cores. The use of such iron should raise the reliability of the rolls in operation.

Improved Foundry Castings Utilizing CAD/CAM (Computer Aided Design/ Computer Aided Manufacture). Volume 1. Overview

DTIC Science & Technology

1988-06-30

casting. 68 Figure 1-9: Line printer representation of roll solidification. 69 Figure I1-1: Test casting model. 76 Figure 11-2: Division of test casting...writing new casting analysis and design routines. The new routines would take advantage of advanced criteria for predicting casting soundness and cast...properties and technical advances in computer hardware and software. 11 2. CONCLUSIONS UPCAST, a comprehensive software package, has been developed for

Effect of processing parameters on the earing and mechanical properties of strip cast type 3004 Al alloy

NASA Astrophysics Data System (ADS)

Es-Said, O. S.; Zeihen, A.; Ruprich, M.; Quattrocchi, J.; Thomas, M.; H. Shin, K.; O'Brien, M.; Johansen, D.; Tijoe, W. H.; Ruhl, D.

1995-06-01

Electrical resistivity, superficial hardness, tensile testing, and quantitative metallography techniques were used in this study. The strip cast type 3004 aluminum alloy received sixteen different thermomechanical treatments before cups were drawn. The top edges of the drawn cups were not flat. Rather there were high points or ears with valleys between them. The homogenization temperature varied form 510 to 621 °C at 24 h. Some samples received an additional 426 °C/24 h homogenization anneal. Most specimens were rolled along the longitudinal direction of the as-cast material, and some were rolled in the transverse direction. Most samples were recrystallized at 454 °C for 24 h in addition to the homogenization treatment. Some were recrystallized for 168 h. All samples were subsequently rolled to 0.33 mm for cup drawing and percent earing determination. The percent earing results of some samples were less than 1.5%, but the mechanical strength was also lowered. The high-temperature recrystallization anneal of 454 °C was the controlling factor in determining the earing and mechanical strength of the final rolled sheet.

Effect of processing parameters on the earing and mechanical properties of strip cast type 3004 Al alloy

NASA Astrophysics Data System (ADS)

Es-Said, O. S.; Zeihen, A.; Ruprich, M.; Quattrocchi, J.; Thomas, M.; Shin, K. H.; O'Brien, M.; Johansen, D.; Tijoe, W. H.; Ruhl, D.

1994-02-01

Electrical resistivity, superficial hardness, tensile testing, and quantitative metallography techniques were used in this study. The strip cast type 3004 aluminum alloy received sixteen different thermomechanical treatments before cups were drawn. The top edges of the drawn cups were not flat. Rather, there were high points or ears with valleys between them. The homogenization temperature varied from 510 to 621 °C at 24 h. Some samples received an additional 426 °C/24 h homogenization anneal. Most specimens were rolled along the longitudinal direction of the as-cast material, and some were rolled in the transverse direction. Most samples were recrystallized at 454 °C for 24 h in addition to the homogenization treatment. Some were recrystallized for 168 h. All samples were subsequently rolled to 0.33 mm for cup drawing and percent earing determination. The percent earing results of some samples were less than 1.5%, but the mechanical strength was also lowered. The high-temperature recrystallization anneal of 454 °C was the controlling factor in determining the earing and mechanical strength of the final rolled sheet.

Study of twin-roll cast Aluminium alloys subjected to severe plastic deformation by equal channel angular pressing

NASA Astrophysics Data System (ADS)

Poková, M.; Cieslar, M.

2014-08-01

Aluminium alloys prepared by twin-roll casting method become widely used in industry applications. Their high solid solution supersaturation and finer grains ensure better mechanical properties when compared with the direct-chill cast ones. One of the possibilities how to enhance their thermal stability is the addition of zirconium. After heat treatment Al3Zr precipitates form and these pin moving grain boundaries when the material is exposed to higher temperatures. In the present work twin-roll cast aluminium alloys based on AA3003 with and without Zr addition were annealed for 8 hours at 450 °C to enable precipitation of Al3Zr phase. Afterwards they were subjected to severe plastic deformation by equal channel angular pressing, which led to the reduction of average grain size under 1 μm. During subsequent isochronal annealing recovery and recrystallization took place. These processes were monitored by microhardness measurements, light optical microscopy and in-situ transmission electron microscopy. The addition of Zr stabilizes the grain size and increases the recrystallization temperature by 100 °C.

Hot Roll Bonding of Aluminum to Twin-Roll Cast (TRC) Magnesium and Its Subsequent Deformation Behavior

NASA Astrophysics Data System (ADS)

Saleh, H.; Schmidtchen, M.; Kawalla, R.

2018-02-01

In an experiment in which twin-roll cast AZ31 magnesium alloy and commercial purity aluminum (AA 1050) sheets were bonded by hot rolling as Al/Mg/Al laminate composites, it was found that increasing the preheating temperatures up to 400 °C enhances the bonding strength of composites. Further increases in the preheating temperatures accelerate the magnesium oxide growth and thus reduce the bonding strength. The influence of the reduction ratio on the bonding properties was also studied, whereby it was observed that increasing the rolling reduction led to an increase in the bonding strength. The experimental results show that the optimum bonding strength can be obtained at rolling temperatures of 375-400 °C with a 50-60% reduction in thickness. On the other hand, the subsequent deformation behavior of composite was assessed using plane strain compression and deep drawing tests. We demonstrate that the composites produced using the optimum roll bonding conditions exhibited sufficient bonding during subsequent deformation and did not reveal any debonding at the bonding interface.

Analysis of rolling fracture of the conticasted and tandem rolled blanks of low alloyed aluminum

NASA Astrophysics Data System (ADS)

Li, Yong; Zeng, Lingping; Jiao Xie, Xian

2018-01-01

Optical microscopy, electron microscopy and energy spectrum were used to test the morphology of grains, as-cast microstructure and secondary phases in confiscated and tandem rolled planks of 8011 low alloying aluminum alloy. It can be concluded that the existence of inhomogeneous secondary FeSiAl phases lead to the fracture of planks during rolling.

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

Joshi, Vineet V.; Paxton, Dean M.; Lavender, Curt A.

Over the past several years Pacific Northwest National Laboratory (PNNL) has been actively involved in supporting the U.S. Department of Energy National Nuclear Security Administration Office of Material Management and Minimization (formerly Global Threat Reduction Initiative). The U.S. High- Power Research Reactor (USHPRR) project is developing alternatives to existing highly enriched uranium alloy fuel to reduce the proliferation threat. One option for a high-density metal fuel is uranium alloyed with 10 wt% molybdenum (U-10Mo). Forming the U-10Mo fuel plates/foils via rolling is an effective technique and is actively being pursued as part of the baseline manufacturing process. The processing ofmore » these fuel plates requires systematic investigation/understanding of the pre- and post-rolling microstructure, end-state mechanical properties, residual stresses, and defects, their effect on the mill during processing, and eventually, their in-reactor performance. In the work documented herein, studies were conducted to determine the effect of cold and hot rolling the as-cast and homogenized U-10Mo on its microstructure and hardness. The samples were homogenized at 900°C for 48 h, then later annealed for several durations and temperatures to investigate the effect on the material’s microstructure and hardness. The rolling of the as-cast plate, both hot and cold, was observed to form a molybdenum-rich and -lean banded structure. The cold rolling was ineffective, and in some cases exacerbated the as-cast defects. The grains elongated along the rolling direction and formed a pancake shape, while the carbides fractured perpendicularly to the rolling direction and left porosity between fractured particles of UC. The subsequent annealing of these samples at sub-eutectoid temperatures led to rapid precipitation of the ' lamellar phase, mainly in the molybdenum-lean regions. Annealing the samples above the eutectoid temperature did not refine the grain size or the banded microstructure. However, annealing the samples led to quick recovery in hardness as evidenced by a drop in Vickers hardness of 20%. Hot rolling was performed at 650 and 800°C. The hot-rolling mill loads (load separation force) were approximately 40 to 50% less than the cold-rolling for the same reduction and thickness. It was observed that hot rolling the samples with 50% or more reduction in thickness were responsible for dynamic recrystallization in the hot-rolled samples and led to grain refinement. Unlike the cold-rolled samples, the hot-rolled samples did not fracture the carbides and appeared to heal the casting defects. The recovery phenomenon was similar to the cold-rolled samples above the eutectoid temperatures, but owing to the refined grain size, the precipitation of the lamellar phase was far more rapid in these samples and the hardness increased more rapidly than in the cold rolled sample when heated below the eutectoid temperature. The data generated from these rolling efforts has been used to make the process modeling efforts more robust and applicable to all USHPRR partner rolling mills. The flow stress for cold rolling the samples was determined to be between 170-190 ksi, with frictional forces between 0.2 and 0.4 for the PNNL mill. The measured roll separation forces and those simulated using finite element methods for hot and cold rolling for the PNNL rolling mill were in good agreement.« less

Ultra-thin grain-oriented silicon steel sheet fabricated by a novel way: Twin-roll strip casting and two-stage cold rolling

NASA Astrophysics Data System (ADS)

Wang, Yin-Ping; Liu, Hai-Tao; Song, Hong-Yu; Liu, Jia-Xin; Shen, Hui-Ying; Jin, Yang; Wang, Guo-Dong

2018-04-01

0.05-0.15 mm-thick ultra-thin grain-oriented silicon steel sheets were successfully produced by a novel processing route including strip casting, hot rolling, normalizing, two-stage cold rolling with intermediate annealing, primary recrystallization annealing and secondary recrystallization annealing. The evolutions of microstructure, texture and inhibitor along the processing were briefly investigated. The results showed that the initial Goss orientation originated due to the heterogenous nucleation of δ-ferrite grains during solidification. Because of the lack of shear deformation, only a few Goss grains were observed in the hot rolled sheet. After the first cold rolling and intermediate annealing, Goss texture was enhanced and distributed in the whole thickness. A small number of Goss grains having a high fraction of high energy boundaries exhibited in the primary recrystallization annealed sheet. A large number of fine and dispersed MnS and AlN and a few co-precipitates MnS and AlN with the size range of 10-70 nm were also observed. Interestingly, a well-developed secondary recrystallization microstructure characterized by 10-60 mm grains and a sharp Goss texture were finally produced in the 0.05-0.15 mm-thick ultra-thin sheets. A magnetic induction B8 of 1.72-1.84 T was obtained. Another new finding was that a few {2 3 0}〈0 0 1〉 and {2 1 0}〈1 2 7〉 grains also can grow up abnormally because of the high fraction of high energy boundaries and the size and number advantage, respectively. These non-Goss grains finally deteriorated the magnetic properties of the ultra-thin sheets. In addition, low surface energies of {hk0} planes may also contribute to the abnormal growth of Goss, {2 3 0}〈0 0 1〉 and {2 1 0}〈1 2 7〉 grains.

Effect of Annealing on Microstructure, Texture and Tensile Properties of Twin-Roll Cast AZ31B

NASA Astrophysics Data System (ADS)

Masoumi, Mohsen; Zarandi, Faramarz; Pekguleryuz, Mihriban O.

Twin-roll cast (TRC) AZ31 alloy (Mg-3wt.%Al-1wt.%Zn) was subjected to heat treatment at 420 °C. As a result, the intensity of the original basal texture was reduced considerably. Crystallographic orientation analysis revealed that such a change in the texture is due to particle-stimulated nucleation of new grains with random orientations. The tensile test results indicate that annealing slightly increases ultimate tensile strength (UTS), however, dramatically improves the elongation.

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.

29 CFR 452.131 - Casting of ballots; delegate elections.

Code of Federal Regulations, 2010 CFR

2010-07-01

... REPORTING AND DISCLOSURE ACT OF 1959 Election Procedures; Rights of Members § 452.131 Casting of ballots... roll call vote, or if only one candidate is nominated for an office, by acclamation or by a motion...

Forging Oxide-Dispersion-Strengthened Superalloys

NASA Technical Reports Server (NTRS)

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

1986-01-01

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

Effect of train type on annoyance and acoustic features of the rolling noise.

PubMed

Kasess, Christian H; Noll, Anton; Majdak, Piotr; Waubke, Holger

2013-08-01

This study investigated the annoyance associated with the rolling noise of different railway stock. Passbys of nine train types (passenger and freight trains) equipped with different braking systems were recorded. Acoustic features showed a clear distinction of the braking system with the A-weighted energy equivalent sound level (LAeq) showing a difference in the range of 10 dB between cast-iron braked trains and trains with disk or K-block brakes. Further, annoyance was evaluated in a psychoacoustic experiment where listeners rated the relative annoyance of the rolling noise for the different train types. Stimuli with and without the original LAeq differences were tested. For the original LAeq differences, the braking system significantly affected the annoyance with cast-iron brakes being most annoying, most likely as a consequence of the increased wheel roughness causing an increased LAeq. Contribution of the acoustic features to the annoyance was investigated revealing that the LAeq explained up to 94% of the variance. For the stimuli without differences in the LAeq, cast-iron braked train types were significantly less annoying and the spectral features explained up to 60% of the variance in the annoyance. The effect of these spectral features on the annoyance of the rolling noise is discussed.

Prediction of Contact Fatigue Life of Alloy Cast Steel Rolls Using Back-Propagation Neural Network

NASA Astrophysics Data System (ADS)

Jin, Huijin; Wu, Sujun; Peng, Yuncheng

2013-12-01

In this study, an artificial neural network (ANN) was employed to predict the contact fatigue life of alloy cast steel rolls (ACSRs) as a function of alloy composition, heat treatment parameters, and contact stress by utilizing the back-propagation algorithm. The ANN was trained and tested using experimental data and a very good performance of the neural network was achieved. The well-trained neural network was then adopted to predict the contact fatigue life of chromium alloyed cast steel rolls with different alloy compositions and heat treatment processes. The prediction results showed that the maximum value of contact fatigue life was obtained with quenching at 960 °C, tempering at 520 °C, and under the contact stress of 2355 MPa. The optimal alloy composition was C-0.54, Si-0.66, Mn-0.67, Cr-4.74, Mo-0.46, V-0.13, Ni-0.34, and Fe-balance (wt.%). Some explanations of the predicted results from the metallurgical viewpoints are given. A convenient and powerful method of optimizing alloy composition and heat treatment parameters of ACSRs has been developed.

METALLOGRAPHIC STUDIES OF SPUTNIK 4 FRAGMENT

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

Kammerer, O.F.; Sadofsky, J.; Gurinsky, D.H.

1963-09-01

Metallographic analyses were performed on a fragment of steel recovered after the disintegration of Sputnik 4 and on a melted agglomerate found on the fragment. The examination indicated that the material was a hot-rolled carbon steel similar in hardness to a structural steel with a tensile strength of 3.8 to 4.1 x 10/sup 10/ dynes/cm/sup 2/. The major portion of the fragment exhibited a banded structure characteristic of hot-rolled material. The upper surface was probably heated to the melting point which resulted in the formation of a narrow band similar to an as-cast Widmannstaettn microstructure. The melted material at themore » bottom of the specimen was a porous mass containing several different varieties of inclusions and compounds. (auth)« less

Non-Heat Treatable Alloy Sheet Products

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

Hayden, H.W.; Barthold, G.W.; Das, S.K.

ALCAR is an innovative approach for conducting multi-company, pre-competitive research and development programs. ALCAR has been formed to crate a partnership of aluminum producers, the American Society of Mechanical Engineers Center for Research and Technology Development (ASME/CRTD), the United States Department of Energy (USDOE), three USDOE National Laboratories, and a Technical Advisory Committee for conducting cooperative, pre-competitive research on the development of flower-cost, non-heat treated (NHT) aluminum alloys for automotive sheet applications with strength, formability and surface appearance similar to current heat treated (HT) aluminum alloys under consideration. The effort has been supported by the USDOE, Office of Transportation Technologymore » (OTT) through a three-year program with 50/50 cost share at a total program cost of $3 million. The program has led to the development of new and modified 5000 series aluminum ally compositions. Pilot production-size ingots have bee n melted, cast, hot rolled and cold rolled. Stamping trials on samples of rolled product for demonstrating production of typical automotive components have been successful.« less

Effect of microstructure of superalloy guide plate on its surface wear resistance

NASA Astrophysics Data System (ADS)

Zhou, Jianbo; Zhang, Xizhen

2018-03-01

The microstructure had been observed for guide plate, the guide plate be made of casting for groove controlling of hot rolled seamless tube, be produced for the production of 1600 seamless steel pipe,which cause obvious surface deformation and can not be normally produced. The alloy elements in matrix and precipitate phase of the guide plate were analyzed with the help of EDS. The results show that the wear resistance of the guide plate is directly affected by the fact that the guide plate is unable to form typical carbides, it shows that the formation of typical carbide strengthening plays an important role in improving the surface wear resistance of the guide plate.

Rolling and aging in temperature-ramp soft adhesion

NASA Astrophysics Data System (ADS)

Boniello, Giuseppe; Tribet, Christophe; Marie, Emmanuelle; Croquette, Vincent; Zanchi, Dražen

2018-01-01

Immediately before adsorption to a horizontal substrate, sinking polymer-coated colloids can undergo a complex sequence of landing, jumping, crawling, and rolling events. Using video tracking, we studied the soft adhesion to a horizontal flat plate of micron-size colloids coated by a controlled molar fraction f of the poly(lysine)-grafted-poly(N-isopropylacrylamide) (PLL-g-PNIPAM) which is a temperature-sensitive polymer. We ramp the temperature from below to above Tc=32 ±1∘C , at which the PNIPAM polymer undergoes a transition, triggering attractive interaction between microparticles and surface. The adsorption rate, the effective in-plane (x -y ) diffusion constant, and the average residence time distribution over z were extracted from the Brownian motion records during last seconds before immobilization. Experimental data are understood within a rate-equations-based model that includes aging effects and includes three populations: the untethered, the rolling, and the arrested colloids. We show that preadsorption dynamics casts a characteristic scaling function α (f ) proportional to the number of available PNIPAM patches met by soft contact during Brownian rolling. In particular, the increase of in-plane diffusivity with increasing f is understood: The stickiest particles have the shortest rolling regime prior to arrest, so that their motion is dominated by the untethered phase.

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.

Reasonable Temperature Schedules for Cold or Hot Charging of Continuously Cast Steel Slabs

NASA Astrophysics Data System (ADS)

Li, Yang; Chen, Xin; Liu, Ke; Wang, Jing; Wen, Jin; Zhang, Jiaquan

2013-12-01

Some continuously cast steel slabs are sensitive to transverse fracture problems during transportation or handling away from their storage state, while some steel slabs are sensitive to surface transverse cracks during the following rolling process in a certain hot charging temperature range. It is revealed that the investigated steel slabs with high fracture tendency under room cooling condition always contain pearlite transformation delayed elements, which lead to the internal brittle bainitic structure formation, while some microalloyed steels exhibit high surface crack susceptibility to hot charging temperatures due to carbonitride precipitation. According to the calculated internal cooling rates and CCT diagrams, the slabs with high fracture tendency during cold charging should be slowly cooled after cutting to length from hot strand or charged to the reheating furnace directly above their bainite formation temperatures. Based on a thermodynamic calculation for carbonitride precipitation in austenite, the sensitive hot charging temperature range of related steels was revealed for the determination of reasonable temperature schedules.

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.

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.

Effect of Fe- and Si-Enriched Secondary Precipitates and Surface Roughness on Pore Formation on Aluminum Plate Surfaces During Anodizing

NASA Astrophysics Data System (ADS)

Zhu, Yuanzhi; Wang, Shizhi; Yang, Qingda; Zhou, Feng

2014-09-01

Two twin roll casts (TRCs) and one hot rolled (HR) AA 1235 aluminum alloy plates with different microstructures are prepared. The plates were electrolyzed in a 1.2 wt% HCl solution with a voltage of 21 V and a current of 1.9 mA. The shape, size, and number of pores formed on the surfaces of these plates were analyzed and correlated with the microstructures of the plates. It is found that pores are easier to form on the alloy plates containing subgrains with a lower dislocation density inside the subgrains, rather than along the grain boundaries. Furthermore, Fe- and Si-enriched particles in the AA1235 aluminum alloys lead to the formation of pores on the surface during electrolyzing; the average precipitate sizes of 4, 3.5, and 2 μm in Alloy 1#, Alloy 2# and Alloy 3# result in the average pore sizes of 3.78, 2.76, and 1.9 μm on the surfaces of the three alloys, respectively; The G.P zone in the alloy also facilitates the surface pore formation. High-surface roughness enhances the possibility of entrapping more lubricants into the plate surface, which eventually blocks the formation of the pores on the surface of the aluminum plates in the following electrolyzing process.

Iron aluminide knife and method thereof

DOEpatents

Sikka, Vinod K.

1997-01-01

Fabricating an article of manufacture having a Fe.sub.3 Al-based alloy cutting edge. The fabrication comprises the steps of casting an Fe.sub.3 Al-based alloy, extruding into rectangular cross section, rolling into a sheet at 800.degree. C. for a period of time followed by rolling at 650.degree. C., cutting the rolled sheet into an article having an edge, and grinding the edge of the article to form a cutting edge.

Development of 1500mm Wide Wrought Magnesium Alloys by Twin Roll Casting Technique in Turkey

NASA Astrophysics Data System (ADS)

Duygulu, Ozgur; Ucuncuoglu, Selda; Oktay, Gizem; Temur, Deniz Sultan; Yucel, Onuralp; Kaya, Ali Arslan

Magnesium alloy AZ31, AZ61, AZ91, AM50 and AM60 sheets were produced by twin roll casting first time in Turkey. Sheets of 4.5-6.5mm thick and 1500mm width were successfully achieved. Microstructure of the sheet was analyzed by optical microscope, scanning electron microscope (SEM) and transmission electron microscope (TEM). Semi-quantitative analyses were performed by SEM-EDS. In addition, X-ray studies were performed for both characterization and texture purposes. Mechanical properties were investigated by tensile tests and also hardness measurements. Homogenization and annealing heat treatments were performed on the produced sheets.

Large grain cavities from pure niobium ingot

DOEpatents

Myneni, Ganapati Rao [Yorktown, VA; Kneisel, Peter [Williamsburg, VA; Cameiro, Tadeu [McMurray, PA

2012-03-06

Niobium cavities are fabricated by the drawing and ironing of as cast niobium ingot slices rather than from cold rolled niobium sheet. This method results in the production of niobium cavities having a minimum of grain boundaries at a significantly reduced cost as compared to the production of such structures from cold rolled sheet.

Effect of cold rolling on the microstructure and mechanical properties of Al 0.25CoCrFe 1.25Ni 1.25 high-entropy alloy

DOE PAGES

Wang, Z.; Gao, M. C.; Ma, S. G.; ...

2015-08-05

Cold rolling can break down the as-cast dendrite microstructure and thus may have pronounced impact on the mechanical behavior of the alloy. In the present study, the effect of cold rolling on the microstructure and mechanical properties of Al 0.25CoCrFe 1.25Ni 1.25 high-entropy alloy in the face-centered cubic structure was investigated. With increasing the thickness reduction from cold rolling, the hardness, the yield strength, and the fracture strength increased at the cost of reducing ductility. At the thickness reduction of 80%, the tensile strength (hardness) was 702 MPa (406 MPa), 1.62 (2.43) times that in the as-cast condition. Compared tomore » traditional alloys, Al 0.25CoCrFe 1.25Ni 1.25 has the highest hardening rate with respect to CR thickness reduction. Lastly, the phase relation and the mixing properties of Gibbs free energy, enthalpy and entropy of Al xCoCrFe 1.25Ni 1.25 were predicted using the CALPHAD method.« less

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

Iron aluminide knife and method thereof

DOEpatents

Sikka, V.K.

1997-08-05

Fabricating an article of manufacture having a Fe{sub 3}Al-based alloy cutting edge is discussed. The fabrication comprises the steps of casting an Fe{sub 3}Al-based alloy, extruding into rectangular cross section, rolling into a sheet at 800 C for a period of time followed by rolling at 650 C, cutting the rolled sheet into an article having an edge, and grinding the edge of the article to form a cutting edge. 1 fig.

Effect of Cold-rolling on Mechanical Properties and Microstructure of an Al-12%Si-0.2%Mg Alloy

NASA Astrophysics Data System (ADS)

Liao, Hengcheng; Cai, Mingdong; Jing, Qiumin; Ding, Ke

2011-11-01

Effect of multi-pass cold-rolling on the mechanical properties and microstructure of a near-eutectic Al-12%Si-0.2%Mg casting alloy was investigated. Optical microscopy, SEM, and TEM were employed to resolve the as-rolled microstructure, and the microstructure of samples after aging treatment. It has been found that Brinell hardness increases considerably with rolling reduction ratio; and further annealing leads to a remarkable drop in hardness. Two mechanisms, namely precipitation hardening and recovery softening, were found to develop simultaneously in the subsequent aging treatment following cold rolling. In contrast, recovery softening dominated the aging of cold-rolled specimen with prior intermediate annealing. Tensile properties were also performed to measure the effect of cold rolling and subsequent aging treatment.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties

PubMed Central

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-01-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties. PMID:27245687

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.

Novel strip-cast Mg/Al clad sheets with excellent tensile and interfacial bonding properties.

PubMed

Kim, Jung-Su; Lee, Dong Ho; Jung, Seung-Pill; Lee, Kwang Seok; Kim, Ki Jong; Kim, Hyoung Seop; Lee, Byeong-Joo; Chang, Young Won; Yuh, Junhan; Lee, Sunghak

2016-06-01

In order to broaden industrial applications of Mg alloys, as lightest-weight metal alloys in practical uses, many efforts have been dedicated to manufacture various clad sheets which can complement inherent shortcomings of Mg alloys. Here, we present a new fabrication method of Mg/Al clad sheets by bonding thin Al alloy sheet on to Mg alloy melt during strip casting. In the as-strip-cast Mg/Al clad sheet, homogeneously distributed equi-axed dendrites existed in the Mg alloy side, and two types of thin reaction layers, i.e., γ (Mg17Al12) and β (Mg2Al3) phases, were formed along the Mg/Al interface. After post-treatments (homogenization, warm rolling, and annealing), the interfacial layers were deformed in a sawtooth shape by forming deformation bands in the Mg alloy and interfacial layers, which favorably led to dramatic improvement in tensile and interfacial bonding properties. This work presents new applications to multi-functional lightweight alloy sheets requiring excellent formability, surface quality, and corrosion resistance as well as tensile and interfacial bonding properties.

Report on Northwestern's Air-cooled, Copper Precipitation Hardened, High Strength, Weldable Steel Cast and Hot Rolled at Oregon Steel Mills

DOT National Transportation Integrated Search

1996-09-27

This research has shown that a Grade 70 construction steel of 1/2- to 1-inch plate thicknesses can be produced without a quench and temper or accelerated cooling from hot-rolling if the Cu content in the steel is sufficiently high. Coherent very fine...

A Study of the Cold Resistance of Pipe Coiled Stock Produced at Foundry-Rolling Works. Part 2

NASA Astrophysics Data System (ADS)

Bagmet, O. A.; Naumenko, V. V.; Smetanin, K. S.

2018-03-01

Results of a study of coiled stock from low-carbon steels alloyed with manganese and silicon and different additives of niobium and titanium are presented. The coiled stock is produced at foundry-rolling works by the method of direct rolling of thin slabs right after their continuous casting. The microdeformation of the crystal lattice and the crystallographic texture are determined. The conditions of formation of the most favorable structure and texture in the steels are specified.

Thermal Microstructural Stability of AZ31 Magnesium after Severe Plastic Deformation

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

Young, John P.; Askari, Hesam A.; Hovanski, Yuri

2015-03-01

Both equal channel angular pressing and friction stir processing have the ability to refine the grain size of twin roll cast AZ31 magnesium and potentially improve its superplastic properties. This work used isochronal and isothermal heat treatments to investigate the microstructural stability of twin roll cast, equal channel angular pressed and friction stir processed AZ31 magnesium. For both heat treatment conditions, it was found that the twin roll casted and equal channel angular pressed materials were more stable than the friction stir processed material. Calculations of the grain growth kinetics showed that severe plastic deformation processing decreased the activation energymore » for grain boundary motion with the equal channel angular pressed material having the greatest Q value of the severely plastically deformed materials and that increasing the tool travel speed of the friction stir processed material improved microstructural stability. The Hollomon-Jaffe parameter was found to be an accurate means of identifying the annealing conditions that will result in substantial grain growth and loss of potential superplastic properties in the severely plastically deformed materials. In addition, Humphreys’s model of cellular microstructural stability accurately predicted the relative microstructural stability of the severely plastically deformed materials and with some modification, closely predicted the maximum grain size ratio achieved by the severely plastically deformed materials.« less

DYNAMIC PROPERTIES OF SHOCK LOADED THIN URANIUM FOILS

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

Robbins, D. L.; Kelly, A. M.; Alexander, D. J.

A series of spall experiments has been completed with thin depleted uranium targets, nominally 0.1 mm thick. The first set of uranium spall targets was cut and ground to final thickness from electro-refined, high-purity, cast uranium. The second set was rolled to final thickness from low purity uranium. The impactors for these experiments were laser-launched 0.05-mm thick copper flyers, 3 mm in diameter. Laser energies were varied to yield a range of flyer impact velocities. This resulted in varying degrees of damage to the uranium spall targets, from deformation to complete spall or separation at the higher velocities. Dynamic measurementsmore » of the uranium target free surface velocities were obtained with dual velocity interferometers. Uranium targets were recovered and sectioned after testing. Free surface velocity profiles were similar for the two types of uranium, but spall strengths (estimated from the magnitude of the pull-back signal) are higher for the high-purity cast uranium. Velocity profiles and microstructural evidence of spall from the sectioned uranium targets are presented.« less

A Soft Casting Technique for Managing Pediatric Hand and Foot Burns.

PubMed

Choi, Young Mee; Nederveld, Cindy; Campbell, Kristen; Moulton, Steven

2018-04-04

Hand and foot burns in children are difficult to dress. The authors have developed a soft casting technique to manage burns to these areas. The aim of this study is to report the outcomes using weekly dressing changes with a soft casting technique to manage pediatric hand and foot burns in the outpatient setting. A retrospective chart review was performed on children with burns to the hands or feet, who underwent dressing changes with a soft casting technique at the Children's Hospital Colorado Burn Center. Soft casting was performed by placing antibiotic ointment-impregnated nonadherent gauze over the burn wound(s), wrapping the extremity using rolled gauze, applying soft cast pad, plaster, soft cast tape, and an elastic bandage. This was changed weekly. Two hundred ninety-eight children with hand burns had a mean age of 16.8 ± 2 months. Two hundred forty-eight children had partial thickness burn injuries (83%), 50 had full thickness burn injuries (17%), and the mean total body surface area (TBSA) was 1 ± 2.4%. The mean time to heal was 10.1 ± 1.7 days for all subjects. Sixty-six children with foot burns were identified with a mean age of 24 ± 2.6 months. Forty-six children had partial thickness injuries (70%), 20 had full thickness burn injuries (30%), and the mean TBSA was 2.3 ± 2.9%. The mean time to heal was 14.1 ± 2.2 days for all subjects. Weekly dressing changes using a soft casting technique are effective for the outpatient management of pediatric hand and foot burns. This method avoids costly inpatient hospital care, reduces the number of painful dressing changes, and allows children to heal in their own environment.

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

Phase transformation kinetics in rolled U-10 wt. % Mo foil: Effect of post-rolling heat treatment and prior γ-UMo grain size

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

Jana, Saumyadeep; Overman, Nicole; Varga, Tamas

The effect of sub-eutectoid heat treatment on the phase transformation behavior in rolled U-10 wt.percent Mo (U10Mo) foils was systematically investigated. The as-cast 5 mm thick foils were initially homogenized at 900 degrees C for 48 hours and were hot rolled to 2 mm and later cold rolled down to 0.2 mm. Three starting microstructures were evaluated: (i) hot- + cold-rolled to 0.2 mm (as-rolled condition), (ii) hot- + cold-rolled to 0.2 mm + annealed at 700 deg. C for 1 hour, and (iii) hot- + cold-rolled to 0.2 mm + annealed at 1000 deg. C for 60 hours. U10Momore » rolled foils went through various degrees of decomposition when subjected to the sub-eutectoid heat-treatment step and formed a lamellar microstructure through a cellular reaction mostly along the previous γ-UMo grain boundaries.« less

Roll to Roll Electric Field "Z" Alignment of Nanoparticles from Polymer Solutions for Manufacturing Multifunctional Capacitor Films.

PubMed

Guo, Yuanhao; Batra, Saurabh; Chen, Yuwei; Wang, Enmin; Cakmak, Miko

2016-07-20

A roll to roll continuous processing method is developed for vertical alignment ("Z" alignment) of barium titanate (BaTiO3) nanoparticle columns in polystyrene (PS)/toluene solutions. This is accomplished by applying an electric field to a two-layer solution film cast on a carrier: one is the top sacrificial layer contacting the electrode and the second is the polymer solution dispersed with BaTiO3 particles. Flexible Teflon coated mesh is utilized as the top electrode that allows the evaporation of solvent through the openings. The kinetics of particle alignment and chain buckling is studied by the custom-built instrument measuring the real time optical light transmission during electric field application and drying steps. The nanoparticles dispersed in the composite bottom layer form chains due to dipole-dipole interaction under an applied electric field. In relatively weak electric fields, the particle chain axis tilts away from electric field direction due to bending caused by the shrinkage of the film during drying. The use of strong electric fields leads to maintenance of alignment of particle chains parallel to the electric field direction overcoming the compression effect. At the end of the process, the surface features of the top porous electrodes are imprinted at the top of the top sacrificial layer. By removing this layer a smooth surface film is obtained. The nanocomposite films with "Z" direction alignment of BaTiO3 particles show substantially increased dielectric permittivity in the thickness direction for enhancing the performance of capacitors.

Microstructure and Mechanical Properties Evolution of the Al, C-Containing CoCrFeNiMn-Type High-Entropy Alloy during Cold Rolling.

PubMed

Klimova, Margarita; Stepanov, Nikita; Shaysultanov, Dmitry; Chernichenko, Ruslan; Yurchenko, Nikita; Sanin, Vladimir; Zherebtsov, Sergey

2017-12-29

The effect of cold rolling on the microstructure and mechanical properties of an Al- and C-containing CoCrFeNiMn-type high-entropy alloy was reported. The alloy with a chemical composition (at %) of (20-23) Co, Cr, Fe, and Ni; 8.82 Mn; 3.37 Al; and 0.69 C was produced by self-propagating high-temperature synthesis with subsequent induction. In the initial as-cast condition the alloy had an face centered cubic single-phase coarse-grained structure. Microstructure evolution was mostly associated with either planar dislocation glide at relatively low deformation during rolling (up to 20%) or deformation twinning and shear banding at higher strain. After 80% reduction, a heavily deformed twinned/subgrained structure was observed. A comparison with the equiatomic CoCrFeNiMn alloy revealed higher dislocation density at all stages of cold rolling and later onset of deformation twinning that was attributed to a stacking fault energy increase in the program alloy; this assumption was confirmed by calculations. In the initial as-cast condition the alloy had low yield strength of 210 MPa with yet very high uniform elongation of 74%. After 80% rolling, yield strength approached 1310 MPa while uniform elongation decreased to 1.3%. Substructure strengthening was found to be dominated at low rolling reductions (<40%), while grain (twin) boundary strengthening prevailed at higher strains.

Perception of object motion in three-dimensional space induced by cast shadows.

PubMed

Katsuyama, Narumi; Usui, Nobuo; Nose, Izuru; Taira, Masato

2011-01-01

Cast shadows can be salient depth cues in three-dimensional (3D) vision. Using a motion illusion in which a ball is perceived to roll in depth on the bottom or to flow in the front plane depending on the slope of the trajectory of its cast shadow, we investigated cortical mechanisms underlying 3D vision based on cast shadows using fMRI techniques. When modified versions of the original illusion, in which the slope of the shadow trajectory (shadow slope) was changed in 5 steps from the same one as the ball trajectory to the horizontal, were presented to participants, their perceived ball trajectory shifted gradually from rolling on the bottom to floating in the front plane as the change of the shadow slope. This observation suggests that the perception of the ball trajectory in this illusion is strongly affected by the motion of the cast shadow. In the fMRI study, cortical activity during observation of the movies of the illusion was investigated. We found that the bilateral posterior-occipital sulcus (POS) and right ventral precuneus showed activation related to the perception of the ball trajectory induced by the cast shadows in the illusion. Of these areas, it was suggested that the right POS may be involved in the inferring of the ball trajectory by the given spatial relation between the ball and the shadow. Our present results suggest that the posterior portion of the medial parietal cortex may be involved in 3D vision by cast shadows. Copyright © 2010 Elsevier Inc. All rights reserved.

49 CFR 238.307 - Periodic mechanical inspection of passenger cars and unpowered vehicles used in passenger trains.

Code of Federal Regulations, 2014 CFR

2014-10-01

... body from separating in case of derailment. (9) All center castings on trucks are not cracked or broken... inspection of all center castings shall be conducted by jacking the equipment and rolling out the trucks at... component; (iii) A crack, break, excessive wear, structural defect, or weakness of a component; (iv) A leak...

Synthesis, Characterization and Cold Workability of Cast Copper-Magnesium-Tin Alloys

NASA Astrophysics Data System (ADS)

Bravo Bénard, Agustín Eduardo; Martínez Hernández, David; González Reyes, José Gonzalo; Ortiz Prado, Armando; Schouwenaars Franssens, Rafael

2014-02-01

The use of Mg as an alloying element in copper alloys has largely been overlooked in scientific literature and technological applications. Its supposed tribological compatibility with iron makes it an interesting option to replace Pb in tribological alloys. This work describes the casting process of high-quality thin slabs of Cu-Mg-Sn alloys with different compositions by means of conventional methods. The resulting phases were analyzed using X-ray diffraction, scanning electron microscopy, optical microscopy, and energy dispersive X-ray spectroscopy techniques. Typical dendritic α-Cu, eutectic Cu2Mg(Sn) and eutectoid non-equilibrium microstructures were found. Tensile tests and Vickers microhardness show the excellent hardening capability of Mg as compared to other copper alloys in the as-cast condition. For some of the slabs and compositions, cold rolling reductions of over 95 pct have been easily achieved. Other compositions and slabs have failed during the deformation process. Failure analysis after cold rolling reveals that one cause for brittleness is the presence of casting defects such as microshrinkage and inclusions, which can be eliminated. However, for high Mg contents, a high volume fraction of the intermetallic phase provides a contiguous path for crack propagation through the connected interdendritic regions.

Microstructural and mechanical responses to various rolling speeds determined in multi-pass break-down rolling of AZ31B alloy

NASA Astrophysics Data System (ADS)

Jia, Weitao; Tang, Yan; Ning, Fangkun; Le, Qichi; Cui, Jianzhong

2018-04-01

Different rolling operations of as-cast AZ31B alloy were performed under different rolling speed (18 ∼ 72 m min‑1) and rolling pass conditions at 400 °C. Microstructural studies, tensile testing and formability evaluation relevant to each rolling operation were investigated. For 1-pass rolling, coarse average grain size (CAGS) region gradually approached the center layer as the rolling speed increased. Moreover, twins, shear bands and coarse-grain structures were the dominant components in the microstructure of plates rolled at 18, 48 and 72 m min‑1, respectively, indicating the severe deformation inhomogeneity under the high reduction per pass condition. For 2-pass rolling and 4-pass rolling, dynamic recrystallization was observed to be well and CAGS region has substantially disappeared, indicating the significant improvement in deformation uniformity and further the grain homogenization under the conditions. Microstructure uniformity degree of 2-pass rolled plates did not vary much as the rolling speed varied. On this basis, shear band distribution dominated the deformation behavior during the uniaxial tension of the 2-pass rolled plates. However, microstructure uniformity accompanied by twin distribution played a leading role in stretching the 4-pass rolled plates.

40 CFR 467.16 - Pretreatment standards for new sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

... Maximum for monthly average mg/off-kg (lb/million off-lbs) of aluminum rolled with neat oils Chromium 0... rolled with neat oils Chromium 0.021 0.009 Cyanide 0.011 0.005 Zinc 0.057 0.024 TTO 0.038 Oil and grease... aluminum cast Chromium 0.00073 0.00029 Cyanide 0.00039 0.00016 Zinc 0.0020 0.00082 TTO 0.0014 Oil and...

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

Jet Mixing in Direct-Chill Casting of Aluminum: Crater Effects and its Consequence on Centerline Segregation

NASA Astrophysics Data System (ADS)

Wagstaff, Samuel R.; Allanore, Antoine

2017-08-01

Recent reports have demonstrated the possibility of mitigating macrosegregation during the Direct-Chill casting of rolling slab ingots using an impinging jet. Herein, an analytical model is presented to predict the shape of the crater formed due to the impact of the jet on the slurry region. The model takes into account alloy composition, physical dimension, and casting speed on the distribution of forces and crater shape. The calculated shape of the crater profile is used to explain the centerline depletion in the impingement region previously reported.

Study of grain structure evolution during annealing of a twin-roll-cast Mg alloy

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

Tripathi, A.; Department of Metallurgical Engineering and Materials Science, IIT Bombay; Department of Materials Engineering, Monash University

2016-04-15

The evolution of microstructure under static annealing was studied for mid-thickness section of a twin-roll-cast (TRC) magnesium alloy. Annealing was performed at 300 °C and 500 °C for different times. Microstructural evolution was quantitatively analyzed, from optical micrographs, using grain path envelope analysis. Additional information from electron backscatter diffraction (EBSD) was used for addressing the possible mechanism(s). It was found that the TRC structure had a bimodal grain size, which was preserved even after annealing at 300 °C. However, the annealing at 500 °C led to a unimodal grain size. This difference in the grain size distribution created a contrastingmore » behavior in the normalized standard deviations. This was primarily attributed to a competition between recovery and recrystallization, and their respective dominance at 300° and 500 °C. A deformation induced recrystallization recovery (DIRR) model was proposed. The proposed model could successfully address the experimental microstructural evolution. - Highlights: • Annealing of twin roll cast (TRC) magnesium alloy was done at temperatures of 300 °C and 500 °C. • TRC had bimodal structure. Bimodality preserved for annealing at 300 °C. Annealing at 500 °C led to unimodal structure. • Grain evolution was described based on the competition between recovery and recrystallization. • Deformation induced recrystallization recovery (DIRR) mechanistic model was developed.« less

49 CFR 238.307 - Periodic mechanical inspection of passenger cars and unpowered vehicles used in passenger trains.

Code of Federal Regulations, 2013 CFR

2013-10-01

... separating in case of derailment. (9) All center castings on trucks are not cracked or broken, to the extent... castings shall be conducted by jacking the equipment and rolling out the trucks at each COT&S cycle... crack, break, excessive wear, structural defect, or weakness of a component; (iv) A leak; (v) Use of a...

40 CFR 467.13 - Effluent limitations representing the degree of effluent reduction attainable by the application...

Code of Federal Regulations, 2012 CFR

2012-07-01

.../off-kg (lb/million off-lbs) of aluminum rolled with neat oils Chromium 0.036 0.015 Cyanide 0.024 0... mg/off-kg (lb/million off-lbs) of aluminum rolled with neat oils Chromium 0.025 0.010 Cyanide 0.016 0.../off-kg (lb/million off-lbs) of aluminum sheet cast Chromium 0.00086 0.00035 Cyanide 0.00057 0.00024...

40 CFR 467.13 - Effluent limitations representing the degree of effluent reduction attainable by the application...

Code of Federal Regulations, 2011 CFR

2011-07-01

.../off-kg (lb/million off-lbs) of aluminum rolled with neat oils Chromium 0.036 0.015 Cyanide 0.024 0... mg/off-kg (lb/million off-lbs) of aluminum rolled with neat oils Chromium 0.025 0.010 Cyanide 0.016 0.../off-kg (lb/million off-lbs) of aluminum sheet cast Chromium 0.00086 0.00035 Cyanide 0.00057 0.00024...

40 CFR 467.15 - Pretreatment standards for existing sources.

Code of Federal Regulations, 2011 CFR

2011-07-01

... aluminum rolled with neat oils Chromium 0.036 0.015 Cyanide 0.024 0.010 Zinc 0.119 0.050 TTO 0.057 Oil and... off-lbs) of aluminum rolled with neat oils Chromium 0.025 0.010 Cyanide 0.016 0.007 Zinc 0.081 0.034... (lb/million off-lbs) of aluminum cast Chromium 0.00086 0.00035 Cyanide 0.00057 0.00024 Zinc 0.0029 0...

Comparison of roll-to-roll replication approaches for microfluidic and optical functions in lab-on-a-chip diagnostic devices

NASA Astrophysics Data System (ADS)

Brecher, Christian; Baum, Christoph; Bastuck, Thomas

2015-03-01

Economically advantageous microfabrication technologies for lab-on-a-chip diagnostic devices substituting commonly used glass etching or injection molding processes are one of the key enablers for the emerging market of microfluidic devices. On-site detection in fields of life sciences, point of care diagnostics and environmental analysis requires compact, disposable and highly functionalized systems. Roll-to-roll production as a high volume process has become the emerging fabrication technology for integrated, complex high technology products within recent years (e.g. fuel cells). Differently functionalized polymer films enable researchers to create a new generation of lab-on-a-chip devices by combining electronic, microfluidic and optical functions in multilayer architecture. For replication of microfluidic and optical functions via roll-to-roll production process competitive approaches are available. One of them is to imprint fluidic channels and optical structures of micro- or nanometer scale from embossing rollers into ultraviolet (UV) curable lacquers on polymer substrates. Depending on dimension, shape and quantity of those structures there are alternative manufacturing technologies for the embossing roller. Ultra-precise diamond turning, electroforming or casting polymer materials are used either for direct structuring or manufacturing of roller sleeves. Mastering methods are selected for application considering replication quality required and structure complexity. Criteria for the replication quality are surface roughness and contour accuracy. Structure complexity is evaluated by shapes producible (e.g. linear, circular) and aspect ratio. Costs for the mastering process and structure lifetime are major cost factors. The alternative replication approaches are introduced and analyzed corresponding to the criteria presented. Advantages and drawbacks of each technology are discussed and exemplary applications are presented.

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

NASA Astrophysics Data System (ADS)

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

2018-05-01

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

Flame-resistant Ca-containing AZ31 magnesium alloy sheets with good mechanical properties fabricated by a combination of strip casting and high-ratio differential speed rolling methods

NASA Astrophysics Data System (ADS)

Kim, Y. H.; Kim, W. J.

2015-03-01

This study reported that a combination of strip casting and high-ratio differential speed rolling (HRDSR) can produce flame-resistant Mg alloy sheets (0.7 wt%Ca-AZ31: 0.7Ca-AZ31) with good room-temperature mechanical properties and high-temperature formability. HRDSR effectively refined the coarse microstructure of the strip-casting processed 0.7Ca-AZ31 alloy. As the result, the (true) grain size was reduced to as small as 2.7 μm and the (Mg, Al)2Ca phase was broken up to fine particles with an average sizes of 0.5 μm. Due to the advantage of having such a highly refined microstructure, the HRDSR-processed 0.7Ca-AZ31 alloy sheet exhibited a high yield stress over 300 MPa and good superplasticity at elevated temperatures. The deformation mechanism of the fine-grained 0.7Ca-AZ31 alloy in the superplastic regime was identified to be grainboundary-diffusion or lattice-diffusion controlled grain boundary sliding.

40 CFR 467.12 - Effluent limitations representing the degree of effluent reduction attainable by the application...

Code of Federal Regulations, 2010 CFR

2010-07-01

... rolled with neat oils Chromium 0.0360 0.0147 Cyanide 0.0237 0.0098 Zinc 0.119 0.0498 Aluminum 0.525 0.257... aluminum rolled with neat oils Chromium 0.0244 0.010 Cyanide 0.0161 0.0067 Zinc 0.0808 0.0338 Aluminum 0... off-lbs) of aluminum sheet cast by continuous methods Chromium 0.00086 0.00035 Cyanide 0.00057 0.00024...

Twin-belt continuous caster with containment and cooling of the exiting cast product for enabling high-speed casting of molten-center product

DOEpatents

Dykes, Charles D.; Daniel, Sabah S.; Wood, J. F. Barry

1990-02-20

In continuously casting molten metal into cast product by a twin-belt machine, it is desirable to achieve dramatic increases in speed (linear feet per minute) at which cast product exits the machine, particularly in installations where steel cast product is intended to feed a downstream regular rolling mill (as distinct from a planetary mill) operating in tandem with the twin-belt caster. Such high-speed casting produces product with a relatively thin shell and molten interior, and the shell tends to bulge outwardly due to metallostatic head pressure of the molten center. A number of cooperative features enable high-speed, twin-belt casting: (1) Each casting belt is slidably supported adjacent to the caster exit pulley for bulge control and enhanced cooling of cast product. (2) Lateral skew steering of each belt provides an effective increase in moving mold length plus a continuity of heat transfer not obtained with prior art belt steering apparatus. (3) The exiting slab is contained and supported downstream from the casting machine to prevent bulging of the shell of the cast product, and (4) spray cooling is incorporated in the exit containment apparatus for secondary cooling of cast product.

