Steel Mold Research Articles

Mechanical characterization of sandwich composite structures with Alumix231 foam core between Al2024/B4C composite plates

Abstract The study investigates the production of lightweight B4C particle-reinforced aluminum sandwich foam (ASF) materials, crucial for high impact and corrosion resistance, particularly in defense and automotive sectors. These materials are manufactured via powder metallurgy. Five different combinations of ASF materials, layered and unlayered with B4C, were examined. Alumix231 served as the primary material in the Al foam, with TiH2 as the blowing agent. In layered ASF materials, Al2024 powder acted as the main material, reinforced by B4C particles. Samples with various configurations, including foam, foam/Al2024 layers, and 5-10–20 % B4C particle-reinforced Al2024 layers, were produced. After powder mixing, they were filled into a hot pressing mold, pre-pressed at 25 MPa, dwelled at 550 °C for 30 min, then hot pressed at 200 MPa to form foamable preform material. B4C particle-layered ASF materials were generated by foaming the preforms in a steel mold at 750 °C for 11 min. Microstructure, density, pore size, and morphology analyses were conducted. Al2024 exhibited the highest density at 99 %, decreasing with increased B4C ratio. With more B4C, compressibility decreased, and agglomeration increased. Pores were observed around TiH2 and Si particles in B4C-lacking materials. The material with the best homogeneity and spherical pore resemblance was noted as Alumix231.

An Initial Study of Ultra High Performance Concrete as Reusable Mold Material for Aluminum Casting.

The initial investigation evaluates the feasibility of ultra high performance concrete (UHPC) as a material for reusable molds in aluminum casting. Two specific UHPC formulations were investigated: one based on ordinary Portland cement (OPC) and another utilizing alkali-activated materials (AAM). The study focused on investigating the surface through roughness measurements and the thermal durability through repeated casting cycles. The thermal stability of the molds was investigated by thermogravimetric analysis, mercury intrusion porosimetry, crack segmentation, optical microscopy, and electron microscopy. Results indicate that molds fabricated from AAM-UHPC exhibit relatively better performance in terms of maintaining structural integrity and surface quality over repeated uses. AAM-UHPC molds were able to withstand up to ten casting cycles with acceptable surface degradation and no significant failure, while OPC-UHPC molds exhibited a faster degradation under similar conditions. Microstructural changes and the interaction of UHPC materials with molten aluminum were investigated, highlighting the low adhesion and defect formation. Additionally, the molds demonstrated sound casting quality, with a grain size comparable to that achieved using traditional steel molds (~ 90 µm), underscoring the potential of UHPC materials for enhancing casting quality and efficiency. The study concludes that UHPC, particularly with alkali-activated formulations, shows promise for low-pressure casting environments.

Low-alloyed steel with superior dry abrasive wear resistance and mechanical properties processed via steel mold casting

Low-alloyed steel with superior dry abrasive wear resistance and mechanical properties processed via steel mold casting

Influence of centrifugal casting parameters on Al-Mg alloy castings microstructure and mechanical properties

The paper is dedicated to the process of obtaining hollow castings on a horizontal centrifugal casting machine. The influence of mold rotation speed and the melt pouring process mechanical properties of as-cast parts made of AlMg5, alloyed by small amount of transition and rare earth metals, is represented. Mold pouring processes and crystallization kinetics depend on mold rotational speeds 1100, 1500 and 2000 rpm were studied by using numerical modeling. The influence of the specified mold rotation speeds on the structure and mechanical properties of castings is shown. It is also determined that the installation of a foam ceramic filter in the pouring cup of a centrifugal casting machine ensures melt laminar flow when pouring it into a mold. It was determined that 1500 rpm is the most favorable rotating speed from the points of optimal hydrodynamic mold filling processes and casting crystallization kinetics. It was also shown that with the increase of a mold rotation speed from 1100 to 2000 rpm, the thickness of the defective inner layer decreases, the alloy structure refines, and the mechanical properties of as-cast detail increase the next way: at 1500 rpm (σ0.2–by 10%, σB − by 25%, δ − 3 times), at 2000 rpm (σ0.2–by 18%, σB − by 31%, δ − 4 times), compared to products obtained by steel mold gravity casting. Centrifugal casting technology ensures the mechanical properties of cast blanks even higher than those of deformed AlMg5 alloys, the values of which approach those of AlMg6 alloy products.

