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Sample records for 316l-type wrought cast

  1. Effects of Thermocapillary Forces during Welding of 316L-Type Wrought, Cast and Powder Metallurgy Austenitic Stainless Steels

    Sgobba, Stefano

    2003-01-01

    The Large Hadron Collider (LHC) is now under construction at the European Organization for Nuclear Research (CERN). This 27 km long accelerator requires 1248 superconducting dipole magnets operating at 1.9 K. The cold mass of the dipole magnets is closed by a shrinking cylinder with two longitudinal welds and two end covers at both extremities of the cylinder. The end covers, for which fabrication by welding, casting or Powder Metallurgy (PM) was considered, are dished-heads equipped with a number of protruding nozzles for the passage of the different cryogenic lines. Structural materials and welds must retain high strength and toughness at cryogenic temperature. AISI 316L-type austenitic stainless steel grades have been selected because of their mechanical properties, ductility, weldability and stability of the austenitic phase against low-temperature spontaneous martensitic transformation. 316LN is chosen for the fabrication of the end covers, while the interconnection components to be welded on the protrud...

  2. Martensitic transformation in 304L and 316L types stainless steels cathodically hydrogen charged

    This paper reports a TEM study on the role of phase transitions at the crack tip in 304L and 316L types stainless steels cathodically hydrogen charged in the absence of any eternally applied forces. The possible role of α prime and epsilon martensite phases in the fracture mechanism is discussed

  3. Comparison of joint designs for laser welding of cast metal plates and wrought wires.

    Takayama, Yasuko; Nomoto, Rie; Nakajima, Hiroyuki; Ohkubo, Chikahiro

    2013-01-01

    The purpose of the present study was to compare joint designs for the laser welding of cast metal plates and wrought wire, and to evaluate the welded area internally using X-ray micro-focus computerized tomography (micro-CT). Cast metal plates (Ti, Co-Cr) and wrought wires (Ti, Co-Cr) were welded using similar metals. The specimens were welded using four joint designs in which the wrought wires and the parent metals were welded directly (two designs) or the wrought wires were welded to the groove of the parent metal from one or both sides (n = 5). The porosity and gap in the welded area were evaluated by micro-CT, and the maximum tensile load of the welded specimens was measured with a universal testing machine. An element analysis was conducted using an electron probe X-ray microanalyzer. The statistical analysis of the results was performed using Bonferroni's multiple comparisons (α = 0.05). The results included that all the specimens fractured at the wrought wire when subjected to tensile testing, although there were specimens that exhibited gaps due to the joint design. The wrought wires were affected by laser irradiation and observed to melt together and onto the filler metal. Both Mo and Sn elements found in the wrought wire were detected in the filler metal of the Ti specimens, and Ni was detected in the filler metal of the Co-Cr specimens. The four joint designs simulating the designs used clinically were confirmed to have adequate joint strength provided by laser welding. PMID:22080283

  4. Optimization of Squeeze Casting Parameters for 2017 A Wrought Al Alloy Using Taguchi Method

    Najib Souissi

    2014-04-01

    Full Text Available This study applies the Taguchi method to investigate the relationship between the ultimate tensile strength, hardness and process variables in a squeeze casting 2017 A wrought aluminium alloy. The effects of various casting parameters including squeeze pressure, melt temperature and die temperature were studied. Therefore, the objectives of the Taguchi method for the squeeze casting process are to establish the optimal combination of process parameters and to reduce the variation in quality between only a few experiments. The experimental results show that the squeeze pressure significantly affects the microstructure and the mechanical properties of 2017 A Al alloy.

  5. Comparison of properties of centrifugally cast and wrought stainless steels with similar chemical composition for DWPF canisters

    This report compares the properties of centrifugally cast stainless steel and plate stainless steel (wrought). The comparison was to determine whether centrifugally cast cylinders are an acceptable alternative to wrought, rolled and welded cylinders. After comparing the two materials, it was found that the castings meet or exceed the requirements of the proposed DWPF (Defense Waste Project Facility) canister design. Recommendations for future action are: that the molten steel used to make the centrifugal castings must be processed by an Argon Oxygen Decarburizer (AOD) prior to casting, and that the effect of partially heat treating an as-cast centrifugal casting should be evaluated. This evaluation is to determine the metallurgical affect of pouring molten borosilicate glass into a casting and allowing the casting cool at ambient temperature

  6. Comparative study: sensitization development in hot-isostatic-pressed cast and wrought structures type 316L(N)-IG stainless steel under isothermal heat treatment

    This work focuses on the relative sensitization resistance of type 316L(N)-IG stainless steel (SS). Cast and wrought structures SS after solid hot-isostatic pressing (solid-HIP) operation are investigated under isothermal heat treatment. Wrought SS/SS solid-HIP joint sensitization is taken also into consideration. These experiments employed the quantitative double-loop electrochemical potentiokinetic reactivation (DL-EPR) and oxalic acid etch screening tests. A copper-copper sulfate-16% sulfuric acid test applied for strongly sensitized cast SS to reinforce the results were received by the methods mentioned above. Results from all employed methods correlate well. Sensitization was detected neither in cast nor in wrought SS in as-HIPed condition excluding wrought SS/SS solid-HIP joints. Significant difference between sensitization development rates was determined in cast and wrought SS structures when annealing at 675 deg. C for a duration up to 50 h

  7. Microstructural refinement of hyper-eutectic Al?Si?Fe?Mn cast alloys to produce a recyclable wrought material

    Umezawa, Osamu; Nakamoto, Munefumi; Osawa, Yoshiaki; Suzuki, Kenta; Kumai, Shinji

    2005-01-01

    Although the cascade of material flow is presently suitable for the aluminum recycling, a better utilization of secondary alloys is required. In order to establish an upgradeable recycling design for developing wrought products from secondary aluminum alloys, a fine distribution of the primary phases in hyper-eutectic Al?Si?Fe?Mn cast materials has been achieved. Two novel processes were adopted. One was repeated thermomechanical treatment (RTMT), which involves a repetition of a multi-step c...

  8. Joining of Cast ZE41A Mg to Wrought 6061 Al by the Cold Spray Process and Friction Stir Welding

    Champagne, Victor Kenneth; West, Michael K.; Reza Rokni, M.; Curtis, Todd; Champagne, Victor; McNally, Baillie

    2016-01-01

    This paper presents a novel method for joining cast ZE41A-T5 Mg to wrought 6061-T6 Al, without forming deleterious, coarse intermetallic compounds, which is not currently possible with conventional technologies. The novel aspect of the process includes the development of a joint design using cold spray (CS) as the enabling technology, to produce a transitional layer onto which a conventional welding technique can be employed to join the two dissimilar materials. The emphasis in this study will be on the CS transitional layer (T-layer) which enables the joining of cast ZE41A-T5 magnesium (Mg) and wrought 6061-T6 aluminum (Al) by friction-stir welding and the subsequent materials characterization to show the structural integrity of the entire joint. In order to join Mg and Al plates by this method, a transitional layer of CS Al is first deposited along the edge of cast ZE41A Mg plate. The CS Al T-layer enables the Mg to be friction stir welded to a plate of wrought 6061 Al, thereby completing the Mg plate to Al plate joint. Friction stir welding was chosen in this study to join the CS Al T-layer to the wrought Al plate; however, other conventional welding techniques could also be employed for joining Mg to Al in this manner. The CS Al T-layer is compatible to the wrought 6061 Al plate and serves as an insulating layer that prevents heat generated during the friction stir welding process from extending into the magnesium, thus preventing the formation of intermetallics. In this study, two sets of samples were produced joining cast ZE41A-T5 magnesium (Mg) and wrought 6061-T6 aluminum: one set using CS 6061 Al as the transition material between the ZE41A Mg plate and 6061 Al plate and the other set using CS 5056 Al as the transition material. Microstructural analysis by scanning and transmission electron microscopy and optical microscopy, along with mechanical test results including triple lug shear, tension, and micro hardness will be presented. Comparisons will be

  9. Development of manufacturing process of wrought magnesium alloy sheets by twin roll casting

    H. Watari

    2007-01-01

    Full Text Available Purpose: The purpose of the work is to development of a strip casting technology for manufacturing magnesiumalloy sheets. The aim of the work is to establish a manufacturing process and technology to facilitate theeconomical manufacture of high-strength magnesium sheet alloys.Design/methodology/approach: A horizontal type twin roll caster was used to manufacture magnesium alloysheets. Pair of copper alloy roll, pure copper roll and steel roll was used for the horizontal type twin roll caster.The diameter of the rolls was 300mm and the width of rolls was 100 and 150mm.Findings: The magnesium alloy sheets could be succcessfully manufactured by the horizontal twin roll caster. Theproduct sheet thickness in the present experiment was 2.0 to 5.0mm. The equiaxed microstrucure was observed incast magnesium alloys when a pair of copper and cupper aolly rolls were used. The mean grain size of the castmagnesium alloys strip was from 30 to 60 micrometers. After hot rolling process, the grain size was reduced to about10 micrometers. The obtained magnesium alloy sheet indicated a good plastic formability by a warm-drawing test.Research limitations/implications: The superheat in the experiment was between 15ºC and 30ºC, also anappropriate hot rolling temperature was 250ºC for AZ31, AZ61 and AM60, 300ºC for AZ91.Practical implications: The proposed manufacturing process was effective from the view point of economicalmanufacturing process as well as of formation of rapid solidification microstructures. Introducing the twin rollcasting technology enable to manufacture magnesium sheet alloys with high aluminum contents, such as AZ61,AM60 and AZ91.Originality/value: AZ31, AM60, AZ61 and AZ91 wrought magnesium alloy sheets can be manufacturedeconomically by twin roll casting. These cast sheet can be hot rolled and the proposed manufacturing processenables manufacturer to manufacure thin magnesium alloy sheets with high aluminum contents such as AM60,AZ61 and AZ

  10. Final Report, Volume 4, The Develpoment of Qualification Standards forCast Super Duplex Stainless Steel (2507 Wrought Equivalent)

    Hariharan, Vasudevan; Lundin, Carl, D.

    2005-09-30

    The objective of the program is to determine the suitability of ASTM A923 Standard Test methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic-Ferritic Stainless Steels for 25 Cr Cast Super Duplex Stainless Steels (ASTM A890-5A). Different tests were carried out on the materials procured from various steel foundries as stated in the ASTM A923. The foundries were designated as Foundry A, B, C and D. All the materials were foundry solution annealed. Materials from Foundry D were solution heat treated at The University of Tennessee also and then they were subjected to heat treatment schedule which was derived from the testing of wrought DSS to establish the A923 specification. This was possible because the material from the same heat was sufficient for conducting the full scope of heat treatment. This was done prior to carrying out various other tests. Charpy samples were machined. The Ferrite content was measured in all the Charpy samples using Feritscope{reg_sign} and ASTM E562 Manual Point Count Method. After the ferrite content was measured the samples were sent to AMC-Vulcan, Inc. in Alabama to conduct the Charpy impact test based on ASTM A923 Test Method B. This was followed by etch testing and corrosion analysis based on ASTM A923 Test Methods A and C respectively at University of Tennessee. Hardness testing using Rockwell B and C was also carried out on these samples. A correlation was derived between all the three test methods and the best method for evaluating the presence of intermetallic in the material was determined. The ferrite content was correlated with the toughness values. Microstructural analysis was carried out on the etch test samples using Scanning Electron Microscopy in order to determine if intermetallic phases were present. The fracture surfaces from Charpy test specimens were also observed under SEM in order to determine the presence of any cracks and whether it was a brittle or a ductile fracture. A correlation

  11. Final Report, Volume 4, The Development of Qualification Standards for Cast Super Duplex Stainless Steel (2507 Wrought Equivalent)

    Hariharan, Vasudevan; Lundin, Carl, W.

    2005-09-30

    The objective of the program is to determine the suitability of ASTM A923 Standard Test methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic-Ferritic Stainless Steels for 25 Cr Cast Super Duplex Stainless Steels (ASTM A890-5A). Different tests were carried out on the materials procured from various steel foundries as stated in the ASTM A923. The foundries were designated as Foundry A, B, C and D. All the materials were foundry solution annealed. Materials from Foundry D were solution heat treated at The University of Tennessee also and then they were subjected to heat treatment schedule which was derived from the testing of wrought DSS to establish the A923 specification. This was possible because the material from the same heat was sufficient for conducting the full scope of heat treatment. This was done prior to carrying out various other tests. Charpy samples were machined. The Ferrite content was measured in all the Charpy samples using Feritscope® and ASTM E562 Manual Point Count Method. After the ferrite content was measured the samples were sent to AMC-Vulcan, Inc. in Alabama to conduct the Charpy impact test based on ASTM A923 Test Method B. This was followed by etch testing and corrosion analysis based on ASTM A923 Test Methods A and C respectively at University of Tennessee. Hardness testing using Rockwell B and C was also carried out on these samples. A correlation was derived between all the three test methods and the best method for evaluating the presence of intermetallic in the material was determined. The ferrite content was correlated with the toughness values. Microstructural analysis was carried out on the etch test samples using Scanning Electron Microscopy in order to determine if intermetallic phases were present. The fracture surfaces from Charpy test specimens were also observed under SEM in order to determine the presence of any cracks and whether it was a brittle or a ductile fracture. A correlation was

  12. Effects of AS-cast and wrought cobalt-chrome-molybdenum and titanium-aluminium-vanadium alloys on cytokine gene expression and protein secretion in J774A.1 macrophages

    S S Jakobsen

    2007-09-01

    Full Text Available Insertion of metal implants is associated with a possible change in the delicate balance between pro- and anti-inflammatory proteins, probably leading to an unfavourable predominantly pro-inflammatory milieu. The most likely cause is an inappropriate activation of macrophages in close relation to the metal implant and wear-products. The aim of the present study was to compare surfaces of as-cast and wrought Cobalt-Chrome-Molybdenum (CoCrMo alloys and Titanium-Aluminium-Vanadium (TiAlV alloy when incubated with mouse macrophage J774A.1 cell cultures. Changes in pro- and anti-inflammatory cytokines [TNF-alpha, IL-6, IL-alpha, IL-1beta, IL-10] and proteins known to induce proliferation [M-CSF], chemotaxis [MCP-1] and osteogenesis [TGF-beta, OPG] were determined by ELISA and Real Time reverse transcriptase - PCR (Real Time rt-PCR. Lactate dehydrogenase (LDH was measured in the medium to asses the cell viability. Surface properties of the discs were characterised with a profilometer and with energy dispersive X-ray spectroscopy. We here report, for the first time, that the prosthetic material surface (non-phagocytable of as-cast high carbon CoCrMo reduces the pro-inflammatory cytokine IL-6 transcription, the chemokine MCP-1 secretion, and M-CSF secretion by 77 %, 36 %, and 62 %, respectively. Furthermore, we found that reducing surface roughness did not affect this reduction. The results suggest that as-cast CoCrMo alloy is more inert than wrought CoCrMo and wrought TiAlV alloys and could prove to be a superior implant material generating less inflammation which might result in less osteolysis.

  13. Effects of AS-cast and wrought cobalt-chrome-molybdenum and titanium-aluminium-vanadium alloys on cytokine gene expression and protein secretion in J774A.1 macrophages

    S S Jakobsen; Larsen, A.; M Stoltenberg; J. M. Bruun; Soballe, K

    2007-01-01

    Insertion of metal implants is associated with a possible change in the delicate balance between pro- and anti-inflammatory proteins, probably leading to an unfavourable predominantly pro-inflammatory milieu. The most likely cause is an inappropriate activation of macrophages in close relation to the metal implant and wear-products. The aim of the present study was to compare surfaces of as-cast and wrought Cobalt-Chrome-Molybdenum (CoCrMo) alloys and Titanium-Aluminium-Vanadium (TiAlV) alloy...

  14. Effects of as-cast and wrought Cobalt-Chrome-Molybdenum and Titanium-Aluminium-Vanadium alloys on cytokine gene expression and protein secretion in J774A.1 macrophages

    Jakobsen, Stig Storgaard; Larsen, Agnete; Stoltenberg, Meredin;

    2007-01-01

    Insertion of metal implants is associated with a possible change in the delicate balance between pro- and anti-inflammatory proteins, probably leading to an unfavourable predominantly pro-inflammatory milieu. The most likely cause is an inappropriate activation of macrophages in close relation to...... the metal implant and wear-products. The aim of the present study was to compare surfaces of as-cast and wrought Cobalt-Chrome-Molybdenum (CoCrMo) alloys and Titanium-Aluminium-Vanadium (TiAlV) alloy when incubated with mouse macrophage J774A.1 cell cultures. Changes in pro- and anti...... asses the cell viability. Surface properties of the discs were characterised with a profilometer and with energy dispersive X-ray spectroscopy. We here report, for the first time, that the prosthetic material surface (non-phagocytable) of as-cast high carbon CoCrMo reduces the pro-inflammatory cytokine...

  15. PRODUCTION OF THE WROUGHT INGOTS OF HYPOEUTECTIC SILUMIN

    V. Ju. Stetsenko

    2010-01-01

    Full Text Available It is shown that casting in crystallizer with flood-fluid power cooling system allows to produce the wrought ingots out of hypereutectic silumin without application of additional operations of thermoplastic deformation and annealing.

  16. PRODUCTION OF THE WROUGHT INGOTS OF HYPOEUTECTIC SILUMIN

    V. Ju. Stetsenko; A. I. Rivkin; A. A. Sidorsky

    2010-01-01

    It is shown that casting in crystallizer with flood-fluid power cooling system allows to produce the wrought ingots out of hypereutectic silumin without application of additional operations of thermoplastic deformation and annealing.

  17. Effect of Yttrium Ion Implantation on the Corrosion Resistance of Stainless Steel AISI 316 L Type in Sulfuric Acid (H2SO4, pH = 1.06) Media

    The effect of yttrium ion implantation on the corrosion resistance of stainless steel AISI 316 L type in sulfuric acid (H2SO4, pH = 1.06) is presented in this paper. Implantation of yttrium ion was carried out by varying the ion dose implanted into target at ion energy of 100 keV. Corrosion resistance properties experiments was carried out electrochemically in sulfuric acid media (H2SO4, pH = 1.06). Yttrium ion implanted into target was analyzed using EDAXS (Energy Dispersive Analysis X-Rays Spectroscopy). It has been found that before implantation, the corrosion current density of the samples was Icorr = 0.2 μA/cm2 (52 x 10-4 mpy). After the samples were implanted at ion dose 1.7 x 1017 ion /cm2, 2.1 x 1017 ion /cm2, 2.6 x 1017 ion /cm2, 3.0 x 1017 ion /cm2 and 3.5 x 1017 ion /cm2, the corrosion current density were 0.033 μA/cm2 (8.581 mpy), 0.033 μA/cm2 (8.581 mpy), 0.01 μA/cm2 (2.6 mpy), 0.033 μA/cm2 (8.581 mpy), and 0.066 μA/cm2 (17.162 mpy) respectively. From elemental analysis using EDAXS, it has been found that before implantation by yttrium ion, the contents of yttrium was 0 %, and after implantation at those ion doses, the contents of yttrium were 0.15 %, 0.17 %, 0.20 %, 0.32 % and 0.43 % weight. From these data, it could be concluded that the best corrosion resistance in sulfuric acid (pH = 1.06) was achieved at 0.20 % weight of yttrium. (author)

  18. MIG (metal inert gas) and laser beam welding of aluminium die castings with wrought aluminium profiles; Soudage MIG et soudage laser de pieces moulees sous pression avec des profils corroyes en alliages d'aluminium

    Wiesner, S.; Rethmeier, M.; Wohlfart, H. [Universite Technique de Brunswick, Institut de Soudure (Germany)

    2003-10-01

    The applicability of different welding techniques to the welding of aluminium die castings, particularly used in automobile engineering, is discussed and experimental results from welding trials of some of these processes are reported. The advantages and disadvantages of using pressure welding, beam welding and gas shielded arc welding techniques to weld aluminium die castings are discussed. Results from welding trials carried out on a number of ductile AlSi and AlMg alloys using MIG and laser welding techniques are reported. Laser-TIG welding was also investigated as an alternative to laser welding with its inherent problems. (authors)

  19. Hydrogen embrittlement of 316L type stainless steel

    Hydrogen embrittlement tests on type 316L stainless steel are performed including cathodic charging during slow strain rate tests. Brittle multiple cracking is observed and relationships between crack growth rate and diffusion are analysed. The influence of hydrogen on the morphology of ductile fracture is found after fractographic examination. Two aspects of ductile failure are observed in accordance with the hydrogen content of the sample; a reduced density of microvoids for higher hydrogen contents and brittle secondary cracking in addition to ductile fracture surfaces for lower hydrogen contents. (orig.)

  20. Thixo forging process of wrought aluminum alloy fabricated by rotational helical shape stirrer

    The manufacture of rheology materials from wrought and casting aluminum alloys using controlling solid fraction and crystal grain is demonstrated in this paper. The equipment to form the rheology material was designed so that shear force and applied pressure could be carefully and simultaneously applied using a mechanical stirrer. The problems caused by using this method with the thixo forging process were studied by investigating the mechanical properties of a sample that had a controlled solid fraction of 45-50 %

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

    Baldwin, M.D. [Sandia National Labs., Albuquerque, NM (United States); Hochanadel, P.W. [Colorado School of Mines, Golden, CO (United States). Dept. of Metallurgical and Materials Engineering

    1995-11-01

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

  2. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30

    Duplex stainless steels (DSS) are being specified for chloride containing environments due to their enhanced pitting and stress corrosion cracking resistance. They exhibit improved corrosion performance over the austenitic stainless steels. Duplex stainless steels also offer improved strength properties and are available in various wrought and cast forms. Selected grades of duplex stainless steel castings and their welds, in comparison with their wrought counterparts, were evaluated, regarding corrosion performance and mechanical properties and weldability. Multiple heats of cast duplex stainless steel were evaluated in the as-cast, solution annealed (SA) static cast and SA centrifugal cast conditions, while their wrought counterparts were characterized in the SA condition and in the form of as-rolled plate. Welding, including extensive assessment of autogenous welds and a preliminary study of composite welds (shielded metal arc weld (SMAW)), was performed. The evaluations included critical pitting temperature (CPT) testing, intergranular corrosion (IGC) testing, ASTM A923 (Methods A, B and C), Charpy impact testing, weldability testing (ASTM A494), ferrite measurement and microstructural evaluations. In the study, the corrosion performances of DSS castings were characterized and assessed, including the wrought counterparts for comparison. The evaluation filled the pore of lack of data for cast duplex stainless steels compared to wrought materials. A database of the pitting corrosion and IGC behavior of cast and wrought materials was generated for a greater depth of understanding for the behavior of cast duplex stainless steel. In addition, improved evaluation methods for DSS castings were developed according to ASTM A923, A262, G48 and A494. The study revealed that when properly heat treated according to the specification, (1) DSS castings have equal or better pitting and intergranular corrosion resistance than their wrought counterparts; (2) Welding reduces the

  3. Final Report, Volume 1, Metallurgical Evaluation of Cast Duplex Stainless Steels and their Weldments

    Wen, Songqing; Lundin, Carl, W.; Batten, Greg, W.

    2005-09-30

    Duplex stainless steels (DSS) are being specified for chloride containing environments due to their enhanced pitting and stress corrosion cracking resistance. They exhibit improved corrosion performance over the austenitic stainless steels. Duplex stainless steels also offer improved strength properties and are available in various wrought and cast forms. Selected grades of duplex stainless steel castings and their welds, in comparison with their wrought counterparts, were evaluated, regarding corrosion performance and mechanical properties and weldability. Multiple heats of cast duplex stainless steel were evaluated in the as-cast, solution annealed (SA) static cast and SA centrifugal cast conditions, while their wrought counterparts were characterized in the SA condition and in the form of as-rolled plate. Welding, including extensive assessment of autogenous welds and a preliminary study of composite welds (shielded metal arc weld (SMAW)), was performed. The evaluations included critical pitting temperature (CPT) testing, intergranular corrosion (IGC) testing, ASTM A923 (Methods A, B and C), Charpy impact testing, weldability testing (ASTM A494), ferrite measurement and microstructural evaluations. In the study, the corrosion performances of DSS castings were characterized and assessed, including the wrought counterparts for comparison. The evaluation filled the pore of lack of data for cast duplex stainless steels compared to wrought materials. A database of the pitting corrosion and IGC behavior of cast and wrought materials was generated for a greater depth of understanding for the behavior of cast duplex stainless steel. In addition, improved evaluation methods for DSS castings were developed according to ASTM A923, A262, G48 and A494. The study revealed that when properly heat treated according to the specification, (1) DSS castings have equal or better pitting and intergranular corrosion resistance than their wrought counterparts; (2) Welding reduces the

  4. Characterization of a 12-pdr wrought-iron cannonball from the Akko 1 shipwreck

    The Akko 1 shipwreck, discovered in Akko harbor, Israel, is the remains of an eastern Mediterranean brig built at the beginning of the 19th century. Among other finds, eleven cannonballs were found in the shipwreck and three of them were retrieved. Two of the cannonballs, the 9- and 24-pdrs, have been studied previously. The present study of the 12-pdr cannonball included γ-rays radiographic testing, XRF analysis, density measurements, optical microscopy and SEM-EDS observation, OES analysis and microhardness tests. The investigation included characterization of the composition, microstructure and slag analysis. The results revealed a quite homogenous microstructure of α-ferrite phase, with glassy, wüstite and fayalite slags, as typical for a wrought-iron—annealed product, a more complicated and an earlier technology, compared to the 9- and 24-pdr that were made of cast-iron. Ferritic cannonballs are extremely rare, especially in the 19th century, when cannonballs were manufactured of cast iron by the sand casting process. The different manufacturing methods may indicate a different place of fabrication, and an apparently earlier production date for the 12-pdr, which might have even been used as ballast. - Highlights: • Three cannonballs were retrieved from the 19th century Akko 1 shipwreck. • The 12-pdr differs from the 9- and 24-pdr cannonballs previously studied. • The 12-pdr was made of high quality annealed wrought-iron, not of cast-iron. • The technology used indicates a date earlier than the middle of the 19th century. • Perhaps the 12-pdr belonged to another navy than the other two or used as ballast

  5. Microstructure and properties of new Mg-Li-Zn wrought alloys

    2005-01-01

    Cold-rolling workability, heat treatment characteristics and mechanical properties of Mg-5%-22 % Li-2 % Zn(mass fraction) wrought alloys were studied. Density of alloys is between 1.19 and 1.62 g/cm3. The limit of reduction for cold rolling of the β phase alloys at 16% and 22%Li exceeds 90% at room temperature. The properties and microstructures of Mg-Li-Zn alloys were studied, which were homogenized, cold rolled, then annealed at different temperatures. Recrystallization behaviors of the alloys were investigated through microstructures observing and hardness measuring. The results show that the cast billets are suitable for rolling after homogenization at 573K for 12 h for Mg-9Li-2Zn-2Ca alloy and at 523K for 24 h for Mg-9Li-2Zn-2Ca alloy. The cold rolled plates were completely recrystallizated by annealing at 573K for 1 h.

  6. Preparation of semi-solid slurry containing fine and globular particles for wrought aluminum alloy 2024

    2007-01-01

    The semi-solid slurry of wrought aluminum alloy 2024 was prepared by a well developed rheocasting process, low superheat pouring with shearing field(LSPSF). The appreciate combination of pouring temperature and rotation speed of barrel, can give rise to a transition of the growth morphology of primary α(Al) from coarse-dendritic to coarse-particle-like and further to fine-globular. The combined effects of both localized rapid cooling and vigorous mixing during the initial stage of solidification can enhance wall nucleation and nuclei survival, which leads to the formation of fine-globular primary α(Al). By using semi-solid slurry prepared by LSPSF, direct squeeze cast cup-shaped component with improved mechanical properties such as yield strength of 198MPa, ultimate tensile strength of 306 MPa and elongation of 10.4%, can be obtained.

  7. Physical and mechanical properties of cast 17-4 PH stainless steel

    The physical and mechanical properties of an overaged 17-4 PH stainless steel casting have been examined. The tensile and compressive properties of cast 17-4 PH are only influenced to a slight degree by changing test temperature and strain rate. However, both the Charpy impact energy and dynamic fracture toughness exhibit a tough-to-brittle transition with decreasing temperature - this transition being related to a change in fracture mode from ductile, dimple to cleavage-like. Finally, although the overaged 17-4 PH casting had a relatively low room temperature Charpy impact energy when compared to wrought 17-4 PH, its fracture toughness was at least comparable to that of wrought 17-4 PH. This observation suggests that prior correlations between Charpy impact energies and fracture toughness, as derived from wrought materials, must be approached with caution when applied to cast alloys

  8. Stress Corrosion Cracking Behavior of Cast Stainless Steels

    Casting of austenitic stainless steels offers the possibility of directly producing large and/or relatively complex structures, such as the first wall shield modules or the diverter cassette for the ITER fusion reactor. Casting offers major cost savings when compared to fabrication via welding of quarter modules machined from large forgings. However, the strength properties of such cast components are typically considered inferior to those of conventionally forged and annealed components. To improve and validate cast stainless steel as a substitute for wrought stainless steel, a development and testing program was initiated, utilizing nitrogen and manganese additions to promote improved performance. This paper focuses on the response of the first set of developmental alloys to neutron-irradiation and susceptibility to stress corrosion cracking. These cast materials may also have applications for different components in light water reactors. Results showed that all steels exhibited irradiation-induced hardening and a corresponding drop in ductility, as expected, although there is still considerable ductility in the irradiated samples. The cast steels all exhibited reduced hardening in comparison to a wrought reference steels, which may be related to a larger grain size. Higher nitrogen contents did not negatively influence irradiation performance. Regarding stress corrosion cracking susceptibility, the large difference in grain size limits the comparison between wrought and cast materials, and inclusions in a reference and archive cast alloy tests complicate analysis of these samples. Results suggest that the irradiated archive heat was more susceptible to cracking than the modified alloys, which may be related to the more complex microstructure. Further, the results suggest that the modified cast steel is at least as SCC resistant as wrought 316LN. The beneficial effect of nitrogen on the mechanical properties of the alloys remains after irradiation and is not

  9. Corrosion Properties of Sintered and Wrought Stainless Seel

    Mathiesen, Troels; Maahn, Ernst Emanuel

    1997-01-01

    The corrosion properties of a range of stainless steels produced by powder metallurgy (PM) are compared with wrought AISI304 and AISI316 Steel. Characterisation of the passivation properties in 0.5M H2SO4 and pittingresistance in 0.3% chloride solution by polarisation show properties of the...

  10. Standard practice for ultrasonic testing of wrought products

    American Society for Testing and Materials. Philadelphia

    2013-01-01

    1.1 Purpose—This practice establishes the minimum requirements for ultrasonic examination of wrought products. Note 1—This standard was adopted to replace MIL-STD-2154, 30 Sept. 1982. This standard is intended to be used for the same applications as the document which it replaced. Users should carefully review its requirements when considering its use for new, or different applications, or both. 1.2 Application—This practice is applicable for examination of materials such as, wrought metals and wrought metal products. 1.2.1 Wrought Aluminum Alloy Products—Examination shall be in accordance with Practice B 594. 1.3 Acceptance Class—When examination is performed in accordance with this practice, engineering drawings, specifications, or other applicable documents shall indicate the acceptance criteria. Five ultrasonic acceptance classes are defined in Table 1. One or more of these classes may be used to establish the acceptance criteria or additional or alternate criteria may be specified. 1.4 Ord...

  11. Wrought Aluminium Alloy Corrosion Propensity in Domestic Food Cooking Environment

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

    2012-01-01

    The study on corrosion behaviour of wrought aluminium alloy in domestic food cooking conditions has been examined using the gravimetric approach. Flat cold rolled and annealed sheets were subjected to solutions of Capsicum annuum, L. esculentum, Allium cepa, and their blend under three conditions, namely, heating and cooling in still air, heating and cooling in refrigerator, and leaving some in open still atmosphere. Results show that corrosion occurred within the test period (288 hours) in t...

  12. Systematic Microstructural and Corrosion Performance Evaluation of CK-3MCuN and CN-3MN High Molybdenum Stainless Steel Castings

    C.D. Lundin; S. Wen; W. Liu; G. Zhou

    2001-10-01

    High molybdenum austenitic stainless steel castings are widely accepted for their high strength, excellent weldability, and good corrosion resistance over a wide range of temperatures in highly oxidizing aqueous and gaseous media in chemical processing and other environments. With their desirable performance, high molybdenum austenitic stainless steel castings are increasingly applied in industry in a similar manner as wrought materials. In general, cast and wrought stainless and high alloy steels are anticipated to possess equivalent resistance to corrosive media, and they are frequently used in conjunction with each other. However, alloying element segregation usually is more evident in castings than in wrought counterparts. Segregation of alloying elements can lead to the formation of secondary phases, such as sigma. Mechanical properties and especially the corrosion resistance of castings may be affected by the secondary phases. In addition, improper heat treatment procedures c an also lead to the formation of carbides and secondary phases in high alloy and austenitic stainless steels.

  13. Light metal compound casting

    Konrad J.M.PAPIS; Joerg F.LOEFFLER; Peter J.UGGOWITZER

    2009-01-01

    'Compound casting'simplifies joining processes by directly casting a metallic melt onto a solid metal substrate. A continuously metallurgic transition is very important for industrial applications, such as joint structures of spaceframe constructions in transport industry. In this project, 'compound casting' of light metals is investigated, aiming at weight-saving. The substrate used is a wrought aluminium alloy of type AA5xxx, containing magnesium as main alloying element. The melts are aluminium alloys, containing various alloying elements (Cu, Si, Zn), and magnesium. By replacing the natural oxygen layer with a zinc layer, the inherent wetting difficulties were avoided, and compounds with flawless interfaces were successfully produced (no contraction defects, cracks or oxides). Electron microscopy and EDX investigations as well as optical micrographs of the interfacial areas revealed their continu-ously metallic constitution. Diffusion of alloying elements leads to heat-treatable microstructures in the vicinity of the joining interfaces in Al-Al couples. This permits significant variability of mechanical properties. Without significantly cutting down on wettability, the formation of low-melting intermetallic phases (Al3Mg2 and AI12Mg17 IMPs) at the interface of Al-Mg couples was avoided by applying a protec-tive coating to the substrate.

  14. Fatigue life of ablation-cast 6061-T6 components

    The fatigue life of 6061-T6 alloy, normally used in its wrought form, was investigated in this study in cast form from parts produced by the new ablation casting process. All specimens were excised from military castings. Unidirectional tensile test results yielded elongation values comparable to forgings and extrusions. A total of 39 fatigue specimens were tested by the rotating cantilever beam technique at five maximum stress levels. Moreover nine specimens excised from a forging were also tested for comparison. Results revealed that the fatigue life of ablation-cast 6061-T6 (i) follows a three-parameter Weibull distribution, and (ii) is comparable to data from the 6061 forging and is superior to conventionally cast Al-7% Si–Mg alloy castings published in the literature. Analysis of the fracture surfaces of ablation-cast 6061-T6 via scanning electron microscopy showed the existence of fracture surface facets and multiple cracks propagating in different directions.

  15. Creep properties and microstructure of the new wrought austenitic steel

    Vlasak, T.; Hakl, J.; Novak, P. [SVUM a.s., Prague (Czech Republic); Vyrostkova, A. [Slovak Academy of Sciences, Kosice (Slovakia). Inst. of Materials Research

    2010-07-01

    The contribution is oriented on the new wrought austenitic steel BGA4 (Cr23Ni15Mn6Cu3W1.5NbVMo) developed by the British Corus Company. Our main aim is to present creep properties studied in SVUM a.s. Prague during COST 536 programme. The dependencies of the creep strength, strength for specific creep strain and minimum creep strain rate were evaluated on the basis of long term creep tests carried out at temperature interval (625; 725) C. Important part of a paper is metallographic analysis. (orig.)

  16. Mechanical properties and microstructures of a wrought AZ91 alloy

    YAN Yunqi; ZHANG Tingjie; ZHOU Lian; DENG Ju

    2004-01-01

    Effects of hot plastic deformation on microstructures and tensile properties of AZ91 alloy were investigated. Compared with as-T4 microstructures, the as-extruded samples of AZ91 alloy with fine grains exhibit better strength and ductility due to dynamic recrystallization. The succeeded rotation forging also provides finer grains while the strength in creases, but the elongation decreases. Simultaneously, wrought AZ91 alloy shows more balance properties than as-T4 condition ones. An interesting elongation of 228.5% is attained in the as-extruded AZ91 alloy in spite of the coarse grains with the size of 85 μm. The two-step method enhances the superplastic property of AZ91 alloy. The microstructure is still keep ing the same scale of grains after superplastic testing.

  17. Light metal compound casting

    Konrad; J.; M.; PAPIS; Joerg; F.; LOEFFLER; Peter; J.; UGGOWITZER

    2009-01-01

    ‘Compound casting’simplifies joining processes by directly casting a metallic melt onto a solid metal substrate. A continuously metallurgic transition is very important for industrial applications, such as joint structures of spaceframe constructions in transport industry. In this project, ‘compound casting’ of light metals is investigated, aiming at weight-saving. The substrate used is a wrought aluminium alloy of type AA5xxx, containing magnesium as main alloying element. The melts are aluminium alloys, containing various alloying elements (Cu, Si, Zn), and magnesium. By replacing the natural oxygen layer with a zinc layer, the inherent wetting difficulties were avoided, and compounds with flawless interfaces were successfully produced (no contraction defects, cracks or oxides). Electron microscopy and EDX investigations as well as optical micrographs of the interfacial areas revealed their continu- ously metallic constitution. Diffusion of alloying elements leads to heat-treatable microstructures in the vicinity of the joining interfaces in Al-Al couples. This permits significant variability of mechanical properties. Without significantly cutting down on wettability, the formation of low-melting intermetallic phases (Al3Mg2 and Al12Mg17 IMPs) at the interface of Al-Mg couples was avoided by applying a protective coating to the substrate.

  18. Control rod drive housing made of recrystallised centrifugal casting

    The possibility of fabricating the Control Rod Drive (CRD) Housings for Boiling Water Reactor (BWR) pressure vessels by recrystallised centrifugal casting without welding was investigated. The material used was to the specification ASME SA-351 CF3M, and after centrifugal casting it was cold formed by a process involving 15% to 30% plastic deformation before the final solution heat treatment, so that recrystallisation can be obtained. Various mechanical, metallurgical and nondestructive tests were performed, and the following superior characteristics were confirmed. Metallurgical tests showed that small austenite grain and 11 to 12% isolated ferrite are uniformly distributed throughout the whole parts of the CRD housing. Tests at room temperature, and up to 3000C on tensile specimens taken from various portions of the CRD housing were satisfactory. The weldability of the recrystallised casting CRD housing to Inconel stub tube was satisfactory. The attenuation of ultrasonic waves of the recrystallised casting was compared with those of cast and wrought material, and it was confirmed that ultrasonic tests can be performed with almost the same sensitivity as on wrought materials. When such nondestructive ultrasonic tests were made on the whole length of a typical sample, supported by liquid penetrant tests, no defective indications were found. (U.K.)

  19. Recent advances of wrought TiAl alloys

    张继; 李世琼; 邹敦叙; 仲增墉

    2002-01-01

    The research achievement on wrought TiAl alloys gained recently in Central Iron and Steel Research Institute, China, was contributed. The progress es mainly include the improved hot deformability and homogenized microstructure after hot deformation due to the significant effects of micro-alloying process. Isothermal compressive test indicated that the TiAl containing minor Ni exhibits better plastic flow behavior and enlarged process window. The effect of Ni on modifying hot deformability of TiAl can be enhanced by incorporated addition of Mg . TEM observations suggested that Ni addition activates dislocations as well as twins at beginning stage of hot deformation and thereafter the higher-density dislocations promote the dynamic recrystallization inside γ-TiAl lamellae. It is a lso identified that breakdown of α2-Ti3Al lamellae produces new disloc ation-free γ-TiAl grains. On the other hand, the homogeneity of deformed microstructure can be increased by transforming the microstructure of the Ni-containing TiAl fro m original lamellar structure to equiaxed grains before hot deformation.

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

    Jablonski, Paul D.; Turner, Paul C.

    2005-09-01

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

  1. SPRAY CASTING

    SALAMCI, Elmas

    2010-01-01

    ABSTRACT This paper is designed to provide a basic review of spray casting. A brief overview of the historical development of spray  casting and the description of plant and equipment have been given. Following metallurgical characteristics of spray formed alloys, process parameters and solidification mechanism of spray deposition have been discussed in detail. Finally, microstructure and mechanical properties of the selected spray cast Al-Zn-Mg-Cu alloys have been presented and compared...

  2. X-ray and back-wall echo ultrasonic examination of wrought iron building structures

    Vidovszky István

    2008-01-01

    Full Text Available The wrought iron building structures constituting part of the architectural heritage, e. g. handrails, gate hinges, columns, arch ties and wall ties represent incorporeal value, but operate as load bearing structures as well. There are few information on their mechanical properties and quality. Due to the inhomogeneity of the material of wrought iron building structures generated during the production, the known metal testing methods, as the tensile and hardness tests or metallographic examination, are not enough to survey the properties of such structures in depth. For the further and more accurate examinations, the application of X-ray and back-wall echo ultrasonic tests are essential. The goal of our paper is the presentation of the application of the examinations used extensively in the machine industry for the testing of wrought iron building structures.

  3. Improved cast stainless steels for shield module applications

    Full text of publication follows: Casting of austenitic stainless steels offers the possibility of directly producing large and/or relatively complex structures, such as the first wall shield modules or the divertor cassette for the International Tokamak Experimental Reactor (ITER). Casting offers major cost savings when compared to fabrication via welding together quarter modules machined from large forgings. However, because of the large grain size, low dislocation density and extensive segregation of alloying elements, the strength properties of such cast components are frequently inferior to those of conventionally forged and annealed components. To improve and validate cast stainless steel as a substitute for wrought stainless steel for shield module applications, a series of test cast steels based on the commercially available CF3M specification have been designed and fabricated. These modifications utilize combinations of Mn and N,which are expected to synergistically result in significant increases in strength. In addition, two other alloys will enhance solid solution strengthening with Cu and W additions to increase strength. It will be necessary to demonstrate that these compositional modifications do not adversely affect performance in the ITER water corrosion and radiation environments Computational thermodynamics and solidification modeling predict that these improved cast steel compositions to be fully austenitic throughout the solidification process. Post-cast heat treatments are a second-route for improving strength and properties of cast materials. Homogenizing treatments to remove second particles have also been explored as means of improving strength in cast stainless steel. In this paper, the physical metallurgy, mechanical properties, and irradiation tolerance of the improved cast stainless steel compositions and heat treatments will be compared to standard cast stainless steel. Fracture toughness, weldability, and non-destructive analysis of

  4. Urinary casts

    ... necrosis , viral disease (such as CMV nephritis ), and kidney transplant rejection . Waxy casts can be found in people with advanced kidney disease and chronic kidney failure . White blood cell ( ...

  5. Hair casts

    Sweta S Parmar

    2014-01-01

    Full Text Available Hair casts or pseudonits are circumferential concretions,which cover the hair shaft in such a way that, it could be easily removed. They are thin, cylindrical, and elongated in length. We present an unusual case of an 8-year-old girl presenting with hair casts. Occurrence of these is unusual, and they may have varied associations. This patient was suffering from developmental delay. It is commonly misdiagnosed as and very important to differentiate from pediculosis capitis.

  6. Dynamic compressive response of wrought and additive manufactured 304L stainless steels

    Nishida Erik

    2015-01-01

    Full Text Available Additive manufacturing (AM technology has been developed to fabricate metal components that include complex prototype fabrication, small lot production, precision repair or feature addition, and tooling. However, the mechanical response of the AM materials is a concern to meet requirements for specific applications. Differences between AM materials as compared to wrought materials might be expected, due to possible differences in porosity (voids, grain size, and residual stress levels. When the AM materials are designed for impact applications, the dynamic mechanical properties in both compression and tension need to be fully characterized and understood for reliable designs. In this study, a 304L stainless steel was manufactured with AM technology. For comparison purposes, both the AM and wrought 304L stainless steels were dynamically characterized in compression Kolsky bar techniques. They dynamic compressive stress-strain curves were obtained and the strain rate effects were determined for both the AM and wrought 304L stainless steels. A comprehensive comparison of dynamic compressive response between the AM and wrought 304L stainless steels was performed. SAND2015-0993 C.

  7. INFLUENCE OF HEAT TREATMENT ON DAMPING BEHAVIOUR OF THE MAGNESIUM WROUGHT ALLOY AZ61

    2007-01-01

    The effect of isochronal heat treatments for 1h on variation of damping, hardness and microstructural change of the magnesium wrought alloy AZ61 was investigated. Damping and hardness behaviour could be attributed to the evolution of precipitation process. The influence of precipitation on damping behaviour was explained in the framework of the dislocation string model of Granato and Lücke.

  8. High speed twin roll casting of 6061 alloy strips

    T. Haga

    2008-05-01

    Full Text Available Purpose: of this paper is to clear the possibility of high speed roll casting of thin strips of two aluminum alloys:6061 and recycled 6061. Mechanical properties of the roll cast 6061 and recycled 6061 strips were investigated inthe frame of this purpose.Design/methodology/approach: Methods used in the present study were high speed twin roll caster and lowtemperature casting. These methods were used to realize rapid solidification and increase the casting speed.Findings: are that 6061 and recycled 6061 could be cast at speed of 60 m/min. Casted strips were about 3 mmthick. As cast strip could be cold-rolled down to sheet of 1 mm thick. 180 degrees bending test was operated on thesheet after T4 heat treatment and crack was not worse than 6022 which is typical aluminum alloy for sheet of theautomobile. This result means the roll cast 6061 can be used as a sheet for body of the automobile instead of 6022.Research limitations/implications: Research limitation is that the width of the strip was 100 mm andinvestigation of the properties were enough for practical use. Wider strip must be cast using the twin roll caster ofthe size for production.Originality/value: The economy sheet of the 6061 for the auto mobile can be produced by the high speed twinroll caster. 6061 is typical wrought aluminum alloy of 6000 series. Therefore, the sheet of 6061 will becomeeconomy. 6061 can be recycled at two times when the 6061 is cast into strip by the high speed roll casting.

  9. Fracture toughness of CF8 stainless steel castings in liquid helium

    Fracture toughness measurements for CF8 stainless steel castings in liquid helium at 4 K are reported. Single-phase (austenite) and duplex (austenite + delta-ferrite) castings were tested. On the basis of estimates from J-integral data, the plane-strain fracture toughness (K/sub Ic/) of castings containing 3.2 to 14.5% delta-ferrite ranged from 84 to 179 MPa.m/sup 1/2/ at 4 K. In contrast, a fully austenitic casting (0% delta-ferrite) exhibited a K/sub Ic/ value of 331 MPa.m/sup 1/2/, which is nearly equivalent to the toughness of a wrought AISI 304 stainless steel of a similar strength. Optical and scanning electron microscopy studies indicate that the inferior toughness of castings containing delta-ferrite may be chiefly attributed to the brittlemenss of this body-centered-cubic phase at cryogenic temperatures and its distribution in the microstructure

  10. Cast Steels for Creep-resistant Parts Used in Heat Treatment Plants

    A. Drotlew

    2012-12-01

    Full Text Available Creep-resistant parts of heat treatment furnaces are in most cases made from high-alloyed chromium-nickel and nickel-chromium ironalloys, both cast and wrought. This paper presents the types of casting alloys used for this particular purpose, since the majority of furnace components are made by the casting process. Standards were cited which give symbols of alloy grades used in technical specifications by the domestic industry. It has been indicated that castings made currently are based on a wider spectrum of the creep-resistant alloy grades than the number of alloys covered by the standards. Alloy grades recommended by the technical literature for individual parts of the furnace equipment were given. The recommendations reflect both the type of the technological process used and the technical tasks performed by individual parts of the furnace equipment. Comments were also made on the role of individual alloying elements in shaping the performance properties of castings.

  11. Solidification and casting

    Cantor, Brian

    2002-01-01

    INDUSTRIAL PERSPECTIVEDirect chillcasting of aluminium alloysContinuous casting of aluminium alloysContinuous casting of steelsCastings in the automotive industryCast aluminium-silicon piston alloysMODELLING AND SIMULATIONModelling direct chill castingMold filling simulation of die castingThe ten casting rulesGrain selection in single crystal superalloy castingsDefects in aluminium shape castingPattern formation during solidificationPeritectic solidificationSTRUCTURE AND DEFECTSHetergeneous nucleation in aluminium alloysCo

  12. Root canal retained restorations: 1. General considerations and custom-made cast posts and cores.

    Edmunds, D H; Dummer, P M

    1990-06-01

    The first article in this series reviews general considerations relating to the use of root canal retained restorations. The authors discuss factors affecting retention, the arguments for cast versus wrought posts, reinforcement of the tooth, and treatment planning. Clinical procedures for constructing custom-made cast posts and cores, using direct and indirect techniques, are also described. The three subsequent articles will deal with threaded and unthreaded prefabricated post-and-core systems, and root-face attachments for the retention of complete and partial overdentures. PMID:2079151

  13. Welding and mechanical properties of cast FAPY (Fe-16 at. % Al-based) alloy slabs

    Sikka, V.K.; Goodwin, G.M.; Alexander, D.J.; Howell, C.R.

    1995-08-01

    The low-aluminum-content iron-aluminum program deals with the development of a Fe-Al alloy with aluminum content such as a produce the minimum environmental effect at room temperature. The FAPY is an Fe-16 at. % Al-based alloy developed at the Oak Ridge National Laboratory as the highest aluminum-containing alloy with essentially no environmental effect. The chemical composition for FAPY in weight percent is: aluminum = 8.46, chromium = 5.50, zirconium = 0.20, carbon = 0.03, molybdenum = 2.00, yttrium = 0.10, and iron = 83.71. The cast ingots of the alloy can be hot worked by extrusion, forging, and rolling processes. The hot- worked cast structure can be cold worked with intermediate anneals at 800{degrees}C. Typical room-temperature ductility of the fine-grained wrought structure is 20 to 25% for this alloy. In contrast to the wrought structure, the cast ductility at room temperature is approximately 1% with a transition temperature of approximately 100 to 150{degrees}C, above which ductility values exceed 20%. The alloy has been melted and processed into bar, sheet, and foil. The alloy has also been cast into slabs, step-blocks of varying thicknesses, and shapes. The purpose of this section is to describe the welding response of cast slabs of three different thicknesses of FAPY alloy. Tensile, creep, and Charpy-impact data of the welded plates are also presented.