Method of fabricating a uranium-bearing foil

DOEpatents

Gooch, Jackie G [Seymour, TN; DeMint, Amy L [Kingston, TN

2012-04-24

Methods of fabricating a uranium-bearing foil are described. The foil may be substantially pure uranium, or may be a uranium alloy such as a uranium-molybdenum alloy. The method typically includes a series of hot rolling operations on a cast plate material to form a thin sheet. These hot rolling operations are typically performed using a process where each pass reduces the thickness of the plate by a substantially constant percentage. The sheet is typically then annealed and then cooled. The process typically concludes with a series of cold rolling passes where each pass reduces the thickness of the plate by a substantially constant thickness amount to form the foil.

The role of heat transfer in strip casting

NASA Astrophysics Data System (ADS)

Misra, Paretosh

The last few years have witnessed rapid developments in the area of strip casting of steel. It involves smaller capital and operating cost, lower greenhouse gas emissions, and an opportunity to create newer products due to a faster solidification rate that leads to a different solidification structure. Thus, ample reasons for interest in the technology exist. At the same time, it needs to be determined if the properties of a strip cast product can match those of a conventional product and if it is possible to produce steel strip at high production rates. The first objective of this work was to characterize the quality, structure, and properties of strip cast material of different chemistries and cast at different machines, to identify the critical operating conditions that would result in the best properties. Determination of the possible range of properties was also aimed, given that the structure of the material is different from the traditional material. The second objective was to investigate ways to increase the rate of heat transfer in strip casting, as that will also enhance the productivity of a strip caster. It was also envisaged to see what effect a high rate of heat transfer will have on the properties of the strip cast material. Results from the strip cast material characterization that was carried out to achieve the first objective indicated that an effective control of heat transfer is very important to get the best properties. Samples that showed best properties had a uniform solidification structure consisting of columnar grains running from the edge of a strip to the centerline, indicating a good control of heat transfer, and their dendrite spacings pointed towards a relatively faster rate of cooling between the rolls. These findings indicated that heat transfer is a core issue in strip casting. The mechanism of increase in the rate of heat transfer in strip casting due to the presence of liquid oxide films at the metal-mold interface was examined. It was discovered that these films originate from the metal itself. A high degree of interdendritic supersaturation can lead to the formation of low melting point oxide phases by the deoxidizing agents in the steel. As the temperature lowers further the film may get ejected out of the metal due to the non-wetting of the metal by the oxide phase. If enough oxide film can be generated then this can result in an almost two-fold increase in the rate of heat transfer during initial solidification---the first 20 milliseconds. The results indicate that if a proper control of these films is ensured then it provides an attractive alternative to increasing the roll diameter as a mechanism of increasing the rate of production of a strip caster. This mechanism will work even with smaller diameter rolls, in fact, perhaps better in that case due to a smaller interface area over which uniformity of heat transfer has to be ensured, thus leveraging its full advantages. If successfully implemented at a plant, this technique can help the strip casting machines to increase their productivity and emerge as a competitive technology to produce steel strip.

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

NASA Astrophysics Data System (ADS)

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

2017-12-01

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

Microstructural Analysis of Severe Plastic Deformed Twin Roll Cast AZ31 for the Optimization of Superplastic Properties

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

Young, John P.; Askari, Hesam A.; Heiden, Michael J.

2013-07-08

In recent years magnesium alloys have attracted significant attention as potential candidates to replace many of the heavier metals used in some automotive applications. However, the limited formability of magnesium and its alloys at room temperature has driven interest in the superplastic forming magnesium as an alternative shaping method. Severe plastic deformation techniques have become a well studied method of refining the grain size and modifying the microstructural characteristics of many magnesium alloys to achieve greater superplastic properties. In this study twin roll cast (TRC) AZ31 magnesium alloy was subjected to equal channel angular pressing (ECAP) and friction stir weldingmore » (FSW). The influence of these severe plastic deformation processes on the grain size, texture and grain boundary character distribution was investigated to identify the optimum severe plastic deformation process for the superplastic forming of AZ31.« less

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.

Effect of Starting As-cast Structure on the Microstructure-Texture Evolution During Subsequent Processing and Finally Ridging Behavior of Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Modak, Pranabananda; Patra, Sudipta; Mitra, Rahul; Chakrabarti, Debalay

2018-03-01

Effect of the initial as-cast structure on the microstructure-texture evolution during thermomechanical processing of 409L grade ferritic stainless steel was studied. Samples from the regions of cast slab having `columnar,' `equiaxed,' and a mixture of `columnar' and `equiaxed' grains were subjected to two different processing schedules: one with intermediate hot-band annealing before cold-rolling followed by final annealing, and another without any hot-band annealing. EBSD study reveals that large columnar crystals with cube orientation are very difficult to deform and recrystallize uniformly. Resultant variations in ferrite grain structure and retention of cube-textured band in cold-rolled and annealed sheet contribute to ridging behavior during stretch forming. Initial equiaxed grain structure is certainly beneficial to reduce or even eliminate ridging defect by producing uniform ferrite grain structure, free from any texture banding. Application of hot-band annealing treatment is also advantageous as it can maximize the evolution of beneficial gamma-fiber texture and eliminate the ridging defect in case of completely `equiaxed' starting structure. Such treatment reduces the severity of ridging even if the initial structure contains typically mixed `columnar-equiaxed' grains.

Effect of Starting As-cast Structure on the Microstructure-Texture Evolution During Subsequent Processing and Finally Ridging Behavior of Ferritic Stainless Steel

NASA Astrophysics Data System (ADS)

Modak, Pranabananda; Patra, Sudipta; Mitra, Rahul; Chakrabarti, Debalay

2018-06-01

Effect of the initial as-cast structure on the microstructure-texture evolution during thermomechanical processing of 409L grade ferritic stainless steel was studied. Samples from the regions of cast slab having `columnar,' `equiaxed,' and a mixture of `columnar' and `equiaxed' grains were subjected to two different processing schedules: one with intermediate hot-band annealing before cold-rolling followed by final annealing, and another without any hot-band annealing. EBSD study reveals that large columnar crystals with cube orientation are very difficult to deform and recrystallize uniformly. Resultant variations in ferrite grain structure and retention of cube-textured band in cold-rolled and annealed sheet contribute to ridging behavior during stretch forming. Initial equiaxed grain structure is certainly beneficial to reduce or even eliminate ridging defect by producing uniform ferrite grain structure, free from any texture banding. Application of hot-band annealing treatment is also advantageous as it can maximize the evolution of beneficial gamma-fiber texture and eliminate the ridging defect in case of completely `equiaxed' starting structure. Such treatment reduces the severity of ridging even if the initial structure contains typically mixed `columnar-equiaxed' grains.

Study of Inclusion Bands in Continuously Cast Steel Billets for Rolling Thermomechanically Treated Rebars

NASA Astrophysics Data System (ADS)

Pandey, J. C.; Choubey, P. N.; Raj, Manish

2008-07-01

The article presents the investigation results of inclusion bands generally formed toward the loose end/inner radius of continuously cast (CC) strands of thermomechanically treated (TMT) rebar grade cast through curved molds. The main analytical tool used for this purpose was an ultrasonic C-scan image analysis system to reveal this band, and the defects detected in this band using the preceding technique were further measured and analyzed in an optical microscope and a scanning electron microscope (SEM) using energy-dispersive system (EDS). The investigation results revealed the presence of macrolevel globular macroinclusions in the size range 50 to 711 μm. The main constituents of the globular inclusions were found to be SiO2 and MnO. Impact test results revealed reduction in ductility in these bands when compared with the billet material without inclusion band toward the opposite face from the inner radius face. In Charpy testing, reduction in the impact energy in these bands was found to be 0.2 kg m. It is important to monitor the severity of macroinclusions present in these bands to avoid the cracking of TMT rebars during hot rolling.

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.

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.

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.

Simulation of the bimetal cast in the case of milling rolls

NASA Astrophysics Data System (ADS)

Mihut, G.; Popa, E.

2015-06-01

In the paper it is proposed, in main, to obtain of a model of numerical simulation, valid general and applicable the whole peculiars cases of bimetal casting, model with which help can be studied through the computer, the optimization possibility of flowing working condition of liquid alloy of the distribution of temperatures field, of the liquid phase and contraction during the solidification, with the minimum price (necessary reimbursement of the software and calculus equipment) in very short time etc.

Microstructural evolution in an ultra-fine YAl{sub 2p} reinforced Mg–14Li–3Al composite during warm-rolling

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

Wang, H.L.; Wu, G.Q.; Zhang, D.C.

2015-06-15

The YAl{sub 2p}/MgLiAl composite prepared by stir casting was initially forged and then rolled at 200 °C to different thicknesses. The microstructural evolution in the composite during warm rolling was investigated by using transmission electron microscope (TEM). It is found that increasing rolling reduction is conducive to the uniform distribution and refinement of the YAl{sub 2} particles. The rolling deformation promoted the precipitation of an α phase, and the α precipitate is semi-coherent to the matrix with an orientation relationship to the β matrix as: (0002){sub α}‖(110){sub β}. In addition, many nano-sized YAl particles with a cubic shape were foundmore » in the matrix of the composite with a high rolling reduction due to the diffusion of Y from YAl{sub 2} to the matrix, which reacted with the Al in the matrix during warm rolling. - Highlights: • The reinforcement YAl{sub 2} particles were distributed more uniformly in the matrix and refined with increasing rolling reduction. • The rolling deformation promoted and refined the precipitation of an α phase with increasing rolling reduction. • Many nano-sized YAl phases were produced and distributed in the matrix of the composite at a high rolling reduction.« less

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.

Micro-mechanisms of Surface Defects Induced on Aluminum Alloys during Plastic Deformation at Elevated Temperatures

NASA Astrophysics Data System (ADS)

Gali, Olufisayo A.

Near-surface deformed layers developed on aluminum alloys significantly influence the corrosion and tribological behavior as well as reduce the surface quality of the rolled aluminum. The evolution of the near-surface microstructures induced on magnesium containing aluminum alloys during thermomechanical processing has been investigated with the aim generating an understanding of the influence of individual forming parameters on its evolution and examine the microstructure of the roll coating induced on the mating steel roll through material transfer during rolling. The micro-mechanisms related to the various features of near-surface microstructure developed during tribological conditions of the simulated hot rolling process were identified. Thermomechanical processing experiments were performed with the aid of hot rolling (operating temperature: 550 to 460 °C, 4, 10 and 20 rolling pass schedules) and hot forming (operating temperature: 350 to 545 °C, strain rate: 4 x 10-2 s-1) tribo-simulators. The surface, near-surface features and material transfer induced during the elevated temperature plastic deformation were examined and characterized employing optical interferometry, SEM/EDS, FIB and TEM. Near-surface features characterized on the rolled aluminum alloys included; cracks, fractured intermetallic particles, aluminum nano-particles, oxide decorated grain boundaries, rolled-in oxides, shingles and blisters. These features were related to various individual rolling parameters which included, the work roll roughness, which induced the formation of shingles, rolling marks and were responsible for the redistribution of surface oxide and the enhancements of the depth of the near-surface damage. The enhanced stresses and strains experienced during rolling were related to the formation and propagation of cracks, the nanocrystalline structure of the near-surface layers and aluminum nano-particles. The mechanism of the evolution of the near-surface microstructure were determined to include grain boundary sliding which induced the cracks at the surface and subsurface of the alloy, magnesium diffusion to free surfaces, crack propagation from shear stresses and the shear strains inducing the nanocrystalline grain structure, the formation of shingles by the shear deformation of micro-wedges induced by the work roll grooves, and the deformation of this oxide covered micro-wedges inducing the rolled-in oxides. Magnesium diffusion to free surfaces was identified as inducing crack healing due to the formation of MgO within cracks and was responsible for the oxide decorated grain boundaries. An examination of the roll coating revealed a complex layered microstructure that was induced through tribo-chemical and mechanical entrapment mechanisms. The microstructure of the roll coating suggested that the work roll material and the rolled aluminum alloy were essential in determining its composition and structure. Subsequent hot forming processes revealed the rich oxide-layer of the near-surface microstructure was beneficial for reducing the coefficient of friction during tribological contact with the steel die. Damage to the microstructure include cracks induced from grain boundary sliding of near-surface grains and the formation of oxide fibres within cracks of the near-surface deformed layers.

Enhanced Mechanical Properties of 316L Stainless Steel Prepared by Aluminothermic Reaction Subjected to Multiple Warm Rolling

NASA Astrophysics Data System (ADS)

Li, Z. N.; Wei, F. A.; La, P. Q.; Ma, F. L.

2018-05-01

Large dimensional bulk 316L stainless steels were prepared by aluminothermic reaction method and rolled at 973 K (700 °C) with different deformation, the microstructures evolution and mechanical properties were characterized in detail. The results showed that the microstructure of casting steel consists of nanocrystalline/submicrocrystalline/microcrystalline austenite and submicrocrystalline ferrite. After rolling to thickness reduction of 30, 50 and 70%, the submicrocrystalline austenite grains were crushed and dispersed more uniformly in the matrix of the steel, the grain size of submicrocrystalline austenite decreased from 246 to 136 nm. The mechanical properties of the rolled steels were significantly enhanced, with the thickness reduction increased from 30 to 70%, the tensile strength increased from 632 to 824 MPa, the yield strength increased from 425 to 615 MPa, and the elongation increased from 11 to 24%. After rolling to thickness reduction of 70%, the optimized combination of high strength and high ductility was obtained.

[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.

40 CFR 63.5840 - By what date must I conduct a performance test or other initial compliance demonstration?

Code of Federal Regulations, 2011 CFR

2011-07-01

.... Open molding and centrifugal casting operations that elect to meet an organic HAP emissions limit on a 12-month rolling average must initiate collection of the required data on the compliance date, and...

40 CFR 63.5840 - By what date must I conduct a performance test or other initial compliance demonstration?

Code of Federal Regulations, 2010 CFR

2010-07-01

.... Open molding and centrifugal casting operations that elect to meet an organic HAP emissions limit on a 12-month rolling average must initiate collection of the required data on the compliance date, and...

40 CFR 63.5840 - By what date must I conduct a performance test or other initial compliance demonstration?

Code of Federal Regulations, 2013 CFR

2013-07-01

.... Open molding and centrifugal casting operations that elect to meet an organic HAP emissions limit on a 12-month rolling average must initiate collection of the required data on the compliance date, and...

40 CFR 63.5840 - By what date must I conduct a performance test or other initial compliance demonstration?

Code of Federal Regulations, 2014 CFR

2014-07-01

.... Open molding and centrifugal casting operations that elect to meet an organic HAP emissions limit on a 12-month rolling average must initiate collection of the required data on the compliance date, and...

Roll type conducting polymer legs for rigid-flexible thermoelectric generator

NASA Astrophysics Data System (ADS)

Park, Teahoon; Lim, Hanwhuy; Hwang, Jong Un; Na, Jongbeom; Lee, Hyunki; Kim, Eunkyoung

2017-07-01

A roll-type conducting polymer film was explored as a flexible organic p-type thermoelectric leg using poly(3,4-ethylenedioxythiophene) (PEDOT) doped with tosylate. The PEDOT films were prepared through solution casting polymerization and rolled up for a roll-type leg. Due to the high flexibility, the roll-type PEDOT leg enabled easy contact to both top and bottom electrodes. Simulation on the dynamic heat transfer and convective cooling for a vertically roosted rod- and roll-type PEDOT leg showed that the temperature difference (ΔT) between the hot and cold sides of the leg was much higher in the roll than that of the rod. The PEDOT legs were integrated with n-type Bi2Te3 blocks, to give a 36-couple rigid-flexible thermoelectric generator (RF-TEG). The maximum output voltage from the 36-couple RF-TEG under a ΔT of 7.9 K was determined as 36.7 mV along with a high output power of 115 nW. A wearable RF-TEG was prepared upon the combination of the 36-couple RF-TEG with an arm warmer, to afford an output voltage of 10.6 mV, which was generated constantly and steadily from human wrist heat.

Physical properties of monolithic U8 wt.%-Mo

NASA Astrophysics Data System (ADS)

Hengstler, R. M.; Beck, L.; Breitkreutz, H.; Jarousse, C.; Jungwirth, R.; Petry, W.; Schmid, W.; Schneider, J.; Wieschalla, N.

2010-07-01

As a possible high density fuel for research reactors, monolithic U8 wt.%-Mo ("U8Mo") was examined with regard to its structural, thermal and electric properties. X-ray diffraction by the Bragg-Brentano method was used to reveal the tetragonal lattice structure of rolled U8Mo. The specific heat capacity of cast U8Mo was determined by differential scanning calorimetry, its thermal diffusivity was measured by the laser flash method and its mass density by Archimedes' principle. From these results, the thermal conductivity of U8Mo in the temperature range from 40 °C to 250 °C was calculated; in the measured temperature range, it is in good accordance with literature data for UMo with 8 and 9 wt.% Mo, is higher than for 10 wt.% Mo and lower than for 5 wt.% Mo. The electric conductivity of rolled and cast U8Mo was measured by a four-wire method and the electron based part of the thermal conductivity calculated by the Wiedemann-Frantz law. Rolled and cast U8Mo was irradiated at about 150 °C with 80 MeV 127I ions to receive the same iodine ion density in the damage peak region as the fission product density in the fuel of a typical high flux reactor after the targeted nuclear burn-up. XRD analysis of irradiated U8Mo showed a change of the lattice parameters as well as the creation of UO 2 in the superficial sample regions; however, a phase change by irradiation was not observed. The determination of the electron based part of the thermal conductivity of the irradiated samples failed due to high measurement errors which are caused by the low thickness of the damage region in the ion irradiated samples.

Physical metallurgy of BATMAN II Ti-bearing martensitic steels

NASA Astrophysics Data System (ADS)

Pilloni, L.; Attura, F.; Calza-Bini, A.; De Santis, G.; Filacchioni, G.; Carosi, A.; Amato, S.

1998-10-01

Seven laboratory experimental casts of 7-9% Cr Ti-bearing martensitic steels were obtained via VIM process. Plates of 25 mm thickness were produced by hot rolling. On each cast CCT diagrams and critical temperatures were determined. Several austenitizing treatments were performed to study the grain size evolution. The effect of microstructure on impact properties were finally investigated. This paper discusses the role of chemical composition on microstructural and physical properties and shows the beneficial effect either of low-temperature austenitizing or double-austenitizing steps on impact properties.

Enhancing Manufacturing Process Education via Computer Simulation and Visualization

ERIC Educational Resources Information Center

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

2014-01-01

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

Aluminum and its light alloys

NASA Technical Reports Server (NTRS)

Merica, Paul D

1920-01-01

Report is a summary of research work which has been done here and abroad on the constitution and mechanical properties of the various alloy systems with aluminum. The mechanical properties and compositions of commercial light alloys for casting, forging, or rolling, obtainable in this country are described.

Microstructure evolution and texture development of hot form-quench (HFQ) AZ31 twin roll cast (TRC) magnesium alloy

NASA Astrophysics Data System (ADS)

Alias, J.; Zhou, X.; Das, Sanjeev; El-Fakir, Omer; Thompson, G. E.

2017-12-01

The present study on the microstructure evolution of hot form-quench (HFQ) AZ31 twin roll cast magnesium alloy attempt to provide an understanding on the grain structure and heterogeneous intermetallic phase formation in the alloy and texture development following the HFQ process. Grain recrystallization and partial dissolution of eutectic β-Mg17Al12 phase particles were occurred during the solution heat treatment at 450°C, leaving the alloy consists of recrystallized grains and discontinuous or random β-Mg17Al12 phase particles distribution with small volume fraction. The particles act as effective nucleation sites for new grains during recrystallization and variation of recrystallization occurrence contributed to texture alteration. The partial or full β-Mg17Al12 phase dissolution following the HFQ induces void formation that act as fracture nucleation site and the corresponding texture alteration in the recrystallized grains led to poor formability in TRC alloy.

The perception of 3-D shape from shadows cast onto curved surfaces.

PubMed

Norman, J Farley; Lee, Young-lim; Phillips, Flip; Norman, Hideko F; Jennings, L RaShae; McBride, T Ryan

2009-05-01

In a natural environment, cast shadows abound. Objects cast shadows both upon themselves and upon background surfaces. Previous research on the perception of 3-D shape from cast shadows has only examined the informativeness of shadows cast upon flat background surfaces. In outdoor environments, however, background surfaces often possess significant curvature (large rocks, trees, hills, etc.), and this background curvature distorts the shape of cast shadows. The purpose of this study was to determine the extent to which observers can "discount" the distorting effects of curved background surfaces. In our experiments, observers viewed deforming or static shadows of naturally shaped objects, which were cast upon flat and curved background surfaces. The results showed that the discrimination of 3-D object shape from cast shadows was generally invariant over the distortions produced by hemispherical background surfaces. The observers often had difficulty, however, in identifying the shadows cast onto saddle-shaped background surfaces. The variations in curvature which occur in different directions on saddle-shaped background surfaces cause shadow distortions that lead to difficulties in object recognition and discrimination.

Preparation of functional layers for anode-supported solid oxide fuel cells by the reverse roll coating process

NASA Astrophysics Data System (ADS)

Mücke, R.; Büchler, O.; Bram, M.; Leonide, A.; Ivers-Tiffée, E.; Buchkremer, H. P.

The roll coating technique represents a novel method for applying functional layers to solid oxide fuel cells (SOFCs). This fast process is already used for mass production in other branches of industry and offers a high degree of automation. It was utilized for coating specially developed anode (NiO + 8YSZ, 8YSZ: 8 mol% yttria-stabilized zirconia) and electrolyte (8YSZ) suspensions on green and pre-sintered tape-cast anode supports (NiO + 8YSZ). The layers formed were co-fired in a single step at 1400 °C for 5 h. As a result, the electrolyte exhibited a thickness of 14-18 μm and sufficient gas tightness. Complete cells with a screen-printed and sintered La 0.65Sr 0.3MnO 3- δ (LSM)/8YSZ cathode yielded a current density of 0.9-1.1 A cm -2 at 800 °C and 0.7 V, which is lower than the performance of non-co-fired slip-cast or screen-printed Jülich standard cells with thinner anode and electrolyte layers. The contribution of the cell components to the total area-specific resistance (ASR) was calculated by analyzing the distribution function of the relaxation times (DRTs) of measured electrochemical impedance spectra (EIS) and indicates the potential improvement in the cell performance achievable by reducing the thickness of the roll-coated layers. The results show that the anode-supported planar half-cells can be fabricated cost-effectively by combining roll coating with subsequent co-firing.

Dimensional accuracy and surface property of titanium casting using gypsum-bonded alumina investment.

PubMed

Yan, Min; Takahashi, Hidekazu; Nishimura, Fumio

2004-12-01

The aim of the present study was to evaluate the dimensional accuracy and surface property of titanium casting obtained using a gypsum-bonded alumina investment. The experimental gypsum-bonded alumina investment with 20 mass% gypsum content mixed with 2 mass% potassium sulfate was used for five cp titanium castings and three Cu-Zn alloy castings. The accuracy, surface roughness (Ra), and reaction layer thickness of these castings were investigated. The accuracy of the castings obtained from the experimental investment ranged from -0.04 to 0.23%, while surface roughness (Ra) ranged from 7.6 to 10.3microm. A reaction layer of about 150 microm thickness under the titanium casting surface was observed. These results suggested that the titanium casting obtained using the experimental investment was acceptable. Although the reaction layer was thin, surface roughness should be improved.

78 FR 58518 - Notification of Proposed Production Activity; Benteler Automotive Corporation (Automotive...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-09-24

.... On its domestic sales, Benteler would be able to choose the duty rate during customs entry procedures...: Metal stampings (crash cans, reinforcement plates, flange plates); bumper beams; toe hooks; cross member shells; side tubes; steel blanks; brackets; gussets; closing plates; castings of aluminum; flat-rolled...

Effect of Annealing on Mechanical Properties and Formability of Cold Rolled Thin Sheets of Fe-P P/M Alloys

NASA Astrophysics Data System (ADS)

Trivedi, Shefali; Ravi Kumar, D.; Aravindan, S.

2016-10-01

Phosphorus in steel is known to increase strength and hardness and decrease ductility. Higher phosphorus content (more than 0.05%), however, promotes brittle behavior due to segregation of Fe3P along the grain boundaries which makes further mechanical working of these alloys difficult. In this work, thin sheets of Fe-P alloys (with phosphorus in range of 0.1-0.35%) have been developed through processing by powder metallurgy followed by hot rolling and cold rolling. The effect of phosphorus content and annealing parameters (temperature and time) on microstructure, mechanical properties, formability in biaxial stretching and fracture behavior of the cold rolled and annealed sheets has been studied. A comparison has also been made between the properties of the sheets made through P/M route and the conventional cast route with similar phosphorus content. It has been shown that thin sheets of Fe-P alloys with phosphorous up to 0.35% possessing a good combination of strength and formability can be produced through rolling of billets of these alloys made through powder metallurgy technique without the problem of segregation.

Manufacturing Demonstration Facility: Roll-to-Roll Processing

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

Datskos, Panos G; Joshi, Pooran C; List III, Frederick Alyious

This Manufacturing Demonstration Facility (MDF)e roll-to-roll processing effort described in this report provided an excellent opportunity to investigate a number of advanced manufacturing approaches to achieve a path for low cost devices and sensors. Critical to this effort is the ability to deposit thin films at low temperatures using nanomaterials derived from nanofermentation. The overarching goal of this project was to develop roll-to-roll manufacturing processes of thin film deposition on low-cost flexible substrates for electronics and sensor applications. This project utilized ORNL s unique Pulse Thermal Processing (PTP) technologies coupled with non-vacuum low temperature deposition techniques, ORNL s clean roommore » facility, slot dye coating, drop casting, spin coating, screen printing and several other equipment including a Dimatix ink jet printer and a large-scale Kyocera ink jet printer. The roll-to-roll processing project had three main tasks: 1) develop and demonstrate zinc-Zn based opto-electronic sensors using low cost nanoparticulate structures manufactured in a related MDF Project using nanofermentation techniques, 2) evaluate the use of silver based conductive inks developed by project partner NovaCentrix for electronic device fabrication, and 3) demonstrate a suite of low cost printed sensors developed using non-vacuum deposition techniques which involved the integration of metal and semiconductor layers to establish a diverse sensor platform technology.« less

Copper foils with gradient structure in thickness direction and different roughnesses on two surfaces fabricated by double rolling

NASA Astrophysics Data System (ADS)

Wang, Xi-yong; Liu, Xue-feng; Zou, Wen-jiang; Xie, Jian-xin

2013-12-01

Copper foils with gradient structure in thickness direction and different roughnesses on two surfaces were fabricated by double rolling. The two surface morphologies of double-rolled copper foils are quite different, and the surface roughness values are 61 and 1095 nm, respectively. The roughness value of matt surface can meet the requirement for bonding the resin matrix with copper foils used for flexible printed circuit boards, thus may omit traditional roughening treatment; the microstructure of double-rolled copper foils demonstrates an obviously asymmetric gradient feature. From bright surface to matt surface in thickness direction, the average grain size first increases from 2.3 to 7.4 μm and then decreases to 3.6 μm; compared with conventional rolled copper foils, the double-rolled copper foils exhibit a remarkably increased bending fatigue life, and the increased range is about 16.2%.

A model for investigating the influence of road surface texture and tyre tread pattern on rolling resistance

NASA Astrophysics Data System (ADS)

Hoever, Carsten; Kropp, Wolfgang

2015-09-01

The reduction of rolling resistance is essential for a more environmentally friendly road transportation sector. Both tyre and road design can be utilised to reduce rolling resistance. In both cases a reliable simulation tool is needed which is able to quantify the influence of design parameters on the rolling resistance of a tyre rolling on a specific road surface. In this work a previously developed tyre/road interaction model is extended to account for different tread patterns and for losses due to small-scale tread deformation. Calculated contact forces and tyre vibrations for tyre/road interaction under steady-state rolling are used to predict rolling losses in the tyre. Rolling resistance is calculated for a series of different tyre/road combinations. Results are compared with rolling resistance measurements. The agreement between simulations and measurements is generally very good. It is found that both the tyre structure and small-scale tread deformations contribute to the rolling losses. The small-scale contribution depends mainly on the road roughness profile. The mean profile depth of the road surface is identified to correlate very well with the rolling resistance. Additional calculations are performed for non-traditional rubberised road surfaces, however, with mixed results. This possibly indicates the existence of additional loss mechanisms for these surfaces.

MULTIPLE SETS OF TWIN SLABS ON THE RUN OUT. THE ...

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

MULTIPLE SETS OF TWIN SLABS ON THE RUN OUT. THE RUN OUT INCLUDES THE TRAVELING TORCH WHICH CUTS SLABS TO DESIRED LENGTH, AN IDENTIFICATION SYSTEM TO INDICATE HEAT NUMBER AND TRACE IDENTITY OF EVERY SLAB, AND A DEBURRING DEVICE TO SMOOTH SLABS. AT LEFT OF ROLLS IS THE DUMMY BAR. DUMMY BAR IS INSERTED UP THROUGH CONTAINMENT SECTION INTO MOLD PRIOR TO START OF CAST. WHEN STEEL IS INTRODUCED INTO MOLD IT CONNECTS WITH BAR AS CAST BEGINS, AT RUN OUT DUMMY BAR DISCONNECTS AND IS STORED. - U.S. Steel, Fairfield Works, Continuous Caster, Fairfield, Jefferson County, AL

MULTIPLE SETS OF TWIN SLABS ON THE RUN OUT. THE ...

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

MULTIPLE SETS OF TWIN SLABS ON THE RUN OUT. THE RUN OUT INCLUDES THE TRAVELING TORCH WHICH CUTS SLABS TO DESIRED LENGTH, AN IDENTIFICATION SYSTEM TO INDICATE HEAT NUMBER AND TRACE IDENTITY OF EVERY SLAB, AND A DEBURRING DEVICE TO SMOOTH SLABS. AT LEFT OF ROLLS IS THE DUMMY BAR. DUMMY BAR IS INSERTED UP THROUGH CONTAINMENT SECTION INTO MOLD PRIOR TO START OF CAST. WHEN STEEL IS INTRODUCED INTO MOLD IT CONNECTS WITH BAR AS CAST BEGINS, AT RUN OUT DUMMY BAR DISCONNECTS AND IS STORED - U.S. Steel, Fairfield Works, Continuous Caster, Fairfield, Jefferson County, AL

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

PubMed

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

1999-03-01

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

Unsteady surface pressure measurements on a slender delta wing undergoing limit cycle wing rock

NASA Technical Reports Server (NTRS)

Arena, Andrew S., Jr.; Nelson, Robert C.

1991-01-01

An experimental investigation of slender wing limit cycle motion known as wing rock was investigated using two unique experimental systems. Dynamic roll moment measurements and visualization data on the leading edge vortices were obtained using a free to roll apparatus that incorporates an airbearing spindle. In addition, both static and unsteady surface pressure data was measured on the top and bottom surfaces of the model. To obtain the unsteady surface pressure data a new computer controller drive system was developed to accurately reproduce the free to roll time history motions. The data from these experiments include, roll angle time histories, vortex trajectory data on the position of the vortices relative to the model's surface, and surface pressure measurements as a function of roll angle when the model is stationary or undergoing a wing rock motion. The roll time history data was numerically differentiated to determine the dynamic roll moment coefficient. An analysis of these data revealed that the primary mechanism for the limit cycle behavior was a time lag in the position of the vortices normal to the wing surface.

The Role of Nano-TiO2 Lubricating Fluid on the Hot Rolled Surface and Metallographic Structure of SS41 Steel

PubMed Central

Meng, Yanan; Sun, Jianlin; Wu, Ping; Dong, Chang; Yan, Xudong

2018-01-01

In this paper, nano-TiO2lubricating fluid was chosen as an advanced rolling lubricant to investigate its effect on the hot rolled surface and metallographic structure of SS41 steel strips. The tribological performances of nano-TiO2 lubricating fluid were measured by a four-ball tribotester. The hot rolling experiments under different lubrication conditions were carried out by a four-high rolling mill. The surface morphology, oxide scales and metallographic structure after hot rolling were observed using a confocal laser scanning microscope and scanning electron microscope (SEM), respectively. The composition of surface attachments was analyzed with X-ray photoelectron spectroscopy (XPS). The results indicate that the nano-TiO2 lubricating fluid has a better tribological performance. The surface defects on the hot rolled surface could be decreased. The phase composition of the surface still appears as a mixture of ferrite and pearlite. The surface of steel strips is not micro-alloyed with titanium as predicted. Additionally, the grain size of rolled steel strips which were lubricated with the nano-TiO2lubricating fluid decreased by nearly 50%, compared with traditional lubricating fluid. Furthermore, it was found that the thickness of the oxide layers on the surface reduced, whilst the Rockwell hardness of the oxide layers was enhanced as nano-TiO2 lubricating fluid was applied. PMID:29462937

The Role of Nano-TiO2 Lubricating Fluid on the Hot Rolled Surface and Metallographic Structure of SS41 Steel.

PubMed

Meng, Yanan; Sun, Jianlin; Wu, Ping; Dong, Chang; Yan, Xudong

2018-02-16

In this paper, nano-TiO2lubricating fluid was chosen as an advanced rolling lubricant to investigate its effect on the hot rolled surface and metallographic structure of SS41 steel strips. The tribological performances of nano-TiO2 lubricating fluid were measured by a four-ball tribotester. The hot rolling experiments under different lubrication conditions were carried out by a four-high rolling mill. The surface morphology, oxide scales and metallographic structure after hot rolling were observed using a confocal laser scanning microscope and scanning electron microscope (SEM), respectively. The composition of surface attachments was analyzed with X-ray photoelectron spectroscopy (XPS). The results indicate that the nano-TiO2 lubricating fluid has a better tribological performance. The surface defects on the hot rolled surface could be decreased. The phase composition of the surface still appears as a mixture of ferrite and pearlite. The surface of steel strips is not micro-alloyed with titanium as predicted. Additionally, the grain size of rolled steel strips which were lubricated with the nano-TiO2lubricating fluid decreased by nearly 50%, compared with traditional lubricating fluid. Furthermore, it was found that the thickness of the oxide layers on the surface reduced, whilst the Rockwell hardness of the oxide layers was enhanced as nano-TiO2 lubricating fluid was applied.

On the Influence of Surface Heterogeneities onto Roll Convection

NASA Astrophysics Data System (ADS)

Gryschka, M.; Drüe, C.; Raasch, S.; Etling, D.

2009-04-01

Roll convection is a common phenomenon in atmospheric convective boundary layers (CBL) with background wind. Roll convection is observed both over land and over sea for different synoptic situations. There is still some debate about the different types of roll convection and their causes or rather the necessary conditions for their appearance. The stability parameter ζ = -zi•L (zi: boundary layer height, L: Monin-Obukhov stability length) is widely used as a predictor for roll convection, since numerous studies suggest that convective rolls only appear when 0 < ζ < 20. In other words, roll development becomes unlikely for strong surface heating and weak vertical wind shear. In contrast to those studies the presence of roll convection in almost any polar cold air outbreak (as can be seen in numerous satellite images as cloud streets) reveals that even for large ζ roll convection can develop. Some studies report roll convection in cold air outbreaks for ζ = 250. Our large eddy simulations (LES) on roll convection suggests that the contrasting results concerning the dependency of roll convection on ζ are due to two different types of roll convection: One type which develops purely by self organization if ζ < 20 ("free rolls") and another type which is triggered by heterogeneities in surface temperature and develops also for large ζ ("forced rolls"). We think that most of the cloud streets observed in polar cold air outbreaks over open water are due to rolls of forced type which are tied to upstream located heterogeneities in the sea-ice distribution. The results of this study suggests that the omission of surface inhomogeneities in previous LES is the reason for the absence of rolls in all LES with strong surface heating and weak vertical wind shear so far. In this contribution we will present a large eddy simulation which successfully represents forced rolls under such conditions.

LANL Experience Rolling Zr-Clad LEU-10Mo Foils for AFIP-7

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

Hammon, Duncan L.; Clarke, Kester D.; Alexander, David J.

2015-05-29

The cleaning, canning, rolling and final trimming of Low Enriched Uranium-10 wt. pct. Molybdenum (LEU-10Mo) foils for ATR (Advanced Test Reactor) fuel plates to be used in the AFIP-7 (ATR Full Size Plate In Center Flux Trap Position) experiments are summarized. Six Zr-clad foils were produced from two LEU-10Mo castings supplied to Los Alamos National Laboratory (LANL) by Y-12 National Security Complex. Details of cleaning and canning procedures are provided. Hot- and cold-rolling results are presented, including rolling schedules, images of foils in-process, metallography and local compositions of regions of interest, and details of final foil dimensions and process yield.more » This report was compiled from the slides for the presentation of the same name given by Duncan Hammon on May 12, 2011 at the AFIP-7 Lessons Learned meeting in Salt Lake City, UT, with Los Alamos National Laboratory document number LA-UR 11-02898.« less

Effect of microstructure and surface features on wetting angle of a Fe-3.2 wt%C.E. cast iron with water

NASA Astrophysics Data System (ADS)

Riahi, Samira; Niroumand, Behzad; Dorri Moghadam, Afsaneh; Rohatgi, Pradeep K.

2018-05-01

In the present study, variation in surface wetting behavior of a hypoeutectic cast iron with its microstructural features and surface roughness was investigated. Samples with an identical composition, i.e. Fe-3.2 wt%C.E., and different microstructures (a gray cast iron with A-type flake graphite and a white cast iron) were fabricated by gravity casting of molten cast iron in a chill mold at different cooling rates. A variation of surface roughness was also developed by polishing, a four-stage electroetching and a four-stage mechanical abrading on the samples. Roughness and water contact angles of all surfaces were then measured. The surface roughness factor and the solid fraction in contact with water by the Wenzel and Cassie-Baxter contact models were also calculated and compared with the corresponding measured contact angles to find out which regime was active. Results indicated that the surface microstructure and the type of constituents present at the surface influenced the cast iron surface wettability and that it was possible to change the surface contact angle by modification of the surface microstructure. The mechanically abraded gray cast iron followed the Wenzel-type regime while the electroetched surfaces of gray cast iron exhibited a transition from Wenzel to Cassie-Baxter type regime. In white cast iron, the results indicated Wenzel type behavior in the electroetched samples while for the mechanically abraded samples, none of these two models could predict the wetting behavior. Furthermore, the wetting angles of both gray and white cast irons were measured after 1, 2, 3 and 4 weeks of air exposure. The results showed that the wetting angles of both samples increased to above 90° after one week of air exposure which was likely due to adsorption of low surface energy hydrocarbons on the surfaces.

Development and Technology of Large Thickness TMCP Steel Plate with 390MPA Grade Used for Engineering Machinery

NASA Astrophysics Data System (ADS)

Wang, Xiaoshu; Zhang, Zhijun; Zhang, Peng

Recently, with the rapid upgrading of the equipment in the steel Corp, the rolling technology of TMCP has been rapidly developed and widely applied. A large amount of steel plate has been produced by using the TMCP technology. The TMCP processes have been used more and more widely and replaced the heat treatment technology of normalizing, quenching and tempering heat process. In this paper, low financial input is considered in steel plate production and the composition of the steel has been designed with low C component, a limited alloy element of the Nb, and certain amounts of Mn element. During the continuous casting process, the size of the continuous casting slab section is 300 mm × 2400 mm. The rolling technology of TMCP is controlled at a lower rolling and red temperature to control the transformation of the microstructure. Four different rolling treatments are chosen to test its effects on the 390MPa grade low carbon steel of bainitic microstructure and properties. This test manages to produce a proper steel plate fulfilling the standard mechanical properties. Specifically, low carbon bainite is observed in the microstructure of the steel plate and the maximum thickness of steel plate under this TMCP technology is up to 80mm. The mechanical property of the steel plate is excellent and the KV2 at -40 °C performs more than 200 J. Moreover, the production costs are greatly reduced when the steel plate is produced by this TMCP technology when replacing the current production process of quenching and tempering. The low cost steel plate could well meet the requirements of producing engineering machinery in the steel market.

29 CFR 1910.213 - Woodworking machinery requirements.

Code of Federal Regulations, 2010 CFR

2010-07-01

... as to be free from sensible vibration when the largest size tool is mounted and run idle at full... lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be... in-running rolls at any point. The guard shall be constructed of heavy material, preferably metal...

29 CFR 1910.213 - Woodworking machinery requirements.

Code of Federal Regulations, 2013 CFR

2013-07-01

... as to be free from sensible vibration when the largest size tool is mounted and run idle at full... lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be... in-running rolls at any point. The guard shall be constructed of heavy material, preferably metal...

29 CFR 1910.213 - Woodworking machinery requirements.

Code of Federal Regulations, 2014 CFR

2014-07-01

... as to be free from sensible vibration when the largest size tool is mounted and run idle at full... lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be... in-running rolls at any point. The guard shall be constructed of heavy material, preferably metal...

29 CFR 1910.213 - Woodworking machinery requirements.

Code of Federal Regulations, 2012 CFR

2012-07-01

... as to be free from sensible vibration when the largest size tool is mounted and run idle at full... lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be... in-running rolls at any point. The guard shall be constructed of heavy material, preferably metal...

29 CFR 1910.213 - Woodworking machinery requirements.

Code of Federal Regulations, 2011 CFR

2011-07-01

... as to be free from sensible vibration when the largest size tool is mounted and run idle at full... lugs cast on the frame or with an equivalent means to limit the size of the saw blade that can be... in-running rolls at any point. The guard shall be constructed of heavy material, preferably metal...

Effects of the Strain Rate and Temperature on the Microstructural Evolution of Twin-Rolled Cast Wrought AZ31B Alloys Sheets

NASA Astrophysics Data System (ADS)

Rodriguez, A. K.; Kridli, G.; Ayoub, G.; Zbib, H.

2013-10-01

This article investigates the effects of the strain rate and temperature on the microstructural evolution of twin-rolled cast wrought AZ31B sheets. This was achieved through static heating and through tensile test performed at strain rates from 10-4 to 10-1 s-1 and temperatures between room temperature (RT) and 300 °C. While brittle fracture with high stresses and limited elongation was observed at the RT, ductile behavior was obtained at higher temperatures with low strain rates. The strain rate sensitivity and activation energy calculations indicate that grain boundary diffusion and lattice diffusion are the two rate-controlling mechanisms at warm and high temperatures, respectively. An analysis of the evolution of the microstructure provided some indications of the most probable deformation mechanisms in the material: twinning operates at lower temperatures, and dynamic recrystallization dominates at higher temperatures. The static evolution of the microstructure was also studied, proving a gradual static grain growth of the AZ31B with annealing temperature and time.

Experimental research on micro-pit defects of SUS 430 stainless steel strip in cold rolling process

NASA Astrophysics Data System (ADS)

Li, Changsheng; Li, Miao; Zhu, Tao; Huo, Gang

2013-05-01

In order to improve surface glossiness of stainless steel strip in tandem cold rolling, experimental research on micro-pit defects of SUS 430 ferrite stainless steel was investigated in laboratory. The surface morphology of micro-pit defects was observed by SEM. The effects of micro-pit defects on rolling reduction, roll surface roughness and emulsion parameters were analyzed. With the pass number increasing, the quantity and surface of micro-pit defects were reduced, uneven peak was decreased and gently along rolling direction, micro-pit defects had equally distributed tendency along tranverse direction. The micro-pit defects were increased with the roll surface roughness increase. The defects ratio was declined with larger gradient at pass number 1 to 3, but gentle slope at pass number 4 to 5. The effects of temperature 55° and 63°, concentration 3% and 6% of emulsion on micro-pit effects had not obvious difference. Maintain of micro-pit was effected by rolling oil or air in the micro-pit, the quality of oil was much more than the air in the micro-pit in lubrication rolling.

Engineering nanoscale surface features to sustain microparticle rolling in flow.

PubMed

Kalasin, Surachate; Santore, Maria M

2015-05-26

Nanoscopic features of channel walls are often engineered to facilitate microfluidic transport, for instance when surface charge enables electro-osmosis or when grooves drive mixing. The dynamic or rolling adhesion of flowing microparticles on a channel wall holds potential to accomplish particle sorting or to selectively transfer reactive species or signals between the wall and flowing particles. Inspired by cell rolling under the direction of adhesion molecules called selectins, we present an engineered platform in which the rolling of flowing microparticles is sustained through the incorporation of entirely synthetic, discrete, nanoscale, attractive features into the nonadhesive (electrostatically repulsive) surface of a flow channel. Focusing on one example or type of nanoscale feature and probing the impact of broad systematic variations in surface feature loading and processing parameters, this study demonstrates how relatively flat, weakly adhesive nanoscale features, positioned with average spacings on the order of tens of nanometers, can produce sustained microparticle rolling. We further demonstrate how the rolling velocity and travel distance depend on flow and surface design. We identify classes of related surfaces that fail to support rolling and present a state space that identifies combinations of surface and processing variables corresponding to transitions between rolling, free particle motion, and arrest. Finally we identify combinations of parameters (surface length scales, particle size, flow rates) where particles can be manipulated with size-selectivity.

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

DOEpatents

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

2002-01-01

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

Mapping cell surface adhesion by rotation tracking and adhesion footprinting

NASA Astrophysics Data System (ADS)

Li, Isaac T. S.; Ha, Taekjip; Chemla, Yann R.

2017-03-01

Rolling adhesion, in which cells passively roll along surfaces under shear flow, is a critical process involved in inflammatory responses and cancer metastasis. Surface adhesion properties regulated by adhesion receptors and membrane tethers are critical in understanding cell rolling behavior. Locally, adhesion molecules are distributed at the tips of membrane tethers. However, how functional adhesion properties are globally distributed on the individual cell’s surface is unknown. Here, we developed a label-free technique to determine the spatial distribution of adhesive properties on rolling cell surfaces. Using dark-field imaging and particle tracking, we extract the rotational motion of individual rolling cells. The rotational information allows us to construct an adhesion map along the contact circumference of a single cell. To complement this approach, we also developed a fluorescent adhesion footprint assay to record the molecular adhesion events from cell rolling. Applying the combination of the two methods on human promyelocytic leukemia cells, our results surprisingly reveal that adhesion is non-uniformly distributed in patches on the cell surfaces. Our label-free adhesion mapping methods are applicable to the variety of cell types that undergo rolling adhesion and provide a quantitative picture of cell surface adhesion at the functional and molecular level.

Developing a Basal Texture with Two Peaks Tilting Towards the Transverse Direction in Hot Rolled Mg-5.7Zn-0.5Zr Plates

NASA Astrophysics Data System (ADS)

Wang, Yannan; Xin, Yunchang; Chapuis, Adrien; Yu, Huihui; Liu, Qing

2016-08-01

Rolled Mg alloys often present a basal texture with the (0002) poles slightly tilting from the normal direction (ND) towards the rolling direction. The current work systematically studies the formation of a double-peaked basal texture tilting from the ND towards the transverse direction (TD) of Mg-5.7Zn-0.5Zr (ZK60) plates hot rolled from the as-cast condition. Our results show that a basal texture forms with the two peaks obviously tilting from the ND towards the TD after rolling to reductions over 19 pct at 673 K (400 °C), but does not appear after rolling at 293 K (20 °C). The TD-tilted double peaks of basal poles disappear after annealing, developing a stronger peak of basal poles around the ND. The microstructural examination indicates that this TD-tilted basal texture mainly results from rolling deformation rather than dynamic recrystallization. Crystal plasticity simulation using the VPSC model was used to understand the effect of slips and twinning on the formation of this TD-tilted basal texture. Simulation demonstrates that, compared to prismatic slip, pyramidal slip is more efficient to generate the basal texture tilting towards the TD. The possible mechanisms affecting the activity of non-basal slips are discussed.

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.