A novel low-cost selective laser-melted 718HH plastic mold steel with an excellent combination of strength and toughness

A novel low-cost selective laser-melted 718HH plastic mold steel with an excellent combination of strength and toughness

Oxynitrided Ti-6Al-4V Coatings Deposited by Twin Wire Arc Spray for Protection of Aluminum Die-Casting Molds

Steel molds used for aluminum die-casting often fail due to excessive wear or cracking phenomena associated with the soldering effect in contact with molten aluminum, which leads to the formation of iron-based intermetallic compounds and causes problems in the cast components. One solution is to apply protective coatings whose composition is less reactive with the molten aluminum and improve its hardness, toughness, wear, and corrosion resistance, thus prolonging its service life. This work evaluates the effectiveness of Ti-6Al-4V coatings deposited by twin wire arc spraying in an air or nitrogen atmosphere. Nitrogen was used as the carrier and shielding gas for the in-flight molten particles. Coatings were deposited by varying the stand-off distance, the nitrogen gas pressures, and the substrate temperature. The microstructure of the coatings is interlayered, one porous layer of dendrites and one highly densified layer. The presence of TiN, TiO2, α-Ti, and β-Ti phases was confirmed by different characterization methods. For instance, x-ray photoelectron spectroscopy measurements confirmed the presence of N-Ti, O-Ti, and N-O bonds, with the oxygen/nitrogen/titanium percentage associated with the formation of a non-stoichiometric (Ti, Al, V)NxOy phase. Finally, the reactivity of selected oxynitrided Ti-6Al-4V coating in contact with molten aluminum showed a low reaction rate compared to the coarse reaction layer suffered by the uncoated steel substrates.

Enhancing surface properties of AISI P20 + Ni mold steel via boronizing: Evaluation of mechanical, tribological, and corrosion performance

Enhancing surface properties of AISI P20 + Ni mold steel via boronizing: Evaluation of mechanical, tribological, and corrosion performance

Mechanical properties and radiological implications of replacing sand with waste ceramic aggregate in ordinary concrete

The mining of aggregates for the production of concrete creates ecological problems. In this study, the effect of partially replacing sand as fine aggregate (FA) with waste ceramic tiles (WCT) on the density, compressive strength (CS), specific radioactivity of naturally occurring radioactive materials (238U, 232Th, and 40K), and the radiation shielding competence of concrete was investigated. Ordinary concrete samples consisting of cement, fine aggregate (river sand), coarse aggregate (granite), and water were prepared in 50 mm × 50 mm x 50 mm cubical steel moulds. The samples were coded as C-WCT0, C-WCT5, C-WCT10, C-WCT15, C-WCT20, and C-WCT25, representing concrete samples in which the FA component was replaced by 0, 5, 10, 15, 20, and 25% pulverized WCT, respectively. The CS and density of the samples were determined after 7-, 14-, and 28-day curing periods. The gamma spectrometric method was used to determine the specific activity of 238U, 232Th, and 40K using a hyper pure germanium detector. The photon and neutron shielding parameters of the concrete blocks were calculated with the aid of the EPICS2017 cross-section library and relevant standard formulae. The mean CS for each concrete category increase with curing age. The density of the concrete varied from 2213 kg/m3 to 2488 kg/m3 as the FA replacement level rose to 15%. Using WCT as a partial replacement for FA altered the chemical composition and decreased the specific activities of 238U, 232Th, and 40K, in the concrete samples. C-WCT15 had the best gamma photon and fast neutron absorption features among the concrete samples. The use of WCT as aggregate in concrete production is a sustainable and environmental-friendly way of producing concrete for general civil engineering and shielding applications in medical and other radiation facilities. This study also affirms that using alternative materials with lower specific activity to replace sand is radiologically desirable in reducing the indoor radiation dose of occupants of concrete-based structures. The replacement of 15% sand by WCT produced stronger, radiologically safer, and more effective radiation absorbing concrete.

