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

Directory of Open Access Journals (Sweden)

Haolong Shangguan

2018-03-01

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

PRECISION CASTING INTO DISPOSABLE CERAMIC MOLD – A HIGH EFFICIENCY METHOD OF PRODUCTION OF CASTINGS OF IRREGULAR SHAPE

Directory of Open Access Journals (Sweden)

B. I. Uvarov

2016-01-01

Full Text Available The article shows the advantages and disadvantages of precision casting into disposable ceramic molds. The high quality shaped castings produced by modernized ceramic molding process are proved the reliability and prospects of this advanced technology.

Measurement of casting parameters in ZnAlCu3 molds created by additive technology

Directory of Open Access Journals (Sweden)

S. Medić

2016-10-01

Full Text Available This paper examines the parameters of casting ZnAl4Cu3 alloy (volume, castability, density and occupancy of the mold in mold made additive technology. Molds made by additive technology are: cheaper in production of a small number of castings, geometrically more accurate and faster made. From obtained results of this paper it is clearly seen that printed mold must be protected with thermal coating because liquid adhesive of powder otherwise evaporates during casting and creates additional moisture in the mold, as it was noted.

3D scanning based mold correction for planar and cylindrical parts in aluminum die casting

Directory of Open Access Journals (Sweden)

Takashi Seno

2015-04-01

Full Text Available Aluminum die casting is an important manufacturing process for mechanical components. Die casting is known to be more accurate than other types of casting; however, post-machining is usually necessary to achieve the required accuracy. The goal of this investigation is to develop machining- free aluminum die casting. Improvement of the accuracy of planar and cylindrical parts is expected by correcting metal molds. In the proposed method, the shape of cast aluminum made with the initial metal molds is measured by 3D scanning. The 3D scan data includes information about deformations that occur during casting. Therefore, it is possible to estimate the deformation and correction amounts by comparing 3D scan data with product computer-aided design (CAD data. We corrected planar and cylindrical parts of the CAD data for the mold. In addition, we corrected the planar part of the metal mold using the corrected mold data. The effectiveness of the proposed method is demonstrated by evaluating the accuracy improvement of the cast aluminum made with the corrected mold.

40 CFR Appendix - Alternative Organic HAP Emissions Limits for Open Molding, Centrifugal Casting, and SMC...

Science.gov (United States)

2010-07-01

... Limits for Open Molding, Centrifugal Casting, and SMC Manufacturing Operations Where the Standards Are..., Table 5 Alternative Organic HAP Emissions Limits for Open Molding, Centrifugal Casting, and SMC... casting—CR/HS 3,4 A vent system that moves heated air through the mold 27 lb/ton. 8. Centrifugal casting...

Analysis of cracking in glass molds made of cast iron

Science.gov (United States)

Leushin, I. O.; Chistyakov, D. G.

2014-09-01

The cracking in the parts of cast iron molds intended for glass is considered, and this cracking substantially affects the operation of glass-blowing equipment, maintainability, and the replacement of mold sets. The processes that cause cracking in the parts of glass molds and initiate crack growth are studied.

Grain Refinement of Permanent Mold Cast Copper Base Alloys

Energy Technology Data Exchange (ETDEWEB)

M.Sadayappan; J.P.Thomson; M.Elboujdaini; G.Ping Gu; M. Sahoo

2005-04-01

Grain refinement is a well established process for many cast and wrought alloys. The mechanical properties of various alloys could be enhanced by reducing the grain size. Refinement is also known to improve casting characteristics such as fluidity and hot tearing. Grain refinement of copper-base alloys is not widely used, especially in sand casting process. However, in permanent mold casting of copper alloys it is now common to use grain refinement to counteract the problem of severe hot tearing which also improves the pressure tightness of plumbing components. The mechanism of grain refinement in copper-base alloys is not well understood. The issues to be studied include the effect of minor alloy additions on the microstructure, their interaction with the grain refiner, effect of cooling rate, and loss of grain refinement (fading). In this investigation, efforts were made to explore and understand grain refinement of copper alloys, especially in permanent mold casting conditions.

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

Science.gov (United States)

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

2017-08-01

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

Heat Transfer Coefficient at Cast-Mold Interface During Centrifugal Casting: Calculation of Air Gap

Science.gov (United States)

Bohacek, Jan; Kharicha, Abdellah; Ludwig, Andreas; Wu, Menghuai; Karimi-Sibaki, Ebrahim

2018-06-01

During centrifugal casting, the thermal resistance at the cast-mold interface represents a main blockage mechanism for heat transfer. In addition to the refractory coating, an air gap begins to form due to the shrinkage of the casting and the mold expansion, under the continuous influence of strong centrifugal forces. Here, the heat transfer coefficient at the cast-mold interface h has been determined from calculations of the air gap thickness d a based on a plane stress model taking into account thermoelastic stresses, centrifugal forces, plastic deformations, and a temperature-dependent Young's modulus. The numerical approach proposed here is rather novel and tries to offer an alternative to the empirical formulas usually used in numerical simulations for a description of a time-dependent heat transfer coefficient h. Several numerical tests were performed for different coating thicknesses d C, rotation rates Ω, and temperatures of solidus T sol. Results demonstrated that the scenario at the interface is unique for each set of parameters, hindering the possibility of employing empirical formulas without a preceding experiment being performed. Initial values of h are simply equivalent to the ratio of the coating thermal conductivity and its thickness ( 1000 Wm-2 K-1). Later, when the air gap is formed, h drops exponentially to values at least one order of magnitude smaller ( 100 Wm-2 K-1).

Casting dimensional control and fatigue life prediction for permanent mold casting dies. Technical progress report, September 29, 1993-- September 30, 1994

Energy Technology Data Exchange (ETDEWEB)

NONE

1994-11-01

First year efforts as part of a three year program to address metal casting dimensional control and fatigue life prediction for permanent mold casting dies are described. Procedures have been developed and implemented to collect dimensional variability data from production steel castings. The influence of process variation and casting geometry variables on dimensional tolerances have been investigated. Preliminary results have shown that these factors have a significant influence on dimensional variability, although this variability is considerably less than the variability indicated in current tolerance standards. Gage repeatability and reproducibility testing must precede dimensional studies to insure that measurement system errors are acceptably small. Also initial efforts leading to the development and validation of a CAD/CAE model to predict the thermal fatigue life of permanent molds for aluminum castings are described. An appropriate thermomechanical property database for metal, mold and coating materials has been constructed. A finite element model has been developed to simulate the mold temperature distribution during repeated casting cycles. Initial validation trials have indicated the validity of the temperature distribution model developed.

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

Energy Technology Data Exchange (ETDEWEB)

Fasoyinu, Yemi [CanmetMATERIALS

2014-03-31

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

Study on Type C Coal Fly ash as an Additive to Molding Sand for Steel Casting

Science.gov (United States)

Palaniappan, Jayanthi

2017-04-01

Study of physio-chemical properties studies such as granulometric analysis, moisture, X ray fluorescence etc. were performed with Type C coal—combustion fly ash to investigate their potential as a distinct option for molding sand in foundry, thereby reducing the dependency on latter. Technological properties study such as compressive strength, tensile strength, permeability and compaction of various compositions of fly ash molding sand (10, 20 and 30 % fly ash substitute to chemically bonded sand) were performed and compared with silica molding sand. Steel casting production using this fly ash molding sand was done and the casting surface finish and typical casting parameters were assessed. It was noted that a good quality steel casting could be produced using type C fly ash molding sand, which effectively replaced 20 % of traditional molding sand and binders thereby providing greater financial profits to the foundry and an effective way of fly ash utilization (waste management).

Analysis of Mold Friction in a Continuous Casting Using Wavelet Transform

Science.gov (United States)

Ma, Yong; Fang, Bohan; Ding, Qiqi; Wang, Fangyin

2018-04-01

Mold friction (MDF) is an important parameter reflecting the lubrication condition between the initial shell and the mold during continuous casting. In this article, based on practical MDF from the slab continuous casting driven by a mechanical vibration device, the characteristics of friction were analyzed by continuous wavelet transform (CWT) and discrete wavelet transform (DWT) in different casting conditions, such as normal casting, level fluctuation, and alarming of the temperature measurement system. The results show that the CWT of friction accurately captures the subtle changes in friction force, such as the periodic characteristic of MDF during normal casting and the disordered feature of MDF during level fluctuation. Most important, the results capture the occurrence of abnormal casting and display the friction frequency characteristics at this abnormal time. In addition, in this article, there are some abnormal casting conditions, and the friction signal is stable until there is a sudden large change when abnormal casting, such as split breakout and submerged entry nozzle breakage, occurs. The DWT has a good ability to capture the friction characteristics for such abnormal situations. In particular, the potential abnormal features of MDF were presented in advance, which provides strong support for identifying abnormal casting and even preventing abnormal casting.

Self-supported ceramic substrates with directional porosity by mold freeze casting

DEFF Research Database (Denmark)

Gurauskis, Jonas; Graves, Christopher R.; Moreno, R.

2016-01-01

in a mold and applying directional freeze casting. Use of optimized suspension, cryoprotector additive and mold proved to deliver defect free ceramic films with high dimensional control. Microstructure analysis demonstrated the formation of desirable aligned porosity at macro-structural scale and resulted...... to be highly dependent on colloidal behaviour and freeze casting conditions. Manufactured green films were joined by lamination at room temperature and sintered to obtain symmetrical cells consisting of two porous self-supported substrate electrodes (∼420 μm) and dense yttria stabilized zirconia electrolyte...

Improvements in Sand Mold/Core Technology: Effects on Casting Finish

Energy Technology Data Exchange (ETDEWEB)

Prof. John J. Lannutti; Prof. Carroll E. Mobley

2005-08-30

In this study, the development and impact of density gradients on metal castings were investigated using sand molds/cores from both industry and from in-house production. In spite of the size of the castings market, almost no quantitative information about density variation within the molds/cores themselves is available. In particular, a predictive understanding of how structure and binder content/chemistry/mixing contribute to the final surface finish of these products does not exist. In this program we attempted to bridge this gap by working directly with domestic companies in examining the issues of surface finish and thermal reclamation costs resulting from the use of sand molds/cores. We show that these can be substantially reduced by the development of an in-depth understanding of density variations that correlate to surface finish. Our experimental tools and our experience with them made us uniquely qualified to achieve technical progress.

Application of heat pipe technology in permanent mold casting of nonferrous alloys

Science.gov (United States)

Elalem, Kaled

The issue of mold cooling is one, which presents a foundry with a dilemma. On the one hand; the use of air for cooling is safe and practical, however, it is not very effective and high cost. On the other hand, water-cooling can be very effective but it raises serious concerns about safety, especially with a metal such as magnesium. An alternative option that is being developed at McGill University uses heat pipe technology to carry out the cooling. The experimental program consisted of designing a permanent mold to produce AZ91E magnesium alloy and A356 aluminum alloy castings with shrinkage defects. Heat pipes were then used to reduce these defects. The heat pipes used in this work are novel and are patent pending. They are referred to as McGill Heat Pipes. Computer modeling was used extensively in designing the mold and the heat pipes. Final designs for the mold and the heat pipes were chosen based on the modeling results. Laboratory tests of the heat pipe were performed before conducting the actual experimental plan. The laboratory testing results verified the excellent performance of the heat pipes as anticipated by the model. An industrial mold made of H13 tool steel was constructed to cast nonferrous alloys. The heat pipes were installed and initial testing and actual industrial trials were conducted. This is the first time where a McGill heat pipe was used in an industrial permanent mold casting process for nonferrous alloys. The effects of cooling using heat pipes on AZ91E and A356 were evaluated using computer modeling and experimental trials. Microstructural analyses were conducted to measure the secondary dendrite arm spacing, SDAS, and the grain size to evaluate the cooling effects on the castings. The modeling and the experimental results agreed quite well. The metallurgical differences between AZ91E and A356 were investigated using modeling and experimental results. Selected results from modeling, laboratory and industrial trials are presented. The

40 CFR 63.5810 - What are my options for meeting the standards for open molding and centrifugal casting operations...

Science.gov (United States)

2010-07-01

... standards for open molding and centrifugal casting operations at new and existing sources? 63.5810 Section... § 63.5810 What are my options for meeting the standards for open molding and centrifugal casting... (d) of this section to meet the standards for open molding or centrifugal casting operations in Table...

Reusable molds for casting U-Zr alloys

International Nuclear Information System (INIS)

Chen, P.S.; Stevens, W.C.; Trybus, C.L.

1992-09-01

Refractory oxides, carbides, nitrides and sulfides were examined as mold coating materials for use in casting nuclear fuel. The molds require excellent high temperature chemical and mechanical stability combined with reasonable room temperature ductility to allow for fuel removal. Coatings were applied onto quartz and refractory metal coupons using various techniques. Sessile drop tests employing molten U-10%Zr (by weight) at 1550 degrees C were used to characterize coating performance. Results indicate that NbC, TiN, and Y 2 O 3 were non-wetting with U-10%Zr. However, only the Y 2 O 3 coating completely prevented adhesion of the fuel. The paper describes coating methods and details of the sessile drop experiments

Interim Report on Mixing During the Casting of LEU-10Mo Plates in the Triple Plate Molds

Energy Technology Data Exchange (ETDEWEB)

Aikin, Jr., Robert M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-04-12

LEU-10%Mo castings are commonly produced by down blending unalloyed HEU with a DU-12.7%Mo master-alloy. This work uses process modeling to provide insight into the mixing of the unalloyed uranium and U-Mo master alloy during melting and mold filling of a triple plate casting. Two different sets of situations are considered: (1) mixing during mold filling from a compositionally stratified crucible and (2) convective mixing of a compositionally stratified crucible during mold heating. The mold filling simulations are performed on the original Y-12 triple plate mold and the horizontal triple plate mold.

Die casting copper motor rotors: mold materials and processing for cost-effective manufacturing

Energy Technology Data Exchange (ETDEWEB)

Peters, D.T.; Cowie, J.G.; Brush, E.F. Jr.

2000-07-01

This project seeks to demonstrate mold materials for copper pressure die-casting that are cost-effective and practical for production use in die-casting copper motor rotors. The incorporation of die-cast copper for conductor bars and end rings of the induction motor in place of aluminum would result in attractive improvements in motor energy efficiency through reductions in motor losses ranging from 15% to 20%. Die-cast motor rotors are produced in aluminum today because rotor fabrication by pressure die-casting is an established practice. Lack of a durable and cost-effective mold material has been the technical barrier preventing manufacture of the die-cast copper rotor. This project tested H-13 steel die inserts that establish the baseline. Nickel-, tungsten-, and molybdenum-based high temperature alloys were extensively tested. Results indicate that substantially extended die life is possible using high temperature die materials, pre-heated and operated at elevated temperatures. Pre-heating and high operating temperatures were shown to be critical in extending the die life by decreasing the cyclic stresses associated with thermal expansion. Extended die life provides the opportunity for economically viable copper motor rotor die-casting. (orig.)

Based on database and asp.net technologies, a web platform of scientific data in the casting forces on the mold-fi lling behavior of titanium melts in vertically rotating molds

Directory of Open Access Journals (Sweden)

Xu Daming

2008-11-01

Full Text Available The vertical centrifugal-casting technique is widely used in the manufacture of various irregularlyshaped castings of advanced structural alloys with thin walls, complex shapes and/or large sizes. These castings are used in the increasing applications in aero-space/aviation industries, human teeth/bone repairs with nearnet shaped components, etc. In a vertically rotating casting system, the mold-filling processes of alloy melts, coupled with solidifi cation-heat transfer, may be much more complicated, because they are driven simultaneously by gravity, centrifugal and Coriolis forces. In the present work, an N-S/VOF-equations-based model, solved using a SOLA-VOF algorithm, under a rotating coordinate system was applied to numerically investigate the impacts of centrifugal and Coriolis forces on metallic melt mold-fi lling processes in different vertical centrifugal-casting configurations with different mold-rotation rates using an authors’ computer-codes system. The computational results show that the Coriolis force may cause remarkable variations in the fl ow patterns in the casting-part-cavities of a large horizontal-section area and directly connected to the sprue via a short ingate in a vertical centrifugalcasting process. A “turn-back” mold-filling technique, which only takes advantage of the centrifugal force in a transient rotating melt system, has been confi rmed to be a rational centrifugal-casting process in order to achieve smooth and layer-by-layer casting-cavities-fi lling control. The simulated mold-fi lling processes of Ti-6Al-4V alloy melt, in a vertical centrifugal-casting system with horizontally-connected plate-casting cavities, show reasonable agreement with experimental results from the literature.

Designing a combined casting mold for manufacture of a gasoline centrifugal pump body using CAD/CAM-systems

Science.gov (United States)

Galin, N. E.; Ogol, I. I.; Chervach, Yu B.; Dammer, V. Kh; Ru, Jia Hong

2017-02-01

The present paper examines designing of a combined casting mold for manufacture of a gasoline centrifugal pump body. The paper offers technological solutions for obtaining high quality castings at the testing stage of the finished mold. The paper is intended for practical use and prepared by order of JSC ‘Tomsk Electrical Engineering Plant’ using software and equipment of the department ‘Technologies of Computer-Aided Machinery Manufacturing’ of the Tomsk Polytechnic University (TPU) under the economic contract within state import substitution program. In preparing the paper, CAD/CAM-systems KOMPAS-3D and PowerMILL were used. In 2015, the designed casting mold was introduced into the production process at JSC ‘Tomsk Electrical Engineering Plant’.

Grain refinement of permanent mold cast copper base alloys. Final report

Energy Technology Data Exchange (ETDEWEB)

Sadayappan, M.; Thomson, J. P.; Elboujdaini, M.; Gu, G. Ping; Sahoo, M.

2004-04-29

Grain refinement behavior of copper alloys cast in permanent molds was investigated. This is one of the least studied subjects in copper alloy castings. Grain refinement is not widely practiced for leaded copper alloys cast in sand molds. Aluminum bronzes and high strength yellow brasses, cast in sand and permanent molds, were usually fine grained due to the presence of more than 2% iron. Grain refinement of the most common permanent mold casting alloys, leaded yellow brass and its lead-free replacement EnviroBrass III, is not universally accepted due to the perceived problem of hard spots in finished castings and for the same reason these alloys contain very low amounts of iron. The yellow brasses and Cu-Si alloys are gaining popularity in North America due to their low lead content and amenability for permanent mold casting. These alloys are prone to hot tearing in permanent mold casting. Grain refinement is one of the solutions for reducing this problem. However, to use this technique it is necessary to understand the mechanism of grain refinement and other issues involved in the process. The following issues were studied during this three year project funded by the US Department of Energy and the copper casting industry: (1) Effect of alloying additions on the grain size of Cu-Zn alloys and their interaction with grain refiners; (2) Effect of two grain refining elements, boron and zirconium, on the grain size of four copper alloys, yellow brass, EnviroBrass II, silicon brass and silicon bronze and the duration of their effect (fading); (3) Prediction of grain refinement using cooling curve analysis and use of this method as an on-line quality control tool; (4) Hard spot formation in yellow brass and EnviroBrass due to grain refinement; (5) Corrosion resistance of the grain refined alloys; (6) Transfer the technology to permanent mold casting foundries; It was found that alloying elements such as tin and zinc do not change the grain size of Cu-Zn alloys

Application of digital pattern-less molding technology to produce art casting

Directory of Open Access Journals (Sweden)

Chen Li1

2014-11-01

Full Text Available Compared with the conventional casting process, digital pattern-less casting technology has many advantages such as good machining accuracy, a short processing cycle, and low production cost. It is a new rapid manufacturing technology for castings, integrated with CAD/CAM, casting, CNC machining and many other advanced technologies. With this digital casting technology, no pattern is needed for making molds; it is precise, flexible, and green. Usually, art castings have complex structures and are made in small batches or even made in a single-piece, especially for large-sized art castings. So it has the shortcomings of high cost, low efficiency and long time for making a pattern to produce art castings with the conventional casting processes. However, the digital pattern-less casting technology can be applied to fabricate art castings, since it can greatly shorten the manufacturing cycle and lower the production cost, thus having a very good prospect. In this study, based on the digital pattern-less casting technology, a plaque casting with artistic Chinese characters (a Chinese poem was designed and manufactured, and the production process was demonstrated in detail.

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

Science.gov (United States)

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

2013-01-01

This study evaluated the casting accuracy of crown margins and metal-ceramic shear bond strength (SBS) of pure titanium injected into casting molds made using 2 investment types at 3 mold temperatures. Sixty crown (30-degree beveled finish line) and 60 cylinder (5mm diameter × 8mm high) patterns were divided into 6 groups (n=10), and cast using a phosphate-bonded investment (P) and a magnesium oxide-bonded investment (U), at 400°C (groups P400 and U400), 550°C (groups P550 and U550) and 700°C (groups P700 and U700) mold temperatures. Crown margins were recorded in impression material, the degree of marginal rounding was measured and margin length deficiencies (µm) were calculated. Titanium-ceramic specimens were prepared using Triceram ceramic (2mm high) and SBS was tested. Failure modes were assessed by optical microscopy. Data were subjected to two-way ANOVA and Tukey's HSD test (α=0.05). For casting accuracy, expressed by marginal deficiency (µm), investment U provided more accurate results (64 ± 11) than P (81 ± 23) (pcasting accuracy for U700 (55 ± 7) and worse for P700 (109 ± 18). Casting accuracy at 700°C (82 ± 31) was significantly different from 400°C (69 ± 9) and 550°C (68 ± 9) (pcasting accuracy than investment P. The SBS was similar for all combinations of investments and temperatures.

Hot-tearing of multicomponent Al-Cu alloys based on casting load measurements in a constrained permanent mold

Energy Technology Data Exchange (ETDEWEB)

Sabau, Adrian S [ORNL; Mirmiran, Seyed [Fiat Chrysler Automobiles North America; Glaspie, Christopher [Fiat Chrysler Automobiles North America; Li, Shimin [Worcester Polytechnic Institute (WPI), MA; Apelian, Diran [Worcester Polytechnic Institute (WPI), MA; Shyam, Amit [ORNL; Haynes, James A [ORNL; Rodriguez, Andres [Nemak, Garza Garcia, N.L., Mexico

2017-01-01

Hot-tearing is a major casting defect that is often difficult to characterize, especially for multicomponent Al alloys used for cylinder head castings. The susceptibility of multicomponent Al-Cu alloys to hot-tearing during permanent mold casting was investigated using a constrained permanent mold in which the load and displacement was measured. The experimental results for hot tearing susceptibility are compared with those obtained from a hot-tearing criterion based temperature range evaluated at fraction solids of 0.87 and 0.94. The Cu composition was varied from approximately 5 to 8 pct. (weight). Casting experiments were conducted without grain refining. The measured load during casting can be used to indicate the severity of hot tearing. However, when small hot-tears are present, the load variation cannot be used to detect and assess hot-tearing susceptibility.

Effect of Flow Rate Controller on Liquid Steel Flow in Continuous Casting Mold using Numerical Modeling

Science.gov (United States)

Gursoy, Kadir Ali; Yavuz, Mehmet Metin

2014-11-01

In continuous casting operation of steel, the flow through tundish to the mold can be controlled by different flow rate control systems including stopper rod and slide-gate. Ladle changes in continuous casting machines result in liquid steel level changes in tundishes. During this transient event of production, the flow rate controller opening is increased to reduce the pressure drop across the opening which helps to keep the mass flow rate at the desired level for the reduced liquid steel level in tundish. In the present study, computational fluid dynamic (CFD) models are developed to investigate the effect of flow rate controller on mold flow structure, and particularly to understand the effect of flow controller opening on meniscus flow. First, a detailed validation of the CFD models is conducted using available experimental data and the performances of different turbulence models are compared. Then, the constant throughput casting operations for different flow rate controller openings are simulated to quantify the opening effect on meniscus region. The results indicate that the meniscus velocities are significantly affected by the flow rate controller and its opening level. The steady state operations, specified as constant throughput casting, do not provide the same mold flow if the controller opening is altered. Thus, for quality and castability purposes, adjusting the flow controller opening to obtain the fixed mold flow structure is proposed. Supported by Middle East Technical University (METU) BAP (Scientific Research Projects) Coordination.

An adaptive neuro-fuzzy controller for mold level control in continuous casting

International Nuclear Information System (INIS)

Zolghadri Jahromi, M.; Abolhassan Tash, F.

2001-01-01

Mold variations in continuous casting are believed to be the main cause of surface defects in the final product. Although a Pid controller is well capable of controlling the level under normal conditions, it cannot prevent large variations of mold level when a disturbance occurs in the form of nozzle unclogging. In this paper, dual controller architecture is presented, a Pid controller is used as the main controller of the plant and an adaptive neuro-fuzzy controller is used as an auxiliary controller to help the Pid during disturbed phases. The control is passed back to the Pid controller after the disturbance is being dealt with. Simulation results prove the effectiveness of this control strategy in reducing mold level variations during the unclogging period

Effect of preparation variables of plaster molds for slip casting of sanitary ware

Directory of Open Access Journals (Sweden)

Rafael E. Ochoa

2017-11-01

Full Text Available A full factorial design was used to evaluate the effect of various preparation conditions for making plaster molds for slip casting of sanitary ware. We investigated the relationships between the processing conditions, microstructure, and final properties of the plaster molds. The results showed that the rheological behavior, and hence, the time during which the plaster suspension is pourable for making the plaster molds (before an important increase in viscosity due to the precipitation of gypsum crystals were dependent on the preparation conditions. Variations in the chemical composition, pore size distribution, and microstructure explained the statistically significant effect of preparation variables (including the mixing time, water temperature, and water quality. Preparation conditions that promoted high initial viscosity of the plaster suspension (accelerative effect of the setting time developed less porous structure in the mold that principally increased the compressive strength (16%, deionized water instead of tap water and the casting rate (9%, water at 25 °C instead of 38 °C. According to the results are proposed optimum conditions to make the molds while avoiding unnecessary energy use. Resumen: Mediante un diseño factorial completo se evaluaron diferentes condiciones de preparación de moldes de yeso para colado tradicional de muebles sanitarios. Se investigó la relación entre procesamiento, microestructura y propiedades del molde. Los resultados mostraron que el comportamiento reológico y por lo tanto el tiempo durante el cual la suspensión de yeso se puede verter para conformar los moldes (antes de un incremento importante de viscosidad debido a la formación de cristales de yeso fueron dependientes de las condiciones de preparación. Variaciones en composición química, distribución de tamaño de poro y microestructura explicaron el efecto estadísticamente significativo de las variables de preparación (que incluyeron

Performance of U-Pu-Zr fuel cast into zirconium molds

International Nuclear Information System (INIS)

Crawford, D.C.; Lahm, C.E.; Tsai, H.

1992-10-01

U-3Zr and U-20.5Pu-3Zr were injection cast into Zr tubes, or sheaths, rather than into quartz molds and clad in 316SS. These elements and standard-cast U-l0Zr and U-IgPu-l0Zr elements were irradiated in EBR-II to 2 at.% and removed for interim examination. Measurements of axial growth at indicate that the Zr-sheathed elements exhibited significantly less axial elongation than the standard-cast elements (1.3 to 1.8% versus 4.9 to 8.1%). Fuel material extruded through the ends of the Zr sheaths. allowing the low-Zr fuel to contact the cladding in some cases. Transverse metallographic sections reveal cracks in the Zr sheath through which fuel extruded and contacted cladding. The sheath is not a sufficient barrier between fuel and cladding to reduce FCCI. and any adverse effects due to increased FCCI will be evident as the elements attain higher burnup

Focused Molding Using Adhesive Pads in Mehta Casting for Early-Onset Scoliosis.

Science.gov (United States)

Abraham, Roby; Sponseller, Paul D

2014-11-01

Prospective clinical series. To determine the effect of adhesive pads placed over the apex of scoliosis curves on curve correction 1) after the first cast and 2) after the final cast. Early-onset scoliosis is often effectively managed by serial casting. Properly localizing the apex of the molds with the cast in place is challenging. The authors explored the effectiveness of a novel technique: incorporation of adhesive pads placed over the major curve apex before Mehta casting. The 27 patients who received body casts (2000-2013) were divided into 2 groups: those without and with apical adhesive pads (5-6 layers of pads placed on the major curve's apex during casting): non-pad (NP) group (n = 12) and pad (P) group (n = 15), respectively. Groups were compared regarding the percentage of Cobb angle change from the first cast and curve correction to a Cobb angle of cast curve correction was 39% ± 18% and 56% ± 17% in the NP and P groups, respectively. Of the 26 patients out of a cast, 11 (42%) had a Cobb angle of casting were effective in increasing the amount of major curve correction from the first cast for idiopathic early-onset scoliosis and in decreasing curves to <25° at final follow-up. Copyright © 2014 Scoliosis Research Society. Published by Elsevier Inc. All rights reserved.

Improvement of composition of core sand and molding sand mixtures for power machine building castings

International Nuclear Information System (INIS)

Velikanov, G.F.; Primak, I.N.; Brechko, A.A.

1982-01-01

Considered is a problem of development and improvement of mixtures, as well as of antisticking coatings with the given parameters providing production of castings of the necessary quality. Requirements to properties of mixtures and antisticking coatings are formulated proceeding from the conditions of guaranteed production of qualitative steel castings with mass from 0.5 up to 20t and wall thickness from 60 up to 200 mm. Formation of film structure of binding compositions is studied, their marginal contact angle and surface tension are determined. In the result of work carried out on improvement of core sand and molding sand mixtures the labour productivity during the production of core and moldings has been increased in 20-25% in average, the quality has also been improved [ru

Compound cast product and method for producing a compound cast product

Science.gov (United States)

Meyer, Thomas N.; Viswanathan, Srinath

2002-09-17

A compound cast product is formed in a casting mold (14) having a mold cavity (16) sized and shaped to form the cast product. A plurality of injectors (24) is supported from a bottom side (26) of the casting mold (14). The injectors (24) are in fluid communication with the mold cavity (16) through the bottom side (26) of the casting mold (14). A molten material holder furnace (12) is located beneath the casting mold (14). The holder furnace (12) defines molten material receiving chambers (36) configured to separately contain supplies of two different molten materials (37, 38). The holder furnace (12) is positioned such that the injectors (24) extend downward into the receiving chamber (36). The receiving chamber (36) is separated into at least two different flow circuits (51, 52). A first molten material (37) is received in a first flow circuit (51), and a second molten material (38) is received into a second flow circuit (52). The first and second molten materials (37, 38) are injected into the mold cavity (16) by the injectors (24) acting against the force of gravity. The injectors (24) are positioned such that the first and second molten materials (37, 38) are injected into different areas of the mold cavity (16). The molten materials (37, 38) are allowed to solidify and the resulting compound cast product is removed from the mold cavity (16).

Solubility of Hydrogen and Nitrogen in liquid cast iron during melting and mold filling

OpenAIRE

Diószegi, Attila; Elfsberg, Jessica; Diószegi, Zoltán

2016-01-01

Defect formation like gas- and shrinkage porosity at cast iron component production is related to the content of gaseous elements in the liquid metal. The present work investigate the solubility of hydrogen and nitrogen in liquid iron aimed for production of lamellar and compacted graphite cast iron. The used methods and instruments are a combination of commercial measuring devices and novel experimental assemblies for measuring solubility of hydrogen and nitrogen during melting and mold fill...

Development of automated system based on neural network algorithm for detecting defects on molds installed on casting machines

Science.gov (United States)

Bazhin, V. Yu; Danilov, I. V.; Petrov, P. A.

2018-05-01

During the casting of light alloys and ligatures based on aluminum and magnesium, problems of the qualitative distribution of the metal and its crystallization in the mold arise. To monitor the defects of molds on the casting conveyor, a camera with a resolution of 780 x 580 pixels and a shooting rate of 75 frames per second was selected. Images of molds from casting machines were used as input data for neural network algorithm. On the preparation of a digital database and its analytical evaluation stage, the architecture of the convolutional neural network was chosen for the algorithm. The information flow from the local controller is transferred to the OPC server and then to the SCADA system of foundry. After the training, accuracy of neural network defect recognition was about 95.1% on a validation split. After the training, weight coefficients of the neural network were used on testing split and algorithm had identical accuracy with validation images. The proposed technical solutions make it possible to increase the efficiency of the automated process control system in the foundry by expanding the digital database.

A coupled model on fluid flow, heat transfer and solidification in continuous casting mold

Directory of Open Access Journals (Sweden)

Xu-bin Zhang

2017-11-01

Full Text Available Fluid flow, heat transfer and solidification of steel in the mold are so complex but crucial, determining the surface quality of the continuous casting slab. In the current study, a 2D numerical model was established by Fluent software to simulate the fluid flow, heat transfer and solidification of the steel in the mold. The VOF model and k-ε model were applied to simulate the flow field of the three phases (steel, slag and air, and solidification model was used to simulate the solidification process. The phenomena at the meniscus were also explored through interfacial tension between the liquid steel and slag as well as the mold oscillation. The model included a 20 mm thick mold to clarify the heat transfer and the temperature distribution of the mold. The simulation results show that the liquid steel flows as upper backflow and lower backflow in the mold, and that a small circulation forms at the meniscus. The liquid slag flows away from the corner at the meniscus or infiltrates into the gap between the mold and the shell with the mold oscillating at the negative strip stage or at the positive strip stage. The simulated pitch and the depth of oscillation marks approximate to the theoretical pitch and measured depth on the slab.

Multiphysics modeling of the steel continuous casting process

Science.gov (United States)

Hibbeler, Lance C.

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

Hot-Tearing Assessment of Multicomponent Nongrain-Refined Al-Cu Alloys for Permanent Mold Castings Based on Load Measurements in a Constrained Mold

Science.gov (United States)

Sabau, Adrian S.; Mirmiran, Seyed; Glaspie, Christopher; Li, Shimin; Apelian, Diran; Shyam, Amit; Allen Haynes, J.; Rodriguez, Andres F.

2018-06-01

The hot-tearing resistance of multicomponent Al-Cu alloys during permanent mold casting was investigated using a constrained permanent mold in which the load and temperature were measured. The nominal Cu composition was varied from 5 to 8 wt pct. Casting experiments were conducted without adding any grain-refining inoculants. The following variables, which were obtained from the measured load data during casting, were considered to assess the hot-tearing resistance of the Al-Cu multicomponent alloys: "V"-like signature in the load rate variation, load at solidus point, and load rate average over the freezing range. In addition, a hot-tearing criterion based on the variation of the fraction of solid in the late stages of solidification was used. It was found that all criteria considered can accurately predict the alloys with the lowest and highest hot-tear resistance, respectively. It was found that the rate of measured load during casting could be used to indicate substantial hot tearing. However, the load rate variation could not be used to detect when small hot tears were present. Among all the criteria considered, the load at the solidus point shows an excellent agreement with experimentally observed hot-tearing resistance for all but one alloy. The poorly resistant hot-tearing alloys exhibited mainly coarse columnar grains while the most hot-tearing resistant alloys exhibited a much more refined grain microstructure. This is the first study in which good hot-tear resistance is demonstrated for multicomponent Al-Cu alloys with nominal Cu content greater than 7 wt pct.

Die Casting Part Distortion: Prediction and Attenuation; FINAL

International Nuclear Information System (INIS)

Allen Miller, R.

2002-01-01

The goal of this research was to predict the part deformation and residual stresses after ejection from the die and cooling to room temperature. A finite element model was built to achieve this goal and several modeling techniques were investigated throughout this research. Die-casting is a very complex process and the researchers are faced with a large number of hard to solve physical problems when modeling the process. Several assumptions are made in our simulation model. The first significant assumption is the instantaneous cavity filling. This means that the cavity filling stage is not considered in our model. Considering the cavity filling stage increases the modeling complexity as a result of different flow patterns. expected in the shot sleeve, gate, runner and different cavity features. The flow of gas from the cavity through the vents is another problem that is ignored in our model as a result of this assumption. Our second assumption is that the cast metal has uniform temperature distribution inside the cavity, at the starting point of simulation. This temperature is assumed to be over liquidus limit, i.e. the solid fraction is 0.0% of the cast metal. The third assumption is due to ABAQUS (commercial software used in this research) limitations. ABAQUS cannot deal with multi-phase models; therefore we use solid elements to define the casting instead of multi-phase (liquid/solid) elements. Liquid elements can carry the hydrostatic pressure from the shot sleeve and apply it on the cavity surfaces, while the solid elements do not have this capability. To compensate for this assumption we add the cavity pressure as a boundary condition and apply it on the cavity surface separately from the part. Another issue with this assumption is that, liquid casting can follow the cavity shape when it distorts. With the use of solid elements to represent the casting during its liquid state, it loses this capability to follow the cavity. Several techniques were tested to

Casting Technology.

Science.gov (United States)

Wright, Michael D.; And Others

1992-01-01

Three articles discuss (1) casting technology as it relates to industry, with comparisons of shell casting, shell molding, and die casting; (2) evaporative pattern casting for metals; and (3) high technological casting with silicone rubber. (JOW)

Mathematics simulation and experiments of continuous casting with strip feeding in mold

Directory of Open Access Journals (Sweden)

M. G. Shen

2017-01-01

Full Text Available Steel strip feeding technology can reduce the degree of superheat of the molten steel, change the solidification order of the molten steel; raise the equiaxed crystal rate of the slab and improve the continuous casting quality. The paper establishes the mathematical model of heat transfer and temperature field of casting billet of steel strip feeding in continuous casting mold. Results show that if Plate Billet is 1 000 mm × 220 mm and the steel strip is 100 mm × 3 mm, feeding position of parallel is 250 mm from the narrow side. When the feeding speed is 3,6 m/min, the superheat degree can be reduced by 5 °C, and the solidification length can be reduced by 2,9 m. When the feeding speed is 6 m/min, the superheat degree can be reduced by about 9 °C, and the solidification length can be reduced by 3,7 m. The results of the test in a steel plant are in good agreement with the experimental results.

Simulation of distortion and residual stress in high pressure die casting – modelling and experiments

International Nuclear Information System (INIS)

Hofer, P; Kaschnitz, E; Schumacher, P

2012-01-01

Two individual high-pressure die-casting geometries were developed in order to study the influence of process parameters and different alloys on the distortion behaviour of castings. These geometries were a stress lattice and a V-shaped sample tending to form residual stress due to different wall thickness respectively by a deliberate massive gating system. In the experimental castings the influence of the most important process parameters such as die temperature and die opening time and the cooling regime was examined. The time evolution of process temperatures was measured using thermal imaging. The heat transfer coefficients were adapted to the observed temperature distributions. Castings were produced from the two alloys AlSi12 and AlSi10MnMg. The distortion of the castings was measured by means of a tactile measuring device. For the alloy AlSi10MnMg thermo-physical and thermo-mechanical data were obtained using differential scanning calorimetry, laser flash technique, dilatometry and tensile testing at elevated temperatures. These data were used for modelling the material behaviour of the AlSi10MnMg alloy in the numerical model while for the alloy AlSi12(Fe) literature data were used. Process and stress simulation were conducted using the commercial FEM software ANSYS Workbench. A survey on the results of the comparison between simulation and experiment is given for both alloys.

Characterization of fold defects in AZ91D and AE42 magnesium alloy permanent mold castings

International Nuclear Information System (INIS)

Bichler, L.; Ravindran, C.

2010-01-01

Casting premium-quality magnesium alloy components for aerospace and automotive applications poses unique challenges. Magnesium alloys are known to freeze rapidly prior to filling a casting cavity, resulting in misruns and cold shuts. In addition, melt oxidation, solute segregation and turbulent metal flow during casting contribute to the formation of fold defects. In this research, formation of fold defects in AZ91D and AE42 magnesium alloys cast via the permanent mold casting process was investigated. Computer simulations of the casting process predicted the development of a turbulent metal flow in a critical casting region with abrupt geometrical transitions. SEM and light optical microscopy examinations revealed the presence of folds in this region for both alloys. However, each alloy exhibited a unique mechanism responsible for fold formation. In the AZ91D alloy, melt oxidation and velocity gradients in the critical casting region prevented fusion of merging metal front streams. In the AE42 alloy, limited solubility of rare-earth intermetallic compounds in the α-Mg phase resulted in segregation of Al 2 RE particles at the leading edge of a metal front and created microstructural inhomogeneity across the fold.

Relationship between casting distortion, mold filling, and interfacial heat transfer. Annual technical report, September 1997 - September 1998

Energy Technology Data Exchange (ETDEWEB)

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

1998-10-22

In the third year of this program, the final castings necessary to evaluate the effect of casting orientation and gating in silica sand lost foam were poured and measured using a CMM machine. Interfacial heat transfer and gap formation measurements continued. However, significant problems were encountered in making accurate measurements. No consistent evidence of gap formation was found in aluminum sand casting. Initial analysis yields heat transfer values below those previously reported in the literature. The program in continuing.

The influence of mold temperature on the fit of cast crowns with commercially pure titanium Influência de temperaturas do molde na adaptação de coroas fundidas em titânio comercialmente puro

Directory of Open Access Journals (Sweden)

Wagner Sotero Fragoso

2005-06-01

Full Text Available Commercially pure titanium (CP Ti has been widely applied to fabricate cast devices because of its favorable properties. However, the mold temperature recommended for the manufacture of casts has been considered relatively low, causing inadequate castability and poor marginal fit of cast crowns. This study evaluated and compared the influence of mold temperature (430°C - as control, 550°C, 670°C on the marginal discrepancies of cast CP Ti crowns. Eight bovine teeth were prepared on a mechanical grinding device and impressions were used to duplicate each tooth and produce eight master dies. Twenty-four crowns were fabricated using CP Ti in three different groups of mold temperature (n = 8: 430°C (as control, 550°C and 670°C. The gap between the crown and the bovine tooth was measured at 50 X magnification with a traveling microscope. The marginal fit values of the cast CP Ti crowns were submitted to the Kruskal-Wallis test (p = 0.03. The 550°C group (95.0 µm showed significantly better marginal fit than the crowns of the 430°C group (203.4 µm and 670°C group (213.8 µm. Better marginal fit for cast CP Ti crowns was observed with the mold temperature of 550°C, differing from the 430°C recommended by the manufacturer.O titânio comercialmente puro (Ti c.p. tem sido largamente empregado na elaboração de estruturas protéticas fundidas devido às suas propriedades favoráveis. Entretanto, a temperatura do molde recomendada pelo fabricante tem sido considerada baixa, causando inadequada fundibilidade e precária adaptação marginal de coroas fundidas. Este estudo avaliou e comparou a influência de temperaturas do molde (430°C - como controle, 550°C, 670°C na discrepância marginal de coroas fundidas em Ti c.p. Oito dentes bovinos foram preparados em um torno mecânico e moldados para produzirem oito modelos-mestre. Vinte e quatro coroas foram confeccionadas em Ti c.p. para três grupos de temperatura do molde (n = 8: 430°C (como

IMPROVEMENT OF EQUIPMENT FOR EFFECTIVE HARDENING SAND MIXTURE BY VACUUM MOLDING

Directory of Open Access Journals (Sweden)

V. S. Doroshenko

2016-01-01

Full Text Available The review deals with the design flask tooling and patterns for effective hardening sand mixture in the vacuum molding (V-Process, and molding on a one-off patterns (Lost Foam Casting. Sealing and evacuating sand mixture – two major factors influence the strength of the casting mold and casting quality, management practices which will enable to improve the casting process.

Method for casting thin metal objects

Science.gov (United States)

Pehrson, Brandon P; Moore, Alan F

2015-04-14

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

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

Science.gov (United States)

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

2006-10-01

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

Characteristics and infl uence factors of mold fi lling process in permanent mold with a slot gating system

Directory of Open Access Journals (Sweden)

Chen Changjun

2009-11-01

Full Text Available The main problems caused by improper gating are entrained aluminum oxide fi lms and entrapped gas. In this study, the slot gating system is employed to improve mold fi lling behavior and therefore, to improve the quality of aluminum castings produced in permanent molds. An equipment as well as operation procedures for real-time X-ray radiography of molten aluminum fl owing into permanent molds have been developed. Graphite molds transparent to X-rays are utilized which make it possible to observe the fl ow pattern through a number of vertically oriented gating systems. The investigation discovers that there are many infl uencing factors on the mold fi lling process. This paper focuses its research on some of the factors, such as the dimensions of the vertical riser and slot thickness, as well as roughness of the coating layer. The results indicate that molten metal can smoothly fi ll into casting cavity with a proper slot gating system. A bigger vertical riser, proper slot thickness and rougher coating can provide not only a better mold fi lling pattern, but also hot melt into the top of the cavity. A proper temperature gradient is obtainable, higher at the bottom and lower at the top of the casting cavity, which is in favor of feeding during casting solidifi cation.