Investigations on Heat Treatment of a High-Speed Steel Roll

NASA Astrophysics Data System (ADS)

Fu, Hanguang; Qu, Yinhu; Xing, Jiandong; Zhi, Xiaohui; Jiang, Zhiqiang; Li, Mingwei; Zhang, Yi

2008-08-01

High-carbon high-speed steels (HSS) are very abrasion-resistant materials primarily due to their high hardness MC-type carbide and high hardness martensitic matrix. The effects of quenching and tempering treatment on the microstructure, mechanical properties, and abrasion resistance of centrifugal casting high-carbon HSS roll were studied. Different microstructures and mechanical properties were obtained after the quenching and tempering temperatures of HSS roll were changed. With air-cooling and sodium silicate solution cooling, when the austenitizing temperature reaches 1273 K, the metallic matrix all transforms into the martensite. Afterwards, the eutectic carbides dissolve into the metallic matrix and their continuous network distribution changes into the broken network. The second hardening temperature of high-carbon HSS roll is around 793 K. No significant changes in tensile strength and elongation percentage are observed unless the tempering temperature is beyond 753 K. The tensile strength increases obviously and the elongation percentage decreases slightly beyond 753 K. However, the tensile strength decreases and the elongation percentage increases when the tempering temperature exceeds 813 K. When the tempering temperature excels 773 K, the impact toughness has a slight decrease. Tempering at 793-813 K, high-carbon HSS roll presents excellent abrasion resistance.

[A surface reacted layer study of titanium-zirconium alloy after dental casting].

PubMed

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

2000-10-01

To investigate the influence of the mold temperature on the surface reacted layer of Ti-Zr alloy castings. Ti-Zr alloy was casted into a mold which was made of a zircon (ZrO2.SiO2) for inner coating and a phosphate-bonded material for outer investing with a casting machine (China) designed as vacuum, pressure and centrifuge. At three mold temperatures (room temperature, 300 degrees C, 600 degrees C) the Ti-Zr alloy was casted separately. The surface roughness of the castings was calculated by instrument of smooth finish (China). From the surface to the inner part the Knoop hardness and thickness in reacted layer of Ti-Zr alloy casting was measured. The structure of the surface reacted layer was analysed by SEM. Elemental analyses of the interfacial zone of the casting was made by element line scanning observation. The surface roughness of the castings was increased significantly with the mold temperature increasing. At a higher mold temperature the Knoop hardness of the reactive layer was increased. At the three mold temperature the outmost surface was very hard, and microhardness data decreased rapidly where they reached constant values. The thickness was about 85 microns for castings at room temperature and 300 degrees C, 105 microns for castings at 600 degrees C. From the SEM micrograph of the Ti-Zr alloy casting, the surface reacted layer could be divided into three different layers. The first layer was called non-structure layer, which thickness was about 10 microns for room temperature group, 20 microns for 300 degrees C and 25 microns for 600 degrees C. The second layer was characterized by coarse-grained acicular crystal, which thickness was about 50 microns for three mold temperatures. The third layer was Ti-Zr alloy. The element line scanning showed non-structure layer with higher level of element of O, Al, Si and Zr, The higher the mold temperature during casting, the deeper the Si permeating and in the second layer the element Si could also be found. The mold temperature is one of the major factors influencing to casting quality. In order to reduce the surface reacted layer of Ti-Zr alloy castings, the lower mold temperature and the investment without Si should be chosen.

76 FR 7810 - Certain Hot-Rolled Carbon Steel Flat Products From India: Notice of Court Decision Not in Harmony...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-02-11

... Policy (``CIP''). See Final Results, and accompanying I&D Memorandum at ``SGOC's Industrial Policy...'' or ``fourth administrative review''), which found that Essar did not benefit from the CIP, cast ``grave doubt'' upon the Department's findings that Essar benefited from the CIP during the fifth POR. See...

Manufacturing Methods for Strategic Materials Reclamation.

DTIC Science & Technology

1979-12-14

86 AIRCO Ingot N o. 4116 Casting Profile ......................................................... 199 87 Identification of Conversion of AIRCO Ingot...No. 4115 to Bar Stock .............. 201 88 6-in. RCS Billet Cutting Layout for Samples of Ingot No. 4115 Sent to P&WA 202 89 Identification of 1-in...132 31 Identification of Foreign Particles Detected in Rolled Plate .......................... 136 32 Mechanical Property Data of

Numerical Simulation of Bulging Deformation for Wide-Thick Slab Under Uneven Cooling Conditions

NASA Astrophysics Data System (ADS)

Wu, Chenhui; Ji, Cheng; Zhu, Miaoyong

2018-06-01

In the present work, the bulging deformation of a wide-thick slab under uneven cooling conditions was studied using finite element method. The non-uniform solidification was first calculated using a 2D heat transfer model. The thermal material properties were derived based on a microsegregation model, and the water flux distribution was measured and applied to calculate the cooling boundary conditions. Based on the solidification results, a 3D bulging model was established. The 2D heat transfer model was verified by the measured shell thickness and the slab surface temperature, and the 3D bulging model was verified by the calculated maximum bulging deflections using formulas. The bulging deformation behavior of the wide-thick slab under uneven cooling condition was then determined, and the effect of uneven solidification, casting speed, and roll misalignment were investigated.

Numerical Simulation of Bulging Deformation for Wide-Thick Slab Under Uneven Cooling Conditions

NASA Astrophysics Data System (ADS)

Wu, Chenhui; Ji, Cheng; Zhu, Miaoyong

2018-02-01

In the present work, the bulging deformation of a wide-thick slab under uneven cooling conditions was studied using finite element method. The non-uniform solidification was first calculated using a 2D heat transfer model. The thermal material properties were derived based on a microsegregation model, and the water flux distribution was measured and applied to calculate the cooling boundary conditions. Based on the solidification results, a 3D bulging model was established. The 2D heat transfer model was verified by the measured shell thickness and the slab surface temperature, and the 3D bulging model was verified by the calculated maximum bulging deflections using formulas. The bulging deformation behavior of the wide-thick slab under uneven cooling condition was then determined, and the effect of uneven solidification, casting speed, and roll misalignment were investigated.

The effect of thermomechanical processing on second phase particle redistribution in U-10 wt%Mo

NASA Astrophysics Data System (ADS)

Hu, Xiaohua; Wang, Xiaowo; Joshi, Vineet V.; Lavender, Curt A.

2018-03-01

The multi-pass hot-rolling process of an annealed uranium-10 wt% molybdenum (U10Mo) coupon was studied by plane-strain compression finite element modeling. As-cast U10Mo typically contains second phase particles such as uranium carbides (UC) and silicides along the grain boundaries. The volume fraction of UC is typically large, while the other phases can be redissolved in the matrix by certain heat treatments. The UC particle distribution is important due to its influence on the recrystallization processes (particle stimulated nucleation) that occur during annealing between rolling passes. Unfavorable particle distribution and fracture after rolling can affect the grain size and also influence the fuel performance in the reactor. A statistical method, i.e., the two-point correlation function (2PCF), was used to analyze the carbide particle distribution after each rolling reduction. The hot rolling simulation results show that the alignment of UC particles along grain boundaries will rotate during rolling until it is parallel to the rolling direction, to form stringer-like distributions which are typically observed in rolled products that contain inclusions. 2PCF analysis shows that the interparticle spacing shrinks along the normal direction (ND) and increases along the rolling direction (RD). The simulated particle distribution is very similar to that measured experimentally for similar rolling reductions. The magnitudes of major peaks of 2PCF along the ND decrease after large reduction. The locations of major peaks indicate the inter-stringer distances. Many more small peaks appear for the 2PCF along the RD, and this is related to the neighboring particles within stringers, which are along the RD.

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

PubMed

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

2017-01-01

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

Phase transformation kinetics in rolled U-10 wt. % Mo foil: Effect of post-rolling heat treatment and prior γ-UMo grain size

DOE PAGES

Jana, Saumyadeep; Overman, Nicole; Varga, Tamas; ...

2017-09-25

Here, the effect of sub-eutectoid heat treatment on the phase transformation behavior in rolled U-10 wt.% Mo (U10Mo) foils was systematically investigated. The as-cast 5 mm thick foils were initially homogenized at 900 °C for 48 h and were hot rolled to 2 mm and later cold rolled down to 0.2 mm. Three starting microstructures were evaluated: (i) hot + cold-rolled to 0.2 mm (as-rolled condition), (ii) hot + cold-rolled to 0.2 mm + annealed at 700 °C for 1 h, and (iii) hot + cold-rolled to 0.2 mm + annealed at 1000 °C for 60 h. Annealing of as-rolledmore » materials at 700 °C resulted in small grain size (15 ± 9 μm average grain size), while annealing at 1000 °C led to very large grains (156 ± 118 μm average grain size) in rolled U10Mo foils. Later the samples were subjected to sub-eutectoid heat-treatment temperatures of 550 °C, 500 °C, and 400 °C for different durations of time starting from 1 h up to 100 h. U10Mo rolled foils went through various degrees of decomposition when subjected to the sub-eutectoid heat-treatment step and formed a lamellar microstructure through a cellular reaction mostly along the previous γ-UMo grain boundaries. The least amount of cellular reaction was observed in the large-grain microstructure at all temperatures. Conversely, a substantial amount of cellular reaction was observed in both the as-rolled and the small-grain microstructure. After 100 h of heat treatment at 500 °C, the volume fraction of the lamellar phase was found to be 4%, 22%, and 82% in large-grain, as-rolled, and small-grain samples, respectively.« less

Phase transformation kinetics in rolled U-10 wt. % Mo foil: Effect of post-rolling heat treatment and prior γ-UMo grain size

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

Jana, Saumyadeep; Overman, Nicole; Varga, Tamas

Here, the effect of sub-eutectoid heat treatment on the phase transformation behavior in rolled U-10 wt.% Mo (U10Mo) foils was systematically investigated. The as-cast 5 mm thick foils were initially homogenized at 900 °C for 48 h and were hot rolled to 2 mm and later cold rolled down to 0.2 mm. Three starting microstructures were evaluated: (i) hot + cold-rolled to 0.2 mm (as-rolled condition), (ii) hot + cold-rolled to 0.2 mm + annealed at 700 °C for 1 h, and (iii) hot + cold-rolled to 0.2 mm + annealed at 1000 °C for 60 h. Annealing of as-rolledmore » materials at 700 °C resulted in small grain size (15 ± 9 μm average grain size), while annealing at 1000 °C led to very large grains (156 ± 118 μm average grain size) in rolled U10Mo foils. Later the samples were subjected to sub-eutectoid heat-treatment temperatures of 550 °C, 500 °C, and 400 °C for different durations of time starting from 1 h up to 100 h. U10Mo rolled foils went through various degrees of decomposition when subjected to the sub-eutectoid heat-treatment step and formed a lamellar microstructure through a cellular reaction mostly along the previous γ-UMo grain boundaries. The least amount of cellular reaction was observed in the large-grain microstructure at all temperatures. Conversely, a substantial amount of cellular reaction was observed in both the as-rolled and the small-grain microstructure. After 100 h of heat treatment at 500 °C, the volume fraction of the lamellar phase was found to be 4%, 22%, and 82% in large-grain, as-rolled, and small-grain samples, respectively.« less

Tracing the Origin of Non-ferrous Oxides in Lamination Defects on Hot-Rolled Coils: Mold Slag Entrainment vs Submerged Entry Nozzle Reaction Products

NASA Astrophysics Data System (ADS)

Sengo, Sabri; Romano Triguero, Patricia; Zinngrebe, Enno; Mensonides, Fokko

2017-06-01

In this work, lamination defects (slivers) on hot-rolled coils of Ca-treated steel were investigated for microstructure and composition using optical and scanning electron microscopy combined with microanalysis (SEM/EDS). The goal was to identify possible origins for the observed defects which contain a complex assemblage of phases, such as different types of calcium aluminates (CA, CA2, CA6), melilite (C2AS), spinel (MA), and a newly identified phase, CNA2. Mold slag similar to that employed during the cast was absent. Analysis of the bulk composition of some of the defects indicated these to be too rich in alumina to be derived from mold slag through steel-slag redox exchange. In contrast, microstructural observation of the inner side of the submerged entry nozzles (SEN) used during casting showed deposits with compositions comparable to those of the defect material. Based on an estimation of the chemical evolution of mold slag interacting with steel, it is found that the defects are not likely to be entrained mold slag but remobilized SEN deposits, as supported by several microstructural and trace phase criteria. However, it should be noted that extensive reduction of mold slag by steel can lead to compositions rich in sodic-calcic aluminates (CNA2). Therefore, differentiation between specific locations of the defect materials within a casting system requires detailed analysis from the potential sources of origin as well as from the materials found in the defects.

Modeling Production Plant Forming Processes

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

Rhee, M; Becker, R; Couch, R

2004-09-22

Engineering has simulation tools and experience in modeling forming processes. Y-12 personnel have expressed interest in validating our tools and experience against their manufacturing process activities such as rolling, casting, and forging etc. We have demonstrated numerical capabilities in a collaborative DOE/OIT project with ALCOA that is nearing successful completion. The goal was to use ALE3D to model Alcoa's slab rolling process in order to demonstrate a computational tool that would allow Alcoa to define a rolling schedule that would minimize the probability of ingot fracture, thus reducing waste and energy consumption. It is intended to lead to long-term collaborationmore » with Y-12 and perhaps involvement with other components of the weapons production complex. Using simulations to aid in design of forming processes can: decrease time to production; reduce forming trials and associated expenses; and guide development of products with greater uniformity and less scrap.« less

On the nature of low temperature internal friction peaks in metallic glasses

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

Khonik, V.A.; Spivak, L.V.

Low temperature (30 < T < 300 K) internal friction in a metallic glass Ni{sub 60}Nb{sub 40} subjected to preliminary inhomogeneous deformation by cold rolling, homogeneous tensile deformation or electrolytic charging with hydrogen is investigated. Cold rolling or hydrogenation result in appearance of similar internal friction peaks and hysteresis damping. Homogeneous deformation has no influence on low temperature internal friction. The phenomenon of microplastic deformation during hydrogenation of weakly stressed samples is revealed. It is argued that microplastic deformation of metallic glasses during hydrogenation without external stress takes place too. Plastic flow both on cold rolling and hydrogenation occurs viamore » formation and motion of dislocation-like defects which are the reason of the observed anelastic anomalies. It is concluded that low temperature internal friction peaks described in the literature for as-cast, cold deformed and hydrogenated samples have common dislocation-like origin.« less

In-Roll Stress Analysis Considering Air-Entrainment at the Roll-Inlet with the Effect of Grooves on Nip Roll Surface

NASA Astrophysics Data System (ADS)

Sasaki, Masashi; Tanimoto, Koshi; Kohno, Kazukiyo; Takahashi, Sadamu; Kometani, Hideo; Hashimoto, Hiromu

High-speed winding of paper web sometimes leads the winding system into unstable states, interlayer slippage of wound roll, paper breakage and so on, due to the excessive air-entrainment at the roll-inlet of nip contact region. These phenomena are more frequently observed on coated paper or plastic film comparing with newspaper, because the former allows little permeation of air and their surface roughness is small. Therefore, it is of vital importance to clarify the in-roll stress of wound roll considering the effect of air-entrainment. Generally, it is known that the amount of air-entrainment is affected by grooving shape of nip roll surface. In this paper, we focused on the grooving shape and investigated the relationship with the air-entrainment into two rolls being pressed each other and the grooving shape in order to achieve stable winding at high speed. We conducted experiments using small sized test machine. Entrained air-film thickness was evaluated applying the solution of the elasto-hydrodynamic lubrication for foil bearing with the consideration of nip profile at the grooved area. Air film thickness was measured to ensure the applicability of the above theory. Consequently, we found that the air film thickness can be estimated considering the effect of grooves on the nip roll surface, and that the validity of the above estimations was ensured from experimental investigations. Furthermore, it became to be able to propose the optimal shape of grooves on nip roll surface to maintain the stable winding at high speed and at large-diameter in reel.

46 CFR 170.295 - Special consideration for free surface of passive roll stabilization tanks.

Code of Federal Regulations, 2014 CFR

2014-10-01

... the moment of inertia of the free surface in the roll tank; (ii) (d) is the density of the liquid in... 46 Shipping 7 2014-10-01 2014-10-01 false Special consideration for free surface of passive roll...) SUBDIVISION AND STABILITY STABILITY REQUIREMENTS FOR ALL INSPECTED VESSELS Free Surface § 170.295 Special...

46 CFR 170.295 - Special consideration for free surface of passive roll stabilization tanks.

Code of Federal Regulations, 2012 CFR

2012-10-01

... the moment of inertia of the free surface in the roll tank; (ii) (d) is the density of the liquid in... 46 Shipping 7 2012-10-01 2012-10-01 false Special consideration for free surface of passive roll...) SUBDIVISION AND STABILITY STABILITY REQUIREMENTS FOR ALL INSPECTED VESSELS Free Surface § 170.295 Special...

46 CFR 170.295 - Special consideration for free surface of passive roll stabilization tanks.

Code of Federal Regulations, 2013 CFR

2013-10-01

... the moment of inertia of the free surface in the roll tank; (ii) (d) is the density of the liquid in... 46 Shipping 7 2013-10-01 2013-10-01 false Special consideration for free surface of passive roll...) SUBDIVISION AND STABILITY STABILITY REQUIREMENTS FOR ALL INSPECTED VESSELS Free Surface § 170.295 Special...

Experiment Research on Hot-Rolling Processing of Nonsmooth Pit Surface.

PubMed

Gu, Yun-Qing; Fan, Tian-Xing; Mou, Jie-Gang; Yu, Wei-Bo; Zhao, Gang; Wang, Evan

2016-01-01

In order to achieve the nonsmooth surface drag reduction structure on the inner polymer coating of oil and gas pipelines and improve the efficiency of pipeline transport, a structural model of the machining robot on the pipe inner coating is established. Based on machining robot, an experimental technique is applied to research embossing and coating problems of rolling-head, and then the molding process rules under different conditions of rolling temperatures speeds and depth are analyzed. Also, an orthogonal experiment analysis method is employed to analyze the different effects of hot-rolling process apparatus on the embossed pits morphology and quality of rolling. The results also reveal that elevating the rolling temperature or decreasing the rolling speed can also improve the pit structure replication rates of the polymer coating surface, and the rolling feed has little effect on replication rates. After the rolling-head separates from the polymer coating, phenomenon of rebounding and refluxing of the polymer coating occurs, which is the reason of inability of the process. A continuous hot-rolling method for processing is used in the robot and the hot-rolling process of the processing apparatus is put in a dynamics analysis.

Experiment Research on Hot-Rolling Processing of Nonsmooth Pit Surface

PubMed Central

Gu, Yun-qing; Fan, Tian-xing; Mou, Jie-gang; Yu, Wei-bo; Zhao, Gang; Wang, Evan

2016-01-01

In order to achieve the nonsmooth surface drag reduction structure on the inner polymer coating of oil and gas pipelines and improve the efficiency of pipeline transport, a structural model of the machining robot on the pipe inner coating is established. Based on machining robot, an experimental technique is applied to research embossing and coating problems of rolling-head, and then the molding process rules under different conditions of rolling temperatures speeds and depth are analyzed. Also, an orthogonal experiment analysis method is employed to analyze the different effects of hot-rolling process apparatus on the embossed pits morphology and quality of rolling. The results also reveal that elevating the rolling temperature or decreasing the rolling speed can also improve the pit structure replication rates of the polymer coating surface, and the rolling feed has little effect on replication rates. After the rolling-head separates from the polymer coating, phenomenon of rebounding and refluxing of the polymer coating occurs, which is the reason of inability of the process. A continuous hot-rolling method for processing is used in the robot and the hot-rolling process of the processing apparatus is put in a dynamics analysis. PMID:27022235

Process optimization of rolling for zincked sheet technology using response surface methodology and genetic algorithm

NASA Astrophysics Data System (ADS)

Ji, Liang-Bo; Chen, Fang

2017-07-01

Numerical simulation and intelligent optimization technology were adopted for rolling and extrusion of zincked sheet. By response surface methodology (RSM), genetic algorithm (GA) and data processing technology, an efficient optimization of process parameters for rolling of zincked sheet was investigated. The influence trend of roller gap, rolling speed and friction factor effects on reduction rate and plate shortening rate were analyzed firstly. Then a predictive response surface model for comprehensive quality index of part was created using RSM. Simulated and predicted values were compared. Through genetic algorithm method, the optimal process parameters for the forming of rolling were solved. They were verified and the optimum process parameters of rolling were obtained. It is feasible and effective.

46 CFR 170.295 - Special consideration for free surface of passive roll stabilization tanks.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 46 Shipping 7 2011-10-01 2011-10-01 false Special consideration for free surface of passive roll stabilization tanks. 170.295 Section 170.295 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED... consideration for free surface of passive roll stabilization tanks. (a) The virtual increase in the vertical...

Study of strength properties of semi-finished products from economically alloyed high-strength aluminium-scandium alloys for application in automobile transport and shipbuilding

NASA Astrophysics Data System (ADS)

Baranov, Vladimir; Sidelnikov, Sergey; Zenkin, Evgeny; Frolov, Viktor; Voroshilov, Denis; Yakivyuk, Olga; Konstantinov, Igor; Sokolov, Ruslan; Belokonova, Irina

2018-04-01

The results of a study on the strength of rolled products from aluminium alloys doped with scandium under various processing conditions of hot and cold rolling are presented. The regularities of metal flow and the level of strength of deformed semi-finished products from aluminum-scandium alloys are established, depending on the total degree of deformation and the various modes of single reduction during rolling. It is shown that when using one heating of a cast billet to obtain high-quality semi-finished products, the temperature during the rolling process should not be lower than 350-370°, and the total degree of deformation does not exceed 50-60%. It was found that the semi-finished products from alloys with a content of scandium in the range 0.11-0.12% in the deformed state had elevated values of ultimate tensile strength and yield strength of the metal, which allows them to be recommended for industrial production of sheet metal products.

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

PubMed Central

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

2017-01-01

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

The Design of 3D-Printed Lattice-Reinforced Thickness-Varying Shell Molds for Castings.

PubMed

Shangguan, Haolong; Kang, Jinwu; Yi, Jihao; Zhang, Xiaochuan; Wang, Xiang; Wang, Haibin; Huang, Tao

2018-03-30

3D printing technologies have been used gradually for the fabrication of sand molds and cores for castings, even though these molds and cores are dense structures. In this paper, a generation method for lattice-reinforced thickness-varying shell molds is proposed and presented. The first step is the discretization of the STL (Stereo Lithography) model of a casting into finite difference meshes. After this, a shell is formed by surrounding the casting with varying thickness, which is roughly proportional to the surface temperature distribution of the casting that is acquired by virtually cooling it in the environment. A regular lattice is subsequently constructed to support the shell. The outside surface of the shell and lattice in the cubic mesh format is then converted to STL format to serve as the external surface of the new shell mold. The internal surface of the new mold is the casting's surface with the normals of all of the triangles in STL format reversed. Experimental verification was performed on an Al alloy wheel hub casting. Its lattice-reinforced thickness-varying shell mold was generated by the proposed method and fabricated by the binder jetting 3D printing. The poured wheel hub casting was sound and of good surface smoothness. The cooling rate of the wheel hub casting was greatly increased due to the shell mold structure. This lattice-reinforced thickness-varying shell mold generation method is of great significance for mold design for castings to achieve cooling control.

Effect of Hot Rolling Process on Microstructure and Properties of Low-Carbon Al-Killed Steels Produced Through TSCR Technology

NASA Astrophysics Data System (ADS)

Paul, S. K.; Ahmed, U.; Megahed, G. M.

2011-10-01

Low-carbon Al-killed hot rolled strips for direct forming, cold rolling, and galvanizing applications are produced from the similar chemistry at Ezz Flat Steel (EFS) through thin slab casting and rolling (TSCR) technology. The desired mechanical and microstructural properties in hot bands for different applications are achieved through control of hot rolling parameters, which in turn control the precipitation and growth of AlN. Nitrogen in solid solution strongly influences the yield strength (YS), ductility, strain aging index (SAI), and other formability properties of steel. The equilibrium solubility of AlN in austenite at different temperatures and its isothermal precipitation have been studied. To achieve the formability properties for direct forming, soluble nitrogen is fixed as AlN by coiling the strip at higher temperatures. For stringent cold forming, boron was added below the stoichiometric ratio with nitrogen, which improved the formability properties dramatically. The requirements of hot band for processing into cold rolled and annealed deep drawing sheets are high SAI and fine-grain microstructure. Higher finish rolling and low coiling temperatures are used to achieve these. Fully processed cold rolled sheets from these hot strips at customer's end have shown good formability properties. Coil break marks observed in some coils during uncoiling were found to be associated with yielding phenomenon. The spike height (difference between upper and lower yield stresses) and yield point elongation (YPE) were found to be the key material parameters for the break marks. Factors affecting these parameters have been studied and the coiling temperature optimized to overcome the problem.

Enhancing wear resistance of working bodies of grinder through lining crushed material

NASA Astrophysics Data System (ADS)

Romanovich, A. A.; Annenko, D. M.; Romanovich, M. A.; Apukhtina, I. V.

2018-03-01

The article presents the analysis of directions of increasing wear resistance of working surfaces of rolls. A technical solution developed at the level of the invention is proposed, which is simple to implement in production conditions and which makes it possible to protect the roll surface from heavy wear due to surfacing of wear-resistant mesh material, cells of which are filling with grinding material in the process of work. Retaining them enables one to protect the roll surface from wear. The paper dwells on conditions of pressing materials in cells of eccentric rolls on the working surface with a grid of rectangular shape. The paper presents an equation for calculation of the cell dimension that provides the lining of the working surface by a mill material with respect to its properties. The article presents results of comparative studies on the grinding process of a press roller grinder (PRG) between rolls with and without a fusion-bonded mesh. It is clarified that the lining of rolls working surface slightly reduces the quality of the grinding, since the material thickness in the cell is small and has a finely divided and compacted structure with high strength.

Abrasive rolling effects on material removal and surface finish in chemical mechanical polishing analyzed by molecular dynamics simulation

NASA Astrophysics Data System (ADS)

Si, Lina; Guo, Dan; Luo, Jianbin; Lu, Xinchun; Xie, Guoxin

2011-04-01

In an abrasive chemical mechanical polishing (CMP) process, materials were considered to be removed by abrasive sliding and rolling. Abrasive sliding has been investigated by many molecular dynamics (MD) studies; while abrasive rolling was usually considered to be negligible and therefore was rarely investigated. In this paper, an MD simulation was used to study the effects of abrasive rolling on material removal and surface finish in the CMP process. As the silica particle rolled across the silicon substrate, some atoms of the substrate were dragged out from their original positions and adhered to the silica particle, leaving some atomic vacancies on the substrate surface. Meanwhile, a high quality surface could be obtained. During the abrasive rolling process, the influencing factors of material removal, e.g., external down force and driving force, were also discussed. Finally, MD simulations were carried out to examine the effects of abrasive sliding on material removal under the same external down force as abrasive rolling. The results showed that the ability of abrasive rolling to remove material on the atomic scale was not notably inferior to that of abrasive sliding. Therefore, it can be proposed that both abrasive sliding and rolling play important roles in material removal in the abrasive CMP of the silicon substrate.

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.

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

PubMed

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

2003-03-01

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

The Design of 3D-Printed Lattice-Reinforced Thickness-Varying Shell Molds for Castings

PubMed Central

Shangguan, Haolong; Kang, Jinwu; Yi, Jihao; Zhang, Xiaochuan; Wang, Xiang; Wang, Haibin; Huang, Tao

2018-01-01

3D printing technologies have been used gradually for the fabrication of sand molds and cores for castings, even though these molds and cores are dense structures. In this paper, a generation method for lattice-reinforced thickness-varying shell molds is proposed and presented. The first step is the discretization of the STL (Stereo Lithography) model of a casting into finite difference meshes. After this, a shell is formed by surrounding the casting with varying thickness, which is roughly proportional to the surface temperature distribution of the casting that is acquired by virtually cooling it in the environment. A regular lattice is subsequently constructed to support the shell. The outside surface of the shell and lattice in the cubic mesh format is then converted to STL format to serve as the external surface of the new shell mold. The internal surface of the new mold is the casting’s surface with the normals of all of the triangles in STL format reversed. Experimental verification was performed on an Al alloy wheel hub casting. Its lattice-reinforced thickness-varying shell mold was generated by the proposed method and fabricated by the binder jetting 3D printing. The poured wheel hub casting was sound and of good surface smoothness. The cooling rate of the wheel hub casting was greatly increased due to the shell mold structure. This lattice-reinforced thickness-varying shell mold generation method is of great significance for mold design for castings to achieve cooling control. PMID:29601543

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

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.

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

PubMed

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

2003-09-01

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

A method to design blended rolled edges for compact range reflectors

NASA Technical Reports Server (NTRS)

Gupta, Inder J.; Burnside, Walter D.

1989-01-01

A method to design blended rolled edges for arbitrary rim shape compact range reflectors is presented. The reflectors may be center-fed or offset-fed. The method leads to rolled edges with minimal surface discontinuities. It is shown that the reflectors designed using the prescribed method can be defined analytically using simple expressions. A procedure to obtain optimum rolled edges parameter is also presented. The procedure leads to blended rolled edges that minimize the diffracted fields emanating from the junction between the paraboloid and the rolled edge surface while satisfying certain constraints regarding the reflector size and the minimum operating frequency of the system.

A method to design blended rolled edges for compact range reflectors

NASA Technical Reports Server (NTRS)

Gupta, Inder J.; Ericksen, Kurt P.; Burnside, Walter D.

1990-01-01

A method to design blended rolled edges for arbitrary rim shape compact range reflectors is presented. The reflectors may be center-fed or offset-fed. The method leads to rolled edges with minimal surface discontinuities. It is shown that the reflectors designed using the prescribed method can be defined analytically using simple expressions. A procedure to obtain optimum rolled edges parameters is also presented. The procedure leads to blended rolled edges that minimize the diffracted fields emanating from the junction between the paraboloid and the rolled edge surface while satisfying certain constraints regarding the reflector size and the minimum operating frequency of the system.

State health insurance and out-of-pocket health expenditures in Andhra Pradesh, India.

PubMed

Fan, Victoria Y; Karan, Anup; Mahal, Ajay

2012-09-01

In 2007 the state of Andhra Pradesh in southern India began rolling out Aarogyasri health insurance to reduce catastrophic health expenditures in households 'below the poverty line'. We exploit variation in program roll-out over time and districts to evaluate the impacts of the scheme using difference-in-differences. Our results suggest that within the first nine months of implementation Phase I of Aarogyasri significantly reduced out-of-pocket inpatient expenditures and, to a lesser extent, outpatient expenditures. These results are robust to checks using quantile regression and matching methods. No clear effects on catastrophic health expenditures or medical impoverishment are seen. Aarogyasri is not benefiting scheduled caste and scheduled tribe households as much as the rest of the population.

Method and apparatus for drying web

DOEpatents

Orloff, David I.; Kloth, Gerald R.; Rudemiller, Gary R.

1992-01-01

The present invention is directed to a method and apparatus for drying a web of paper utilizing impulse drying techniques. In the method of the invention for drying a paper web, the paper web is transported through a pair of rolls wherein at least one of the rolls has been heated to an elevated temperature. The heated roll is provided with a surface having a low thermal diffusivity of less than about 1.times.10.sup.-6 m.sup.2 /s. The surface material of the roll is preferably prepared from a material selected from the group consisting of ceramics, polymers, glass, inorganic plastics, composite materials and cermets. The heated roll may be constructed entirely from the material having a low thermal diffusivity or the roll may be formed from metal, such as steel or aluminum, or other suitable material which is provided with a surface layer of a material having a low thermal diffusivity.

Fault Diagnosis for Centre Wear Fault of Roll Grinder Based on a Resonance Demodulation Scheme

NASA Astrophysics Data System (ADS)

Wang, Liming; Shao, Yimin; Yin, Lei; Yuan, Yilin; Liu, Jing

2017-05-01

Roll grinder is one of the important parts in the rolling machinery, and the grinding precision of roll surface has direct influence on the surface quality of steel strip. However, during the grinding process, the centre bears the gravity of the roll and alternating stress. Therefore, wear or spalling faults are easily observed on the centre, which will lead to an anomalous vibration of the roll grinder. In this study, a resonance demodulation scheme is proposed to detect the centre wear fault of roll grinder. Firstly, fast kurtogram method is employed to help select the sub-band filter parameters for optimal resonance demodulation. Further, the envelope spectrum are derived based on the filtered signal. Finally, two health indicators are designed to conduct the fault diagnosis for centre wear fault. The proposed scheme is assessed by analysing experimental data from a roll grinder of twenty-high rolling mill. The results show that the proposed scheme can effectively detect the centre wear fault of the roll grinder.

Investigation of the influence of the chemical composition of HSLA steel grades on the microstructure homogeneity during hot rolling in continuous rolling mills using a fast layer model

NASA Astrophysics Data System (ADS)

Schmidtchen, M.; Rimnac, A.; Warczok, P.; Kozeschnik, E.; Bernhard, C.; Bragin, S.; Kawalla, R.; Linzer, B.

2016-03-01

The newly developed LaySiMS simulation tool provides new insight for inhomogeneous material flow and microstructure evolution in an endless strip production (ESP) plant. A deepened understanding of the influence of inhomogeneities in initial material state, temperature profile and material flow and their impact on the finished product can be reached e.g. by allowing for variable layer thickness distributions in the roll gap. Coupling temperature, deformation work and work hardening/recrystallization phenomena accounts for covering important effects in the roll gap. The underlying concept of the LaySiMS approach will be outlined and new insight gained regarding microstructural evolution, shear and inhomogeneous stress and strain states in the roll gap as well as local residual stresses will be presented. For the case of thin slab casting and direct rolling (TSDR) the interrelation of inhomogeneous initial state, micro structure evolution and dissolution state of micro alloying elements within the roughing section of an ESP line will be discussed. Special emphasis is put on the influence of the local chemical composition arising from direct charging on throughthickness homogeneity of the final product. It is concluded that, due to the specific combination of large reductions in the high reduction mills (HRM) and the highly inhomogeneous inverse temperature profile, the ESP-concept provides great opportunities for homogenizing the microstructure across the strip thickness.

Burnishing rolling process of the surface prepared in the turning process

NASA Astrophysics Data System (ADS)

Kulakowska, Agnieszka; Kukielka, Leon; Kaldunski, Pawel; Bohdal, Lukasz; Patyk, Radoslaw; Chodor, Jaroslaw; Kukielka, Krzysztof

2018-05-01

The aim of this article is to demonstrate the possibility of using burnishing rolling process as the technology of product development. The experimental researches were carried out, showing the ability to form the surface layer of the product with the desired properties. First, during turning rolling the surfaces of the samples were prepared. Then, the surfaces were burnished. The influence of turning process on the state of the surface layer parameters of C45 steel shafts are shown. Among the examined aspects the surface roughness, nano-roughness, material bearing, surface microstructure, metallographic structure were considered. Numerical simulation were conducted. Conclusions from the experiments and simulation were given.

Increased compactibility of acetames after roll compaction.

PubMed

Kuntz, Theresia; Schubert, Martin A; Kleinebudde, Peter

2011-01-01

A common technique for manufacturing granules in a continuous way is the combination of roll compaction and subsequent milling. Roll compaction can considerably impact tableting performance of a material. The purpose of this study was to investigate the influence of roll compaction/dry granulation on the compaction behavior of acetames, a class of active pharmaceutical substances, which are mainly used for the treatment of central nervous diseases. Some representatives of acetames were roll compacted and then compressed into tablets. Compactibility of granules was compared with the compaction behavior of the directly compressed drug powders. In contrast to many other materials, the roll compaction step induced an increase in compactibility for all investigated acetames. Specific surface areas of the untreated and the roll compacted drugs were determined by nitrogen adsorption. The raise in compactibility observed was accompanied by an increase in specific surface area during roll compaction. Copyright © 2010 Elsevier B.V. All rights reserved.

Multilength Scale Patterning of Functional Layers by Roll-to-Roll Ultraviolet-Light-Assisted Nanoimprint Lithography.

PubMed

Leitgeb, Markus; Nees, Dieter; Ruttloff, Stephan; Palfinger, Ursula; Götz, Johannes; Liska, Robert; Belegratis, Maria R; Stadlober, Barbara

2016-05-24

Top-down fabrication of nanostructures with high throughput is still a challenge. We demonstrate the fast (>10 m/min) and continuous fabrication of multilength scale structures by roll-to-roll UV-nanoimprint lithography on a 250 mm wide web. The large-area nanopatterning is enabled by a multicomponent UV-curable resist system (JRcure) with viscous, mechanical, and surface properties that are tunable over a wide range to either allow for usage as polymer stamp material or as imprint resist. The adjustable elasticity and surface chemistry of the resist system enable multistep self-replication of structured resist layers. Decisive for defect-free UV-nanoimprinting in roll-to-roll is the minimization of the surface energies of stamp and resist, and the stepwise reduction of the stiffness from one layer to the next is essential for optimizing the reproduction fidelity especially for nanoscale features. Accordingly, we demonstrate the continuous replication of 3D nanostructures and the high-throughput fabrication of multilength scale resist structures resulting in flexible polyethylenetherephtalate film rolls with superhydrophobic properties. Moreover, a water-soluble UV-imprint resist (JRlift) is introduced that enables residue-free nanoimprinting in roll-to-roll. Thereby we could demonstrate high-throughput fabrication of metallic patterns with only 200 nm line width.

Roll-to-Roll Manufacturing of Robust Superhydrophobic Coating on Metallic Engineering Materials.

PubMed

Dong, Shuliang; Wang, Zhenlong; Wang, Yukui; Bai, Xuelin; Fu, Yong Qing; Guo, Bin; Tan, Chaoliang; Zhang, Jia; Hu, PingAn

2018-01-17

Creating a robust superhydrophobic surface on the conventional engineering materials at mass production is of great importance for a self-cleaning, anti-icing, nonwetting surface and low flow resistance in industrial applications. Herein, we report a roll-to-roll strategy to create durable and robust superhydrophobic surfaces with designed micro-/nanoscale hierarchical structures on many conventional engineering materials by combining electrical discharge machining and coating of carbon nanoparticles, followed by oil penetration and drying. The treated surface shows good superhydrophobic properties with a static water contact angle of 170 ± 2° and slide angle of 3 ± 1°. The treated surface also exhibits good resilience and maintains the performance after being tested in various harsh conditions, including water flushing for several days, sand abrasion, scratching with sandpapers, and corrosive solution. Significantly, the superhydrophobic surfaces also show a high efficiency of self-cleaning properties even after oil contamination during applications.

Casting technology for manufacturing metal rods from simulated metallic spent fuels

NASA Astrophysics Data System (ADS)

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

2000-09-01

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

Vortex Simulation of Turbulent Combustion

DTIC Science & Technology

1992-11-19

used in this simulation was more representative of that of a wake . The difference between the stability and long-time behavior of wakes and shear...several important issues, summarized next, cast some doubt on the conclusions of these simulations. Using desingularized vortex sheets to model shear...17, 1991. 8. Krishnan, A. and Ghoniem, A.F., "Simulation of the Roll-up and Mixing in Rayleigh- Taylor Flow using the Vortex /Transport Element Method

Neponset River Basin Massachusetts, Flood Plain Management Study.

DTIC Science & Technology

1982-03-01

extensive water power. There are in the southern village, two rolling mills, for the manufacture of copper bolts and sheathing, on a large scale; two...furnaces for refining copper , and casting bells and brass cannon (operated by Paul Revere): forges and furnaces for the manufacture of iron wheels and...Dedha Granodiorite, Westwood Granite, Sharon Syenite, and Blue Rills Granite Porphyry . Crushed Stone. The Mattapan Volcanic Complex and Westwood

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.

Mimicking the Interfacial Dynamics of Flowing White Blood Cells

NASA Astrophysics Data System (ADS)

Santore, Maria

2015-03-01

The rolling of particles on surfaces, facilitated by hydrodynamic forces combined with localized surface interactions of the appropriate strengths, spatial arrangements, and ranges, is a technologically useful means of transporting and manipulating particles. One's intuition for the rolling of a marble or a car tire cannot be extrapolated down to microparticle length scales because the microparticle interactions are dominated by electrostatic, van der Waals, and hydrogen bonding interactions rather than a friction that depends on an imposed normal force. Indeed, our microparticle rolling systems are inspired by the rolling of white blood cells on the inner walls of venules as part of the innate immune response: Selectin molecules engage with their counterparts on the opposing surfaces to slow cell motion relative to that for freely flowing cells. In the resulting rolling signature, ligand-receptor binding and crack closing on the front of the cell are balanced with molecular dis-bonding and crack opening at the rear. The contact region is relatively static, allowing other interactions (for instance signaling) to occur for a finite duration. Thus, achieving particle rolling in synthetic systems is important because it facilitates particle-surface interactions in a continuous nonfouling fashion where the contact surface is continually renewed. In developing a synthetic model for this system, we employ polymers to modify flowing particles and /or planar collectors, producing heterogeneous interfaces which can support rolling or produce other motion signatures such as skipping, arrest, or free flow. We identify, in the synthetic system, combinations of variables that produce rolling and demonstrate how the distinction between rolling and arrest is not a simple matter of the adhesion strength between the particles and the collector. Rolling is a cooperative process and the coordination of binding in one location with dis-bonding in another requires appropriate length scales in the design of the interface and in the processing parameters as well.

High Temperature Deformation of Twin-Roll Cast Al-Mn-Based Alloys after Equal Channel Angular Pressing.

PubMed

Málek, Přemysl; Šlapáková Poková, Michaela; Cieslar, Miroslav

2015-11-12

Twin roll cast Al-Mn- and Al-Mn-Zr-based alloys were subjected to four passes of equal channel angular pressing. The resulting grain size of 400 nm contributes to a significant strengthening at room temperature. This microstructure is not fully stable at elevated temperatures and recrystallization and vast grain growth occur at temperatures between 350 and 450 °C. The onset of these microstructure changes depends on chemical and phase composition. Better stability is observed in the Al-Mn-Zr-based alloy. High temperature tensile tests reveal that equal channel angular pressing results in a softening of all studied materials at high temperatures. This can be explained by an active role of grain boundaries in the deformation process. The maximum values of ductility and strain rate sensitivity parameter m found in the Al-Mn-Zr-based alloy are below the bottom limit of superplasticity (155%, m = 0.25). However, some features typical for superplastic behavior were observed-the strain rate dependence of the parameter m , the strengthening with increasing grain size, and the fracture by diffuse necking. Grain boundary sliding is believed to contribute partially to the overall strain in specimens where the grain size remained in the microcrystalline range.

High Temperature Deformation of Twin-Roll Cast Al-Mn-Based Alloys after Equal Channel Angular Pressing

PubMed Central

Málek, Přemysl; Šlapáková Poková, Michaela; Cieslar, Miroslav

2015-01-01

Twin roll cast Al-Mn- and Al-Mn-Zr-based alloys were subjected to four passes of equal channel angular pressing. The resulting grain size of 400 nm contributes to a significant strengthening at room temperature. This microstructure is not fully stable at elevated temperatures and recrystallization and vast grain growth occur at temperatures between 350 and 450 °C. The onset of these microstructure changes depends on chemical and phase composition. Better stability is observed in the Al-Mn-Zr-based alloy. High temperature tensile tests reveal that equal channel angular pressing results in a softening of all studied materials at high temperatures. This can be explained by an active role of grain boundaries in the deformation process. The maximum values of ductility and strain rate sensitivity parameter m found in the Al-Mn-Zr-based alloy are below the bottom limit of superplasticity (155%, m = 0.25). However, some features typical for superplastic behavior were observed—the strain rate dependence of the parameter m, the strengthening with increasing grain size, and the fracture by diffuse necking. Grain boundary sliding is believed to contribute partially to the overall strain in specimens where the grain size remained in the microcrystalline range. PMID:28793667

Effects of homogenization treatment on recrystallization behavior of 7150 aluminum sheet during post-rolling annealing

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

Guo, Zhanying; Department of Applied Science, University of Québec at Chicoutimi, Saguenay, QC G7H 2B1; Zhao, Gang

2016-04-15

The effects of two homogenization treatments applied to the direct chill (DC) cast billet on the recrystallization behavior in 7150 aluminum alloy during post-rolling annealing have been investigated using the electron backscatter diffraction (EBSD) technique. Following hot and cold rolling to the sheet, measured orientation maps, the recrystallization fraction and grain size, the misorientation angle and the subgrain size were used to characterize the recovery and recrystallization processes at different annealing temperatures. The results were compared between the conventional one-step homogenization and the new two-step homogenization, with the first step being pretreated at 250 °C. Al{sub 3}Zr dispersoids with highermore » densities and smaller sizes were obtained after the two-step homogenization, which strongly retarded subgrain/grain boundary mobility and inhibited recrystallization. Compared with the conventional one-step homogenized samples, a significantly lower recrystallized fraction and a smaller recrystallized grain size were obtained under all annealing conditions after cold rolling in the two-step homogenized samples. - Highlights: • Effects of two homogenization treatments on recrystallization in 7150 Al sheets • Quantitative study on the recrystallization evolution during post-rolling annealing • Al{sub 3}Zr dispersoids with higher densities and smaller sizes after two-step treatment • Higher recrystallization resistance of 7150 sheets with two-step homogenization.« less

Method of forming magnesium alloy sheets

DOEpatents

Mualidharan, Govindarajan; Muth, Thomas R.; Harper, David C.

2015-12-22

A machine for asymmetric rolling of a work-piece includes pair of rollers disposed in an arrangement to apply opposing, asymmetric rolling forces to roll a work-piece therebetween, wherein a surface of the work-piece is rolled faster than an opposite surface of the work-piece; and an exit constraint die rigidly disposed adjacent an exit side of the pair of rollers so that, as the work-piece exits the pair of rollers, the work-piece contacts the exit constraint die to constrain curling of the work-piece.

Origins of Rolling Friction

ERIC Educational Resources Information Center

Cross, Rod

2017-01-01

When a hard object rolls on a soft surface, or vice versa, rolling friction arises from deformation of the soft object or the soft surface. The friction force can be described in terms of an offset in the normal reaction force or in terms of energy loss arising from the deformation. The origin of the friction force itself is not entirely clear. It…

Why Low Bounce Balls Exhibit High Rolling Resistance

ERIC Educational Resources Information Center

Cross, Rod

2015-01-01

A simple experiment is described to measure the coefficient of rolling friction for a low bounce ball rolling on a horizontal surface. As observed previously by others, the coefficient increased with rolling speed. The energy loss due to rolling friction can be explained in terms of the measured coefficient of restitution for the ball, meaning…

Validation of a model for the cast-film process

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

Chambon, F.; Ohlsson, S.; Silagy, D.

1996-12-31

We have developed a model of the cast-film process and compared theoretical predictions against experiments on a pilot line. Three polyethylenes with a markedly different level of melt elasticity were used in this evaluation; namely, a high pressure low density polyethylene, LDPE, and two linear low density polyethylenes, LLDPE-1 and LLDPE-2. The final film dimensions of the LDPE were found to be in good agreement with 1-D viscoelastic stationary predictions. Flow field visualization experiments indicate, however, a 2-D velocity field in the airgap between the extrusion die and the chill roll. Taking this observation into account, evolutions of the freemore » surface of the web along the airgap were recorded with LLDPE-2, our least elastic melt. An excellent agreement is found between these measurements and predictions of neck-in and edge bead with 2-D Newtonian stationary simulations. The time-dependent solution, which is based on a linear stability analysis, allows to identify a zone of draw resonance within the working space of the process, defined by the draw ratio, the Deborah number, and the web aspect ratio. It is predicted that increasing this latter parameter stabilizes the process until an optimum value is reached. Experiments with LLDPE-1 are shown to validate this unique theoretical result, thus allowing to increase the draw ratio by about 75%.« less

Advances in compact manufacturing for shape and performance controllability of large-scale components-a review

NASA Astrophysics Data System (ADS)

Qin, Fangcheng; Li, Yongtang; Qi, Huiping; Ju, Li

2017-01-01

Research on compact manufacturing technology for shape and performance controllability of metallic components can realize the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for further development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

A rolling-sliding bench test for investigating rear axle lubrication

DOE PAGES

Stump, Benjamin C.; Zhou, Yan; Viola, Michael B.; ...

