Low Cast Research Articles

Effect of cast part size on the microstructure and mechanical properties of a bainitic High-Carbon and High-Silicon Cast Steel

This study aims at assessing the impact of casting size on the bainitic transformation, resulting microstructures, and tensile properties of a high-carbon, high-silicon steel austempered at different temperatures. The casting size was analyzed by using Y blocks of two different thicknesses. The microsegregation, a common occurrence in cast parts, leads to different bainitic transformation rates at the microscopic scale. Specifically, interdendritic areas with higher alloying contents exhibit a slower transformation, resulting in a lower degree of transformation and a higher amount of blocky austenite. Despite differences in solidification structure and distribution of alloying elements, samples obtained from the thinner and thicker Y blocks yield comparable transformation times and mechanical properties, leading to enhanced uniformity in the mechanical behavior of the entire component. However, it is essential to ensure that the bainitic transformation is completed to minimize the detrimental effects of microsegregation in these cast steel components. The presence of very fine microstructures results in ultra-high strength with low ductility cast steel.

Overview on aluminium alloys as sinks for end-of-life vehicle scrap

Abstract A fundamental principle in metallurgy is that the higher the purity of metals and alloys, the more favourable their properties will be. However, as the recycling of materials in production becomes increasingly significant, the levels of impurities are also on the rise. In the case of aluminium, the consequences can be detrimental due to the low solubility of most elements in this metal, which leads to the formation of brittle intermetallic phases (IMPs). Moreover, once impurities have entered aluminium, it is difficult to remove them. In 2017, almost 100 million cars were produced worldwide. Historically, vehicle design prioritised performance, resulting in a multi-material mix to utilise the best materials for each application. This included over 40 different wrought and cast aluminium alloys, Cu-based materials for electrics, and steels for high-strength applications. In the recycling of end-of-life vehicles (ELVs), high purity wrought Al alloys are today down-cycled to low purity cast engine blocks. However, recent advancements show that the drawback of increase IMP-fractions can be turned into benefits through the strategic design of heterostructured alloys. A first successful alloy example from this approach enables interesting forming properties, previously only found in 5xxx series wrought aluminium alloys, in combination with a matrix composition and age-hardening potential known from 6xxx series wrought aluminium alloys. A second examples reviews compositions directly resulting from ELV scrap. By manipulating IMPs it is feasible to create heterostructures with an interesting balance of strength and ductility. These approaches challenge traditional views, allowing for a greater volume fraction of intermetallic phases. Understanding the formation and role of intermetallic particles is crucial. This work gives an overview to the current problem and the state of the art and addressed the potential of upcycled aluminium alloys that tolerate high impurity levels by using intermetallic phases as impurity sinks.

Exploring the structural, electronic, mechanical, magnetic and optical properties of Cs-based hydride-perovskites CsXH3 (X = Cr, Mn) for hydrogen storage application

Low cast hydride-perovskites are more efficient in power conversion and for energy storage. Here in, structural investigation, electronic, mechanical and optical properties of hydrogen based CsXH3 (X = Cr, Mn) compounds using the density functional theory. The result shows that both materials crystallize into cubic structure. The thermodynamic and dynamic stabilities are conformed through formation energy and phonon dispersion curve. The optimized lattice constants are 3.52 Å and 3.54 Å for CsCrH3 and CsMnH3 respectively. Both materials are found to be half metallic in nature. IR-Elast package are used to obtain elastic constants. The elastic study presents that both materials are ductile and have anisotropic nature. The optical parameters are studied in the range of 0–10 eV. The optical results show that both materials have an excellent optical absorption. The values obtained of gravimetric hydrogen storage capacity for these compounds are 1.55 % and 1.58 % for CsMnH3 and CsCrH3 respectively indicating that these materials can be an excellent candidate for hydrogen energy storage.