Solidification and casting

CERN Document Server

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

Measurement and simulation of deformation and stresses in steel casting

Science.gov (United States)

Galles, D.; Monroe, C. A.; Beckermann, C.

2012-07-01

Experiments are conducted to measure displacements and forces during casting of a steel bar in a sand mold. In some experiments the bar is allowed to contract freely, while in others the bar is manually strained using embedded rods connected to a frame. Solidification and cooling of the experimental castings are simulated using a commercial code, and good agreement between measured and predicted temperatures is obtained. The deformations and stresses in the experiments are simulated using an elasto-viscoplastic finite-element model. The high temperature mechanical properties are estimated from data available in the literature. The mush is modeled using porous metal plasticity theory, where the coherency and coalescence solid fraction are taken into account. Good agreement is obtained between measured and predicted displacements and forces. The results shed considerable light on the modeling of stresses in steel casting and help in developing more accurate models for predicting hot tears and casting distortions.

Measurement and simulation of deformation and stresses in steel casting

International Nuclear Information System (INIS)

Galles, D; Beckermann, C; Monroe, C A

2012-01-01

Experiments are conducted to measure displacements and forces during casting of a steel bar in a sand mold. In some experiments the bar is allowed to contract freely, while in others the bar is manually strained using embedded rods connected to a frame. Solidification and cooling of the experimental castings are simulated using a commercial code, and good agreement between measured and predicted temperatures is obtained. The deformations and stresses in the experiments are simulated using an elasto-viscoplastic finite-element model. The high temperature mechanical properties are estimated from data available in the literature. The mush is modeled using porous metal plasticity theory, where the coherency and coalescence solid fraction are taken into account. Good agreement is obtained between measured and predicted displacements and forces. The results shed considerable light on the modeling of stresses in steel casting and help in developing more accurate models for predicting hot tears and casting distortions.

Nonaqueous slip casting of high temperature ceramic superconductors using an investment casting technique

Science.gov (United States)

Hooker, Matthew W. (Inventor); Taylor, Theodore D. (Inventor); Wise, Stephanie A. (Inventor); Buckley, John D. (Inventor); Vasquez, Peter (Inventor); Buck, Gregory M. (Inventor); Hicks, Lana P. (Inventor)

1993-01-01

A process for slip casting ceramic articles that does not employ parting agents and affords the casting of complete, detailed, precision articles that do not possess parting lines is presented. This process is especially useful for high temperature superconductors and water-sensitive ceramics. A wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell mold of the calcium sulfate-bonded investment material. The shell mold is cooled to room temperature, and a ceramic slip, created by dispersing a ceramic powder in an organic liquid, is poured therein. After a ceramic shell of desired thickness or a solid article has set up in the shell mold, excess ceramic slip is poured out. The shell mold is misted with water and peeled away from the ceramic article, after which the ceramic is fired to provide a complete, detailed, precision, high temperature superconductive ceramic article without parting lines. The casting technique may take place in the presence of a magnetic field to orient the ceramic powders during the casting process.

Fan Fuel Casting Final Report

Energy Technology Data Exchange (ETDEWEB)

Imhoff, Seth D. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-09-28

LANL was approached to provide material and design guidance for a fan-shaped fuel element. A total of at least three castings were planned. The first casting is a simple billet mold to be made from high carbon DU-10Mo charge material. The second and third castings are for optimization of the actual fuel plate mold. The experimental scope for optimization is only broad enough for a second iteration of the mold design. It is important to note that partway through FY17, this project was cancelled by the sponsor. This report is being written in order to capture the knowledge gained should this project resume at a later date.

Numerical and Physical Parametric Analysis of a SEN with Flow Conditioners in Slab Continuous Casting Mold

Directory of Open Access Journals (Sweden)

Gonzalez-Trejo J.

2017-06-01

Full Text Available Some of the most recent technologies that improves the performance in continuous casting process has installed infrastructure outside the mold to modify the natural fluid flow pattern to obtain a quasi-steady condition and promote a uniform solidified shell of steel. The submerged entry nozzle distributes the liquid steel in the mold and can be used to obtain the flow symmetry condition with external geometry improvements. The fluid flow conditioners were located near the outlet ports of the nozzle. The aim of the modifiers is to impose a pseudo symmetric pattern in the upper zone of the mold by inhibiting the fluid exchange between the zones created by conditioners. This work evaluates the effect of the thickness and length of the fluid-flow modifiers on the overall performance of the submerged nozzle. These properties of the fluid-flow modifiers were normalized based on two of the geometric dimensions of the standard equipment. Numerical and physical simulations suggest that the flow modifier should be as thin as possible.

Developing technological process of obtaining giality casts

Directory of Open Access Journals (Sweden)

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.

Production of an Amorphous Fe_<75>Si_<10>B_<15> Sheet by a Metallic Mold Casting Method and its Properties

OpenAIRE

Inoue, Akihisa; Yamamoto, Hirokazu; Saito, Takanobu; Masumoto, Tsuyosi

1993-01-01

The application of a metallic mold casting method to an Fe_Si_B_ alloy with the largest glass-forming ability in (Fe, Co, Ni)-Si-B system was found to cause the formation of a mostly single amorphous phase in a sheet form with a thickness of 0.1 mm. No distinct difference in thermal stability (crystallization temperature and heat of crystallization), hardness, Curie temperature and magnetization is detected between the as-cast sheet and the melt-spun amorphous ribbon with a thickness of 0.02 ...

Premature melt solidification during mold filling and its influence on the as-cast structure

Science.gov (United States)

Wu, M.; Ahmadein, M.; Ludwig, A.

2018-03-01

Premature melt solidification is the solidification of a melt during mold filling. In this study, a numerical model is used to analyze the influence of the pouring process on the premature solidification. The numerical model considers three phases, namely, air, melt, and equiaxed crystals. The crystals are assumed to have originated from the heterogeneous nucleation in the undercooled melt resulting from the first contact of the melt with the cold mold during pouring. The transport of the crystals by the melt flow, in accordance with the socalled "big bang" theory, is considered. The crystals are assumed globular in morphology and capable of growing according to the local constitutional undercooling. These crystals can also be remelted by mixing with the superheated melt. As the modeling results, the evolutionary trends of the number density of the crystals and the volume fraction of the solid crystals in the melt during pouring are presented. The calculated number density of the crystals and the volume fraction of the solid crystals in the melt at the end of pouring are used as the initial conditions for the subsequent solidification simulation of the evolution of the as-cast structure. A five-phase volume-average model for mixed columnar-equiaxed solidification is used for the solidification simulation. An improved agreement between the simulation and experimental results is achieved by considering the effect of premature melt solidification during mold filling. Finally, the influences of pouring parameters, namely, pouring temperature, initial mold temperature, and pouring rate, on the premature melt solidification are discussed.

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

Science.gov (United States)

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

2000-10-01

To investigate the influence of the mold temperature on the surface reacted layer of Ti-Zr alloy castings. Ti-Zr alloy was casted into a mold which was made of a zircon (ZrO2.SiO2) for inner coating and a phosphate-bonded material for outer investing with a casting machine (China) designed as vacuum, pressure and centrifuge. At three mold temperatures (room temperature, 300 degrees C, 600 degrees C) the Ti-Zr alloy was casted separately. The surface roughness of the castings was calculated by instrument of smooth finish (China). From the surface to the inner part the Knoop hardness and thickness in reacted layer of Ti-Zr alloy casting was measured. The structure of the surface reacted layer was analysed by SEM. Elemental analyses of the interfacial zone of the casting was made by element line scanning observation. The surface roughness of the castings was increased significantly with the mold temperature increasing. At a higher mold temperature the Knoop hardness of the reactive layer was increased. At the three mold temperature the outmost surface was very hard, and microhardness data decreased rapidly where they reached constant values. The thickness was about 85 microns for castings at room temperature and 300 degrees C, 105 microns for castings at 600 degrees C. From the SEM micrograph of the Ti-Zr alloy casting, the surface reacted layer could be divided into three different layers. The first layer was called non-structure layer, which thickness was about 10 microns for room temperature group, 20 microns for 300 degrees C and 25 microns for 600 degrees C. The second layer was characterized by coarse-grained acicular crystal, which thickness was about 50 microns for three mold temperatures. The third layer was Ti-Zr alloy. The element line scanning showed non-structure layer with higher level of element of O, Al, Si and Zr, The higher the mold temperature during casting, the deeper the Si permeating and in the second layer the element Si could also be found

Simulation of transient fluid flow in mold region during steel continuous casting

International Nuclear Information System (INIS)

Liu, R; Thomas, B G; Sengupta, J

2012-01-01

A system of models has been developed to study transient flow during continuous casting and applied to simulate an event of multiple stopper-rod movements. It includes four sub-models to incorporate different aspects in this transient event. A three-dimensional (3-D) porous-flow model of the nozzle wall calculates the rate argon gas flow into the liquid steel, and the initial mean bubble size is estimated. Transient CFD models simulate multiphase flow of steel and gas bubbles in the Submerged Entry Nozzle (SEN) and mold and have been validated with experimental data from both nail dipping and Sub-meniscus Velocity Control (SVC) measurements. To obtain the transient inlet boundary conditions for the simulation, two semi-empirical models, a stopper-rod-position based model and a metal-level-based model, predict the liquid steel flow rate through the SEN based on recorded plant data. Finally the model system was applied to study the effects of stopper rod movements on SEN/mold flow patterns. Meniscus level fluctuations were calculated using a simple pressure method and compared well with plant measurements. Insights were gained from the simulation results to explain the cause of meniscus level fluctuations and the formation of sliver defects during stopper rod movements.

Study on the Surface Microstructure of a Modified STD61 Steel Mold Used for the Die Casting Process

Energy Technology Data Exchange (ETDEWEB)

Yu, Ha-Young; Lee, Seung-Joon; Kang, Minwoo; Lee, Suk-Jin; Lee, Young-Kook [Yonsei University, Seoul (Korea, Republic of); Yang, Won Jon [Korea Institute of Materials Science, Changwon (Korea, Republic of); Jeong, Jae Suk; Kim, Byung-Hoon [Doosan Heavy Industries and Construction, Changwon (Korea, Republic of)

2016-09-15

The surface microstructure and crack formation of an aluminum die-casting mold were investigated. The mold was made of a modified STD61 steel, and was used for more than 165,000 cycles. The mold surface consisted of four layers; an oxidized layer, a decarburized layer, a network carbide layer and a tempered martensite matrix. The depth down to the hardest network carbide layer was ⁓200 μm. Inside the matrix, M{sub 3}C transition carbides were dissolved so that solute C joined pre-existing M{sub 2}3C{sub 6} and MC carbides to make them coarse. About 60% of thermal fatigue cracks had a depth less than 200 μm due to the hard network carbide layer, which obstructed the propagation of cracks. Cracks of over 200 μm were filled with oxide wedges of Al and Si which was which flown from the molten alloy as well as the Fe oxide.

Centrifugal vacuum casting for fuel cladding tube blanks

International Nuclear Information System (INIS)

Zelenskii, V.F.; Neklyudov, I.M.; Chernyi, B.P.; Zeidlits, M.P.; Vanzha, A.F.; Rubashko, V.G.; Ryabchikov, L.N.; Smirnov, Y.K.; Bespalova, V.R.; Mashkarova, V.T.; Rybal'chenko, N.D.

1990-01-01

An advanced technique for making tube blanks with an acceptable level of nonmetallic inclusions is vacuum induction melting combined with centrifugal casting, as the latter gives a cylindrical casting having an axial hole, while the cast metal has elevated density and contains fewer nonmetallic inclusions than does the metal cast in a stationary mold. The reduction in the nonmetallic inclusions occurs because of increased rates of floating up in the rotating mold on account of the centrifugal force and the rejection to the inner surface. One can choose the parameters such as the pouring speed, rotational speed, mold cooling, and liquid-metal temperature and can introduce a deoxidizer to remove the nonmetallic inclusions or reduce the grain size of them and produce an appropriate cast structure and obtain a metal whose quality is the same as that on vacuum induction melting with secondary arc remelting. For these purposes, the authors have developed centrifugal-casting machines for use under vacuum or in inert gases with horizontal and vertical mold rotation axes

Fabrication of sacrificial anode cathodic protection through casting method

International Nuclear Information System (INIS)

Mohd Sharif Sattar; Muhamad Daud; Siti Radiah Mohd Kamarudin; Azali Muhamad; Zaiton Selamat; Rusni Rejab

2007-01-01

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)

HFIR Fuel Casting Support

Energy Technology Data Exchange (ETDEWEB)

Imhoff, Seth D. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Gibbs, Paul Jacob [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Solis, Eunice Martinez [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-09-28

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

Simulation of the injection casting of metallic fuels

International Nuclear Information System (INIS)

Nakagawa, Tomokazu; Ogata, Takanari; Tokiwai, Moriyasu.

1989-01-01

For the fabrication of metallic fuel pins, injection casting is a preferable process because the simplicity of the process is suitable for remote operation. In this process, the molten metal in the crucible is injected into evacuated molds (suspended above the crucible) by pressurizing the casting furnace. Argonne National Laboratory has already adopted this process in the Integral Fast Reactor program. To obtain fuel pins with good quality, the casting parameters, such as the molten metal temperature, the magnitude of the pressure applied, the pressurizing rate, the cooling time, etc., must be optimized. Otherwise, bad-quality castings (short castings, rough surfaces, shrinkage cavities, mold fracture) may result. Therefore, it is very important in designing the casting equipment and optimizing the operation conditions to be able to predict the fluid and thermal behavior of the castings. This paper describes methods to simulate the heat and mass transfer in the molds and molten metallic fuel during injection casting. The results obtained by simulation are compared with experimental ones. Also, appropriate casting conditions for the uranium-plutonium-zirconium alloy are discussed based on the simulated results

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

Science.gov (United States)

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

2017-08-01

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

CASTING FURNACES

Science.gov (United States)

Ruppel, R.H.; Winters, C.E.

1961-01-01

A device is described for casting uranium which comprises a crucible, a rotatable table holding a plurality of molds, and a shell around both the crucible and the table. The bottom of the crucible has an eccentrically arranged pouring hole aligned with one of the molds at a time. The shell can be connected with a vacuum.

Casting materials

Science.gov (United States)

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

2011-06-14

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

Casting AISI 316 steel by gel cast

International Nuclear Information System (INIS)

Ozols, A; Thern, G; Rozenberg, S; Barreiro, M; Marajofsky, A

2004-01-01

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 1160 o C to 1300 o C 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)

Numerical simulation of low pressure die-casting aluminum wheel

Directory of Open Access Journals (Sweden)

Mi Guofa

2009-02-01

Full Text Available The FDM numerical simulation software, ViewCast system, was employed to simulate the low pressure die casting (LPDC of an aluminum wheel. By analyzing the mold-fi lling and solidifi cation stage of the LPDC process, the distribution of liquid fraction, temperature field and solidification pattern of castings were studied. The potential shrinkage defects were predicted to be formed at the rim/spoke junctions, which is in consistence with the X-ray detection result. The distribution pattern of the defects has also been studied. A solution towards reducing such defects has been presented. The cooling capacity of the mold was improved by installing water pipes both in the side mold and the top mold. Analysis on the shrinkage defects under forced cooling mode proved that adding the cooling system in the mold is an effective method for reduction of shrinkage defects.

CASTING APPARATUS

Science.gov (United States)

Gray, C.F.; Thompson, R.H.

1958-09-23

An apparatus is described for casting small quantities of uranlum. It consists of a crucible having a hole in the bottom with a mold positioned below. A vertical rcd passes through the hole in the crucible and has at its upper end a piercing head adapted to break the oxide skin encasing a molten uranium body. An air tight cylinder surrounds the crucible and mold, and is arranged to be evacuated.

Computer Texture Mapping for Laser Texturing of Injection Mold

Directory of Open Access Journals (Sweden)

Yongquan Zhou

2014-04-01

Full Text Available Laser texturing is a relatively new multiprocess technique that has been used for machining 3D curved surfaces; it is more flexible and efficient to create decorative texture on 3D curved surfaces of injection molds so as to improve the surface quality and achieve cosmetic surface of molded plastic parts. In this paper, a novel method of laser texturing 3D curved surface based on 3-axis galvanometer scanning unit has been presented to prevent the texturing of injection mold surface from much distortion which is often caused by traditional texturing processes. The novel method has been based on the computer texture mapping technology which has been developed and presented. The developed texture mapping algorithm includes surface triangulation, notations, distortion measurement, control, and numerical method. An interface of computer texture mapping has been built to implement the algorithm of texture mapping approach to controlled distortion rate of 3D texture math model from 2D original texture applied to curvature surface. Through a case study of laser texturing of a high curvature surface of injection mold of a mice top case, it shows that the novel method of laser texturing meets the quality standard of laser texturing of injection mold.

Fabrication of a zirconia MEMS-based microthruster by gel casting on PDMS soft molds

International Nuclear Information System (INIS)

Cheah, K H; Khiew, P S; Chin, J K

2012-01-01

A zirconia microelectromechanical-system-based microthruster was fabricated through a newly developed fabrication route. Gel casting of homogenously dispersed zirconia suspension on polydimethylsiloxane soft mold was utilized to replicate the geometries of microthruster design onto a ceramic layer of about 1.2 mm thick. Lamination of the patterned ceramic layer to another flat ceramic layer and subsequent sintering produced the microthruster. Characterizations on the fabricated prototype showed good shape retention on the replicated geometries and good quality of lamination. Shrinkage of about 10–15% was noted after sintering. The current fabrication route is particularly promising for the development of high-performance micropropulsion systems which require their structural material to survive in an extreme environment which is corrosive, of high temperature and highly oxidative. (paper)

Metallic Fuel Casting Development and Parameter Optimization Simulations

International Nuclear Information System (INIS)

Fielding, Randall S.; Kennedy, J.R.; Crapps, J.; Unal, C.

2013-01-01

Conclusions: • Gravity casting is a feasible process for casting of metallic fuels: – May not be as robust as CGIC, more parameter dependent to find right “sweet spot” for high quality castings; – Fluid flow is very important and is affected by mold design, vent size, super heat, etc.; – Pressure differential assist was found to be detrimental. • Simulation found that vent location was important to allow adequate filling of mold; • Surface tension plays an important role in determining casting quality; • Casting and simulations high light the need for better characterized fluid physical and thermal properties; • Results from simulations will be incorporated in GACS design such as vent location and physical property characterization

Studies on the Castability of Pure Titanium (Part 3) Influence of casting pressure and sprue diameter on the titanium castability

OpenAIRE

YONEDA, TAKANORI; KUROIWA, AKIHIRO; IGARASHI, YOSHIMASA; OHNO, TAKAFUMI; SEKIGUCHI, YUUJI; INOUE, YOSHIHISA; MIGO, SHINYA

1998-01-01

We analyzed the external defects of castings with mesh grid patterns with 3 different kinds of phosphate bonded casting molds with 2 parameters (sprue diameter and casting pressure). Castability with pure titanium was affected by the parameters of sprue diameter, and casting pressure with different casting molds. The sprue condition was the most affective casting condition in the all directional pressure type casting machine. In 2 types of casting molds, one was strongly affected by the casti...

Fabrication of Microfluidic Valves Using a Hydrogel Molding Method.

Science.gov (United States)

Sugiura, Yusuke; Hirama, Hirotada; Torii, Toru

2015-08-24

In this paper, a method for fabricating a microfluidic valve made of polydimethylsiloxane (PDMS) using a rapid prototyping method for microchannels through hydrogel cast molding is discussed. Currently, the valves in microchannels play an important role in various microfluidic devices. The technology to prototype microfluidic valves rapidly is actively being developed. For the rapid prototyping of PDMS microchannels, a method that uses a hydrogel as the casting mold has been recently developed. This technique can be used to prepare a three-dimensional structure through simple and uncomplicated methods. In this study, we were able to fabricate microfluidic valves easily using this rapid prototyping method that utilizes hydrogel cast molding. In addition, we confirmed that the valve displacement could be predicted within a range of constant pressures. Moreover, because microfluidic valves fabricated using this method can be directly observed from a cross-sectional direction, we anticipate that this technology will significantly contribute to clarifying fluid behavior and other phenomena in microchannels and microfluidic valves with complex structures.

Casting methods

Science.gov (United States)

Marsden, Kenneth C.; Meyer, Mitchell K.; Grover, Blair K.; Fielding, Randall S.; Wolfensberger, Billy W.

2012-12-18

A casting device includes a covered crucible having a top opening and a bottom orifice, a lid covering the top opening, a stopper rod sealing the bottom orifice, and a reusable mold having at least one chamber, a top end of the chamber being open to and positioned below the bottom orifice and a vacuum tap into the chamber being below the top end of the chamber. A casting method includes charging a crucible with a solid material and covering the crucible, heating the crucible, melting the material, evacuating a chamber of a mold to less than 1 atm absolute through a vacuum tap into the chamber, draining the melted material into the evacuated chamber, solidifying the material in the chamber, and removing the solidified material from the chamber without damaging the chamber.

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

Science.gov (United States)

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

1993-01-01

A primary concern in modern fluid dynamics research is the experimental verification of computational aerothermodynamic codes. This research requires high precision and detail in the test model employed. Ceramic materials are used for these models because of their low heat conductivity and their survivability at high temperatures. To fabricate such models, slip casting techniques were developed to provide net-form, precision casting capability for high-purity ceramic materials in aqueous solutions. In previous slip casting techniques, block, or flask molds made of plaster-of-paris were used to draw liquid from the slip material. Upon setting, parts were removed from the flask mold and cured in a kiln at high temperatures. Casting detail was usually limited with this technique -- detailed parts were frequently damaged upon separation from the flask mold, as the molded parts are extremely delicate in the uncured state, and the flask mold is inflexible. Ceramic surfaces were also marred by 'parting lines' caused by mold separation. This adversely affected the aerodynamic surface quality of the model as well. (Parting lines are invariably necessary on or near the leading edges of wings, nosetips, and fins for mold separation. These areas are also critical for flow boundary layer control.) Parting agents used in the casting process also affected surface quality. These agents eventually soaked into the mold, the model, or flaked off when releasing the case model. Different materials were tried, such as oils, paraffin, and even an algae. The algae released best, but some of it remained on the model and imparted an uneven texture and discoloration on the model surface when cured. According to the present invention, a wax pattern for a shell mold is provided, and an aqueous mixture of a calcium sulfate-bonded investment material is applied as a coating to the wax pattern. The coated wax pattern is then dried, followed by curing to vaporize the wax pattern and leave a shell

Optimization of the investment casting process

Directory of Open Access Journals (Sweden)

M. Martinez-Hernandez

2012-04-01

Full Text Available Rapid prototyping is an important technique for manufacturing. This work refers to the manufacture of hollow patterns made of polymeric materials by rapid prototyping technologies for its use in the preparation of ceramic molds in the investment casting process. This work is focused on the development of a process for manufacturing patterns different from those that currently exist due to its hollow interior design, allowing its direct use in the fabrication of ceramic molds; avoiding cracking and fracture during the investment casting process, which is an important process for the foundry industry.

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

Science.gov (United States)

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

2018-03-01

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

The effects of casting speed on steel continuous casting process

Energy Technology Data Exchange (ETDEWEB)

Sadat, Mohammad; Honarvar Gheysari, Ali; Sadat, Saeid [Islamic Azad University, Department of Mechanics, Mashhad Branch, Mashhad (Iran, Islamic Republic of)

2011-12-15

A three dimensional simulation of molten steel flow, heat transfer and solidification in mold and ''secondary cooling zone'' of Continuous Casting machine was performed with consideration of standard k-{epsilon} model. For this purpose, computational fluid dynamics software, FLUENT was utilized. From the simulation standpoint, the main distinction between this work and preceding ones is that, the phase change process (solidification) and flow (turbulent in mold section and laminar in secondary cooling zone) have been coupled and solved jointly instead of dividing it into ''transient heat conduction'' and ''steady fluid flow'' that can lead to more realistic simulation. Determining the appropriate boundary conditions in secondary cooling zone is very complicated because of various forms of heat transfer involved, including natural and forced convection and simultaneous radiation heat transfer. The main objective of this work is to have better understanding of heat transfer and solidification in the continuous casting process. Also, effects of casting speed on heat flux and shell thickness and role of radiation in total heat transfer is discussed. (orig.)

MATERIALS FOR PRODUCTION OF METAL MOLDS

Directory of Open Access Journals (Sweden)

A. Ju. Jakovlev

2007-01-01

Full Text Available The influence of alloying with manganese, chromium, nickel, copper and molybdenum on mechanical characteristics and thermocyclic endurance of grayed steel and possibility of its application for metal casting molds is investigated.

Use of a general-purpose heat-transfer code for casting simulation

International Nuclear Information System (INIS)

Erickson, W.C.

1975-07-01

The practical use of numerical techniques in simulating casting solidification dictate that a general purpose heat transfer code be used and that results be obtained in an easy-to-analyze format. Color film plotting routines were developed for use with NASA's CINDA-3G heat transfer code; the combination of which meet the above criteria. The subroutine LQSLTR written for SINDA, the successor to CINDA-3G, was verified by comparing calculated results obtained using LQSLTR with those obtained using the specific heat method for handling the heat of fusion. Excellent agreement existed when similar data was used. When the more restrictive requirement of a 1 0 F melting range was used, comparable results were obtained. Uranium and lead rod castings were cast in instrumented graphite molds and the solidification sequence simulated using CINDA-3G. Discrepancies attributed to initial assumptions of instantaneous mold filling, uniform melt temperature, and intimate metal/mold contact were encountered. Further calculations using a model incorporating a gap between the mold and casting showed that the intimate contact assumption could not be used; a three-dimensional model also showed that the thermocouple assemblies used with the platinum--platinum-10 percent rhodium were a significant perturbation to the system. An L-shaped steel casting was simulated and the results compared to those reported in the literature. The experimental data for this casting were reproduced within the accuracy permitted by the thermal conductivity of the sand, thus demonstrating that agreement can be obtained when the mold material does not act as a chill. (U.S.)

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

Science.gov (United States)

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

2014-07-01

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

Modeling of TiAl Alloy Grating by Investment Casting

Directory of Open Access Journals (Sweden)

Yi Jia

2015-12-01

Full Text Available The investment casting of TiAl alloys has become the most promising cost-effective technique for manufacturing TiAl components. This study aimed to investigate a series of problems associated with the investment casting of TiAl alloys. The mold filling and solidification of this casting model were numerically simulated using ProCAST. Shrinkage porosity was quantitatively predicted by a built-in feeding criterion. The results obtained from the numerical simulations were compared with experiments, which were carried out on Vacuum Skull Furnace using an investment block mold. The investment casting of TiAl grating was conducted for verifying the correctness and feasibility of the proposed method. The tensile test results indicated that, at room temperature, the tensile strength and elongation were approximately 675 MPa and 1.7%, respectively. The microstructure and mechanical property of the investment cast TiAl alloy were discussed.

40 CFR 464.20 - Applicability; description of the copper casting subcategory.

Science.gov (United States)

2010-07-01

... copper casting subcategory. 464.20 Section 464.20 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Copper Casting Subcategory § 464.20 Applicability; description of the copper casting subcategory. The...

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

Science.gov (United States)

2010-07-01

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

40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

Science.gov (United States)

2010-07-01

... aluminum casting subcategory. 464.10 Section 464.10 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Aluminum Casting Subcategory § 464.10 Applicability; description of the aluminum casting subcategory. The...

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

Science.gov (United States)

2010-07-01

... casting subcategory. 464.40 Section 464.40 Protection of Environment ENVIRONMENTAL PROTECTION AGENCY (CONTINUED) EFFLUENT GUIDELINES AND STANDARDS METAL MOLDING AND CASTING POINT SOURCE CATEGORY Zinc Casting Subcategory § 464.40 Applicability; description of the zinc casting subcategory. The provisions of this...

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

Energy Technology Data Exchange (ETDEWEB)

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

Preparation of thin actinide metal disks using a multiple disk casting technique

International Nuclear Information System (INIS)

Conner, W.V.

1975-01-01

A casting technique has been developed for preparing multiple actinide metal disks which have a minimum thickness of 0.006 inch. This technique was based on an injection casting procedure which utilizes the weight of a tantalum metal rod to force the molten metal into the mold cavity. Using the proper mold design and casting parameters, it has been possible to prepare ten 1/2 inch diameter neptunium or plutonium metal disks in a single casting, This casting technique is capable of producing disks which are very uniform. The average thickness of the disks from a typical casting will vary no more than 0.001 inch and the variation in the thickness of the individual disks will range from 0.0001 to 0.0005 inch. (Auth.)

Preparation of thin actinide metal disks using a multiple disk casting technique

International Nuclear Information System (INIS)

Conner, W.V.

1976-01-01

A casting technique has been developed for preparing multiple actinide metal disks which have a minimum thickness of 0.006 inch. This technique was based on an injection casting procedure which utilizes the weight of a tantalum metal rod to force the molten metal into the mold cavity. Using the proper mold design and casting parameters, it has been possible to prepare ten 1/2 inch diameter neptunium or plutonium metal disks in a single casting. This casting technique is capable of producing disks which are very uniform. The average thickness of the disks from a typical casting will vary no more than 0.001 inch and the variation in the thickness of the individual disks will range from 0.0001 to 0.0005 inch. (author)

The development of lab-on-a-chip fabricated from two molds

Science.gov (United States)

Pramuanjaroenkij, A.; Bunta, J.; Thiangpadung, J.; Sansaradee, S.; Kamsopa, P.; Sodsai, S.; Vichainsan, S.; Wongpanit, K.; Maturos, T.; Lomas, T.; Tuantranont, A.; Cetin, B.; Phankhoksoong, S.; Tongkratoke, A.

2018-01-01

Development of diagnostic technique of microfluidic or lab-on-a-chip (LOCs) is currently of great interest for researchers and inventors for their many advantages. It can be used as a real laboratory was many ways to help to the diagnosis faster. This research aims to develop Polydimethylsiloxane (PDMS) lab-on-a-chip (LOCs) which were produced from different molds; the silicon wafer mold and the stainless mold to investigate the flow of the biological sample as the flow in nanochannels. In addition, this research proposes a means to leakage and the blockage of the channel flow. The experimental results were found that the LOCs casted from the silicon wafer mold sandwiched by both the plasma cleaner machine and H shaped acrylic sheets showed leakages around the electrode areas because the first new electrodes were too thick, the proper thickness of the nickel electrode was at 0.05 millimeters. The LOCs casted from the stainless mold were inserted by the nickel electrodes produced by the from the prototype shaped electroplating process; this LOCs using nickel plated electrodes 2 times to make a groove on the nickel electrode backsides when pouring the PDMS into the LOCs casted from the stainless mold. It was found that PDMS was able to flow under the nickel electrode and the PDMS sheet could stick with the glass slide smoothly. In conclusion, it was possible to develop these LOC designs and new electrode fabrications continually under helps from Micro-Electro-Mechanical system, Thailand National Electronics and Computer Technology Center, since causes of the LOC problems were found, and demonstrated the feasibility of developing the LOCs for chemical detection and disease diagnostics.

Application of the lattice Boltzmann method for simulation of the mold filling process in the casting industry

Science.gov (United States)

Szucki, Michal; Suchy, J. S.; Lelito, J.; Malinowski, P.; Sobczyk, J.

2017-12-01

The aim of this work is the development of the lattice Boltzmann model for simulation of the mold filling process. The authors present a simplified approach to the modeling of liquid metal-gas flows with particular emphasis on the interactions between these phases. The boundary condition for momentum transfer of the moving free surface to the gaseous phase is shown. Simultaneously, the method for modeling influence of gas back pressure on a position and shape of the interfacial boundary is explained in details. The problem of the lattice Boltzmann method (LBM) stability is also analyzed. Since large differences in viscosity of both fluids are a source of the model instability, the so-called fractional step (FS) method allowing to improve the computation stability is applied. The presented solution is verified on the bases of the available reference data and the results of experiments. It is shown that the model describes properly such effects as: gas bubbles formation and air back pressure, accompanying liquid-gas flows in the casting mold. At the same time the proposed approach is easy to be implemented and characterized by a lower demand of operating memory as compared to typical LBM models of two-phase flows.

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

Energy Technology Data Exchange (ETDEWEB)

Aikin, Jr., Robert M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)

2017-10-04

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

Graphite nodules in fatigue-tested cast iron characterized in 2D and 3D

DEFF Research Database (Denmark)

Mukherjee, Krishnendu; Fæster, Søren; Hansen, Niels

2017-01-01

Thick-walled ductile iron casts have been studied by applying (i) cooling rate calculations by FVM, (ii) microstructural characterization by 2D SEM and 3D X-ray tomography techniques and (iii) fatigue testing of samples drawn from components cast in sand molds and metal molds. An analysis has shown...... correlations between cooling rate, structure and fatigue strengths demonstrating the benefit of 3D structural characterization to identify possible causes of premature fatigue failure of ductile cast iron....

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

Science.gov (United States)

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

2018-05-01

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

Numerical simulation of stress-strain state of electrophoretic shell molds

Science.gov (United States)

Sviridov, A. V.; Odinokov, V. I.; Dmitriev, E. A.; Evstigneev, A. I.; Bashkov, O. V.

2017-10-01

In the foundry engineering, castings obtained in one-piece non-gas-generating high-refractory electrophoretic shell molds (ShM) by investment patterns (IP) have an increased rejects percentage associated with low deformation resistance and crack resistance of the SM at different stages of their formation and manufacturing. Crack resistance of the ShM based on IP depends mainly on their stress-strain state (SSS) at various stages of mold forming. SSS decrease significantly improves their crack resistance and decreases their rejects percentage of castings occurring due to clogging and surface defects. In addition, the known methods of decreasing the SSS are still poorly understood. Thus, current research trends are to determine SSS at each stage of ShM forming and develop the ways to decrease it. Theoretical predicting of crack formation in multiple-layer axisymmetric shell molds is given in the work [1], and SSS of multiple-layer axisymmetric shell molds is given in the work [2]. Monolayer electrophoretic ShM had a lack of concern in this field, thus it became an argument for the present workMathematical Model of ShM SSS

Cork is used to make tooling patterns and molds

Science.gov (United States)

Hoffman, F. J.

1965-01-01

Sheet and waste cork are cemented together to provide a tooling pattern or mold. The cork form withstands moderately high temperatures under vacuum or pressure with minimum expansion, shrinkage, or distortion.

In-Situ Real Time Monitoring and Control of Mold Making and Filling Processes: Final Report

Energy Technology Data Exchange (ETDEWEB)

Mohamed Abdelrahman; Kenneth Currie

2010-12-22

This project presents a model for addressing several objectives envisioned by the metal casting industries through the integration of research and educational components. It provides an innovative approach to introduce technologies for real time characterization of sand molds, lost foam patterns and monitoring of the mold filling process. The technology developed will enable better control over the casting process. It is expected to reduce scrap and variance in the casting quality. A strong educational component is integrated into the research plan to utilize increased awareness of the industry professional, the potential benefits of the developed technology, and the potential benefits of cross cutting technologies.

CASTING METHOD AND APPARATUS

Science.gov (United States)

Gray, C.F.; Thompson, R.H.

1958-10-01

An improved apparatus for the melting and casting of uranium is described. A vacuum chamber is positioned over the casting mold and connected thereto, and a rod to pierce the oxide skin of the molten uranium is fitted into the bottom of the melting chamber. The entire apparatus is surrounded by a jacket, and operations are conducted under a vacuum. The improvement in this apparatus lies in the fact that the top of the melting chamber is fitted with a plunger which allows squeezing of the oxide skin to force out any molten uranium remaining after the skin has been broken and the molten charge has been cast.

Deep UV patterning of acrylic masters for molding biomimetic dry adhesives

International Nuclear Information System (INIS)

Sameoto, D; Menon, C

2010-01-01

We present a novel fabrication method for the production of biomimetic dry adhesives that allows enormous variation in fiber shapes and sizes. The technology is based on deep-UV patterning of commercial acrylic with semi-collimated light available from germicidal lamps, and combined careful processing conditions, material selection and novel developer choices to produce relatively high-aspect-ratio fibers with overhanging caps on large areas. These acrylic fibers are used as a master mold for subsequent silicone rubber negative mold casting. Because the bulk acrylic demonstrates little inherent adhesion to silicone rubbers, the master molds created in this process do not require any surface treatments to achieve high-yield demolding of interlocked structures. Multiple polymers can be cast from silicone rubber negative molds and this process could be used to structure smart materials on areas over multiple square feet. Using direct photopatterning of acrylic allows many of the desired structures for biomimetic dry adhesives to be produced with relative ease compared to silicon-based molding processes, including angled fibers and hierarchical structures. Optimized fiber shapes for a variety of polymers can be produced using this process, and adhesion measurements on a well-characterized polyurethane, ST-1060, are used to determine the effect of fiber geometry on adhesion performance

Modeling of TiAl Alloy Grating by Investment Casting

OpenAIRE

Yi Jia; Shulong Xiao; Jing Tian; Lijuan Xu; Yuyong Chen

2015-01-01

The investment casting of TiAl alloys has become the most promising cost-effective technique for manufacturing TiAl components. This study aimed to investigate a series of problems associated with the investment casting of TiAl alloys. The mold filling and solidification of this casting model were numerically simulated using ProCAST. Shrinkage porosity was quantitatively predicted by a built-in feeding criterion. The results obtained from the numerical simulations were compared with experimen...

A poly(dimethylsiloxane)-coated flexible mold for nanoimprint lithography

International Nuclear Information System (INIS)

Lee, Nae Yoon; Kim, Youn Sang

2007-01-01

In this paper, we introduce an anti-adhesion poly(dimethylsiloxane) (PDMS)-coated flexible mold and its applications for room-temperature imprint lithography. The flexible mold is fabricated using an ultraviolet-curable prepolymer on a flexible substrate, and its surface is passivated with a thin layer of PDMS to impart an anti-adhesion property. The highly flexible mold enables conformal contact with a substrate on which a low-viscosity polymer resist is spin-cast in a thin layer. Large-area imprinting is then realized at room temperature under significantly reduced pressure. The mold was durable even after repetitive imprinting of over 200 times. Also, we show a double imprinting on the substrate with a PDMS-coated replica polymeric mold having 500 nm line patterns. This enables the formation of matrix patterns with varying feature heights in less than 7 min

Replication of specifically microstructured surfaces in A356-alloy via lost wax investment casting

International Nuclear Information System (INIS)

Ivanov, Todor; Bührig-Polaczek, Andreas; Vroomen, Uwe; Hartmann, Claudia; Holtkamp, Jens; Gillner, Arnold; Bobzin, Kirsten; Bagcivan, Nazlim; Theiss, Sebastian

2011-01-01

A common way of realizing microstructural features on metallic surfaces is to generate the designated pattern on each single part by means of microstructuring technologies such as e.g. laser ablation, electric discharge machining or micromilling. The disadvantage of these process chains is the limited productivity due to the additional processing of each part. The approach of this work is to replicate microstructured surfaces from a master pattern via lost wax investment casting in order to reach a higher productivity. We show that microholes of different sizes ( 15–22 µm at depths of 6–14 µm) can be replicated in AlSi7Mg-alloy from a laser-structured master pattern via investment casting. However, some loss of molding accuracy during the multi-stage molding process occurs. Approximately 50% of the original microfeature's heights are lost during the wax injection step. In the following process step of manufacturing a gypsum-bonded mold, a further loss in the surface quality of the microfeatures can be observed. In the final process step of casting the aluminum melt, the microfeatures are filled without any loss of molding accuracy and replicate the surface quality of the gypsum mold. The contact angle measurements of ultrapure water on the cast surfaces show a decrease in wettability on the microstructured regions (75°) compared to the unstructured region (60°)

Development of magnesium semi-solid injection molding; Magnesium han`yoyu shashutsu seikei gijutsu no kaihatsu

Energy Technology Data Exchange (ETDEWEB)

Sakamoto, K; Sakate, N; Ishida, K; Yamamoto, Y; Nishimura, K [Mazda Motor Corp., Hiroshima (Japan)

1997-10-01

Magnesium semi-solid injection molding is safety and clean process. We have investigated influence of molding conditions on mechanical properties and dimension accuracy of products by semi-solid injection molding. As a result it was proved that the accuracy of products by this process is superior to die casting. This advantage as well as better mechanical properties can be utilized for net shape molding of some automobile parts. 4 refs., 8 figs., 3 tabs.

Manufacturability evaluation for molded parts using fictitious physical models, and its application in topology optimization

OpenAIRE

Sato, Yuki; Yamada, Takayuki; Izui, Kazuhiro; Nishiwaki, Shinji

2017-01-01

Manufacturing methods using molds, such as casting and injection molding, are widely used in industries. A basic requirement when using such manufacturing methods is that design engineers must design products so that they incorporate certain geometrical features that allow the mold parts to be removed from the created solid object. In the present study, we propose a manufacturability evaluation method especially adapted for the use of molds. To evaluate the manufacturability, we introduce fic...

Microstructure And Mechanical Properties Of An Al-Zn-Mg-Cu Alloy Produced By Gravity Casting Process

Directory of Open Access Journals (Sweden)

Saikawa S.

2015-06-01

Full Text Available High-strength aluminum alloy are widely used for structural components in aerospace, transportation and racing car applications. The objective of this study is to enhance the strength of the Al-Zn-Mg-Cu alloy used for gravity casting process. All alloys cast into stepped-form sand mold (Sand-mold Casting; SC and Y-block shaped metal mold(Permanent mold Casting; PC C and then two –step aged at 398-423 K after solution treated at 743 K for 36 ks. The tensile strength and total elongation of the two-step aged SC alloys were 353-387 MPa and about 0.4% respectively. This low tensile properties of the SC alloys might be caused by remaining of undissolved crystallized phase such as Al2CuM, MgZn2 and Al-Fe-Cu system compounds. However, good tensile properties were obtained from PC alloys, tensile strength and 0.2% proof stress and elongation were 503-537 MPa, 474-519 MPa and 1.3-3.3%.

Flop casting of nuclear materials for advanced fuel cycle research - 5247

International Nuclear Information System (INIS)

Swift, A.J.; Koury, D.J.; Czerwinski, K.R.; Vollmer, J.M.