2018-02-07

An automotive rear axle is composed of a set of hypoid gears, whose contact surfaces experience a complex combination of rolling contact fatigue damage and sliding wear. Full-scale rear axle dynamometer tests are used in the industry for efficiency and durability assessment. Here, this study developed a bench-scale rolling-sliding test protocol by simulating the contact pressure, oil temperature, and lubrication regime experienced in a dynamometer duty cycle test. Initial bench results have demonstrated the ability of generating both rolling contact-induced micropitting and sliding wear and the feasibility of investigating the impact of slide-to-roll ratio, surface roughness, test duration, and oilmore » temperature on the friction behavior, vibration noise, and surface damage. Finally, this bench test will allow studying candidate rear axle lubricants and materials under relevant conditions.« less

A rolling-sliding bench test for investigating rear axle lubrication

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

Stump, Benjamin C.; Zhou, Yan; Viola, Michael B.

An automotive rear axle is composed of a set of hypoid gears, whose contact surfaces experience a complex combination of rolling contact fatigue damage and sliding wear. Full-scale rear axle dynamometer tests are used in the industry for efficiency and durability assessment. Here, this study developed a bench-scale rolling-sliding test protocol by simulating the contact pressure, oil temperature, and lubrication regime experienced in a dynamometer duty cycle test. Initial bench results have demonstrated the ability of generating both rolling contact-induced micropitting and sliding wear and the feasibility of investigating the impact of slide-to-roll ratio, surface roughness, test duration, and oilmore » temperature on the friction behavior, vibration noise, and surface damage. Finally, this bench test will allow studying candidate rear axle lubricants and materials under relevant conditions.« less

Near-surface coherent structures explored by large eddy simulation of entire tropical cyclones.

PubMed

Ito, Junshi; Oizumi, Tsutao; Niino, Hiroshi

2017-06-19

Taking advantage of the huge computational power of a massive parallel supercomputer (K-supercomputer), this study conducts large eddy simulations of entire tropical cyclones by employing a numerical weather prediction model, and explores near-surface coherent structures. The maximum of the near-surface wind changes little from that simulated based on coarse-resolution runs. Three kinds of coherent structures appeared inside the boundary layer. The first is a Type-A roll, which is caused by an inflection-point instability of the radial flow and prevails outside the radius of maximum wind. The second is a Type-B roll that also appears to be caused by an inflection-point instability but of both radial and tangential winds. Its roll axis is almost orthogonal to the Type-A roll. The third is a Type-C roll, which occurs inside the radius of maximum wind and only near the surface. It transports horizontal momentum in an up-gradient sense and causes the largest gusts.

Core-free rolled actuators for Braille displays using P(VDF-TrFE-CFE)

NASA Astrophysics Data System (ADS)

Levard, Thomas; Diglio, Paul J.; Lu, Sheng-Guo; Rahn, Christopher D.; Zhang, Q. M.

2012-01-01

Refreshable Braille displays require many small diameter actuators to move the pins. The electrostrictive P(VDF-TrFE-CFE) terpolymer can provide the high strain and actuation force under modest electric fields that are required for this application. In this paper, we develop core-free tubular actuators and integrate them into a 3 × 2 Braille cell. The terpolymer films are solution cast, stretched to 6 μm thick, electroded, laminated into a bilayer, rolled into a 2 mm diameter tube, bonded, and provided with top and bottom contacts. Experimental testing of 17 actuators demonstrates significant strains (up to 4%) and blocking forces (1 N) at moderate electric fields (100 MV m-1). A novel Braille cell is designed and fabricated using six of these actuators.

Aluminum-based one- and two-dimensional micro fin array structures: high-throughput fabrication and heat transfer testing

NASA Astrophysics Data System (ADS)

Primeaux, Philip A.; Zhang, Bin; Zhang, Xiaoman; Miller, Jacob; Meng, W. J.; KC, Pratik; Moore, Arden L.

2017-02-01

Microscale fin array structures were replicated onto surfaces of aluminum 1100 and aluminum 6061 alloy (Al1100/Al6061) sheet metals through room-temperature instrumented roll molding. Aluminum-based micro fin arrays were replicated at room temperature, and the fabrication process is one with high throughput and low cost. One-dimensional (1D) micro fin arrays were made through one-pass rolling, while two-dimensional (2D) micro fin arrays were made by sequential 90° cross rolling with the same roller sleeve. For roll molding of 1D micro fins, fin heights greater than 600 µm were achieved and were shown to be proportional to the normal load force per feature width. At a given normal load force, the fin height was further shown to scale inversely with the hardness of the sheet metal. For sequential 90° cross rolling, morphologies of roll molded 2D micro fin arrays were examined, which provided clues to understand how plastic deformation occurred under cross rolling conditions. A series of pool boiling experiments on low profile Al micro fin array structures were performed within Novec 7100, a widely used commercial dielectric coolant. Results for both horizontal and vertical surface orientations show that roll molded Al micro fin arrays can increase heat flux at fixed surface temperature as compared to un-patterned Al sheet. The present results further suggest that many factors beyond just increased surface area can influence heat transfer performance, including surface finish and the important multiphase transport mechanisms in and around the fin geometry. These factors must also be considered when designing and optimizing micro fin array structures for heat transfer applications.

Optical scattering from rough-rolled aluminum surfaces.

PubMed

Rönnelid, M; Adsten, M; Lindström, T; Nostell, P; Wäckelgård, E

2001-05-01

Bidirectional, angular resolved scatterometry was used to evaluate the feasibility of using rolled aluminum as reflectors in solar thermal collectors and solar cells. Two types of rolled aluminum with different surface roughnesses were investigated. The results show that the smoother of the two samples [rms height, (0.20 ? 0.02) mum] can be used as a nonimaging, concentrating reflector with moderate reflection losses compared with those of optically smooth aluminum reflectors. The sample with the rougher surface [rms height, (0.6 ? 0.1) mum] is not suitable as a concentrating element but can be used as planar reflectors. The orientation of the rolling grooves is then of importance for minimizing reflection losses in the system.

Phase-field modeling of liquids splitting between separating surfaces and its application to high-resolution roll-based printing technologies

NASA Astrophysics Data System (ADS)

Hizir, F. E.; Hardt, D. E.

2017-05-01

An in-depth understanding of the liquid transport in roll-based printing systems is essential for advancing the roll-based printing technology and enhancing the performance of the printed products. In this study, phase-field simulations are performed to characterize the liquid transport in roll-based printing systems, and the phase-field method is shown to be an effective tool to simulate the liquid transport. In the phase-field simulations, the liquid transport through the ink transfer rollers is approximated as the stretching and splitting of liquid bridges with pinned or moving contact lines between vertically separating surfaces. First, the effect of the phase-field parameters and the mesh characteristics on the simulation results is examined. The simulation results show that a sharp interface limit is approached as the capillary width decreases while keeping the mobility proportional to the capillary width squared. Close to the sharp interface limit, the mobility changes over a specified range are observed to have no significant influence on the simulation results. Next, the ink transfer from the cells on the surface of an ink-metering roller to the surface of stamp features is simulated. Under negligible inertial effects and in the absence of gravity, the amount of liquid ink transferred from an axisymmetric cell with low surface wettability to a stamp with high surface wettability is found to increase as the cell sidewall steepness and the cell surface wettability decrease and the stamp surface wettability and the capillary number increase. Strategies for improving the resolution and quality of roll-based printing are derived based on an analysis of the simulation results. The application of novel materials that contain cells with irregular surface topography to stamp inking in high-resolution roll-based printing is assessed.

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.

Armor Plate Ballistic Testing

DTIC Science & Technology

1944-08-02

sistanoe to penotration characteristics. However, it is one of the most important factors involved, and when the type of steel , its soundness and its...this test and not to use it in comparing radically differdnt types of plates, such as steel and Dural. Such a comparison can be made only by examining...in many oases, For this reason it became necessary to develop an additional test for the oharaoteristio in rolled armor ( steel "soundness) and cast

Rolling process for producing biaxially textured substrates

DOEpatents

Goyal, Amit

2004-05-25

A method of preparing a biaxially textured article includes the steps of: rolling a metal preform while applying shear force thereto to form as-rolled biaxially textured substrate having an a rotated cube texture wherein a (100) cube face thereof is parallel to a surface of said substrate, and wherein a [100] direction thereof is at an angle of at least 30.degree. relative to the rolling direction; and depositing onto the surface of the biaxially textured substrate at least one epitaxial layer of another material to form a biaxially textured article.

Crystallographic texture of straight-rolled ?-uranium foils via neutron and X-ray diffraction

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

Einhorn, J. R.; Steiner, M. A.; Vogel, S. C.

The texture of recrystallized straight-rolled ?-uranium foils, a component in prospective irradiation target designs for medical isotope production, has been measured by neutron diffraction, as well as X-ray diffraction using both Cu and Mo sources. Variations in the penetration depth of neutron and X-ray radiation allow for determination of both the bulk and surface textures. The bulk ?-uranium foil texture is similar to the warm straight-rolled plate texture, with the addition of a notable splitting of the (001) poles along the transverse direction. The surface texture of the foils is similar to the bulk, with an additional (001) texture componentmore » that is oriented between the rolling and normal directions. Differences between the surface and bulk textures are expected to arise from shear forces during the rolling process and the influence that distinct strain histories have on subsequent texture evolution during recrystallization.« less

Crystallographic texture of straight-rolled ?-uranium foils via neutron and X-ray diffraction

DOE PAGES

Einhorn, J. R.; Steiner, M. A.; Vogel, S. C.; ...

2017-05-25

The texture of recrystallized straight-rolled ?-uranium foils, a component in prospective irradiation target designs for medical isotope production, has been measured by neutron diffraction, as well as X-ray diffraction using both Cu and Mo sources. Variations in the penetration depth of neutron and X-ray radiation allow for determination of both the bulk and surface textures. The bulk ?-uranium foil texture is similar to the warm straight-rolled plate texture, with the addition of a notable splitting of the (001) poles along the transverse direction. The surface texture of the foils is similar to the bulk, with an additional (001) texture componentmore » that is oriented between the rolling and normal directions. Differences between the surface and bulk textures are expected to arise from shear forces during the rolling process and the influence that distinct strain histories have on subsequent texture evolution during recrystallization.« 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.

40 CFR 1066.225 - Roll runout and diameter verification procedure.

Code of Federal Regulations, 2013 CFR

2013-07-01

... section. (2) Measure roll diameter using a Pi Tape®. Orient the Pi Tape® to the marker line at the desired measurement location with the Pi Tape® hook pointed outward. Temporarily secure the Pi Tape® to the roll near the hook end with adhesive tape. Slowly turn the roll, wrapping the Pi Tape® around the roll surface...

40 CFR 1066.225 - Roll runout and diameter verification procedure.

Code of Federal Regulations, 2014 CFR

2014-07-01

...) Measure roll diameter using a Pi Tape®. Orient the Pi Tape® to the marker line at the desired measurement location with the Pi Tape® hook pointed outward. Temporarily secure the Pi Tape® to the roll near the hook end with adhesive tape. Slowly turn the roll, wrapping the Pi Tape® around the roll surface. Ensure...

40 CFR 1066.225 - Roll runout and diameter verification procedure.

Code of Federal Regulations, 2012 CFR

2012-07-01

... section. (2) Measure roll diameter using a Pi Tape®. Orient the Pi Tape® to the marker line at the desired measurement location with the Pi Tape® hook pointed outward. Temporarily secure the Pi Tape® to the roll near the hook end with adhesive tape. Slowly turn the roll, wrapping the Pi Tape® around the roll surface...

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.

Simultaneous Strength-Ductility Enhancement of a Nano-Lamellar AlCoCrFeNi2.1 Eutectic High Entropy Alloy by Cryo-Rolling and Annealing.

PubMed

Bhattacharjee, T; Wani, I S; Sheikh, S; Clark, I T; Okawa, T; Guo, S; Bhattacharjee, P P; Tsuji, N

2018-02-19

Nano-lamellar (L1 2  + B2) AlCoCrFeNi 2.1 eutectic high entropy alloy (EHEA) was processed by cryo-rolling and annealing. The EHEA developed a novel hierarchical microstructure featured by fine lamellar regions consisting of FCC lamellae filled with ultrafine FCC grains (average size ~200-250 nm) and B2 lamellae, and coarse non-lamellar regions consisting of ultrafine FCC (average size ~200-250 nm), few coarse recrystallized FCC grains and rather coarse unrecrystallized B2 phase (~2.5 µm). This complex and hierarchical microstructure originated from differences in strain-partitioning amongst the constituent phases, affecting the driving force for recrystallization. The hierarchical microstructure of the cryo-rolled and annealed material resulted in simultaneous enhancement in strength (Yield Strength/YS: 1437 ± 26 MPa, Ultimate Tensile Strength/UTS: 1562 ± 33 MPa) and ductility (elongation to failure/e f  ~ 14 ± 1%) as compared to the as-cast as well as cold-rolled and annealed materials. The present study for the first time demonstrated that cryo-deformation and annealing could be a novel microstructural design strategy for overcoming strength-ductility trade off in multiphase high entropy alloys.

Adhesion Casting In Low Gravity

NASA Technical Reports Server (NTRS)

Noever, David A.; Cronise, Raymond J.

1996-01-01

Adhesion casting in low gravity proposed as technique for making new and improved materials. Advantages of low-gravity adhesion casting, in comparison with adhesion casting in normal Earth gravity, comes from better control over, and greater uniformity of, thicknesses of liquid films that form on and adhere to solid surfaces during casting.

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.

Pneumatic gap sensor and method

DOEpatents

Bagdal, Karl T.; King, Edward L.; Follstaedt, Donald W.

1992-01-01

An apparatus and method for monitoring and maintaining a predetermined width in the gap between a casting nozzle and a casting wheel, wherein the gap is monitored by means of at least one pneumatic gap sensor. The pneumatic gap sensor is mounted on the casting nozzle in proximity to the casting surface and is connected by means of a tube to a regulator and a transducer. The regulator provides a flow of gas through a restictor to the pneumatic gap sensor, and the transducer translates the changes in the gas pressure caused by the proximity of the casting wheel to the pneumatic gap sensor outlet into a signal intelligible to a control device. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces. The apparatus and method enables accurate monitoring of the actual casting gap in a simple and reliable manner resistant to the extreme temperatures and otherwise hostile casting environment.

Pneumatic gap sensor and method

DOEpatents

Bagdal, K.T.; King, E.L.; Follstaedt, D.W.

1992-03-03

An apparatus and method for monitoring and maintaining a predetermined width in the gap between a casting nozzle and a casting wheel, wherein the gap is monitored by means of at least one pneumatic gap sensor. The pneumatic gap sensor is mounted on the casting nozzle in proximity to the casting surface and is connected by means of a tube to a regulator and a transducer. The regulator provides a flow of gas through a restictor to the pneumatic gap sensor, and the transducer translates the changes in the gas pressure caused by the proximity of the casting wheel to the pneumatic gap sensor outlet into a signal intelligible to a control device. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces. The apparatus and method enables accurate monitoring of the actual casting gap in a simple and reliable manner resistant to the extreme temperatures and otherwise hostile casting environment. 6 figs.

Rolling viscous drops on a non-wettable surface containing both micro- and macro-scale roughness

NASA Astrophysics Data System (ADS)

Abolghasemibizaki, Mehran; Robertson, Connor J.; Fergusson, Christian P.; McMasters, Robert L.; Mohammadi, Reza

2018-02-01

It has previously been shown that when a liquid drop of high viscosity is placed on a non-wettable inclined surface, it rolls down at a constant descent velocity determined by the balance between viscous dissipation and the reduction rate of its gravitational potential energy. Since increasing the roughness of the surface boosts its non-wetting property, the drop should move faster on a surface structured with macrotextures (ribbed surface). Such a surface was obtained from a superhydrophobic soot coating on a solid specimen printed with an extruder-type 3D printer. The sample became superoleophobic after a functionalization process. The descent velocity of glycerol drops of different radii was then measured on the prepared surface for varied tilting angles. Our data show that the drops roll down on the ribbed surface approximately 27% faster (along the ridges) than on the macroscopically smooth counterpart. This faster velocity demonstrates that ribbed surfaces can be promising candidates for drag-reduction and self-cleaning applications. Moreover, we came up with a modified scaling model to predict the descent velocity of viscous rolling drops more accurately than what has previously been reported in the literature.

Advanced rotary engine components utilizing fiber reinforced Mg castings

NASA Technical Reports Server (NTRS)

Goddard, D.; Whitman, W.; Pumphrey, R.; Lee, C.-M.

1986-01-01

Under a two-phase program sponsored by NASA, the technology for producing advanced rotary engine components utilizing graphite fiber-reinforced magnesium alloy casting is being developed. In Phase I, the successful casting of a simulated intermediate housing was demonstrated. In Phase II, the goal is to produce an operating rotor housing. The effort involves generation of a material property data base, optimization of parameters, and development of wear- and corrosion-resistant cast surfaces and surface coatings. Results to date are described.

The development of compact electroactive polymer actuators suitable for use in full page Braille displays

NASA Astrophysics Data System (ADS)

Gorny, Lee J.; Zellers, Brian C.; Lin, Minren; Liu, Sheng; Zhang, Qiming M.

2010-04-01

Piezoceramic actuators, presently used in commercial Braille displays, are limited by the material's relatively small strain and brittle nature. For this reason, it is a challenge to develop full page, compact, graphic Braille displays that are affordable. A newly developed material composed of P(VDF-TrFE-CFE) terpolymer blended with 5% P(VDF-CTFE) electrostrictive actuators exhibits large strains (~5% at 150V/μm), fast actuation (>5 mm/s), and has a relatively high elastic modulus (1.2 GPa). This material exhibits more than double the elastic energy density and a 50% higher modulus of the original electrostrictive terpolymer. Hence, the potential for viable actuators in compact, full page Braille displays is greater than ever, provided actuators can be manufactured reliably in quantity. This talk presents recent work in scaling production of such rolled actuators. Actuators extend .5 mm, are confined to the 2.5 mm grid spacing of conventional Braille text, generate >0.5 N force and operate at less than 200V, thus meeting the primary requirements for a commercialized Braille display. To manufacture these actuators, cast films are stretched using a roll-to-roll zone drawing machine that is capable of producing quantities of 2 μm thick film with high quality. What follows is a discussion of this machine, the roll-to-roll film stretching process and an assessment of the resulting stretched film for use as linear strain actuators, like those used in our Braille cell.

Development of a continuous roll-to-roll processing system for mass production of plastic optical film

NASA Astrophysics Data System (ADS)

Chang, Chih-Yuan; Tsai, Meng-Hsun

2015-12-01

This paper reports a highly effective method for the mass production of large-area plastic optical films with a microlens array pattern based on a continuous roll-to-roll film extrusion and roller embossing process. In this study, a thin steel mold with a micro-circular hole array pattern is fabricated by photolithography and a wet chemical etching process. The thin steel mold was then wrapped onto a metal cylinder to form an embossing roller mold. During the roll-to-roll process operation, a thermoplastic raw material (polycarbonate grains) was put into the barrel of the plastic extruder with a flat T-die. Then, the molten polymer film was extruded and immediately pressed against the surface of the embossing roller mold. Under the proper processing conditions, the molten polymer will just partially fill the micro-circular holes of the mold and due to surface tension form a convex lens surface. A continuous plastic optical film with a microlens array pattern was obtained. Experiments are carried out to investigate the effect of plastic microlens formation on the roll-to-roll process. Finally, the geometrical and optical properties of the fabricated plastic optical film were measured and proved satisfactory. This technique shows great potential for the mass production of large-area plastic optical films with a microlens array pattern.

The effects of weld-repair and hot isostatic pressing on the fracture properties of Ti-5Al-2.5Sn ELI castings

NASA Technical Reports Server (NTRS)

Misra, M. S.; Lemeshewsky, S.; Bolstad, D.

1982-01-01

The Ti-5Al-2.5Sn extremely low interstitial alloy employed in the large castings which form the critical attachment fittings of the Space Shuttle External Tank was selected because of its high fracture resistance at cryogenic temperatures. Casting was selected over alternative fabrication methods because of its lower cost and adaptability to design changes, although it was found necessary to weld-repair surface and subsurface casting defects in order to reduce the scrap rate and maintain the inherent cost advantage of the castings. Hot Isostatic Pressing was experimentally found to heal the surface and internal defects of the castings, but did not improve tensile or fracture properties and was therefore rejected as a production technique. Production castings are instead weld-repaired, without any mechanical property degradation.

Self-positioning ability of a sphericon-shaped magnetic millirobot rolling on an inclined surface

NASA Astrophysics Data System (ADS)

Jeon, Seungmun

2018-05-01

This paper introduces the novel self-positioning ability of a sphericon-shaped magnetic millirobot (SSMM) on an inclined surface. The SSMM is comprised of four identical half cones with a cylindrical magnet inserted into the geometric center, and it can roll along a straight line on a surface with repeated rolling cone motions actuated by an external wobbling magnetic field (EWMF). Due to the restoring moment induced by a conservative gravitational force, the SSMM can maintain (self-position) its equilibrium position on the surface, even when the EWMF is removed. This paper derived several equations to quantify the condition in which the SSMM can steadily generate self-positioning motions. It also examined the self-positioning ability of the SSMM by constructing a prototype SSMM and demonstrating its rolling and self-positioning motions by using a magnetic navigation system.

Formation of β-NiAl Phase During Casting of a Ni-Based Superalloy

NASA Astrophysics Data System (ADS)

Detrois, Martin; Jablonski, Paul D.

2018-04-01

A high-refractory Ni-based superalloy prototype was melted on a research scale while simulating industry practices. Ingots were vacuum induction melted and subjected to a computationally optimized homogenization heat treatment prior to fabrication which consisted of forging and hot rolling. Failure of one of the ingots at the early stage of the forging process was attributed to the precipitation of the β-NiAl phase during melting which stabilized the eutectic constituent.

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

NASA Astrophysics Data System (ADS)

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

2018-06-01

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

A New Predictive Model of Centerline Segregation in Continuous Cast Steel Slabs by Using Multivariate Adaptive Regression Splines Approach

PubMed Central

García Nieto, Paulino José; González Suárez, Victor Manuel; Álvarez Antón, Juan Carlos; Mayo Bayón, Ricardo; Sirgo Blanco, José Ángel; Díaz Fernández, Ana María

2015-01-01

The aim of this study was to obtain a predictive model able to perform an early detection of central segregation severity in continuous cast steel slabs. Segregation in steel cast products is an internal defect that can be very harmful when slabs are rolled in heavy plate mills. In this research work, the central segregation was studied with success using the data mining methodology based on multivariate adaptive regression splines (MARS) technique. For this purpose, the most important physical-chemical parameters are considered. The results of the present study are two-fold. In the first place, the significance of each physical-chemical variable on the segregation is presented through the model. Second, a model for forecasting segregation is obtained. Regression with optimal hyperparameters was performed and coefficients of determination equal to 0.93 for continuity factor estimation and 0.95 for average width were obtained when the MARS technique was applied to the experimental dataset, respectively. The agreement between experimental data and the model confirmed the good performance of the latter.

Tensile Properties of Molybdenum and Tungsten from 2500 to 3700 F

NASA Technical Reports Server (NTRS)

Hall, Robert W.; Sikora, Paul F.

1959-01-01

Specimens of commercially pure sintered tungsten, arc-cast unalloyed molybdenum, and two arc-cast molybdenum-base alloys (one with 0.5 percent titanium, the other with 0.46 percent titanium and 0.07 percent zirconium) were fabricated from 1/2-inch-diameter rolled or swaged bars. All specimens were evaluated in short-time tensile tests in the as-received condition, and all except the molybdenum-titanium-zirconium alloy were tested after a 30-minute recrystallization anneal at 3800 F in a vacuum of approximately 0.1 micron. Results showed that the tungsten was considerably stronger than either the arc-cast unalloyed molybdenum or the molybdenum-base alloys over the 2500 to 3700 F temperature range. Recrystallization of swaged tungsten at 3800 F considerably reduced its tensile strength at 2500 F. However, above 3100 F, the as-swaged tungsten specimens recrystallized during testing, and had about the same strength as when recrystallized at 3800 F before evaluation. The ductility of molybdenum-base materials was very high at all test temperatures; the ductility of tungsten decreased sharply above about 3120 F.

Experimental determination of heat transfer coefficients in roll bite and air cooling for computer simulations of 1100 MPa carbon steel rolling

NASA Astrophysics Data System (ADS)

Leinonen, Olli; Ilmola, Joonas; Seppälä, Oskari; Pohjonen, Aarne; Paavola, Jussi; Koskenniska, Sami; Larkiola, Jari

2018-05-01

In modeling of hot rolling pass schedules the heat transfer phenomena have to be known. Radiation to ambient, between rolls and a steel slab as well as heat transfer in contacts must be considered to achieve accurate temperature distribution and thereby accurate material behavior in simulations. Additional heat is generated by friction between the slab and the work roll and by plastic deformation. These phenomena must be taken into account when the effective heat transfer coefficient is determined from experimental data. In this paper we determine the effective heat transfer coefficient at the contact interface and emissivity factor of slab surface for 1100MPa strength carbon steel for hot rolling simulations. Experimental pilot rolling test were carried out and slab temperatures gathered right below the interface and at the mid thickness of the slab. Emissivity factor tests were carried out in the same manner but without rolling. Experimental data is utilized to derive contact heat transfer coefficient at the interface and emissivity factor of slab surface. Pilot rolling test is reproduced in FE-analysis to further refine the heat transfer coefficient and emissivity factor. Material mechanical properties at rolling temperatures were determined by Gleeble™ thermo-mechanical simulator and IDS thermodynamic-kinetic-empirical software.

Physical Therapy for a Child With Infantile Idiopathic Scoliosis and Motor Delay.

PubMed

Hall, Rhea K; Rapport, Mary Jane

2017-07-01

The purpose of this case report is to describe physical therapy (PT) for a child with infantile idiopathic scoliosis and motor delay. A 10-month-old boy with a 28° left thoracolumbar scoliosis was referred for PT and was seen weekly in his home over a 6-month period following a diagnosis of scoliosis and delayed gross motor milestones. Before the initiation of PT, the child was scheduled to undergo serial casting for correction of the spinal curve and was not yet rolling or transitioning in or out of sitting. By the end of the 6-month intervention period, the spinal curve had resolved to 12° without the need for serial casting and the child was walking independently. PT appeared to have a positive effect on reduction of the spinal curve and achievement of gross motor milestones.

I-domain of lymphocyte function-associated antigen-1 mediates rolling of polystyrene particles on ICAM-1 under flow.

PubMed

Eniola, A Omolola; Krasik, Ellen F; Smith, Lee A; Song, Gang; Hammer, Daniel A

2005-11-01

In their active state, beta(2)-integrins, such as LFA-1, mediate the firm arrest of leukocytes by binding intercellular adhesion molecules (ICAMs) expressed on endothelium. Although the primary function of LFA-1 is assumed to be the ability to mediate firm adhesion, recent work has shown that LFA-1 can contribute to cell tethering and rolling under hydrodynamic flow, a role previously largely attributed to the selectins. The inserted (I) domain of LFA-1 has recently been crystallized in the wild-type (wt) and locked-open conformations and has been shown to, respectively, support rolling and firm adhesion under flow when expressed in alpha(L)beta(2) heterodimers or as isolated domains on cells. Here, we report results from cell-free adhesion assays where wt I-domain-coated polystyrene particles were allowed to interact with ICAM-1-coated surfaces in shear flow. We show that wt I-domain can independently mediate the capture of particles from flow and support their rolling on ICAM-1 surfaces in a manner similar to how carbohydrate-selectin interactions mediate rolling. Adhesion is specific and blocked by appropriate antibodies. We also show that the rolling velocity of I-domain-coated particles depends on the wall shear stress in flow chamber, I-domain site density on microsphere surfaces, and ICAM-1 site density on substrate surfaces. Furthermore, we show that rolling is less sensitive to wall shear stress and ICAM-1 substrate density at high density of I-domain on the microsphere surface. Computer simulations using adhesive dynamics can recreate bead rolling dynamics and show that the mechanochemical properties of ICAM-1-I-domain interactions are similar to those of carbohydrate-selectin interactions. Understanding the biophysics of adhesion mediated by the I-domain of LFA-1 can elucidate the complex roles this integrin plays in leukocyte adhesion in inflammation.

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

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

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

Polymer quenched prealloyed metal powder

DOEpatents

Hajaligol, Mohammad R.; Fleischhauer, Grier; German, Randall M.

2001-01-01

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3 % Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

DOEpatents

Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleishhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

2003-12-09

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Thermomechanical processing of plasma sprayed intermetallic sheets

DOEpatents

Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleischhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

2001-01-01

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Method of manufacturing aluminide sheet by thermomechanical processing of aluminide powders

DOEpatents

Hajaligol, Mohammad R.; Scorey, Clive; Sikka, Vinod K.; Deevi, Seetharama C.; Fleischhauer, Grier; Lilly, Jr., A. Clifton; German, Randall M.

2000-01-01

A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr.ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3% Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.

Bioinspired superhydrophobic surfaces, fabricated through simple and scalable roll-to-roll processing

PubMed Central

Park, Sung-Hoon; Lee, Sangeui; Moreira, David; Bandaru, Prabhakar R.; Han, InTaek; Yun, Dong-Jin

2015-01-01

A simple, scalable, non-lithographic, technique for fabricating durable superhydrophobic (SH) surfaces, based on the fingering instabilities associated with non-Newtonian flow and shear tearing, has been developed. The high viscosity of the nanotube/elastomer paste has been exploited for the fabrication. The fabricated SH surfaces had the appearance of bristled shark skin and were robust with respect to mechanical forces. While flow instability is regarded as adverse to roll-coating processes for fabricating uniform films, we especially use the effect to create the SH surface. Along with their durability and self-cleaning capabilities, we have demonstrated drag reduction effects of the fabricated films through dynamic flow measurements. PMID:26490133

Bioinspired superhydrophobic surfaces, fabricated through simple and scalable roll-to-roll processing.

PubMed

Park, Sung-Hoon; Lee, Sangeui; Moreira, David; Bandaru, Prabhakar R; Han, InTaek; Yun, Dong-Jin

2015-10-22

A simple, scalable, non-lithographic, technique for fabricating durable superhydrophobic (SH) surfaces, based on the fingering instabilities associated with non-Newtonian flow and shear tearing, has been developed. The high viscosity of the nanotube/elastomer paste has been exploited for the fabrication. The fabricated SH surfaces had the appearance of bristled shark skin and were robust with respect to mechanical forces. While flow instability is regarded as adverse to roll-coating processes for fabricating uniform films, we especially use the effect to create the SH surface. Along with their durability and self-cleaning capabilities, we have demonstrated drag reduction effects of the fabricated films through dynamic flow measurements.

Disinfection procedures: their efficacy and effect on dimensional accuracy and surface quality of an irreversible hydrocolloid impression material.

PubMed

Rentzia, A; Coleman, D C; O'Donnell, M J; Dowling, A H; O'Sullivan, M

2011-02-01

This study investigated the antibacterial efficacy and effect of 0.55% ortho-phthalaldehyde (Cidex OPA(®)) and 0.5% sodium hypochlorite (NaOCl) on the dimensional accuracy and surface quality of gypsum casts retrieved from an irreversible hydrocolloid impression material. A simulated clinical cast and technique was developed to compare the dimensional accuracy and surface quality changes of the test gypsum casts with controls. Dimensional accuracy measurements were completed between fixed points using a travelling microscope under low angle illumination at a magnification of ×3. Surface quality changes of "smooth" and "rough" areas on the cast were evaluated by means of optical profilometry. The efficacy of the disinfection procedures against Pseudomonas aeruginosa was evaluated by determining the number of colony forming units (cfu) recovered after disinfection of alginate discs inoculated with 1×10⁶cfu for defined intervals. The dimensional accuracy of the gypsum casts was not significantly affected by the disinfection protocols. Neither disinfectant solution nor immersion time had an effect on the surface roughness of the "smooth" area on the cast, however, a significant increase in surface roughness was observed with increasing immersion time for the "rough" surface. Complete elimination of viable Pseudomonas aeruginosa cells from alginate discs was obtained after 30 and 120 s immersion in Cidex OPA(®) and NaOCl, respectively. Immersion of irreversible hydrocolloid impressions in Cidex OPA(®) for 30 s was proved to be the most effective disinfection procedure. Copyright © 2010 Elsevier Ltd. All rights reserved.

Comparative study of the surface characteristics, microstructure, and magnetic retentive forces of laser-welded dowel-keepers and cast dowel-keepers for use with magnetic attachments.

PubMed

Chao, Yonglie; Du, Li; Yang, Ling

2005-05-01

Information regarding the merits and problems associated with connecting a keeper to a dowel and coping using a laser welding technique has not been explored extensively in the dental literature. This in vitro study compared the surface characteristics, microstructure, and magnetic retentive forces for a dowel and coping-keeper mechanism fabricated using a laser welding process and a cast-to casting technique. Five cast-to and 6 laser-welded dowel and coping-keeper specimens were tested. Using 5 freestanding keepers as the control group, the surface characteristics and microstructures of the specimens were examined by means of stereomicroscopy, metallographic microscopy, and scanning electron microscopy (SEM). Energy-dispersive spectroscopic (EDS) microanalysis with SEM provided elemental concentration information for the test specimens. The vertical magnetic retentive forces (N) of the 3 groups were measured using a universal testing machine. The results were statistically compared using 1-way analysis of variance and the Newman-Keuls multiple range test (alpha =.05). The laser-welded dowel-keeper generally maintained its original surface smoothness as well as the original microstructure. Elements diffused readily through the fusion zone. The surface of the cast dowel-keeper became rough with the formation of an oxide layer, the microstructure changed, and there was only limited elemental diffusion in the fusion zone. The average vertical magnetic retentive force of the laser-welded group, the cast group, and the control group were 4.2 +/- 0.2 N, 3.8 +/- 0.3 N, and 5.6 +/- 0.3 N, respectively. Statistically significant differences in vertical magnetic retentive force were found between the control group and both the laser-welded and cast groups (P <.01). Compared with the cast dowel-keepers, the average vertical magnetic retentive force of the laser-welded dowel-keepers was significantly higher (P <.05). The laser welding technique had less influence on the surface characteristics, the microstructure, and the magnetic retentive forces of keepers relative to techniques that incorporate a keeper at the time of cast dowel and coping fabrication.

NDE of PWA 1480 single crystal turbine blade material

NASA Technical Reports Server (NTRS)

Klima, Stanley J.; Orange, Thomas W.; Dreshfield, Robert L.

1993-01-01

Cantilever bending fatigue specimens were examined by fluorescent liquid penetrant and radioactive gas penetrant (Krypton) non-destructive evaluation (NDE) methods and tested. Specimens with cast, ground, or polished surface were evaluated to study the effect of surface condition on NDE and fatigue crack initiation. Fractographic and metallurgical analyses were performed to determine the nature of crack precursors. Preliminary results show that fatigue strength was lower for specimens with cast surfaces than for specimens with machined surfaces. The liquid penetrant and gas penetrant techniques both provided indications of a large population of defects on the cast surfaces. On ground or polished specimen surfaces, the gas penetrant appeared to estimate the actual number of voids more accurately than the liquid penetrant.

A comparative study of roll compaction of free-flowing and cohesive pharmaceutical powders.

PubMed

Yu, Shen; Gururajan, Bindhu; Reynolds, Gavin; Roberts, Ron; Adams, Michael J; Wu, Chuan-Yu

2012-05-30

Roll compaction is widely adopted as a dry granulation method in the pharmaceutical industry. The roll compaction behaviour of feed powders is primarily governed by two parameters: the maximum pressure and the nip angle. Although the maximum pressure can be measured directly using pressure sensors fitted in the rolls, it is not a trivial task to determine the nip angle, which is a measure of the size of the compaction zone and hence the degree of compression. Thus a robust approach based upon the calculation of the pressure gradient, which can be obtained directly from experiments using an instrumented roll compactor, was developed. It has been shown that the resulting nip angles are comparable to those obtained using the methods reported in literature. Nevertheless, the proposed approach has distinctive advantages including (1) it is based on the intrinsic features of slip and no-slip interactions between the powder and roll surface and (2) it is not necessary to carry out wall friction measurements that involve plates that may not be representative of the roll compactor in terms of the surface topography and surface energy. The method was evaluated by investigating the effect of roll speed for two pharmaceutical excipients with distinctive material properties: microcrystalline cellulose (MCC) and di-calcium phosphate dihydrate (DCPD). It was found that the maximum pressure and nip angle for DCPD, which is a cohesive powder, decrease sharply with increasing roll speed whereas they are essentially independent of roll speed for MCC, which is an easy flowing powder. The roll compaction behaviour of MCC-DCPD mixtures with various compositions was also investigated in order to evaluate the effect of flowability. It was found that the nip angle and maximum pressure generally increased with improved flowability of the feed powders. Copyright © 2012 Elsevier B.V. All rights reserved.

NBS: Nondestructive evaluation of nonuniformities in 2219 aluminum alloy plate: Relationship to processing

NASA Technical Reports Server (NTRS)

Swartzendruber, L.; Boettinger, W.; Ives, L.; Coriell, S.; Ballard, D.; Laughlin, D.; Clough, R.; Biancanieilo, F.; Blau, P.; Cahn, J.

1980-01-01

The compositional homogeneity, microstructure, hardness, electrical conductivity and mechanical properties of 2219 aluminum alloy plates are influenced by the process variables during casting, rolling and thermomechanical treatment. The details of these relationships wre investigated for correctly processed 2219 plate as well as for deviations caused by improper quenching after solution heat treatment. Primary emphasis was been placed on the reliability of eddy current electrical conductivity and hardness as NDE tools to detect variations in mechanical properties.

CHARGING SIDE OF #130 ELECTRIC FURNACE CO. REHEAT FURNACE IN ...

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

CHARGING SIDE OF #130 ELECTRIC FURNACE CO. REHEAT FURNACE IN REROLL BAY. CAKES FROM THE CASTING SHOP ARE BROUGHT UP TO ROLLING TEMPERATURE IN ONE OF TWO (#130 AND 146) GAS-FIRED FURNACES. A RADIO-CONTROLLED OVERHEAD CRANE TRANSFERS CAKES FROM FLATCARS TO THE ROLLER LINE LEADING INTO THE FURNACE. CAKES ARE HEATED AT 900-1000 DEGREES FAHRENHEIT FOR THREE TO FOUR HOURS. RATED FURNACE CAPACITY IS 100,000 LBS.\\HOUR. - American Brass Foundry, 70 Sayre Street, Buffalo, Erie County, NY

Method for fabricating uranium foils and uranium alloy foils

DOEpatents

Hofman, Gerard L [Downers Grove, IL; Meyer, Mitchell K [Idaho Falls, ID; Knighton, Gaven C [Moore, ID; Clark, Curtis R [Idaho Falls, ID

2006-09-05

A method of producing thin foils of uranium or an alloy. The uranium or alloy is cast as a plate or sheet having a thickness less than about 5 mm and thereafter cold rolled in one or more passes at substantially ambient temperatures until the uranium or alloy thereof is in the shape of a foil having a thickness less than about 1.0 mm. The uranium alloy includes one or more of Zr, Nb, Mo, Cr, Fe, Si, Ni, Cu or Al.

The Ins and Outs of Relief Casting.

ERIC Educational Resources Information Center

Greene, Yvonne

2000-01-01

Describes a unit on clay casting that introduces students to relief sculpture. The unit takes three 45 to 50 minute class periods three weeks apart. Discusses each class session in detail: (1) creating the casting; (2) turning out and rinsing the casting; and (3) enriching the surface with color. (CMK)

Rolling Maneuver Load Alleviation using active controls

NASA Technical Reports Server (NTRS)

Woods-Vedeler, Jessica A.; Pototzky, Anthony S.

1992-01-01

Rolling Maneuver Load Alleviation (RMLA) has been demonstrated on the Active Flexible Wing (AFW) wind tunnel model in the NASA Langley Transonic Dynamics Tunnel. The design objective was to develop a systematic approach for developing active control laws to alleviate wing incremental loads during roll maneuvers. Using linear load models for the AFW wind-tunnel model which were based on experimental measurements, two RMLA control laws were developed based on a single-degree-of-freedom roll model. The RMLA control laws utilized actuation of outboard control surface pairs to counteract incremental loads generated during rolling maneuvers and actuation of the trailing edge inboard control surface pairs to maintain roll performance. To evaluate the RMLA control laws, roll maneuvers were performed in the wind tunnel at dynamic pressures of 150, 200, and 250 psf and Mach numbers of 0.33, .38 and .44, respectively. Loads obtained during these maneuvers were compared to baseline maneuver loads. For both RMLA controllers, the incremental torsion moments were reduced by up to 60 percent at all dynamic pressures and performance times. Results for bending moment load reductions during roll maneuvers varied. In addition, in a multiple function test, RMLA and flutter suppression system control laws were operated simultaneously during roll maneuvers at dynamic pressures 11 percent above the open-loop flutter dynamic pressure.

Effect of Surface Densification on the Microstructure and Mechanical Properties of Powder Metallurgical Gears by Using a Surface Rolling Process

PubMed Central

Peng, Jingguang; Zhao, Yan; Chen, Di; Li, Kiade; Lu, Wei; Yan, Biao

2016-01-01

Powder metallurgy (PM) components are widely used in the auto industry due to the advantage of net-shape forming, low cost, and high efficiency. Still, usage of PM components is limited in the auto industry when encountering rigorous situations, like heavy load, due to lower strength, hardness, wear resistance, and other properties compared to wrought components due to the existence of massive pores in the PM components. In this study, through combining the powder metallurgy process and rolling process, the pores in the PM components were decreased and a homogenous densified layer was formed on the surface, which resulted in the enhancement of the strength, hardness, wear resistance, and other properties, which can expand its range of application. In this paper, we study the impact of different rolling feeds on the performance of the components’ surfaces. We found that with the increase of the rolling feed, the depth of the densified layer increased. PMID:28773970

Effect of Surface Densification on the Microstructure and Mechanical Properties of Powder Metallurgical Gears by Using a Surface Rolling Process.

PubMed

Peng, Jingguang; Zhao, Yan; Chen, Di; Li, Kiade; Lu, Wei; Yan, Biao

2016-10-19

Powder metallurgy (PM) components are widely used in the auto industry due to the advantage of net-shape forming, low cost, and high efficiency. Still, usage of PM components is limited in the auto industry when encountering rigorous situations, like heavy load, due to lower strength, hardness, wear resistance, and other properties compared to wrought components due to the existence of massive pores in the PM components. In this study, through combining the powder metallurgy process and rolling process, the pores in the PM components were decreased and a homogenous densified layer was formed on the surface, which resulted in the enhancement of the strength, hardness, wear resistance, and other properties, which can expand its range of application. In this paper, we study the impact of different rolling feeds on the performance of the components' surfaces. We found that with the increase of the rolling feed, the depth of the densified layer increased.

New Nomenclatures for Heat Treatments of Additively Manufactured Titanium Alloys

NASA Astrophysics Data System (ADS)

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

2017-07-01

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

Advanced Response Surface Modeling of Ares I Roll Control Jet Aerodynamic Interactions

NASA Technical Reports Server (NTRS)

Favaregh, Noah M.

2010-01-01

The Ares I rocket uses roll control jets. These jets have aerodynamic implications as they impinge on the surface and protuberances of the vehicle. The jet interaction on the body can cause an amplification or a reduction of the rolling moment produced by the jet itself, either increasing the jet effectiveness or creating an adverse effect. A design of experiments test was planned and carried out using computation fluid dynamics, and a subsequent response surface analysis ensued on the available data to characterize the jet interaction across the ascent portion of the Ares I flight envelope. Four response surface schemes were compared including a single response surface covering the entire design space, separate sector responses that did not overlap, continuously overlapping surfaces, and recursive weighted response surfaces. These surfaces were evaluated on traditional statistical metrics as well as visual inspection. Validation of the recursive weighted response surface was performed using additionally available data at off-design point locations.

Corrosion behavior of cast Ti-6Al-4V alloyed with Cu.

PubMed

Koike, Marie; Cai, Zhuo; Oda, Yutaka; Hattori, Masayuki; Fujii, Hiroyuki; Okabe, Toru

2005-05-01

It has recently been found that alloying with copper improved the inherently poor grindability and wear resistance of titanium. This study characterized the corrosion behavior of cast Ti-6Al-4V alloyed with copper. Alloys (0.9 or 3.5 mass % Cu) were cast with the use of a magnesia-based investment in a centrifugal casting machine. Three specimen surfaces were tested: ground, sandblasted, and as cast. Commercially pure titanium and Ti-6Al-4V served as controls. Open-circuit potential measurement, linear polarization, and potentiodynamic cathodic polarization were performed in aerated (air + 10% CO(2)) modified Tani-Zucchi synthetic saliva at 37 degrees C. Potentiodynamic anodic polarization was conducted in the same medium deaerated by N(2) + 10% CO(2). Polarization resistance (R(p)), Tafel slopes, and corrosion current density (I(corr)) were determined. A passive region occurred for the alloy specimens with ground and sandblasted surfaces, as for CP Ti. However, no passivation was observed on the as-cast alloys or on CP Ti. There were significant differences among all metals tested for R(p) and I(corr) and significantly higher R(p) and lower I(corr) values for CP Ti compared to Ti-6Al-4V or the alloys with Cu. Alloying up to 3.5 mass % Cu to Ti-6Al-4V did not change the corrosion behavior. Specimens with ground or sandblasted surfaces were superior to specimens with as-cast surfaces. (c) 2005 Wiley Periodicals, Inc.

Antibody-immobilized column for quick cell separation based on cell rolling.

PubMed

Mahara, Atsushi; Yamaoka, Tetsuji

2010-01-01

Cell separation using methodological standards that ensure high purity is a very important step in cell transplantation for regenerative medicine and for stem cell research. A separation protocol using magnetic beads has been widely used for cell separation to isolate negative and positive cells. However, not only the surface marker pattern, e.g., negative or positive, but also the density of a cell depends on its developmental stage and differentiation ability. Rapid and label-free separation procedures based on surface marker density are the focus of our interest. In this study, we have successfully developed an antiCD34 antibody-immobilized cell-rolling column, that can separate cells depending on the CD34 density of the cell surfaces. Various conditions for the cell-rolling column were optimized including graft copolymerization, and adjustment of the column tilt angle, and medium flow rate. Using CD34-positive and -negative cell lines, the cell separation potential of the column was established. We observed a difference in the rolling velocities between CD34-positive and CD34-negative cells on antibody-immobilized microfluidic device. Cell separation was achieved by tilting the surface 20 degrees and the increasing medium flow. Surface marker characteristics of the isolated cells in each fraction were analyzed using a cell-sorting system, and it was found that populations containing high density of CD34 were eluted in the delayed fractions. These results demonstrate that cells with a given surface marker density can be continuously separated using the cell rolling column.

Corrosion casts of big bubbles formed during deep anterior lamellar keratoplasty.

PubMed

Feizi, Sepehr; Kanavi, Mozhgan Rezaei; Kharaghani, Davood; Balagholi, Sahar; Meskinfam, Masoumeh; Javadi, Mohammad Ali

2016-11-01

To characterize the walls of big bubbles formed during deep anterior lamellar keratoplasty (DALK) using the corrosion casting technique. Fresh corneoscleral buttons with normal transparency and without any known eye diseases (n = 11) were obtained from 11 human donors. A 20-gauge needle was used to inject a solution of 20 % polyvinyl alcohol (PVA) immediately beneath the corneal endothelium to form big bubbles in eight corneoscleral buttons. In the second experiment on three corneoscleral buttons, a big bubble was first formed by air injection beneath the endothelium. Thereafter, 20 % PVA was injected into the bubble space. Scanning electron microscopy was used to characterize the surfaces of the casts, which replicated the walls of the big bubbles. A type-1 bubble was formed in all corneas. In one cornea, one type-1 bubble was initially formed centrally, and while it was enlarged, an eccentric type-2 bubble appeared. Scanning electron microscopy showed that the casts of type-1 bubbles had two distinct surfaces. The anterior surface demonstrated several holes or pits, depending on the material used for the bubble formation, whereas the posterior surface exhibited an uneven surface. The anterior and posterior surfaces of the type-2 cast were more or less similar. A communication measuring 531.9 µm in length and 171.4 µm in diameter was found between the two bubbles. The corrosion casting technique provides a permanent three-dimensional record of the potential spaces and barriers in the posterior corneal stroma, which explains several features associated with big-bubble DALK.

Swiss roll nanomembranes with controlled proton diffusion as redox micro-supercapacitors.

PubMed

Ji, Hengxing; Mei, Yongfeng; Schmidt, Oliver G

2010-06-14

We demonstrate a redox Swiss roll micro-supercapacitor by rolling up a multilayered nanomembrane with an electrochemical active layer at either the outer or inner surface for different proton diffusion behaviors. The Swiss roll micro-supercapacitor could achieve high performance (e.g. capacity and life time) in a microscale power source and is helpful for studying charge transfer at the electrolyte/electrode interface.