Study of Li2O reduction in mould slag for continuous casting of low-carbon steel slab

The addition of Li2O increases production costs for continuous casting, despite its enhancement of the melting and flow properties of mould slag. Initially, laboratory research focused on assessing the individual impacts of Li2O, F, Na2O and Al2O3 on the viscosity and melting temperature of the slag, using a basicity of 0.95. Subsequently, four stages of industrial testing were conducted to optimise the slag, evaluating parameters such as temperature and friction force curves of the mould copper plate thermocouple, steel slag consumption per ton and strand surface quality. The optimised slag achieved a basicity of 0.98, a viscosity of 0.29 Pa·s and a melting temperature of 1115 °C, meeting all performance requirements for low-carbon steel mould slag. Compared to the original flux, the mass percentage of Li2O decreased significantly from 1.54 to 0 wt-%, while Na2O increased from 2.36 to 7.35 wt-%, and Al2O3 decreased from 7.28 to 3.49 wt-%. The operation of the optimised flux remained stable, with smooth fluctuations observed in the mould copper plate thermocouple temperature and friction force curves. These research findings hold significant reference and practical value for further development and application.

Effect of Resin Content on the Properties of Roofing Tile for Building Materials

The production process of roofing tile materials uses among other materials thermosetting adhesive resins normally urea formaldehyde (UF), phenol formaldehyde (PF), di-isocyanate (PMDI) at various content mixtures, 3wt%, 5wt%, 7wt%, 9w% and 11wt% with a usual thickness of 6 mm. The fibers, adhesives, and other materials are then placed into a steel mold with the standard dimensions of 400 mm x 400 mm, to be then hydraulically pressed at high pressure and the required temperature. Overall, PMDI synthetic adhesives have better physical and mechanical properties than PF synthetic adhesives, however the thermal properties of UF and PF synthetic adhesives are better than PMDI. The physical properties testing were density, humidity content, absorption of water, thickness inflated and water permeability. The mechanical properties such as modulus of rupture (MOR) and modulus of elasticity (MOE), impact strength and tensile strength are all measured according to JIS A 5908-2003, ASTM D 256-2006a,TIS 535-2556 and ASTM D1037-12.The testing for the thermal conductivity, thermal resistivity and solar reflectance were done according to ASTM C177-2010 and ASTM E 891-87. The type of resin content and adhesive used had a significant impact on the physical, mechanical and thermal properties of the roofing tile materials of showed in the results of the analysis of variance (p >0.05). The produced roofing tile has an improved thermal conductivity and heat insulation which can be a substitute for hazardous asbestos based roofing materials.

Prediction of feed force with machine learning algorithms in boring of AISI P20 plastic mold steel

Feed force plays a critical role in machining performance, including efficiency, hole quality, energy consumption, and tool life. While feed force is typically measured using dynamometers, these devices are often impractical in real-world experiments due to their complexity and cost. In particular, boring operations, which are essential for enlarging holes within tight tolerances, depend on precise feed force control to maintain high-quality hole outcomes. Achieving this precision requires reliable pre-process feed force estimation. However, traditional analytical methods for calculating feed force in boring operations often fall short, largely due to factors such as in-hole dynamics, the inclination of the rake surface, and the slenderness of the boring bar. This study aims to apply single and hybrid machine learning methods to accurately model and predict feed force in the boring process. Unlike previous research, which focused on feature selection, we propose the use of all possible combinations of input feature subsets to determine the optimal input features. The results indicate that feed force can be predicted effectively using these optimized feature combinations. Such accurate feed force prediction is crucial for effective process optimization, material selection, and process planning.

