Foundry Techniques Research Articles

KARAKTERISTIK METALURGI PADA ZAMAN ZULKARNAIN DALAM KAJIAN SAINS: BESI DAN TEMBAGA

Zulkarnain's story is found along the line of Al-Kahfi's letters. One of the most popular was when Zulkarnain was asked by the creatures living between the two mountains to stop the exit of yakjuj and makjuj the destroyer. Zulkarnain was asked to make fortifications or high walls as a barrier to the destroyer. By Iskandar Zulkarnain made a fort with pieces of hot iron doused with melted copper. The characteristics of the mixture of steel and copper when combined will produce a sturdy and strong steel iron. Some elements are combined with steel in order to improve the tensile ability of steel iron. In some studies, it is combining steel with copper. Copper alloy steel is expected to increase the attractiveness of the steel iron. This will be seen by obtaining existing data on the mixture between steel and copper. The purpose of this study is to find out the relationship between science and Zulkarnain's story and to know how the characteristics of the mixture of iron with copper in the manufacture of barrier walls. In the manufacture of barrier fortifications using casting techniques. For data collection through the study of literature. In collecting data, the author collects data and information related to the Quranic interpretation of iron and copper, characteristics of steel, characteristics of copper, foundry techniques, and quranic interpretation of the story of Zulkarnain through supporting data sourced from research journals. . The method used uses a qualitative method that contains descriptive explanations with existing data. The results of the research obtained that from several studies it is known that the alloy between copper metal and steel iron produces a strong steel attraction and has a high ultimate stress compare.d to without an alloy. The alloy also prevents from the effects of corrosion on iron

Foundry Sand Source Reduction Options: Life Cycle Assessment Evaluation

Foundries represent a significant part of the world’s economy and are a large consumer of energy and producer of solid waste. Sand-handling processes can use 5–10% of a foundry’s total energy. The goal of this research was to explore source reduction and waste minimization at a foundry, using both economic and Life Cycle Assessment (LCA) techniques to compare three secondary sand-reclamation options. LCA software modeled all sand processes at a mid-sized ferrous foundry in the USA. The LCA showed all secondary reclamation technologies, while more energy intensive at the foundry, lowered life cycle environmental impacts, including GHG emissions, ecotoxicity, and human health indicators, due primarily to source reduction and corresponding reduction in transportation both from the virgin sand source and to the landfill. Varying transportation distance had a large impact on LCA results to the point where the life cycle benefit of secondary reclamation became a liability in a zero distance scenario. Varying electricity generation to favor greener sources was also examined, but proved to have minimal impact on the LCA results. This research suggests that the greatest reduction of life cycle impacts in the sand-handling processes for a foundry is to find a geographically closer source for virgin sand.

Two-dimensional beam steering using a thermo-optic silicon photonic optical phased array

Many components for free-space optical (FSO) communication systems have shrunken in size over the last decade. However, the steering systems have remained large and power hungry. Nonmechanical beam steering offers a path to reducing the size of these systems. Optical phased arrays can allow integrated beam steering elements. One of the most important aspects of an optical phased array technology is its scalability to a large number of elements. Silicon photonics can potentially offer this scalability using CMOS foundry techniques. A phased array that can steer in two dimensions using the thermo-optic effect is demonstrated. No wavelength tuning of the input laser is needed and the design allows a simple control system with only two inputs. A benchtop FSO link with the phased array in both transmit and receive mode is demonstrated.

From Cannon to Steam Propulsion: The origins of Clyde marine engineering

This article revisits the origins of the Clyde's marine engineering works' contribution to steam propulsion, much of which has previously relied upon hagiographical accounts from contemporaries such as Robert and David Napier. It highlights the role of the Board of Ordnance during the French Revolutionary and Napoleonic Wars in expanding its private sector suppliers of cannon across the country, which necessitated more up-to-date foundry techniques, particularly in furnaces and casting, and boring machinery capable of greater accuracy than hitherto to comply with exacting standards. This necessitated capital expenditure often with the aid of business networks and the experience gained was successfully transferred to the rapidly growing market for steamship engines and auxiliary equipment to service the burgeoning Clyde shipbuilding and marine engineering industries.