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

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.

Metallurgical reactions in two industrially strip-cast aluminum-manganese alloys

NASA Astrophysics Data System (ADS)

Hansen, V.; Andersson, B.; Tibballs, J. E.; Gjønnes, J.

1995-08-01

Precipitation, phase transformation, subgrain growth, and recrystallization that occur during heat treatment of two strip-cast, cold-rolled, high manganese aluminum alloys have been studied mainly by transmission electron microscopy (TEM). The alloys differ in silicon content. The isothermal heat treatments have been performed in a salt bath at temperatures between 330 °C and 530 °C for times up to 1000 hours. Size distributions for each type of secondary particle have been determined. After short annealing times, small quasicrystals precipitated and subsequently transformed to α phase. The densities of these precipitates controlled dislocation movement and regulated subgrain sizes. Prolonged heating resulted in peritectoid reactions to Al6Mn or Al12Mn. Recrystallization, which is associated with the formation of Al12Mn, is advanced by increasing the silicon content; the nucleation and growth of Al12Mn occurs only at the expense of other phases that stabilize the subgrain network.

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

NASA Astrophysics Data System (ADS)

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

2017-03-01

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

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

PubMed

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

2017-03-27

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

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

PubMed Central

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

2017-01-01

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

Development of Fine-Grained, Low-Carbon Bainitic Steels with High Strength and Toughness Produced Through the Conventional Hot-Rolling and Air-Cooling

NASA Astrophysics Data System (ADS)

Dhua, Sanjay Kumar; Sarkar, Partha Pratim; Saxena, Atul; Jha, Bimal Kumar

2016-12-01

Low-carbon bainitic steels have created enormous interest among scientists across the world in the past few decades because of their high strength, toughness, and weldability replacing the conventional quenched and tempered medium-carbon steels. Three experimental steels with varying alloy additions were made in a 100-kg laboratory induction furnace and cast into 100-mm-diameter cylindrical ingots. These ingots were hot-rolled and air-cooled to 6-mm plates in an experimental rolling mill with selected thermomechanical parameters. Steels processed through this process provided an ultrafine low-carbon bainitic microstructure with maximum yield strength (YS) and ultimate tensile strength (UTS) 575 and 705 MPa, respectively. The Charpy impact toughness of the experimental steels was excellent, and at 253 K (-20 °C), it varied from 114 to 170 Joules. Cu-B-added steel was found to give an optimum combination of strength, YS-575 MPa, and toughness, 114 J at 253 K (-20 °C). Thus, fine-grained, low-carbon bainitic steels could be developed with a proper combination of alloying elements and thermomechanical parameters even by air-cooling.

Control law parameterization for an aeroelastic wind-tunnel model equipped with an active roll control system and comparison with experiment

NASA Technical Reports Server (NTRS)

Perry, Boyd, III; Dunn, H. J.; Sandford, Maynard C.

1988-01-01

Nominal roll control laws were designed, implemented, and tested on an aeroelastically-scaled free-to-roll wind-tunnel model of an advanced fighter configuration. The tests were performed in the NASA Langley Transonic Dynamics Tunnel. A parametric study of the nominal roll control system was conducted. This parametric study determined possible control system gain variations which yielded identical closed-loop stability (roll mode pole location) and identical roll response but different maximum control-surface deflections. Comparison of analytical predictions with wind-tunnel results was generally very good.

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

Online aptitude automatic surface quality inspection system for hot rolled strips steel

NASA Astrophysics Data System (ADS)

Lin, Jin; Xie, Zhi-jiang; Wang, Xue; Sun, Nan-Nan

2005-12-01

Defects on the surface of hot rolled steel strips are main factors to evaluate quality of steel strips, an improved image recognition algorithm are used to extract the feature of Defects on the surface of steel strips. Base on the Machine vision and Artificial Neural Networks, establish a defect recognition method to select defect on the surface of steel strips. Base on these research. A surface inspection system and advanced algorithms for image processing to hot rolled strips is developed. Preparing two different fashion to lighting, adopting line blast vidicon of CCD on the surface steel strips on-line. Opening up capacity-diagnose-system with level the surface of steel strips on line, toward the above and undersurface of steel strips with ferric oxide, injure, stamp etc of defects on the surface to analyze and estimate. Miscarriage of justice and alternate of justice rate not preponderate over 5%.Geting hold of applications on some big enterprises of steel at home. Experiment proved that this measure is feasible and effective.

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

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

Wright, Robert D.; Kilgo, Alice C.; Grant, Richard P.

2005-02-01

The stainless steel alloy 17-4PH contains a martensitic microstructure and second phase delta ({delta}) ferrite. Strengthening of 17-4PH is attributed to Cu-rich precipitates produced during age hardening treatments at 900-1150 F (H900-H1150). For wrought 17-4PH, the effects of heat treatment and microstructure on mechanical properties are well-documented [for example, Ref. 1]. Fewer studies are available on cast 17-4PH, although it has been a popular casting alloy for high strength applications where moderate corrosion resistance is needed. Microstructural features and defects particular to castings may have adverse effects on properties, especially when the alloy is heat treated to high strength. Themore » objective of this work was to outline the effects of microstructural features specific to castings, such as shrinkage/solidification porosity, on the mechanical behavior of investment cast 17-4PH. Besides heat treatment effects, the results of metallography and SEM studies showed that the largest effect on mechanical properties is from shrinkage/solidification porosity. Figure 1a shows stress-strain curves obtained from samples machined from castings in the H925 condition. The strength levels were fairly similar but the ductility varied significantly. Figure 1b shows an example of porosity on a fracture surface from a room-temperature, quasi-static tensile test. The rounded features represent the surfaces of dendrites which did not fuse or only partially fused together during solidification. Some evidence of local areas of fracture is found on some dendrite surfaces. The shrinkage pores are due to inadequate backfilling of liquid metal and simultaneous solidification shrinkage during casting. A summary of percent elongation results is displayed in Figure 2a. It was found that higher amounts of porosity generally result in lower ductility. Note that the porosity content was measured on the fracture surfaces. The results are qualitatively similar to those found by Gokhale et al. and Surappa et al. in cast A356 Al and by Gokhale et al. for a cast Mg alloys. The quantitative fractography and metallography work by Gokhale et al. illustrated the strong preference for fracture in regions of porosity in cast material. That is, the fracture process is not correlated to the average microstructure in the material but is related to the extremes in microstructure (local regions of high void content). In the present study, image analysis on random cross-sections of several heats indicated an overall porosity content of 0.03%. In contrast, the area % porosity was as high as 16% when measured on fracture surfaces of tensile specimens using stereology techniques. The results confirm that the fracture properties of cast 17-4PH cannot be predicted based on the overall 'average' porosity content in the castings.« less

Modeling the surface contamination of dental titanium investment castings.

PubMed

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

2005-02-01

The objective of this study was to develop a computational tool for assisting the design of titanium dental castings with minimal defects and to compare computational simulations with casting experiments. Modeling. An in-house cellular-automata solidification and finite-difference diffusion program was coupled with a commercial casting program and applied to (a) simple geometric wedge models and (b) a 3D-laser scan of a molar crown casting. Experimental. Wedges and molar crowns were hand-waxed and investment cast in commercial purity grade 1 (CP-1) titanium by a commercial dental laboratory. The castings were sectioned and analyzed using light and scanning electron microscopy, X-ray microanalysis, and microhardness testing. In the wedge sample, contamination with impurities (Al, Si), including intermetallic precipitates, was found to extend to a depth ranging from 30 to 120 microm depending on the section thickness and hence the local cooling rate. Microstructural and mechanical (hardness) effects were found to a depth ranging from 80 to 250 microm. The coupled micro/macro model predictions showed reasonable agreement for the pattern of contamination. Dental and medical applications demand close dimensional tolerance and freedom from surface impurities and structural flaws in castings having unique shapes. The ability to predict the structural, mechanical, and chemical changes resulting from the casting process will help to design the casting and post-casting processes to minimize these problems.

Surface chemical structure for soft contact lenses as a function of polymer processing.

PubMed

Grobe, G L; Valint, P L; Ammon, D M

1996-09-01

The surface chemistry and topography of cast-molded Etafilcon-A and doubled-sided lathed Etafilcon-A soft contact lenses were determined to be significantly different. The variations in surface chemical and morphologic structure between the two lenses were the result of contact lens manufacturing methods. The surface of the cast-molded Etafilcon-A had a consistently less rough surface compared to the doubled sided lathed Etafilcon-A as determined by atomic force microscopy. The surface of the doubled sided lathed Etafilcon-A contained primarily silicone and wax contamination in addition to minute amounts of HEMA. The cast-molded Etafilcon-A had an elemental and chemical content which was consistent with the polymer stoichiometry. Contact angle wettability profiles revealed inherent wettability differences between the two lenses types. The cast-molded Etafilcon-A had an inherently greater water wettability, polarity, and critical surface tension. This means that these two lenses cannot be compared as similar or identical lens materials in terms of surface composition. The manufacturing method used to produce a soft contact lens directly determines the surface elemental and chemical structure as well as the morphology of the finished lens material. These results suggest possible differences in the clinical comfort, spoilage, and lubricity felt during patient wear.

Electronic gap sensor and method

DOEpatents

Williams, R.S.; King, E.L.; Campbell, S.L.

1991-08-06

Disclosed are an apparatus and method for regulating the gap between a casting nozzle and a casting wheel in which the gap between the casting nozzle and the casting wheel is monitored by means of at least one sensing element protruding from the face of the casting nozzle. The sensing element is preferably connected to a voltage source and the casting wheel grounded. When the sensing element contacts the casting wheel, an electric circuit is completed. The completion of the circuit can be registered by an indicator, and the presence or absence of a completed circuit indicates the relative position of the casting nozzle to the casting wheel. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces. 5 figures.

Electronic gap sensor and method

DOEpatents

Williams, Robert S.; King, Edward L.; Campbell, Steven L.

1991-01-01

An apparatus and method for regulating the gap between a casting nozzle and a casting wheel in which the gap between the casting nozzle and the casting wheel is monitored by means of at least one sensing element protruding from the face of the casting nozzle. The sensing element is preferably connected to a voltage source and the casting wheel grounded. When the sensing element contacts the casting wheel, an electric circuit is completed. The completion of the circuit can be registered by an indicator, and the presence or absence of a completed circuit indicates the relative position of the casting nozzle to the casting wheel. The relative positions of the casting nozzle and casting wheel can thereby be selectively adjusted to continually maintain a predetermined distance between their adjacent surfaces.

The fractography of casting alloys

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

Powell, G.W.

1994-10-01

Several types of casting alloys were fractured using various loading modes (uniaxial tension, bending, impact, and torsion, and cyclic stressing), and the corresponding mechanical properties were determined. The unetched and etched fracture surfaces and the microstructures were examined using conventional techniques. The types of casting alloys that were the subjects f these investigations include gray iron, ductile iron, cast steel, and aluminum-base alloys (A380, A356, and 319). The fractographic studies have yielded these generalizations regarding the topography of the fracture surfaces. In the case of low-ductility alloys such as gray iron and the aluminum-base alloys, the tensile edge of amore » fracture surface produced by a stress system with a strong bending-moment component has a highly irregular contour, whereas the compressive edge of the fracture surface is quite straight and parallel to the bend axis. On the other hand, the periphery of a fracture surface produced by uniaxial tension has a completely irregular contour. The fracture surface produced by cyclic loading of a gray iron does not display any macroscopic evidence (such as a thumb nail) of the loading mode. However, the fracture surface of each of the other casting alloys displays clear, macroscopic evidence of failure induced by fatigue. The aluminum-base alloys fracture completely within the interdendritic region of the microstructure when subjected to monotonic loading by uniaxial tension or bending, whereas a fatigue crack propagates predominantly through the primary crystals of the microstructure.« less

Anisotropy of mechanical and thermal properties of AZ31 sheets prepared using the ARB technique

NASA Astrophysics Data System (ADS)

Halmešová, K.; Trojanová, Z.; Džugan, J.; Drozd, Z.; Minárik, P.; Knapek, M.

2017-07-01

In the accumulative roll bonding (ARB) technique, repeated stacking of material followed by conventional roll-bonding is carried out. For this process the surfaces are cleaned with ethanol and then joined together by rolling. The rolled material is then cut into two halves, again surface treated and roll-bonded. This process may be repeated several times. For the magnesium alloy AZ31 (Mg-3Al-1Zn) rolling at an elevated temperature of 400 °C is necessary for ARB because of the low plasticity of hexagonal magnesium alloys at lower temperatures. Samples for this study were prepared using 1 to 3 ARB passes through the rolling mill. It was found that the ARB substantially refined the grain size of sheets to the micrometer scale. The microstructure and texture of the deformed samples were studied by light and electron microscopy. The mechanical properties of the ARB samples were explored using tensile test-pieces cut from the sheets with the tensile axis taken either parallel or perpendicular to the rolling direction, where a significant anisotropy in both mechanical properties and Young’s modulus was found. Anisotropy is explained on the basis of the specific microstructure and texture formed during the ARB process.

Skimming the Surface: Teaching Kayak Support Strokes and Rolls.

ERIC Educational Resources Information Center

Higgins, Peter; Morgan, Alastair

1997-01-01

Teaching novice kayakers only the biomechanics of a roll and other "closed" (nonadaptable) skills does not create opportunities for flexible skill development. A wider approach teaches support strokes and rolls by focusing on "open" skills that can be transferred or adapted to any situation, including emergency decision making,…

Optimization technique for rolled edge control process based on the acentric tool influence functions.

PubMed

Du, Hang; Song, Ci; Li, Shengyi; Xu, Mingjin; Peng, Xiaoqiang

2017-05-20

In the process of computer controlled optical surfacing (CCOS), the uncontrollable rolled edge restricts further improvements of the machining accuracy and efficiency. Two reasons are responsible for the rolled edge problem during small tool polishing. One is that the edge areas cannot be processed because of the orbit movement. The other is that changing the tool influence function (TIF) is difficult to compensate for in algorithms, since pressure step appears in the local pressure distribution at the surface edge. In this paper, an acentric tool influence function (A-TIF) is designed to remove the rolled edge after CCOS polishing. The model of A-TIF is analyzed theoretically, and a control point translation dwell time algorithm is used to verify that the full aperture of the workpiece can be covered by the peak removal point of the tool influence functions. Thus, surface residual error in the full aperture can be effectively corrected. Finally, the experiments are carried out. Two fused silica glass samples of 100  mm×100  mm are polished by traditional CCOS and the A-TIF method, respectively. The rolled edge was clearly produced in the sample polished by the traditional CCOS, while residual errors do not show this problem the sample polished by the A-TIF method. Therefore, the rolled edge caused by the traditional CCOS process is successfully suppressed during the A-TIF process. The ability to suppress the rolled edge of the designed A-TIF has been confirmed.

Control of surface thermal scratch of strip in tandem cold rolling

NASA Astrophysics Data System (ADS)

Chen, Jinshan; Li, Changsheng

2014-07-01

The thermal scratch seriously affects the surface quality of the cold rolled stainless steel strip. Some researchers have carried out qualitative and theoretical studies in this field. However, there is currently a lack of research on effective forecast and control of thermal scratch defects in practical production, especially in tandem cold rolling. In order to establish precise mathematical model of oil film thickness in deformation zone, the lubrication in cold rolling process of SUS410L stainless steel strip is studied, and major factors affecting oil film thickness are also analyzed. According to the principle of statistics, mathematical model of critical oil film thickness in deformation zone for thermal scratch is built, with fitting and regression analytical method, and then based on temperature comparison method, the criterion for deciding thermal scratch defects is put forward. Storing and calling data through SQL Server 2010, a software on thermal scratch defects control is developed through Microsoft Visual Studio 2008 by MFC technique for stainless steel in tandem cold rolling, and then it is put into practical production. Statistics indicate that the hit rate of thermal scratch is as high as 92.38%, and the occurrence rate of thermal scratch is decreased by 89.13%. Owing to the application of the software, the rolling speed is increased by approximately 9.3%. The software developed provides an effective solution to the problem of thermal scratch defects in tandem cold rolling, and helps to promote products surface quality of stainless steel strips in practical production.

Scuffing Characteristics of High-Load Rolling/Sliding Contacts Operating in Liquid Oxygen: Effects of Materials and Surface Roughness

NASA Technical Reports Server (NTRS)

Chang, L.; Hall, P. B.; Thom, R.

1996-01-01

This research reports on an experimental study of the effects of materials and surface roughness on the scuffing characteristics of rolling/sliding contacts cooled and lubricated with liquid oxygen. Experiments were carried out under heavy loading with a Hertzian pressure in the range of 2.0 GPa to 3.0 GPa and with a high rolling velocity of up to 48 m/s. For contacts between AISI 440 C stainless-steel elements, the results showed that the scuffing behavior of the system was fairly consistent under a wide range of rolling velocity. Scuffing commenced at a small slide-to-roll ratio of around 0.02, and the scuffing behavior of the contact was not sensitive to surface roughness for the test-sample RMS roughness ranging from 0.02 microns to 0.10 microns. For contacts between 440 C and Si3N4 elements, on the other hand, the scuffing behavior of the system was not very consistent and somewhat unpredictable. The results were sensitive to surface roughness particularly that of the Si3N4 test sample. With well polished test samples, consistent results were obtained; the level of traction was lower than that with a 440 C toroid and scuffing did not take place up to a slide-to-roll ratio of near 0.03. The results strongly suggest that significant hydrodynamic effect can be generated by liquid oxygen under heavy loading and high velocity conditions. The results also suggest that the hydrodynamic action is likely generated by the conventional viscous mechanism as it can be largely destroyed by a narrow circumferential surface scratch running through the central region of the contact.

Failure analysis of an aluminum alloy material framework component induced by casting defects

NASA Astrophysics Data System (ADS)

Li, Bo; Hu, Weiye

2017-09-01

Failure analysis on a fractured radome framework component was carried out through visual observations, metallographic examination using optical microscope, fractog-raphy inspections using scanning electron microscope and chemical composition analysis. The failed frame was made of casting Al-Si7-Mg0.4 aluminum alloy. It had suffered a former vi-bration performance tests. It was indicated that the fractures were attributed to fatigue cracks which were induced by casting porosities at the outer surfaces of frame. Failure analysis was carefully conducted for the semi-penetrating crack appearing on the framework. According to the fractography inspected by scanning electron microscope, it was indicated that numerous casting porosities at the outer surface of the framework played the role of multiple fracture sources due to some applied stresses. Optical microstructure observations suggested that the dendrite-shaped casting porosities largely contributed to the crack-initiation. The groove-shaped structure at roots of spatial convex-bodies on the edge of casting porosities supplied the preferred paths of the crack-propagation. Besides, the brittle silicon eutectic particles distrib-uting along grain boundaries induced the intergranular fracture mode in the region of the over-load final fracture surface.

Thermal etching of silver: Influence of rolling defects

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

Ollivier, M., E-mail: o.maelig@imperial.ac.uk

2016-08-15

Silver is well known to be thermally etched in an oxygen-rich atmosphere and has been extensively studied in the laboratory to understand thermal etching and to limit its effect when this material is used as a catalyst. Yet, in many industrial applications the surface of rolled silver sheets is used without particular surface preparation. Here, it is shown by combining FIB-tomography, FIB-SIMS and analytical SEM that the kinetics of thermal etch pitting are significantly faster on rolled Ag surfaces than on polished surfaces. This occurs due to range of interacting phenomena including (i) the reaction of subsurface carbon-contamination with dissolvedmore » oxygen to form pores that grow to intersect the surface, (ii) surface reconstruction around corrosion pits and surface scratches, and (iii) sublimation at low pressure and high temperature. A method to identify subsurface pores is developed to show that the pores have (111) and (100) internal facets and may be filled with a gas coming from the chemical reaction of oxygen and carbon contamination. - Highlights: Thermal etching of industrial silver sheets vs. polished silver sheets Effect of annealing atmosphere on the thermal etching of silver: surface and subsurface characterization Link between etch pitting and defects induced by rolling. FIB-tomography coupled with EBSD for determining crystal planes of the facets of subsurface pores. FIB-SIMS characterization to probe the gas confined inside subsurface pores.« less

Freckle Defect Formation near the Casting Interfaces of Directionally Solidified Superalloys

PubMed Central

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

2016-01-01

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

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

PubMed

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

2016-11-16

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

Stress ratio effects in fatigue of lost foam cast aluminum alloy 356

NASA Astrophysics Data System (ADS)

Palmer, David E.

Lost foam casting is a highly versatile metalcasting process that offers significant benefits in terms of design flexibility, energy consumption, and environmental impact. In the present work, the fatigue behavior of lost foam cast aluminum alloy 356, in conditions T6 and T7, was investigated, under both zero and non-zero mean stress conditions, with either as-cast or machined surface finish. Scanning electron microscopy was used to identify and measure the defect from which fatigue fracture initiated. Based on the results, the applicability of nine different fatigue mean stress equations was compared. The widely-used Goodman equation was found to be highly non-conservative, while the Stulen, Topper-Sandor, and Walker equations performed reasonably well. Each of these three equations includes a material-dependent term for stress ratio sensitivity. The stress ratio sensitivity was found to be affected by heat treatment, with the T6 condition having greater sensitivity than the T7 condition. The surface condition (as-cast vs. machined) did not significantly affect the stress ratio sensitivity. The fatigue life of as-cast specimens was found to be approximately 60--70% lower than that of machined specimens at the same equivalent stress. This reduction could not be attributed to pore size alone, and is suspected to be due to the greater concentration of pyrolysis products at the as-cast surface. Directions for future work, including improved testing methods and some possible methods of improving the properties of lost foam castings, are discussed.

Modeling the investment casting of a titanium crown.

PubMed

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

2007-01-01

The objective of this study was to apply computational modeling tools to assist in the design of titanium dental castings. The tools developed should incorporate state-of-the-art micromodels to predict the depth to which the mechanical properties of the crown are affected by contamination from the mold. The model should also be validated by comparison of macro- and micro-defects found in a typical investment cast titanium tooth crown. Crowns were hand-waxed and investment cast in commercial purity grade 1 (CP-1) titanium by a commercial dental laboratory. The castings were analyzed using X-ray microtomography (XMT). Following sectioning, analysis continued with optical and scanning electron microscopy, and microhardness testing. An in-house cellular-automata solidification and finite-difference diffusion program was coupled with a commercial casting program to model the investment casting process. A three-dimensional (3D) digital image generated by X-ray tomography was used to generate an accurate geometric representation of a molar crown casting. Previously reported work was significantly expanded upon by including transport of dissolved oxygen and impurity sources upon the arbitrarily shaped surface of the crown, and improved coupling of micro- and macro-scale simulations. Macroscale modeling was found to be sufficient to accurately predict the location of the large internal porosity. These are shrinkage pores located in the thick sections of the cusp. The model was used to determine the influence of sprue design on the size and location of these pores. Combining microscale with macroscale modeling allowed the microstructure and depth of contamination to be predicted qualitatively. This combined model predicted a surprising result--the dissolution of silicon from the mold into the molten titanium is sufficient to depress the freezing point of the liquid metal such that the crown solidifies the subsurface. Solidification then progresses inwards and back out to the surface through the silicon-enriched near-surface layer. The microstructure and compositional analysis of the near-surface region are consistent with this prediction. A multiscale model was developed and validated, which can be used to design CP-Ti dental castings to minimize both macro- and micro-defects, including shrinkage porosity, grain size and the extent of surface contamination due to reaction with the mold material. The model predicted the surprising result that the extent of Si contamination from the mold was sufficient to suppress the liquidus temperature to the extent that the surface (to a depth of approximately 100 microm) of the casting solidifies after the bulk. This significantly increases the oxygen pickup, thereby increasing the depth of formation of alpha casing. The trend towards mold materials with reduced Si in order to produce easier-to-finish titanium castings is a correct approach.

Layer texture of hot-rolled BCC metals and its significance for stress-corrosion cracking of main gas pipelines

NASA Astrophysics Data System (ADS)

Perlovich, Yu. A.; Isaenkova, M. G.; Krymskaya, O. A.; Morozov, N. S.

2016-10-01

Based on data of X-ray texture analysis of hot-rolled BCC materials it was shown that the layerwise texture inhomogeneity of products is formed during their manufacturing. The effect can be explained by saturation with interstitial impurities of the surface layer, resulting in dynamical deformation aging (DDA). DDA prevents the dislocation slip under rolling and leads to an increase of lattice parameters in the external layer. The degree of arising inhomogeneity correlates with the tendency of hot-rolled sheets and obtained therefrom tubes to stress-corrosion cracking under exploitation, since internal layers have a compressive effect on external layers, and prevents opening of corrosion cracks at the tube surface.

Mirror mount

DOEpatents

Humpal, H.H.

1987-11-10

A mirror mount is provided that allows free pitch, yaw and roll motion of the mirror while keeping the location of a point on the surface of the mirror fixed in the rest frame of reference of the mount. Yaw movement is provided by two yaw cylinders that are bearing mounted to provide rotation. Pitch and roll motion is provided by a spherically annular shell that is air bearing mounted to move between a clamp and an upper pedestal bearing. The centers of curvature of the spherical surfaces of the shell lie upon the point. Pitch motion and roll motion are separately and independently imparted to mirror by a pair of pitch paddles and a pair of roll paddles that are independently and separately moved by control rods driven by motors. 5 figs.

Mirror mount

DOEpatents

Humpal, H.H.

1986-03-21

A mirror mount is provided that allows free pitch, yaw and roll motion of the mirror while keeping the location of a point on the surface of the mirror fixed in the rest frame of reference of the mount. Yaw movement is provided by two yaw cylinders that are bearing mounted to provide rotation. Pitch and roll motion is provided by a spherically annular shell that is air bearing mounted to move between a clamp and an upper pedestal bearing. The centers of curvature of the spherical surfaces of the shell lie upon the point. Pitch motion and roll motion are separately and independently imparted to mirror by a pair of pitch paddles and a pair of roll paddles that are independently and separately moved by control rods driven by motors.

Main roll for an air press of a papermaking machine

DOEpatents

Beck, David A.

2004-03-09

A roll for use in an air press assembly of a papermaking machine has a pair of ends associated therewith. The roll includes a pair of edge portions with each edge portion extending to one of the pair of ends. Each edge portion has an edge surface portion composed of a first material, the first material having a first hardness. The roll further includes a middle portion located between the pair of edge portions, the middle portion having a middle surface portion composed of a second material. The second material has a second hardness, the second material being harder than the first material. The first material is preferably a soft, seal material which promotes reduced air leakage from the air press assembly.

An improved segmentation method for defects inspection on steel roller surface

NASA Astrophysics Data System (ADS)

Xu, Jirui; Li, Xuekun; Cao, Yuzhong; Shi, Depeng; Yang, Jun; Jiang, Sheng; Rong, Yiming

2018-05-01

In the field of metal rolling, the quality of the steel roller's surface is significant for the final rolling products, e.g. metal sheets or foils. Besides the dimensional accuracy and surface roughness, the optical uniformity of the roller surface is also required for high quality rolling application. The typical optical defects of rollers after finish grinding include speckles, chatter marks, feed traces, and combination of all above. Unlike surface roughness, the optical defects can hardly be characterized by the topography or scanning electrical microscope measurement. Only the inspection by bared eyes of experienced engineers appears to be the effective manner for surface optical defects examination for large steel rollers. In this paper, an on-site machine vision system is designed to add on to the roller grinding machine to capture the surface image, and then an improved optical defects segmentation algorithm is developed based on the active contour model. Finally, experiments are carried out to verify the efficacy of the improved model.

Friction surfaced Stellite6 coatings

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

Rao, K. Prasad; Damodaram, R.; Rafi, H. Khalid, E-mail: khalidrafi@gmail.com

2012-08-15

Solid state Stellite6 coatings were deposited on steel substrate by friction surfacing and compared with Stellite6 cast rod and coatings deposited by gas tungsten arc and plasma transferred arc welding processes. Friction surfaced coatings exhibited finer and uniformly distributed carbides and were characterized by the absence of solidification structure and compositional homogeneity compared to cast rod, gas tungsten arc and plasma transferred coatings. Friction surfaced coating showed relatively higher hardness. X-ray diffraction of samples showed only face centered cubic Co peaks while cold worked coating showed hexagonally close packed Co also. - Highlights: Black-Right-Pointing-Pointer Stellite6 used as coating material formore » friction surfacing. Black-Right-Pointing-Pointer Friction surfaced (FS) coatings compared with casting, GTA and PTA processes. Black-Right-Pointing-Pointer Finer and uniformly distributed carbides in friction surfaced coatings. Black-Right-Pointing-Pointer Absence of melting results compositional homogeneity in FS Stellite6 coatings.« less

METHOD OF HOT ROLLING URANIUM METAL

DOEpatents

Kaufmann, A.R.

1959-03-10

A method is given for quickly and efficiently hot rolling uranium metal in the upper part of the alpha phase temperature region to obtain sound bars and sheets possessing a good surface finish. The uranium metal billet is heated to a temperature in the range of 1000 deg F to 1220 deg F by immersion iii a molten lead bath. The heated billet is then passed through the rolls. The temperature is restored to the desired range between successive passes through the rolls, and the rolls are turned down approximately 0.050 inch between successive passes.

Rolling contact fatigue of surface modified 440C using a 'Ge-Polymet' type disc rod test rig

NASA Technical Reports Server (NTRS)

Thom, Robert L.

1989-01-01

Through hardened 440 C martensitic stainless steel test specimens were surface modified and tested for changes in rolling contact fatigue using a disc on rod test rig. The surface modifications consisted of nitrogen, boron, titanium, chromium, tantalum, carbon, or molybdenum ion implantation at various ion fluences and energies. Tests were also performed on specimens reactively sputtered with titanium nitride.

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

PubMed

Hansen, Paul A; Beatty, Mark W

2017-02-01

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

Convective Heat Transfer from Castings of Ice Roughened Surfaces in Horizontal Flight

NASA Technical Reports Server (NTRS)

Dukhan, Nihad; Vanfossen, G. James, Jr.; Masiulaniec, K. Cyril; Dewitt, Kenneth J.

1995-01-01

A technique was developed to cast frozen ice shapes that had been grown on a metal surface. This technique was applied to a series of ice shapes that were grown in the NASA Lewis Icing Research Tunnel on flat plates. Eight different types of ice growths, characterizing different types of roughness, were obtained from these plates, from which aluminum castings were made. Test strips taken from these castings were outfitted with heat flux gages, such that when placed in a dry wind tunnel, they could be used to experimentally map out the convective heat transfer coefficient in the direction of flow from the roughened surfaces. The effects on the heat transfer coefficient for parallel flow, which simulates horizontal flight, were studied. The results of this investigation can be used to help size heaters for wings, helicopter rotor blades, jet engine intakes, etc., or de-icing for anti-icing applications where the flow is parallel to the iced surface.

The behaviour of entrainment defects formed in commercial purity Mg alloy cast under a cover gas of SF6

NASA Astrophysics Data System (ADS)

Li, T.; Griffiths, W. D.

2016-03-01

In the casting of light alloys, the oxidised film on the melt surface can be folded due to surface turbulence, thus forming entrainment defects that have a significant negative effect on the mechanical properties of castings. Previous researchers reported that the surface film of Mg alloys formed in an atmosphere containing SF6 had a complicated structure composed of MgO and MgF2. The work reported here aims to investigate the behaviour of entrainment defects formed in magnesium alloys protected by SF6-containing atmospheres. Tensile test bars of commercial purity Mg were cast in an unsealed environment under a cover gas of pure SF6. 34Scanning electron microscopy (SEM) of the fracture surface of the test bars indicated entrainment defects that consisted of symmetrical films containing MgO, but also sulphur and fluorine. The results of these examinations of the symmetrical films were used to infer the potential formation and development of entrainment defects in commercial purity Mg alloy.

On the impact of forced roll convection on vertical turbulent transport in cold air outbreaks

NASA Astrophysics Data System (ADS)

Gryschka, Micha; Fricke, Jens; Raasch, Siegfried

2014-11-01

We investigated the impact of roll convection on the convective boundary layer and vertical transports in different cold air outbreak (CAO) scenarios using large eddy simulations (LES). The organization of convection into rolls was triggered by upstream heterogeneities in the surface temperature, representing ice and water. By changing the sea ice distribution in our LES, we were able to simulate a roll and a nonroll case for each scenario. Furthermore, the roll wavelength was varied by changing the scale of the heterogeneity. The characteristics of the simulated rolls and cloud streets, such as aspect ratios, orientation of the roll axes, and downstream extensions of single rolls agreed closely with observations in CAO situations. The vertical turbulent fluxes, calculated for each simulation, were decomposed into contributions from rolls and from unorganized turbulence. Even though our results confirmed that rolls triggered by upstream heterogeneities can substantially contribute to vertical turbulent fluxes, the total fluxes were not affected by the rolls.

AMCC casting development. Volume 1: Executive Summary

NASA Technical Reports Server (NTRS)

1995-01-01

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

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

PubMed

Ohno, H

1976-11-01

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

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.

Report on results of current and future metal casting

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

Unal, Cetin; Carlson, Neil N.

2015-09-28

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

78 FR 11555 - Special Conditions: Embraer S.A., Model EMB-550 Airplane; Design Roll Maneuver for Electronic...

Federal Register 2010, 2011, 2012, 2013, 2014

2013-02-19

...; Design Roll Maneuver for Electronic Flight Controls AGENCY: Federal Aviation Administration (FAA), DOT... design roll maneuver for electronic flight controls, specifically an electronic flight control system... control surfaces. The Model EMB-550 airplane is designed for 8 passengers, with a maximum of 12 passengers...

Edge-Cracking Behavior of CoCrFeMnNi High-Entropy Alloy During Hot Rolling

NASA Astrophysics Data System (ADS)

Won, Jong Woo; Kang, Minju; Kwon, Heoun-Jun; Lim, Ka Ram; Seo, Seong Moon; Na, Young Sang

2018-05-01

This work investigated edge-cracking behavior of equiatomic CoCrFeMnNi high-entropy alloy during hot rolling at rolling temperatures 500 ≤ T R ≤ 1000 °C. Edge cracks did not form in the material rolled at 500 °C, but widened and deepened into the inside of plate as T R increased from 500 °C. Edge cracks were most severe in the material rolled at 1000 °C. Mn-Cr-O type non-metallic inclusion and oxidation were identified as major factors that caused edge cracking. The inclusions near edge region acted as preferential sites for crack formation. Connection between inclusion cracks and surface cracks induced edge cracking. Rolling at T R ≥ 600 °C generated distinct inclusion cracks whereas they were not serious at T R = 500 °C, so noticeable edge cracks formed at T R ≥ 600 °C. At T R = 1000 °C, significant oxidation occurred at the crack surface. This accelerated edge crack penetration by embrittling the crack tip, so severe edge cracking occurred at T R = 1000 °C.

Role of the endothelial surface layer in neutrophil recruitment.

PubMed

Marki, Alex; Esko, Jeffrey D; Pries, Axel R; Ley, Klaus

2015-10-01

Neutrophil recruitment in most tissues is limited to postcapillary venules, where E- and P-selectins are inducibly expressed by venular endothelial cells. These molecules support neutrophil rolling via binding of PSGL-1 and other ligands on neutrophils. Selectins extend ≤ 38 nm above the endothelial plasma membrane, and PSGL-1 extends to 50 nm above the neutrophil plasma membrane. However, endothelial cells are covered with an ESL composed of glycosaminoglycans that is ≥ 500 nm thick and has measurable resistance against compression. The neutrophil surface is also covered with a surface layer. These surface layers would be expected to completely shield adhesion molecules; thus, neutrophils should not be able to roll and adhere. However, in the cremaster muscle and in many other models investigated using intravital microscopy, neutrophils clearly roll, and their rolling is easily and quickly induced. This conundrum was thought to be resolved by the observation that the induction of selectins is accompanied by ESL shedding; however, ESL shedding only partially reduces the ESL thickness (to 200 nm) and thus is insufficient to expose adhesion molecules. In addition to its antiadhesive functions, the ESL also presents neutrophil arrest-inducing chemokines. ESL heparan sulfate can also bind L-selectin expressed by the neutrophils, which contributes to rolling and arrest. We conclude that ESL has both proadhesive and antiadhesive functions. However, most previous studies considered either only the proadhesive or only the antiadhesive effects of the ESL. An integrated model for the role of the ESL in neutrophil rolling, arrest, and transmigration is needed. © Society for Leukocyte Biology.

Role of the endothelial surface layer in neutrophil recruitment

PubMed Central

Marki, Alex; Esko, Jeffrey D.; Pries, Axel R.; Ley, Klaus

2015-01-01

Neutrophil recruitment in most tissues is limited to postcapillary venules, where E- and P-selectins are inducibly expressed by venular endothelial cells. These molecules support neutrophil rolling via binding of PSGL-1 and other ligands on neutrophils. Selectins extend ≤38 nm above the endothelial plasma membrane, and PSGL-1 extends to 50 nm above the neutrophil plasma membrane. However, endothelial cells are covered with an ESL composed of glycosaminoglycans that is ≥500 nm thick and has measurable resistance against compression. The neutrophil surface is also covered with a surface layer. These surface layers would be expected to completely shield adhesion molecules; thus, neutrophils should not be able to roll and adhere. However, in the cremaster muscle and in many other models investigated using intravital microscopy, neutrophils clearly roll, and their rolling is easily and quickly induced. This conundrum was thought to be resolved by the observation that the induction of selectins is accompanied by ESL shedding; however, ESL shedding only partially reduces the ESL thickness (to 200 nm) and thus is insufficient to expose adhesion molecules. In addition to its antiadhesive functions, the ESL also presents neutrophil arrest-inducing chemokines. ESL heparan sulfate can also bind L-selectin expressed by the neutrophils, which contributes to rolling and arrest. We conclude that ESL has both proadhesive and antiadhesive functions. However, most previous studies considered either only the proadhesive or only the antiadhesive effects of the ESL. An integrated model for the role of the ESL in neutrophil rolling, arrest, and transmigration is needed. PMID:25979432

Changes Found on Run-In and Scuffed Surfaces of Steel Chrome Plate, and Cast Iron

NASA Technical Reports Server (NTRS)

Good, J. N.; Godfrey, Douglas

1947-01-01

A study was made of run-in and scuffed steel, chrome-plate, and cast-iron surfaces. X-ray and electron diffraction techniques, micro-hardness determinations, and microscopy were used. Surface changes varied and were found to include three classes: chemical reaction, hardening, and crystallite-size alteration. The principal chemical reactions were oxidation and carburization.

Reduced Blood Coagulation on Roll-to-Roll, Shrink-Induced Superhydrophobic Plastics.

PubMed

Nokes, Jolie M; Liedert, Ralph; Kim, Monica Y; Siddiqui, Ali; Chu, Michael; Lee, Eugene K; Khine, Michelle

2016-03-09

The unique antiwetting properties of superhydrophobic (SH) surfaces prevent the adhesion of water and bodily fluids, including blood, urine, and saliva. While typical manufacturable approaches to create SH surfaces rely on chemical and structural modifications, such approaches are expensive, require postprocessing, and are often not biocompatible. By contrast, it is demonstrated that purely structural SH features are easily formed using high throughput roll-to-roll (R2R) manufacturing by shrinking a prestressed thermoplastic with a thin, stiff layer of silver and calcium. These features are subsequently embossed into any commercially available and Food and Drug Administration (FDA)-approved plastic. The R2R SH surfaces have contact angles >150° and contact angle hysteresis <10°. Importantly, the surfaces minimize blood adhesion, leading to reduced blood coagulation without the need for anticoagulants. SH surfaces have >4200× reduction of blood residue area compared to the nonstructured controls of the same material. In addition, blood clotting is reduced >5× using whole blood directly from the patient. Furthermore, these surfaces can be easily configured into 3D shapes, as demonstrated with SH tubes. With the simple scale-up production and the eliminated need for anticoagulants to prevent clotting, the proposed conformable SH surfaces can be impactful for a wide range of medical tools, including catheters and microfluidic channels. © 2016 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

1. VIEW OF THE CONTROL ROOM FOR THE XY RETRIEVER. ...

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

1. VIEW OF THE CONTROL ROOM FOR THE X-Y RETRIEVER. USING THE X-Y RETRIEVER, OPERATORS RETRIEVED PLUTONIUM METAL FROM THE PLUTONIUM STORAGE VAULTS (IN MODULE K) AND CONVEYED IT TO THE X-Y SHUTTLE AREA WHERE IT WAS CUT AND WEIGHED. FROM THE SHUTTLE AREA THE PLUTONIUM WAS CONVEYED TO MODULES A, J OR K FOR CASTING, OR MODULE B FOR ROLLING AND FORMING. (5/17/71) - Rocky Flats Plant, Plutonium Manufacturing Facility, North-central section of Plant, just south of Building 776/777, Golden, Jefferson County, CO

Chemical Degradation of the Cathodic Electrical Contact Between Carbon and Cast Iron in Aluminum Production Cells

NASA Astrophysics Data System (ADS)

Brassard, Martin; Désilets, Martin; Soucy, Gervais; Bilodeau, Jean-François; Forté, Martin

2017-06-01

The cathodic carbon to cast iron electrical contact degradation is one of the factors to consider in the cathode voltage drop (CVD) increase over the lifetime of aluminum production cells. Lab-scale experiments were carried out to study the cast iron to carbon interface chemical degradation and the impact of important cell parameters like temperature and bath chemistry. Laboratory degradation results were compared with industrial samples. A thermoelectric Ansys numerical model was then used to predict the effect of cast iron surface degradation over CVD. Results show that the aluminum formation on the cast iron surface and its subsequent diffusion creates an immiscible mixture of Fe-Al metal alloy and electrolytic bath. Disparities were also observed between industrial samples taken from two different technologies, suggesting that the degradation can be slowed down. Thermoelectric calculations finally revealed that the impact of the contact resistance augmentation is by far greater than the cast iron degradation.

Evidence of a rolling motion of a microparticle on a silicon wafer in a liquid environment

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

Schiwek, Simon; Stark, Robert W., E-mail: stark@csi.tu-darmstadt.de, E-mail: dietz@csi.tu-darmstadt.de; Dietz, Christian, E-mail: stark@csi.tu-darmstadt.de, E-mail: dietz@csi.tu-darmstadt.de

2016-05-21

The interaction of micro- and nanometer-sized particles with surfaces plays a crucial role when small-scale structures are built in a bottom-up approach or structured surfaces are cleaned in the semiconductor industry. For a reliable quantification of the interaction between individual particles and a specific surface, however, the motion type of the particle must be known. We developed an approach to unambiguously distinguish between sliding and rolling particles. To this end, fluorescent particles were partially bleached in a confocal laser scanning microscope to tailor an optical inhomogeneity, which allowed for the identification of the characteristic motion pattern. For the manipulation, themore » water flow generated by a fast moving cantilever-tip of an atomic force microscope enabled the contactless pushing of the particle. We thus experimentally evidenced a rolling motion of a micrometer-sized particle directly with a fluorescence microscope. A similar approach could help to discriminate between rolling and sliding particles in liquid flows of microfluidic systems.« less

Calculation of a vacuum system of the installation for cleaning the surface of metal rolling by a cathode spot of a vacuum arc

NASA Astrophysics Data System (ADS)

Kuznetsov, V. G.; Kurbanov, T. A.; Kostrin, D. K.

2017-07-01

In this work are presented the installations for cleaning the surface of rolled products (wire and ribbon) from scale and technological lubricant with gateway systems of open type. The calculation of gateway devices and the optimal selection of pumping systems are shown.

Effects of rolling friction on a spinning coin or disk

NASA Astrophysics Data System (ADS)

Cross, Rod

2018-05-01

Experimental and theoretical results are presented concerning the motion of a spinning disk on a horizontal surface. The disk precesses about a vertical axis while falling either quickly or slowly onto the surface depending on the coefficient of rolling friction. The rate of fall also depends on the offset distance, in the rolling direction, between the centre of mass and the line of action of the normal reaction force. Euler’s angular momentum equations are solved to obtain estimates of both the coefficient of friction and the offset distance for a 50.6 mm diameter brass disk spinning on three different surfaces. The fall times varied from about 3 s on P800 emery paper to about 30 s on glass.

Effect of rolling geometry on the mechanical properties, microstructure and recrystallization texture of Al-Mg-Si alloys

NASA Astrophysics Data System (ADS)

Wang, Xiao-feng; Guo, Ming-xing; Cao, Ling-yong; Wang, Fei; Zhang, Ji-shan; Zhuang, Lin-zhong

2015-07-01

The effect of rolling geometry on mechanical properties, microstructure, and recrystallization texture of Al-Mg-Si alloys was studied by means of tensile tests, microstructural observations, and electron backscatter diffraction measurements. The results reveal that the elongation and the average plasticity strain ratio ( r) values of the T4P (pre-aging plus natural aging)-treated alloy sheet with a rolling geometry value between 1 and 3 are somewhat higher than those of the T4P-treated sheet with a rolling geometry value between 3 and 6. The deformation and recrystallization microstructures of the sheet with a rolling geometry value between 1 and 3 are more uniform than those of the sheet with a rolling geometry value between 3 and 6. The former also possesses somewhat higher surface quality. H {001}<110> and Goss {110}<001> orientations are the main recrystallization texture components for the former case, whereas the latter case only includes H{001}<110> orientation. Texture gradients are present in the two alloy sheets. Shear texture component F on the surface of the sheet with a rolling geometry value between 3 and 6 and its higher texture gradients have revealed that non-uniform deformation occurred during cold rolling. The effects of texture on the yield strength and r value were also discussed.

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

Ayala, Alicia; Corral, Erica L.; Loehman, Ronald E.

A tape casting procedure for fabricating ceramic magnesium oxide tapes has been developed as a method to produce flat sheets of sintered MgO that are thin and porous. Thickness of single layer tapes is in the range of 200-400 {micro}m with corresponding surface roughness values in the range of 10-20 {micro}m as measured by laser profilometry. Development of the tape casting technique required optimization of pretreatment for the starting magnesium oxide (MgO) powder as well as a detailed study of the casting slurry preparation and subsequent heat treatments for sintering and final tape flattening. Milling time of the ceramic powder,more » plasticizer, and binder mixture was identified as a primary factor affecting surface morphology of the tapes. In general, longer milling times resulted in green tapes with a noticeably smoother surface. This work demonstrates that meticulous control of the entire tape casting operation is necessary to obtain high-quality MgO tapes.« less

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

PubMed

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

2014-10-01

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

Experimental und numerical investigations on cooling efficiency of Air-Mist nozzles on steel during continuous casting

NASA Astrophysics Data System (ADS)

Arth, G.; Taferner, M.; Bernhard, C.; Michelic, S.

2016-07-01

Cooling strategies in continuous casting of steel can vary from rapid cooling to slow cooling, mainly controlled by adjusting the amount of water sprayed onto the surface of the product. Inadequate adjustment however can lead to local surface undercooling or reheating, leading to surface and inner defects. This paper focuses on cooling efficiency of Air-Mist nozzles on casted steel and the experimental and numerical prediction of surface temperature distributions over the product width. The first part explains the determination of heat transfer coefficients (HTC) on laboratory scale, using a so called nozzle measuring stand (NMS). Based on measured water distributions and determined HTC's for air-mist nozzles using the NMS, surface temperatures are calculated by a transient 2D-model on a simple steel plate, explained in the second part of this paper. Simulations are carried out varying water impact density and spray water distribution, consequently influencing the local HTC distribution over the plate width. Furthermore, these results will be interpreted with regard to their consequence for surface and internal quality of the cast product. The results reveal the difficulty of correct adjustment of the amount of sprayed water, concurrent influencing water distribution and thus changing HTC distribution and surface temperature.

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.

Active load control during rolling maneuvers. [performed in the Langley Transonic Dynamics Tunnel

NASA Technical Reports Server (NTRS)

Woods-Vedeler, Jessica A.; Pototzky, Anthony S.; Hoadley, Sherwood T.

1994-01-01

A rolling maneuver load alleviation (RMLA) system has been demonstrated on the active flexible wing (AFW) wind tunnel model in the Langley Transonic Dynamics Tunnel (TDT). The objective was to develop a systematic approach for designing active control laws to alleviate wing loads during rolling maneuvers. Two RMLA control laws were developed that utilized outboard control-surface pairs (leading and trailing edge) to counteract the loads and that used inboard trailing-edge control-surface pairs to maintain roll performance. Rolling maneuver load tests were performed in the TDT at several dynamic pressures that included two below and one 11 percent above open-loop flutter dynamic pressure. The RMLA system was operated simultaneously with an active flutter suppression system above open-loop flutter dynamic pressure. At all dynamic pressures for which baseline results were obtained, torsion-moment loads were reduced for both RMLA control laws. Results for bending-moment load reductions were mixed; however, design equations developed in this study provided conservative estimates of load reduction in all cases.