2015-01-01

Full text of publication follows. Next generation fast reactor designs of nuclear reactors utilizing metallic fuel are being developed as an alternative fuel cycle option in an effort to reduce carbon emissions. Metallic fuel systems are attractive because of their high thermal conductivity, fissile atom density, and inherent safety. Metallic fuel systems are also being investigated because of their potential to reach high burnups. The increased targeted burnups for metallic fuels lead to higher concentrations of actinides, lanthanides, and other fission products, which alter the fuel properties and impact the performance of the fuel. Before designs can be implemented, the fission product concentrations must be studied at variable fuel geometries and stages of fuel burnup. Arc flop casting serves as a viable option for casting alloys as the molds can be tailored to fit design specific requirements while cutting costs in time-consuming machining. Arc casting is done as the final preparation step in a small arc furnace with an argon or 5% hydrogen-argon atmosphere after the sample has been subsequently melted, overturned, and re-melted. The flop casting mold is then fitted to the chamber as needed and the previously prepared sample is quickly hit with a high current arc causing the molten metal to fill the copper mold. The U-Zr-Pu system will serve as the basis for this research as it has been extensively studied since the 1950 years, although flop casting can be adapted to any metallic fuel system. Multiple U-Zr-Pu with varying fission product concentrations alloys, Technetium metal, and Plutonium alloys have been flop cast based on burnup calculations. Prepared samples were cast using different molds and dimensions, then characterized by Scanning Electron Microscopy, X-ray diffraction, and Thermogravimetric Analysis. The goal of this research is to test and develop flop casting techniques for the production of metallic fuel alloys applicable for various stages and

Analysis of Meniscus Fluctuation in a Continuous Casting Slab Mold

Science.gov (United States)

Zhang, Kaitian; Liu, Jianhua; Cui, Heng; Xiao, Chao

2018-03-01

A water model of slab mold was established to analyze the microscopic and macroscopic fluctuation of meniscus. The fast Fourier transform and wavelet entropy were adopted to analyze the wave amplitude, frequency, and components of fluctuation. The flow patterns under the meniscus were measured by using particle image velocimetry measurement and then the mechanisms of meniscus fluctuation were discussed. The results reflected that wavelet entropy had multi-scale and statistical properties, and it was suitable for the study of meniscus fluctuation details both in time and frequency domain. The basic wave, frequency of which exceeding 1 Hz in the condition of no mold oscillation, was demonstrated in this work. In fact, three basic waves were found: long-wave with low frequency, middle-wave with middle frequency, and short-wave with high frequency. In addition, the upper roll flow in mold had significant effect on meniscus fluctuation. When the position of flow impinged was far from the meniscus, long-wave dominated the fluctuation and the stability of meniscus was enhanced. However, when the velocity of flow was increased, the short-wave dominated the meniscus fluctuation and the meniscus stability was decreased.

Mathematical model of the crystallizing blank`s thermal state at the horizontal continuous casting machine

Directory of Open Access Journals (Sweden)

Kryukov Igor Yu.

2017-01-01

Full Text Available Present article is devoted to the development of the mathematical model, which describes thermal state and crystallization process of the rectangular cross-section blank while continious process of extraction from a horysontal continious casting machine (HCCM.The developed model took cue for the heat-transfer properties of non-iron metal teeming; its temperature on entry to the casting mold; cooling conditions of blank in the carbon molds in the presence of a copper water cooler. Besides, has been considered the asymmetry of heat interchange from blank`s head and drag at mold, coming out from fluid contraction and features of the horizontal casting mold. The developed mathematical model allows to determine alterations in crystallizing blank of the following factors with respect to time: temperature pattern of crystallizing blank under different technical working regimes of HCCM; boundaries of solid two-phase field and liquid two-phase filed; blank`s thickness variation under shrinkage of the ingot`s material

Neutron radiography inspection of investment castings

International Nuclear Information System (INIS)

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

2004-01-01

Investment casting, also known as the lost wax process, is a manufacturing method employed to produce near net shape metal articles. Traditionally, investment casting has been used to produce structural titanium castings for aero-engine applications with wall thickness less than 1 in (2.54 cm). Recently, airframe manufacturers have been exploring the use of titanium investment casting to replace components traditionally produced from forgings. Use of titanium investment castings for these applications reduces weight, cost, lead time, and part count. Recently, the investment casting process has been selected to produce fracture critical structural titanium airframe components. These airframe components have pushed the traditional inspection techniques to their physical limits due to cross sections on the order of 3 in (7.6 cm). To overcome these inspection limitations, a process incorporating neutron radiography (n-ray) has been developed. In this process, the facecoat of the investment casting mold material contains a cocalcined mixture of yttrium oxide and gadolinium oxide. The presence of the gadolinium oxide, allows for neutron radiographic imaging (and eventual removal and repair) of mold facecoat inclusions that remain within these thick cross sectional castings. Probability of detection (POD) studies have shown a 3x improvement of detecting a 0.050x0.007 in 2 (1.270x0.178 mm 2 ) inclusion of this cocalcined material using n-ray techniques when compared to the POD using traditional X-ray techniques. Further, it has been shown that this n-ray compatible mold facecoat material produces titanium castings of equal metallurgical quality when compared to the traditional materials. Since investment castings can be very large and heavy, the neutron radiography facilities at the University of California, Davis McClellan Nuclear Radiation Center (UCD/MNRC) were used to develop the inspection techniques. The UCD/MNRC has very unique facilities that can handle large parts

Quality Management and Control of Low Pressure Cast Aluminum Alloy

Science.gov (United States)

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

2018-01-01

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

Optimization of casting defects analysis with supply chain in cast iron foundry process

Directory of Open Access Journals (Sweden)

C. Narayanaswamy

2016-10-01

Full Text Available Some of the foundries are in need of meeting production targets and due to the urgency they ignore the rejections. The objective of this paper is to analyze the various defects, [1] from molding process in a cast iron foundry. The Failure Mode Effects Analysis (FMEA in quality control [2-6] with suitable supply chain for mold making process considering rejection rates are identified and analyzed in terms of Risk Priority Number (RPN to prioritize the attention for each of the problem. The optimum levels of selected parameters [7] are obtained in this analysis.

The role of water in slip casting

Science.gov (United States)

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

1984-01-01

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

Numerical Simulation of Cast Distortion in Gas Turbine Engine Components

International Nuclear Information System (INIS)

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

2015-01-01

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

Material properties of Al-Si-Cu aluminium alloy produced by the rotational cast technology

Directory of Open Access Journals (Sweden)

Muhammad Syahid

2017-03-01

Full Text Available The aim of the present study is to explore microstructural and mechanical properties of cast Al-Si-Cu aluminum alloy (ADC12. To obtain excellent material properties, the cast Al alloys were produced by an originally developed mold rotational machine, namely liquid aluminum alloy is solidified during high speed rotating. The casting process was conducted under various casting conditions, in which the following factors were altered, e.g., melt temperature, metal mold temperature and different rotational speed. Microstructural characteristics were examined by direct observation using an optical microscope and a scanning electron microscope (SEM, and the secondary dendrite arm spacing of alpha-Al phase (SDAS and the size of Si eutectic phase were identified. Mechanical properties were investigated by micro-hardness and tensile tests. Rotation speed and melt temperature were directly attributed to the SDAS, and severe shear stress arising from the rotation made fine and complicated grain structure, leading to the high mechanical properties. The extent of the shear stress was altered depending on the area of the sample due to the different shear stress. Furthermore, high melt temperature and high rotational speed decrease the size of Si eutectic phases. The high mechanical properties were detected for the cast samples produced by the casting condition as follows: melt temperature 700oC, mold temperature 400oC and rotation speed 400 rpm

Casting Freedom, 1860-1862

Science.gov (United States)

Social Education, 2005

2005-01-01

Thomas Crawford, an American Sculptor, created the full-size figure of Freedom in clay. Molds were made, from which a full-size positive plaster model was cast in five main sections. This model is on view today in the basement rotunda of the Russell Senate Office Building. Clark Mills was a self-taught American sculptor with experience in casting…

Assessment of the stress transmitted to dental implants connected to screw-retained bars using different casting techniques.

Science.gov (United States)

Haselhuhn, Klaus; Marotti, Juliana; Tortamano, Pedro; Weiss, Claudia; Suleiman, Lubna; Wolfart, Stefan

2014-12-01

Passive fit of the prosthetic superstructure is important to avoid complications; however, evaluation of passive fit is not possible using conventional procedures. Thus, the aim of this study was to check and locate mechanical stress in bar restorations fabricated using two casting techniques. Fifteen patients received four implants in the interforaminal region of the mandible, and a bar was fabricated using either the cast-on abutment or lost-wax casting technique. The fit accuracy was checked according to the Sheffield's test criteria. Measurements were recorded on the master model with a gap-free, passive fit using foil strain gauges both before and after tightening the prosthetic screws. Data acquisition and processing was analyzed with computer software and submitted to statistical analysis (ANOVA). The greatest axial distortion was at position 42 with the cast-on abutment technique, with a mean distortion of 450 μm/m. The lowest axial distortion occurred at position 44 with the lost-wax casting technique, with a mean distortion of 100 μm/m. The minimal differences between the means of axial distortion do not indicate any significant differences between the techniques (P = 0.2076). Analysis of the sensor axial distortion in relation to the implant position produced a significant difference (P casting techniques, with no significant difference between the sides.

Dominância coronariana em corações humanos em moldes por corrosão Coronary dominance patterns in the human heart investigated by corrosion casting

Directory of Open Access Journals (Sweden)

Décio Cavalet Soares Abuchaim

2009-12-01

Full Text Available OBJETIVO: Esse trabalho tem como objetivo analisar os padrões de dominância circulatória de corações humanos, o número de ramos que a artéria coronária direita fornece ao ventrículo esquerdo, o número de ramos que a artéria coronária esquerda fornece ao direito e a presença de anastomoses intercoronarianas, com sua localização e frequência. MÉTODOS: Foram produzidos 25 moldes de corações submetidos à instilação de acrílico colorido e posterior corrosão com ácido clorídrico, no Laboratório de Cirurgia Experimental da FURB. Peças com lesões e cicatrizes não foram usadas. RESULTADOS: Os corações pertenciam a indivíduos de ambos os sexos, sendo 17 (68% de indivíduos do sexo masculino, com idade média de 40,2 anos (15 a 70 anos. A dominância direita ocorreu em 18 (72% peças, com 1, 2, 3 e 4 ramos em 2, 14, 2 e 1 moldes, respectivamente; a dominância esquerda foi observada em 5 (20% casos, com 1 ramo em 4 moldes e 2 em 1 molde; e a dominância balanceada foi verificada em 2 (8% moldes. Houve diferença significativa entre a dominância direita e esquerda (α > 5%, direita e balanceada (α > 5% e sem significância entre esquerda e balanceada (α OBJECTIVES: The aim of this work was to analyze the dominance patterns of the circulation of the human heart, the number of branches from the right coronary artery to the left ventricle, the number of branches from the left coronary artery to the right ventricle and the frequency and location of intercoronary anastomoses. METHODS: Casts were made of 25 hearts by the injection of colored acrylic resin and subsequent corrosion using hydrochloric acid at the experimental surgery laboratory of Furb. Specimens with lesions or scars were discarded. RESULTS: The hearts, from both men (17 - 68% and women (8 - 32%, had a mean age of 40.2 (15 to 70 years-old. Right dominance occurred in 18 (72% subjects, with 1, 2, 3 and 4 branches leading to the left ventricle in 2, 14, 2 and 2

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

Science.gov (United States)

Migliaccio, Christopher P.; Lazarus, Nathan

2015-10-01

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

Stress and Friction Distribution around Slab Corner in Continuous Casting Mold with Different Corner Structures

Science.gov (United States)

Yu, Sheng; Long, Mujun; Chen, Huabiao; Chen, Dengfu; Liu, Tao; Duan, Huamei; Cao, Junsheng

2018-02-01

The non-uniform friction and thermal stress in the mold are important as causes of the transverse cracks around strand corner. To analyze the stress distribution features around strand corner, a three-dimensional thermo-elastoplastic finite-element mold model with different corner structures (right-angle, big-chamfer, multi-chamfer, and fillet) was established. The temperature field in the mold was indirectly coupled through a three-dimensional fluid flow and heat transfer model. In addition, the non-uniform mold friction stress loaded on the strand surface was calculated through a friction model. The results show that the stress distribution on the shell is similar to the temperature distribution. The stress concentration appears in the strand corner and the lower part of wide face. The friction stress enhances the corner stress around the edge of the air-gap. For chamfered molds, the stress around the corner between the wide face and chamfer face is larger than that between the narrow face and chamfer face. Around the corner region, both the stress peak and the area of the large stress zone of the right-angle strand are the largest, while those of big-chamfered, multi-chamfered, and fillet strands decrease in that order. The stress peak position of the chamfered strands is closer to the mold exit than that of the right-angle strand. Compared with the use of the right-angle mold, the application of chamfered molds is able to reduce the stress concentration around the strand corner.

Stress and Friction Distribution around Slab Corner in Continuous Casting Mold with Different Corner Structures

Science.gov (United States)

Yu, Sheng; Long, Mujun; Chen, Huabiao; Chen, Dengfu; Liu, Tao; Duan, Huamei; Cao, Junsheng

2018-06-01

The non-uniform friction and thermal stress in the mold are important as causes of the transverse cracks around strand corner. To analyze the stress distribution features around strand corner, a three-dimensional thermo-elastoplastic finite-element mold model with different corner structures (right-angle, big-chamfer, multi-chamfer, and fillet) was established. The temperature field in the mold was indirectly coupled through a three-dimensional fluid flow and heat transfer model. In addition, the non-uniform mold friction stress loaded on the strand surface was calculated through a friction model. The results show that the stress distribution on the shell is similar to the temperature distribution. The stress concentration appears in the strand corner and the lower part of wide face. The friction stress enhances the corner stress around the edge of the air-gap. For chamfered molds, the stress around the corner between the wide face and chamfer face is larger than that between the narrow face and chamfer face. Around the corner region, both the stress peak and the area of the large stress zone of the right-angle strand are the largest, while those of big-chamfered, multi-chamfered, and fillet strands decrease in that order. The stress peak position of the chamfered strands is closer to the mold exit than that of the right-angle strand. Compared with the use of the right-angle mold, the application of chamfered molds is able to reduce the stress concentration around the strand corner.

Traceability of Height Measurements on Green Sand Molds using Optical 3D Scanning

DEFF Research Database (Denmark)

Mohaghegh, Kamran; Yazdanbakhsh, S.A.; Tiedje, N. S.

2016-01-01

Establishing a reliable measurement procedure for dimensional measurements on green sand molds is a prerequisite for analysis of geometric deviations in mass production of quality castings. Surface of the green sand mold is not suitable for measurements using a tactile coordinate measuring machine....... This paper presents a metrological approach for height measurement on green sand molds using an optical 3D scanner with fringe projection. A new sand sample was developed with a hard binder to withstand the contact force of a touch probe, while keeping optical cooperativeness similar to green sand...

Engineering design of centrifugal casting machine

Science.gov (United States)

Kusnowo, Roni; Gunara, Sophiadi

2017-06-01

Centrifugal casting is a metal casting process in which metal liquid is poured into a rotating mold at a specific temperature. Given round will generate a centrifugal force that will affect the outcome of the casting. Casting method is suitable in the manufacture of the casting cylinder to obtain better results. This research was performed to design a prototype machine by using the concept of centrifugal casting. The design method was a step-by-step systematic approach in the process of thinking to achieve the desired goal of realizing the idea and build bridges between idea and the product. Design process was commenced by the conceptual design phase and followed by the embodiment design stage and detailed design stage. With an engineering design process based on the method developed by G. E. Dieter, draft prototype of centrifugal casting machine with dimension of 550×450×400 mm, ¼ HP motor power, pulley and belt mechanism, diameter of 120-150mm, simultaneously with the characteristics of simple casting product, easy manufacture and maintenance, and relatively inexpensive, was generated.

Castability of Ti-6Al-7Nb alloy for dental casting

OpenAIRE

Wang, Tie Jun; 小林, 郁夫; 土居, 壽; 米山, 隆之

1999-01-01

Castability of Ti-6Al-7Nb alloy, CP Ti, and Co-Cr alloy was examined for mesh type and plate type specimens. The casting was carried out with a pressure type casting machine and commercial molding material. The castability of the mesh type specimen was evaluated in terms of the number of cast segments (castability index), and that of the plate type was evaluated by the area of the speci­men (casting rate). X-ray images processed by a digital imaging technique were used to identify the casting...

Influence of reaction chamber shape on cast-iron spheroidization process in-mold

Directory of Open Access Journals (Sweden)

S. Pietrowski

2010-01-01

Full Text Available This paper presents a results concerning the influence of reaction chamber shape on cast – iron spheroidization process in form. The volume of the tested reaction chambers was about 118000mm3. Reaction chambers in the shape of: rectangular, cylinder and spherical cap were examined. It has been shown that the best graphite spheroidizing process was provided by spherical cap chamber shape. The reaction of cast – iron with magnesium in reaction chamber depends on the flow of cast – iron in the chamber. In rectangular and cylinder shape chambers proceed the impact of diphase stream on flat bottom wall. It causes the creation on its surface film, called: cast – iron “film”, where single grains of magnesium master alloy exist. The largest part of master alloy is drifted by liquid cast – iron to the top and only there graphite spheroidization process proceed. In the spherical cap shape reaction chamber, as a result of rotation movement of liquid cast – iron throughout its volume, graphite spheroidization process proceed. Apart from the reaction chamber shape, applying of mixing chamber ensure full cast – iron spheroidization process.

Improved Life of Die Casting Dies of H13 Steel by Attaining Improved Mechanical Properties and Distortion Control During Heat Treatment

Energy Technology Data Exchange (ETDEWEB)

J. F. Wallace; D. Schwam

1998-10-01

The ultimate goal of this project is to increase die casting die life by using fast enough quenching rates to obtain good toughness and fatigue resistance in premium grade H-13 steel dies. The main tasks of the project were to compile a database on physical and mechanical properties of H-13; conduct gas quenching experiments to determine cooling rates of dies in difference vacuum furnaces; measure the as-quenched distortion of dies and the residual stresses; generate finite element analysis models to predict cooling rates, distortion, and residual stress of gas quenched dies; and establish rules and create PC-based expert system for prediction of cooling rates, distortion, and residual stress in vacuum/gas quenched H-13 dies. Cooling curves during gas quenching of H-13 blocks and die shapes have been measured under a variety of gas pressure. Dimensional changes caused by the gas quenching processes have been determined by accurate mapping of all surfaces with coordinate measuring machines before and after the quench. Residual stresses were determined by the ASTM E837 hole-drilling strain gage method. To facilitate the computer modeling work, a comprehensive database of H-13 mechanical and physical properties has been compiled. Finite element analysis of the heat treated shapes has been conducted using the TRAST/ABAQUS codes. There is a good fit between the predicted and measured distortion contours. However, the magnitude of the predicted distortion and residual stresses does not match well the measured values. Further fine tuning of the model is required before it can be used to predict distortion and residual stress in a quantitative manner. This last step is a prerequisite to generating rules for a reliable expert system.

Structure Distribution in Precise Cast Iron Moulded on Meltable Model

Directory of Open Access Journals (Sweden)

Skrbek B.

2015-12-01

Full Text Available Topic of this work is to compare metalurgy of cast irons poured into sand moulds and into shell molds at IEG Jihlava company and from it following differencies in structures of thin- and thick-walled castings. This work is dealing with investigation and experimental measurement on surfaces and sections suitable thin- and thick-walled investment castings at IEG Jihlava. Cast irons with flake graphite (grey cast iron and cast irons with spheroidal graphite (ductile cast iron. Both mechanical and physical properties are determined using calculations from as measured values of wall thicknesses L and Lu, Vickers hardness and remanent magnetism. Measurement results are discussed, findings are formulated and methods for castings metallurgical quality improvement are recommended finally.

APPLICATION OF EXOTHERMIC PLUGS AT PRODUCTION OF STEEL CASTING IS THE WAY TO ECONOMY

Directory of Open Access Journals (Sweden)

V. M. Gatsuro

2008-01-01

Full Text Available It is shown that application of exothermic plugs allows to decrease steel intensity of casting mold, labor intensiveness for trim, expenses for melting of 1 ton of good casting, material expenses for burden materials.

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

Directory of Open Access Journals (Sweden)

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.

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

International Nuclear Information System (INIS)

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

2011-01-01

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

Low Cost Al-Si Casting Alloy As In-Situ Composite for High Temperature Applications

Science.gov (United States)

Lee, Jonathan A.

2000-01-01

A new aluminum-silicon (Al-Si) alloy has been successfully developed at NASA- Marshall Space Flight Center (MSFC) that has significant improvement in tensile and fatigue strength at elevated temperatures (500 F-700 F). The alloy offers a number of benefits such as light weight, high hardness, low thermal expansion and high surface wear resistance. In hypereutectic form, this alloy is considered as an in-situ Al-Si composite with tensile strength of about 90% higher than the auto industry 390 alloy at 600 F. This composite is very economically produced by using either conventional permanent steel molds or die casting. The projected material cost is less than $0.90 per pound, and automotive components such as pistons can be cast for high production rate using conventional casting techniques with a low and fully accounted cost. Key Words: Metal matrix composites, In-situ composite, aluminum-silicon alloy, hypereutectic alloy, permanent mold casting, die casting.

A 1-D Analytical Model for the Thermally Induced Stresses in the Mould Surface During Die Casting

DEFF Research Database (Denmark)

Hattel, Jesper; Hansen, Preben

1994-01-01

This paper presents an anlytically based method for predicting the normal stresses in a die mold surface exposed to a thermal load. A example of application of the method is the high-pressure di casting process where the surface stresses in critical cases lead to cracks. Expressions for the normal...... stresses as afunction of the thermal and mechanical properties have been developed for a casting both without and with a coating. Finally, the resulting relationships are derived and evaluated, with particular emphasis on the effect of the heat transfer coefficient between the casting and the mold....

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

Energy Technology Data Exchange (ETDEWEB)

Sabau, Adrian S [ORNL; Hatfield, Edward C [ORNL; Dinwiddie, Ralph Barton [ORNL; Kuwana, Kazunori [University of Kentucky; Viti, Valerio [University of Kentucky, Lexington; Hassan, Mohamed I [University of Kentucky, Lexington; Saito, Kozo [University of Kentucky

2007-09-01

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

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

Science.gov (United States)

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

2017-09-01

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

Methodology supporting production control in a foundry applying modern DISAMATIC molding line

Directory of Open Access Journals (Sweden)

Sika Robert

2017-01-01

Full Text Available The paper presents methodology of production control using statistical methods in foundry conditions, using the automatic DISAMATIC molding line. The authors were inspired by many years of experience in implementing IT tools for foundries. The authors noticed that there is a lack of basic IT tools dedicated to specific casting processes, that would greatly facilitate their oversight and thus improve the quality of manufactured products. More and more systems are installed in the ERP or CAx area, but they integrate processes only partially, mainly in the area of technology design and business management from finance and control. Monitoring of foundry processes can generate a large amount of process-related data. This is particularly noticeable in automated processes. An example is the modern DISAMATIC molding line, which integrates several casting processes, such as mold preparation, assembly, pouring or shake out. The authors proposed a methodology that supports the control of the above-mentioned foundry processes using statistical methods. Such an approach can be successfully used, for example, during periodic external audits. The mentioned methodology in the innovative DISAM-ProdC computer tool was implemented.

Development of casting technology and localization for a medical radioisotope transport cask

International Nuclear Information System (INIS)

Lee, Y. S.; Kim, H. S.; Jang, S. J.; Seo, K. S.; Kim, C. G.

2003-01-01

In order to localize the shielding casks for shipping medical isotopes, this research was carried out. The various casting factors such as the diameter of shielding casting, the temperature of melt and the temperature gradient of a mold were determined with the calculation results of solidification analysis computer code. Through the experiment, the manufacturing method of Ti core was developed to have no defects causing casting failure. As a results of casting experiment, depleted uranium shielding castings were successfully cast without any defect. Also as the results of the radiation shielding capability test, it was good enough to satisfied the standards of transport regulations

Rapid prototyping of biodegradable microneedle arrays by integrating CO2 laser processing and polymer molding

International Nuclear Information System (INIS)

Tu, K T; Chung, C K

2016-01-01

An integrated technology of CO 2 laser processing and polymer molding has been demonstrated for the rapid prototyping of biodegradable poly-lactic-co-glycolic acid (PLGA) microneedle arrays. Rapid and low-cost CO 2 laser processing was used for the fabrication of a high-aspect-ratio microneedle master mold instead of conventional time-consuming and expensive photolithography and etching processes. It is crucial to use flexible polydimethylsiloxane (PDMS) to detach PLGA. However, the direct CO 2 laser-ablated PDMS could generate poor surfaces with bulges, scorches, re-solidification and shrinkage. Here, we have combined the polymethyl methacrylate (PMMA) ablation and two-step PDMS casting process to form a PDMS female microneedle mold to eliminate the problem of direct ablation. A self-assembled monolayer polyethylene glycol was coated to prevent stiction between the two PDMS layers during the peeling-off step in the PDMS-to-PDMS replication. Then the PLGA microneedle array was successfully released by bending the second-cast PDMS mold with flexibility and hydrophobic property. The depth of the polymer microneedles can range from hundreds of micrometers to millimeters. It is linked to the PMMA pattern profile and can be adjusted by CO 2 laser power and scanning speed. The proposed integration process is maskless, simple and low-cost for rapid prototyping with a reusable mold. (paper)

Rapid prototyping of biodegradable microneedle arrays by integrating CO2 laser processing and polymer molding

Science.gov (United States)

Tu, K. T.; Chung, C. K.

2016-06-01

An integrated technology of CO2 laser processing and polymer molding has been demonstrated for the rapid prototyping of biodegradable poly-lactic-co-glycolic acid (PLGA) microneedle arrays. Rapid and low-cost CO2 laser processing was used for the fabrication of a high-aspect-ratio microneedle master mold instead of conventional time-consuming and expensive photolithography and etching processes. It is crucial to use flexible polydimethylsiloxane (PDMS) to detach PLGA. However, the direct CO2 laser-ablated PDMS could generate poor surfaces with bulges, scorches, re-solidification and shrinkage. Here, we have combined the polymethyl methacrylate (PMMA) ablation and two-step PDMS casting process to form a PDMS female microneedle mold to eliminate the problem of direct ablation. A self-assembled monolayer polyethylene glycol was coated to prevent stiction between the two PDMS layers during the peeling-off step in the PDMS-to-PDMS replication. Then the PLGA microneedle array was successfully released by bending the second-cast PDMS mold with flexibility and hydrophobic property. The depth of the polymer microneedles can range from hundreds of micrometers to millimeters. It is linked to the PMMA pattern profile and can be adjusted by CO2 laser power and scanning speed. The proposed integration process is maskless, simple and low-cost for rapid prototyping with a reusable mold.

A comparison between the dimensions of positive transtibial residual limb molds prepared by air pressure casting and weight-bearing casting methods.

Science.gov (United States)

Hajiaghaei, Behnam; Ebrahimi, Ismail; Kamyab, Mojtaba; Saeedi, Hassan; Jalali, Maryam

2016-01-01

Creating a socket with proper fit is an important factor to ensure the comfort and control of prosthetic devices. Several techniques are commonly used to cast transtibial stumps but their effect on stump shape deformation is not well understood. This study compares the dimensions, circumferences and volumes of the positive casts and also the socket comfort between two casting methods. Our hypothesis was that the casts prepared by air pressure method have less volume and are more comfortable than those prepared by weight bearing method. Fifteen transtibial unilateral amputees participated in the study. Two weight bearing and air pressure casting methods were utilized for their residual limbs. The diameters and circumferences of various areas of the residual limbs and positive casts were compared. The volumes of two types of casts were measured by a volumeter and compared. Visual Analogue Scale (VAS) was used to measure the sockets fit comfort. Circumferences at 10 and 15 cm below the patella on the casts were significantly smaller in air pressure casting method compared to the weight bearing method (p=0.00 and 0.01 respectively). The volume of the cast in air pressure method was lower than that of the weight bearing method (p=0.006). The amputees found the fit of the sockets prepared by air pressure method more comfortable than the weight bearing sockets (p=0.015). The air pressure casting reduced the circumferences of the distal portion of residual limbs which has more soft tissue and because of its snug fit it provided more comfort for amputees, according to the VAS measurements.

Clean Metal Casting

Energy Technology Data Exchange (ETDEWEB)

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.

Manufacture of tube billets for fuel cans by vacuum centrifugal casting

International Nuclear Information System (INIS)

Zelenskij, V.F.; Neklyudov, I.M.; Chernyj, B.P.

1989-01-01

Vacuum device for induction melting with centrifugal casting in the ingot mold with rotation vertical or horisontal axis is presented. Removing and grinding of nonmetallic inclusions are realized by selection of casting conditions and of chemically active reducer, sound metal with high ductility is obtained. Data on micro- and macrostructure of casted tube billets made of 08Kh18N10T and 06Kh16H15M3B stainless steels, designed for manufacture of fuel cans are presented

Influence of disinfection with peracetic acid and hypochlorite in dimensional alterations of casts obtained from addition silicone and polyether impressions.

Science.gov (United States)

Queiroz, Daher Antonio; Peçanha, Marcelo Massaroni; Neves, Ana Christina Claro; Frizzera, Fausto; Tonetto, Mateus Rodrigues; Silva-Concílio, Laís Regiane

2013-11-01

Dental impressions disinfection is important to reduce the risk of cross contamination but this process may produce dimensional distortions. Peracetic acid is a disinfectant agent with several favorable characteristics yet underutilized in Dentistry. The aim of this paper is to compare the dimensional stability of casts obtained from addition silicone and polyether impressions that were immersed for 10 minutes in a solution of 0.2% peracetic acid or 1% sodium hypochlorite. Sixty samples in type IV gypsum were produced after a master cast that simulated a full crown preparation of a maxillary premolar. Samples were divided in 6 groups (n = 10) according to the impression material and disinfection agent: Group AC--addition silicone control (without disinfectant); Group APA--addition silicone + 0.2% peracetic acid; Group AH--addition silicone + 1% sodium hypochlorite; Group PC--polyether control (without disinfectant); Group PPA--polyether + 0.2% peracetic acid; Group PH--polyether + 1% sodium hypochlorite. Cast height, base and top diameter were measured and a mean value was obtained for each sample and group all data was statistically analyzed (ANOVA, p polyether impressions regardless of the disinfectant materials. It can be concluded that disinfection with the proposed agents did not produce significant alterations of the impressions and the peracetic acid could be considered a reliable material to disinfect dental molds.

Casting of Hearth Plates from High-chromium Steel

Directory of Open Access Journals (Sweden)

Drotlew A.

2014-12-01

Full Text Available The paper presents the results of studies on the development of manufacturing technologies to cast hearth plates operating in chamber furnaces for heat treatment. Castings made from the heat-resistant G-X40CrNiSi27-4 steel were poured in hand-made green sand molds. The following operations were performed: computer simulation to predict the distribution of internal defects in castings produced by the above mentioned technology with risers bare and coated with exothermic and insulating sleeves, analysis of each variant of the technology, and manufacture of experimental castings. As a result of the conducted studies and analysis it was found that the use of risers with exothermic sleeves does not affect to a significant degree the quality of the produced castings of hearth plates, but it significantly improves the metal yield.

Quantification of Feeding Effects of Spot Feeding Ductile Iron Castings made in Vertically Parted Moulds

DEFF Research Database (Denmark)

Vedel-Smith, Nikolaj Kjelgaard; Tiedje, Niels Skat; Sällström, J.

In vertically parted molds it is traditionally difficult to feed heavy sections that cannot be reached by traditional side/top feeders or other conventional methods. This project aims at quantifying the effects of using molded-in ram-up spot feeders as a means of feeding isolated sections in cast...

Application of metal oxide refractories for melting and casting reactive metals

International Nuclear Information System (INIS)

Jessen, N.C. Jr.; Holcombe, C.E. Jr.; Townsend, A.B.

1979-01-01

Extensive investigations have been conducted to develop metal oxide refractories for containment of molten uranium and uranium alloys. Since uranium and uranium alloys are readily susceptable to the formation of complex oxides, carbides, nitrides, intermetallic compounds, and suboxide reactions, severe problems exist for the production of quality castings. These contamination reactions are dependent on temperature, pressure, and molten metal interfacial reactions. The need for high purity metals to meet specification repeatedly has resulted in the development of improved metal oxide refractories and sophisticated furnace controls. Applications of Y 2 O 3 for use as a crucible and mold coating, precision molds and cores, and high temperature castable ceramics are discussed. Experimental results on melt impurity levels, thermal controls during melting, surface interactions and casting quality are presented

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

Energy Technology Data Exchange (ETDEWEB)

Dr. Von L. Richards

2011-09-30

This project addresses improvements in metal casting processes by reducing scrap and reducing the cost of production, due to scrap reduction from investment casting and yield improvement offered by lost foam casting as compared to no-bake or green sand molding. The objectives for the investment casting portion of the subtask are to improve knowledge of fracture toughness of mold shells and the sources of strength limiting flaws and to understand the effects of wax reclamation procedures on wax properties. Applying 'clean steel' approaches to pouring technology and cleanliness in investment casting of steel are anticipated to improve incoming materials inspection procedures as they affect the microstructure and toughness of the shell. This project focused on two areas of study in the production of steel castings to reduce scrap and save energy: (1) Reducing the amount of shell cracking in investment cast steel production; (2) Investigate the potential of lost foam steel casting The basic findings regarding investment casting shell cracking were: (1) In the case of post pouring cracking, this could be related to phase changes in silica upon cooling and could be delayed by pouring arrangement strategies that maintained the shell surface at temperature for longer time. Employing this delay resulted in less adherent oxidation of castings since the casting was cooler at the time o fair exposure. (2) A model for heat transfer through water saturated shell materials under steam pressure was developed. (3) Initial modeling result of autoclave de-waxing indicated the higher pressure and temperature in the autoclave would impose a steeper temperature gradient on the wax pattern, causing some melt flow prior to bulk expansion and decreasing the stress on the green shell. Basic findings regarding lost foam casting of steel at atmospheric pressure: (1) EPS foam generally decomposes by the collapse mode in steel casting. (2) There is an accumulation of carbon pick-up at

Design optimization of clutch housing mold by fluid flow and solidification simulation

Energy Technology Data Exchange (ETDEWEB)

Hosseini, Seyedeh Maryam; Utlu, Zafer [Istanbul Aydin Univ., Istanbul (Turkmenistan)

2016-06-15

Aluminum die casting is so complex where flow momentum is critical matter in the mould filling process due the high velocity of the liquid metal. Actually, in complex parts the exact calculation of mould filling performance with using experimental knowledge is almost impossible. Aluminum die castings play a definitive role in the manufacturing of lightweight automobile bodies. Hence it is more essential today that these castings be produced with the high quality methods. In this condition the simulation is becoming more important in the designing procedure. This saves time and reduces the cost of the casting system design, which is an advantage of using simulation programs. Also, economical utilization of materials can be obtained when the quantity of test castings is decreased. This paper describes the advantages of the clutch housing die casting mold simulations to achieve better casting system design in High pressure die castings (HPDC). Filling analysis is used to determine the size and location of the gate as well as proper runner system design for ensuring a complete and balanced filling of the clutch housing part.

Study on hardness and microstructural characteristics of sand cast ...

Indian Academy of Sciences (India)

Administrator

casting in green sand molds at 690°C. The solution treatment has been performed at 500°C for 7 h and then ... that specimens were water quenched to obtain super satu- ... structure and (b) distribution of silicon platelets (grey) and fine.

Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast

Directory of Open Access Journals (Sweden)

Gaspar S.

2016-06-01

Full Text Available Recent research in the process of aluminum alloy die castings production, which is nowadays deeply implemented into the rapidly growing automobile, shipping and aircraft industries, is aimed at increasing the useful qualitative properties of the die casting in order to obtain its high mechanical properties at acceptable economic cost. Problem of technological factors of high pressure die casting has been a subject of worldwide research (EU, US, Japan, etc.. The final performance properties of die castings are subjected to a large number of technological factors. The main technological factors of high pressure die casting are as follows: plunger pressing speed, specific (increase pressure, mold temperature as well as alloy temperature. The contribution discusses the impact of the plunger pressing speed and specific (increase pressure on the mechanical properties of the casting aluminum alloy.

Precision casting of Ti-15V-3Cr-3Al-3Sn alloy setting

OpenAIRE

Nan Hai; Liu Changkui; Huang Dong

2008-01-01

In this research, Ti-15V-3Cr-3Al-3Sn alloy ingots were prepared using ceramic mold and centrifugal casting. The Ti-15V-3Cr-3Al-3Sn setting casting, for aeronautic engine, with 1.5 mm in thickness was manufactured. The alloy melting process, precision casting process, and problems in casting application were discussed. Effects of Hot Isostatic Pressing and heat treatment on the mechanical properties and microstructure of the Ti-15V-3Cr-3Al-3Sn alloy were studied.

Filler metal alloy for welding cast nickel aluminide alloys

Science.gov (United States)

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

1998-03-10

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

Molding and casting process of a depleted uranium shield for a multipurpose type B (U) transport package of radioactive substances

International Nuclear Information System (INIS)

Raffaeli, Hector A.; Acosta, Mario; Ilarri, Sergio; Alonso, Paula R.; Gargano, Pablo H.; Rubiolo, Gerardo H.

2009-01-01

Anticipating future demand for transport of radioisotopes, a high performance transport package (BU-MAN) with a gamma barrier built in depleted uranium (DU) has been designed by the Radioisotope and Radiation Program (P4) of CNEA in 2003. The shield is a hollow cylinder of approximately 173 mm outside diameter, 223 mm in height, a cylindrical hollow interior 63 mm diameter and 166 mm in height, and a cylindrical plug 58 mm diameter and 57 mm height. Its total weight is 84 Kg. In the period 2004-2006 the Special Alloys Group (DM-GIDAT-GAEN-CNEA) has conducted several developments in order to obtain the mentioned shield, including a manufacturing test casting SAE 1010 in a sand mold. The confirmation of its properties, mechanical and gamma shield are being evaluated by licensing tests of the whole package. In this paper we show all metallurgical processes involved to get the shield in metallic DU. (author)

Effects of microstructures on low cycle fatigue behavior in Al-Si-Mg cast alloys

International Nuclear Information System (INIS)

Han, Sang Won; Kim, Sug Won

2002-01-01

Low cycle fatigue tests were carried out using four kinds of Al-7%Si-0.4Mg cast alloys, i.e., two kinds of sand mold casts, permanent mold cast and semi-solid die cast. They were heat-treated in the condition of under aging and over aging to investigate effects of precipitates on fatigue. All tests were conducted under axial plastic strain amplitude control. Stress level of cyclic hardening curves increased sensitively with needle like eutectic Si particle, refine grain size and dendrite arm spacing (DAS). In particular, the refined grain structure of under aged matrix was more effective encourager for cyclic hardening compared with DAS and eutectic Si particle size. After rapid increase in cyclic hardening during several number of cycles, the stress amplitude kept increasing steadily until fracture in under aged alloys strengthened by shearable G.P. zone. On the other hand, over aged alloys strengthened by non-shearable β ' precipitates generated more drastic initial hardening and the stress amplitude reached the saturation state in quite early stage of the fatigue

Effect of technological parameters on formability of semi-solid rheological casting-forging 6061 alloy

Directory of Open Access Journals (Sweden)

Jianbo TAN

2016-02-01

Full Text Available The 6061 alloy cooling curve is determined by analysis software, and the 6061 semi-solid alloy is prepared by manual paddling process. The primary solid fraction is tested through prepared water quenched samples under different temperature. With H1F100 type servo press and cup type test mold, the forming of the 6061 semi-solid alloy rheological casting-forging is made. The influence of alloy temperature, forming pressure, upper mould temperature and holding time on the formability of 6061 alloy is researched. The results show that within the same set of mold completing casting and forging of the alloy is feasible. Along with the increase of the alloy temperature and the upper mould temperature, the formability of finished products becomes better. Under this experimentation, when the temperature of the semi-solid alloy is amongst 642 ℃ to 645 ℃ and the upper mould preheating temperature is amongst 200 ℃ to 300 ℃, casting defects such as cold insulation will form in the casting-forging sample of semi-solid 6061 alloy with the prolongation of holding time.

Clean Metal Casting; FINAL

International Nuclear Information System (INIS)

Makhlouf M. Makhlouf; Diran Apelian

2002-01-01

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

Fabrication of Hierarchically Micro- and Nano-structured Mold Surfaces Using Laser Ablation for Mass Production of Superhydrophobic Surfaces

Science.gov (United States)

Noh, Jiwhan; Lee, Jae-Hoon; Na, Suckjoo; Lim, Hyuneui; Jung, Dae-Hwan

2010-10-01

Many studies have examined the formation of surfaces with mixed patterns of micro- and nano-sized lotus leaves that have hydrophobic properties. In this study, micro- and nano-shapes such as lotus leaves were fabricated on a metal mold surface using laser ablation and ripple formation. A microstructure on the mold surface was replicated onto poly(dimethylsiloxane) (PDMS) using the polymer casting method to manufacture low-cost hydrophobic surfaces. A PDMS surface with micro- and nano-structures that were the inverse image of a lotus leaf showed hydrophobic characteristics (water contact angle: 157°). From these results, we deduced that portions of the microstructures were wet and that air gaps existed between the microstructures and the water drops. In this paper we suggest the possibility of the mass production of hydrophobic plastic surfaces and the development of a methodology for the hydrophobic texturing of various polymer surfaces, using the polymer casting method with laser-processed molds.

Influence of gating design on microstructure and fluidity of thin sections AA320.0 cast hypo-eutectic Al-Si alloy

Science.gov (United States)

Ramadan, Mohamed

2018-05-01

Influence of gating design especially number of ingrates on microstructure and fluidity of thin sections of 2, 4, 6 mm AA320.0 cast hypo-eutectic Al-Si alloy was evaluated for sand casting molding technique. Increasing the number of ingates improves the microstructe to be fine and more globular. About 87 μm of α-Al grain size, 0.6 α-Al grain sphericity and 37 μm dendrite arm spacing DAS are achieved by using 4 ingates in gating system. Increasing the number of ingates up to 3 increases hardness, filling area and related fluditiy of all cast samples. The minimum thickness of 2.5 mm for each ingate should be considered in order to successfully production of high quality light weight thin sections castings in sand mold.

Intelligent Machine Vision Based Modeling and Positioning System in Sand Casting Process

Directory of Open Access Journals (Sweden)

Shahid Ikramullah Butt

2017-01-01

Full Text Available Advanced vision solutions enable manufacturers in the technology sector to reconcile both competitive and regulatory concerns and address the need for immaculate fault detection and quality assurance. The modern manufacturing has completely shifted from the manual inspections to the machine assisted vision inspection methodology. Furthermore, the research outcomes in industrial automation have revolutionized the whole product development strategy. The purpose of this research paper is to introduce a new scheme of automation in the sand casting process by means of machine vision based technology for mold positioning. Automation has been achieved by developing a novel system in which casting molds of different sizes, having different pouring cup location and radius, position themselves in front of the induction furnace such that the center of pouring cup comes directly beneath the pouring point of furnace. The coordinates of the center of pouring cup are found by using computer vision algorithms. The output is then transferred to a microcontroller which controls the alignment mechanism on which the mold is placed at the optimum location.

INFLUENCE OF DIVIDING COVERINGS ON QUALITY OF CASTINGS AT MOLDING OF ALUMINUM ALLOYS UNDER PRESSURE

Directory of Open Access Journals (Sweden)

A. A. Pivovarchik

2014-01-01

Full Text Available The results of researches on influence of separating coverings on such properties of castings as corrosion resistance, roughness of cast surface, casting density are given in article.

Transferencia de calor en la colada continua de aceros. I parte. El molde

Directory of Open Access Journals (Sweden)

Cicutti, C.

1997-10-01

Full Text Available The continuous casting mold plays the important role of receiving the liquid steel and allowing an uniform and defect free solidified skin to be developed. In this work, the different heat transfer mechanisms which are present from the liquid steel to the mold cooling water are reviewed. The effect of operating variables on heat extraction and the relationship between global and distributed heat flux are also analyzed.

El molde de colada continua cumple la importante función de recibir el acero líquido y permitir que se desarrolle una capa solidificada uniforme y libre de defectos. En este trabajo se revisan los distintos mecanismos implicados en el proceso de transferencia de calor, desde el acero líquido hasta el agua de refrigeración del molde. Se analiza también el efecto de las distintas variables de funcionamiento en la extracción calórica producida y la relación entre el flujo global de calor y su distribución a lo largo del molde.

Manufacture of mold of polymeric composite water pipe reinforced charcoal

Science.gov (United States)

Zulfikar; Misdawati; Idris, M.; Nasution, F. K.; Harahap, U. N.; Simanjuntak, R. K.; Jufrizal; Pranoto, S.

