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Sample records for mold casting dies

  1. Die Casting Mold Design for Aluminum Alloy Shell of Instrument

    Li Yuanyuan

    2015-01-01

    Full Text Available This paper is about die casting mold design for aluminum alloy shell of instrument. Three-dimensional model of the casting and mold are designed by using Pro/Engineer and AutoCad which can analyze forming quality. Digital design and theoretical calculation can greatly shorten product development cycle and mold design cycle, improve the accuracy of product design and mold design, and reduce the cost of mold design.

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

    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.)

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

    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.

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

    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.

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

    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.

  6. Rubber molds for investment casting

    Sibtain, S.N.

    2011-01-01

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

  7. Dimensional control of die castings

    Karve, Aniruddha Ajit

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

  8. Microstructured metal molds fabricated via investment casting

    Cannon, Andrew H; King, William P

    2010-01-01

    This paper describes an investment casting process to produce aluminum molds having integrated microstructures. Unlike conventional micromolding tools, the aluminum mold was large and had complex curved surfaces. The aluminum was cast from curved microstructured ceramic molds which were themselves cast from curved microstructured rubber. The aluminum microstructures had an aspect ratio of 1:1 and sizes ranging from 25 to 50 µm. Many structures were successfully cast into the aluminum with excellent replication fidelity, including circular, square and triangular holes. We demonstrate molding of large, curved surfaces having surface microstructures using the aluminum mold.

  9. Numerical simulation of low pressure die-casting aluminum wheel

    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.

  10. Casting Technology.

    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)

  11. Analysis of cracking in glass molds made of cast iron

    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.

  12. Method and mold for casting thin metal objects

    Pehrson, Brandon P; Moore, Alan F

    2014-04-29

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

  13. Modeling the Mechanical Performance of Die Casting Dies

    R. Allen Miller

    2004-02-27

    The following report covers work performed at Ohio State on modeling the mechanical performance of dies. The focus of the project was development and particularly verification of finite element techniques used to model and predict displacements and stresses in die casting dies. The work entails a major case study performed with and industrial partner on a production die and laboratory experiments performed at Ohio State.

  14. Casting metal microstructures from a flexible and reusable mold

    Cannon, Andrew H; King, William P

    2009-01-01

    This paper describes casting-based microfabrication of metal microstructures and nanostructures. The metal was cast into flexible silicone molds which were themselves cast from microfabricated silicon templates. Microcasting is demonstrated in two metal alloys of melting temperature 70 °C or 138 °C. Many structures were successfully cast into the metal with excellent replication fidelity, including ridges with periodicity 400 nm and holes or pillars with diameter in the range 10–100 µm and aspect ratio up to 2:1. The flexibility of the silicone mold permits casting of curved surfaces, which we demonstrate by fabricating a cylindrical metal roller of diameter 8 mm covered with microstructures. The metal microstructures can be in turn used as a reusable molding tool

  15. High pressure die casting of Fe-based metallic glass

    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

  16. High pressure die casting of Fe-based metallic glass.

    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.

  17. High pressure die casting of Fe-based metallic glass

    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.

  18. Precision casting into disposable ceramic mold – a high efficiency method of production of castings of irregular shape

    Уваров, Б. И.; Лущик, П. Е.; Андриц, А. А.; Долгий, Л. П.; Заблоцкий, А. В.

    2016-01-01

    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.

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

    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.

  20. Grain Refinement of Permanent Mold Cast Copper Base Alloys

    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.

  1. ''Heat Transfer at the Mold-Metal Interface in Permanent Mold Casting of Aluminum Alloys'' Final Project Report; FINAL

    Pehlke, R. D.; Cookson, John M.; Shouwei Hao; Prasad Krishna; Bilkey, Kevin T.

    2001-01-01

    This project on heat transfer coefficients in metal permanent mold casting has been conducted in three areas. They are the theoretical study at the University of Michigan, the experimental investigation of squeeze casting at CMI-Tech Center (Now Hayes-Lemmerz Technical Center) and the experimental investigation of low pressure permanent mold casting at Amcast Automotive

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

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

    1994-06-01

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

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

    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.

  4. 40 CFR Appendix - Alternative Organic HAP Emissions Limits for Open Molding, Centrifugal Casting, and SMC...

    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...

  5. Economical surface treatment of die casting dies to prevent soldering in high pressure casting

    Fraser, D.T.; Jahedi, M.Z.

    2001-01-01

    This paper describes the use of a gas oxidation treatment of H13 tool steel to develop a compact iron oxide layer at the surface of core pins to prevent soldering in high pressure die casting. The performance of oxide layers in the protection of die steel against soldering during high pressure die casting was tested in a specially designed die using removable core pins and Al-11 Si-3 Cu casting alloy. The gas oxidation treatment can be applied at low temperatures and to large areas of the die surface. In addition this process is very cost effective compared to other coating processes such as physical vapour deposition (PVD), or thermo-reactive diffusion (TRD) coatings. This work demonstrated that surface treatment producing pure magnetite (Fe 3 O 4 ) layers are more protective than oxide layers containing a combination of Fe 3 O 4 (magnetite) and Fe 3 O 3 (haematite). The magnetite layer acts as a barrier between the die steel/casting alloy interface and prevents the formation of inter-metallic phases. Optical microscopy and scanning electron microscope were used to determine the thickness of the oxide layer, while X-ray diffraction was performed to determine the oxide phase structure

  6. Thermal Fatigue of Die-Casting Dies: An Overview

    Abdulhadi Hassan A.

    2016-01-01

    Full Text Available Coupled studies by experimental and numerical simulations are necessary for an increased understanding of the material behaviour as related to the interaction between the thermal and mechanical conditions. This paper focus on the mechanisms of thermal fatigue in the failure of dies and cores used in the die casting of aluminum alloys. The thermal fatigue resistance is expressed by two crack parameters which are the average maximum crack and the average cracked area. Samples of various types of H13 steel were compared with a standard H13 steel by testing under identical thermal fatigue cycles. To determine the thermal constraint developed in the sample during the test, a finite difference technique was used to obtain the temperature distribution, based on temperature measurements at the boundaries. The resulting stresses and strains were computed, and the strain calculated at the edge or weakest point of the sample was used to correlate the number of cycles to crack initiation. As the strain at the edge increased, the number of cycles to failure decreased. The influence of various factors on thermal fatigue behavior was studied including austenitizing temperature, surface condition, stress relieving, casting, vacuum melting, and resulfurization. The thermal fatigue resistance improved as the austenitizing temperature increased from 1750 to 2050ºF.

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

    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.

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

    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.

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

    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.

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

    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.

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

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

    2017-01-04

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

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

    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.

  13. Reusable molds for casting U-Zr alloys

    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

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

    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....

  15. Measurement of casting parameters in ZnAlCu3 molds created by additive technology

    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.

  16. Evaluation of porosity in Al alloy die castings

    M. Říhová

    2012-01-01

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

  17. Modeling of high temperature- and diffusion-controlled die soldering in aluminum high pressure die casting

    Domkin, Konstantin; Hattel, Jesper Henri; Thorborg, Jesper

    2009-01-01

    of the die lifetime based on a quantitative analysis of die soldering in the framework of the numerical simulations of the die-casting process. Full 3D simulations of the process, including the filling. solidification, and the die cooling, are carried out using the casting simulation software MAGMAsoft....... The resulting transient temperature fields on the die surface and in the casting are then post-processed to estimate the die soldering. The present work deals only with the metallurgical/chemical kind of soldering which occurs at high temperatures and involves formation and growth of intermetallic layers...

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

    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).

  19. Development of ion beam sputtering technology for mold and die

    Lee, Jaehyung; Park, J.; Lee, J.; Jil, J.; Yang, D.; Noh, Y.; You, B.; You, J.

    2003-06-01

    Ion beam sputtering technique, one of the surface modification techniques, is to reduce surface roughness of materials with selective detaching atoms and micro particles from the surface by bombarding energetic ions of a few to a few tens keV onto the materials surfaces. This technique can be applied for the surfaces that need to have sub micrometer surface roughness, and it has already been used by companies and/or Institute over the world. Although this is relatively high cost process, it has been widely demanded in the industries with developing the eco-friend equipment due to its high quality of products. In the domestic industry, it has been pointed out that the mechanical polishing technique for molds and dies is relatively expensive and does not produce the required surface roughness. Therefore, in this R and D, techniques obtained from the ion source and the ion beam irradiation techniques developed for the proton accelerator has been applied to polish the surface of molds and dies to solve the above-mentioned problems that take place during mechanical polishing. In case that ion beam polishing technique is used, we expect not only producing the high quality polished surfaces but also producing the economically valuable end-products. In this R and D project, we are aiming at establishing ion beam techniques for industrialization as well as mass production of low cost products with developing the economical instrumentation techniques. Also, as a result of this R and D it is expected that importing of precise molds and dies may be reduced and technical competitiveness will be enhanced

  20. Development of heat pipe technology for permanent mold casting of magnesium alloys

    Elalem, K.; Mucciardi, F.; Gruzleski, J.E.; Carbonneau, Y.

    2002-01-01

    One of the key techniques for producing sound permanent mold castings is to use controlled mold cooling such as air cooling, water cooling and heat pipe cooling. Air-cooling has limited applications in permanent mold casting due to its low cooling capability and high cost. Water-cooling is widely used in permanent mold casting, but has some disadvantages such as safety issues and the facilities required. The early applications of heat pipes in permanent mold casting have shown tremendous results due to their high cooling rates, low cost and safety. In this work, a permanent mold for magnesium casting has been designed with the intention of producing shrinkage defects in the castings. Novel heat pipes that can generate high cooling rates have been constructed and used to direct the solidification in order to reduce the shrinkage. In this paper, the design of the mold and that of the heat pipes are presented. The results of some of the computer simulations that were conducted to determine casting conditions along with the potential of using heat pipes to direct the solidification are also presented. Moreover, a preliminary evaluation of the performance of heat pipes in the permanent mold casting of magnesium will also be discussed. (author)

  1. New trends in cold-chamber die casting machine design

    R. Dańko

    2015-07-01

    Full Text Available Larger and larger proportions of aluminium castings, especially those produced by the die casting process, can be observed during recent years in the automotive industry, house-hold articles and others. In case of the automotive industry, apart from the traditional elements produced by the die pressure method such as engine blocks or crank shaft bedplates, aluminium is displacing steel from structural parts of cars (‘body in white’. The current state and development directions of the structural solutions of cold-chamber die castings are analysed in this paper. These solutions drive the prospective development of these machines and die casting technology. The focus is mainly on essential functional systems such as: hydraulic drives of closing and locking units, as well as pressing in die machines of known companies present on the European market.

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

    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).

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

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

    2014-01-01

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

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

    Chen, Wen-Cheng, E-mail: wencchen@fcu.edu.tw [Advanced Medical Devices and Composites Laboratory, Department of Fiber and Composite Materials, College of Engineering, Feng Chia University, Taichung 40724, Taiwan (China); Teng, Fu-Yuan [Department of Dentistry, Kaohsiung Armed Forces General Hospital, Kaohsiung 802, Taiwan (China); School of Dentistry, College of Dental Medicine, Kaohsiung Medical University, Kaohsiung 807, Taiwan (China); Hung, Chun-Cheng [School of Dentistry, College of Dental Medicine, Kaohsiung Medical University, Kaohsiung 807, Taiwan (China); Department of Dentistry, Kaohsiung Medical University Hospital, Kaohsiung 807, Taiwan (China)

    2014-02-01

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

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

    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

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

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

    2014-02-01

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

  7. Permanent Mold Casting of JIS-AC4C Aluminum Alloy Using a Low-Temperature Mold

    Yamagata, Hiroshi; Nikawa, Makoto

    2011-01-01

    Permanent mold casting using mold temperatures below 200 deg. C was conducted to obtain a high-strength, thin-walled casting. Al-7.36 mass% Si -0.18 Cu- 0.27Mg-0.34Fe alloy JIS-AC4C was cast using a bottom pouring cast plan. The product had a rectangular tube shape (70 mm W x 68 mm D x 180 mm H) with wall thicknesses of 1, 3 and 5 mm. The effect of heat insulation at the melt path was compared when using a sand runner insert and when using a steel runner insert as well as a powder mold release agent. Fine microstructures were observed in the casting. The smaller the thickness, the higher the hardness with smaller secondary dendrite arm spacing (SDAS). However, the hardness and the SDAS were unaffected by the mold temperature. It was proposed that the avoidance of the formation of primary α dendrite at the melt path generates a higher strength casting with adequate mold filling.

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

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

    2017-01-01

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

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

    Yunbing Zong

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

  10. 40 CFR 63.5810 - What are my options for meeting the standards for open molding and centrifugal casting operations...

    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...

  11. Microstructures and properties of aluminum die casting alloys

    M. M. Makhlouf; D. Apelian; L. Wang

    1998-10-01

    This document provides descriptions of the microstructure of different aluminum die casting alloys and to relate the various microstructures to the alloy chemistry. It relates the microstructures of the alloys to their main engineering properties such as ultimate tensile strength, yield strength, elongation, fatigue life, impact resistance, wear resistance, hardness, thermal conductivity and electrical conductivity. Finally, it serves as a reference source for aluminum die casting alloys.

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

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

    1992-01-01

    Current fabrication techniques for the integral fast reactor (IFR) fuel utilize injection casting into quartz molds after reprocessing in the IFR fuel cycle facility. The quartz molds are destroyed during the fuel demolding process, and the quartz residue must therefore be treated as contaminated waste. Alternatively, if the fuel can be cast into molds that remain as part of the fuel slugs (i.e., if the fuel can be left inside the molds for irradiation), then the quartz mold contribution to the waste stream can be eliminated. This possibility is being addresssed in an ongoing effort to evaluate the irradiation performance of fuel cast into zirconium sheaths rather than quartz molds. Zirconium was chosen as the sheath material because it is the component of the U-Pu-Zr fuel alloy that raises the alloy solidus temperatures and provides resistance to fuel-cladding chemical interaction (FCCI)

  13. Effects of heat pipe cooling on permanent mold castings of aluminum alloys

    Zhang, C.; Mucciardi, F.; Gruzleski, J.E.

    2002-01-01

    The temperature distribution within molds is a critical parameter in determining the ultimate casting quality in permanent mold casting processes, so there is a considerable incentive to develop a more effective method of mold cooling. Based on this consideration, a novel, effective and controllable heat pipe has been successfully developed and used as a new method of permanent mold cooling. Symmetric step casting of A356 alloy have been produced in an experimental permanent mold made of H13 tool steel, which is cooled by such heat pipes. The experimental results show that heat pipes can provide extremely high cooling rates in permanent mold castings of aluminum. The dendrite arm spacing of A356 alloy is refined considerably, and porosity and shrinkage of the castings are redistributed by the heat pipe cooling. Moreover, the heat pipe can be used to determine the time when the air gap forms at the interface between the mold and the casting. The effect of heat pipe cooling on solidification time of castings of A356 alloy with different coating types is also discussed in this paper. (author)

  14. Solidification and casting

    Cantor, Brian

    2002-01-01

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

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

    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.

  16. Die design and process optimization of die cast V6 engine blocks

    Henry Hu

    2005-02-01

    Full Text Available The use of aluminum, particularly for engine blocks, has grown considerably in the past ten years, and continues to rise in the automotive industry. In order to enhance the quality and engineering functionality of die cast engine blocks, die design and processes have to be optimized. In this study, a computer simulation software, MAGMAsoft, as an advanced tool for optimizing die design and casting process, was emplooyed to virtually visualize cavity filling and patterns of a V6 engine block. The original die design and process was simulated first to establish a baseline. A reality check was used to verify the predicted results. Then, the die modification with a different unner system was made by using a CAD software, Unigraphics (UG. The simulation on combinations of the modified die design and revised process was performed to examine the effect of die modification and process change on flow filling of V6 engine blocks. The simulated prediction indicateds that the enhancement of cavity filling due to the die and process modification minimizeds the occurrence of defects during casting, and consequently improves the quality of blocks. The results of mechanical testing show a significant increase in fatigue strengths, and a moderately improvement on tensile properties for the blocks die cast with the new die design and prpocess in comparison with those produced by the original ones.

  17. Strength and deformation behaviour of magnesium die casting alloys

    Regener, D.; Schick, E.; Wagner, I.; Heyse, H.

    1999-01-01

    Modern magnesium die casting alloys are used for the manufacturing of automotive parts due to their low density, fortunate mechanical and physical properties as well as good castability and machinability. However, in comparison to other materials the automotive application of these alloys is still low. The reasons for this are among other things the shortage of relevant materials values, insufficient knowledge concerning the correlation between the microstructure and the mechanical properties as well as deficits in relation to the die cast technology. This paper investigates the influence of the microstructure and manufacture-induced defects like micro-shrinkage and gas pores on the strength and deformability of the alloys AZ91, AM50 and AE42 under tensile and bend loading. To characterise the microstructure in the dependence on the wall thickness, the investigations are mainly carried out using in situ specimens obtained from die castings. (orig.)

  18. Strength Estimation of Die Cast Beams Considering Equivalent Porous Defects

    Park, Moon Shik [Hannam Univ., Daejeon (Korea, Republic of)

    2017-05-15

    As a shop practice, a strength estimation method for die cast parts is suggested, in which various defects such as pores can be allowed. The equivalent porosity is evaluated by combining the stiffness data from a simple elastic test at the part level during the shop practice and the theoretical stiffness data, which are defect free. A porosity equation is derived from Eshelby's inclusion theory. Then, using the Mori-Tanaka method, the porosity value is used to draw a stress-strain curve for the porous material. In this paper, the Hollomon equation is used to capture the strain hardening effect. This stress-strain curve can be used to estimate the strength of a die cast part with porous defects. An elastoplastic theoretical solution is derived for the three-point bending of a die cast beam by using the plastic hinge method as a reference solution for a part with porous defects.

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

    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.

  20. Metallic Reinforcement of Direct Squeeze Die Casting Aluminum Alloys for Improved Strength and Fracture Resistance

    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

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

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

    2018-03-30

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

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

    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.

  3. Reducing non value adding aluminium alloy in production of parts through high pressure die casting

    Pereira, MFVT

    2010-10-01

    Full Text Available in the cast part feed system, including overflows. CSIR intends using the results of this research for further development and application of high temperature die construction materials in high pressure die casting processes of light metal alloys...

  4. Analysis of Mold Friction in a Continuous Casting Using Wavelet Transform

    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.

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

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

    2018-01-01

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

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

    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.

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

    S. J. Świłło

    2011-07-01

    Full Text Available A new camera based machine vision system for the automatic inspection of surface defects in aluminum die casting was developed by the authors. The problem of surface defects in aluminum die casting is widespread throughout the foundry industry and their detection is of paramount importance in maintaining product quality. The casting surfaces are the most highly loaded regions of materials and components. Mechanical and thermal loads as well as corrosion or irradiation attacks are directed primarily at the surface of the castings. Depending on part design and processing techniques, castings may develop surface discontinuities such as cracks or tears, inclusions due to chemical reactions or foreign material in the molten metal, and pores that greatly influence the material ability to withstand these loads. Surface defects may act as a stress concentrator initiating a fracture point. If a pressure is applied in this area, the casting can fracture. The human visual system is well adapted to perform in areas of variety and change; the visual inspection processes, on the other hand, require observing the same type of image repeatedly to detect anomalies. Slow, expensive, erratic inspection usually is the result. Computer based visual inspection provides a viable alternative to human inspectors. Developed by authors machine vision system uses an image processing algorithm based on modified Laplacian of Gaussian edge detection method to detect defects with different sizes and shapes. The defect inspection algorithm consists of three parameters. One is a parameter of defects sensitivity, the second parameter is a threshold level and the third parameter is to identify the detected defects size and shape. The machine vision system has been successfully tested for the different types of defects on the surface of castings.

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

    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.

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

    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...

  10. Study of protective coatings for aluminum die casting molds

    Peter, Ildiko, E-mail: ildiko.peter@polito.it; Rosso, Mario; Gobber, Federico Simone

    2015-12-15

    Highlights: • Development and characterization of some protective coatings on steel substrate, realized by plasma spray techniques, were presented. • The substrate material used is a Cr–Mo–V based hot work tool steel. • The main attention is on the study of wear and on the characterization of the interface, because of their key role in determining the resistance of the coating layer. • Simulation of friction and wear processes is performed by pin-on-disk test and the tested samples are observed by scanning electron microscopy. - Abstract: In this paper, the development and characterization of some protective coatings on steel substrate are presented. The coatings are realized by plasma spray techniques. The substrate material used is a Cr–Mo–V based hot work tool steel, initially submitted to vacuum heat treatment to achieve homogeneous hardness. The main attention is focused on the study of wear and on the characterization of the interface between the substrate material and the coating layer, because of their key role in determining the resistance of the coating layer. Simulation of friction and wear processes is performed by pin-on-disk test and the tested samples are observed by scanning electron microscopy.

  11. Energy and resource efficiency in aluminium die casting

    Heinemann, Tim

    2016-01-01

    This monograph provides a field-proven approach to analyze industrial production with a cross-company scope as well as regarding all hierarchical system levels of manufacturing enterprises. The book exemplifies this approach in the context of aluminum  die casting, and presents a set of measures which allow a 30 percent energy reduction along the value chain. The target audience primarily comprises researchers and experts in the field but the book may also be beneficial for graduate students.

  12. Casting defects and mechanical properties of high pressure die cast Mg-Zn-Al-RE alloys

    Xiao, Wenlong; Easton, Mark A.; Zhu, Suming; Nie, Jianfeng [CAST Cooperative Research Centre, Department of Materials Engineering Monash University, Melbourne, VIC (Australia); Dargusch, Matthew S. [School of Mechanical and Mining Engineering, University of Queensland, Brisbane, QLD (Australia); Gibson, Mark A. [CSIRO Process Science and Engineering, Melbourne, VIC (Australia); Jia, Shusheng [Key Laboratory of Automobile Materials, Ministry of Education, Department of Materials Science and Engineering Jilin University, Changchun (China)

    2012-02-15

    The die casting defects and tensile properties of high pressure die cast (HPDC) Mg-Zn-Al-RE alloys with various combinations of Zn and Al were studied. The results show that die casting defects in Mg-Zn-Al-RE alloys are affected by the percentage of Zn and Al contents. The hot tearing susceptibility (HTS) of Mg-Zn-Al-RE alloys tends to increase with increasing Zn content up to 6 wt%, while a further increase of Al and/or Zn content reduces the HTS. In tensile tests, the yield strength (YS) is generally improved by increasing Zn or Al content, whereas the tensile strength (TS) and ductility appear to depend largely on the presence of casting defects. Compared with Mg-Zn-Al alloys, the mechanical properties of the Mg-Zn-Al-RE alloy are significantly improved. The Mg-4Zn-4Al-4RE alloy is found to have few casting defects and the optimal tensile properties. (Copyright copyright 2012 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

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

    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.

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

    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...

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

    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...

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

    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.

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

    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.

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

    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.

  19. Precision grinding of microarray lens molding die with 4-axes controlled microwheel

    Yuji Yamamoto, Hirofumi Suzuki, Takashi Onishi1, Tadashi Okino and Toshimichi Moriwaki

    2007-01-01

    Full Text Available This paper deals with precision grinding of microarray lens (fly eye molding die by using a resinoid bonded diamond wheel. An ultra-precision grinding system of microarray lens molding die and new truing method of resinoid bonded diamond wheel were developed. In this system, a grinding wheel was four-dimensionally controlled with 1 nm resolution by linear scale feedback system and scanned on the workpiece surface. New truing method by using a vanadium alloy tool was developed and its performance was obtained with high preciseness and low wheel wear. Finally, the microarray lens molding dies of fine grain tungsten carbide (WC was tested with the resinoid bonded diamond wheel to evaluate grinding performance.

  20. Analysis of Meniscus Fluctuation in a Continuous Casting Slab Mold

    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.

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

    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.

  2. Development of Thin Section Zinc Die Casting Technology

    Goodwin, Frank [International Lead Zinc Research Org., Inc., Durham, NC (United States)

    2013-10-31

    A new high fluidity zinc high pressure die casting alloy, termed the HF alloy, was developed during laboratory trials and proven in industrial production. The HF alloy permits castings to be achieved with section thicknesses of 0.3 mm or less. Technology transfer activities were conducted to develop usage of the HF high fluidity alloy. These included production of a brochure and a one-hour webinar on the HF alloy. The brochure was then sent to 1,184 product designers in the Interzinc database. There was excellent reception to this mailing, and from this initial contact 5 technology transfer seminars were conducted for 81 participants from 30 companies across a wide range of business sectors. Many of the successful applications to date involve high quality surface finishes. Design and manufacturing assistance was given for development of selected applications.

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

    Stefan Stein

    Full Text Available The application of piezoelectric transducers to structural body parts of machines or vehicles enables the combination of passive mechanical components with sensor and actuator functions in one single structure. According to Herold et al. [1] and Staeves [2] this approach indicates significant potential regarding smart lightweight construction. To obtain the highest yield, the piezoelectric transducers need to be integrated into the flux of forces (load path of load bearing structures. Application in a downstream process reduces yield and process efficiency during manufacturing and operation, due to the necessity of a subsequent process step of sensor/actuator application. The die casting process offers the possibility for integration of piezoelectric transducers into metal structures. Aluminum castings are particularly favorable due to their high quality and feasibility for high unit production at low cost (Brunhuber [3], Nogowizin [4]. Such molded aluminum parts with integrated piezoelectric transducers enable functions like active vibration damping, structural health monitoring or energy harvesting resulting in significant possibilities of weight reduction, which is an increasingly important driving force of automotive and aerospace industry (Klein [5], Siebenpfeiffer [6] due to increasingly stringent environmental protection laws. In the scope of those developments, this paper focuses on the entire process chain enabling the generation of lightweight metal structures with sensor and actuator function, starting from the manufacturing of piezoelectric modules over electrical and mechanical bonding to the integration of such modules into aluminum (Al matrices by die casting. To achieve this challenging goal, piezoceramic sensors/actuator modules, so-called LTCC/PZT modules (LPM were developed, since ceramic based piezoelectric modules are more likely to withstand the thermal stress of about 700 °C introduced by the casting process (Flössel et

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

    Iban Vicario

    2016-01-01

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

  5. Vacuum die casting of silicon sheet for photovoltaic applications. First quarterly report, March 16-June 30, 1979

    None

    1979-01-01

    The obtective of this program is to develop a vacuum die-casting process for producing silicon sheet suitable for photovoltaic cells and to develop production techniques for optimization of polycrystallie silicon solar cell output. Efforts will examine process methods which are directed toward minimum cost processing of silicon into a quality suitable for producing solar cells with a terrestrial efficiency greater than 12% and having the potential to be scaled for large quantity production. In the vacuum die casting technique, silicon is melted under vacuum, and an evacuated die with a thin rectangular cavity is inserted into the melt. Liquid silicon is then injected into the die using a positive pressure of an inert gas. The major portion of the die casting work will be performed at Stanford Research Institute International under subcontract. The initial approach will follow parallel tracks: (1) obtain mechanical design parameters by using boron nitride, which has been shown to be non-wetting to silicon; (2) optimize silicon nitride material composition and coatings by sessile drop experiments; (3) test effectiveness of fluoride salt interfacial media with a graphite mold; and (4) test effect of surface finish using both boron nitride and graphite. Having established the material and mechanical boundary conditions, a finalized version of the prototype assembly will be constructed and the casting varibles determined. Polycrystalline silicon solar cells, with and without impurities, will be fabricated, characterized, and optimized at ARCCO Solar. The major activities will focus on the use of Wacker SILCO, HEM and in-house materials until vacuum die cast wafers are available. A baseline process with vacuum metallized contacts will be established and a reference mass production process with screen-printed metallization and high-throughput diffusions will also be obtained.