Dimensional and Shape Analysis of Additively Manufactured Shaped Parts of DIEVAR Steel Moulds

Dimensional and Shape Analysis of Additively Manufactured Shaped Parts of DIEVAR Steel Moulds

Compressive stress-strain response of freshly compressed rubberized concrete: An experimental and theoretical study

Although using crumb tire rubber concrete (CTRC) in constructing structural elements is accompanied by various environmental and economic advantages, it always comes with challenges due to a significant loss in some mechanical properties of this concrete type. To tackle this challenge, a novel technique of compressing fresh concrete was used, and its impacts on improving the mechanical features of CTRC were investigated. For this purpose, concrete specimens containing crumb tire rubber (CTR), as the fine aggregate substitute, were constructed considering the variables of the water-to-cement ratio (w/c), volume percentage of CTR, and the fresh concrete pressure level as a fraction of steel tube (mold) yielding stress. After the application of a specified short-term pressure to the fresh mix inside the steel molds and the time required for the concrete setting, the steel tubes were removed after curing, and the concrete core alone was exposed to an axial compressive load. According to the test results, the mechanical properties, weight loss resulting from compressing the fresh concrete, energy absorption, failure pattern, the concrete microstructure, water absorption, and porosity were evaluated. By applying an initial axial pressure of 25–80 MPa on the mixes containing 0 %, 15 %, and 30 % CTR replacing the fine aggregate, the compressive strength, the ultimate strain, the toughness, and the initial modulus of elasticity experienced 100–140 % increase, 130–420 % increase, 120–1140 % increase, and 66–70 % decrease, respectively, compared with the uncompressed specimen. Finally, a regression analysis was employed to propose prediction models for the compressive capacity, modulus of elasticity, peak strain, ultimate strain, and relative toughness of freshly compressed concrete containing CTR particles; these models show proper agreement with the experimental results.

Influence of manufacturing parameters on bioactive glass 45S5: Structural analysis and applications in bone tissue engineering

Bioactive glass (BG-45S5) production through the melting process is affected by a wide variety of parameters. This study investigated the synthesis of BG-45S5 granules and the process variables to produce a bioactive and osteoinductive BG for bone grafting applications. The melting process was initially analyzed by varying parameters such as crucible type and pouring environment using P2O5 as phosphorus precursor. The obtained products were characterized by crystalline phases, characteristic chemical groups, particle size distribution, and chemical composition. Materials poured into graphite or steel molds resulted in particle sizes more suitable for applications in granular form. Using a platinum crucible yielded a chemical composition closer to the target when compared with another ceramic crucible. Subsequently, the melting process was evaluated to different phosphorus precursor (P2O5 or Na2HPO4) and melting duration (1 or 2 h) in a platinum crucible verifying their effects on the thermal behavior, chemical composition and structure of BG-45S5. Employing Na2HPO4 as a precursor led to higher glass transition and crystallization temperatures as compared to P2O5, enhancing glass homogeneity and structural stability. The product with better characteristics in terms of composition and structure was further characterized for bioactivity and cell culture behavior, showing a greater amount of mineralization nodules when compared to commercial hydroxyapatite. This is particularly due to its behavior as the solubility and interaction in biological environments.

Effects of particle size, binder wettability, and sintering atmosphere on the microstructural and mechanical properties of binder jetted 18Ni300 alloy

A fully dense 18Ni300 mold steel was firstly prepared by the binder jetting (BJ) process. We developed a water-based binder characterized by its low viscosity, which significantly enhanced the penetration of binder into the fine powder layer. This process resulted in a deep, narrow cross-section due to reduced flow resistance, leading to strong inter-layer bonding and high surface quality of the green part. The densification behavior of 18Ni300 BJ green parts with different particle sizes was meticulously analyzed. A remarkable tensile property of YS = 783 MPa, UTS = 1012 MPa and EL = 8.8% were obtained in sintered 18Ni300 alloy with fine powder under 1460 °C and 50 mTorr vacuum. Building on thermodynamic theory, we introduced a novel criterion to assess the oxidation reactions in 18Ni300 parts fabricated by the BJ method during sintering under different atmospheric conditions.