2018-03-01

In general, household wastewater pipelines currently use thermoplastic pipes of Polyvinyl Chloride (PVC). This material is known to be not high heat resistant, contains hazardous chemicals (toxins), relatively inhospitable, and relatively more expensive. Therefore, researchers make innovations utilizing natural materials in the form of wood charcoal as the basic material of making the water pipe. Making this pipe requires a simple mold design that can be worked in the scale of household and intermediate industries. This research aims to produce water pipe mold with simple design, easy to do, and making time relatively short. Some considerations for molding materials are weight of mold, ease of raw material, strong, sturdy, and able to cast. Pipe molds are grouped into 4 (four) main parts, including: outer diameter pipe molding, pipe inside diameter, pipe holder, and pipe alignment control. Some materials have been tested as raw materials for outer diameter of pipes, such as wood, iron / steel, cement, and thermoset. The best results are obtained on thermoset material, where the process of disassembling is easier and the resulting mold weight is relatively lighter. For the inside diameter of the pipe is used stainless steel, because in addition to be resistant to chemical processes that occur, in this part of the mold must hold the press load due to shrinkage of raw materials of the pipe during the process of hardening (polymerization). Therefore, it needs high pressure resistant material and does not blend with the raw material of the pipe. The base of the mold is made of stainless steel material because it must be resistant to corrosion due to chemical processes. As for the adjustment of the pipe is made of ST 37 carbon steel, because its function is only as a regulator of the alignment of the pipe structure.

Fluid flow and heat transfer modeling for castings

International Nuclear Information System (INIS)

Domanus, H.M.; Liu, Y.Y.; Sha, W.T.

1986-01-01

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

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool

Directory of Open Access Journals (Sweden)

Jose Mario Paiva

2018-02-01

Full Text Available In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,AlN deposited by physical vapor deposition (PVD have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC and one central rotating cathode (CERC. The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES, scanning electron microscopy (SEM, and X-ray diffraction (XRD, respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si3N4 nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

Tribological and Wear Performance of Nanocomposite PVD Hard Coatings Deposited on Aluminum Die Casting Tool.

Science.gov (United States)

Paiva, Jose Mario; Fox-Rabinovich, German; Locks Junior, Edinei; Stolf, Pietro; Seid Ahmed, Yassmin; Matos Martins, Marcelo; Bork, Carlos; Veldhuis, Stephen

2018-02-28

In the aluminum die casting process, erosion, corrosion, soldering, and die sticking have a significant influence on tool life and product quality. A number of coatings such as TiN, CrN, and (Cr,Al)N deposited by physical vapor deposition (PVD) have been employed to act as protective coatings due to their high hardness and chemical stability. In this study, the wear performance of two nanocomposite AlTiN and AlCrN coatings with different structures were evaluated. These coatings were deposited on aluminum die casting mold tool substrates (AISI H13 hot work steel) by PVD using pulsed cathodic arc evaporation, equipped with three lateral arc-rotating cathodes (LARC) and one central rotating cathode (CERC). The research was performed in two stages: in the first stage, the outlined coatings were characterized regarding their chemical composition, morphology, and structure using glow discharge optical emission spectroscopy (GDOES), scanning electron microscopy (SEM), and X-ray diffraction (XRD), respectively. Surface morphology and mechanical properties were evaluated by atomic force microscopy (AFM) and nanoindentation. The coating adhesion was studied using Mersedes test and scratch testing. During the second stage, industrial tests were carried out for coated die casting molds. In parallel, tribological tests were also performed in order to determine if a correlation between laboratory and industrial tests can be drawn. All of the results were compared with a benchmark monolayer AlCrN coating. The data obtained show that the best performance was achieved for the AlCrN/Si₃N₄ nanocomposite coating that displays an optimum combination of hardness, adhesion, soldering behavior, oxidation resistance, and stress state. These characteristics are essential for improving the die mold service life. Therefore, this coating emerges as a novelty to be used to protect aluminum die casting molds.

Effect of Y additions on the solidification behavior of a copper mold cast CuZrAl alloy with high oxygen content

International Nuclear Information System (INIS)

Coury, F.G.; Batalha, W.; Botta, W.J.; Bolfarini, C.; Kiminami, C.S.

2014-01-01

Bulk glassy samples of the CuAlZr system were produced by copper mold casting in the form of wedges with different amounts of yttrium (0 , 0.3 and 2 at%) , the processing conditions led to high oxygen contents on the samples (1000ppm). A reportedly good glass-former composition was chosen as the base alloy, it’s nominal composition is Cu47Zr45Al8. This study aimed to understand the influence of oxygen and yttrium in the solidification of these alloys. The samples were analyzed by scanning and transmission electron microscopy, differential scanning calorimetry and X-Ray diffraction. The sequence of formation of crystalline phases in these alloys was determined as a function of the different cooling rates inherent in the process. It was observed that the formation of CuZr2 phase was inhibited in samples with Y allowing the production of a fully glassy 8mm. (author)

Comparison in processing routes by copper mold casting injection and suction in the Cu46Zr42Al7Y5 vitreous alloy

International Nuclear Information System (INIS)

Batalha, W.; Aliaga, L.C.R.; Bolfarini, C.; Botta, W.J.; Kiminami, C.S.

2014-01-01

To expand the application of glassy metals, the development of processing routes and compositions that allow the production of parts with dimensions of millimeters or even centimeters, is very important. The present work aims the contribution to the technological development of processing routes for the production of Cu-based bulk metallic glasses. Wedge-shaped samples of Cu 46 Zr 42 Al 7 Y 5 (atom percent) chemical composition were processed using copper mold casting by suction and injection. Characterization was made combining scanning electron microscopy, x-ray diffraction and differential scanning calorimetry. The critical amorphous thickness obtained by those two different routes was carefully observed. The suction route allow obtaining the best results with critical amorphous thickness about 8 mm. This result was analyzed considering the different extrinsic parameters to the glass forming ability of the alloy. (author)

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

Science.gov (United States)

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

2018-01-01

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

Elimination or Minimization of Oscillation Marks: A Path To Improved Cast Surface Quality

Energy Technology Data Exchange (ETDEWEB)

Dr. Alan W. Cramb

2007-12-17

Oscillation marks are the most recognizable feature of continuous casting and can be related to the subsurface defects that can be found on product rolled from continuous cast slabs. The purpose of this work was to develop strategies that can be used on industrial continuous casters to reduce oscillation mark depth and, in particular, to minimize the formation of hook type defects that are prevalent on ultra low carbon grades. The major focus of the work was on developing a technique to allow heat transfer in the meniscus region of the continuous caster to be measured and the effect of mold slag chemistry and chrystallization to be documented. A new experimental technique was developed that allowed the effect of mold flux chemistry and chrystallization on the radiation heat transfer rate to be measured dynamically.

Using a micro-molding process to fabricate polymeric wavelength filters

Science.gov (United States)

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

2008-08-01

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

Casting Characteristics of High Cerium Content Aluminum Alloys

Energy Technology Data Exchange (ETDEWEB)

Weiss, D; Rios, O R; Sims, Z C; McCall, S K; Ott, R T

2017-09-05

This paper compares the castability of the near eutectic aluminum-cerium alloy system to the aluminum-silicon and aluminum-copper systems. The alloys are compared based on die filling capability, feeding characteristics and tendency to hot tear in both sand cast and permanent mold applications. The castability ranking of the binary Al–Ce systems is as good as the aluminum-silicon system with some deterioration as additional alloying elements are added. In alloy systems that use cerium in combination with common aluminum alloying elements such as silicon, magnesium and/or copper, the casting characteristics are generally better than the aluminum-copper system. In general, production systems for melting, de-gassing and other processing of aluminum-silicon or aluminum-copper alloys can be used without modification for conventional casting of aluminum-cerium alloys.

Thermal distortion of disc-shaped ductile iron castings in vertically parted moulds

DEFF Research Database (Denmark)

Vedel-Smith, Nikolaj Kjelgaard; Rasmussen, Jakob; Tiedje, Niels Skat

2015-01-01

A disc-shaped casting with an inner boss and an outer rim, separated by a thin walled section, was examined. This measurable deformation varied with the feeding modulus. The influence of alloy composition, particularly Si content, was examined with a pearlitic ductile iron (EN-GJS-500-7) and a fu......A disc-shaped casting with an inner boss and an outer rim, separated by a thin walled section, was examined. This measurable deformation varied with the feeding modulus. The influence of alloy composition, particularly Si content, was examined with a pearlitic ductile iron (EN-GJS-500......-7) and a fully ferritic ductile iron (EN-GJS-450-10). The experiment showed that both the alloy composition and choice of feeder influenced the degreeof deformation measured in the finished casting. It was found that the deformation of the pearlitic alloy was influenced controllably by changing the feeder...

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

International Nuclear Information System (INIS)

Robertson, E.

1993-09-01

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

Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Clean Steel Casting Production

Energy Technology Data Exchange (ETDEWEB)

Kuyucak, Selcuk [CanmetMATERIALS; Li, Delin [CanmetMATERIALS

2013-12-31

Inclusions in steel castings can cause rework, scrap, poor machining, and reduced casting performance, which can obviously result in excess energy consumption. Significant progress in understanding inclusion source, formation and control has been made. Inclusions can be defined as non-metallic materials such as refractory, sand, slag, or coatings, embedded in a metallic matrix. This research project has focused on the mold filling aspects to examine the effects of pouring methods and gating designs on the steel casting cleanliness through water modeling, computer modeling, and melting/casting experiments. Early in the research project, comprehensive studies of bottom-pouring water modeling and low-alloy steel casting experiments were completed. The extent of air entrainment in bottom-poured large castings was demonstrated by water modeling. Current gating systems are designed to prevent air aspiration. However, air entrainment is equally harmful and no prevention measures are in current practice. In this study, new basin designs included a basin dam, submerged nozzle, and nozzle extension. The entrained air and inclusions from the gating system were significantly reduced using the new basin method. Near the end of the project, there has been close collaboration with Wescast Industries Inc., a company manufacturing automotive exhaust components. Both computer modeling using Magma software and melting/casting experiments on thin wall turbo-housing stainless steel castings were completed in this short period of time. Six gating designs were created, including the current gating on the pattern, non-pressurized, partially pressurized, naturally pressurized, naturally pressurized without filter, and radial choke gating without filter, for Magma modeling. The melt filling velocity and temperature were determined from the modeling. Based on the simulation results, three gating designs were chosen for further melting and casting experiments on the same casting pattern using

Effect of reinforcement amount, mold temperature, superheat, and mold thickness on fluidity of in-situ Al-Mg2Si composites

Directory of Open Access Journals (Sweden)

Reza Vatankhah Barenji

2018-01-01

Full Text Available In the present study, the effects of mold temperature, superheat, mold thickness, and Mg2Si amount on the fluidity of the Al-Mg2Si as-cast in-situ composites were investigated using the mathematical models. Composites with different amounts of Mg2Si were fabricated, and the fluidity and microstructure of each were then analyzed. For this purpose, the experiments were designed using a central composite rotatable design, and the relationship between parameters and fluidity were developed using the response surface method. In addition, optical and scanning electron microscopes were used for microstructural observation. The ANOVA shows that the mathematical models can predict the fluidity accurately. The results show that by increasing the mold temperature from 25 °C to 200 °C, superheat from 50 °C to 250 °C, and thickness from 3 mm to 12 mm, the fluidity of the composites decreases, where the mold thickness is more effective than other factors. In addition, the higher amounts of Mg2Si in the range from 15wt.% to 25wt.% lead to the lower fluidity of the composites. For example, when the mold temperature, superheat, and thickness are respectively 100 °C, 150 °C, and 7 mm, the fluidity length is changed in the range of 11.9 cm to 15.3 cm. By increasing the amount of Mg2Si, the morphology of the primary Mg2Si becomes irregular and the size of primary Mg2Si is increased. Moreover, the change of solidification mode from skin to pasty mode is the most noticeable microstructural effect on the fluidity.

Microstructural evolution and mechanical properties of as-cast and T6-treated AA2195 DC cast alloy

International Nuclear Information System (INIS)

Hekmat-Ardakan, A.; Elgallad, E.M.; Ajersch, F.; Chen, X.-G.

2012-01-01

The use of direct chill (DC) cast ingot plates of AA2195 alloys has been recently extended for large mold applications in the plastics and automotive industries. The microstructural evolution of the as-cast AA2195 alloy was investigated using the Factsage thermodynamic software under both equilibrium and non-equilibrium conditions, and was compared with the results from differential scanning calorimetry (DSC) analysis and microstructural observations. The as-cast microstructure exhibited the presence of Al 2 CuMg, Al 2 Cu and Al 2 CuLi intermetallic phases formed at the aluminum dendrite boundaries, which can be completely dissolved in the α-Al matrix during the solution treatment. A significant improvement in the mechanical properties of the AA2195 cast alloy after the T6 heat treatment is attributed to the formation of nano-scale θ′ (Al 2 Cu) and T1 (Al 2 CuLi) precipitates. However, the non-uniform distribution of T1 precipitates together with the large size and low density indicate that the role of θ′ precipitates in strengthening the AA2195 cast alloy is more dominant than that of the T1 precipitates, in contrast with the strengthening mechanism of the pre-deformed AA2195-T8 rolled products.

Numerical and Experimental Analysis on the Cavity Formation and Shrinkage for Investment Cast Alloy 738 4 mm-Thick Rectangular Tube

International Nuclear Information System (INIS)

Park, Myeong-Il; Choi, Yoon Suk; Yoo, Jae-Hyun; Park, Sang-Hu; Kim, Kyeong-Min; Lee, Yeong-Chul; Lee, Jung-Seok; Lee, Jae-Hyun

2017-01-01

Investment casting for the thin (4 mm thick) rectangular tube (40 mm wide, 80 mm high and 200 mm long) was carried out numerically and experimentally for Alloy 738, which is a precipitation-hardened Ni-base superalloy. Two types of rectangular tubes, one with a regular array (10 mm by 10 mm square array) of protruded rods (3 mm in diameter and 3mm in height) embedded on the outer surface and the other with just smooth surface, were investment-cast at the same time through the side feeding mold design. The investment casting simulation predicted the presence of cavities, particularly in the area away from the gate for both types of rectangular tubes. In particular, for the rectangular tube with embedded protruded rods cavities were found mainly in the areas between the protruded rods. This simulation result was qualitatively consistent with the experimental observation from the X-ray analysis. Also, both prediction and experiment showed that the dimensional shrinkage (particularly in the longitudinal direction) of the investment-cast rectangular tube is reduced by having protruded rods embedded on the outer surface. Additional numerical attempts were made to check how the amount of cavities and dimensional shrinkage change by varying the preheating temperature and the thickness of the mold. The results predicted that the amount of cavities and the dimensional shrinkage are significantly reduced by increasing the preheating temperature of the mold by 200 ℃. However, an increase in mold thickness from 10 mm to 12 mm showed almost no difference in cavity population and a slight decrease in dimensional shrinkage.

Numerical and Experimental Analysis on the Cavity Formation and Shrinkage for Investment Cast Alloy 738 4 mm-Thick Rectangular Tube

Energy Technology Data Exchange (ETDEWEB)

Park, Myeong-Il; Choi, Yoon Suk; Yoo, Jae-Hyun; Park, Sang-Hu [Pusan National University, Busan (Korea, Republic of); Kim, Kyeong-Min; Lee, Yeong-Chul [Sung Il Turbine Co., Ltd., Busan (Korea, Republic of); Lee, Jung-Seok; Lee, Jae-Hyun [Changwon National University, Changwon (Korea, Republic of)

2017-02-15

Investment casting for the thin (4 mm thick) rectangular tube (40 mm wide, 80 mm high and 200 mm long) was carried out numerically and experimentally for Alloy 738, which is a precipitation-hardened Ni-base superalloy. Two types of rectangular tubes, one with a regular array (10 mm by 10 mm square array) of protruded rods (3 mm in diameter and 3mm in height) embedded on the outer surface and the other with just smooth surface, were investment-cast at the same time through the side feeding mold design. The investment casting simulation predicted the presence of cavities, particularly in the area away from the gate for both types of rectangular tubes. In particular, for the rectangular tube with embedded protruded rods cavities were found mainly in the areas between the protruded rods. This simulation result was qualitatively consistent with the experimental observation from the X-ray analysis. Also, both prediction and experiment showed that the dimensional shrinkage (particularly in the longitudinal direction) of the investment-cast rectangular tube is reduced by having protruded rods embedded on the outer surface. Additional numerical attempts were made to check how the amount of cavities and dimensional shrinkage change by varying the preheating temperature and the thickness of the mold. The results predicted that the amount of cavities and the dimensional shrinkage are significantly reduced by increasing the preheating temperature of the mold by 200 ℃. However, an increase in mold thickness from 10 mm to 12 mm showed almost no difference in cavity population and a slight decrease in dimensional shrinkage.

APPLICATION OF POLYSTYRENE FOAM CORE FUSIBLE PATTERNS IN PRODUCTION OF GAS TURBINES’ CAST PARTS

Directory of Open Access Journals (Sweden)

O. I. Shinsky

2016-01-01

Full Text Available The task of replacing the LVM dissolves polystyrene molding on models is at the present time, technologically, economically and environmentally promising from the point of view of industrial applications for gas turbine plants in Ukraine. The authors proposed and tested manufacturing process of casting ceramic molds way to remove the polystyrene model of the dissolution of her organic solvents. Kinetic parameters of the process of dissolving and removing patterns of degradation products the polystyrene in the group of solvents depending on the type and amount of polystyrene were identified. The absence of surface defects of castings, reduction of roughness, increased their accuracy class in comparison to accepted technological regulations of the process of production, which reduced the cost of machined parts and increased utilization of expensive heat-resistant alloys were produced.

Fabrication of Ti-0.48Al Alloy by Centrifugal Casting.

Science.gov (United States)

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

2018-09-01

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

Preliminary study on tensile properties and fractography of the recycled aluminum cast product

International Nuclear Information System (INIS)

Hishamuddin Hussain; Mohd Harun; Hafizal Yazid; Shaiful Rizam Shamsudin; Zaiton Selamat; Mohd Shariff Sattar

2004-01-01

Among many mechanical properties of materials, tensile properties are probably the most frequently considered, evaluated, and referred by the industry. This paper presents the result of preliminary study regarding the tensile properties and fractography of the recycled aluminum cast product. For this purpose, three sets of specimen were prepared for tensile testing by using permanent mold casting technique. The cast products are in durable shaped tensile specimens with the gauge length of 50mm. The tensile testing was conducted in accordance with BS EN 10002-1 and ISO 6892 standards. Fracture surface analysis was also conducted to understand materials behaviour. (Author)

Fabricación de piezas de fundición con grafito esferoidal en molde metálico

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Urrestarazu, A.

2013-10-01

Full Text Available 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.En este trabajo se estudia el empleo de moldes metálicos o permanentes para la fabricación de piezas de fundición esferoidal con elevados requerimientos funcionales y se analizan sus propiedades, comparándolas con piezas obtenidas utilizando moldes de arena de sílice, de acuerdo con las metodologías más habituales para este tipo de procesos. La elevada velocidad de solidificación y el posterior enfriamiento rápido de la austenita formada en estado sólido se erigen como los principales factores diferenciadores que originan las modificaciones estructurales detectadas en las piezas. Las propiedades físicas, mecánicas y microestructurales obtenidas directamente sobre pieza son destacables debido, entre otros aspectos, al gran número de esferoides grafíticos obtenidos en las piezas. Se discuten también las ventajas e inconvenientes encontrados en esta metodología de producción que emplea moldes fabricados con una aleación metálica específica.

Interface Structure and Elements Diffusion of As-Cast and Annealed Ductile Iron/Stainless Steel Bimetal Castings

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M. Ramadan

2018-04-01

Full Text Available Bimetal casting is considered to a promising technique for the production of high performance function materials. Heat treatment process for bimetal castings became an essential tool for improving interface structure and metallurgical diffusion bond. Molten iron alloy with carbon equivalent of 4.40 is poured into sand mold cavities containing solid 304 stainless steel strips insert. Specimens are heated to 7200C in an electrical heating furnace and holded at 720 0C for 60min and 180min. For as-cast specimens, a good coherent interface structure of ductile cast iron/304 stainless bimetal with four layers interfacial microstructure are obtained. Low temperature annealing at 720oC has a significat effect on the interface layers structure, where, three layers of interface structure are obtained after 180min annealing time because of the complete dissolving of thin layer of ferrite and multi carbides (Layer 2. Low temperature annealing shows a significant effect on the diffusion of C and otherwise shows slightly effect on the diffusion of Cr and Ni. Plearlite phase of Layer 3 is trsformed to spheroidal shape instead of lamallar shape in as-cast bimetals by low tempeature annealing at 720oC. The percent of the performed spheroidal cementit increases by increasing anneaaling time. Hardness of interface layers is changed by low temperauture annealing due to the significant carbon deffussion.

Advanced Lost Foam Casting Technology; FINAL

International Nuclear Information System (INIS)

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

2000-01-01

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

Casting Simulation of an Austrian Bronze Age Sword Hilt

Science.gov (United States)

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

2015-07-01

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

Low Loss Advanced Metallic Fuel Casting Evaluation

International Nuclear Information System (INIS)

Kim, Kihwan; Ko, Youngmo; Kim, Jonghwan; Song, Hoon; Lee Chanbock

2014-01-01

The fabrication process for SFR fuel is composed of fuel slug casting, loading and fabrication of the fuel rods, and the fabrication of the final fuel assemblies. Fuel slug casting is the dominant source of fuel losses and recycles streams in the fabrication process. Recycle streams include fuel slug reworks, returned scraps, and fuel casting heels, which are a special concern in the counter gravity injection casting process because of the large masses involved. Large recycle and waste streams result in lowering the productivity and the economic efficiency of fuel production. To increase efficiency the fuel losses in the furnace chamber, crucible, and the mold, after casting a considerable amount of fuel alloy in the casting furnace, will be quantitatively evaluated. After evaluation the losses will be identified and minimized. It is expected that this study will contribute to the minimization of fuel losses and the wastes streams in the fabrication process of the fuel slugs. Also through this study the technical readiness level of the metallic fuel fabrication process will be further enhanced. In this study, U-Zr alloy system fuel slugs were fabricated by a gravity casting method. Metallic fuel slugs were successfully fabricated with 19 slugs/batch with diameter of 5mm and length of 300mm. Fuel losses was quantitatively evaluated in casting process for the fuel slugs. Fuel losses of the fuel slugs were so low, 0.1∼1.0%. Injection casting experiments have been performed to reduce the fuel loss and improve the casting method. U-Zr fuel slug having φ5.4-L250mm was soundly fabricated with 0.1% in fuel loss. The fuel losses could be minimized to 0.1%, which showed that casting technology of fuel slugs can be a feasible approach to reach the goal of the fuel losses of 0.1% or less in commercial scale

Dome style heavy wall steel casting manufactured by metallic core mould system

International Nuclear Information System (INIS)

Yamamoto, Shiro; Saeki, Keiji; Hirose, Yutaka; Takebayashi, Kazunari; Kawasaki, Masatoshi

1986-01-01

Semi-spherical thick walled steel castings are one of the main products of Nippon Chutanko K.K., but there have been the problems of internal defects peculiar to large thick walled steel castings, and the various improvements have been carried out so far for the manufacturing method, but still some of those remains. Based on the anxiety about the reliability of large steel castings, the conversion to forging has been studied. For the purpose of thoroughly improving the internal quality of thick walled steel castings to compete with forgings, on the basis of the operating experience of chills, the development of the casting techniques changing cores completely to metallic cores has been advanced. After the preliminary experiment using models, a semi-spherical thick walled steel casting mentioned before was manufactured by this metallic core casting method for trial, and the detailed investigation was carried out. As the result, the excellent internal quality was confirmed, accordingly at present, the production is made by this method. The form, dimensions and specification of the semi-spherical thick walled steel castings, the conventional casting plan, the metallic core casting plan, the design of metallic cores, molding and casting, and the examination of the castings made for trial are reported. (Kako, I.)

A coupled analysis of fluid flow, heat transfer and deformation behavior of solidifying shell in continuously cast beam blank

Energy Technology Data Exchange (ETDEWEB)

Lee, Jung Eui; Yeo, Tae Jung; Oh, Kyu Hwan; Yoon, Jong Kyu [School of Materials Science and Engineering, Seoul Nat` l Univ., Seoul (Korea, Republic of); Han, Heung Nam [Oxford Center for Advanced Materials and Composites, Department of Materials, Univ. of Oxford (United Kingdom)

1998-12-31

A mathematical model for a coupled analysis of fluid flow, heat transfer and deformation behavior in the continuously cast beam blank has been developed. The fluid flow, heat transfer and solidification in the mold region were analyzed with 3-dimensional finite difference method (FDM) based on control volume method. A body fitted coordinate system was introduced for the complex geometry of the beam blank. The effects of turbulence and natural convection of molten steel were taken into account in determining the fluid flow in the strand. The thermo-elasto-plastic deformation behavior in the cast strand and the formation of air gap between the solidifying shell and the mold were analyzed by the finite element method (FEM) using the 2-dimensional slice temperature profile calculated by the FDM. The heat flow between the strand and the mold was evaluated by the coupled analysis between the fluid flow-heat transfer analysis and the thermo-elasto-plastic stress analysis. In order to determine the solid fraction in the mushy zone, the microsegregation of solute element was assessed. The effects of fluid flow on the heat transfer, the solidification of steel and the distribution of shell thickness during the casting of the beam blank were simulated. The deformation behavior of the solidifying shell and the possibility of cracking of the strand were also investigated. The recirculating flows were developed in the regions of the web and the flange tip. The impinging of the inlet flow from the nozzle retarded the growing of solidifying shell in the regions of the fillet and the flange. The air gap between the strand and the mold was formed near the region of the corner of the flange tip. At the initial stage of casting, the probability of the surface cracking was high in the regions of the fillet and the flange tip. After the middle stage of casting, the internal cracking was predicted in the regions of the flange tip, and between the fillet and the flange tip. (author) 38

A coupled analysis of fluid flow, heat transfer and deformation behavior of solidifying shell in continuously cast beam blank

Energy Technology Data Exchange (ETDEWEB)

Lee, Jung Eui; Yeo, Tae Jung; Oh, Kyu Hwan; Yoon, Jong Kyu [School of Materials Science and Engineering, Seoul Nat`l Univ., Seoul (Korea, Republic of); Han, Heung Nam [Oxford Center for Advanced Materials and Composites, Department of Materials, Univ. of Oxford (United Kingdom)

1997-12-31

A mathematical model for a coupled analysis of fluid flow, heat transfer and deformation behavior in the continuously cast beam blank has been developed. The fluid flow, heat transfer and solidification in the mold region were analyzed with 3-dimensional finite difference method (FDM) based on control volume method. A body fitted coordinate system was introduced for the complex geometry of the beam blank. The effects of turbulence and natural convection of molten steel were taken into account in determining the fluid flow in the strand. The thermo-elasto-plastic deformation behavior in the cast strand and the formation of air gap between the solidifying shell and the mold were analyzed by the finite element method (FEM) using the 2-dimensional slice temperature profile calculated by the FDM. The heat flow between the strand and the mold was evaluated by the coupled analysis between the fluid flow-heat transfer analysis and the thermo-elasto-plastic stress analysis. In order to determine the solid fraction in the mushy zone, the microsegregation of solute element was assessed. The effects of fluid flow on the heat transfer, the solidification of steel and the distribution of shell thickness during the casting of the beam blank were simulated. The deformation behavior of the solidifying shell and the possibility of cracking of the strand were also investigated. The recirculating flows were developed in the regions of the web and the flange tip. The impinging of the inlet flow from the nozzle retarded the growing of solidifying shell in the regions of the fillet and the flange. The air gap between the strand and the mold was formed near the region of the corner of the flange tip. At the initial stage of casting, the probability of the surface cracking was high in the regions of the fillet and the flange tip. After the middle stage of casting, the internal cracking was predicted in the regions of the flange tip, and between the fillet and the flange tip. (author) 38

Dynamic of taking out molding parts at injection molding

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E. Ragan

2012-10-01

Full Text Available Most plastic parts used in automobile production are manufactured by injection molding. Their quality depends also on taking out molding and on the manipulators for it. Task of this contribution is to theoretically describe a transport of molding at taking out after injection molding in relation on its regulation. The following quantities are derived at it: the transition characteristic of the taking out system, the blocking diagram of taking out molding regulation, the amplitude and phase characteristic and the transition characteristic of action quantity at taking out molding regulation.

Finite volume modeling of the solidification of an axial steel cast impeller

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M. Copur

2014-04-01

Full Text Available In the foundry industry, obtaining the solidification contours in cast geometries are extremely important to know the last location(s to solidify in order to define the correct feeding path and the number of risers. This paper presents three-dimensional simulation of transient conduction heat transfer within an axial impeller, made of AISI 1016 steel, poured and solidified in chemically bonded mold and core medium, by using FVM technique and ANSYS CFX. Specific heat, density and thermal conductivity of AISI 1016 steel, mold and Core materials are considered as functions of temperatures. In this transient thermal analysis, the convection heat transfer phenomenon is also considered at the outer surfaces of the mold. In order to shorten the run-time, the nonlinear transient analysis has been made for 600/3600 segment of the impeller, core and mold. The solidification contours of the impeller as well as isothermal lines in core and mold have been obtained in 3-D. The cooling curves of diff erent points are also shown in the result section.

Grindability of cast Ti-Hf alloys.

Science.gov (United States)

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

2006-04-01

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

Development of casting technology for manufacturing metal rods with simulated metallic spent fuels

International Nuclear Information System (INIS)

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

1999-01-01

The advanced casting equipment based on the directional solidification method was developed for manufacturing the uranium metal rod having 13.5 mm diameter and 1,200 mm length. In order to prevent surface-shrunk holes revealed easily in course of casting the small diameter and long rods, the vacuum casting furnace has the four pre-heaters equipped with temperature controller. On the other hand, the computer simulation to estimate the defective location and to analyze the solidus behavior of molten uranium in the mold were also performed by using MAGMA Code. As a result of the experimental and theoretical study, the sound rod has successfully been manufactured

Enhanced Injection Molding Simulation of Advanced Injection Molds

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Béla Zink

2017-02-01

Full Text Available The most time-consuming phase of the injection molding cycle is cooling. Cooling efficiency can be enhanced with the application of conformal cooling systems or high thermal conductivity copper molds. The conformal cooling channels are placed along the geometry of the injection-molded product, and thus they can extract more heat and heat removal is more uniform than in the case of conventional cooling systems. In the case of copper mold inserts, cooling channels are made by drilling and heat removal is facilitated by the high thermal conductivity coefficient of copper, which is several times that of steel. Designing optimal cooling systems is a complex process; a proper design requires injection molding simulations, but the accuracy of calculations depends on how precise the input parameters and boundary conditions are. In this study, three cooling circuit designs and three mold materials (Ampcoloy 940, 1.2311 (P20 steel, and MS1 steel were used and compared using numerical methods. The effect of different mold designs and materials on cooling efficiency were examined using calculated and measured results. The simulation model was adjusted to the measurement results by considering the joint gap between the mold inserts.

Evaluation of the distortion rate of panoramic and peri apical radiographs in erupted third molar inclination

International Nuclear Information System (INIS)

Ezoddini Ardakani, F.; Zangouie Booshehri, M.; Behniafar, B.

2011-01-01

Panoramic and peri apical radiographs are normally used in impacted third molar teeth surgeries. The aim of the present study was to evaluate and compare the distortion of the erupted third molar teeth on panoramic and peri apical radiographs. Patients and Methods: A total of 44 radiographs were obtained of 22 patients (age range, 18-24 years) referred to the faculty of dentistry for orthodontic treatment. A plaster cast was prepared and panoramic radiography was taken for all patients to plan the orthodontic treatment and peri apical radiography was taken for investigation of tooth structure details. Therefore, a total of 66 views and samples were studied by two methods: 1) Measuring the angle between the longitudinal plane of the third molar and occlusal plane. 2) Measuring the angle between the longitudinal plane of second and third molar. Finally, 132 records were evaluated by one individual. Results: There was no significant statistical difference between the mean position of the third molar on panoramic, peri apical radiographs and the casts. However, measurements of the third molars on peri apical radiographs were slightly closer to the measurements of the casts compared to the panoramic radiographs. Conclusion: Distortion does not have a specific effect on the diagnosis of the position of the third erupted molars by peri apical or panoramic radiographs, though various studies have shown that these radiographs have an amount of distortion and peri apical radiographical distortion is less than that in panoramic radiography.

High pressure die casting of Fe-based metallic glass

Science.gov (United States)

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-01-01

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications. PMID:27725780

High pressure die casting of Fe-based metallic glass.

Science.gov (United States)

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-10-11

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.

High pressure die casting of Fe-based metallic glass

Science.gov (United States)

Ramasamy, Parthiban; Szabo, Attila; Borzel, Stefan; Eckert, Jürgen; Stoica, Mihai; Bárdos, András

2016-10-01

Soft ferromagnetic Fe-based bulk metallic glass key-shaped specimens with a maximum and minimum width of 25.4 and 5 mm, respectively, were successfully produced using a high pressure die casting (HPDC) method, The influence of die material, alloy temperature and flow rate on the microstructure, thermal stability and soft ferromagnetic properties has been studied. The results suggest that a steel die in which the molten metal flows at low rate and high temperature can be used to produce completely glassy samples. This can be attributed to the laminar filling of the mold and to a lower heat transfer coefficient, which avoids the skin effect in the steel mold. In addition, magnetic measurements reveal that the amorphous structure of the material is maintained throughout the key-shaped samples. Although it is difficult to control the flow and cooling rate of the molten metal in the corners of the key due to different cross sections, this can be overcome by proper tool geometry. The present results confirm that HPDC is a suitable method for the casting of Fe-based bulk glassy alloys even with complex geometries for a broad range of applications.

In-situ surface hardening of cast iron by surface layer metallurgy

International Nuclear Information System (INIS)

Fischer, Sebastian F.; Muschna, Stefan; Bührig-Polaczek, Andreas; Bünck, Matthias

2014-01-01

Abrasive wear is a serious problem in many cast iron castings used in industry. To minimize failure and repair of these components, different strategies exist to improve their surface microhardness thus enhancing their wear resistance. However, most of these methods lead to very brittle and/or expensive castings. In the current work a new method for surface hardening is presented which utilizes surface layer metallurgy to generate in-situ a boron-enriched white cast iron surface layer with a high microhardness on a gray cast iron casting. To do this, sand molds are coated with a ferroboron suspension and cast with a cast iron melt. After solidification, a 100–900 µm thick layer of boron-enriched ledeburite is formed on the surface of the casting which produces an increase in the average microhardness from 284 HV 0.1 ±52 HV 0.1 to 505 HV 0.1 ±87 HV 0.1 . Analyses of the samples' core reveal a typical cast iron microstructure which leads to the conclusion that the coating mainly affects the castings' surface. By varying the grain size of the ferroboron powder in the coatings, it is shown that a powder size ≤100 µm is most suitable to create a boron-enriched ledeburite surface layer possessing high hardness values

Three solutions to a single problem: alternative casting frames for treating infantile idiopathic scoliosis.

Science.gov (United States)

Halanski, Matthew A; Harper, Benjamin L; Cassidy, Jeffry A; Crawford, Haemish A

2013-07-01

This is a technique article discussing 3 alternative frames for casting children with infantile scoliosis. To provide surgeons with alternatives to expensive specialized casting tables to allow local treatment of these children utilizing readily available materials present at most institutions. Casting for infantile scoliosis has become more popular as reports have shown promising results with this technique without the morbidity and complications associated with more invasive procedures. However, without a specialized casting table, treating these patients has been limited to a few centers throughout the country often causing patients to travel large distances to receive care. Three different alternatives to commercially available casting frames are presented. Requirements, setup, and techniques are discussed. Each surgeon has had success with each of these frames. These provide adequate support and traction while allowing enough access to the trunk to apply a well-molded cast. Cotrel/Metha casting for infantile scoliosis can be accomplished without a specialized table using commonly available equipment.

Strain gauges′s analysis on implant-retained prosthesis′ cast accuracy

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Mariana A Rodrigues

2014-01-01

Conclusions: The splinting technique was considered to be as efficient as the conventional technique. The strain gauge methodology was accurate for strain measurements and cast distortion evaluation. There was no correlation between strain and marginal misfit.

Surface Replication of Molded Products with Microneedle Features in Injection Molding

Science.gov (United States)

Uchiumi, Kazuyasu; Takayama, Tetsuo; Ito, Hiroshi; Inou, Akinori

Micro-molding of microneedle features was conducted using several injection-molding techniques. Injection compression molding and injection molding were performed with supercritical carbon dioxide fluid and with or without vacuum processing inside the mold cavity. Effects of process parameters on processability and surface replication of the molded parts were evaluated. The height replication ratio for microneedles was improved using injection compression molding. At a shorter compression stroke, the needle height was improved, and the influence of compression delay time was also small. Moreover, the effects of vacuum processing inside the mold cavity under the filling process were slight. The height replication ratio for microneedles showed the highest values using injection molding using supercritical carbon dioxide fluid with vacuum inside the mold cavity.

Precision glass molding: Toward an optimal fabrication of optical lenses

Science.gov (United States)

Zhang, Liangchi; Liu, Weidong

2017-03-01

It is costly and time consuming to use machining processes, such as grinding, polishing and lapping, to produce optical glass lenses with complex features. Precision glass molding (PGM) has thus been developed to realize an efficient manufacture of such optical components in a single step. However, PGM faces various technical challenges. For example, a PGM process must be carried out within the super-cooled region of optical glass above its glass transition temperature, in which the material has an unstable non-equilibrium structure. Within a narrow window of allowable temperature variation, the glass viscosity can change from 105 to 1012 Pas due to the kinetic fragility of the super-cooled liquid. This makes a PGM process sensitive to its molding temperature. In addition, because of the structural relaxation in this temperature window, the atomic structure that governs the material properties is strongly dependent on time and thermal history. Such complexity often leads to residual stresses and shape distortion in a lens molded, causing unexpected changes in density and refractive index. This review will discuss some of the central issues in PGM processes and provide a method based on a manufacturing chain consideration from mold material selection, property and deformation characterization of optical glass to process optimization. The realization of such optimization is a necessary step for the Industry 4.0 of PGM.

Influence of Cast Iron Structure on the Glassmold Equipment Operational Defects

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I. O. Leushin

2015-01-01

Full Text Available The growing demand for glass packaging contributes to the increase in production capacity of glass-container plants. Their equipment (cast iron glass-forming sets operates in continuous mode under complex cyclic thermal loads, which lead to the formation of operational defects on the working surfaces of details: graphite falling, cracks, oxidation, etc. Particular influence on the formation of these defects renders the microstructure of the material at the time of installation of details on the line.The article identifies the causes for formation of operational defects, formulates the ways to remedy them and prevent their occurrence.The authors studied details made from grey cast iron with flake and spherical forms of graphite. It is found that in the process of exploitation of the material is greatly reducing its hardness, strength, resistance to oxidation through of graphitization processes, chemical interaction of glass and iron, shock loads working edges. It is proved that the choice of initial microstructure of cast iron (the metal base, the graphite form, the presence of structural-free cementite exercises a determining influence on the durability of the mold tooling. The article proposes differential (layered arrangement of the graphite phase of cast iron in the alloy matrix (ferrite. This arrangement of high-carbon phase can simultaneously increase the thermal and oxidation resistance of the material. The formation of a layered structure of iron is produced by the intensification of the processes of alloying, modifying and directional freezing the melt.These data can be used to select the material of details by manufacturers glass-molds tooling.

Formation Mechanism of Surface Crack in Low Pressure Casting of A360 Alloy

Science.gov (United States)

Liu, Shan-Guang; Cao, Fu-Yang; Ying, Tao; Zhao, Xin-Yi; Liu, Jing-Shun; Shen, Hong-Xian; Guo, Shu; Sun, Jian-Fei

2017-12-01

A surface crack defect is normally found in low pressure castings of Al alloy with a sudden contraction structure. To further understand the formation mechanism of the defect, the mold filling process is simulated by a two-phase flow model. The experimental results indicate that the main reason for the defect deformation is the mismatching between the height of liquid surface in the mold and pressure in the crucible. In the case of filling, a sudden contraction structure with an area ratio smaller than 0.5 is obtained, and the velocity of the liquid front increases dramatically with the influence of inertia. Meanwhile, the pressurizing speed in the crucible remains unchanged, resulting in the pressure not being able to support the height of the liquid level. Then the liquid metal flows back to the crucible and forms a relatively thin layer solidification shell on the mold wall. With the increasing pressure in the crucible, the liquid level rises again, engulfing the shell and leading to a surface crack. As the filling velocity is characterized by the damping oscillations, surface cracks will form at different heights. The results shed light on designing a suitable pressurizing speed for the low pressure casting process.

Fractography of STIR casted Al-ZrO2 composites

International Nuclear Information System (INIS)

Baghchesara, M. A.; Abdizadeh, H.; Baharvandi, H. R.

2009-01-01

In this study, Al-ZrO 2 composites were produced by Vortex method using ZrO 2 powder with 1 micron average diameter as reinforce particles and Al-356 as the matrix metal. The melt composites were stirred for 13 minutes, then casted into a metallic mold. Different samples of 5, 10 and 15 volume percent of ZrO 2 , in different casting temperatures of 750, 850 and 950 d eg C were produced. The latter 2 casting temperatures are not a common practice but were chosen to enhance fluidity. Effects of volume percent of ZrO 2 particles and casting temperature on tensile strength, microstructure, and fracture surfaces of Al-ZrO 2 composites have been investigated. The highest tensile strength was achieved in the specimen containing 15 vol. % ZrO 2 produced at 750 d eg C which shows an increase of 60% in comparison to the Al-356 non-reinforced alloy. Microscopic investigations of fracture surfaces revealed that fracture in a brittle manner with little or no necking happening. By increasing ZrO 2 content and casting temperature, the composites fracture goes in a more severely brittle manner.

High Cost/High Risk Components to Chalcogenide Molded Lens Model: Molding Preforms and Mold Technology

Energy Technology Data Exchange (ETDEWEB)

Bernacki, Bruce E.

2012-10-05

This brief report contains a critique of two key components of FiveFocal's cost model for glass compression molding of chalcogenide lenses for infrared applications. Molding preforms and mold technology have the greatest influence on the ultimate cost of the product and help determine the volumes needed to select glass molding over conventional single-point diamond turning or grinding and polishing. This brief report highlights key areas of both technologies with recommendations for further study.

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

Science.gov (United States)

Spencer, J.E.

1999-01-01

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

Wetting Behavior of Mold Flux Droplet on Steel Substrate With or Without Interfacial Reaction

Science.gov (United States)

Zhou, Lejun; Li, Jingwen; Wang, Wanlin; Sohn, Il

2017-08-01

The slag entrapment in mold tends to cause severe defects on the slab surface, especially for casting steels containing active alloy elements such as Al, Ti, and Mn. The wetting behavior of molten mold flux on the initial solidified shell is considered to be a key factor to determine the entrapment of mold slag on the shell surface. Therefore, the wetting behavior of mold flux droplet on the steel substrate with or without interfacial reaction was investigated by the sessile drop method. The results indicated that the melting process of mold flux has a significant influence on the variation of contact angle, and the final contact angle for Flux1 droplet on 20Mn23AlV is only 15 deg, which is lower than the other two cases due to the intensive interracial reactions occurring in this case. In addition, the thickness of the interaction layer for the case of Flux1 on 20Mn23AlV is 10- μm greater than the other two cases, which confirms that the most intensive reactions occurred at the interface area. The microstructure and element distribution at the interface analyzed by a scanning electron microscope (SEM) and energy dispersive spectrum (EDS) suggested that the increase of wettability of mold flux droplet on the steel substrate is caused by the migration of Al, Mn, and Si elements occurring in the vicinity of the interface. The results obtained in this article can reveal the mechanism of flux entrapment by hook or shell and provide theoretic guidance for mold flux design and optimization.