Simulating Surface Oil Transport During the Deepwater Horizon Oil Spill: Experiments with the BioCast System

DTIC Science & Technology

2014-01-25

Virtual Special Issue Gulf of Mexico Modelling – Lessons from the spill Simulating surface oil transport during the Deepwater Horizon oil spill ...ocean surface materials. The Deepwater Horizon oil spill in the Gulf of Mexico provided a test case for the Bio-Optical Forecasting (BioCast) system...addition of explicit sources and sinks of surface oil concentrations provides a framework for increasingly complex oil spill modeling efforts that extend

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.

Direct laser interference patterning of metallic sleeves for roll-to-roll hot embossing

NASA Astrophysics Data System (ADS)

Lang, Valentin; Rank, Andreas; Lasagni, Andrés. F.

2017-03-01

Surfaces equipped with periodic patterns with feature sizes in the micrometer, submicrometer and nanometer range present outstanding surface properties. Many of these surfaces can be found on different plants and animals. However, there are few methods capable to produce such patterns in a one-step process on relevant technological materials. Direct laser interference patterning (DLIP) provides both high resolution as well as high throughput. Recently, fabrication rates up to 1 m2·min-1 could be achieved. However, resolution was limited to a few micrometers due to typical thermal effects that arise when nanosecond pulsed laser systems are used. Therefore, this study introduces an alternative to ns-DLIP for the fabrication of multi-scaled micrometer and submicrometer structures on nickel surfaces using picosecond pulses (10 ps at a wavelength of 1064 nm). Due to the nature of the interaction process of the metallic surfaces with the ultrashort laser pulses, it was not only possible to directly transfer the shape of the interference pattern intensity distribution to the material (with spatial periods ranging from 1.5 μm to 5.7 μm), but also to selectively obtain laser induce periodic surface structures with feature sizes in the submicrometer and nanometer range. Finally, the structured nickel sleeves are utilized in a roll-to-roll hot embossing unit for structuring of polymer foils. Processing speeds up to 25 m·min-1 are reported.

Preliminary Study into Shell Mold Casting of Nominal 60-Nitinol Alloy

DTIC Science & Technology

The present study was initiated to determine the feasibility of shell mold casting nominal 60- Nitinol into suitable EOD (Explosive Ordnance Disposal...surface finish and definition and property response of cast alloy. Based upon the results, 60- Nitinol appears quite suited to shell molding and a...concern lies in the casting porosity associated with the relatively large liquid-to-solid shrinkage of nominal 60- Nitinol .

Competition between surface adsorption and folding of fibril-forming polypeptides

NASA Astrophysics Data System (ADS)

Ni, Ran; Kleijn, J. Mieke; Abeln, Sanne; Cohen Stuart, Martien A.; Bolhuis, Peter G.

2015-02-01

Self-assembly of polypeptides into fibrillar structures can be initiated by planar surfaces that interact favorably with certain residues. Using a coarse-grained model, we systematically studied the folding and adsorption behavior of a β -roll forming polypeptide. We find that there are two different folding pathways depending on the temperature: (i) at low temperature, the polypeptide folds in solution into a β -roll before adsorbing onto the attractive surface; (ii) at higher temperature, the polypeptide first adsorbs in a disordered state and folds while on the surface. The folding temperature increases with increasing attraction as the folded β -roll is stabilized by the surface. Surprisingly, further increasing the attraction lowers the folding temperature again, as strong attraction also stabilizes the adsorbed disordered state, which competes with folding of the polypeptide. Our results suggest that to enhance the folding, one should use a weakly attractive surface. They also explain the recent experimental observation of the nonmonotonic effect of charge on the fibril formation on an oppositely charged surface [C. Charbonneau et al., ACS Nano 8, 2328 (2014), 10.1021/nn405799t].

Corrosion resistance and biological activity of TiO2 implant coatings produced in oxygen-rich environments.

PubMed

Zhang, Rui; Wan, Yi; Ai, Xing; Liu, Zhanqiang; Zhang, Dong

2017-01-01

The physical and chemical properties of bio-titanium alloy implant surfaces play an important role in their corrosion resistance and biological activity. New turning and turning-rolling processes are presented, employing an oxygen-rich environment in order to obtain titanium dioxide layers that can both protect implants from corrosion and also promote cell adhesion. The surface topographies, surface roughnesses and chemical compositions of the sample surfaces were obtained using scanning electron microscopy, a white light interferometer, and the Auger electron spectroscopy, respectively. The corrosion resistance of the samples in a simulated body fluid was determined using electrochemical testing. Biological activity on the samples was also analyzed, using a vitro cell culture system. The results show that compared with titanium oxide layers formed using a turning process in air, the thickness of the titanium oxide layers formed using turning and turning-rolling processes in an oxygen-rich environment increased by 4.6 and 7.3 times, respectively. Using an oxygen-rich atmosphere in the rolling process greatly improves the corrosion resistance of the resulting samples in a simulated body fluid. On samples produced using the turning-rolling process, cells spread quickly and exhibited the best adhesion characteristics.

Bioactive treatment promotes osteoblast differentiation on titanium materials fabricated by selective laser melting technology.

PubMed

Tsukanaka, Masako; Fujibayashi, Shunsuke; Takemoto, Mitsuru; Matsushita, Tomiharu; Kokubo, Tadashi; Nakamura, Takashi; Sasaki, Kiyoyuki; Matsuda, Shuichi

2016-01-01

Selective laser melting (SLM) technology is useful for the fabrication of porous titanium implants with complex shapes and structures. The materials fabricated by SLM characteristically have a very rough surface (average surface roughness, Ra=24.58 µm). In this study, we evaluated morphologically and biochemically the specific effects of this very rough surface and the additional effects of a bioactive treatment on osteoblast proliferation and differentiation. Flat-rolled titanium materials (Ra=1.02 µm) were used as the controls. On the treated materials fabricated by SLM, we observed enhanced osteoblast differentiation compared with the flat-rolled materials and the untreated materials fabricated by SLM. No significant differences were observed between the flat-rolled materials and the untreated materials fabricated by SLM in their effects on osteoblast differentiation. We concluded that the very rough surface fabricated by SLM had to undergo a bioactive treatment to obtain a positive effect on osteoblast differentiation.

Vision-based surface defect inspection for thick steel plates

NASA Astrophysics Data System (ADS)

Yun, Jong Pil; Kim, Dongseob; Kim, KyuHwan; Lee, Sang Jun; Park, Chang Hyun; Kim, Sang Woo

2017-05-01

There are several types of steel products, such as wire rods, cold-rolled coils, hot-rolled coils, thick plates, and electrical sheets. Surface stains on cold-rolled coils are considered defects. However, surface stains on thick plates are not considered defects. A conventional optical structure is composed of a camera and lighting module. A defect inspection system that uses a dual lighting structure to distinguish uneven defects and color changes by surface noise is proposed. In addition, an image processing algorithm that can be used to detect defects is presented in this paper. The algorithm consists of a Gabor filter that detects the switching pattern and employs the binarization method to extract the shape of the defect. The optics module and detection algorithm optimized using a simulator were installed at a real plant, and the experimental results conducted on thick steel plate images obtained from the steel production line show the effectiveness of the proposed method.

Suspension system for a wheel rolling on a flat track. [bearings for directional antennas

NASA Technical Reports Server (NTRS)

Mcginness, H. D. (Inventor)

1981-01-01

An improved suspension system for an uncrowned wheel rolling on a flat track is presented. It is characterized by a wheel frame assembly including a wheel frame and at least one uncrowned wheel connected in supporting relation with the frame. It is adapted to be seated in rolling engagement with a flat track, a load supporting bed, and a plurality of flexural struts interconnecting the bed in supported relation with the frame. Each of said struts is disposed in a plane passing through the center of the uncrowned wheel surface along a line substantially bisecting the line of contact established between the wheel surface and the flat surface of the truck and characterized by a modulus of elasticity sufficient for maintaining the axis of rotation for the wheel in substantial parallelism with the line of contact established between the surfaces of the wheel and track.

Automatic casting surface defect recognition and classification

NASA Astrophysics Data System (ADS)

Wong, Boon K.; Elliot, M. P.; Rapley, C. W.

1995-03-01

High integrity castings require surfaces free from defects to reduce, if not eliminate, vulnerability to component failure from such as physical or thermal fatigue or corrosion attack. Previous studies have shown that defects on casting surfaces can be optically enhanced from the surrounding randomly textured surface by liquid penetrants, magnetic particle and other methods. However, very little has been reported on recognition and classification of the defects. The basic problem is one of shape recognition and classification, where the shape can vary in size and orientation as well as in actual shape generally within an envelope that classifies it as a particular defect. The initial work done towards this has focused on recognizing and classifying standard shapes such as the circle, square, rectangle and triangle. Various approaches were tried and this led eventually to a series of fuzzy logic based algorithms from which very good results were obtained. From this work fuzzy logic memberships were generated for the detection of defects found on casting surfaces. Simulated model shapes of such as the quench crack, mechanical crack and hole have been used to test the generated algorithm and the results for recognition and classification are very encouraging.

Effect of Binder and Mold parameters on Collapsibility and Surface Finish of Gray Cast Iron No-bake Sand Molds

NASA Astrophysics Data System (ADS)

Srinivasulu Reddy, K.; Venkata Reddy, Vajrala; Mandava, Ravi Kumar

2017-08-01

Chemically bonded no-bake molds and cores have good mechanical properties and produce dimensionally accurate castings compared to green sand molds. Poor collapsibility property of CO2 hardened sodium silicate bonded sand mold and phenolic urethane no-bake (PUN) binder system, made the reclamation of the sands more important. In the present work fine silica sand is mixed with phenolic urethane no-bake binder and the sand sets in a very short time within few minutes. In this paper it is focused on optimizing the process parameters of PUN binder based sand castings for better collapsibility and surface finish of gray cast iron using Taguchi design. The findings were successfully verified through experiments.

High-Performance As-Cast Nonfullerene Polymer Solar Cells with Thicker Active Layer and Large Area Exceeding 11% Power Conversion Efficiency.

PubMed

Fan, Qunping; Wang, Yan; Zhang, Maojie; Wu, Bo; Guo, Xia; Jiang, Yufeng; Li, Wanbin; Guo, Bing; Ye, Chennan; Su, Wenyan; Fang, Jin; Ou, Xuemei; Liu, Feng; Wei, Zhixiang; Sum, Tze Chien; Russell, Thomas P; Li, Yongfang

2018-02-01

In this work, a nonfullerene polymer solar cell (PSC) based on a wide bandgap polymer donor PM6 containing fluorinated thienyl benzodithiophene (BDT-2F) unit and a narrow bandgap small molecule acceptor 2,2'-((2Z,2'Z)-((4,4,9,9-tetrahexyl-4,9-dihydro-s-indaceno[1,2-b:5,6-b']dithiophene-2,7-diyl)bis(methanylylidene))bis(3-oxo-2,3-dihydro-1H-indene-2,1-diylidene))dimalononitrile (IDIC) is developed. In addition to matched energy levels and complementary absorption spectrum with IDIC, PM6 possesses high crystallinity and strong π-π stacking alignment, which are favorable to charge carrier transport and hence suppress recombination in devices. As a result, the PM6:IDIC-based PSCs without extra treatments show an outstanding power conversion efficiency (PCE) of 11.9%, which is the record value for the as-cast PSC devices reported in the literature to date. Moreover, the device performances are insensitive to the active layer thickness (≈95-255 nm) and device area (0.20-0.81 cm 2 ) with PCEs of over 11%. Besides, the PM6:IDIC-based flexible PSCs with a large device area of 1.25 cm 2 exhibit a high PCE of 6.54%. These results indicate that the PM6:IDIC blend is a promising candidate for future roll-to-roll mass manufacturing and practical application of highly efficient PSCs. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

The effects of surface condition on abdominal muscle activity during single-legged hold exercise.

PubMed

Ha, Sung-min; Oh, Jae-seop; Jeon, In-cheol; Kwon, Oh-yun

2015-02-01

To treat low-back pain, various spinal stability exercises are commonly used to improve trunk muscle function and strength. Because human movement for normal daily activity occurs in multi-dimensions, the importance of exercise in multi-dimensions or on unstable surfaces has been emphasized. Recently, a motorized rotating platform (MRP) for facilitating multi-dimensions dynamic movement was introduced for clinical use. However, the abdominal muscle activity with this device has not been reported. The purpose of this study was to compare the abdominal muscle activity (rectus abdominis, external and internal oblique muscles) during an active single-leg-hold (SLH) exercise on a floor (stable surface), foam roll, and motorized rotating platform (MRP). Thirteen healthy male subjects participated in this study. Using electromyography, the abdominal muscle activity was measured while the subjects performed SLH exercises on floor (stable surface), foam roll, and MRP. There were significant differences in the abdominal muscle activities among conditions (P<.05), except for left EO (P>.05) (Fig. 2). After the Bonferroni correction, however, no significant differences among conditions remained, except for differences in both side IO muscle activity between the floor and foam roll conditions (padj<0.017). The findings suggest that performing the SLH exercises on a foam roll and MRP is more effective increased activities of both side of RA and IO, and Rt. EO compared to floor condition. However, there were no significant differences in abdominal muscles activity in the multiple comparison between conditions (mean difference were smaller than the standard deviation in the abdominal muscle activities) (padj>0.017), except for differences in both side IO muscle activity between the floor (stable surface) and foam roll (padj<0.017) (effect size: 0.79/0.62 (non-supporting/supporting leg) for foam-roll versus floor). Copyright © 2014 Elsevier Ltd. All rights reserved.

Evaluation of Different Disinfactants on Dimensional Accuracy and Surface Quality of Type IV Gypsum Casts Retrieved from Elastomeric Impression Materials.

PubMed

Pal, P K; Kamble, Suresh S; Chaurasia, Ranjitkumar Rampratap; Chaurasia, Vishwajit Rampratap; Tiwari, Samarth; Bansal, Deepak

2014-06-01

The present study was done to evaluate the dimensional stability and surface quality of Type IV gypsum casts retrieved from disinfected elastomeric impression materials. In an in vitro study contaminated impression material with known bacterial species was disinfected with disinfectants followed by culturing the swab sample to assess reduction in level of bacterial colony. Changes in surface detail reproduction of impression were assessed fallowing disinfection. All the three disinfectants used in the study produced a 100% reduction in colony forming units of the test organisms. All the three disinfectants produced complete disinfection, and didn't cause any deterioration in surface detail reproduction. How to cite the article: Pal PK, Kamble SS, Chaurasia RR, Chaurasia VR, Tiwari S, Bansal D. Evaluation of dimensional stability and surface quality of type IV gypsum casts retrieved from disinfected elastomeric impression materials. J Int Oral Health 2014;6(3):77-81.

Ultra-smooth finishing of aspheric surfaces using CAST technology

NASA Astrophysics Data System (ADS)

Kong, John; Young, Kevin

2014-06-01

Growing applications for astronomical ground-based adaptive systems and air-born telescope systems demand complex optical surface designs combined with ultra-smooth finishing. The use of more sophisticated and accurate optics, especially aspheric ones, allows for shorter optical trains with smaller sizes and a reduced number of components. This in turn reduces fabrication and alignment time and costs. These aspheric components include the following: steep surfaces with large aspheric departures; more complex surface feature designs like stand-alone off-axis-parabola (OAP) and free form optics that combine surface complexity with a requirement for ultra-high smoothness, as well as special optic materials such as lightweight silicon carbide (SiC) for air-born systems. Various fabrication technologies for finishing ultra-smooth aspheric surfaces are progressing to meet these growing and demanding challenges, especially Magnetorheological Finishing (MRF) and ion-milling. These methods have demonstrated some good success as well as a certain level of limitations. Amongst them, computer-controlled asphere surface-finishing technology (CAST), developed by Precision Asphere Inc. (PAI), plays an important role in a cost effective manufacturing environment and has successfully delivered numerous products for the applications mentioned above. One of the most recent successes is the Gemini Planet Imager (GPI), the world's most powerful planet-hunting instrument, with critical aspheric components (seven OAPs and free form optics) made using CAST technology. GPI showed off its first images in a press release on January 7, 2014 . This paper reviews features of today's technologies in handling the ultra-smooth aspheric optics, especially the capabilities of CAST on these challenging products. As examples, three groups of aspheres deployed in astronomical optics systems, both polished and finished using CAST, will be discussed in detail.

KSC-99pp0532

NASA Image and Video Library

1999-05-16

KENNEDY SPACE CENTER, FLA. -- Casting a giant shadow across the crawlerway, a crawler transporter slowly maneuvers Space Shuttle Discovery, with its external tank and solid rocket boosters, toward High Bay 1 of the Vehicle Assembly Building to repair damage to the external tank's foam insulation caused by hail. The necessary repair work could not be performed at Pad 39B due to limited access to the damaged areas. The work is expected to take two to three days, allowing Discovery to roll back to the pad by midweek for launch of mission STS-96, the 94th launch in the Space Shuttle Program. This is only the 13th time since 1981 that a Shuttle has had to roll back from the pad. Liftoff will occur no earlier than May 27. STS-96 is a logistics and resupply mission for the International Space Station, carrying such payloads as a Russian crane, the Strela; a U.S.-built crane; the Spacehab Oceaneering Space System Box (SHOSS), a logistics items carrier; and STARSHINE, a student-shared experiment

Solution processed flexible organic thin film back-gated transistors based on polyimide dielectric films

NASA Astrophysics Data System (ADS)

Park, Janghoon; Min, Yoonki; Lee, Dongjin

2018-04-01

An organic thin film back-gated transistor (OBGT) was fabricated and characterized. The gate electrode was printed on the back side of substrate, and the dielectric layer was omitted by substituting the dielectric layer with the polyimide (PI) film substrate. Roll-to-roll (R2R) gravure printing, doctor blading, and drop casting methods were used to fabricate the OBGT. The printed OBGT device shows better performance compared with an OTFT device based on dielectric layer of BaTiO3. Additionally, a calendering process enhanced the performance by a factor of 3 to 7 (mobility: 0.016 cm2/V.s, on/off ratio: 9.17×103). A bending test was conducted to confirm the flexibility and durability of the OBGT device. The results show the fabricated device endures 20000-cyclic motions. The realized OBGT device was successfully fabricated and working, which is meaningful for production engineering from the viewpoint of process development.

Formation of the structure of thin-sheet rolled product from a high-strength sparingly alloyed aluminum alloy ``nikalin''

NASA Astrophysics Data System (ADS)

Shurkin, P. K.; Belov, N. A.; Akopyan, T. K.; Alabin, A. N.; Aleshchenko, A. S.; Avxentieva, N. N.

2017-09-01

The regime of thermomechanical treatment of flat ingots of a high-strength sparingly alloyed alloy based on the Al-Zn-Mg-Ni-Fe system upon the production of thin-sheet rolled products with a reduction of more than 97% has been substantiated. Using experimental and calculated methods, the structure and phase composition of the experimental alloy in the as cast and deformed state and after heat treatment including quenching with subsequent aging have been studied. It has been found that the structure of the wrought semi-finished products after aging according to T and T1 regimes consists of the precipitation-hardened aluminum matrix and uniformly distributed isolated particles of Al9FeNi with a size of 1-2 μm, which provides a combination of high strength and satisfactory plasticity at the level of standard high-strength aluminum alloys of the Al-Zn-Mg-Cu system. The fractographic analysis confirmed that the tested samples underwent a ductile fracture.

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

Dai, Qiang; Kelly, Jarod C.; Burnham, Andrew

This report serves as an update for the life-cycle analysis (LCA) of aluminum production based on the most recent data representing the state-of-the-art of the industry in North America. The 2013 Aluminum Association (AA) LCA report on the environmental footprint of semifinished aluminum products in North America provides the basis for the update (The Aluminum Association, 2013). The scope of this study covers primary aluminum production, secondary aluminum production, as well as aluminum semi-fabrication processes including hot rolling, cold rolling, extrusion and shape casting. This report focuses on energy consumptions, material inputs and criteria air pollutant emissions for each processmore » from the cradle-to-gate of aluminum, which starts from bauxite extraction, and ends with manufacturing of semi-fabricated aluminum products. The life-cycle inventory (LCI) tables compiled are to be incorporated into the vehicle cycle model of Argonne National Laboratory’s Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation (GREET) Model for the release of its 2015 version.« less

Nonlinear dynamic modeling of surface defects in rolling element bearing systems

NASA Astrophysics Data System (ADS)

Rafsanjani, Ahmad; Abbasion, Saeed; Farshidianfar, Anoushiravan; Moeenfard, Hamid

2009-01-01

In this paper an analytical model is proposed to study the nonlinear dynamic behavior of rolling element bearing systems including surface defects. Various surface defects due to local imperfections on raceways and rolling elements are introduced to the proposed model. The contact force of each rolling element described according to nonlinear Hertzian contact deformation and the effect of internal radial clearance has been taken into account. Mathematical expressions were derived for inner race, outer race and rolling element local defects. To overcome the strong nonlinearity of the governing equations of motion, a modified Newmark time integration technique was used to solve the equations of motion numerically. The results were obtained in the form of time series, frequency responses and phase trajectories. The validity of the proposed model verified by comparison of frequency components of the system response with those obtained from experiments. The classical Floquet theory has been applied to the proposed model to investigate the linear stability of the defective bearing rotor systems as the parameters of the system changes. The peak-to-peak frequency response of the system for each case is obtained and the basic routes to periodic, quasi-periodic and chaotic motions for different internal radial clearances are determined. The current study provides a powerful tool for design and health monitoring of machine systems.

Flight Test of the F/A-18 Active Aeroelastic Wing Airplane

NASA Technical Reports Server (NTRS)

Voracek, David

2007-01-01

A viewgraph presentation of flight tests performed on the F/A active aeroelastic wing airplane is shown. The topics include: 1) F/A-18 AAW Airplane; 2) F/A-18 AAW Control Surfaces; 3) Flight Test Background; 4) Roll Control Effectiveness Regions; 5) AAW Design Test Points; 6) AAW Phase I Test Maneuvers; 7) OBES Pitch Doublets; 8) OBES Roll Doublets; 9) AAW Aileron Flexibility; 10) Phase I - Lessons Learned; 11) Control Law Development and Verification & Validation Testing; 12) AAW Phase II RFCS Envelopes; 13) AAW 1-g Phase II Flight Test; 14) Region I - Subsonic 1-g Rolls; 15) Region I - Subsonic 1-g 360 Roll; 16) Region II - Supersonic 1-g Rolls; 17) Region II - Supersonic 1-g 360 Roll; 18) Region III - Subsonic 1-g Rolls; 19) Roll Axis HOS/LOS Comparison Region II - Supersonic (open-loop); 20) Roll Axis HOS/LOS Comparison Region II - Supersonic (closed-loop); 21) AAW Phase II Elevated-g Flight Test; 22) Region I - Subsonic 4-g RPO; and 23) Phase II - Lessons Learned

The Effects of Metallurgical Factors on PWSCC Crack Growth Rates in TT Alloy 690 in Simulated PWR Primary Water

NASA Astrophysics Data System (ADS)

Yonezawa, Toshio; Watanabe, Masashi; Hashimoto, Atsushi

2015-06-01

Primary water stress corrosion cracking growth rates (PWSCCGRs) in highly cold-worked thermally treated (TT) Alloy 690 have been recently reported as exhibiting significant heat-to-heat variability. Authors hypothesized that these significant differences could be due to the metallurgical characteristics of each heat. In order to confirm this hypothesis, the effect of fundamental metallurgical characteristics on PWSCCGR measurements in cold-worked TT Alloy 690 has been investigated. The following new observations were made in this study: (1) Microcracks and voids were observed in or near eutectic crystals of grain boundary (GB) M23C6 carbides (primary carbides) after cold rolling, but were not observed before cold rolling. These primary carbides with microcracks and voids were observed in both lightly forged and as-cast and cold-rolled TT Alloy 690 (heat A) as well as in a cold-rolled TT Alloy 690 (heat Y) that simulated the chemical composition and carbide banded structure of the material previously tested by Paraventi and Moshier. However, this was not observed in precipitated (secondary) M23C6 GB carbides in heavily forged and cold-rolled TT Alloy 690 heat A and a cold-rolled commercial TT Alloy 690. (2) From microstructural analyses carried out on the various TT Alloy 690 test materials before and after cold rolling, the amount of eutectic crystals (primary carbides and nitrides) M23C6 and TiN depended on the chemical composition. In particular, the amount of M23C6 depended on the fabrication process. Microcracks and voids in or near the M23C6 and TiN precipitates were generated by the cold rolling process. (3) The PWSCCGRs observed in TT Alloy 690 were different for each heat and fabrication process. The PWSCCGR decreased with increasing Vickers hardness of each heat. However, for the same heats and fabrication processes, the PWSCCGR increased with increasing Vickers hardness due to cold work. Thus, the PWSCCGR must be affected not only by hardness (or equivalently the cold working ratio) but also by grain size, microcracks, and voids of primary M23C6 carbides, etc., which in turn depend on chemical composition and the fabrication process.

Lubricant effects on bearing life

NASA Technical Reports Server (NTRS)

Zaretsky, Erwin V.

1986-01-01

Lubricant considerations for rolling-element bearings have within the last two decades taken on added importance in the design and operation of mechanical systems. The phenomenon which limits the useful life of bearings is rolling-element or surface pitting fatigue. The elastohydrodynamic (EHD) film thickness which separates the ball or roller surface from those of the raceways of the bearing directly affects bearing life. Chemical additives added to the lubricant can also significantly affect bearings life and reliability. The interaction of these physical and chemical effects is important to the design engineer and user of these systems. Design methods and lubricant selection for rolling-element bearings are presented and discussed.

Kinematic stability of roller pairs in free rolling contact

NASA Technical Reports Server (NTRS)

Savage, M.; Loewenthal, S. H.

1976-01-01

A set of generalized stability equations was developed for roller pairs in free rolling contact. A symmetric, dual contact model was used. Four possible external contact profiles that possess continuous contacting surfaces were studied. It was found that kinematic stability would be insured if the larger radius of transverse curvature, in absolute value, and the smaller rolling radius both exist on the roller that has the apex of its conical surface outboard of its main body. The stability criteria developed are considered to be useful for assessing axial restraint requirements for a variety of roller mechanisms and in the selection of roller contact geometry for traction drive devices.

Roll-to-roll, shrink-induced superhydrophobic surfaces for antibacterial applications, enhanced point-of-care detection, and blood anticoagulation

NASA Astrophysics Data System (ADS)

Nokes, Jolie McLane

Superhydrophobic (SH) surfaces are desirable because of their unique anti-wetting behavior. Fluid prefers to bead up (contact angle >150°) and roll off (contact angle hysteresis <10°) a SH surface because micro- and nanostructure features trap air pockets. Fluid only adheres to the peaks of the structures, causing minimal adhesion to the surface. Here, shrink-induced SH plastics are fabricated for a plethora of applications, including antibacterial applications, enhanced point-of-care (POC) detection, and reduced blood coagulation. Additionally, these purely structural SH surfaces are achieved in a roll-to-roll (R2R) platform for scalable manufacturing. Because their self-cleaning and water resistant properties, structurally modified SH surfaces prohibit bacterial growth and obviate bacterial chemical resistance. Antibacterial properties are demonstrated in a variety of SH plastics by preventing gram-negative Escherichia coli (E. coli) bacterial growth >150x compared to flat when fluid is rinsed and >20x without rinsing. Therefore, a robust and stable means to prevent bacteria growth is possible. Next, protein in urine is detected using a simple colorimetric output by evaporating droplets on a SH surface. Contrary to evaporation on a flat surface, evaporation on a SH surface allows fluid to dramatically concentrate because the weak adhesion constantly decreases the footprint area. On a SH surface, molecules in solution are confined to a footprint area 8.5x smaller than the original. By concentrating molecules, greater than 160x improvements in detection sensitivity are achieved compared to controls. Utility is demonstrated by detecting protein in urine in the pre-eclampsia range (150-300microgmL -1) for pregnant women. Further, SH surfaces repel bodily fluids including blood, urine, and saliva. Importantly, the surfaces minimize blood adhesion, leading to reduced blood coagulation without the need for anticoagulants. SH surfaces have >4200x and >28x reduction of blood residue area and volume compared to the non-structured controls of the same material. In addition, blood clotting area is reduced >5x using whole blood directly from the patient. In this study, biocompatible SH surfaces are achieved using commodity shrink-wrap film and are scaled up for R2R manufacturing. The purely structural modification negates complex and expensive post processing, and SH features are achieved in commercially-available and FDA-approved plastics.

Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum

NASA Astrophysics Data System (ADS)

Hsu, Fu-Yuan

2016-06-01

In aluminum gravity casting, as liquid aluminum fell through a vertical sprue and impacted on the horizontal flat surface, a phenomenon known as hydraulic jump ( i.e., flow transition from super-critical to sub-critical flows) was observed. As the jump was transformed, a reverse eddy motion on the surface of the jump was created. This motion entrained aluminum oxide film from the surface into aluminum melt. This folded film (so-called "bifilm" defect) was engulfed by the melt and caused its quality to deteriorate. To understand this phenomenon, aluminum casting experiments and computational modeling were conducted. In the casting experiment, a radius ( R j) to the point where the circular hydraulic jump occurred was measured. This is the circular region of `irregular surface feature', a rough oxidized surface texture near the center area of the castings. To quantify contents of the bifilm defects in the outer region of the jump, the samples in this region were sectioned and re-melted for doing re-melted reduced pressure test (re-melt RPT). An "area-normalized" bifilm index map was plotted to analyze bifilms' population in the samples. The flow transition in the hydraulic jump of liquid aluminum depended on three pressure heads: inertial, gravitational, and surface-tension pressures. A new theoretical equation containing surface tension for describing the flow transition of liquid metal was proposed.

Enhanced heat transfer surface for cast-in-bump-covered cooling surfaces and methods of enhancing heat transfer

DOEpatents

Chiu, Rong-Shi Paul; Hasz, Wayne Charles; Johnson, Robert Alan; Lee, Ching-Pang; Abuaf, Nesim

2002-01-01

An annular turbine shroud separates a hot gas path from a cooling plenum containing a cooling medium. Bumps are cast in the surface on the cooling side of the shroud. A surface coating overlies the cooling side surface of the shroud, including the bumps, and contains cooling enhancement material. The surface area ratio of the cooling side of the shroud with the bumps and coating is in excess of a surface area ratio of the cooling side surface with bumps without the coating to afford increased heat transfer across the element relative to the heat transfer across the element without the coating.

Mudslide and/or animal attack are more plausible causes and circumstances of death for AL 288 ('Lucy'): A forensic anthropology analysis.

PubMed

Charlier, Phillippe; Coppens, Yves; Augias, Anaïs; Deo, Saudamini; Froesch, Philippe; Huynh-Charlier, Isabelle

2018-01-01

Following a global morphological and micro-CT scan examination of the original and cast of the skeleton of Australopithecus afarensis AL 288 ('Lucy'), Kappelman et al. have recently proposed a diagnosis of a fall from a significant height (a tree) as a cause of her death. According to topographical data from the discovery site, complete re-examination of a high-quality resin cast of the whole skeleton and forensic experience, we propose that the physical process of a vertical deceleration cannot be the only cause for her observed injuries. Two different factors were involved: rolling and multiple impacts in the context of a mudslide and an animal attack with bite marks, multi-focal fractures and violent movement of the body. It is important to consider a differential diagnosis of the observed fossil lesions because environmental factors should not be excluded in this ancient archaeological context as with any modern forensic anthropological case.

A Removable Long-arm Soft Cast to Treat Nondisplaced Pediatric Elbow Fractures: A Randomized, Controlled Trial.

PubMed

Silva, Mauricio; Sadlik, Gal; Avoian, Tigran; Ebramzadeh, Edward

2018-04-01

The ideal type of immobilization for nondisplaced pediatric elbow fractures has not been established. We hypothesized that the use of a long-arm cylinder made of soft cast material will result in similar outcomes to those obtained with a traditional long-arm hard cast. We randomly assigned 100 consecutive children who presented with a closed, nondisplaced, type I supracondylar humeral fracture or an occult, closed, acute elbow injury, to 1 of 2 groups: group A (n=50) received a long-arm, traditional fiberglass (hard) cast. Group B (n=50) received a long-arm, soft fiberglass cast. After 4 weeks, the cast was removed in group A by a member of our staff using a cast saw, and in group B by one of the patient's parents by rolling back the soft fiberglass material. We compared the amount of fracture displacement and/or angulation, recovery of range of motion, elbow pain, and patient satisfaction. There were no instances of unplanned removal of the cast by the patient or parent. No evidence of fracture displacement or angulation was seen in either group. The final carrying angle of the affected elbow was nearly identical of that of the normal, contralateral elbow in both groups (P=0.64). At the latest follow-up appointment, elbows in groups A and B had a similar mean arc of motion (156 vs. 154 degrees; P=0.45), and had achieved identical relative arc of motion of 99.6% and 99.5% of that of the normal, contralateral side, respectively (P=0.94). Main pain scores were low and comparable over the study period. All patients in both groups reported the highest rate of satisfaction at the eighth week of follow-up. The results indicate that children with nondisplaced supracondylar humeral fractures can be successfully managed with the use of a removable long-arm soft cast, maintaining fracture alignment and resulting in comparable rates of range of motion, pain, and patient satisfaction. The use of a removable immobilization that can reliably maintain fracture alignment and result in similar outcomes, while minimizing the risk of noncompliance, could be advantageous. Although we elected to remove the soft cast during a scheduled follow-up, it appears that such immobilization could be removed easily and safely at home, potentially resulting in a lower number of patient visits, decreased health care costs, and higher patient/parent satisfaction. Level I.

Turbine vane structure

DOEpatents

Irwin, John A.

1980-08-19

A liquid cooled stator blade assembly for a gas turbine engine includes an outer shroud having a pair of liquid inlets and a pair of liquid outlets supplied through a header and wherein means including tubes support the header radially outwardly of the shroud and also couple the header with the pair of liquid inlets and outlets. A pair of turbine vanes extend radially between the shroud and a vane platform to define a gas turbine motive fluid passage therebetween; and each of the vanes is cooled by an internal body casting of super alloy material with a grooved layer of highly heat conductive material that includes spaced apart flat surface trailing edges in alignment with a flat trailing edge of the casting joined to wall segments of the liner which are juxtaposed with respect to the internal casting to form an array of parallel liquid inlet passages on one side of the vane and a second plurality of parallel liquid return passages on the opposite side of the vane; and a superalloy heat and wear resistant imperforate skin covers the outer surface of the composite blade including the internal casting and the heat conductive layer; a separate trailing edge section includes an internal casting and an outer skin butt connected to the end surfaces of the internal casting and the heat conductive layer to form an easily assembled liquid cooled trailing edge section in the turbine vane.

The influence of tyre characteristics on measures of rolling performance during cross-country mountain biking.

PubMed

Macdermid, Paul William; Fink, Philip W; Stannard, Stephen R

2015-01-01

This investigation sets out to assess the effect of five different models of mountain bike tyre on rolling performance over hard-pack mud. Independent characteristics included total weight, volume, tread surface area and tread depth. One male cyclist performed multiple (30) trials of a deceleration field test to assess reliability. Further tests performed on a separate occasion included multiple (15) trials of the deceleration test and six fixed power output hill climb tests for each tyre. The deceleration test proved to be reliable as a means of assessing rolling performance via differences in initial and final speed (coefficient of variation (CV) = 4.52%). Overall differences between tyre performance for both deceleration test (P = 0.014) and hill climb (P = 0.032) were found, enabling significant (P < 0.0001 and P = 0.049) models to be generated, allowing tyre performance prediction based on tyre characteristics. The ideal tyre for rolling and climbing performance on hard-pack surfaces would be to decrease tyre weight by way of reductions in tread surface area and tread depth while keeping volume high.

Texture and mechanical properties of Al-0.5Mg-1.0Si-0.5Cu alloy sheets manufactured via a cross rolling method

NASA Astrophysics Data System (ADS)

Jeon, Jae-Yeol; Son, Hyeon-Taek; Woo, Kee-Do; Lee, Kwang-Jin

2012-04-01

The relationship between the texture and mechanical properties of 6xxx aluminum alloy sheets processed via cross rolling was investigated. The microstructures of the conventional rolled and cross rolled sheets after annealing were analyzed using optical micrographs (OM). The texture distribution across the thickness in the Al-Mg-Si-Cu alloy, conventional rolled sheets, and cross rolled sheets both before and after annealing was investigated via X-ray texture measurements. The texture was analyzed in three layers from the surface to the center of the sheet. The β-fiber texture of the conventional rolled sheet was typical of the texture obtained using aluminumoll ring. After annealing, the typical β-fiber orientations were changed to recrystallization textures: cube{001}<100> and normal direction (ND)-rotated cubes. However, the texture of the cross rolled sheet was composed of an asymmetrical, rolling direction (RD)-rotated cubes. After annealing, the asymmetrical orientations in the cross rolled sheet were changed to a randomized texture. The average R-value of the annealed cross rolled sheets was higher than that of the conventional rolled sheets. The limit dome height (LDH) test results demonstrated that cross rolling is effective in improving the formability of the Al-Mg-Si-Cu alloy sheets.

Sixty Years of Casting Research

NASA Astrophysics Data System (ADS)

Campbell, John

2015-11-01

The 60 years of solidification research since the publication of Chalmer's constitutional undercooling in 1953 has been a dramatic advance of understanding which has and continues to be an inspiration. In contrast, 60 years of casting research has seen mixed fortunes. One of its success stories relates to improvements in inoculation of gray irons, and another to the discovery of spheroidal graphite iron, although both of these can be classified as metallurgical rather than casting advances. It is suggested that true casting advances have dated from the author's lab in 1992 when a critical surface turbulence condition was defined for the first time. These last 20 years have seen the surface entrainment issues of castings developed to a sufficient sophistication to revolutionize the performance of light alloy and steel foundries. However, there is still a long way to go, with large sections of the steel and Ni-base casting industries still in denial that casting defects are important or even exist. The result has been that special ingots are still cast poorly, and shaped casting operations have suffered massive losses. For secondary melted and cast materials, electro-slag remelting has the potential to be much superior to expensive vacuum arc remelting, which has cost our aerospace and defense industries dearly over the years. This failure to address and upgrade our processing of liquid metals is a serious concern, since the principle entrainment defect, the bifilm, is seen as the principle initiator of cracks in metals; in general, bifilms are the Griffith cracks that initiate failures by cracking. A new generation of crack resistant metals and engineering structures can now be envisaged.

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.

Rolling Motion of a Ball Spinning about a Near-Vertical Axis

ERIC Educational Resources Information Center

Cross, Rod

2012-01-01

A ball that is projected forward without spin on a horizontal surface will slide for a short distance before it starts rolling. Sliding friction acts to decrease the translation speed v and it acts to increase the rotation speed [omega]. When v = R[omega], where R is the ball radius, the ball will start rolling and the friction force drops almost…

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.

Surface dosimetry for breast radiotherapy in the presence of immobilization cast material

NASA Astrophysics Data System (ADS)

Kelly, Andrew; Hardcastle, Nicholas; Metcalfe, Peter; Cutajar, Dean; Quinn, Alexandra; Foo, Kerwyn; Cardoso, Michael; Barlin, Sheree; Rosenfeld, Anatoly

2011-02-01

Curative breast radiotherapy typically leaves patients with varying degrees of cosmetic damage. One problem interfering with cosmetically acceptable breast radiotherapy is the external contour for large pendulous breasts which often results in high doses to skin folds. Thermoplastic casts are often employed to secure the breasts to maintain setup reproducibility and limit the presence of skin folds. This paper aims to determine changes in surface dose that can be attributed to the use of thermoplastic immobilization casts. Skin dose for a clinical hybrid conformal/IMRT breast plan was measured using radiochromic film and MOSFET detectors at a range of water equivalent depths representative of the different skin layers. The radiochromic film was used as an integrating dosimeter, while the MOSFETs were used for real-time dosimetry to isolate the contribution of skin dose from individual IMRT segments. Strips of film were placed at various locations on the breast and the MOSFETs were used to measure skin dose at 16 positions spaced along the film strips for comparison of data. The results showed an increase in skin dose in the presence of the immobilization cast of up to 45.7% and 62.3% of the skin dose without the immobilization cast present as measured with Gafchromic EBT film and MOSFETs, respectively. The increase in skin dose due to the immobilization cast varied with the angle of beam incidence and was greatest when the beam was normally incident on the phantom. The increase in surface dose with the immobilization cast was greater under entrance dose conditions compared to exit dose conditions.

Effect of surface reaction layer on grindability of cast titanium alloys.

PubMed

Ohkubo, Chikahiro; Hosoi, Toshio; Ford, J Phillip; Watanabe, Ikuya

2006-03-01

The purpose of this study was to investigate the effect of the cast surface reaction layer on the grindability of titanium alloys, including free-machining titanium alloy (DT2F), and to compare the results with the grindability of two dental casting alloys (gold and Co-Cr). All titanium specimens (pure Ti, Ti-6Al-4V and DT2F) were cast using a centrifugal casting machine in magnesia-based investment molds. Two specimen sizes were used to cast the titanium metals so that the larger castings would be the same size as the smaller gold and Co-Cr alloy specimens after removal of the surface reaction layer (alpha-case). Grindability was measured as volume loss ground from a specimen for 1 min using a handpiece engine with a SiC abrasive wheel at 0.1 kgf and four circumferential wheel speeds. For the titanium and gold alloys, grindability increased as the rotational speed increased. There was no statistical difference (p>0.05) in grindability for all titanium specimens either with or without the alpha-case. Of the titanium metals tested, Ti-6 Al-4V had the greatest grindability at higher speeds, followed by DT2F and CP Ti. The grindability of the gold alloy was similar to that of Ti-6 Al-4V, whereas the Co-Cr alloy had the lowest grindability. The results of this study indicated that the alpha-case did not significantly affect the grindability of the titanium alloys. The free-machining titanium alloy had improved grindability compared to CP Ti.

Fabrication of multifilamentary Nb/sub 3/(Al,Ge) wires through a modified jelly roll process

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

Tachikawa, K.; Kamisada, Y.; Suzuki, E.

Recently, development of Nb/sub 3/Al multifilamentary wires has gained much interests since high-field performance superior to that of Nb/sub 3/Sn can be expected in these wires. In this study, Nb/Al-Ge alloy composites were fabricated into multifilamentary wires through a modified jelly roll (MJR) process. A Nb mesh sheet produced at the Teledyne Wah Chang Co. was used as Nb component. An Al-Ge alloy prepared by a conventional casting process was forged and rolled into a sheet of 0.2 mm in thickness. The Nb/Al-Ge composite was prepared by wrapping the Nb mesh sheet together with the Al-Ge alloy sheet around amore » Nb core into a jelly roll form. The MJR composite was encased in a Cu-Ni alloy tube of which outer diameter was 43 mm. The resulting composite was hydrostatically pressed and extruded into a rod of 18 mm in diameter. A Nb barrier was then inserted between the MJR and the Cu-Ni jacket. The composite rod was swaged and drawn into a wire without any intermediate annealing. The wire was able to be drawn down to a very small diameter of 0.1 mm. The cross-sectional configuration of the MJR composite was not much disturbed by the fabrication. Superconducting transition temperature Tc of the wire, after different heat treatment including a rapid quenching from high temperatures by a continuous electron beam irradiation, was studied, and an onset Tc of 19.3K has been achieved.« less

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.

Investigation of the Influence of Shapes-Texture on Surface Deformation of UHMWPE as a Bearing Material in Static Normal Load and Rolling Contact

NASA Astrophysics Data System (ADS)

Lestari, W. D.; Ismail, R.; Jamari, J.; Bayuseno, A. P.

2017-05-01

Surface texture is a common method for improving wear properties of a tribo-pair of soft and hard bearing material. The reduction of wear rates on the contacting surface material is becoming important issues. In the present study, analysis of the contact pressure on the flat surface of UHMWPE (Ultra High Molecular Weight Polyethylene) under the static- and rolling motion with the surface of steel ball used the 3D finite element method (FEM) (the ABAQUS software version 6.12). Five shaped-texture models (square, circle, ellipse, triangle, and chevron) were presented on the flat surface for analysis. The normal load of 17, 30 and 50 N was deliberately set-up for static and rolling contact analysis. The contact pressure was determined to predict the wear behavior of the shaped-texture on the flat surface of UHMWPE. The results have shown that the static normal load yielded the lowest von-Mises stress distribution on the shaped-texture of the ellipse for all values applied a load, while the square shape experienced the highest stress distribution. Under rolling contact, however, the increasing load yielded the increasing von Mises stress distribution for the texture with a triangle shape. Moreover, the texture shapes for circle, ellipse, and chevron respectively, may undergo the lowest stress distribution for all load. The wear calculation provided that the circle and square shape may undergo the highest wear rates. Obviously, the surface texture of circle, ellipse, and chevron may experience the lowest wear rates and is potential for use in the surface engineering of bearing materials.

Measurement of the residual stress in hot rolled strip using strain gauge method

NASA Astrophysics Data System (ADS)

Kumar, Lokendra; Majumdar, Shrabani; Sahu, Raj Kumar

2017-07-01

Measurement of the surface residual stress in a flat hot rolled steel strip using strain gauge method is considered in this paper. Residual stresses arise in the flat strips when the shear cut and laser cut is applied. Bending, twisting, central buckled and edge waviness is the common defects occur during the cutting and uncoiling process. These defects arise due to the non-uniform elastic-plastic deformation, phase transformation occurring during cooling and coiling-uncoiling process. The residual stress analysis is very important because with early detection it is possible to prevent an object from failure. The goal of this paper is to measure the surface residual stress in flat hot rolled strip using strain gauge method. The residual stress was measured in the head and tail end of hot rolled strip considering as a critical part of the strip.

Mirror mount

DOEpatents

Humpal, Harold H.

1987-01-01

A mirror mount (10) is provided that allows free pitch, yaw and roll motion of the mirror (28) while keeping the location of a point (56) on the surface of the mirror (28) fixed in the rest frame of reference of the mount (10). Yaw movement is provided by two yaw cylinders (30,32) that are bearing (52) mounted to provide rotation. Pitch and roll motion is provided by a spherically annular shell (42) that is air bearing (72,74) mounted to move between a clamp (60) and an upper pedestal bearing (44). The centers of curvature of the spherical surfaces of the shell (42) lie upon the point (56). Pitch motion and roll motion are separately and independently imparted to mirror (28) by a pair of pitch paddles (34) and a pair of roll paddles (36) that are independently and separately moved by control rods (76,80) driven by motors (78,82).

Response of Leaf Water Potential, Stomatal Resistance, and Leaf Rolling to Water Stress

PubMed Central

O'Toole, John C.; Cruz, Rolando T.

1980-01-01

Numerous studies have associated increased stomatal resistance with response to water deficit in cereals. However, consideration of change in leaf form seems to have been neglected. The response of adaxial and abaxial stomatal resistance and leaf rolling in rice to decreasing leaf water potential was investigated. Two rice cultivars were subjected to control and water stress treatments in a deep (1-meter) aerobic soil. Concurrent measurements of leaf water potential, stomatal resistance, and degree of leaf rolling were made through a 29-day period after cessation of irrigation. Kinandang Patong, an upland adapted cultivar, maintained higher dawn and midday leaf water potential than IR28, a hybrid selected in irrigated conditions. This was not explained by differences in leaf diffusive resistance or leaf rolling, and is assumed to result from a difference in root system extent. Stomatal resistance increased more on the abaxial than the adaxial leaf surface in both cultivars. This was associated with a change in leaf form or rolling inward of the upper leaf surface. Both responses, increased stomatal resistance and leaf rolling, were initiated in a similar leaf water potential range (−8 to −12 bars). Leaves of IR28 became fully rolled at leaf water potential of about −22 bars; however, total leaf diffusive resistance was only about 4 to 5 seconds per centimeter (conductance 0.25 to 0.2 centimeter per second) at that stage. Leaf diffusive resistance and degree of leaf rolling were linearly related to leaf water potential. Thus, leaf rolling in rice may be used as an estimate of the other two less obvious effects of water deficit. PMID:16661206

Large-Amplitude, High-Rate Roll Oscillations of a 65 deg Delta Wing at High Incidence

NASA Technical Reports Server (NTRS)

Chaderjian, Neal M.; Schiff, Lewis B.