Structure of AlSi Skeleton Castings

Skeleton castings macrostructure can be shaped in many ways, by choosing an appropriate material of cores and manufacturing technologies. Important factor, which puts foundry techniques over the other technologies of periodic cellular materials, is ability to adjust mechanical properties by changing the microstructure of an alloy from which the casting is made. The influence on the microstructure of the skeleton casting can be implemented by choosing the thermal properties, mainly thermal conductivity factor, of mould and core materials. Macro- and microstructure of skeleton castings with octahedron elementary cells was presented in this paper. The analysis concerns the differences in morphology of eutectic silicone depending on the location of measurements cross sections areas. The use of thermo-insulating material with appropriate properties assures correct fill of mould cavity and homogeneous microstructure on whole volume of skeleton casting. The selection of technological parameters of the casting process if very important as well.

Characterization of Stir Cast Al—Cu—(fly ash + SiC) Hybrid Metal Matrix Composites

Metal matrix composites are engineered materials with a combination of two or more dissimilar materials, (at least one of which is a metal) to obtain enhanced properties. In the present investigation Al-4.5% Cu alloy was used as the matrix and fly ash and silicon carbide (SiC) as reinforcements. The hybrid metal matrix composite was produced using conventional foundry techniques. The fly ash and SiC were added in 5%, 10%, and 15% by weight (equal proportion) to the molten metal. The hybrid composite was tested for fluidity, hardness, density, mechanical properties, impact strength, dry sliding wear, slurry erosive wear, and corrosion. The microstructure examination was done using scanning electron microscope to assess the distribution of particulates in the aluminum matrix. The results show that there is an increase in hardness with increase in the particulates content. The density decreases with increase in fly ash and SiC content. The tensile strength, compression strength, and impact strength increases with increase in fly ash and SiC. The resistances to dry wear and slurry erosive wear increases with increase in fly ash and SiC content. Corrosion increases with increase in fly ash and SiC content. This material can be used as bearing material.

Developments in Design and Materials for Cast SPF Tooling

Large titanium and aluminum sheet parts can now be formed into very complex assemblies by the process of superplastic forming. This has resulted in the need for major work to develop new alloys, new design methods and new manufacturing routes to ensure the production of high quality tooling. SPF tooling represents a significant part of the total cost of producing the super-plastically formed part. Careful selection of the material and its manufacturing route is essential in order to obtain the “right quality at the least cost” commensurate with the conditions of use. For many years the optimization of the alloy composition, the melting and casting foundry techniques and the design of the tools was done in a semi-empirical way, being largely based on practical experience. This method meant that the development was slow and unwieldy, and therefore, not compatible with the rapidly changing constraints of the SPF industry today. The fact that extremely powerful modelling programmes such as ThermoCalc and DICTRA are available for the design of new alloys, or Thercast for the optimization of the foundry melting and processing, makes it possible to introduce innovative techniques faster and with more immediate certitude as to their success. Thus, the casting process has become the most competitive and appropriate method of manufacture of the high performance tools in use today. This paper will discuss how these current technologies have been developed, and coupled with the experiences in the foundry, have assisted in the production of new materials, that optimize the tooling required in SPF operations.

Biophotonics in the rendering of a general systems language

My current foundry research methods combine a calculus of physics, grid computation (supercomputer) algorithms, systems modeling for simulation, and biochemistry, with classical foundry techniques. The aim of this fusion is a sculptural work in cast metal that gives haptic and visual channels for the audience to become aware of the protein dynamics that produce biophotonic light. This light is unique in that it occurs through the direct transduction of organismic motion into light, proposed via a symmetry in bonded electron orbitals.

Heat Transfer Simulation in the Mold With Generalized Curvilinear Formulation

The production of a part by foundry techniques is influenced by its complex geometry configuration, which affects the solidification conditions and subsequent cooling. For example certain pipes, some vessels and most valves are produced by casting. To model the solidification of the complex shapes such as valves is difficult if Cartesian coordinates are used. Even simpler parts like pipes may become difficult to model because they usually are not orthogonally ruled shapes. The main objective of this paper is to describe the development of a finite volume method intended to simulate the heat transfer phenomena during the phase change process. Because of the mold design complexity, the finite volume is described using the generalized curvilinear formulation.