Semi-continuous casting of magnesium alloy AZ91 using a filtered melt delivery system

Directory of Open Access Journals (Sweden)

Mainul Hasan

2015-12-01

Full Text Available A 3-D numerical simulation of an industrial-sized slab caster for magnesium alloy AZ91 has been carried out for the steady state operational phase of the caster. The simulated model consists of an open-top melt delivery system fitted with a porous filter near the hot-top. The melt flow through the porous filter was modeled on the basis of Brinkmann-Forchimier-Extended non-Darcy model for turbulent flow. An in-house 3-D CFD code was modified to account for the melt flow through the porous filter. Results are obtained for four casting speeds namely, 40, 60, 80, and 100 mm/min. The metal-mold contact region as well as the convective heat transfer coefficient at the mold wall were also varied. In addition to the above, the Darcy number for the porous media was also changed. All parametric studies were performed for a fixed inlet melt superheat of 64 °C. The results are presented pictorially in the form of temperature and velocity fields. The sump depth, mushy region thickness, solid shell thickness at the exit of the mold and axial temperature profiles are also presented and correlated with the casting speed through regression analysis.

Microstructures and creep properties of Mg–4Al–(1–4) La alloys produced by different casting techniques

International Nuclear Information System (INIS)

Bai Jing; Sun Yangshan; Xue Feng; Qiang Jing

2012-01-01

The microstructures, mechanical properties and creep resistance of Mg–4Al–(1–4) La alloys produced by permanent mold casting and high pressure die casting (HPDC) were investigated. In addition to solute atoms in α-Mg matrix, Al element may exist in the form of three different intermetallic phases in the present alloys depending on the experimental conditions. In both casting states, the increase of La addition results in a rise in the volume fraction of Al 11 La 3 eutectic, and simultaneously Mg 17 Al 12 phase, including divorced eutectic in as-cast state and discontinuous precipitation after creep, is suppressed until completely disappears. This leads to a gradual increase in creep resistance. The formation of more Mg 17 Al 12 phase in HPDC alloys is considered a major factor in causing their worse creep properties by comparison with that of the permanent mold casting alloys when La content is in a lower level below 2 wt.%. By contrast, the HPDC alloys show better creep resistance with La content added above 2 wt.% owing to the formation of denser network distribution of Al 11 La 3 phase along grain/dendrite boundaries as a result of more rapid solidification rate and higher solidification pressure. For the alloys studied, grain/dendrite boundary sliding is suggested to be a possible controlling mechanism responsible for creep deformation at elevated temperatures.

Numerical simulation and optimization of Al alloy cylinder body by low pressure die casting

Directory of Open Access Journals (Sweden)

Mi Guofa

2008-05-01

Full Text Available Shrinkage defects can be formed easily at Critical location during low pressure die casting (LPDC of aluminum alloy cylinder body. It has harmful effect on the products. Mold fi lling and solidifi cation process of a cylinder body was simulated by using of Z-CAST software. The casting method was improved based on the simulation results. In order to create effective feeding passage, the structure of casting was modifi ed by changing the location of strengthening ribs at the bottom, without causing any adverse effect on the part’s performance. Inserting copper billet at suitable location of the die is a valid way to create suitable solidifi cation sequence that is benefi cial to the feeding. Using these methods, the shrinkage defect was completely eliminated at the critical location.

Prediction of hot-ductility of steels during continuous casting using artificial neural networks

International Nuclear Information System (INIS)

Liu, W.J.; Emadi, D.; Essadiqi, E.

2000-01-01

During continuous casting, transversal cracks can be developed due to tensile stress in temperature regions where the steel exhibits a low ductility. The cracking tendency during continuous casting depends on the steel chemistry and the casting parameters such as lubrication, mold type, secondary cooling and bending/unbending temperatures. To prevent cracking one needs to predict the hot-ductility of a material under continuous-casting conditions. However, hot-ductility is one of the poorly understood material behaviors and cannot be readily modeled using conventional techniques. In the present study, we used an alternative method, namely Artificial Neural Networks (ANN), to model the ductility of a steel under continuous casting conditions. A hot-ductility database was established based on published literature. Several standard three-layer ANN models were then trained using data randomly selected from the database. The outputs of the ANN models were subsequently compared with the remaining data in the database. The results indicate that ANN is a suitable modelling technique for hot-ductility prediction. (author)

Centrifugally cast Zn-27Al-xMg-ySi alloys and their in situ (Mg2Si + Si)/ZA27 composites

International Nuclear Information System (INIS)

Wang Qudong; Chen Yongjun; Chen Wenzhou; Wei Yinhong; Zhai Chunquan; Ding Wenjiang

2005-01-01

Effects of composition, mold temperature, rotating rate and modification on microstructure of centrifugally cast Zn-27Al-xMg-ySi alloys have been investigated. In situ composites of Zn-27Al-6.3Mg-3.7Si and Zn-27Al-9.8Mg-5.2Si alloys were fabricated by centrifugal casting using heated permanent mold. These composites consist of three layers: inner layer segregates lots of blocky primary Mg 2 Si and a litter blocky primary Si, middle layer contains without primary Mg 2 Si and primary Si, outer layer contains primary Mg 2 Si and primary Si. The position, quantity and distribution of primary Mg 2 Si and primary Si in the composites are determined jointly by alloy composition, solidification velocity under the effect of centrifugal force and their floating velocity inward. Na salt modifier can refine grain and primary Mg 2 Si and make primary Mg 2 Si distribute more evenly and make primary Si nodular. For centrifugally cast Zn-27Al-3.2Mg-1.8Si alloy, the microstructures of inner layer, middle layer and outer layer are almost similar, single layer materials without primary Mg 2 Si and primary Si are obtained, and their grain sizes increased with the mold temperature increasing

Energy-Saving Melting and Revert Reduction Technology (E-SMARRT): Lost Foam Thin Wall - Feasibility of Producing Lost Foam Castings in Aluminum and Magnesium Based Alloys

Energy Technology Data Exchange (ETDEWEB)

Fasoyinu, Yemi [CanmetMATERIALS; Griffin, John A. [University of Alabama - Birmingham

2014-03-31

With the increased emphasis on vehicle weight reduction, production of near-net shape components by lost foam casting will make significant inroad into the next-generation of engineering component designs. The lost foam casting process is a cost effective method for producing complex castings using an expandable polystyrene pattern and un-bonded sand. The use of un-bonded molding media in the lost foam process will impose less constraint on the solidifying casting, making hot tearing less prevalent. This is especially true in Al-Mg and Al-Cu alloy systems that are prone to hot tearing when poured in rigid molds partially due to their long freezing range. Some of the unique advantages of using the lost foam casting process are closer dimensional tolerance, higher casting yield, and the elimination of sand cores and binders. Most of the aluminum alloys poured using the lost foam process are based on the Al-Si system. Very limited research work has been performed with Al-Mg and Al-Cu type alloys. With the increased emphasis on vehicle weight reduction, and given the high-strength-to-weight-ratio of magnesium, significant weight savings can be achieved by casting thin-wall (≤ 3 mm) engineering components from both aluminum- and magnesium-base alloys.

Vacuum-induction melting, refining, and casting of uranium and its alloys

Energy Technology Data Exchange (ETDEWEB)

Jackson, R J

1989-10-11

The vacuum-induction melting (VIM), refining, and casting of uranium and its alloys are discussed. Emphasis is placed on historical development, VIM equipment, crucible and mold design, furnace atmospheres, melting parameters, impurity pickup, ingot quality, and economics. The VIM procedures used to produce high-purity, high-quality sound ingots at the US Department of Energy Rocky Flats Plant are discussed in detail.

Effect of heat treatment on corrosion behavior of low pressure sand cast Mg-10Gd-3Y-0.5Zr alloys

Directory of Open Access Journals (Sweden)

Qian-qian Wu

2016-07-01

Full Text Available The corrosion behaviors of low-pressure sand cast Mg-10Gd-3Y-0.5Zr (wt.% alloys in as-cast, solution treated (T4 and aged (T6 conditions were studied by means of immersion test and electrochemical measurements in 5wt.% NaCl solution saturated with Mg(OH2. It was observed that the corrosion rate in the T4 condition was lower than that of the as-cast and T6 conditions by both sand casting and permanent mold casting with the same order of as-cast>T6>T4; while the corrosion resistance of the permanent mold casting is superior to the sand casting. The morphologies of the corrosion products are similar porous structures consisting of tiny erect flakes perpendicular to the corroded surface of the alloy, irrespective of the heat treatment conditions. Especially, the corrosion film in T4 condition is more compact than that in the other two conditions. In addition, the severer corrosion happening to the as-cast condition is correlated with the galvanic corrosion between the matrix and the eutectic compounds; while improved corrosion resistance for the T4 and T6 conditions is ascribed to the dissolution of the secondary eutectic compounds. The measured corrosion current densities of Mg-10Gd-3Y-0.5Zr alloys in as-cast, T4, and T6 conditions are 36 μA·cm-2, 10 μA·cm-2, and 33 μA·cm-2, respectively. The proposed equivalent circuit [Rs(CPE1(Rt(RfCPE2] by Zview software matches well with the tested electrochemical impedance spectra (EIS data.

Feeding and Distribution of Porosity in Cast Al-Si Alloys as Function of Alloy Composition and Modification

DEFF Research Database (Denmark)

Tiedje, Niels Skat; Taylor, John A.; Easton, Mark A.

2012-01-01

Unmodified, Na-modified, and Sr-modified castings of Al-7 pct Si and Al-12.5 pct Si alloys were cast in molds in which it was possible to create different cooling conditions. It is shown how solidification influences the distribution of porosity at the surface and the center of the castings...... of the casting, while Sr-modified castings solidify in a mushy manner that creates a more homogeneous distribution of porosity in the casting. The amount of porosity was highest in the Sr-modified alloys, lower in the Na-modified alloys, and lowest in the unmodified alloys. The size of the porosity-free layer...... as a function of modification and Si content in sand- and chill-cast samples. Eutectic modification, Si content, and cooling conditions have a great impact on the distribution of porosity. Unmodified and Na-modified castings are more easily fed with porosity tending to congregate near the centerline...

Mechanical properties and grindability of dental cast Ti-Nb alloys.

Science.gov (United States)

Kikuchi, Masafumi; Takahashi, Masatoshi; Okuno, Osamu

2003-09-01

Aiming at developing a dental titanium alloy with better mechanical properties and machinability than unalloyed titanium, a series of Ti-Nb alloys with Nb concentrations up to 30% was made. They were cast into magnesia-based molds using a dental casting machine and the mechanical properties and grindability of the castings were examined. The hardness of the alloys with Nb concentrations of 5% and above was significantly higher than that of titanium. The yield strength and tensile strength of the alloys with Nb concentrations of 10% and above were significantly higher than those of titanium, while the elongation was significantly lower. A small addition of niobium to titanium did not contribute to improving the grindability of titanium. The Ti-30% Nb alloy exhibited significantly better grindability at low grinding speed with higher hardness, strength, and Young's modulus than titanium, presumably due to precipitation of the omega phase in the beta matrix.

Rapid control of mold temperature during injection molding process

Energy Technology Data Exchange (ETDEWEB)

Liparoti, Sara; Titomanlio, Giuseppe [Department of Industrial Engineering, University of Salerno Via Giovanni Paolo II, 132, 84084 Fisciano (Italy); Hunag, Tsang Min; Cakmak, Mukerrem [Department of Polymer Engineering, The University of Akron, Akron, OH 44325 (United States); Sorrentino, Andrea [Institute for Polymers, Composite and Biomaterials (IPCB) - CNR, P. Enrico Fermi 1, 80055 Portici (Italy)

2015-05-22

The control of mold surface temperature is an important factor that determines surface morphology and its dimension in thickness direction. It can also affect the frozen molecular orientation and the mold surface replicability in injection molded products. In this work, thin thermally active films were used to quickly control the mold surface temperature. In particular, an active high electrical conductivity carbon black loaded polyimide composites sandwiched between two insulating thin polymeric layers was used to condition the mold surface. By controlling the heating time, it was possible to control precisely the temporal variation of the mold temperature surface during the entire cycle. The surface heating rate was about 40°C/s and upon contact with the polymer the surface temperature decreased back to 40°C within about 5 s; the overall cycle time increased only slightly. The effect on cross section sample morphology of samples of iPP were analyzed and discussed on the basis of the recorded temperature evolution.

A computational study of low-head direct chill slab casting of aluminum alloy AA2024

Science.gov (United States)

Hasan, Mainul; Begum, Latifa

2016-04-01

The steady state casting of an industrial-sized AA2024 slab has been modeled for a vertical low-head direct chill caster. The previously verified 3-D CFD code is used to investigate the solidification phenomena of the said long-range alloy by varying the pouring temperature, casting speed and the metal-mold contact heat transfer coefficient from 654 to 702 °C, 60-180 mm/min, and 1.0-4.0 kW/(m2 K), respectively. The important predicted results are presented and thoroughly discussed.

Allergies, asthma, and molds

Science.gov (United States)

Reactive airway - mold; Bronchial asthma - mold; Triggers - mold; Allergic rhinitis - pollen ... Things that make allergies or asthma worse are called triggers. Mold is a common trigger. When your asthma or allergies become worse due to mold, you are ...

The Effect of Shell Thickness, Insulation and Casting Temperature on Defects Formation During Investment Casting of Ni-base Turbine Blades

Directory of Open Access Journals (Sweden)

Raza M.

2015-12-01

Full Text Available Turbine blades have complex geometries with free form surface. Blades have different thickness at the trailing and leading edges as well as sharp bends at the chord-tip shroud junction and sharp fins at the tip shroud. In investment casting of blades, shrinkage at the tip-shroud and cord junction is a common casting problem. Because of high temperature applications, grain structure is also critical in these castings in order to avoid creep. The aim of this work is to evaluate the effect of different process parameters, such as, shell thickness, insulation and casting temperature on shrinkage porosity and grain size. The test geometry used in this study was a thin-walled air-foil structure which is representative of a typical hot-gas-path rotating turbine component. It was observed that, in thin sections, increased shell thickness helps to increase the feeding distance and thus avoid interdendritic shrinkage. It was also observed that grain size is not significantly affected by shell thickness in thin sections. Slower cooling rate due to the added insulation and steeper thermal gradient at metal mold interface induced by the thicker shell not only helps to avoid shrinkage porosity but also increases fill-ability in thinner sections.

Development of High-Performance Cast Crankshafts. Final Technical Report

Energy Technology Data Exchange (ETDEWEB)

Bauer, Mark E [General Motors, Detroit, MI (United States)

2017-03-31

simulations with existing materials models to optimize crankshaft cost and performance. Prototype crankshafts of the final design were to be produced and validated using laboratory bench testing and on-engine durability testing. ICME process simulation tools were used to investigate a broad range of processing concepts. These concepts included casting orientation, various mold and core materials, and various filling and feeding strategies. Each crankshaft was first simulated without gating and risers, which is termed natural solidification. The natural solidification results were used as a baseline for strategy development of each concept. Casting process simulations and ICME tools were proven to be reasonable predictors of real world results. Potential alloys were developed that could meet the project material property goals with appropriate normalization and temper treatments. For the alloys considered, post-normalization temper treatments proved to be necessary to achieve the desired yield strengths and elongations and appropriate heat treatments were designed using ICME tools. The experimental data of all the alloys were analyzed in combination with ICME tools to establish chemistry-process-structure relations. Several GM small gas engine (SGE) crankshafts were successfully cast in sand molds using two different sprue, runner, gate, riser, chill designs. These crankshafts were cast in two different steel alloys developed during the project, but casting finishing (e.g. riser removal) remains a cost challenge. A long list of future work was left unfinished when this project was unexpectedly terminated.

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

Science.gov (United States)

Yuan, Chen; Jones, Sam; Blackburn, Stuart

2012-12-01

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

Microcapillary Features in Silicon Alloyed High-Strength Cast Iron

Directory of Open Access Journals (Sweden)

R.K. Hasanli

2017-04-01

Full Text Available Present study explores features of silicon micro capillary in alloyed high-strength cast iron with nodular graphite (ductile iron produced in metal molds. It identified the nature and mechanism of micro liquation of silicon in a ductile iron alloyed with Nickel and copper, and demonstrated significant change of structural-quality characteristics. It was concluded that the matrix of alloyed ductile iron has a heterogeneous structure with cross reinforcement and high-silicon excrement areas.

Cast iron - a predictable material

Directory of Open Access Journals (Sweden)

Jorg C. Sturm

2011-02-01

stresses in castings are also gaining increasing attention. State-of-the-art tools allow the prediction of residual stresses and iron casting distortion quantitatively. Cracks in castings can be assessed, as well as the reduction of casting stresses during heat treatment. As the property requirements for cast iron as a material in design strongly increase, new alloys and materials such as ADI might become more attractive, where latest software developments allow the modeling of the required heat treatment. Phases can be predicted and parametric studies can be performed to optimize the alloy dependent heat treatment conditions during austenitization, quenching and ausferritization. All this quantitative information about the material's performance is most valuable if it can be used during casting design. The transfer of local properties into the designer抯 world, to predict fatigue and durability as a function of the entire manufacturing route, will increase the trust in this old but highly innovative material and will open new opportunities for cast iron in the future. The paper will give an overview on current capabilities to quantitatively predict cast iron specific defects and casting performance and will highlight latest developments in modeling the manufacture of cast iron and ADI as well as the prediction of iron casting stresses.

Indirect three-dimensional printing of synthetic polymer scaffold based on thermal molding process

International Nuclear Information System (INIS)

Park, Jeong Hun; Jung, Jin Woo; Cho, Dong-Woo; Kang, Hyun-Wook

2014-01-01

One of the major issues in tissue engineering has been the development of three-dimensional (3D) scaffolds, which serve as a structural template for cell growth and extracellular matrix formation. In scaffold-based tissue engineering, 3D printing (3DP) technology has been successfully applied for the fabrication of complex 3D scaffolds by using both direct and indirect techniques. In principle, direct 3DP techniques rely on the straightforward utilization of the final scaffold materials during the actual scaffold fabrication process. In contrast, indirect 3DP techniques use a negative mold based on a scaffold design, to which the desired biomaterial is cast and then sacrificed to obtain the final scaffold. Such indirect 3DP techniques generally impose a solvent-based process for scaffold fabrication, resulting in a considerable increase in the fabrication time and poor mechanical properties. In addition, the internal architecture of the resulting scaffold is affected by the properties of the biomaterial solution. In this study, we propose an advanced indirect 3DP technique using projection-based micro-stereolithography and an injection molding system (IMS) in order to address these challenges. The scaffold was fabricated by a thermal molding process using IMS to overcome the limitation of the solvent-based molding process in indirect 3DP techniques. The results indicate that the thermal molding process using an IMS has achieved a substantial reduction in scaffold fabrication time and has also provided the scaffold with higher mechanical modulus and strength. In addition, cell adhesion and proliferation studies have indicated no significant difference in cell activity between the scaffolds prepared by solvent-based and thermal molding processes. (paper)

Research on investment casting of TiAl alloy agitator treated by HIP and HT

Directory of Open Access Journals (Sweden)

LI Zhen-xi

2007-05-01

Full Text Available Using TiAl alloy to substitute superalloy is a hot topic in aeroengine industry because of its low density,high elevated temperature strength, and anti-oxidization ability. In this research, Ti-47.5AL-2Cr-2Nb-0.2B alloy was used as the test material. By applying a combination process of ceramic shell mold and core making, vacuum arc melting and centrifugal pouring, and heat isostatic pressing (HIP and heat treatment (HT etc., the TiAl vortex agitator casting for aeroengine was successfully made. This paper introduced key techniques in making the TiAl vortex agitator with investment casting process, provided some experimental results including mechanical properties and machinability, and explained some concerns that could affect applications of TiAl castings.

Cast irons

CERN Document Server

1996-01-01

Cast iron offers the design engineer a low-cost, high-strength material that can be easily melted and poured into a wide variety of useful, and sometimes complex, shapes. This latest handbook from ASM covers the entire spectrum of one of the most widely used and versatile of all engineered materials. The reader will find the basic, but vital, information on metallurgy, solidification characteristics, and properties. Extensive reviews are presented on the low-alloy gray, ductile, compacted graphite, and malleable irons. New and expanded material has been added covering high-alloy white irons used for abrasion resistance and high-alloy graphitic irons for heat and corrosion resistance. Also discussed are melting furnaces and foundry practices such as melting, inoculation, alloying, pouring, gating and rising, and molding. Heat treating practices including stress relieving, annealing, normalizing, hardening and tempering, autempering (of ductile irons), and surface-hardening treatments are covered, too. ASM Spec...

Process to Continuously Melt, Refine and Cast High Quality Steel

Energy Technology Data Exchange (ETDEWEB)

None

2005-09-01

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

Modeling of solidification of MMC composites during gravity casting process

Directory of Open Access Journals (Sweden)

R. Zagórski

2013-04-01

Full Text Available The paper deals with computer simulation of gravity casting of the metal matrix composites reinforced with ceramics (MMC into sand mold. The subject of our interest is aluminum matrix composite (AlMMC reinforced with ceramic particles i.e. silicon carbide SiC and glass carbon Cg. The created model describes the process taking into account solidification and its influence on the distribution of reinforcement particles. The computer calculation has been carried out in 2D system with the use of Navier-Stokes equations using ANSYS FLUENT 13. The Volume of Fluid approach (VOF and enthalpy method have been used to model the air-fluid free surface (and also volume fraction of particular continuous phases and the solidification of the cast, respectively.

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

Science.gov (United States)

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

2018-04-01

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

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

Science.gov (United States)

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

2018-06-01

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

Evaluation of marginal gap of Ni-Cr copings made with conventional and accelerated casting techniques.

Science.gov (United States)

Tannamala, Pavan Kumar; Azhagarasan, Nagarasampatti Sivaprakasam; Shankar, K Chitra

2013-01-01

Conventional casting techniques following the manufacturers' recommendations are time consuming. Accelerated casting techniques have been reported, but their accuracy with base metal alloys has not been adequately studied. We measured the vertical marginal gap of nickel-chromium copings made by conventional and accelerated casting techniques and determined the clinical acceptability of the cast copings in this study. Experimental design, in vitro study, lab settings. Ten copings each were cast by conventional and accelerated casting techniques. All copings were identical, only their mold preparation schedules differed. Microscopic measurements were recorded at ×80 magnification on the perpendicular to the axial wall at four predetermined sites. The marginal gap values were evaluated by paired t test. The mean marginal gap by conventional technique (34.02 μm) is approximately 10 μm lesser than that of accelerated casting technique (44.62 μm). As the P value is less than 0.0001, there is highly significant difference between the two techniques with regard to vertical marginal gap. The accelerated casting technique is time saving and the marginal gap measured was within the clinically acceptable limits and could be an alternative to time-consuming conventional techniques.

The simulation of magnesium wheel low pressure die casting based on PAM-CASTTM

International Nuclear Information System (INIS)

Peng Yinghong; Wang Yingchun; Li Dayong; Zeng Xiaoqin

2004-01-01

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

Hierarchical modeling of professional skills in the field of castings manufacture engineering

Science.gov (United States)

Samuilă, V.; Soporan, V. F.; Conțiu, G.; Pădurețu, S.; Lehene, T. R.; Vescan, M. M.

2017-06-01

The paper presents a method of hierarchizing professional skills in the manufacturing of molded parts (castings) by using and adapting the FAHP algorithm (Fuzzy Analitical Hierarchy Process). Assessments are made regarding the peculiarities of the professional training process, specifying the activities to be carried out and the competences necessary for their development. The contribution of the design of the method extends to the design of the hierarchy system architecture, the linguistic determination of the importance of each characteristic, the construction of the fuzzy ordering matrices for each stage of the process, the determination of the share of the characteristics for each hierarchy step and establishing the hierarchy of the characteristics taking into account the influences of the others, grouped at the level of the steps and within the global matrix. The research carried out represents the support for generating an instrument of hierarchy of professional competencies that can be used in various professional and institutional contexts. Case study on the hierarchy of professional skills in the manufacturing of molded parts engineering. Keywords: Materials engineering, castings manufacture professional skills, hierarchy, AHP method, standard occupational curriculum.

Grindability of cast Ti-Cu alloys.

Science.gov (United States)

Kikuchi, Masafumi; Takada, Yukyo; Kiyosue, Seigo; Yoda, Masanobu; Woldu, Margaret; Cai, Zhuo; Okuno, Osamu; Okabe, Toru

2003-07-01

The purpose of the present study was to evaluate the grindability of a series of cast Ti-Cu alloys in order to develop a titanium alloy with better grindability than commercially pure titanium (CP Ti), which is considered to be one of the most difficult metals to machine. Experimental Ti-Cu alloys (0.5, 1.0, 2.0, 5.0, and 10.0 mass% Cu) were made in an argon-arc melting furnace. Each alloy was cast into a magnesia mold using a centrifugal casting machine. Cast alloy slabs (3.5 mm x 8.5 mm x 30.5 mm), from which the hardened surface layer (250 microm) was removed, were ground using a SiC abrasive wheel on an electric handpiece at four circumferential speeds (500, 750, 1000, or 1250 m/min) at 0.98 N (100 gf). Grindability was evaluated by measuring the amount of metal volume removed after grinding for 1min. Data were compared to those for CP Ti and Ti-6Al-4V. For all speeds, Ti-10% Cu alloy exhibited the highest grindability. For the Ti-Cu alloys with a Cu content of 2% or less, the highest grindability corresponded to an intermediate speed. It was observed that the grindability increased with an increase in the Cu concentration compared to CP Ti, particularly for the 5 or 10% Cu alloys at a circumferential speed of 1000 m/min or above. By alloying with copper, the cast titanium exhibited better grindability at high speed. The continuous precipitation of Ti(2)Cu among the alpha-matrix grains made this material less ductile and facilitated more effective grinding because small broken segments more readily formed.

Effects of heat treatment on the microstructure and mechanical properties of AA2618 DC cast alloy

International Nuclear Information System (INIS)

Elgallad, E.M.; Shen, P.; Zhang, Z.; Chen, X.-G.

2014-01-01

Highlights: • The microstructure and mechanical properties of AA2618 DC cast alloy were studied. • The Al 2 CuMg, Al 2 Cu, Al 7 Cu 4 Ni, Al 7 Cu 2 (Fe,Ni) and Al 9 FeNi phases were identified. • Solution treatment at 530 °C for 5 h is the optimum solution treatment. • Different combinations of strength and ductility can be achieved. • The strengthening of AA2618 DC cast alloy was caused by GPB zones and S′ phase. - Abstract: Direct chill (DC) cast ingot plates of AA2618 alloy have been increasingly used for large-mold applications in the plastics and automotive industries. The effects of different heat treatments on the microstructure and mechanical properties of AA2618 DC cast alloy were investigated using scanning electron microscopy (SEM), transmission electron microscopy (TEM) and hardness and tensile testing. The as-cast microstructure contained a considerable amount of coarse intermetallic phases, including Al 2 CuMg, Al 2 Cu, Al 7 Cu 4 Ni, Al 7 Cu 2 (Fe,Ni) and Al 9 FeNi, resulting in poor mechanical properties. Solution treatment at 530 °C for 5 h dissolved the first three phases into the solid solution and consequently improved the mechanical properties of the alloy. By utilizing the appropriate aging temperature and time, different combinations of strength and ductility could be obtained to fulfill the design requirements of large-mold applications. The strengthening of AA2618 DC cast alloy under the aging conditions studied was caused by GPB zones and S′ precipitates. The evolution of both precipitates in terms of their size and density was observed to have a significant effect on the mechanical properties of the alloy

Modes of fossil preservation

Science.gov (United States)

Schopf, J.M.

1975-01-01

The processes of geologic preservation are important for understanding the organisms represented by fossils. Some fossil differences are due to basic differences in organization of animals and plants, but the interpretation of fossils has also tended to be influenced by modes of preservation. Four modes of preservation generally can be distinguished: (1) Cellular permineralization ("petrifaction") preserves anatomical detail, and, occasionally, even cytologic structures. (2) Coalified compression, best illustrated by structures from coal but characteristic of many plant fossils in shale, preserves anatomical details in distorted form and produces surface replicas (impressions) on enclosing matrix. (3) Authigenic preservation replicates surface form or outline (molds and casts) prior to distortion by compression and, depending on cementation and timing, may intergrade with fossils that have been subject to compression. (4) Duripartic (hard part) preservation is characteristic of fossil skeletal remains, predominantly animal. Molds, pseudomorphs, or casts may form as bulk replacements following dissolution of the original fossil material, usually by leaching. Classification of the kinds of preservation in fossils will aid in identifying the processes responsible for modifying the fossil remains of both animals and plants. ?? 1975.

Molds in the Environment

Science.gov (United States)

... on Facebook Tweet Share Compartir Molds in the Environment What are molds? What are some of the ... molds found? Molds are found in virtually every environment and can be detected, both indoors and outdoors, ...

[Comparison of surface light scattering of acrylic intraocular lenses made by lathe-cutting and cast-molding methods--long-term observation and experimental study].

Science.gov (United States)

Nishihara, Hitoshi; Ayaki, Masahiko; Watanabe, Tomiko; Ohnishi, Takeo; Kageyama, Toshiyuki; Yaguchi, Shigeo

2004-03-01

To compare the long-term clinical and experimental results of soft acrylic intraocular lenses(IOLs) manufactured by the lathe-cut(LC) method and by the cast-molding(CM) method. This was a retrospective study of 20 patients(22 eyes) who were examined in a 5- and 7-year follow-up study. Sixteen eyes were implanted with polyacrylic IOLs manufactured by the LC method and 6 eyes were implanted with polyacrylic IOLs manufactured by the CM method. Postoperative measurements included best corrected visual acuity, contrast sensitivity, biomicroscopic examination, and Scheimpflug slit-lamp images to evaluate surface light scattering. Scanning electron microscopy and three-dimensional surface analysis were conducted. At 7 years, the mean visual acuity was 1.08 +/- 0.24 (mean +/- standard deviation) in the LC group and 1.22 +/- 0.27 in the CM group. Surface light-seatter was 12.0 +/- 4.0 computer compatible tapes(CCT) in the LC group and 37.4 +/- 5.4 CCT in the CM group. Mean surface roughness was 0.70 +/- 0.07 nm in the LC group and 6.16 +/- 0.97 nm in the CM group. Acrylic IOLs manufactured by the LC method are more stable in long-termuse.

Production and characterization of cast aluminum sponges

International Nuclear Information System (INIS)

Rivarola, M.E; Marmo Lupano, J.M; Malachevsky, M.T

2004-01-01

Cellular materials have unique physical features that make them particularly appropriate for applications that require high mechanical resistance and low weight. They can be produced in different ways: by powder metallurgy, by infiltration over plastic foams, adding a releasing agent of gas to a fused metal or simply injecting gas into it. Cellular structures can also be formed by casting onto a pore forming material. This work proposes a method that is basically similar to the last one mentioned but that allows the resulting material's porosity and topology to be controlled. Thus, the mechanical or thermal features of the material that is being manufactured can be predicted and/or designed. First the three dimensional print of a mold is made in a 3D printer, which is the negative of the piece that will be produced. Then a vacuum assisted aluminum cast is made. A preliminary study is presented for the applicability of this method and the mechanical properties of the resulting sponges (CW)

Zr O2-Y2 O3 ceramic bodies forming by slip casting

International Nuclear Information System (INIS)

Menezes, Cristiane A.B. de; Menezes, Fernanda; Ussui, Valter; Lazar, Dolores R.R.; Paschoal, Jose Otavio A.

1996-01-01

Slip casting technique of 3 mol% yttria stabilized zirconia powders suspensions has been used for ceramic bodies forming. The powders were produced by coprecipitation process with ammonium hydroxide in the Zirconium Pilot Plant of IPEN (Institute for Energy and Nuclear Researches, Sao Paulo, SP, (Brazil). Experiments were performed by preparing suspensions of powders with dispersing agents. These suspensions were submitted to milling and casting in plaster molds. After drying and heating at 700 deg C, the obtained specimens were sintered at 1500 deg C for 3 hours. The ceramic bodies were investigated by scanning electron microscopy and X-ray diffraction, and tested in high temperature conditions. (author)

Phenolic Molding Compounds

Science.gov (United States)

Koizumi, Koji; Charles, Ted; de Keyser, Hendrik

Phenolic Molding Compounds continue to exhibit well balanced properties such as heat resistance, chemical resistance, dimensional stability, and creep resistance. They are widely applied in electrical, appliance, small engine, commutator, and automotive applications. As the focus of the automotive industry is weight reduction for greater fuel efficiency, phenolic molding compounds become appealing alternatives to metals. Current market volumes and trends, formulation components and its impact on properties, and a review of common manufacturing methods are presented. Molding processes as well as unique advanced techniques such as high temperature molding, live sprue, and injection/compression technique provide additional benefits in improving the performance characterisitics of phenolic molding compounds. Of special interest are descriptions of some of the latest innovations in automotive components, such as the phenolic intake manifold and valve block for dual clutch transmissions. The chapter also characterizes the most recent developments in new materials, including long glass phenolic molding compounds and carbon fiber reinforced phenolic molding compounds exhibiting a 10-20-fold increase in Charpy impact strength when compared to short fiber filled materials. The role of fatigue testing and fatigue fracture behavior presents some insight into long-term reliability and durability of glass-filled phenolic molding compounds. A section on new technology outlines the important factors to consider in modeling phenolic parts by finite element analysis and flow simulation.

Investigation of gating parameter, temperature and density effects on mold filling in the lost foam casting (LFC process by direct observation method

Directory of Open Access Journals (Sweden)

A. Sharifi

2013-03-01

Full Text Available Mold filling sequence of A356 aluminum alloy was investigated with the aid of direct observation method (photography method. The results show that increase of the foam density causes decrease of the filling rate and increase of the filling time. Foam density has more pronounced effect on mold filling rate rather than pouring temperature. Gating design also affects the profile of molten metal advancement in the mold. The results show that the higher filling rate was obtained with G2 gating than with other gating system. Regarding the mold filling pattern, G3 gating system has more effective contact interface than G2 gating system and has lower filling time. Filling time in G4 gating and G1 gating system are nearly the same.

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

Science.gov (United States)

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

2012-01-01

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

Investigation of the tensile properties of continuous steel wire-reinforced gray cast iron composite

Energy Technology Data Exchange (ETDEWEB)

Akdemir, Ahmet [Department of Mechanical Engineering, Selcuk University, Konya (Turkey); Kus, Recai [Department of Mechanical Education, Selcuk University, Konya (Turkey); Simsir, Mehmet, E-mail: msimsir@cumhuriyet.edu.tr [Department of Metallurgical and Materials Engineering, Cumhuriyet University, Kayseri Yolu 7. Km, 58140 Sivas (Turkey)

2011-04-25

Research highlights: {yields} Metal matrix composite (MMC) is an important structural material. {yields} Gray cast irons as a matrix material in MMC have more advantages than other cast irons. {yields} Interface greatly determines the mechanical properties of MMC. {yields} Interface formed by diffusion of carbon atoms. {yields} While decarburizing takes place in gray cast iron, carburiszing takes place in steel near the interface. - Abstract: The aim of the present study was to improve the tensile properties of gray cast iron by reinforcing the material with a steel wire. The composite was produced by sand mold casting, and the specimens were normalized by applying heat treatments at 800 deg. C, 850 deg. C, and 900 deg. C. Tension tests were conducted on gray cast iron and composite specimens, and the microstructure of the specimens was examined with an optical microscope. The fracture surface of the tension test specimens was examined with a scanning electron microscope (SEM), and graphite-free transition regions with high degrees of hardness were observed due to the diffusion of carbon from the cast iron to the steel wire. The microstructure of the transition region (fine pearlitic phase with partially dissolved graphite flakes) and the bond quality in the transition region increased the tensile properties of cast iron composites. Also, it is concluded that the tensile properties of gray cast iron increased with an increase in the normalization temperature.

Investigation of the tensile properties of continuous steel wire-reinforced gray cast iron composite

International Nuclear Information System (INIS)

Akdemir, Ahmet; Kus, Recai; Simsir, Mehmet

2011-01-01

Research highlights: → Metal matrix composite (MMC) is an important structural material. → Gray cast irons as a matrix material in MMC have more advantages than other cast irons. → Interface greatly determines the mechanical properties of MMC. → Interface formed by diffusion of carbon atoms. → While decarburizing takes place in gray cast iron, carburiszing takes place in steel near the interface. - Abstract: The aim of the present study was to improve the tensile properties of gray cast iron by reinforcing the material with a steel wire. The composite was produced by sand mold casting, and the specimens were normalized by applying heat treatments at 800 deg. C, 850 deg. C, and 900 deg. C. Tension tests were conducted on gray cast iron and composite specimens, and the microstructure of the specimens was examined with an optical microscope. The fracture surface of the tension test specimens was examined with a scanning electron microscope (SEM), and graphite-free transition regions with high degrees of hardness were observed due to the diffusion of carbon from the cast iron to the steel wire. The microstructure of the transition region (fine pearlitic phase with partially dissolved graphite flakes) and the bond quality in the transition region increased the tensile properties of cast iron composites. Also, it is concluded that the tensile properties of gray cast iron increased with an increase in the normalization temperature.

Transferability of glass lens molding

Science.gov (United States)

Katsuki, Masahide

2006-02-01

Sphere lenses have been used for long time. But it is well known that sphere lenses theoretically have spherical aberration, coma and so on. And, aspheric lenses attract attention recently. Plastic lenses are molded easily with injection machines, and are relatively low cost. They are suitable for mass production. On the other hand, glass lenses have several excellent features such as high refractive index, heat resistance and so on. Many aspheric glass lenses came to be used for the latest digital camera and mobile phone camera module. It is very difficult to produce aspheric glass lenses by conventional process of curve generating and polishing. For the solution of this problem, Glass Molding Machine was developed and is spreading through the market. High precision mold is necessary to mold glass lenses with Glass Molding Machine. The mold core is ground or turned by high precision NC aspheric generator. To obtain higher transferability of the mold core, the function of the molding machine and the conditions of molding are very important. But because of high molding temperature, there are factors of thermal expansion and contraction of the mold and glass material. And it is hard to avoid the factors. In this session, I introduce following items. [1] Technology of glass molding and the machine is introduced. [2] The transferability of glass molding is analyzed with some data of glass lenses molded. [3] Compensation of molding shape error is discussed with examples.

Resistant metatarsus adductus: prospective randomized trial of casting versus orthosis.

Science.gov (United States)

Herzenberg, John E; Burghardt, Rolf D

2014-03-01

Metatarsus adductus is a common pediatric foot deformity related to intrauterine molding. It is usually a mild deformity that responds well to simple observation or minimal treatment with a home program of stretching. Resistant cases may need a more aggressive approach such as serial casting or special bracing to avoid the need for surgical intervention. We compared clinical outcomes using serial casting with orthoses for resistant metatarsus adductus. We prospectively treated 27 infants (43 feet) between the ages 3 and 9 months who failed home stretching treatment. Patients were randomized to either serial plaster casting or Bebax orthoses. Footprints and simulated weight-bearing anteroposterior and lateral view radiographs were made at entry and follow-up. There was no statistical difference between casting and Bebax for the following parameters: age at study entry, length of treatment, number of clinic visits, follow-up, and follow-up maintenance treatments. Both groups showed improvement in footprint and radiographic measurements post-treatment, without worsening of heel valgus. The Bebax group had greater improvement in the footprint heel bisector measurement than the casting group. The Bebax treatment requires more active parental cooperation. A simulated cost analysis of materials and office visit charges, however, revealed that Bebax treatment was significantly less expensive, about half the cost of casting. Because of the cost savings and virtually identical clinical results, we recommend the Bebax orthosis for resistant metatarsus in pre-walking infants with parents who are compliant. Other considerations include specific insurance plans, which may pay for casts but not orthoses.

Stress analysis of biomass fuel molding machine piston type stamping forming cone

Directory of Open Access Journals (Sweden)

Wu Gaofeng

2015-01-01

Full Text Available It is established the ram biomass straw machine as the analysis object in this paper,the molding machine cones of stress in the forming process of the analysis of the system. We used pottery instead of Wear-resistant cast iron for improving the performance of forming sleeve. The structure of the forming sleeve was analyzed with the mechanical module of a soft named Pro/engineer in this paper. The result indicated that the program was feasible. With the sensitivity analysis we identified the suitable angle for the sleeve.

Metal Injection Molding (MIM of Magnesium and Its Alloys

Directory of Open Access Journals (Sweden)

Martin Wolff

2016-05-01

Full Text Available Current research has highlighted that magnesium and its alloys as biodegradable material are highly suitable for biomedical applications. The new material fully degrades into nontoxic elements and offers material properties matching those of human bone tissue. As biomedical implants are rather small and complex in shape, the metal injection molding (MIM technique seems to be well suited for the near net shape mass production of such parts. Furthermore, MIM of Mg-alloys is of high interest in further technical fields. This study focusses on the performance of MIM-processing of magnesium alloy powders. It includes Mg-specific development of powder blending, feedstock preparation, injection molding, solvent and thermal debinding and final sintering. Even though Mg is a highly oxygen-affine material forming a stable oxide layer on each particle surface, the material can be sintered to nearly dense parts, providing mechanical properties matching those of as cast material. An ultimate tensile strength of 142 MPa, yield strength of 67 MPa, elastic modulus of 40 GPa and 8% elongation at fracture could be achieved using novel organic polymer binders for the feedstock preparation. Thus, first implant demonstrator parts could be successfully produced by the MIM technique.

Chemorheology of in-mold coating for compression molded SMC applications

Science.gov (United States)

Ko, Seunghyun; Straus, Elliott J.; Castro, Jose M.

2015-05-01

In-mold coating (IMC) is applied to compression molded sheet molding compound (SMC) exterior automotive or truck body panels as an environmentally friendly alternative to make the surface conductive for subsequent electrostatic painting operations. The coating is a thermosetting liquid that when injected onto the surface of the part cures and bonds to provide a smooth conductive surface. In order to optimize the IMC process, it is essential to predict the time available for flow, that is the time before the thermosetting reaction starts (inhibition time) as well as the time when the coating has enough structural integrity so that the mold can be opened without damaging the part surface (cure time). To predict both the inhibition time and the cure time, it is critical to study the chemorheology of IMC. In this paper, we study the chemorheology for a typical commercial IMC system, and show its relevance to both the flow and cure time for the IMC stage during SMC compression molding.

Position Accuracy of Implant Analogs on 3D Printed Polymer versus Conventional Dental Stone Casts Measured Using a Coordinate Measuring Machine.

Science.gov (United States)

Revilla-León, Marta; Gonzalez-Martín, Óscar; Pérez López, Javier; Sánchez-Rubio, José Luis; Özcan, Mutlu

2017-11-17

To compare the accuracy of implant analog positions on complete edentulous maxillary casts made of either dental stone or additive manufactured polymers using a coordinate measuring machine (CMM). A completely edentulous maxillary model of a patient with 7 implant analogs was obtained. From this model, two types of casts were duplicated, namely conventional dental stone (CDS) using a custom tray impression technique after splinting (N = 5) and polymer cast using additive manufacturing based on the STL file generated. Polymer casts (N = 20; n = 5 per group) were fabricated using 4 different additive manufacturing technologies (multijet printing-MJP1, direct light processing-DLP, stereolithography-SLA, multijet printing-MJP2). CMM was used to measure the correct position of each implant, and distortion was calculated for each system at x-, y-, and z-axes. Measurements were repeated 3 times per specimen in each axis yielding a total of 546 measurements. Data were analyzed using ANOVA, Sheffé tests, and Bonferroni correction (α = 0.05). Compared to CMM, the mean distortion (μm) ranged from 22.7 to 74.9, 23.4 to 49.1, and 11.0 to 85.8 in the x-, y-, and z-axes, respectively. CDS method (x-axis: 37.1; z-axis: 27.62) showed a significant difference compared to DLP on the x-axis (22.7) (p = 0.037) and to MJP1 on the z-axis (11.0) (p = 0.003). Regardless of the cast system, x-axes showed more distortion (42.6) compared to y- (34.6) and z-axes (35.97). Among additive manufacturing technologies, MJP2 presented the highest (64.3 ± 83.6), and MJP1 (21.57 ± 16.3) and DLP (27.07 ± 20.23) the lowest distortion, which was not significantly different from CDS (32.3 ± 22.73) (p > 0.05). For the fabrication of the definitive casts for implant prostheses, one of the multijet printing systems and direct light processing additive manufacturing technologies showed similar results to conventional dental stone. Conventional dental stone casts could be accurately duplicated using some

Thermal Stress of Surface of Mold Cavities and Parting Line of Silicone Molds

Directory of Open Access Journals (Sweden)

Bajčičák Martin

2014-06-01

Full Text Available The paper is focused on the study of thermal stress of surface of mold cavities and parting line of silicone molds after pouring. The silicone mold White SD - THT was thermally stressed by pouring of ZnAl4Cu3 zinc alloy with pouring cycle 20, 30 and 40 seconds. The most thermally stressed part of surface at each pouring cycle is gating system and mold cavities. It could be further concluded that linear increase of the pouring cycle time leads to the exponential increasing of the maximum temperature of mold surface after its cooling. The elongated pouring cycle increases the temperature accumulated on the surface of cavities and the ability of silicone mold to conduct the heat on its surface decreases, because the low thermal conductivity of silicone molds enables the conduction of larger amount of heat into ambient environment.