Research Status and Development Trend of Wire Arc Additive Manufacturing Technology for Aluminum Alloys

It is difficult for traditional aluminum alloy manufacturing technology to meet the requirements of large-scale and high-precision complex shape structural parts. Wire Arc additive manufacturing technology (WAAM) is an innovative production method that presents the unique advantages of high material utilization, a large degree of design freedom, fast prototyping speed, and low cast. As a result, WAAM is suitable for near-net forming of large-scale complex industrial production and has a wide range of applications in aerospace, automobile manufacturing, and marine engineering fields. In order to serve as a reference for the further development of WAAM technology, this paper provides an overview of the current developments in WAAM both from the digital control system and processing parameters in summary of the recent research progress. This work firstly summarized the principle of simulation layering and path planning and discussed the influence of relative technological parameters, such as current, wire feeding speed, welding speed, shielding gas, and so on. It can be seen that both the welding current and wire feeding speed are directly proportional to the heat input while the travel speed is inversely proportional to the heat input. This process regulation is an important means to improve the quality of deposited parts. This paper then summarized various methods including heat input, alloy composition, and heat treatment. The results showed that in the process of WAAM, it is necessary to control the appropriate heat input to achieve minimum heat accumulation and improve the performance of the deposited parts. To obtain higher mechanical properties (tensile strength has been increased by 28%–45%), aluminum matrix composites by WAAM have proved to be an effective method. The corresponding proper heat treatment can also increase the tensile strength of WAAM Al alloy by 104.3%. In addition, mechanical properties are always assessed to evaluate the quality of deposited parts. The mechanical properties including the tensile strength, yield strength, and hardness of the deposited parts under different processing conditions have been summarized to provide a reference for the quality evaluation of the deposition. Examples of industrial products fabricated by WAAM are also introduced. Finally, the application status of WAAM aluminum alloy is summarized and the corresponding future research direction is prospected.

Recent advances on hydrogen generation based on inorganic metal oxide nano-catalyst using water electrolysis approach

Abstract Today world is looking for a cheap, environment friendly and efficient substitute of fossil fuel. Because due to large consumption of the fossil fuels on daily basis in whole world, emission of hazardous gases have produced lethal effects on human being. In this scenario hydrogen energy has emerged in form of clean, renewable and more efficient energy. Now the key challenge is that efficient production of the green hydrogen at commercial scale to meet demand of hydrogen. The electrolysis of water is the best pathway to achieve efficient hydrogen production. For this purpose the synthesis and improvement of low cast, active as well as stable catalysts or electrolysis is prerequisite for hydrogen production by electro-catalytic method for splitting of water. Main focus of this review is that, how we can perform the electrolysis of water by various techniques using novel methods especially electro-catalysts in term of activity, efficiency, large surface area, porosity, and stability. This will be performed by the method of two-half cell reaction one is the Hydrogen Evolution Reaction (HER) other one Oxygen Evolution Reaction (OER), where reaction proceeded in both medium acidic as well as alkaline phases. Particular attention is given to produce green clean hydrogen production from usable water and its physical and chemical storages for further uses for the support of human sustainability. Basically the recent strategy is to prepare, design and development of nanoscale materials/composite with non-noble metals and with also nanostructured with noble-metals will be discussed in this approach. The increased efficiency and utility have been the focal points of the use of diverse materials from different classes. To increase the electro-catalytic efficiency in OER and HER, we will discuss about new analyses methods and insights into studying the chemical compositions, shapes, surface area, porosity, and synergy of catalysts and the active sites of nanostructured electro-catalysts. This review will further provide the picture of current state of developments as well as recent progress for mechanized efficient production of clean hydrogen (i.e., HER) from water by electrocatalytic method using various nanoscale materials in a broad scale.

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Effect of tempering temperature on microstructure and properties of low silicon hypereutectic high chromium cast iron

Design and Manufacturing of Air Conditioning Coil

This paper consists of the detail design process of a cooling coil which is used in Evaporator of VARC System for given cooling load. The process consists of designing a part using the calculation and various other parameters. The stability of long-term materials is becoming increasingly important as the demand for air conditioning systems in commercial and residential applications grows. Because of temperature variations and heat flow, materials in air conditioning systems can fail, reducing the cooling effect of the system. Low thermal transitions through the coil's material cause a significant amount of heat to be wasted in the evaporator coil, which lowers the system's overall efficiency. This paper outlines the methodology used to choose the right material for the evaporator coil in an air conditioning system using the CES Granta design software. Based on design and functional requirements, nickel-chromium alloys, pure titanium, copper, low alloy steel, cast iron, and pure titanium are the candidates that made the shortlist for evaporator coils. The best candidates are low alloy steel, titanium, and stainless steel.