2000-01-01

The IAR/WL 65 deg delta wing experimental results provide both detail pressure measurements and a wide range of flow conditions covering from simple attached flow, through fully developed vortex and vortex burst flow, up to fully-stalled flow at very high incidence. Thus, the Computational Unsteady Aerodynamics researchers can use it at different level of validating the corresponding code. In this section a range of CFD results are provided for the 65 deg delta wing at selected flow conditions. The time-dependent, three-dimensional, Reynolds-averaged, Navier-Stokes (RANS) equations are used to numerically simulate the unsteady vertical flow. Two sting angles and two large- amplitude, high-rate, forced-roll motions and a damped free-to-roll motion are presented. The free-to-roll motion is computed by coupling the time-dependent RANS equations to the flight dynamic equation of motion. The computed results are compared with experimental pressures, forces, moments and roll angle time history. In addition, surface and off-surface flow particle streaks are also presented.

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.

The state diagram for cell adhesion under flow: leukocyte rolling and firm adhesion.

PubMed

Chang, K C; Tees, D F; Hammer, D A

2000-10-10

Leukocyte adhesion under flow in the microvasculature is mediated by binding between cell surface receptors and complementary ligands expressed on the surface of the endothelium. Leukocytes adhere to endothelium in a two-step mechanism: rolling (primarily mediated by selectins) followed by firm adhesion (primarily mediated by integrins). Using a computational method called "Adhesive Dynamics," we have simulated the adhesion of a cell to a surface in flow, and elucidated the relationship between receptor-ligand functional properties and the dynamics of adhesion. We express this relationship in a state diagram, a one-to-one map between the biophysical properties of adhesion molecules and various adhesive behaviors. Behaviors that are observed in simulations include firm adhesion, transient adhesion (rolling), and no adhesion. We varied the dissociative properties, association rate, bond elasticity, and shear rate and found that the unstressed dissociation rate, k(r)(o), and the bond interaction length, gamma, are the most important molecular properties controlling the dynamics of adhesion. Experimental k(r)(o) and gamma values from the literature for molecules that are known to mediate rolling adhesion fall within the rolling region of the state diagram. We explain why L-selectin-mediated rolling, which has faster k(r)(o) than other selectins, is accompanied by a smaller value for gamma. We also show how changes in association rate, shear rate, and bond elasticity alter the dynamics of adhesion. The state diagram (which must be mapped for each receptor-ligand system) presents a concise and comprehensive means of understanding the relationship between bond functional properties and the dynamics of adhesion mediated by receptor-ligand bonds.

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.

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

PubMed

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

2016-12-01

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

Features of Wear-Resistant Cast Iron Coating Formation During Plasma-Powder Surfacing

NASA Astrophysics Data System (ADS)

Vdovin, K. N.; Emelyushin, A. N.; Nefed'ev, S. P.

2017-09-01

The structure of coatings deposited on steel 45 by plasma-powder surfacing of white wear-resistant cast iron is studied. The effects of surfacing regime and additional production effects on the welding bath during surfacing produced by current modulation, accelerated cooling of the deposited beads by blowing with air, and accelerated cooling of the substrate with running water on the structure, are determined. A new composition is suggested for powder material for depositing wear-resistant and corrosion-resistant coatings on a carbon steel by the plasma-powder process.

Oceanic influence on seasonal malaria outbreaks over Senegal and Sahel. Predictability using S4CAST model

NASA Astrophysics Data System (ADS)

Diouf, Ibrahima; Deme, Abdoulaye; Rodriguez-Fonseca, Belen; Suárez-Moreno, Roberto; Cisse, Moustapha; Ndione, Jacques-André; Thierno Gaye, Amadou

2014-05-01

Senegal and, in general, West African regions are affected by important outbreaks of diseases with destructive consequences for human population, livestock and country's economy. The vector-borne diseases such as mainly malaria, Rift Valley Fever and dengue are affected by the interanual to decadal variability of climate. Analysis of the spatial and temporal variability of climate parameters and associated oceanic patterns is important in order to assess the climate impact on malaria transmission. In this study, the approach developed to study the malaria-climate link is predefined by the QWeCI project (Quantifying Weather and Climate Impacts on Health in Developing Countries). Preliminary observations and simulations results over Senegal Ferlo region, confirm that the risk of malaria transmission is mainly linked to climate parameters such as rainfall, temperature and relative humidity; and a lag of one to two months between the maximum of malaria and the maximum of climate parameters as rainfall is observed. As climate variables are able to be predicted from oceanic SST variability in remote regions, this study explores seasonal predictability of malaria incidence outbreaks from previous sea surface temperatures conditions in different ocean basins. We have found causal or coincident relationship between El Niño and malaria parameters by coupling LMM UNILIV malaria model and S4CAST statistiscal model with the aim of predicting the malaria parameters with more than 6 months in advance. In particular, El Niño is linked to an important decrease of the number of mosquitoes and the malaria incidence. Results from this research, after assessing the seasonal malaria parameters, are expected to be useful for decision makers to better access to climate forecasts and application on health in the framework of rolling back malaria transmission.

Utilization of surface differences to improve dyeing properties of poly( m-phenylene isophthalamide) membranes

NASA Astrophysics Data System (ADS)

Ouyang, Shenshen; Wang, Tao; Zhong, Longgang; Wang, Shunli; Wang, Sheng

2018-06-01

Bulk poly( m-phenylene isophthalamide) (PMIA) can achieve flexibility upon dissolution by a LiCl/dimethylacetamide co-solvent, but remains hydrophobic despite the occasional emergence of cis amide groups providing a weak negative charge. In this study, based on the significant surface differences between PMIA membranes processed by nanofiber electrospinning and casting, a series of chemical analyses, in-situ Au nanoparticle depositions, and dye-adsorption experiments revealed that more cis-configuration amide groups appeared on the surface of the electrospun PMIA membrane than on that of the cast membrane. Based on this surface difference, a strategy was proposed to improve the dyeing properties of PMIA by reversibly changing the cis/trans configurations of electrospun and cast membranes. The reversible chain-segment switch mechanism is a novel method for tuning the macroscale properties of polymer materials based on inherent molecular characteristics.

Utilization of surface differences to improve dyeing properties of poly(m-phenylene isophthalamide) membranes

NASA Astrophysics Data System (ADS)

Ouyang, Shenshen; Wang, Tao; Zhong, Longgang; Wang, Shunli; Wang, Sheng

2018-05-01

Bulk poly(m-phenylene isophthalamide) (PMIA) can achieve flexibility upon dissolution by a LiCl/dimethylacetamide co-solvent, but remains hydrophobic despite the occasional emergence of cis amide groups providing a weak negative charge. In this study, based on the significant surface differences between PMIA membranes processed by nanofiber electrospinning and casting, a series of chemical analyses, in-situ Au nanoparticle depositions, and dye-adsorption experiments revealed that more cis-configuration amide groups appeared on the surface of the electrospun PMIA membrane than on that of the cast membrane. Based on this surface difference, a strategy was proposed to improve the dyeing properties of PMIA by reversibly changing the cis/trans configurations of electrospun and cast membranes. The reversible chain-segment switch mechanism is a novel method for tuning the macroscale properties of polymer materials based on inherent molecular characteristics.

Heat Transfer Measurements during DC Casting of Aluminium Part I: Measurement Technique

NASA Astrophysics Data System (ADS)

Bakken, J. A.; Bergström, T.

A method for determination of surface heat transfer to the cooling water and mould based on in-situ temperature measurements in the DC cast ingot has been developed. Three or more steel mantled coaxial thermocouples (0.5 mm diam.) are mounted on a wire frame called a "harp". Allowing the "harp" to freeze into the solid ingots during the casting time-temperature plots T1 (t), T2(t), T3 (t) are obtained for three moving points positioned typically 3, 7 and 11 mm from the ingot surface. From these measurements surface temperature, heat flux and heat transfer coefficients are computed as functions of vertical distance. The computer program is based on steady-state two-dimensional heat balances with convective terms for two fixed volume elements: one around thermocouple T1 and one surface element. A special numerical smoothing procedure is incorporated. The heat of solidification is taken into account.

Method of fabricating a prestressed cast iron vessel

DOEpatents

Lampe, Robert F.

1982-01-01

A method of fabricating a prestressed cast iron vessel wherein double wall cast iron body segments each have an arcuate inner wall and a spaced apart substantially parallel outer wall with a plurality of radially extending webs interconnecting the inner wall and the outer wall, the bottom surface and the two exposed radial side surfaces of each body segment are machined and eight body segments are formed into a ring. The top surfaces and outer surfaces of the outer walls are machined and keyways are provided across the juncture of adjacent end walls of the body segments. A liner segment complementary in shape to a selected inner wall of one of the body segments is mounted to each of the body segments and again formed into a ring. The liner segments of each ring are welded to form unitary liner rings and thereafter the cast iron body segments are prestressed to complete the ring assembly. Ring assemblies are stacked to form the vessel and adjacent unitary liner rings are welded. A top head covers the top ring assembly to close the vessel and axially extending tendons retain the top and bottom heads in place under pressure.

On-Line Flatness Measurement in the Steelmaking Industry

PubMed Central

Molleda, Julio; Usamentiaga, Rubén; Garcίa, Daniel F.

2013-01-01

Shape is a key characteristic to determine the quality of outgoing flat-rolled products in the steel industry. It is greatly influenced by flatness, a feature to describe how the surface of a rolled product approaches a plane. Flatness is of the utmost importance in steelmaking, since it is used by most downstream processes and customers for the acceptance or rejection of rolled products. Flatness sensors compute flatness measurements based on comparing the length of several longitudinal fibers of the surface of the product under inspection. Two main different approaches are commonly used. On the one hand, most mechanical sensors measure the tensile stress across the width of the rolled product, while manufacturing and estimating the fiber lengths from this stress. On the other hand, optical sensors measure the length of the fibers by means of light patterns projected onto the product surface. In this paper, we review the techniques and the main sensors used in the steelmaking industry to measure and quantify flatness defects in steel plates, sheets and strips. Most of these techniques and sensors can be used in other industries involving rolling mills or continuous production lines, such as aluminum, copper and paper, to name a few. Encompassed in the special issue, State-of-the-Art Sensors Technology in Spain 2013, this paper also reviews the most important flatness sensors designed and developed for the steelmaking industry in Spain. PMID:23939583

On-line flatness measurement in the steelmaking industry.

PubMed

Molleda, Julio; Usamentiaga, Rubén; García, Daniel F

2013-08-09

Shape is a key characteristic to determine the quality of outgoing flat-rolled products in the steel industry. It is greatly influenced by flatness, a feature to describe how the surface of a rolled product approaches a plane. Flatness is of the utmost importance in steelmaking, since it is used by most downstream processes and customers for the acceptance or rejection of rolled products. Flatness sensors compute flatness measurements based on comparing the length of several longitudinal fibers of the surface of the product under inspection. Two main different approaches are commonly used. On the one hand, most mechanical sensors measure the tensile stress across the width of the rolled product, while manufacturing and estimating the fiber lengths from this stress. On the other hand, optical sensors measure the length of the fibers by means of light patterns projected onto the product surface. In this paper, we review the techniques and the main sensors used in the steelmaking industry to measure and quantify flatness defects in steel plates, sheets and strips. Most of these techniques and sensors can be used in other industries involving rolling mills or continuous production lines, such as aluminum, copper and paper, to name a few. Encompassed in the special issue, State-of-the-Art Sensors Technology in Spain 2013, this paper also reviews the most important flatness sensors designed and developed for the steelmaking industry in Spain.

Experimental study of tyre/road contact forces in rolling conditions for noise prediction

NASA Astrophysics Data System (ADS)

Cesbron, Julien; Anfosso-Lédée, Fabienne; Duhamel, Denis; Ping Yin, Hai; Le Houédec, Donatien

2009-02-01

This paper deals with the experimental study of dynamical tyre/road contact for noise prediction. In situ measurements of contact forces and close proximity noise levels were carried out for a slick tyre rolling on six different road surfaces between 30 and 50 km/h. Additional texture profiles of the tested surfaces were taken on the wheel track. Normal contact stresses were measured at a sampling frequency of 10752 Hz using a line of pressure sensitive cells placed both along and perpendicular to the rolling direction. The contact areas obtained during rolling were smaller than in static conditions. This is mainly explained by the dynamical properties of tyre compounds, like the viscoelastic behaviour of the rubber. Additionally the root-mean-square of the resultant contact forces at various speeds was in the same order for a given road surface, while their spectra were quite different. This is certainly due to a spectral influence of bending waves propagating in the tyre during rolling, especially when the wavelength is small in comparison with the size of the contact patch. Finally, the levels of contact forces and close proximity noise measured at 30 km/h were correlated. Additional correlations with texture levels were performed. The results show that the macro-texture generates contact forces linearly around 800 Hz and consequently noise levels between 500 and 1000 Hz via the vibrations transmitted to the tyre.

Transforming Roving-Rolling Explorer (TRREx) for Planetary Exploration

NASA Astrophysics Data System (ADS)

Edwin, Lionel Ernest

All planetary surface exploration missions thus far have employed traditional rovers with a rocker-bogie suspension. These rovers can navigate moderately rough and flat terrain, but are not designed to traverse rugged terrain with steep slopes. The fact is, however, that many scientifically interesting missions require exploration platforms with capabilities for navigating such types of chaotic terrain. This issue motivates the development of new kinds of rovers that take advantage of the latest advances in robotic technologies to traverse rugged terrain efficiently. This dissertation proposes and analyses one such rover concept called the Transforming Roving-Rolling Explorer (TRREx) that is principally aimed at addressing the above issue. Biologically inspired by the way the armadillo curls up into a ball when threatened, and the way the golden wheel spider uses the dynamic advantages of a sphere to roll down hills when escaping danger, the novel TRREx rover can traverse like a traditional 6-wheeled rover over conventional terrain, but can also transform itself into a sphere, when necessary, to travel down steep inclines, or navigate rough terrain. This work presents the proposed design architecture and capabilities followed by the development of mathematical models and experiments that facilitate the mobility analysis of the TRREx in the rolling mode. The ability of the rover to self-propel in the rolling mode in the absence of a negative gradient increases its versatility and concept value. Therefore, a dynamic model of a planar version of the problem is first used to investigate the feasibility and value of such self-propelled locomotion - 'actuated rolling'. Construction and testing of a prototype Planar/Cylindrical TRREx that is capable of demonstrating actuated rolling is presented, and the results from the planar dynamic model are experimentally validated. This planar model is then built upon to develop a mathematical model of the spherical TRREx in the rolling mode, i.e. when the rover is a sphere and can steer itself through actuations that shift its center of mass to achieve the desired direction of roll. Case studies that demonstrate the capabilities of the rover in rolling mode and parametric analyses that investigate the dependence of the rover's mobility on its design are presented. This work highlights the contribution of the spherical rolling mode to the enhanced mobility of the TRREx rover and how it could enable challenging surface exploration missions in the future. It represents an important step toward developing a rover capable of traversing a variety of terrains that are impassible by the current fleet of rover designs, and thus has the potential to revolutionize planetary surface exploration.

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

PubMed

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

2017-11-01

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

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

Effects of recasting on the biocompatibility of a Ni-Cr alloy.

PubMed

Zhang, Chang Yuan; Cheng, Hui; Lin, Dong Hong; Zheng, Ming; Ozcan, Mutlu; Zhao, Wei; Yu, Hao

2012-01-01

To evaluate the effects of recasting on the biocompatibility of a commercially available Ni-Cr alloy. The alloy tested was cast and subsequently recast four more times. For each cast condition, 24 disk shaped specimens were fabricated (5 mm in diameter, 0.5 mm in thickness). All the recasting was performed without adding new alloy. After the first cast and following each recast, the surface composition and microstructure of the alloy were determined using an X-ray fluorescence spectrometer and optical microscope, respectively. The in vitro cytotoxicity and in vivo mucous irritation potential of the cast and recast Ni-Cr alloy were investigated. The results were statistically analysed at the significance level of 0.05. Recasting neither yielded to cytotoxicity or to changes in the surface composition of the Ni-Cr alloy tested. However, an increase in impurities and porosity of the surface structure was observed with recasting. Also, the segregation of the impurities to grain boundaries was evident after multiple castings. After the fourth recast, the alloys showed significantly greater mucosal irritation than the control. After fourth recast, the alloy of this type may contribute to mucosal inflammation. Furthermore, there is a need for diverse methods addressing different biological endpoints for the evaluation of dental alloys.

Metallic superhydrophobic surfaces via thermal sensitization

NASA Astrophysics Data System (ADS)

Vahabi, Hamed; Wang, Wei; Popat, Ketul C.; Kwon, Gibum; Holland, Troy B.; Kota, Arun K.

2017-06-01

Superhydrophobic surfaces (i.e., surfaces extremely repellent to water) allow water droplets to bead up and easily roll off from the surface. While a few methods have been developed to fabricate metallic superhydrophobic surfaces, these methods typically involve expensive equipment, environmental hazards, or multi-step processes. In this work, we developed a universal, scalable, solvent-free, one-step methodology based on thermal sensitization to create appropriate surface texture and fabricate metallic superhydrophobic surfaces. To demonstrate the feasibility of our methodology and elucidate the underlying mechanism, we fabricated superhydrophobic surfaces using ferritic (430) and austenitic (316) stainless steels (representative alloys) with roll off angles as low as 4° and 7°, respectively. We envision that our approach will enable the fabrication of superhydrophobic metal alloys for a wide range of civilian and military applications.

Influence of Ultrasonic Surface Rolling on Microstructure and Wear Behavior of Selective Laser Melted Ti-6Al-4V Alloy

PubMed Central

Wang, Zhen; Xiao, Zhiyu; Huang, Chuanshou; Wen, Liping; Zhang, Weiwen

2017-01-01

The present article studied the effect of ultrasonic surface rolling process (USRP) on the microstructure and wear behavior of a selective laser melted Ti-6Al-4V alloy. Surface characteristics were investigated using optical microscope, nano-indentation, scanning electron microscope, transmission electron microscope and laser scanning confocal microscope. Results indicated that the thickness of pore-free surfaces increased to 100~200 μm with the increasing ultrasonic surface rolling numbers. Severe work hardening occurred in the densified layer, resulting in the formation of refined grains, dislocation walls and deformation twins. After 1000 N 6 passes, about 15.5% and 14.1% increment in surficial Nano-hardness and Vickers-hardness was obtained, respectively. The hardness decreased gradually from the top surface to the substrate. Wear tests revealed that the friction coefficient declined from 0.74 (polished surface) to 0.64 (USRP treated surface) and the wear volume reduced from 0.205 mm−3 to 0.195 mm−3. The difference in wear volume between USRP treated and polished samples increased with sliding time. The enhanced wear resistance was concluded to be associated with the improvement of hardness and shear resistance and also the inhibition of delamination initiation. PMID:29048344

Engineering study for a melting, casting, rolling and fabrication facility for recycled contaminated stainless steel

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

NONE

This Preliminary Report is prepared to study the facilities required for recycling contaminated stainless steel scrap into plate which will be fabricated into boxes suitable for the storage of contaminated wastes and rubble. The study is based upon the underlying premise that the most cost effective way to produce stainless steel is to use the same processes employed by companies now in production of high quality stainless steel. Therefore, the method selected for this study for the production of stainless steel plate from scrap is conventional process using an Electric Arc Furnace for meltdown to hot metal, a Continuous Castermore » for production of cast slabs, and a Reversing Hot Mill for rolling the slabs into plate. The fabrication of boxes from the plate utilizes standard Shears, Punch Presses and welding equipment with Robotic Manipulators. This Study presumes that all process fumes, building dusts and vapors will be cycled through a baghouse and a nuclear grade HEPA filter facility prior to discharge. Also, all process waste water will be evaporated into the hot flue gas stream from the furnace utilizing a quench tank; so there will be no liquid discharges from the facility and all vapors will be processed through a HEPA filter. Even though HEPA filters are used today in controlling radioactive contamination from nuclear facilities there is a sparsity of data concerning radioactivity levels and composition of waste that may be collected from contaminated scrap steel processing. This report suggests some solutions to these problems but it is recommended that additional study must be given to these environmental problems.« less

Method and mold for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2014-04-29

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

Method for casting thin metal objects

DOEpatents

Pehrson, Brandon P; Moore, Alan F

2015-04-14

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

Evaluation of Surface Fatigue Strength Based on Surface Temperature

NASA Astrophysics Data System (ADS)

Deng, Gang; Nakanishi, Tsutomu

Surface temperature is considered to be an integrated index that is dependent on not only the load and the dimensions at the contact point but also the sliding velocity, rolling velocity, surface roughness, and lubrication conditions. Therefore, the surface durability of rollers and gears can be evaluated more exactly and simply by the use of surface temperature rather than Hertzian stress. In this research, surface temperatures of rollers under different rolling and sliding conditions are measured using a thermocouple. The effects of load P, mean velocity Vm and sliding velocity Vs on surface temperature are clarified. An experimental formula, which expresses the linear relationship between surface temperature and the P0.86Vs1.31Vm-0.83 value, is used to determine surface temperature. By comparing calculated and measured temperature on the tooth surface of a gear, this formula is confirmed to be applicable for gear tooth surface temperature calculation.

Vibration analysis of paper machine's asymmetric tube roll supported by spherical roller bearings

NASA Astrophysics Data System (ADS)

Heikkinen, Janne E.; Ghalamchi, Behnam; Viitala, Raine; Sopanen, Jussi; Juhanko, Jari; Mikkola, Aki; Kuosmanen, Petri

2018-05-01

This paper presents a simulation method that is used to study subcritical vibrations of a tube roll in a paper machine. This study employs asymmetric 3D beam elements based on the Timoshenko beam theory. An asymmetric beam model accounts for varying stiffness and mass distributions. Additionally, a detailed rolling element bearing model defines the excitations arising from the set of spherical roller bearings at both ends of the rotor. The results obtained from the simulation model are compared against the results from the measurements. The results indicate that the waviness of the bearing rolling surfaces contributes significantly to the subcritical vibrations while the asymmetric properties of the tube roll have only a fractional effect on the studied vibrations.

Dynamics of solid dispersions in oil during the lubrication of point contacts. Part 1: Graphite

NASA Technical Reports Server (NTRS)

Cusano, C.; Sliney, H. E.

1981-01-01

A Hertzian contact was lubricated with dispersed graphite in mineral oils under boundary lubrication conditions. The contact was optically observed under pure rolling, combined rolling and sliding, and pure sliding conditions. The contact was formed with a steel ball on the flat surface of a glass disk. Photomicrographs are presented which show the distribution of the graphite in and around the contact. Friction and surface damage are also shown for conditions when the base oils are used alone and when graphite is added to the base oils. Under pure rolling and combined rolling and sliding conditions, it is found that, for low speeds, a graphite film can form which will separate the contacting surfaces. Under pure sliding conditions, graphite accumulates at the inlet and sweeps around the contact, but very little of the graphite passes through the contact. The accumulated graphite appears to act as a barrier which reduces the supply of oil available to the contact for boundary lubrication. Friction data show no clear short term beneficial or detrimental effect caused by addition of graphite to the base oil. However, during pure sliding, more abrasion occurs on the polished balls lubricated with the dispersion than on those lubricated with the base oil alone. All observations were for the special case of a highly-polished ball on a glass surface and may not be applicable to other geometries and materials, or to rougher surfaces.

A model for prediction of profile and flatness of hot and cold rolled flat products in four-high mills

NASA Astrophysics Data System (ADS)

Overhagen, Christian; Mauk, Paul Josef

2018-05-01

For flat rolled products, the thickness profile in the transversal direction is one of the most important product properties. For further processing, a defined crown of the product is necessary. In the rolling process, several mechanical and thermal influences interact with each other to form the strip shape at the roll gap exit. In the present analysis, a process model for rolling of strip and sheet is presented. The core feature of the process model is a two-dimensional stress distribution model based on von Karman's differential equation. Sub models for the mechanical influences of work roll flattening as well as work and backup roll deflection and the thermal influence of work roll expansion have been developed or extended. The two-dimensional stress distribution serves as an input parameter for the roll deformation models. For work roll flattening, a three-dimensional model based on the Boussinesq problem is adopted, while the work and backup roll deflection, including contact flattening is calculated by means of finite beam elements. The thermal work roll crown is calculated with help of an axisymmetric numerical solution of the heat equation for the work roll, considering azimuthal averaging for the boundary conditions at the work roll surface. Results are presented for hot rolling of a strip in a seven-stand finishing train of a hot strip mill, showing the calculated evolution of the strip profile. A variation of the strip profile from the first to the 20th rolled strip is shown. This variation is addressed to the progressive increase of work roll temperature during the first 20 strips. It is shown that a CVC® system can lead to improvements in strip profile and therefore flatness.

Analysis of surface scale on the Ni-based superalloy CMSX-10N and proposed mechanism of formation

NASA Astrophysics Data System (ADS)

Simmonds, S.; D'Souza, N.; Ryder, K. S.; Dong, H.

2012-01-01

There is a continuing demand to raise the operating temperature of jet engine turbine blades to meet the need for higher turbine entry temperatures (TET) in order to increase thermal efficiency and thrust. Modern, high-pressure turbine blades are made from Ni-based superalloys in single-crystal form via the investment casting process. One important post-cast surface defect, known as 'surface scale', has been investigated on the alloy CMSX-10N. This is an area of distinct discolouration of the aerofoil seen after casting. Auger electron and X-ray photoelectron spectroscopy analysis were carried out on both scaled and un-scaled areas. In the scaled region, a thin layer (~800nm) of Ni oxide is evident. In the un-scaled regions there is a thicker Al2O3 layer. It is shown that, as the blade cools during casting, differential thermal contraction of mould and alloy causes the solid blade to 'detach' from the mould in these scaled areas. The formation of Ni Oxides is facilitated by this separation.

The Anti-Biofouling Properties of Superhydrophobic Surfaces are Short-Lived.

PubMed

Hwang, Gi Byoung; Page, Kristopher; Patir, Adnan; Nair, Sean P; Allan, Elaine; Parkin, Ivan P

2018-06-12

Superhydrophobic surfaces are present in nature on the leaves of many plant species. Water rolls on these surfaces, and the rolling motion picks up particles including bacteria and viruses. Man-made superhydrophobic surfaces have been made in an effort to reduce biofouling. We show here that the anti-biofouling property of a superhydrophobic surface is due to an entrapped air-bubble layer that reduces contact between the bacteria and the surface. Further, we showed that prolonged immersion of superhydrophobic surfaces in water led to loss of the bubble-layer and subsequent bacterial adhesion that unexpectedly exceeded that of the control materials. This behavior was not restricted to one particular type of material but was evident on different types of superhydrophobic surfaces. This work is important in that it suggests that superhydrophobic surfaces may actually encourage bacterial adhesion during longer term exposure.

NASA Tech Briefs, November 2007

NASA Technical Reports Server (NTRS)

2007-01-01

Topics include: Wireless Measurement of Contact and Motion Between Contact Surfaces; Wireless Measurement of Rotation and Displacement Rate; Portable Microleak-Detection System; Free-to-Roll Testing of Airplane Models in Wind Tunnels; Cryogenic Shrouds for Testing Thermal-Insulation Panels; Optoelectronic System Measures Distances to Multiple Targets; Tachometers Derived From a Brushless DC Motor; Algorithm-Based Fault Tolerance for Numerical Subroutines; Computational Support for Technology- Investment Decisions; DSN Resource Scheduling; Distributed Operations Planning; Phase-Oriented Gear Systems; Freeze Tape Casting of Functionally Graded Porous Ceramics; Electrophoretic Deposition on Porous Non- Conductors; Two Devices for Removing Sludge From Bioreactor Wastewater; Portable Unit for Metabolic Analysis; Flash Diffusivity Technique Applied to Individual Fibers; System for Thermal Imaging of Hot Moving Objects; Large Solar-Rejection Filter; Improved Readout Scheme for SQUID-Based Thermometry; Error Rates and Channel Capacities in Multipulse PPM; Two Mathematical Models of Nonlinear Vibrations; Simpler Adaptive Selection of Golomb Power-of- Two Codes; VCO PLL Frequency Synthesizers for Spacecraft Transponders; Wide Tuning Capability for Spacecraft Transponders; Adaptive Deadband Synchronization for a Spacecraft Formation; Analysis of Performance of Stereoscopic-Vision Software; Estimating the Inertia Matrix of a Spacecraft; Spatial Coverage Planning for Exploration Robots; and Increasing the Life of a Xenon-Ion Spacecraft Thruster.

An Update on C458 Al-Li

NASA Technical Reports Server (NTRS)

Babel, Hank; Rioja, Robert

2003-01-01

The 1.8 Li content and consequently the 0.0945 lb.cu in density of C458 along with its higher modulus and good strength and toughness at ambient and cryogenic temperatures made it an attractive alloy for single and multiple use cryogenic tankage and unpressurized structure for space launch and operational vehicles. A major effort during the past year was directed towards establishing a production capability for C458 plate. Alcoa established a production ingot casting capability under Air Force Research Laboratory and NASA's Space Launch Initiative (SLI) sponsorship. Three heat lots of material were rolled so that the criterion for S-basis allowables could be met for AMS specifications. Lot acceptance testing showed that the strength and toughness values equaled and exceeded those obtained under the earlier Air Force Program when the alloy was developed. The details of this effort and the results achieved will be described. During the testing of compact tension specimens, particularly at cryogenic temperatures, delaminations were noted on the fractured surface. An investigation was initiated to better understand this condition. The results of this investigation will be presented which includes some of the successful production application of alloys with and without Li that exhibit this type of behavior.

Organic materials and devices for detecting ionizing radiation

DOEpatents

Doty, F Patrick [Livermore, CA; Chinn, Douglas A [Livermore, CA

2007-03-06

A .pi.-conjugated organic material for detecting ionizing radiation, and particularly for detecting low energy fission neutrons. The .pi.-conjugated materials comprise a class of organic materials whose members are intrinsic semiconducting materials. Included in this class are .pi.-conjugated polymers, polyaromatic hydrocarbon molecules, and quinolates. Because of their high resistivities (.gtoreq.10.sup.9 ohmcm), these .pi.-conjugated organic materials exhibit very low leakage currents. A device for detecting and measuring ionizing radiation can be made by applying an electric field to a layer of the .pi.-conjugated polymer material to measure electron/hole pair formation. A layer of the .pi.-conjugated polymer material can be made by conventional polymer fabrication methods and can be cast into sheets capable of covering large areas. These sheets of polymer radiation detector material can be deposited between flexible electrodes and rolled up to form a radiation detector occupying a small volume but having a large surface area. The semiconducting polymer material can be easily fabricated in layers about 10 .mu.m to 100 .mu.m thick. These thin polymer layers and their associated electrodes can be stacked to form unique multi-layer detector arrangements that occupy small volume.

A Study of the Batch Annealing of Cold-Rolled HSLA Steels Containing Niobium or Titanium

NASA Astrophysics Data System (ADS)

Fang, Chao; Garcia, C. Isaac; Choi, Shi-Hoon; DeArdo, Anthony J.

2015-08-01

The batch annealing behavior of two cold-rolled, microalloyed HSLA steels has been studied in this program. One steel was microalloyed with niobium while the other with titanium. A successfully batch annealed steel will exhibit minimum variation in properties along the length of the coil, even though the inner and outer wraps experience faster heating and cooling rates and lower soaking temperatures, i.e., the so-called "cold spot" areas, than the mid-length portion of the coil, i.e., the so-called "hot spot" areas. The variation in strength and ductility is caused by differences in the extent of annealing in the different areas. It has been known for 30 years that titanium-bearing HSLA steels show more variability after batch annealing than do the niobium-bearing steels. One of the goals of this study was to try to explain this observation. In this study, the annealing kinetics of the surface and center layers of the cold-rolled sheet were compared. The surface and center layers of the niobium steel and the surface layer of the titanium steel all showed similar annealing kinetics, while the center layer of the titanium steel exhibited much slower kinetics. Metallographic results indicate that the stored energy of the cold-rolled condition, as revealed by grain center sub-grain boundary density, appeared to strongly influence the annealing kinetics. The kinetics were followed by the Kernel Average Misorientation reconstruction of the microstructure at different stages on annealing. Possible pinning effects caused by microalloy precipitates were also considered. Methods of improving uniformity and increasing kinetics, involving optimizing both hot-rolled and cold-rolled microstructure, are suggested.

Roll-to-roll-compatible, flexible, transparent electrodes based on self-nanoembedded Cu nanowires using intense pulsed light irradiation

NASA Astrophysics Data System (ADS)

Zhong, Zhaoyang; Woo, Kyoohee; Kim, Inhyuk; Hwang, Hyewon; Kwon, Sin; Choi, Young-Man; Lee, Youngu; Lee, Taik-Min; Kim, Kwangyoung; Moon, Jooho

2016-04-01

Copper nanowire (Cu NW)-based flexible transparent conductive electrodes (FTCEs) have been investigated in detail for use in various applications such as flexible touch screens, organic photovoltaics and organic light-emitting diodes. In this study, hexadecylamine (HDA) adsorbed onto the surface of NWs is changed into polyvinylpyrrolidone (PVP) via a ligand exchange process; the high-molecular-weight PVP enables high dispersion stability. Intense pulsed light (IPL) irradiation is used to remove organic species present on the surface of the NWs and to form direct connections between the NWs rapidly without any atmospheric control. NWs are self-nanoembedded into a plastic substrate after IPL irradiation, which results in a smooth surface, strong NW/substrate adhesion, excellent mechanical flexibility and enhanced oxidation stability. Moreover, Cu NW FTCEs with high uniformities are successfully fabricated on a large area (150 mm × 200 mm) via successive IPL irradiation that is synchronized with the motion of the sample stage. This study demonstrates the possibility of roll-to-roll-based, large-scale production of low-cost, high-performance Cu NW-based FTCEs.Copper nanowire (Cu NW)-based flexible transparent conductive electrodes (FTCEs) have been investigated in detail for use in various applications such as flexible touch screens, organic photovoltaics and organic light-emitting diodes. In this study, hexadecylamine (HDA) adsorbed onto the surface of NWs is changed into polyvinylpyrrolidone (PVP) via a ligand exchange process; the high-molecular-weight PVP enables high dispersion stability. Intense pulsed light (IPL) irradiation is used to remove organic species present on the surface of the NWs and to form direct connections between the NWs rapidly without any atmospheric control. NWs are self-nanoembedded into a plastic substrate after IPL irradiation, which results in a smooth surface, strong NW/substrate adhesion, excellent mechanical flexibility and enhanced oxidation stability. Moreover, Cu NW FTCEs with high uniformities are successfully fabricated on a large area (150 mm × 200 mm) via successive IPL irradiation that is synchronized with the motion of the sample stage. This study demonstrates the possibility of roll-to-roll-based, large-scale production of low-cost, high-performance Cu NW-based FTCEs. Electronic supplementary information (ESI) available. See DOI: 10.1039/c6nr00444j

Method of casting aerogels

DOEpatents

Poco, John F.

1993-01-01

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

Rolling Contact Fatigue and Wear Behavior of High-Performance Railway Wheel Steels Under Various Rolling-Sliding Contact Conditions

NASA Astrophysics Data System (ADS)

Faccoli, Michela; Petrogalli, Candida; Lancini, Matteo; Ghidini, Andrea; Mazzù, Angelo

2017-07-01

An experimental investigation was carried out to study and compare the response to cyclic loading of the high-performance railway wheel steels ER8 EN13262 and SUPERLOS®. Rolling contact tests were performed with the same contact pressure, rolling speed and sliding/rolling ratio, varying the lubrication regime to simulate different climatic conditions. The samples, machined out of wheel rims at two depths within the reprofiling layer, were coupled with UIC 900A rail steel samples. The wear rates, friction coefficients and hardness were correlated with the deformation beneath the contact surface. The crack morphology was studied, and the damage mechanisms were identified. The distribution of crack length and depth at the end of the dry tests was analyzed to quantify the damage. The main difference between the steels lies in the response of the external samples to dry contact: SUPERLOS® is subjected to a higher wear and lower friction coefficient than ER8, and this reduces the density of surface cracks that can propagate under wet contact conditions. The analysis of feedback data from in-service wheels confirmed the experimental results.

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.

Strip casting apparatus and method

DOEpatents

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

1988-09-20

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

Strip casting apparatus and method

DOEpatents

Williams, Robert S.; Baker, Donald F.

1988-01-01

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

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

NASA Astrophysics Data System (ADS)

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

2013-01-01

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

14 CFR 125.225 - Flight data recorders.

Code of Federal Regulations, 2014 CFR

2014-01-01

... acceleration; (5) Heading; (6) Time of each radio transmission to or from air traffic control; (7) Pitch attitude; (8) Roll attitude; (9) Longitudinal acceleration; (10) Control column or pitch control surface... control; (7) Pitch attitude; (8) Roll attitude; (9) Longitudinal acceleration; (10) Pitch trim position...

Microstructure and Mechanical Properties of Fe-18Mn-18Cr-0.5N Austenitic Nonmagnetic Stainless Steel in Asymmetric Hot Rolling

NASA Astrophysics Data System (ADS)

Song, Y. L.; Li, C. S.; Ma, B.; Han, Y. H.

2017-05-01

Asymmetric hot rolling (ASHR) with a mismatch speed ratio of 1.15 in a single pass was applied to Fe-18Mn-18Cr-0.5N steel and was compared with symmetric hot rolling (SHR). The results indicated that a through-thickness microstructure gradient was formed in the plate due to the shear strain (0.36) introduced by ASHR. A fine-grained layer with the average size of 3 μm was achieved at the top surface of ASHR plate, while numerous elongated grains with a few recrystallized grains were presented at the center layer. The texture was distributed randomly at the top surface of ASHR plate, and a weaker intensity of typical hot-rolled texture in austenitic steel was obtained at the center layer of ASHR plate compared to SHR plate. An excellent combination of microhardness, strength and ductility was obtained in the ASHR plate, which was attributed to gradient microstructure induced by ASHR.

A method to achieve comparable thermal states of car brakes during braking on the road and on a high-speed roll-stand

NASA Astrophysics Data System (ADS)

Wolff, Andrzej

2010-01-01

The temperature of a brake friction surface influences significantly the braking effectiveness. The paper describes a heat transfer process in car brakes. Using a developed program of finite element method, the temperature distributions in brake rotors (disc and drum brake) of a light truck have been calculated. As a preliminary consistency criterion of the brake thermal state in road and roll-stand braking conditions, a balance of the energy cumulated in the brake rotor has been taken into account. As the most reliable consistency criterion an equality of average temperatures of the friction surface has been assumed. The presented method allows to achieve on a roll-stand the analogical thermal states of automotive brakes, which are observed during braking in road conditions. Basing on this method, it is possible to calculate the braking time and force for a high-speed roll-stand. In contrast to the previous papers of the author, new calculation results have been presented.

Lipid raft-associated β-adducin is required for PSGL-1-mediated neutrophil rolling on P-selectin.

PubMed

Xu, Tingshuang; Liu, Wenai; Yang, Chen; Ba, Xueqing; Wang, Xiaoguang; Jiang, Yong; Zeng, Xianlu

2015-02-01

Lipid rafts, a liquid-ordered plasma membrane microdomain, are related to cell-surface receptor function. PSGL-1, a major surface receptor protein for leukocyte, also acts as a signaling receptor in leukocyte rolling. To investigate the role of lipid raft in PSGL-1 signaling in human neutrophils, we quantitatively analyzed lipid raft proteome of human promyelocytic leukemia cell line HL-60 cells and identified a lipid raft-associated protein β-adducin. PSGL-1 ligation induced dissociation of the raft-associated protein β-adducin from lipid rafts and actin, as well as phosphorylation of β-adducin, indicating a transient uncoupling of lipid rafts from the actin cytoskeleton. Knockdown of β-adducin greatly attenuated HL-60 cells rolling on P-selectin. We also showed that Src kinase is crucial for PSGL-1 ligation-induced β-adducin phosphorylation and relocation. Taken together, these results show that β-adducin is a pivotal lipid raft-associated protein in PSGL-1-mediated neutrophil rolling on P-selectin. © Society for Leukocyte Biology.

Anatomical calibration for wearable motion capture systems: Video calibrated anatomical system technique.

PubMed

Bisi, Maria Cristina; Stagni, Rita; Caroselli, Alessio; Cappello, Angelo

2015-08-01

Inertial sensors are becoming widely used for the assessment of human movement in both clinical and research applications, thanks to their usability out of the laboratory. This work aims to propose a method for calibrating anatomical landmark position in the wearable sensor reference frame with an ease to use, portable and low cost device. An off-the-shelf camera, a stick and a pattern, attached to the inertial sensor, compose the device. The proposed technique is referred to as video Calibrated Anatomical System Technique (vCAST). The absolute orientation of a synthetic femur was tracked both using the vCAST together with an inertial sensor and using stereo-photogrammetry as reference. Anatomical landmark calibration showed mean absolute error of 0.6±0.5 mm: these errors are smaller than those affecting the in-vivo identification of anatomical landmarks. The roll, pitch and yaw anatomical frame orientations showed root mean square errors close to the accuracy limit of the wearable sensor used (1°), highlighting the reliability of the proposed technique. In conclusion, the present paper proposes and preliminarily verifies the performance of a method (vCAST) for calibrating anatomical landmark position in the wearable sensor reference frame: the technique is low time consuming, highly portable, easy to implement and usable outside laboratory. Copyright © 2015 IPEM. Published by Elsevier Ltd. All rights reserved.

Rolling with the flow: bumblebees flying in unsteady wakes.

PubMed

Ravi, Sridhar; Crall, James D; Fisher, Alex; Combes, Stacey A

2013-11-15

Our understanding of how variable wind in natural environments affects flying insects is limited because most studies of insect flight are conducted in either smooth flow or still air conditions. Here, we investigate the effects of structured, unsteady flow (the von Karman vortex street behind a cylinder) on the flight performance of bumblebees (Bombus impatiens). Bumblebees are 'all-weather' foragers and thus frequently experience variable aerial conditions, ranging from fully mixed, turbulent flow to unsteady, structured vortices near objects such as branches and stems. We examined how bumblebee flight performance differs in unsteady versus smooth flow, as well as how the orientation of unsteady flow structures affects their flight performance, by filming bumblebees flying in a wind tunnel under various flow conditions. The three-dimensional flight trajectories and orientations of bumblebees were quantified in each of three flow conditions: (1) smooth flow, (2) the unsteady wake of a vertical cylinder (inducing strong lateral disturbances) and (3) the unsteady wake of a horizontal cylinder (inducing strong vertical disturbances). In both unsteady conditions, bumblebees attenuated the disturbances induced by the wind quite effectively, but still experienced significant translational and rotational fluctuations as compared with flight in smooth flow. Bees appeared to be most sensitive to disturbance along the lateral axis, displaying large lateral accelerations, translations and rolling motions in response to both unsteady flow conditions, regardless of orientation. Bees also displayed the greatest agility around the roll axis, initiating voluntary casting maneuvers and correcting for lateral disturbances mainly through roll in all flow conditions. Both unsteady flow conditions reduced the upstream flight speed of bees, suggesting an increased cost of flight in unsteady flow, with potential implications for foraging patterns and colony energetics in natural, variable wind environments.

Final Technical Report: Development of an Abrasion-Resistant Antisoiling Coating for Front-Surface Reflectors

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

Gee, Randy C.

A high-performance reflective film has been successfully developed for Concentrating Solar Power (CSP) solar concentrators. Anti-soiling properties and abrasion resistance have been incorporated into the reflector to reduce reflector cleaning costs and to enhance durability. This approach has also resulted in higher reflectance and improved specularity. From the outset of this project we focused on the use of established high-volume roll-to-roll manufacturing techniques to achieve low manufacturing costs on a per ubit area basis. Roll-to-roll manufacturng equipment has a high capital cost so there is an entire industry devoted to roll-to-roll “toll” manufacturing, where the equipment is operated “around themore » clock” to produce a multitude of products for a large variety of uses. Using this approach, the reflective film can be manufactured by toll coaters/converters on an as-needed basis.« less

Surface temperatures and glassy state investigations in tribology, part 1

NASA Technical Reports Server (NTRS)

Winer, W. O.; Sanborn, D. M.

1978-01-01

The research in this report is divided into two categories: (1) lubricant rheological behavior, and (2) thermal behavior of a simulated elastohydrodynamic contact. The studies of the lubricant rheological behavior consists of high pressure, low shear rate viscosity measurements, viscoelastic transition measurements, by volume dilatometry, dielectric transitions at atmospheric pressure and light scattering transitions. Lubricant shear stress-strain behavior in the amorphous glassy state was measured on several fluids. It appears clear from these investigations that many lubricants undergo viscoplastic transitions in typical EHD contacts and that the lubricant has a limiting maximum shear stress it can support which in turn will determine the traction in the contact except in cases of very low slide-roll ratio. Surface temperature measurements were made for a naphthenic mineral oil and a polyphenyl ether. The maximum surface temperature in these experiments was approximately symmetrical about the zero slide-roll ration except for absolute values of slide-roll ratio greater than about 0.9. Additional surface temperature measurements were made in contacts with rough surfaces where the composite surface roughness was approximately equal to the EHD film thickness. A regression analysis was done to obtain a predictive equation for surface temperatures as a function of pressure, sliding speed, and surface roughness. A correction factor for surface roughness effects to the typical flash temperature analysis was found.

Imposed Thermal Fatigue and Post-Thermal-Cycle Wear Resistance of Biomimetic Gray Cast Iron by Laser Treatment

NASA Astrophysics Data System (ADS)

Sui, Qi; Zhou, Hong; Zhang, Deping; Chen, Zhikai; Zhang, Peng

2017-08-01

The present study aims to create coupling biomimetic units on gray cast iron substrate by laser surface treatment (LST). LSTs for single-step (LST1) and two-step (LST2) processes, were carried out on gray cast iron in different media (air and water). Their effects on microstructure, thermal fatigue, and post-thermal-cycle wear (PTW) resistance on the specimens were studied. The tests were carried out to examine the influence of crack-resistance behavior as well as the biomimetic surface on its post-thermal-cycle wear behavior and different units, with different laser treatments for comparison. Results showed that LST2 enhanced the PTW behaviors of gray cast iron, which then led to an increase in its crack resistance. Among the treated cast irons, the one treated by LST2 in air showed the lowest residual stress, due to the positive effect of the lower steepness of the thermal gradient. Moreover, the same specimen showed the best PTW performance, due to its superior crack resistance and higher hardness as a result of it.

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.

An advanced dissymmetric rolling model for online regulation

NASA Astrophysics Data System (ADS)

Cao, Trong-Son

2017-10-01

Roll-bite model is employed to predict the rolling force, torque as well as to estimate the forward slip for preset or online regulation at industrial rolling mills. The rolling process is often dissymmetric in terms of work-rolls rotation speeds and diameters as well as the friction conditions at upper and lower contact surfaces between work-rolls and the strip. The roll-bite model thus must be able to account for these dissymmetries and in the same time has to be accurate and fast enough for online applications. In the present study, a new method, namely Adapted Discretization Slab Method (ADSM) is proposed to obtain a robust roll-bite model, which can take into account the aforementioned dissymmetries and has a very short response time, lower than one millisecond. This model is based on the slab method, with an adaptive discretization and a global Newton-Raphson procedure to improve the convergence speed. The model was validated by comparing with other dissymmetric models proposed in the literature, as well as Finite Element simulations and industrial pilot trials. Furthermore, back-calculation tool was also constructed for friction management for both offline and online applications. With very short CPU time, the ADSM-based model is thus attractive for all online applications, both for cold and hot rolling.

Roll compaction/dry granulation: comparison between roll mill and oscillating granulator in dry granulation.

PubMed

Sakwanichol, Jarunee; Puttipipatkhachorn, Satit; Ingenerf, Gernot; Kleinebudde, Peter

2012-01-01

Different experimental factorial designs were employed to evaluate granule properties obtained from oscillating granulator and roll mill. Four oscillating-granulator parameters were varied, i.e. rotor speed, oscillating angle, aperture of mesh screen and rotor type. Six roll-mill parameters that were throughput, speed ratio in both first and second stages, gap between roll pair in both stages and roll-surface texture were also investigated. Afterwards, the granule properties obtained from two milling types with similar median particle size were compared. All milling parameters in both milling types affected significantly the median particle size, size distribution and amount of fine particles (P < 0.05), except the rotor types of oscillating granulator on fines. Only three milling parameters influenced significantly the flowability (P < 0.05). These were the throughput and the gap size in the first stage of roll mill and the sieve size of oscillating granulator. In comparison between milling types, the differences of granule properties were not practically relevant. However, the roll mill had much higher capacity than the oscillating granulator about seven times, resulting in improving energy savings per unit of product. Consequently, the roll mill can be applied instead of oscillating granulator for roll compaction/dry granulation technique.