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

International Nuclear Information System (INIS)

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

2015-01-01

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

Internal Casting Stresses and Dimensional Stability

DEFF Research Database (Denmark)

Andriollo, Tito; Vedel-Smith, Nikolaj Kjelgaard; Thorborg, Jesper

2017-01-01

, accelerated stress corrosion, decreased fatigue resistance, and so on. In addition, they can also be responsible for undesirable shape distortions, which may compromise the fulfillment of geometrical tolerance requirements. As a consequence, a good understanding of what residual stresses are, how they form......It is common knowledge that cast iron components may be affected by the presence of residual stresses. This often represents a serious threat, because residual stresses almost invariably cause a significant degradation of the most important material properties, such as reduced fracture toughness...

Experimental and Numerical Modeling of Fluid Flow Processes in Continuous Casting: Results from the LIMMCAST-Project

Science.gov (United States)

Timmel, K.; Kratzsch, C.; Asad, A.; Schurmann, D.; Schwarze, R.; Eckert, S.

2017-07-01

The present paper reports about numerical simulations and model experiments concerned with the fluid flow in the continuous casting process of steel. This work was carried out in the LIMMCAST project in the framework of the Helmholtz alliance LIMTECH. A brief description of the LIMMCAST facilities used for the experimental modeling at HZDR is given here. Ultrasonic and inductive techniques and the X-ray radioscopy were employed for flow measurements or visualizations of two-phase flow regimes occurring in the submerged entry nozzle and the mold. Corresponding numerical simulations were performed at TUBAF taking into account the dimensions and properties of the model experiments. Numerical models were successfully validated using the experimental data base. The reasonable and in many cases excellent agreement of numerical with experimental data allows to extrapolate the models to real casting configurations. Exemplary results will be presented here showing the effect of electromagnetic brakes or electromagnetic stirrers on the flow in the mold or illustrating the properties of two-phase flows resulting from an Ar injection through the stopper rod.

Rapid prototyping of a complex model for the manufacture of plaster molds for slip casting ceramic

Directory of Open Access Journals (Sweden)

D. P. C. Velazco

2014-12-01

Full Text Available Computer assisted designing (CAD is well known for several decades and employed for ceramic manufacturing almost since the beginning, but usually employed in the first part of the projectual ideation processes, neither in the prototyping nor in the manufacturing stages. The rapid prototyping machines, also known as 3D printers, have the capacity to produce in a few hours real pieces using plastic materials of high resistance, with great precision and similarity with respect to the original, based on unprecedented digital models produced by means of modeling with specific design software or from the digitalization of existing parts using the so-called 3D scanners. The main objective of the work is to develop the methodology used in the entire process of building a part in ceramics from the interrelationship between traditional techniques and new technologies for the manufacture of prototypes. And to take advantage of the benefits that allow us this new reproduction technology. The experience was based on the generation of a complex piece, in digital format, which served as the model. A regular 15 cm icosahedron presented features complex enough not to advise the production of the model by means of the traditional techniques of ceramics (manual or mechanical. From this digital model, a plaster mold was made in the traditional way in order to slip cast clay based slurries, freely dried in air and fired and glazed in the traditional way. This experience has shown the working hypothesis and opens up the possibility of new lines of work to academic and technological levels that will be explored in the near future. This technology provides a wide range of options to address the formal aspect of a part to be performed for the field of design, architecture, industrial design, the traditional pottery, ceramic art, etc., which allow you to amplify the formal possibilities, save time and therefore costs when drafting the necessary and appropriate matrixes

Hydrogen silsesquioxane mold coatings for improved replication of nanopatterns by injection molding

DEFF Research Database (Denmark)

Hobæk, Thor Christian; Matschuk, Maria; Kafka, Jan

2015-01-01

of replication, thus allowing more time to fill the nanoscale cavities compared to standard metal molds. A monolayer of a fluorinated silane (heptadecafluorotrichlorosilane) deposited on the mold surface reduces the mold/polymer interfacial energy to support demolding of the polymer replica. The mechanical...

Distortion

OpenAIRE

Schultz, Isabella Odorico; Zmylon, Nanna Nielsen; Britze, Juliane

2014-01-01

This paper investigates the audience’s perception of the music festival Distortion. By conducting a field-study focusing on the subject’s perception of Distortion, their perception of the Distortion-attendants, and their perception on the promotion of Distortion, the paper will relate the audience perception to the promotion of the event. Using the group’s own research on the promotion of Distortion, the paper points out both the consistencies and the inconsistencies between the promotion and...

Experimental Observation and Analytical Modeling of Melting and Solidification during Aluminum Alloy Repair by Turbulence Flow Casting

Directory of Open Access Journals (Sweden)

Muki Satya Permana

2015-10-01

Full Text Available This paper presents an overview on the state of the art of applicable casting technology for applications in the field of repairing aluminum alloy components. Repair process on the Al alloy sample using similar metal has been carried out to investigate the micro-structural effect. Joining occurs as a result of convection heat transfer of molten flow into the sand mold which melts the existing base metal inside the mold and subsequent solidification. The analytical model has been developed to describe aluminum alloy component repair by turbulence flow casting. The model is designed based on heat transfer principle that can handle the phenomena of heat flow. The experimental result and analytical model analyses pointed out that joint quality are greatly affected by parameters of preheating temperature and duration of molten metal flow in the mold. To obtain a desired metallurgical sound at the joint, the optimum temperature and time were adjusted in order to obtain a similarity of microstructure between filler and base metal. This model is aimed to predict the use of the process parameter ranges in order to have the optimum parameters when it is applied to the experiment. The fixed parameters are flow rate, sand ratio, and pouring temperature. The process parameters are preheating temperature and pouring time. It is concluded that analytical modeling has good agreement with the experimental result.

Experimental Observation and Analytical Modeling of Melting and Solidification during Aluminum Alloy Repair by Turbulence Flow Casting

Directory of Open Access Journals (Sweden)

Muki Satya Permana

2017-03-01

Full Text Available This paper presents an overview on the state of the art of applicable casting technology for applications in the field of repairing Aluminium Alloy components. Repair process on the Aluminium sample using similar metal has been carried out to investigate the micro-structural effect. Joining occurs as a result of convection heat transfer of molten flow into the sand mold which melts the existing base metal inside the mold and subsequent solidification. The analytical model has been developed to describe aluminium component repair by Turbulence Flow Casting. The model built is based on heat transfer principle that can handle the phenomena of heat flow. The experimental result and analytical model analyses pointed out that joint quality are greatly affected by parameters of preheating temperature and duration of molten metal flow in the mold. To obtain a desired metallurgical sound at the joint, the optimum temperature and time were adjusted in order to obtain a similarity of microstructure between filler and base metal. This model is aimed to predict the use of the process parameter ranges in order to have the optimum parameters when it is applied to the experiment. The fixed parameters are flow rate, sand ratio, and pouring temperature. The process parameters are preheating temperature and pouring time. It is concluded that anaytical modeling has good agreement with the experimental result

Study of the Mechanism of Liquid Slag Infiltration for Lubrication in Slab Continuous Casting

Science.gov (United States)

Zhang, Shaoda; Wang, Qiangqiang; He, Shengping; Wang, Qian

2018-04-01

Consistent and uniform lubrication of the solidifying shell, especially in the meniscus, is crucial for the smooth continuous casting operation and production of strands free of surface defects. Thus, the current study established a coupled model to study the inflow behavior of liquid slag to the mold-strand channel, taking the solidification of steel and slag and the periodic oscillation of mold into account. The difficulties and solutions for the simulation were described in detail. The predicted profiles of the slag rim and initial shell were in good agreement with the reports. The main results indicated that liquid slag could be squeezed out and back into the slag pool in a negative strip period while a large amount of liquid slag could infiltrate into the mold-strand channel. Thus, the amount of slag consumed in the negative strip period was relatively small compared with that in the positive strip period. The predicted variation of slag consumption during mold oscillation was periodic, and the average value was 0.274 kg/m2, which agreed well with the slag consumption in industrial practice. The current model can predict and optimize the oscillation parameters aiming at stable lubrication conditions.

Interactive Mold House Tour

Science.gov (United States)

Get a quick glimpse of some of the most important ways to protect your home from mold by this interactive tour of the Mold House. Room-by-room, you'll learn about common mold issues and how to address them.

A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties

Directory of Open Access Journals (Sweden)

Xuezheng Zhang

2016-05-01

Full Text Available Microstructural and mechanical characterization of 10 vol% SiC particles (SiCp reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF was investigated in comparison with the PTF and permanent mold cast (PMC 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiCp, which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

A Comparative Study on Permanent Mold Cast and Powder Thixoforming 6061 Aluminum Alloy and Sicp/6061Al Composite: Microstructures and Mechanical Properties.

Science.gov (United States)

Zhang, Xuezheng; Chen, Tijun; Qin, He; Wang, Chong

2016-05-24

Microstructural and mechanical characterization of 10 vol% SiC particles (SiC p ) reinforced 6061 Al-based composite fabricated by powder thixoforming (PTF) was investigated in comparison with the PTF and permanent mold cast (PMC) 6061 monolithic alloys. The results reveal that the microstructure of the PMC alloy consists of coarse and equiaxed α dendrites and interdendritic net-like eutectic phases. However, the microstructure of the PTF composite, similar to that of the PTF alloy, consists of near-spheroidal primary particles and intergranular secondarily solidified structures except SiC p , which are distributed in the secondarily solidified structures. The eutectics amount in the PTF materials is distinctly lower than that in the PMC alloy, and the microstructures of the former materials are quite compact while that of the latter alloy is porous. Therefore, the PTF alloy shows better tensile properties than the PMC alloy. Owing to the existence of the SiC reinforcing particles, the PTF composite attains an ultimate tensile strength and yield strength of 230 MPa and 128 MPa, representing an enhancement of 27.8% and 29.3% than those (180 MPa and 99 MPa) of the PTF alloy. A modified model based on three strengthening mechanisms was proposed to calculate the yield strength of the PTF composite. The obtained theoretical results were quite consistent with the experimental data.

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

Science.gov (United States)

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

2016-11-16

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

Freckle Defect Formation near the Casting Interfaces of Directionally Solidified Superalloys

Directory of Open Access Journals (Sweden)

Jianping Hong

2016-11-01

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

FY 1999 report on the results of the research and development project for new industry creating type industrial science and technology. Innovated casting simulation technology; 1999 nendo kakushinteki chuzo simulation gijutsu seika hokokusho

Energy Technology Data Exchange (ETDEWEB)

NONE

2000-03-01

Described herein are the results of the FY1999 research and development project, implemented for development of the casting process simulation technologies, with the objectives to improve productivity, reduce cost, reduce the development periods, and so on for casting. For development of the mold filling and solidification process simulation programs, the fundamental algorithm and basic designs of the three-dimensional programs are developed, and the two-dimensional programs are made on a trial basis. For the analysis of the two-dimensional mold filling models, it is found that gas entrapment may occur even in the case of sand mold casting with low permeability. For development of the solidification structure and defect formation simulation programs, the basic investigations are done for the fundamental algorithms to simulate the solidification structures and porosity defects, and for the mechanisms involved in formation of these defects. These efforts lead to adoption of the CA method, and development of the algorithms for reducing CPU time and computational memory requirements by the active block method. For development of the related measurement techniques, the construction plans and specifications of an electromagnetic levitation furnace are investigated for the underground microgravity test center. (NEDO)

An easy mold

International Nuclear Information System (INIS)

Kim, Nam Hun; Choe, Jong Sun

1988-04-01

This book deals with an easy mold, which introduces what is a mold kinds and classification of mold. It gives descriptions of easy theories such as basic knowledge on shearing work, clearance, power for punching and shear angle, basic knowledge for bending such as transform by bending, the minimal bending radius, spring back, the length of material, flexural strength for bending, fundamental knowledge for drawing work with transform of drawing and limitation of drawing.

No Correlation between Distorted Body Representations Underlying Tactile Distance Perception and Position Sense

Directory of Open Access Journals (Sweden)

Matthew R. Longo

2016-11-01

Full Text Available Both tactile distance perception and position sense are believed to require that immediate afferent signals be referenced to a stored representation of body size and shape (the body model. For both of these abilities, recent studies have reported that the stored body representations involved are highly distorted, at least in the case of the hand, with the hand dorsum represented as wider and squatter than it actually is. Here, we investigated whether individual differences in the magnitude of these distortions are shared between tactile distance perception and position sense, as would be predicted by the hypothesis that a single distorted body model underlies both tasks. We used established task to measure distortions of the represented shape of the hand dorsum. Consistent with previous results, in both cases there were clear biases to overestimate distances oriented along the medio-lateral axis of the hand compared to the proximo-distal axis. Moreover, within each task there were clear split-half correlations, demonstrating that both tasks show consistent individual differences. Critically, however, there was no correlation between the magnitudes of distortion in the two tasks. This casts doubt on the proposal that a common body model underlies both tactile distance perception and position sense.

The effect of annealing temperatures and cooling rates on microstructure and mechanical properties of investment cast Ti-6Al-4V alloy

International Nuclear Information System (INIS)

Jovanovic, M.T.; Tadic, S.; Zec, S.; Miskovic, Z.; Bobic, I.

2006-01-01

Production of investment castings of titanium alloys was considerably increased during last years due to the significant cost savings compared to complicated machined parts. However, the disadvantage of as-cast titanium alloys is that the heat-treatment remains only a limited option for improvement of their properties. The object of this paper was to study the effect of heat-treatment of investment cast Ti-6Al-4V alloy performing X-ray diffraction analysis, light microscopy and quantitative metallography together with hardness and room temperature tensile tests. The effect of annealing temperatures (above and below β transus temperature) and cooling rates on microstructure and mechanical properties was discussed in terms of the β → α transformation. The results of this paper also show that, besides heat treatment parameters, melting and casting practice together with mold technology strongly influence the properties of castings

Formation mechanism of spheroidal carbide in ultra-low carbon ductile cast iron

Directory of Open Access Journals (Sweden)

Bin-guo Fu

2016-09-01

Full Text Available The formation mechanism of the spheroidal carbide in the ultra-low carbon ductile cast iron fabricated by the metal mold casting technique was systematically investigated. The results demonstrated that the spheroidal carbide belonged to eutectic carbide and crystallized in the isolated eutectic liquid phase area. The formation process of the spheroidal carbide was related to the contact and the intersection between the primary dendrite and the secondary dendrite of austenite. The oxides of magnesium, rare earths and other elements can act as heterogeneous nucleation sites for the spheroidal carbide. It was also found that the amount of the spheroidal carbide would increase with an increase in carbon content. The cooling rate has an important influence on the spheroidal carbide under the same chemical composition condition.

Hydrophobicity Tuning by the Fast Evolution of Mold Temperature during Injection Molding

Directory of Open Access Journals (Sweden)

Sara Liparoti

2018-03-01

Full Text Available The surface topography of a molded part strongly affects its functional properties, such as hydrophobicity, cleaning capabilities, adhesion, biological defense and frictional resistance. In this paper, the possibility to tune and increase the hydrophobicity of a molded polymeric part was explored. An isotactic polypropylene was injection molded with fast cavity surface temperature evolutions, obtained adopting a specifically designed heating system layered below the cavity surface. The surface topology was characterized by atomic force microscopy (AFM and, concerning of hydrophobicity, by measuring the water static contact angle. Results show that the hydrophobicity increases with both the temperature level and the time the cavity surface temperature was kept high. In particular, the contact angle of the molded sample was found to increase from 90°, with conventional molding conditions, up to 113° with 160 °C of cavity surface temperature kept for 18 s. This increase was found to be due to the presence of sub-micro and nano-structures characterized by high values of spatial frequencies which could be more accurately replicated by adopting high heating temperatures and times. The surface topography and the hydrophobicity resulted therefore tunable by selecting appropriate injection molding conditions.

Grindability of dental cast Ti-Ag and Ti-Cu alloys.

Science.gov (United States)

Kikuchi, Masafumi; Takahashi, Masatoshi; Okabe, Toru; Okuno, Osamu

2003-06-01

Experimental Ti-Ag alloys (5, 10, and 20 mass% Ag) and Ti-Cu alloys (2, 5, and 10 mass% Cu) were cast into magnesia molds using a dental casting machine, and their grindability was investigated. At the lowest grinding speed (500 m min(-1)), there were no statistical differences among the grindability values of the titanium and titanium alloys. The grindability of the alloys increased as the grinding speed increased. At the highest grinding speed (1500 m x min(-1)), the grindability of the 20% Ag, 5% Cu, and 10% Cu alloys was significantly higher than that of titanium. It was found that alloying with silver or copper improved the grindability of titanium, particularly at a high speed. It appeared that the decrease in elongation caused by the precipitation of small amounts of intermetallic compounds primarily contributed to the favorable grindability of the experimental alloys.

Effecting aging time of epoxy molding compound to molding process for integrated circuit packaging

Science.gov (United States)

Tachapitunsuk, Jirayu; Ugsornrat, Kessararat; Srisuwitthanon, Warayoot; Thonglor, Panakamon

2017-09-01

This research studied about effecting aging time of epoxy molding compound (EMC) that effect to reliability performance of integrated circuit (IC) package in molding process. Molding process is so important of IC packaging process for protecting IC chip (or die) from temperature and humidity environment using encapsulated EMC. For general molding process, EMC are stored in the frozen at 5°C and left at room temperature at 25 °C for aging time on self before molding of die onto lead frame is 24 hours. The aging time effect to reliability performance of IC package due to different temperature and humidity inside the package. In experiment, aging time of EMC were varied from 0 to 24 hours for molding process of SOIC-8L packages. For analysis, these packages were tested by x-ray and scanning acoustic microscope to analyze properties of EMC with an aging time and also analyzed delamination, internal void, and wire sweep inside the packages with different aging time. The results revealed that different aging time of EMC effect to properties and reliability performance of molding process.

Effect of surface reaction layer on grindability of cast titanium alloys.

Science.gov (United States)

Ohkubo, Chikahiro; Hosoi, Toshio; Ford, J Phillip; Watanabe, Ikuya

2006-03-01

The purpose of this study was to investigate the effect of the cast surface reaction layer on the grindability of titanium alloys, including free-machining titanium alloy (DT2F), and to compare the results with the grindability of two dental casting alloys (gold and Co-Cr). All titanium specimens (pure Ti, Ti-6Al-4V and DT2F) were cast using a centrifugal casting machine in magnesia-based investment molds. Two specimen sizes were used to cast the titanium metals so that the larger castings would be the same size as the smaller gold and Co-Cr alloy specimens after removal of the surface reaction layer (alpha-case). Grindability was measured as volume loss ground from a specimen for 1 min using a handpiece engine with a SiC abrasive wheel at 0.1 kgf and four circumferential wheel speeds. For the titanium and gold alloys, grindability increased as the rotational speed increased. There was no statistical difference (p>0.05) in grindability for all titanium specimens either with or without the alpha-case. Of the titanium metals tested, Ti-6 Al-4V had the greatest grindability at higher speeds, followed by DT2F and CP Ti. The grindability of the gold alloy was similar to that of Ti-6 Al-4V, whereas the Co-Cr alloy had the lowest grindability. The results of this study indicated that the alpha-case did not significantly affect the grindability of the titanium alloys. The free-machining titanium alloy had improved grindability compared to CP Ti.

Effects of mold geometry on fiber orientation of powder injection molded metal matrix composites

Energy Technology Data Exchange (ETDEWEB)

Ahmad, Faiz, E-mail: faizahmad@petronas.com.my; Aslam, Muhammad, E-mail: klaira73@gmail.com; Altaf, Khurram, E-mail: khurram.altaf@petronas.com.my; Shirazi, Irfan, E-mail: irfanshirazi@hotmail.com [Mechanical Engineering Universiti Teknologi PETRONAS Malaysia (Malaysia)

2015-07-22

Fiber orientations in metal matrix composites have significant effect on improving tensile properties. Control of fiber orientations in metal injection molded metal composites is a difficult task. In this study, two mold cavities of dimensions 6x6x90 mm and 10x20x180 mm were used for comparison of fiber orientation in injection molded metal composites test parts. In both mold cavities, convergent and divergent flows were developed by modifying the sprue dimensions. Scanning electron microscope (SEM) was used to examine the fiber orientations within the test samples. The results showed highly aligned fiber in injection molded test bars developed from the convergent melt flow. Random orientation of fibers was noted in the composites test bars produced from divergent melt flow.

A Study of the Heat Transfer Behavior of Mold Fluxes with Different Amounts of Al2O3

Directory of Open Access Journals (Sweden)

Lejun Zhou

2016-06-01

Full Text Available The element Al in molten aluminum containing steel reacts with the liquid mold flux and thus be transferred into the mold flux during the continuous casting process. Additionally, the increase in alumina in a mold flux changes its performance significantly. Thus, in this paper, the heat transfer properties of mold fluxes with the Al2O3 content ranging from 7 to 40 wt. % were studied with the Infrared Emitter Technique (IET. Results found that heat flux at the final steady state decreased from 423 kW·m−2 to 372 kW·m−2 with the increase in Al2O3 content from 7% to 30%, but it increased to 383 kW·m−2 when the Al2O3 content was further increased to 40%. Both crystalline layer thickness and crystalline fraction first increased, then decreased with the further addition of A2O3 content. Moreover, it indicated that the heat transfer process inside the mold was dominated by both a crystallization of mold flux and the resulting interfacial thermal resistance. Further, the Rint increased from 9.2 × 10−4 m2·kW−1 to 11.0 × 10−4 m2·kW−1 and then to 16.0 × 10−4 m2·kW−1 when the addition of Al2O3 content increased from 7% to 20% and then to 30%, respectively; however, it decreased to 13.6 × 10−4 m2·kW−1 when the Al2O3 content reached 40%.

Creating mold-free buildings: a key to avoiding health effects of indoor molds.

Science.gov (United States)

Small, Bruce M

2003-08-01

In view of the high costs of building diagnostics and repair subsequent to water damage--as well as the large medical diagnostic and healthcare costs associated with mold growth in buildings--commitment to a philosophy of proactive preventive maintenance for home, apartment, school, and commercial buildings could result in considerable cost savings and avoidance of major health problems among building occupants. The author identifies common causes of mold growth in buildings and summarizes key building design and construction principles essential for preventing mold contamination indoors. Physicians and healthcare workers must be made aware of conditions within buildings that can give rise to mold growth, and of resulting health problems. Timely advice provided to patients already sensitized by exposure to molds could save these individuals, and their families, from further exposures as a result of inadequate building maintenance or an inappropriate choice of replacement housing.

Gas-liquid Two Phase Flow Modelling of Incompressible Fluid and Experimental Validation Studies in Vertical Centrifugal Casting

International Nuclear Information System (INIS)

Zhou, J X; Shen, X; Yin, Y J; Guo, Z; Wang, H

2015-01-01

In this paper, Gas-liquid two phase flow mathematic models of incompressible fluid were proposed to explore the feature of fluid under certain centrifugal force in vertical centrifugal casting (VCC). Modified projection-level-set method was introduced to solve the mathematic models. To validate the simulation results, two methods were used in this study. In the first method, the simulation result of basic VCC flow process was compared with its analytic solution. The relationship between the numerical solution and deterministic analytic solution was presented to verify the correctness of numerical algorithms. In the second method, systematic water simulation experiments were developed. In this initial experiment, special experimental vertical centrifugal device and casting shapes were designed to describe typical mold-filling processes in VCC. High speed camera system and data collection devices were used to capture flow shape during the mold-filling process. Moreover, fluid characteristic at different rotation speed (from 40rpm, 60rpmand 80rpm) was discussed to provide comparative resource for simulation results. As compared with the simulation results, the proposed mathematical models could be proven and the experimental design could help us advance the accuracy of simulation and further studies for VCC. (paper)

Functional nanostructures on injection molded plastic

DEFF Research Database (Denmark)

Johansson, Alicia Charlotte; Søgaard, Emil; Andersen, Nis Korsgaard

Nanotechnology can be used to make inexpensive plastic parts with functional surfaces. The plastic parts can be molded using a standard injection molding process. The nanostructures are directly transferred from the surface of the molding tool to the surface of the molded plastic part during...

Surface hardening of two cast irons by friction stir processing

International Nuclear Information System (INIS)

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

2009-01-01

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

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

Science.gov (United States)

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

2003-09-01

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

Traditional Mold Analysis Compared to a DNA-based Method of Mold Analysis with Applications in Asthmatics' Homes

Science.gov (United States)

Traditional environmental mold analysis is based-on microscopic observations and counting of mold structures collected from the air on a sticky surface or culturing of molds on growth media for identification and quantification. A DNA-based method of mold analysis called mol...

A transparent model of the human scala tympani cavity.

Science.gov (United States)

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

1996-01-01

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

Computer-aided injection molding system

Science.gov (United States)

Wang, K. K.; Shen, S. F.; Cohen, C.; Hieber, C. A.; Isayev, A. I.

1982-10-01

Achievements are reported in cavity-filling simulation, modeling viscoelastic effects, measuring and predicting frozen-in birefringence in molded parts, measuring residual stresses and associated mechanical properties of molded parts, and developing an interactive mold-assembly design program and an automatic NC maching data generation and verification program. The Cornell Injection Molding Program (CIMP) consortium is discussed as are computer user manuals that have been published by the consortium. Major tasks which should be addressed in future efforts are listed, including: (1) predict and experimentally determine the post-fillin behavior of thermoplastics; (2) simulate and experimentally investigate the injection molding of thermosets and filled materials; and (3) further investigate residual stresses, orientation and mechanical properties.

Performance of molded plastic scintillators

International Nuclear Information System (INIS)

Gen, N.S.; Leman, V.E.; Solomonov, V.M.

1989-01-01

The performance of molded plastic scintillators is studied. The plastic scintillators studied were formed by transfer molding and intrusion from a scintillation composition consisting of polystyrene and a standard system of luminescent additives: 2 mass % of paraterphenyl + 0.06 mass % 1,4-di-/2-[5-phenyloxazoyly]/benzene and a plasticizer. The combined effect of mechanical load and temperature was studied. The effect of radiation on molded plastic scintillators was studied using gamma radiation from a 60 Co source. The studies show that the main operating characteristics of molded plastic scintillators are on a par with those of polymerized plastic scintillators. At the same time, molded plastic scintillators are superior in thermal stability at temperatures below the glass transition temperature and with respect to their working temperature range

High coercivity microcrystalline Nd-rich Nd–Fe–Co–Al–B bulk magnets prepared by direct copper mold casting

Energy Technology Data Exchange (ETDEWEB)

Zhao, L.Z.; Hong, Y. [School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640 (China); Fang, X.G. [Institute for Advanced Materials and Laboratory of Quantum Engineering and Quantum Materials, South China Normal University, Guangzhou 510640 (China); Qiu, Z.G.; Zhong, X.C. [School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640 (China); Gao, X.S. [Institute for Advanced Materials and Laboratory of Quantum Engineering and Quantum Materials, South China Normal University, Guangzhou 510640 (China); Liu, Z.W., E-mail: zwliu@scut.edu.cn [School of Materials Science and Engineering, South China University of Technology, Guangzhou 510640 (China)

2016-06-15

High coercivity Nd{sub 25}Fe{sub 40}Co{sub 20}Al{sub 15−x}B{sub x} (x=7–15) hard magnets were prepared by a simple process of injection casting. Different from many previous investigations on nanocomposite compositions, the magnets in this work contain hard magnetic Nd{sub 2}(FeCoAl){sub 14}B, Nd-rich, and Nd{sub 1+ε}(FeCo){sub 4}B{sub 4} phases. The magnetic properties, phase evolution, and microstructure of the as-cast and annealed magnets were investigated. As the boron content increased from 7 to 11 at%, the intrinsic coercivity H{sub cj} of the as-cast magnet increased from 816 to 1140 kA/m. The magnets annealed at 750 °C have shown more regular and smaller grains than the as-cast alloys, especially for the x=11 alloy. The high intrinsic coercivities for the annealed alloys with x=8~11 result from the presence of small-sized grains in the microstructure. The highest H{sub cj} of 1427 kA/m was obtained for the heat treated alloy with x=10. This work provides an alternative approach for preparing fully dense Nd-rich bulk hard magnets with relatively good properties. - Highlights: • 2 mm hard magnetic Nd{sub 25}Fe{sub 40}Co{sub 20}Al{sub 15−x}B{sub x} rods were prepared by direct casting. • High coercivity of 1.78 T was achieved in x=11 sample after heat treatment. • Small grains are responsible for the significant increase in H{sub C} after annealing. • Nd{sub 2}Fe{sub 14}B grains with two different sizes lead to two-step demagnetization process.

Optimization of die filling in high pressure die cast part using MAGMAsoft®

DEFF Research Database (Denmark)

Kotas, Petr; Hattel, Jesper Henri

2008-01-01

Integrated modeling of an entire casting process has become a tool which favors design and optimization of manufactured parts. The aim of this project was to examine and optimize a high-pressure die cast part and its production process with respect to die filling and issues of residual stresses...... in the process and machine parameters were done and assessed. All simulations revealed that, the main causes of the problems were: a poor geometry of the casting leading to an improper filling pattern, and a massive gating system bringing thermal imbalance into the solidification process. Thus deformations due...... to residual stresses occurred. The numerical results were evaluated and appeared to be in agreement with the results from the actual manufacturing process. Based on these findings, proposals for improvements were given. In order to avoid distortions and cold shuts further geometrical adjustments should...

Critical Thinking on the Introduction of Digitization Within Engineering Training Systems in the Manufacturing Stage of Cast Parts

Science.gov (United States)

Lehene, T. R.; Samoilă, V.; Soporan, V. F.; Pădurețu, S.; Vescan, M. M.

2018-06-01

The paper aims to present a methodology for the analysis of the engineering training systems at the manufacturing stage of castings through critical engineering thinking. Its use [4, 5] requires the development of procedures capable of responding to the problems faced by engineering training in terms of acquiring the tools and procedures. The structure of the analysis took into consideration the following aspects: the motivation to use the proposed procedure, considerations on the engineering behavior, the design of the reasoning adapted to the analysis of the engineering training systems, the determination of the correlations in the processes of obtaining the cast products, the definition and calibration of the digital experiment, the definition and analysis of the factors influencing the last solidification area (the nature of the alloy, the shape of the mold and the casting geometry).

Dimensional changes in plaster cast models due to the position of the impression tray during setting

Directory of Open Access Journals (Sweden)

Betina Grehs Porto

2014-01-01

Full Text Available Introduction: The objective of this study was to assess whether the positioning of the impression tray could cause distortion to plaster casts during gypsum setting time.Materials and Methods: Fifteen pairs of master models were cast with alginate impression material and immediately filled with gypsum. Impressions were allowed to set with the tray in the noninverted position (Group A or in the inverted position (Group B. The plaster models were digitized using a laser scanner (3Shape R-700, 3Shape A/S, Copenhagen, Denmark. Measurements of tooth size and distance were obtained using O3d software (Widialabs, Brazil measurement tools. Data were analyzed by paired t-test and linear regression with 5% significance.Results and Conclusion: Most of the measurements from both groups were similar, except forthe lower intermolar distance. It was not possible to corroborate the presence of distortions due to the position of the impression tray during gypsum setting time.

Novel casting processes for single-crystal turbine blades of superalloys

Science.gov (United States)

Ma, Dexin

2018-03-01

This paper presents a brief review of the current casting techniques for single-crystal (SC) blades, as well as an analysis of the solidification process in complex turbine blades. A series of novel casting methods based on the Bridgman process were presented to illustrate the development in the production of SC blades from superalloys. The grain continuator and the heat conductor techniques were developed to remove geometry-related grain defects. In these techniques, the heat barrier that hinders lateral SC growth from the blade airfoil into the extremities of the platform is minimized. The parallel heating and cooling system was developed to achieve symmetric thermal conditions for SC solidification in blade clusters, thus considerably decreasing the negative shadow effect and its related defects in the current Bridgman process. The dipping and heaving technique, in which thinshell molds are utilized, was developed to enable the establishment of a high temperature gradient for SC growth and the freckle-free solidification of superalloy castings. Moreover, by applying the targeted cooling and heating technique, a novel concept for the three-dimensional and precise control of SC growth, a proper thermal arrangement may be dynamically established for the microscopic control of SC growth in the critical areas of large industrial gas turbine blades.

Steel castings of valves for nuclear power station

International Nuclear Information System (INIS)

Yamasaki, Yutaka

1975-01-01

The manufacturing of the steel castings of valves for nuclear power plants is reported. The report is divided in six parts. The first part describes the reliability of the steel castings of valves for nuclear power plants. Particular attention must be paid to larger diameter and lower pressure rating for the valves in nuclear power plants than those in thermal power plants. The second part describes the characteristics of steel casting quality, defects and their cause. The defects that may be produced in steel castings are as follows: (a) cavities caused by the insufficient supply of molten steel, (b) sand bites caused by the mold destruction due to thermal shock, and (c) pinholes caused by the gas absorption of molten steel. The third part describes the clarification of quality level and the measures quality project. Gaseous defects and the indications detected by magnetic powder test are attributed to electric furnace steel making. In particular, the method to minimize gas content is important. The fourth part describes the quality control of manufacturing processes. In practice, thirteen semi-automatic testers using gamma radiation are employed. A full automatic inspection plant having capacity of 20,000 radiographs per month is under design. The fifth part describes a quality warrant system. A check sheet system concerning quality and safety is employed in all work shops. The reliability of all testers and measuring instruments as well as the skill of workmen are examined periodically. The seventh part deals with future problems. The manufacturing plan must be controlled so that non-destructive inspection becomes the main means for quality control. (Iwakiri, K.)

Floods and Mold Growth

Science.gov (United States)

Mold growth may be a problem after flooding. Excess moisture in the home is cause for concern about indoor air quality primarily because it provides breeding conditions for pests, molds and other microorganisms.

Environmental Sustainability and Mold Hygiene in Buildings.

Science.gov (United States)

Wu, Haoxiang; Ng, Tsz Wai; Wong, Jonathan Wc; Lai, Ka Man

2018-04-04

Environmental sustainability is one of the key issues in building management. In Hong Kong, one of the initiatives is to reduce the operation hours of air-conditioning in buildings to cut down energy consumption. In this study, we reported a mold contamination case in a newly refurbished laboratory, in which the air-conditioner was switched from 24- to 18-h mode after refurbishment. In order to prevent mold recurrence, the air-conditioner was switched back to 24-h mode in the laboratory. During the mold investigation, visible mold patches in the laboratory were searched and then cultured, counted and identified. Building and environmental conditions were recorded, and used to deduce different causes of mold contamination. Eight contaminated sites including a wall, a bench, some metal and plastic surfaces and seven types of molds including two Cladosporium spp., two Aspergillus spp., one Rhizopus sp., one Trichoderma sp., and one Tritirachium sp. were identified. Cladosporium spp. were the most abundant and frequently found molds in the laboratory. The contaminated areas could have one to five different species on them. Based on the mold and environmental conditions, several scenarios causing the mold contamination were deduced, and different mold control measures were discussed to compare them with the current solution of using 24-h air-conditioning to control mold growth. This study highlights the importance of mold hygiene in sustainable building management.

Environmental Sustainability and Mold Hygiene in Buildings

Directory of Open Access Journals (Sweden)

Haoxiang Wu

2018-04-01

Full Text Available Environmental sustainability is one of the key issues in building management. In Hong Kong, one of the initiatives is to reduce the operation hours of air-conditioning in buildings to cut down energy consumption. In this study, we reported a mold contamination case in a newly refurbished laboratory, in which the air-conditioner was switched from 24- to 18-h mode after refurbishment. In order to prevent mold recurrence, the air-conditioner was switched back to 24-h mode in the laboratory. During the mold investigation, visible mold patches in the laboratory were searched and then cultured, counted and identified. Building and environmental conditions were recorded, and used to deduce different causes of mold contamination. Eight contaminated sites including a wall, a bench, some metal and plastic surfaces and seven types of molds including two Cladosporium spp., two Aspergillus spp., one Rhizopus sp., one Trichoderma sp., and one Tritirachium sp. were identified. Cladosporium spp. were the most abundant and frequently found molds in the laboratory. The contaminated areas could have one to five different species on them. Based on the mold and environmental conditions, several scenarios causing the mold contamination were deduced, and different mold control measures were discussed to compare them with the current solution of using 24-h air-conditioning to control mold growth. This study highlights the importance of mold hygiene in sustainable building management.

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

Science.gov (United States)

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

2003-03-01

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

Predicting shrinkage and warpage in injection molding: Towards automatized mold design

Science.gov (United States)

Zwicke, Florian; Behr, Marek; Elgeti, Stefanie

2017-10-01

It is an inevitable part of any plastics molding process that the material undergoes some shrinkage during solidification. Mainly due to unavoidable inhomogeneities in the cooling process, the overall shrinkage cannot be assumed as homogeneous in all volumetric directions. The direct consequence is warpage. The accurate prediction of such shrinkage and warpage effects has been the subject of a considerable amount of research, but it is important to note that this behavior depends greatly on the type of material that is used as well as the process details. Without limiting ourselves to any specific properties of certain materials or process designs, we aim to develop a method for the automatized design of a mold cavity that will produce correctly shaped moldings after solidification. Essentially, this can be stated as a shape optimization problem, where the cavity shape is optimized to fulfill some objective function that measures defects in the molding shape. In order to be able to develop and evaluate such a method, we first require simulation methods for the diffierent steps involved in the injection molding process that can represent the phenomena responsible for shrinkage and warpage ina sufficiently accurate manner. As a starting point, we consider the solidification of purely amorphous materials. In this case, the material slowly transitions from fluid-like to solid-like behavior as it cools down. This behavior is modeled using adjusted viscoelastic material models. Once the material has passed a certain temperature threshold during cooling, any viscous effects are neglected and the behavior is assumed to be fully elastic. Non-linear elastic laws are used to predict shrinkage and warpage that occur after this point. We will present the current state of these simulation methods and show some first approaches towards optimizing the mold cavity shape based on these methods.

Comparing suppository mold variability which can lead to dosage errors for suppositories prepared with the same or different molds.

Science.gov (United States)

Alexander, Kenneth S; Baki, Gabriella; Hart, Christine; Hejduk, Courtney; Chillas, Stephanie

2013-01-01

Suppository molds must be properly calibrated to ensure accurate dosing. There are often slight differences between molds and even in the cavities within a mold. A method is presented for the calibration of standard aluminum 6-, 12-, 50-, or 100-well suppository molds. Ten different molds were tested using water for volume calibration, and cocoa butter for standardization involving establishing the density factor. This method is shown to be straightforward and appropriate for calibrating suppository molds.

Mechanical Properties of Porous Titanium Structure Fabricated by Investment Casting with Pressurization/Depressurization System

International Nuclear Information System (INIS)

Kang, San; Lee, Ji-Woon; Hyun, Soong-Keun; Lee, Byong-Pil; Kim, Myoung-Gyun; Kim, Young-Jig

2014-01-01

A porous titanium structure was fabricated by investment casting with a pressurization/depressurization system, and its mechanical properties were studied. A Micro-Vickers hardness profile revealed that hardness gradually increased from the matrix to the metal/mold interface. A compression test was conducted on a single cell of the porous Ti structure. The theoretical and experimental values of yield strength were in good agreement. Such agreement suggested that the reaction layer did not affect the macro-mechanical properties of the porous Ti structure.

Molding method of buffer material for underground disposal of radiation-contaminated material, and molded buffer material

International Nuclear Information System (INIS)

Akasaka, Hidenari; Shimura, Satoshi; Kawakami, Susumu; Ninomiya, Nobuo; Yamagata, Junji; Asano, Eiichi

1995-01-01

Upon molding of a buffer material to be used upon burying a vessel containing radiation-contaminated materials in a sealed state, a powdery buffer material to be molded such as bentonite is disposed at the periphery of a mandrel having a cylindrical portion somewhat larger than contaminate container to be subjected to underground disposal. In addition, it is subjected to integration-molding such as cold isotropic press with a plastic film being disposed therearound, to form a molding product at high density. The molding product is released and taken out with the plastic film being disposed thereon. Releasability from an elastic mold is improved by the presence of the plastic film. In addition, if it is stored or transported while having the plastic film being disposed thereon, swelling of the buffer material due to water absorption or moisture absorption can be suppressed. (T.M.)

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

Science.gov (United States)

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

2016-08-01

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

Deposition of ultrafine aerosols in F344/N rat nasal casts

Energy Technology Data Exchange (ETDEWEB)

Cheng, Y S; Hansen, G K; Su, Y F; Yeh, H C; Morgan, K T [Chemical Industry Institute of Toxicology, Research Triangle Park, NC (United States)

1988-12-01

Determination of regional respiratory deposition of inhaled aerosols is critical for evaluation of the health effects of air pollutants. Information on deposition of larger particles (> 0.02 {mu}m) in the nasal passages of laboratory animals is available; the deposition fraction increases with increasing particle size. Little information on ultrafine particles less than 0.2 {mu}m is available. Molds (models) were prepared from replica casts of the nasal passages of F344/N rats, using clear casting plastic. Total deposition of ultrafine aerosols in these casts was then determined using a unidirectional flow system. Measured pressure drops in the casts were a function of flow rate to the power of 1.4-1.6, indicating that the flow through the nasal passage was not laminar. Deposition data were obtained from these casts, using monodisperse sodium chloride aerosols with particle size ranging from 0.2 to 0.005 {mu}m, at inspiratory and expiratory flow rates of 200 to 600 cc/min. Similar deposition data were obtained for the three casts studied. The deposition efficiency was greatest for the smallest particles, and decreased with increasing particle size and flow rate, indicating that diffusion was the dominant mechanism for deposition. At an inspiratory flow rate of 400 cc/min, which is comparable to a respiratory minute volume of 200 cc/min for mature male F344/N rats, deposition efficiencies reached 40 and 70% for 0.01 and 0.005 {mu}m particles, respectively. Turbulent diffusion was considered to be the dominant mechanism for deposition of ultrafine particles in the nasal passage. This information is important for understanding the toxicity and carcinogenicity of submicrometer particles, including diesel soot, radon progeny and vapors. (author)

Fast Mold Temperature Evolution on Micro Features Replication Quality during Injection Molding

DEFF Research Database (Denmark)

Liparoti, S.; Calaon, Matteo; Speranza, V.

2016-01-01

lithography and subsequent nickel electroplating. The mold temperature was controlled by a thin heating device (composed by polyimide as insulating layer and polyimide carbon black loaded aselectrical conductive layer) able to increase the temperature on mold surface in a few seconds (40°C/s) by Joule effect...