Section thickness effect on microstructure, mechanical and electrical properties of permanent steel mold cast eutectic Al-1.8Fe alloy

Abstract A eutectic aluminum alloy, with a composition of 1.8 wt% iron, underwent casting using permanent steel mold casting (PSMC) across three distinct section thicknesses: 2mm, 8mm, and 20mm. The microstructure of the as-cast alloy was analysed by the scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). The microstructure analyses indicated that the cast Al-1.8Fe alloy consisted of the primary Al phase, eutectic Al phase, micron-sized eutectic Al-Fe phase, and nano-sized eutectic Al-Fe phase. The results of tensile testing revealed notable improvements in mechanical properties for the cast Al-1.8Fe alloy as the section thickness decreased from 20mm to 2mm. Specifically, Ultimate Tensile Strength (UTS), Yield Strength (YS), elongation (ef), modulus, toughness, resilience, and electrical conductivity increased from 85.99 MPa, 28.33 MPa, 15%, 63 GPa, 8.58 MJ/m3, 6.37 kJ/m3, 48.44 %IACS to 157.74 MPa, 84.83 MPa, 19%, 66.4 GPa, 23.87 MJ/3, 54.17 kJ/m3, 51.09 %IACS, respectively. Conversely, porosity levels decreased from 5.17% to 1.87% as thickness increased from 2mm to 20mm. The enhanced mechanical properties and electrical conductivity observed in the 2mm sample are attributed to its fine microstructure and low porosity. Additionally, SEM fractography revealed that fracture behavior in PSMC Al-1.8Fe was influenced by section thickness.

Performance of Geopolymer Insulation Bricks Synthesized from Industrial Waste

In the current work, aluminum dross from the aluminum industry and fired-clay brick waste (Homra) were combined with alkaline activators (Na2SiO3/NaOH) with varying molarities of NaOH to create insulating geopolymer bricks. An alkaline activator with an (S/L) ratio of 3/1 was combined with Homra to replace it partly. The mixture was then molded into 50 × 50 × 50 mm3 stainless steel molds. Water absorption, compressive strength, bulk density, and apparent porosity of the produced geopolymer were measured at various curing durations and NaOH molarities. The findings showed that adding more aluminum dross waste replacement leads to a decrease in bulk density and compressive strength and an increase in the creation of pores that improve the produced bricks’ ability to insulate against heat. Using 8 M of NaOH after 28 days, the findings revealed that 3% aluminum dross waste replacement has a compressive strength of about 8.6 MPa, water absorption of 14.6%, bulk density of 1.307 g/cm3, and thermal conductivity of 0.32 W/m·K. The Egyptian standard, ASTM C62, satisfies these outcomes. Using DesignBuilder energy simulation software version 6.1.06, the constructed insulating brick under ideal circumstances was utilized to calculate its contribution performance in energy consumption. The annual energy consumption was reduced by about 21% compared to traditional hollow cement bricks.

Experimental analysis and machine learning with IoT monitor in two-way abrasive flow machine polishing on P20 mold components