The Effects of Forming Parameters on Conical Ring Rolling Process

PubMed Central

Meng, Wen; Zhao, Guoqun; Guan, Yanjin

2014-01-01

The plastic penetration condition and biting-in condition of a radial conical ring rolling process with a closed die structure on the top and bottom of driven roll, simplified as RCRRCDS, were established. The reasonable value range of mandrel feed rate in rolling process was deduced. A coupled thermomechanical 3D FE model of RCRRCDS process was established. The changing laws of equivalent plastic strain (PEEQ) and temperature distributions with rolling time were investigated. The effects of ring's outer radius growth rate and rolls sizes on the uniformities of PEEQ and temperature distributions, average rolling force, and average rolling moment were studied. The results indicate that the PEEQ at the inner layer and outer layer of rolled ring are larger than that at the middle layer of ring; the temperatures at the “obtuse angle zone” of ring's cross-section are higher than those at “acute angle zone”; the temperature at the central part of ring is higher than that at the middle part of ring's outer surfaces. As the ring's outer radius growth rate increases at its reasonable value ranges, the uniformities of PEEQ and temperature distributions increase. Finally, the optimal values of the ring's outer radius growth rate and rolls sizes were obtained. PMID:25202716

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.

Systematic approach to optimal design of induction heating installations for aluminum extrusion process

NASA Astrophysics Data System (ADS)

Zimin, L. S.; Sorokin, A. G.; Egiazaryan, A. S.; Filimonova, O. V.

2018-03-01

An induction heating system has a number of inherent benefits compared to traditional heating systems due to a non-contact heating process. It is widely used in vehicle manufacture, cast-rolling, forging, preheating before rolling, heat treatment, galvanizing and so on. Compared to other heating technologies, induction heating has the advantages of high efficiency, fast heating rate and easy control. The paper presents a new systematic approach to the design and operation of induction heating installations (IHI) in aluminum alloys production. The heating temperature in industrial complexes “induction heating - deformation” is not fixed in advance, but is determined in accordance with the maximization or minimization of the total economic performance during the process of metal heating and deformation. It is indicated that the energy efficient technological complex “IHI – Metal Forming (MF)” can be designed only with regard to its power supply system (PSS). So the task of designing systems of induction heating is to provide, together with the power supply system and forming equipment, the minimum energy costs for the metal retreating.

Advances in Integrated Computational Materials Engineering "ICME"

NASA Astrophysics Data System (ADS)

Hirsch, Jürgen

The methods of Integrated Computational Materials Engineering that were developed and successfully applied for Aluminium have been constantly improved. The main aspects and recent advances of integrated material and process modeling are simulations of material properties like strength and forming properties and for the specific microstructure evolution during processing (rolling, extrusion, annealing) under the influence of material constitution and process variations through the production process down to the final application. Examples are discussed for the through-process simulation of microstructures and related properties of Aluminium sheet, including DC ingot casting, pre-heating and homogenization, hot and cold rolling, final annealing. New results are included of simulation solution annealing and age hardening of 6xxx alloys for automotive applications. Physically based quantitative descriptions and computer assisted evaluation methods are new ICME methods of integrating new simulation tools also for customer applications, like heat affected zones in welding of age hardening alloys. The aspects of estimating the effect of specific elements due to growing recycling volumes requested also for high end Aluminium products are also discussed, being of special interest in the Aluminium producing industries.

Application of round grating angle measurement composite error amendment in the online measurement accuracy improvement of large diameter

NASA Astrophysics Data System (ADS)

Wang, Biao; Yu, Xiaofen; Li, Qinzhao; Zheng, Yu

2008-10-01

The paper aiming at the influence factor of round grating dividing error, rolling-wheel produce eccentricity and surface shape errors provides an amendment method based on rolling-wheel to get the composite error model which includes all influence factors above, and then corrects the non-circle measurement angle error of the rolling-wheel. We make soft simulation verification and have experiment; the result indicates that the composite error amendment method can improve the diameter measurement accuracy with rolling-wheel theory. It has wide application prospect for the measurement accuracy higher than 5 μm/m.

Investigation of test methods, material properties, and processes for solar cell encapsulants

NASA Technical Reports Server (NTRS)

Willis, P. B.; Baum, B.; Goulet, A.

1981-01-01

The development of pottant compounds is emphasized. Formulation of the butyl acrylate syrup/casting pottant was completed. The formulation contains an ultraviolet stabilizer system and may be cured with an initiator that, unlike former selections, presents no shipping of handling hazards to the user. The catalyzed syrup is stable at room temperature and has a pot life of at least eight hours. The formulation of the ethylene/methyl acrylate lamination pottant was also completed. This compound is the alternative pottant to EVA and is similarly produced as an extruded sheet that is wound into rolls. This resin is inherently nonblocking.

Silicon Ingot Casting: Heat Exchanger Method. Multi-wire Slicing: Fixed Abrasine Slicing Technique, Phase 3

NASA Technical Reports Server (NTRS)

Schmid, F.; Khattak, C. P.

1979-01-01

Ingot casting was scaled up to 16 cm by 16 cm square cross section size and ingots weighing up to 8.1 kg were cast. The high degree of crystallinity was maintained in the large ingot. For large sizes, the nonuniformity of heat treatment causes chipping of the surface of the ingot. Progress was made in the development of a uniform graded structure in the silica crucibles. The high speed slicer blade-head weight was reduced to 37 pounds, allowing surface speeds of up to 500 feet per minute. Slicing of 10 cm diameter workpieces at these speeds increased the through-put of the machine to 0.145 mm/min.

Impacts of leaves, roots, and earthworms on soil organic matter composition and distribution in sycamore maple stands

NASA Astrophysics Data System (ADS)

Rivera, N.; Mueller, K. E.; Mueller, C. W.; Oleksyn, J.; Hale, C.; Freeman, K. H.; Eissenstat, D.

2009-12-01

The relative contributions of leaf and root material to soil organic matter (SOM) are poorly understood despite the importance of constraining SOM sources to conceptual and numeric models of SOM dynamics. Selective ingestion and bioturbation of litter and soil by earthworms can alter the fate and spatial distribution of OM in soils, including stabilization pathways of leaf and root litter. However, studies on the contributions of leaves, roots, and earthworms to SOM dynamics are rare. In 3 stands of sycamore maple (Acer pseudoplatanus) with minimal O horizon development and high earthworm activity, we sampled surface litter (> 2 mm) from the Oi horizon, fine roots (< 2 mm), bulk mineral soils (0-20 cm depth), and earthworm casts from Lumbricus terrestris middens. The chemical composition of these samples was estimated by wet-chemical degradation followed by GC-MS analysis. In addition, elemental analyses (C and N) were performed on bulk soils and earthworm casts, before and after physical fractionation by means of particle size and density. Relative to bulk soils, earthworm casts were highly enriched in organic matter, dominated by large particulate OM, and had lower acid to aldehyde ratios among lignin monomers (a proxy for extent of decomposition), confirming that L. terrestris casts stabilize recent plant litter inputs. Maple fine roots and surface litter were distinguished by different profiles of carboxylic acids estimated by GC-MS, facilitating interpretation of OM sources in bulk soil and earthworm casts. Earthworm casts were characterized by a distribution of carboxylic acids similar to that of surface litter while bulk soils had a carboxylic acid profile much closer to that of roots. These results confirm that L. terrestris is primarily a surface, leaf feeder and suggest that OM in the bulk soil may be dominated by root inputs. In bulk soils, the ratio of lignin to hydroxy- and diacids derived from suberin and cutin was low relative to plant litter, confirming the often-observed selective preservation of aliphatic over aromatic biomolecules. The ratio of lignin to cutin/suberin acids in earthworm casts was also low; based on the minimal extent of decomposition in casts evident by lignin acid to aldehyde ratios, we attribute this to selective ingestion by L. terrestris of leaf litter rich in aliphatic biomolecules at the expense of woody debris and petioles rich in lignin, rather than selective preservation.

Leukocyte adhesion: High-speed cells with ABS.

PubMed

van der Merwe, P A

1999-06-03

In order to decide where to exit blood vessels and enter tissues, leukocytes roll along endothelial surfaces. Recent studies suggest that an 'automatic braking system' (ABS), involving selectin cell-adhesion molecules, enables leukocytes to roll at a fairly constant velocity despite large variations in blood flow rate.

Numerical Simulation of Rolling-Airframes Using a Multi-Level Cartesian Method

NASA Technical Reports Server (NTRS)

Murman, Scott M.; Aftosmis, Michael J.; Berger, Marsha J.; Kwak, Dochan (Technical Monitor)

2002-01-01

A supersonic rolling missile with two synchronous canard control surfaces is analyzed using an automated, inviscid, Cartesian method. Sequential-static and time-dependent dynamic simulations of the complete motion are computed for canard dither schedules for level flight, pitch, and yaw maneuver. The dynamic simulations are compared directly against both high-resolution viscous simulations and relevant experimental data, and are also utilized to compute dynamic stability derivatives. The results show that both the body roll rate and canard dither motion influence the roll-averaged forces and moments on the body. At the relatively, low roll rates analyzed in the current work these dynamic effects are modest, however the dynamic computations are effective in predicting the dynamic stability derivatives which can be significant for highly-maneuverable missiles.

Method of casting aerogels

DOEpatents

Poco, J.F.

1993-09-07

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

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

NASA Astrophysics Data System (ADS)

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

2018-04-01

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

Computer program for post-flight evaluation of the control surface response for an attitude controlled missile

NASA Technical Reports Server (NTRS)

Knauber, R. N.

1982-01-01

A FORTRAN IV coded computer program is presented for post-flight analysis of a missile's control surface response. It includes preprocessing of digitized telemetry data for time lags, biases, non-linear calibration changes and filtering. Measurements include autopilot attitude rate and displacement gyro output and four control surface deflections. Simple first order lags are assumed for the pitch, yaw and roll axes of control. Each actuator is also assumed to be represented by a first order lag. Mixing of pitch, yaw and roll commands to four control surfaces is assumed. A pseudo-inverse technique is used to obtain the pitch, yaw and roll components from the four measured deflections. This program has been used for over 10 years on the NASA/SCOUT launch vehicle for post-flight analysis and was helpful in detecting incipient actuator stall due to excessive hinge moments. The program is currently set up for a CDC CYBER 175 computer system. It requires 34K words of memory and contains 675 cards. A sample problem presented herein including the optional plotting requires eleven (11) seconds of central processor time.

Effects of Fragmented Fe Intermetallic Compounds on Ductility in Al-Si-Mg Alloys.

PubMed

Kim, JaeHwang; Kim, DaeHwan

2018-03-01

Fe is intentionally added in order to form the Fe intermetallic compounds (Fe-IMCs) during casting. Field emission scanning electron microscope with energy dispersive spectrometer (EDS) was conducted to understand microstructural changes and chemical composition analyses. The needlelike Fe-IMCs based on two dimensional observation with hundreds of micro size are modified to fragmented particles with the minimum size of 300 nm through clod rolling with 80% thickness reduction. The ratio of Fe:Si on the fragmented Fe-IMCs after 80% reduction is close to 1:1, representing the β-Al5FeSi. The yield and tensile strengths are increased with increasing reduction rate. On the other hand, the elongation is decreased with the 40% reduction, but slightly increased with the 60% reduction. The elongation is dramatically increased over two times for the specimen of 80% reduction compared with that of the as-cast. Fracture behavior is strongly affected by the morphology and size of Fe-IMCs. The fracture mode is changed from brittle to ductile with the microstructure modification of Fe-IMCs.

Tensile Properties and Microstructure of Inconel 718 Fabricated with Electron Beam Freeform Fabrication (EBF(sup 3))

NASA Technical Reports Server (NTRS)

Bird, R. Keith; Hibberd, Joshua

2009-01-01

Electron beam freeform fabrication (EBF3) direct metal deposition processing was used to fabricate two Inconel 718 single-bead-width wall builds and one multiple-bead-width block build. Specimens were machined to evaluate microstructure and room temperature tensile properties. The tensile strength and yield strength of the as-deposited material from the wall and block builds were greater than those for conventional Inconel 718 castings but were less than those for conventional cold-rolled sheet. Ductility levels for the EBF3 material were similar to those for conventionally-processed sheet and castings. An unexpected result was that the modulus of the EBF3-deposited Inconel 718 was significantly lower than that of the conventional material. This low modulus may be associated with a preferred crystallographic orientation resultant from the deposition and rapid solidification process. A heat treatment with a high solution treatment temperature resulted in a recrystallized microstructure and an increased modulus. However, the modulus was not increased to the level that is expected for Inconel 718.

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

Simulation of surface hardening in the deep rolling process by means of an axial symmetric nodal averaged finite element

NASA Astrophysics Data System (ADS)

Morrev, P. G.; Gordon, V. A.

2018-03-01

Surface hardening by deep rolling can be considered as the axial symmetric problem in some special events (namely, when large R and small r radii of the deforming roller meet the requirement R>> r). An axisymmetric nodal averaged stabilized finite element is formulated. The formulation is based on a variational principle with a penalty (stabilizing) item in order to involve large elastic-plastic strain and near to incompressible materials. The deep rolling process for a steel rod is analyzed. Axial residual stress, yield stress, and Odkvist’s parameter are calculated. The residual stress is compared with the data obtained by other authors using a three-dimensional statement of the problem. The results obtained demonstrate essential advantages of the newly developed finite element.

46 CFR 170.295 - Special consideration for free surface of passive roll stabilization tanks.

Code of Federal Regulations, 2010 CFR

2010-10-01

...) The factor (K) must be calculated as follows: (1) Plot (I/d)tan T on Graph 170.295 where— (i) (I) is... the roll tank; and (iii) (T) is the angle of heel. (2) Plot the moments of transference of the liquid...

Surface Hardening of Composite Material by the Centrifugal-Casting Method

NASA Astrophysics Data System (ADS)

Eidelman, E. D.; Durnev, M. A.

2018-04-01

The effect of rotation flow emerging under centrifugal casting on the first-order phase transition, i.e., crystallization, has been studied using the example of producing a gradient composite material of AK12 aluminum alloy in a mixture with basalt fibers. It has been shown that a material with a hardened surface can be created. Distribution of admixtures in the main material when there is macroscopic motion has been found.

Process for slip casting textured tubular structures

DOEpatents

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

2002-01-01

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

Evaluation of left ventricular assist device pump bladders cast from ion-sputtered polytetrafluorethylene mandrels

NASA Technical Reports Server (NTRS)

1982-01-01

A highly thromboresistant blood contacting interface for use in implanatable blood pump is investigated. Biomaterials mechanics, dynamics, durability, surface morphology, and chemistry are among the critical consideration pertinent to the choice of an appropriate blood pump bladder material. The use of transfer cast biopolymers from ion beam textured surfaces is investigated to detect subtle variations in blood pump surface morphology using Biomer as the biomaterial of choice. The efficacy of ion beam sputtering as an acceptable method of fabricating textured blood interfaces is evaluated. Aortic grafts and left ventricular assist devices were implanted in claves; the blood interfaces were fabricated by transfer casting methods from ion beam textured polytetrafluorethylene mandrels. The mandrels were textured by superimposing a 15 micron screen mesh; ion sputtering conditions were 300 volts beam energy, 40 to 50 mA beam, and a mandrel to source distance of 25 microns.

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

Ritchie, IAltenberger, RKNalla, YSano LWagner, RO

The effect of surface treatment on the stress/life fatigue behavior of a titanium Ti-6Al-4V turbine fan blade alloy is investigated in the regime of 102 to 106 cycles to failure under fully reversed stress-controlled isothermal push-pull loading between 25? and 550?C at a frequency of 5 Hz. Specifically, the fatigue behavior was examined in specimens in the deep-rolled and laser-shock peened surface conditions, and compared to results on samples in the untreated (machined and stress annealed) condition. Although the fatigue resistance of the Ti-6Al-4V alloy declined with increasing test temperature regardless of surface condition, deep-rolling and laser-shock peening surface treatmentsmore » were found to extend the fatigue lives by factors of more than 30 and 5-10, respectively, in the high-cycle and low-cycle fatigue regimes at temperatures as high as 550?C. At these temperatures, compressive residual stresses are essentially relaxed; however, it is the presence of near-surface work hardened layers, with a nanocystalline structure in the case of deep-rolling and dense dislocation tangles in the case of laser-shock peening, which remain fairly stable even after cycling at 450?-550?C, that provide the basis for the beneficial role of mechanical surface treatments on the fatigue strength of Ti-6Al-4V at elevated temperatures.« less

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

Fracture resistance of Ti-5Al-2.5Sn extra-low interstitial castings

NASA Technical Reports Server (NTRS)

Fiftal, C. F.; Bolstad, D. A.; Misra, M. S.

1978-01-01

Fracture toughness and cyclic crack propagation data for Ti-5Al-2.5Sn extra-low interstitial (ELI) castings, 0.51 and 2.54 cm (0.20 and 1.00 in.) thick, at 394, 294, 77, and 20 K (250, 70, -320, and -423 F), are presented. Both surface flaw and compact tension geometries were tested. Comparison is made with other titanium alloys in both wrought and cast forms. Crack propagation resistance is comparable to wrought Ti-5Al-2.5Sn ELI, even with the extremely coarse as-cast grain size encountered.

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.

A comparison of the fatigue behavior of cast Ti-7.5Mo with c.p. titanium, Ti-6Al-4V and Ti-13Nb-13Zr alloys.

PubMed

Lin, Chia-Wei; Ju, Chien-Ping; Chern Lin, Jiin-Huey

2005-06-01

The purpose of the present study is to compare the high-cycle fatigue behavior of newly developed Ti-7.5Mo alloy with that of c.p. Ti, Ti-13Nb-13Zr and Ti-6Al-4V alloys in their as-cast state. Experimental results indicate that Ti-6Al-4V and c.p. Ti have higher stress-controlled fatigue resistance but lower strain-controlled fatigue resistance than Ti-7.5Mo and Ti-13Nb-13Zr. Among four materials Ti-7.5Mo demonstrates the best strain-controlled fatigue performance. The fracture surfaces of the present materials are comprised of three morphologically distinct zones: crack initiation zone, crack propagation zone, and the final-stage overload zone. The fatigue cracks almost always initiate from casting-induced surface/subsurface pores. A river pattern is observed in the propagation zone. In the overload zone dimples are typically observed. Three factors most significantly affecting the fatigue performance of the present materials are the presence of the casting-induced surface/subsurface pores; the location of the pores; and the inherent mechanical properties of the materials.

Judging rolling wheels: Dynamic and kinematic aspects of rotation-translation coupling

NASA Technical Reports Server (NTRS)

Hecht, Heiko

1993-01-01

Four experiments were carried out to investigate observers' abilities to judge rolling motions. The experiments were designed to assess whether two important aspects of such motions are appreciated: the kinematic coupling of rotation and translation, and the dynamic effects of gravity. Different motion contexts of rolling wheels were created using computer-generated displays. The first experiment involved wheels rolling down an inclined plane. Observers spontaneously appreciated the anomaly of wheels that failed to accelerate, but they were not able to differentiate between different acceleration functions. Moreover, their judgements were almost exclusively based on the translation component of the rolling motion, neglecting the rotation component. In a second experiment it was found that observers could accurately estimate the perimeter of various objects. Thus, their inability to consider rotation information is not attributable to misperceptions of the geometry of wheels. In a third experiment the finding that rolling wheels appear to overrotate was replicated; however, findings from this experiment also showed, together with those from a fourth experiment, that observers are able to make very accurate judgments about translation-rotation coupling in rolling wheels when information is provided about the orientation of the wheel and the texture of the surface on which it rolls.

Judging rolling wheels: dynamic and kinematic aspects of rotation-translation coupling.

PubMed

Hecht, H

1993-01-01

Four experiments were carried out to investigate observers' abilities to judge rolling motions. The experiments were designed to assess whether two important aspects of such motions are appreciated: the kinematic coupling of rotation and translation, and the dynamic effects of gravity. Different motion contexts of rolling wheels were created using computer-generated displays. The first experiment involved wheels rolling down an inclined plane. Observers spontaneously appreciated the anomaly of wheels that failed to accelerate, but they were not able to differentiate between different acceleration functions. Moreover, their judgments were almost exclusively based on the translation component of the rolling motion, neglecting the rotation component. In a second experiment it was found that observers could accurately estimate the perimeter of various objects. Thus, their inability to consider rotation information is not attributable to misperceptions of the geometry of wheels. In a third experiment the finding that rolling wheels appear to overrotate was replicated; however, findings from this experiment also showed, together with those from a fourth experiment, that observers are able to make very accurate judgments about translation-rotation coupling in rolling wheels when information is provided about the orientation of the wheel and the texture of the surface on which it rolls.

Rolling Process Modeling Report. Finite-Element Model Validation and Parametric Study on various Rolling Process parameters

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

Soulami, Ayoub; Lavender, Curt A.; Paxton, Dean M.

2015-06-15

Pacific Northwest National Laboratory (PNNL) has been investigating manufacturing processes for the uranium-10% molybdenum alloy plate-type fuel for high-performance research reactors in the United States. This work supports the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization Reactor Conversion Program. This report documents modeling results of PNNL’s efforts to perform finite-element simulations to predict roll-separating forces for various rolling mill geometries for PNNL, Babcock & Wilcox Co., Y-12 National Security Complex, Los Alamos National Laboratory, and Idaho National Laboratory. The model developed and presented in a previous report has been subjected to further validationmore » study using new sets of experimental data generated from a rolling mill at PNNL. Simulation results of both hot rolling and cold rolling of uranium-10% molybdenum coupons have been compared with experimental results. The model was used to predict roll-separating forces at different temperatures and reductions for five rolling mills within the National Nuclear Security Administration Fuel Fabrication Capability project. This report also presents initial results of a finite-element model microstructure-based approach to study the surface roughness at the interface between zirconium and uranium-10% molybdenum.« less

A method for the determination of the coefficient of rolling friction using cycloidal pendulum

NASA Astrophysics Data System (ADS)

Ciornei, M. C.; Alaci, S.; Ciornei, F. C.; Romanu, I. C.

2017-08-01

The paper presents a method for experimental finding of coefficient of rolling friction appropriate for biomedical applications based on the theory of cycloidal pendulum. When a mobile circle rolls over a fixed straight line, the points from the circle describe trajectories called normal cycloids. To materialize this model, it is sufficient that a small region from boundary surfaces of a moving rigid body is spherical. Assuming pure rolling motion, the equation of motion of the cycloidal pendulum is obtained - an ordinary nonlinear differential equation. The experimental device is composed by two interconnected balls rolling over the material to be studied. The inertial characteristics of the pendulum can be adjusted via weights placed on a rod. A laser spot oscillates together to the pendulum and provides the amplitude of oscillations. After finding the experimental parameters necessary in differential equation of motion, it can be integrated using the Runge-Kutta of fourth order method. The equation was integrated for several materials and found values of rolling friction coefficients. Two main conclusions are drawn: the coefficient of rolling friction influenced significantly the amplitude of oscillation but the effect upon the period of oscillation is practically imperceptible. A methodology is proposed for finding the rolling friction coefficient and the pure rolling condition is verified.

Compressible sleeve provides automatic centering for grinding or turning of cylinders

NASA Technical Reports Server (NTRS)

Rohrer, J. A.

1968-01-01

Elastomeric sleeve supported on a threaded mandrel automatically centers cylindrical castings for grinding or turning. By expanding the diameter of the sleeve with pressure against the ends, the casting becomes rigidly supported and the surfacing operation can be completed.

Corrosion behaviours of the dental magnetic keeper complexes made by different alloys and methods.

PubMed

Wu, Min-Ke; Song, Ning; Liu, Fei; Kou, Liang; Lu, Xiao-Wen; Wang, Min; Wang, Hang; Shen, Jie-Fei

2016-09-29

The keeper and cast dowel-coping, as a primary component for a magnetic attachment, is easily subjected to corrosion in a wet environment, such as the oral cavity, which contains electrolyte-rich saliva, complex microflora and chewing behaviour and so on. The objective of this in vitro study was to examine the corrosion resistance of a dowel and coping-keeper complex fabricated by finish keeper and three alloys (cobalt-chromium, CoCr; silver-palladium-gold, PdAu; gold-platinum, AuPt) using a laser-welding process and a casting technique. The surface morphology characteristics and microstructures of the samples were examined by means of metallographic microscope and scanning electron microscope (SEM). Energy-dispersive spectroscopy (EDS) with SEM provided elements analysis information for the test samples after 10% oxalic acid solution etching test. Tafel polarization curve recordings demonstrated parameter values indicating corrosion of the samples when subjected to electrochemical testing. This study has suggested that massive oxides are attached to the surface of the CoCr-keeper complex but not to the AuPt-keeper complex. Only the keeper area of cast CoCr-keeper complex displayed obvious intergranular corrosion and changes in the Fe and Co elements. Both cast and laser-welded AuPt-keeper complexes had the highest free corrosion potential, followed by the PdAu-keeper complex. We concluded that although the corrosion resistance of the CoCr-keeper complex was worst, the keeper surface passive film was actually preserved to its maximum extent. The laser-welded CoCr- and PdAu-keeper complexes possessed superior corrosion resistance as compared with their cast specimens, but no significant difference was found between the cast and laser-welded AuPt-keeper complexes. The Fe-poor and Cr-rich band, appearing on the edge of the keeper when casting, has been proven to be a corrosion-prone area.

Corrosion behaviours of the dental magnetic keeper complexes made by different alloys and methods

PubMed Central

Wu, Min-Ke; Song, Ning; Liu, Fei; Kou, Liang; Lu, Xiao-Wen; Wang, Min; Wang, Hang; Shen, Jie-Fei

2016-01-01

The keeper and cast dowel–coping, as a primary component for a magnetic attachment, is easily subjected to corrosion in a wet environment, such as the oral cavity, which contains electrolyte-rich saliva, complex microflora and chewing behaviour and so on. The objective of this in vitro study was to examine the corrosion resistance of a dowel and coping-keeper complex fabricated by finish keeper and three alloys (cobalt–chromium, CoCr; silver–palladium–gold, PdAu; gold–platinum, AuPt) using a laser-welding process and a casting technique. The surface morphology characteristics and microstructures of the samples were examined by means of metallographic microscope and scanning electron microscope (SEM). Energy-dispersive spectroscopy (EDS) with SEM provided elements analysis information for the test samples after 10% oxalic acid solution etching test. Tafel polarization curve recordings demonstrated parameter values indicating corrosion of the samples when subjected to electrochemical testing. This study has suggested that massive oxides are attached to the surface of the CoCr–keeper complex but not to the AuPt–keeper complex. Only the keeper area of cast CoCr–keeper complex displayed obvious intergranular corrosion and changes in the Fe and Co elements. Both cast and laser-welded AuPt–keeper complexes had the highest free corrosion potential, followed by the PdAu–keeper complex. We concluded that although the corrosion resistance of the CoCr–keeper complex was worst, the keeper surface passive film was actually preserved to its maximum extent. The laser-welded CoCr– and PdAu–keeper complexes possessed superior corrosion resistance as compared with their cast specimens, but no significant difference was found between the cast and laser-welded AuPt–keeper complexes. The Fe-poor and Cr-rich band, appearing on the edge of the keeper when casting, has been proven to be a corrosion-prone area. PMID:27388806

Experimental analysis of two-layered dissimilar metals by roll bonding

NASA Astrophysics Data System (ADS)

Zhao, Guanghui; Li, Yugui; Li, Juan; Huang, Qingxue; Ma, Lifeng

2018-02-01

Rolling reduction and base layers thickness have important implications for rolling compounding. A two-layered 304 stainless steel/Q345R low alloyed steel was roll bonded. The roll bonding was performed at the three thickness reductions of 25%, 40% and 55% with base layers of various thicknesses (Q345R). The microstructures of the composite were investigated by the ultra-deep microscope (OM) and scanning electron microscope (SEM) and Transmission electron microscope (TEM). Simultaneously, the mechanical properties of the composite were experimentally measured and the tensile fracture surfaces were observed by SEM. The interfaces were successfully bonded without any cracking or voids, which indicated a good fabrication of the 304/Q345R composite. The rolling reduction rate and thinning increase of the substrate contributed to the bonding effects appearance of the roll bonded sheet. The Cr and Ni enriched diffusion layer was formed by the interface elements diffusion. The Cr and Ni diffusion led to the formation of ˜10 μm wide Cr and Ni layers on the carbon steel side.

A comparative study of the influence of alpha-lactose monohydrate particle morphology on granule and tablet properties after roll compaction/dry granulation.

PubMed

Grote, Simon; Kleinebudde, Peter

2018-05-29

The influence of particle morphology and size of alpha-lactose monohydrate on dry granules and tablets was studied. Four different morphologies were investigated: Two grades of primary crystals, which differed in their particle size and structure (compact crystals vs. agglomerates). The materials were roll compacted at different specific compaction forces and changes in the particle size distribution and the specific surface area were measured. Afterwards, two fractions of granules were pressed to tablets and the tensile strength was compared to that from tablets compressed from the raw materials. The specific surface area was increased induced by roll compaction/dry granulation for all materials. At increased specific compaction forces, the materials showed sufficient size enlargement. The morphology of lactose determined the strength of direct compressed tablets. In contrast, the strength of granule tablets was leveled by the previous compression step during roll compaction/dry granulation. Thus, the tensile strength of tablets compressed directly from the powder mixtures determined whether materials exhibited a loss in tabletability after roll compaction/dry granulation or not. The granule size had only a slight influence on the strength of produced tablets. In some cases, the fraction of smaller granules showed a higher tensile strength compared to the larger fraction.

Efficient rolling texture predictions and texture-sensitive properties of α-uranium foils

DOE PAGES

Steiner, Matthew A.; Klein, Robert W.; Calhoun, Christopher A.; ...

2017-01-01

Here, finite element (FE) analysis was used to simulate the strain history of an α-uranium foil during cold-rolling, with the sheet modeled as an isotropic elastoplastic continuum. The resulting strain history was then used as input for a viscoplastic self-consistent (VPSC) polycrystal plasticity model to simulate crystallographic texture evolution. Mid-plane textures predicted via the combined FE→VPSC approach show alignment of the (010) poles along the rolling direction (RD), and the (001) poles along the normal direction (ND) with a symmetric splitting along RD. The surface texture is similar to that of the mid-plane, but with a shear-induced asymmetry that favorsmore » one of the RD split features of the (001) pole figure. Both the mid-plane and surface textures predicted by the FE→VPSC approach agree with published experimental results for cold-rolled α-uranium plates, as well as predictions made by a more computationally intensive full-field crystal plasticity based finite element model. α-uranium foils produced by cold-rolling must typically undergo a final recrystallization anneal to restore ductility prior to their final application, resulting in significant texture evolution from the cold-rolled plate deformation texture. Using the texture measured from a foil in the final recrystallized state, coefficients of the thermal expansion and elastic stiffness tensors were calculated using a thermo-elastic self-consistent model, and the anisotropic yield loci and flow curves along the RD, TD, and ND were predicted using the VPSC code.« less

Efficient rolling texture predictions and texture-sensitive properties of α-uranium foils

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

Steiner, Matthew A.; Klein, Robert W.; Calhoun, Christopher A.

Here, finite element (FE) analysis was used to simulate the strain history of an α-uranium foil during cold-rolling, with the sheet modeled as an isotropic elastoplastic continuum. The resulting strain history was then used as input for a viscoplastic self-consistent (VPSC) polycrystal plasticity model to simulate crystallographic texture evolution. Mid-plane textures predicted via the combined FE→VPSC approach show alignment of the (010) poles along the rolling direction (RD), and the (001) poles along the normal direction (ND) with a symmetric splitting along RD. The surface texture is similar to that of the mid-plane, but with a shear-induced asymmetry that favorsmore » one of the RD split features of the (001) pole figure. Both the mid-plane and surface textures predicted by the FE→VPSC approach agree with published experimental results for cold-rolled α-uranium plates, as well as predictions made by a more computationally intensive full-field crystal plasticity based finite element model. α-uranium foils produced by cold-rolling must typically undergo a final recrystallization anneal to restore ductility prior to their final application, resulting in significant texture evolution from the cold-rolled plate deformation texture. Using the texture measured from a foil in the final recrystallized state, coefficients of the thermal expansion and elastic stiffness tensors were calculated using a thermo-elastic self-consistent model, and the anisotropic yield loci and flow curves along the RD, TD, and ND were predicted using the VPSC code.« less

Efficient rolling texture predictions and texture-sensitive thermomechanical properties of α-uranium foils

NASA Astrophysics Data System (ADS)

Steiner, Matthew A.; Klein, Robert W.; Calhoun, Christopher A.; Knezevic, Marko; Garlea, Elena; Agnew, Sean R.

2017-11-01

Finite element (FE) analysis was used to simulate the strain history of an α-uranium foil during cold straight-rolling, with the sheet modeled as an isotropic elastoplastic continuum. The resulting strain history was then used as input for a viscoplastic self-consistent (VPSC) polycrystal plasticity model to simulate crystallographic texture evolution. Mid-plane textures predicted via the combined FE→VPSC approach show alignment of the (010) poles along the rolling direction (RD), and the (001) poles along the normal direction (ND) with a symmetric splitting along RD. The surface texture is similar to that of the mid-plane, but with a shear-induced asymmetry that favors one of the RD split features of the (001) pole figure. Both the mid-plane and surface textures predicted by the FE→VPSC approach agree with published experimental results for cold straight-rolled α-uranium plates, as well as predictions made by a more computationally intensive full-field crystal plasticity based finite element model. α-uranium foils produced by cold-rolling must typically undergo a recrystallization anneal to restore ductility prior to their final application, resulting in significant texture evolution from the cold-rolled plate deformation texture. Using the texture measured from a foil in the final recrystallized state, coefficients of thermal expansion and the elastic stiffness tensors were calculated using a thermo-elastic self-consistent model, and the anisotropic yield loci and flow curves along the RD, TD, and ND were predicted using the VPSC code.

Fatigue resistant carbon coatings for rolling/sliding contacts

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

Singh, Harpal; Ramirez, Giovanni; Eryilmaz, Osman

2016-06-01

The growing demands for renewable energy production have recently resulted in a significant increase in wind plant installation. Field data from these plants show that wind turbines suffer from costly repair, maintenance and high failure rates. Often times the reliability issues are linked with tribological components used in wind turbine drivetrains. The primary failure modes in bearings and gears are associated with micropitting, wear, brinelling, scuffing, smearing and macropitting all of which occur at or near the surface. Accordingly, a variety of surface engineering approaches are currently being considered to alter the near surface properties of such bearings and gearsmore » to prevent these tribological failures. In the present work, we have evaluated the tribological performance of compliant highly hydrogenated diamond like carbon coating developed at Argonne National Laboratory, under mixed rolling/sliding contact conditions for wind turbine drivetrain components. The coating was deposited on AISI 52100 steel specimens using a magnetron sputter deposition system. The experiments were performed on a PCS Micro-Pitting-Rig (MPR) with four material pairs at 1.79 GPa contact stress, 40% slide to roll ratio and in polyalphaolefin (PAO4) basestock oil (to ensure extreme boundary conditions). The post-test analysis was performed using optical microscopy, surface profilometry, and Raman spectroscopy. The results obtained show a potential for these coatings in sliding/rolling contact applications as no failures were observed with coated specimens even after 100 million cycles compared to uncoated pair in which they failed after 32 million cycles, under the given test conditions.« less

Surface fatigue life of M50NiL and AISI 9310 spur gears and R C bars

NASA Technical Reports Server (NTRS)

Townsend, Dennis P.; Bamberger, Eric N.

1991-01-01

Spur gear endurance tests and rolling element surface fatigue tests were conducted to study vacuum induction melted, vacuum arc remelted (VIM-VAR) M50NiL steel for use as a gear steel in advanced aircraft applications, to determine its endurance characteristics, and to compare the results with those for standard VAR and VIM-VAR AISI 9310 gear material. Tests were conducted with spur gears and rolling contact bars manufactured from VIM-VAR M50NiL and VAR and VIM-VAR AISI 9310. The gear pitch diameter was 8.9 cm. Gear test conditions were an inlet oil temperature of 320 K, and outlet oil temperature of 350 K, a maximum Hertz stress of 1.71 GPa, and a speed of 10000 rpm. Bench rolling element fatigue tests were conducted at ambient temperatures with a bar speed of 12,500 rpm and a maximum Hertz stress of 4.83 GPa. The VIM-VAR M50NiL gears had a surface fatigue life that was 4.5 and 11.5 times that for VIM-VAR and VAR AISI 9310 gears, respectively. The surface fatigue life of the VIM-VAR M50NiL rolling contact bars was 13.2 and 21.6 times that for the VIM-VAR and VAR AISI 9310, respectively. The VIM-VAR M50NiL material was shown to have good resistance to fracture through a fatigue spall and superior fatigue life to both other gears.

Epitaxial-Growth-Induced Junction Welding of Silver Nanowire Network Electrodes.

PubMed

Kang, Hyungseok; Song, Sol-Ji; Sul, Young Eun; An, Byeong-Seon; Yin, Zhenxing; Choi, Yongsuk; Pu, Lyongsun; Yang, Cheol-Woong; Kim, Youn Sang; Cho, Sung Min; Kim, Jung-Gu; Cho, Jeong Ho

2018-05-22

In this study, we developed a roll-to-roll Ag electroplating process for metallic nanowire electrodes using a galvanostatic mode. Electroplating is a low-cost and facile method for deposition of metal onto a target surface with precise control of both the composition and the thickness. Metallic nanowire networks [silver nanowires (AgNWs) and copper nanowires (CuNWs)] coated onto a polyethylene terephthalate (PET) film were immersed directly in an electroplating bath containing AgNO 3 . Solvated silver ions (Ag + ions) were deposited onto the nanowire surface through application of a constant current via an external circuit between the nanowire networks (cathode) and a Ag plate (anode). The amount of electroplated Ag was systematically controlled by changing both the applied current density and the electroplating time, which enabled precise control of the sheet resistance and optical transmittance of the metallic nanowire networks. The optimized Ag-electroplated AgNW (Ag-AgNW) films exhibited a sheet resistance of ∼19 Ω/sq at an optical transmittance of 90% (550 nm). A transmission electron microscopy study confirmed that Ag grew epitaxially on the AgNW surface, but a polycrystalline Ag structure was formed on the CuNW surface. The Ag-electroplated metallic nanowire electrodes were successfully applied to various electronic devices such as organic light-emitting diodes, triboelectric nanogenerators, and a resistive touch panel. The proposed roll-to-roll Ag electroplating process provides a simple, low-cost, and scalable method for the fabrication of enhanced transparent conductive electrode materials for next-generation electronic devices.

Future of the Particle Replication in Nonwetting Templates (PRINT) Technology

PubMed Central

Xu, Jing; Wong, Dominica H. C.; Byrne, James D.; Chen, Kai; Bowerman, Charles

2014-01-01

Particle replication in nonwetting templates (PRINT) is a continuous, roll-to-roll, high-resolution molding technology which allows the design and synthesis of precisely defined micro- and nanoparticles. This technology adapts the lithographic techniques from the microelectronics industry and marries these with the roll-to-roll processes from the photographic film industry to enable researchers to have unprecedented control over particle size, shape, chemical composition, cargo, modulus, and surface properties. In addition, PRINT is a GMP-compliant (GMP = good manufacturing practice) platform amenable for particle fabrication on a large scale. Herein, we describe some of our most recent work involving the PRINT technology for application in the biomedical and material sciences. PMID:23670869

Leading edge flap system for aircraft control augmentation

NASA Technical Reports Server (NTRS)

Rao, D. M. (Inventor)

1984-01-01

Traditional roll control systems such as ailerons, elevons or spoilers are least effective at high angles of attack due to boundary layer separation over the wing. This invention uses independently deployed leading edge flaps on the upper surfaces of vortex stabilized wings to shift the center of lift outboard. A rolling moment is created that is used to control roll in flight at high angles of attack. The effectiveness of the rolling moment increases linearly with angle of attack. No adverse yaw effects are induced. In an alternate mode of operation, both leading edge flaps are deployed together at cruise speeds to create a very effective airbrake without appreciable modification in pitching moment. Little trim change is required.

Lunar surface engineering properties experiment definition. Volume 2: Mechanics of rolling sphere-soil slope interaction

NASA Technical Reports Server (NTRS)

Hovland, H. J.; Mitchell, J. K.

1971-01-01

The soil deformation mode under the action of a rolling sphere (boulder) was determined, and a theory based on actual soil failure mechanism was developed which provides a remote reconnaissance technique for study of soil conditions using boulder track observations. The failure mechanism was investigated by using models and by testing an instrumented spherical wheel. The wheel was specifically designed to measure contact pressure, but it also provided information on the failure mechanism. Further tests included rolling some 200 spheres down sand slopes. Films were taken of the rolling spheres, and the tracks were measured. Implications of the results and reevaluation of the lunar boulder tracks are discussed.

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.

Heterofunctional nanosheet controlling cell adhesion properties by collagen coating.

PubMed

Niwa, Daisuke; Fujie, Toshinori; Lang, Thorsten; Goda, Nobuhito; Takeoka, Shinji

2012-08-01

Recently, biomaterials have been widely used in a variety of medical applications. We previously reported that a poly-l-lactic acid (PLLA) nanosheet shows anti-adhesive properties and constitutes a useful biomaterial for preventing unwanted wound adhesion in surgical operations. In this article, we examine whether the PLLA nanosheet can be specifically modified with biomacromolecules on one surface only. Such an approach would endow each side of the nanosheet with discrete functions, that is anti-adhesive and pro-healing properties. We fabricated two distinct PLLA nanosheets: (i) collagen cast on the surface of a PLLA nanosheet (Col-Cast-PLLA) and (ii) collagen spin-coated on the nanosheet (Col-Spin-PLLA). In the Col-Spin-PLLA nanosheet, the collagen layer had a thickness of 5-10 nm on the PLLA surface and displayed increased hydrophilicity compared to both PLLA and Col-Cast-PLLA nanosheets. In addition, atomic force microscopy showed disorganized collagen fibril formation on the PLLA layer when covered using the spin-coating method, while apparent bundle formations of collagen were formed in the Col-Cast-PLLA nanosheet. The Col-Spin-PLLA nanosheet provided a microenvironment for cells to adhere and spread. By contrast, the Col-Cast-PLLA nanosheet displayed reduced cell adhesion compared to the Col-Spin-PLLA nanosheet. Consistent with these findings, immunocytochemical analysis clearly showed fine networks of actin filaments in cells cultured on the Col-Spin-PLLA, but not the Col-Cast-PLLA nanosheet. Therefore, the Col-Spin-PLLA nanosheet was shown to be more suitable for acting as a scaffold. In conclusion, we have succeeded in developing a heterofunctional nanosheet comprising a collagen modified side, which has the ability to rapidly adhere cells, and an unmodified side, which acts as an adhesion barrier, by using a spin-coating technique.

Study of ultrasonic melt treatment on the quality of horizontal continuously cast Al-1%Si alloy.

PubMed

Li, Xin-Tao; Li, Ting-Ju; Li, Xi-Meng; Jin, Jun-Ze

2006-02-01

The fluctuation of the melt temperature in a tundish was measured during casting and experiments were conducted to investigate the effects of ultrasonic melt treatment on the surface quality and solidification structures of Al-1%Si ingots. The results show that the uniformity of melt temperature was enhanced with the application of ultrasonic melt treatment. When the ultrasonic power is 1,000W, the surface quality was evidently improved and grains of cast ingots were refined. Moreover, EPMA analysis was adopted to study the relationship between the ultrasonic power and boundary segregation of Si element. The result shows that boundary segregation is suppressed with the increase of ultrasonic power and the phenomenon was theoretically interpreted.

The effect of surface tension, superheat and surface films on the rate of heat transfer from an iron droplet to a water cooled copper mold

NASA Astrophysics Data System (ADS)

Phinichka, Natthapong

In strip casting the cast surface forms during the initial stage of solidification and the phenomenon that occurs during the first 50 milliseconds of contact time between the liquid steel and the mold define the cast surface and its quality. However the exact mechanism of the initial solidification and the process variables that affect initial solidification phenomena during that time are not well understood. The primary goal of this work is to develop a fundamental understanding of factors controlling strip casting. The purpose of the experimental study is to better understand the role of processing parameters on initial solidification phenomena, heat transfer rate and the formation of the cast steel surface. An investigation was made to evaluate the heat transfer rate of different kinds of steels. The experimental apparatus was designed for millisecond resolution of heat transfer behavior. A novel approach of simultaneous in-situ observation and measurement of rapid heat transfer was developed and enabled a coupling between the interfacial heat transfer rate and droplet solidification rate. The solidification rate was estimated from the varying position of the solidification front as captured by a CCD camera. The effects of experimental parameters such as melt superheat, sulfur content and oxide accumulation at the interface on measured heat flux were studied. It was found that the heat flux increased slightly when the percent of sulfur and increased significantly when superheat increased. The oxide accumulation at the interface was found to be manganese and silicon based oxide. When the liquid steel droplets were ejected onto the copper substrate repeatedly, without cleaning the substrate surface between the ejections, a large increase in the interfacial heat flux was observed. The results of the film study indicated that a liquid oxide film existed at the interface. The surface roughness measurement of the solidified specimen decreased with repeated experimentation and better contact between the droplet and the mold was found to be the cause of the improved heat transfer rate.

Evaluation of Surface Roughness and Tensile Strength of Base Metal Alloys Used for Crown and Bridge on Recasting (Recycling).

PubMed

Agrawal, Amit; Hashmi, Syed W; Rao, Yogesh; Garg, Akanksha

2015-07-01

Dental casting alloys play a prominent role in the restoration of the partial dentition. Casting alloys have to survive long term in the mouth and also have the combination of structure, molecules, wear resistance and biologic compatibility. According to ADA system casting alloys were divided into three groups (wt%); high noble, Noble and predominantly base metal alloys. To evaluate the mechanical properties such as tensile strength and surface roughness of the new and recast base metal (nickel-chromium) alloys. Recasting of the base metal alloys derived from sprue and button, to make it reusable has been done. A total of 200 test specimens were fabricated using specially fabricated jig of metal and divided into two groups- 100 specimens of new alloy and 100 specimens of recast alloys, which were tested for tensile strength on universal testing machine and surface roughness on surface roughness tester. Tensile strength of new alloy showed no statistically significant difference (p-value>0.05) from recast alloy whereas new alloy had statistically significant surface roughness (Maximum and Average surface roughness) difference (p-value<0.01) as compared to recast alloy. Within the limitations of the study it is concluded that the tensile strength will not be affected by recasting of nickel-chromium alloy whereas surface roughness increases markedly.

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.

Dynamic modeling and mobility analysis of the transforming roving-rolling explorer (TRREx) as it Traverses Rugged Martian Terrain

NASA Astrophysics Data System (ADS)

Edwin, Lionel E.; Mazzoleni, Andre P.

2016-03-01

All planetary surface exploration missions thus far have employed traditional rovers with a rocker-bogie suspension. These rovers can navigate moderately rough and flat terrain, but are not designed to traverse rugged terrain with steep slopes. The fact is, however, that the most scientifically interesting missions require exploration platforms with capabilities for navigating such types of rugged terrain. This issue motivates the development of new kinds of rovers that take advantage of the latest advances in robotic technologies to traverse rugged terrain efficiently. This work analyzes one such rover concept called the Transforming Roving-Rolling Explorer (TRREx) that is principally aimed at addressing the above issue. Biologically inspired by the way the armadillo curls up into a ball when threatened, and the way the golden wheel spider uses the dynamic advantages of a sphere to roll down hills when escaping danger, the TRREx rover can traverse like a traditional 6-wheeled rover over conventional terrain, but can also transform itself into a sphere, when necessary, to travel down steep inclines, or navigate rough terrain. This paper investigates the mobility of the TRREx when it is in its rolling mode, i.e. when it is a sphere and can steer itself through actuations that shift its center of mass to achieve the desired direction of roll. A mathematical model describing the dynamics of the rover in this spherical configuration is presented, and actuated rolling is demonstrated through computer simulation. Parametric analyzes that investigate the rover's mobility as a function of its design parameters are also presented. This work highlights the contribution of the spherical rolling mode to the enhanced mobility of the TRREx rover and how it could enable challenging surface exploration missions in the future.