Evaluation of the Characteristics of the Aluminum Alloy Casting Material by Heat Treatment

International Nuclear Information System (INIS)

Lee, Syung Yul; Park, Dong Hyun; Won, Jong Pil; Kim, Yun Hae; Lee, Myung Hoon; Moon, Kyung Man; Jeong, Jae Hyun

2012-01-01

Aluminum is on active metal, but it is well known that its oxide film plays a role as protective barrier which is comparatively stable in air and neutral aqueous solution. Thus, aluminum alloys have been widely applied in architectural trim, cold and hot-water storage vessels and piping etc., furthermore, the aluminum alloy of AC8A have been widely used in mold casting material of engine piston because of its properties of temperature and wear resistance. In recent years, the oil price is getting higher and higher, thus the using of low quality oil has been significantly increased in engines of ship and vehicle. Therefore it is considered that evaluation of corrosion resistance as well as wear resistance of AC8A material is also important to improve its property and prolong its lifetime. In this study, the effect of solution and tempering heat treatment to corrosion and wear resistance is investigated with electrochemical method and measurement of hardness. The hardness decreased with solution heat treatment compared to mold casting condition, but its value increased with tempering heat treatment and exhibited the highest value of hardness with tempering heat treatment temperature at 190 .deg. C for 24hrs. Furthermore, corrosion resistance increased with decreasing of the hardness, and decreased with increasing of the hardness reversely. As a result, it is suggested that the optimum heat treatment to improve both corrosion and wear resistance is tempering heat treatment temperature at 190 .deg. C for 16hrs

Algorithm for prevention of molten steel sticking onto mold in continous casting process

Directory of Open Access Journals (Sweden)

Blažević, D.

2008-01-01

Full Text Available In continuous casting steel production a significant loss reduction – in terms of scrap material, time and money – can be achieved by developing an appropriate algorithm for the prevention of molten steel sticking onto mould. The logic of such algorithm should be simple and manageable to ensure its practical implementation on a computer system via the usage of thermo sensors. This suggests that both the algorithm and the automated data collection can be implemented by means of applicative software. Despite its simplicity, the algorithm should accurately trace physical phenomena in molten steel.

Remelt Ingot Production Technology

Science.gov (United States)

Grandfield, J. F.

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

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

Science.gov (United States)

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

2014-08-01

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

Injection Molding of High Aspect Ratio Nanostructures

DEFF Research Database (Denmark)

Matschuk, Maria; Larsen, Niels Bent

We present a process for injection molding of 40 nm wide and >100 nm high pillars (pitch: 200 nm). We explored the effects of mold coatings and injection molding conditions on the replication quality of nanostructures in cyclic olefin copolymer. We found that optimization of molding parameters...

Silane based coating of aluminium mold

DEFF Research Database (Denmark)

2013-01-01

having at least one closed cavity is provided, at least one surface of the at least one cavity being an aluminium surface coated with a silane based coating layer. The silane based anti-stiction coating improves the anti-stiction properties of the mold which may allow for molding and demolding...... of structures which would otherwise be difficult to mold. The resistance of the coated aluminium mold is significantly improved by applying a silane-based coating layer....

Molded ultra-low density microcellular foams

International Nuclear Information System (INIS)

Rand, P.B.; Montoya, O.J.

1986-07-01

Ultra-low density (< 0.01 g/cc) microcellular foams were required for the NARYA pulsed-power-driven x-ray laser development program. Because of their extreme fragility, molded pieces would be necessary to successfully field these foams in the pulsed power accelerator. All of the foams evaluated were made by the thermally induced phase separation technique from solutions of water soluble polymers. The process involved rapidly freezing the solution to induce the phase separation, and then freeze drying to remove the water without destroying the foam's structure. More than sixty water soluble polymers were evaluated by attempting to make their solutions into foams. The foams were evaluated for shrinkage, density, and microstructure to determine their suitability for molding and meeting the required density and cell size requirements of 5.0 mg/cc and less than twenty μmeters. Several promising water soluble polymers were identified including the polyactylic acids, guar gums, polyactylamide, and polyethylene oxide. Because of thier purity, structure, and low shrinkage, the polyacrylic acids were chosen to develop molding processes. The initial requirements were for 2.0 cm. long molded rods with diameters of 1.0, 2.0. and 3.0 mm. These rods were made by freezing the solution in thin walled silicon rubber molds, extracting the frozen preform from the mold, and then freeze drying. Requirements for half rods and half annuli necessitated using aluminum molds. Again we successfully molded these shapes. Our best efforts to date involve molding annuli with 3.0 mm outside diameters and 2.0 mm inside diameters

Mold

Science.gov (United States)

... has developed a device known as an acoustical generator that can create and disperse molds for rodent ... Sciences) . 2004. Damp Indoor Spaces and Health. Washington, DC: The National Academies Press. 3 WHO ( World Health ...

Does 6 Hours of Contact With Alginate Impression Material Affect Dental Cast Properties?

Science.gov (United States)

Ibrahim, Amna Adam; Alhajj, Mohammed Nasser; Khalifa, Nadia; Gilada, Magdi Wadie

2017-06-01

Alginate impression (irreversible hydrocolloid) material is commonly used in dental practice because it is easy to mix, low in cost, and well tolerated by patients. The material is not dimensionally stable, however; thus, it is necessary to pour the impression immediately after the molding is accomplished, or within 60 minutes if the impression is kept in 100% humidity. Excessive contact of the alginate impression with the cast model over time may affect the model's properties. In this study, the authors tested the effect of contact time between an alginate impression and type III dental stone on cast model properties. Sixty-seven cast models were obtained from a stainless steel cylinder by using irreversible hydrocolloid impression material and type III dental stone. Thirty-seven cast models were separated from the impression after 1 hour (control group) and 30 cast models were separated after 6 hours (study group). The samples were evaluated under light microscope for surface details and measured by digital caliper for dimensional stability. An indentation on the cast was made and the depth of the indentation was then measured with a digital caliper to measure hardness. The dimensional stability of the cast models was not affected when contact time was increased from 1 hour to 6 hours (P = .507). Surface details did not deteriorate when contact time was increased, as all of the samples could reproduce all details after the 1-hour and 6-hour interval periods. However, hardness was greater after 1 hour of contact time (P = .001) than after 6 hours of contact time. In conclusion, contact between alginate impression material and type III dental stone up to 6 hours did not affect the dimensional stability and richness of the surface; hardness, though, was significantly affected.

Mold After a Disaster

Science.gov (United States)

... should clean up the mold and fix any water problem, such as leaks in roofs, walls, or plumbing. Controlling moisture in your home is the most critical factor for preventing mold growth. To ... use commercial products, soap and water, or a bleach solution of no more than ...

Microstructures and mechanical properties of grain refined Al-Li-Mg casting alloy by containing Zr and Ti

International Nuclear Information System (INIS)

Saikawa, Seiji; Nakai, Kiyoshi; Sugiura, Yasuo; Kamio, Akihiko.

1995-01-01

Mechanical properties and microstructures of various Al-Li-Mg alloy castings containing small amount of Zr and/or Ti were investigated. The δ(AlLi) phase was observed to crystallize in the dendrite-cell gaps as well as on the grain boundaries. Microsegregation of Mg also occurred in the solidified castings. The β(Al 3 Zr) or Al-Zr-Ti compounds crystallize during solidification and remain even after solid solution treatment at 803 K for 36 ks. The grain sizes of Al-2.5%Li-2%Mg alloy castings become finer by the addition of 0.15%Zr and 0.12%Ti compared with each addition of 0.15%Zr or 0.12%Ti. The age hardening is accelerated by the addition of 0.15%Zr. In an Al-2.5%Li-2%Mg-0.15%Zr-0.12%Ti alloy casting poured into a metallic mold and aged at 453 K for 36 ks, ultimate tensile strength, Young's modulus and density were 417 MPa, 80 GPa and was 2.52 g/cm 3 , respectively. Its specific strength and modulus are higher by 50.3 and 13.9% than those of the conventional AC4C-T6 casting. (author)

Sputtering and emission intensity of cast irons with different metallurgical structures in a Grimm glow lamp

International Nuclear Information System (INIS)

Fujita, M.; Kashima, J.; Naganuma, K.

1981-01-01

The cathodic sputtering and emission intensities for the white, gray and malleable cast irons in the Grimm glow lamp are discussed. The intensities of the Fe 247.98-nm line for the samples of the three types depend linearly on the electrical power but the slopes of the plots differ. The intensity of the carbon line at 247.86 nm for malleable cast iron is weaker than those for the others. Sputtering is influenced by the form of the graphite, which can lead to distortion of the electrical field. Graphite on malleable cast iron is sputtered not only as atomic carbon but also as moieties containing several carbon atoms. The higher the supplied voltage, the shorter the time for the intensities of the Fe I and C I lines to reach constant values. (Auth.)

The effect of mold surface topography on plastic parat in-process shrinkage in injection molding

DEFF Research Database (Denmark)

Arlø, Uffe Rolf; Hansen, Hans Nørgaard; Kjær, Erik Michael

2003-01-01

An experimental study of the effect of mold surface roughness on in-process in-flow linear part shrinkage in injection molding has been carried out. The investigation is based on an experimental two-cavity tool, where the cavities have different surface topographies, but are otherwise identical....... The study has been carried out for typical commercial polystyrene and polypropylene grades. The relationship between mold surface topography and linear shrinkage has been investigated with an experimental two-cavity mold producing simple rectangular parts with the nominal dimensions 1 x 25 x 50 mm (see...... figure 1). The cavities have different surface topographies on one side, but are otherwise identical (see discussion of other contribution factors)....

Rapid and Low-cost Prototyping of Medical Devices Using 3D Printed Molds for Liquid Injection Molding

Science.gov (United States)

Chung, Philip; Heller, J. Alex; Etemadi, Mozziyar; Ottoson, Paige E.; Liu, Jonathan A.; Rand, Larry; Roy, Shuvo

2014-01-01

Biologically inert elastomers such as silicone are favorable materials for medical device fabrication, but forming and curing these elastomers using traditional liquid injection molding processes can be an expensive process due to tooling and equipment costs. As a result, it has traditionally been impractical to use liquid injection molding for low-cost, rapid prototyping applications. We have devised a method for rapid and low-cost production of liquid elastomer injection molded devices that utilizes fused deposition modeling 3D printers for mold design and a modified desiccator as an injection system. Low costs and rapid turnaround time in this technique lower the barrier to iteratively designing and prototyping complex elastomer devices. Furthermore, CAD models developed in this process can be later adapted for metal mold tooling design, enabling an easy transition to a traditional injection molding process. We have used this technique to manufacture intravaginal probes involving complex geometries, as well as overmolding over metal parts, using tools commonly available within an academic research laboratory. However, this technique can be easily adapted to create liquid injection molded devices for many other applications. PMID:24998993

Effect of quenching rate on precipitation kinetics in AA2219 DC cast alloy

Energy Technology Data Exchange (ETDEWEB)

Elgallad, E.M., E-mail: eelgalla@uqac.ca; Zhang, Z.; Chen, X.-G.

2017-06-01

Slow quenching of direct chill (DC) cast aluminum ingot plates used in large mold applications is often used to decrease quench-induced residual stresses, which can deteriorate the machining performance of these plates. Slow quenching may negatively affect the mechanical properties of the cast plates when using highly quench-sensitive aluminum alloys because of its negative effect on the precipitation hardening behavior of such alloys. The effect of the quenching rate on precipitation kinetics in AA2219 DC cast alloy was systematically studied under water and air quenching conditions using differential scanning calorimetry (DSC) technique. Transmission electron microscopy (TEM) was also used to characterize the precipitate microstructure. The results showed that the precipitation kinetics of the θ′ phase in the air-quenched condition was mostly slower than that in the water-quenched one. Air quenching continuously increased the precipitation kinetics of the θ phase compared to water quenching. These results revealed the contributions of the inadequate precipitation of the strengthening θ′ phase and the increased precipitation of the equilibrium θ phase to the deterioration of the mechanical properties of air-quenched AA2219 DC cast plates. The preexisting GP zones and quenched-in dislocations affected the kinetics of the θ′ phase, whereas the preceding precipitation of the θ′ phase affected the kinetics of the θ phase by controlling its precipitation mechanism.

High-throughput creation of micropatterned PDMS surfaces using microscale dual roller casting

International Nuclear Information System (INIS)

DiBartolomeo, Franklin J; Ge, Ning; Trinkle, Christine A

2012-01-01

This work introduces microscale dual roller casting (MDRC), a novel high-throughput fabrication method for creating continuous micropatterned surfaces using thermosetting polymers. MDRC utilizes a pair of rotating, heated cylindrical molds with microscale surface patterns to cure a continuous microstructured film. Using unmodified polydimethylsiloxane as the thermosetting polymer, we were able to create optically transparent, biocompatible surfaces with submicron patterning fidelity. Compared to other roll-to-roll fabrication processes, this method offers increased flexibility in the types of materials and topography that can be generated, including dual-sided patterning, embedded materials and tunable film thickness. (paper)

Nodular cast iron and casting monitoring

Directory of Open Access Journals (Sweden)

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.

Implementation of Molding Constraints in Topology Optimization

DEFF Research Database (Denmark)

Marx, S.; Kristensen, Anders Schmidt

2009-01-01

In many cases the topology optimization method yield inadmissible solutions in respect to a particular manufacturing process, e.g. injection molding. In the present work it is chosen to focus on the most common injection molding parameters/factors determining the quality of the mold geometry, i.......e. uniform thickness, filling of the die and ejection of the molded item, i.e. extrusion. The mentioned injection mold parameters/factors are introduced in the topology optimization by defining a centerline of the initial domain and then penalize elements in respect to the distance to the defined centerline...

Microinjection molding of thermoplastic polymers: morphological comparison with conventional injection molding

International Nuclear Information System (INIS)

Giboz, Julien; Mélé, Patrice; Copponnex, Thierry

2009-01-01

The skin–core crystalline morphology of injection-molded semi-crystalline polymers is well documented in the scientific literature. The thermomechanical environment provokes temperature and shear gradients throughout the entire thickness of the part during molding, thus influencing the polymer crystallization. Crystalline morphologies of a high-density polyethylene (HDPE) micromolded part (μpart) and a classical part (macropart) are compared with optical, thermal and x-ray diffraction analyses. Results show that the crystalline morphologies with regard to thickness vary between the two parts. While a 'skin–core' morphology is present for the macropart, the μpart exhibits a specific 'core-free' morphology, i.e. no spherulite is present at the center of the thickness. This result seems to be generated under the specific conditions used in microinjection molding that lead to the formation of smaller and more oriented crystalline entities

Properties of pre-cast terrazzo tiles and recommended specifications Propriedades de telhas de terrazzo pré-moldadas e especificações recomendadas

Directory of Open Access Journals (Sweden)

G. Karam

2009-03-01

Full Text Available A targeted experimental program was carried out to establish basic reference physical and mechanical properties of commercially available pre-cast marble chip terrazzo tiles and to investigate the effects of varying manufacturing process parameters on those properties. The transverse strength, density, water absorption, and abrasion resistance were measured as a function of casting pressure and residence time in the casting mold for a standard mix design. A simple surface abrasion index test was developed and applied comparing pre-cast terrazzo tiles with reference natural tiling stones. Recommendations for improving existing specifications and developing quality control measures are presented.Foi feito um programa experimental direcionado para estabelecer propriedades físicas e mecânicas como referências básicas de telhas de terrazzo de peças de mármore pré-moldadas disponíveis comercialmente e para investigar os efeitos de vários parâmetros de processo de fabricação nessas propriedades. A resistência transversal, a densidade, a absorção de água e a resistência ao desgaste foram medidas em função da pressão de moldagem e do tempo de residência do molde de um projeto de mistura padrão. Um teste simples de índice de desgaste de superfície foi desenvolvido e aplicado na comparação de telhas de terrazzo pré-moldadas com pedras de telhas naturais de referência. As recomendações para a melhoria das especificações existentes e o desenvolvimento de medidas para controle de qualidade são apresentadas.

Effect of SiO2 concentration in silica sol on interface reaction during titanium alloy investment casting

Directory of Open Access Journals (Sweden)

Ya-meng Wei

2018-01-01

Full Text Available Using silica sol as a binder for titanium investment casting is very attractive due to its good stability and reasonable cost as compared with yttrium sol and zirconium sol. However, the mechanism of interface reaction in the related system remains unclear. In this investigation, the interface reaction between Y2O3-SiO2 (Y-Si shell mold and titanium alloys was studied. A group of shell molds were prepared by using Y2O3 sand and silica sol with different contents of SiO2. Ti-6Al-4V alloy was cast under vacuum by gravity casting through cold crucible induction melting (CCIM method. Scanning electron microscopy (SEM and energy dispersive x-ray spectroscopy (EDS were employed to characterize the micromorphology and composition of the reaction area, respectively. X-ray photoelectron spectroscopy (XPS was used to confirm the valence state of relevant elements. White light interferometer (WLI was used to obtain the surface topography of Y-Si shells. The results show that the thickness of reaction layers is below 3 μm when the SiO2 content of silica sol is below 20wt.%. Whereas, when the SiO2 content increases to 25wt.%, the thickness of the reaction layer increases sharply to about 15 μm. There is a good balance between chemical inertness and mechanical performance when the SiO2 content is between 15 and 20wt.%. Moreover, it was found that the distribution of SiO2 and the roughness at the surface of the shell are the key factors that determine the level of reaction.

Mold

Centers for Disease Control (CDC) Podcasts

2011-05-02

This podcast answers a listener's question about the risks associated with mold after a natural disaster or severe weather.  Created: 5/2/2011 by National Center for Environmental Health (NCEH).   Date Released: 5/2/2011.

Digital Twin concept for smart injection molding

Science.gov (United States)

Liau, Y.; Lee, H.; Ryu, K.

2018-03-01

Injection molding industry has evolved over decades and became the most common method to manufacture plastic parts. Monitoring and improvement in the injection molding industry are usually performed separately in each stage, i.e. mold design, mold making and injection molding process. However, in order to make a breakthrough and survive in the industrial revolution, all the stages in injection molding need to be linked and communicated with each other. Any changes in one stage will cause a certain effect in other stage because there is a correlation between each other. Hence, the simulation should not only based on the input of historical data, but it also needs to include the current condition of equipment and prediction of future events in other stages to make the responsive decision. This can be achieved by implementing the concept of Digital Twin that models the entire process as a virtual model and enables bidirectional control with the physical process. This paper presented types of data and technology required to build the Digital Twin for the injection molding industry. The concept includes Digital Twin of each stage and integration of these Digital Twin model as a thoroughgoing model of the injection molding industry.

An All-Freeze-Casting Strategy to Design Typographical Supercapacitors with Integrated Architectures.

Science.gov (United States)

Wang, Qingrong; Wang, Xinyu; Wan, Fang; Chen, Kena; Niu, Zhiqiang; Chen, Jun

2018-06-01

The emergence of flexible and wearable electronics has raised the demand for flexible supercapacitors with accurate sizes and aesthetic shapes. Here, a strategy is developed to prepare flexible all-in-one integrated supercapacitors by combining all-freeze-casting with typography technique. The continuous seamless connection of all-in-one supercapacitor devices enhances the load and/or electron transfer capacity and avoids displacing and detaching between their neighboring components at bending status. Therefore, such a unique structure of all-in-one integrated devices is beneficial for retaining stable electrochemical performance at different bending levels. More importantly, the sizes and aesthetic shapes of integrated supercapacitors could be controlled by the designed molds, like type matrices of typography. The molds could be assembled together and typeset randomly, achieving the controllable construction and series and/or parallel connection of several supercapacitor devices. The preparation of flexible integrated supercapacitors will pave the way for assembling programmable all-in-one energy storage devices into highly flexible electronics. © 2018 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Mold inhibition on unseasoned southern pine

Science.gov (United States)

Carol A. Clausen; Vina W. Yang

2003-01-01

Concerns about indoor air quality due to mold growth have increased dramatically in the United States. In the absence of moisture management, fungicides need to be developed for indoor use to control mold establishment. An ideal fungicide for prevention of indoor mold growth on wood-based materials needs to specifically prevent spore germination and provide long-term...

Medical diagnostics for indoor mold exposure.

Science.gov (United States)

Hurraß, Julia; Heinzow, Birger; Aurbach, Ute; Bergmann, Karl-Christian; Bufe, Albrecht; Buzina, Walter; Cornely, Oliver A; Engelhart, Steffen; Fischer, Guido; Gabrio, Thomas; Heinz, Werner; Herr, Caroline E W; Kleine-Tebbe, Jörg; Klimek, Ludger; Köberle, Martin; Lichtnecker, Herbert; Lob-Corzilius, Thomas; Merget, Rolf; Mülleneisen, Norbert; Nowak, Dennis; Rabe, Uta; Raulf, Monika; Seidl, Hans Peter; Steiß, Jens-Oliver; Szewszyk, Regine; Thomas, Peter; Valtanen, Kerttu; Wiesmüller, Gerhard A

2017-04-01

In April 2016, the German Society of Hygiene, Environmental Medicine and Preventative Medicine (Gesellschaft für Hygiene, Umweltmedizin und Präventivmedizin (GHUP)) together with other scientific medical societies, German and Austrian medical societies, physician unions and experts has provided an AWMF (Association of the Scientific Medical Societies) guideline 'Medical diagnostics for indoor mold exposure'. This guideline shall help physicians to advise and treat patients exposed indoors to mold. Indoor mold growth is a potential health risk, even without a quantitative and/or causal association between the occurrence of individual mold species and health effects. Apart from the allergic bronchopulmonary aspergillosis (ABPA) and the mycoses caused by mold, there is only sufficient evidence for the following associations between moisture/mold damages and different health effects: Allergic respiratory diseases, asthma (manifestation, progression, exacerbation), allergic rhinitis, exogenous allergic alveolitis and respiratory tract infections/bronchitis. In comparison to other environmental allergens, the sensitizing potential of molds is estimated to be low. Recent studies show a prevalence of sensitization of 3-10% in the total population of Europe. The evidence for associations to mucous membrane irritation and atopic eczema (manifestation, progression, exacerbation) is classified as limited or suspected. Inadequate or insufficient evidence for an association is given for COPD, acute idiopathic pulmonary hemorrhage in children, rheumatism/arthritis, sarcoidosis, and cancer. The risk of infections from indoor molds is low for healthy individuals. Only molds that are capable to form toxins can cause intoxications. The environmental and growth conditions and especially the substrate determine whether toxin formation occurs, but indoor air concentrations are always very low. In the case of indoor moisture/mold damages, everyone can be affected by odor effects and

Effect of different impression materials and techniques on the dimensional accuracy of implant definitive casts.

Science.gov (United States)

Ebadian, Behnaz; Rismanchian, Mansor; Dastgheib, Badrosadat; Bajoghli, Farshad

2015-01-01

Different factors such as impression techniques and materials can affect the passive fit between the superstructure and implant. The aim of this study was to determine the effect of different impression materials and techniques on the dimensional accuracy of implant definitive casts. Four internal hex implants (Biohorizons Ø4 mm) were placed on a metal maxillary model perpendicular to the horizontal plane in maxillary lateral incisors, right canine and left first premolar areas. Three impression techniques including open tray, closed tray using ball top screw abutments and closed tray using short impression copings and two impression materials (polyether and polyvinyl siloxane) were evaluated (n = 60). The changes in distances between implant analogues in mediolateral (x) and anteroposterior (y) directions and analogue angles in x/z and y/z directions in the horizontal plane on the definitive casts were measured by coordinate measuring machine. The data were analyzed by multivariate two-way analysis of variance and one sample t-test (α = 0.05). No statistical significant differences were observed between different impression techniques and materials. However, deviation and distortion of definitive casts had a significant difference with the master model when short impression copings and polyvinyl siloxane impression material were used (P impression materials (P impression techniques; however, less distortion and deviation were observed in the open tray technique. In the closed tray impression technique, ball top screw was more accurate than short impression copings.

The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

Science.gov (United States)

Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

2011-02-01

In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

The reflectivity, wettability and scratch durability of microsurface features molded in the injection molding process using a dynamic tool tempering system

International Nuclear Information System (INIS)

Kuhn, Sascha; Burr, August; Kübler, Michael; Deckert, Matthias; Bleesen, Christoph

2011-01-01

In this paper the replication qualities of periodically and randomly arranged micro-features molded in the injection molding process and their effects on surface properties are studied. The features are molded in PC, PMMA and PP at different mold wall temperatures in order to point out the necessity and profitability of a variotherm mold wall temperature control system. A one-dimensional heat conduction model is proposed to predict the cycle times of the variotherm injection molding processes. With regard to these processes, the molding results are compared to the molded surface feature heights using an atomic force microscope. In addition, the effects of the molded surface features on macroscopic surfaces are characterized in terms of light reflection using a spectrometer and in terms of water wettability by measuring the static contact angle. Furthermore, due to the sensitivity of the surface features on the molded parts, their durability is compared in a scratch test with a diamond tip. This leads to successful implementation in applications in which the optical appearance, in terms of gloss and reflection, and the water repellence, in terms of drag flow and adhesion, are of importance.

Fast prototyping of injection molded polymer microfluidic chips

DEFF Research Database (Denmark)

Hansen, Thomas Steen; Selmeczi, David; Larsen, Niels Bent

2010-01-01

We present fast prototyping of injection molding tools by the definition of microfluidic structures in a light-curable epoxy (SU-8) directly on planar nickel mold inserts. Optimized prototype mold structures could withstand injection molding of more than 300 replicas in cyclic olefin copolymer (COC...

Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

Science.gov (United States)

Lee, Jonathan A.

2009-01-01

In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

Immune Response among Patients Exposed to Molds

Directory of Open Access Journals (Sweden)

Jordan N. Fink

2009-12-01

Full Text Available Macrocyclic trichothecenes, mycotoxins produced by Stachybotrys chartarum, have been implicated in adverse reactions in individuals exposed to mold-contaminated environments. Cellular and humoral immune responses and the presence of trichothecenes were evaluated in patients with mold-related health complaints. Patients underwent history, physical examination, skin prick/puncture tests with mold extracts, immunological evaluations and their sera were analyzed for trichothecenes. T-cell proliferation, macrocyclic trichothecenes, and mold specific IgG and IgA levels were not significantly different than controls; however 70% of the patients had positive skin tests to molds. Thus, IgE mediated or other non-immune mechanisms could be the cause of their symptoms.

Application of a dynamic-nanoindentation method to analyze the local structure of an Fe-18 at.% Gd cast alloy

Energy Technology Data Exchange (ETDEWEB)

Choi, Yong; Baik, Youl [Dept. of Materials Science and Technology, Dankook University, Cheonan(Korea, Republic of); Moon, Byung M. [Liquid Processing and Casting Technology R and D Group, KITECH, Incheon (Korea, Republic of); Sohn, Dong Seong [Nuclear Engineering Department, UNIST, Ulsan (Korea, Republic of)

2017-04-15

A dynamic nanoindentation method was applied to study an Fe-18 at.% Gd alloy as a neutron-absorbing material prepared by vacuum arc-melting and cast in a mold. The Fe-18 at.% Gd cast alloy had a microstructure with matrix phases and an Fe-rich primary dendrite of Fe9Gd. Rietveld refinement of the X-ray spectra showed that the Fe-18 at.% Gd cast alloy consisted of 35.84 at.% Fe3Gd, 6.58 at.% Fe5Gd, 16.22 at.% Fe9Gd, 1.87 at.% Fe2Gd, and 39.49 at.% β-Fe17Gd2. The average nanohardness of the primary dendrite phase and the matrix phases were 8.7 GPa and 9.3 GPa, respectively. The fatigue limit of the matrix phase was approximately 37% higher than that of the primary dendrite phase. The dynamic nanoindentation method is useful for identifying local phases and for analyzing local mechanical properties.

Effects of fast mold temperature evolution on micro features replication quality during injection molding

DEFF Research Database (Denmark)

Liparoti, S.; Calaon, M.; Speranza, V.

2017-01-01

lithography and subsequent nickel electroplating. The mold temperature was controlled by a thin heating device (composed by polyimide as insulating layer and polyimide carbon black loaded as electrical conductive layer) able to increase the temperature on mold surface in a few seconds (40°C/s) by Joule...

Three-Dimensional Modeling of Glass Lens Molding

DEFF Research Database (Denmark)

Sarhadi, Ali; Hattel, Jesper Henri; Hansen, Hans Nørgaard

2015-01-01

The required accuracy for the final dimensions of the molded lenses in wafer-based precision glass molding as well as the need for elimination of costly experimental trial and error calls for numerical simulations. This study deals with 3D thermo-mechanical modeling of the wafer-based precision...... glass lens molding process. First, a comprehensive 3D thermo-mechanical model of glass is implemented into a FORTRAN user subroutine (UMAT) in the FE program ABAQUS, and the developed FE model is validated with both a well-known sandwich seal test and experimental results of precision molding of several...... glass rings. Afterward, 3D thermo-mechanical modeling of the wafer-based glass lens manufacturing is performed to suggest a proper molding program (i.e., the proper set of process parameters including preset force-time and temperature-time histories) for molding a wafer to a desired dimension...

Emission of BTEX and PAHs from molding sands with furan cold setting resins containing different contents of free furfuryl alcohol during production of cast iron

Directory of Open Access Journals (Sweden)

Mariusz Holtzer

2015-11-01

Full Text Available At present, furan resin is the largest selling no-bake system of moulding sands. The most commonly used furan no-bake binders (FNB are condensation products of furfuryl alcohol (FA urea, formaldehyde and phenol. They are generally cured by exposure to organic sulfonic acids. FNB provide excellent mold and core strength, cure rapidly and allow the sand to be reclaimed at fairly high yields, generally 75%-80%, especially in applications where due allowance is made for the need to keep total sulfur content below 0.1%. However, due to probable carcinogenic properties of furfuryl alcohol, the EU Directive limits the content of this substance (in a monomer form in resin to 25%. The classification of furfuryl alcohol and the resulting furan resin products has changed from "harmful" to "toxic" by inhalation? The aim of this study was to determine the effect of free furfuryl alcohol content in the resin on the emission of harmful substances from the BTEX (Benzene Toluene Ethylbenzene & Xylene and PAHs (polycyclic aromatic hydrocarbon group exposed to high temperature and how it affects the emissions allowance of reclaimed sand in the matrix. Three resins from a leading manufacturer were examined, which contain a free furfuryl alcohol content of 71%-72%, about 50% and < 25%, respectively. The hardener for each resin was 65% aqueous solution of paratoluenesulfonic acid. Tests were carried out in semi-industrial conditions where liquid cast-iron was poured into sample sand mold at 1,350 ìC. The matrix of the studied sands was reclaimed in the amount of 0, 50%, 100%, respectively. With the increase of free furfuryl alcohol content, the volume of evolved gases decreased. For all resins the main component from the BTEX group dominating in the emitted gases was benzene; however toluene also appeared in the amount of a few percentages. In contrast, ethylbenzene and xylenes occurred only in the gases emitted from resin-bonded sands with the largest furfuryl

Process for molding improved polyethylene

International Nuclear Information System (INIS)

Kanai, Masanori; Aine, Norio; Nakada, Shinsaku.

1962-01-01

Various configurations in size and shape of polyethylene are molded by: (a) irradiating powders of polyethylene with ionizing radiations in the presence of oxygen to the extent of producing substantially no cross-linking among the molecules of polyethylene, and thereafter (b) molding the thus irradiated powders of polyethylene at 100-250 0 C to cross-link the molding. In this process, a uniform and desirable degree of cross-linking and any desirable configuration are provided for the polyethylene molding. Any extruder and any molding machine producing heat can be employed in this process. In embodiments, the radiation dose units may preferably be 1x10 6 to 1.5x10 7 roentgen. The ionizing radiations may be X-rays, gamma-rays or electron beams, but preferably gamma-rays. The preheating prior to molding may be effected in vacuum, in inert gas, or in oxygen at 100-250 0 C, but preferably in oxygen at 100 0 C. In an example, a polyethylene powder of 100 mesh was irradiated with gamma-rays from a Co-60 source with a dose of 3.1x10 6 r at a dose rate of 5.5x10 4 r/hr in air, then preheated in air at 80 0 C for 1 hr, and finally extruded to form a rod of 5 mm phi at 200 0 C. max. The degree of product cross-linking was 0% after irradiation in step (a), and 38% after heating in step (b). (Iwakiri, K.)

Integration of Digital Dental Casts in Cone-Beam Computed Tomography Scans

Science.gov (United States)

Rangel, Frits A.; Maal, Thomas J. J.; Bergé, Stefaan J.; Kuijpers-Jagtman, Anne Marie

2012-01-01

Cone-beam computed tomography (CBCT) is widely used in maxillofacial surgery. The CBCT image of the dental arches, however, is of insufficient quality to use in digital planning of orthognathic surgery. Several authors have described methods to integrate digital dental casts into CBCT scans, but all reported methods have drawbacks. The aim of this feasibility study is to present a new simplified method to integrate digital dental casts into CBCT scans. In a patient scheduled for orthognathic surgery, titanium markers were glued to the gingiva. Next, a CBCT scan and dental impressions were made. During the impression-taking procedure, the titanium markers were transferred to the impression. The impressions were scanned, and all CBCT datasets were exported in DICOM format. The two datasets were matched, and the dentition derived from the scanned impressions was transferred to the CBCT of the patient. After matching the two datasets, the average distance between the corresponding markers was 0.1 mm. This novel method allows for the integration of digital dental casts into CBCT scans, overcoming problems such as unwanted extra radiation exposure, distortion of soft tissues due to the use of bite jigs, and time-consuming digital data handling. PMID:23050159

Aplikasi Cetakan Permanen untuk Meningkatkan Produksi dan Kualitas Produk IKM Pengecoran Logam Kuningan di Ngawen, Sidokarto, Godean, Yogyakarta

Directory of Open Access Journals (Sweden)

Suyitno Suyitno

2016-12-01

Full Text Available Small and Medium Enterprises (SME brass foundry in Ngawen Sidokarto, District of Godean, Sleman, Yogyakarta mostly produced cow necklace accessories (klonthong and jathilan accessories (klinthing. Te industry and business management are arranged within the scope of family. Te products are relatively low in quality and its market share is limited and tend to be traditional. Tis condition is caused by the weak knowledge of the management and the method of casting metals and metal science. Brass casting methode, that was used at IKM partner, is casting with mold of sand or soil. Tis process requires the making process of sand molds, that is removed afer the brass solidify. For large quantities products, this process is inefcient and takes a long time. It would require a more efcient and faster method in the production process. Method of sand casting and ceramics have been used by SMEs cast brass in Yogyakarta, however it  has many disadvantages in terms of increased productivity and quality as well as the expansion of product applications. Te permanent mold casting of iron is a casting method which has many advantages over other methods, but the use for SMEs has not been applied in the SME of cast brass. Te permanen mold casting methods was introduced to SME partners. Tis replaces the sand mold materials and molding sand. It is expected the casting process is faster because the mold can be used for a large number of products. Te results show that the application of the technology results in products with precision and consistent in shape and size. Community Service of UGM with Appropriate Technology has also collaborated with  Industry and Trade service of Yogyakarta donation of production machinery for making permanent mold. It can be concluded that the application of permanen mold in the brass foundry industry improve the product precision and the speed of produsction.

A study on the composition optimization and mechanical properties of Al-Mg-Si cast alloys

International Nuclear Information System (INIS)

Zhang, X.H.; Su, G.C.; Han, Y.Y.; Ai, X.H.; Yan, W.L.

2010-01-01

The mechanical properties of Al-Mg-Si cast alloys with different chemical compositions were investigated using an orthogonal test method. The optimized chemical compositions of Al alloy are given in wt% as follows: 7.0%Si-0.35%Mg-2.0%Cu-0.2%Mn-0.2%Ni-0.1%V-0.8%RE-89.35%Al. The optimized Al-Mg-Si alloy with metal mold casting had excellent mechanical properties. The softening resistance of the optimized alloy was better than that of ZL101 at elevated temperatures. The scanning electron microscopy fractographs of the tensile samples of ZL101 and optimized Al alloy at different magnifications revealed that all the specimens were fractured in a ductile manner, consisting of well-developed dimples over the entire surface. The alloys failed in a mixed-mode fracture, comprised predominantly of transgranular shears and a small amount of quasi-cleavages.

Fabrication of silicon molds for polymer optics

DEFF Research Database (Denmark)

Nilsson, Daniel; Jensen, Søren; Menon, Aric Kumaran

2003-01-01

A silicon mold used for structuring polymer microcavities for optical applications is fabricated, using a combination of DRIE (deep reactive ion etching) and anisotropic chemical wet etching with KOH + IPA. For polymer optical microcavities, low surface roughness and vertical sidewalls are often ...... and KOH + IPA etch have been optimized. To reduce stiction between the silicon mold and the polymers used for molding, the mold is coated with a teflon-like material using the DRIE system. Released polymer microstructures characterized with AFM and SEM are also presented....

Evolution of Surface Texture and Cracks During Injection Molding of Fiber-Reinforced, Additively-Manufactured, Injection Molding Inserts

DEFF Research Database (Denmark)

Hofstätter, Thomas; Mischkot, Michael; Pedersen, David Bue

2016-01-01

This paper investigates the lifetime and surfacedeterioration of additively-manufactured, injection-moulding inserts. The inserts were produced using digital light processing and were reinforcedwith oriented short carbon fibers. Theinserts were used during injection molding oflow-density polyethy......This paper investigates the lifetime and surfacedeterioration of additively-manufactured, injection-moulding inserts. The inserts were produced using digital light processing and were reinforcedwith oriented short carbon fibers. Theinserts were used during injection molding oflow......-density polyethylene until their failure. The molded products were used to analyse the development of the surface roughness and wear. By enhancing the lifetime of injection-molding inserts,this work contributes to the establishment of additively manufactured inserts in pilot production....

Solvent-assisted polymer micro-molding

Institute of Scientific and Technical Information of China (English)

HAN LuLu; ZHOU Jing; GONG Xiao; GAO ChangYou

2009-01-01

The micro-molding technology has played an important role in fabrication of polymer micro-patterns and development of functional devices.In such a process,suitable solvent can swell or dissolve the polymer films to decrease their glass transition temperature (Tg) and viscosity and thereby improve flowing ability.Consequently,it is easy to obtain the 2D and 3D patterns with high fidelity by the solvent-assisted micro-molding.Compared with the high temperature molding,this technology overcomes some shortcomings such as shrinking after cooling,degradation at high temperature,difficulty in processing some functional materials having high Tg,etc.It can be applied to making patterns not only on polymer monolayers but also on polyelectrolyte multilayers.Moreover,the compressioninduced patterns on the multilayers are chemically homogenous but physically heterogeneous.In this review,the controlling factors on the pattern quality are also discussed,including materials of the mold,solvent,pressure,temperature and pattern density.

Bainite obtaining in cast iron with carbides castings

Directory of Open Access Journals (Sweden)

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.

Comparison of marginal accuracy of castings fabricated by conventional casting technique and accelerated casting technique: an in vitro study.

Science.gov (United States)

Reddy, S Srikanth; Revathi, Kakkirala; Reddy, S Kranthikumar

2013-01-01

Conventional casting technique is time consuming when compared to accelerated casting technique. In this study, marginal accuracy of castings fabricated using accelerated and conventional casting technique was compared. 20 wax patterns were fabricated and the marginal discrepancy between the die and patterns were measured using Optical stereomicroscope. Ten wax patterns were used for Conventional casting and the rest for Accelerated casting. A Nickel-Chromium alloy was used for the casting. The castings were measured for marginal discrepancies and compared. Castings fabricated using Conventional casting technique showed less vertical marginal discrepancy than the castings fabricated by Accelerated casting technique. The values were statistically highly significant. Conventional casting technique produced better marginal accuracy when compared to Accelerated casting. The vertical marginal discrepancy produced by the Accelerated casting technique was well within the maximum clinical tolerance limits. Accelerated casting technique can be used to save lab time to fabricate clinical crowns with acceptable vertical marginal discrepancy.

Indoor visible mold and mold odor are associated with new-onset childhood wheeze in a dose-dependent manner.

Science.gov (United States)

Shorter, Caroline; Crane, Julian; Pierse, Nevil; Barnes, Phillipa; Kang, Janice; Wickens, Kristin; Douwes, Jeroen; Stanley, Thorsten; Täubel, Martin; Hyvärinen, Anne; Howden-Chapman, Philippa

2018-01-01

Evidence is accumulating that indoor dampness and mold are associated with the development of asthma. The underlying mechanisms remain unknown. New Zealand has high rates of both asthma and indoor mold and is ideally placed to investigate this. We conducted an incident case-control study involving 150 children with new-onset wheeze, aged between 1 and 7 years, each matched to two control children with no history of wheezing. Each participant's home was assessed for moisture damage, condensation, and mold growth by researchers, an independent building assessor and parents. Repeated measures of temperature and humidity were made, and electrostatic dust cloths were used to collect airborne microbes. Cloths were analyzed using qPCR. Children were skin prick tested for aeroallergens to establish atopy. Strong positive associations were found between observations of visible mold and new-onset wheezing in children (adjusted odds ratios ranged between 1.30 and 3.56; P ≤ .05). Visible mold and mold odor were consistently associated with new-onset wheezing in a dose-dependent manner. Measurements of qPCR microbial levels, temperature, and humidity were not associated with new-onset wheezing. The association between mold and new-onset wheeze was not modified by atopic status, suggesting a non-allergic association. © 2017 John Wiley & Sons A/S. Published by John Wiley & Sons Ltd.

Porous media heat transfer for injection molding

Science.gov (United States)

Beer, Neil Reginald

2016-05-31

The cooling of injection molded plastic is targeted. Coolant flows into a porous medium disposed within an injection molding component via a porous medium inlet. The porous medium is thermally coupled to a mold cavity configured to receive injected liquid plastic. The porous medium beneficially allows for an increased rate of heat transfer from the injected liquid plastic to the coolant and provides additional structural support over a hollow cooling well. When the temperature of the injected liquid plastic falls below a solidifying temperature threshold, the molded component is ejected and collected.

Melting and casting of FeAl-based cast alloy

Energy Technology Data Exchange (ETDEWEB)

Sikka, V.K. [Oak Ridge National Lab., TN (United States); Wilkening, D. [Columbia Falls Aluminum Co., Columbia Falls, MT (United States); Liebetrau, J.; Mackey, B. [AFFCO, L.L.C., Anaconda, MT (United States)

1998-11-01

The FeAl-based intermetallic alloys are of great interest because of their low density, low raw material cost, and excellent resistance to high-temperature oxidation, sulfidation, carburization, and molten salts. The applications based on these unique properties of FeAl require methods to melt and cast these alloys into complex-shaped castings and centrifugal cast tubes. This paper addresses the melting-related issues and the effect of chemistry on the microstructure and hardness of castings. It is concluded that the use of the Exo-Melt{trademark} process for melting and the proper selection of the aluminum melt stock can result in porosity-free castings. The FeAl alloys can be melted and cast from the virgin and revert stock. A large variation in carbon content of the alloys is possible before the precipitation of graphite flakes occurs. Titanium is a very potent addition to refine the grain size of castings. A range of complex sand castings and two different sizes of centrifugal cast tubes of the alloy have already been cast.

Depth of array micro-holes with large aspect ratio in Al based cast alloy

Science.gov (United States)

Jin, Meiling; Qu, Yingdong; Li, Rongde

2018-03-01

In order to study on the depth of array micro-holes on Al base cast alloy, micro-hole with depth of 50 mm and diameter of 0.55 mm are successfully prepared by using poor wetting between carbon and Al. Accordingly, the mold of depth is established, the results show that calculated depth of micro-hole is 53.22 mm, relative error is 6% compare with the actual measured depth, and the depth of hole exponentially increases with the increasing of distance between two micro-holes. Surface tension and metallostatic pressure of metal molten are mainly affecting factors for depth of micro-holes.