  14. Texture evolution in upset-forged P/M and wrought tantalum: Experimentation and modeling

    Preferred orientations in polycrystalline materials can significantly affect their physical and mechanical response through the retention of anisotropic properties inherent to the single crystal. In this study the texture evolution in upset-forged PIM and wrought tantalum was measured as a function of initial texture, compressive strain, and relative position in the pressing. A / duplex fiber texture parallel to the compression axis was generally observed, with varying degrees of a radial component evident in the wrought material. The development of deformation textures derives from restricted crystallographic slip conditions that generate lattice rotations, and these grain reorientations can be modeled as a function of the prescribed deformation gradient. Texture development was simulated for equivalent deformations using both a modified Taylor approach and a viscoplastic self-consistent (VPSC) model. A comparison between the predicted evolution and experimental results shows a good correlation with the texture components, but an overly sharp prediction at large strains from both the Taylor and VPSC models

  15. An Innovative Two-Stage Reheating Process for Wrought Aluminum Alloy During Thixoforming

    Wang, JiaoJiao; Brabazon, D.; Phillion, A. B.; Lu, GuiMin

    2015-09-01

    An innovative two-stage reheating process has been developed to improve the thixotropic behavior of semi-solid wrought aluminum alloy during thixoforming. The variation of the microstructural evolution mechanisms with temperature and holding time during a traditional process and two-stage reheating process are presented in this paper. A preferred semi-solid microstructure with spherical-like grains surrounded by a uniform liquid film was obtained in the two-stage reheating process. The semi-solid microstructure obtained via this two-stage reheating process had a number of features beneficial for semi-solid metal processing, including smaller equivalent diameters, a higher degree of sphericity, a lower coarsening rate constant of solid grains and a reduced amount of entrapped liquid compared with that produced by the traditional reheating process. These results indicate that the two-stage reheating process is a promising method for manufacturing wrought aluminum alloy during thixoforming.

  16. Analysis of the potential for new automotive uses of wrought magnesium

    Gaines, L.; Cuenca, R.; Wu, S. [Argonne National Lab., IL (United States); Stodolsky, F. [Argonne National Lab., IL (United States)]|[Argonne National Lab., Washington, DC (United States)

    1996-02-01

    The Center for Transportation Research at Argonne National Laboratory has performed a study for the Lightweight Materials Program within the US Department of Energy`s Office of Transportation Materials to evaluate the suitability of wrought magnesium and its alloys to replace steel or aluminum for automotive structural and sheet applications. Vehicle weight reduction is one of the major means available for improving automotive fuel efficiency. Although high-strength steels, Al, and polymers are already being used to achieve significant weight reductions, substantial additional weight reductions could be achieved by increased use of Mg (whose density is less than one-fourth that of steel and only two-thirds that of Al). This study shows that Mg sheet could be used in automotive body nonstructural and semistructural applications, whereas extrusions could be used in such structural applications as spaceframes. The primary barrier to such uses of wrought Mg is high cost.

  17. Temperature Dependence of Density and Thermal Expansion of Wrought Aluminum Alloys 7041, 7075 and 7095 by Gamma Ray Attenuation Method

    Nallacheruvu Gopi Krishna; Ammiraju Sowbhagya Madhusudhan Rao; Kalvala Gopal Kishan Rao; Kethireddy Narender

    2013-01-01

      The gamma quanta attenuation studies have been carried out to determine mass attenuation coefficients of 7041, 7075 and 7095 wrought aluminum alloys. The temperature dependence of linear attenuation coefficient, density and thermal expansion of these wrought aluminum alloys in the temperature range 300 K - 850 K have been reported. The measurements were done by using a gamma ray densitometer designed and fabricated in our laboratory. The data on variation of density and linear thermal expa...

  18. Deformation dynamics study of a wrought magnesium alloy by real-time in situ neutron diffraction

    The deformation dynamics and the effect of deformation history on plastic deformation in a wrought magnesium alloy at room temperature have been studied by real-time in situ neutron diffraction measurements under a continuous loading condition. The experimental results reveal that no detwinning occurred during unloading after compression and even in an elastic region during reverse tension. It is found that the serration behavior is closely related to the twinning- and detwinning-dominated deformation

  19. An in situ corrosion study of Middle Ages wrought iron bar chains in the Amiens Cathedral

    Grassini, S.; Angelini, E.; Parvis, M.; Bouchar, M.; Dillmann, P.; Neff, D.

    2013-12-01

    The corrosion behaviour of Middle Ages wrought iron bar chains exposed to indoor atmospheric corrosion for hundred of years in the Notre Dame Cathedral of Amiens (France) has been evaluated by means of Electrochemical Impedance Spectroscopy (EIS), a well-established electrochemical technique extensively used for testing anticorrosive properties of metal coatings. The measurements have been performed in situ with a portable EIS instrument designed to work as a standalone device, in six different areas of the wrought iron bar chains characterized by different aesthetical appearance. Moreover, a properly designed electrochemical cell has been employed to carry out the impedance measurements without affecting the artefacts surfaces. The wrought iron bar chains, as evidenced by μ-Raman and microscopic analyses, are covered by corrosion products constituted by iron oxides and oxyhydroxides, such as goethite, lepidocrocite, maghemite, akaganeite, organized in complex layered structures. In situ EIS allows one to investigate the phenomena involved at the electrochemical interfaces among the various corrosion products and to assess and predict their corrosion behaviour. From the analysis of the experimental findings of this monitoring campaign, EIS measurements can be proposed to restorers/conservators as a reliable indicator of dangerous situations on which they must act for the preservation of the iron artefacts.

  20. Evaluation of the mechanical properties of Niobium modified cast AISI H 13 hot work tool steel

    In this research, the effects of partially replacing of vanadium and molybdenum with niobium on the mechanical properties of AISIH 13 hot-work tool steel have been studied. Cast samples made of the modified new steel were homogenized and austenitized at different conditions, followed by tempering at the specified temperature ranges. Hardness, red hardness, three point bending test and Charpy impact test were carried out to evaluate the mechanical properties together with characterizing the microstructure of the modified steel using scanning electron microscope. The results show that niobium addition modifies the cast structure of Nb-alloyed steel, and increases its maximum hardness. It was found that bending strength; bending strain, impact strength, and red hardness of the modified cast steel are also higher than those of the cast H13 steel, and lower than those of the wrought H13 steel.

  1. Nodular cast iron and casting monitoring

    S. Pietrowski

    2008-10-01

    Full Text Available In this paper quality monitoring of nodular cast iron and casting made of it is presented. A control system of initial liquid cast iron to spheroidization, after spheroidization and inoculation with using of TDA method was shown. An application of an ultrasonic method to assessment of the graphite form and the metal matrix microstructure of castings was investigated.

  2. Effect of casting temperature on grain size of Al-Si alloys refined by a novel grain refiner

    Bolzoni, L.; Nowak, M.; Hari Babu, N

    2014-01-01

    The automotive industry is willing of employing a greater amount of light metals like aluminium, magnesium and titanium, in order to reduce the total weight of the cars and, consequently, fuel consumption. Even though some casting aluminium alloys are commonly employed for automotive structural applications, their mechanical performances can be improved by means of appropriate grain refining by heterogeneous nucleation. This practise is well established for wrought aluminium alloys by using A...

  3. Structure-property relationships in centrifugally cast IMI 550 (Ti4Al-4Mo-2Sn-0.5Si)

    Centrifugal casting technology has been used to produce test pieces and hard-point bracket components for a determination of the structure-property relationships in the age-hardenable titanium alloy IMI 550. Tensile, high cycle fatigue, fracture toughness and elevated temperature creep results have shown that an attractive combination of property levels can be achieved in this alloy. It has been established that the tensile, fatigue and creep performance of cast plus Hot Isostatically Pressed (HIP) IMI 550 approaches that of conventionally wrought material while fracture toughness is superior. The improvement obtained in fracture toughness is a direct result of the presence of the highly acicular Widmanstatten or transformed beta microstructure produced by casting compared with the more traditional equiaxed alpha + beta structure exhibited by wrought products. HIP'ing has been shown to eliminate all traces of as cast internal shrinkage porosity and to thus yield a dramatic improvement in high cycle fatigue performance. HIP'ing was accompanied by general coarsening of the acicular alpha phases present in the micro-structure after casting. Macro and microstructural analysis of the castings indicated a refined and uniform beta grain size which it is believed is due to the presence of silicon in the alloy. 16 references

  4. Fracture toughness of CF8 castings at four kelvin

    The first fracture toughness measurements for CF8 stainless steel castings in liquid helium at 4 K are reported. Single-phase (austenite) and duplex (austenite + delta-ferrite) castings were tested. On the basis of estimates from J-integral data, the plane-strain fracture toughness (K /SUB lc/ ) of castings containing 3.2 to 14.5 pct delta-ferrite ranged from 84 to 179 MPa X m /SUP 1/2/ at 4 K. In contrast, a fully austenitic casting (0 pct delta-ferrite) exhibited a K /SUB lc/ value of 331 MPa X m /SUP 1/2/ , which is nearly equivalent to the toughness of a wrought AISI 304 stainless steel of a similar strength. Light and scanning electron microscop studies indicate that the inferior toughness of castings containing delta-ferrite may be attributed to the brittleness of this body-centered-cubic phase at cryogenic temperatures and its distribution in th microstructure. The relative stability of the austenitic phase with respect to martensitic phase transformation may also play a significant role

  5. Tensile behavior of CF8-CPF8-304H and CF8M-CPF8M-316H stainless steel static and centrifugal castings

    We have analyzed the tensile behavior of 11 heats of grades CF8-CPF8-304H and 13 heats of grades CF8M-CPF8M-316H static and centrifugal castings from room temperature to 6500C. Except for anomalous conditions, the centrifugal castings exhibited uniform composition. All CPF8-304H centrifugal castings contained only radial columnar grains, but some CPF8M-316H castings had columnar, banded, or equiaxed structures. Ultimate tensile strength and total elongation were the properties in which castings showed the most inferiority to wrought material. With increasing ferrite content, 0.2% yield strength and ultimate tensile strength increased while uniform elongation, total elongation, and reduction of area decreased. Although centrifugal castings did not exhibit significant end-to-end variation in tensile behavior, the 0.2% yield strength displayed anisotropy, with axial and circumferential values being greater than radial

  6. Manufacture of centrifugal Castings

    Minář, Martin

    2015-01-01

    The main goal of this bachelor thesis is to collect basic information related to the production of castings by centrifugal casting. It is focused on horizontal and vertical centrigugal casting, casting of various metals and their alloys, such as zinc, aluminum, iron, steel and silumin. This technology is compared with other casting methods in terms of specific characteristics, amount of usage, production economics, advantages, disadvantages, the resulting quality of castings and other factors.

  7. Wrought stainless steel compositions having engineered microstructures for improved heat resistance

    Maziasz, Philip J [Oak Ridge, TN; Swindeman, Robert W [Oak Ridge, TN; Pint, Bruce A [Knoxville, TN; Santella, Michael L [Knoxville, TN; More, Karren L [Knoxville, TN

    2007-08-21

    A wrought stainless steel alloy composition includes 12% to 25% Cr, 8% to 25% Ni, 0.05% to 1% Nb, 0.05% to 10% Mn, 0.02% to 0.15% C, 0.02% to 0.5% N, with the balance iron, the composition having the capability of developing an engineered microstructure at a temperature above 550.degree. C. The engineered microstructure includes an austenite matrix having therein a dispersion of intragranular NbC precipitates in a concentration in the range of 10.sup.10 to 10.sup.17 precipitates per cm.sup.3.

  8. Fused metallic slurry coatings for improving the oxidation resistance of wrought alloys

    Segura-Cedillo, Ismael

    2011-01-01

    The aim of this project was to investigate the potential of fused-slurry coatings for improving the oxidation resistance of wrought alloys. Slurry-aluminised coatings were deposited on Alloy 800H (Fe-33Ni-20Cr), Alloy HCM12A (Fe-12Cr-2W), Alloy 214 (Ni-16Cr-4Al-3Fe), Fe-27Cr-4Al and Fe-14Cr-4Al alloys. The slurry contained a cellulose-based binder in an aqueous carrier and spherical aluminium powder, with a particle size below 20 microns. The slurries were applied with a paint-brush, dried in...

  9. Defect Investigation of Plastically Deformed Al 5454 Wrought Alloy using PADBS and Electrical Measurements

    Positron Annihilation Doppler Broadening Spectroscopy (PADPS) is a nondestructive technique used in material science. Electrical measurements are one of the oldest techniques used also in material science. This paper aimed to discuss the availability of using both PADPS and electrical measurements as diagnostic techniques to detect the defects in a set of plastically deformed 5454 wrought aluminum alloy. The results of the positron annihilation measurements and the electrical measurements were analyzed in terms of the two-state trapping model. This model can be used to investigate both defect and dislocation densities of the samples under investigation. Results obtained by both nuclear and electrical techniques have been reportedity

  10. The UK Casting Industry

    Jincheng Liu

    2006-01-01

    The casting production in the UK in 2004 is presented and analysed. The UK casting industry has played an important role in world casting and manufacturing production. However recent years the rapid development of some developing countries has been shifting the casting production from the western industrialized countries including the UK. The UK casting industry and associated research and technology organizations, universities have been working together very hard to face the serious competition to make the UK casting industry have a sustainable future. The UK casting industry remains strong and plays an important role in world casting and manufacturing production.

  11. CA Investment Casting Process of Complex Castings

    2002-01-01

    CA (Computer aided) investment casting technique used in superalloy castings of aerospace engine parts was presented. CA investment casting integrated computer application, RP (Rapid Prototyping) process, solidification simulation and investment casting process. It broke the bottle neck of making metal die. Solid model of complex parts were produced by UGII or other software, then translated into STL(Stereolithography) file, after RP process of SLS(Selective Laser Sintering), wax pattern used in investment ...

  12. The ancient Chinese casting techniques

    Tan Derui; Lian Haiping

    2011-01-01

    In the course of Chinese civilization, which lasted more than 5,000 years, casting production has made a huge contribution. In this paper, some representative metal castings were presented. According to their forming techniques, they can be grouped into stone mould casting, clay mould casting, ablation casting, lost wax casting, stack casting, permanent mould casting, sand casting, etc. According to their materials, they can be categorized into tin bronze, bimetallic bronze, malleable cast ir...

  13. Non-dendritic structural 7075 aluminum alloy byliquidus cast and its semi-solid compression behavior

    2000-01-01

    Fine, equiaxed, non-dendritic structure needed by semi-solid processing was obtained by liquidus cast, i.e.7075 wrought aluminum alloy cast from liquidus temperature. The microstructures after heat treatment at different tem-peratures and time in the semi-solid range were observed, and the compression deformation behavior at different tempera-tures (490 ~ 600 C) and strain rates (5 × 10-3 ~ 5s-1) was investigated by means of Gleeble-1500 thermal-mechenicalsimulator. Thc results show that the deformation resistance of the non-dendritic structure attained by liquidus cast in semi-solid is remarkably lower than that of conventional dendritic structure. The formability of non-dendritic structure is betterthan that of dendritic structure

  14. Special thermite cast irons

    Yu. Zhiguts; I. Kurytnik

    2008-01-01

    The given paper deals with the problems of the synthesis of cast iron by metallothermy synthesis. On the basis of investigated method of calculations structures of charges have been arranged and cast iron has been synthesized further. Peculiarities metallothermic smelting were found, mechanical properties and structure of received cast iron were investigated and different technologies for cast iron receiving were worked out.

  15. Thin Wall Iron Castings

    J.F. Cuttino; D.M. Stefanescu; T.S. Piwonka

    2001-10-31

    Results of an investigation made to develop methods of making iron castings having wall thicknesses as small as 2.5 mm in green sand molds are presented. It was found that thin wall ductile and compacted graphite iron castings can be made and have properties consistent with heavier castings. Green sand molding variables that affect casting dimensions were also identified.

  16. Effects of heat treatment on mechanical properties of modified cast AISI D3 tool steel

    Highlights: • Secondary hardening occurred when tempered at 500 °C and austenitized at 1050 °C. • Hardness of new steel is about 1 HRC higher than D3 steel, when tempered at 300 °C. • New steel has less bending strength and strain compared with D3 steel. • With increasing hardness wear resistance is improved about 56%. • Linear relationship observed between weight loss and hardness of modified steel. - Abstract: In this research new modified as-cast cold work AISI D3 tool steel was produced by increasing Ti and Nb and decreasing Cr. At first, Cast samples were homogenized at optimized cycle and then austenitized and tempered within the specified temperature ranges. Mechanical properties and wear behavior were determined by performing hardness test, three point bending test and pin on disc wear test. Also, scanning electron microscope was employed to characterize the new modified steel. For the specimens austenitized and tempered at 1050 °C and 500 °C respectively, the secondary hardening effect was observed which was consistent with lower weight loss of pin on disc wear test results. The results show that, the new modified as-cast steel represents hardness and wear resistance equal to or better than that of standard wrought D3 steel, while its strength and toughness are lower than those of wrought steel

  17. Microstructures of ancient and modern cast silver–copper alloys

    Northover, S.M., E-mail: s.m.northover@open.ac.uk [Materials Engineering, The Open University, Walton Hall, Milton Keynes MK7 6AA (United Kingdom); Northover, J.P., E-mail: peter.northover@materials.ox.ac.uk [Department of Materials, University of Oxford, Parks Rd, Oxford OX1 3PH,UK (United Kingdom)

    2014-04-01

    The microstructures of modern cast Sterling silver and of cast silver objects about 2500 years old have been compared using optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), scanning transmission electron microscopy (STEM), energy dispersive X-ray microanalysis (EDX) and electron backscatter diffraction (EBSD). Microstructures of both ancient and modern alloys were typified by silver-rich dendrites with a few pools of eutectic and occasional cuprite particles with an oxidised rim on the outer surface. EBSD showed the dendrites to have a complex internal structure, often involving extensive twinning. There was copious intragranular precipitation within the dendrites, in the form of very fine copper-rich rods which TEM, X-ray diffraction (XRD), SEM and STEM suggest to be of a metastable face-centred-cubic (FCC) phase with a cube–cube orientation relationship to the silver-rich matrix but a higher silver content than the copper-rich β in the eutectic. Samples from ancient objects displayed a wider range of microstructures including a fine scale interpenetration of the adjoining grains not seen in the modern material. Although this study found no unambiguous evidence that this resulted from microstructural change produced over archaeological time, the copper supersaturation remaining after intragranular precipitation suggests that such changes, previously proposed for wrought and annealed material, may indeed occur in ancient silver castings. - Highlights: • Similar twinned structures and oxidised surfaces seen in ancient and modern cast silver • General precipitation of fine Cu-rich rods apparently formed by discontinuous precipitation is characteristic of as-cast silver. • The fine rods are cube-cube related to the matrix in contrast with the eutectic. • The silver-rich phase remains supersaturated with copper. • Possibly age-related grain boundary features seen in ancient cast silver.

  18. Influence of heat treatment on tribological behaviors of novel wrought aluminum bronze

    张卫文; 倪东惠; 夏伟; 邱诚; 陈维平

    2002-01-01

    Influence of heat treatment on mechanica l properties and tribologica l behaviors of Ti and B modified wrought aluminum bronze were studied. The res ults show that different strength and plasticity combination of the alloy after solu tion treatment can be obtained by adjusting the ageing temperature. When aged at 45 0 ℃, the tensile strength σb, yield strength σ0.2, elongatio n δ and hardness of the alloy are 1 050 MPa, 780 MPa, 4.5%, HB282, respectively. When aged at 650 ℃, those of the alloy are 905 MPa, 600 MPa, 12%, HB232, respectively. Under boundary l ubri cation condition with pressure above 22.2 MPa, alloy with low temperature agei ng has the best wear property. However, under the condition involving impact or sh ock loading, alloy with high temperature ageing is preferable. If the load is no t heavy, the alloy under extrusion state is favorable for wear-resisting parts.

  19. Special thermite cast irons

    Yu. Zhiguts

    2008-07-01

    Full Text Available The given paper deals with the problems of the synthesis of cast iron by metallothermy synthesis. On the basis of investigated method of calculations structures of charges have been arranged and cast iron has been synthesized further. Peculiarities metallothermic smelting were found, mechanical properties and structure of received cast iron were investigated and different technologies for cast iron receiving were worked out.

  20. Caste and power

    Roy, Dayabati

    2011-01-01

    relations and caste identities have overarching dimensions in the day-to-day politics of the study villages. Though caste almost ceases to operate in relation to strict religious strictures, under economic compulsion the division of labour largely coincides with caste division. In the cultural...

  1. Influence of supply of heat to cobalt-chromium frameworks during soldering and subsequent hardening heat treatment of wrought clasps.

    Eriksson, T; Sjögren, G; Bergman, M

    1983-01-01

    Retentive clasp arms of wrought gold alloy wire were soldered to frameworks made of three dental cobalt-chromium alloys. The clasps were then subjected to a conventional hardening heat treatment. Microstructure and hardness of the cobalt-chromium alloys were determined before and after these operations. The results reveal that the supply of heat during soldering and hardening heat treatment of the clasp does not influence the microstructure and hardness of the cobalt-chromium alloys. PMID:6134347

  2. Development of Deformation-Semisolid-Casting (D-SSC) Process and Applications to Some Aluminum Alloys

    2008-01-01

    Recent advances in the semisolid casting technologies are introduced for aluminum alloys. The advantages of the rheocast and thixocast methods to fabricate alloys with refined spheroidized α-Al particles are described.The deformation-semisolid-casting (D-SSC) process developed by the author's group is presented. The D-SSC process is extremely effective to produce microstructures of refined intermetallic compound particles as well as the spheroidized α-Al particles in the Al-Si based alloys containing highly concentrated Fe. In the D-SSC processed Al-Si-Cu alloy high elongation of about 20% was achieved even contained concentrated impurity of Fe. The D-SSC process is also useful to produce wrought aluminum alloys with microstructures of refined α-Al particles.

  3. Final Report, Volume 3, Guidance Document for the Evaluation of Cast Super Duplex Stainless Steel

    Hariharan, Vasudevan; Lundin, Carl, W.

    2005-09-30

    Volume 3 is comprised of the Development of Qualification Standards for Cast Super Duplex Stainless Steel (A890-5A) which is equivalent to wrought 2507. The objective of this work was to determine the suitability of ASTM A923 Standard Test methods for Detecting Detrimental Intermetallic Phase in Duplex Austenitic-Ferritic Stainless Steels for 25 Cr Cast Super Duplex Stainless Steels (ASTM A890-5A). The various tests which were carried out were ASTM A923 Test Method A, B and C (Sodium Hydroxide Etch Test, Charpy Impact Test and Ferric Chloride Corrosion Test), ferrite measurement using Feritscope®, ASTM E562 Manual Point Count Method and X-Ray Diffraction, hardness measurement using Rockwell B and C and microstructural analysis using SEM and EDS.

  4. Final Report, Volume 3, Guidance Document for the Evaluation of Cast Super Duplex Stainless Steel

    Hariharan, Vasudevan; Lundin, Carl, D.

    2005-09-30

    Volume 3 comprises of the Development of Qualification Standards for Cast Super Duplex Stainless Steel (A890-5A) which is equivalent to wrought 2507. The objective of this work was to determine the suitability of ASTM A923 Standard Test methods for Detecting Detrimental Intermetallic Phase in Duplex Austenitic-Ferritic Stainless Steels for 25 Cr Cast Super Duplex Stainless Steels (ASTM A890-5A). The various tests which were carried out were ASTM A923 Test Method A, B and C (Sodium Hydroxide Etch Test, Charpy Impact Test and Ferric Chloride Corrosion Test), ferrite measurement using Feritscope{reg_sign}, ASTM E562 Manual Point Count Method and X-Ray Diffraction, hardness measurement using Rockwell B and C and microstructural analysis using SEM and EDS.

  5. Microstructure and mechanical properties of wrought magnesium alloy AZ31B welded by laser-TIG hybrid

    刘黎明; 宋刚; 王继锋; 梁国俐

    2004-01-01

    The laser-TIG hybrid welding was mainly used to weld the wrought magnesium alloy AZ31B. The technical characteristics of laser-TIG hybrid welding process was investigated and the interactional mechanism between laser and arc was discussed, at the same time the microstructure and mechanical properties of the wrought magnesium alloy AZ31B using laser-TIG hybrid welding were analyzed by optical microscope, EPMA, SEM, tensile machine, hardness machine. The experimental results show that the presence of laser beam boosts up the stability of the arc during high speed welding and augments the penetration of weld; the crystal grains of magnesium alloy weld are fine without porosity and cracks in the best welding criterion and the microstructure of HAZ does not become coarse obviously. The elements profile analysis reveals that Mg content in the weld is lower than that of the base metal, but Al content is higher slightly. Under this experimental condition, the wrought magnesium alloy AZ31B joint can be achieved using laser-TIG hybrid process and the tensile strength of the joint is equivalent to that of the base metal.

  6. Final Report, Volume 2, The Development of Qualification Standards for Cast Duplex Stainless Steel

    Russell, Steven, W.; Lundin, Carl, D.

    2005-09-30

    The scope of testing cast Duplex Stainless Steel (DSS) required testing to several ASTM specifications, while formulating and conducting industry round robin tests to verify and study the reproducibility of the results. ASTM E562 (Standard Test Method for Determining Volume Fraction by Systematic manual Point Count) and ASTM A923 (Standard Test Methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic/Ferritic Stainless Steels) were the specifications utilized in conducting this work. An ASTM E562 industry round robin, ASTM A923 applicability study, ASTM A923 industry round robin, and an ASTM A923 study of the effectiveness of existing foundry solution annealing procedures for producing cast DSS without intermetallic phases were implemented. In the ASTM E562 study, 5 samples were extracted from various cast austenitic and DSS in order to have varying amounts of ferrite. Each sample was metallographically prepared by UT and sent to each of 8 participants for volume fraction of ferrite measurements. Volume fraction of ferrite was measured using manual point count per ASTM E562. FN was measured from the Feritescope{reg_sign} and converted to volume fraction of ferrite. Results indicate that ASTM E562 is applicable to DSS and the results have excellent lab-to-lab reproducibility. Also, volume fraction of ferrite conversions from the FN measured by the Feritescope{reg_sign} were similar to volume fraction of ferrite measured per ASTM E562. In the ASTM A923 applicability to cast DSS study, 8 different heat treatments were performed on 3 lots of ASTM A890-4A (CD3MN) castings and 1 lot of 2205 wrought DSS. The heat treatments were selected to produce a wide range of cooling rates and hold times in order to study the suitability of ASTM A923 to the response of varying amounts on intermetallic phases [117]. The test parameters were identical to those used to develop ASTM A923 for wrought DSS. Charpy V-notch impact samples were extracted from the

  7. Final Report, Volume 2, The Development of Qualification Standards for Cast Duplex Stainless Steel

    Russell, Steven, W.; Lundin, Carl, W.

    2005-09-30

    The scope of testing cast Duplex Stainless Steel (DSS) required testing to several ASTM specifications, while formulating and conducting industry round robin tests to verify and study the reproducibility of the results. ASTM E562 (Standard Test Method for Determining Volume Fraction by Systematic manual Point Count) and ASTM A923 (Standard Test Methods for Detecting Detrimental Intermetallic Phase in Wrought Duplex Austenitic/Ferritic Stainless Steels) were the specifications utilized in conducting this work. An ASTM E562 industry round robin, ASTM A923 applicability study, ASTM A923 industry round robin, and an ASTM A923 study of the effectiveness of existing foundry solution annealing procedures for producing cast DSS without intermetallic phases were implemented. In the ASTM E562 study, 5 samples were extracted from various cast austenitic and DSS in order to have varying amounts of ferrite. Each sample was metallographically prepared by UT and sent to each of 8 participants for volume fraction of ferrite measurements. Volume fraction of ferrite was measured using manual point count per ASTM E562. FN was measured from the Feritescope® and converted to volume fraction of ferrite. Results indicate that ASTM E562 is applicable to DSS and the results have excellent lab-to-lab reproducibility. Also, volume fraction of ferrite conversions from the FN measured by the Feritescope® were similar to volume fraction of ferrite measured per ASTM E562. In the ASTM A923 applicability to cast DSS study, 8 different heat treatments were performed on 3 lots of ASTM A890-4A (CD3MN) castings and 1 lot of 2205 wrought DSS. The heat treatments were selected to produce a wide range of cooling rates and hold times in order to study the suitability of ASTM A923 to the response of varying amounts on intermetallic phases [117]. The test parameters were identical to those used to develop ASTM A923 for wrought DSS. Charpy V-notch impact samples were extracted from the castings and wrought

  8. Long-Term Cyclic Oxidation Behavior of Wrought Commercial Alloys at High Temperatures

    Bingtao Li

    2003-08-05

    The oxidation resistance of a high-temperature alloy is dependent upon sustaining the formation of a protective scale, which is strongly related to the alloying composition and the oxidation condition. The protective oxide scale only provides a finite period of oxidation resistance owing to its eventual breakdown, which is especially accelerated under thermal cycling conditions. This current study focuses on the long-term cyclic oxidation behavior of a number of commercial wrought alloys. The alloys studied were Fe- and Ni-based, containing different levels of minor elements, such as Si, Al, Mn, and Ti. Oxidation testing was conducted at 1000 and 1100 C in still air under both isothermal and thermal cycling conditions (1-day and 7-days). The specific aspects studied were the oxidation behavior of chromia-forming alloys that are used extensively in industry. The current study analyzed the effects of alloying elements, especially the effect of minor element Si, on cyclic oxidation resistance. The behavior of oxide scale growth, scale spallation, subsurface changes, and chromium interdiffusion in the alloy were analyzed in detail. A novel model was developed in the current study to predict the life-time during cyclic oxidation by simulating oxidation kinetics and chromium interdiffusion in the subsurface of chromia-forming alloys.

  9. Effect of Thermal Aging on the Corrosion Behavior of Wrought and Welded Alloy 22

    Alloy 22 (UNS N06022) is a candidate material for the external wall of the high level nuclear waste containers for the potential repository site at Yucca Mountain. In the mill-annealed (MA) condition, Alloy 22 is a single face centered cubic phase. When exposed to temperatures on the order of 600 C and above for times higher than 1 h, this alloy may develop secondary phases that are brittle and offer a lower corrosion resistance than the MA condition. The objective of this work was to age Alloy 22 at temperatures between 482 C and 800 C for times between 0.25 h and 3,000 h and to study the corrosion performance of the resulting material. Aging was carried out using wrought specimens as well as gas tungsten arc welded (GTAW) specimens. The corrosion performance was characterized using standard immersion tests in aggressive acidic solutions and electrochemical tests in multi-component solutions. Results show that, in general, in aggressive acidic solutions the corrosion rate increased as the aging temperature and aging time increased. However, in multi ionic environments that could be relevant to the potential Yucca Mountain site, the corrosion rate of aged material was the same as the corrosion rate of the MA material

  10. Effect of Thermal Aging on the Corrosion Behavior of Wrought and Welded Alloy 22

    R.B. Rebak; T.S. Edgecumbe Summers; T. Lian

    2002-07-02

    Alloy 22 (UNS N06022) is a candidate material for the external wall of the high level nuclear waste containers for the potential repository site at Yucca Mountain. In the mill-annealed (MA) condition, Alloy 22 is a single face centered cubic phase. When exposed to temperatures on the order of 600 C and above for times higher than 1 h, this alloy may develop secondary phases that are brittle and offer a lower corrosion resistance than the MA condition. The objective of this work was to age Alloy 22 at temperatures between 482 C and 800 C for times between 0.25 h and 3,000 h and to study the corrosion performance of the resulting material. Aging was carried out using wrought specimens as well as gas tungsten arc welded (GTAW) specimens. The corrosion performance was characterized using standard immersion tests in aggressive acidic solutions and electrochemical tests in multi-component solutions. Results show that, in general, in aggressive acidic solutions the corrosion rate increased as the aging temperature and aging time increased. However, in multi ionic environments that could be relevant to the potential Yucca Mountain site, the corrosion rate of aged material was the same as the corrosion rate of the MA material.

  11. Effect of Thermal Aging on the Corrosion Behavior of Wrought and Welded Alloy 22

    Rebak, R.B.; Edgecumbe, T.S.; Lian, T.; Carranza, R.M.; Dillman, J.R.; Corbin, T.; Crook, P.

    2002-01-02

    Alloy 22 (UNS N06022) is a candidate material for the external wall of the high level nuclear waste containers for the potential repository site at Yucca Mountain. In the mill-annealed (MA) condition, Alloy 22 is a single face centered cubic phase. When exposed to temperatures on the order of 600 C and above for times higher than 1 h, this alloy may develop secondary phases that are brittle and offer a lower corrosion resistance than the MA condition. The objective of this work was to age Alloy 22 at temperatures between 482 C and 800 C for times between 0.25 h and 3,000 h and to study the corrosion performance of the resulting material. Aging was carried out using wrought specimens as well as gas tungsten arc welded (GTAW) specimens. The corrosion performance was characterized using standard immersion tests in aggressive acidic solutions and electrochemical tests in multi-component solutions. Results show that, in general, in aggressive acidic solutions the corrosion rate increased as the aging temperature and aging time increased. However, in multi ionic environments that could be relevant to the potential Yucca Mountain site, the corrosion rate of aged material was the same as the corrosion rate of the MA material.

  12. Glovebox Advanced Casting System Casting Optimization

    Fielding, Randall Sidney [Idaho National Lab. (INL), Idaho Falls, ID (United States)

    2016-03-01

    Casting optimization in the GACS included three broad areas; casting of U-10Zr pins, incorporation of an integral FCCI barrier, and development of a permanent crucible coating. U-10Zr casting was improved over last year’s results by modifying the crucible design to minimize contact with the colder mold. Through these modifications casting of a three pin batch was successful. Incorporation of an integral FCCI barrier also was optimized through furnace chamber pressure changes during the casting cycle to reduce gas pressures in the mold cavities which led to three full length pins being cast which incorporated FCCI barriers of three different thicknesses. Permanent crucible coatings were tested against a base case; 1500°C for 10 minutes in a U-20Pu-10Zr molten alloy. None of the candidate coating materials showed evidence of failure upon initial visual examination. In all areas of work a large amount of characterization will be needed to fully determine the effects of the optimization activities. The characterization activities and future work will occur next year.

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

    Mackie, D.; Robson, J.D.; Withers, P.J. [School of Materials, University of Manchester, Manchester M13 9PL (United Kingdom); Turski, M. [Magnesium Elektron UK, Rake Lane, Manchester, M27 8BF (United Kingdom)

    2015-06-15

    Wrought magnesium alloys for demanding structural applications require high quality defect free cast feedstock. The aim of this study was to first identify and characterise typical defects in direct chill cast magnesium–aluminium–zinc (AZ) alloy billet and then use modelling to understand the origins of these defects so they can be prevented. Defects were first located using ultrasonic inspection and were then characterised using X-ray computed tomography (XCT) and serial sectioning, establishing the presence of oxide films and intermetallic particles Al{sub 8}Mn{sub 5} in all defects. A model was developed to predict the flow patterns and growth kinetics of the intermetallic phases during casting, which influence the formation of defects. Simulation of the growth of the intermetallic particles demonstrated that precipitation from the liquid occurs in the mould. The combination of the entrained oxide films and intermetallic particles recirculates in the liquid metal and continues to grow, until large enough to settle, which is predicted to occur at the centre of the mould where the flow is the slowest. Based on these predictions, strategies to reduce the susceptibility to defect formation are suggested. - Highlights: • Casting defects in magnesium direct chill casting have been imaged and characterised in 3-dimensions. • The occurrences of co-located clusters of particles and oxide films have been characterised and explained. • A coupled model has been developed to help interpret the observed trend for defects located towards the centre of billets.

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

    Wrought magnesium alloys for demanding structural applications require high quality defect free cast feedstock. The aim of this study was to first identify and characterise typical defects in direct chill cast magnesium–aluminium–zinc (AZ) alloy billet and then use modelling to understand the origins of these defects so they can be prevented. Defects were first located using ultrasonic inspection and were then characterised using X-ray computed tomography (XCT) and serial sectioning, establishing the presence of oxide films and intermetallic particles Al8Mn5 in all defects. A model was developed to predict the flow patterns and growth kinetics of the intermetallic phases during casting, which influence the formation of defects. Simulation of the growth of the intermetallic particles demonstrated that precipitation from the liquid occurs in the mould. The combination of the entrained oxide films and intermetallic particles recirculates in the liquid metal and continues to grow, until large enough to settle, which is predicted to occur at the centre of the mould where the flow is the slowest. Based on these predictions, strategies to reduce the susceptibility to defect formation are suggested. - Highlights: • Casting defects in magnesium direct chill casting have been imaged and characterised in 3-dimensions. • The occurrences of co-located clusters of particles and oxide films have been characterised and explained. • A coupled model has been developed to help interpret the observed trend for defects located towards the centre of billets

  15. New casting coatings

    In this project the results of the researches about the influence of the four types of ceramic coatings of the evaporating patterns (on the basis of talc, mullite, zircon and cordierite) on the talc of the Lost Foam process and the castings quality are presented. For the valid evaluation of the results, some parallel examinations of the quality of castings obtained by casting in sand were carried out. (Original)

  16. Casting in Sport

    DeCarlo, Mark; Malone, Kathy; Darmelio, John; Rettig, Arthur

    1994-01-01

    Attempts by sports medicine professionals to return high school athletes with hand and wrist injuries to competition quickly and safely have been the source of confusion and debate on many playing fields around the country. In addition to the differing views regarding the appropriateness of playing cast usage in high school football, a debate exists among sports medicine professionals as to which material is best suited for playing cast construction. Materials used in playing cast constructio...

  17. Microstructures and mechanical properties of Mg–Zn–Zr–Dy wrought magnesium alloys

    Z H Huang; W J Qi; K H Zheng; X M Zhang; M Liu; Z M Yu; J Xu

    2013-06-01

    Microstructures and phase compositions of as-cast and extruded ZK60–Dy ( = 0–5) alloys were analysed by optical microscope, scanning electron microscope, X-ray diffraction and differential scanning calorimetry. Meanwhile, the tensile mechanical property was tested.With increasing Dy content, Mg–Zn–Dy new phase increases gradually, while MgZn2 phase decreases gradually to disappear. As-cast microstructure is refined gradually; meanwhile extruded one is refined further with decreasing average grain size to 1 m for ZK60–4.32Dy alloy. Second phase, tending to distribute along grain boundary by continuous network in as-cast state, breaks and distributes dispersedly in extrusion state. As-cast tensile mechanical property remains almost unchanged at ambient temperature; however, extruded ones are enhanced significantly at ambient and elevated temperatures, respectively. Tensile strength at 298 and 473 K increases gradually from 355 and 120 MPa for ZK60 alloy to 395 and 171 MPa for ZK60–4.32Dy alloy, respectively. Extruded tensile fractures exhibit a typical character of ductile fracture.

  18. Irradiation damage behavior of low alloy steel wrought and weld materials

    A study was undertaken to evaluate the irradiation damage response of several different types of low alloy steel. The materials included vitange type ASTM A302 Grade B (A302B) plates and welds containing different nickel (Ni) and copper (Cu) concentrations, 3.5% Ni steels similar to ASTM A508 Class 4, welds containing about 1% Ni (similar to type 105S), and 3.5% Ni steels with 'superclean' composition (extremely low phosphorus, sulfur, manganese and silicon). To determine irradiation damage behavior, all materials were irradiated at several different irradiation damage levels ranging from 0.0003 dpa to 0.06 dpa at an irradiation damage levels ranging from 0.003 dpa to 0.06 dpa at an irradiation temperature of about 232 degrees C (450 degrees F). Complete Charpy V-notch impact energy transition temperature curves were generated for all materials before and after irradiation to determine the transition temperature at 41J (30 ft-lb) or 47J (35 ft-lb) and the upper shelf energy. The irradiation damage behavior was measured by the shift in the Charpy 41J or 47J transition temperature (ΔTT41J or ΔTT47J) and lowering of the upper shelf Charpy energy at a given irradiation damage level. It was found that chemical composition greatly influenced irradiation damage behavior. The highest irradiation damage (greatest ΔTT) was found in an A302B type weld contaiNing 1.28% Ni and 0.20% CU while the least irradiation damage was found in the 3.5% Ni, 0.05% Cu, superclean wrought materials

  19. Mechanical properties of stainless steel castings at 4 K

    Ten heats of cast CF8M stainless steel, which is the casting equivalent of AISI 316, were produced by a commercial vendor. In five of the heats the chromium and nickel contents were varied to obtain different delta-ferritie contents, ranging from 1.1 to 28.5 percent. The other five heats all had approximately 8 percent delta-ferrite and the nitrogen content was varied from 0.02 to 0.20 percent. As was expected from previous data on weldments and wrought materials, an increase in either delta-ferrite or nitrogen content increases the yield strength. In the five heats with varying nitrogen content the increase in strength resulted in a corresponding decrease in fracture toughness. An increase in delta-ferrite content also gave a decrease in fracture toughness up to approximately 15 percent dela-ferrite. Above this level the fracture toughness remained constant with increasing delta-ferrite content. This has been shown, by metallographic and fractographic evidence, to be due to the establishment of a continuous delta-ferrite crack path, at approximately 15 percent delta-ferrite

  20. Effect of Cu, Zn, and Mg Concentration on Heat Treating Behavior of Squeeze Cast Al-(10 to 12)Zn-(3.0 to 3.4)Mg-(0.8 to 1)Cu

    Ferguson, J B; Benjamin F. Schultz; John C. Mantas; Hassan Shokouhi; Pradeep K. Rohatgi

    2014-01-01

    Aluminum Alloy AA-7034 is a high strength wrought alloy with reasonable ductility containing 10–12 wt% Zn, 2–3 wt% Mg, and 0.8–1.2 wt% Cu. This work investigates the effect of varying the concentration of Zn (10–12 wt%) and Cu (0.8–1 wt%) on the solutionizing and aging behavior of squeeze cast AA-7034 samples. The same behaviors were investigated when Mg content was increased beyond 3 wt%. The solutionizing heat treatment dissolved much of the macroscopic second phases present in the as-cast ...

  1. Cast iron - a predictable material

    Jorg C. Sturm; Guido Busch

    2011-01-01

    High strength compacted graphite iron (CGI) or alloyed cast iron components are substituting previously used non-ferrous castings in automotive power train applications. The mechanical engineering industry has recognized the value in substituting forged or welded structures with stiff and light-weight cast iron castings. New products such as wind turbines have opened new markets for an entire suite of highly reliable ductile iron cast components. During the last 20 years, casting process s...

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

    Muralidharan, Govindarajan [ORNL; Yamamoto, Yukinori [ORNL; Brady, Michael P [ORNL; Pint, Bruce A [ORNL; Pankiw, Roman [Duraloy Technologies Inc; Voke, Don [Duraloy Technologies Inc

    2015-01-01

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

  3. The ancient Chinese casting techniques

    Tan Derui

    2011-02-01

    Full Text Available In the course of Chinese civilization, which lasted more than 5,000 years, casting production has made a huge contribution. In this paper, some representative metal castings were presented. According to their forming techniques, they can be grouped into stone mould casting, clay mould casting, ablation casting, lost wax casting, stack casting, permanent mould casting, sand casting, etc. According to their materials, they can be categorized into tin bronze, bimetallic bronze, malleable cast iron, ductile cast iron, brass, cupronickel alloy (Packtong, etc. According to their surface decorative techniques they can be devided into gem inlay, gilding, gold and silver inlay, copper inlay, engraved decoration, surface tin-enrichment, mother-of-pearl inlay, burnished works with gold or silver inlay, surface coloring and cloisonné enamel, etc.

  4. Clean Metal Casting

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

  5. Casting in sport.

    Decarlo, M; Malone, K; Darmelio, J; Rettig, A

    1994-03-01

    Attempts by sports medicine professionals to return high school athletes with hand and wrist injuries to competition quickly and safely have been the source of confusion and debate on many playing fields around the country. In addition to the differing views regarding the appropriateness of playing cast usage in high school football, a debate exists among sports medicine professionals as to which material is best suited for playing cast construction. Materials used in playing cast construction should be hard enough to provide sufficient stabilization to the injured area and include adequate padding to absorb blunt impact forces. The purpose of the biomechanical portion of this investigation was to attempt to determine the most appropriate materials for use in constructing playing casts for the hand and wrist by assessing different materials for: 1) hardness using a Shore durometer, and 2) ability to absorb impact using a force platform. Results revealed that RTV11 and Scotchcast were the "least hard" of the underlying casting materials and that Temper Stick foam greatly increased the ability of RTV11 to absorb impact. Assessment of the mechanical properties of playing cast materials and review of current developments in high school football rules are used to aid practitioners in choosing the most appropriate materials for playing cast construction. PMID:16558257

  6. Semi-solid process of 2024 wrought aluminum alloy by strain induced melt activation

    Surachai Numsarapatnuk

    2013-10-01

    Full Text Available The aim of this study is to develop a production process of a fine globular structure feedstock of the 2024 aluminumalloy suitable for subsequent semi-solid forming. The 2024 wrought aluminum alloy was first annealed to reduce the effect ofwork hardening. Then, strain was induced in the alloy by cold compression. After that the microstructural evolution duringpartial melting was investigated. The samples were subjected to full annealing at 415°C for 3 hrs prior to cold compression of40% reduction of area (RA with 3 mm/min strain rate. After that samples were partially melted at 620°C with varying holdingtime from 0 to 60 min followed by water quenching. The grain size and the average grain diameter of solid grains weremeasured using the linear intercept method. The globularization was interpreted in terms of shape factor. Liquid fraction andthe distribution of the eutectic liquid was also investigated. It was found that during partial melting, the globular morphologywas formed by the liquid wetting and fragmentation of high angle boundaries of recrystallized grains. The suitable semi-solidmicrostructure was obtained from a condition of full annealing, 40% cold working and partial melting at 620°C for 6 minholding time. The near globular grains obtained in the range of 0-60 min consisted of uniform spheroid grains with an averagegrain diameter ranged from 73 to 121 m, quenched liquid fraction was approximately 13–27% and the shape factor was greaterthan 0.6. At a holding time of less than 6 min, grain coarsening was dominant by the immigration of high-angle grainboundaries. At a longer holding time, liquid fraction increased and Ostwald ripening was dominant. The coarsening rateconstant for the 2024 Al alloy was 400.36 mm3.s-1. At a soaking time of 60 min, it was found that a minimum diameter differencewas 1.06% with coarsening index n=3 in a power law equation. The non-dendritic slug of 2024 alloy was rapid compressedinto a disc with 90%RA

  7. Symptomatic stent cast.

    Keohane, John

    2012-02-03

    Biliary stent occlusion is a major complication of endoscopic stent insertion and results in repeat procedures. Various theories as to the etiology have been proposed, the most frequently studied is the attachment of gram negative bacteria within the stent. Several studies have shown prolongation of stent patency with antibiotic prophylaxis. We report the case of stent occlusion from a cast of a previously inserted straight biliary stent; a "stent cast" in an 86-year-old woman with obstructive jaundice. This was retrieved with the lithotrypter and she made an uneventful recovery. This is the first reported case of a biliary stent cast.

  8. Energy Saving Melting and Revert Reduction (E-SMARRT): Optimization of Heat Treatments on Stainless Steel Castings for Improved Corrosion Resistance and Mechanical Properties

    John N. DuPont; Jeffrey D. Farren; Andrew W. Stockdale; Brett M. Leister

    2012-06-30

    It is commonly believed that high alloy steel castings have inferior corrosion resistance to their wrought counterparts as a result of the increased amount of microsegregation remaining in the as-cast structure. Homogenization and dissolution heat treatments are often utilized to reduce or eliminate the residual microsegregation and dissolve the secondary phases. Detailed electron probe microanalysis (EPMA) and light optical microscopy (LOM) were utilized to correlate the amount of homogenization and dissolution present after various thermal treatments with calculated values and with the resultant corrosion resistance of the alloys.The influence of heat treatment time and temperature on the homogenization and dissolution kinetics were investigated using stainless steel alloys CN3MN and CK3MCuN. The influence of heat treatment time and temperature on the impact toughness and corrosion reistance of cast stainless steel alloys CF-3, CF-3M, CF-8, and CF-8M was also investigated.

  9. Bainite obtaining in cast iron with carbides castings

    S. Pietrowski

    2010-01-01

    Full Text Available In these paper the possibility of upper and lower bainite obtaining in cast iron with carbides castings are presented. Conditions, when in cast iron with carbides castings during continuous free air cooling austenite transformation to upper bainite or its mixture with lower bainte proceeds, have been given. A mechanism of this transformation has been given, Si, Ni, Mn and Mo distribution in the eutectic cell has been tested and hardness of tested castings has been determined.

  10. Colour Metallography of Cast Iron

    Zhou Jiyang; Liu Jincheng

    2011-01-01

    White Cast Iron (Ⅰ) White cast iron or ‘white iron' refers to the type of cast iron in which all of the carbon exists as carbide;there is no graphite in the as-cast structure and the fractured surface shows a white colour.White cast iron can be divided in three classes:· Normal white cast iron — this iron contains only C,Si,Mn,P and S,with no other alloying elements.· Low-alloy white cast iron — the total mass fraction of alloying elements is less than 5%.