  6. Die Casting Part Distortion: Prediction and Attenuation; FINAL

    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

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

    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

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

    Singh, Rupinder

    2018-02-01

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

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

    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.

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

    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

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

    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

  12. Structural materialization of stainless steel molds and dies by the low temperature high density plasma nitriding

    Aizawa Tatsuhiko

    2015-01-01

    Full Text Available Various kinds of stainless steels have been widely utilized as a mold substrate material for injection molding and as a die for mold-stamping and direct stamping processes. Since they suffered from high temperature transients and thermal cycles in practice, they must be surface-treated by dry and wet coatings, or, by plasma nitriding. Martensitic stainless steel mold was first wet plated by the nickel phosphate (NiP, which was unstable at the high temperature stamping condition; and, was easy to crystalize or to fracture by itself. This issue of nuisance significantly lowered the productivity in fabrication of optical elements at present. In the present paper, the stainless steel mold was surface-treated by the low-temperature plasma nitriding. The nitrided layer by this surface modification had higher nitrogen solute content than 4 mass%; the maximum solid-solubility of nitrogen is usually 0.1 mass% in the equilibrium phase diagram. Owing to this solid-solution with high nitrogen concentration, the nitrided layer had high hardness of 1400 Hv within its thickness of 40 μm without any formation of nitrides after 14.4 ks plasma nitriding at 693 K. This nitrogen solid-solution treated stainless steel had thermal resistivity even at the mold-stamping conditions up to 900 K.

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

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

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

  14. Application of laser additive manufacturing to produce dies for aluminium high pressure die casting

    Pereira, MFVT

    2012-07-01

    Full Text Available through immersion in liquid aluminium. The dipping cycle closely resembles the heating and cooling cycle of a typical aluminium die under casting conditions. The suitability of any LAM technology, that can produce fully dense metallic components... cost vs wrought manufactured 5.2 1,7 2. 2 Average cost Very High Medium High Table 3: Processing and finishing costs of test coupons 3.1 Cyclic Immersion in Molten Aluminium Figure 3 below shows the testing apparatus developed to simulate...

  15. Modeling and Analysis of The Pressure Die Casting Using Response Surface Methodology

    Kittur, Jayant K.; Herwadkar, T. V.; Parappagoudar, M. B.

    2010-01-01

    Pressure die casting is successfully used in the manufacture of Aluminum alloys components for automobile and many other industries. Die casting is a process involving many process parameters having complex relationship with the quality of the cast product. Though various process parameters have influence on the quality of die cast component, major influence is seen by the die casting machine parameters and their proper settings. In the present work, non-linear regression models have been developed for making predictions and analyzing the effect of die casting machine parameters on the performance characteristics of die casting process. Design of Experiments (DOE) with Response Surface Methodology (RSM) has been used to analyze the effect of effect of input parameters and their interaction on the response and further used to develop nonlinear input-output relationships. Die casting machine parameters, namely, fast shot velocity, slow shot to fast shot change over point, intensification pressure and holding time have been considered as the input variables. The quality characteristics of the cast product were determined by porosity, hardness and surface rough roughness (output/responses). Design of experiments has been used to plan the experiments and analyze the impact of variables on the quality of casting. On the other-hand Response Surface Methodology (Central Composite Design) is utilized to develop non-linear input-output relationships (regression models). The developed regression models have been tested for their statistical adequacy through ANOVA test. The practical usefulness of these models has been tested with some test cases. These models can be used to make the predictions about different quality characteristics, for the known set of die casting machine parameters, without conducting the experiments.

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

    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

  17. 77 FR 6587 - PHB Die Casting a Subsidiary of PHB, Inc., Including On-Site Leased Workers From Career Concepts...

    2012-02-08

    ... DEPARTMENT OF LABOR Employment and Training Administration [TA-W-64,292] PHB Die Casting a... 19, 2008, applicable to workers of PHB Die Casting, a subsidiary of PHB, Inc., including on-site... production of die castings. New information shows that a worker from Burns Industrial Group (BIG Inc) was...

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

    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.

  19. Fabrication of sacrificial anode cathodic protection through casting method

    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)

  20. 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

    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

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

    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

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

    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’.

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

    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.

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

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

    1989-01-01

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

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

    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.

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

    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.

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

    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

  8. Mold

    ... 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 ...

  9. Kinetics of steel heavy ingot formation in dies of semicontinuous-casting machines

    Tsukerman, V.Ya.; Marchenko, I.K.

    1986-01-01

    Formation kinetics of round section ingot of up to 0.67 m in diameter was analyzed in dies of semicontinuous-casting machines on casting of the most usable assortment steels: medium-carbon low-alloyed and chromium-nickel stainless steels. It is established that solidification coefficient decreases in direct proportion to ingot diameter. Value of different-thickness ingot skin at die outlet is in direct proportion to a casted steel overheating temperature, ingot diameter and inversely proportional to the number and diameter of holes in a ladder nozzle and square root of ingot drawing rate

  10. SPH based modelling of oxide and oxide film formation in gravity die castings

    Ellingsen, K; M'Hamdi, M; Coudert, T

    2015-01-01

    Gravity die casting is an important casting process which has the capability of making complicated, high-integrity components for e.g. the automotive industry. Oxides and oxide films formed during filling affect the cast product quality. The Smoothed particle hydrodynamics (SPH) method is particularly suited to follow complex flows. The SPH method has been used to study filling of a gravity die including the formation and transport of oxides and oxide films for two different filling velocities. A low inlet velocity leads to a higher amount of oxides and oxide films in the casting. The study demonstrates the usefulness of the SPH method for an increased understanding of the effect of different filling procedures on the cast quality. (paper)

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

    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)

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

    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.

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

    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.

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

    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.

  15. Mold

    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.

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

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

    2014-10-01

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

  17. Corrosion behavior of die-cast Mg-4Al-2Sn-xCa alloy

    Park, Kyung Chul; Kim, Byeong Ho; Kim, Kyung Ro [Defence Agency for Technology and Quality, Jinju (Korea, Republic of); Cho, Dae Hyun; Park, Ik Min [Pusan National University, Busan (Korea, Republic of)

    2016-05-15

    In the present work, the effect of Ca additions on microstructure and corrosion characteristics of high pressure die-cast Mg-4Al-2Sn alloy has been investigated. Mg-4Al-2Sn-xCa (x= 0, 0.3 and 0.7wt.%) alloy was prepared by using a high pressure die-casting method. Results indicated that the microstructure of Mg-4Al-2Sn alloy consisted of α-Mg, Mg{sub 17}Al{sub 12} and Mg{sub 2}Sn phase. With increase of Ca additions, CaMgSn phase was newly formed and grain size was sharply decreased. From the test results, the corrosion resistance of die-cast Mg-4Al-2Sn alloy was significantly improved by Ca addition. It is considered that stabilization of Mg(OH){sub 2} layer and refinements of microstructure with increase of Ca additions.

  18. Microstructural analysis of the creep resistance of die-cast Mg-4Al-2RE alloy

    Zhu, S.M. [CAST CRC, Department of Materials Engineering, Monash University, Victoria 3800 (Australia)], E-mail: suming.zhu@eng.monash.edu.au; Gibson, M.A. [CAST CRC, CSIRO Materials Science and Engineering, Private Bag 33, Clayton South MDC, Clayton, Victoria 3169 (Australia); Nie, J.F.; Easton, M.A. [CAST CRC, Department of Materials Engineering, Monash University, Victoria 3800 (Australia); Abbott, T.B. [Advanced Magnesium Technologies, Milton, Queensland 4064 (Australia)

    2008-03-15

    The microstructure and microstructural stability of die-cast AE42 (Mg-4Al-2RE) alloy were investigated by transmission electron microscopy. It is shown that the formation of Mg{sub 17}Al{sub 12} after ageing at 200 deg. C is not due to the decomposition of A1{sub 11}RE{sub 3} as reported in the literature, but, rather, is associated with the supersaturation of Al solute in the {alpha}-Mg matrix. The level of Al solute retained in the {alpha}-Mg matrix after die-casting is suggested to be an important factor in influencing creep resistance.

  19. Mortality among workers in a die-casting and electroplating plant.

    Silverstein, M; Mirer, F; Kotelchuck, D; Silverstein, B; Bennett, M

    1981-01-01

    A proportional mortality and case-referent analysis of 238 deaths among hourly employees in an automobile hardware manufacturing plant was conducted. The major operations of the plant were zinc die casting and electroplating. Chemical exposure included die-casting emissions and mists from chrome and nickel plating. The chief proportional mortality finding was a significant excess of lung cancer among both white men and women. A case-referent analysis indicated a possible association between lung cancer and work in certain departments. The findings support the hypothesis of a work-related carcinogenic risk. Follow-up recommendations have been made.

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

    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 ...

  1. Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997

    Miller, R.A.; Lu, S.C.; Rebello, A.B.

    1998-05-01

    The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information from the voxel model for display to the user.

  2. Simple visualization techniques for die casting part and die design. Final report, July 1, 1995--September 30, 1997

    Miller, R.A.; Lu, S.C.; Rebello, A.B.

    1998-05-01

    The objective of this work was to develop and test die casting design evaluation techniques based on the visualization of geometric data that is related to potential defects of problems. Specifically, thickness information is used to provide insight into potential thermal problems in the part and die. Distance from the gate and a special type of animation of the fill pattern is used to provide an assessment of gate, vent and overflow locations. Techniques have been developed to convert part design information in the form of STL files to a volume-based representation called a voxel model. The use of STL files makes the process CAD system independent. Once in voxel form, methods that were developed in this work are used to identify thick regions in the part, thin regions in the part and/or die, distance from user specified entry locations (gates), and the qualitative depiction of the fill pattern. The methods were tested with a prototype implementation on the UNIX platform. The results of comparisons with numerical simulation and field reported defects were surprisingly good. The fill-related methods were also compared against short-shots and a water analog study using high speed video. The report contains the results of the testing plus detailed background material on the construction of voxel models, the methods used for displaying results, and the computational geometric reasoning methods used to create die casting-related information form the voxel model for display to the user.

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

    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.

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

    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.

  5. Study on interfacial heat transfer coefficient at metal/die interface during high pressure die casting process of AZ91D alloy

    GUO Zhi-peng

    2007-02-01

    Full Text Available The high pressure die casting (HPDC process is one of the fastest growing and most efficient methods for the production of complex shape castings of magnesium and aluminum alloys in today’s manufacturing industry.In this study, a high pressure die casting experiment using AZ91D magnesium alloy was conducted, and the temperature profiles inside the die were Measured. By using a computer program based on solving the inverse heat problem, the metal/die interfacial heat transfer coefficient (IHTC was calculated and studied. The results show that the IHTC between the metal and die increases right after the liquid metal is brought into the cavity by the plunger,and decreases as the solidification process of the liquid metal proceeds until the liquid metal is completely solidified,when the IHTC tends to be stable. The interfacial heat transfer coefficient shows different characteristics under different casting wall thicknesses and varies with the change of solidification behavior.

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

    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.

  7. Inventory of pollution reduction options for an aluminium pressure die casting plant

    Neto, B.A.F.; Kroeze, C.; Hordijk, L.; Costa, C.

    2009-01-01

    This study presents an overview of options aiming to reduce emissions to air, soil and water from an aluminium die casting plant located in Portugal. We identify eighteen pollution reduction options and then estimate their potential to reduce the pollution, and the costs associated with their

  8. Low cycle fatigue behavior of die cast Mg-Al-Mn-Ce magnesium alloy

    Wu Wei

    2013-11-01

    Full Text Available Fatigue failure is a main failure mode for magnesium and other alloys. It is beneficial for fatigue design and fatigue life improvement to investigate the low cycle fatigue behavior of magnesium alloys. In order to investigate the low cycle fatigue behavior of die cast Mg-Al-Mn-Ce magnesium alloy, the strain controlled fatigue experiments were performed at room temperature and fatigue fracture surfaces of specimens were observed with scanning election microscopy for the alloys under die-cast and aged states. Cyclic stress response curves, strain amplitude versus reversals to failure curve, total strain amplitude versus fatigue life curves and cyclic stress-strain curves of Mg-Al-Mn-Ce alloys were analyzed. The results show that the Mg-Al-Mn-Ce alloys under die-cast (F and aged (T5 states exhibit cyclic strain hardening under the applied total strain amplitudes, and aging treatment could greatly increase the cyclic stress amplitudes of die cast Mg-Al-Mn-Ce alloys. The relationships between the plastic strain amplitude, the elastic strain amplitude and reversals to failure of Mg-Al-Mn-Ce magnesium alloy under different treatment states could be described by Coffin-Manson and Basquin equations, respectively. Observations on the fatigue fracture surface of specimens reveal that the fatigue cracks initiate on the surface of specimens and propagate transgranularly.

  9. Strategies to reduce the environmental impact of an aluminium pressure die casting plant: A scenario analysis

    Neto, B.; Kroeze, C.; Hordijk, L.; Costa, C.; Pulles, M.P.J.

    2009-01-01

    This study explores a model (MIKADO) to analyse scenarios for the reduction of the environmental impact of an aluminium die casting plant. Our model calculates the potential to reduce emissions, and the costs associated with implementation of reduction options. In an earlier paper [Neto, B., Kroeze,

  10. Semi-solid high pressure die casting of metal matrix composites produced by liquid state processing

    Ivanchev, L

    2012-10-01

    Full Text Available stirring. The composite was then transferred to a High Pressure Die Casting (HPDC) machine in the semi-solid state. The micron size particles were found to be predominantly in the intergranular eutectic while the nano-particles were predominantly...

  11. Age hardening in die-cast Mg–Al–RE alloys due to minor Mn additions

    Zhu, S.M., E-mail: suming.zhu@rmit.edu.au [School Engineering, RMIT University, Carlton, Victoria 3053 (Australia); Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); Abbott, T.B. [School Engineering, RMIT University, Carlton, Victoria 3053 (Australia); Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); Magontec Limited, Sydney, New South Wales 2000 (Australia); Gibson, M.A. [School Engineering, RMIT University, Carlton, Victoria 3053 (Australia); Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); CSIRO Manufacturing Flagship, Clayton, Victoria 3168 (Australia); Nie, J.F. [Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); Easton, M.A. [School Engineering, RMIT University, Carlton, Victoria 3053 (Australia)

    2016-02-22

    Die-cast Mg–Al–rare earth (RE) alloys are normally used in the as-cast condition without the application of heat treatment because it is a common perception that heat treatment will not provide benefit to these alloys. This paper reports, for the first time, that enhanced age hardenability can be achieved in die-cast Mg–Al–RE alloys with minor Mn additions. For example, the yield strength of Mg–4 wt%Al–3 wt%La alloy with 0.32 wt% Mn is increased by ∼34 MPa (∼26%) after ageing at 200 °C for 32 h (T5). The enhanced age hardenability is associated with the precipitation of nanoscale Al–Mn particles during ageing.

  12. Simulation of Stress Distribution in a Thick- Walled Bushing Produced by Die-Casting

    Pisarek B.P.

    2017-12-01

    Full Text Available Metallographic investigations and a computer simulation of stresses in a gravity die-casting bushing were performed. Simulation of the casting process, solidification of the thick-walled bushing and calculations of the stress was performed using MAGMA5.3 software. The size variability of phases κII affecting the formation of phase stresses σf, depending on the location of the metallographic test area, was identified. The distribution of thermal σt and shrinkage stresses σs, depending on the location of the control point SC in the bushing's volume, was estimated. Probably the nature of these stresses will change slightly even after machining. This can cause variations in operating characteristics (friction coefficient, wear. Due to the strong inhomogeneity of the stress distribution in the bushing's casting, it is necessary to perform further tests of the possibility to conduct thermal treatment guaranteeing homogenization of the internal stresses in the casting, as well as to introduce changes in the bushing' s construction and the casting technology. The paper presents the continuation of the results of research aimed at identifying the causes of defects in the thick-walled bushing, die-casting made of CuAl10Fe5Ni5Cr aluminium bronze.

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

    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.

  14. Tribological Properties of AlSi11-SiCp Composite Castings Produced by Pressure Die Casting Method

    Konopka Z.

    2014-08-01

    Full Text Available The measurement results concerning the abrasive wear of AlSi11-SiC particles composites are presented in paper. The method of preparing a composite slurry composed of AlSi11 alloy matrix and 10, 20% vol.% of SiC particles, as well as the method of its high-pressure die casting was described. Composite slurry was injected into metal mould of cold chamber pressure die cast machine and castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. Very good uniform arrangement of SiC particles in volume composite matrix was observed and these results were publicated early in this journal. The kinetics of abrasive wear and correlation with SiC particles arrangement in composite matrix were presented. Better wear resistance of composite was observed in comparison with aluminium alloy. Very strong linear correlation between abrasive wear and particle arrangement was observed. The conclusion gives the analysis and the interpretation of the obtained results.

  15. Modeling of microstructure evolution of magnesium alloy during the high pressure die casting process

    Wu Mengwu; Xiong Shoumei

    2012-01-01

    Two important microstructure characteristics of high pressure die cast magnesium alloy are the externally solidified crystals (ESCs) and the fully divorced eutectic which form at the filling stage of the shot sleeve and at the last stage of solidification in the die cavity, respectively. Both of them have a significant influence on the mechanical properties and performance of magnesium alloy die castings. In the present paper, a numerical model based on the cellular automaton (CA) method was developed to simulate the microstructure evolution of magnesium alloy during cold-chamber high pressure die casting (HPDC) process. Modeling of dendritic growth of magnesium alloy with six-fold symmetry was achieved by defining a special neighbourhood configuration and calculating of the growth kinetics from complete solution of the transport equations. Special attention was paid to establish a nucleation model considering both of the nucleation of externally solidified crystals in the shot sleeve and the massive nucleation in the die cavity. Meanwhile, simulation of the formation of fully divorced eutectic was also taken into account in the present CA model. Validation was performed and the capability of the present model was addressed by comparing the simulated results with those obtained by experiments.

  16. Mathematical modeling of porosity formation in die cast A356 wheels

    Maijer, D.; Cockcroft, S.L.; Wells, M.A.; Luciuk, T.; Hermesmann, C.

    2000-01-01

    In an effort to leverage recent advances in modeling and process simulation tools, a mathematical model has been developed to predict porosity formation in die cast A356 wheels as part of a collaborative research agreement between researchers at the University of British Columbia and Canadian Autoparts Toyota Incorporated. The heat transfer model represents a three-dimensional, 30 o , slice of the wheel and die and is based on the commercial finite element code ABAQUS. Extensive temperature measurements in the die and in the wheel taken over several cycles in the casting process were used to fine tune and validate the model. Initial work on predicting porosity formation has focused on using the Niyama parameter as a measure of the probability of porosity. To date Niyama porosity predictions agree well with plant experience and show promise for reducing losses associated with porosity. (author)

  17. 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

    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.

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

    Carter, Jon T. [General Motors LLC, Warren, MI (United States); Wang, Gerry [Meridian Lightweight Technologies, Plymouth MI (United States); Luo, Alan [General Motors LLC, Warren, MI (United States)

    2017-11-29

    The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improve the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some

  19. Analysis of the Causes of Cracks in a Thick-Walled Bush Made of Die-Cast Aluminum Bronze

    Pisarek B.P.

    2016-12-01

    Full Text Available For the die casting conditions of aluminium bronzes assumed based on the literature data, a thick-walled bush was cast, made of complex aluminium bronze (Cu-Al-Fe-Ni-Cr. After the cast was removed from the mould, cracks were observed inside it. In order to identify the stage in the technological production process at which, potentially, the formation of stresses damaging the continuity of the microstructure created in the cast was possible (hot cracking and/or cold cracking, a computer simulation was performed. The article presents the results of the computer simulation of the process of casting the material into the gravity die as well as solidifying and cooling of the cast in the shape of a thick-walled bush. The simulation was performed with the use of the MAGMA5 program and by application of the CuAl10Ni5,5Fe4,5 alloy from the MAGMA5 program database. The results were compared with the location of the defects identified in the actual cast. As a result of the simulation of the die-casting process of this bush, potential regions were identified where significant principal stresses accumulate, which can cause local hot and cold cracking. Until now, no research has been made of die-cast aluminium bronzes with a Cr addition. Correlating the results of the computer simulation validated by the analysis of the actual cast made it possible to clearly determine the critical regions in the cast exposed to cracking and point to the causes of its occurrence. Proposals of changes in the bush die casting process were elaborated, in order to avoid hot tearing and cold cracking. The article discusses the results of preliminary tests being a prologue to the optimization of the die-casting process parameters of complex aluminium bronze thick-walled bushs.

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

    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

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

    David Schwam

    2012-12-15

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

  2. The effect of equipment efficiency on occurrence of non-conforming products in die casting

    S. Borkowski

    2010-01-01

    Full Text Available This study focuses on determination of the relationships between equipment efficiency in casting machines and the level of quality. The determination was made based on coefficients of Total Productive Maintenance and r correlation coefficient. The degree at which break-downs and downtime affect the occurrence of non-conforming products was also evaluated. The goal of further investigations is to deter-mine the structure of downtime and finding which downtime types have greatest impact on the quality of die-casting products.

  3. Marginal adaptation of four inlay casting waxes on stone, titanium, and zirconia dies.

    Michalakis, Konstantinos X; Kapsampeli, Vassiliki; Kitsou, Aikaterini; Kirmanidou, Yvone; Fotiou, Anna; Pissiotis, Argirios L; Calvani, Pasquale Lino; Hirayama, Hiroshi; Kudara, Yukio

    2014-07-01

    Different inlay casting waxes do not produce copings with satisfactory marginal accuracy when used on different die materials. The purpose of this study was to evaluate the marginal accuracy of 4 inlay casting waxes on stone dies and titanium and zirconia abutments and to correlate the findings with the degree of wetting between the die specimens and the inlay casting waxes. The inlay casting waxes tested were Starwax (Dentaurum), Unterziehwachs (Bredent), SU Esthetic wax (Schuler), and Sculpturing wax (Renfert). The marginal opening of the waxes was measured with a stereomicroscope on high-strength stone dies and on titanium and zirconia abutments. Photographic images were obtained, and the mean marginal opening for each specimen was calculated. A total of 1440 measurements were made. Wetting between die materials and waxes was determined after fabricating stone, titanium, and zirconia rectangular specimens. A calibrated pipette was used to place a drop of molten wax onto each specimen. The contact angle was calculated with software after an image of each specimen had been made with a digital camera. Collected data were subjected to a 2-way analysis of variance (α=.05). Any association between marginal accuracy and wetting of different materials was found by using the Pearson correlation. The wax factor had a statistically significant effect both on the marginal discrepancy (F=158.31, P<.001) and contact angle values (F=68.09, P<.001). A statistically significant effect of the die material factor both on the marginal adaptation (F=503.47, P<.001) and contact angle values (F=585.02, P<.001) was detected. A significant correlation between the marginal accuracy and the contact angle values (Pearson=0.881, P=.01) was also found. Stone dies provided wax copings with the best marginal integrity, followed by titanium and zirconia abutments. Unterziehwachs (Bredent), wax produced the best marginal adaptation on different die materials. A significant correlation was found

  4. Development of materials for the rapid manufacture of die cast tooling

    Hardro, Peter Jason

    The focus of this research is to develop a material composition that can be processed by rapid prototyping (RP) in order to produce tooling for the die casting process. Where these rapidly produced tools will be superior to traditional tooling production methods by offering one or more of the following advantages: reduced tooling cost, shortened tooling creation time, reduced man-hours for tool creation, increased tool life, and shortened die casting cycle time. By utilizing RP's additive build process and vast material selection, there was a prospect that die cast tooling may be produced quicker and with superior material properties. To this end, the material properties that influence die life and cycle time were determined, and a list of materials that fulfill these "optimal" properties were highlighted. Physical testing was conducted in order to grade the processability of each of the material systems and to optimize the manufacturing process for the downselected material system. Sample specimens were produced and microscopy techniques were utilized to determine a number of physical properties of the material system. Additionally, a benchmark geometry was selected and die casting dies were produced from traditional tool materials (H13 steel) and techniques (machining) and from the newly developed materials and RP techniques (selective laser sintering (SLS) and laser engineered net shaping (LENS)). Once the tools were created, a die cast alloy was selected and a preset number of parts were shot into each tool. During tool creation, the manufacturing time and cost was closely monitored and an economic model was developed to compare traditional tooling to RP tooling. This model allows one to determine, in the early design stages, when it is advantageous to implement RP tooling and when traditional tooling would be best. The results of the physical testing and economic analysis has shown that RP tooling is able to achieve a number of the research objectives, namely

  5. Dislocation analysis of die-cast Mg-Al-Ca alloy after creep deformation

    Terada, Yoshihiro; Itoh, Daigo; Sato, Tatsuo

    2009-01-01

    Tensile creep tests were combined with detailed transmission electron microscopy in order to characterize the dislocation movements during creep and to explain the creep properties of the Mg-Al-Ca AX52 die-cast alloy at 473 K and stresses from 15 to 70 MPa. TEM observations indicate that dislocations are generated within the primary α-Mg grain in the die-casting process, which consist of both the basal and non-basal segments. The basal segments of dislocations are able to bow out and glide on the basal planes under the influence of a stress, and the jogs follow the basal segments with the help of climb during creep. The creep mechanism for the alloy is deduced as dislocation climb due to the formation of sub-boundaries during creep, while the easy glide of the basal segments of dislocations is controlling the creep rates immediately after the stress application of creep tests.

  6. Influence of refining process on the porosity of high pressure die casting alloy Al-Si

    A.W. Orlowicz

    2009-04-01

    Full Text Available This study presents research results of the influence that refining and transfer of AlSi12S alloy on the porosity of high pressure diecastings.Tests were conducted under production conditions of Die-casting Foundry META-ZEL Sp z o.o. The operation of refining was conducted in a melting furnace, with the use of an FDU Mini Degasser. Decay of the refining effect was assessed by evaluating the porosity content and metallographic examination.