Microstructure evolution during solidification in a low superheat casting process of the Al-Mg2Si composites having excess Si: A phase field study

A two-dimensional phase field (PF) model of solidification during low superheat casting has been developed to grab insight into the microstructure formation mechanism of the Al-xMg2Si-ySi composite, having extra Si as the grain refining agent. The developed PF model employs a seed undercooling based nucleation model to simulate the formation of primary Mg2Si and α-Al grains, wherein the interfacial energy of the Al-melt interface is taken from literature, and a Molecular Dynamics (MD) model is employed to calculate the interfacial energy of the Mg2Si-melt interface. The simulation study predicts the microstructural parameters such as grain size, and sphericity of the primary Al and primary Mg2Si phases, as well identifies the appropriate numerical parameters such as mobility, anisotropy parameters to study the microstructure evolution in the Al-xMg2Si-ySi composites. The kinetics of grain growth of both α-Al and primary Mg2Si have been studied. Novelty of the study lies in developing a near-accurate PF model capable of optimising the weight fraction of Mg2Si and excess Si in the low superheat cast Al-xMg2Si-ySi composite system, in view of obtaining the lower grain size and higher sphericity of both primary Al and primary Mg2Si grains, which is in line with the experimental observations. The proposed PF model is capable of predicting the faceted growth of Mg2Si particles in the Al-xMg2Si-ySi composite, in presence of extra Si and during low superheat casting, and the dendritic growth of Mg2Si in the binary Al-Mg2Si composite having high Mg2Si weight fraction. Following the Jackson’s model of interface growth, it has been demonstrated that the modification of kinetic coefficient leads to a transformation of morphology of Mg2Si particles from large dendritic to faceted ones.

#2622 Very late renal recovery in patient with light chain cast nephropathy: the prognostic value of renal biopsy

Abstract Background and Aims Renal biopsy is not necessary to assess LCCN (Light Chain Cast Nephropathy) in patients with laboratory features suggestive of the disease. However, it has been shown that the histological picture often correlates with renal outcome. We present the case of a 55-year-old man with no significant previous medical history that was evaluated in the emergency department for a stage 3 AKI (sCr 17.3 mg/dl, eGFR 3 ml/min/1.73 m2). Laboratory tests showed a Lambda Micromolecular Myeloma (K chains 44.6 mg/l, λ 4160 mg/l and K/ λ 0.01); Bence Jones not evaluable due to anuria. Bone marrow plasmacytosis was 70%. Method The patient started chemotherapy with Bortezomib and Dexamethasone and hemodialysis thrice a week with a PMMA hemofilter in order to improve the FLC (Free Light Chain) removal rate. After three months of treatment the patient achieved a complete hematologic response but he didn't reach any renal response. In order to assess a more precise renal prognosis a kidney biopsy was performed. The histopathological exam showed a Cast Nephropathy (< 5 casts/mm2) associated with low grade interstitial fibrosis and tubular atrophy (IFTA +1). After 5 cycles with Bortezomib and Dexamethasone, one year after onset, the patient underwent ASCT (Autologous Stem Cell Transplantation). Results In the following months, a progressive increase in renal function allowed us to perform a gradual reduction of dialysis rate, until discontinuation occurred 16 months after disease onset. To date, three years after onset, complete hematologic and renal remission persists with an eGFR of 20 ml/min/1.73 m2. Conclusion Renal biopsy, performed even several months after disease onset, could play a pivotal role in cases of LCCN with a discordance between hematologic and renal response. A low cast number and low IFTA grade are known to be positive prognostic factors for renal outcome and they can predict a renal recovery that sometimes could be exceptionally late.

Single-Atom-Based Nanoenzyme in Tissue Repair.

Since the discovery of ferromagnetic nanoparticles Fe3O4 that exhibit enzyme-like activity in 2007, the research on nanoenzymes has made significant progress. With the in-depth study of various nanoenzymes and the rapid development of related nanotechnology, nanoenzymes have emerged as a promising alternative to natural enzymes. Within nanozymes, there is a category of metal-based single-atom nanozymes that has been rapidly developed due to low cast, convenient preparation, long storage, less immunogenicity, and especially higher efficiency. More importantly, single-atom nanozymes possess the capacity to scavenge reactive oxygen species through various mechanisms, which is beneficial in the tissue repair process. Herein, this paper systemically highlights the types of metal single-atom nanozymes, their catalytic mechanisms, and their recent applications in tissue repair. The existing challenges are identified and the prospects of future research on nanozymes composed of metallic nanomaterials are proposed. We hope this review will illuminate the potential of single-atom nanozymes in tissue repair, encouraging their sequential clinical translation.