Numerical simulation of the aluminum alloys solidification in complex geometries

The process of mould design in the foundry industry has been based on the intuition and experience of foundry engineers and designers. To bring the industry to a more scientific basis the design process should be integrated with scientific analysis such as heat transfer. The production by foundry techniques is influenced by the geometry configuration, which affects the solidification conditions and subsequent cooling. Numerical simulation and/or experiments make possible the selection of adequate materials, reducing cycle times and minimizing production costs. The main propose of this work is to study the heat transfer phenomena in the mould considering the phase change of the cast-part. Due to complex geometry of the mould, a block unstructured grid and a generalized curvilinear formulation engaged with the finite volume method is described and applied. Two types of boundary conditions, diffusive and Newtonian, are used and compared. The developed numerical code is tested in real case and the main results are compared with experimental data. The results showed that the solidification time is about 6 seconds for diffusive boundary conditions and 14.8 seconds for Newtonian boundary conditions. The use of the block unstructured grid in combination with a generalized curvilinear formulation works well with the finite volume method and allows the development of more efficient algorithms with better capacity to describe the part contours through a lesser number of elements.

Performance of an Al-Si-graphite particle composite piston in a diesel engine

Al-Si-graphite particle composite alloy pistons containing different percentages of about 80 μm uncoated graphite particles were successfully cast by foundry techniques. Tests with a 5 hp single-cylinder diesel engine show that Al-Si-graphite particle composite pistons can withstand an endurance test of 500 h without any apparent deterioration and do not seize during the running-in period. The use of the Al-Si-3% graphite particle composite piston also results in (a) up to 3% reduction in the specific fuel consumption, (b) considerable reduction in the wear of all four piston rings, (c) a reduction in piston wear, (d) a 9% reduction in the frictional horsepower losses of the engine as determined by the motoring test and (e) a slight increase in the exhaust gas temperature. These reductions (a)–(d) appear to be due to increased lubrication from the graphite particles which are smeared on the bearing surface, the higher damping capacity of the composite pistons and the reduced coefficient of thermal expansion of the composite pistons. Preliminary results indicate that aluminum-graphite particle composite alloy is a promising material for automotive pistons.

AMPCOLOY 570

Abstract AMPCOLOY 570 is a cast copper-nickel-aluminum-cobalt-iron alloy specially developed for applications involving severe stresses and high temperatures, such as glass-making molds and plate-glass rolls. It is significantly superior to cast iron which has been commonly used for glass-making molds. Good foundry techniques will yield high-quality castings of Ampcoloy 570 in a wide range of section sizes. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on high temperature performance and corrosion resistance as well as casting, heat treating, machining, and joining. Filing Code: Cu-392. Producer or source: Ampco Metal Inc..

Titanium Casting with Sand Foundry Techniques

The ability to produce a east titanium configuration has a history of approximately 10 years. It is presently being done in the United States by six companies. Casting of titanium is no simple task when one considers the thousands of foundries in existence producing cast parts from other metals. The difficulties are that titanium must be handled more carefully because molten titanium is very reactive to liquids, gases, and solids. At present, consumable vacuum arc melting offers the only suitable commercial method of producing titanium castings. The rapid contamination of titanium at elevated temperature by oxygen and nitrogen and the severe damage to ductility by small percentages of such contaminants requires that melting of titanium be done in the absence of air. Because liquid titanium is an extremely effective solvent, problems of containing the molten metal within a crucible during the melting operation are encountered. A water-cooled copper crucible is used to extract heat so rapidly from the liquid metal that it solidifies before its solvent reaction can take effect. This provides a thin film of solid titanium between the molten titanium and the copper crucible. This is referred to as skull melting. The liquidus to solidus range of titanium is quite narrow and problems of fluidity exist. When enough molten titanium is accumulated in the crucible, the power is cut, the electrode is rapidly withdrawn, and the pot is tilted, all within a few seconds or the pool will solidify. A centrifuge is used within the furnace vacuum chamber during the pouring of the melt. The high g forces during the casting operation help overcome the lack of fluidity. The centrifuge action assists in filling mold cavities with metal densities vastly superior to those from conventional sand foundry static casting. Conventional materials such as sand, shell, or ceramic molds are unsatisfactory for titanium since titanium above or near its melting point will violently react with these materials. A water soluble, expendable graphite mold system is a relatively new development in titanium casting and configurations with close tolerances and excellent surface finish are obtainable. New information related to the production of titanium castings with the latest applied technology was presented.