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

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

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

  8. Energy Saving Melting and Revert Reduction Technology: Improved Die Casting Process to Preserve the Life of the Inserts

    David Schwam, PI; Xuejun Zhu, Sr. Research Associate

    2012-09-30

    The goal of this project was to study the combined effects of die design, proper internal cooling and efficient die lubricants on die life. The project targeted improvements in die casting insert life by: Optomized Die Design for Reduced Surface Temperature: The life of die casting dies is significantly shorter when the die is exposed to elevated temperature for significant periods of time. Any die operated under conditions leading to surface temperature in excess of 1050oF undergoes structural changes that reduce its strength. Optimized die design can improve die life significantly. This improvement can be accomplished by means of cooling lines, baffles and bubblers in the die. A key objective of the project was to establish criteria for the minimal distance of the cooling lines from the surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. The Uddeholm Dievar steel evaluated in this program showed superior resistance to thermal fatigue resistance. Based on the experimental evidence, cooling lines could be placed as close as 0.5" from the surface. Die Life Extension by Optimized Die Lubrication: The life of die casting dies is affected by additions made to its surface with the proper lubricants. These lubricants will protect the surface from the considerable temperature peaks that occur when the molten melt enters the die. Dies will reach a significantly higher temperature without this lubricant being applied. The amount and type of the lubricant are critical variables in the die casting process. However, these lubricants must not corrode the die surface. This effort was supported with alloys and machining by BohlerUddeholm, Dunn Steel, HH Stark and Rex Buckeye. In plant testing and evaluation was conducted as in-kind cost share at St. Clair Die Casting. Chem- Trend participated in the program with die

  9. An establish attempt of reasons of machining splinter formation in AC44200 alloy high pressure die castings

    J. Mutwil

    2008-01-01

    A problem of splinter formation during machining the AC44200 alloy high pressure die casting has been experimental investigated. Inorder to establish the reason of this occurrence a set of 200 high pressure die casting of the tensile strength samples have been prepared. The tensile tests were carried out using a Zwick Z050 universal testing machine. JM-SPC program has been used for statistical analysis of test results. A large variability of tensile strength results has been found. In order t...

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

    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.

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

    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.

  12. High performance milling techniques on molding dies. Development of new roughing techniques for large molding die; Plastic kanagata seisaku ni okeru kokoritsu kako gijutsu. Ogata plastic yo kanagata no keijo arakako gijutsu no kochiku

    Otsuka, H; Kohama, S; Yamakawa, M [Mazda Motor Corp., Hiroshima (Japan); Egusa, H [Mazda Tooling and Engineering Co. Inc., Hiroshima (Japan)

    1997-10-01

    It needs long time to carve a molding die of bumper, which has a large and deep cavity. To shorten the milling time, we must make the machining more performable and accurate, and develop the new technology of CAM. In the milling sequence, Primary Roughing, which cut out 90% of the stock, should be more and more performable. So we established Tilt-Plunging and Curve-Fit Spiral Cutting techniques. These techniques will reduce lateral force to the tool, and make remains more small. With the techniques, we reduced both machining and NCdata preparing time to one half. 1 ref., 14 figs.

  13. Fatigue Life Prediction in Rapid Die Casting - Preliminary Work in View of Current Research

    Chuan Huat Ng; Grote, Karl-Heinrich; Baehr, Ruediger

    2007-01-01

    Numerical simulation technique as a prediction tool is slowly adopted in metal casting industry for predicting design modelling solidification analysis. The reasons for this activity is found in the need to further enhance the geometrical design and mechanical properties of the tool design and the correct prediction methodology to fulfil industrial needs. The present state of numerical simulation capabilities in rapid die casting technologies is reviewed and the failure mode mechanisms of thermal fatigue, aimed at developing a numerical simulation with a systematic design guidance for predicting the thermal cyclic loading analysis and improvement is presented along with several other methods. The economic benefits of a numerical simulation technique in die casting are limited to tool life time, mechanical properties and design guidance. The extensive computer capabilities of a numerical simulation with a systematic design guidance methodology are exploited to provide a solution for flexible design, mechanical properties and mould life time. Related research carried out worldwide by different organisations and academic institutions are discussed

  14. Effect of parameters of high-pressure die casting on occurrence of casting nonconformities in sleeves of silumin alloy EN AB 47100

    Pałyga Ł.

    2017-03-01

    Full Text Available The paper presents a research on the effect of extreme - for the technology of the considered silumin EN AB 47100 - parameters of high-pressure die casting on occurrence of casting nonconformities. Considered was influence of the way of assembling the mould cooled-down to 140-160°C, non-standard for the selected casting, and pouring temperature in the range of 705 to 720°C (higher than the recommended of non-refined alloy. The castings were prepared with use of a high-pressure casting machine made by Kirov with mould closing force of 2500 kN. Occurrence of nonconformities was evaluated on properly prepared specimens taken from the castings manufactured with various parameters of the injection piston and various multiplication pressures. The results were subjected to quantitative and qualitative analyses of casting nonconformities and distribution of major alloying elements. It was found that proper selection of working parameters of the casting machine, in spite of disadvantageous pouring conditions, makes it possible to reduce occurrence of some casting defects, like shrinkage cavities and porosity, to improve tightness of castings even when the alloy refining process is omitted.

  15. Water mist effect on cooling range and efficiency of casting die

    R. Władysiak

    2008-12-01

    Full Text Available This project is showing investigation results of cooling process of casting die in the temperature range 570÷100 °C with 0.40 MPa compressed air and water mist streamed under pressure 0.25÷0.45 MPa in air jet 0.25÷0.50 MPa using open cooling system.The character and the speed of changes of temperature, forming of the temperture’s gradient along parallel layer to cooled surface of die is shawing with thermal and derivative curves. The effect of kind of cooling factor on the temperature and time and distance from cooling nozzle is presented in the paper. A designed device for generating the water mist cooling the die and the view of sprying water stream is shown here. It’s proved that using of the water mist together with the change of heat transfer interface increases intensity of cooling in the zone and makes less the range cooling zone and reduces the porosity of cast microstructure.

  16. Determining the optimal index of heat stress in foundry, die casting and road construction industries using FAHP_Topsis

    Maryam Dehghanipoor

    2016-12-01

    Full Text Available Introduction: Heat stress is one of the harmful risks in casting and die casting industries, which can not only cause work-related diseases but also can impair the performance and safety of workers. Since the indicators that are used to evaluate heat stress are very different, it is very difficult to choose a suitable index. The aim of this study was to determine the optimum heat stress index in foundry, die-cast, and road construction industries using FAHP and Topsis methods. Material and Method: In order to determine optimum heat stress index in foundry, die-cast, and road construction industries, first, the prioritization criteria were defined by experts (including ease of measurement, measurement accuracy, comprehensiveness, time, cost, and correlation. Then, considering these criteria, the best heat stress index was determined based on experts’ opinions and using FAHP and Topsis methods. Result: The results of this study suggest that given the current conditions and criteria, WBGT and P4SR is the best indices for foundry, die casting and construction. Conclusion: The results showed that according to comprehensiveness, accuracy and correlation criteria, the WBGT index is considered as the best indicator of heat stress assessment in foundry, die-cast and road construction industries. Moreover, the HSI ranked in the last place due to the complexity and cost of its calculation.

  17. Microstructure and Properties of Cobalt-and Zinc-Containing Magnetic Magnesium Alloys Processed by High-Pressure Die Casting

    Klose, Christian; Demminger, Christian; Maier, Hans Jürgen

    The inherent magnetic properties of lightweight alloys based on magnesium and cobalt offer a novel way in order to measure mechanical loads throughout the entire structural component using the magnetoelastic effect. Because the solubility of cobalt in the magnesium matrix is negligible, the magnetic properties mainly originate from Co-rich precipitates. Thus, the size and distribution of Co-containing phases within the alloy's microstructure wields a major influence on the amplitude of the load-sensitive properties which can be measured by employing the harmonic analysis of eddy-current signals. In this study, Mg-Co-based alloys are produced by several casting methods which allow the application of different cooling rates, e.g. gravity die casting and high-pressure die casting. The differences between the manufactured alloys' micro- and phase structures are compared depending on the applied cooling rate and the superior magnetic and mechanical properties of the high-pressure die cast material are demonstrated.

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

    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.

  19. Technical-economic modelling of an aluminium high pressure die casting system for automotive parts fabrication

    Faura, F.

    1997-01-01

    In the present paper a technical-economic model for an aluminium high pressure die casting system has been developed. In order to obtain the necessary data for correlations utilized by the model, has been analyzed the production systems of companies that use these processes. This has allowed to determine the most important technological variables that affect to the economical aspect of the process. A computer application has been developed which allows to explore easily the influence of different system parameters. (Author) 12 refs

  20. Micro-texturing into DLC/diamond coated molds and dies via high density oxygen plasma etching

    Yunata Ersyzario Edo

    2015-01-01

    Full Text Available Diamond-Like Carbon (DLC and Chemical Vapor Deposition (CVD-diamond films have been widely utilized not only as a hard protective coating for molds and dies but also as a functional substrate for bio-MEMS/NEMS. Micro-texturing into these hard coated molds and dies provides a productive tool to duplicate the original mother micro-patterns onto various work materials and to construct any tailored micro-textures for sensors and actuators. In the present paper, the high density oxygen plasma etching method is utilized to make micro-line and micro-groove patterns onto the DLC and diamond coatings. Our developing oxygen plasma etching system is introduced together with characterization on the plasma state during etching. In this quantitative plasma diagnosis, both the population of activated species and the electron and ion densities are identified through the emissive light spectroscopy and the Langmuir probe method. In addition, the on-line monitoring of the plasmas helps to describe the etching process. DLC coated WC (Co specimen is first employed to describe the etching mechanism by the present method. Chemical Vapor Deposition (CVD diamond coated WC (Co is also employed to demonstrate the reliable capacity of the present high density oxygen plasma etching. This oxygen plasma etching performance is discussed by comparison of the etching rates.

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

    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.

  2. Annealing of chromium oxycarbide coatings deposited by plasma immersion ion processing (PIIP) for aluminum die casting

    Peters, A.M.; He, X.M.; Trkula, M.; Nastasi, M.

    2001-01-01

    Chromium oxycarbide coatings have been investigated for use as non-wetting coatings for aluminum die casting. This paper examines Cr-C-O coating stability and non-wetability at elevated temperatures for extended periods. Coatings were deposited onto 304 stainless steel from chromium carbonyl [Cr(CO) 6 ] by plasma immersion ion processing. The coatings were annealed in air at an aluminum die casting temperature of 700 deg. C up to 8 h. Coatings were analyzed using resonant ion backscattering spectroscopy, nanoindentation and pin-on-disk tribometry. Molten aluminum was used to determine coating wetting and contact angle. Results indicate that the surface oxide layer reaches a maximum thickness of 900 nm. Oxygen concentrations in the coatings increased from 24% to 34%, while the surface concentration rose to almost 45%. Hardness values ranged from 22.1 to 6.7 GPa, wear coefficients ranged from 21 to 8x10 -6 mm 3 /Nm and contact angles ranged from 156 deg. to 127 deg

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

    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)

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

    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.

  5. Improved design and durability of aluminum die casting horizontal shot sleeves

    Birceanu, Sebastian

    The design and performance of shot sleeves is critical in meeting the engineering requirements of aluminum die cast parts. Improvement in shot sleeve materials have a major impact on dimensional stability, reproducibility and quality of the product. This investigation was undertaken in order to improve the life of aluminum die casting horizontal shot sleeves. Preliminary pin tests were run to evaluate the soldering, wash-out and thermal fatigue behavior of commercially available materials and coatings. An experimental rig was designed and constructed for shot sleeve configuration evaluation. Fabrication and testing of experimental shot sleeves was based upon preliminary results and manufacturing costs. Three shot sleeve designs and materials were compared to a reference nitrided H13 sleeve. Nitrided H13 is the preferred material for aluminum die casting shot sleeves because of wear resistance, strength and relative good soldering and wash-out resistance. The study was directed towards damage evaluation on the area under the pouring hole. This area is the most susceptible to damage because of high temperatures and impingement of molten aluminum. The results of this study showed that tungsten and molybdenum had the least amount of soldering and wash-out damage, and the best thermal fatigue resistance. Low solubility in molten aluminum and stability of intermetallic layers are main factors that determine the soldering and wash-out behavior. Thermal conductivity and thermal expansion coefficient directly influence thermal fatigue behavior. TiAlN nanolayered coating was chosen as the material with the best damage resistance among several commercial PVD coatings, because of relatively large thickness and simple deposition conditions. The results show that molybdenum thermal sprayed coating provided the best protection against damage under the pouring hole. Improved bonding is however required for life extension of the coating. TiAlN PVD coating applied on H13 nitrided

  6. Influence of capillary die geometry on wall slip of highly filled powder injection molding compounds

    Sanétrník, D.; Hausnerová, B.; Filip, Petr; Hnátková, E.

    2018-01-01

    Roč. 325, February (2018), s. 615-619 ISSN 0032-5910 R&D Projects: GA ČR GA17-26808S Grant - others:Ministerstvo školství, mládeže a tělovýchovy (MŠMT)(CZ) LO1504 Institutional support: RVO:67985874 Keywords : powder injection molding * highly filled polymer * wall slip * capillary entrance angle Subject RIV: BK - Fluid Dynamics OBOR OECD: Fluids and plasma physics (including surface physics) Impact factor: 2.942, year: 2016

  7. Case study of lean manufacturing application in a die casting manufacturing company

    Ching, Ng Tan; Hoe, Clarence Chan Kok; Hong, Tang Sai; Ghobakhloo, Morteza; Pin, Chen Kah

    2015-05-01

    The case study of lean manufacturing aims to study the application of lean manufacturing in a die casting manufacturing company located in Pulau Penang, Malaysia. This case study describes mainly about the important concepts and applications of lean manufacturing which could gradually help the company in increasing the profit by studying and analyzing their current manufacturing process and company culture. Many approaches of lean manufacturing are studied in this project which includes: 5S housekeeping, Kaizen, and Takt Time. Besides, the lean tools mentioned, quality tool such as the House of Quality is being used as an analysis tool to continuously improve the product quality. In short, the existing lean culture in the company is studied and analyzed, with recommendations written at the end of this paper.

  8. A Study on Development of High Strength Al-Zn Based alloy for Die Casting

    Shin, Sang-Soo; Park, Ik-Min [Pusan National University, Busan (Korea, Republic of); Yeom, Gil-Young; Lim, Kyoung-Mook [Korea Institute of Industrial Technology, Incheon (Korea, Republic of); Son, Hyun-Jin [Oh-Sung Co. Ltd., Siheung (Korea, Republic of)

    2015-09-15

    In this study, the microstructural evolution and various characteristics of Al-20⁓45wt%Zn alloys were investigated. In terms of microstructure, as the amount of Zn addition to the alloys increased, the α-phase size decreased and the α+η non-equilibrium solidification phase fraction increased. Also, increasing Zn content improved the wear resistance of the alloys, but reduced the damping capacity and toughness of the alloys. Their physical properties of the Al-Zn alloy with high Zn content, specifically the wear resistance and toughness, were superior to those of commercial ALDC12 alloys for die-casting. Based on these results, we considered the possibility of application of the developed Al-Zn alloy as a structural material.

  9. Evaluations of antimony and strontium interaction in an Al–Si–Cu–Zn die cast alloy

    Farahany, Saeed, E-mail: saeedfarahany@gmail.com; Idris, Mohd Hasbullah; Ourdjini, Ali

    2014-05-01

    Graphical abstract: - Highlights: • Probable interactions between Sb and Sr in a complex Al–Si alloy were evaluated. • Sequence of addition did not affect thermal and microscopical characteristics. • Threshold ratio for the Sb and Sr interaction is proposed. - Abstract: The interaction between antimony and strontium in an ADC12 die casting alloy is investigated comprehensively by using a computer aided cooling curve thermal analysis coupled with microstructure inspection. The results of the thermal analysis show significant changes in Al–Si eutectic reaction based on different concentrations of Sb and Sr. Sb reduces the efficiency of Sr in modifying the eutectic Si. Based upon the data obtained in this study, the threshold Sr/Sb ratio should exceed about 0.5 in order to obtain fully modified structure. Moreover, a pre-eutectic reaction of Al{sub 2}Si{sub 2}Sr intermetallic was detected for high concentrations of Sr.

  10. A Study on Development of High Strength Al-Zn Based alloy for Die Casting

    Shin, Sang-Soo; Park, Ik-Min; Yeom, Gil-Young; Lim, Kyoung-Mook; Son, Hyun-Jin

    2015-01-01

    In this study, the microstructural evolution and various characteristics of Al-20⁓45wt%Zn alloys were investigated. In terms of microstructure, as the amount of Zn addition to the alloys increased, the α-phase size decreased and the α+η non-equilibrium solidification phase fraction increased. Also, increasing Zn content improved the wear resistance of the alloys, but reduced the damping capacity and toughness of the alloys. Their physical properties of the Al-Zn alloy with high Zn content, specifically the wear resistance and toughness, were superior to those of commercial ALDC12 alloys for die-casting. Based on these results, we considered the possibility of application of the developed Al-Zn alloy as a structural material.

  11. Numerical modeling of the thickness dependence of zinc die-cast materials

    Page, Maria Angeles Martinez; Ruf, Matthias; Hartmann, Stefan

    2017-11-01

    Zinc die casting alloys show varying material properties over the thickness in their final solid state, which causes a change in the mechanical response for specimens with different thicknesses. In this article, we propose a modeling concept to account for the varying porosity in the constitutive modeling. The material properties are effectively incorporated by combining a partial differential equation describing the distribution of the pores by a structural parameter with the Mori-Tanaka approach for linear elasticity. The distribution of the porosity is determined by polished cut images, for which the procedure is explained in detail. Finite element simulations of the coupled system incorporating the thickness dependence show the applicability of this approach.

  12. Energy Saving Melting and Revert Reduction Technology (E-SMARRT): Development of Surface Engineered Coating Systems for Aluminum Pressure Die Casting Dies: Towards a 'Smart' Die Coating

    Dr. John J. Moore; Dr. Jianliang Lin,

    2012-07-31

    The main objective of this research program was to design and develop an optimal coating system that extends die life by minimizing premature die failure. In high-pressure aluminum die-casting, the die, core pins and inserts must withstand severe processing conditions. Many of the dies and tools in the industry are being coated to improve wear-resistance and decrease down-time for maintenance. However, thermal fatigue in metal itself can still be a major problem, especially since it often leads to catastrophic failure (i.e. die breakage) as opposed to a wear-based failure (parts begin to go out of tolerance). Tooling costs remain the largest portion of production costs for many of these parts, so the ability prevent catastrophic failures would be transformative for the manufacturing industry.The technology offers energy savings through reduced energy use in the die casting process from several factors, including increased life of the tools and dies, reuse of the dies and die components, reduction/elimination of lubricants, and reduced machine down time, and reduction of Al solder sticking on the die. The use of the optimized die coating system will also reduce environmental wastes and scrap parts. Current (2012) annual energy saving estimates, based on initial dissemination to the casting industry in 2010 and market penetration of 80% by 2020, is 3.1 trillion BTU's/year. The average annual estimate of CO2 reduction per year through 2020 is 0.63 Million Metric Tons of Carbon Equivalent (MM TCE).

  13. Failure behavior of high pressure die casting AZ91D magnesium alloy

    Li, X.; Xiong, S.M. [School of Materials Science and Engineering, Tsinghua University, Beijing 100084 (China); Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Tsinghua University, Beijing 100084 (China); Guo, Z., E-mail: zhipeng_guo@mail.tsinghua.edu.cn [School of Materials Science and Engineering, Tsinghua University, Beijing 100084 (China); Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Tsinghua University, Beijing 100084 (China)

    2016-08-30

    The failure behavior of high pressure die casting AZ91D magnesium alloy during both tensile and fatigue tests was studied in situ by using scanning electron microscope. Attention was focused on the role of microstructure played in crack initiation and propagation. Results showed that the defects in castings, including gas pore, shrinkage pore and defect band, were the crack initiation sources. In tensile test, the crack propagated in a combination of intergranular and transgranular modes, and the specimen fractured by connecting defects at the section with minimum effective force bearing area. In fatigue test, the crack propagated in a transgranular mode at specific crystalline planes. When the crack was in contact with the β-phase, the crack would pass through, and fracture the network β-phase, whereas bypass the island β-phase by detaching it from the surrounding α-Mg grains. Besides, defects in front of the crack would act as the secondary crack initiation sources, from which new cracks would initiate and propagate. With the propagation of the fatigue crack, the actual maximum cyclic stress would increase to the fracture stress of the left cross section and lead to the final fracture of the specimen.

  14. The ‘full sleeve’ application in the horizontal cold-chamber machine for pressure die casting of aluminium alloys

    Z. Konopka

    2008-04-01

    Full Text Available The ‘full sleeve’ construction has been designed and accomplished in the horizontal cold-chamber pressure die casting machine. Main part of this solution is a counter plunger placed in a movable die half which allows for full filling of the shot sleeve and precisely fixes the metal quantity needed for casting. The purpose of this new construction solution is mainly the reduction of the casting porosity caused by air entrapment and the improvement of both castability and accuracy of the die cavity reproduction. For such a redesigned machine there have been performed examinations consisting in pressure casting of AlSi9Cu alloy (EN AC-46000 at varying plunger velocity in the second stage of injection and varying intensification pressure. The alloy castability (the die filling ability has been measured for each parameter setting. For the purpose of comparison, similar measurements have been performed also for the conventional system without a counter plunger. The castability examination has been done by means of a specially designed die with an impression of a trial casting of variable wall thickness. The experiments have been held according to the assumed factor design 22, what allowed for determining the mathematical models describing the influence of die filling parameters on the castability and the die cavity reproduction level. Both alternatives of the experiment confirmed the positive influence of plunger velocity and intensification pressure increase on the improvement of castability, the measure of the latter being the filled length of the impression. Applying of the new ‘full sleeve’ solution has improved castability for each experiment by about 20% as compared with conventional alternative. Castability in the ‘full sleeve’ system has been increased even for low values of plunger velocity and intensification pressure. For both alternative systems the influence of plunger velocity has been found, as an average, by four times

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

    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.

  16. Comparative study on laser welding and TIG welding of semi-solid high pressure die cast A356 aluminium alloy

    Govender, G

    2007-07-01

    Full Text Available components. The low porosity levels in SSM high pressure die castings (HPDC) improves the weldability of these components. The aim of the current research was to perform a comparative study of laser and TIG welding of SSM HPDC aluminium alloy A356. SSM...

  17. Microstructure investigation and first-principle analysis of die-cast AZ91 alloy with calcium addition

    Lin, L.; Wang, F.; Yang, L.; Chen, L.J.; Liu, Z.; Wang, Y.M.

    2011-01-01

    Highlights: → Die-cast AZ91 with Ca addition was investigated experimentally and theoretically. → Precipitation sequence was confirmed with increasing Ca addition. → Phase stability difference was verified by first-principle calculation. → Valence configurations were associated with alloying effects of Al, Mg and Ca. - Abstract: In order to get improved mechanical properties of die-cast AZ91 alloy under elevated temperatures, Ca element was added as a cost-effective alloying constituent. It appeared that minor Ca addition less than 0.5 wt% would result in no apparent change in microstructure, but the tensile strength at elevated temperatures was improved considerably. When increasing Ca addition to more than 1.0 wt%, Al 2 Ca phase will precipitate during solidification, no Mg 2 Ca phase was discovered. Homogeneous microstructure and high temperature stability in tensile strength of die-cast AZ91 alloy with Ca addition was mainly attributed to the precipitation of Al 2 Ca phase, which considerably refined the bulky β-Mg 17 Al 12 phase distributed originally at the grain boundaries of die-cast AZ91 alloy with no Ca addition. The priority of Al 2 Ca phase compared to Mg 2 Ca phase in precipitation sequence was verified by first-principle calculation of their cohesive energy and formation enthalpy, and can also be associated with more bounding electrons between Al and Ca atoms.

  18. Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast

    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.

  19. The Influence of Pressure Die Casting Parameters on the Castability of AlSi11-SiCp Composites

    Konopka Z.

    2015-03-01

    Full Text Available The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as the method of its high-pressure die casting and the measurement results concerning the castability of the obtained composite. Composite castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. There were found the regression equations describing the change of castability of the examined composite as a function of pressure die casting process parameters. The conclusion gives the analysis and the interpretation of the obtained results.

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

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

    2017-10-01

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

  1. Comparative study on microstructures and mechanical properties of the heat-treated Al–5.0Cu–0.6Mn–xFe alloys prepared by gravity die casting and squeeze casting

    Lin, Bo; Zhang, WeiWen; Lou, ZhaoHui; Zhang, DaTong; Li, YuanYuan

    2014-01-01

    Highlights: • Only two kind Fe-rich intermetallics are found in the heat-treated Al–5.0Cu–0.6Mn–xFe alloys. • Squeeze cast Al–5.0Cu–0.6Mn alloys containing 1.5% Fe have desirable mechanical properties. • The difference between gravity die cast and squeeze cast Al–5.0Cu–0.6Mn–xFe alloys. - Abstract: The Al–5.0 wt% Cu–0.6 wt% Mn alloys with different Fe contents were prepared by gravity die casting and squeeze casting. The difference in microstructures and mechanical properties of the T5 heat-treated alloys was examined by tensile test, optical microscopy, deep etching technique, scanning electron microscope and electron probe micro-analyzer. The results show that both β-Fe and α (CuFe) are observed in T5 heat-treated gravity die cast alloy and only α (CuFe) appears in the squeeze cast alloy when the Fe content is 0.5 wt%. When the Fe content is more than 1.0 wt%, the main Fe-rich intermetallics is α (CuFe) in both squeeze cast and gravity die cast alloys. The mechanical properties of both the gravity die cast and squeeze cast alloys decrease gradually with the increase of Fe content due to the decreased volume fraction of precipitation particles, the increased volume fraction of Fe-rich intermetallics and the increased size of α (Al) dendrites. The squeeze cast alloys with different Fe contents have superior mechanical properties compared to the gravity die cast alloys, which is mainly attributed to the reduction of porosity and refinement of Fe-rich intermetallics and α (Al) dendrite. In particularly, the elongation of the squeeze cast alloys is less sensitive to the Fe content than that of the gravity die cast alloys. An elongation level of 13.7% is obtained in squeeze cast alloy even when the Fe content is as high as 1.5%, while that of the gravity die cast alloy is only 5.3%

  2. Analysis of the creep behaviour of die-cast Mg–3Al–1Si alloy

    Zhu, S.M.; Easton, M.A.; Gibson, M.A.; Dargusch, M.S.; Nie, J.F.