  11. Centrifugal casting process

    Centrifugal casting is not one of the most common metalforming techniques, but there are a few applications of great value, for example in gas cooled reactors. In this article a few examples of these applications are discussed

  12. Simulation of mechanical properties of forged and casted steel 42CrMo4 specimen

    B. Smoljan

    2010-12-01

    Full Text Available Purpose: In this paper, the prediction of working stress of quenched and tempered shaft has been done. Prediction was done for two different manufacture processes. In the first manufacture process the shaft was made of steel and in second one the shaft was made of cast steel. The working stress was characterized by yield strength and impact toughness. The method of computer simulation of working stress was applied in workpiece of complex form.Design/methodology/approach: Hardness distribution of quenched and tempered workpiece of complex form was predicted by computer simulation of quenching using a finite volume method. Hardness of quenched and tempered steel can be expressed as function of maximal hardness of actual steel, hardness of steel with 50% of martensite in microstructure, according to the time and temperature of tempering. The algorithm of estimation of yield strength and impact energy was based on hardness, HV. Starting point in studying of the mechanical properties of steel castings can be the fact that the mechanical properties of steel castings are derived from the mechanical properties of ordinary steel metal matrix reduced by the influence of the typical as-cast structure, i.e. casting defects on those properties. Hardness and yield strength will be unaffected by most defects. The only effect will be that due to the reduction in area. Coarse as-cast microstructure of cast steel lowers ductility and toughness. Impact energy of quenched and tempered cast steel was predicted based on pouring temperature, temperature of mould during the pouring and fact that steel castings are not subjected to different metallurgical and mechanical processes of microstructure improvement in so far as wrought steels.Findings: It can be concluded that working stress of quenched and tempered shaft can be successfully predicted by proposed method.Practical implications: Estimation of hardness distribution can be based on time, relevant for structure

  13. Skeleton castings dynamic load resistance

    M. Cholewa; J. Szajnar; T. Szuter

    2013-01-01

    Purpose: The article is to show selected results of research in a field of new type of cast spatial composite reinforcements. This article shows skeleton casting case as a particular approach to continuous, spatial composite reinforcement.Design/methodology/approach: The research is concerning properties of cast spatial microlattice structures called skeleton castings. In this paper results of impact test of skeleton casting with octahedron elementary cell were shown. The selection of interna...

  14. (Continuous casting 1985)

    Wilde, R.A.

    1985-06-12

    The report covers the Continuous Casting '85 Conference including informal discussions with conference attendees. In general, the papers presented at the conference concerned an overview of continuous steel casting worldwide, state-of-the-art aspects of steel continuous casting technology including caster startup problems, modifications, control system strategies, energy use profiles, quality control aspects, steel chemistry control, refractories, operational aspects of continuous casters, etc. No papers were presented in the development of thin section or thin strip casting of steel. Informal discussions were held with several conference attendees including (1) Bernard Trentini, Executive Director of the Association Technique De La Siderurgie Francaise in Paris, France (similar to the American Iron and Steel Institute); (2) Dr. Wolfgang Reichelt and Dr. Peter Voss-Spilker both of Mannesmann Demag Huttentechnik -a continuous casting and other steel making machine builder in-lieu of meeting at their plant in Duisburg, FRG on May 31; (3) Ewan C. Hewitt of Devote McKee Corp., Sheffield, England; (4) Wilfried Heinemann, head of R D Dept. at Concast Standard AG in Zurich, Switzerland; and (5) Hideo Ueno, engineer of melting section, Mitsubishi Steel Mfg. Co. Ltd, Tokyo Japan. A visit was made to the Teesside Laboratories of British Steel Corp. for discussions of their thin section casting research program in particular and R D program in general.

  15. Casting AISI 316 steel by gel cast

    The feasibility of producing AISI 316 steel components from their powders and avoiding their compaction is analyzed. A casting technique is tested that is similar to gel casting, used for ceramic materials. In the initial stage, the process consists of the formulation of a concentrated barbotine of powdered metal in a solution of water soluble organic monomers, which is cast in a mold and polymerized in situ to form a raw piece in the shape of the cavity. The process can be performed under controlled conditions using barbotines with a high monomer content from the acrylimide family. Then, the molded piece is slowly heated until the polymer is eliminated, and it is sintered at temperatures of 1160oC to 1300oC under a dry hydrogen atmosphere, until the desired densities are attained. The density and micro structure of the materials obtained are compared with those for the materials compacted and synthesized by the conventional processes. The preliminary results show the feasibility of the process for the production of certain kinds of structural components (CW)

  16. Alloy Design and Development of Cast Cr-W-V Ferritic Steels for Improved High-Temperature Strength for Power Generation Applications

    Klueh, R L; Maziasz, P J; Vitek, J M; Evans, N D; Hashimoto, N

    2006-09-23

    Economic and environmental concerns demand that the power-generation industry seek increased efficiency for gas turbines. Higher efficiency requires higher operating temperatures, with the objective temperature for the hottest sections of new systems {approx} 593 C, and increasing to {approx} 650 C. Because of their good thermal properties, Cr-Mo-V cast ferritic steels are currently used for components such as rotors, casings, pipes, etc., but new steels are required for the new operating conditions. The Oak Ridge National Laboratory (ORNL) has developed new wrought Cr-W-V steels with 3-9% Cr, 2-3% W, 0.25% V (compositions are in wt.%), and minor amounts of additional elements. These steels have the strength and toughness required for turbine applications. Since cast alloys are expected to behave differently from wrought material, work was pursued to develop new cast steels based on the ORNL wrought compositions. Nine casting test blocks with 3, 9, and 11% Cr were obtained. Eight were Cr-W-V-Ta-type steels based on the ORNL wrought steels; the ninth was COST CB2, a 9Cr-Mo-Co-V-Nb cast steel, which was the most promising cast steel developed in a European alloy-development program. The COST CB2 was used as a control to which the new compositions were compared, and this also provided a comparison between Cr-W-V-Ta and Cr-Mo-V-Nb compositions. Heat treatment studies were carried out on the nine castings to determine normalizing-and-tempering treatments. Microstructures were characterized by both optical and transmission electron microscopy (TEM). Tensile, impact, and creep tests were conducted. Test results on the first nine cast steel compositions indicated that properties of the 9Cr-Mo-Co-V-Nb composition of COST CB2 were better than those of the 3Cr-, 9Cr-, and 11Cr-W-V-Ta steels. Analysis of the results of this first iteration using computational thermodynamics raised the question of the effectiveness in cast steels of the Cr-W-V-Ta combination versus the Cr

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

    Thangirala, Mani

    2015-09-30

    demonstrated the importance of proper heat treat cycles for Homogenization, and Solutionizing parameters selection and implementation. 3) Step blocks casting of Nimonic 263: Carried out casting solidification simulation analysis, NDT inspection methods evaluation, detailed test matrix for Chemical, Tensile, LCF, stress rupture, CVN impact, hardness and J1C Fracture toughness section sensitivity data and were reported. 4) Centrifugal Casting of Haynes 282, weighing 1400 lbs. with hybrid mold (half Graphite and half Chromite sand) mold assembly was cast using compressor casing production tooling. This test provided Mold cooling rates influence on centrifugally cast microstructure and mechanical properties. Graphite mold section out performs sand mold across all temperatures for 0.2% YS; %Elongation, %RA, UTS at 1400°F. Both Stress-LMP and conditional Fracture toughness plots data were in the scatter band of the wrought alloy. 5) Fundamental Studies on Cooling rates and SDAS test program. Evaluated the influence of 6 mold materials Silica, Chromite, Alumina, Silica with Indirect Chills, Zircon and Graphite on casting solidification cooling rates. Actual Casting cooling rates through Liquidus to Solidus phase transition were measured with 3 different locations based thermocouples placed in each mold. Compared with solidification simulation cooling rates and measurement of SDAS, microstructure features were reported. The test results provided engineered casting potential methods, applicable for heavy section Haynes 282 castings for optimal properties, with foundry process methods and tools. 6) Large casting of Haynes 282 Drawings and Engineering FEM models and supplemental requirements with applicable specifications were provided to suppliers for the steam turbine proto type feature valve casing casting. Molding, melting and casting pouring completed per approved Manufacturing Process Plan during 2014 Q4. The partial valve casing was successfully cast after casting methods were

  18. The CAST experiment

    CAST (CERN Axion Solar Telescope) is a helioscope looking for axions coming from the solar core to the Earth. The experiment, located at CERN, is based on the Primakoff effect and uses a magnetic field of 9 Tesla provided by a decommissioned LHC magnet. CAST is able to follow the Sun during sunrise and sunset and therefore three X-ray detectors are mounted on both ends of the magnet waiting for a photon from axion-to-photon conversion due to the Primakoff effect. During its first phase, which concluded in 2004, CAST has been looking for axions with masses up to 0.02 eV. CAST's second phase manages to re-establish the coherence needed to scan for axions with masses up to 1.16 eV by using a buffer gas. This technique enables the experiment to look into the theoretical regions for axions. During the years 2005 and 2006, the use of 4He in CAST has already provided coherence in order to look for axions with masses up to 0.4 eV

  19. Influence of texture and microstructure on mechanical properties of high-strength wrought magnesium alloy AZ80

    ZHANG Ping; J. LINDEMANN; C. LEYENS

    2006-01-01

    Monotonic (tensile and compressive) and high cycle fatigue properties of the forged magnesium alloy AZ80 were investigated by using specimens with load axis parallel to longitude (L) or transverse (T) direction. A pronounced directional anisotropy in monotonic tests was observed in AZ80, i.e. the yield stress in T-direction is significantly lower than that in L direction. However, the directional anisotropy is absent in fatigue, fatigue strengths in both L- and T-directions are essentially equal. The absence of directional anisotropy in fatigue is possibly associated with the microstructure of AZ80. A homogeneous single phase structure probably alleviates the directional anisotropy of fatigue properties of the wrought magnesium alloy.

  20. Casting Characteristics of Aluminum Die Casting Alloys

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

    The research program investigates the casting characteristics of selected aluminum die casting alloys. Specifically, the alloys' tendencies towards die soldering and sludge formation, and the alloys' fluidity and machinability are evaluated. It was found that: When the Fe and Mn contents of the alloy are low; caution has to be taken against possible die soldering. When the alloy has a high sludge factor, particularly a high level of Fe, measures must be taken to prevent the formation of large hardspots. For this kind of alloy, the Fe content should be kept at its lowest allowable level and the Mn content should be at its highest possible level. If there are problems in die filling, measures other than changing the alloy chemistry need to be considered first. In terms of alloy chemistry, the elements that form high temperature compounds must be kept at their lowest allowable levels. The alloys should not have machining problems when appropriate machining techniques and machining parameters are used.

  1. Strip casting of stainless steels

    Raabe, D.

    1997-01-01

    FLAT PRODUCTS OF STAINLESS STEELS ARE CONVENTIONALLY MANUFACTURED BY CONTINUOUS CASTING, HOT ROLLING, HOT BAND ANNEALING, PICKLING, COLD ROLLING AND RECRYSTALLISATION. IN THE LAST YEARS STRIP CASTING HAS INCREASINGLY ATTRACTED ATTENTION. IT OFFERS THREE IMPROVEMENTS IN COMPARISON TO THE CONVENTIONAL METHOD.1.) IT ALLOWS TO CAST STEEL SHEETS WITH THE SAME THICKNESS AND WIDTH AS THOSE PRODUCED BY HOT ROLLING. THIS MEANS THAT THE HOT ROLLING PROCESSIS BYPASSED. 2.) THE STRIP CAST STEEL REVEALS A...

  2. Strengthening of cast Ti-25Nb-3Mo-3Zr-2Sn alloy through precipitation of α in two discrete crystallographic orientations

    Research highlights: → The study demonstrates that the excellent age hardening response of a biomedical, β Ti-25Nb-3Mo-3Zr-2Sn alloy in the as-cast condition. Properties comparable to other biomedical β alloys attained in the wrought condition were achieved. Enhanced strengthening of the alloy was due to precipitation of fine scale α laths formed in two different crystallographic orientations throughout the β matrix via heterogeneous nucleation on athermal ω phase present in the cast alloy. - Abstract: A detailed study of the microstructural development during aging of a Ti-25Nb-3Mo-3Zr-2Sn alloy is presented. Transmission electron microscopy observations show the as-cast microstructure is comprised of large β grains containing fine coherent ω precipitates. Fine scale α laths form in two different crystallographic orientations throughout the β matrix when the alloy is aged directly from the as-cast condition. The α laths typically have habit planes close to {1 1 1}β or {2 3 3}β. Aging at 450 deg. C doubles the yield strength as compared to that in the as-cast condition. We suggest that the differently orientated α laths may contribute to this significant increase in the strength of the alloy. Martensitic α'' phase, with its habit plane close to {4 3 3}β, was observed in the as-cast microstructure subsequent to deformation.

  3. Scheduled Caste Women: Problems And Challenges

    Vijayakumar Murthy; Jaikishan Thakur

    2013-01-01

    The paper analyzed the Caste system based on Varnas during the ancient India. It also examined the demerits of caste attached to the present scheduled castes in general and scheduled caste women in particular. The scheduled caste women are disadvantaged by their caste and gender and as such they are subject to exploitation and discrimination by their family members, by their caste people and by forward castes. Hence, there is increase in exploitation, discrimination and violence against the s...

  4. Colour Metallography of Cast Iron

    Zhou Jiyang; Ph.D Liu Jincheng

    2010-01-01

    @@ Note: This book consists of five sections: Chapter 1 Introduction, Chapter 2 Grey Iron, Chapter 3 Spheroidal Graphite Cast Iron, Chapter 4 Vermicular Cast Iron, and Chapter 5 White Cast Iron. CHINA FOUNDRY publishes this book in several parts serially, starting from the first issue of 2009.

  5. HYDROMODELLING OF CASTING PROCESSES

    E. I. Marukovich

    2016-02-01

    Full Text Available The description of equipment for hydrodynamic experiments and methods of hydromodeling of foundry processes, allowing to carry out three-dimensional modeling of filling process, is given. This method can be used for identification of numerical models and development of casting technology of the new types of production.

  6. Extrusion cast explosive

    Scribner, Kenneth J.

    1985-01-01

    Improved, multiphase, high performance, high energy, extrusion cast explosive compositions, comprising, a crystalline explosive material; an energetic liquid plasticizer; a urethane prepolymer, comprising a blend of polyvinyl formal, and polycaprolactone; a polyfunctional isocyanate; and a catalyst are disclosed. These new explosive compositions exhibit higher explosive content, a smooth detonation front, excellent stability over long periods of storage, and lower sensitivity to mechanical stimulants.

  7. Evaluation of an improved centrifugal casting machine.

    Donovan, T E; White, L E

    1985-05-01

    A Type III gold alloy, a silver-palladium alloy, and a base metal alloy were cast in two different centrifugal casting machines. With the number of complete cast mesh squares as an indicator of castability, the Airspin casting machine produced superior castings with all three alloys. The base metal alloy produced the greatest number of complete squares with both casting machines. PMID:3889295

  8. Bulk metallic glass tube casting

    Research highlights: → Tubular specimens of Zr55Cu30Al10Ni5 cast in custom arc-melting furnace. → Tilt casting supplemented by suction casting. → Bulk metallic glass formed only with optimized processing parameters. → Fully amorphous tubes with 1.8 mm wall thickness and 25 mm diameter. - Abstract: Tubular bulk metallic glass specimens were produced, using a custom-built combined arc-melting tilt-casting furnace. Zr55Cu30Al10Ni5 tubes with outer diameter of 25 mm and 0.8-3 mm wall thicknesses were cast, with both tilt and suction casting to ensure mold filling. Tilt casting was found to fill one side of the tube mold first, with the rest of the tube circumference filled subsequently by suction casting. Optimized casting parameters were required to fully fill the mold and ensure glass formation. Too small melt mass and too low arc power filled the mold only partially. However, too large melt mass and higher arc power which lead to the best mold filling also lead to partial crystallization. Variations in processing parameters were explored, until a glassy ring with 1.8 mm thickness was produced. Different sections of the as-cast ring were investigated by X-ray diffraction (XRD), differential scanning calorimetry (DSC), and instrumented indentation to ensure amorphous microstructure. Atomic force microscopy (AFM) was used to compare the surface qualities of the first- and last-filled sections. These measurements confirmed the glassy structure of the cast ring, and that, the tilt cast tube section consistently showed better surface quality than the suction cast section. Optimized casting parameters are required to fully realize the potential of directly manufacturing complex shapes out of high-purity bulk metallic glasses by tilt casting.

  9. Colour Metallography of Cast Iron

    Zhou Jiyang; Liu Jincheng

    2010-01-01

    @@ Chapter 3 Spheroidal Graphite Cast Iron(I) Spheroidal Graphite Cast Iron, SG iron in short, refers to the cast iron in which graphite precipitates as spheroidal shape during solidification of liquid iron. The graphite in common commercial cast iron can only be changed from flake to spheroidal shape by spheroidising treatment. Since spheroidal graphite reduces the cutting effect of stress concentration, the metal matrix strength of SG iron can be applied around 70%-90%, thus the mechanical property of SG iron is significantly superior to other cast irons;even the tensile strength of SG iron is higher than that carbon steel.

  10. [Casting faults and structural studies on bonded alloys comparing centrifugal castings and vacuum pressure castings].

    Fuchs, P; Küfmann, W

    1978-07-01

    The casting processes in use today such as centrifugal casting and vacuum pressure casting were compared with one another. An effort was made to answer the question whether the occurrence of shrink cavities and the mean diameter of the grain of the alloy is dependent on the method of casting. 80 crowns were made by both processes from the baked alloys Degudent Universal, Degudent N and the trial alloy 4437 of the firm Degusa. Slice sections were examined for macro and micro-porosity and the structural appearance was evaluated by linear analysis. Statistical analysis showed that casting faults and casting structure is independent of the method used and their causes must be found in the conditions of casting and the composition of the alloy. PMID:352670

  11. Casting larger polycrystalline silicon ingots

    Wohlgemuth, J.; Tomlinson, T.; Cliber, J.; Shea, S.; Narayanan, M.

    1995-08-01

    Solarex has developed and patented a directional solidification casting process specifically designed for photovoltaics. In this process, silicon feedstock is melted in a ceramic crucible and solidified into a large grained semicrystalline silicon ingot. In-house manufacture of low cost, high purity ceramics is a key to the low cost fabrication of Solarex polycrystalline wafers. The casting process is performed in Solarex designed casting stations. The casting operation is computer controlled. There are no moving parts (except for the loading and unloading) so the growth process proceeds with virtually no operator intervention Today Solarex casting stations are used to produce ingots from which 4 bricks, each 11.4 cm by 11.4 cm in cross section, are cut. The stations themselves are physically capable of holding larger ingots, that would yield either: 4 bricks, 15 cm by 15 an; or 9 bricks, 11.4 cm by 11.4 an in cross-section. One of the tasks in the Solarex Cast Polycrystalline Silicon PVMaT Program is to design and modify one of the castings stations to cast these larger ingots. If successful, this effort will increase the production capacity of Solarex`s casting stations by 73% and reduce the labor content for casting by an equivalent percentage.

  12. Fracture Mechanisms in Steel Castings

    Z. Stradomski

    2013-07-01

    Full Text Available The investigations were inspired with the problem of cracking of steel castings during the production process. A single mechanism of decohesion - the intergranular one - occurs in the case of hot cracking, while a variety of structural factors is decisive for hot cracking initiation, depending on chemical composition of the cast steel. The low-carbon and low-alloyed steel castings crack due to the presence of the type II sulphides, the cause of cracking of the high-carbon tool cast steels is the net of secondary cementite and/or ledeburite precipitated along the boundaries of solidified grains. Also the brittle phosphor and carbide eutectics precipitated in the final stage solidification are responsible for cracking of castings made of Hadfield steel. The examination of mechanical properties at 1050°C revealed low or very low strength of high-carbon cast steels.

  13. X-ray photoelectron spectroscopy study of the passive films formed on thermally sprayed and wrought Inconel 625

    Bakare, M. S.; Voisey, K. T.; Roe, M. J.; McCartney, D. G.

    2010-11-01

    There is a well known performance gap in corrosion resistance between thermally sprayed corrosion resistant coatings and the equivalent bulk materials. Interconnected porosity has an important and well known effect, however there are additional relevant microstructural effects. Previous work has shown that a compositional difference exists between the regions of resolidified and non-melted material that exist in the as-sprayed coatings. The resolidified regions are depleted in oxide forming elements due to formation of oxides during coating deposition. Formation of galvanic cells between these different regions is believed to decrease the corrosion resistance of the coating. In order to increase understanding of the details of this effect, this work uses X-ray photoelectron spectroscopy (XPS) to study the passive films formed on thermally sprayed coatings (HVOF) and bulk Inconel 625, a commercially available corrosion resistant Ni-Cr-Mo-Nb alloy. Passive films produced by potentiodynamic scanning to 400 mV in 0.5 M sulphuric acid were compared with air-formed films. The poorer corrosion performance of the thermally sprayed coatings was attributed to Ni(OH) 2, which forms a loose, non-adherent and therefore non-protective film. The good corrosion resistance of wrought Inconel 625 is due to formation of Cr, Mo and Nb oxides.

  14. The role of stress state on the fracture toughness and toughening mechanisms of wrought molybdenum and molybdenum alloys

    Rolling unalloyed molybdenum, molybdenum alloys, and Oxide Dispersion Strengthened (ODS) molybdenum into sheet produces microstructures with elongated, pancake shaped grains that can result in anisotropic mechanical properties. In this work, unalloyed molybdenum, molybdenum alloys, and ODS molybdenum are rolled to thinner sheet and then subjected to tensile and fracture toughness testing and examination of the toughening mechanism. The ductile laminate toughening mechanism observed for wrought molybdenum results from a lower toughness in the short-transverse orientation that leads to separation of the layers of sheet-like grains of the microstructure along the grain boundaries in the regions of stress concentration. This splitting of the microstructure results in the formation of ligaments of grains, or non-constrained laminates, that are stretched to failure under a plane stress-state with large amounts of plastic deformation. The thinner specimens exhibit higher fracture toughness values and lower Ductile to Brittle Transition Temperature (DBTT) values than for thicker specimens machined from thicker starting material from the same alloy. The lower constraint of the thinner specimens tested in this work results in higher toughness and lower DBTT values. The finer grain size, finer precipitate size, and state of plane stress achieved for the thinner sheet specimens appears to enhance the ductile laminate toughening to result in higher fracture toughness and lower DBTT values. The detrimental effect of crack initiation from brittle carbides, oxides, and second phases is also observed to be diminished under a stress-state of plane stress.

  15. Development and property evaluation of nuclear grade wrought FeCrAl fuel cladding for light water reactors

    Yamamoto, Y.; Pint, B. A.; Terrani, K. A.; Field, K. G.; Yang, Y.; Snead, L. L.

    2015-12-01

    Development of nuclear grade, iron-based wrought FeCrAl alloys has been initiated for light water reactor (LWR) fuel cladding to serve as a substitute for zirconium-based alloys with enhanced accident tolerance. Ferritic alloys with sufficient chromium and aluminum additions can exhibit significantly improved oxidation kinetics in high-temperature steam environments when compared to zirconium-based alloys. In the first phase, a set of model FeCrAl alloys containing 10-20Cr, 3-5Al, and 0-0.12Y in weight percent, were prepared by conventional arc-melting and hot-working processes to explore the effect of composition on the properties of FeCrAlY alloys. It was found that the tensile properties were insensitive to the alloy compositions studied; however, the steam oxidation resistance strongly depended on both the chromium and the aluminum contents. The second phase development focused on strengthening Fe-13Cr-5Al with minor alloying additions of molybdenum, niobium, and silicon. Combined with an optimized thermo-mechanical treatment, a thermally stable microstructure was produced with improved tensile properties at temperatures up to 741 °C.

  16. Cast dielectric composite linear accelerator

    Sanders, David M.; Sampayan, Stephen; Slenes, Kirk; Stoller, H. M.

    2009-11-10

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

  17. Skeleton castings dynamic load resistance

    M. Cholewa

    2013-06-01

    Full Text Available Purpose: The article is to show selected results of research in a field of new type of cast spatial composite reinforcements. This article shows skeleton casting case as a particular approach to continuous, spatial composite reinforcement.Design/methodology/approach: The research is concerning properties of cast spatial microlattice structures called skeleton castings. In this paper results of impact test of skeleton casting with octahedron elementary cell were shown. The selection of internal topology of skeleton casting was based on numerical simulations of stress distribution.Findings: The possibility of manufacturing of geometrically complex skeleton castings without use of advanced techniques was confirmed.Research limitations/implications: With use of computer tomography, analysis of deformation mechanisms was carried out. Different levels of impact energies were usedPractical implications: Spatial skeleton casting with octahedron elementary cell confirmed their usefulness as impact energy absorbers.Originality/value: The overall aim of presented research was to determine the mechanisms of skeleton castings deformation processes. Thanks to CT data next step will be to create accurate numerical model for further simulation and design optimization.

  18. Design and Test of Fuzzy-PI Controller for Copper Disc Casting Machine Casting Electronic Balance

    Fanzhi Kong; Qun Sun; Chong Wang; Chengqiang Yin; Song Hu

    2015-01-01

    Casting electronic scale is the key part of copper casting machine; its control precision directly affects the quality of casting. For this problem, this paper analyzes 16 casting machine casting structures and control principles. According to the movement characteristics of casting, a cast Fuzzy-PI composite controller of electronic scale was designed. On this basis, the hardware system based on PLC and the expansion modules were developed, and casting electronic control programs were design...

  19. Modification of Magnesium Alloys by Ceramic Particles in Gravity Die Casting

    Urs Haßlinger

    2014-01-01

    Full Text Available A critical drawback for the application of magnesium wrought alloys is the limited formability of semifinished products that arises from a strong texture formation during thermomechanical treatment. The ability of second phase particles embedded into the metal matrix to alter this texture evolution is of great interest. Therefore, the fabrication of particle modified magnesium alloys (particle content 0.5–1 wt.-% by gravity die casting has been studied. Five different types of micron sized ceramic powders (AlN, MgB2, MgO, SiC, and ZrB2 have been investigated to identify applicable particles for the modification. Agglomeration of the particles is revealed to be the central problem for the fabrication process. The main factors that influence the agglomerate size are the particle size and the intensity of melt stirring. Concerning handling, chemical stability in the Mg-Al-Zn alloy system, settling and wetting in the melt, and formation of the microstructure in most cases, the investigated powders show satisfying properties. However, SiC is chemically unstable in aluminum containing alloys. The high density of ZrB2 causes large particles to settle subsequent to stirring resulting in an inhomogeneous distribution of the particles over the cast billet.

  20. Development of Refractories for Continuous Casting

    TIAN Shouxin; JIN Congjin; YAO Jinfu; LI Zeya

    2004-01-01

    The paper introduces refractories for continuous casting, especially, refractories for continuous casting for clean steel in baosteel. Developing direction of refractories for continuous casting has been pointed out to satisfy the new metallurgical operating practice.

  1. Scheduled Caste Women: Problems And Challenges

    Vijayakumar Murthy

    2013-12-01

    Full Text Available The paper analyzed the Caste system based on Varnas during the ancient India. It also examined the demerits of caste attached to the present scheduled castes in general and scheduled caste women in particular. The scheduled caste women are disadvantaged by their caste and gender and as such they are subject to exploitation and discrimination by their family members, by their caste people and by forward castes. Hence, there is increase in exploitation, discrimination and violence against the scheduled caste women. The female feticide, illiteracy, gender inequality, Devadasi, Jogini practice, Nude Service to Deity, different types of violence, dowry, child marriage, etc are few of the problems faced by scheduled caste women in present society. Statistics of the violence acts against the scheduled caste women is discussed in the paper and there is need to strictly enforce the legislations passed to protect the violence against scheduled caste women. For this purpose, there is need of enquiry from lady police officials.

  2. Segregation in cast products

    A Ghosh

    2001-02-01

    Microsegregation gets eliminated significantly if subsequent hot working and/or annealing are done on cast products. Macrosegregation however persists, causing problems in quality, and hence, has to be attended to. Microsegregation is a consequence of rejection of solutes by the solid into the interdendritic liquid. Scheil’s equation is mostly employed. However, other equations have been proposed, which take into account diffusion in solid phase and/or incomplete mixing in liquid. Macrosegregation results from movements of microsegregated regions over macroscopic distances due to motion of liquid and free crystals. Motion of impure interdendritic liquid causes regions of positive macrosegregation, whereas purer solid crystals yield negative macrosegregation. Flow of interdendritic liquid is primarily natural convection due to thermal and solutal buoyancy, and partly forced convection due to suction by shrinkage cavity formation etc. The present paper briefly deals with fundamentals of the above and contains some recent studies as well. Experimental investigations in molten alloys do not allow visualization of the complex flow pattern as well as other phenomena, such as dendrite-tip detachment. Experiments with room temperature analogues, and mathematical modelling have supplemented these efforts. However, the complexity of the phenomena demands simplifying assumptions. The agreement with experimental data is mostly qualitative. The paper also briefly discusses centreline macrosegregation during continuous casting of steel, methods to avoid it, and the, importance of early columnar-to-equiaxed transition (CET) as well as the fundamentals of CET.

  3. Colour Metallography of Cast Iron

    Zhou Jiyang; Liu Jincheng

    2009-01-01

    @@ This book consists of five sections:Chapter 1 Introduction,Chapter 2 Grey Iron,Chapter 3 Ductile Iron,Chapter 4Vermicular Cast Iron,and Chapter 5 White Cast Iron. CHINA FOUNDRY publishs this book in several parts serially,starting from the first issue of 2009.

  4. CONTINUOUS HORIZONTAL CASTING OF PIPE BRONZE BILLET

    E. I. Marukovich

    2015-05-01

    Full Text Available An experimental and calculated thermal analysis of the continuous casting of bronze tube billets is developed. Calculated allowable thermal conditions of drawing for stable casting.

  5. The effect of Sn addition on aging behavior and mechanical properties of wrought AZ80 magnesium alloy

    Highlights: • Thermodynamic and precipitation kinetics calculation was used to analyze aging hardening after addition of Sn. • Precipitation sequences were determined by the content of Sn element. • The microstructure of Mg17Al12 discontinuous precipitates were influenced by Mg2Sn precipitates. - Abstract: The microstructure and mechanical properties of AZ80 wrought magnesium alloys with varying Sn contents (0, 1, 2 and 4 wt.%) have been studied by thermodynamic and precipitation kinetics calculation and examined using scanning electron microscopy (SEM), transmission electron microscopy (TEM), hardness test and uniaxial tensile test at room temperature in this paper. The results of thermodynamic and precipitation kinetics calculation showed that the precipitation sequences were determined by the content of Sn element. It was found that in the aging treatment of this work, Mg17Al12 phase precipitated sooner than Mg2Sn phase in the alloys with less than 1.72 wt.% Sn and there was a contrary precipitation sequence of these two phases in the alloys with more than 1.72 wt.% Sn. Experimental results were in agreement with those of calculation. According to SEM and TEM observation, Sn promoted precipitation of Mg17Al12 on aging temperature, however the preferential Mg2Sn phase suppressed discontinuous Mg17Al12 precipitates by hindering the growth of these in their growth direction. AZ80 with 1–2 wt.% Sn as-aged alloys exhibited outstanding mechanical property that UTS, YS and EL were ∼420 MPa, ∼290 MPa and ∼5%, respectively

  6. Effect of Ablation Casting on Microstructure and Casting Properties of A356 Aluminium Casting Alloy

    V.Bohlooli; M.Shabani Mahalli; S.M.A.Boutorabi

    2013-01-01

    Recently the Ablation Casting Technology was invented as a new casting process to improve foundry products quality.In this study,the effects of processing variables on the porosity content,microstructure and feedability of A356 casting alloy were investigated.Secondary dendrite arm spacing (SDAS) and eutectic silicon morphologies were studied to evaluate the influence of Ablation Casting on the microstructure.Casting density was measured in order to identify porosity content and feedability of ablated and non-ablated specimens.In addition,solidification behavior of the samples was investigated by using thermal analysis technique.The cooling curves and the first derivative curves were plotted and compared with each other.Results showed the ablation process could increase solidification rate significantly.In addition,the microstructural evidences revealed that Ablation Casting process results in more fine and homogeneous structure compared to the nonablated casting.The feedability improved,SDAS reduced to 35% and porosity content decreased to 3.84 vol.% by implementing this process.It concluded the Ablation Casting is an effective process to gain higher quality in aluminum foundry.

  7. Al - BASED CAST COMPOSITES

    Rakesh Kumar Yadav

    2011-08-01

    Full Text Available The economy is very important feature nowadays in themarket. The researches are playing an important role inengineering field to increase the life of machine parts /components and decrease the cost. The compositematerials have the potential to replace widely used steeland aluminium due to their good characteristics withbetter performance. The Al-based composites have foundextensive applications in automobile industries andaerospace industries due to their increased stiffness,strength, thermal conductivity and wear resistanceproperties. A number of particulate phases have beenemployed in the Al-alloy matrix. The cast aluminiumceramicparticulate composites are finding applications inpistons, connecting rods, cylinder liner, engine cylinderblock, electrical contacts etc.The present investigation isbased on study of the effect of particulate phase on theSEM study, micro-hardness, elastic modulus, tensilestrength and the wear behaviour of Al-5 % SiC-7 % Fe,Al-10 % SiC-6 % Fe and Al-15 % SiC-5 % Fe composites.

  8. Centrifugally cast for top performance

    Centrifugally cast nickel-chromium alloy components, supplied by Fahralloy-Wisconsin Ltd. are being used for the lattice tubes in CANDU reactors. Horizontal centrifugal casting facilities enable tubular shapes to be made with outside diameters of 3 to 23 in.; lengths of up to 162 in. A unique feature of horizontal casting is that the mechanical properties are the same in all directions. The structure is also completely homogeneous and combines characteristically high resistance to heat and corrosion with enhanced physical and mechanical properties. (R.A.)

  9. Development and Determination of the Age Hardening Characteristics of Al-2.00Mg-2.66Si Wrought Alloy

    Ihom, A.P.; Offiong, Aniekan

    2016-01-01

    International audience The study, was carried out by developing the alloy using the foundry route of melting, alloying, and casting. The produced test samples were machined to produce test specimens which were subjected to precipitation hardening treatment. The test specimens were for impact and hardness test to inference the response of the developed alloy to age hardening treatment. The ageing temperature was 190 o C, and the ageing time was from 1-5 hrs. The control specimen was not age...

  10. Modelling of flow phenomena during DC casting

    Zuidema, J.

    2005-01-01

    Modelling of Flow Phenomena during DC Casting Jan Zuidema The production of aluminium ingots, by semi-continuous casting, is a complex process. DC Casting stands for direct chill casting. During this process liquid aluminium transforms to solid aluminium while cooling down. This is not an instanta

  11. Casting technique for light metal alloy

    Light metal alloys such as aluminum, magnesium, zinc and etc. can be produced in the various forms by casting technique. The casting technique for aluminum is classified as mold casting either using a sand mold or permanent mold; or both. Aluminum alloys casting are the most versatile of all common foundry alloys and generally have the highest castability ratings. Aluminum is adaptable to many of the commonly used casting methods and can be readily cast in metal molds. This work is attempted to investigate the availability and reliability of casting technique in obtaining of finish product. (Author)

  12. Niobium in gray cast iron

    The potential for utilization of niobium in gray cast iron is appraised and reviewed. Experiments described in literature indicate that niobium provides structural refinement of the eutectic cells and also promotes pearlite formation. (Author)

  13. Colour Metallography of Cast Iron

    Zhou Jiyang

    2009-01-01

    @@ Preface Cast iron, as a traditional metal material, has advantages of low total cost, good castability and machinability, good wear resistance and low notch sensitivity, and is still facing tough challenge in quality, property and variety of types etc.

  14. Colour Metallography of Cast Iron

    Zhou Jiyang; Liu Jincheng

    2011-01-01

    @@ Vermicular graphite cast iron(VG iron for short in the following sections)is a type of cast iron in which the graphite is intermediate in shape between flake and spheroidal.Compared with the normal flake graphite in grey iron, the graphite in VG iron is shorter and thicker and shows a curved, more rounded shape.Because its outer contour is exactly like a worm, hence it is called vermicular graphite.

  15. Inoculation of chromium white cast iron

    D. Kopyciński

    2009-01-01

    Full Text Available It has been proved that an addition of boron carbide introduced as an inoculant to the chromium white cast iron changes the structureof castings. Castings after inoculation revealed a different structure with numerous grains. Primary precipitates of chromium carbide also appeared, reducing the mechanical properties of as-cast parts. Properly established heat treatment regime makes chromium iron castings regain their, originally high, mechanical properties.

  16. Inoculation of chromium white cast iron

    D. Kopyciński

    2009-01-01

    It has been proved that an addition of boron carbide introduced as an inoculant to the chromium white cast iron changes the structureof castings. Castings after inoculation revealed a different structure with numerous grains. Primary precipitates of chromium carbide also appeared, reducing the mechanical properties of as-cast parts. Properly established heat treatment regime makes chromium iron castings regain their, originally high, mechanical properties.

  17. Modelling of flow phenomena during DC casting

    Zuidema, J.

    2005-01-01

    Modelling of Flow Phenomena during DC Casting Jan Zuidema The production of aluminium ingots, by semi-continuous casting, is a complex process. DC Casting stands for direct chill casting. During this process liquid aluminium transforms to solid aluminium while cooling down. This is not an instantaneous transformation, but occurs in temperature interval. In the casting process the latent heat is moved away by convection and conduction. A number of problems may occur during solidification, beca...

  18. Virtualisation of casting engineering

    J.S. Suchy

    2007-09-01

    Full Text Available Purpose: Fast response to an enquiry, minimization of costs of identification of best-suited process solution, as well as a capacity to tackle new challenges is the shortest description of the requirements posed by the contemporary market of machines and equipment. These, in consequence, called for making use of mathematical models and their solution by means of simulation algorithms.Design/methodology/approach: The notable effectiveness of numerical methods streamlined the production preparation process. Maintaining competitiveness, even more tough because of economic factors, is only possible due to cost-effective operation, high quality and well-timed order completion. These, on the other hand, can be facilitated by a broad application of IT tools aiding production management and preparation.Findings: Integration of systems aiding design processes, systems used for simulating selected elements of technologies, as well as of systems supporting instrumentation manufacturing calls for a need to solve a number of complex problems related to IT, mathematical modelling, logistics and knowledge management. Software packages for a simulation of processes that are indispensable in order to achieve the designed distribution of matter structures and condition are of particular importance.Research limitations/implications: Despite the fact that there is a wide range of software for these purposes available on the market, there is a need to build and integrate into IT systems new purpose-developed solutions customised to technologies applied and non-standard problems.Originality/value: Virtualization of casting engineering

  19. Untouchable castes of Uttar Pradesh

    Kharinin Artem Igorevich

    2015-04-01

    Full Text Available The Untouchable Castes of Uttar Pradesh are examined in this article. This region is one of the most populated in India. Also it is one of the most social mixed-composed in whole State. That’s why main conclusions which were made on this material can be extrapolated to all social space of country. The authors choose four ethno-caste groups, which represent the majority in untouchables and the three smallest in jaties. Their positions in regional hierarchy and economic specialization are analyzed in detail. There are a lot of information about their number, social structure, literacy rating, endogamy, day-to-day practices, customs and other features. Special accents were pointed on mind orientation of their elites toward integration in modern society or, conversely, toward the conservation of traditional forms of existence. The issues of origin and social evolution of untouchable castes of Uttar Pradesh are examined. There is assessment of castes’ sanskritization or other forms of social selfdevelopment. The quality of “scheduled” castes social environment is analyzed. As a marks of its positiveness the data about discrimination untouchables from other social groups and degree of political representativeness of “scheduled” castes, accessibility of education and labour were chosen. The conclusions were made about development degree of some castes. The factors that play role in positive changes in contemporary conditions were determined. The authors put forward their own hypothesis of future development of untouchable castes in Uttar Pradesh. Empiric base of this article was established on sources that have Indian origin and historical and social research of outstanding western indologies.

  20. Fillability of Thin-Wall Steel Castings

    Robert C. Voigt; Joseph Bertoletti; Andrew Kaley; Sandi Ricotta; Travis Sunday

    2002-07-30

    The use of steel components is being challenged by lighter nonferrous or cast iron components. The development of techniques for enhancing and ensuring the filability of thin-wall mold cavities is most critical for thinner wall cast steel production. The purpose of this research was to develop thin-wall casting techniques that can be used to reliably produce thin-wall castings from traditional gravity poured sand casting processes. The focus of the research was to enhance the filling behavior to prevent misrunds. Experiments were conducted to investigate the influence of various foundry variables on the filling of thin section steel castings. These variables include casting design, heat transfer, gating design, and metal fluidity. Wall thickness and pouring temperature have the greatest effect on casting fill. As wall thickness increases the volume to surface area of the casting increases, which increases the solidification time, allowing the metal to flow further in thicker sect ions. Pouring time is another significant variable affecting casting fill. Increases or decreases of 20% in the pouring time were found to have a significant effect on the filling of thin-wall production castings. Gating variables, including venting, pouring head height, and mold tilting also significantly affected thin-wall casting fill. Filters offer less turbulent, steadier flow, which is appropriate for thicker castings, but they do not enhance thin-wall casting fill.

  1. Instant Casting Movie Theater: The Future Cast System

    Maejima, Akinobu; Wemler, Shuhei; Machida, Tamotsu; Takebayashi, Masao; Morishima, Shigeo

    We have developed a visual entertainment system called “Future Cast” which enables anyone to easily participate in a pre-recorded or pre-created film as an instant CG movie star. This system provides audiences with the amazing opportunity to join the cast of a movie in real-time. The Future Cast System can automatically perform all the processes required to make this possible, from capturing participants' facial characteristics to rendering them into the movie. Our system can also be applied to any movie created using the same production process. We conducted our first experimental trial demonstration of the Future Cast System at the Mitsui-Toshiba pavilion at the 2005 World Exposition in Aichi Japan.

  2. Research progress on squeeze casting in China

    Li Yuanyuan; Zhang Weiwen; Zhao Haidong; You Dongdong; Zhang Datong; Shao Ming; Zhang Wen

    2014-01-01

    Squeeze casting is a technology with short route, high efficiency and precise forming, possessing features of casting and plastic processing. It is widely used to produce high performance metallic structural parts. As energy conservation and environmental protection concerns have risen, lightweight and high performance metal parts are urgently needed, which accelerated the development of squeeze casting technology over the past two decades in China. In this paper, research progress on squeeze casting aloys, typical parts manufacturing and development of squeeze casting equipment in China are introduced. The future trend and development priorities of squeeze casting are discussed.

  3. Research on the squeeze cast technology of the castings with large ratio of height to thickness

    LI Chen-xi; SAN Jing-chao; XU Na; CAO Liang; BAI Yan-hua; LI Rong-de

    2005-01-01

    The squeeze cast technology is only applicable, at present, to the castings with a ratio of height to thickness less than 3.5. Researching the squeeze cast technology for castings with a large ratio of height to thickness will broaden the applicable range of the advanced casting technology. This paper describes a study of the temperature distribution during solidification for castings with a ratio of height to thickness of 7 by the methods of experiment and computer simulation. The shrinkage porosity distribution in the castings and the mechanical properties of the castings were also researched. The experimental and simulated results show that increasing squeeze force, or enhancing mold temperature,cannot reduce the shrinkage porosities in the castings. When castings solidify in a sequential manner and the squeeze force effectively acts on the surface of the liquid metal, the shrinkage porosities in the castings are eliminated and mechanical properties are clearly improved.

  4. Centrifugal slip casting of components

    Research in layered and functionally gradient materials has emerged because of the increasing demand for high-performance engineering materials. Many techniques have been used to produce layered and functionally gradient components. Common examples include thermal spray processing, powder processing, chemical and physical vapor deposition, high-temperature or combustion synthesis, diffusion treatments, microwave processing and infiltration. Of these techniques, powder processing routes offer excellent microstructural control and product quality, and they are capable of producing large components. Centrifugal slip casting is a powder-processing technique combining the effects of slip casting and centrifugation. In slip casting, consolidation takes place as fluid is removed by the porous mold. Particles within the slip move with the suspending fluid until reaching the mold wall, at which point they are consolidated. In centrifugation, particles within the slip move through the fluid at a rate dependent upon the gravitational force and particle drag

  5. Search for chameleons with CAST

    Anastassopoulos, V.; Arik, M.; Aune, S.(IRFU, Centre d' Etudes Nucléaires de Saclay (CEA-Saclay), Gif-sur-Yvette, France); Barth, K.; Belov, A.; Bräuninger, H.; Cantatore, G.; Carmona, J.M.; Cetin, S.A.; Christensen, F.; J. I. Collar; T. Dafni; Davenport, M.; K. Desch; Dermenev, A.

    2015-01-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter ($\\\\beta_{\\\\rm m}$) and to photons ($\\\\beta_{\\\\gamma}$) via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1$\\\\,$keV to 400$\\\\,$eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600$\\\\,$eV. Even t...

  6. Now-casting Irish GDP

    D'Agostino, Antonello; McQuinn, Kieran; O'Brien, Derry

    2008-01-01

    In this paper we present "now-casts" of Irish GDP using timely data from a panel data set of 41 different variables. The approach seeks to resolve two issues which commonly confront forecastors of GDP - how to parsimoniously avail of the many different series, which can potentially influence GDP and how to reconcile the within-quarterly release of many of these series with the quarterly estimates of GDP? The now-casts in this paper are generated by firstly, using dynamic factor analysis to ex...

  7. Cementite Solidification in Cast Iron

    Coronado, J. J.; Sinatora, A.; Albertin, E.

    2014-06-01

    Two hypereutectic cast irons (5.01 pct Cr and 5.19 pct V) were cast and the polished surfaces of test pieces were deep-etched and analyzed via scanning electron microscopy. The results show that graphite lamellae intersect the cementite and a thin austenite film nucleates and grows on the cementite plates. For both compositions, graphite and cementite can coexist as equilibrium phases, with the former always nucleating and growing first. The eutectic carbides grow from the austenite dendrites in a direction perpendicular to the primary plates.

  8. Casting behavior of titanium alloys in a centrifugal casting machine.

    Watanabe, K; Miyakawa, O; Takada, Y; Okuno, O; Okabe, T

    2003-05-01

    Since dental casting requires replication of complex shapes with great accuracy, this study examined how well some commercial titanium alloys and experimental titanium-copper alloys filled a mold cavity. The metals examined were three types of commercial dental titanium [commercially pure titanium (hereinafter noted as CP-Ti), Ti-6Al-4V (T64) and Ti-6Al-7Nb (T67)], and experimental titanium-copper alloys [3%, 5% and 10% Cu (mass %)]. The volume percentage filling the cavity was evaluated in castings prepared in a very thin perforated sheet pattern and cast in a centrifugal casting machine. The flow behavior of the molten metal was also examined using a so-called "tracer element technique." The amounts of CP-Ti and all the Ti-Cu alloys filling the cavity were similar; less T64 and T67 filled the cavity. However, the Ti-Cu alloys failed to reach the end of the cavities due to a lower fluidity compared to the other metals. A mold prepared with specially designed perforated sheets was effective at differentiating the flow behavior of the metals tested. The present technique also revealed that the more viscous Ti-Cu alloys with a wide freezing range failed to sequentially flow to the end of the cavity. PMID:12593955

  9. WEAR-RESISTANCE OF CHROMIC CAST IRONS OF EUTECTIC COMPOSITION

    K. E. Baranovskij

    2009-01-01

    Full Text Available Casting of wear-resistant chrome cast irons in combined molds and iron chills is studied. Application of these ways of casting results in blending of carbides and increasing of hardness of castings.

  10. The heat treatment of Fermanal cast steel

    F. Binczyk; A. Smoliński; J. Szymszal

    2007-01-01

    The study discloses the results of microstructural examinations, testing of magnetic properties and hardness measurements as cast and after heat treatment conducted on the Fermanal cast steel. A characteristic feature of this cast steel is its density lower by about 10% than the density of carbon cast steel [4]. It has been proved that the factor deciding about the composition of microstructure (fraction of ferrite and austenite) is the content of aluminium. The matrix totally austenitic is p...

  11. Developing technological process of obtaining giality casts

    A. Issagulov

    2014-10-01

    Full Text Available The article considers the process of manufacturing castings using sand-resin forms and alloying furnace. Were the optimal technological parameters of manufacturing shell molds for the manufacture of castings of heating equipment. Using the same upon receipt of castings by casting in shell molds furnace alloying and deoxidation of the metal will provide consumers with quality products and have a positive impact on the economy in general engineering.

  12. Chimerical categories: caste, race, and genetics.

    Sabir, Sharjeel

    2003-12-01

    Is discrimination based on caste equivalent to racism? This paper explores the complex relationship between genetic, race and caste. It also discusses the debate over the exclusion of a discussion of caste-based discrimination at the 2001 World Conference against Racism, Racial Discrimination, Xenophobia and Related Intolerance held in Durban, South Africa. PMID:14768649

  13. Pressure distribution in centrifugal dental casting.

    Nielsen, J P

    1978-02-01

    Equations are developed for liquid metal pressure in centrifugal dental casting, given the instantaneous rotational velocity, density, and certain dimensions of the casting machine and casting pattern. A "reference parabola" is introduced making the fluid pressure concept more understandable. A specially designed specimen demonstrates experimentally the reference parabola at freezing. PMID:355283

  14. Colour Metallography of Cast Iron

    Zhou Jiyang; Liu Jincheng

    2010-01-01

    @@ Spheroidal Graphite Cast Iron(Ⅳ) 3.7 Segregation of SG iron The non-uniform distribution of solute elements during solidification results in the micro segregation of SG iron.As for the redistribution of elements in the phases of the solidification structure,there is no intrinsic difference between SG iron and grey iron[132].

  15. Inoculation Effects of Cast Iron

    E. Fraś

    2012-12-01

    Full Text Available The paper presents a solidification sequence of graphite eutectic cells of A and D types, as well as globular and cementite eutectics. The morphology of eutectic cells in cast iron, the equations for their growth and the distances between the graphite precipitations in A and D eutectic types were analyzed. It is observed a critical eutectic growth rate at which one type of eutectic transformed into another. A mathematical formula was derived that combined the maximum degree of undercooling, the cooling rate of cast iron, eutectic cell count and the eutectic growth rate. One type of eutectic structure turned smoothly into the other at a particular transition rate, transformation temperature and transformational eutectic cell count. Inoculation of cast iron increased the number of eutectic cells with flake graphite and the graphite nodule count in ductile iron, while reducing the undercooling. An increase in intensity of inoculation caused a smooth transition from a cementite eutectic structure to a mixture of cementite and D type eutectic structure, then to a mixture of D and A types of eutectics up to the presence of only the A type of eutectic structure. Moreover, the mechanism of inoculation of cast iron was studied.