Recent Developments in High-Energy Alnico Alloys

A brief review of the ``state of the art'' with emphasis on developments of the past several years is given. It is shown that with but two major exceptions, all significant advancements in energy product enhancement have been achieved by special foundry techniques to promote crystal anisotropy, and not by alloy composition variations. The exceptions are found in the advent of the family of high-coercive-force alloys using increased amounts of cobalt and titanium known today as Alnico 8, and in secondary recrystallizing techniques on special forms of Alnico 5 to produce a single large crystal from a polycrystalline aggregate. The latter technique was described in an earlier paper at this conference [E. Steinort et al., J. Appl. Phys. Suppl. 33, 1310 (1962)]. Work on producing crystalline anisotropy in a modified form of Alnico 8 has produced energy products as high as 10.5 MG·Oe and magnets are commercially available as Alnico 9 with energy products averaging 9.0 MG·Oe. Further work is described which shows that it is possible to apply the techniques of secondary recrystallization to a columnar aggregate of Alnico 9 and achieve further energy product enhancement to 12.5 MG·Oe for a large single crystal.

The Formation of Monocrystalline Alnico Magnets by Secondary Recrystalization Methods

A brief review of the progress of the ``Alnico Art'' is given, tracing early attempts at increasing energy yield by changes in composition to present day techniques of promoting polycrystalline growth parallel to the magnetic axis. Energy product values have steadily risen to the present commercially available level of 7.5 (MGO). Since research has apparently reached a temporary impasse in further improvement in polycrystalline Alnico magnets, except by an uneconomic fabrication from a much larger initial casting or expensive foundry mold techniques an, attempt to take advantage of the 12.0 mega gauss-oe energy product available from single crystals of Alnico is an obvious solution. Two known methods of producing single crystals sufficiently large to be of practical value are described, and the obvious economic and production problems discussed. New work on a third method is described in which normal foundry techniques are used, but the formation of a single monocrystal of the entire magnet is promoted by secondary recrystallization. It is shown that if a sufficiently large grain edge strain can be induced in a polycrystalline aggregate, resulting in secondary recrystallization, formation of a single large crystal is possible. It is also shown that if a sufficiently large internal stress can be introduced by both mechanical and thermal means, the required grain-edge shift can be accomplished. The additions of normally prohibitive amounts of either carbon, nitrogen, manganese, or other ``gamma-phase'' promoting elements will serve to provide the necessary mechanical strain, and methods of controlling their effect on the magnetic results are shown. The thermal stresses are accomplished by a simple maintainance of 60–80°C gradient across the magnet poles. This process has yielded single crystals approaching ¼ lb in size whose energy product is 11.0 megagauss-oe. The practical nature of this process is discussed, and possible mass production techniques outlined.

Economic Design of Light-Alloy Castings

Light-alloy castings can already be produced to consistently close limits by well-established die-casting methods, so the post-war developments of precision moulds are of more benefit to the other non-ferrous and ferrous foundry industries. Furthermore, the special light- alloy foundry techniques, the heat treatment and other processes, and the free-cutting properties of light alloys should be related to design and costs of production. Test-bar specifications for a number of aluminium and magnesium alloys are given, and are discussed in relation to strength and weight of castings, and also to certain features of design, and to the cost of a machined casting in cast iron and various light alloys. High-tensile steel bolts are necessary to shear screw threads in light alloys, and results of tensile tests on inserts and fastenings are given, together with estimates of cost of each method of assembly. Where inserts and fastenings are used, precautions to avoid galvanic action between dissimilar metals are necessary only on exposed junctions, whilst for corrosion generally, precautions are just as necessary for the common light alloys as for the common iron and steels.

Spettroscopia, archeologia e metallurgia

The possible scope of spectrochemical analysis in its application to the unsolved problems of archaeology and of ancient foundry techniques is outlined.