    2013-01-01

    The creep behaviour of die-cast Mg–3Al–1Si (AS31) alloy has been studied at 125 °C, 150 °C and 175 °C with stresses ranging 50–110 MPa. The alloy exhibits anomalously high stress exponents, i.e. 14.4 at 125 °C, 11.6 at 150 °C and 9.5 at 175 °C. Contrary to work reported previously, these high stress exponents cannot be rationalised using the threshold stress approach that is commonly adopted in analysing creep behaviour of dispersion strengthened alloys or metal matrix composites. It is shown that the observed high stress exponents are associated with the dominance of power-law breakdown creep in this study, and the stress dependence can be well described by the Garofalo sinh relationship with the natural exponent of 5. Transmission electron microscopy (TEM) observations reveal that cross-slip of 〈a〉 type dislocations is probably the controlling creep mechanism

  3. New high pressure die cast magnesium alloy AM-HP2 for powertrain applications

    Gibson, M.A. [Queensland Univ., Brisbane (Australia). CAST CRC]|[CSIRO Manufacturing and Materials Technology, Clayton (Australia); Zhu, S.M.; Nie, J.F. [Queensland Univ., Brisbane (Australia). CAST CRC]|[Monash Univ., Monash (Australia). Dept. of Materials Engineering

    2007-07-01

    In order to improve the benefits available through weight savings on engine emissions, magnesium alloys must gain wider acceptance in transmission and engine applications. This paper provided details of a new alloy with exceptional creep properties developed for automotive powertrain applications. The AM-HP2 alloy was developed as part of a broader research program investigating the relationship between the composition, structure and properties of magnesium rare earth (Mg-RE) based alloys and high-pressure die casting (HPDC). Cylindrical test specimens of various alloys were produced on a cold chamber HPDC machine. Tensile creep tests were then conducted under a constant load at 177 degrees C for a period of 600 hours. Microstructures of specimens were characterized using a CM20 transmission electron microscope. Results of the tests indicated that near-grain boundary microstructure was an important parameter in securing optimum elevated temperature properties. The RE element had a significant effect on the creep behaviour of the HPDC Mg-RE alloys. It was concluded that further research is needed to investigate the influence of the RE mixture in improving creep performance. 15 refs., 2 tabs., 6 figs.

  4. Analysis of the creep behaviour of die-cast Mg–3Al–1Si alloy

    Zhu, S.M., E-mail: suming.zhu@monash.edu [CAST Cooperative Research Centre, Department of Materials Engineering, Monash University, Victoria 3800 (Australia); ARC Centre of Excellence for Design in Light Metals, Department of Materials Engineering, Monash University, Victoria 3800 (Australia); Easton, M.A. [CAST Cooperative Research Centre, Department of Materials Engineering, Monash University, Victoria 3800 (Australia); Gibson, M.A. [CAST Cooperative Research Centre, CSIRO Process Science and Engineering, Clayton, Victoria 3169 (Australia); Dargusch, M.S. [Centre for Advanced Materials Processing and Manufacturing, School of Mechanical and Mining Engineering, The University of Queensland, Queensland 4075 (Australia); Defence Materials Technology Centre, The University of Queensland, Queensland 4075 (Australia); Nie, J.F. [ARC Centre of Excellence for Design in Light Metals, Department of Materials Engineering, Monash University, Victoria 3800 (Australia)

    2013-08-20

    The creep behaviour of die-cast Mg–3Al–1Si (AS31) alloy has been studied at 125 °C, 150 °C and 175 °C with stresses ranging 50–110 MPa. The alloy exhibits anomalously high stress exponents, i.e. 14.4 at 125 °C, 11.6 at 150 °C and 9.5 at 175 °C. Contrary to work reported previously, these high stress exponents cannot be rationalised using the threshold stress approach that is commonly adopted in analysing creep behaviour of dispersion strengthened alloys or metal matrix composites. It is shown that the observed high stress exponents are associated with the dominance of power-law breakdown creep in this study, and the stress dependence can be well described by the Garofalo sinh relationship with the natural exponent of 5. Transmission electron microscopy (TEM) observations reveal that cross-slip of 〈a〉 type dislocations is probably the controlling creep mechanism.

  5. Microstructural effects of phosphorus on pressure die cast Al-12Si components

    Suárez-Peña, B.

    2007-10-01

    Full Text Available The refinement of cuboidal silicon in eutectic Al-Si alloys by phosphorus additions used to manufacture pressure die cast components was studied. The results show that the addition of phosphorus in the form of AlFeP mother alloy before process degassing, leads to the best refinement of the size of the Si-cuboids phase, among several phosphorus additions analysed in the present research.

    Se ha estudiado el afino del silicio cuboidal en aleaciones eutécticas Al-Si por acción del fósforo, en piezas obtenidas mediante la técnica de fundición a presión. Tras la adición de fósforo en pruebas industriales, en las que dicho elemento se incorpora al baño con diversas composiciones, los mejores resultados se obtienen con la adición de la aleación madre AlFeP, previa al desgasificado industrial.

  6. Microstructure and mechanical properties of AM50 alloy according to thickness and forming condition of the products by a high pressure die-casting process

    Park, Joon Hong [Dong-A University, Busan (Korea, Republic of); Kang, Chung Gil [Pusan National University, Busan (Korea, Republic of)

    2013-10-15

    In recent years, Magnesium (Mg) and its alloys have become a center of special interest in the automotive industry. Due to their high specific mechanical properties, they offer a significant weight saving potential in modern vehicle constructions. Most Mg alloys show very good machinability and processability, and even the most complicated die casting parts can be easily produced. The die casting process is a fast production method capable of a high degree of automation for which certain Mg alloys are ideally suited. Although Mg alloys are fulfilling the demands for low specific weight materials with excellent machining and casting abilities, they are still not used in die casting process to the same extent as the competing material aluminum. One of the reasons is that effects of various forming variables for die casting process is not closely examined from the viewpoint of die design. In this study, step die and flowability tests for AM50 were performed by die casting process according to various combination of casting pressure and plunger velocity. Microstructure, Vickers hardness and tensile tests were examined and performed for each specimen to verify effects of forming conditions.

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

    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.

  8. An establish attempt of reasons of machining splinter formation in AC44200 alloy high pressure die castings

    J. Mutwil

    2008-10-01

    Full Text Available A problem of splinter formation during machining the AC44200 alloy high pressure die casting has been experimental investigated. Inorder to establish the reason of this occurrence a set of 200 high pressure die casting of the tensile strength samples have been prepared. The tensile tests were carried out using a Zwick Z050 universal testing machine. JM-SPC program has been used for statistical analysis of test results. A large variability of tensile strength results has been found. In order to find the reason of this variability the fracture surface investigations (macrographs for all of samples and SEM micrographs for chosen samples have been carried out. It has been establish that in all cases a significant decrease of tensile strength was caused by presence of inclusions or porosity. In lot of cases the inclusions have a form of oxide film.

  9. Conceptos del maquinado con altas velocidades de corte aplicado en moldes y matrices. // Concepts of the machining with high speeds cutting applied in molds and dies.

    F. Martínez Aneiro

    2007-01-01

    Full Text Available La demanda de componentes mecánicos de alta calidad y gran exactitud para sistemas de elevada precisión estaaumentando considerablemente en los últimos años a nivel mundial. Este hecho ha provocado el desarrollo de nuevastecnologías aplicadas a los procesos de corte.El desarrollo integral de las máquinas herramientas (controles, husillos de alta velocidad de las herramientas de corte(nuevos materiales para los substratos y capas y de la tecnología de maquinado posibilitó la aplicación del corte a altasvelocidades (High speed Cutting HSC. El aumento de las velocidades de corte es una de las formas de incrementar laeficiencia de los procesos productivos a través de la reducción de los tiempos de fabricación. La disminución en variasveces de los tiempos de fabricación, se logra no solo por los tiempos de maquinado sino también por la sustitución oreducción de otros procesos de elaboración que forman parte de la cadena productiva, que en ocasiones son relativamentelentos como son la electroerosión, el acabado manual en la producción de moldes y troqueles así como los cambios deoperaciones de la pieza bruta.Por ser un proceso relativamente nuevo, apenas desde los años 90 es que se implementa la introducción del HSC y muchascuestiones tecnológicas aun están sin respuesta. Por otro lado las características ya conocidas de esta nueva tecnologíaindican una buena perspectiva de aplicación en los más diversos segmentos de la industria.Palabras claves: HSC, HSM, velocidad de corte, velocidad de maquinado._______________________________________________________________________________Abstract.The demand of mechanical components of high quality and great accuracy for systems of high precision, increasingconsiderably in the last years at world level. This fact has caused the development of new applied technologies to thecutting processes.The integral development of machine tools (you control, high-speed spindle of the cutting tools

  10. Ejection Performance of Coated Core Pins Intended for Application on High Pressure Die Casting Tools for Aluminium Alloys Processing

    P. Terek

    2017-09-01

    Full Text Available In high pressure die casting (HPDC process of aluminium alloys cast alloy soldering severely damages tool surfaces. It hampers casting ejection, reduces the casting quality and decreases the overall production efficiency. Thin ceramic PVD (physical vapor deposition coatings applied on tool surfaces successfully reduce these effects. However, their performance is still not recognised for surfaces with various topographies. In this investigation, soldering tendency of Al-Si-Cu alloy toward EN X27CrMoV51 steel, plasma nitrided steel, CrN and TiAlN duplex PVD coatings is evaluated using ejection test. The coatings were prepared to a range of surface roughness and topographies. After the tests sample surfaces were analysed by different microscopy techniques and profilometry. It was found that the ejection performance is independent of the chemical composition of investigated materials. After the ejection, the cast alloy soldering layer was found on surfaces of all tested materials. This built-up layer formed by effects of mechanical soldering, without corrosion reactions. Coated samples displayed a pronounced dependence of ejection force on surface roughness and topography. By decreasing roughness, ejection force increased, which is a consequence of intensified adhesion effects. Presented findings are a novel information important for efficient application of PVD coatings intendent for protection of HPDC tools.

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

    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.

  12. An eco design strategy for high pressure die casting components: microstructural analysis applied to mass reducing processes

    Suarez-Pena, B.; Asensio-Lozano, J.

    2009-01-01

    In this work the study focused on the possibility of use of new aluminium alloys with optimized microstructures that ensure the mechanical properties requested for cast components made by high pressure die casting. The objective was to check the possibility of manufacture of structurally sound eco-steps for escalators with reduced structural integrity. The former arises as a result of a new redesign of the traditional steps aiming at a significant weight reduction. The experimental results show that it is feasible to cut the use of materials during processing and therefore to reduce the impact of the components during its lifetime, whilst the performance and safety standards are kept identical or even improved. (Author) 17 refs

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

    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.

  14. The correlation between microstructure and mechanical properties of high-pressure die-cast AM50 alloy

    Song Jie; Xiong Shoumei; Li Mei; Allison, John

    2009-01-01

    Scanning acoustic microscopy was used to characterize the micro-voids distribution for specimens in non-destructive mode. In addition, the in-situ scanning electron microscopy observation was performed during tensile deformation of high-pressure die-cast (HPDC) of AM50 alloy to obtain the mechanism of fracture induced by micro-voids. The effects of micro-voids on the mechanical properties were discussed. The results obtained from the examination suggest that fracture tends to occur at bigger micro-voids or in the cluster micro-voids area.

  15. Clean Metal Casting

    Makhlouf M. Makhlouf; Diran Apelian

    2002-02-05

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

  16. Clean Metal Casting; FINAL

    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

  17. CASTING FURNACES

    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.

  18. Theoretic and Experimental Studies on the Casting of Large Die-Type Parts Made of Lamellar Graphite Grey Pig Irons by Using the Technology of Polystyrene Moulds Casting from Two Sprue Cups

    Constantin Marta

    2012-01-01

    Full Text Available This paper presents a comparative analysis between the practical results of pig iron die-type part casting and the results reached by simulation. The insert was made of polystyrene, and the casting was downward vertical. As after the part casting and heat treatment cracks were observed in the part, it became necessary to locate and identify these fissures and to establish some measures for eliminating the casting defects and for locating them. The research method was the comparisons of defects identified through verifications, measurements, and metallographic analyses applied to the cast part with the results of some criteria specific to simulation after simulating the casting process. In order to verify the compatibility between reality and simulation, we then simulated the part casting respecting the real conditions in which it was cast. By visualising certain sections of the cast part during solidification, relevant details occur about the possible evolution of defects. The simulation software was AnyCasting, the measurements were done through nondestructive methods.

  19. Experiments on the Model Testing of the 2nd Phase of Die Casting Process Compared with the Results of Numerical Simulation

    Dańko R.

    2015-12-01

    Full Text Available Experiments of filling the model moulds cavity of various inner shapes inserted in rectangular cavity of the casting die (dimensions: 280 mm (height × 190 mm (width × 10 mm (depth by applying model liquids of various density and viscosity are presented in the paper. Influence of die venting as well as inlet system area and inlet velocity on the volumetric rate of filling of the model liquid - achieved by means of filming the process in the system of a cold-chamber casting die was tested. Experiments compared with the results of simulation performed by means of the calculation module Novacast (Novaflow&Solid for the selected various casting conditions - are also presented in the paper.

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

    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)

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

    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)

  2. Die-cast of a hypo-eutectic AL-SI alloy: influence of injection temperature on microstructure and mechanical properties

    Santos, Silvano Leal dos; Santos, Sydney Ferreira

    2014-01-01

    Die-casting is widely used for manufacturing light alloy components for automotive industry. Among others, hypo-eutectic Al-Si alloys are currently processed by die-casting. To obtain high quality die-cast components, a better understanding on the correlations between processing parameters, microstructures, and mechanical properties are of utmost importance. In this study, we investigate the effect of injection temperature of liquid metal on the microstructure and mechanical properties of Al-Si alloy EN AC 46000 (DIN designation). The injection temperatures were 579, 589, 643, and 709 deg C. As-cast components had their microstructures analyzed by X-ray diffraction, optical and scanning electron microscopy, and X-ray energy dispersive spectroscopy. The mechanical properties were examined by micro-hardness and tensile tests. It was observed that the ultimate tensile strength slightly increased with the increase of injection temperature. The same trend was observed for micro-hardness. The amount of porosity in the samples varies in a small amount for different injection temperatures. On the other hand, the microstructure of the alloys seems more refined for higher temperatures of injection. This refinement in microstructure might play a major role on the mechanical properties of the Al-Si die-cast alloy. (author)

  3. Casting materials

    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.

  4. REDUCING REJECTION/REWORK IN PRESSURE DIE CASTING PROCESS BY APPLICATION OF DMAIC METHODOLOGY OF SIX SIGMA

    Javedhusen Malek

    2015-12-01

    Full Text Available In today's ever-changing customer driven market, industries are needed to improve their products and processes to satisfy customer requirements. The Six Sigma approach has set a new paradigm of business excellence. Six Sigma as a process driven improvement methodology has been adopted successfully by many industries. From the review of various literatures, it is revealed that Six Sigma is well adopted in large scale enterprise but having less evidence of adoption in Indian SMEs. This paper is focused on providing path to Indian SMEs for initiating Six Sigma approach in their industries. The paper discusses the real life case where Six Sigma has been successfully applied at one of the Indian small-scale unit to improve rejection/rework rate in manufacturing products by pressure die casting process. This paper describes phase wise application of all the phases of define-measure-analyse-improve-control (DMAIC which also shows impact of Six Sigma in quality improvement.

  5. Microstructural stability of heat-resistant high-pressure die-cast Mg-4Al-4Ce alloy

    Wang, Wei; Zhang, Jinghuai; Li, Guoqiang; Feng, Yan; Su, Minliang; Wu, Ruizhi; Zhang, Zhongwu [Harbin Engineering Univ. (China). Key Laboratory of Superlight Material and Surface Technology; Jiao, Yufeng [Jiamusi Univ. (China). College of Materials Science and Engineering

    2017-05-15

    The thermal stability of Al-RE (rare earth) intermetallic phases with individual RE for heat-resistant high-pressure die-casting Mg-Al-RE alloys is investigated. The results of this study show that the main strengthening phase of Mg-4Al-4Ce alloy is Al{sub 11}Ce{sub 3}, whose content is about 5 wt.% according to quantitative X-ray diffraction phase analysis. The Al{sub 11}Ce{sub 3} phase appears to have high thermal stability at 200 C and 300 C, while phase morphology change with no phase structure transition could occur for Al{sub 11}Ce{sub 3} when the temperature reaches 400 C. Furthermore, besides the kinds of rare earths and temperature, stress is also an influencing factor in the microstructural stability of Mg-4Al-4Ce alloy.

  6. Fabrication of ZnO Nanowires Arrays by Anodization and High-Vacuum Die Casting Technique, and Their Piezoelectric Properties

    Kuo, Chin-Guo; Chang, Ho; Wang, Jian-Hao

    2016-01-01

    In this investigation, anodic aluminum oxide (AAO) with arrayed and regularly arranged nanopores is used as a template in the high-vacuum die casting of molten zinc metal (Zn) into the nanopores. The proposed technique yields arrayed Zn nanowires with an aspect ratio of over 600. After annealing, arrayed zinc oxide (ZnO) nanowires are obtained. Varying the anodizing time yields AAO templates with thicknesses of approximately 50 μm, 60 μm, and 70 μm that can be used in the fabrication of nanowires of three lengths with high aspect ratios. Experimental results reveal that a longer nanowire generates a greater measured piezoelectric current. The ZnO nanowires that are fabricated using an alumina template are anodized for 7 h and produce higher piezoelectric current of up to 69 pA. PMID:27023546

  7. Fabrication of ZnO Nanowires Arrays by Anodization and High-Vacuum Die Casting Technique, and Their Piezoelectric Properties

    Chin-Guo Kuo

    2016-03-01

    Full Text Available In this investigation, anodic aluminum oxide (AAO with arrayed and regularly arranged nanopores is used as a template in the high-vacuum die casting of molten zinc metal (Zn into the nanopores. The proposed technique yields arrayed Zn nanowires with an aspect ratio of over 600. After annealing, arrayed zinc oxide (ZnO nanowires are obtained. Varying the anodizing time yields AAO templates with thicknesses of approximately 50 μm, 60 μm, and 70 μm that can be used in the fabrication of nanowires of three lengths with high aspect ratios. Experimental results reveal that a longer nanowire generates a greater measured piezoelectric current. The ZnO nanowires that are fabricated using an alumina template are anodized for 7 h and produce higher piezoelectric current of up to 69 pA.

  8. Fabrication of ZnO Nanowires Arrays by Anodization and High-Vacuum Die Casting Technique, and Their Piezoelectric Properties.

    Kuo, Chin-Guo; Chang, Ho; Wang, Jian-Hao

    2016-03-24

    In this investigation, anodic aluminum oxide (AAO) with arrayed and regularly arranged nanopores is used as a template in the high-vacuum die casting of molten zinc metal (Zn) into the nanopores. The proposed technique yields arrayed Zn nanowires with an aspect ratio of over 600. After annealing, arrayed zinc oxide (ZnO) nanowires are obtained. Varying the anodizing time yields AAO templates with thicknesses of approximately 50 μm, 60 μm, and 70 μm that can be used in the fabrication of nanowires of three lengths with high aspect ratios. Experimental results reveal that a longer nanowire generates a greater measured piezoelectric current. The ZnO nanowires that are fabricated using an alumina template are anodized for 7 h and produce higher piezoelectric current of up to 69 pA.

  9. Rapid die manufacturing - high pressure casting of low volume non ferrous metals components

    Pereira, MFV

    2006-11-01

    Full Text Available .csir.co.za Models of assembled Die Slide 12 © CSIR 2006 www.csir.co.za 3. Die manufacture, assembly and data capturing 21.521.521.525.5total 4electrode 3Fitting3Fitting3Fitting3Fitting 2Polish2Polish2Polish2Polish 7SER 3F grind3F grind...3F grind4F grind Heat trHeat trHeat tr1Heat tr Jig boreJig boreJig boreJig bore GrindingGrindingGrinding2Grinding 13.5DMLS13.5DMLS13.5DMLS2.5Milling HrsCostProcessHrsCostProcessHrsCostProcessHrsCostProcess Core 4Core 3Core 2Core 1 NB. Times...

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

    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.

  11. Die-cast heterophase composites with AlSi13Mg1CuNi matrix

    M. Dyzia

    2010-01-01

    Full Text Available On the basis of the performed tests, an advantageous interaction of glassy carbon particles in a couple consisting of a heterophase composite and a spheroidal cast iron has been corroborated. It was found that, the presence of glassy carbon in the heterophase composite (SiC+C affects the stabilization of the friction coefficient value as a function of the friction distance and reduces the intensity of the wearing-in stage of the interacting surfaces. Both a decrease of the friction coefficient and the wear of the heterophase composites may be connected with the carbon particles' chipping effect and the deposition of its fragments on the surface of the interacting components of the friction couple, which forms a kind of a solid lubricating agent in the system. This should allow applying of this material to the composite piston - cylinder sleeve system in piston air-compressors. Further works will concern the selection of the matrix alloy composition with the purpose of reducing the phenomenon of particles chipping during machining. It seems that one of the possibilities is the application of a more plastic matrix and optimizing the fraction of reinforcing phases and their gradient distribution in the casting.

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

    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.

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

    Kotas, Petr; Hattel, Jesper Henri; Thorborg, Jesper

    2009-01-01

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

  14. The effect of natural pre-ageing on the mechanical properties of Rheo-High pressure die cast aluminium alloy 2139

    Chauke, L

    2015-07-01

    Full Text Available -high pressure die casting process (R-HPDC). Alloy 2139 is a Ag-containing aluminium alloy from the Al-Cu-Mg 2xxx series family. The addition of Ag enhances the age hardening response through the formation of co-clusters that act as precursors to the formation...

  15. The Influence of Pressure Die Casting Parameters on the Mechanical Properties of AlSi11/10 Vol.% SiC Composite

    Konopka Z.

    2014-03-01

    Full Text Available The paper presents the method of preparing a composite slurry composed of AlSi11 alloy matrix and 10 vol.% of SiC particles, as well as the method of its high-pressure die casting and the measurement results concerning the tensile strength, the yield point, the elongation and hardness of the obtained composite. Composite castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. There were found the regression equations describing the change of mechanical properties of the examined composite as a function of pressure die casting process parameters. The conclusion gives the analysis and the interpretation of the obtained results.

  16. The Influence of Pressure Die Casting Parameters on Distribution of Reinforcing Particles in the AlSi11/10% SiC Composite

    Pasieka A.

    2013-09-01

    Full Text Available The method of pressure die casting of composites with AlSi11 alloy matrix reinforced with 10 vol. % of SiC particles and the analysis of the distribution of particles within the matrix is presented. The composite castings were produced at various values of the piston velocity in the second stage of injection, at diverse intensification pressure values, and various injection gate width values. The distribution of particles over the entire cross-section of the tensile specimen is shown. The index of distribution was determined on the basis of particle count in elementary measuring fields. The regression equation describing the change of the considered index was found as a function of the pressure die casting parameters. The conclusion presents an analysis of the obtained results and their interpretation.

  17. Dimensional Evaluation of Stone Die from Irreversíble Hydrocolloid Impression afther Disinfection Avaliação Dimensional de Troquéis de Gesso Obtidos de Moldes de Hidrocolóide Irreversível após Desinfecção

    Marcos Frossard

    2004-10-01

    Full Text Available During routine molding procedures in Dentistry, the material gets in touch with oral fluids such as blood, saliva, exudates and others, which can carry pathogenic microorganisms that cause contagious diseases such us herpes, hepatitis, tuberculosis, AIDS, among others. Disinfection by immersing the molds in chemical solutions has been adopted. This work evaluated dimensional alterations in casts obtained from an irreversible hydrocolloid, after disinfection. A molding device with a standard metallic die representing the tooth ready to receive the crown was used during the evaluation. The molds were then immersed in deionized water and gluteraldehyde at 2% for 30 minutes. Only the control group was not immersed: they were poured in a special type IV (Durone, immediately after being taken. A special standard metallic crown, which adapted itself to the referred casts, was used to evaluate their dimensions. The combination die plus standard crown was submitted to a microscopic analysis by a depth microscope. Data from the evaluation were submitted to a statistical analysis, and the results showed no statistically difference among the groups studied. Nos procedimentos de moldagens, rotineiramente executados em Odontologia, os materiais entram em contacto com fluidos bucais, como: sangue, saliva, exudatos e outros que podem conter microorganismos patogênicos e, pelos moldes, podem transmitir doenças infecto-contagiosas como: herpes, hepatite, tuberculose, AIDS, dentre outras. O tratamento por imersão desses moldes em substâncias químicas, tem sido adotado no sentido de promover a desinfecção dos mesmos. Este trabalho avaliou a alteração dimensional de troquéis de gesso obtidos de moldes de hidrocolóide irreversível (alginato, após desinfecção. Utilizou-se, para isso, um dispositivo de moldagem que contém um troquel-padrão metálico, representando um dente preparado para receber uma coroa. Após a obtenção dos moldes, os mesmos foram

  18. CASTING APPARATUS

    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.

  19. Large Eddy Simulations of Electromagnetic Braking Effects on Argon Bubble Transport and Capture in a Steel Continuous Casting Mold

    Jin, Kai; Vanka, Surya P.; Thomas, Brian G.

    2018-06-01

    In continuous casting of steel, argon gas is often injected to prevent clogging of the nozzle, but the bubbles affect the flow pattern, and may become entrapped to form defects in the final product. Further, an electromagnetic field is frequently applied to induce a braking effect on the flow field and modify the inclusion transport. In this study, a previously validated GPU-based in-house code CUFLOW is used to investigate the effect of electromagnetic braking on turbulent flow, bubble transport, and capture. Well-resolved large eddy simulations are combined with two-way coupled Lagrangian computations of the bubbles. The drag coefficient on the bubbles is modified to account for the effects of the magnetic field. The distribution of the argon bubbles, capture, and escape rates, are presented and compared with and without the magnetic field. The bubble capture patterns are also compared with results of a previous RANS model as well as with plant measurements.

  20. Morphology transition of the primary silicon particles in a hypereutectic A390 alloy in high pressure die casting.

    Wang, J; Guo, Z; Song, J L; Hu, W X; Li, J C; Xiong, S M

    2017-11-03

    The microstructure of a high-pressure die-cast hypereutectic A390 alloy, including PSPs, pores, α-Al grains and Cu-rich phases, was characterized using synchrotron X-ray tomography, together with SEM, TEM and EBSD. The Cu-rich phases exhibited a net morphology and distributed at the boundaries of the α-Al grains, which in turn surrounded the PSPs. Statistical analysis of the reconstructed 1000 PSPs showed that both equivalent diameter and shape factor of the PSPs exhibited a unimodal distribution with peaks corresponding to 25 μm and 0.78, respectively.) PSPs morphology with multiple twinning were observed and morphological or growth transition of the PSPs from regular octahedral shape (with a shape factor of 0.85 was mainly caused by the constraint of the Cu-rich phases. In particular, the presence of the Cu-rich phases restricted the growth of the α-Al grains, inducing stress on the internal silicon particles, which caused multiple twinning occurrence with higher growth potential and consequently led to growth transitions of the PSPs.