CURE-Net: A Cascaded Deep Network for Underwater Image Enhancement

Underwater imaging is usually degraded by low contrast or color cast due to light absorption and scattering. This fact limits the accuracy of object recognition in underwater and marine environments. In this article, to address this issue, we propose a CURE-Net that progressively improves degraded underwater images in a coarse-to-fine way. To be specific, our CURE-Net consists of three cascaded subnetworks. The first two subnetworks use attention and gate fusion to learn multiscale contextual information, whereas the third subnetwork preserves fine spatial details. A detail enhancement block and a supervised recovery block are deployed between subnetworks to further improve the recovery of colors and details. Our proposed CURE-Net is extensively evaluated on popular data sets and achieves state-of-the-art performance. Compared with its peers, our method is also more friendly to object recognition—underwater objects are more easily recognized after being processed by our method.

Thermal fatigue degradation progress in SiMo ductile cast iron under oxidation conditions

Thermal fatigue tests were conducted on a high Si low Mo ductile cast iron (DCI) under oxidation conditions at 600 °C. The study aimed to understand the evolution of surface degradation, focusing on complex composed graphite nodules, pearlite islets, and their impact on crack initiation and growth in relation to oxidation processes, etc. Degenerated graphite nodules, that include ferrite particles, and areas of increased graphite nodule density, along with pearlite islets, were examined for their oxidation behavior. At lower thermal cycles numbers cracks primarily initiated of at the graphite-matrix interface and grew faster in the case of successively arranged graphite nodules and their higher local number density. Graphite degradation involved debonding between graphite and matrix, followed by complex oxidation processes. Degenerated nodules exhibited higher oxidation rates due to the presence of ferrite which acts as oxidation pathways. Areas with increased graphite density and larger sizes facilitated accelerated oxidation via crack formation. Additionally, pearlite degradation started with cracked cementite lamellae, followed by oxidation. Strategies to enhance thermal fatigue resistance included reducing graphite nodule diameter, ensuring their uniform distribution, preventing of formation of degenerated nodules and eliminating porosity. These findings improve understanding of thermal fatigue behavior in DCI that has proven to be even more complex than previously thought. The findings will guide the development of advanced materials for demanding applications.

Flexible and low roughness cast films: promising candidates for capacitor applications

Flexible and low roughness cast films: promising candidates for capacitor applications

Adaptive rule-based colour component weight assignment strategy for underwater video enhancement

ABSTRACT Images and videos collected in an underwater environment often have low contrast, blur, and colour cast due to two significant sources of distortion; light scattering and absorption. In an underwater image/video, suspended particles attenuate red and blue components more than green channels. This article presents two adaptive weight allocation strategies based on rule assignment for red, green, and blue channels. Firstly, an improved balanced contrast enhancement technique (IBCET) is proposed using an adaptive contrast enhancement scheme based on colour component weight assignment. Secondly, a modified fuzzy contrast enhancement technique which obtains the intensification factor based on the weight of each component is developed. Finally, principal component analysis fusion is employed to improve the overall colour and contrast of the output video frames. Qualitative and quantitative evaluations on the standard underwater video dataset are demonstrated to validate the improved performance of the proposed algorithm.

Low cycle fatigue response and fracture mechanism in a novel Al-3.5Si-0.5Mg-0.4Cu casting alloy

The LCF (low-cycle fatigue) behavior of a T6-treated low silicon cast aluminum alloy Al-3.5Si-0.5Mg-0.4Cu was investigated under axial symmetric tension-compression cyclic loading conditions. LCF behavior and results of experiment (under 6 different total strain amplitudes from 0.25 % to 0.5 %) are included. OM (Optical Microscopy), SEM (Scanning Electron Microscope), XRD (X-Ray Diffraction) and TEM (Transmission Electron Microscope) are employed to observe and analyze the fracture morphology and microstructure evolution. The results demonstrate that cracks were initiated from surface or subsurface defects. A higher total strain amplitude led to a smaller sum area of fatigue crack initiation region as well as a steady crack propagation regime, and a larger fatigue striation bandwidth. Furthermore, crack propagates along the interface between eutectic silicon and α-Al matrix under lower strain amplitudes. Otherwise, it extends through eutectic silicon particles if higher strain amplitudes are applied.