  16. Search for chameleons with CAST

    Anastassopoulos, V.; Arik, M.; Aune, S.;

    2015-01-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter (βm) and to photons (βΥ) via the Primako eect. By reducing the X-ray detectio...

  17. Advanced Lost Foam Casting Technology

    Charles E. Bates; Harry E. Littleton; Don Askeland; Taras Molibog; Jason Hopper; Ben Vatankhah

    2000-11-30

    This report describes the research done under the six tasks to improve the process and make it more functional in an industrial environment. Task 1: Pattern Pyrolysis Products and Pattern Properties Task 2: Coating Quality Control Task 3: Fill and Solidification Code Task 4: Alternate Pattern Materials Task 5: Casting Distortion Task 6: Technology Transfer

  18. CENTRIFUGAL CASTING OF ANTIFRICTION SILUMIN

    V. Ju. Stetsenko; A. I. Rivkin; A. P. Gutev

    2016-01-01

    It is shown that the way of centrifugal casting into water-cooled mould with vertical rotation axis enables to receive hollow slugs with diameter 100–250 mm, with height under 200 mm with wall thickness under 15 mm of antifriction silumin АК15М3, which will replace expensive antifriction bronze.

  19. CENTRIFUGAL CASTING OF ANTIFRICTION SILUMIN

    V. Ju. Stetsenko

    2016-02-01

    Full Text Available It is shown that the way of centrifugal casting into water-cooled mould with vertical rotation axis enables to receive hollow slugs with diameter 100–250 mm, with height under 200 mm with wall thickness under 15 mm of antifriction silumin АК15М3, which will replace expensive antifriction bronze.

  20. CastML – a language for description of casting products and processes

    A. Stawowy; R. Wrona; A. Macioł

    2008-01-01

    This work presents CastML – an XML dialect for description of casting products and processes. CastML is extension of MatML which is an extensible markup language designed specifically for the exchange of materials information. The set of CastML tags allows to describe materials’ information as well as technological processes, engineering drawings, products classifications and products manufacturers. CastML is simple, understandable and flexible language which makes it attractive for the speci...

  1. Studies of the transition zone in steel – chromium cast iron bimetallic casting

    S. Tenerowicz

    2010-01-01

    Full Text Available In this work authors presented the results of transition zone studies on steel – cast iron interface in bimetallic casting. During the investigations cylindrical castings with different diameter were prepared of cast iron with steel rods placed in the center. From each bimetallic casting a microsection was prepared for microhardness tests and metalographic analysis, consisting of transition zone measurement, point and linear analysis as well as quantitative analysis.

  2. Effect of Cu, Zn, and Mg Concentration on Heat Treating Behavior of Squeeze Cast Al-(10 to 12Zn-(3.0 to 3.4Mg-(0.8 to 1Cu

    J.B. Ferguson

    2014-06-01

    Full Text Available Aluminum Alloy AA-7034 is a high strength wrought alloy with reasonable ductility containing 10–12 wt% Zn, 2–3 wt% Mg, and 0.8–1.2 wt% Cu. This work investigates the effect of varying the concentration of Zn (10–12 wt% and Cu (0.8–1 wt% on the solutionizing and aging behavior of squeeze cast AA-7034 samples. The same behaviors were investigated when Mg content was increased beyond 3 wt%. The solutionizing heat treatment dissolved much of the macroscopic second phases present in the as-cast AA-7034 alloys, but a significant amount of second phases remain after solutionizing in alloys with >3 wt% Mg. The behaviors of the various Al-Zn-Mg-Cu alloys are compared to squeeze cast Al-A206 casting alloy heat-treated to the T7 condition. All Al-Zn-Mg-Cu alloys obtained higher hardness values than those obtained by Al-A206-T7.

  3. Process development of thin strip steel casting

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

    1990-12-01

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

  4. Prediction of Part Distortion in Die Casting

    R. Allen Miller

    2005-03-30

    The die casting process is one of the net shape manufacturing techniques and is widely used to produce high production castings with tight tolerances for many industries. An understanding of the stress distribution and the deformation pattern of parts produced by die casting will result in less deviation from the part design specification, a better die design and eventually more productivity and cost savings. This report presents methods that can be used to simulate the die casting process in order to predict the deformation and stresses in the produced part and assesses the degree to which distortion modeling is practical for die casting at the current time. A coupled thermal-mechanical finite elements model was used to simulate the die casting process. The simulation models the effect of thermal and mechanical interaction between the casting and the die. It also includes the temperature dependant material properties of the casting. Based on a designed experiment, a sensitivity analysis was conducted on the model to investigate the effect of key factors. These factors include the casting material model, material properties and thermal interaction between casting and dies. To verify the casting distortion predictions, it was compared against the measured dimensions of produced parts. The comparison included dimensions along and across the parting plane and the flatness of one surface.

  5. Fabrication of sacrificial anode cathodic protection through casting method

    Aluminum is one of the few metals that can be cast by all of the processes used in casting metals. These processes consist of die casting, permanent mold casting, sand casting (green sand and dry sand), plaster casting, investment casting, and continuous casting. Other processes such as lost foam, squeeze casting, and hot isostatic pressing are also used. Permanent mold casting method was selected in which used for fabricating of sacrificial anode cathodic protection. This product was ground for surface finished and fabricated in the cylindrical form and reinforced with carbon steel at a center of the anode. (Author)

  6. Recent developments of InteCAST software and its applications on special castings

    2005-01-01

    with the development of computer technology, foundry CAE technology has made rapid progress. Commercial software packages of casting process simulation, therefore, have become more and more practical. This paper introduces both the recent developments and some applications of InteCAST software, a commercial numerical simulation software package for foundry industry, with more than 120 customers all over the world. The function modules of InteCAST8.0 and some new techniques, such as uneven mesh technology for mold filling simulation and numerical mouse technology for data visualization, were introduced. Several applications on special castings such as investment casting, low pressure die casting, and high pressure die casting, were given. These applications showed that the software can help engineers to optimize casting process by forecasting casting defect.

  7. Inner surface roughness of complete cast crowns made by centrifugal casting machines.

    Ogura, H; Raptis, C N; Asgar, K

    1981-05-01

    Six variables that could affect the surface roughness of a casting were investigated. The variables were (1) type of alloy, (2) mold temperature, (3) metal casting temperature, (4) casting machine, (5) sandblasting, and (6) location of each section. It was determined that the training portion of a complete cast crown had rougher surfaces than the leading portion. Higher mold and casting temperatures produced rougher castings, and this effect was more pronounced in the case of the base metal alloy. Sandblasting reduced the roughness, but produced scratched surfaces. Sandblasting had a more pronounced affect on the surface roughness of the base metal alloy cast either at a higher mold temperature or metal casting temperature. The morphology and the roughness profile of the original cast surface differed considerably with the type of alloy used. PMID:7012322

  8. Search for chameleons with CAST

    Anastassopoulos, V; Aune, S; Barth, K; Belov, A; Bräuninger, H; Cantatore, G; Carmona, J M; Cetin, S A; Christensen, F; Collar, J I; Dafni, T; Davenport, M; Desch, K; Dermenev, A; Eleftheriadis, C; Fanourakis, G; Ferrer-Ribas, E; Friedrich, P; Galán, J; García, J A; Gardikiotis, A; Garza, J G; Gazis, E N; Geralis, T; Giomataris, I; Hailey, C; Haug, F; Hasinoff, M D; Hofmann, D H H; Iguaz, F J; Irastorza, I G; Jacoby, J; Jakobsen, A; Jakovčić, K; Kaminski, J; Karuza, M; Kavuk, M; Krčmar, M; Krieger, C; Krüger, A; Lakić, B; Laurent, J M; Liolios, A; Ljubičić, A; Luzón, G; Neff, S; Ortega, I; Papaevangelou, T; Pivovarov, M J; Raffelt, G; Riege, H; Rosu, M; Ruz, J; Savvidis, I; Solanki, S K; Vafeiadis, T; Villar, J A; Vogel, J K; Yildiz, S C; Zioutas, K; Brax, P; Lavrentyev, I; Upadhye, A

    2015-01-01

    In this work we present a search for (solar) chameleons with the CERN Axion Solar Telescope (CAST). This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter ($\\beta_{\\rm m}$) and to photons ($\\beta_{\\gamma}$) via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1$\\,$keV to 400$\\,$eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600$\\,$eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of $\\beta_{\\gamma}\\!\\lesssim\\!10^{11}$ for $1<\\beta_{\\rm m}<10^6$.

  9. Search for chameleons with CAST

    V. Anastassopoulos

    2015-10-01

    Full Text Available In this work we present a search for (solar chameleons with the CERN Axion Solar Telescope (CAST. This novel experimental technique, in the field of dark energy research, exploits both the chameleon coupling to matter (βm and to photons (βγ via the Primakoff effect. By reducing the X-ray detection energy threshold used for axions from 1 keV to 400 eV CAST became sensitive to the converted solar chameleon spectrum which peaks around 600 eV. Even though we have not observed any excess above background, we can provide a 95% C.L. limit for the coupling strength of chameleons to photons of βγ≲1011 for 1<βm<106.

  10. Casting and Mechanized Titanium Restorations

    Madrigal, A.; Lopez, I; Suarez, MJ; Salido, MP.

    2002-01-01

    INTRODUCTION: New materials and methods for clinical dentistry are continuously being introduced. There is a growing interest in the use of titanium as a restorative material for several reasons: its relatively low cost, favorable physical properties and biocompatibility. However, titanium is technically more difficult to handle than conventional metal alloys. There are two fabrication methods for titanium restorations: casting and mechanized (a combination of machine duplication and spark er...

  11. Al-Al compound casting

    Papis, Konrad; Uggowitzer, Peter; Loeffler, Joerg [ETH Zurich, Laboratory of Metal Physics and Technology, Zurich (Switzerland)

    2007-07-01

    'Compound casting' is a process where a melt is cast onto or around a solid metallic 'insert'. It is the realization of a simple joining procedure for light metals aimed at weight-saving. Difficulties inherent in joining aluminium are its natural oxide layer and the formation of intermetallic phases. In this project, both the solid substrate and the melt used are aluminium alloys containing various alloying elements (Cu, Si, Zn in the melt, Mg in the substrate). Compounds with flawless interfaces (no contraction defects, no oxides) were successfully produced by replacing the oxide layer with a zinc layer. This was accomplished by pickling the substrate in a solution containing zincate ions, implying a redox reaction by which zinc is deposited in its metallic form. The composition and mechanical properties of the compounds' interfacial regions were investigated by SEM/EDX and microhardness measurements following the 'compound casting' process and successive heat treatments. DICTRA calculations were carried out to simulate the diffusion processes at the interface. The results from the mechanical characterization were compared to the simulations, the conclusion being that diffusion of alloying elements led to precipitation hardening of the compound.

  12. Rubber molds for investment casting

    The main objective of the project is to investigate different types of molding rubbers used for investment casting. The level of shape complexity which can be achieved by using these rubber molds is also studied. It was almost impossible to make complex shapes molds using metal molds, in that cases rubber molds are very important because they arc flexible and give accurate and precise part dimensions. Turbine blades are hi-tech components with air-foil geometries that have close dimensional tolerances. They are made of super-alloys and manufactured by investment casting. The final blade profile depends upon the dimensional accuracy in each of the processing steps. In the present work experimental study for the production of high quality low cost castings of turbine blades using rubber molds and injected wax patterns is presented. Natural Rubber molds and wax patterns from these molds were made. Different types of molding rubbers were studied including natural rubber, silicone rubber and liquid silicone rubber. It was found that by using rubber molds we can make most complex shape with very less finishing required. The shrinkage was 12% as compared to original master pattern. Rubber molds were made using laboratory hot press. Three layers of rubber above and below the master pattern. After that vulcanization was done by giving temperature and pressure. (author)

  13. Computer precision simulation for titanium casting centrifugal mold filling of prescision titanium castings

    Daming XU

    2004-08-01

    Full Text Available Computer simulation codes were developed based on proposed mathematical model for centrifugal mold filling processes and previous computer software for 3D mold filling and solidification of castings. Sample simulations were implemented for mold filling processes of precision titanium castings under gravity and different centrifugal casting techniques. The computation results show that the alloy melt has a much stronger mold filling ability for thin section castings unde a centrifugal force field than that only under the gravity. A "return back" mold filling manner is showed to be a reasonable technique for centrifugal casting processes, especially for thin section prcision castings.

  14. Gating of Permanent Molds for ALuminum Casting

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-03-30

    This report summarizes a two-year project, DE-FC07-01ID13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings.

  15. Clean Cast Steel Technology, Phase IV

    Charles E. Bates

    2003-02-24

    The objective of the Clean Cast Steel Technology Program was to improve casting product quality by removing or minimizing oxide defects and to allow the production of higher integrity castings for high speed machining lines. Previous research has concentrated on macro-inclusions that break, chip, or crack machine tool cutters and drills and cause immediate shutdown of the machining lines. The overall goal of the project is to reduce the amount of surface macro-inclusions and improve the machinability of steel castings. Macro-inclusions and improve the machinability of steel castings. Macro-inclusions have been identified by industrial sponsors as a major barrier to improving the quality and marketability of steel castings.

  16. Chilling Tendency and Chill of Cast Iron

    E. Fra(s); M. Górny; W. Kapturkiewicz; H. López

    2008-01-01

    An analytical expression is presented for the susceptibility of liquid cast iron to solidify according tothe Fe-C-X metastable system (also known as the chilling tendency of cast iron, CT). The analysis incorpo-rates the nucleation and growth processes associated with the eutectic transformation. The CT is related tothe physicochemical state of the liquid, the eutectic cells in the flake graphite, and the number of nodules innodular cast iron. In particular, the CT can be related to the critical wall thickness, Scr, or the chill width, Wcr,in wedge shaped castings. Finally, this work serves as a guide for understanding the effect of technical fac-tors such as the melt chemistry, the spheroidizing and inoculation practice, and the holding time and tam-perature on the resultant CT and chill of the cast iron. Theoretical calculations of Scr and Wcr compare wellwith experimental data for flake graphite and nodular cast iron.

  17. Investigation on Structure and Properties of Brass Casting

    M.M.Haque; A.A.Khan

    2008-01-01

    In this work, alpha (α) brass was poured in green sand mould and metallic chill mould at about 1050℃. Sand casting method and metallic chill casting method are representing the slow and fast cooling rates of the castings, respectively. The slow cooling rate in the sand mould produces larger grains, while the metallic chill mould produces smaller grains in the castings. As the grain size decreases, the strength of the cast brass increases; micro-porosity in the casting decreases and the tendency for the casting to fracture during solidification decreases. Thus, the faster cooling rate casting offers higher strength, density and hardness compared to the slow cooling rate casting.

  18. RESEARCH AND APPLICATION OF AS-CAST WEAR RESISTANCE HIGH CHROMIUM CAST IRON

    1998-01-01

    The influence of alloy elements, such as boron and silicon, on the microstructure and properties of as-cast high chromium cast iron is studied. The results show that boron and silicon have a great effect on the mechanical properties and the wear resistance. Through proper addition of boron and silicon, the properties of as-cast high chromium cast iron can be improved effectively. Through analyzing the distribution of elements by scanning electron microscope, it has been shown that the addition of boron and silicon lowers the mass fraction of chromium saturated in as-cast austenite, and makes it unstable and liable to be transformed into martensite. The as-cast high chromium cast iron with proper content of boron and silicon is suitable for the manufacture of lining for asphalt concrete mixer and its wear resistance is 14 times that of lining made of low alloy white cast iron.

  19. Newly developed vacuum differential pressure casting of thin-walled complicated Al-alloy castings

    Xuanpu DONG

    2005-05-01

    Full Text Available The newly designed vacuum differential pressure casting (VDPC unit was introduced, by which the capability of the VDPC process to produce thin-walled complicated Al-alloy castings, that are free from oxides, gas pore and shrinkage cavity and thus enhance overall part quality, was studied. Experimental results were compared with those of traditional gravity pouring and vacuum suction casting. The first series of experiments were focused on investigating thecastability of thin section Al-alloy casting. In the second series of experiments the metallographic evidence, casting strength and soundness were examined. Finally, case studies of very interesting thin walled complicated casting applications were described. The advantages of the described technique have made possible to produce thin walled complicated Al-alloy casting (up to a section thickness of 1 mm, which is not practical for gravity pouring and vacuum suction casting.

  20. COOLING METHOD OF SILUMINA CASTINGS AK15M3 AT VERTICAL CENTRIFUGAL CASTING

    V. Yu. Stecenko; K. N. Baranov; A. P. Gutev

    2013-01-01

    The way of cooling of castings from silumin AK15M3 is developed at the vertical centrifugal casting, enabling to receive bimetallic blanks with high-disperse eutectic and hypereutectic microstructures and minimal allowance for machining.

  1. COOLING METHOD OF SILUMINA CASTINGS AK15M3 AT VERTICAL CENTRIFUGAL CASTING

    V. Yu. Stecenko

    2013-01-01

    Full Text Available The way of cooling of castings from silumin AK15M3 is developed at the vertical centrifugal casting, enabling to receive bimetallic blanks with high-disperse eutectic and hypereutectic microstructures and minimal allowance for machining.

  2. Physiology as a caste-defining feature

    Robinson, E. J. H.

    2009-01-01

    Division of labour is a key factor in the ecological success of social insects. Groups of individuals specializing on a particular behaviour are known as castes and are usually distinguished by morphology or age. Physiology plays a key role in both these types of caste, in either the developmental physiology which determines morphology, or the temporal changes in physiology over an insect's life. Physiological correlates of morphological or temporal caste include differences in gland structur...

  3. Thermal gradient analysis of solidifying casting

    J. Suchoń; M. Cholewa; M. Kondracki

    2008-01-01

    For description of casting solidification and crystallization process the thermal derivative analysis (TDA) is commonly used. Besides the process kinetics considered in TDA method to describe the solidification process, the thermal gradient analysis can be also used for this purpose [1, 2]. In conducted studies analysis of thermal gradient distribution inside the solidifying wedge casting was shown which enabled determination of heat flow intensity on casting section.

  4. Thermal gradient analysis of solidifying casting

    J. Suchoń

    2008-08-01

    Full Text Available For description of casting solidification and crystallization process the thermal derivative analysis (TDA is commonly used. Besides the process kinetics considered in TDA method to describe the solidification process, the thermal gradient analysis can be also used for this purpose [1, 2]. In conducted studies analysis of thermal gradient distribution inside the solidifying wedge casting was shown which enabled determination of heat flow intensity on casting section.

  5. Development and application of titanium alloy casting technology in China

    NAN Hai; XIE Cheng-mu; ZHAO Jia-qi

    2005-01-01

    The development and research of titanium cast alloy and its casting technology, especially its application inaeronautical industry in China are presented. The technology of molding, melting and casting of titanium alloy, casting quality control are introduced. The existing problems and development trend in titanium alloy casting technology are also discussed.

  6. Computer precision simulation for titanium casting centrifugal mold filling of prescision titanium castings

    Xu, Daming; LI, XIN; Geving AN

    2004-01-01

    Computer simulation codes were developed based on proposed mathematical model for centrifugal mold filling processes and previous computer software for 3D mold filling and solidification of castings. Sample simulations were implemented for mold filling processes of precision titanium castings under gravity and different centrifugal casting techniques. The computation results show that the alloy melt has a much stronger mold filling ability for thin section castings unde a centrifugal force fi...

  7. Friction Stir Processing of Cast Superalloys Project

    National Aeronautics and Space Administration — This SBIR Phase I effort examines the feasibility of an innovative fabrication technology incorporating sand casting and friction stir processing (FSP) for...

  8. Aluminium Alloy Cast Shell Development for Torpedoes

    Vijaya Singh

    2005-01-01

    Full Text Available The sand-cast aluminium alloy cylindrical shells were developed for the advanced experimental torpedo applications. The components had intricate geometry, thin-walled sections, and stringent property requirements. The casting defects, such as shrinkage, porosity, incomplete filling of thin sections, cold shuts, inclusions and dimensional eccentricity, etc were found inthe initial castings trials. improvements in casting quality were achieved through modified methodology, selective chilling, risering, and by introducing ceramic-foam filters in the gatingsystem. The heat-treated and machined components met radiographic class I grade C/E standards, mechanical properties to BS1490 specifications, and leakage and hydraulic pressure testrequirements relevant for such applications.

  9. Vacuum-sealed casting process under pressure

    LI Chen-xi; GUO Tai-ming; WU Chun-jing; WANG Hong

    2006-01-01

    A new casting method, the vacuum-sealed mold casting under pressure, has been developed, and thin wall iron castings with high precision and smooth surface have been produced successfully with this casting method. The experimental results show that the liquid iron has a very excellent filling ability because a high negative pressure is formed in the mold cavity during filling process. The vacuum-sealed mold under pressure has very high compressive strength greater than 650 kPa, which is 3-4 times as high as that of the molds produced by high-pressure molding process or vacuum-sealed molding process.

  10. Friction Stir Processing of Cast Superalloys Project

    National Aeronautics and Space Administration — This SBIR effort examines the feasibility of an innovative fabrication technology incorporating sand casting and friction stir processing (FSP) for producing...

  11. Cast functional accessories for heat treatment furnaces

    A. Drotlew

    2010-10-01

    Full Text Available The study gives examples of the cast functional accessories operating in furnaces for the heat treatment of metals and alloys. The describeddesign solutions of castings and their respective assemblies are used for charge preparation and handling. They were put in systematicorder depending on furnace design and the technological purpose of heat treatment. Basic grades of austenitic cast steel, used for castings of this type, were enumerated, and examples of general guidelines formulated for their use were stated. The functional accessories described in this study were designed and made by the Foundry Research Laboratory of West Pomeranian University of Technology.

  12. Ductile iron castings fabricated using metallic moulds

    The features and suitability of high requirements ductile iron castings production using metallic moulds have been studied in the present work. The structural and mechanical properties of the produced castings have been analysed and compared to the corresponding ones but fabricated using green sand moulds according to a conventional production process. The higher cooling rate in the metallic moulds is the main cause for the appearance of the detected structural changes in castings. The mechanical and microstructural properties obtained directly on castings are remarkable due to the higher nodule count among other factors. Finally, the benefits and inconveniences found in this kind of production methodology using metallic moulds are also discussed. (Author)

  13. Spray casting project final report

    Lockheed Martin Energy Systems, Inc. (Energy Systems), along with other participating organizations, has been exploring the feasibility of spray casting depleted uranium (DU) to near-net shape as a waste minimization effort. Although this technology would be useful in a variety of applications where DU was the material of choice, this effort was aimed primarily at gamma-shielding components for use in storage and transportation canisters for high-level radioactive waste, particularly in the Multipurpose Canister (MPC) application. In addition to the waste-minimization benefits, spray casting would simplify the manufacturing process by allowing the shielding components for MPC to be produced as a single component, as opposed to multiple components with many fabrication and assembly steps. In earlier experiments, surrogate materials were used to simulate the properties (specifically reactivity and density) of DU. Based on the positive results from those studies, the project participants decided that further evaluation of the issues and concerns that would accompany spraying DU was warranted. That evaluation occupied substantially all of Fiscal Year 1995, yielding conceptual designs for both an intermediate facility and a production facility and their associated engineering estimates. An intermediate facility was included in this study to allow further technology development in spraying DU. Although spraying DU to near-net shape seems to be feasible, a number of technical, engineering, and safety issues would need to be evaluated before proceeding with a production facility. This report is intended to document the results from the spray-casting project and to provide information needed by anyone interested in proceeding to the next step

  14. The temperature gradient on section of casting in process of primary crystallization of chromium cast iron

    A. Studnicki

    2008-08-01

    Full Text Available The methodology of defining in article was introduced the temperature gradient in process of primary crystallization during cooling the casting from chromium cast iron on basis of measurements of thermal field in test DTA-K3. Insert also the preliminary results of investigations of influence temperature gradient on structure of studied wear resistance chromium cast iron.

  15. Microdefects in cast multicrystalline silicon

    Wolf, E.; Klinger, D.; Bergmann, S. [Inst. of Crystal Growth Berlin (Germany)

    1995-08-01

    The microdefect etching behavior of cast multicrystalline BAYSIX and SILSO samples is mainly the same as that of EFG silicon, in spite of the very different growth parameters applied to these two techniques and the different carbon contents of the investigated materials. Intentional decorating of mc silicon with copper, iron and gold did not influence the results of etching and with help of infrared transmission microscopy no metal precipitates at the assumed microdefects could be established. There are many open questions concerning the origin of the assumed, not yet doubtless proved microdefects.

  16. Control of Cast Iron Microstructure

    Graham, J.; Lillybeck, N.; Franco, N.; Stefanescu, D. M.

    1985-01-01

    The use of microgravity for industrial research in the processing of cast iron was investigated. Solidification experiments were conducted using the KC-135 and F-104 aircraft, and an experiment plan was developed for follow-on experiments using the Shuttle. Three areas of interest are identified: (1) measurement of thermophysical properties in the melt; (2) understanding of the relative roles of homogeneous nucleation, grain multiplication, and innocultants in forming the microstructure; and (3) exploring the possibility of obtaining an aligned graphite structure in hypereutectic Fe, Ni, and Co.

  17. 77 to 1200 K tensile properties of several wrought superalloys after long-term 1093 K heat treatment in air and vacuum

    Whittenberger, J. D.

    1994-02-01

    The 77 to 1200 K tensile properties of approximately 1.3 mm thick wrought sheet Co-base Haynes alloy 188 and Ni-base Haynes alloy 230 and Inconel 617 have been measured after heat treatment in air and vacuum for periods up to 22,500 h at 1093 K. Significant changes in structure were produced by prior exposures, including precipitation of second phases and, in the case of heat treatment in air, oxide scale and surface-connected grain boundary pits/oxides, as deep as 50 to 70 µm, in all three superalloys. Due to the geometry of the experiment, the vacuum-exposed samples were protected from loss of volatile elements by evaporation; hence, such specimens were simply given 1093 K anneals in an innocuous environment, which produced very little surface attack. Compared to the properties of as-received alloys, prior exposure tended to reduce both the yield strength and ultimate tensile strength, with the greatest reductions at 77 and 298 K. The most dramatic effect of heat treatment was found in the low-temperature residual tensile elongation, where decreases from 40 to 5% at 77 K were found. Ductility is the only property that was found to have a consistent dependency on environment, with air exposure always yielding less tensile elongation than vacuum exposure.

  18. Effects of solution treatment and aging process on microstructure refining of semi-solid slurry of wrought aluminum alloy 7A09

    WU Xin; HAN Fei; WANG Wei-wei

    2009-01-01

    A new method was exploited using solution treatment and aging process as a pretreatment in preparing semi-solid slurry with fine microstructure before isothermal treatment of wrought aluminum alloy 7A09. Parameters of pretreatment were optimized by orthogonal experiment design and proper precursor was prepared. The evolution of microstructure of semi-solid slurry during isothermal treatment was analyzed and the mechanism of microstructure refining was discussed. The result of orthogonal experiment design shows that the optimum parameters are 462 ℃ for solution temperature, 40 min for solution time, 132 ℃ for aging temperature and 14 h for aging time. Microstructure of isothermal treatment is fine, homogenous, with globular solid grains and a solid fraction between 50% and 70%, which is qualified for later semi-solid forming process. Mechanism of microstmcture evolution includes the agglomeration of α-phase and Ostwald ripening. Precipitations prepared by solution and aging treatment prevent the grains from coarsening and promote the grain ripening to globular shape.

  19. The development of high strength corrosion resistant precipitation hardening cast steels

    Abrahams, Rachel A.

    Precipitation Hardened Cast Stainless Steels (PHCSS) are a corrosion resistant class of materials which derive their properties from secondary aging after a normalizing heat treatment step. While PHCSS materials are available in austenitic and semi-austenitic forms, the martensitic PHCSS are most widely used due to a combination of high strength, good toughness, and corrosion resistance. If higher strength levels can be achieved in these alloys, these materials can be used as a lower-cost alternative to titanium for high specific strength applications where corrosion resistance is a factor. Although wrought precipitation hardened materials have been in use and specified for more than half a century, the specification and use of PHCSS has only been recent. The effects of composition and processing on performance have received little attention in the cast steel literature. The work presented in these investigations is concerned with the experimental study and modeling of microstructural development in cast martensitic precipitation hardened steels at high strength levels. Particular attention is focused on improving the performance of the high strength CB7Cu alloy by control of detrimental secondary phases, notably delta ferrite and retained austenite, which is detrimental to strength, but potentially beneficial in terms of fracture and impact toughness. The relationship between age processing and mechanical properties is also investigated, and a new age hardening model based on simultaneous precipitation hardening and tempering has been modified for use with these steels. Because the CB7Cu system has limited strength even with improved processing, a higher strength prototype Fe-Ni-Cr-Mo-Ti system has been designed and adapted for use in casting. This prototype is expected to develop high strengths matching or exceed that of cast Ti-6Al-4V alloys. Traditional multicomponent constitution phase diagrams widely used for phase estimation in conventional stainless steels

  20. Yield Improvement in Steel Casting (Yield II)

    Richard A. Hardin; Christoph Beckermann; Tim Hays

    2002-02-18

    This report presents work conducted on the following main projects tasks undertaken in the Yield Improvement in Steel Casting research program: Improvement of Conventional Feeding and Risering Methods, Use of Unconventional Yield Improvement Techniques, and Case Studies in Yield Improvement. Casting trials were conducted and then simulated using the precise casting conditions as recorded by the participating SFSA foundries. These results present a statistically meaningful set of experimental data on soundness versus feeding length. Comparisons between these casting trials and casting trials performed more than forty years ago by Pellini and the SFSA are quite good and appear reasonable. Comparisons between the current SFSA feeding rules and feeding rules based on the minimum Niyama criterion reveal that the Niyama-based rules are generally less conservative. The niyama-based rules also agree better with both the trials presented here, and the casting trails performed by Pellini an d the SFSA years ago. Furthermore, the use of the Niyama criterion to predict centerline shrinkage for horizontally fed plate sections has a theoretical basis according to the casting literature reviewed here. These results strongly support the use of improved feeding rules for horizontal plate sections based on the Niyama criterion, which can be tailored to the casting conditions for a given alloy and to a desired level of soundness. The reliability and repeatability of ASTM shrinkage x-ray ratings was investigated in a statistical study performed on 128 x-rays, each of which were rated seven different times. A manual ''Feeding and Risering Guidelines for Steel Castings' is given in this final report. Results of casting trials performed to test unconventional techniques for improving casting yield are presented. These use a stacked arrangement of castings and riser pressurization to increase the casting yield. Riser pressurization was demonstrated to feed a casting up to

  1. Clean cast steel technology. Final report

    Bates, C.E.; Griffin, J.A.

    1998-06-01

    This report documents the results obtained from the Clean Cast Steel Technology Program financially supported by the DOE Metal Casting Competitiveness Research Program and industry. The primary objective of this program is to develop technology for delivering steel free of oxide macroinclusions to mold cavities. The overall objective is to improve the quality of cast steel by developing and demonstrating the technology for substantially reducing surface and sub-surface oxide inclusions. Two approaches are discussed here. A total of 23 castings were produced by submerge pouring along with sixty conventionally poured castings. The submerged poured castings contained, on average, 96% fewer observable surface inclusions (11.9 vs 0.4) compared to the conventionally poured cast parts. The variation in the population of surface inclusions also decreased by 88% from 5.5 to 0.7. The machinability of the casting was also improved by submerged pouring. The submerge poured castings required fewer cutting tool changes and less operator intervention during machining. Subsequent to these trials, the foundry has decided to purchase more shrouds for continued experimentation on other problem castings where submerge pouring is possible. An examination of melting and pouring practices in four foundries has been carried out. Three of the four foundries showed significant improvement in casting quality by manipulating the melting practice. These melting practice variables can be grouped into two separate categories. The first category is the pouring and filling practice. The second category concerns the concentration of oxidizable elements contained in the steel. Silicon, manganese, and aluminum concentrations were important factors in all four foundries. Clean heats can consistently be produced through improved melting practice and reducing exposure of the steel to atmospheric oxygen during pouring and filling.

  2. Automated flaw detection scheme for cast austenitic stainless steel weld specimens using Hilbert-Huang transform of ultrasonic phased array data

    Khan, Tariq; Majumdar, Shantanu; Udpa, Lalita [Dept. of Electrical and Comupter Engineering, Michian State University, East Lansing, MI 48824 (United States); Ramuhalli, Pradeep; Crawford, Susan; Diaz, Aaron; Anderson, Michael T. [Pacific Northwest National Laboratory, Richland, WA 99354 (United States)

    2012-05-17

    The objective of this work is to develop processing algorithms to detect and localize flaws using ultrasonic phased-array data. Data was collected on cast austenitic stainless stell (CASS) weld specimens onloan from the U.S. nuclear power industry' Pressurized Walter Reactor Owners Group (PWROG) traveling specimen set. Each specimen consists of a centrifugally cast stainless stell (CCSS) pipe section welded to a statically cst(SCSS) or wrought (WRSS) section. The paper presents a novel automated flaw detection and localization scheme using low frequency ultrasonic phased array inspection singals from the weld and heat affected zone of the based materials. The major steps of the overall scheme are preprocessing and region of interest (ROI) detection followed by the Hilbert-Huang transform (HHT) of A-scans in the detected ROIs. HHT offers time-frequency-energy distribution for each ROI. The Accumulation of energy in a particular frequency band is used as a classification feature for the particular ROI.

  3. Energy use in selected metal casting facilities - 2003

    Eppich, Robert E. [Eppich Technologies, Syracuse, IN (United States)

    2004-05-01

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

  4. Laboratory grey cast iron continuous casting line with electromagnetic forced convection support

    J. Szajnar

    2010-07-01

    Full Text Available The article describes the construction of a 20 mm diameter grey cast iron ingots continuous casting laboratory line. This line is made ofthree main units: melting unit (induction furnace, casting unit and the pulling unit. In order to improve the homogeneity of themicrostructure of ingots (by applying forced convection of liquid metal during the crystallization process in this case a crystallizer system generating the forced movement of liquid metal based on a system of electrical power windings of the AC specific frequency. Thissolution allowed to obtain a homogeneous microstructure of the continuous casting of cast iron EN-GJL-200 species.

  5. Casting defects in low-pressure die-cast aluminum alloy wheels

    Zhang, B.; Cockcroft, S. L.; Maijer, D. M.; Zhu, J. D.; Phillion, A. B.

    2005-11-01

    Defects in automotive aluminum alloy casting continue to challenge metallurgists and production engineers as greater emphasis is placed on product quality and production cost. A range of casting-related defects found in low-pressure die-cast aluminum wheels were examined metallographically in samples taken from several industrial wheel-casting facilities. The defects examined include macro- and micro- porosity, entrained oxide films, and exogenous oxide inclusions. Particular emphasis is placed on the impact of these defects with respect to the three main casting-related criteria by which automotive wheel quality are judged: wheel cosmetics, air-tightness, and wheel mechanical performance.

  6. Casting fine grained, fully dense, strong inorganic materials

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

    2015-11-24

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

  7. DEVELOPMENTS IN THE FIELD OF STEEL AND CAST IRON

    Ten, E. B.; V. D. Belov

    2015-01-01

    The article describes the use of a number of promising casting technologies applied to produce the castings of steel and cast iron with special properties. Such as, technology of centrifugal casting of large-size workpieces made of steel, forecasting method composition of slag in the smelting of high-manganese steels, method of complex modifying chromium cast irons, analysis of properties of perspective high-alloy aluminium cast iron.

  8. DEVELOPMENTS IN THE FIELD OF STEEL AND CAST IRON

    E. B. Ten

    2015-05-01

    Full Text Available The article describes the use of a number of promising casting technologies applied to produce the castings of steel and cast iron with special properties. Such as, technology of centrifugal casting of large-size workpieces made of steel, forecasting method composition of slag in the smelting of high-manganese steels, method of complex modifying chromium cast irons, analysis of properties of perspective high-alloy aluminium cast iron.

  9. The heat treatment of Fermanal cast steel

    F. Binczyk

    2007-12-01

    Full Text Available The study discloses the results of microstructural examinations, testing of magnetic properties and hardness measurements as cast and after heat treatment conducted on the Fermanal cast steel. A characteristic feature of this cast steel is its density lower by about 10% than the density of carbon cast steel [4]. It has been proved that the factor deciding about the composition of microstructure (fraction of ferrite and austenite is the content of aluminium. The matrix totally austenitic is present in cast steel containing from 0,8 to 0,9% C, from 22 to 24% Mn, and from 4,5 to 5,5% Al. The magnetic properties examined on samples of the Fermanal cast steel were determined by spectroscopy of the Mössbauer effect with isotope 57Fe. The magnetic properties represented by a mean value of the hyperfine magnetic field Bhf and relative magnetic permeability were determined. It has been stated that the level of magnetic properties of the Fermanal cast steel depends on the content of ferrite. The effect of the parameters of solutioning and ageing on the cast steel microstructure and hardness after modification with additions of B, Ti and Nb was investigated.

  10. Detection of Cast Shadows in Surveillance Applications

    Erbou, Søren G.; Sørensen, Helge Bjarne Dissing; Stage, Bjarne

    2005-01-01

    Cast shadows from moving objects reduce the general ability of robust classification and tracking of these objects, in outdoor surveillance applications. A method for segmentation of cast shadows is proposed, combining statistical features with a new similarity feature, derived from a physics...

  11. Casting of Titanium and its Alloys

    R. L. Saha; K. T. Jacob

    1986-01-01

    Titaniuni and its alloys have many applications in aerospace, marine and other engineering industries. Titanium requires special melting techniques because of its high reactivity at elevated temperatures and needs special mould materials and methods for castings. This paper reviews the development of titanium casting technology.

  12. Casting of Titanium and its Alloys

    R. L. Saha

    1986-04-01

    Full Text Available Titaniuni and its alloys have many applications in aerospace, marine and other engineering industries. Titanium requires special melting techniques because of its high reactivity at elevated temperatures and needs special mould materials and methods for castings. This paper reviews the development of titanium casting technology.

  13. Spatial Bimetallic Castings Manufactured from Iron Alloys

    M. Cholewa

    2007-07-01

    Full Text Available In this paper a conception for manufacturing method of skeleton castings with composite features was shown. Main application of such castings are the working organs of machines subjected to intensive abrasive and erosive wear. Skeleton geometry was based on three-dimensional cubic net consisting of circular connectors and nodes joining 6 connectors according to Cartesian co-ordinate system. Dimension of an elementary cell was equal to 10 mm and diameter of single connector was equal to 5 mm. For bimetallic castings preparation two Fe based alloys were used: L25SHMN cast steel for skeleton substrate and ZlCr15NiMo cast iron for working part of the casting. In presented work obtained structure was analyzed with indication of characteristic regions. Authors described phenomena occurring at the alloys interface and phases in transition zone. A thesis was formulated concerning localization of transition zone at the cast iron matrix – cast steel reinforcement interface. Direction of further studies were indicated.

  14. Low-alloy constructional cast steel

    D. Bartocha

    2011-07-01

    Full Text Available Production of constructional casting competitive for welded structure of high-strength steel first of all required high metallurgical quality of cast steel. Assumptions, methodology and results of investigation which the aim was determination of the most advantageous: configuration and parameters of metallurgical treatments and ways to modify, in aspects of reach the low-alloy cast steel of the highest quality as possible, are presented. A series of low-alloy cast steel melts modeled on cast steel L20HGSNM was performed, the way of argoning in laboratory induction furnace with a capacity of 50kg was worked out, modifications with additions of FeNb, FeV and master alloy MgCe were performed. During each melts samples of cast steel direct from metal bath were get and series of experimental casting was made. Chemical compositions of melted cast steel, contents of O, N and H were determined as well as influence of additions on structure and nature of impact strength samples fracture were estimated.

  15. 14 CFR 23.621 - Casting factors.

    2010-01-01

    ... structural castings except castings that are pressure tested as parts of hydraulic or other fluid systems and..., seat, berth, safety belt, and fuel and oil tank supports and attachments, and cabin pressure valves. (d... either magnetic particle, penetrant or other approved equivalent non-destructive inspection method;...

  16. The quality of the joint between alloy steel and unalloyed cast steel in bimetallic layered castings

    T. Wróbel

    2012-01-01

    Full Text Available In paper is presented technology of bimetallic layered castings based on founding method of layer coating directly in cast process so-called method of mould cavity preparation. Prepared castings consist two fundamental parts i.e. bearing part and working part (layer. The bearing part of bimetallic layered casting is typical foundry material i.e. ferritic-pearlitic unalloyed cast steel, whereas working part (layer is plate of austenitic alloy steel sort X2CrNi 18-9. The ratio of thickness between bearing and working part is 8:1. The aim of paper was assessed the quality of the joint between bearing and working part in dependence of pouring temperature and carbon concentration in cast steel. The quality of the joint in bimetallic layered castings was evaluated on the basis of ultrasonic non-destructive testing, structure and microhardness researches.

  17. Quality improvement of continuously cast round billets

    F. Chowaniec

    2008-07-01

    Full Text Available Paper is focused on the observation of the conditions causing defects origin in continuously cast billets in the first phase of solidification and shell formation in the mould. Work is also focused on the area of casting failures. Experiences were aimed at steel preparation for casting from the viewpoint of desoxidation and modification of inclusions, facility influence on solidification and formation of shell, influence of the taper of the mould, and on vibrations influence and origin within primary cooling system – oscillation mechanism – mould. The method of measurement was tested, incl. the analysis of acoustic spectrum for phenomena assessment within continuous casting. Conclusions resulted in modification and changes of shapes of moulds, incl. casting technology of round billets.

  18. Standard digital reference images for titanium castings

    American Society for Testing and Materials. Philadelphia

    2010-01-01

    1.1 The digital reference images provided in the adjunct to this standard illustrate various types and degrees of discontinuities occurring in titanium castings. Use of this standard for the specification or grading of castings requires procurement of the adjunct digital reference images, which illustrate the discontinuity types and severity levels. They are intended to provide the following: 1.1.1 A guide enabling recognition of titanium casting discontinuities and their differentiation both as to type and degree through digital radiographic examination. 1.1.2 Example digital radiographic illustrations of discontinuities and a nomenclature for reference in acceptance standards, specifications and drawings. 1.2 The digital reference images consist of seventeen digital files each illustrating eight grades of increasing severity. The files illustrate seven common discontinuity types representing casting sections up to 1-in. (25.4-mm). 1.3 The reference radiographs were developed for casting sections up to 1...

  19. The present status of dental titanium casting

    Okabe, Toru; Ohkubo, Chikahiro; Watanabe, Ikuya; Okuno, Osamu; Takada, Yukyo

    1998-09-01

    Experimentation in all aspects of titanium casting at universities and industries throughout the world for the last 20 years has made titanium and titanium-alloy casting nearly feasible for fabricating sound cast dental prostheses, including crowns, inlays, and partial and complete dentures. Titanium casting in dentistry has now almost reached the stage where it can seriously be considered as a new method to compete with dental casting using conventional noble and base-metal alloys. More than anything else, the strength of titanium’s appeal lies in its excellent biocompatibility, coupled with its comparatively low price and abundant supply. Research efforts to overcome some problems associated with this method, including studies on the development of new titanium alloys suitable for dental use, will continue at many research sites internationally.

  20. Possible segregation caused by centrifugal titanium casting.

    Watanabe, K; Okawa, S; Kanatani, M; Nakano, S; Miyakawa, O; Kobayashi, M

    1996-12-01

    The possibility of the segregation under solidification process using a centrifugal casting machine was investigated using an electron probe microanalyzer with elemental distribution map, line analysis and quantitative analysis. When a very small quantity of platinum was added to local molten titanium during the casting process, macroscopic segregation was observed under conditions of density difference of 0.1 g/cm3 at the most, confirming that the centrifugal force of the casting machine is extremely strong. When a Ti-6Al-4V alloy was cast, however, no macroscopic segregation was observed. The centrifugal force of the casting machine examined in the present study hardly results in the body-force segregation in this titanium alloy. PMID:9550020

  1. Lead casting process of shielding container for transporting nuclear assembly

    The main radiation shielding of transporting container for the reactor coolant pump hydraulic assembly is a lead casting Layer. The authors investigate in detail the lead casting process. In order to assure casting quality, the different technical design for different parts is adopted. The shielding case is completed on its first cast by bottom casting, sequential solidify etc. But the lead layer of chassis base is cast at first, then pressed, followed by machining to the right size. Casting system assure the realization of technical design. Two parts cast finally prove that the performance is in accord with requirement through NDT

  2. Bioinspired Design: Magnetic Freeze Casting

    Porter, Michael Martin

    Nature is the ultimate experimental scientist, having billions of years of evolution to design, test, and adapt a variety of multifunctional systems for a plethora of diverse applications. Next-generation materials that draw inspiration from the structure-property-function relationships of natural biological materials have led to many high-performance structural materials with hybrid, hierarchical architectures that fit form to function. In this dissertation, a novel materials processing method, magnetic freeze casting, is introduced to develop porous scaffolds and hybrid composites with micro-architectures that emulate bone, abalone nacre, and other hard biological materials. This method uses ice as a template to form ceramic-based materials with continuously, interconnected microstructures and magnetic fields to control the alignment of these structures in multiple directions. The resulting materials have anisotropic properties with enhanced mechanical performance that have potential applications as bone implants or lightweight structural composites, among others.

  3. Application of Integrated Database to the Casting Design

    In-Sung Cho; Seung-Mok Yoo; Chae-Ho Lim; Jeong-Kil Choi

    2008-01-01

    Construction of integrated database including casting shapes with their casting design, technical knowledge, and thermophysical properties of the casting alloys were introduced in the present study. Recognition tech- nique for casting design by industrial computer tomography was used for the construction of shape database. Technical knowledge of the casting processes such as ferrous and non-ferrous alloys and their manufacturing process of the castings were accumulated and the search engine for the knowledge was developed. Database of thermophysical properties of the casting alloys were obtained via the experimental study, and the properties were used for .the in-house computer simulation of casting process. The databases were linked with intelligent casting expert system developed in center for e-design, KITECH. It is expected that the databases can help non casting experts to devise the casting and its process. Various examples of the application by using the databases were shown in the present study.

  4. Effect of Some Parameters on the Cast Component Properties in Hot Chamber Die Casting

    Singh, Rupinder; Singh, Harvir

    2016-04-01

    Hot chamber die casting process is designed to achieve high dimensional accuracy for small products by forcing molten metal under high pressure into reusable moulds, called dies. The present research work is aimed at study of some parameters (as a case study of spring adjuster) on cast component properties in hot chamber die casting process. Three controllable factors of the hot chamber die casting process (namely: pressure at second phase, metal pouring temperature and die opening time) were studied at three levels each by Taguchi's parametric approach and single-response optimization was conducted to identify the main factors controlling surface hardness, dimensional accuracy and weight of the casting. Castings were produced using aluminium alloy, at recommended parameters through hot chamber die casting process. Analysis shows that in hot chamber die casting process the percentage contribution of second phase pressure, die opening time, metal pouring temperature for surface hardness is 82.48, 9.24 and 6.78 % respectively. While in the case of weight of cast component the contribution of second phase pressure is 94.03 %, followed by metal pouring temperature and die opening time (4.58 and 0.35 % respectively). Further for dimensional accuracy contribution of die opening time is 76.97 %, metal pouring temperature is 20.05 % and second phase pressure is 1.56 %. Confirmation experiments were conducted at an optimal condition showed that the surface hardness, dimensional accuracy and weight of the castings were improved significantly.

  5. Experimental study of residual stresses in laser clad AISI P20 tool steel on pre-hardened wrought P20 substrate

    Chen, J.-Y., E-mail: jianyin.chen@nrc.gc.ca [Industrial Materials Institute, National Research Council of Canada, 800 Collip Circle, London, Ontario, N6G 4X8 (Canada); Conlon, K. [Steacie Institute for Molecular Sciences, National Research Council of Canada, Chalk River Laboratories, Stn.18, Chalk River, Ontario, K0J 1J0 (Canada); Xue, L. [Industrial Materials Institute, National Research Council of Canada, 800 Collip Circle, London, Ontario, N6G 4X8 (Canada); Rogge, R. [Steacie Institute for Molecular Sciences, National Research Council of Canada, Chalk River Laboratories, Stn.18, Chalk River, Ontario, K0J 1J0 (Canada)

    2010-10-25

    Research highlights: {yields} Laser cladding of P20 tool steel. {yields} Residual stress analysis of laser clad P20 tool steel. {yields} Microstructure of laser clad P20 tool steel. {yields} Tooling Repair using laser cladding. {yields} Stress reliving treatment of laser clad P20 tool steel. - Abstract: Laser cladding is to deposit desired material onto the surface of a base material (or substrate) with a relatively low heat input to form a metallurgically sound and dense clad. This process has been successfully applied for repairing damaged high-value tooling to reduce their through-life cost. However, laser cladding, which needs to melt a small amount of a substrate along with cladding material, inevitably introduces residual stresses in both clad and substrate. The tensile residual stresses in the clad could adversely affect mechanical performance of the substrate being deposited. This paper presents an experimental study on process-induced residual stresses in laser clad AISI P20 tool steel onto pre-hardened wrought P20 base material and the correlation with microstructures using hole-drilling and neutron diffraction methods. Combined with X-ray diffraction and scanning electron microscopic analyses, the roles of solid-state phase transformations in the clad and heat-affected zone (HAZ) of the substrate during cladding and post-cladding heat treatments on the development and controllability of residual stresses in the P20 clad have been investigated, and the results could be beneficial to more effective repair of damaged plastic injection molds made by P20 tool steel.

  6. Experimental study of residual stresses in laser clad AISI P20 tool steel on pre-hardened wrought P20 substrate

    Research highlights: → Laser cladding of P20 tool steel. → Residual stress analysis of laser clad P20 tool steel. → Microstructure of laser clad P20 tool steel. → Tooling Repair using laser cladding. → Stress reliving treatment of laser clad P20 tool steel. - Abstract: Laser cladding is to deposit desired material onto the surface of a base material (or substrate) with a relatively low heat input to form a metallurgically sound and dense clad. This process has been successfully applied for repairing damaged high-value tooling to reduce their through-life cost. However, laser cladding, which needs to melt a small amount of a substrate along with cladding material, inevitably introduces residual stresses in both clad and substrate. The tensile residual stresses in the clad could adversely affect mechanical performance of the substrate being deposited. This paper presents an experimental study on process-induced residual stresses in laser clad AISI P20 tool steel onto pre-hardened wrought P20 base material and the correlation with microstructures using hole-drilling and neutron diffraction methods. Combined with X-ray diffraction and scanning electron microscopic analyses, the roles of solid-state phase transformations in the clad and heat-affected zone (HAZ) of the substrate during cladding and post-cladding heat treatments on the development and controllability of residual stresses in the P20 clad have been investigated, and the results could be beneficial to more effective repair of damaged plastic injection molds made by P20 tool steel.