  1. Microstructure, Tensile Properties, and Corrosion Behavior of Die-Cast Mg-7Al-1Ca- xSn Alloys

    Wang, Feng; Dong, Haikuo; Sun, Shijie; Wang, Zhi; Mao, Pingli; Liu, Zheng

    2018-02-01

    The microstructure, tensile properties, and corrosion behavior of die-cast Mg-7Al-1Ca- xSn ( x = 0, 0.5, 1.0, and 2.0 wt.%) alloys were studied using OM, SEM/EDS, tensile test, weight loss test, and electrochemical test. The experimental results showed that Sn addition effectively refined grains and intermetallic phases and increased the amount of intermetallic phases. Meanwhile, Sn addition to the alloys suppressed the formation of the (Mg,Al)2Ca phase and resulted in the formation of the ternary CaMgSn phase and the binary Mg2Sn phase. The Mg-7Al-1Ca-0.5Sn alloy exhibited best tensile properties at room temperature, while Mg-7Al-1Ca-1.0Sn alloy exhibited best tensile properties at elevated temperature. The corrosion resistance of studied alloys was improved by the Sn addition, and the Mg-7Al-1Ca-0.5Sn alloy presented the best corrosion resistance.

  2. Vacuum Die Casting Process and Simulation for Manufacturing 0.8 mm-Thick Aluminum Plate with Four Maze Shapes

    Chul Kyu Jin

    2015-02-01

    Full Text Available Using vacuum die casting, 0.8 mm-thick plates in complicated shapes are manufactured with the highly castable aluminum alloy Silafont-36 (AlSi9MgMn. The sizes and shapes of the cavities, made of thin plates, feature four different mazes. To investigate formability and mechanical properties by shot condition, a total of six parameters (melt temperatures of 730 °C and 710 °C; plunger speeds of 3.0 m/s and 2.5 m/s; vacuum pressure of 250 mbar and no vacuum are varied in experiments, and corresponding simulations are performed. Simulation results obtained through MAGMA software show similar tendencies to those of the experiments. When the melt pouring temperature is set to 730 °C rather than 710 °C, formability and mechanical properties are superior, and when the plunger speed is set to 3.0 m/s rather than to 2.5 m/s, a fine, even structure is obtained with better mechanical properties. The non-vacuumed sample is half unfilled. The tensile strength and elongation of the sample fabricated under a melt temperature of 730 °C, plunger speed of 3.0 m/s, and vacuum pressure of 250 mbar are 265 MPa and 8.5%, respectively.

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

    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.

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

    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.

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

    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.

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

    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.

  7. Effect of substituting cerium-rich mischmetal with lanthanum on high temperature properties of die-cast Mg-Zn-Al-Ca-RE alloys

    Anyanwu, Ifeanyi A.; Gokan, Yasuhiro; Suzuki, Atsuya; Kamado, Shigeharu; Kojima, Yo; Takeda, Suguru; Ishida, Taketoshi

    2004-01-01

    Mg-Zn-Al-Ca-RE alloys have been found to be promising materials for substituting aluminum alloys used for automatic transmission case applications in the automobile industry. Particularly, Mg-0.5%Zn-6%Al-1%Ca-3%RE (ZAXE05613) alloy exhibits comparable creep resistance as ADC12 die-casting aluminum alloy that is currently used for automatic transmission case applications. Changing the rare earth (RE) content of the alloy from mischmetal to lanthanum gives a further improvement in the creep properties of the alloy. Lanthanum addition results in the crystallization of a large amount of acicular Al 11 RE 3 (Al 11 La 3 ) compound along the grain boundaries as well as across the grain boundaries and this effectively controls grain boundary sliding and dislocation motion in the vicinity of the grain boundaries. As a result, die-cast ZAXLa05613 alloy exhibits a higher creep resistance than that of ZAXE05613 alloy

  8. Endurance in Al Alloy Melts and Wear Resistance of Titanium Matrix Composite Shot-Sleeve for Aluminum Alloy Die-casting

    Choi, Bong-Jae; Kim, Young-Jig; Sung, Si-Young

    2012-01-01

    The main purpose of this study was to evaluate the endurance against Al alloy melts and wear resistance of an in-situ synthesized titanium matrix composite (TMC) sleeve for aluminum alloy die-casting. The conventional die-casting shot sleeve material was STD61 tool steel. TMCs have great thermal stability, wear and oxidation resistance. The in-situ reaction between Ti and B4C leads to two kinds of thermodynamically stable reinforcements, such as TiBw and TiCp. To evaluate the feasibility of the application to a TMCs diecasting shot sleeve, the interfacial reaction behavior was examined between Al alloys melts with TMCs and STD61 tool steel. The pin-on-disk type dry sliding wear test was also investigated for TMCs and STD61 tool steel.

  9. Procedure of a secure design calculation for transmission housings made of aluminium die cast; Ablauf einer sicheren Auslegungsberechnung von Getriebegehaeusen aus Aluminiumdruckguss

    Varenkamp, Marco; Schoen, Michael [ZF Friedrichshafen AG, Friedrichshafen (Germany). Fachbereich Berechnung und Simulation

    2011-07-01

    The challenges in life time calculation of transmission housings made of aluminium die cast are on the one hand the complex geometry of the parts and on the other hand the defects in the material such as pores resulting from the die-cast process. The calculations are carried out using the finite element method and the local strain approach. The problem of transferability within the local strain approach is mastered by comparison with component tests and improvement of the transfer functions based on statistical evaluation. The secure design is assured by a safety factor derived from the confidence probability. With the help of an example the procedure will be explained. In addition it will be shown that under uniaxial variable amplitude loading the calculation result can be improved using the damage parameter PJ. (orig.)

  10. A new approach to assess the effects of Sr and Bi interaction in ADC12 Al–Si die casting alloy

    Farahany, Saeed, E-mail: saeedfarahany@gmail.com; Ourdjini, Ali; Abu Bakar, Tuty Asma; Idris, Mohd Hasbullah

    2014-01-10

    Highlights: • Interactive effect between Bi and Sr has been invesitigated comprehensively. • Sequence of addition did not affect thermal and microscopical characteristics. • A new map has been established to assess the final microstructure of castings. - Abstract: In the present paper, the possible interaction between bismuth and strontium in ADC12 die casting alloy was investigated comprehensively by using in situ thermal analysis technique. The characteristic temperatures including nucleation, minimum and growth temperatures of eutectic Al–Si were also analyzed. The results show that with Bi present in the Al–Si alloy melt the efficiency of Sr in modifying the eutectic Si is reduced. A threshold Sr/Bi ratio of at least 0.5 is required for a fully modified Si structure to form. A new map based on the characteristic temperatures, Sr/Bi ratio and microstructure, was established to assess the microstructure of fully solidified Al–Si castings.

  11. A new approach to assess the effects of Sr and Bi interaction in ADC12 Al–Si die casting alloy

    Farahany, Saeed; Ourdjini, Ali; Abu Bakar, Tuty Asma; Idris, Mohd Hasbullah

    2014-01-01

    Highlights: • Interactive effect between Bi and Sr has been invesitigated comprehensively. • Sequence of addition did not affect thermal and microscopical characteristics. • A new map has been established to assess the final microstructure of castings. - Abstract: In the present paper, the possible interaction between bismuth and strontium in ADC12 die casting alloy was investigated comprehensively by using in situ thermal analysis technique. The characteristic temperatures including nucleation, minimum and growth temperatures of eutectic Al–Si were also analyzed. The results show that with Bi present in the Al–Si alloy melt the efficiency of Sr in modifying the eutectic Si is reduced. A threshold Sr/Bi ratio of at least 0.5 is required for a fully modified Si structure to form. A new map based on the characteristic temperatures, Sr/Bi ratio and microstructure, was established to assess the microstructure of fully solidified Al–Si castings

  12. Correlations Between Arrangement of Reinforcing Particles and Mechanical Properties in Pressure Die Cast AlSi11-SiC Composites

    Konopka Z.

    2014-06-01

    Full Text Available The work presents the investigation results concerning the structure of composite pressure die castings with AlSi11 alloy matrix reinforced with SiC particles. Examination has been held for composites containing 10 and 20 volume percent of SiC particles. The arrangement of the reinforcing particles within the matrix has been qualitatively assessed in specimens cut out of the castings. The index of distribution was determined on the basis of particle count in elementary measuring fields. The tensile strength, the yield point and elongation of the obtained composite were measured. Composite castings were produced at various values of the piston velocity in the second stage of injection, diverse intensification pressure values, and various injection gate width values. The regression equation describing the change of the considered arrangement particles index and mechanical properties were found as a function of the pressure die casting parameters. The infuence of particle arrangement in composite matrix on mechanical properties these material was examined and the functions of correlations between values were obtained. The conclusion gives the analysis and the interpretation of the obtained results.

  13. 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

    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

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

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

    2018-01-01

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

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

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

    2018-05-01

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

  16. The Effect of Water Mist Cooling of Casting Die on the Solidification, Microstructure and Properties of AlSi20 Alloy

    Władysiak R.

    2017-03-01

    Full Text Available Unmodified AlSi20 alloy were casted at the research station, allowing for sequential multipoint cooling using a dedicated computer- controlled program. This method allows for the formation of the microstructure of hypereutectic AlSi20 alloy and also increases hardness. Primary silicon dendrites were found in the microstructure of cooled samples. Based on these dendrites, the formation of primary silicon particles is explained. Cooling of casting die with a water mist stream causes changes in solidification, which leads to expansion of the boundary layer with columnar crystals and shrinkage of the core zone with equiaxed crystals. It also causes more regular hardness distribution around pre-eutectic Si crystals, which can lead to tensile strength and machinability improvement.

  17. Improved life of die casting dies of H13 steel by attaining improved mechanical properties and distortion control during heat treatment. Year 1 report, October 1994--September 1995

    Wallace, J.F.; Schwam, D. [Case Western Reserve Univ., Cleveland, OH (United States)

    1995-03-01

    Optimum heat treatment of dies (quenching) is critical in ensuring satisfactory service performance: rapid cooling rates increase the thermal fatigue/heat checking resistance of the steel, although very fast cooling rates can also lead to distortion and lower fracture toughness, increasing the danger of catastrophic fracture. Goal of this project is to increase die life by using fast enough quenching rates (> 30 F/min ave cooling rate from 1750 to 550 F, 1/2 in. below working surfaces) to obtain good toughness and fatigue resistance in Premium grade H-13 steel dies. An iterative approach of computer modeling validated by experiment was taken. Cooling curves during gas quenching of H-13 blocks and die shapes were measured under 2, 5, and 7.5 bar N2 and 4 bar Ar. Resulting dimensional changes and residual stresses were determined. To facilitate the computer modeling work, a database of H-13 mechanical and physical properties was compiled. Finite element analysis of the heat treated shapes was conducted. Good fit of modeled vs measured quenched rates was demonstrated for simple die shapes. The models predict well the phase transformation products from the quench. There is good fit between predicted and measured distortion contours; however magnitude of predicted distortion and residual stresses does not match well the measured values. Further fine tuning of the model is required.

  18. Investigation of microporosity in die-cast AlSi12(Cu) alloys by neutron- and X-ray radiography

    Zsolt, S.; Marton, B.

    1999-01-01

    The porosity of the casting can dramatically reduce the solidity and reliability of the objects made from aluminum alloys. The X-ray radiography is able to find the placement of the porosity of the aluminum devices. After a special 'water saturation' process the dynamic neutron radiography is available to discover the 'dangerous' surface nearporosity in the aluminum samples. The X-ray and neutron radiography were used as complementary examination techniques to study the porosity of the aluminum castings.(author)

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

    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.

  20. Simulation and experimental verification of the filling process of semi-solid die forging for cup shell

    Jianbo TAN; Zichao WANG; Dongxu WANG

    2015-01-01

    The filling mold process of semi-solid alloy blank influences severely the forming and properties of finished piece. In this paper, DEFORM is applied to simulate the process of cup-type 6061 alloy die forging casting. The influences of the temperature of semi-solid alloy blank, preheating temperature, and downward press speed of pressure head on process of mold filling and velocity field are investigated. The results show that the mold filling of semi-solid alloy paste smoothly fills along th...

  1. Microstructural and mechanical properties of gravity-die-cast A356 alloy inoculated with yttrium and Al-Ti-B grain refiner simultaneously

    Y.P. Lim

    2011-10-01

    Full Text Available In the present work, the effect of inoculating yttrium and Al-5Ti-1B simultaneously on A356 aluminum alloy has been studied. Gravity die casting process is used to cast the ASTM tensile test specimens for analysis. In each experiment, the Ti and B contents were maintained constantly at 0.1 and 0.02 wt% respectively. The addition of yttrium was manipulated at the amount of 0, 0.1, 0.2, 0.3, 0.4 and 0.5 wt%. Microstructural characterization of the as-cast A356 alloy was investigated by means of optical microscope and its phases are detected by XRD. The mechanical properties tested are tensile strength and hardness. The inoculation of yttrium was found to enhance the grain refinement effect of Al-5Ti-1B grain refiner and improve the mechanical properties. The optimal weight percentage of yttrium was found to be 0.3. The grain refining efficiency of combining yttrium and Al-5Ti-1B on A356 aluminum alloy was mainly attributed to the heterogeneous nucleation of TiB2 and TiAl3 particles which were dispersed more evenly in the presence of yttrium and the grain growth restriction effected by the accumulation of Al-Y compound at grain boundaries.

  2. Microstructure, Mechanical and Surface Morphological Properties of Al5Ti5Cr Master Alloy as Friction Material Prepared by Stir Die Casting

    Ahmed, Syed Faisal; Srivastava, Sanjay; Agarwal, Alka Bani

    2018-04-01

    Metal matrix composite offers outstanding properties for better performance of disc brakes. In the present study, the composite of AlTiCr master alloy was prepared by stir die casting method. The developed material was reinforced with (0-10 wt%) silicon carbide (SiC) and boron carbide (B4C). The effects of SiC reinforcement from 0 to 10 wt% on mechanical, microstructure and surface morphological properties of Al MMC was investigated and compared with B4C reinforcement. Physical properties like density and micro Vickers hardness number show an increasing trend with an increase in the percentage of SiC and B4C reinforcement. Mechanical properties viz. UTS, yield strength and percentage of elongation are improved with increasing the fraction of reinforcement. The surface morphology and phase were identified from scanning electron microscopy (SEM) and X-ray diffraction analysis and the oxidized product formed during the casting was investigated by Fourier transformation infrared spectroscopy. This confirms the presence of crystallization of corundum (α-Al2O3) in small traces as one of the alumina phases, within casting sample. Micro-structural characterization by SEM depicted that the particles tend to be more agglomerated more and more with the percentage of the reinforcement. The AFM results reveal that the surface roughness value shows a decreasing trend with SiC reinforcement while roughness increases with increase the percentage of B4C.

  3. Casting methods

    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.

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

    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...

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

    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)

  6. Assembly optimization realized by a die-cast magnesium construction; Montageverbesserungen verwirklicht durch eine Magnesium-Druckguss-Konstruktion

    Tikal, F.; Vollmer, C.; Pippert, J.

    1996-11-01

    Vehicle development today cannot be envisaged without non-contact and slip free distance- and speed-measurement. As it is superior to contact methods in terms of reliability and accuracy, it has gained more and more acceptance in the past few years and now provides measurement results of the utmost precision. This is particularly necessary in the large application range of tyre and vehicle development to ensure high safety levels; moreover, it is required for future vehicle control systems, as they need precise speed information for ABS, ASC, or for navigation methods. In principle, optical acoustic and microwave sensors can be used for these applications. The microwave sensors can be used for these applications. The microwave-Doppler principle provides certain advantages over optical or ultrasound methods as it can be used under any weather conditions and provides a larger vertical operating range and a long lifespan. Datron-Messtechnik, market leader in the field of correlator optical speed sensors, has made use of this measurement principle and with its microwave sensor introduces a new development covering the great demands of speed measurement. (orig.) [Deutsch] Die Pkw-Tuer, ein Bestandteil der Karosserie, ist im Laufe der Automobilgeschichte nicht wesentlich veraendert worden. Jedoch mussten in den letzten Jahren Flankenschutz, Seitenairbag und andere neue Bauteile in die Tuer integriert werden. Diese Elemente der passiven Sicherheit sind vom Verbraucher gewuenschte Schutzmassnahmen. Mit dem gehobenen Sicherheitsimage bemuehen sich die Produzenten, den potentiellen Kaeufer zum Kauf ihres Produktes zu bewegen. Am Institut fuer Produktionstechnik und Logistik (IPL) der Universitaet Gesamthochschule Kassel (GhK) wurde eine Pkw-Tuer, basierend auf einem Magnesium-Druckgussrahmen, entwickelt. Zur Orientierung und Studienzwecken ist ein Holzmodell erstellt worden. Mit dem praxisnahen Modell konnte die Montage und der Einbau in das Automobil getestet werden. Das

  7. Die-cast of a hypo-eutectic AL-SI alloy: influence of injection temperature on microstructure and mechanical properties; Fundicao sob pressao das ligas de AL-SI: influencia da temperatura de injecao nas microestruturas e propriedades mecanicas

    Santos, Silvano Leal dos; Santos, Sydney Ferreira, E-mail: silvano_lleal@yahoo.com.br [Universidade Federal do ABC (UFABC), SP (Brazil)

    2014-07-01

    Die-casting is widely used for manufacturing light alloy components for automotive industry. Among others, hypo-eutectic Al-Si alloys are currently processed by die-casting. To obtain high quality die-cast components, a better understanding on the correlations between processing parameters, microstructures, and mechanical properties are of utmost importance. In this study, we investigate the effect of injection temperature of liquid metal on the microstructure and mechanical properties of Al-Si alloy EN AC 46000 (DIN designation). The injection temperatures were 579, 589, 643, and 709 deg C. As-cast components had their microstructures analyzed by X-ray diffraction, optical and scanning electron microscopy, and X-ray energy dispersive spectroscopy. The mechanical properties were examined by micro-hardness and tensile tests. It was observed that the ultimate tensile strength slightly increased with the increase of injection temperature. The same trend was observed for micro-hardness. The amount of porosity in the samples varies in a small amount for different injection temperatures. On the other hand, the microstructure of the alloys seems more refined for higher temperatures of injection. This refinement in microstructure might play a major role on the mechanical properties of the Al-Si die-cast alloy. (author)

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

    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

  9. Effect of Heat Treatment on Commercial AlSi12Cu1(Fe) and AlSi12(b) Aluminum Alloy Die Castings

    Battaglia, E.; Bonollo, F.; Ferro, P.; Fabrizi, A.

    2018-03-01

    High-pressure die castings (HPDCs) cannot normally be heat-treated at a high temperature because of the presence of inner air/gas- or shrinkage-porosity that may lead to the formation of undesired surface blisters. In this paper, an unconventional heat treatment is proposed. Two secondary Al-Si alloys, AlSi12(b) and AlSi12Cu1(Fe), were stabilization heat-treated at 624 K (350 °C) with soaking times ranging from 1 to 8 hours. Enhancement of both static and dynamic mechanical properties was found to be related to the fragmentation of interconnected eutectic Si particles and the smoothing of coarser crystals. Increased ductility after heat treatment was correlated with a decrease in hardness and Si particle roundness. The formation of Si precipitates within the α-Al matrix was also observed.

  10. MATERIALS FOR PRODUCTION OF METAL MOLDS

    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.

  11. Fan Fuel Casting Final Report

    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.

  12. Developing technological process of obtaining giality casts

    A. Issagulov

    2014-10-01

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

  13. Morphology and Performance of 5Cr5MoV Casting Die Steel in the Process of Surfacing

    Song, Yulai; Kong, Xiangrui; Yang, Pengcong; Fu, Hongde; Wang, Xuezhu

    2017-12-01

    To investigate the microstructures and mechanical properties of the deposited metal on surface of die steel, two layer of weld-seam were prepared on the surface of 5Cr5MoV die steel by arc surfacing. The surface microstructures and microhardness were characterized by scanning electron microscopy, energy dispersive spectrometer and Vickers microhardness tester, respectively. The effect of load on the abrasion resistance and wear mechanism of the base metal and surfacing metal was studied by pin-on-disk tribometer. The results showed that martensite and retained austenite exist in weld-seam, both of them grow up in the form of dendrites and equiaxed grains and microhardness reach 774.2HV. The microstructures of the quenching zone mainly consist of martensite and retained austenite, while tempered martensite is the dominant phase in partial quenching zone. The abrasion resistance of the surfacing metal is superior to the base metal based on the results of wear test. The wear rates of surfacing metal and base metal raise with the increase of load. The wear rates of base metal raise extremely when the load reach 210N. Both of two kinds of materials have the similar wear mechanism, namely, abrasive wear at low load, oxidative wear and adhesive wear at high load.

  14. IMPROVEMENT OF EQUIPMENT FOR EFFECTIVE HARDENING SAND MIXTURE BY VACUUM MOLDING

    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.

  15. A Physical Model to Study the Effects of Nozzle Design on Dispersed Two-Phase Flows in a Slab Mold Casting Ultra-Low-Carbon Steels

    Salazar-Campoy, María M.; Morales, R. D.; Nájera-Bastida, A.; Calderón-Ramos, Ismael; Cedillo-Hernández, Valentín; Delgado-Pureco, J. C.

    2018-04-01

    The effects of nozzle design on dispersed, two-phase flows of the steel-argon system in a slab mold are studied using a water-air model with particle image velocimetry and ultrasound probe velocimetry techniques. Three nozzle designs were tested with the same bore size and different port geometries, including square (S), special bottom design with square ports (U), and circular (C). The meniscus velocities of the liquid increase two- or threefold in two-phase flows regarding one-phase flows using low flow rates of the gas phase. This effect is due to the dragging effects on bubbles by the liquid jets forming two-way coupled flows. Liquid velocities (primary phase) along the narrow face of the mold also are higher for two-phase flows. Flows using nozzle U are less dependent on the effects of the secondary phase (air). The smallest bubble sizes are obtained using nozzle U, which confirms that bubble breakup is dependent on the strain rates of the fluid and dissipation of kinetic energy in the nozzle bottom and port edges. Through dimensionless analysis, it was found that the bubble sizes are inversely proportional to the dissipation rate of the turbulent kinetic energy, ɛ 0.4. A simple expression involving ɛ, surface tension, and density of metal is derived to scale up bubble sizes in water to bubble sizes in steel with different degrees of deoxidation. The validity of water-air models to study steel-argon flows is discussed. Prior works related with experiments to model argon bubbling in steel slab molds under nonwetting conditions are critically reviewed.

  16. Implementation of Molding Constraints in Topology Optimization

    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...

  17. Allergies, asthma, and molds

    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 ...

  18. Casting Characteristics of High Cerium Content Aluminum Alloys

    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.

  19. Synergistic effects of composition and heat treatment on microstructure and properties of vacuum die cast Al-Si-Mg-Mn alloys

    Jun-jie Xu

    2018-03-01

    Full Text Available The purpose of this study was to prepare high-quality Al-Si-Mg-Mn alloy with a good combination of strength and ductility employing the vacuum-assisted high-pressure die cast process. An orthogonal study of heat treatments was conducted to design an optimized T6 heat treatment process for both Al-10%Si-0.3%Mg-Mn and Al-11%Si-0.6%Mg-Mn alloys. The results demonstrate that no obvious blisters and warpage were observed in these two alloys with solid solution treatment. After the optimal T6 heat treatment of 530°C×3h + 165°C×6h, Al-11%Si-0.6%Mg-Mn alloy has better mechanical properties, of which tensile strength, yield strength and elongation reached 377.3 MPa, 307.8 MPa and 9%, respectively. The improvement of mechanical properties can be attributed to the high density of needle-like β″(Mg5Si6 precipitation after aging treatment and the fine and spherical eutectic Si particles uniformly distributed in the α-Al matrix.

  20. On the microstructural factors affecting creep resistance of die-cast Mg–La-rare earth (Nd, Y or Gd) alloys

    Gavras, S. [Magnesium Innovation Centre, Helmholtz-Zentrum Geesthacht, Max-Planck-Straße 1, Geesthacht (Germany); Zhu, S.M. [School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, Carlton, Victoria 3053 (Australia); Nie, J.F. [Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); Gibson, M.A. [School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, Carlton, Victoria 3053 (Australia); Department of Materials Science and Engineering, Monash University, Victoria 3800 (Australia); CSIRO Manufacturing, Clayton, Victoria 3168 (Australia); Easton, M.A. [School of Aerospace, Mechanical and Manufacturing Engineering, RMIT University, Carlton, Victoria 3053 (Australia)

    2016-10-15

    Creep properties of high-pressure die-cast Mg–La-RE (Nd, Y or Gd) alloys, varying in ternary RE additions and in different heat treatment conditions, have been investigated. Through the use of short-term solution treatments (1 h at 520 °C) it was shown that the continuous intermetallic phase present in the eutectic at grain boundaries became discontinuous. This effect, in combination with the likely removal of the localised region of supersaturated solute in solid solution near grain boundaries, reduced the creep resistance. When relatively high concentrations of ternary alloying additions were used, solid solution strengthening and precipitation hardening appeared to compensate for the negative effect of reduced grain boundary reinforcement. Microstructural investigation revealed that Nd-containing alloys had fewer and larger dynamic precipitates present in the α-Mg matrix following creep testing at 177 °C and 90 MPa. It was concluded that grain boundary reinforcement in combination with the thermal stability of the precipitates formed, which is ultimately related to the diffusivity of solute in solid solution, are also contributing factors to creep resistance.

  1. Strengthening effect of nano-scale precipitates in a die-cast Mg–4Al–5.6Sm–0.3Mn alloy

    Yang, Qiang [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China); Bu, Fanqiang [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China); University of Chinese Academy of Sciences, Beijing 100049 (China); Qiu, Xin [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China); Yangzhou Hongfu Aluminium Co. Ltd, Yangzhou 100049 (China); Li, Yangde; Li, Weirong [E-ande Scientific & Technology Co. Ltd, Dongguan 523000 (China); Sun, Wei [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China); Liu, Xiaojuan, E-mail: lxjuan@ciac.ac.cn [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China); Meng, Jian, E-mail: jmeng@ciac.jl.cn [State Key Laboratory of Rare Earth Resource Utilization, Changchun Institute of Applied Chemistry, Chinese Academy of Sciences, Changchun 130022 (China)

    2016-04-25

    In this paper we report a quantitative study of the age-hardening in the high-pressure die-cast Mg–4Al−5.6Sm−0.3Mn alloy. The results indicate that a number of nano-scale spherical precipitates identified as Al{sub 3}Sm using high-angle annular dark-field scanning transmission electron microscopy, precipitated in Mg matrix after aging at 150–225 °C, with no obvious changes on grain sizes, intermetallic phases formed during solidification, and dislocation densities. From the existing strengthening theory equations in which some lacking parameters were taken from the first-principles density functional theory (DFT) calculations, a quantitative insight into the strengthening mechanisms of the nano-scale precipitate was formulated. The results are in reasonable agreement with the experimental values, and the operative mechanism of precipitation strengthening was revealed as Orowan dislocation bypassing. - Highlights: • The yield strength of Mg–Al–Sm alloy was improved by aging treatment. • A number of nano-scale precipitates formed in matrix after aging treatments. • The nanoscale precipitate was confirmed as Al{sub 3}Sm based on the data of HAADF-STEM study. • The strengthening mechanisms of the nano-scale precipitate were quantitatively formulated. • The operative mechanism of precipitate strengthening is Orowan dislocation bypassing.