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

Energy Technology Data Exchange (ETDEWEB)

Crapps, Justin M. [Los Alamos National Laboratory; Galloway, Jack D. [Los Alamos National Laboratory; Decroix, David S. [Los Alamos National Laboratory; Korzekwa, David A. [Los Alamos National Laboratory; Aikin, Robert M. Jr. [Los Alamos National Laboratory; Unal, Cetin [Los Alamos National Laboratory; Fielding, R. [Idaho National Laboratory; Kennedy, R [Idaho National Laboratory

2012-06-29

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

Tool steel quality and surface finishing of plastic molds

Directory of Open Access Journals (Sweden)

Rafael Agnelli Mesquita

2010-01-01

Full Text Available Plastic industry is today in a constant growth, demanding several products from other segments, which includes the plastic molds, mainly used in the injection molding process. Considering all the requirements of plastic molds, the surface finishing is of special interest, as the injected plastic part is able to reproduce any details (and also defects from the mold surface. Therefore, several aspects on mold finishing are important, mainly related to manufacturing conditions - machining, grinding, polishing and texturing, and also related to the tool steel quality, in relation to microstructure homogeneity and non-metallic inclusions (cleanliness. The present paper is then focused on this interrelationship between steel quality and manufacturing process, which are both related to the final quality of plastic mold surfaces. Examples are discussed in terms of surface finishing of plastic molds and the properties or the microstructure of mold steels.

Effect of Functional Nano Channel Structures Different Widths on Injection Molding and Compression Molding Replication Capabilities

DEFF Research Database (Denmark)

Calaon, M.; Tosello, G.; Garnaes, J.

The present study investigates the capabilities of the two employed processes, injection molding (IM) and injection compression molding (ICM) on replicating different channel cross sections. Statistical design of experiment was adopted to optimize replication quality of produced polymer parts wit...

Effect of pressure on heat transfer coefficient at the metal/mold interface of A356 aluminum alloy

DEFF Research Database (Denmark)

Fardi Ilkhchy, A.; Jabbari, Masoud; Davami, P.

2012-01-01

The aim of this paper is to correlate interfacial heat transfer coefficient (IHTC) to applied external pressure, in which IHTC at the interface between A356 aluminum alloy and metallic mold during the solidification of casting under different pressures were obtained using the inverse heat...... conduction problem (IHCP) method. The method covers the expedient of comparing theoretical and experimental thermal histories. Temperature profiles obtained from thermocouples were used in a finite difference heat flow program to estimate the transient heat transfer coefficients. The new simple formula...... was presented for correlation between external pressure and heat transfer coefficient. Acceptable agreement with data in literature shows the accuracy of the proposed formula....

Surface microstructure replication in injection molding

DEFF Research Database (Denmark)

Theilade, Uffe Arlø; Hansen, Hans Nørgaard

2006-01-01

topography is transcribed onto the plastic part through complex mechanisms. This replication, however, is not perfect, and the replication quality depends on the plastic material properties, the topography itself, and the process conditions. This paper describes and discusses an investigation of injection...... molding of surface microstructures. The fundamental problem of surface microstructure replication has been studied. The research is based on specific microstructures as found in lab-on-a-chip products and on rough surfaces generated from EDM (electro discharge machining) mold cavities. Emphasis is put...... on the ability to replicate surface microstructures under normal injection-molding conditions, i.e., with commodity materials within typical process windows. It was found that within typical process windows the replication quality depends significantly on several process parameters, and especially the mold...

Dependence Of The Structure And Magnetic Properties Of Cast Plate-Shaped Nd60Fe30Al10 Samples On Their Thickness

Directory of Open Access Journals (Sweden)

Michalski B.

2015-09-01

Full Text Available The hard magnetic Nd-Fe-Al alloys are inferior to Nd-Fe-B magnets as far as the magnetic properties are concerned, but their great advantage is that they need no additional annealing to achieve good magnetic properties. These properties depend on the cooling rate from the melting state, and on the thickness of the sample - the best values are achieved at the quenching rates at which the samples have a thickness of 0.3-2 mm. The present study is concerned with the correlation between the magnetic properties of the plate-shaped Nd60Fe30Al10 samples and their size - thickness. Two casting ways: with the melt stream perpendicular direction and parallel to the surface of the plates were used. The plates were produced by pressure casting and suction casting. The studies have shown that the cooling rates depends on local propagation on liquid metal in the mold resulting in heterogeneity of structure and properties.

Injection molding of high aspect ratio sub-100 nm nanostructures

DEFF Research Database (Denmark)

Matschuk, Maria; Larsen, Niels B

2013-01-01

We have explored the use of mold coatings and optimized processing conditions to injection mold high aspect ratio nanostructures (height-to-width >1) in cyclic olefin copolymer (COC). Optimizing the molding parameters on uncoated nickel molds resulted in slight improvements in replication quality...... as described by height, width and uniformity of the nanoscopic features. Use of a mold temperature transiently above the polymer glass transition temperature (Tg) was the most important factor in increasing the replication fidelity. Surface coating of the nickel molds with a fluorocarbon-containing thin film...... (FDTS) greatly enhanced the quality of replicated features, in particular at transient mold temperatures above Tg. Injection molding using the latter mold temperature regime resulted in a bimodal distribution of pillar heights, corresponding to either full or very poor replication of the individual...

'Distorted structure modelling' - a more physical approach to Rapid Distortion Theory

International Nuclear Information System (INIS)

Savill, A.M.

1979-11-01

Rapid Distortion Theory is reviewed in the light of the modern mechanistic approach to turbulent motion. The apparent failure of current models, based on this theory, to predict stress intensity ratios accurately in distorted shear flows is attributed to their oversimplistic assumptions concerning the inherent turbulence structure of such flows. A more realistic picture of this structure and the manner in which it responds to distortion is presented in terms of interactions between the mean flow and three principal types of eddies. If Rapid Distortion Theory is modified to account for this it is shown that the stress intensity ratios can be accurately predicted in three test flows. It is concluded that a computational scheme based on Rapid Distortion Theory might ultimately be capable of predicting turbulence parameters in the highly complex geometries of reactor cooling systems. (author)

The machinability of cast titanium and Ti-6Al-4V.

Science.gov (United States)

Ohkubo, C; Watanabe, I; Ford, J P; Nakajima, H; Hosoi, T; Okabe, T

2000-02-01

This study investigated the machinability (ease of metal removal) of commercially pure (CP) titanium and Ti-6Al-4V alloy. Both CP Ti and Ti-6Al-4V were cast into magnesia molds. Two types of specimens (with alpha-case and without alpha-case) were made for CP Ti and Ti-6Al-4V. Machinability (n = 5) was evaluated as volume loss (mm3) by cutting/grinding the 3.0 mm surface using fissure burs and silicon carbide (SiC) under two machining conditions: (1) two machining forces (100 or 300 gf) at two rotational speeds (15000 or 30000 rpm) for 1 min, and (2) constant machining force of 100 gf and rotational speed of 15000 rpm for 1, 2, 5, 10, and 30 min. As controls, conventionally cast Co-Cr and Type IV gold alloys were evaluated in the same manner as the titanium. When fissure burs were used, there was a significant difference in the machinability between CP titanium with alpha-case and without alpha-case. On the other hand, there was no appreciable difference in the amount of metal removed for each tested metal when using the SiC points.

Nanostructuring steel for injection molding tools

International Nuclear Information System (INIS)

Al-Azawi, A; Smistrup, K; Kristensen, A

2014-01-01

The production of nanostructured plastic items by injection molding with ridges down to 400 nm in width, which is the smallest line width replicated from nanostructured steel shims, is presented. Here we detail a micro-fabrication method where electron beam lithography, nano-imprint lithography and ion beam etching are combined to nanostructure the planar surface of a steel wafer. Injection molded plastic parts with enhanced surface properties, like anti-reflective, superhydrophobic and structural colors can be achieved by micro- and nanostructuring the surface of the steel molds. We investigate the minimum line width that can be realized by our fabrication method and the influence of etching angle on the structure profile during the ion beam etching process. Trenches down to 400 nm in width have been successfully fabricated into a 316 type electro-polished steel wafer. Afterward a plastic replica has been produced by injection molding with good structure transfer fidelity. Thus we have demonstrated that by utilizing well-established fabrication techniques, nanostructured steel shims that are used in injection molding, a technique that allows low cost mass fabrication of plastic items, are produced. (paper)

COMPUTER AIDED THREE DIMENSIONAL DESIGN OF MOLD COMPONENTS

Directory of Open Access Journals (Sweden)

Kerim ÇETİNKAYA

2000-02-01

Full Text Available Sheet metal molding design with classical methods is formed in very long times calculates and drafts. At the molding design, selection and drafting of most of the components requires very long time because of similar repetative processes. In this study, a molding design program has been developed by using AutoLISP which has been adapted AutoCAD packet program. With this study, design of sheet metal molding, dimensioning, assemly drafting has been realized.

Geometric study of transparent superhydrophobic surfaces of molded and grid patterned polydimethylsiloxane (PDMS)

Science.gov (United States)

Davaasuren, Gaasuren; Ngo, Chi-Vinh; Oh, Hyun-Seok; Chun, Doo-Man

2014-09-01

Herein we describe an economical method to fabricate a transparent superhydrophobic surface that uses grid patterning, and we report on the effects of grid geometry in determining the wettability and transparency of the fabricated surfaces. A polymer casting method was utilized because of its applicability to economical manufacturing and mass production; the material polydimethylsiloxane (PDMS) was selected because of its moldability and transparency. PDMS was replicated from a laser textured mold fabricated by a UV nanosecond pulsed laser. Sapphire wafer was used for the mold because it has very low surface roughness (Ra ≤0.3 nm) and adequate mechanical properties. To study geometric effects, grid patterns of a series of step sizes were fabricated. The maximum water droplet contact angle (WDCA) observed was 171°. WDCAs depended on the wetting area and the wetting state. The experimental results of WDCA were analyzed with Wenzel and Cassie-Baxter equations. The designed grid pattern was suitably transparent and structurally stable. Transmittance of the optimal transparent superhydrophobic surface was measured by using a spectrophotometer. Transmittance loss due to the presence of the grid was around 2-4% over the wavelength region measured (300-1000 nm); the minimum transmittance observed was 83.1% at 300 nm. This study also demonstrates the possibility of using a nanosecond pulsed laser for the surface texturing of a superhydrophobic surface.

Residual thermal stresses in a solid sphere cast from a thermosetting material

Science.gov (United States)

Levitsky, M.; Shaffer, B. W.

1975-01-01

Expressions are developed for the residual thermal stresses in a solid sphere cast from a chemically hardening thermosetting material in a rigid spherical mold. The description of the heat generation rate and temperature variation is derived from a first-order chemical reaction. Solidification is described by the continuous transformation of the material from an inviscid liquidlike state into an elastic solid, with intermediate properties determined by the degree of chemical reaction. Residual stress components are obtained as functions of the parameters of the hardening process and the properties of the hardening material. Variation of the residual stresses with a nondimensionalized reaction rate parameter and the relative compressibility of the hardened material is discussed in detail.

Solidified structure of Al-Pb-Cu alloys

International Nuclear Information System (INIS)

Ikeda, Tetsuyuki; Nishi, Seiki; Kumeuchi, Hiroyuki; Tatsuta, Yoshinori.

1986-01-01

Al-Pb-Cu alloys were cast into bars or plates in different two metal mold casting processes in order to suppress gravity segregation of Pb and to achieve homogeneous dispersion of Pb phase in the alloys. Solidified structures were analyzed by a video-pattern-analyzer. Plate castings 15 to 20 mm in thickness of Al-Pb-1 % Cu alloy containing Pb up to 5 % in which Pb phase particles up to 10 μm disperse are achieved through water cooled metal mold casting. The plates up to 5 mm in thickness containing Pb as much as 8 to 10 % cast in this process have dispersed Pb particles up to 5 μm in diameter in the surface layer. Al-8 % Pb-1 % Cu alloy bars 40 mm in diameter and 180 mm in height in which gravity segregation of Pb is prevented can be cast by movable and water sprayed metal mold casting at casting temperature 920 deg C and mold moving speed 1.0 mm/s. Pb phase particles 10 μm in mean size are dispersed in the bars. (author)

Compensating additional optical power in the central zone of a multifocal contact lens forminimization of the shrinkage error of the shell mold in the injection molding process.

Science.gov (United States)

Vu, Lien T; Chen, Chao-Chang A; Lee, Chia-Cheng; Yu, Chia-Wei

2018-04-20

This study aims to develop a compensating method to minimize the shrinkage error of the shell mold (SM) in the injection molding (IM) process to obtain uniform optical power in the central optical zone of soft axial symmetric multifocal contact lenses (CL). The Z-shrinkage error along the Z axis or axial axis of the anterior SM corresponding to the anterior surface of a dry contact lens in the IM process can be minimized by optimizing IM process parameters and then by compensating for additional (Add) powers in the central zone of the original lens design. First, the shrinkage error is minimized by optimizing three levels of four IM parameters, including mold temperature, injection velocity, packing pressure, and cooling time in 18 IM simulations based on an orthogonal array L 18 (2 1 ×3 4 ). Then, based on the Z-shrinkage error from IM simulation, three new contact lens designs are obtained by increasing the Add power in the central zone of the original multifocal CL design to compensate for the optical power errors. Results obtained from IM process simulations and the optical simulations show that the new CL design with 0.1 D increasing in Add power has the closest shrinkage profile to the original anterior SM profile with percentage of reduction in absolute Z-shrinkage error of 55% and more uniform power in the central zone than in the other two cases. Moreover, actual experiments of IM of SM for casting soft multifocal CLs have been performed. The final product of wet CLs has been completed for the original design and the new design. Results of the optical performance have verified the improvement of the compensated design of CLs. The feasibility of this compensating method has been proven based on the measurement results of the produced soft multifocal CLs of the new design. Results of this study can be further applied to predict or compensate for the total optical power errors of the soft multifocal CLs.

Fabrication of a roller type PDMS stamp using SU-8 concave molds and its application for roll contact printing

International Nuclear Information System (INIS)

Park, Jongho; Kim, Beomjoon

2016-01-01

Continuous fabrication of micropatterns at low-cost is attracting attention in various applications within industrial fields. To meet such demands, we have demonstrated a roll contact printing technique, using roller type polydimethylsiloxane (PDMS) stamps with roll-to-flat and roll-to-roll stages. Roller type PDMS stamps for roll contact printing were fabricated using a custom-made metal support and SU-8 microstructures fabricated on concave substrates as a mold. The molding/casting method which we developed here provided faster and easier fabrication than conventional methods for roller type stamps. Next, roll contact printing was performed using fabricated roller type PDMS stamps with roll-to-flat and roll-to-roll stages. Patterns with minimum widths of 3 μm and 2.1 μm were continuously fabricated for each stage, respectively. In addition, the relationship between applied pressures and dimensional changes of roll contact printed patterns was investigated. Finally, we confirmed that roll contact printing and the new fabrication method for roller stamps presented in this study demonstrated the feasibility for industrial applications. (paper)

Nano-ceramics and its molding technologies

International Nuclear Information System (INIS)

Liu Jian; Xu Yunshu

2007-01-01

Nano-ceramics and its related knowledge were introduced. Fabrication of nano-ceramic powder, as well as the molding and sintering technologies of nano-ceramics were reviewed. Features of the present molding technologies were analyzed. The applications of nano-ceramics were prospected. (authors)

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

Science.gov (United States)

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

2018-05-01

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

40 CFR 63.5790 - What parts of my plant does this subpart cover?

Science.gov (United States)

2010-07-01

... operations: Open molding, closed molding, centrifugal casting, continuous lamination, continuous casting... shops on military bases); prepreg materials as defined in § 63.5935; non-gel coat surface coatings...

Factors influencing microinjection molding replication quality

Science.gov (United States)

Vera, Julie; Brulez, Anne-Catherine; Contraires, Elise; Larochette, Mathieu; Trannoy-Orban, Nathalie; Pignon, Maxime; Mauclair, Cyril; Valette, Stéphane; Benayoun, Stéphane

2018-01-01

In recent years, there has been increased interest in producing and providing high-precision plastic parts that can be manufactured by microinjection molding: gears, pumps, optical grating elements, and so on. For all of these applications, the replication quality is essential. This study has two goals: (1) fabrication of high-precision parts using the conventional injection molding machine; (2) identification of robust parameters that ensure production quality. Thus, different technological solutions have been used: cavity vacuuming and the use of a mold coated with DLC or CrN deposits. AFM and SEM analyses were carried out to characterize the replication profile. The replication quality was studied in terms of the process parameters, coated and uncoated molds and crystallinity of the polymer. Specific studies were processed to quantify the replicability of injection molded parts (ABS, PC and PP). Analysis of the Taguchi experimental designs permits prioritization of the impact of each parameter on the replication quality. A discussion taking into account these new parameters and the thermal and spreading properties on the coatings is proposed. It appeared that, in general, increasing the mold temperature improves the molten polymer fill in submicron features except for the steel insert (for which the presence of a vacuum is the most important factor). Moreover, the DLC coating was the best coating to increase the quality of the replication. This result could be explained by the lower thermal diffusivity of this coating. We noted that the viscosity of the polymers is not a primordial factor of the replication quality.

Fibreglass Total Contact Casting, Removable Cast Walkers, and Irremovable Cast Walkers to Treat Diabetic Neuropathic Foot Ulcers: A Health Technology Assessment

Science.gov (United States)

Costa, Vania; Tu, Hong Anh; Wells, David; Weir, Mark; Holubowich, Corinne; Walter, Melissa

2017-01-01

Background Diabetic neuropathic foot ulcers are a risk factor for lower leg amputation. Many experts recommend offloading with fibreglass total contact casting, removable cast walkers, and irremovable cast walkers as a way to treat these ulcers. Methods We completed a health technology assessment, which included an evaluation of clinical benefits and harms, value for money, and patient preferences for offloading devices. We performed a systematic literature search on August 17, 2016, to identify randomized controlled trials that compared fibreglass total contact casting, removable cast walkers, and irremovable cast walkers with other treatments (offloading or non-offloading) in patients with diabetic neuropathic foot ulcers. We developed a decision-analytic model to assess the cost-effectiveness of fibreglass total contact casting, removable cast walkers, and irremovable cast walkers, and we conducted a 5-year budget impact analysis. Finally, we interviewed people with diabetes who had lived experience with foot ulcers, asking them about the different offloading devices and the factors that influenced their treatment choices. Results We identified 13 randomized controlled trials. The evidence suggests that total contact casting, removable cast walkers, and irremovable cast walkers are beneficial in the treatment of neuropathic, noninfected foot ulcers in patients with diabetes but without severe peripheral arterial disease. Compared to removable cast walkers, ulcer healing was improved with total contact casting (moderate quality evidence; risk difference 0.17 [95% confidence interval 0.00–0.33]) and irremovable cast walkers (low quality evidence; risk difference 0.21 [95% confidence interval 0.01–0.40]). We found no difference in ulcer healing between total contact casting and irremovable cast walkers (low quality evidence; risk difference 0.02 [95% confidence interval −0.11–0.14]). The economic analysis showed that total contact casting and irremovable

Holographic measurement of distortion during laser melting: Additive distortion from overlapping pulses

Science.gov (United States)

Haglund, Peter; Frostevarg, Jan; Powell, John; Eriksson, Ingemar; Kaplan, Alexander F. H.

2018-03-01

Laser - material interactions such as welding, heat treatment and thermal bending generate thermal gradients which give rise to thermal stresses and strains which often result in a permanent distortion of the heated object. This paper investigates the thermal distortion response which results from pulsed laser surface melting of a stainless steel sheet. Pulsed holography has been used to accurately monitor, in real time, the out-of-plane distortion of stainless steel samples melted on one face by with both single and multiple laser pulses. It has been shown that surface melting by additional laser pulses increases the out of plane distortion of the sample without significantly increasing the melt depth. The distortion differences between the primary pulse and subsequent pulses has also been analysed for fully and partially overlapping laser pulses.

Ceramic injection molding

International Nuclear Information System (INIS)

Agueda, Horacio; Russo, Diego

1988-01-01

Interest in making complex net-shape ceramic parts with good surface finishing and sharp tolerances without machining is a driving force for studying the injection molding technique. This method consists of softhening the ceramic material by means of adding some plastic and heating in order to inject the mixture under pressure into a relatively cold mold where solidification takes place. Essentially, it is the same process used in thermoplastic industry but, in the present case, the ceramic powder load ranges between 80 to 90 wt.%. This work shows results obtained from the fabrication of pieces of different ceramic materials (alumina, barium titanate ferrites, etc.) in a small scale, using equipments developed and constructed in the laboratory. (Author) [es

Effects of aluminum and copper chill on mechanical properties and microstructures of Cu-Zn-Al alloys with sand casting

Science.gov (United States)

Ardhyananta, Hosta; Wibisono, Alvian Toto; Ramadhani, Mavindra; Widyastuti, Farid, Muhammad; Gumilang, Muhammad Shena

2018-04-01

Cu-Zn-Al alloy is one type of brass, which has high strength and high corrosion resistant. It has been applied on ship propellers and marine equipment. In this research, the addition of aluminum (Al) with variation of 1, 2, 3, 4% aluminum to know the effect on mechanical properties and micro structure at casting process using a copper chill and without copper chill. This alloy is melted using furnace in 1100°C without holding. Then, the molten metal is poured into the mold with copper chill and without copper chill. The speciment of Cu-Zn-Al alloy were chracterized by using Optical Emission Spectroscopy (OES), Metallography Test, X-Ray Diffraction (XRD), Hardness Test of Rockwell B and Charpy Impact Test. The result is the addition of aluminum and the use of copper chill on the molds can reduce the grain size, increases the value of hardness and impact.

Evaluation of AS-CAST U-Mo alloys processed in graphite crucible coated with boron nitride

Energy Technology Data Exchange (ETDEWEB)

Marra, Kleiner M., E-mail: kleiner.marra@prof.una.br [Centro Universitario UNA, Belo Horizonte, MG (Brazil). Curso de Engenharia Mecânica; Reis, Sérgio C.; Paula, João B. de; Pedrosa, Tércio A., E-mail: reissc@cdtn.br, E-mail: jbp@cdtn.br, E-mail: tap@cdtn.br [Centro de Desenvolvimento da Tecnologia Nuclear (CDTN/CNEN-MG), Belo Horizonte, MG (Brazil)

2017-07-01

This paper reports the production of uranium-molybdenum alloys, which have been considered promising fuel for test and research nuclear reactors. U-Mo alloys were produced in three molybdenum contents: 5w%, 7w%, and 10w%, using an electric vacuum induction furnace. A boron nitride-coated graphite crucible was employed in the production of the alloys and, after melting, the material was immediately poured into a boron nitride-coated graphite mold. The incorporation of carbon was observed, but it happened in a lower intensity than in the case of the non-coated crucible/mold. It is observed that the carbon incorporation increased and alloys density decreased with Mo addition. It was also noticed that the increase in the carbon or molybdenum content did not seem to change the as-cast structure in terms of granulation. The three alloys presented body-centered cubic crystal structure (γ-phase), after solidification, besides a seeming negative microsegregation of molybdenum, from the center to the periphery of the grains. There were signs of macrosegregation, from the base to the top of the ingots. (author)

Public health and economic impact of dampness and mold

Energy Technology Data Exchange (ETDEWEB)

Mudarri, David; Fisk, William J.

2007-06-01

The public health risk and economic impact of dampness and mold exposures was assessed using current asthma as a health endpoint. Individual risk of current asthma from exposure to dampness and mold in homes from Fisk et al. (2007), and asthma risks calculated from additional studies that reported the prevalence of dampness and mold in homes were used to estimate the proportion of U.S. current asthma cases that are attributable to dampness and mold exposure at 21% (95% confidence internal 12-29%). An examination of the literature covering dampness and mold in schools, offices, and institutional buildings, which is summarized in the appendix, suggests that risks from exposure in these buildings are similar to risks from exposures in homes. Of the 21.8 million people reported to have asthma in the U.S., approximately 4.6 (2.7-6.3) million cases are estimated to be attributable to dampness and mold exposure in the home. Estimates of the national cost of asthma from two prior studies were updated to 2004 and used to estimate the economic impact of dampness and mold exposures. By applying the attributable fraction to the updated national annual cost of asthma, the national annual cost of asthma that is attributable to dampness and mold exposure in the home is estimated to be $3.5 billion ($2.1-4.8 billion). Analysis indicates that exposure to dampness and mold in buildings poses significant public health and economic risks in the U.S. These findings are compatible with public policies and programs that help control moisture and mold in buildings.

Predicting and preventing mold spoilage of food products.

Science.gov (United States)

Dagnas, Stéphane; Membré, Jeanne-Marie

2013-03-01

This article is a review of how to quantify mold spoilage and consequently shelf life of a food product. Mold spoilage results from having a product contaminated with fungal spores that germinate and form a visible mycelium before the end of the shelf life. The spoilage can be then expressed as the combination of the probability of having a product contaminated and the probability of mold growth (germination and proliferation) up to a visible mycelium before the end of the shelf life. For products packed before being distributed to the retailers, the probability of having a product contaminated is a function of factors strictly linked to the factory design, process, and environment. The in-factory fungal contamination of a product might be controlled by good manufacturing hygiene practices and reduced by particular processing practices such as an adequate air-renewal system. To determine the probability of mold growth, both germination and mycelium proliferation can be mathematically described by primary models. When mold contamination on the product is scarce, the spores are spread on the product and more than a few spores are unlikely to be found at the same spot. In such a case, models applicable for a single spore should be used. Secondary models can be used to describe the effect of intrinsic and extrinsic factors on either the germination or proliferation of molds. Several polynomial models and gamma-type models quantifying the effect of water activity and temperature on mold growth are available. To a lesser extent, the effect of pH, ethanol, heat treatment, addition of preservatives, and modified atmospheres on mold growth also have been quantified. However, mold species variability has not yet been properly addressed, and only a few secondary models have been validated for food products. Once the probability of having mold spoilage is calculated for various shelf lives and product formulations, the model can be implemented as part of a risk management

Additive Manufacturing of Wind Turbine Molds

Energy Technology Data Exchange (ETDEWEB)

Post, Brian [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Richardson, Bradley [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Lloyd, Peter [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Love, Lonnie [Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Nolet, Stephen [TPI Composites, Scottsdale, AZ (United States); Hannan, James [TPI Composites, Scottsdale, AZ (United States)

2017-07-01

The objective of this project was to explore the utility of Big Area Additive Manufacturing (BAAM) for low cost manufacturing of wind turbine molds. Engineers at Oak Ridge National Laboratory (ORNL) and TPI Composites (TPI) collaborated to design and manufacture a printed mold that can be used for resin infusion of wind turbine components. Specific focus was on required material properties (operating temperatures and pressures, coefficient of thermal expansion (CTE), thermal conductivity), surface finish (accuracy and coatings) and system integration (integrated vacuum ports, and heating element). The project began with a simple proof of principle components, targeting surface coatings and material properties for printing a small section (approximately 4’ x 4’ x 2’) of a mold. Next, the second phase scaled up and integrated with the objective of capturing all of the necessary components (integrated heating to accelerate cure time, and vacuum, sealing) for resin infusion on a mold of significant size (8’ x 20’ x 6’).

Effect of Jahn-Teller distortion on the short range magnetic order in copper ferrite

Energy Technology Data Exchange (ETDEWEB)

Abdellatif, M.H., E-mail: Mohamed.abdellatif@iit.it [Nanostrctures Department, Istituto Italiano di Tecnologia, via Morego 30, I-16163 Genova (Italy); Innocenti, Claudia [INSTM—Department of Chemistry, University of Florence, via della Lastruccia 3, I-50019 Sesto Fiorentino, FI (Italy); Liakos, Ioannis [Nanostrctures Department, Istituto Italiano di Tecnologia, via Morego 30, I-16163 Genova (Italy); Scarpellini, Alice; Marras, Sergio [Nanochemistry Department, Istituto Italiano di Tecnologia, via Morego 30, I-16163 Genova (Italy); Salerno, Marco [Nanostrctures Department, Istituto Italiano di Tecnologia, via Morego 30, I-16163 Genova (Italy)

2017-02-15

Copper ferrite of spinel crystal structure was synthesized in the form of nano-particles using citrate-gel auto-combustion method. The sample morphology and composition were identified using scanning electron microscopy, X-ray diffraction, and X-ray spectroscopy. The latter technique reveals an inverse spinel structure with Jahn-Teller tetragonal distortion. The static magnetization was measured using vibrating sample magnetometer. Magnetic force microscopy was used in combination with the magnetization data to demonstrate the finite size effect of the magnetic spins and their casting behavior due to the introduction of copper ions in the tetrahedral magnetic sub-lattices, which results in tetragonal distorting the spinel structure of the copper ferrite. The magnetic properties of materials are a result of the collective behavior of the magnetic spins, and magnetic force microscopy can probe the collective behavior of the magnetic spins in copper ferrite, yet providing a sufficient resolution to map the effects below the micrometer size scale, such as the magnetic spin canting. A theoretical study was done to clarify the finite size effect of Jahn-Teller distortion on the magnetic properties of the material. When the particles are in the nano-scale, below the single domain size, their magnetic properties are very sensitive to their size change. - Highlights: • The spin canting due to Jahn-Teller distortion in Copper ferrite can be detected using magnetic force microscope. • The contrast in the magnetic AFM image can be analyzed to give information not only about the surface spins but also about the canting of the core spins inside the aggregated cluster of magnetic nanoparticle.

Injection molded self-cleaning surfaces

DEFF Research Database (Denmark)

Søgaard, Emil

that are superhydrophobic based on topography rather than chemical compounds. Therefore, a novel method for fabricating superhydrophobic polymer surfaces with excellent water-repellant properties is developed. The method is based on microstructure fabrication and superposed nanostructures on silicon wafers. The nano......- and microstructured silicon is electroplated with nickel and the resulting nickel shim with inverse polarity is used in an injection molding process. A versatile injection molding process capable of producing different nano- and microstructures on areas larger than 10 cm2 is developed. Variotherm mold heating is used...... hierarchical structures with nanograss and holes. Water wetting tests are carried out using a pressure cell to control the water pressure. Microscopic wetting behavior of the structures is studied by optical transmission microscopy. Interestingly, it is found that the surface chemistry of the polymer changes...

Mathematical modeling of the in-mold coating process for injection-molded thermoplastic parts

Science.gov (United States)

Chen, Xu

In-Mold Coating (IMC) has been successfully used for many years for exterior body panels made from compression molded Sheet Molding Compound (SMC). The coating material is a single component reactive fluid, designed to improve the surface quality of SMC moldings in terms of functional and cosmetic properties. When injected onto a cured SMC part, IMC cures and bonds to provide a pain-like surface. Because of its distinct advantages, IMC is being considered for application to injection molded thermoplastic parts. For a successful in mold coating operation, there are two key issues related to the flow of the coating. First, the injection nozzle should be located such that the thermoplastic substrate is totally covered and the potential for air trapping is minimized. The selected location should be cosmetically acceptable since it most likely will leave a mark on the coated surface. The nozzle location also needs to be accessible for easy of maintenance. Secondly, the hydraulic force generated by the coating injection pressure should not exceed the available clamping tonnage. If the clamping force is exceeded, coating leakage will occur. In this study, mathematical models for IMC flow on the compressible thermoplastic substrate have been developed. Finite Difference Method (FDM) is first used to solve the 1 dimensional (1D) IMC flow problem. In order to investigate the application of Control Volume based Finite Element Method (CV/FEM) to more complicated two dimensional IMC flow, that method is first evaluated by solving the 1D IMC flow problem. An analytical solution, which can be obtained when a linear relationship between the coating thickness and coating injection pressure is assumed, is used to verify the numerical results. The mathematical models for the 2 dimensional (2D) IMC flow are based on the generalized Hele-Shaw approximation. It has been found experimentally that the power law viscosity model adequately predicts the rheological behavior of the coating

Mechanical Properties Distribution within Polypropylene Injection Molded Samples: Effect of Mold Temperature under Uneven Thermal Conditions

Directory of Open Access Journals (Sweden)

Sara Liparoti

2017-11-01

Full Text Available The quality of the polymer parts produced by injection molding is strongly affected by the processing conditions. Uncontrolled deviations from the proper process parameters could significantly affect both internal structure and final material properties. In this work, to mimic an uneven temperature field, a strong asymmetric heating is applied during the production of injection-molded polypropylene samples. The morphology of the samples is characterized by optical and atomic force microscopy (AFM, whereas the distribution of mechanical modulus at different scales is obtained by Indentation and HarmoniX AFM tests. Results clearly show that the temperature differences between the two mold surfaces significantly affect the morphology distributions of the molded parts. This is due to both the uneven temperature field evolutions and to the asymmetric flow field. The final mechanical property distributions are determined by competition between the local molecular stretch and the local structuring achieved during solidification. The cooling rate changes affect internal structures in terms of relaxation/reorganization levels and give rise to an asymmetric distribution of mechanical properties.

Numerical simulation of machining distortions on a forged aerospace component following a one and a multi-step approaches

Science.gov (United States)

Prete, Antonio Del; Franchi, Rodolfo; Antermite, Fabrizio; Donatiello, Iolanda

2018-05-01

Residual stresses appear in a component as a consequence of thermo-mechanical processes (e.g. ring rolling process) casting and heat treatments. When machining these kinds of components, distortions arise due to the redistribution of residual stresses due to the foregoing process history inside the material. If distortions are excessive, they can lead to a large number of scrap parts. Since dimensional accuracy can affect directly the engines efficiency, the dimensional control for aerospace components is a non-trivial issue. In this paper, the problem related to the distortions of large thin walled aeroengines components in nickel superalloys has been addressed. In order to estimate distortions on inner diameters after internal turning operations, a 3D Finite Element Method (FEM) analysis has been developed on a real industrial test case. All the process history, has been taken into account by developing FEM models of ring rolling process and heat treatments. Three different strategies of ring rolling process have been studied and the combination of related parameters which allows to obtain the best dimensional accuracy has been found. Furthermore, grain size evolution and recrystallization phenomena during manufacturing process has been numerically investigated using a semi empirical Johnson-Mehl-Avrami-Kohnogorov (JMAK) model. The volume subtractions have been simulated by boolean trimming: a one step and a multi step analysis have been performed. The multi-step procedure has allowed to choose the best material removal sequence in order to reduce machining distortions.

ELABORATION OF MANAGEMENT PLAN OF SOLID WASTE FROM SMALL CAST IRON FOUNDRIES

Directory of Open Access Journals (Sweden)

Carlos Alberto Mendes Moraes

2013-12-01

Full Text Available The foundry industry contributes to society meeting the demand of metal scrap recycling, but, at the same time, it brings a high risk of environmental impact for its many potentially pollutant wastes. Among these, there are slag and used foundry sand (cold cure molding. Through a survey about the production process of a small cast iron company, the collected data was compiled to determine the organizational setting in terms of generation and segregation of waste. From a complete environmental diagnosis carried out in eight small cast iron foundries, one of them was chosen to be a basis for the elaboration of an industrial solid waste management plan, which is becoming necessary to know and manage the generation of wastes qualitatively and quantitatively. A data assessment about the production process was carried out and compiled to determine the actual organizational scenario. As a result of that, it is possible to create a favorable environment to develop tools for environmental impacts prevention, which will permit the migration for more complex actions on the direction of more efficient process, cleaner production, and internal and external recycling of exceeding materials.

Molded polymer solar water heater

Science.gov (United States)

Bourne, Richard C.; Lee, Brian E.

2004-11-09

A solar water heater has a rotationally-molded water box and a glazing subassembly disposed over the water box that enhances solar gain and provides an insulating air space between the outside environment and the water box. When used with a pressurized water system, an internal heat exchanger is integrally molded within the water box. Mounting and connection hardware is included to provide a rapid and secure method of installation.

A cast partial obturator with hollow occlusal shim and semi-precision attachment

Directory of Open Access Journals (Sweden)

Mukesh Kumar Singhal

2018-01-01

Full Text Available A maxillofacial patient's quality of life is distorted and social integration becomes difficult. An obturator is a maxillofacial prosthesis used to close a congenital or acquired tissue defect, primarily of the hard palate and/or contiguous alveolar/soft-tissue structures. Subsequently, it restores the esthetics, speech, and function. The present clinical report aimed for the prosthetic rehabilitation of a maxillectomy defect by the incorporation of a semi-precision attachment as PRECI-SAGIX – male part of 2.2 mm on fixed partial denture (#22 and #23 teeth and matrix – plastic female part of size 2.2 mm and height 4.2 mm of yellow on cast partial in polymer base. It aids in the retention of a hollow lightweight obturator. The technique also described the method to make a bulbless obturator with a hollow self-cured acrylic resin occlusal shim. A patient is quite satisfied with bulb less, lightweight cast partial and hollow shim palatal obturator.

Control of cast iron and casts manufacturing by Inmold method

Directory of Open Access Journals (Sweden)

S. Pietrowski

2009-07-01

Full Text Available In this paper the usability of cast iron spheroidizing process in mould control by ATD method as well as by ultrasonic method were presented. Structure of instrumentation needed for control form performance of cast iron spheroidizing by Inmold method was illustrated. Author, pointed out that amount of magnesium master alloy should obtain 0,8 ÷ 1,0% of mass in form at all. Such quantity of preliminary alloy assure of obtain of nodular graphite in cast iron. In consequence of this, is reduce the cast iron liquidus temperature and decrease of recalescence temperature of graphite-eutectic crystallization in compare with initial cast iron. Control of casts can be carried out by ultrasonic method. In plain cast iron, ferritic-pearlitic microstructure is obtaining. Additives of 1,5% Cu ensure pearlitic structure.

Applying simulation to optimize plastic molded optical parts

Science.gov (United States)

Jaworski, Matthew; Bakharev, Alexander; Costa, Franco; Friedl, Chris

2012-10-01

Optical injection molded parts are used in many different industries including electronics, consumer, medical and automotive due to their cost and performance advantages compared to alternative materials such as glass. The injection molding process, however, induces elastic (residual stress) and viscoelastic (flow orientation stress) deformation into the molded article which alters the material's refractive index to be anisotropic in different directions. Being able to predict and correct optical performance issues associated with birefringence early in the design phase is a huge competitive advantage. This paper reviews how to apply simulation analysis of the entire molding process to optimize manufacturability and part performance.

Mold exposure and health effects following hurricanes Katrina and Rita.

Science.gov (United States)

Barbeau, Deborah N; Grimsley, L Faye; White, LuAnn E; El-Dahr, Jane M; Lichtveld, Maureen

2010-01-01

The extensive flooding in the aftermath of Hurricanes Katrina and Rita created conditions ideal for indoor mold growth, raising concerns about the possible adverse health effects associated with indoor mold exposure. Studies evaluating the levels of indoor and outdoor molds in the months following the hurricanes found high levels of mold growth. Homes with greater flood damage, especially those with >3 feet of indoor flooding, demonstrated higher levels of mold growth compared with homes with little or no flooding. Water intrusion due to roof damage was also associated with mold growth. However, no increase in the occurrence of adverse health outcomes has been observed in published reports to date. This article considers reasons why studies of mold exposure after the hurricane do not show a greater health impact.

The casting of western sculpture during the XIXth century: sand casting versus lost wax casting

NARCIS (Netherlands)

Beentjes, T.P.C.

2014-01-01

This paper will discuss research into bronze casting techniques as practiced during the XIXth and early XXth century. Both natural sand casting (fonte au sable naturel) and lost wax casting (fonte à la cire perdue) were employed during this period and sometimes rivalled for commissions. Before the

Metallic Reinforcement of Direct Squeeze Die Casting Aluminum Alloys for Improved Strength and Fracture Resistance

Energy Technology Data Exchange (ETDEWEB)

D. Schwam: J.F. Wallace: Y. Zhu: J.W. Ki

2004-10-01

The utilization of aluminum die casting as enclosures where internal equipment is rotating inside of the casting and could fracture requires a strong housing to restrain the fractured parts. A typical example would be a supercharger. In case of a failure, unless adequately contained, fractured parts could injure people operating the equipment. A number of potential reinforcement materials were investigated. The initial work was conducted in sand molds to create experimental conditions that promote prolonged contact of the reinforcing material with molten aluminum. Bonding of Aluminum bronze, Cast iron, and Ni-resist inserts with various electroplated coatings and surface treatments were analyzed. Also toughening of A354 aluminum cast alloy by steel and stainless steel wire mesh with various conditions was analyzed. A practical approach to reinforcement of die cast aluminum components is to use a reinforcing steel preform. Such performs can be fabricated from steel wire mesh or perforated metal sheet by stamping or deep drawing. A hemispherical, dome shaped casting was selected in this investigation. A deep drawing die was used to fabricate the reinforcing performs. The tendency of aluminum cast enclosures to fracture could be significantly reduced by installing a wire mesh of austenitic stainless steel or a punched austenitic stainless steel sheet within the casting. The use of reinforcements made of austenitic stainless steel wire mesh or punched austenitic stainless steel sheet provided marked improvement in reducing the fragmentation of the casting. The best strengthening was obtained with austenitic stainless steel wire and with a punched stainless steel sheet without annealing this material. Somewhat lower results were obtained with the annealed punched stainless steel sheet. When the annealed 1020 steel wire mesh was used, the results were only slightly improved because of the lower mechanical properties of this unalloyed steel. The lowest results were

Material and technique of S i-Mo heatresistant vermicular iron exhaust manifold

Directory of Open Access Journals (Sweden)

Jin Yong-xi

2006-08-01

Full Text Available Si-Mo vermicular iron is an ideal material for exhaust manifold that works in high temperature and therm alcycle conditions because its properties oftherm alfatigue resistance and thermal distortion resistance are significantly better than that of gray cast iron and nodular iron. This paper explains that the verm icularity of Si-Mo verm icular iron is better to be controlled approxim ately to 50% for the applications of exhaust manifold castings, and generalizes the successful experience ofverm icularizing technique thatuses sandwich(pouroverprocess combining with cored-wire injection in trough process together,and uses rare earths-magnesium-silicon as verm icularizing alloy in Disa high speed molding line and autom atic plug rod airpressure pouring furnace. In addition, this paper also describes the method to solve the shrinkage hole and porosity defects in the exhaustm anifold production.

Validation of three-dimensional micro injection molding simulation accuracy

DEFF Research Database (Denmark)

Tosello, Guido; Costa, F.S.; Hansen, Hans Nørgaard

2011-01-01

length, injection pressure profile, molding mass and flow pattern. The importance of calibrated micro molding process monitoring for an accurate implementation strategy of the simulation and its validation has been demonstrated. In fact, inconsistencies and uncertainties in the experimental data must...... be minimized to avoid introducing uncertainties in the simulation calculations. Simulations of bulky sub-100 milligrams micro molded parts have been validated and a methodology for accurate micro molding simulations was established....

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

Science.gov (United States)

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

2012-02-01

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

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

International Nuclear Information System (INIS)

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

2012-01-01

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

Facts about Stachybotrys chartarum and Other Molds

Science.gov (United States)

... there is moisture from water damage, excessive humidity, water leaks, condensation, water infiltration, or flooding. Constant moisture is ... visible mold. The conditions causing mold (such as water leaks, condensation, infiltration, or flooding) should be corrected to ...

The Effect of Epoxy Molding Compound Floor Life to Reliability Performance and mold ability for QFN Package

Science.gov (United States)

Peanpunga, Udom; Ugsornrat, Kessararat; Thorlor, Panakamol; Sumithpibul, Chalermsak

2017-09-01

This research studied about an epoxy molding compound (EMC) floor life to reliability performance of integrated circuit (IC) package. Molding is the process for protecting the die of IC package form mechanical and chemical reaction from external environment by shaping EMC. From normal manufacturing process, the EMC is stored in the frozen at 5oC and left at around room temperature for aging time or floor life before molding process. The EMC floor life effect to its properties and reliability performance of IC package. Therefore, this work interested in varied the floor life of EMC before molding process to analyze properties of EMC such as spiral flow length, gelation time, and viscosity. In experiment, the floor life of EMC was varied to check the effect of its property to reliability performance. The EMC floor life were varied from 0 hours to 60 hours with a step of 12 hours and observed wire sweep, incomplete EMC, and delamination inside the packages for 3x3, 5x5 and 8x8 mm2 of QFN packages. The evaluation showed about clearly effect of EMC floor life to IC packaging reliability. EMC floor life is not any concern for EMC property, moldabilty, and reliability from 0 hours to 48 hours for molding process of 3x3,5x5 and 8x8 mm2 QFN packaging manufacturing

Microstructure and mechanical properties of Al–1Mn and Al–10Si alloy circular clad ingot prepared by direct chill casting