  7. Characterization of Technetium Speciation in Cast Stone

    Um, Wooyong; Jung, Hun Bok; Wang, Guohui; Westsik, Joseph H.; Peterson, Reid A.

    2013-11-11

    This report describes the results from laboratory tests performed at Pacific Northwest National Laboratory (PNNL) for the U.S. Department of Energy (DOE) EM-31 Support Program (EMSP) subtask, “Production and Long-Term Performance of Low Temperature Waste Forms” to provide additional information on technetium (Tc) speciation characterization in the Cast Stone waste form. To support the use of Cast Stone as an alternative to vitrification for solidifying low-activity waste (LAW) and as the current baseline waste form for secondary waste streams at the Hanford Site, additional understanding of Tc speciation in Cast Stone is needed to predict the long-term Tc leachability from Cast Stone and to meet the regulatory disposal-facility performance requirements for the Integrated Disposal Facility (IDF). Characterizations of the Tc speciation within the Cast Stone after leaching under various conditions provide insights into how the Tc is retained and released. The data generated by the laboratory tests described in this report provide both empirical and more scientific information to increase our understanding of Tc speciation in Cast Stone and its release mechanism under relevant leaching processes for the purpose of filling data gaps and to support the long-term risk and performance assessments of Cast Stone in the IDF at the Hanford Site.

  8. Fatigue Properties of Cast Magnesium Wheels

    Li, Zhenming; Luo, Alan A.; Wang, Qigui; Peng, Liming; Zhang, Peng

    2016-05-01

    This paper investigates the fatigue properties and deformation behavior of a newly developed Mg-2.96Nd-0.21Zn-0.39Zr magnesium alloy wheel in both as-cast and T6 conditions. Compared with the as-cast alloy, the T6-treated alloy shows a significant increase in fatigue strength and cyclic stress amplitude. This is believed to be attributed to the change of defect type from porosity to oxides and the increased matrix strength in the T6 (peak-aged) condition. For the as-cast alloy wheel, fatigue failure mainly originated from the cast defects including porosity, oxide film, and inclusion at or near the sample surface. In the T6-treated alloy, however, oxides and inclusions or slip bands initiate the fatigue cracks. Solution treatment appears to reduce or eliminate the shrinkage porosity because of grain growth and dissolution of as-cast eutectic phases in the grain boundaries. The cyclic stress amplitude of the as-cast alloy increases with increasing the number of cycles, while the T6-treated alloy shows cyclic softening after the stress reaches a maximum value. The Coffin-Manson law and Basquin equation can be used to evaluate the life of low cycle fatigue. The developed long crack model and multi-scale fatigue (MSF) models can be used to predict high-cycle fatigue life of the Mg-2.96Nd-0.21Zn-0.39Zr alloys with or without casting defects.

  9. Cracks in high-manganese cast steel

    A. Chojecki

    2009-10-01

    Full Text Available The reasons which account for the formation of in service cracks in castings made from Hadfield steel were discussed. To explain the source of existence of the nuclei of brittle fractures, the properties of cast steel were examined within the range of solidification temperatures, remembering that feeding of this material is specially difficult, causing microporosity in hot spots. This creates conditions promoting the formation of microcracks which tend to propagate during service conditions involving high dynamic stresses, and explains why the cracks are mainly characterized by a brittle nature. The reason for crack formation in service are micro-porosities formed during casting solidification.

  10. Analysis of Fly Fishing Rod Casting Dynamics

    Gang Wang; Norman Wereley

    2011-01-01

    An analysis of fly fishing rod casting dynamics was developed comprising of a nonlinear finite element representation of the composite fly rod and a lumped parameter model for the fly line. A nonlinear finite element model was used to analyze the transient response of the fly rod, in which fly rod responses were simulated for a forward casting stroke. The lumped parameter method was used to discretize the fly line system. Fly line motions were simulated during a cast based on fly rod tip resp...

  11. PHYSICAL SIMULATION OF CONTINUOUS ROLL CASTING PROCESS

    L.H. Zhan; J. Zhong; X.Q. Li; M.H. Huang

    2005-01-01

    A series of simulating experimental studies on the rheological behavior and its influential factors of aluminum alloy in continuous roll-casting process have been explored in this paper with a Gleeble-1500 Thermal-Mechanical Simulation Tester and a set of special clamp system. Relevant rheological rules in the process of coupling transient solidification and continuous deformation of roll-casting conditions are obtained. Experimental results indicate that four different characteristic stages exist in the whole rheological process, and relative constitutive models suitable for the given conditions of continuous roll casting process have been established through multivariable linear regression analysis of the experimental data.

  12. Roll casting of 5182 aluminium alloy

    Haga, T; M. Mtsuo; D. Kunigo; Hatanaka, Y; R. Nakamuta; H. Watari; S. Kumai

    2009-01-01

    Purpose: of this paper is investigation of the ability of the high speed roll casting of 5182 aluminium alloy. Appropriate twin roll caster to cast the 5182 strip was researched.Design/methodology/approach: Method used in the present study was an unequal diameter twin roll caster and a vertical type high speed twin roll caster equipped with mild steel rolls without parting material.Findings: are that the vertical type high speed twin roll caster was effective to cast 5182 strip at high speed....

  13. The X-ray Telescope of CAST

    M. Kuster(Technische Universität Darmstadt); Bräuninger, H.; Cébrian, S.; Davenport, M.; Elefteriadis, C.; Englhauser, J.; Fischer, H.; Franz, J.; Friedrich, P.; Hartmann, R.; Heinsius, F. H.; Hoffmann, D H H; Hoffmeister, G.; Joux, J. N.; Kang, D.

    2007-01-01

    The Cern Axion Solar Telescope (CAST) is in operation and taking data since 2003. The main objective of the CAST experiment is to search for a hypothetical pseudoscalar boson, the axion, which might be produced in the core of the sun. The basic physics process CAST is based on is the time inverted Primakoff effect, by which an axion can be converted into a detectable photon in an external electromagnetic field. The resulting X-ray photons are expected to be thermally distributed between 1 and...

  14. Perspectives of single cast nanowires technology

    The paper is dedicated to production potential of glass-coated cast nanowire with metal-, semimetal- and semiconductor-based cores by means of Taylor-Ulitovsky method. Criteria of melted core-formative material penetration into a drawing capillary were analyzed. Theoretical preconditions of the reduction of cast microwire diameter up to nano-dimensions of core are reviewed and an improved method of cast nanowire manufacturing is proposed. Correctness of conclusions was experimentally proved and laboratory samples of micro- and nano-wires with core diameter of about 200-300 nanometers were produced, even in case of materials with poor adhesion.

  15. Optimization of the Chemical Composition of Cast Iron Used for Casting Ball Bearing Grinding Disks

    Aurel Crisan; Sorin Ion; Munteanu; Ioan Ciobanu; Iulian Riposan

    2008-01-01

    The chemical composition of cast iron used for casting ball bearing machining disks was varied to optimize the properties such as castability, hardenability, and durability in ball machining. The cast iron characteristics were most strongly dependent on the Ni content and the carbon saturation degree, So. This paper describes the types of test specimens, the working conditions, and the experimental results. The in-crease of the degree of carbon saturation reduces the tendency to form shrinkholes in the castings. The de-crease in the Ni content negatively affects the final hardening treatment. A way to control solidification de-fects in cast iron, by reducing the Ni content, has been verified on cast disks.

  16. 49 CFR 192.275 - Cast iron pipe.

    2010-10-01

    ... 49 Transportation 3 2010-10-01 2010-10-01 false Cast iron pipe. 192.275 Section 192.275... Cast iron pipe. (a) Each caulked bell and spigot joint in cast iron pipe must be sealed with mechanical leak clamps. (b) Each mechanical joint in cast iron pipe must have a gasket made of a...

  17. Structure and mechanical properties of vermicular cast iron in cylinder head casting

    Guzik, E.; S. Dzik

    2009-01-01

    The paper discusses the problem of grain density and ferrite content in microstructure of vermicular graphite iron cast in bars of different section diameters and cylinder head casting. The experimental results regarding the section effect demonstrate that the nodule count, grain density and ferrite content are all function of the cast bar diameter in this particular case ranging from 0.6 to 8.0 cm and microstructure and mechanical properties in the cylinder head. The nodule count (or grain d...

  18. Casting directly from a computer model by using advanced simulation software FLOW-3D Cast ®

    M. Sirviö; M. Woś

    2009-01-01

    ConiferRob - A patternless casting technique, originally conceived at VTT Technical Research Centre of Finland and furtherdeveloped at its spin-off company, Simtech Systems, offers up to 40% savings in product development costs, and up to two months shorterdevelopment times compared to conventional techniques. Savings of this order can be very valuable on today's highly competitivemarkets. Casting simulation is commonly used for designing of casting systems. However, most of the software are ...

  19. EXPLOITATION OF SCHEDULED CASTE WOMEN THROUGH CASTE AND PATRIARCHY–A STUDY OF DEVADASI SYSTEM

    Shailaja Saibanna

    2015-01-01

    Caste system is a peculiar feature and a complex system of social stratification in Indian Society. Caste is studied with different approaches and theories such as Manu's theory, Resley's theory, anthropological, sociological approaches. Originating from the Portuguese word, caste meaning breed it is now defined by the Encyclopedia of Social Sciences as, an endogamous and hereditary subdivision of ethnic group occupying a position of superior or inferior rank or social esteem in comparison...

  20. The change of temperature gradient in solidification of hypereutectic chromium cast iron casting

    A. Studnicki

    2010-01-01

    In article the analysis of temperature gradient of solidification in section of hypereutectic chromium cast iron model casting was introduced. On this example was presented the method (DTGA – derivative and thermal gradient analysis), which was worked out in Department of Foundry Silesian University of Technology enabling the record of indispensable data to execution of analysis the temperature gradient and its derivative after time on section of model casting. It multichanneled apparatus to ...

  1. The change of temperature gradient in solidification of hypereutectic chromium cast iron casting

    A. Studnicki

    2010-01-01

    Full Text Available In article the analysis of temperature gradient of solidification in section of hypereutectic chromium cast iron model casting was introduced. On this example was presented the method (DTGA – derivative and thermal gradient analysis, which was worked out in Department of Foundry Silesian University of Technology enabling the record of indispensable data to execution of analysis the temperature gradient and its derivative after time on section of model casting. It multichanneled apparatus to registration of data was used Crystaldigraph - PC.

  2. Solidification Conditions and Microstructure in Continuously Cast Aluminum

    Buxmann, K.; Gold, E.

    1982-04-01

    The well-known relationship between cell size or dendrite spacing and local solidification time gives the possibility of calculating the thermal parameters of solidification from the microstructure of the as-cast product. As a basis for such calculations, the dendrite spacing of different aluminum castings (DC cast ingots of different diameters, cast in conventional and electromagnetic molds; cast strip from roll casters, belt casters, and block casters; and Properzi cast rod) has been measured through their cross sections. Based on these measurements, a qualitative discussion of the thermal conditions during the solidification of these products is given, and the influence of a variation in the casting conditions discussed.

  3. Investigations of Protective Coatings for Castings of High-manganese Cast Steels

    M. Holtzer

    2013-01-01

    Full Text Available When cast steel castings are made in moulding sands on matrices of high-silica sand, which has a low fire resistance the problem of theso-called chemical penetration is distinctly visible. Whereas this effect appears to a small degree only when moulding sand matrices are of chromite, zircon or olivine sands. Therefore in case of making castings of high-manganese cast steel (e.g. Hadfield steel sands not containing free silica should be applied (e.g. olivine sand or in case of a high-silica matrix protective coatings for moulds and cores should be used. Two protective coatings, magnesite alcoholic (marked as coating 1 and coating 2 originated from different producers and intended for moulds for castings of the Hadfield steel, were selected for investigations. Examinations of the basic properties were performed for these coatings: viscosity, thermal analysis, sedimentation properties, wear resistance. In order to estimate the effectiveness of protective coatings the experimental castings were prepared. When applying coating 1, the surface quality of the casting was worse and traces of interaction between the casting material (cast steel and the coating were seen. When protective coating 2 was used none interactions were seen and the surface quality was better.

  4. Advanced lost foam from casting technology

    Bates, C. E.; Littleton, H. E.; Askeland, D.; Griffin, J.; Miller, B. A.; Sheldon, D. S.

    1996-05-01

    Previous research made significant advances in understanding the Lost Foam Casting (LFC) Process and clearly identified areas where additional research was needed to improve the process and make it more functional in an industrial environment. The current project focused on five areas listed as follows: Task 1: Precision Pattern Production Task 2: Pattern Coating Consistency Task 3: Sand Fill and Compaction Effects Task 4: Pattern Gating Task 5: Mechanical Properties of Castings. This report summarizes the work done under the current contract in all five areas in the period of October 1, 1994 through December 31, 1995. Twenty-eight (28) companies jointly participate in the project. These companies represent a variety of disciplines, including pattern designers, pattern producers, coating manufacturers, plant design companies, compaction equipment manufacturers, casting producers, and casting buyers.

  5. NUMERICAL SIMULATION OF CASTING'S MOLD FILLING PROCESS

    J.X. Zhou; R.X. Liu; L.L. Chen; D.M. Liao; H.S. Wei

    2005-01-01

    Numerical simulation of casting's mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the development of computer hardware, numerical simulation of casting' s mold filling process has made rapid progress. The simulation results, therefore, have become more and more practical. This study tries to find some clues of the computational time of mold filling process. Firstly, this paper introduces mathematic model and the basic route of numerical simulation of casting's mold filling process. Then the computational time of mold filling process has been carefully studied, and some new and useful results have been gained from the study of the computational time. Finally, this paper has given some real applications of numerical simulation of casting's mold filling process.

  6. Modelling of Level Fluctuation in Continuous Casting

    Xiao LIU; Huanxin ZHANG; Rongjun XU; Yongquan LI; Houfa SHEN; Baicheng LIU

    2003-01-01

    The free surface profile and fluid flow in the mold of continuous casting have been calculated by the VOF method couplingthe SIMPLER algorithm. The SIMPLER-VOF model developed is validated by solving a classical experiment, broken damproblem. The calculat

  7. Slip casting alumina with Na-CMC

    Ruys, A.J.; Sorrell, C.C. [Univ. of New South Wales, Sydney, New South Wales (Australia)

    1996-11-01

    Many forming methods are in common use for engineering ceramics. Of these, slip casting is an ideal forming method because of its low cost, simplicity and flexibility, potential for uniform particle packing and suitability to the production of articles of intricate shape. Slip casting nonclay materials, such as alumina, requires the use of both a deflocculant and a binder. There are many commercially available deflocculants and binders that can be tested in alumina casting slips. However, determination of a suitable deflocculant/binder combination and quantification of the optimal additions of the deflocculant/binder pair can be time consuming. Certain deflocculants are capable of acting as binders. One such additive is sodium carboxymethylcellulose (Na-cmc), a cellulose ether. Na-cmc is a powerful binder. It is a member of the carbohydrate binder group--the binder group with the strongest binding power. It is capable of acting as a deflocculant in glazes and nonclay casting slips.

  8. ToxCast/ToxRefDB

    U.S. Environmental Protection Agency — ToxCast is used as a cost-effective approach for efficiently prioritizing the toxicity testing of thousands of chemicals. It uses data from state-of-the-art high...

  9. CAST-CERN Axion Solar Telescope

    CAST (CERN Axion Solar Telescope) is a helioscope looking for axions coming from the solar core to the Earth. The experiment, located at CERN, is based on the Primakoff effect and uses a magnetic field of 9 T provided by a decommissioned LHC magnet. CAST is able to follow the Sun during sunrise and sunset and therefore three X-ray detectors are mounted on both ends of the magnet waiting for a photon from axion-to-photon conversion due to Primakoff effect. During its first phase, which concluded in 2004, CAST has been looking for axions with masses up to 0.02 eV. The second phase did already start and first data were taken in December 2005. CAST's second phase manages to reestablish the coherence needed to scan for axions with masses up to 0.83 eV by using a buffer gas. This enables the experiment to look into the theoretical regions for axions

  10. Palatal Surface Area of Maxillary Plaster Casts

    Darvann, Tron Andre; Hermann, Nuno V.; Ersbøll, Bjarne Kjær;

    2007-01-01

    Objective: To investigate the relationship between corresponding two-dimensional and three-dimensional measurements on maxillary plaster casts taken from photographs and three-dimensional surface scans, respectively. Materials and Methods: Corresponding two-dimensional and three-dimensional measu......Objective: To investigate the relationship between corresponding two-dimensional and three-dimensional measurements on maxillary plaster casts taken from photographs and three-dimensional surface scans, respectively. Materials and Methods: Corresponding two-dimensional and three...

  11. Recycled materials for the investment casting process

    Matysiak, H.; R. Haratym; R. Biernacki

    2010-01-01

    The possibility of using materials in the investment casting process is discussed within this paper. Wax recycled from the assembles andaluminosilicates recycled from the shell systems are the materials of interest. The recycling process was performed with the view on thefallowing issues: decreasing the amount of waste and transforming the waste into the production material that could be used in theinvestment casting process on the regular basis. In addition, the ecological aspect of the recy...

  12. CAST Xi'an Branch Established

    2008-01-01

    @@ China Academy of Space Technology (CAST) Xi'an Branch was established on April 8,2008.The new branch consists of the headquarters of the former Xi'an Institute of Space Radio Technology (XISRT) of CAST and five former subsidiaries of the XISRT,i.e.the Institute of Space Electronic Technology,the Institute of Microwave Technology,the Institute of Space Antenna Technology,the Manufacturing Center for Space Electronics and Civilian High-tech Company.

  13. Computed Tomography For Internal Inspection Of Castings

    Hanna, Timothy L.

    1995-01-01

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

  14. Combination Of Investment And Centrifugal Casting

    Creeger, Gordon A.

    1994-01-01

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

  15. Quality of as cast ingots with extreme large shapes

    Chen, Zhiye

    2015-01-01

    The quality of as-cast ingots and continuous cast products are controlled by solidification process mainly. Regarding to this, investigation on casting and solidification process of ingots and continuous cast products is considerable important in control of the quality of as-cast products especially for products with extremely heavy weight like several hundred tons. The present work focuses on the solidification process of large ingots. The complex solidification phenomena in large ingots hav...

  16. Cast support for a pressure vessel at high internal pressure

    The invention concerns a cast support for a pressure vessel, which is sealed with a liner. In order to prevent bulging of the liner which is not fixed to the cast support, a supporting intermediate layer is situated between the liner and the cast support. The cast support is only anchored in the supporting intermediate layer in certain areas. Several types of anchoring are described for the cast support. (orig.)

  17. Fabrication of bulk metallic glasses by centrifugal casting method

    R. Nowosielski; R. Babilas

    2007-01-01

    Purpose: The aim of the present work is characterization of the centrifugal casting method, apparatus andproduced amorphous materials, which are also known as bulk metallic glassesDesign/methodology/approach: The studied centrifugal casting system consists of two main parts: castingapparatus and injection system of molten alloy. The described centrifugal casting method was presented bypreparing a casting apparatus “CentriCast – 5”. The apparatus includes a cylindrical copper mold, which isrot...

  18. Low Background Micromegas in CAST

    Garza, J G; Aznar, F.; Calvet, D.; Castel, J.F.; Christensen, F.E.; Dafni, T.; Davenport, M.; Decker, T.; Ferrer-Ribas, E.; Galán, J.; García, J.A.; Giomataris, I.; Hill, R.M.; Iguaz, F.J.; Irastorza, I.G.; Jakobsen, A.C.; Jourde, D.; Mirallas, H.; Ortega, I.; Papaevangelou, T.; Pivovaroff, M.J.; Ruz, J.; Tomás, A.; Vafeiadis, T.; Vogel, J.K.

    2015-01-01

    Solar axions could be converted into x-rays inside the strong magnetic field of an axion helioscope, triggering the detection of this elusive particle. Low background x-ray detectors are an essential component for the sensitivity of these searches. We report on the latest developments of the Micromegas detectors for the CERN Axion Solar Telescope (CAST), including technological pathfinder activities for the future International Axion Observatory (IAXO). The use of low background techniques and the application of discrimination algorithms based on the high granularity of the readout have led to background levels below 10$^{-6}$ counts/keV/cm$^2$/s, more than a factor 100 lower than the first generation of Micromegas detectors. The best levels achieved at the Canfranc Underground Laboratory (LSC) are as low as 10$^{-7}$ counts/keV/cm$^2$/s, showing good prospects for the application of this technology in IAXO. The current background model, based on underground and surface measurements, is presented, as well as ...

  19. Last cast for the LHC

    2005-01-01

    The first major contract signed for the LHC is drawing to a close. Belgian firm Cockerill Sambre (a member of the Arcelor Group) has just completed production of 50,000 tonnes of steel sheets for the accelerator's superconducting magnet yokes, in what has proved to be an exemplary partnership with CERN. Philippe Lebrun, Head of the AT Department, Lyn Evans, LHC Project Leader, and Lucio Rossi, Head of the AT-MAS Group, in front of the last batch of steel for the LHC at Cockerill Sambre. It was a bright red-letter day at the end of May, when Belgian firm Cockerill Sambre of the Arcelor Group marked the completion of one of the largest contracts for the LHC machine by casting the last batch of steel sheets for the LHC superconducting magnet yokes in the presence of LHC Project Leader Lyn Evans, AT Department Head Philippe Lebrun, Magnets and Superconductors (AT-MAS) Group Leader Lucio Rossi and Head of the AT-MAS Group's components centre Francesco Bertinelli. The yokes constitute approximately 80% of the acc...

  20. Latest results of cast and future prospects

    Vafeiadis, Theodoros

    2014-01-01

    CERN Axion Solar Telescope (CAST) is currently the most sensitive axion helioscope designed to search for axions and axion-like particles produced in the Sun. CAST completed successfully the second part of CAST phase II where the magnet bores were lled with 3He gas at variable pressure scanning axion masses up to 1.2 eV In the absence of signal it has set the best experimental limit on the axion-photon coupling constant over a broad range of axion masses. In 2013 CAST has improved its sensitivity to solar axions with rest mass below 0.02 eV by upgrading the Micromegas detectors and it will continue in 2014 with the implementation of a second X-ray optic and a new type detector (InGRID). In addition, CAST has extended its sensitivity into the sub-keV energy range using a silicon detector (SDD), to search for solar chameleons. Thus, CAST also became sensitive to dark energy particles. A new generation axion helioscope (IAXO) aims to improve the current axion-photon coupling by 1-1.5 orders of magnitude. This wi...

  1. Structure analysis of Al cast alloy

    L.A. Dobrzański

    2008-03-01

    Full Text Available Purpose: The developed design methodologies both the material and technological ones will make it possible to improve shortly the quality of materials from the light alloys in the technological process, and the automatic process flow correction will make the production cost reduction possible, and - first of all - to reduce the amount of the waste products.Design/methodology/approach: Castings were analysed in the paper of car engine blocks and heads from the Al-Si-Cu alloys of the AC-AlSi7Cu3Mg type fabricated with the “Cosworth” technological process. In this work the AC-AlSi7Cu3Mg alloy structure was investigated, of this alloy samples were cut of for structure analysis of the cylinder part as well of crankshaft of a fuel engine. The investigation show a difference in the (phase structure morphology as a result of cast cooling rate.Findings: On the quality of casting has influence the walls thickness of car engine elements’.Practical implications: In the metal casting industry, an improvement of component quality depends mainly on better control over the production parameters.Originality/value: The value of the applied methodology was to correct identify the casting effects that occurred during the casting process.

  2. Recycling process of casting molds applying to precision castings

    M. Drajewicz

    2012-12-01

    Full Text Available Purpose: The present work relates to investigations about the possibility of recycling and producing sinters from ceramic molds. These molds are applied for producing precise single crystal casts of nickel based superalloys to elements witch are applied to the hot section of aircraft jet engines.Design/methodology/approach: The processes of milling were carried out using the vibratory mill Herzog HSM 100H and the planetary grinder Pulverisette 7 - Fritsch Company. The measurements of all kinds of powders were conducted by using of the Kamika IPS U Analyzer and Malvern Nanosizer-ZS. To the purpose of analysis of the chemical composition an X-ray microanalysis technique was applied with the dispersion of the energy (EDS using of Thermo and Noran equipment. Findings: On the basis of examinations carried out on the powders before and after processes of milling and after processes of pressing and sintering of powders, it is possible to state that technological processes of reuse and further applying of used molds are possible. Processes of pressing were conducted applying different amounts of powders. Powders were pressed both without the addition as well as with the addition of modifiers which were added to basic powder in appropriate amounts. It was found that processes of pressing and sintering in both cases showed good results. Surfaces of pressed and sintered tablets were smooth and not-delaminated as well as did not shell.Research limitations/implications: Results will be used for future researches among others concerning the research on mechanical and thermal properties.Practical implications: Waste products and their reuse, recycling and especially consolidation of dangerous and hazardous compounds including of ceramic materials from foundry industry, will have an important place in the future on account of problems with their recycling and the storage.Originality/value: Researches on new possibilities of the application and properties of

  3. The effect of upper limb casting on gait pattern.

    Dreyfuss, Daniel; Elbaz, Avi; Mor, Amit; Segal, Ganit; Calif, Edward

    2016-06-01

    Casting of the arm may interfere with normal walking patterns because of additional load of the cast or prevention of arm swing. This study aimed to determine the effect of applying various casts on temporospatial walking parameters, including gait velocity and cadence, step length, and single limb support. A computerized gait system was used to assess these variables for 23 healthy individuals in four walking modes: normal walking, with a cast above the elbow and a sling, and with a cast below the elbow, with and without a sling. Thirteen participants had their dominant hand casted and 10 had their nondominant hand casted. On average, casted participants took significantly smaller steps with the leg on the casted side and spent less time supported on the casted side. The least changes were noted with the arm in a cast below the elbow and no sling, and the greatest changes were noted with the arm in a cast above the elbow and in a sling. This difference was heightened when the dominant hand was casted and lessened when the nondominant hand was casted. No differences were found in walking velocity or cadence between the walking modes. Casting of the upper limb has significant effects on gait, which should be taken into consideration, especially in individuals with previous gait abnormalities. PMID:26855024

  4. Equal-channel angular pressing of medium- to high-strength precipitation hardening aluminium wrought alloys; ECAP-Umformung mittel- und hochfester ausscheidungshaertbarer Aluminiumknetlegierungen

    Hockauf, M.; Schoenherr, R.; Wagner, S.; Meyer, L.W. [Technische Universitaet Chemnitz, Lehrstuhl Werkstoffe des Maschinenbaus, Erfenschlager Str. 73, 09125 Chemnitz (Germany); Podlesak, H.; Muecklich, S.; Wielage, B.; Weber, D. [Technische Universitaet Chemnitz, Professur fuer Verbundwerkstoffe (Germany); Krueger, L. [Technische Universitaet Bergakademie Freiberg, Institut fuer Werkstofftechnik (Germany); Hahn, F. [Hochschule Mittweida, Fachbereich Maschinenbau/Feinwerktechnik (Germany)

    2009-07-15

    The study deals with the optimisation of medium- to high-strength aluminium wrought alloys. The goal is to define processing routes in order to improve the mechanical properties if compared to their commercial counterparts. It is shown for the Al-Mg-Si and the Al-Cu-Mg-Si system that the application of ECAP enables a significant increase in strength. The strengthening as well as the grain size reduction respectively, benefit from increasing alloying as well as from the degree of aging. It is also shown that the presence of a considerably fine particulate reinforcement hardens the material tremendously during ECAP. The combination of a pre- or post-ECAP heat treatment enables the improvement of the workability on the one hand, reducing the loads on the die, and also gives a better ductility on the other hand. This positive effect is particularly pronounced for low alloying contents and high aging temperatures and can be attributed to the interaction of deformation induced defects and the precipitation activity. The combination of an appropriate set of ECAP parameters (heat treatment condition, ECAP-strain, -temperature, -backpressure) enables the efficient production of outstanding properties. Due to the low workability of AA7075 (Al-Zn-Mg-Cu system) no significant improvement in properties was achieved. (Abstract Copyright [2009], Wiley Periodicals, Inc.) [German] Die Studie befasst sich mit der Eigenschaftsoptimierung verschiedener mittel- und hochfester Aluminiumknetlegierungen. Im Fokus steht die Optimierung von Prozessabfolgen mit denen im Vergleich zu den kommerziell verfuegbaren Referenzzustaenden deutlich bessere mechanische Eigenschaften eingestellt werden koennen. Fuer das Al-Mg-Si- und das Al-Cu-Mg-Si-System wird gezeigt, dass die ECAP-Umformung sehr hohe Festigkeiten ermoeglicht. Je groesser der Legierungsgehalt bzw. Aushaertegrad ist, desto hoehere Festigkeiten und geringere Korngroessen koennen durch ECAP erreicht werden. Ebenso extrem verfestigend

  5. Low-Level Radioactive Waste Management in the United States: What Have We Wrought? The Richard S. Hodes, M.D. Honor Lecture Award - 12222

    implement its obligations under the 1985 amendments to the Low-Level Radioactive Waste Policy Act. But, the last three decades have not been a total loss. A great deal has been learned about radioactive waste disposal since 1979 and the efforts of the public and private sector have shaped and focused the work to be done in the future. So, this lecturer asks the question: 'What have we wrought?' to which he provides his perspective and his recommendations for radioactive waste management policy for the next 30 years. (author)

  6. Texture evolution of continuous cast and direct chill cast AA 3003 aluminum alloys during cold rolling

    The texture evolution of continuous cast (CC) and direct chill cast (DC) AA 3003 aluminum alloys during cold rolling was investigated by X-ray diffraction. The relationship between texture volume fractions and rolling true strain was described quantitatively by mathematical formulae. The effect of processing method (CC vs. DC) on texture evolution was determined

  7. Methods and apparatus for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    Stoddard, Nathan G

    2014-01-14

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  8. Methods and apparatuses for manufacturing monocrystalline cast silicon and monocrystalline cast silicon bodies for photovoltaics

    Stoddard, Nathan G.

    2011-11-01

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of monocrystalline silicon may be formed that is free of, or substantially free of, radially-distributed impurities and defects and having at least two dimensions that are each at least about 35 cm is provided.

  9. National Metal Casting Research Institute final report. Volume 2, Die casting research

    Jensen, D. [University of Northern Iowa, Cedar Falls, IA (United States). Dept. of Industrial Technology] [comp.

    1994-06-01

    Four subprojects were completed: development and evaluation of die coatings, accelerated die life characterization of die materials, evaluation of fluid flow and solidification modeling programs, selection and characterization of Al-based die casting alloys, and influence of die materials and coatings on die casting quality.

  10. Stereological parameters of carbides on section of casting made from modified chromium cast iron

    A. Studnicki

    2011-07-01

    Full Text Available The analysis of stereological parameters of carbides on the section of the model castingmade from modified (the mixture FeNb+FeV+RE wear resistance chromium cast iron was introduced in the article. The jump change of some stereological parameters of carbides in certain distance from the surface of the casting was observed.

  11. Comparison of phosphor bronze metal sheet produced by twin roll casting and horizontal continuous casting

    Hwang, J. D.; Li, B. J.; Hwang, W. S.; Hu, C. T.

    1998-08-01

    Much effort recently has been expended to study the strip casting process used to produce thin metal strip with a near final thickness. This process eliminates the need for hot rolling, consumes less energy, and offers a feasible method of producing various hard-to-shape alloys. The finer microstructure that results from the high cooling rate used during the casting process enhances mechanical properties. In this study, strips of phosphor bronzes (Cu-Sn-P) metal were produced using a twin roll strip casting process as well as a conventional horizontal continuous casting (HCC) process. The microstructures, macrosegregations, textures, and mechanical properties of the as-cast and as-rolled metal sheet produced by these two methods were examined carefully for comparative purposes. The results indicate that cast strip produced by a twin roll caster exhibit significantly less inverse segregation of tin compared to that produced by the HCC process. The mechanical properties including tensile strength, elongation, and microhardness of the products produced by the twin roll strip casting process are comparable to those of the HCC processed sheet. These properties meet specifications JIS H3110 and ASTM B 103M for commercial phosphor bronze sheet. The texture of the as-rolled sheet from these two processes, as measured from XRD pole figures, were found to be virtually the same, even though a significant difference exists between them in the as-cast condition.

  12. FORMATION OF WEAR-RESISTANT CHROMIUM CAST IRON CASTING INTO THE CHILL MOLD

    E. I. Marukovich

    2015-05-01

    Full Text Available The analysis of thermal processes of formation of castings from wearproof chromic cast irons for replaceable details of centrifugal mills and crushers is carried out. Influence of protective and dividing coverings on intensity of heating of the chill mold is investigated.

  13. FORMATION OF WEAR-RESISTANT CHROMIUM CAST IRON CASTING INTO THE CHILL MOLD

    E. I. Marukovich; V. M. Ilyushenko; P. Yu. Duvalov

    2015-01-01

    The analysis of thermal processes of formation of castings from wearproof chromic cast irons for replaceable details of centrifugal mills and crushers is carried out. Influence of protective and dividing coverings on intensity of heating of the chill mold is investigated.

  14. Precision Casting via Advanced Simulation and Manufacturing

    1997-01-01

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

  15. Colour Metallography of Cast Iron - Chapter 3: Spheroidal Graphite Cast Iron (Ⅰ

    Zhou Jiyang

    2010-02-01

    Full Text Available Cast iron, as a traditional metal material, has advantages of low total cost, good castability and machinability, good wear resistance and low notch sensitivity, and is still facing tough challenge in quality, property and variety of types etc. Experts and engineers studying and producing iron castings all around world extremely concern this serious challenge. Over more than 30 years, a great of research work has been carried out on how to further improve its property, expand its application and combine cast iron technology with some hi-techs (for example, computer technology. Nevertheless, cast iron is a multi-element and multi-phase alloy and has complex and variety of structures and still has great development potential in structure and property. For further studying and developing cast iron, theoretical research work is important promise, and the study on solidification process and control mechanism of graphite morphology is fundamental for improving property of cast iron and developing new type of cast iron. Metallography of cast iron normally includes two sections: liquid phase transformation and solid phase transformation. The book, Colour Metallography of Cast Iron, uses colour metallography technique to study solidification structures of cast irons: graphite, carbides, austenite and eutectics; and focuses on solidification processes. With progress of modern solidification theory, the control of material solidification process becomes important measure for improving traditional materials and developing new materials. Solidification structure not only influences mechanical and physical properties of cast iron, but also affects its internal quality. The book uses a large amount of colour photos to describe the formation of solidification structures and their relations. Crystallization phenomena, which cannot be displayed with traditional metallography, are presented and more phase transformation information is obtained from these colour

  16. Colour Metallography of Cast Iron - Chapter 4: Vermicular Graphite Cast Iron (Ⅱ

    Zhou Jiyang

    2011-05-01

    Full Text Available Cast iron, as a traditional metal material, has advantages of low total cost, good castability and machinability, good wear resistance and low notch sensitivity, and is still facing tough challenge in quality, property and variety of types etc. Experts and engineers studying and producing iron castings all around world extremely concern this serious challenge. Over more than 30 years, a great of research work has been carried out on how to further improve its property, expand its application and combine cast iron technology with some hi-techs (for example, computer technology. Nevertheless, cast iron is a multi-element and multi-phase alloy and has complex and variety of structures and still has great development potential in structure and property. For further studying and developing cast iron, theoretical research work is important promise, and the study on solidification process and control mechanism of graphite morphology is fundamental for improving property of cast iron and developing new type of cast iron. Metallography of cast iron normally includes two sections: liquid phase transformation and solid phase transformation. The book, Colour Metallography of Cast Iron, uses colour metallography technique to study solidification structures of cast irons: graphite, carbides, austenite and eutectics; and focuses on solidification processes. With progress of modern solidification theory, the control of material solidification process becomes important measure for improving traditional materials and developing new materials. Solidification structure not only influences mechanical and physical properties of cast iron, but also affects its internal quality. The book uses a large amount of colour photos to describe the formation of solidification structures and their relations. Crystallization phenomena, which cannot be displayed with traditional metallography, are presented and more phase transformation information is obtained from these colour

  17. Colour Metallography of Cast Iron - Chapter 3: Spheroidal Graphite Cast Iron (Ⅳ

    Zhou Jiyang

    2010-11-01

    Full Text Available Cast iron, as a traditional metal material, has advantages of low total cost, good castability and machinability, good wear resistance and low notch sensitivity, and is still facing tough challenge in quality, property and variety of types etc. Experts and engineers studying and producing iron castings all around world extremely concern this serious challenge. Over more than 30 years, a great of research work has been carried out on how to further improve its property, expand its application and combine cast iron technology with some hi-techs (for example, computer technology. Nevertheless, cast iron is a multi-element and multi-phase alloy and has complex and variety of structures and still has great development potential in structure and property. For further studying and developing cast iron, theoretical research work is important promise, and the study on solidification process and control mechanism of graphite morphology is fundamental for improving property of cast iron and developing new type of cast iron. Metallography of cast iron normally includes two sections: liquid phase transformation and solid phase transformation. The book, Colour Metallography of Cast Iron, uses colour metallography technique to study solidification structures of cast irons: graphite, carbides, austenite and eutectics; and focuses on solidification processes. With progress of modern solidification theory, the control of material solidification process becomes important measure for improving traditional materials and developing new materials. Solidification structure not only influences mechanical and physical properties of cast iron, but also affects its internal quality. The book uses a large amount of colour photos to describe the formation of solidification structures and their relations. Crystallization phenomena, which cannot be displayed with traditional metallography, are presented and more phase transformation information is obtained from these colour

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

    Sabau, Adrian S [ORNL

    2005-09-01

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

  19. Applying RP-FDM Technology to Produce Prototype Castings Using the Investment Casting Method

    M. Macků

    2012-09-01

    Full Text Available The research focused on the production of prototype castings, which is mapped out starting from the drawing documentation up to theproduction of the casting itself. The FDM method was applied for the production of the 3D pattern. Its main objective was to find out whatdimensional changes happened during individual production stages, starting from the 3D pattern printing through a silicon mouldproduction, wax patterns casting, making shells, melting out wax from shells and drying, up to the production of the final casting itself.Five measurements of determined dimensions were made during the production, which were processed and evaluated mathematically.A determination of shrinkage and a proposal of measures to maintain the dimensional stability of the final casting so as to meetrequirements specified by a customer were the results.

  20. Analysis of the structure of castings made from chromium white cast iron resistant to abrasive wear

    D. Kopyciński

    2009-10-01

    Full Text Available It has been proved that an addition of boron carbide and disintegrated steel scrap introduced as an inoculant to the chromium white cast iron changes the structure of castings. The said operation increases the number of crystallization nuclei for dendrites of the primary austenite. In this case, the iron particles act as substrates for the nucleation of primary austenite due to a similar crystallographic lattice. The more numerous are the dendrites of primary austenite and the structure more refined and the mechanical properties higher. Castings after B4C inoculation revealed a different structure of fine grained fracture. Primary precipitates of chromium carbide also appeared, reducing the mechanical properties of as-cast parts. Properly established heat treatment regime makes chromium iron castings regain their, originally high, mechanical properties.

  1. Evaluation of porosity in Al alloy die castings

    M. Říhová

    2012-01-01

    Full Text Available Mechanical properties of an Al-alloy die casting depend significantly on its structural properties. Porosity in Al-alloy castings is one of the most frequent causes of waste castings. Gas pores are responsible for impaired mechanical-technological properties of cast materials. On the basis of a complex evaluation of experiments conducted on AlSi9Cu3 alloy samples taken from the upper engine block which was die- cast with and without local squeeze casting it can be said that castings manufactured without squeeze casting exhibit maximum porosity in the longitudinal section. The area without local squeeze casting exhibits a certain reduction in mechanical properties and porosity increased to as much as 5%. However, this still meets the norms set by SKODA AUTO a.s.

  2. Biaxial casting method and apparatus for isolating radioactive waste

    Hazardous radioactive waste is compacted and cast into safely handled monolithic castings having a radiation barrier wall completely enclosing the radioactive waste by centrifugal casting processes in which the barrier wall may be either a pre-formed shell transported to the jobsite or it may be formed by biaxial centrifugal casting and curing of the barrier wall in a mold. When a pre-formed shell is used, means are provided for thickening the radiation barrier if necessary by biaxial casting of additional barrier material inside of the shell. Castable radioactive material is cast inside the barrier wall before removal of the casting mold from the finished cast monolith. The cast monolith is supported for rotation as the mold is removed therefrom so that additional impact resisting and radiation barrier material can also easily be applied to the exterior surface monolith if radiation leakage exceeds tolerance levels. (author) figs

  3. The deformation of wax patterns and castings in investment casting technology

    A. Herman

    2012-01-01

    Full Text Available The dimensional accuracy of the final casting of Inconel alloy 738 LC is affected by many aspects. One of them is the choice of method and time of cooling wax model for precision investment casting. The main objective was to study the initial deformation of the complex shape of the casting of the rotor blades. Various approaches have been tested for cooling wax pattern. When wax models are cooling on the air, without clamping in jig for cooling, deviations from the ideal shape of the casting are very noticeable (up to 8 mm and most are in extreme positions of the model. When blade is cooled in fixing jig in water environment, the resulting deviations compared with cooling in air are significantly larger, sometimes up to 10 mm. This itself does not mean that the final shape of the casting is dimensionally more accurate with usage of wax models, which have deviations from the ideal position smaller. Another deformation occurs when shell mould is produced around wax pattern and furthermore deformations emerge while casting of blade is cooling. This paper demonstrates first steps in describing complex process of deformations of Inconel alloy blades produced with investment casting technology by comparing results from thermal imagery, simulations in foundry simulation software ProCAST 2010 and measurements from CNC scanning system Carl Zeiss MC 850. Conclusions are so far not groundbreaking, but it seems deformations of wax pattern and deformations of castings do in some cases cancel each other by having opposite directions. Describing entirely whole process of deformations will help increase precision of blade castings so that models at the beginning and blades in the end are the same.

  4. INDIAN CASTE SYSTEM: HISTORICAL AND PSYCHOANALYTIC VIEWS.

    Vallabhaneni, Madhusudana Rao

    2015-12-01

    This paper elucidates the historical origins and transformations of India's caste system. Surveying the complex developments over many centuries, it points out that three positions have been taken in this regard. One suggests that the caste one is born into can be transcended within one's lifetime by performing good deeds. The other declares caste to be immutable forever. And, the third says that one can be reborn into a higher caste if one lives a virtuous life. Moving on to the sociopolitical realm, the paper notes how these positions have been used and exploited. The paper then attempts to anchor the existence and purpose of the Hindu caste system in Freud's ideas about group psychology and Klein's proposals of splitting and projective identification. The paper also deploys the large group psychology concepts of Volkan and the culturally nuanced psychoanalytic anthropology of Roland and Kakar. It concludes with delineating some ameliorative strategies for this tragic problem in the otherwise robust democratic society of India. PMID:26611129

  5. The X-ray Telescope of CAST

    Kuster, M; Cebrián, S; Davenport, M; Elefteriadis, C; Englhauser, J; Fischer, H; Franz, J; Friedrich, P; Hartmann, R; Heinsius, F H; Hoffmann, Dieter H H; Hoffmeister, G; Joux, J N; Königsmann, K C; Kang, D; Kotthaus, R; Lasseur, C; Lippitsch, A; Lutz, G; Morales, J; Papaevangelou, T; Rodríguez, A; Strüder, L; Vogel, J; Zioutas, K

    2007-01-01

    The Cern Axion Solar Telescope (CAST) is in operation and taking data since 2003. The main objective of the CAST experiment is to search for a hypothetical pseudoscalar boson, the axion, which might be produced in the core of the sun. The basic physics process CAST is based on is the time inverted Primakoff effect, by which an axion can be converted into a detectable photon in an external electromagnetic field. The resulting X-ray photons are expected to be thermally distributed between 1 and 7 keV. The most sensitive detector system of CAST is a pn-CCD detector combined with a Wolter I type X-ray mirror system. With the X-ray telescope of CAST a background reduction of more than 2 orders off magnitude is achieved, such that for the first time the axion photon coupling constant g_agg can be probed beyond the best astrophysical constraints g_agg < 1 x 10^-10 GeV^-1.

  6. CASTing light on dark matter particles

    2005-01-01

    CERN's CAST collaboration recently released first results from its search for solar axions, a candidate dark matter particle. Though they haven't found any axions yet, they have done much to narrow the hunt. The CAST experiment. Physicists think the universe is permeated with dark matter, particles that don't emit or absorb radiation and so are invisible to traditional telescopes. So far no one has found direct signs of dark matter. A different breed of telescope, however, may be able to see such particles. CERN's Axion Solar Telescope (CAST), currently the world's only working axion helioscope, is a superconducting test magnet from the Large Hadron Collider (LHC) that has been refurbished and outfitted with X-ray detectors, plus a focusing mirror system for X-rays that was recovered from the German space program. CAST stares into the sun in search of particles called axions, one of the leading candidates for dark matter. On 9 November, the CAST collaboration released the results of their first experimen...

  7. Solvent casting flow from slot die

    Lee, Semi; Nam, Jaewook

    2015-11-01

    A continuous solvent casting method using a slot die can precisely control the film thickness by adjusting the operating conditions, such as the belt speed and pumping rate, not the liquid property. Therefore, it is a suitable method for high precision continuous film production. In this particular method, the dope, or casting solution, is pumped through the feed slot to form a short curtain between the die and the moving belt. Although this method is widely used in producing films for various applications, it is difficult to find indepth analyses of such flow. In this study, we developed a finite element computational model for the steady-state two-dimensional sovent casting flow from the slot die. The effect of die configurations, rheological properties and operating conditions on the behavior and shape of the gas/liquid interfaces and the location of the dynamic contact line, which is the place where the dope meets the moving belt, were investigated.

  8. Maintenance system improvement in cast iron foundry

    S. Kukla

    2011-07-01

    Full Text Available The work presents the issue of technical equipment management in an iron foundry basing on the assumptions of the TPM system (Total Productive Maintenance. Exploitation analysis of automatic casting lines has been carried out and their work’s influence on the whole production system’s functioning has been researched. Within maintenance system improvement, implementation of autonomic service and planned lines’ review have been proposed in order to minimize the time of breakdown stoppages. The SMED method was used to optimize changeover time, and the OEE (Overall Equipment Effectiveness was applied to evaluate the level of resources usage before and after implementing changes. Further, the influence of the maintenance strategy of casting devices’ efficiency on own costs of casting manufac- ture was estimated.

  9. Cast construction elements for heat treatment furnaces

    B. Piekarski

    2011-07-01

    Full Text Available The study presents sketches and photos of the cast creep-resistant components used in various types of heat treatment furnaces. The shape of the elements results from the type of the operation carried out in the furnace, while dimensions are adjusted to the size of the furnace working chamber. The castings are mainly made from the high-alloyed, austenitic chromium-nickel or nickel-chromium steel, selecting the grade in accordance with the furnace operating conditions described by the rated temperature, the type and parameters of the applied operating atmosphere, and the charge weight. Typical examples in this family of construction elements are: crucibles, roller tracks, radiant tubes and guides. The majority of castings are produced in sand moulds.

  10. The World's Largest Steel Casting Poured Successfully

    2008-01-01

    @@ The world's largest steel casting -- the upper beam (or the top head) for free forging oil hydraulic press with a 18,000-ton force capacity, was poured successfully by CITIC Heavy Machinery Co., Ltd. (CITICHM) on May 22, 2008. This head piece is 11.95 meters long, 3.8 meters wide, 4.59 meters high and about 520 tons in gross weight. Pouring is the most important and critical step during its manufacturing process. The production of this huge casting requires about 830 tons of refined molten steel from 10 smelting furnaces and pouring with six ladles into the mold cavity at one time, which made it currently the world's largest steel casting poured and the most one-time molten steel organized.

  11. Thin wall ductile and austempered iron castings

    E. Fraś

    2010-07-01

    Full Text Available It has been shown that it is possible to produce thin wall castings made of ductile iron with wall thickness in the range of 1.2 to 2.9 mm(without chills, cold laps and misruns. Thin wall ductile iron castings can be lighter (380 g than their substitutes made of aluminium alloys (580g. The kinetics of austenitising transformation was studied in unalloyed ductile iron. The advance of transformations during austenitising was monitored by measurement the fraction of martensite and also by dilatometic studies. It has been shown that in thin wall ductile iron castings austenitising at 880 oC for 20 minutes is adequate to obtain the austenite matrix at the end of the first stage of austempering heat treatment cycle.

  12. Land-based turbine casting initiative

    Mueller, B.A.; Spicer, R.A. [Howmet Corp., Whitehall, MI (United States)

    1995-10-01

    The Advanced Turbine Systems (ATS) program has set goals which include a large-scale utility turbine efficiency that exceeds 60 percent (LHV) on natural gas and an industrial turbine system heat rate improvement of 15 percent. To meet these goals, technological advances developed for aircraft gas turbine engines need to be applied to land based gas turbines. These technological advances include: directionally solidified and single crystal castings, alloys tailored to exploit these microstructures, complex internal cooling schemes, and coatings. Equiaxed and directionally solidified castings are employed in current land based power generation equipment. These castings do not possess the ability to meet the efficiency targets as outlined above. The production use of premium single crystal components with complex internal cooling schemes in the latest generation of alloys is necessary to meet the ATS goals. However, at present, the use of single crystal components with complex internal cooling schemes is restricted to industrial sized or aeroderivative engines, and prototype utility sized components.

  13. Diffusion of C and Cr During Creation of Surface Layer on Cast Steel Casting

    Szajnar J.