  2. Corrosion Behavior of High Pressure Die Cast Al-Ni and Al-Ni-Ca Alloys in 3.5% NaCl Solution

    Arthanari, Srinivasan; Jang, Jae Cheol; Shin, Kwang Seon [Seoul National University, Seoul (Korea, Republic of)

    2017-06-15

    In this investigation corrosion behavior of newly developed high-pressure die cast Al-Ni (N15) and Al-Ni-Ca (NX1503) alloys was studied in 3.5% NaCl solution. The electrochemical corrosion behavior was evaluated using open circuit potential (OCP) measurement, potentiodynamic polarization, and electrochemical impedance spectroscopy (EIS) techniques. Potentiodynamic polarization results validated that NX1503 alloy exhibited lower corrosion current density (i{sub corr}) value (5.969 μA/cm{sup 2}) compared to N15 (7.387 μA/cm{sup 2}). EIS-Bode plots revealed a higher impedance (|Z|) value and maximum phase angle value for NX1503 than N15 alloy. Equivalent circuit curve fitting analysis revealed that surface layer (R{sub 1}) and charge transfer resistance (R{sub ct}) values of NX1503 alloy was higher compared to N15 alloy. Immersion corrosion studies were also conducted for alloys using fishing line specimen arrangement to simultaneously measure corrosion rates from weight loss (P{sub W}) and hydrogen volume (P{sub H}) after 72 hours and NX1503 alloy had lower corrosion rate compared to N15 alloy. The addition of Ca to N15 alloy significantly reduced the Al{sub 3}Ni intermetallic phase and further grain refinement may be attributed for reduction in the corrosion rate.

  3. HFIR Fuel Casting Support

    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.

  4. Method for casting thin metal objects

    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.

  5. Compound cast product and method for producing a compound cast product

    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).

  6. Microstructure and property evaluation of high-pressure die-cast Mg–La–rare earth (Nd, Y or Gd) alloys

    Gavras, Serge; Easton, Mark A.; Gibson, Mark A.; Zhu, Suming; Nie, Jian-Feng

    2014-01-01

    Highlights: • Different rare earth elements have remarkably different effects on Mg castability. • For the addition of each RE element, the alloy castability follows a unique pattern. • The effects of RE elements on the castability can be modelled. - Abstract: Microstructure, castability and tensile properties were investigated in high-pressure die-cast Mg–La–Nd, Mg–La–Y and Mg–La–Gd alloy series, with a constant La concentration at approximately 2.5 wt.% and the concentrations of Nd, Y or Gd were varied. All three alloy series had a dendritic microstructure with a Mg–La-rich eutectic with increasing Nd, Y or Gd content and containing a Mg 12 RE intermetallic phase. The morphology of the eutectic at ternary alloying additions of equal to or less than 1.0 wt.% was lamellar but became increasingly divorced at higher ternary concentrations. This was however more obvious in Mg–La–Y and Mg–La–Gd than Mg–La–Nd alloys. The hot tearing susceptibility in all three alloy series increased markedly with even micro-alloying additions of Nd, Y or Gd, and began to decrease again in alloys with more than 0.5 wt.% Y or 1.0 wt.% Gd, but did not decrease significantly for Mg–La–Nd. A model using the temperature–fraction solid curves as input parameters was used to estimate hot tearing susceptibility for Mg–La–Nd alloys. Tensile testing at room temperature showed that Mg–La–Nd alloy series had higher 0.2% proof stress and lower elongation to failure than either the Mg–La–Y or the Mg–La–Gd alloy series for Nd concentrations greater than 1 wt.% due to a greater effectiveness of grain boundary reinforcement

  7. Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route.

    Hangai, Yoshihiko; Kamada, Hiroto; Utsunomiya, Takao; Kitahara, Soichiro; Kuwazuru, Osamu; Yoshikawa, Nobuhiro

    2014-03-21

    Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%-78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT) observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE) analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

  8. Tensile Properties and Fracture Behavior of Aluminum Alloy Foam Fabricated from Die Castings without Using Blowing Agent by Friction Stir Processing Route

    Yoshihiko Hangai

    2014-03-01

    Full Text Available Al foam has been used in a wide range of applications owing to its light weight, high energy absorption and high sound insulation. One of the promising processes for fabricating Al foam involves the use of a foamable precursor. In this study, ADC12 Al foams with porosities of 67%–78% were fabricated from Al alloy die castings without using a blowing agent by the friction stir processing route. The pore structure and tensile properties of the ADC12 foams were investigated and compared with those of commercially available ALPORAS. From X-ray computed tomography (X-ray CT observations of the pore structure of ADC12 foams, it was found that they have smaller pores with a narrower distribution than those in ALPORAS. Tensile tests on the ADC12 foams indicated that as their porosity increased, the tensile strength and tensile strain decreased, with strong relation between the porosity, tensile strength, and tensile strain. ADC12 foams exhibited brittle fracture, whereas ALPORAS exhibited ductile fracture, which is due to the nature of the Al alloy used as the base material of the foams. By image-based finite element (FE analysis using X-ray CT images corresponding to the tensile tests on ADC12 foams, it was shown that the fracture path of ADC12 foams observed in tensile tests and the regions of high stress obtained from FE analysis correspond to each other. Therefore, it is considered that the fracture behavior of ADC12 foams in relation to their pore structure distribution can be investigated by image-based FE analysis.

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

    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.

  10. Molds in the Environment

    ... 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, ...

  11. CASTING METHOD AND APPARATUS

    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.

  12. Casting thermal simulation

    Shamsuddin bin Sulaiman

    1994-01-01

    The whole of this study is concerned with process simulation in casting processes. This study describes the application of the finite element method as an aid to simulating the thermal design of a high pressure die casting die by analysing the cooling transients in the casting cycle. Two types of investigation were carried out to model the linear and non-linear cooling behavior with consideration of a thermal interface effect. The simulated cooling for different stages were presented in temperature contour form. These illustrate the successful application of the Finite Element Method to model the process and they illustrate the significance of the thermal interface at low pressure

  13. Cast irons

    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...

  14. An eco design strategy for high pressure die casting components: microstructural analysis applied to mass reducing processes; Una estrategia de ecodiseno de piezas obtenidas mediante moldeo a presion: analisis microestructrual aplicado a la desmaterializacion

    Suarez-Pena, B.; Asensio-Lozano, J.

    2009-07-01

    In this work the study focused on the possibility of use of new aluminium alloys with optimized microstructures that ensure the mechanical properties requested for cast components made by high pressure die casting. The objective was to check the possibility of manufacture of structurally sound eco-steps for escalators with reduced structural integrity. The former arises as a result of a new redesign of the traditional steps aiming at a significant weight reduction. The experimental results show that it is feasible to cut the use of materials during processing and therefore to reduce the impact of the components during its lifetime, whilst the performance and safety standards are kept identical or even improved. (Author) 17 refs.

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

    Reji P Gopalan

    2018-01-01

    Conclusion: The marginal adaptation of all the three materials used, was well within the acceptable range of 25–70 μm. The resin pattern materials studied revealed significantly less dimensional change than inlay casting wax on storage at 1, 12, and 24 h time intervals. They may be employed in situations where high precision and delayed investing is expected.

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

    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

  17. Casting AISI 316 steel by gel cast

    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)

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

    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.

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

    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...

  20. Mold production for polymer optics

    Boerret, Rainer; Raab, Jonas; Speich, Marco

    2014-09-01

    The fields of application for polymer optics are huge and thus the need for polymer optics is steadily growing. Most polymer optics are produced in high numbers by injection molding. Therefore molds and dies that fulfill special requirements are needed. Polishing is usually the last process in the common process chain for production of molds for polymer optics. Usually this process step is done manually by experienced polishers. Due to the small number of skilled professionals and health problems because of the monotonous work the idea was to support or probably supersede manual polishing. Polishing using an industrial robot as movement system enables totally new possibilities in automated polishing. This work focuses on the surface generation with a newly designed polishing setup and on the code generation for the robot movement. The process starts on ground surfaces and with different tools and polishing agents surfaces that fulfill the requirements for injection molding of optics can be achieved. To achieve this the attention has to be focused not only on the process itself but also on tool path generation. A proprietary software developed in the Centre for Optical Technologies in Aalen University allows the tool path generation on almost any surface. This allows the usage of the newly developed polishing processes on different surfaces and enables an easy adaption. Details of process and software development will be presented as well as results from different polishing tests on different surfaces.

  1. die rol van die unieverdedigingsmag in die onderdrukking van die

    agv regeringsoptrede nie.39. Siotsom. In die geskiedenis van die Unieverdedigings- mag word die gebeure random die 1914-staking oorskadu deur die Rebellie en Suid-Afrika se deelname aan die Eerste Wereldoorlog. Tog was dit 'n belangrike mylpaal in die geskiedenis van die organisasie, omdat dit sy eerste optrede ...

  2. Casting Freedom, 1860-1862

    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…

  3. Determining casting defects in near-net shape casting aluminum parts by computed tomography

    Li, Jiehua; Oberdorfer, Bernd; Habe, Daniel; Schumacher, Peter

    2018-03-01

    Three types of near-net shape casting aluminum parts were investigated by computed tomography to determine casting defects and evaluate quality. The first, second, and third parts were produced by low-pressure die casting (Al-12Si-0.8Cu-0.5Fe-0.9Mg-0.7Ni-0.2Zn alloy), die casting (A356, Al-7Si-0.3Mg), and semi-solid casting (A356, Al-7Si-0.3Mg), respectively. Unlike die casting (second part), low-pressure die casting (first part) significantly reduced the formation of casting defects (i.e., porosity) due to its smooth filling and solidification under pressure. No significant casting defect was observed in the third part, and this absence of defects indicates that semi-solid casting could produce high-quality near-net shape casting aluminum parts. Moreover, casting defects were mostly distributed along the eutectic grain boundaries. This finding reveals that refinement of eutectic grains is necessary to optimize the distribution of casting defects and reduce their size. This investigation demonstrated that computed tomography is an efficient method to determine casting defects in near-net shape casting aluminum parts.

  4. Quality Management and Control of Low Pressure Cast Aluminum Alloy

    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.

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

    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.

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

    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.

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

    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.

  8. Floods and Mold Growth

    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.

  9. Numerical optimization of die geometry in open die forging

    Christiansen, Peter; Hattel, Jesper Henri; Bay, Niels

    2013-01-01

    This paper deals with numerical optimization of open die forging of large metallic ingots made by casting implying risk of defects, e.g. central pores. Different material hardening properties and die geometries are combined in order to investigate, which geometry gives rise to maximum closure...

  10. Interactive Mold House Tour

    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.

  11. Effect of Contact Time on Interface Reaction between Aluminum Silicon (7% and 11% Alloy and Steel Dies SKD 61

    Bambang Suharno

    2010-10-01

    Full Text Available Die soldering (die sticking is a defect of metal casting in which molten metal “welds” to the metallic die mold surface during casting process. Die soldering is the result of an interface reaction between the molten aluminum and the die material. Aluminum alloy with 7 and 11% silicon and SKD 61 die steel are the most common melt and die material used in aluminum die casting. This research is done to study the morphology and the characteristics of the formed AlxFeySiz intermetallic layer during interface reaction at dipping test. The samples of as-anneal SKD 61 tool steel was dipped into the molten of Al-7%Si held at temperature 680oC and into molten Al-11%Si held at temperature 710oC with the different contact time of 10 minutes; 30 minutes; and 50 minutes. The research results showed that the interface reaction can form a compact intermetallic layer with AlxFey phase and a broken intermetallic layer with AlxFeySiz phase on the surface of SKD 61 tool steel. The increasing of the contact time by the immersion of material SKD 61 tool steel in both of molten Al-7%Si and Al-11%Si will increase the thickness of the AlxFeySiz intermetallic layer until an optimum point and then decreasing. The micro hardness of the AlxFeySiz intermetallic layer depends on the content of the iron. Increasing of the iron content in intermetallic layer will increase the micro hardness of the AlxFeySiz. This condition happened because the increasing of Fe content will cause forming of intermetallic AlxFeySiz phase becomes quicker.

  12. Die binding van die konfessie

    P. J. Coetzee

    1970-05-01

    Full Text Available Ons moet waak teen twee uiterstes. Aan die een kant het die dogma as onversoenlike vyand die dogmatisme en aan die ander kant die antidogmatisme — dit hou enersyds die gevaar in van verabsolutering (oorskatting, en ander- syds die gevaar van relativisme (onderskatting.

  13. Die Region braucht die Kultur - die Kultur braucht die Region

    Klemm, Ulrich

    1995-01-01

    Die Region braucht die Kultur - die Kultur braucht die Region. - In: Region in Aktion - oder: Region im Abseits? - Boxberg-Wölchingen : Eigenständige Regionalentwicklung Baden-Württemberg, 1995. - S. 25 f.

  14. Comparison in processing routes by copper mold casting injection and suction in the Cu{sub 46}Zr{sub 42}Al{sub 7}Y{sub 5} vitreous alloy; Comparacao entre as rotas de processamento por fundicao com injecao e com succao da liga vitrea Cu{sub 46}Zr{sub 42}Al{sub 7}Y{sub 5}

    Batalha, W.; Aliaga, L.C.R.; Bolfarini, C.; Botta, W.J.; Kiminami, C.S. [Universidade Federal de Sao Carlos (UFSCar), SP (Brazil). Departamento de Engenharia de Materiais

    2014-07-01

    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{sub 46}Zr{sub 42}Al{sub 7}Y{sub 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)

  15. 40 CFR 464.40 - Applicability; description of the zinc casting subcategory.

    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...

  16. 40 CFR 464.20 - Applicability; description of the copper casting subcategory.

    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...

  17. 40 CFR 464.30 - Applicability; description of the ferrous casting subcategory.

    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...

  18. 40 CFR 464.10 - Applicability; description of the aluminum casting subcategory.

    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...

  19. FY 2000 report on the results of the regional consortium R and D project - Regional consortium energy R and D field. Third year report. R and D of a working material processing eco system using powder mold-releasing lubricant; 2000 nendo chiiki consortium kenkyu kaihatsu jigyo - chiiki consortium energy kenkyu kaihatsu bun'ya. Funtai rigata junkatsuzai wo mochiita sokeizai kako eco system no kenkyu kaihatsu (dai 3 nendo) seika hokokusho

    NONE

    2001-03-01

    For the purpose of constructing the industry of processing low cost/low environmental load working materials, the development was proceeded with of a block die type powder mold-releasing system. Studies were made in the following 6 fields: 1) optimization/commercialization of new adhesion/flow methods; 2) optimization/commercialization of new powder mold-releasing lubricant; 3) demonstrative experiment and optimization of an eco die cast system; 4) optimization of a powder mold-releasing forging system; 5) application test on the actual mold-releasing lubricant reduction type system; 6) comprehensive investigational study. In 1), studied were a method to integrate the profile of supply pressure of powder conveying air flow and the basic information on adhesion behavior into the practical process, and optimization of powder supply method and supply device control sequence. In 2), the development was made of a sleeve use high thermal insulation type powder mold-releasing lubricant (composed mostly of Al(OH){sub 3}, graphite and wax). This powder mold-releasing lubricant remarkably improved forging ability of the ultra-thin material with 0.4mm thickness and materials with complex shapes and markedly decreased fracture chills. (NEDO)

  20. Modeling of TiAl Alloy Grating by Investment Casting

    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...

  1. The effect of Fe-rich intermetallics on the microstructure, hardness and tensile properties of Al–Mg2Si die-cast composite

    Emamy, M.; Emami, A.R.; Khorshidi, R.; Ghorbani, M.R.

    2013-01-01

    Highlights: ► Effect of Fe on the microstructure and mechanical properties of Al–Mg 2 Si composite. ► Fe changed the size of primary Mg 2 Si from 33 μm to 15 μm. ► Higher hardness, YS, UTS and Quality Index values obtained from Fe addition. ► Different morphologies of Fe-intermetallics were found with higher Fe contents. - Abstract: In present paper, an attempt was made to examine the effect of different concentrations of Fe (0.5, 1, 1.5, 2 and 3 wt.%) on the microstructure and tensile properties of an in situ Al–15wt.%Mg 2 Si metal matrix composite (MMC). The composite was made by casting process and characterized by optical microscope, scanning electron microscope (SEM) equipped with energy dispersive X-ray spectroscopy. The results depicted that the addition of 2 wt.% Fe to the MMC changes the morphology of primary Mg 2 Si from irregular to polyhedral shape and reduces its average particle size from 33 μm to 15 μm. The microstructural studies also showed that the addition of Fe leads to the formation of Fe-rich intermetallics with polyhedral, plate-like and star-like morphology. Hardness results demonstrated that Fe addition to Al–15%Mg 2 Si composite has a positive effect on the hardness improvement. Further investigations on tensile tests revealed optimum Fe (1 wt.%) level for improving tensile properties. In the point of fracture behavior of the composite, Fe-containing specimens showed a brittle mode of failure

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

    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

  3. Die nabyheid van die Koninkryk

    W.J. Snyman

    1963-03-01

    Full Text Available Vanweë die belangrikheid daarvan volg hier ’n breër bespreking van die proefskrif van dr. Tjaart van der Walt oor die nabyheid van die Koninkryk as wat in ’n gewone resensie kan geskied. Die vraagstuk wat onder oë gesien word is so oud as die kerk en die teologie, soms minder en soms meer op die voorgrond. Tans kan gesê word, staan dit in die middelpunt. Daarby is dit nie maar ’n akademiese vraagstuk nie, maar ’n vraagstuk waarvoor elke nadenkende leser van die Skrif te staan kom.

  4. An easy mold

    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.

  5. Optimization of the investment casting process

    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.

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

    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.

  7. Die topkwark

    R. Tegen

    1998-07-01

    Full Text Available ’n Oorsig van die belangrikheid van die onlangs ontdekte topkwark by Fermilab in Chicago word gegee. Daar word aangetnon dat die topkwark belangrik is in fisika van die Oerknal, oftewel "Big Bang", en in die Standaard Model van Elementêredeeltjie-fisika. Toepaslike literatuur vir verdere studie kan van die lys van verwysings in hierdie kort, nietegniese artikel, nagegaan word.

  8. Phenolic Molding Compounds

    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.

  9. Mold After a Disaster

    ... 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 ...

  10. Effect of cast steel production metallurgy on the emergence of casting defects

    L. Čamek

    2016-10-01

    Full Text Available The paper documents metallurgical possibilities of high alloy cast steel production in open induction medium frequency furnaces and an electric arc furnace in a gravity die casting foundry. The observation was focused on the emergence of gas defects in steel castings. The content of gases achieved during the metallurgical processes was evaluated for every unit of the production equipment and the casting ladle before casting into disposable sand moulds. The sand mould area was considered to be constant. The aim was to evaluate the current metallurgical possibilities of affecting the content of gases in high alloy cast steel in the current technical conditions of the foundry.

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

    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....

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

    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.

  13. Modeling of TiAl Alloy Grating by Investment Casting

    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.

  14. SPRAY CASTING

    SALAMCI, Elmas

    2010-01-01

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

  15. Modelado del sistema de enfriamiento primario en máquinas de colada de acero con cristalizador curvo//Modelling of continuos casting steel during first cooling system with curve mold

    Yusdel Díaz‐Hernández

    2014-01-01

    Full Text Available En el proceso de enfriamiento primario durante la colada continua de aceros sucede una serie de transformaciones físicas que inciden directamente en la calidad final del producto. Los modelos matemáticos que explican este fenómeno no pueden ser tratados indistintamente para una instalación u otra debido a las disímiles variables implicadas en el proceso. En esta investigación se obtuvo un modelo físico- estadístico mediante regresiones múltiples sucesivas para el caudal necesario de agua en máquinas de colada continua de aceros con cristalizador curvo. Para el modelado se tuvo en cuenta las variables de operación del enfriamiento en cristalizadores curvos así como la validación estadística encondiciones de explotación en tiempo real. El modelo obtenido permitió estimar el comportamiento de las variables de control del proceso con suficiente precisión.Palabras claves: enfriamiento, solidificación, colada continua, modelado, aceración.______________________________________________________________________________AbstractIn the process of primary cooling in the continuous casting of Steel there are physical transformations that affect directly the quality of the final product. The mathematical models that explain this phenomenon cannot be applied to different installations because the variables involved in the process are different. Inthis research, a physical-statistical model was obtained through multiple and successive regression for the flow of water which is necessary in this complex process. For the modeling the variables of operations in the cured cooling systems were taken into account as well as the statistical validation in conditions ofexploitation in real time. The model permitted to predict the behavior of the variables with sufficient precision.Key words: cooling, solidifications, continuous casting, modeling, steelmaking.

  16. Impact properties of zinc die cast alloys

    Schrems, Karol K.; Dogan, Omer N.; Manahan, M.P. (MPM Technologies, Inc.); Goodwin, F.E. (ILZRO)

    2005-01-01

    Alloys 3, 5, AcuZinc 5, and ZA-8 were tested at five temperatures between -40 C and room temperature to determine impact properties. Izod impact energy data was obtained in accordance with ASTM D256. Unlike ASTM E23, these samples were tested with a milled notch in order to compare with plastic samples. In addition, flexural data was obtained for design use.

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

    Heestand, G. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States); Jaskolski, T. [Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

    2017-10-16

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

  18. Mold: Cleanup and Remediation

    ... National Center for Environmental Health (NCEH) Cleanup and Remediation Recommend on Facebook Tweet Share Compartir On This ... CDC and EPA on mold cleanup, removal and remediation. Cleanup information for you and your family Homeowner’s ...

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

    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.

  20. Simulation of the injection casting of metallic fuels

    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

  1. Caste System

    Hoff, Karla

    2016-01-01

    In standard economics, individuals are rational actors and economic forces undermine institutions that impose large inefficiencies. The persistence of the caste system is evidence of the need for psychologically more realistic models of decision-making in economics. The caste system divides South Asian society into hereditary groups whose lowest ranks are represented as innately polluted. ...

  2. Transferability of glass lens molding

    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.

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

    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.

  4. The role of water in slip casting

    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.

  5. Structure Distribution in Precise Cast Iron Moulded on Meltable Model

    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.

  6. Die funksie van die belydenis in die struktuur van die kerk en die ...

    Ter wille van die argument wat in hierdie voordrag na vore gebring word, word vier sodanige konstituerende elemente van die kerklike struktuur onderskei, te wete die belydenis, die teologie, die verkondi- ging (meer bepaald die prediking) en die kerkorde (kerkwet volgens ons terminologie). Ons gaan nou elkeen hiervan ...

  7. Dynamic of taking out molding parts at injection molding

    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.

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

    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

  9. The effects of casting speed on steel continuous casting process

    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.)

  10. Results obtained so far with the production of turbine and valve casings made of the new 9% Cr cast steel types G-X 12 CrMoWVNbN 10 11 and G-X 12 CrMoVNbN 91; Erfahrungsbericht ueber die Herstellung von Turbinen- und Ventilgehaeusen aus den neuen 9% Cr-Stahlgusssorten G-X 12 CrMoWVNbN 10 1 1 und G-X 12 CrMoVNbN 91

    Schuster, F.; Buberl, A.; Hanus, R. [VOEST-ALPINE STAHL LINZ GmbH, Linz (Austria); Cerjak, H. [Technische Univ., Graz (Austria)

    1996-12-31

    In the course of production start-up of new 9-10% Cr cast steel types, and application of R and D results to practice, the following examinations and modifications have been performed: 1. Reduction of average chromium content from 10.5 to 9.5% in order to suppress delta ferrite segregation, and adjustment of austenite and ferrite stabilizing alloying constituents. 2. Analysis of typical defects in castings, and modification of casting and feeding techniques in compliance with the saturation behaviour of the new 9-10% Cr steels. These measures achieved a reduction of feeding-based flaws (shrinkage) in the last few cast pieces. 3. The good weldability was proven of the new 9-10% Cr steels by means of welding tests and crack-free production and construction welds made in cast pieces. (orig./MM) [Deutsch] Im Zuge der Produktionsaufnahme neuer 9-10% Cr-Stahlgusssorten und der Ueberleitung der F and E Ergebnisse in die betriebliche Praxis wurden folgende Untersuchungen und Anpassungen vorgenommen: 1. Um die Deltaferritausscheidung zu unterdruecken, wurde der mittlere Chromgehalt von 10,5 auf 9,5% abgesenkt und die austenit- und ferritstabilisierenden Legierungselemente besser angepasst. 2. Die Analyse typischer Fehlererscheinungen an Gussstuecken machten eine Anpassung der Giess- und Speisungstechnik an das Saettigungsverhalten der neuen 9-10% Cr-Staehle erforderlich. Diese Massnahmen fuehrten zu einer Verringerung der Speisungsfehler (Lunker) bei den zuletzt abgegossenen Gussstuecken. 3. Bei Schweissversuchen und an Gussstuecken rissfrei ausgefuehrten Fertigungs- und Konstruktionsschweissungen konnte die gute Schweisseignung der neuen 9-10% Cr-Staehle nachgewiesen werden. (orig./MM)

  11. Manufacture of mold of polymeric composite water pipe reinforced charcoal

    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.

  12. Optimization of Composition and Heat Treating of Die Steels for Extended Lifetime; FINAL

    David Schwam; John F, Wallace; Quanyou Zhou

    2002-01-01

    An ''average'' die casting die costs fifty thousand dollars. A die used in making die cast aluminum engine blocks can cost well over one million dollars. These costs provide a strong incentive for extension of die life. While vacuum quenched Premium Grade H13 dies have become the most widely used in the United States, tool makers and die casters are constantly searching for new steels and heat treating procedures to extend die life. This project was undertaken to investigate the effects of composition and heat treating on die life and optimize these parameters

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

    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

  14. Metallic Fuel Casting Development and Parameter Optimization Simulations

    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

  15. Die posisie van die Helper in die sending

    I. J. van der Walt

    1972-05-01

    Full Text Available Gedurende die aanvangsjare van die sending het die helper ’n onmisbare funksie vervul. Hulle het die onherbergsame binnelande geken, waardevolle kontakpunte vir die sendelinge geopen en hulle mense geestelik help voorlig en voorberei.

  16. Hair casts

    Sweta S Parmar; Kirti S Parmar; Bela J Shah

    2014-01-01

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

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

    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.

  18. Centrifugal vacuum casting for fuel cladding tube blanks

    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

  19. DIE GESKIEDENIS VAN DIE PERSONEELFUNKSIE IN DIE SA ...

    stel (kortdiensstelsel). Met die uitbreek van die oorlog in 1939 het die. Unieverdedigingsmag uit 40% Staandemag en. 60% aktiewe Burgermag bestaan. Op 22 Sept. 1939 is magtiging aan die Aktiewe Burgermag- eenhede verleen om vrywilligers vir die duur van die oorlog te aanvaar. Agv beswaar dat die Verdedigingswet.