Enhancing Fe content tolerance in A356 alloys for achieving low carbon footprint aluminum structure castings

Low carbon footprint aluminum structure castings are the mainstream development direction of aluminum alloys in the future. Enhancing the Fe content tolerance upper limit in casting aluminum alloys is considered an effective way to promote the application of recycled aluminum production. In this work, it was found that with the Ce and TiCN NPs (nanoparticles) addition simultaneously to A356 alloys, the acicular Fe-rich phases (β-Al5FeSi) which damages the properties can be changed into beneficial phases (core-shell heterostructures) for the alloy, and hence the mechanical properties of A356 alloys can be improved. The TiCN nanoparticles and rare element Ce play crucial roles in the formation of core-shell heterostructures. The formation mechanism of core-shell heterostructure was also systematically researched from the perspective of thermodynamics and kinetics. This study provides a simple and feasible strategy to eliminate the harmful effects of Fe impurity and contributes to the industrialization of low carbon footprint aluminum structure castings.

Optimisation of melt pouring temperature and low superheat casting of Al-15Mg2Si-4.5Si composite

ABSTRACT In this study, a computational fluid dynamics (CFD) model is employed to optimise the melt pouring temperature during Low superheat casting (LSC) of the Al-15 Mg2Si-4.5Si composite. The die cavity considered to perform the die filling simulations corresponds to the as-cast tensile specimens, as per ASTM B557 guidelines. The findings of the study include melt temperature distribution, solid fraction distribution during filling as well as during solidification, velocity distribution of the melt and surface defect concentration. Experimentation is performed to develop low superheat cast composite based on the numerically estimated optimum melt pouring temperature of 650°C. Mixture of irregular dendritic, polygonal and equiaxed shaped primary Mg2Si grains are observed within the cast parts, whereas primary Al grains are found to be of dendritic morphology with occasional presence of spheroids. Marked improvements in microstructure and mechanical properties have been evidenced in the LSC composite compared to its conventional cast counterpart.

Synergy Study Between a Lubricant Oil Layer and a Microstructural Graphite to Reduce Friction and Wear of a Thermally Modified Low-Carbon Gray Cast-Iron Cylinder Liner

The results of a sliding wear tests on base and thermal treated gray cast iron (GCI) samples from internal combustion engine cylinder liner are reported here for dry and lubricated conditions. A thermal treatment was applied to samples of 10 x 10 mm to avoid the effect of residual stress and to obtain the microstructure of interest. Tribological tests were carried out up to 27000 cycles at room temperature. A frequency of 15 Hz, a stroke amplitude of 6 mm, and a maximum contact pressure of 1.12 GPa were selected. Under the unlubricated settings, a noticeable decrease in friction coefficient and specific wear rate are attributed to the appearance of irregular graphite nodules in the heating–quenching process. The significance of thermal treatment applied to low carbon cast iron in the derived self-lubricating function and its synergistic role with the oil lubricant is discussed. In this context, this work illustrates, for the first time, how the change in the morphology from flake graphite to irregular nodule graphite positively determines the reliability of gray casting irons.

Research on dye sensitized solar cells: recent advancement toward the various constituents of dye sensitized solar cells for efficiency enhancement and future prospects.

It is universally accepted that the financial advancement of a state is essentially dependent upon the energy sector as it is essential in the growth, development, and improvement of the farming, mechanical, and defense sectors. A dependable source of energy is expected to enhance society's expectation of everyday comforts. Modern industrial advancement, which is indispensable for any nation, relies upon electricity. The principal explanation behind the energy emergency is rapidly increasing the use of hydrocarbon resources. Thus, the use of renewable resources is essential to overcome this dilemma. The consumption of hydrocarbon fuels and their discharge has destructive consequences on our surroundings. Third-generation photovoltaic (solar) cells are latest encouraging option in solar cells. Currently, dye-sensitized solar cells (DSSC) utilize organic (natural and synthetic) dye and inorganic (ruthenium) as a sensitizer. The nature of this dye combined with different variables has brought about a change in its use. Natural dyes are a feasible alternative in comparison to expensive and rare ruthenium dye owing to their low cast, easy utility, abundant supply of resources, and no environmental threat. In this review, the dyes generally utilized in DSSC are discussed. The DSSC criteria and components are explained, and the progress in inorganic and natural dyes is monitored. Scientists involved in this emerging technology will benefit from this examination.

Preprocessing of Laser-Induced Breakdown Spectra of Low Alloy Steels and Cast Irons Using Partial Least-Squares Regression Analysis

Preprocessing of Laser-Induced Breakdown Spectra of Low Alloy Steels and Cast Irons Using Partial Least-Squares Regression Analysis