    2014-10-01

    Full Text Available In paper a method of improvement in utility properties of unalloyed cast steel casting in result of diffusion of C and Cr in process of creation of surface layer is presented. The aim of paper was determination of diffusion range of basic elements of alloyed surface layer. Moreover a quantitative analysis of carbides phase strengthens alloyed surface layer of casting was carried out. The results of studies shown that important factors of surface layer creation are maximal temperature Tmax on granular insert – cast steel boundary dependent of pouring temperature, granularity Zw of Fe-Cr-C alloy insert and thickness of casting wall gśo. On the basis of obtained results was affirmed that with increase of thickness of casting wall increases range of diffusion in solid state in Fe-Cr-C grains and in liquid state. Moreover the range of Tmax = 13001500oC favours creation of the proper alloyed surface layers on cast steel.

  14. Quality control of cast brake discs

    M. Stawarz

    2008-04-01

    Full Text Available The largest industrial application so far have the gray cast irons which are characterized by low tensile and bending strength, while at the same time they have good ultimate comprehensive strength. Additionally, the fatigue strength of gray cast irons is comparatively low and they are only to some extend sensitive for the surface waters effects. Cast iron is the material, which is comparatively easy to be processed, and for this reason – it is not expensive. Brake discs are exploited in particularly hard conditions. They must be resistant both against the thermal fatigue and abrasion wearing (at dry friction as well as against seizing, corrosion and mechanical load [1-3]. The gray cast iron, better than other materials, fulfills all the requirements necessary for making the material for the casts resistant against such tough conditions. This work reflects the researches aiming to define the quality of cast brake discs (ventilated and non-ventilated ones upon a period of their exploitation in real conditions. The following researches were performed: evaluations of the disc surface condition, measurement of disc thickness, examination of run – out flank and metallographic analysis. In order to more detailed recognition of mechanisms and reasons of brake discs wearing in real conditions, one should conduct additional examinations: computer analysis of the microstructure, chemical composition analysis, etc., as well as study of the technology of their production in foundries, where they are manufactured [4]. By obtaining the full set of the mentioned above data one can draw final conclusions and remove causes of possible defects.

  15. Technetium Getters to Improve Cast Stone Performance

    Neeway, James J.; Lawter, Amanda R.; Serne, R. Jeffrey; Asmussen, Robert M.; Qafoku, Nikolla

    2015-10-15

    The cementitious material known as Cast Stone has been selected as the preferred waste form for solidification of aqueous secondary liquid effluents from the Hanford Tank Waste Treatment and Immobilization Plant (WTP) process condensates and low-activity waste (LAW) melter off-gas caustic scrubber effluents. Cast Stone is also being evaluated as a supplemental immobilization technology to provide the necessary LAW treatment capacity to complete the Hanford tank waste cleanup mission in a timely and cost effective manner. Two radionuclides of particular concern in these waste streams are technetium-99 (99Tc) and iodine-129 (129I). These radioactive tank waste components contribute the most to the environmental impacts associated with the cleanup of the Hanford site. A recent environmental assessment of Cast Stone performance, which assumes a diffusion controlled release of contaminants from the waste form, calculates groundwater in excess of the allowable maximum permissible concentrations for both contaminants. There is, therefore, a need and an opportunity to improve the retention of both 99Tc and 129I in Cast Stone. One method to improve the performance of Cast Stone is through the addition of “getters” that selectively sequester Tc and I, therefore reducing their diffusion out of Cast Stone. In this paper, we present results of Tc and I removal from solution with various getters with batch sorption experiments conducted in deionized water (DIW) and a highly caustic 7.8 M Na Ave LAW simulant. In general, the data show that the selected getters are effective in DIW but their performance is comprised when experiments are performed with the 7.8 M Na Ave LAW simulant. Reasons for the mitigated performance in the LAW simulant may be due to competition with Cr present in the 7.8 M Na Ave LAW simulant and to a pH effect.

  16. Casting of microstructured shark skin surfaces and possible applications on aluminum casting parts

    Todor Ivanov

    2011-02-01

    Full Text Available Within the project Functional Surfaces via Micro- and Nanoscaled Structures?which is part of the Cluster of Excellence 揑ntegrative Production Technology?established and financed by the German Research Foundation (DFG, an investment casting process to produce 3-dimensional functional surfaces down to a structural size of 1 μm on near-net-shape-casting parts has been developed. The common way to realize functional microstructures on metallic surfaces is to use laser ablation, electro discharge machining or micro milling. The handicap of these processes is their limited productivity. The approach of this project to raise the efficiency is to use the investment casting process to replicate microstructured surfaces by moulding from a laser-microstructured grand master pattern. The main research objective deals with the investigation of the single process steps of the investment casting process with regard to the moulding accuracy. Actual results concerning making of the wax pattern, suitability of ceramic mould and core materials for casting of an AlSi7Mg0.3 alloy as well as the knock-out behavior of the shells are presented. By using of the example of an intake manifold of a gasoline race car engine, a technical shark skin surface has been realized to reduce the drag of the intake air. The intake manifold consists of an air-restrictor with a defined inner diameter which is microstructured with technical shark skin riblets. For this reason the inner diameter cannot be drilled after casting and demands a very high accuracy of the casting part. A technology for the fabrication and demoulding of accurate microstructured castings are shown. Shrinkage factors of different moulding steps of the macroscopic casting part as well as the microscopic riblet structure have been examined as well.

  17. Combining the casting and punching technology

    Zh. Ashkeyev

    2016-07-01

    Full Text Available In the article there are presented the results of studying the microstructure of metals obtained by the method of casting and punching in equal-channel step matrixes (ECSM. The analysis of the microstructure of metals obtained on the scanning and transmission microscope showed that owing to realization of intensive shift deformations on the inclined portion of ECSM there emerge shear bands which extend practically in parallel to zones of the matrix channels connection and influence positively closing and sealing all internal defects of cast blanks.

  18. Ageing of cast stainless steel components

    The nuclear industry uses cast stainless steels in areas where it is paramount to ensure reactor safety. Investigations into the resistance of cast stainless steels to intergranular stress corrosion cracking (SCC) in simulated light water reactor conditions have shown contrary to expectation, some nuclear grade steels are indeed susceptible to SCC. The paper sets out of determine whether the information available in the various life extension databanks is sufficient for the application of the various empirical and theoretical models to the relevant safety analyses or if not, to identify areas where data is deficient. (Author)

  19. Dynamic fracture behavior of nodular cast iron

    Ferritic nodular cast iron has been found to be a much tougher material than previously believed based on Charpy impact test results. As a result this material is being considered as a substitute for Stainless Steel in nuclear waste transport containers. We have determined Klc and Kld values for nodular cast iron with varying values of silicon and percentage of pearlite in the matrix. Regular V-notch charpy bars and fatigue precracked charpy bars have been tested to determine the initiation and propagation energy and the effect of notch acuity on transition temperature. (author)

  20. Thin Wall Ductile Iron Castings: Technological Aspects

    E Fraś

    2013-01-01

    Full Text Available The paper discusses the reasons for the current trend of substituting ductile iron castings by aluminum alloys castings.However, it has been shown that ductile iron is superior to aluminum alloys in many applications. In particular it has beendemonstrated that is possible to produce thin wall wheel rim made of ductile iron without the development of chills, coldlaps or misruns. In addition it has been shown that thin wall wheel rim made of ductile iron can have the same weight, andbetter mechanical properties, than their substitutes made of aluminum alloys.

  1. Development Of Pallan Caste In Tamil Nadu - Hindrance And Contributive Factors

    B. Jawaharlal Nehru

    2013-01-01

    Pallan caste is sub – sect of scheduled castes in Tamil Nadu. Pallan caste people possess their own cultural heritage among the scheduled caste. This paper narrates about the hindrance contributive and factors for development of Pallan in Tamil Nadu.

  2. Development of vacuum continuous casting technology for uranium

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

    2001-02-01

    The spent fuel disposal process of new dry storage concept has been developed in KAERI, in which the uranium metal abstracted by Li-reduction of spent fuel will be formed to long rods and then the rods will be arranged uniformly in canister. The objective of this study is to review the feasibility of applying the continuous casting method to cast a long rod with modifying the vacuum high-frequency induction furnace to vacuum continuous casting system, which was normally used to cast the uranium. The results are as follows. With the nozzle size of 3mm and the withdrawal speed of 3.5 mm/sec, the length of 160mm, diameter of 30 mm continuous casting uranium bar was successfully cast. This result shows there might be a possibility of continuous casting of uranium and helps the design and fabrication of new continuous casting equipment.

  3. Manufacturing of thin walled near net shape iron castings

    Larsen, Per Leif

    2003-01-01

    substituting iron casings with aluminum castings. Substituting iron castings with aluminum castings is not as easy as first believed, and hence the substitution is very slow. This combined with the lack of fully exploiting the potential in iron castings, makes research in iron castings interesting. The 60......The demand for near net shape thin walled iron castings is growing. This has several reasons, the main one is the need for lowering the fuel consumption of cars; the easiest way to do that is to lower the weight of the cars. The best way to do this was for a period of time believed to be.......000.000 cars produced world wide each year consumes enormous amounts of cast parts ! The aim of the project is to develop the green sand molding method on DISAMATIC to be able to deal with the new demands for thin walled near net shape castings in iron....

  4. Opportunities and challenges of Chinese die-casting market

    2004-01-01

    The present status and perspectives of Chinese die-casting market were commented. In 2003, the total output of die castings in the whole country was 708 000 tons, in which the outputs of Al-alloy, Zn-alloy, Mg-alloy, Cu-alloy die castings were 474 600 tons, 222 000 tons, 5 800 tons, 5 600 tons, respectively, each accounted for 67%, 31.35%, 0.85%,0.8% of the total. The annual sale volume of die-casting machines was approximately 1 800. And the gross output value of dies approached RMB 38 billion, in which die-casting dies accounted for about 10%. In the die-casting industry of the entire country, the foreign capital enterprises, public-run enterprises, township and village enterprises, private enterprises accounted for over 80% of the total die-casting enterprises. Super huge die-casting groups are forming.

  5. Development of vacuum continuous casting technology for uranium

    The spent fuel disposal process of new dry storage concept has been developed in KAERI, in which the uranium metal abstracted by Li-reduction of spent fuel will be formed to long rods and then the rods will be arranged uniformly in canister. The objective of this study is to review the feasibility of applying the continuous casting method to cast a long rod with modifying the vacuum high-frequency induction furnace to vacuum continuous casting system, which was normally used to cast the uranium. The results are as follows. With the nozzle size of 3mm and the withdrawal speed of 3.5 mm/sec, the length of 160mm, diameter of 30 mm continuous casting uranium bar was successfully cast. This result shows there might be a possibility of continuous casting of uranium and helps the design and fabrication of new continuous casting equipment

  6. Metallic Fuel Casting Development and Parameter Optimization Simulations

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

  7. Plans and Measures for Avoiding Casting-Air-Pollution

    ZHOU Jian

    2003-01-01

    This article presents plans of preventing casting-air-pollution in practice, and some avoiding methods in detail. In modern times, environment protection is looked high upon day by day; green-casting thus becomes more and more important.

  8. Enhancements in Magnesium Die Casting Impact Properties

    David Schwam; John F. Wallace; Yulong Zhu; Srinath Viswanathan; Shafik Iskander

    2000-06-30

    The need to produce lighter components in transportation equipment is the main driver in the increasing demand for magnesium castings. In many automotive applications, components can be made of magnesium or aluminum. While being lighter, often times the magnesium parts have lower impact and fatigue properties than the aluminum. The main objective of this study was to identify potential improvements in the impact resistance of magnesium alloys. The most common magnesium alloys in automotive applications are AZ91D, AM50 and AM60. Accordingly, these alloys were selected as the main candidates for the study. Experimental quantities of these alloys were melted in an electrical furnace under a protective atmosphere comprising sulfur hexafluoride, carbon dioxide and dry air. The alloys were cast both in a permanent mold and in a UBE 315 Ton squeeze caster. Extensive evaluation of tensile, impact and fatigue properties was conducted at CWRU on permanent mold and squeeze cast test bars of AZ91, AM60 and AM50. Ultimate tensile strength values between 20ksi and 30ksi were obtained. The respective elongations varied between 25 and 115. the Charpy V-notch impact strength varied between 1.6 ft-lb and 5 ft-lb depending on the alloy and processing conditions. Preliminary bending fatigue evaluation indicates a fatigue limit of 11-12 ksi for AM50 and AM60. This is about 0.4 of the UTS, typical for these alloys. The microstructures of the cast specimens were investigated with optical and scanning electron microscopy. Concomitantly, a study of the fracture toughness in AM60 was conducted at ORNL as part of the study. The results are in line with values published in the literature and are representative of current state of the art in casting magnesium alloys. The experimental results confirm the strong relationship between aluminum content of the alloys and the mechanical properties, in particular the impact strength and the elongation. As the aluminum content increases from about 5

  9. The influence of martensitic transformation on mechanical properties of cast high alloyed CrMnNi-steel under various strain rates and temperatures

    Metastable austenitic steels show excellent mechanical properties, such as high strength combined with excellent ductility and toughness due to martensitic transformation under mechanical loading (transformation induced plasticity effect). A good energy consumption, and, in the case of high-alloyed metastable austenitic steels, a high corrosion resistance, increase the potential of these materials for diverse applications, also in regard of safety requirements. Up to now, numerous wrought alloys were investigated concerning mechanical behaviour, TRIP-effect, martensitic transformation behaviour and modelling of transformation kinetics or stress-strain behaviour. New high alloyed cast CrMnNi-steels, developed at Technical University Bergakademie Freiberg, provide the chance to reduce processing steps, production time and costs. In order to understand the influence of temperature on the martensitic phase transformation behaviour and therefore on mechanical properties and failure, the mechanical response under tensile loading in a temperature range between -700C and 2000C was investigated. The mechanical behaviour under compressive loading was also examined in a wide range of strain rates between 10-4 s-1 and 103 s-1 to obtain information about the strain rate effect on stress-strain behaviour and microstructural changes.

  10. Report on results of current and future metal casting

    Unal, Cetin [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Carlson, Neil N. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

    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.

  11. High speed twin roll casting of 6061 alloy strips

    T. Haga; H. Sakaguchi; Watari, H; S. Kumai

    2008-01-01

    Purpose: of this paper is to clear the possibility of high speed roll casting of thin strips of two aluminum alloys:6061 and recycled 6061. Mechanical properties of the roll cast 6061 and recycled 6061 strips were investigated inthe frame of this purpose.Design/methodology/approach: Methods used in the present study were high speed twin roll caster and lowtemperature casting. These methods were used to realize rapid solidification and increase the casting speed.Findings: are that 6061 and rec...

  12. Control of the metallurgical processing of ICDP cast irons

    Hampl, Jiří; Válek, Tomáš; Lichý, Petr; Elbel, Tomáš

    2014-01-01

    The article is focused on the use of the measurement of oxygen activity for the management of cast-iron metallurgical processing in the operating conditions of a centrifugal-roll casting foundry. The paper presents the results of the oxygen-activity measurement recorded during the metallurgical processing of cast iron from the beginning of the melting to the inoculation of cast iron. The measurement of oxygen activity was made with specifically developed devices and the probes with a...

  13. Complex Doping of Uranium under Centrifugal Casting in Zirconium Mold

    The paper presents the results of the investigation on the structure and distribution pattern of the doping elements in uranium casting, produced by the centrifugal casting in a sealed zirconium mold. It is investigated the possibility of complex zirconium and iron doping of uranium. The values of the zirconium mold dissolution rate against the centrifugal casting time are provided. The mechanism is suggested for doping uranium with the elements included in the mold material during the fuel rod fabrication by the centrifugal casting

  14. Undercooling and nodule count in thin walled ductile iron castings

    Pedersen, Karl Martin; Tiedje, Niels Skat

    2007-01-01

    Casting experiments have been performed with eutectic and hypereutectic castings with plate thicknesses from 2 to 8 mm involving both temperature measurements during solidification and microstructural examination afterwards. The nodule count was the same for the eutectic and hypereutectic castings in the thin plates (≤4.3 mm) while in the 8 mm plate the nodule count was higher in the hypereutectic than in the eutectic castings. The minimum temperature before the eutectic recalescence (Tmin) w...

  15. Clean Cast Steel Technology - Machinability and Technology Transfer

    C. E. Bates; J. A. Griffin

    2000-05-01

    There were two main tasks in the Clean Cast Steel Technology - Machinability and Technology Transfer Project. These were (1) determine the processing facts that control the machinability of cast steel and (2) determine the ability of ladle stirring to homogenize ladle temperature, reduce the tap and pouring temperatures, and reduce casting scrap.

  16. 46 CFR 153.239 - Use of cast iron.

    2010-10-01

    ... 46 Shipping 5 2010-10-01 2010-10-01 false Use of cast iron. 153.239 Section 153.239 Shipping COAST GUARD, DEPARTMENT OF HOMELAND SECURITY (CONTINUED) CERTAIN BULK DANGEROUS CARGOES SHIPS CARRYING BULK... Systems § 153.239 Use of cast iron. (a) Cast iron used in a cargo containment system must meet...

  17. CASTING OF DETAILS OF WEAR-RESISTANT CHROME CAST IRONS FOR CHROMIC MILLS IN COMBINED MOLDS AND CHILLS

    K. E. Baranovskij

    2009-01-01

    Full Text Available Relative wear resistance of chrome cast irons of eutectic composition is determined in laboratory and industry conditions. Complex alloyed eutectic cast iron with increased wear resistance and mechanical characteristics is developed.

  18. Structure and mechanical properties of vermicular cast iron in cylinder head casting

    E. Guzik

    2009-01-01

    Full Text Available The paper discusses the problem of grain density and ferrite content in microstructure of vermicular graphite iron cast in bars of different section diameters and cylinder head casting. The experimental results regarding the section effect demonstrate that the nodule count, grain density and ferrite content are all function of the cast bar diameter in this particular case ranging from 0.6 to 8.0 cm and microstructure and mechanical properties in the cylinder head. The nodule count (or grain density has been reported to increase, while ferrite content was decreasing with decreasing casting diameter. The density number of the grains Nv has been related (by regression analysis to the undercooling degree

  19. Study on Compatibility between Converters and Casting Machines for Daily Steelmaking and Continuous Casting Scheduling

    MA Feng-cai; ZHANG Qun

    2009-01-01

    In this paper, daily production scheduling is studied based on the Third Steelmaking Plant of Wuhan Iron and steel corporation (WISCO). To make sure the daily production plan is feasible, method of casting gToup is established, and the compatibility between two converters and three continuous casting devices in the Third Steelmaking Plant of WISCO is analyzed. The process flow chart of daily production scheduling is given in this paper. Then, algorithms and procedures for the simulation of daily production plan is developed. Using the actual data from the Third Steelmaking Plant, the feasible daily steelmaking plan and cast plan are given. The plan contains 7 groups of cast plan, figured out 54 converters, and a- bout 13,500 tons steel.

  20. Casting directly from a computer model by using advanced simulation software FLOW-3D Cast ®

    M. Sirviö

    2009-01-01

    Full Text Available ConiferRob - A patternless casting technique, originally conceived at VTT Technical Research Centre of Finland and furtherdeveloped at its spin-off company, Simtech Systems, offers up to 40% savings in product development costs, and up to two months shorterdevelopment times compared to conventional techniques. Savings of this order can be very valuable on today's highly competitivemarkets. Casting simulation is commonly used for designing of casting systems. However, most of the software are today old fashioned and predicting just shrinkage porosity. Flow Science, VTT and Simtech have developed new software called FLOW-3D Cast ® , whichcan simulate surface defects, air entrainment, filters, core gas problems and even a cavitation.

  1. New progresses of Chinese art casting

    TAN De-rui

    2007-01-01

    @@ The Chinese art casting with 5 000 years history has been rapidly developed in recent ten years. This benefits from the great development of Chinese economy, the large-scale urban construction and transformation, the increasing demands for the cultural work of art, the loose religious environment and the expanding international market.

  2. As-cast titanium aluminides microstructure modification

    A. Duarte

    1999-07-01

    Full Text Available Two cast g titanium aluminides, Ti47Al and Ti50Al (at. %, were obtained by arc melting under an argon atmosphere. The as-cast microstructure modification by annealing under protective argon atmosphere and hot isostatic pressing (HIP was analysed by optical and scanning electron microscopy with microanalysis facilities. As-cast structures presented strong microsegregations, being composed of primary a dendrites (with low Al content, which transformed into lamellar a2 + g during solid state cooling, and interdendritic g phase (with high Al content. Annealing in the a + g field was responsible for a partial reduction of microsegregation, a decreasing of the volume fraction of a2 + g lamellar dendrites, an increasing of g volume fraction and the occurrence of a small fraction of a2 particles and plates in some of the g grains. Annealing in the a field at 1400 °C for one hour was insufficient to eliminate the as-cast microstructure in the Ti50Al alloy and produced large equiaxed lamellar colonies of a2+g in the Ti47Al alloy. HIP in the a + g field (to avoid excessive grain growth was responsible for microstructure modifications similar to the ones obtained by heat treating under similar soaking conditions.

  3. Status and perspectives of the CAST experiment

    Lakic, B; Aune, S; Barth, K; Belov, A; Borghi, S; Brauninger, H; Cantatore, G; Carmona, J M; Cetin, S A; Collar, J I; Dafni, T; Davenport, M; Eleftheriadis, C; Elias, N; Ezer, C; Fanourakis, G; Ferrer-Ribas, E; Friedrich, P; Galan, J; Garcia, J A; Gardikiotis, A; Gazis, E N; Geralis, T; Giomataris, I; Gninenko, S; Gomez, H; Gruber, E; Guthorl, T; Hartmann, R; Haug, F; Hasinoff, M D; Hoffmann, D H H; Iguaz, F J; Irastorza, I G; Jacoby, J; Jakovcic, K; Karuza, M; Konigsmann, K; Kotthaus, R; Krcmar, M; Kuster, M; Laurent, J M; Liolios, A; Ljubicic, A; Lozza, V; Lutz, G; Luzon, G; Morales, J; Niinikoski, T; Nordt, A; Papaevangelou, T; Pivovaroff, M J; Raffelt, G; Rashba, T; Riege, H; Rodriguez, A; Rosu, M; Ruz, J; Savvidis, I; Silva, P S; Solanki, S K; Stewart, L; Tomas, A; Tsagri, M; van Bibber, K; Vafeiadis, T; Villar, J; Vogel, J K; Yildiz, S C; Zioutas, K

    2012-01-01

    The CERN Axion Solar Telescope (CAST) is currently the most sensitive axion helioscope designed to search for axions produced by the Primakoff process in the solar core. CAST is using a Large Hadron Collider (LHC) test magnet where axions could be converted into X-rays with energies up to 10 keV. During the phase I, the experiment operated with vacuum inside the magnet bores and covered axion masses up to 0.02 eV. In the phase II, the magnet bores were filled with a buffer gas (first (4)He and later (3)He) at various densities in order to extend the sensitivity to higher axion masses (up to f .18 eV). The phase II data taking was completed in 2011. So far, no evidence of axion signal has been found and CAST set the most restrictive experimental limit on the axion-photon coupling constant over a broad range of axion masses. The latest CAST results with (3)He data in the mass range 0.39 eV < ma < 0.64 eV will be presented.

  4. Fermilab joins in global live Web cast

    Polansek, Tom

    2005-01-01

    From 2 to 3:30 p.m., Lederman, who won the Nobel Prize for physics in 1988, will host his own wacky, science-centered talk show at Fermi National Accelerator Laboratory as part of a lvie, 12-hour, international Web cast celebrating Albert Einstein and the world Year of Physics (2/3 page)

  5. Costs Analysis of Iron Casts Manufacturing

    S. Kukla

    2012-04-01

    Full Text Available The article presents the issues of costs analysis of iron casts manufacturing using automated foundry lines. Particular attention was paid to departmental costs, conversion costs and costs of in-plant transport. After the Pareto analysis had been carried out, it was possible to set the model area of the process and focus on improving activities related to finishing of a chosen group of casts. In order to eliminate losses, the activities realised in this domain were divided into activities with added value, activities with partially added value and activities without added value. To streamline the production flow, it was proposed to change the location of workstations related to grinding, control and machining of casts. Within the process of constant improvement of manufacturing processes, the aspect of work ergonomics at a workstation was taken into account. As a result of the undertaken actions, some activities without added value were eliminated, efficiency was increased and prime costs of manufacturing casts with regard to finishing treatment were lowered.

  6. 14 CFR 25.621 - Casting factors.

    2010-01-01

    ... except castings that are pressure tested as parts of hydraulic or other fluid systems and do not support... surface hinges and balance weight attachments, seat, berth, safety belt, and fuel and oil tank supports....25; and (ii) Receive 100 percent inspection by visual, radiographic, and magnetic particle...

  7. CAST reaches milestone but keeps on searching

    CERN Courier (september 2011 issue)

    2011-01-01

    After eight years of searching for the emission of a dark matter candidate particle, the axion, from the Sun, the CERN Axion Solar Telescope (CAST) has fulfilled its original physics programme.   Members of the CAST collaboration in July, together with dipole-based helioscope. CAST, the world’s most sensitive axion helioscope, points a recycled prototype LHC dipole magnet at the Sun at dawn and dusk, looking for the conversion of axions to X-rays. It incorporates four state-of-the-art X-ray detectors: three Micromegas detectors and a pn-CCD imaging camera attached to a focusing X-ray telescope that was recovered from the German space programme (see CERN Courier April 2010).  Over the years, CAST has operated with the magnet bores - the location of the axion conversion - in different conditions: first in vacuum, covering axion masses up to 20 meV/c2, and then with a buffer gas (4He and later 3He) at various densities, finally reaching the goal of 1.17 eV/c2 on 22 ...

  8. Solidification modeling of continuous casting process

    Lerner, V. S.; Lerner, Y. S.

    2005-04-01

    The aim of the present work was to utilize a new systematic mathematical-informational approach based on informational macrodynamics (IMD) to model and optimize the casting process, taking as an example horizontal continuous casting (HCC). The IMD model takes into account the interrelated thermal, diffusion, kinetic, hydrodynamic, and mechanical effects that are essential for the given casting process. The optimum technological process parameters are determined by the simultaneous solution of problems of identification and optimal control. The control functions of the synthesized optimal model are found from the extremum of the entropy functional having a particular sense of an integrated assessment of the continuous cast bar physicochemical properties. For the physical system considered, the IMD structures of the optimal model are connected with controllable equations of nonequilibrium thermodynamics. This approach was applied to the HCC of ductile iron, and the results were compared with experimental data and numerical simulation. Good agreement was confirmed between the predicted and practical data, as well as between new and traditional methods.

  9. Gelcasting Alumina Cores for Investment Casting

    Janney, M A; Klug, F J

    2001-01-01

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

  10. THE THERMAL PROCESSES’ MATHEMATICAL SIMULATION DURING CASTING INTO METAL MOULD OF THE SHORT HOLLOW CYLINDRICFL CASTING

    Клименко, Леонід Павлович; Дихта, Леонід Михайлович; Андреєв, В’ячеслав Іванович

    2015-01-01

    Mathematical simulation is made for thermal processes associated with the removal overheat melt, solidification and subsequent cooling of the short hollow cylindrical casting during its manufacturing by the method of centrifugal casting in metal mould. In the paper the mentioned processes’ mathematical simulation is reduced to the solution of a number of boundary-value problems of heat conductivity theory. Some significant mathematical difficulties caused by the presence of liquid core and mo...

  11. Casting and stress-strain simulations of a cast ductile iron component using microstructure based mechanical behavior

    Olofsson, Jakob; Ingvar L. Svensson

    2012-01-01

    The industrial demand for increased component performance with concurrent reductions in component weight, development times and verifications using physical prototypes drives the need to use the full potential of casting and Finite Element Method (FEM) simulations to correctly predict the mechanical behavior of cast components in service. The mechanical behavior of the component is determined by the casting process, and factors as component geometry and casting process parameters are known to...

  12. Laser surface treatment of cast magnesium alloys

    L.A. Dobrzański

    2009-02-01

    Full Text Available Purpose: The goal of this work was to investigate influence of laser treatment on structure and properties MCMgAl3Zn1, MCMgAl6Zn1, MCMgAl9Zn1 and MCMgAl12Zn1 cast magnesium alloys.Design/methodology/approach: Tests were made on the experimental MCMgAl3Zn1 MCMgAl6Zn1 MCMgAl9Zn1 and MCMgAl12Zn1 casting magnesium alloys. Laser treatment was made using the Rofin DL020 HPDL high power diode laser in the argon shield gas cover with the technique of the continuous powder supply to the remelted pool area.Findings: Investigations of the surface layers carried out confirm that laser treatment of the surface layer of the Mg-Al-Zn casting magnesium alloys is feasible using the HPDL high power diode laser ensuring better properties compared to alloys properties after the regular heat treatment after employing the relevant process parameters. Occurrences were found based on the metallographic examinations of the remelted zone (RZ and the heat affected zone (HAZ in alloyed surface layer of the investigated casting magnesium alloy.Research limitations/implications: This investigation presents different laser power and in this research was used two powders, namely tungsten-, and titanium carbide.Practical implications: Reinforcing the surface of cast magnesium alloys by adding TiC and WC particles is such a possible way to achieve the possibilities of the laser melt injection process, which is a potential technique to produce a Metal-Matrix Composite (MMC layer in the top layer of a metal workpiece.Originality/value: The originality of this work is applying of High Power Diode Laser for alloying of magnesium alloy using hard particles like tungsten- and titanium carbide.

  13. Temperature and microstructure characteristics of silumin casting AlSi9 made with investment casting method

    S. Pietrowski

    2011-07-01

    Full Text Available This work presents the research result of the temperature distribution and the microstructure in certain parts of the field-glass body frame casting made from silumin AlSi9 using the investment casting method in the ceramic mould. It was proved that the highest temperature of the silumin appears in the sprue in which the silumin is in the liquid-solid state, though the process of silumin crystallization in the casting is finished. It was stated that in certain elements of the casting the side opposite to the runner crystallizes and cools fastest. The differences in the rate of crystalline growth and cooling of certain casting elements cause differ- ent microstructure in them which can also influence the mechanic properties.It is necessary to state that the temperature of the initial heating of the ceramic mold equal to 60oC guarantees obtaining of the castings without defects and of little porosity. Incomplete modification of the silumin with strontium causes silica precipitation to appear close to the spherical ones.

  14. Aluminium Foam and Magnesium Compound Casting Produced by High-Pressure Die Casting

    Iban Vicario

    2016-01-01

    Full Text Available Nowadays, fuel consumption and carbon dioxide emissions are two of the main focal points in vehicle design, promoting the reduction in the weight of vehicles by using lighter materials. The aim of the work is to evaluate the influence of different aluminium foams and injection parameters in order to obtain compound castings with a compromise between the obtained properties and weight by high-pressure die cast (HPDC using aluminium foams as cores into a magnesium cast part. To evaluate the influence of the different aluminium foams and injection parameters on the final casting products quality, the type and density of the aluminium foam, metal temperature, plunger speed, and multiplication pressure have been varied within a range of suitable values. The obtained compound HPDC castings have been studied by performing visual and RX inspections, obtaining sound composite castings with aluminium foam cores. The presence of an external continuous layer on the foam surface and the correct placement of the foam to support injection conditions permit obtaining good quality parts. A HPDC processed magnesium-aluminium foam composite has been developed for a bicycle application obtaining a suitable combination of mechanical properties and, especially, a reduced weight in the demonstration part.

  15. Recent development of ductile cast iron production technology in China

    Cai Qizhou

    2008-05-01

    Full Text Available Recent progress in the production and technology of ductile cast iron castings in China is reviewed. The manufacture and process control of as-cast ductile iron are discussed. The microstructure, properties and application of partial austenitization normalizing ductile iron and austempered ductile iron (ADI are briefl y depicted. The new development of ductile iron production techniques, such as cored-wire injection (wire-feeding nodularization process, tundish cover ladle nodularizing process, horizontal continuous casting, and EPC process (lost foam for ductile iron castings, etc., are summarized.

  16. Recent development of ductile cast iron production technology in China

    Cai Qizhou; Wei Bokang

    2008-01-01

    Recent progress in the production and technology of ductile cast iron castings in China is reviewed.The manufacture and process control of as-cast ductile iron are discussed.The microstructure.properties and application of partial austenitization normalizing ductile iron and austempered duclile iron(ADI)are briefly depicted.The new development of duclile iron production techniques,such as cored-wire injection(wire-feeding nodularization)process,tundish cover ladle nodularizing process,horizontal continuous casting,and EPC process (lost foam)for ductile iron castings,etc.,are summarized.

  17. Bench mark test casting: Modeling of mold filling and solidification

    Layton, M.A.; Wang, C.M.; Cheng, C.; Yu, K.O.; Paul, A.J. [Concurrent Technologies Corp., Johnstown, PA (United States)

    1995-12-31

    This paper presents the results of simulating the mold filling and solidification of an aluminum plate casting designed as the Bench Mark Test Casting for this conference. An in-house simulation software, RAPID/CAST{reg_sign}, has been used to conduct this simulation. The output of this simulation include flow front location during mold filling, cooling curves at various points in the casting, temperature distribution, and isochron plots of solidification times. The simulation results indicate that the mold filling time of the entire casting is 2.2 seconds and that the last region to solidify is located around the ingate.

  18. Myoglobin casts in renal biopsies: immunohistochemistry and morphologic spectrum.

    Liapis, Helen; Boils, Christie; Hennigar, Randolph; Silva, Fred

    2016-08-01

    Five hundred eighty renal biopsies from a pool of 27850 archived cases were identified in which a myoglobin stain was performed because of atypical casts. Two hundred and thirty-eight (41%) of these biopsies were found to be positive for myoglobin casts. The morphology of the myoglobin casts ranged from light, almost translucent and refractile, to pink, to dark red and slightly brown granular casts by hematoxylin and eosin, to beaded globular casts that stained brightly fuchsinophilic with Masson trichrome and partially argyrophilic with silver methenamine. All biopsies displayed acute tubular injury associated with intratubular debris and thinning and vacuolization of tubular epithelium. Approximately 20% of myoglobin-positive biopsies showed calcium oxalate or phosphate deposition. Positive myoglobin staining was present in casts, proximal tubular epithelial cells without casts, and also dehisced epithelial cells. Collecting ducts and occasionally the distal tubular epithelium also stained positive. One case showed concurrent myeloma cast nephropathy with "fractured" casts and translucent myoglobin-positive casts. Herein, we describe the morphologic spectrum of myoglobin-positive casts. We conclude that utilization of myoglobin immunohistochemistry is advantageous and, when not available, knowledge of the morphologic spectrum is important. PMID:27038680

  19. Preferential dissolution behaviour in Ni–Cr dental cast alloy

    Viswanathan S Saji; Han Cheol Choe

    2010-08-01

    A Ni–Cr–Mo dental alloy was fabricated by three different casting methods, viz. centrifugal casting, high frequency induction casting and vacuum pressure casting. The dependence of cast microstructure on the electrochemical corrosion behaviour was investigated using potentiodynamic cyclic and potentiostatic polarization techniques, impedance spectroscopy and scanning electron microscopy. The experimental results were compared and discussed with those obtained for a Co–Cr–Mo counterpart. The results of the study showed that the variation in casting morphologies with casting methods has only marginal influence in the overall corrosion resistance of Ni–Cr and Co–Cr dental alloys. There was severe preferential dissolution of Ni rich, Cr and Mo depleted zones from the Ni–Cr–Mo alloy. The overall corrosion resistance property of the Co–Cr base alloy was better than that of the Ni–Cr base alloy.

  20. Undercooling and nodule count in thin walled ductile iron castings

    Pedersen, Karl Martin; Tiedje, Niels Skat

    2007-01-01

    Casting experiments have been performed with eutectic and hypereutectic castings with plate thick¬nesses from 2 to 8 mm involving both temperature measurements during solidification and micro¬structural examination afterwards. The nodule count was the same for the eutectic and hypereutectic...... castings in the thin plates ( 4.3 mm) while in the 8 mm plate the nodule count was higher in the hypereutectic than in the eutectic castings. The minimum temperature prior to the eutectic recalescence (Tmin) was 15 to 20C lower for the eutectic than the hypereutectic castings. This is due to nucleation...... of graphite nodules which begins at a lover temperature in the eutectic than in the hypereutectic castings The recalescence (Trec) was however also larger for the eutectic casting and in the thin plates the maximum temperature after recalescence (Tmax) was the same in the eutectic and hypereutectic...

  1. Undercooling and nodule count in thin walled ductile iron castings

    Pedersen, Karl Martin; Tiedje, Niels Skat

    2007-01-01

    Casting experiments have been performed with eutectic and hypereutectic castings with plate thicknesses from 2 to 8 mm involving both temperature measurements during solidification and microstructural examination afterwards. The nodule count was the same for the eutectic and hypereutectic castings...... in the thin plates (≤4.3 mm) while in the 8 mm plate the nodule count was higher in the hypereutectic than in the eutectic castings. The minimum temperature before the eutectic recalescence (Tmin) was 15 to 20ºC lower for the eutectic than for the hypereutectic castings. This is due to nucleation of...... graphite nodules which begins at a lower temperature in the eutectic than in the hypereutectic castings. The recalescence ∆Trec was however also larger for the eutectic casting and in the thin plates the maximum temperature after recalescence (Tmax) was the same in the eutectic and hypereutectic plates...

  2. Comparison of residual stresses in sand- and chill casting of ductile cast iron wind turbine main shafts

    Sonne, Mads Rostgaard; Frandsen, J. O.; Hattel, Jesper Henri

    2015-01-01

    In this work, simulations of pouring, solidification and cooling, and residual stress evolution of sand and chill cast wind turbine main shafts is performed. The models are made in the commercial software MAGMAsoft. As expected, the cooling rate of the sand casting is shown to be much lower than...... for the chill casting, resulting in a very course microstructure.From the simulations the nodule count is found to be 17 nodules per mm2 and 159 nodules permm2 for the sand and chill casting, respectively, in the critical region of the main bearing seat.This is verified from nodule counts performed on...... the real cast main shafts. Residual stressevaluations show an overall increase of the maximum principal stress field for the chill casting,which is expected. However, the stresses are found to be in compression on the surface of thechill cast main shaft, which is unforeseen....

  3. Utilization of heat treatment aimed to spheroidization of eutectic silicon for silumin castings produced by squeeze casting

    B. Vanko

    2012-01-01

    Full Text Available This paper describes the possibility of using very short periods of solution annealing in the heat treatment of unmodified hypoeutectic silumin alloy AlSi7Mg0,3 casted by method of casting with crystallization under pressure with forced convection (direct squeeze casting process. Castings prepared at different casting parameters were subjected to special heat treatment called SST (Silicon Spheroidization Treatment, which were originally used only for the modified silumin alloys to spheroidization of eutectic silicon. Temperature holding time in solution annealing of T6 heat treatment is limited in the SST process to only a few minutes. It was studied the effect of casting parameters and periods of solution annealing on ultimate strength, yield strength, and especially ductility that in the unmodified silumin alloy castings is relatively low.

  4. Phase Transformation in Cast Superaustenitic Stainless Steels

    Nathaniel Steven Lee Phillips

    2006-12-12

    Superaustenitic stainless steels constitute a group of Fe-based alloys that are compositionally balanced to have a purely austenitic matrix and exhibit favorable pitting and crevice corrosion resistant properties and mechanical strength. However, intermetallic precipitates such as sigma and Laves can form during casting or exposure to high-temperature processing, which degrade the corrosion and mechanical properties of the material. The goal of this study was to accurately characterize the solid-solid phase transformations seen in cast superaustenitic stainless steels. Heat treatments were performed to understand the time and temperature ranges for intermetallic phase formations in alloys CN3MN and CK3MCuN. Microstructures were characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy and wavelength dispersive spectroscopy (EDS, WDS). The equilibrium microstructures, composed primarily of sigma and Laves within purely austenitic matrices, showed slow transformation kinetics. Factors that determine the extent of transformation, including diffusion, nucleation, and growth, are discussed.

  5. Fundamentals of Numerical Modelling of Casting Processes

    Pryds, Nini; Thorborg, Jesper; Lipinski, Marek;

    Fundamentals of Numerical Modelling of Casting Processes comprises a thorough presentation of the basic phenomena that need to be addressed in numerical simulation of casting processes. The main philosophy of the book is to present the topics in view of their physical meaning, whenever possible......, rather than relying strictly on mathematical formalism. The book, aimed both at the researcher and the practicing engineer, as well as the student, is naturally divided into four parts. Part I (Chapters 1-3) introduces the fundamentals of modelling in a 1-dimensional framework. Part II (Chapter 4......) presents the most important aspects of solidification theory related to modelling. Part III (Chapter 5) describes the fluid flow phenomena and in part IV (Chapter 6) the stress-strain analysis is addressed. For all parts, both numerical formulations as well as some important analytical solutions...

  6. Solidification control in continuous casting of steel

    S Mazumdar; S K Ray

    2001-02-01

    An integrated understanding of heat transfer during solidification, friction/lubrication at solid-liquid interface, high temperature properties of the solidifying shell etc. is necessary to control the continuous casting process. The present paper elaborates upon the knowledge developed in the areas of initial shell formation, mode of mould oscillation, and lubrication mechanism. The effect of these issues on the caster productivity and the quality of the product has been discussed. The influence of steel chemistry on solidification dynamics, particularly with respect to mode of solidification and its consequence on strength and ductility of the solidifying shell, has been dealt with in detail. The application of these basic principles for casting of stainless steel slabs and processing to obtain good quality products have been covered.

  7. Level measurement in electromagnetic continuous casting

    Level measurement method of molten metal have been investigated to apply in the electromagnetic continuous casting. The level measuring principle was based on the electromagnetic induction and search coil type of magnetic sensor was chosen as a level sensor, Before construct the level meter, the artificial cold charges was used to characterize the sensor output according to the level, the coil current, and the aging. Considering the results of basic experiments, we constructed a level measurement system and applied it to electromagnetic continuous casting at a billet caster of POSCO works. The developed level meter showed that the resolution of the level was within ±0.3 mm, the dynamic range of sensing was from the top of the mold to 300 mm below the top of the mold. It worked well with the existing control device in supplying the molten steel to the mold.

  8. The CAST experiment: status and perspectives

    Iguaz, F. J.

    2011-01-01

    The status of the solar axion search with the CERN Axion Solar Telescope (CAST) will be discussed. Results from the first part of CAST phase II where the magnet bores were filled with 4He gas at variable pressure in order to scan axion masses up to 0.4 eV will be presented. From the absence of excess X-rays when the magnet was pointing to the Sun, we set a typical upper limit on the axion-photon coupling of g < 2.17 x 10^10 GeV$-1 at 95% CL for axion masses lower than 0.4 eV, the exact result...

  9. Solar axion search with the CAST experiment

    Arik, E; Autiero, D; Barth, K; Belov, A; Beltrán, B; Borghi, S; Boydag, F S; Bräuninger, H; Cantatore, G; Carmona, J M; Cetin, S A; Collar, J I; Dafni, T; Davenport, M; Di Lella, L; Dogan, O B; Eleftheriadis, C; Elias, N; Fanourakis, G K; Ferrer-Ribas, E; Fischer, H; Franz, J; Galan, J; Gazis, E; Geralis, T; Giomataris, Yu; Gninenko, S; Gomez, H; Hasinoff, M; Heinsius, F H; Hikmet, I; Hoffmann, D H H; Irastorza, I G; Jacoby, J; Jakovcic, K; Kang, D; Karageorgopoulou, T; Karuza, M; Königsmann, K C; Kotthaus, R; Krcmar, M; Kousouris, K; Kuster, M; Lakic, B; Lasseur, C; Liolios, A; Ljubcici, A; Lozza, V; Lutz, G; Luzón, G; Miller, D; Morales, J; Niinikoski, T; Nordt, A; Ortiz, A; Papaevangelou, T; Pivovaroff, M; Placci, A; Raiteri, G; Raffelt, G; Riege, H; Rodríguez, A; Ruz, J; Savvidis, I; Semertzidis, Y; Serpico, P; Solanki, S K; Soufli, R; Stewart, L; Tsagri, M; Van Bibber, K; Villar, J; Vogel, J; Walckiers, L; Zioutas, K

    2008-01-01

    The CAST (CERN Axion Solar Telescope) experiment is searching for solar axions by their conversion into photons inside the magnet pipe of an LHC dipole. The analysis of the data recorded during the first phase of the experiment with vacuum in the magnet pipes has resulted in the most restrictive experimental limit on the coupling constant of axions to photons. In the second phase, CAST is operating with a buffer gas inside the magnet pipes in order to extent the sensitivity of the experiment to higher axion masses. We will present the first results on the $^4{He}$ data taking as well as the system upgrades that have been operated in the last year in order to adapt the experiment for the $^3{He}$ data taking. Expected sensitivities on the coupling constant of axions to photons will be given for the recent $^3{He}$ run just started in March 2008.

  10. Volatile species retention during metallic fuel casting

    Fielding, Randall S., E-mail: randall.fielding@inl.gov; Porter, Douglas L.

    2013-10-15

    Metallic nuclear fuels are candidate transmutation fuel forms for advanced fuel cycles. Through the operation of the Experimental Breeder Reactor II metallic nuclear fuels have been shown to be robust and easily manufactured. However, concerns have been raised concerning loss of americium during the casting process because of its high vapor pressure. In order to address these concerns a gaseous diffusion model was developed and a series of experiments using both manganese and samarium as surrogates for americium were conducted. The modeling results showed that volatility losses can be controlled to essentially no losses with a modest overpressure. Experimental results also showed volatile species retention down to no detectable losses through overpressure, and although the loss values varied from the model results the same trend was seen. Based on these results it is very probable that americium losses through volatility can be controlled to no detectable losses through application of a modest overpressure during casting.

  11. Simulation of the stir casting process

    Naher, Sumsun; BRABAZON, Dermot; Looney, Lisa

    2003-01-01

    Non homogeneous particle distribution is one of the greatest problems in casting Metal Matrix Composites (MMC's). To optimize some of the parameters for uniform particle distribution for batch compocasting the present simulation studies were conducted. The simulation involves visualisation experiments. In the visualisation experiments liquid and semi solid aluminium are replaced by other fluids with similar characteristics. SiC reinforcement particulate similar to that used in aluminium MMC's...

  12. Thin Wall Cast Iron: Phase II

    Doru M. Stefanescu

    2005-07-21

    The development of thin-wall technology allows the designers of energy consuming equipment to select the most appropriate material based on cost/material properties considerations, and not solely on density. The technology developed in this research project will permit the designers working for the automotive industry to make a better informed choice between competing materials and thin wall cast iron, thus decreasing the overall cost of the automobile.

  13. REVIEW ON DEFECTS ON STONE CRUSHER CASTINGS

    K. Subrahmanyam; Ch. Venkata Rajesh; V. Varun Kumar

    2014-01-01

    This processes to prepare the product to fallow the step by step procedures are pattern making is the first stage for developing a new casting .this pattern is typically constructed from teak wood and the mould is formed in a mould box, which is typically constructed in two halves to assist in removing the pattern, by using electric induction furnace to prepare the molten metal this metal preparation to mix the correct proposition of alloys. Molten metal is Transferred from th...

  14. Crystallization of nodular cast iron with carbides

    S. Pietrowski

    2008-12-01

    Full Text Available In this paper a crystallization process of nodular cast iron with carbides having a different chemical composition have been presented. It have been found, that an increase of molybdenum above 0,30% causes the ledeburutic carbides crystallization after (γ+ graphite eutectic phase crystallization. When Mo content is lower, these carbides crystallize as a pre-eutectic phase. In this article causes of this effect have been given.

  15. Mechanical properties of magnesium casting alloys

    L.A. Dobrzański

    2007-10-01

    Full Text Available Purpose: In the following paper there have been the properties of the MCMgAl12Zn1, MCMgAl9Zn1, MCMgAl6Zn1, MCMgAl3Zn1 magnesium cast alloy as-cast state and after a heat treatment presented.Design/methodology/approach: A casting cycle of alloys has been carried out in an induction crucible furnace using a protective salt bath Flux 12 equipped with two ceramic filters at the melting temperature of 750±10ºC, suitable for the manufactured material. The following results concern sliding friction, mechanical properties, scanning microscopy.Findings: The different heat treatment kinds employed contributed to the improvement of mechanical properties of the alloy with the slight reduction of its plastic properties.Research limitations/implications: According to the alloys characteristic, the applied cooling rate and alloy additions seems to be a good compromise for mechanical properties and microstructures, nevertheless further tests should be carried out in order to examine different cooling rates and parameters of solution treatment process and aging process.Practical implications: The concrete examples of the employment of castings from magnesium alloys in the automotive industry are elements of the suspension of the front and rear axes of cars, propeller shaft tunnel, pedals, dashboards, elements of seats, steering wheels, elements of timer-distributors, air filters, wheel bands, oil sumps, elements and housings of the gearbox, framing of doors and sunroofs, and others, etc.Originality/value: Contemporary materials should possess high mechanical properties, physical and chemical, as well as technological ones, to ensure long and reliable use. The above mentioned requirements and expectations regarding the contemporary materials are met by the non-ferrous metals alloys used nowadays, including the magnesium alloys.

  16. Ceramic technology for the investment casting industry

    The development of the ceramic shell system used in investment casting is described along with a number of other ceramic related techniques which have led to the establishment of the process at the forefront of metal forming technology. A number of raw material requirements are examined along with improvements in property measurement techniques at the system's operating temperature. The shells were investigated using x-ray diffraction. 13 refs., 18 figs., 5 tabs

  17. Ultrasonic examination of cast stainless steel

    We present the recent results of a program between CEA and EDF concerning ultrasonic examination of cast stainless steel. We compare the results obtained with different transducers, in particular large aperture composite transducers. We present different signal processing techniques (Spit Spectrum Processing) and image processing, developed to increase signal to noise ratio. Detection capabilities for artificial defects in different structures (equiaxed, columnar structures) are discussed. (authors). 2 refs., 15 figs

  18. Development and investigation of electroslag continuous casting

    Ximin Zang; Zhouhua Jiang; Tieyi Pan

    2007-01-01

    The principle and technological design of electroslag continuous casting (ESCC), including bifilar mode, T-shaped mould,and metal level detecting system, are detailed. Remelting was carried out for 1Cr18Ni9Ti stainless steel with ESCC. The surface finish, chemical composition, macro- and microstructures, and inclusions of the remelted billets were characterized. ESCC reduces the cost and increases the productivity in comparison to traditional ESR, while achieves comparably excellent products.