  20. Die Formatestadt

    Günter Trojan

    2013-01-01

    Zu Zeiten von DV oder VHS (wer kennt das eigentlich noch?) war die Welt noch in Ordnung: Da hatte man eine Kassette in der Hand und wenn das passende Gerät gefunden wurde konnte man das Video auch abspielen. Günter Trojan diskutiert die Geschichte und Gegenwart unterschiedlicher Videoformate ...

  1. Die Formatestadt

    Günter Trojan

    2013-06-01

    Full Text Available Zu Zeiten von DV oder VHS (wer kennt das eigentlich noch? war die Welt noch in Ordnung: Da hatte man eine Kassette in der Hand und wenn das passende Gerät gefunden wurde konnte man das Video auch abspielen. Günter Trojan diskutiert die Geschichte und Gegenwart unterschiedlicher Videoformate ...

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

    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.

  3. Simulation and experimental verification of the filling process of semi-solid die forging for cup shell

    Jianbo TAN

    2015-06-01

    Full Text Available The filling mold process of semi-solid alloy blank influences severely the forming and properties of finished piece. In this paper, DEFORM is applied to simulate the process of cup-type 6061 alloy die forging casting. The influences of the temperature of semi-solid alloy blank, preheating temperature, and downward press speed of pressure head on process of mold filling and velocity field are investigated. The results show that the mold filling of semi-solid alloy paste smoothly fills along the whole of mould cavity in “total wall thickness” form when the temperature of semi-solid alloy blank is 620 ℃, preheating temperature of pressure head is 200 ℃ and speed of pressure head is 40 mm/s. Along with the increase of the preheating temperature of pressure head, the filling process of the semi-solid alloy paste trends toward stable when the temperature of semi-solid alloy blank is 620 ℃ and the speed of pressure head is 20 mm/s. Along with the increasing of the temperature of semi-solid alloy, the process of mould filling becomes off balance and the liquid becomes turbulent flow. The velocity field in the process of mould filling affects severely the structure uniformity of the finished product.

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

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

    2016-02-01

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

  5. Engineering design of centrifugal casting machine

    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.

  6. Rapid die manufacturing using direct laser metal deposition

    Pereira, MFVT

    2009-01-01

    Full Text Available This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die...

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

    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

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

    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...

  9. Fabrication of Microfluidic Valves Using a Hydrogel Molding Method.

    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.

  10. Ceramic injection molding

    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

  11. Neutron radiography inspection of investment castings

    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

  12. Low Loss Advanced Metallic Fuel Casting Evaluation

    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

  13. Die funksie van die skeppingstradisie in die boek Jeremia

    gedeeites voor wat sterk ooreenkomste toon met die beskrywings van die skep pingsgebeure in die boek Jeremia. • Volgpns Von Rad (1957:144-146) het daar wel 'n groep bestaan wat belange ge- had liet by die oorlewering van die skeppingstradisies. Dit was waarskynlik die. Sadokitiese priesters wat om twee redes aan ...

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

    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...

  15. Die regsposisie van die gemolesteerde kind 1

    P.J. Schabort

    1991-03-01

    Full Text Available Hoe reik die reg uit na die seksueel gemolesteerde kind? As na die reg in wye verband gekyk word, sou dit alie wetgewing en alle gemeneregsbeginsels en alle regsprosedures insluit waardeur die Staat poog om molestering te voorkom en die gemolesteerde kind in beskerming te neem. Dit le baie wyd en sou byvoorbeeld die maatreels insluit van die Kindenvet 33 van 1960; die Wet op Egskeiding 70 van 1979; die Wet op Kindersorg 74 van 1983; die Wet op die Status van Kinders 82 van 1987 en die Wet op Bemiddeling in Sekere Egskeidingsaangeleenthede 24 van 1987. Eersdaags sal dit moontlik ook ’n Manifes vir die Regte van Kinders insluit wat vermoedelik geskoei sal wees op die W O se Konvensie vir die Regte van die Kind (1989 w a arv an die RSA tan s nog nie ’n ondertekenaar is nie.

  16. Titanium Aluminide Casting Technology Development

    Bünck, Matthias; Stoyanov, Todor; Schievenbusch, Jan; Michels, Heiner; Gußfeld, Alexander

    2017-12-01

    Titanium aluminide alloys have been successfully introduced into civil aircraft engine technology in recent years, and a significant order volume increase is expected in the near future. Due to its beneficial buy-to-fly ratio, investment casting bears the highest potential for cost reduction of all competing production technologies for TiAl-LPTB. However, highest mechanical properties can be achieved by TiAl forging. In view of this, Access e.V. has developed technologies for the production of TiAl investment cast parts and TiAl die cast billets for forging purposes. While these parts meet the highest requirements, establishing series production and further optimizing resource and economic efficiency are present challenges. In order to meet these goals, Access has recently been certified according to aircraft standards, aiming at qualifying parts for production on technology readiness level 6. The present work gives an overview of the phases of development and certification.

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

    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.

  18. Nodular cast iron and casting monitoring

    S. Pietrowski

    2008-10-01

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

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

    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.

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

    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

  1. Enhanced Injection Molding Simulation of Advanced Injection Molds

    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.

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

    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.)

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

    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)

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

    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.

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

    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...

  6. Filler metal alloy for welding cast nickel aluminide alloys

    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.

  7. Performance of molded plastic scintillators

    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

  8. Manufacture of tube billets for fuel cans by vacuum centrifugal casting

    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

  9. Die rol van die blanke werker in die motivering van die swart werker

    G. J. Oosthuizen

    1980-11-01

    Opsomming Die motivering van die Swart werker kan nie in die huidige situasie in isolasie bestudeer word nie, omdat die Blanke werker steeds in die bestuursposisie is en daarom die motivering van die Swart werker kan beïnvloed. Hierdie ondersoek was daarop gerig om die rol van die Blanke werker in die motivering van die Swart werker nader te ondersoek. Die houding en die leierskapsbenadering van die Blanke werker teenoor die Swart werker is gemeet, asook die behoeftes wat volgens die Blanke werker by die Swart werker bestaan, bevredig is, of nie bestaan nie. Die behoeftes van Swart werkers, soos deur hulleself gesien, is ook ondersoek. Ten opsigte van sekere aspekte is beduidende verskille gevind.

  10. The Effect of Epoxy Molding Compound Floor Life to Reliability Performance and mold ability for QFN Package

    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

  11. Multiphysics modeling of the steel continuous casting process

    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

  12. Casting the Spirit: A Handmade Legacy

    Rutenberg, Mona

    2008-01-01

    This article discusses how an art therapist working in a hospital palliative care unit has incorporated a ritual of hand casting to help bring closure to dying patients and family members who are grieving as death approaches. The finished hand sculptures depict the hands of the patients and, sometimes, of their loved ones. They are faithful and…

  13. Casting of Hearth Plates from High-chromium Steel

    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.

  14. Die hervertolking van die paradigma in verband met die ...

    Kerkorde van De Mist en die Algemene Reglement van 1816, wat onderskeidelik vir die Kaapse Kerk en die .... Een van die eerstes was Sam Freiherr von Pufendorf (1632-1694) wat in sy werk De habitu religionis ..... Koning was weer aan bewind (vgl Diepenhorst sj:74w; De Visser 1926/1927 lll:202w). 43.1 JD Janssen ...

  15. die heidelbergse kategismus en die kategesemateriaal van die ned

    subjek, objek, leerstof en die metodiek van die senior kategese. Bloemfontein: Algemene Jeugkommissie Sondagskoolboekhandel. de rAAd oer ned ger kerken in Zuid AfrikA. 1921. De zevende vergadering: handelinge. 1925. De negende vergadering: handelinge. de villierS, d. W. 1957. Die Kategese in die Ned. Geref.

  16. die sinodale verband van die nederduitse gereformeerde kerk in die

    Liezel

    Strauss. Die sinodale verband van die Nederduitse Gereformeerde Kerk. 122 die Vrystaatse Sinode anti-veranderingsgesind of eerder gesond-behoudend of gereformeerd-gematig? Veral as dit .... howe) in moeilike omstandighede gebring is (NG Kerk in die OVS 1865-1912:5). In 'n brief op 8 Augustus 1864 ontken Ds.

  17. Die kerkregtelike posisie van die ouderling en diaken in die ...

    ... drie dekades die Kerkreg gevestig as 'n selfstandige vak in die teologiese curriculum, maar ook 'n baie groot rol gespeel daarin dat die beginsels van die kerk like reg beter begryp word. Naas sy wetenskaplike bydrae word met eweveel genoegdoening gedink aan sy bcsondere persoonlikheid, sy werkvermoe, sy humor-.

  18. Rapid control of mold temperature during injection molding process

    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.

  19. Effect of road deicing salt on the susceptibility of amphibian embryos to infection by water molds.

    Karraker, Nancy E; Ruthig, Gregory R

    2009-01-01

    Some causative agents of amphibian declines act synergistically to impact individual amphibians and their populations. In particular, pathogenic water molds (aquatic oomycetes) interact with environmental stressors and increase mortality in amphibian embryos. We documented colonization of eggs of three amphibian species, the wood frog (Rana sylvatica), the green frog (Rana clamitans), and the spotted salamander (Ambystoma maculatum), by water molds in the field and examined the interactive effects of road deicing salt and water molds, two known sources of mortality for amphibian embryos, on two species, R. clamitans and A. maculatum in the laboratory. We found that exposure to water molds did not affect embryonic survivorship in either A. maculatum or R. clamitans, regardless of the concentration of road salt to which their eggs were exposed. Road salt decreased survivorship of A. maculatum, but not R. clamitans, and frequency of malformations increased significantly in both species at the highest salinity concentration. The lack of an effect of water molds on survival of embryos and no interaction between road salt and water molds indicates that observations of colonization of these eggs by water molds in the field probably represent a secondary invasion of unfertilized eggs or of embryos that had died of other causes. Given increasing salinization of freshwater habitats on several continents and the global distribution of water molds, our results suggest that some amphibian species may not be susceptible to the combined effects of these factors, permitting amphibian decline researchers to devote their attention to other potential causes.

  20. Functional nanostructures on injection molded plastic

    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...

  1. Injection Molding of High Aspect Ratio Nanostructures

    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...

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

    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.

  3. Mechanism and application of a newly developed pressure casting process: horizontal squeeze casting

    Li Peijie

    2014-07-01

    Full Text Available Compared to traditional high-pressure die casting (HPDC, horizontal squeeze casting (HSC is a more promising way to fabricate high-integrity castings, owing to a reduced number of gas and shrinkage porosities produced in the casting. In this paper, the differences between HSC and HPDC are assessed, through which it is shown that the cavity filling velocity and the size of the gating system to be the most notable differences. Equipment development and related applications are also reviewed. Furthermore, numerical simulation is used to analyze the three fundamental characteristics of HSC: slow cavity filling, squeeze feeding and slow sleeve filling. From this, a selection principle is given based on the three related critical casting parameters: cavity filling velocity, gate size and sleeve filling velocity. Finally, two specific applications of HSC are introduced, and the future direction of HSC development is discussed.

  4. White mold of Jerusalem artichoke

    Jerusalem artichoke (Helianthus tuberosus) is a Native American food plant closely related to the common sunflower (Helianthus annuus). Tubers of Jerusalem artichoke are increasingly available in retail grocery outlets. White mold (Sclerotinia stem rot), caused by the fungus, Sclerotinia sclerotioru...

  5. Molded polymer solar water heater

    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.

  6. Riglyne vir die onderwys.

    J. L. du Plooy

    1960-03-01

    Full Text Available In die afgelope vyftig jaar sedert die Unie tot stand gekom het, is veel op die gebied van onderwys tot stand gebring. Dit is heel natuurlik dat ’n mens sou vra: Wat van die toekoms?

  7. Squeeze casting of aluminum alloy A380: Microstructure and tensile behavior

    Li Fang

    2015-09-01

    Full Text Available A380 alloy with a relatively thick cross-section of 25 mm was squeeze cast using a hydraulic press with an applied pressure of 90 MPa. Microstructure and tensile properties of the squeeze cast A380 were characterized and evaluated in comparison with the die cast counterpart. Results show that the squeeze cast A380 possesses a porosity level much lower than the die cast alloy, which is disclosed by both optical microscopy and the density measurement technique. The results of tensile testing indicate the improved tensile properties, specifically ultimate tensile strength (UTS: 215.9 MPa and elongation (Ef: 5.4%, for the squeeze cast samples over those of the conventional high-pressure die cast part (UTS: 173.7 MPa, Ef: 1.0%. The analysis of tensile behavior shows that the squeeze cast A380 exhibits a high tensile toughness (8.5 MJ·m-3 and resilience (179.3 kJ·m-3 compared with the die cast alloy (toughness: 1.4 MJ·m-3, resilience: 140.6 kJ·m-3, despite that, during the onset of plastic deformation, the strain-hardening rate of the die cast specimen is higher than that of the squeeze cast specimens. The microstructure analyzed by the scanning electron microscopy (SEM shows that both the squeeze and die cast specimens contain the primary α-Al, Al2Cu, Al5FeSi phase and the eutectic Si phase. But, the Al2Cu phase present in the squeeze cast alloy is relatively large in size and quantity. The SEM fractography evidently reveals the ductile fracture features of the squeeze cast A380 alloy.

  8. Die partypolitiek en die toekoms van die Afrikaanse volkskultuur

    A.P. Treurnicht

    1970-03-01

    Full Text Available Reeds in 1853 het die Zuid Afrikaan hom soos volg uitgelaat: „Dis ’n dwaling wat ons reeds meermale bestry het dat ons as Britse onderdane verplig sou wees, om die Britse nasionaliteit ons s’n te maak. Die Kolonis van Hollandse oorsprong kan geen Engelsman word nie, en moet ook geen Nederlander wil wees nie. Wanneer hy weet om sy standpunt te waardeer, dan sal hy as verligte kolonis die grondtrekke van die Engelse volkskarakter met dié van die Nederlandse harmonies leer verenig en daardeur word wat hy as Kapenaar moet word.”

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

    S. Pietrowski

    2011-07-01

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

  10. Die Voortrekker-Monument

    Gerard Moerdyk

    1938-03-01

    Full Text Available Die Eeufeesjaar is vir die Afrikaner ’n tydperk van besieling. Nog nooit sedert die ontstaan van ons volk het een enkele gebeurtenis soveel nasietrots gewek as die honderdjarige herdenking van die Groot Trek. Vir die eerste keer in ons geskiedenis voel ons ons nie meer Kapenaars, Vrystaters, Natalers, en Transvalers nie, maar Afrikaners, saamgesnoer deur die tradisies van ’n selfstandige kultuurvolk. Wanneer die klimaks van die Ossewatrek met die hocksteenlegging van die Voortrekker-Monument bereik word, sal die besieling nie uitsterf nie, die krag wat geskep is sal bly voortgroei tot ’n onweerstaanbare mag. Die Afrikaner sal homself vind, en as die Monument na sowat vyf jaar onthul word, sal die saad wat in hierdie jaar gesaai is, tot voile rypheid gekom het. Dan sal die Monument self tot die volk spreek; intussen egter, is dit wenslik, nee noodsaaklik selfs, om die Monument aan die Afrikaners te verklaar, om ‘n uiteensetting te gee van die noodsaaklikheid van so ’n Monument, sowel as om die motief te verduidelik wat as inspirasie gedien het vir die ontwerpdaar van.

  11. Optimization of squeeze casting parameters for non symmetrical AC2A aluminium alloy castings through Taguchi method

    Senthil, P.; Amirthagadeswaran, K. S.

    2012-01-01

    This paper reports a research in which an attempt was made to prepare AC2A aluminium alloy castings of a non symmetrical component through squeeze casting process. The primary objective was to investigate the influence of process parameters on mechanical properties of the castings. Experiments were conducted based on orthogonal array suggested in Taguchi's offline quality control concept. The experimental results showed that squeeze pressure, die preheating temperature and compression holding time were the parameters making significant improvement in mechanical properties. The optimal squeeze casting condition was found and mathematical models were also developed for the process

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

    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)

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

    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.

  14. Deep UV patterning of acrylic masters for molding biomimetic dry adhesives

    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

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

    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.

  16. Die Britse owerheid en die onderwys op Heidelberg gedurende die ...

    The establishment of Christian National Education (CNE) Schools stimulated the concept of mother tongue education. Oor die klaskamerpraktyk en die werklike gehalte van onderrig tydens die kampskooltydperk is daar min bekend. Heidelberg wat na 1902 in 'n belangrike onderwyssentrum in Transvaal ontwikkel het, het ...

  17. Die belangrikste kenmerk van die diereproduksie- bedrywe oor die ...

    digdhede teen 1980 uit 'n kudde van 30 rnilj.skape ge- produseer moet word. Tweedens sal die faktore ... die Republiek van Suid-Mrika teen 1980 in totaal 28 milj. sal wees. Indien die produsente dit as 'n ..... Appendix Table 4 in Digestive Physiology and nutrition of ruminants Vol. 3 Ed. and Publ. D.C. Church, Oregon State ...

  18. DIE ROL VAN DIE TAALWETENSKAP IN DIE ONTWIKKELING VAN ...

    aanslag op die sogenaamde "Intentional Fallacy", heelwat verder. n. Mens sou hier eintlik ook op die invloed van Lacan se toepassing van. De Sacs sure op Freud moet wys, en op Macherey se Theory of Literary. Production. Barthes is naamlik besig om repressie teen te werk, en die teks as produksieproses in stede van ...

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

    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.

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

    Thangirala, Mani

    2015-09-30

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

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

    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.

  2. Relationship between casting modulus and grain size in cast A356 aluminium alloys

    Niklas, A; Abaunza, U; Fernández-Calvo, A I; Lacaze, J

    2012-01-01

    Microstructure of Al-Si alloy castings depends most generally on melt preparation and on the cooling rate imposed by the thermal modulus of the component. In the case of Al-Si alloys, emphasis is put during melt preparation on refinement of pro-eutectic (Al) grains and on modification of the Al-Si eutectic. Thermal analysis has been used since long to check melt preparation before casting, i.e. by analysis of the cooling curve during solidification of a sample cast in an instrumented cup. The conclusions drawn from such analysis are however valid for the particular cooling conditions of the cups. It thus appeared of interest to investigate how these conclusions could extrapolate to predict microstructure in complicated cast parts showing local changes in the solidification conditions. For that purpose, thermal analysis cups and instrumented sand and die castings with different thermal moduli and thus cooling rates have been made, and the whole set of cooling curves thus recorded has been analysed. A statistical analysis of the characteristic features of the cooling curves related to grain refinement in sand and die castings allowed determining the most significant parameters and expressing the cube of grain size as a polynomial of these parameters. After introduction of a further parameter quantifying melt refining an excellent correlation, with a R 2 factor of 0.99 was obtained.

  3. Wêreldmededingendheid en die tegnologie

    C. W. I. Pistorius

    1996-07-01

    Full Text Available Afgesien van die interne uitdagings wat die Heropbou- en Ontwikkelingsprogram (HOP aan Suid-Afrika bied, moet die land ook tred hou met die veranderende globale omgewing, spesifiek die toenemende belangrikheid van ekonomiese sekuriteit as komponent van nasionale sekuriteit. Die konsep van mededingendheid vergestalt die doelwit wat nagestreef moet word ten einde die ontluikende globale ekonomiese stryd aan te durf. As ’n belangrike drywer van ekonomiese welvaart is tegnologie een van die belangrikste sleutels tot internasionale mededingendheid. Tegnologiese innovasie is die proses wat as hefboom hiervoor gebruik moet word. Dit is egter nodig dat tegnologie, en spesifiek die proses van tegnologiese innovasie, formeel en gestruktureerd bestuur moet word, sowel op nasionale as firmavlak. Op nasionale vlak is die voorsiene Nasionale Innovasiestelsel beslis ’n stap in die regte rigting.

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

    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.

  5. Process for molding improved polyethylene

    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.)

  6. Measurement and simulation of deformation and stresses in steel casting

    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.

  7. Casting Simulation of an Austrian Bronze Age Sword Hilt

    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.

  8. Measurement and simulation of deformation and stresses in steel casting

    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.

  9. Die spel van assosiasies in en om 'Die verlossing van die beeld' van Breyten Breytenbach

    P.A. du Toit

    2005-07-01

    Full Text Available The play of association in and around 'The liberation of the image' by Breyten Breytenbach This analysis focuses on the conjunction of memory and imagination, which is an important impulse in, and key to, Breytenbach’s work. The play with language and with associations, the foregrounding, in the short story, “Die verlossing van die beeld” (Breytenbach, 1983 with its metafictional title and apparently divergent motifs (rain/water, watch, onion, the death and burial of a grandfather acts, as it were, as an invitation to the reader to become a co-player. The reader ventures on a search for traces, intertextual links within the Breytenbach oeuvre and for already acknowledged influences such as Surrealism (which in turn casts some light on the strange title of the story and the Eastern philosophies such as Zen and the even older Taoism. The analysis also takes into account the context in which “Mouroir” was written, namely Breytenbach’s term in prison (1975-1982. Seeing that the writer had to hand in his manuscripts to the jail authorities regularly, he might have decided, consciously or by intuition, to hide some thoughts and feelings behind a screen or a mask, in, for example in “Die verlossing van die beeld”, a lighter tone and irony.

  10. die ontstaan en die ontwikkeling van die skoolkadette-stelsel in die rsa

    toe algemene diensplig ingestel is. Die diens- plig het intussen sy volle beslag gekry en in. Weermagkringe het die gedagte posgevat dat skoolkadette. 'n deeglike ondersoek vereis ten einde die skoolgaande seun vir sy komende nasionale diensplig te orienteer. Tydens kadetopleldlng leer die seuns al die fynere kunsles ...

  11. Van die Gasredakteur

    cherish and teach.'1. Die Fakulteit Geneeskunde van die Universiteit van die Oranje-Vrystaat het pragtig gegroei ge- durende die eerste 21 jaar van sy bestaan. Die entoesiasme, doelgerigtheid, harde werk en inisia- tiewe van 'n groot aantal persone was hiervoor verantwoordelik. 'If we see a bit more clearly than they, it is ...

  12. Halfkrone vir die Nagmaal

    Owner

    die omgewing van Velddrif en Laaiplek, ook noordwaarts verby Lambertsbaai tot by. Doringbaai en Strandfontein. “Haar seeverhale is Sussie (Kotze) se belangrikste bydrae tot die Afrikaanse letterkunde”, sê Kotzé-Myburgh in die voorwoord van die versamelbundel. Die leser word herinner aan Kotze se debuutroman, ...

  13. Marginal Accuracy of Castings Produced with Different Investment Systems.

    Yadav, R K

    2009-04-01

    The use of casting ring to produce accurate castings has been challenged with the introduction of a ringless casting technique. This study compared the marginal accuracy of all - metal complete coverage crowns fabricated with ringless, split plastic ring and metal ring investment systems. A total of 40 all- metal complete coverage crowns were fabricated on a metal die. The crowns were divided in 4 groups (Group A, B, C and D) of 10 patterns each. A ringless system of investing and casting was used for group A whereas a split plastic ring system was used for group B. Groups C and D utilized metal ring with single and double layers of asbestos free cellulose acetate liner respectively for investing and casting procedures. The restorations were seated on the metal die and the vertical marginal discrepancy was evaluated by measuring the gap between the finish line on the die and the margins of the crown on four specific sites with an optical microscope. Statistical analysis was carried out using ANOVA and multiple comparison "t" test. The mean vertical marginal discrepancy for groups A, B, C and D was 95μm, 136μm, 128μm and 104μm respectively. Vertical marginal discrepancy on each surface was compared among the four groups. Difference of vertical marginal discrepancy on buccal surface (p0.05). Accurate castings with better marginal fit can be produced with ringless casting technique.

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

    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°)

  15. Die teologie in gesprek met die ekonomie

    (1723-1790) sy vertrekpunt neem, ontwikkel, as oorwinnaars uit die Franse Revolu .... Die onmiddellike sukses van Adam Smith se 'Wealth of Nations' was .... alle vorme van sosialisme niks anders as 'kommunisme' (Wassenaar 1977:12) nie.

  16. Wall-slip of highly filled powder injection molding compounds: Effect of flow channel geometry and roughness

    Hausnerova, Berenika; Sanetrnik, Daniel; Paravanova, Gordana

    2014-05-01

    The paper deals with the rheological behavior of highly filled compounds proceeded via powder injection molding (PIM) and applied in many sectors of industry (automotive, medicine, electronic or military). Online rheometer equipped with slit dies varying in surface roughness and dimensions was applied to investigate the wall-slip as a rheological phenomenon, which can be considered as a parameter indicating the separation of compound components (polymer binder and metallic powder) during high shear rates when injection molded.

  17. Segregation in cast products

    Unknown

    The agreement with experimental data is mostly qualitative. The paper also ... For example, a high degree of positive segregation in the central region .... solute in a cast product, important ones being: size of casting, rate of solidification, mode.

  18. Facts about Stachybotrys chartarum and Other Molds

    ... 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 ...

  19. Die dogmatiese binding van die prediking

    genoemde probleemstelling wat ons homileties na riglyne wil soek, sonder die pretensie dat finale oplossings gevind sal word. Om hierdie probleem te ontleed is dit nodig om eers kortliks 'n begripsbepaling van die begrippe dogma, binding en prediking te maak. Vanuit die begripsbepaling kan ons dan probeer vasstel wat ...

  20. DIE PERSOON VAN VREDE IN DIE SENDING

    aan dat 'n lewe onder die gesag van God tot volle vrede lei: “In coming under the rule of Yahweh, moreover, life was made whole and safe.” Dit is spesifiek in die tempel waar die volheid van God se vrede ondervind word (1997:662):. The temple is indeed the place where Israel entered into Yahweh's full zone of shalom.

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

    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.

  2. Silane based coating of aluminium mold

    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....

  3. n Oorsig van die huidige stand van navorsing oor die

    Test

    7 Jun 2011 ... Die eerste maal wat dit as deel van die teks van 1 Johannes aangehaal word, is in die. 4de eeu in 'n Latynse teks, Liber Apologeticus (hf 4). Eers aan die einde van die 16de eeu is dit in 'n amptelike Katolieke uitgawe van die Vulgaat ingesluit. Die doel van die Johannesbriewe. Waarom is die Briewe ...

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

    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...

  5. Environmental Sustainability and Mold Hygiene in Buildings.

    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.

  6. Environmental Sustainability and Mold Hygiene in Buildings

    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.

  7. Mold inhibition on unseasoned southern pine

    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...

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

    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.