The purpose of this paper was to reveal the effects of pressure and time on the surface roughness (Ra) and compare the experimental design (Factorial Regression) and machine learning (ML) of steel mold workpieces. Methodology began with turning, and fine sandpaper P180 to P1200 and measured with an initial value of Ra compared with the final value of Ra at the end of the two-way prototype AFM process. The process parameters are as follows; abrasive particle size (alumina; Al2O3) 5.0 μm in Silicone Oil (concentration 50% by weight) at pressures (p) of 10 bar and 20 bar, processing time (t) 5, 15, and 25 min, specimens P20 Mold steel. The experimental results show that under these conditions. The average surface roughness of the specimens differed from the initial value by Ra 0.034 to 0.021 μm, with delta values ranging from 0.011 μm to 0.005 μm. The results showed a smoother profile between before and after polishing. The approach to the topic is DOE and ML, and the theoretical or subject scope of the paper is Statistical and AI. The original value of the paper is applied to the ESP32 Arduino to control and display critical parameters. A General Factorial Regression statistical value of 76.39% is acceptable. A pressure factor of 20 bars and a time of 25 minutes gives the best effect on surface roughness. ML assisted in predicting the Surface Roughness for optimization based on the experiment.

Comparison of Various Surface Treatment Procedures on the Roughness and Susceptibility to Staining of Provisional Prosthodontic Materials.

Esthetically pleasing temporary prostheses are often necessary for extended periods in a variety of clinical scenarios. Adjustments to the occlusion or margins are commonly needed before cementing the temporary prosthesis. Therefore, it is clinically necessary to repolish the rough surface to avoid biological and esthetic issues associated with rough surfaces. The purpose of this in vitro study was to assess and compare the impact of various polishing protocols on the surface roughness and color stability of three resin materials used for provisional crowns. A total of 150 specimens were fabricated from auto-polymerizing polymethyl methacrylate, bis-acryl composite, and Methyl methacrylate-LC resin using a stainless steel mold. Each material group was divided into five groups (n = 10) based on the applied surface treatment: positive control group (G1): no roughening or surface treatment, Negative control group (G2): acrylic bur-roughened surface without any polishing, the different surface treatment groups of silicon carbide and aluminum oxide stone polishing (G3), diamond-coated rubber twist (G4), and Surface Glaze (G5). An optical profilometer was used to assess the surface roughness of all samples. After undergoing 6000 cycles of thermocycling followed by immersion in a coffee solution for 15 days at 37 °C, color parameters were measured using a spectrophotometer both before and after a storage period to evaluate color differences. A two-way ANOVA test with α = 0.05 significance level was carried out to determine the impacts of both the materials utilized and the polishing protocol. Among the three types of resin examined, the bisacryl group exhibited superior surface quality in positive control groups, while PMMA resin demonstrated higher polishability. The diamond-coated rubber twits resulted in lower Ra values of 0.36 (0.01) µm, 0.52 (0.11) µm, and 0.28 (0.05) µm for PMMA, BAMA, and MMLC resins, respectively. The application of photo-polymerized surface glaze led to a plaque accumulation threshold of 0.2 µm across all resin groups. The greatest mean color change occurred in the negative control group, indicating a propensity for more staining on rougher surfaces. The Bisacryl resin exhibited higher ΔE values, whereas PMMA showed better color stability. The lowest ΔE values were found when the surface glaze was applied to all of the provisional crown resins. Untreated Bisacryl resin exhibited the lowest Ra values, while PMMA resins demonstrated superior surface morphology after polishing. PMMA provisional crown resins showed increased resistance to staining. The use of surface glaze enhanced both smoothness and color stability on the surfaces.

Study on the influence mechanism of austenitizing temperature on the surface of corrosion-resistant mold steel

Abstract The microstructure of 4Cr13 corrosion-resistant plastic mold steel was studied. The martensitic experimental steel obtained by different heat treatment processes was used as the object. The effect of austenitizing temperature on its corrosion behavior was studied by microstructure characterization and electrochemical test. The results show that the microstructure of the test steel is mainly composed of martensite laths. Under the same experimental conditions, the corrosion resistance of the test steel decreases with the increase of austenitizing temperature, and the corrosion products are mainly composed of iron-containing oxides. The austenitizing temperature of 1000°C improves the corrosion resistance of the material, because the precipitation of a large number of small-sized Cr-containing carbides hinders the further erosion of the material and improves the surface quality.