  19. Efficient Runner Networks for Investment Castings

    GIVLER,RICHARD C.; SAYLORS,DAVID B.

    2000-07-18

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

  20. The prediction of bubble defects in castings

    Lawrence, James Andrew

    2004-01-01

    Objective of this research was to develop models that capture the entrainment, breakup and transport of gas bubbles in solidifying TiAl castings. The candidate has reviewed the literature, programmed in FORTRAN code, and validated a number of competing techniques for two phase flow relevant to the filling of moulds. He has developed a hybrid (Donor-acceptor/ Level Set) method, which captures the characteristics of gas bubbles based on the surface tension —fluid inertia balance on the free sur...

  1. Maintenance system improvement in cast iron foundry

    S. Kukla

    2011-01-01

    The work presents the issue of technical equipment management in an iron foundry basing on the assumptions of the TPM system (Total Productive Maintenance). Exploitation analysis of automatic casting lines has been carried out and their work’s influence on the whole production system’s functioning has been researched. Within maintenance system improvement, implementation of autonomic service and planned lines’ review have been proposed in order to minimize the time of breakdown stoppages. The...

  2. Pouring mould during centrifugal casting process

    J. Śleziona

    2007-07-01

    Full Text Available Purpose: The paper presents the model and the example simulations of the centrifugal casting of metal matrix composite reinforced with SiC, especially the distribution of the velocity of liquid composite for the initial stage of pouring the mould (up to 1s.Design/methodology/approach: Numerical simulations have been performed using the CFD program FLUENT 6.1.To simulate pouring the mould, axisymmetric swirl model has been applied. To model the air-matrix free surface (and also volume fraction of particular continuous phases and dispersed phase, Vo lume of Fluid approach (VOF and Discrete Phase Model (DPM have been used, respectively. The turbulent flow of the fluid has been simulated by the standard k-ε model of turbulence.Findings: The results show that the behaviour of composite in pouring process depends strongly on the existence of reinforcement and process parameters and the initial stage of the casting can probably have an influence on the segregation and various final distribution of reinforcement particles.Research limitations/implications: The implemented simulational scheme can be used to study the behaviour of liquid composite during casting and the final simulational structure of composite should be verified experimentally.Practical implications: The simulation by CFD program (Fluent can be treated as an attractive and useful tool for modelling centrifugal casting process of metal matrix composite reinforced by ceramic particles. The created model and procedures can be come the basis for more advanced researches.Originality/value: The development of CFD program and the computer technology allow to study even complicated problems. Hence, we have implemented the CFD program to simulate the centrifugal casing of composite.

  3. BETWEEN THE DENDRITE STRUCTURE QUALITY, THE CASTING TECHNOLOGY AND THE DEFECTS IN CONTINUOUSLY CAST SLABS

    Slavomír Peľák

    2009-11-01

    Full Text Available The paper presents the results of analysis of surface defects of continuously cast slabs. Longitudinal central cracks of type II, accompanied by local depression, were found. The local depressions were formed in areas with the thinnest slab chill zone. We suppose that they were caused by heterogeneous contraction of solidified shell. The second part of the paper analyzes the relationships between the chemical composition, the dendrite structure parameters, the casting technology parameters and the occurrence of defects in continuously cast slabs. To determine the susceptibility of the steel to longitudinal cracking, we analyzed the relationships between a large variety of data (slab chemical composition, casting speed, casting and overheating temperatures, primary and secondary dendrite arm spacing, etc.. The longitudinal defects were more frequent in overheated steel, with a small central zone, great dendrite arm spacing and with a higher than recommended sulphur and phosphorus content. Numerically expressed, cracking developed at the segregation index values IS bigger/same 100, with the surface cracking index IPT bigger/same 60.

  4. Aging degradation of cast stainless steel

    A program is being conducted to investigate the significance of in-service embrittlement of cast-duplex stainless steels under light-water reactor operating conditions. Data from room-temperature Charpy-impact tests for several heats of cast stainless steel aged up to 10,000 h at 350, 400, and 4500C are presented and compared with results from other studies. Microstructures of cast-duplex stainless steels subjected to long-term aging either in the laboratory or in reactor service have been characterized. The results indicate that at least two processes contribute to the low-temperature embrittleent of duplex stainless steels, viz., weakening of the ferrite/austenite phase boundary by carbide precipitation and embrittlement of ferrite matrix by the formation of additional phases such as G-phase, Type X, or the α' phase. Carbide precipitation has a significant effect on the onset of embrittlement of CF-8 and -8M grades of stainless steels aged at 400 or 4500C. The existing correlations do not accurately represent the embrittlement behavior over the temperature range 300 to 4500C. 18 refs., 13 figs

  5. Aging degradation of cast stainless steel

    A program is being conducted to investigate the significance of in-service embrittlement of cast duplex stainless steels under light-water reactor operating conditions. Microstructures of cast materials subjected to long-term aging either in reactor service or in the laboratory have been characterized by TEM, SANS, and APFIM techniques. Two precipitate phases, i.e., the Cr-rich α' and Ni- and Si-rich G phase, have been identified in the ferrite matrix of the aged steels. The results indicate that the low-temperature embrittlement is primarily caused by α' precipitates which form by spinodal decomposition. The relative contribution of G phase to loss of toughness is now known. Microstructural data also indicate that weakening of ferrite/austenite phase boundary by carbide precipitates has a significant effect on the onset and extent of embrittlement of the high-carbon CF-8 and CF-8M grades of stainless steels, particularly after aging at 400 or 4500C. Data from Charpy-impact, tensile, and J-R curve tests for several heats of cast stainless steel aged up to 10,000 h at 350, 400, and 4500C are presented and correlated with the microstructural results. Thermal aging of the steels results in an increase in tensile strength and a decrease in impact energy, J/sub IC/, and tearing modulus. The fracture toughness results show good agreement with the Charpy-impact data. The effects of compositional and metallurgical variables on loss of toughness are discussed

  6. Aging degradation of cast stainless steel

    Chopra, O.K.; Chung, H.M.

    1985-10-01

    A program is being conducted to investigate the significance of in-service embrittlement of cast-duplex stainless steels under light-water reactor operating conditions. Data from room-temperature Charpy-impact tests for several heats of cast stainless steel aged up to 10,000 h at 350, 400, and 450/sup 0/C are presented and compared with results from other studies. Microstructures of cast-duplex stainless steels subjected to long-term aging either in the laboratory or in reactor service have been characterized. The results indicate that at least two processes contribute to the low-temperature embrittleent of duplex stainless steels, viz., weakening of the ferrite/austenite phase boundary by carbide precipitation and embrittlement of ferrite matrix by the formation of additional phases such as G-phase, Type X, or the ..cap alpha..' phase. Carbide precipitation has a significant effect on the onset of embrittlement of CF-8 and -8M grades of stainless steels aged at 400 or 450/sup 0/C. The existing correlations do not accurately represent the embrittlement behavior over the temperature range 300 to 450/sup 0/C. 18 refs., 13 figs.

  7. Weldments and castings for liquid helium service

    The FY 81 results of the NBS program to evaluate weldments and castings for liquid helium service are reviewed. The tensile properties and fracture toughness of a series of five CF8M castings with delta-ferrite contents ranging from 0 to 28% were measured at 4 K. Work is continuing on a study to relate metallographic observations of duplex austenite delta-ferrite microstructures to the deformation and fracture of stainless steel welds and castings. The fracture toughness and fatigue crack growth rates of a 25Mn-5Cr-1Ni alloy, plate and welds, were measured at 4 K. Two 316L stainless steel weldments were tested at 4 K in support of the LCP program. The elastic properties of 316L stainless steel welds have been related to the texture in the weldment. An improved method of ultrasonic testing of stainless steel weldments was conceived and demonstrated; the method uses electromagnetic acoustic transducers (EMATs) to inspect the weldments with horizontal shear (SH) waves that are inherently less sensitive to the anisotropy of stainless steel welds. The research planned for FY 82 is also described

  8. Successful magnet quench test for CAST.

    Brice Maximilien

    2002-01-01

    The CERN Axion Solar Telescope (CAST) consists of a prototype LHC dipole magnet with photon detectors at each end. It searches for very weakly interacting neutral particles called axions, which should originate in the core of the Sun. The telescope, located at Point 8, can move vertically within its wheeled platform, which travels horizontally along tracks in the floor. In this way, the telescope can view the Sun at sunrise through one end and at sunset through the other end. It has been cooled down to below 1.8 K and reached ~95% of its final magnetic field of 9 tesla before a quench was induced to test the whole cryogenic system under such conditions. The cryogenic system responded as expected to the magnet quench and CAST is now ready to start its three-year search for solar axions. Photos 01 & 02 : Members of the LHC cryogenics team pose in front of the axion telescope on the day of the first quench test, together with some of the CAST collaboration.

  9. Fabrication and ageing of cast austenitic steels

    An investigation has been undertaken to determine the magnitude of any reduction in properties which may occur in cast duplex stainless steels and weldments during long term exposure to reactor operating conditions. Test panels were fabricated in CF3 stainless steel by a manual metal arc (MMA) process using 19.9.L (Type 308L) consumables. The mechanical properties and intergranular corrosion resistance of parent material and weldments were measured following accelerated ageing at 3750 and 4000C for up to 10,000 hours. Both the impact energy and J/sub R/ fracture toughness properties of the cast austenitic/ferritic stainless steel were reduced following aging at 4000C for 10,000 hours, whereas austenitic stainless steel MMA weld metals exhibited a reduction in J/sub R/ fracture toughness but no change in impact energy. Even in the unaged state, MMA weld metals were shown to have a much lower resistance to stable crack growth than the parent cast steel, and, following aging, there is a further reduction in the ductile tearing resistance of such weld metals. Therefore, in any assessment of the structural integrity of the reactor coolant pump bowl for a pressurized water reactor (PWR), the weld metal fracture properties during service are likely to be of considerable importance

  10. Simulation study on three casting processes for a marine propeller hub body

    Wang Tongmin; Li Jia; Wu Li

    2013-01-01

    The mold filling and solidification process of a marine propeller hub were simulated using ProCAST? Three casting processes ?gravity casting, centrifugal casting and low pressure casting ?were compared in order to get the best process. The heat transfer coefficient of the casting/mold interface was determined using a reverse method. The simulated results of velocity, temperature and shrinkage porosity distribution were discussed in detail for the three casting processes. A smooth filling was ...

  11. Centrifugal Casting Features/Metallurgical Characterization of Aluminum Alloys

    This paper deals with the study of centrifugal effects on aluminium castings under high G values. Most of the studies in this domain (FGMs obtained by centrifugal casting) deal with functionally graded composites reinforced with a solid phase such as silicon particles or others. However, in this study it will be shown that unreinforced aluminium alloys may be significantly influenced by the centrifugal effect and that functionally graded castings are also obtained. It has been observed that the centrifugal effect may increase in some alloys, depending on the relative position in the castings, the rupture strength by approx. 50%, and rupture strain by about 300%, as compared to the gravity casting technique. The Young's modulus may also increase by about 20%. It has also been reported that in vertical centrifugal castings there are mainly three aspects that affect the components thus obtained, namely: fluid dynamics; vibration (inherent to the system); and centrifugal force. These features have a different effect on the castings depending on the aluminium alloy. In this paper, an analysis of the most important effects of the centrifugal casting process on metallurgical features is conducted. A solidification characterization at several points along the mould will be made in order to have an accurate idea of both the fluid dynamics inside the mould during the casting and the solidification behavior in different parts of the component. These two analyses will be related to the metallurgical properties (phase distribution; SDAS; eutectic silicon content and shape, pores density and shape) along the component and mainly along the direction of the centrifugal pressure. A comparison between castings obtained by both centrifugal casting technique and gravity casting technique is made for reference (gravity casting)

  12. Centrifugal Casting Features/Metallurgical Characterization of Aluminum Alloys

    Chirita, G.; Stefanescu, I.; Soares, D.; Cruz, D.; Silva, F. S.

    2008-02-01

    This paper deals with the study of centrifugal effects on aluminium castings under high G values. Most of the studies in this domain (FGMs obtained by centrifugal casting) deal with functionally graded composites reinforced with a solid phase such as silicon particles or others. However, in this study it will be shown that unreinforced aluminium alloys may be significantly influenced by the centrifugal effect and that functionally graded castings are also obtained. It has been observed that the centrifugal effect may increase in some alloys, depending on the relative position in the castings, the rupture strength by approx. 50%, and rupture strain by about 300%, as compared to the gravity casting technique. The Young's modulus may also increase by about 20%. It has also been reported that in vertical centrifugal castings there are mainly three aspects that affect the components thus obtained, namely: fluid dynamics; vibration (inherent to the system); and centrifugal force. These features have a different effect on the castings depending on the aluminium alloy. In this paper, an analysis of the most important effects of the centrifugal casting process on metallurgical features is conducted. A solidification characterization at several points along the mould will be made in order to have an accurate idea of both the fluid dynamics inside the mould during the casting and the solidification behavior in different parts of the component. These two analyses will be related to the metallurgical properties (phase distribution; SDAS; eutectic silicon content and shape, pores density and shape) along the component and mainly along the direction of the centrifugal pressure. A comparison between castings obtained by both centrifugal casting technique and gravity casting technique is made for reference (gravity casting).

  13. Thin wall ductile iron casting as a substitute for aluminum alloy casting in automotive industry

    M. Górny

    2009-01-01

    Full Text Available In paper it is presented thin wall ductile iron casting (TWDI as a substitute of aluminium alloy casting. Upper control arm made of ductile iron with wall thickness ranging from 2 – 3.7 mm was produced by inmold process. Structure, mechanical properties and computer simulations were investigated. Structural analysis of TWDI shows pearlitic-ferritic matrix free from chills and porosity. Mechanical testing disclose superior ultimate tensile strength (Rm, yield strength (Rp0,2 and slightly lower elongation (E of TWDI in comparison with forged control arm made of aluminium alloy (6061-T6. Moreover results of computer simulation of static loading for tested control arms are presented. Analysis show that the light-weight ductile iron casting can be loaded to similar working conditions as the forged Al alloy without any potential failures.

  14. Abrasion Resistance of as-Cast High-Chromium Cast Iron

    Pokusová Marcela

    2014-12-01

    Full Text Available High chromium cast irons are widely used as abrasion resistant materials. Their properties and wear resistance depend on carbides and on the nature of the matrix supporting these carbides. The paper presents test results of irons which contain (in wt.% 18-22 Cr and 2-5 C, and is alloyed by 1.7 Mo + 5 Ni + 2 Mn to improve the toughness. Tests showed as-cast irons with mostly austenitic matrix achieved hardness 36-53 HRC but their relative abrasion-resistance was higher than the tool steel STN 19436 heat treated on hardness 60 HRC.

  15. Steel castings Ultrasonic examination, Part 2: Steel castings for highly stressed components

    International Organization for Standardization. Geneva

    2004-01-01

    This European Standard specifies the requirements for the ultrasonic examination of steel castings (with ferritic structure) for highly stressed components and the methods for determining internal discontinuities by the pulse echo technique. This European Standard applies to the ultrasonic examination of steel castings which have usually received a grain refining heat treatment and which have wall thicknesses up to and including 600 mm. For greater wall thicknesses, special agreements apply with respect to test procedure and recording levels. This European Standard does not apply to austenitic steels and joint welds.

  16. Effect of potassium on as-cast microstructure of a hypereutectic high chromium cast iron

    Liu Qing; Yang Hua; Ding Haimin

    2011-01-01

    The present work mainly evaluates the effect of potassium (K) on as-cast microstructure of a hypereutectic high chromium cast iron by means of a field emission scanning electron microscope (FESEM) and an X-ray diffractometer using CuKα radiation with a 2θ range of 30-130°. Results showed that, with the addition of K-containing modifier, the large lath-like and/or rod-like primary M7C3 carbides can be modified to the hexagonal prisms, and the eutectic carbides can also be refined. In addition,...

  17. The impact of breaks during foundry work of the pressure casting machine on casting quality

    S. Borkowski

    2010-10-01

    Full Text Available The result in the appearance of the technical object damage are its failures, which are considered as the most important causes of productivity loss in the technical objects. The article introduces main types of losses resulting from the downtimes of a casting machine. The time impact analysis of the font mould failure and the remaining time of the machine's failures on the castings quality was conducted. The failure time structure of the font mould and other failures of the machine was presented.

  18. Examples of material solutions in bimetallic layered castings

    S. Tenerowicz

    2011-07-01

    Full Text Available In paper is presented technology of bimetallic layered castings based on founding method of layer coating directly in cast process so-called method of mould cavity preparation. Prepared castings consist two fundamental parts i.e. bearing part and working part (layer. The bearing part of bimetallic layered casting is typical foundry material i.e. pearlitic grey cast iron, whereas working part (layer is depending on accepted variant plates of alloy steels sort X6Cr13, X12Cr13, X10CrNi18-8 and X2CrNiMoN22-5-3. The ratio of thickness between bearing and working part is 8:1. The verification of the bimetallic layered castings was evaluated on the basis of ultrasonic NDT (non-destructive testing, structure and macro- and microhardness researches.

  19. Using finite difference method to simulate casting thermal stress

    Liao Dunming; Zhang Bin; Zhou Jianxin

    2011-01-01

    Thermal stress simulation can provide a scientific reference to eliminate defects such as crack, residual stress centralization and deformation etc., caused by thermal stress during casting solidification. To study the thermal stress distribution during casting process, a unilateral thermal-stress coupling model was employed to simulate 3D casting stress using Finite Difference Method (FDM), namely all the traditional thermal-elastic-plastic equations are numerically and differentially discre...

  20. Caste Discrimination, Land Reforms and Land Market Performance in Nepal

    Aryal, Jeetendra P.; Holden, Stein T.

    2011-01-01

    This paper assesses the implications of caste discrimination and past land reforms on the land rental market performance, land productivity and land use intensity in Nepal. The most severely discriminated group in the caste system is the Dalits, the so-called “untouchables”. Dalits faced religious, occupational and even, territorial discrimination. The study uses data from western Nepal. The low-caste households remain poorer than other households, have significantly smaller land endowments, ...

  1. Automatic inspection of surface defects in die castings after machining

    S. J. Świłło; M. Perzyk

    2011-01-01

    A new camera based machine vision system for the automatic inspection of surface defects in aluminum die casting was developed by the authors. The problem of surface defects in aluminum die casting is widespread throughout the foundry industry and their detection is of paramount importance in maintaining product quality. The casting surfaces are the most highly loaded regions of materials and components. Mechanical and thermal loads as well as corrosion or irradiation attacks are directed pri...

  2. Working-class royalty: bees beat the caste system

    Wenseleers, Tom; Ratnieks, Francis L. W.; de F Ribeiro, Marcia; de A Alves, Denise; Imperatriz-Fonseca, Vera-Lucia

    2005-01-01

    The struggle among social classes or castes is well known in humans. Here, we show that caste inequality similarly affects societies of ants, bees and wasps, where castes are morphologically distinct and workers have greatly reduced reproductive potential compared with queens. In social insects, an individual normally has no control over its own fate, whether queen or worker, as this is socially determined during rearing. Here, for the first time, we quantify a strategy for overcoming social ...

  3. A new approach to develop complicated superalloy castings

    WU Jian-tao

    2006-05-01

    Full Text Available An integrative computer aided investment casting (CAIC technology for making complicated superalloy castings was described. Key processes of CAIC were discussed including the choice of SLS (Selectively Laser Sintering materials, sintering parameters, solidification simulation and gating and risering system optimization. Using CAIC process, many large-sized quality superalloy castings with complicated shape and thin wall have been produced successfully and economically in Central Iron & steel Research Institute (CISRI.

  4. CHOICE OF MATERIAL AND MANUFACTURING TECHNOLOGY OF CASTING

    L. I. Kupriyanova

    2016-04-01

    Full Text Available As a result of the carried out work abundant type of steel was chosen for casting production of asterisk of the excavator «Kamatsu». This type of steel is widely used as the wearproof steel working in the conditions of abrasive and shock – abrasive wear. Mathematical modeling of process of filling and hardening of casting was done and it confirmed a choice of the technology to produce casting without faulty parts.

  5. Caste differences in Pseudopolybia compressa (Hymenoptera: Vespidae: Polistinae)

    Laura Chavarría Pizarro; Noll, Fernando B; Sidnei Mateus

    2009-01-01

    Studies of morphological caste syndromes in the tribe Epiponini help us to understand the evolution of social behavior in insects. Few studies have integrated morphological syndromes of various species from the same or distinct genera. We studied morphological differences between castes from three colonies of Pseudopolybia compressa de Saussure, 1854, in order to relate their caste syndrome with those of other species in the genus. We took eight morphometric measures and females were classifi...

  6. Fabrication of bulk metallic glasses by centrifugal casting method

    R. Nowosielski

    2007-01-01

    Full Text Available Purpose: The aim of the present work is characterization of the centrifugal casting method, apparatus andproduced amorphous materials, which are also known as bulk metallic glassesDesign/methodology/approach: The studied centrifugal casting system consists of two main parts: castingapparatus and injection system of molten alloy. The described centrifugal casting method was presented bypreparing a casting apparatus “CentriCast – 5”. The apparatus includes a cylindrical copper mold, which isrotated by a motor. The transmission allows to changing the speed of rotating mold.Findings: Bulk metallic glasses are a novel class of engineering materials, which exhibit excelent mechanical,thermal, magnetic and corrosion properties. Centrifugal casting is a useful method to produce bulk amorphousmaterials in form of rings, tubes or cylindrical parts. Presented centrifugal casting method and casting apparatushas been prepared to fabricate the samples of bulk metallic glass in form of rings with an outer diameter of 25mm and controlled thicknesses by changing the weight of the molten alloy.Research limitations/implications: Studied centrifugal casting method and casting apparatus has beenprepared to fabricate the samples of bulk metallic glass. For future research a characterization of microstructureand properties of prepared material will be performed.Practical implications: The centrifugal casting is a useful process to produce bulk amorphous materials in formof rings, tubes or graded amorphous matrix composites. It seems to be a very simple method, which allows toobtain BMG materials.Originality/value: The centrifugal casting method allows to produce bulk amorphous rings with thicknessabove 1-mm.

  7. Eutectic solidification mode of spheroidal graphite cast iron and graphitization

    Hideo Nakae; Sanghoon Jung; Takayuki Kitazawa

    2007-01-01

    The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG) cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal...

  8. The history and present of art casting in China

    2004-01-01

    @@ A compendiary review of art casting in China: History of art casting in china has been over 5000 years. In the past few thousand years, numerous forming and decorating skills of art castings had been created, and left behind precious treasures in the world metal arts and crafts. In individual historical period and at different terrain, a unique artistic style formed,which flashed brilliant light in world artistic treasury.

  9. Microporosity Prediction and Validation for Ni-based Superalloy Castings

    Guo, J.; Beckermann, C.; Carlson, K.; Hirvo, D.; Bell, K.; Moreland, T.; Gu, J.; Clews, J.; Scott, S.; Couturier, G.; Backman, D.

    2015-06-01

    Microporosityin high performance aerospace castings can reduce mechanical properties and consequently degrade both component life and durability. Therefore, casting engineers must be able to both predict and reduce casting microporosity. A dimensionless Niyama model has been developed [1] that predicts local microporosity by accounting for local thermal conditions during casting as well as the properties and solidification characteristics of the cast alloy. Unlike the well-known Niyama criterion, application of the dimensionless Niyama model avoids the need to find a threshold Niyama criterion below which shrinkage porosity forms - a criterion which can be determined only via extensive alloy dependent experimentation. In the present study, the dimensionless Niyama model is integrated with a commercial finite element casting simulation software, which can now more accurately predict the location-specific shrinkage porosity volume fraction during solidification of superalloy castings. These microporosity predictions are validated by comparing modelled results against radiographically and metallographically measured porosity for several Ni-based superalloy equiaxed castings that vary in alloy chemistry with a focus on plates of changing draft angle and thickness. The simulation results agree well with experimental measurements. The simulation results also show that the dimensionless Niyama model can not only identify the location but also the average volume fraction of microporosity distribution in these equiaxed investment cast Ni-based superalloy experiments of relatively simple geometry.

  10. Investment casting or powder metallurgy – the ecological aspect

    J. Tomasik

    2009-04-01

    Full Text Available The paper presents an analysis of manufacturing methods of material-saving products in relation to investment castings and sinteredpowder technology. Surface microgeometry, shape accuracy, performance parameters, manufacturing costs and energy consumption weretaken into account to make the optimal choice. The analysis was conducted by comparing test results for sintered powder products basedon Distaloy AB alloy that consists of 0.55% C, 1.5% Cu, 1.75% Ni and 0.5% Mo and investment castings made of high alloy cast steel andnodular cast iron. The analysis made it possible to choose the best technology, considering also the ecological aspect.

  11. Awareness Programs and Change in Taste-based Caste Prejudice

    Banerjee, Ritwik; Gupta, Nabanita Datta

    2015-01-01

    Becker's theory of taste-based discrimination predicts that relative employment of the discriminated social group will improve if there is a decrease in the level of prejudice for the marginally discriminating employer. In this paper we experimentally test this prediction offered by Garry Becker in...... his seminal work on taste based discrimination, in the context of caste in India, with management students (potential employers in the near future) as subjects. First, we measure caste prejudice and show that awareness through a TV social program reduces implicit prejudice against the lower caste and...... exhibit favorable opinion about reservation in jobs for the lower caste....

  12. Modeling and Analysis of a Horizontal Direct Chill Casting Process

    Garðar Garðarsson 1984

    2012-01-01

    The objective of this study is to investigate bleedouts in Horizontal Direct Chill casting process and to make a complete finite volume model of such process. The casting machine that was investigated and used as a reference for the numerical model, was the HDC casting machine at Alcoa Fjarðaál in Iceland. One of Fjarðaál‘s main production problems are bleedouts in the HDC casting machine and the consequences of recurrent bleedouts is production loss. To analyse the problem, historical data w...

  13. Japanese R&D on new cast alloys and materials

    Hayden, H.W.

    1996-05-01

    On the basis of observations of the JTEC team, it appears that Japanese universities and research institutes are leading long-term R&D thrusts for development of new materials casting technologies. Significant efforts include amorphous metals, intermetallics, application of MHD in continuous casting of steel, and energy efficient furnace technology. Industrial R&D seems focused more on process improvements than on new product technologies, but significant efforts in new cast materials included cast metal matrix composites, materials substitutions for thinner wall products, and advanced ceramic products for foundry industry applications.

  14. Wear resistance of chromium cast iron – research and application

    A. Studnicki

    2006-04-01

    Full Text Available Purpose: A short characteristic of wear resistance chromium cast iron has been presented as well as possibilities of this material researches realization in Foundry Department have been discussed.Design/methodology/approach: Main attention was given on research process of crystallization and analysis of chromium cast iron microstructure and its resistance on erosion wears. Separate part of paper was devoted to discuss the bimetallic castings with chromium cast iron layer as well as typical applications of chromium cast iron castings in minig, proccesing, metallurgical and power industry.Findings: The new method of crystallization process research with three testers (DTA-K3 was found in the work. The method makes possible to characterize sensitivity of chromium cast iron on cooling kinetic.Research limitations/implications: DTA-K3 method can be used for research of crystallization proccess of cast materials particularly for abrasion-resisting alloy.Practical implications: Wide scope researches of chromium cast iron in Foundry Department enable extending applications its material in many industries.Originality/value: Value of the paper is the presentation of researches possibilities which undertaken in Foundry Department within the range of wear resistant materials.

  15. Numerical Simulation System for Casting Process in Concurrent Engineering

    1999-01-01

    According to the implementing principle and application background of the Concurrent Engineering (CE) project, studies on the integration of numerical simulation system for casting process with CE, simulation of turbulent phenomena in filling process of casting by Algebraic Stress Model (ASM), computation efficiency of filling process and quantitative prediction of shrinkage cavity and porosity under feeding condition of several risers are discussed. After the simulation of casting process of typical magnesium-based alloy casting with complicated structure, remarkable success in assuring the quality is also presented.

  16. Reengineering of Permanent Mould Casting with Lean Manufacturing Methods

    R. Władysiak

    2007-07-01

    Full Text Available At the work were introduced main areas of production system project of casts produced in permanent moulds, that constitutes reengineering of conventional production system according to Lean Manufacturing (LM methods. New resolution of cooling of dies with water mist was shown to casting of car wheels made from aluminium alloys in low pressure casting process. It was implemented as a part of goal-oriented project in R.H. Alurad Sp.z o.o. in Gorzyce. Its using intensifies solidification and self-cooling of casts shortening the time of casting cycle by the 30%. It was described reorganizing casting stations into multi-machines cells production and the process of their fast tool’s exchange with applying the SMED method. A project of the system was described controlling the production of the foundry with the computer aided light Kanban system. A visualization of the process was shown the production of casts with use the value stream mapping method. They proved that applying casting new method in the technology and LM methods allowed to eliminate down-times, to reduce the level of stocks, to increase the productivity and the flow of the castings production.

  17. Aging degradation of cast stainless steel

    A program is being conducted to investigate the significance of in-service embrittlement of cast duplex stainless steels under light-water reactor operating conditions. Microstructures of cast materials subjected to long-term aging either in reactor service or in the laboratory have been characterized by TEM, SANS, and APFIM techniques. Two precipitate phases, i.e., the Cr-rich α' phase and the Ni- and Si-rich G phase, have been identified in the ferrite matrix of the aged steels. The results indicate that the low-temperature embrittlement is primarily caused by α' precipitates which form by spinodal decomposition. The relative contribution of the G phase to loss of toughness is now known. Microstructural data also indicate that weakening of the ferrite/austenite phase boundary by carbide precipitates has a significant effect on the onset and extent of embrittlement of the high-carbon CF-8 and CF-8M grades of stainless steels, particularly after aging at 400 or 4500C. Data from Charpy-impact, tensile, and J-R curve tests for several heats of cast stainless steel aged up to 10,000 h at 350, 400, and 4500C are presented and correlated with the microstructural results. Thermal aging of the steels results in an increase in tensile strength and a decrease in impact energy, J/sub IC/, and tearing modulus. The fracture toughness results show good agreement with the Charpy-impact data. The effects of compositional and metallurgical variables on loss of toughness are discussed

  18. Degradation of stainless castings. A literature study

    Duplex cast stainless steels, containing mainly austenite and some ferrite, is used for different components in light water reactors. These alloys have good mechanical properties, good weldability, and they are resistant to intergranular stress corrosion cracking (IGSCC). Examples of components where cast duplex stainless steel is used are pump housings, valves and pipe elbows. A model for the aging/embrittlement of these materials when used in light water reactors has been developed. The model is based on regression of a large data matrix. It is mainly the impact energy (Charpy V) that has been regarded. The model only requires knowledge of the chemical composition of the material but the prediction can be improved if additional data like initial impact properties and measured ferrite content are available. The model is also capable of predicting fracture toughness. The susceptibility to IGSCC in BWR environment is primarily determined by the amount of ferrite and the carbon content of the material. When the amount of ferrite exceeds 12%, IGSCC has not been observed regardless of the carbon content. At carbon contents lower than 0.035% in weld-sensitized material IGSCC was not observed regardless of the ferrite content. Data for corrosion fatigue in primary PWR and BWR environment are available. Under BWR conditions the crack propagation rate is decreased with decreasing corrosion potential, consequently also with decreasing oxygen content of the water. Some areas have been identified where additional work is needed. In all cases the efforts should focus on characterizing cast duplex stainless steel components removed from Swedish reactors. The characterization should include: Microstructure and chemical analysis, susceptibility to IGSCC, and a comparison with existing models for embrittlement. 24 refs, 12 figs

  19. Centerline Depletion in Direct-Chill Cast Aluminum Alloys: The Avalanche Effect and Its Consequence for Turbulent Jet Casting

    Wagstaff, Samuel R.; Allanore, Antoine

    2016-07-01

    Avalanche dynamics of sedimenting grains in direct-chill casting of aluminum ingots is investigated as a primary driving force for centerline segregation. An analytical model predicting the importance of avalanche events as a function of casting parameters is proposed and validated with prior art results. New experimental results investigating the transient and steady-state centerline segregation of DC casting with a turbulent jet are reported.

  20. High temperature corrosion of cast irons and cast steels in dry air

    Tholence, F.; Norell, M. [Chalmers Univ. of Technology, Goeteborg (Sweden). Dept. of Engineering Metals

    2001-07-01

    The oxidation in dry air of four cast alloys intended for exhaust gas systems has been examined. Particular interest was directed to how the oxide growth was related to the microstructures. The examined alloys were two cast ductile irons, a SiMo alloy (Fe3,86Si0,6Mo3C) and a Ni-Resist alloy (Fe32Ni5,3Si2,1C), and two cast stainless steels, one ferritic (Fe18Cr2,1Mn0,32C) and one austenitic (Fe20Cr9Ni0,47C). Coupons were oxidised for 50 h at temperatures between 650 C and 1050 C. The samples were characterised by using XRD, SEM/EDX and AES. As expected, the overall oxide thickness increased with temperature and partial spallation occurred at the highest temperatures for all alloys. Porous Fe oxide nodules nucleate at the graphite nodules on the ductile irons. These Fe-oxide nodules formed above a continuous layer of Fe-Si-oxide for the SiMo and mixed Fe-Ni-Si oxides for the Ni-Resist. The total oxide thickness is about (60 {mu}m). Thick oxides at the interdendritic regions in the cast steels were attributed to non-Cr-carbides. Segregation of Cr directed the formation of iron oxide nodules to the centre of the dendrites in the austenitic alloy. (orig.)

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

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

    2013-02-01

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

  2. Uranium casting furnace automatic temperature control development

    Development of an automatic molten uranium temperature control system for use on batch-type induction casting furnaces is described. Implementation of a two-color optical pyrometer, development of an optical scanner for the pyrometer, determination of furnace thermal dynamics, and design of control systems are addressed. The optical scanning system is shown to greatly improve pyrometer measurement repeatability, particularly where heavy floating slag accumulations cause surface temperature gradients. Thermal dynamics of the furnaces were determined by applying least-squares system identification techniques to actual production data. A unity feedback control system utilizing a proportional-integral-derivative compensator is designed by using frequency-domain techniques. 14 refs

  3. Phase Transformations in Cast Duplex Stainless Steels

    Yoon-Jun Kim

    2004-12-19

    Duplex stainless steels (DSS) constitute both ferrite and austenite as a matrix. Such a microstructure confers a high corrosion resistance with favorable mechanical properties. However, intermetallic phases such as {sigma} and {chi} can also form during casting or high-temperature processing and can degrade the properties of the DSS. This research was initiated to develop time-temperature-transformation (TTT) and continuous-cooling-transformation (CCT) diagrams of two types of cast duplex stainless steels, CD3MN (Fe-22Cr-5Ni-Mo-N) and CD3MWCuN (Fe-25Cr-7Ni-Mo-W-Cu-N), in order to understand the time and temperature ranges for intermetallic phase formation. The alloys were heat treated isothermally or under controlled cooling conditions and then characterized using conventional metallographic methods that included tint etching, and also using electron microscopy (SEM, TEM) and wavelength dispersive spectroscopy (WDS). The kinetics of intermetallic-phase ({sigma} + {chi}) formation were analyzed using the Johnson-Mehl-Avrami (MA) equation in the case of isothermal transformations and a modified form of this equation in the case of continuous cooling transformations. The rate of intermetallic-phase formation was found to be much faster in CD3MWCuN than CD3MN due mainly to differences in the major alloying contents such as Cr, Ni and Mo. To examine in more detail the effects of these elements of the phase stabilities; a series of eight steel castings was designed with the Cr, Ni and Mo contents systematically varied with respect to the nominal composition of CD3MN. The effects of varying the contents of alloying additions on the formation of intermetallic phases were also studied computationally using the commercial thermodynamic software package, Thermo-Calc. In general, {sigma} was stabilized with increasing Cr addition and {chi} by increasing Mo addition. However, a delicate balance among Ni and other minor elements such as N and Si also exists. Phase equilibria in

  4. Electromagnetic continuous casting project: Final report

    Battles, J.E.; Rote, D.M.; Misra, B.; Praeg, W.F.; Hull, J.R.; Turner, L.R.; Shah, V.L.; Lari, R.J.; Gopalsami, N.; Wiencek, T.

    1988-10-01

    This report describes the work on development of an electromagnetic casting process for steel, which was carried out at Argonne National Laboratory between January 1985 and December 1987. This effort was concerned principally with analysis and design work on magnet technology, liquid metal feed system, coolant system, and sensors and process controllers. Experimentation primarily involved (1) electromagnetic studies to determine the conditions and controlling parameters for stable levitation and (2) feed-system studies to establish important parameters that control and influence fluid flow from the liquid metal source to the caster. 73 refs., 91 figs., 11 tabs.

  5. Internal adaptation of cast titanium crowns

    Sicknan Soares da Rocha

    2007-08-01

    Full Text Available As the adaptation of titanium crowns obtained by Rematitan Plus investment, specific for titanium, is not recognized to be suitable, this study evaluated the effect of the concentration of the specific liquid and the temperature of the mold of investments on the internal misfit of crowns cast on commercially pure titanium. Individual dies of epoxy resin were obtained, representing teeth prepared for full-crown restoration with a 6-degree axial surface convergence angle and shoulder (1.0 mm. For the waxing of each crown, a ring-shaped stainless steel matrix (8.0mm internal diameter; 7.5 mm height was adapted above the individual dies of epoxy resin. The Rematian Plus investment was mixed according to the manufacturer's instructions using two different concentrations of the specific liquid: 100%, 75%. Casting was performed in a Discovery Plasma Ar-arc vacuum-pressure casting machine with molds at temperatures of 430ºC, 515ºC and 600ºC. The crowns were cleaned individually in a solution (1% HF + 13% HNO3 for 10 min using a ultrasonic cleaner, with no internal adaptations, and luted with zinc phosphate cement under a 5 kg static load. The crown and die assemblies were embedded in resin and sectioned longitudinally. The area occupied by cement was observed using stereoscopic lens (10X and measured by the Leica Qwin image analysis system (mm². The data for each experimental condition (n=8 were analyzed by Kruskal-Wallis non-parametric test (á=0.05. The results showed that liquid dilution and the increase in mold temperature did not significantly influence the levels of internal fit of the cast titanium crowns. The lowest means (±SD of internal misfit were obtained for the 430ºC/100%: (7.25 mm² ±1.59 and 600ºC/100% (8.8 mm² ±2.25 groups, which presented statistically similar levels of internal misfit.

  6. Continuation of Crosscutting Technology Development at Cast

    Yoon, Roe-Hoan

    2012-03-31

    This Final Technical Report describes progress made on the sub-projects awarded in the Cooperative Agreement DE-FC26-05NT42457: Continuation of Crosscutting Technology Development at Center for Advanced Separation Technologies (CAST). The final reports for each sub-project are attached in the appendix. Much of the research to be conducted with Cooperative Agreement funds will be longer-term, high-risk, basic research and will be carried out in five broad areas: a) Solid-solid separation b) Solid-liquid separation c) Chemical/Biological Extraction d) Modeling and Control, and e) Environmental Control.

  7. Phase transformations in cast duplex stainless steels

    Kim, Yoon-Jun

    Duplex stainless steels (DSS) constitute both ferrite and austenite as a matrix. Such a microstructure confers a high corrosion resistance with favorable mechanical properties. However, intermetallic phases such as sigma (sigma) and chi (chi) can also form during casting or high-temperature processing and can degrade the properties of the DSS. This research was initiated to develop time-temperature-transformation (TTT) and continuous-cooling-transformation (CCT) diagrams of two types of cast duplex stainless steels, CD3MN (Fe-22Cr-5Ni-Mo-N) and CD3MWCuN (Fe-25Cr-7Ni-Mo-W-Cu-N), in order to understand the time and temperature ranges for intermetallic phase formation. The alloys were heat treated isothermally or under controlled cooling conditions and then characterized using conventional metallographic methods that included tint etching, and also using electron microscopy (SEM, TEM) and wavelength dispersive spectroscopy (WDS). The kinetics of intermetallic-phase (sigma + chi) formation were analyzed using the Johnson-Mehl-Avrami (JMA) equation in the case of isothermal transformations and a modified form of this equation in the case of continuous cooling transformations. The rate of intermetallic-phase formation was found to be much faster in CD3MWCuN than CD3MN due mainly to differences in the major alloying contents such as Cr, Ni and Mo. To examine in more detail the effects of these elements of the phase stabilities, a series of eight steel castings was designed with the Cr, Ni and Mo contents systematically varied with respect to the nominal composition of CD3MN. The effects of varying the contents of alloying additions on the formation of intermetallic phases were also studied computationally using the commercial thermodynamic software package, Thermo-Calc. In general, a was stabilized with increasing Cr addition and chi by increasing Mo addition. However, a delicate balance among Ni and other minor elements such as N and Si also exists. Phase equilibria in

  8. Materials on dies for pressure die casting

    E. Ragan

    2012-01-01

    Full Text Available In the contribution the stress of die materials of thermal fatigue is defi ned and material life is derived theoretically and compared with the measured values. The important properties of the die materials as thermal conductivity, coeffi cient of thermal expansivity, modulus of elasticity and mechanical properties are described. Binding to it single die materials as carbon steels and chrome-tungsten steels are analyzed. As the perspective die material for pressure die casting of ferrous metals appears molybdenum with regard to advantageous properties.

  9. Sharing casting technological data on web site

    Sun Xun; Li Hailan; Wang Junqing; Piao Dongxue; Hou Gang; Guan Yang; Wang Penghua; Zhu Qiang; Xle Huasheng

    2008-01-01

    Based on database and asp.net technologies, a web platform of scientific data in the casting technology field has been developed. This paper presents the relevant data system structure, the approaches to the data collection, the applying methods and policy in data sharing, and depicts the collected and shared data recently finished. Statistics showed that there are about 20,000 visitors in China every day visiting the related data through the web, proving that many engineers or other relevant persons are interested in the data.

  10. Pouring mould during centrifugal casting process

    J. Śleziona; R. Zagórski

    2007-01-01

    Purpose: The paper presents the model and the example simulations of the centrifugal casting of metal matrix composite reinforced with SiC, especially the distribution of the velocity of liquid composite for the initial stage of pouring the mould (up to 1s).Design/methodology/approach: Numerical simulations have been performed using the CFD program FLUENT 6.1.To simulate pouring the mould, axisymmetric swirl model has been applied. To model the air-matrix free surface (and also volume fractio...

  11. Simulation study on three casting processes for a marine propeller hub body

    Wang Tongmin

    2013-11-01

    Full Text Available The mold filling and solidification process of a marine propeller hub were simulated using ProCAST? Three casting processes ?gravity casting, centrifugal casting and low pressure casting ?were compared in order to get the best process. The heat transfer coefficient of the casting/mold interface was determined using a reverse method. The simulated results of velocity, temperature and shrinkage porosity distribution were discussed in detail for the three casting processes. A smooth filling was found in all three casting processes, especially the low pressure casting exhibiting a better filling performance than the other two, but the solidification processes were different. The casting did not experience the sequential solidification, and the feeding paths were blocked, leading to shrinkage porosity defects in the riser and the bottom of the casting in gravity casting and in the upper zone of the casting in low pressure casting. While, the sequential solidification was well controlled in the solidification process of centrifugal casting, and majority of the shrinkage porosity defects can only be observed in the riser. It could be concluded that the centrifugal casting process is the most suitable casting process for the production of propeller hub body. The casting experiments verified the simulation results, and a defect-free propeller hub was obtained by centrifugal casting with a rotational speed of 150 r.in-1.

  12. Spall behavior of cast iron with varying microstructures

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

  13. China’s Aluminum Alloy Die Castings Industry has Promising Prospects

    2013-01-01

    <正>Engine aluminum alloy engine block die casting experienced rapid development in recent years. Domestic enterprises introduced large die casting machine automatic production lines, and developed large aluminum alloy die cast-

  14. Announcement on the Ranking List of China's Large Casting Enterprises in 2005

    2006-01-01

    @@ China is the largest country in casting production worldwide and with many excellent casting producers. Advanced manufacturing technology, scientific management ideas, enormous economic benefit in these enterprises makes them the pioneers of the national casting industry.

  15. Shallow water model for horizontal centrifugal casting

    Boháček, J.; Kharicha, A.; Ludwig, A.; Wu, M.

    2012-07-01

    A numerical model was proposed to simulate the solidification process of an outer shell of work roll made by the horizontal centrifugal casting technique. Shallow water model was adopted to solve the 2D average flow dynamics of melt spreading and the average temperature distribution inside the centrifugal casting mould by considering the centrifugal force, Coriolis force, viscous force due to zero velocity on the mould wall, gravity, and energy transport by the flow. Additionally, a 1D sub-model was implemented to consider the heat transfer in the radial direction from the solidifying shell to the mould. The solidification front was tracked by fulfilling the Stefan condition. Radiative and convective heat losses were included from both, the free liquid surface and the outer wall of the mould. Several cases were simulated with the following assumed initial conditions: constant height of the liquid metal (10, 20, and 30 mm), uniform temperature of the free liquid surface (1755 K). The simulation results have shown that while the solidification front remained rather flat, the free surface was disturbed by waves. The amplitude of waves increased with the liquid height. Free surface waves diminished as the solidification proceeded.

  16. Tape casting using fine ceramic powders

    This paper discusses tape casting technology, developed for the production of ceramic composites using fine powders of alumina and zirconia with an average particle size in the range 0.25-0.3 μm. These powders require careful control of the dispersant/solids ratio in order to minimize the slip viscosity, and to prevent the rejection of excess dispersant during solvent evaporation. In this regard phosphate ester has been found to be an effective dispersant. The choice of solvent is also important, with a non-polar solvent exhibiting more forgiving behavior. The use of such fine powders lowers the solids loading permitted in the tape casting slip to about 22 vol. %, with a resulting green density of less than 54% of theoretical. However, high sintered densities can be achieved in both single tapes and laminates. Constraints imposed on the tape during solvent evaporation lead to a difference in green density within the tapes, and strategies need to be developed to counteract this

  17. Casting routes for porous metals production

    P. Lichy

    2012-01-01

    Full Text Available The last decade has seen growing interest in professional public about applications of porous metallic materials. Porous metals represent a new type of materials with low densities, large specific surface, and novel physical and mechanical properties, characterized by low density and large specific surface. They are very suitable for specific applications due to good combination of physical and mechanical properties such as high specific strength and high energy absorption capability. Since the discovery of metal foams have been developed many methods and techniques of production in liquid, solid and gas phases. Condition for the use of metal foams - advanced materials with unique usability features, are inexpensive ways to manage their production. Mastering of production of metallic foams with defined structure and properties using gravity casting into sand or metallic foundry moulds will contribute to an expansion of the assortment produced in foundries by completely new type of material, which has unique service properties thanks to its structure, and which fulfils the current demanding ecological requirements. The aim of research conducted at the department of metallurgy and foundry of VSB-Technical University Ostrava is to verify the possibilities of production of metallic foams by conventional foundry processes, to study the process conditions and physical and mechanical properties of metal foam produced. Two procedures are used to create porous metal structures: Infiltration of liquid metal into the mold cavity filled with precursors or preforms and two stage investment casting.

  18. Fracture analysis of chilled cast iron camshaft

    Li Ping; Li Fengjun; Cai Anke; Wei Bokang

    2009-01-01

    The fracture of a camshaft made of chilled cast iron, installed in a home-made Fukang car, happened only after running over a distance of 6,200 km. The fractured camshaft was received to conduct a series of failure analyses using visual inspection, SEM observation of fracture section, microstructure analysis, chemical composition analysis and hardness examination and so on, while those of CKD camshaft made by Citroen Company in France was also simultaneously analyzed to compare the difference between them. The results showed that the fracture of the camshaft mainly results from white section in macrostructure and Ledeburite in microstructure; the crack in the fractured camshaft should be recognized to initiate at the boundary of coarser needle-like carbide and matrix, and then propagate through the transverse section. At the same time, the casting defects such as dendritic shrinkage, accumulated inclusion and initiated crack and abnormal external force might stimulate the fracture of camshaft as well. Based on failure analysis, some measures have been employed, and as a result, the fracture of home-made camshafts has been effectively prevented.

  19. Shallow water model for horizontal centrifugal casting

    A numerical model was proposed to simulate the solidification process of an outer shell of work roll made by the horizontal centrifugal casting technique. Shallow water model was adopted to solve the 2D average flow dynamics of melt spreading and the average temperature distribution inside the centrifugal casting mould by considering the centrifugal force, Coriolis force, viscous force due to zero velocity on the mould wall, gravity, and energy transport by the flow. Additionally, a 1D sub-model was implemented to consider the heat transfer in the radial direction from the solidifying shell to the mould. The solidification front was tracked by fulfilling the Stefan condition. Radiative and convective heat losses were included from both, the free liquid surface and the outer wall of the mould. Several cases were simulated with the following assumed initial conditions: constant height of the liquid metal (10, 20, and 30 mm), uniform temperature of the free liquid surface (1755 K). The simulation results have shown that while the solidification front remained rather flat, the free surface was disturbed by waves. The amplitude of waves increased with the liquid height. Free surface waves diminished as the solidification proceeded.

  20. Inoculated Slightly Hypereutectic Gray Cast Irons

    Chisamera, Mihai; Riposan, Iulian; Stan, Stelian; Militaru, Cristina; Anton, Irina; Barstow, Michael

    2012-03-01

    The current experimental investigation in this article was designed to characterize the structure of mold (M) and ladle (L) inoculated, low-S (0.025 wt.% S), low-Al (0.003 wt.% Al), slightly hypereutectic (CE = 4.4-4.5 wt.%) electric melted gray irons, typical for high performance thin-wall castings. It describes the effect of a Ca, Al, Zr-FeSi inoculant addition of 0-0.25 wt.% on structure characteristics, and compares to similar treatments with hypoeutectic irons (3.5-3.6 wt.% CE, 0.025 wt.% S, and 0.003 wt.% Al). A complex structure including primary graphite, austenite dendrites, and eutectic cells is obtained in hypereutectic irons, as the result of nonequilibrium solidification following the concept of a coexisting region. Dendrites appear to be distributed between eutectic cells at higher eutectic undercooling, while in inoculated irons and for lower undercooling, the eutectic cells are "reinforced" by eutectic austenite dendrites. A Zr, Ca, Al-FeSi alloy appears to be an effective inoculant in low S, low Al, gray cast irons, especially for a late inoculation technique, with beneficial effects on both graphite and austenite phases. First, inoculation influenced the nucleation of graphite/eutectic cell, and then their characteristics. A further role of these active elements directly contributed to form nucleation sites for austenite, as complex (Mn,X)S particles.