  9. Die Ware Buch und die Philologie

    Bernhard Hurch

    2017-10-01

    Full Text Available Die im 19. Jahrhundert sich verändernden Produktionsbedingungen für Druckwerke (Buchdruck, Satz, Papier, Bindung wirkten katalysierend auf die Fachkonstitution und Institutionalisierung der Philologien. Hier steht der tatsächliche Buchmarkt im Vordergrund der Darstellung, das Käuferpublikum und die Voraussetzungen des Vertriebs. Dazu gehören auch die Rezension als entstehende Textsorte und die rasch arbeitenden Rezensionsorgane. F.-R. Hausmann wurde in den letzten Jahren unentbehrlicher Mitarbeiter dieses im Rahmen des Grazer Schuchardt-Projekts "Netzwerk des Wissens" angesiedelten Ansatzes.

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

    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.)

  11. Surface Replication of Molded Products with Microneedle Features in Injection Molding

    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.

  12. Process to Continuously Melt, Refine and Cast High Quality Steel

    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.

  13. Microcapillary Features in Silicon Alloyed High-Strength Cast Iron

    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.

  14. Fiscal 1999 achievement report on regional consortium research and development project. Regional consortium research and development of energy (High-quality low-cost metal dies for molding rubber and plastic - 2nd year); 1999 nendo gomu plastic yo kohin'i tei cost kanagata no kenkyu kaihatsu seika hokokusho. 2

    NONE

    2000-03-01

    Metal die surfaces are improved in their resistance to abrasion and corrosion and, in particular, in their release from rubber materials and resistance to contamination. In an effort to develop techniques for optimum metal die surface modification, a PBII (plasma based ion implantation) unit is operated to implant ions into various kinds of metal die surfaces by means of nitrogen or fluorine gas plasma, and optimum conditions are studied by analyzing and evaluating the surface layers after treatment. In an effort to develop a novel ion implantation device to work on 3-dimensional shapes, conditions for stable ion implantation are determined, for which PBII gas concentration, arc plasma power, pulse frequency, application voltage, processing time, etc., are allowed to vary. In the quest for suitable conditions for metal die treatment by the PBII unit, tests are conducted involving natural rubber, butadiene rubber, nitrile rubber, chloroprene rubber, and ethylene propylene rubber and studies are conducted about their release from and contamination of metal dies and 3-dimensional metal dies into which ions have been implanted using fluorine plasma. (NEDO)

  15. Development of a new concrete pipe molding machine using topology optimization

    Park, Hong Seok; Dahal, Prakash; Nguyen, Trung Thanh

    2016-01-01

    Sulfur polymer concrete (SPC) is a relatively new material used to replace Portland cement for manufacturing sewer pipes. The objective of this work is to develop an efficient molding machine with an inner rotating die to mix, compress and shape the SPC pipe. First, the alternative concepts were generated based on the TRIZ principles to overcome the drawbacks of existing machines. Then, the concept scoring technique was used to identify the best design in terms of machine structure and product quality. Finally, topology optimization was applied with the support of the density method to reduce mass and to displace the inner die. Results showed that the die volume can be reduced by approximately 9% and the displacement can be decreased by approximately 3% when compared with the initial design. This work is expected to improve the manufacturing efficiency of the concrete pipe molding machine

  16. Development of a new concrete pipe molding machine using topology optimization

    Park, Hong Seok; Dahal, Prakash [School of Mechanical and Automotive Engineering, University of Ulsan, Ulsan (Korea, Republic of); Nguyen, Trung Thanh [Faculty of Mechanical Engineering, Le Quy Don Technical University, Hanoi (Viet Nam)

    2016-08-15

    Sulfur polymer concrete (SPC) is a relatively new material used to replace Portland cement for manufacturing sewer pipes. The objective of this work is to develop an efficient molding machine with an inner rotating die to mix, compress and shape the SPC pipe. First, the alternative concepts were generated based on the TRIZ principles to overcome the drawbacks of existing machines. Then, the concept scoring technique was used to identify the best design in terms of machine structure and product quality. Finally, topology optimization was applied with the support of the density method to reduce mass and to displace the inner die. Results showed that the die volume can be reduced by approximately 9% and the displacement can be decreased by approximately 3% when compared with the initial design. This work is expected to improve the manufacturing efficiency of the concrete pipe molding machine.

  17. Travelling Through Caste

    Kumar, Raj

    2016-01-01

    With its peculiar caste system, India is considered the most stratified of all known societies in human history. This system is ‘peculiar’ as it divides human beings into higher and lower castes and this division is backed by certain religious sanctions based on the sociological concepts of ‘purity’ and ‘pollution’. While the higher caste is associated with ‘purity’, the lower caste is associated with ‘pollution’. The people of the lower castes are not allowed to undertake religious journeys ...

  18. Fluid flow and heat transfer modeling for castings

    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

  19. Die vrede van Münster / Westfale en die betekenis daarvan vir die ...

    In die Suid-Afrikaanse kerkgeskiedenis egter is die Vrede van Münster as epogmakende gebeure tot dusver nie net in die algemeen verwaarloos nie, maar boonop is die direkte verband tussen hierdie sentrale historiese baken aan die een kant en aan die ander kant die vestiging van die VOC se verversingspos aan die ...

  20. Numerical simulation of stress-strain state of electrophoretic shell molds

    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

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

    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

  2. Tegnologie en die mens

    omgewingsbesoedeling, volgend op industrialisasie en verstedeliking, gee uit- ing tot krete van wanhoop en frustrasie. Die maatskaplike ontwrigting agv outomatisasie het die begrippe van vervreemding en naam- loosheid op die voorgrond van sosiale be- wustheid geplaas. • Die Neutrale Siening. Tegnologie was nag. 34.

  3. GODSBEELDE IN DIE LITURGIE

    15 Mei 2010 ... Biezeveld, de Boer, Brümmer, Muis. 2001; Brown 2006; Durand 2007). ... Wanneer sal hy weer in God se teenwoordigheid verskyn (vers 3)? Dié vraag is vol onsekerheid. (Schuman 2004:8). Sy onsekerheid ... God se volk en die enkeling in die geskiedenis het al die trou van God ervaar waarop die digter ...

  4. Die ontwikkeling van die bestuursmotiveringsvraelys (BMV

    A. S. Engelbrecht

    1991-06-01

    Full Text Available The development of the Managerial Motivation Questionnaire (MMQ: Several criticisms of the psychometric suitability of existing measures of managerial motivation are reported in the literature. This study aimed at developing a new psychometrically sound instrument, the Managerial Motivation Questionnaire (MMQ. This was done on the basis of a comprehensive study of the literature on managerial motivation and the role-motivation theory. The preliminary MMQ was systematically shortened and refined until the final MMQ of 98 items was composed. This was based on social desirability and semantic appraisal, item analysis and factor analysis of the questionnaire. The results indicate that it was possible to develop a final MMQ that was relatively free of social desirability. It further demonstrated satsifactory internal consistencies on two samples (a = 0/90, N = 360; a = 0/91, N = 535, where all subscale items were found to be relatively pure measures of the isolated factors. Although some evidence was found providing support for the reliability of the MMQ, a need for further research on the construct validity of managerial motivation still exists. Opsomming In die literatuur word verskeie punte van kritiek teen die psigometriese geskiktheid van bestaande meetinstrumente van bestuursmotivering gerapporteer. Die doelstelling van hierdie studie was dus om aan die hand van die konseptuele omiyning van bestuursmotivering, en die rolmotiveringsteorie as algemene verwysingsraamwerk, 'n nuwe psigometries aanvaarbare meetinstrument, die Bestuursmotiveringsvraelys (BMV, te ontwikkel. Op grond van sosiale wenslikheids- en semantiese beoordeling, itemontleding en faktorontleding van die voorlopige BMV is die vraelys stelselmatig verkort en verfyn totdat die finale BMV van 98 items saamgestel is. Die resultate dui daarop dat hierdie studie wel daarin geslaag het om 'n finale BMV te ontwikkel wat relatief vry van sosiale wenslikheid is, bevredigende interne

  5. Varswateralge en die ekonomie

    W. E. Scott

    1988-03-01

    Full Text Available Die artikel bespreek die ekonomiese belong wat varswateralge alreeds het en hul moontlike verdere ontginning in die toekoms. Sowel gewenste as ongewenste aspekte word oorweeg en hoofsaaklik met voorbeelde uit Suid-Afrika geïllustreer. Die oormatige ontwikkeling van ongewenste alge in varswater verlaag die watergehalte dear verskeie chemiese veranderinge, wat kan wissel van smake en geure tot die produksie van verbindings wat gesondheidsgevare vir mens of dier inhou. Verwydering van ongewenste alge dra aansienlik by tot die koste van waterbehandeling. Oormatige alggroei belemmer ontspanningsgebruike en kan eiendomswaardes langs rivier- en damoewers beïnvloed.

  6. Prediking aan die hand van die metafoor van fiksieskryf

    p1243322

    HTS 64(3) 2008 siening van die self en waarheid. In die pre-moderne paradigma kan die dominante metafoor verstaan word aan die hand van 'n spieël wat die lig uit 'n transendente oorsprong weerkaats, terwyl die moderne paradigma uitgedruk word met die metafoor van 'n lamp wat 'n eie, oorspronklike lig binne die self.

  7. e .Kuraioriufn. DIE W ETENSKAPLIKE BETEKENIS VAN DIE W ERK

    Test

    ENGELBRECHT ver antwoordelik vir die Ou-Testamentiese vakke en Hebreeus. Die aan stelling van 'n derde professor het noodsaaklik geword, want dit sou. 85 .... De .Spreuken ran 5a/o?no omvat die nuwe vertaling en die ekse gese van die eerste 24 hoofstukke van die Spreukeboek. Die geskoold- heid in die Semitiese ...

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

    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.)

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

    Hansen, Paul A; Beatty, Mark W

    2017-02-01

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

  10. Die dialogiese prinsipe

    J. J. de Klerk

    1981-08-01

    Full Text Available Met die dialogiese prinsipe word daardie beginsel bedoel, waarin die tweerigtingverkeer of kommunikasie onder, of met, of deur die mense op 'n heel besondere gesprekmatige wyse gere�l word. Tot die wese van die dialogiese prinsipe behoort "als Grundvoraussetzung das Ernstnehmen des Gesprachspartners und das darin enthaltene zuhoren-konnen. Dialog ist also etwas anderes als Disput oder Diskussion. Er setzt gegenseitiges Vertrauen und Hochachtung voraus."

  11. Die sestienpersoonlikheidsfaktorvraelys as hulpmiddel by die takseersentrum

    J. C. D. Augustyn

    1988-05-01

    Full Text Available The 16PF Personality Test as an aid to the assessment centre Assessment centres still remains costly and thime consuming. This study investigates the reduction of time and costs by the use of the 16 PF Personality Test as a method for measuring management dimensions. Promising results were obtained with a relatively small sample for the prediction of initiative and perseverance. Significant multiple correlations were also found for three criteria of management success. Further research may establish the use of the 16 PF as an aid to management assessment and thereby reduce the costs and time involved in assessment centres. Opsomming Takseersentrums se grootste probleem is gelee in die koste en tyd wat dit behels. Hierdie studie ondersoek die moontlikheid om beide te verminder deur die aanwending van die 16 PF Persoonlikheidsvraelys vir die meting van bestuursdimensies. Belowende resultate is met 'n relatiewe klein steekproef bevind ten opsigte van die voorspelling van inisiatiefen deursettingsvermoe. Beduidende meervoudige korrelasies is ook ten opsigte van drie kriteria van bestuursukses bevind. Verdere navorsing kan die gebruik van die 16 PF as hulpmiddel by bestuursevaluering vestig en sodoende die tydsduur en koste van takseersentrums verminder.

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

    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

  13. Reengineering of Permanent Mould Casting with Lean Manufacturing Methods

    R. Władysiak

    2007-07-01

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

  14. Research on Accuracy of Automatic System for Casting Measuring

    Jaworski J.

    2016-09-01

    Full Text Available Ensuring the required quality of castings is an important part of the production process. The quality control should be carried out in a fast and accurate way. These requirements can be met by the use of an optical measuring system installed on the arm of an industrial robot. In the article a methodology for assessing the quality of robotic measurement system to control certain feature of the casting, based on the analysis of repeatability and reproducibility is presented. It was shown that industrial robots equipped with optical measuring systems have the accuracy allowing their use in the process of dimensional control of castings manufactured by lost-wax process, permanent-mould casting, and pressure die-casting.

  15. Grindability of cast Ti-Cu alloys.

    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.

  16. DIE GESKIEDENIS VAN AFDELING LOGISTIEK

    1 Aug 1978 ... dan ook aangebied, Agv die probleem wat ont- staan het met die gebrek aan goedgekeurde poste vir die Afdeling en as gevolg van die ver- wagte vertraging met die ondersoek van die. DOS-span, het die Afdeling Logistiek en Afde- ling Personeel oorleg gepleeg en laasgenoemde het ingestem dat die ...

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

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

    2017-08-30

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

  18. Caste and power

    Roy, Dayabati

    2011-01-01

    This paper explores the institution of caste and its operation in a micro-level village setting of West Bengal, an Indian state, where state politics at grass roots level is vibrant with functioning local self-government and entrenched political parties. This ethnographic study reveals that caste...... relations and caste identities have overarching dimensions in the day-to-day politics of the study villages. Though caste almost ceases to operate in relation to strict religious strictures, under economic compulsion the division of labour largely coincides with caste division. In the cultural......–ideological field, the concept of caste-hierarchy seems to continue as an influencing factor, even in the operation of leftist politics....

  19. SLIP CASTING METHOD

    Allison, A.G.

    1959-09-01

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

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

    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.

  1. Die relevansie van die boek Prediker

    ook in die dogmatiek te bespeur is nie. 'n Vinnige oorsig oor die teksverwysings van. 'n paar wydgelese dogmatiekhandboeke kan dit bevestig. In Karl Barth se omvang- ryke Kirchliche Dogmatik word Prediker slegs vyf en dertig maal aangehaal en slegs sewe maal word teksgedeeltes bespreek. Emil Brunner haal Prediker ...

  2. Caste in Itself, Caste and Class, or Caste in Class

    Ramkrishna Mukherjee

    2015-01-01

    After the British conquered Bengal and eventually the whole of India,they set out to administer the colony. In this context they encountered two phenomena with which they were not familiar: (1) the relation of people to land for production (and not for revenue receiving, household living, etc.), and (2) the caste system of India, viz. the jati strati?cation of society.

  3. Grindability of cast Ti-Hf alloys.

    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.

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

    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.

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

    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

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

    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)

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

    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.

  8. Microstructural and mechanical properties investigation of Mg-Al-Zn alloy counter gravity investment cast

    Mutombo, K

    2009-10-01

    Full Text Available . The most common manufacturing method for the production of Mg components is via High Pressure Die Casting (HPDC), however, this process is suitable for high volume thin walled components. Investment casting offers the capability of producing complex near...

  9. P. J. N. Smal, Die Universalisme in die Psalms. Academisch ...

    Test

    dat die historiese element in Israel se Godsopenbaring en daarmee die insig in sy betekenis te kort gedoen word. Die betekenis van die studie vir die historia revelationis is daardeur gering; as duidelike „tydlose” sistematisering van Outestamentiese gegewens oor die betrokke onder- werpe, soos die laaste hoofstuk, bl.

  10. DIE ONTVC'ERP VAN 'N SENDINGBELEID IN DIE HUIDIGE ...

    Test

    DIE ONTVC'ERP VAN 'N SENDINGBELEID IN DIE. HUIDIGE SITUASIE. Sending is 'n deel van die vervulling van die apostoliese opdrag van die kerk. Dit geskied op grond van en in gehoorsaamheid aan Gods. \\C'oord. Teologiese besinning is daarom die eerste en grondliggende vereiste by die ontwerp van 'n ...

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

    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...

  12. DIE PLEK VAN SANG EN MUSIEK IN DIE PROTESTANTSE ...

    Test

    Sy moet hierdie opdrag uitvoer deur mid del van die Prediking d.w.s. deur middel van die Woord-vorm, maar ook deur die bediening van die sakramente, dws. deur middel van die vorm van die Daad. Maar nou wil God nie hê dat die Kerk slegs één maal die Evangelie sal predik en die mense sal doop om hulle daarna.

  13. Porous media heat transfer for injection molding

    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.

  14. Fabrication of silicon molds for polymer optics

    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....

  15. Packaged die heater

    Spielberger, Richard; Ohme, Bruce Walker; Jensen, Ronald J.

    2011-06-21

    A heater for heating packaged die for burn-in and heat testing is described. The heater may be a ceramic-type heater with a metal filament. The heater may be incorporated into the integrated circuit package as an additional ceramic layer of the package, or may be an external heater placed in contact with the package to heat the die. Many different types of integrated circuit packages may be accommodated. The method provides increased energy efficiency for heating the die while reducing temperature stresses on testing equipment. The method allows the use of multiple heaters to heat die to different temperatures. Faulty die may be heated to weaken die attach material to facilitate removal of the die. The heater filament or a separate temperature thermistor located in the package may be used to accurately measure die temperature.

  16. Die radio in Afrika

    S. de Villiers

    1966-03-01

    Full Text Available Omvang van radio-uitsendings in en na Afrika. — Redes vir die versnelde tempo van uitbreiding. — Radio as die geskikste massa-kommunikasiemiddel vir Afrika. — Faktore wat die verspreiding bemoeilik. — Skouspelagtige toename in luistertalle.Toe Plinius, wat in die jaar 79 oorlede is, in sy „Historia Naturalis” verklaar het dat daar altyd iets nuuts uit Afrika afkomstig is, kon hy nouliks voorsien het dat die „iets" negentien eeue later in die lug sou setel wat hierdie reuse-vasteland oorspan — ’n Babelse spraakverwarring en ’n ongekende, verbete woorde-oorlog in die etergolwe, onder meer daarop bereken om die harte en hoofde van derduisendes te verower.

  17. Casting the Die before the Die Is Cast: The Importance of the Home Numeracy Environment for Preschool Children

    Niklas, Frank; Schneider, Wolfgang

    2014-01-01

    Mathematical competencies are important not only for academic achievement at school but also for professional success later in life. Although we know a lot about the impact of "Home Literacy Environment" on the development of early linguistic competencies, research on "Home Numeracy Environment" (HNE) and the assessment of its…

  18. Casting Footprints for Eternity

    1999-01-01

    Apollo 11 Astronaut Buzz Aldrin has his footprints casted during the dedication ceremony of the rocket fountain at Building 4200 at Marshall Space Flight Center. The casts of Aldrin's footprints will be placed in the newly constructed Von Braun courtyard representing the accomplishments of the Apollo 11 lunar landing.

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

    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...

  20. Old soldiers never die ...

    Boomsma, Jacobus Jan; Nygaard, Sanne

    2012-01-01

    An ancestral supersoldier phenotype of Pheidole ants can be recovered when selection for supersoldiers re-emerges, indicating that the developmental potential for caste pathways is retained.......An ancestral supersoldier phenotype of Pheidole ants can be recovered when selection for supersoldiers re-emerges, indicating that the developmental potential for caste pathways is retained....

  1. Die Erfindung des Manuskripts

    Benne, Christian

    Die Entstehung der literarischen Moderne ging seit dem 18. Jahrhundert damit einher, dass die Anzahl literarischer Manuskripte ebenso wuchs wie deren Bedeutung. Der Buchdruck hatte die Handschrift keineswegs überflüssig gemacht, sondern provozierte im Gegenteil einen neuen, am Autographen...

  2. Metal Injection Molding (MIM of Magnesium and Its Alloys

    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.

  3. Multi-layers castings

    J. Szajnar

    2010-01-01

    Full Text Available In paper is presented the possibility of making of multi-layers cast steel castings in result of connection of casting and welding coating technologies. First layer was composite surface layer on the basis of Fe-Cr-C alloy, which was put directly in founding process of cast carbon steel 200–450 with use of preparation of mould cavity method. Second layer were padding welds, which were put with use of TIG – Tungsten Inert Gas surfacing by welding technology with filler on Ni matrix, Ni and Co matrix with wolfram carbides WC and on the basis on Fe-Cr-C alloy, which has the same chemical composition with alloy, which was used for making of composite surface layer. Usability for industrial applications of surface layers of castings were estimated by criterion of hardness and abrasive wear resistance of type metal-mineral.

  4. Die begrafnisdíens

    Num 20: 1; Jos 24: 30; Hand 5: 5 - 11). Selfs van die ... Gebruike rondom die begrafnis het van geslag tot geslag gewissel. De Vaux ... der geskied deur die hoorders 'te onderrig, te vermaan, te vertroos en te bestraf, soos dit in elke geval ..... gehandhaaf hoef te word, veral in die lig van die feit dat die predikant die kerklike.

  5. Die gebruik van parallelplaatreologie vir die bepaling van die intrinsieke viskositeit van poli-etileentereftalaat

    O. C. Vorster

    2005-09-01

    Full Text Available Die bepaling van die intrinsieke viskositeit van poli-etileentereftalaat word bemoeilik deur die feit dat daar tans slegs twee metodes in gebruik is. In die eerste metode word die bepaling deur middel van oplossingsviskometrie gedoen, maar die toksisiteit van die oplosmiddel, asook die tydperk wat dit neem om die bepaling te doen, is ’n probleem. Die tweede metode word beperk deur die kompleksiteit en beskikbaarheid van die apparatuur in Suid-Afrika. In hierdie studie word ’n alternatiewe metode, gebaseer op parallelplaatreologie, voorgestel wat albei hierdie probleme oorkom en die resultate sodoende verkry, word vergelyk met dié wat met bestaande metodes verkry is.

  6. Die invloed van die neo-marxistiese kultuuranalise op die Wêreldraad van Kerke en die Gereformeerde Kerke van Nederland

    J. M. Vorster

    1979-05-01

    Full Text Available Toe die studente dwarsoor die VSA en Europa in die laat sestigerjare ’n plotselinge en radikale verset openbaar het teen die bestaande orde, het hulle die deur geopen vir ’n nuwe mededinger om die hart van die Westerse kultuur. Dit is die nou reeds bekende neo-Marxisme. Sedertdien het hierdie jongeling sy voetspore op vele vlakke van die Westerse kultuur gelaat.

  7. Caste in Itself, Caste and Class, or Caste in Class

    Ramkrishna Mukherjee

    2015-08-01

    Full Text Available After the British conquered Bengal and eventually the whole of India,they set out to administer the colony. In this context they encountered two phenomena with which they were not familiar: (1 the relation of people to land for production (and not for revenue receiving, household living, etc., and (2 the caste system of India, viz. the jati strati?cation of society.

  8. Application of optical scanning for measurements of castings and cores

    M. Wieczorowski

    2010-01-01

    Full Text Available In the paper application of non destructive method for dimensional control of elements in initial phase of car manufacturing, at Volks-wagen Poznań foundry was presented. VW foundry in Poznań is responsible of series production of chill and dies castings made of light alloys using contemporary technologies. Castings have a complex shape: they are die castings of housings for steering columns and gravity chill castings of cylinder heads, for which cores are manufactured using both hot box and cold box method. Manufacturing capabilities of VW foundry in Poznań reach 26.000 tons of aluminum castings per year. Optical system ATOS at Volkswagen Poznań foundry is used to digitize object and determination of all dimensions and shapes of inspected object. This technology is applied in car industry, reverse engineering, quality analysis and control and to solve many similar tasks. System is based on triangulation: sensor head projects different fringes patterns onto a measured object while scanner observes their trajectories using two cameras. Basing on optical transform equations a processing unit automatically and with a great accuracy calculates 3D coordinates for every pixel of camera. Depending on camera reso-lution as an effect of such a scan we obtain a cloud of up to 4 million points for every single measurement. In the paper examples of di-mensional analysis regarding castings and cores were presented.

  9. die pers as bron oor die geskiedenis van die eerste vrydeidsoorlog

    dood agv wonde wat hy tydens die slag opgedoen het. Dit was vir die Britse volk onaanvaarbaar dat slegs twee Boere gedood is nadat daar tussen. 20 000 en 30 000 rondtes op die Boere afgevuur is. Die pers kon net nie die ware syfers publiseer nie, want dit sou na 'n onwaarheid Iyk. Het die. Britse volk egter die Boere ...

  10. die impak van metodologie op die verstaan van die nuwe testament

    voorbeeld eers een maal deur die bril van die vorm- en redaksiekritiek na die Evangelies gekyk het, dink jy vir altyd anders oor hulle tot- standkoming. Inderdaad, nuwe metodes lei tot nuwe perspektiewe! Dit is dan ook waar die fokus van hierdie artikel val: die impak van metodologie op die verstaan van die Nuwe ...

  11. Verskuiwing in die moraal?

    S.P. van der Walt

    1974-03-01

    Full Text Available Modewoorde het ons deesdae oorgenoeg in die Christelike sedeleer en hulle kan nogal verwarring stig. U moet my vergun om met u te spreek oor een so ’n modewoord nl „verskuiwing’’ in die moraal. Dis nogal ’n mooi woord, wat so dikwels gebruik word op baie terreine en tog meer wil aandui as maar net ’n veranderde sienswyse, ’n wysiging in opvattinge of nuwe riglyne wat al gangbaar geword het in die praktyk. Die begrip wil eintlik die ewolusionêre gang beklemtoon, want dit is dan eintlik net die ou norme wat effens anders bekyk word of nie meer so nou geneem of dik onderstreep word nie. Die verskuiwing beteken dan dat alles nog dieselfde bly, net die posisie of plek het verander. Verskuiwing beteken tog plekverandering of plekwisseling en dan sekerlik nie in die sin dat die plekke ver uitmekaar lê nie. Verskuiwing beteken net maar vlak langs die vorige te staan kom. As dit dan ’n beter plek is, is dit ewolusie, ontwikkeling, verbetering.

  12. Evaluation of Cracking Causes of AlSi5Cu3 Alloy Castings

    Eperješi Š.

    2014-10-01

    Full Text Available Recently, the castings made from aluminum-silicon alloys by pressure die casting are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these defects. Evaluation of structure of the AlSi5Cu3 alloy and causes of failure were the subjects of investigation presented in this article.

  13. Nano-ceramics and its molding technologies

    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)

  14. Digital Twin concept for smart injection molding

    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.

  15. 75 FR 20387 - Contech Castings, LLC, Including Workers Whose Unemployment Insurance (UI) Wages Are Reported...

    2010-04-19

    ... Apply for Worker Adjustment Assistance In accordance with Section 223 of the Trade Act of 1974, as... aluminum and magnesium die casted component parts for automobiles. New information shows that the assets of... workers of the subject firm who were adversely affected by increased imports of aluminum and magnesium die...

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

    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.

  17. Immune Response among Patients Exposed to Molds

    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.

  18. Computer-aided injection molding system

    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.

  19. Symptomatic stent cast.

    Keohane, John

    2012-02-03

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

  20. oor die inhoud en boodskap van die heidelbergse kategismus

    Smit. Oor die Inhoud en Boodskap van die Heidelbergse Kategismus. 52. Uiteraard sal dié tema saamhang met die bedoelinge agter die opstel van die Kategismus. Ook die vraag na moontlike bedoelinge of motiewe is egter 'n ingewikkelder vraag as wat miskien gedink mag word. Uiteraard was daar agter elke kategismus ...