  1. Material accountancy for metallic fuel pin casting

    The operation of the Fuel Conditioning Facility (FCF) is based on the electrometallurgical processing of spent metallic reactor fuel. The pin casting operation, although only one of several operations in FCF, was the first to be on-line. As such, it has served to demonstrate the material accountancy system in many of its facets. This paper details, for the operation of the pin casting process with depleted uranium, the interaction between the mass tracking system (MTG) and some of the ancillary computer codes which generate pertinent information for operations and material accountancy. It is necessary to distinguish between two types of material balance calculations -- closeout for operations and material accountancy for safeguards. The two have much in common, for example, the mass tracking system database and the calculation of an inventory difference, but, in general, are not congruent with regard to balance period and balance spatial domain. Moreover, the objective, assessment, and reporting requirements of the calculated inventory difference are very different in the two cases

  2. Modelling of Filling, Microstructure Formation, Local Mechanical Properties and Stress – Strain Development in High-Pressure Die Cast Aluminium Castings

    Kotas, Petr; Hattel, Jesper Henri; Thorborg, Jesper; Svensson, Ingvar L; Seifeddine, Salem

    2009-01-01

    .e. whether the casting is based on cast iron- or aluminium-alloys. The distribution of local properties in a casting might vary substantially which makes it complex to optimize the casting with good accuracy. Often, mechanical simulations of the load situation are based on the assumption that the cast...... in an aluminium alloy is considered including simulation of the entire casting process with emphasis on microstructure formation related to mechanical properties such as elastic modulus, yield stress, ultimate strength and elongation as well as residual stresses. Subsequently, the casting is...

  3. TESTING OF ALUMINUM-SILICON ALLOYS MECHANICAL PROPERTIES ON SEPARATELY CASTED SPECIMENS

    Krushenko, G.

    2010-01-01

    The mechanical properties of aluminum alloys before casting into moulds were determined on separately casted control specimens casted in horizontal or vertical forms. A comparison of the mechanical properties (tensile strength t, elongation 8, hardness HB) of 12-mm-diameter individually casted of AK7ch alloy control specimens and its density in the solid state (p) showed that it is necessary to use specimens casted in a horizontal mold for evaluation of castings quality. It was estimated that...

  4. Casting Porosity-Free Grain Refined Magnesium Alloys

    Schwam, David [Case Western Reserve University

    2013-08-12

    The objective of this project was to identify the root causes for micro-porosity in magnesium alloy castings and recommend remedies that can be implemented in production. The findings confirm the key role played by utilizing optimal gating and risering practices in minimizing porosity in magnesium castings. 

  5. GUIDES TO POLLUTION PREVENTION: METAL CASTING AND HEAT TREATING INDUSTRY

    This guide provides an overview of the major waste generating process of metal casting and heat treating operations and presents options for reducing this waste through source reduction and recycling. ost waste generated by the metal casting, or foundry, industry is from melting ...

  6. The surface layer of austempered ductile iron investment castings properties

    D. Myszka

    2009-01-01

    Full Text Available The article presents a unique process of carbonnitriding and nitriding the precision casting surfaces of austempered ductile iron. The results of the research are pointing that adequate process parameters allow to obtain multiple increase of wear resistance and a significant increase of corrosion resistance. Also, changes of cast microstructure and hardness are presented.

  7. Multilayer tape cast SOFC – Effect of anode sintering temperature

    Hauch, Anne; Birkl, Christoph; Brodersen, Karen; Jørgensen, Peter Stanley

    2012-01-01

    Multilayer tape casting (MTC) is considered a promising, cost-efficient, up-scalable shaping process for production of planar anode supported solid oxide fuel cells (SOFC). Multilayer tape casting of the three layers comprising the half cell (anode support/active anode/electrolyte) can potentially...

  8. AUTOMATION SYSTEM OF THE CONTINUOUS CASTING LINE CONTROL

    V. A. Harkov

    2016-02-01

    Full Text Available The peculiarities of automation of the continuous horizontal casting line are examined in the article. The variants of application of different cutoff mechanisms are analyzed, the description of automatic contour band cutoff unit, working in combination with continuous casting line, is given.

  9. Virtual Mold Technique in Thermal Stress Analysis during Casting Process

    Si-Young Kwak; Jae-Wook Baek; Jeong-Ho Nam; Jeong-Kil Choi

    2008-01-01

    It is important to analyse the casting product and the mold at the same time considering thermal contraction of the casting and thermal expansion of the mold. The analysis considering contact of the casting and the mold induces the precise prediction of stress distribution and the defect such as hot tearing. But it is difficult to generate FEM mesh for the interface of the casting and the mold. Moreover the mesh for the mold domain spends lots of computational time and memory for the analysis due to a number of meshes. Consequently we proposed the virtual mold technique which only uses mesh of the casting part for thermal stress analysis in casting process. The spring bar element in virtual mold technique is used to consider the contact of the casting and the mold. In general, a volume of the mold is much bigger than that of casting part, so the proposed technique decreases the number of mesh and saves the computational memory and time greatly. In this study, the proposed technique was verified by the comparison with the traditional contact technique on a specimen. And the proposed technique gave satisfactory results.

  10. Total contact cast for neuropathic diabetic foot ulcers

    To determine the outcome of diabetic neuropathic foot ulcers treated with Total Contact Cast (TCC) in terms of percentage of ulcers healed and time to heal. The study included diabetic patients with non-ischemic neuropathic foot ulcers of upto grade 2 of Wagner's classification. Ulcers were debrided off necrotic tissues and Total Contact Cast (TCC) was applied. TCC was renewed every 2 weeks till healing. Cases were labeled as cast failure when there was no reduction in wound size in 4 consecutive weeks or worsening to a higher grade. Main outcome measures were the percentage of ulcers healed and time to heal in the cast. Thirty four (87.17%) patients were males and 5(12.82%) were females. The mean age was 62 +- 13.05 years. All patients had NIDDM. Out of the 52 ulcers, 41(78.84%) healed with TCC in an average 2 casts duration (mean 32 days). There were 11(21.15%) cast failure. Majority (63.63%) of cast failure ulcers were located on pressure bearing area of heel. Most (90%) of the ulcers on forefoot and midsole region healed with TCC (p<0.001). Longer ulcer duration (mean 57.45 +- 29.64 days) significantly reduced ulcer healing (p<0.001). Total contact cast was an effective treatment modality for neuropathic diabetic foot ulcers of Wagner's grade 2, located on forefoot and midsole region. (author)

  11. Probabilistic modeling of solidification grain structure in investment castings

    Upadhya, G.K.; Yu, K.O.; Layton, M.A.; Paul, A.J. [Concurrent Technologies Corp., Johnstown, PA (United States)

    1995-12-31

    A probabilistic approach for modeling the evolution of grain structure in investment castings has been developed. The approach differs from the classical Monte Carlo simulations of microstructural evolution in that it uses the results from a heat transfer simulation of the investment casting process for determining the probabilities of nucleation and growth. The model was used to predict the solidification grain structure in castings. The model is quasi-3D, since it uses the information from a 3D simulation of heat transfer to predict the grain structure developed in any 2D-section of the casting. Structural transitions such as columnar/equiaxed transition can also be predicted, using suitable transition criteria. Results from the model have been validated by comparison with actual micrographs from experimental investment castings. In the first case, simulations were performed for a simple plate shaped casting of superalloy Rene 77. The effects of mold insulation as well as metal pour and mold preheat temperatures on the grain size of the casting were studied. In the second example, the casting of a complex-shaped jet engine component made of superalloy IN718 was simulated. Simulation results were seen to match very well with experiments.

  12. Colour Metallography of Cast Iron - Chapter 1: Introduction (Ⅰ

    Zhou Jiyang

    2009-02-01

    Full Text Available Cast iron, as a traditional metal material, has advantages of low total cost, good castability and machinability, good wear resistance and low notch sensitivity, and is still facing tough challenge in quality, property and variety of types etc. Experts and engineers studying and producing iron castings all around world extremely concern this serious challenge. Over more than 30 years, a great of research work has been carried out on how to further improve its property, expand its application and combine cast iron technology with some hi-techs (for example, computer technology. Nevertheless, cast iron is a multi-element and multi-phase alloy and has complex and variety of structures and still has great development potential in structure and property. For further studying and developing cast iron, theoretical research work is important promise, and the study on solidification process and control mechanism of graphite morphology is fundamental for improving property of cast iron and developing new type of cast iron. Metallography of cast iron normally includes two sections: liquid phase transformation and solid phase transformation. The book, Colour Metallography of Cast Iron, uses colour metallography technique to study solidification structures of cast irons: graphite, carbides, austenite and eutectics; and focuses on solidification processes. With progress of modern solidification theory, the control of material solidification process becomes important measure for improving traditional materials and developing new materials. Solidification structure not only influences mechanical and physical properties of cast iron, but also affects its internal quality. The book uses a large amount of colour photos to describe the formation of solidification structures and their relations. Crystallization phenomena, which cannot be displayed with traditional metallography, are presented and more phase transformation information is obtained from these colour

  13. Tundish Technology for Casting Clean Steel: A Review

    Sahai, Yogeshwar

    2016-03-01

    With increasing demand of high-quality clean steel, cleanliness is of paramount importance in steel production and casting. Tundish plays an important role in controlling the continuously cast steel quality as it links a batch vessel, ladle, to a continuous casting mold. Tundish is also the last vessel in which metal flows before solidifying in mold. For controlling the quality of steel, flow and temperature control of the melt are critical, and these are presented in this paper. Use of proper flux, design of flow control devices, and gas injection in tundish become important factors in casting clean steel. Recycling of hot tundish, centrifugal flow tundish, H-shaped tundish, etc. are some of the developments which were implemented to cast clean steel and these are discussed.

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

    Sabau, Adrian S [ORNL

    2006-01-01

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

  15. Casting Defect Detection and Quality Improvement by Industrial CT

    A 3D-CT system provides complete volume information on the testing objects and gives us many possibilities in the nondestructive testing area. As the development in automobile and aircraft industry, needs for casting parts with high quality and reliability become more and more important. The 3D-CT system can be applied not only to the sample testing in order to find and avoid casting defects by mass production but also to the development of a prototype. In this work porosities and shrinkages in die-casting parts were analyzed with the CT system to make improvement in the quality of castings. The CT scan system combined with simulation technology in the field of mold filling and solidification is expected to be the most effective tool for improving productivity in the die-casting production.

  16. Thermodynamic stability of austenitic Ni-Mn-Cu cast iron

    A. Janus

    2014-07-01

    Full Text Available The performed research was aimed at determining thermodynamic stability of structures of Ni-Mn-Cu cast iron castings. Examined were 35 alloys. The castings were tempered at 900 °C for 2 hours. Two cooling speeds were used: furnace-cooling and water-cooling. In the alloys with the nickel equivalent value less than 20,0 %, partial transition of austenite to martensite took place. The austenite decomposition ratio and the related growth of hardness was higher for smaller nickel equivalent value and was clearly larger in annealed castings than in hardened ones. Obtaining thermodynamically stable structure of castings requires larger than 20,0 % value of the nickel equivalent.

  17. Caste differences in Pseudopolybia compressa (Hymenoptera: Vespidae: Polistinae

    Laura Chavarría Pizarro

    2009-12-01

    Full Text Available Studies of morphological caste syndromes in the tribe Epiponini help us to understand the evolution of social behavior in insects. Few studies have integrated morphological syndromes of various species from the same or distinct genera. We studied morphological differences between castes from three colonies of Pseudopolybia compressa de Saussure, 1854, in order to relate their caste syndrome with those of other species in the genus. We took eight morphometric measures and females were classified in relation to ovarian development and spermathecal contents. Females of Colony 1 (C1 present a higher distinction between castes than females of Colonies 2 and 3 (C2 and C3, and, in general, queens of the three colonies are larger than workers in some measures but smaller in others. In Pseudopolybia Dalla Torre, 1894, shape rather than size is a more important trait in caste divergence.

  18. Tensile-property characterization of thermally aged cast stainless steels

    Michaud, W.F.; Toben, P.T.; Soppet, W.K.; Chopra, O.K. [Argonne National Lab., IL (United States)

    1994-02-01

    The effect of thermal aging on tensile properties of cast stainless steels during service in light water reactors has been evaluated. Tensile data for several experimental and commercial heats of cast stainless steels are presented. Thermal aging increases the tensile strength of these steels. The high-C Mo-bearing CF-8M steels are more susceptible to thermal aging than the Mo-free CF-3 or CF-8 steels. A procedure and correlations are presented for predicting the change in tensile flow and yield stresses and engineering stress-vs.-strain curve of cast stainless steel as a function of time and temperature of service. The tensile properties of aged cast stainless steel are estimated from known material information, i.e., chemical composition and the initial tensile strength of the steel. The correlations described in this report may be used for assessing thermal embrittlement of cast stainless steel components.

  19. Tundish Technology for Casting Clean Steel: A Review

    Sahai, Yogeshwar

    2016-08-01

    With increasing demand of high-quality clean steel, cleanliness is of paramount importance in steel production and casting. Tundish plays an important role in controlling the continuously cast steel quality as it links a batch vessel, ladle, to a continuous casting mold. Tundish is also the last vessel in which metal flows before solidifying in mold. For controlling the quality of steel, flow and temperature control of the melt are critical, and these are presented in this paper. Use of proper flux, design of flow control devices, and gas injection in tundish become important factors in casting clean steel. Recycling of hot tundish, centrifugal flow tundish, H-shaped tundish, etc. are some of the developments which were implemented to cast clean steel and these are discussed.

  20. Integration of CAD/CAE System for Casting Process Design

    周舰; 荆涛

    2003-01-01

    Concurrent engineering is needed to modernize the foundry industry and to reduce the scrap from castings and thus increase the economic profit. This paper presents an integrated 3-D CAD/CAE system for a foundry using concurrent engineering which considers casting structure, casting type, and manufacturing properties in the CAD module to design the pouring system, the riser, the chill core and so on. A visualized solid model is developed for the casting component with the model design enhanced by CAE analysis. Heat transfer and fluid flow simulation are used to analyze the initial design. The whole product development process is analyzed using concurrent engineering methods. The application shows that the integrated system can improve the efficiency of the design and manufacturing process of die casting.

  1. DESIGN AND FABRICATION OF A CENTRIFUGAL CASTING MACHINE

    Adedipe Oyewole

    2011-12-01

    Full Text Available The design and fabrication of a centrifugal casting machine was successfully carried out. The operation of the machine was based on the principle of centrifugal force. Suitable design theory, analysis and calculation were adopted carried out in the course of the work. The mold is bolted to the base plate which can rotate at moderatespeeds thereby forcing the molten metal against the inner walls of the mold. This machine could be used to cast small engineering components. The centrifugal force on the machine was determined to be 3207.3N, while the required power on the machine was 854.7W. A test was carried out on the fabricated centrifugal casting machine with aluminum alloy and the machine was able to cast 6kg of aluminum alloy and the casting was successful.

  2. Twin-roll strip casting of magnesium alloys in China

    2008-01-01

    The development status of twin-roll strip casting for magnesium alloys in China was summarized as well as the new progress when several kinds of twin-roll strip casting technologies were developed and used.Horizontal twin-roll casting (HTRC) of magnesium alloys has attracted much attention and has been industrialized in China.Vertical twin roll casting(VTRC) of the magnesium alloys can reach a speed of higher than 30 m/min and its research and development are just beginning and exhibit exciting potential.By comparing the process characteristics of the two technologies,the process stability of HTRC for the magnesium alloys is better,and the casting speed and the cooling rate of VTRC for the magnesium alloys are higher.The quality of the products by the two technologies needs to be improved and further investigated.

  3. Eutectic solidification mode of spheroidal graphite cast iron and graphitization

    Hideo Nakae

    2007-02-01

    Full Text Available The shrinkage and chilling tendency of spheroidal graphite (abbreviated SG cast iron is much greater than that of the flake graphite cast iron in spite of its higher amount of C and Si contents. Why? The main reason should be the difference in their graphitization during the eutectic solidification. In this paper, we discuss the difference in the solidification mechanism of both cast irons for solving these problems using unidirectional solidification and the cooling curves of the spheroidal graphite cast iron. The eutectic solidification rate of the SG cast iron is controlled by the diffusion of carbon through the austenite shell, and the final thickness is 1.4 times the radius of the SG, therefore, the reduction of the SG size, namely, the increase in the number, is the main solution of these problems.

  4. Tensile-property characterization of thermally aged cast stainless steels

    The effect of thermal aging on tensile properties of cast stainless steels during service in light water reactors has been evaluated. Tensile data for several experimental and commercial heats of cast stainless steels are presented. Thermal aging increases the tensile strength of these steels. The high-C Mo-bearing CF-8M steels are more susceptible to thermal aging than the Mo-free CF-3 or CF-8 steels. A procedure and correlations are presented for predicting the change in tensile flow and yield stresses and engineering stress-vs.-strain curve of cast stainless steel as a function of time and temperature of service. The tensile properties of aged cast stainless steel are estimated from known material information, i.e., chemical composition and the initial tensile strength of the steel. The correlations described in this report may be used for assessing thermal embrittlement of cast stainless steel components

  5. Relationship Between Casting Distortion, Mold Filling, and Interfacial Heat Transfer in Sand Molds

    J. K. Parker; K. A. Woodbury; T. S. Piwonka; Y. Owusu

    1999-09-30

    This project sought to determine the relationship between casting dimensions and interfacial heat transfer in aluminum alloy sand castings. The program had four parts; measurement of interfacial heat transfer coefficients in resin bonded and green sand molds, the measurement of gap formation in these molds, the analysis of castings made in varying gatings, orientations and thicknesses, and the measurement of residual stresses in castings in the as-cast and gate removed condition. New values for interfacial heat transfer coefficients were measured, a novel method for gap formation was developed, and the variation of casting dimensions with casting method, gating, and casting orientation in the mold was documented.

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

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

    2013-12-13

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

  7. Cast Stone Formulation At Higher Sodium Concentrations

    Fox, K. M.; Edwards, T. A.; Roberts, K. B.

    2013-10-02

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  8. Cast Stone Formulation At Higher Sodium Concentrations

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2013-09-17

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  9. Cast Stone Formulation At Higher Sodium Concentrations

    Fox, K. M.; Roberts, K. A.; Edwards, T. B.

    2014-02-28

    A low temperature waste form known as Cast Stone is being considered to provide supplemental Low Activity Waste (LAW) immobilization capacity for the Hanford site. Formulation of Cast Stone at high sodium concentrations is of interest since a significant reduction in the necessary volume of Cast Stone and subsequent disposal costs could be achieved if an acceptable waste form can be produced with a high sodium molarity salt solution combined with a high water to premix (or dry blend) ratio. The objectives of this study were to evaluate the factors involved with increasing the sodium concentration in Cast Stone, including production and performance properties and the retention and release of specific components of interest. Three factors were identified for the experimental matrix: the concentration of sodium in the simulated salt solution, the water to premix ratio, and the blast furnace slag portion of the premix. The salt solution simulants used in this study were formulated to represent the overall average waste composition. The cement, blast furnace slag, and fly ash were sourced from a supplier in the Hanford area in order to be representative. The test mixes were prepared in the laboratory and fresh properties were measured. Fresh density increased with increasing sodium molarity and with decreasing water to premix ratio, as expected given the individual densities of these components. Rheology measurements showed that all of the test mixes produced very fluid slurries. The fresh density and rheology data are of potential value in designing a future Cast Stone production facility. Standing water and density gradient testing showed that settling is not of particular concern for the high sodium compositions studied. Heat of hydration measurements may provide some insight into the reactions that occur within the test mixes, which may in turn be related to the properties and performance of the waste form. These measurements showed that increased sodium

  10. Gating of Permanent Molds for Aluminum Casting

    David Schwam; John F. Wallace; Tom Engle; Qingming Chang

    2004-01-01

    This report summarizes a two-year project, DE-FC07-011D13983 that concerns the gating of aluminum castings in permanent molds. The main goal of the project is to improve the quality of aluminum castings produced in permanent molds. The approach taken was to determine how the vertical type gating systems used for permanent mold castings can be designed to fill the mold cavity with a minimum of damage to the quality of the resulting casting. It is evident that somewhat different systems are preferred for different shapes and sizes of aluminum castings. The main problems caused by improper gating are entrained aluminum oxide films and entrapped gas. The project highlights the characteristic features of gating systems used in permanent mold aluminum foundries and recommends gating procedures designed to avoid common defects. The study also provides direct evidence on the filling pattern and heat flow behavior in permanent mold castings. Equipment and procedure for real time X-Ray radiography of molten aluminum flow into permanent molds have been developed. Other studies have been conducted using water flow and behavior of liquid aluminum in sand mold using real time photography. This investigation utilizes graphite molds transparent to X-Rays making it possible to observe the flow pattern through a number of vertically oriented grating systems. These have included systems that are choked at the base of a rounded vertical sprue and vertical gating systems with a variety of different ingates into the bottom of a mold cavity. These systems have also been changed to include gating systems with vertical and horizontal gate configurations. Several conclusions can be derived from this study. A sprue-well, as designed in these experiments, does not eliminate the vena contracta. Because of the swirling at the sprue-base, the circulating metal begins to push the entering metal stream toward the open runner mitigating the intended effect of the sprue-well. Improved designs of

  11. Methods and apparatuses for manufacturing geometric multicrystalline cast silicon and geometric multicrystalline cast silicon bodies for photovoltaics

    Stoddard, Nathan G

    2015-02-10

    Methods and apparatuses are provided for casting silicon for photovoltaic cells and other applications. With such methods and apparatuses, a cast body of geometrically ordered multi-crystalline silicon may be formed that is free or substantially free of radially-distributed impurities and defects and having at least two dimensions that are each at least about 10 cm is provided.

  12. Spreader equipment for open cast mining

    Nies, G.; Jurisch, H. [MAN TAKRAF Foerdertechnik GmbH, Lauchhammer (Germany)

    1999-03-01

    In open cast mining in unconsolidated rock, continuous excavation and dumping has asserted itself throughout the world. A milestone of this development was the use of the first overburden conveyor bridge in the Lusatian open cast mine Plessa in 1924. Handling capacities of 36.000 m{sup 3}/h of loose overburden and discharge boom lengths of approx. 200 m were the highlights of the TAKRAF spreading equipment technology in unconsolidated rock. The past decade has shown that spreader equipment technology of medium-size dominated the industry. The described case studies in unconsolidated rock in Yuan Bao Shan in China and Mae Moh and Lampang in Thailand confirm this just as much as further cases in which TAKRAF spreaders are used, for example in Oslomej/Macedonia, which we have not described here. With the application of in-pit crushers, spreaders also found use in hard rock open cast mining; initially used to transport the crushed waste rock. However, with the development of the heap leach technology, they were soon also used for dumping the leached ore residues. The possibility of achieving large dumping depths with short discharge booms, makes the compact spreader the predominant spreader type for hard rock. (orig./MSK) [Deutsch] Im uebertaegigen Bergbau im Lockergestein hat sich weltweit die kontinuierliche Foerderung und Verkippung durchgesetzt. Ein Meilenstein dieser Entwicklung war 1924 der Einsatz der ersten Abraumfoerderbruecke im Lausitzer Tagebau Plessa. Foerderleistungen von 36.000 m{sup 3}/h geschuettetem Abraum und Abwurfauslegerlaengen von ca. 200 m waren Hoehenpunkte der Absetzergeraetetechnik von TAKRAF im Lockergestein. Das vergangene Jahrzehnt hat gezeigt, dass Absetzergeraetetechnik der mittleren Groessenordnung bestimmend war. Die erlaeuterten Einsatzfaelle im Lockergestein in Yuan Bao Shan in China sowie Mae Moh und Lampang in Thailand bestaetigen das ebenso wie weitere Einsatzfaelle von TAKRAF-Absetzern, wie zum Beispiel Oslomej in Mazedonien, die

  13. Low speed centrifugal casting of Functionally Graded solid cast ingot by anomalous particle distribution

    Mer, K. K. S.; Ray, S.

    2011-12-01

    Functionally graded cylindrical ingot of Al-Al2O3 composite synthesized by centrifugal casting shows particle distribution and hardness decreasing radially from the outer radius to inner radius. The progressive decrease in alumina content and hardness from the outer radius towards the center may be attributed to higher centrifugal force acting on relatively denser alumina particles during rotation, as compared to that acting on lighter alloy melt. It is also observed, as one moves down from the top to the bottom of cast ingot the alumina content decreases. This is surprising in view of higher density of alumina particles relative to the melt. The particle settling should have resulted at more particles towards the bottom, but distribution observed is in contradiction.

  14. Effect of potassium on as-cast microstructure of a hypereutectic high chromium cast iron

    Liu Qing

    2011-05-01

    Full Text Available The present work mainly evaluates the effect of potassium (K on as-cast microstructure of a hypereutectic high chromium cast iron by means of a field emission scanning electron microscope (FESEM and an X-ray diffractometer using CuKα radiation with a 2θ range of 30-130°. Results showed that, with the addition of K-containing modifier, the large lath-like and/or rod-like primary M7C3 carbides can be modified to the hexagonal prisms, and the eutectic carbides can also be refined. In addition, the carbides are distributed much more homogeneously in the matrix. The modification effect of K is due to its aggregation at the liquid-solid interface and the adsorption on the relatively fast growing planes during the solidification, which influence the growth rates of different crystal planes and lead to the modification of the carbides.

  15. The effect of cast-to-cast variations on the quality of thin section nickel alloy welded joints

    The welding behaviour of 26 commercial casts of Alloy 800 has been quantified for mechanised, autogenous, full penetration, bead-on-strip tungsten inert gas welding tests. Weld front and back widths have been measured and correlated with minor element variations. Casts with similar welding responses have been sorted into groups. The behaviour of the weld pool, surface slags and arc have been compared and a convection controlled model has been used to account for differences between the groups of casts. The main factors governing laboratory process control variability have been identified and a statistical method has been used to identify all the components of weld variance. An optimum size of welding test matrix has been proposed to determine typical cast-to-cast variations at high significance levels. (author)

  16. Effect of Manganese on As-Cast Microstructure and Hardening Behavior of High Chromium White Cast Iron

    SUN Zhi-ping; SHEN Bao-luo; WANG Jun; LIU Hao-huai; LUO Cheng

    2005-01-01

    The effect of manganese on the as-cast structure and hardening behavior of high chromium white cast iron subjected to sub-critical treatment was studied. The results indicate that the fraction of retained austenite and the manganese distribution in as-cast alloys are controlled by manganese content. The manganese distribution in as-cast alloys is not homogeneous. The manganese content in carbide is higher than that in matrix. Whether the secondary hardening occurs or not and the peak hardness of secondary hardening is controlled by manganese content in retained austenite in as-cast structure. Higher manganese content can cause more retained austenite. The secondary hardening occurs in sub-critical treating process if the fraction of retained austenite is high.

  17. Microstructure and Property of Hypereutectic High Chromium Cast Iron Prepared by Slope Cooling Body-Centrifugal Casting Method

    Zhifu HUANG; Jiandong XING; Anfeng ZHANG

    2006-01-01

    In this paper, the ring-type ingot of hypereutectic high Cr cast iron was obtained by slope cooling bodycentrifugal casting method (SC-CCM), and its microstructure and impact toughness were investigated, respectively. The results indicated that, first, the primary carbides in the microstructure are prominently finer than those in the hypereutectic high Cr cast iron prepared by conventional casting method. Second, in the ring-type ingot, the primary carbides near radial outer field are finer than those near radial inner field; furthermore, there is dividing field in the microstructure. Finally, the impact toughness values of the specimens impacted on the radial outer face and on the radial inner face are improved respectively about 36% and 138%more than that of the hypereutectic high Cr one prepared by conventional casting method.

  18. CENTER FOR ADVANCED SEPARATION TECHNOLOGY (CAST) PROGRAM

    Yoon, Roe-Hoan; Hull, Christopher

    2014-09-30

    The U.S. is the largest producer of mining products in the world. In 2011, U.S. mining operations contributed a total of $232 billion to the nation’s GDP plus $138 billion in labor income. Of this the coal mining industry contributed a total of $97.5 billion to GDP plus $53 billion in labor income. Despite these contributions, the industry has not been well supported with research and development funds as compared to mining industries in other countries. To overcome this problem, the Center for Advanced Separation Technologies (CAST) was established to develop technologies that can be used by the U.S. mining industry to create new products, reduce production costs, and meet environmental regulations.

  19. Vascular corrosion casting of human heart

    J. Vasudeva Reddy

    2013-06-01

    Full Text Available Variation in the morphological pattern of coronary arteries and their major branches is an important factor in the assessment and treatment of coronary heart disease. Detailed knowledge of the blood supply of the heart is necessary today because of the wider practice of cardiac surgery, and also for better understanding of the anomalous branches, anastomosis and dominance pattern in circulation caused by coronary vasculature. We utilized 80 human heart specimens and found right dominance in 69 specimens, left dominance in 9 specimens and balanced type of circulation in 2 specimens. We observed anastomosis between the major arteries in arteriogram but in vascular corrosion method we did not found because cast substance interpretation to minor vessels is too difficult. The present study acknowledges about Coronary vascular pattern, circulatory dominance of the arteries and by using the vascular corrosion method. [Int J Res Med Sci 2013; 1(3.000: 237-239

  20. Thermal aging of cast duplex stainless steels

    Cast duplex stainless steels of CR8M and CF8 are used in major components because of their superior characteristics, such as corrosion resistance, weldability and so on. But, these stainless steels are known to have tendency of thermal aging embrittlement after long term service. Therefore, mechanical properties have been investigated using Charpy impact specimens and fracture toughness specimens aged at 300∼400 C up to 40,000 hours. As the results, effects of thermal aging on mechanical properties of these stainless steels were identified and a good relationship between Charpy impact energy and fracture toughness was obtained. In addition, prediction method for Charpy absorbed energy and fracture toughness was established

  1. Acoustic energy transmission in cast iron pipelines

    Kiziroglou, Michail E.; Boyle, David E.; Wright, Steven W.; Yeatman, Eric M.

    2015-12-01

    In this paper we propose acoustic power transfer as a method for the remote powering of pipeline sensor nodes. A theoretical framework of acoustic power propagation in the ceramic transducers and the metal structures is drawn, based on the Mason equivalent circuit. The effect of mounting on the electrical response of piezoelectric transducers is studied experimentally. Using two identical transducer structures, power transmission of 0.33 mW through a 1 m long, 118 mm diameter cast iron pipe, with 8 mm wall thickness is demonstrated, at 1 V received voltage amplitude. A near-linear relationship between input and output voltage is observed. These results show that it is possible to deliver significant power to sensor nodes through acoustic waves in solid structures. The proposed method may enable the implementation of acoustic - powered wireless sensor nodes for structural and operation monitoring of pipeline infrastructure.

  2. Ceramica sphere production by a gel casting

    The technology of (Th,U)O2 microspheres production by gel casting and subsequente thermal treatment has been transferred from NUKEM GmbH assisted by Kraftwerk Union A.G., both West Germany, to NUCLEBRAS, where it was jointly adapted to produce microspheres suitable for pressing. As a result, there are now available various possibilities to produce ceramic spheres with different characteristics that can be used in different applications. Examples of these characteristics are the range of gel sphere diameters (200 to 5000 μmm) and the value of the specific surface (about 50m2/g for calcined (Th, U)O2 and potentially higher than m2/g for other ceramic materials) (Author)

  3. Numerical simulation of centrifugal casting of pipes

    A numerical simulation model for the horizontal centrifugal pipe casting process was developed with the commercial simulation package Flow3D. It considers - additionally to mass, energy and momentum conservation equations and free surface tracking - the fast radial and slower horizontal movement of the mold. The iron inflow is not steady state but time dependent. Of special importance is the friction between the liquid and the mold in connection with the viscosity and turbulence of the iron. Experiments with the mold at controlled revolution speeds were carried out using a high-speed camera. From these experiments friction coefficients for the description of the interaction between mold and melt were obtained. With the simulation model, the influence of typical process parameters (e.g. melts inflow, mold movement, melt temperature, cooling media) on the wall thickness of the pipes can be studied. The comparison to results of pipes from production shows a good agreement between simulation and reality.

  4. Numerical simulation of centrifugal casting of pipes

    Kaschnitz, E.

    2012-07-01

    A numerical simulation model for the horizontal centrifugal pipe casting process was developed with the commercial simulation package Flow3D. It considers - additionally to mass, energy and momentum conservation equations and free surface tracking - the fast radial and slower horizontal movement of the mold. The iron inflow is not steady state but time dependent. Of special importance is the friction between the liquid and the mold in connection with the viscosity and turbulence of the iron. Experiments with the mold at controlled revolution speeds were carried out using a high-speed camera. From these experiments friction coefficients for the description of the interaction between mold and melt were obtained. With the simulation model, the influence of typical process parameters (e.g. melts inflow, mold movement, melt temperature, cooling media) on the wall thickness of the pipes can be studied. The comparison to results of pipes from production shows a good agreement between simulation and reality.

  5. Fractal structures in casting films from chlorophyll

    Pedro, G. C.; Gorza, F. D. S.; de Souza, N. C.; Silva, J. R.

    2014-04-01

    Chlorophyll (Chl) molecules are important because they can act as natural light-harvesting devices during the photosynthesis. In addition, they have potential for application as component of solar cell. In this work, we have prepared casting films from chlorophyll (Chl) and demonstrated the occurrence of fractal structures when the films were submitted to different concentrations. By using optical microscopy and the box-count method, we have found that the fractal dimension is Df = 1.55. This value is close to predicted by the diffusion-limited aggregation (DLA) model. This suggests that the major mechanism - which determines the growth of the fractal structures from Chl molecules - is the molecular diffusion. Since the efficiencies of solar cells depend on the morphology of their interfaces, these finds can be useful to improve this kind of device.

  6. The CERN axion solar telescope (CAST)

    Aalseth, C E; Autiero, D; Avignone, F T; Barth, K; Bowyer, S M; Bräuninger, H; Brodzinski, R L; Carmona, J M; Cebrián, S; Celebi, G; Cetin, S A; Collar, J I; Creswick, R; Delbart, A; Delattre, M; Di Lella, L; De Oliveira, R; Eleftheriadis, C; Erdutan, N; Fanourakis, G K; Farach, H A; Fiorini, C; Geralis, T; Giomataris, Ioanis; Girard, T A; Gninenko, S N; Golubev, N A; Hasinoff, M D; Hoffmann, D; Irastorza, I G; Jacoby, J; Jeanneau, F; Knopf, M A; Kovzelev, A; Kotthaus, R; Krcmar, M; Krecak, Z; Lakic, B; Liolios, A; Ljubicic, A; Lutz, Gerhard; Longoni, A; Luzón, G; Mailov, A; Matveev, V A; Miley, H S; Morales, A; Morales, J; Mutterer, M; Nikolaidis, A; Nussinov, S; Ortiz, A; Pitts, W K; Placci, A; Postoev, V E; Raffelt, G G; Riege, H; Sampietro, M; Sarsa, M; Savvidis, I; Stipcevic, M; Thomas, C W; Thompson, R C; Valco, P; Villar, J A; Villierme, B; Walckiers, L; Wilcox, W; Zachariadou, K; Zioutas, Konstantin

    2002-01-01

    A decommissioned LHC test magnet is being prepared as the CERN Axion Solar Telescope (CAST) experiment. The magnet has a field of 9.6 Tesla and length of 10 meters. It is being mounted on a platform to track the sun over +-8 deg. vertically and +-45 deg. , horizontally. A sensitivity in axion-photon coupling g alpha gamma gamma < 5 x 10 sup - sup 1 sup 1 GeV sup - sup 1 can be reached for m subalpha <= 10 sup - sup 2 eV, and with a gas filled tube-can reach g alpha gamma gamma <= 10 sup - sup 1 sup 0 GeV sup - sup 1 for axion masses m subalpha < 2eV.

  7. Size Effect on Magnesium Alloy Castings

    Li, Zhenming; Wang, Qigui; Luo, Alan A.; Zhang, Peng; Peng, Liming

    2016-06-01

    The effect of grain size on tensile and fatigue properties has been investigated in cast Mg alloys of Mg-2.98Nd-0.19Zn (1530 μm) and Mg-2.99Nd-0.2Zn-0.51Zr (41 μm). The difference between RB and push-pull fatigue testing was also evaluated in both alloys. The NZ30K05-T6 alloy shows much better tensile strengths (increased by 246 pct in YS and 159 pct in UTS) and fatigue strength (improved by ~80 pct) in comparison with NZ30-T6 alloy. RB fatigue testing results in higher fatigue strength compared with push-pull fatigue testing, mainly due to the stress/strain gradient in the RB specimen cross section. The material with coarse grains could be hardened more in the cyclic loading condition than in the monotonic loading condition, corresponding to the lower σ f and the higher σ f/ σ b or σ f/ σ 0.2 ratio compared to the materials with fine grains. The fatigue crack initiation sites and failure mechanism are mainly determined by the applied stress/strain amplitude. In LCF, fatigue failure mainly originates from the PSBs within the surface or subsurface grains of the samples. In HCF, cyclic deformation and damage irreversibly caused by environment-assisted cyclic slip is the crucial factor to influence the fatigue crack. The Coffin-Manson law and Basquin equation, and the developed MSF models and fatigue strength models can be used to predict fatigue lives and fatigue strengths of cast magnesium alloys.

  8. Methodology of analysis of casting defects

    L.A. Dobrzański

    2006-08-01

    Full Text Available Purpose: The goal of this publication is to present the methodology of the automatic supervision and controlof the technological process of manufacturing the elements from aluminium alloys and of the methodology ofthe automatic quality assessment of these elements basing on analysis of images obtained with the X-ray defectdetection, employing the artificial intelligence tools. The methodologies developed will make identification andclassification of defects possible and the appropriate process control will make it possible to reduce them andto eliminate them - at least in part.Design/methodology/approach: The methodology is presented in the paper, making it possible to determine thetypes and classes of defects developed during casting the elements from aluminium alloys, making use photosobtained with the flaw detection method with the X-ray radiation. It is very important to prepare the neuralnetwork data in the appropriate way, including their standardization, carrying out the proper image analysis andcorrect selection and calculation of the geometrical coefficients of flaws in the X-ray images. The computersoftware was developed for this task.Findings: Combining of all methods making use of image analysis, geometrical shape coefficients, and neuralnetworks will make it possible to achieve the better efficiency of class recognition of flaws developed in thematerial.Practical implications: The presented issues may be essential, among others, for manufacturers of carsubassemblies from light alloys, where meeting the stringent quality requirements ensures the demanded servicelife of the manufactured products.Originality/value: The correctly specified number of products enables such technological process control thatthe number of castings defects can be reduced by means of the proper correction of the process.

  9. A dynamic control water distribution model of steel in continuous casting

    After investigation in many continuous casting shop of steel, a dynamic water distribution model is proposed for flexible control on secondary cooling in continuous casting. In this model, the water cooling intensity is determined by the model casting speed instead of the real casting speed. When the casting speed is steady, the model casting speed is equal to the real casting speed. When the real casting speed is changing, the model casting speed according to calculating algorithm to adjust and approaches to the real one, but there is a time delay between them, so it can avoid the slab surface temperature fluctuated due to casting speed changes. The secondary cooling can be dynamically controlled by monitoring the model casting speed. The compare of the simulation results and the measured results reveals that the temperature field and thickness of slab shell in simulations agree very well with the real production situations.

  10. CastScan: High energy tomography for continuous casting of metals

    The goal of CastScan is the development of a real-time, non-invasive solidification sensor for the metal casting industry. In metal casting processes, there always exists a solidification front, or liquid-solid interface, the shape and stability of which determines the production rate and quality and has a significant economic impact. Current technologies for monitoring the shape and position of the solidification front have their limitations. We have built a tomographic imager, which we have used to determine the shape of the liquid-solid interface in solidifying aluminum. The operating principle of the sensor is based on the density change between liquid and solid which ranges from 4% to 12% for most metals. For high energy x-rays, the absorption is essentially dependent only on the density of the material. The system includes a 6 MeV compact linac and a 128 element detector array. Typical spatial resolutions are ∼1.6 mm with a density precision of ∼2%

  11. Irradiation response of delta ferrite in as-cast and thermally aged cast stainless steel

    Li, Zhangbo; Lo, Wei-Yang; Chen, Yiren; Pakarinen, Janne; Wu, Yaqiao; Allen, Todd; Yang, Yong

    2015-11-01

    To enable the life extension of Light Water Reactors (LWRs) beyond 60 years, it is critical to gain adequate knowledge for making conclusive predictions to assure the integrity of duplex stainless steel reactor components, e.g. primary pressure boundary and reactor vessel internal. Microstructural changes in the ferrite of thermally aged, neutron irradiated only, and neutron irradiated after being thermally aged cast austenitic stainless steels (CASS) were investigated using atom probe tomography. The thermal aging was performed at 400 °C for 10,000 h and the irradiation was conducted in the Halden reactor at ˜315 °C to 0.08 dpa (5.6 × 1019 n/cm2, E > 1 MeV). Low dose neutron irradiation at a dose rate of 5 × 10-9 dpa/s was found to induce spinodal decomposition in the ferrite of as-cast microstructure, and further to enhance the spinodal decomposition in the thermally aged cast alloys. Regarding the G-phase precipitates, the neutron irradiation dramatically increases the precipitate size, and alters the composition of the precipitates with increased, Mn, Ni, Si and Mo and reduced Fe and Cr contents. The results have shown that low dose neutron irradiation can further accelerate the degradation of ferrite in a duplex stainless steel at the LWR relevant condition.

  12. Fluid flow and heat transfer modeling for castings

    Casting is fundamental to manufacturing of many types of equipment and products. Although casting is a very old technology that has been in existence for hundreds of years, it remains a highly empirical technology, and production of new castings requires an expensive and time-consuming trial-and-error approach. In recent years, mathematical modeling of casting has received increasing attention; however, a majority of the modeling work has been in the area of heat transfer and solidification. Very little work has been done in modeling fluid flow of the liquid melt. This paper presents a model of fluid flow coupled with heat transfer of a liquid melt for casting processes. The model to be described in this paper is an extension of the COMMIX code and is capable of handling castings with any shape, size, and material. A feature of this model is the ability to track the liquid/gas interface and liquid/solid interface. The flow of liquid melt through the sprue and runners and into the mold cavity is calculated as well as three-dimensional temperature and velocity distributions of the liquid melt throughout the casting process. 14 refs., 13 figs

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

    Williams, R.S.

    1994-04-01

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

  14. The structure of high-quality aluminium cast iron

    D. Kopyciński

    2012-01-01

    Full Text Available In this study presents the analyse of aluminium iron cast structure (as-cast condition which are used in high temperature. While producing the casts of aluminium iron major influence has been preserve the structure of technological process parameters. The addition to Fe-C-Al alloy V, Ti, Cr leads to the improvement of functional and mechanical cast qualities. In this study, a method was investigated to eliminate the presence of undesirable Al4C3 phases in a aluminium cast iron structure and thus improve the production process. V and Ti additions in aluminium cast iron allows to development of FeAl - VC or TiC alloys. In particular, V or Ti contents above 5 wt.% were found to totally eliminate the presence of Al4C3. In addition, preliminary work indicates that the alloy with the FeAl - VC or TiC structure reveals high oxidation resistance. The introduction of 5 wt.% chromium to aluminium cast iron strengthened Al4C3 precipitate. Thus, the resultant alloy can be considered an intermetallic FeAl matrix strengthened by VC and TiC or modified Al4C3 reinforcements.

  15. Simulation of mould filling process for composite skeleton castings

    M. Dziuba

    2008-04-01

    Full Text Available In this work authors showed selected results of simulation and experimental studies on temperature distribution during solidification of skeleton casting and mould filling process. The aim of conducted simulations was the choice of thermal and geometrical parameters for the needs of designed calculations of the skeleton castings and the estimation of the guidelines for the technology of manufacturing. The subject of numerical simulation was the analysis of ability of filling the channels of core by liquid metal at estability technological parameters.. Below the assumptions and results of the initial simulated calculations are presented. The total number of the nodes in the casting was 1920 and of the connectors was 5280 what gave filling of 100% for the nodes and 99,56% for the connectors in the results of the simulation. Together it resulted as 99,78 % of filling the volume of the casting. The nodes and connectors were filled up to the 30 level of the casting in the simulation. The all connectors were filled up to the 25 level of the casting in the simulation. Starting from the 25 level individual connectors at the side surface of the casting weren’t filled up. The connectors weren’t supplied by multi-level getting system. The differences of filling the levels are little (maximally 5 per cent.

  16. Formation of microstructures in the spheroidal graphite cast iron

    Pipeline systems for hydraulic networks are obtained via centrifugal casting of spheroidal graphite cast iron. The very high cooling rate that is achieved in the skin of the product can sometimes lead to carbide instead of graphite in cast iron. An experimental device has been built in the laboratory that allows reproducing the extreme thermal conditions encountered during formation of skin of centrifugally cast pipes. Liquid metal droplets fall on a cold substrate. Rapid directional solidification occurs. The temperature evolution of the lower surface of the droplet is recorded during the very first moment of the solidification (t < 200 ms) thanks to a photodiode, which is located below the substrate. The microstructures that are obtained in laboratory are characterised in both the as-cast state and the heat-treated state. They are compared to the centrifugally cast ones. A model of directional solidification of cast iron under a very large temperature gradient has been built. It allows explaining the transition from stable to metastable micro structure that was observed in the products and reproduced in the laboratory samples.

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

    Sabau, Adrian S [ORNL

    2008-04-01

    Efforts during Phase III focused mainly on the shell-alloy systems. A high melting point alloy, 17-4PH stainless steel, was considered. The experimental part of the program was conducted at ORNL and commercial foundries, where wax patterns were injected, molds were invested, and alloys were poured. Shell molds made of fused-silica and alumino-silicates were considered. A literature review was conducted on thermophysical and thermomechanical properties alumino-silicates. Material property data, which were not available from material suppliers, was obtained. For all the properties of 17-4PH stainless steel, the experimental data available in the literature did not cover the entire temperature range necessary for process simulation. Thus, some material properties were evaluated using ProCAST, based on CompuTherm database. A comparison between the predicted material property data and measured property data was made. It was found that most material properties were accurately predicted only over several temperature ranges. No experimental data for plastic modulus were found. Thus, several assumptions were made and ProCAST recommendations were followed in order to obtain a complete set of mechanical property data at high temperatures. Thermal expansion measurements for the 17-4PH alloy were conducted during heating and cooling. As a function of temperature, the thermal expansion for both the alloy and shell mold materials showed different evolution on heating and cooling. Numerical simulations were performed using ProCAST for the investment casting of 17-4PH stainless steel parts in fused silica molds using the thermal expansion obtained on heating and another one with thermal expansion obtained on cooling. Since the fused silica shells had the lowest thermal expansion properties in the industry, the dewaxing phase, including the coupling between wax-shell systems, was neglected. The shell mold was considered to be a pure elastic material. The alloy dimensions were

  18. Effect of annealing on mechanical properties of ledeburitic cast steel

    E. Rożniata

    2007-01-01

    Full Text Available Purpose: The paper presents evaluation of influence of grain normalization (refinement as a result of repeatedaustenitizing, and the inclination to precipitate the hypereutectoid cementite in Widmannstätten structure inG200CrMoNi4-6-3 cast steel. Four temperatures of heat refining have been applied.Design/methodology/approach: Basic research of G200CrMoNi4-6-3 cast steel included metallographicanalysis, and hardness and impact strength tests. The heat treatment has been planned on the basis of CCTdiagram prepared for that alloy cast steel.Findings: The test material has been G200CrMoNi4-6-3 hypereutectoid cast steel. The evaluation has beencarried out for four annealing temperatures, i.e. 850°C, 900°C, 950°C and 1050°C. At all annealing temperaturesin the structure of cast steel the precipitation of hypereutectoid cementite along grain boundaries of formeraustenite took place. At the temperature of 850°C one may observe the coagulated hypereutectoid cementiteprecipitates inside of primary grains of austenite. Whereas beginning from the temperature of 900°C thecementite in G200CrMoNi4-6-3 cast steel forms distinct „subgrains” inside of primary grains of austenite.Research limitations/implications: Research financed by the Ministry of Scientific Research and InformationTechnology, grant No. 3 T08B 057 29.Practical implications: G200CrMoNi4-6-3 cast steel of ledeburite class is used mainly for rolls production.Any data related to the structure and mechanical properties of that cast steel are precious for the manufacturersand users of the mill rolls.Originality/value: The new heat treatment of G200CrMoNi4-6-3 cast steel

  19. The Properties of Ammonium Dinitramine (ADN): Part 2: Melt Casting

    Hahma, A.; Edvinsson, H.; Östmark, H.

    2010-04-01

    A melt casting technique for ammonium dinitramine (ADN) and ADN/aluminum was developed. ADN proved relatively easy to cast, when 1% of magnesium oxide was used as a stabilizer and crystallization kernels. Densities of ADN/MgO 99/1 were 92 to 97% of theoretical mean density (TMD) and those of ADN/Al/MgO 64/35/1 were between 95 and 99% of TMD. Sedimentation of Al in the melt was prevented and the particle wetting was ensured by selecting a suitable particle size for Al. No gelling agents or other additives were used. The casting process and factors influencing it are discussed.

  20. Finger printing of medieval investment cast idols by radiography

    Among the various methods, radiography is an important technique that can be used to fingerprint an idol. This is because, these idols are cast structures, and radiography is the most reliable technique for the detection of internal features like casting defects. This paper presents the radiographic methodology adopted and the results of the studies to characterise radiographically three medieval cast idols belonging to different periods 9th, 13th, and 16th century obtained from the government museum Madras. (author). 2 refs., 1 fig., 2 tabs