This lecture provides an introduction to the techniques used to produce castings and to the range of castings produced; it aims at gaining an appreciation of the production and application of castings.
This lecture provides an introduction to factors affecting the quality of molten aluminium. Basic knowledge of foundry practice is assumed. The student should be able to appreciate the differences between good and bad melting practices in a foundry.
TALAT Lecture 3207: Solidification Defects in CastingsCORE-Materials
This lecture provides an introduction to the causes and remedies of the main solidification defects in castings. The students should be able to diagnose the major defects in castings and propose methods of preventing them. Basic knowledge of physics and foundry practice is assumed.
This lecture describes the function and design of all parts of the running and gating systems used in the production of castings. The students will be able to tackle the design of a simple running system in a systematic manner. Basic knowledge of foundry processes and basic mathematics is assumed.
Electrosteel Castings Limited is one of the premier manufactures of Ductile Iron Fittings in India. Ductile Iron pipes made by Electrosteel Castings Ltd. conform to the Indian and International standards.Please visit: https://www.electrosteel.com/
This document outlines the key details of a home sale located at 123 Main St from the seller John Doe to the buyer Jane Smith. The three bedroom, two bathroom home was sold for $250,000 with the transaction closing on February 15th, 2023. Both the buyer and seller signed the contract agreeing to the terms of the sale.
Psychology is the science of the mind and behavior. The word "psychology" comes from the Greek word psyche meaning "breath, spirit, soul", and the Greek word logia meaning the study of something.
According to Medilexicon's medical dictionary, psychology is "The profession (clinical psychology), scholarly discipline (academic psychology), and science (research psychology) concerned with the behavior of humans and animals, and related mental and physiologic processes." Although psychology may also include the study of the mind and behavior of animals, in this article psychology refers to humans.
This document discusses the material and energy requirements for aluminum production. It notes that in 2010, global aluminum production was 41.4 million tons, requiring 621 billion kWh of electricity, which accounted for 3% of total global electricity production. Aluminum is primarily produced through the Bayer process to refine bauxite into alumina, followed by the Hall-Héroult process to reduce alumina into aluminum. Secondary aluminum production involves recycling aluminum scrap and hydroxide. Producing 1kg of aluminum requires mining 5,900kg of earth, 5.1kg of bauxite, 1.93kg of alumina, and 0.45kg of carbon anode. Recycling aluminum hydroxide
This lecture provides an introduction to factors affecting the quality of molten aluminium. Basic knowledge of foundry practice is assumed. The student should be able to appreciate the differences between good and bad melting practices in a foundry.
TALAT Lecture 3207: Solidification Defects in CastingsCORE-Materials
This lecture provides an introduction to the causes and remedies of the main solidification defects in castings. The students should be able to diagnose the major defects in castings and propose methods of preventing them. Basic knowledge of physics and foundry practice is assumed.
This lecture describes the function and design of all parts of the running and gating systems used in the production of castings. The students will be able to tackle the design of a simple running system in a systematic manner. Basic knowledge of foundry processes and basic mathematics is assumed.
Electrosteel Castings Limited is one of the premier manufactures of Ductile Iron Fittings in India. Ductile Iron pipes made by Electrosteel Castings Ltd. conform to the Indian and International standards.Please visit: https://www.electrosteel.com/
This document outlines the key details of a home sale located at 123 Main St from the seller John Doe to the buyer Jane Smith. The three bedroom, two bathroom home was sold for $250,000 with the transaction closing on February 15th, 2023. Both the buyer and seller signed the contract agreeing to the terms of the sale.
Psychology is the science of the mind and behavior. The word "psychology" comes from the Greek word psyche meaning "breath, spirit, soul", and the Greek word logia meaning the study of something.
According to Medilexicon's medical dictionary, psychology is "The profession (clinical psychology), scholarly discipline (academic psychology), and science (research psychology) concerned with the behavior of humans and animals, and related mental and physiologic processes." Although psychology may also include the study of the mind and behavior of animals, in this article psychology refers to humans.
This document discusses the material and energy requirements for aluminum production. It notes that in 2010, global aluminum production was 41.4 million tons, requiring 621 billion kWh of electricity, which accounted for 3% of total global electricity production. Aluminum is primarily produced through the Bayer process to refine bauxite into alumina, followed by the Hall-Héroult process to reduce alumina into aluminum. Secondary aluminum production involves recycling aluminum scrap and hydroxide. Producing 1kg of aluminum requires mining 5,900kg of earth, 5.1kg of bauxite, 1.93kg of alumina, and 0.45kg of carbon anode. Recycling aluminum hydroxide
The document discusses multi response optimization of friction stir welding (FSW) parameters for aluminum alloy AA6105 using the Taguchi method. It first provides background on welding processes including FSW. It then discusses factors that affect FSW quality like rotational speed, welding speed, and tilt angle. The document proposes using an L9 orthogonal array experiment with three control factors and mechanical properties and microstructure as response variables. The methodology involves conducting experiments, applying Taguchi analysis and ANOVA to optimize parameters for properties like tensile strength and hardness. The research aims to minimize defects and improve joint quality of AA6105. Equipment for FSW and response testing is also detailed.
This 3 sentence summary provides the key details about the industrial training report:
The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.
This document provides an overview of Autokast Limited, an iron casting company located in Cherthala, Kerala, India. It discusses the company's production processes which include molding, melting, pouring, fettling, and inspection. Autokast produces grey iron and spheroidal graphite iron castings up to 8.5 metric tons for applications in automotive, pumps, valves, and machinery. The training report aims to study Autokast's operations and understand how its various departments work together to manufacture cast iron components.
This document provides an overview of the sintering process used in iron ore pellet production. It discusses the history and development of sintering technology, the key equipment and phases in the sintering process, raw materials used and their properties, reactions that occur during sintering, and quality requirements for the sinter product. The document outlines the full sintering process from proportioning materials through cooling and breaking of the sinter product.
This document discusses various non-destructive testing (NDT) methods used to detect defects in gas turbine components, including visual inspection, dye penetrant testing, magnetic particle testing, ultrasonic testing, eddy current testing, replication, radiography, and manual ultrasonic inspection. It provides examples of applying these methods to examine surfaces of gas turbine blades, detect impact damage and white deposits on turbine parts, and identify mid-span sidewall cracking and trailing edge damage.
Thar Coal, A Black Treasure OF Pakistan ( Series of Presentations, (No. 2/17)Malik Tariq Sarwar Awan
This is Series if Presentations, total 17 Presentations, this is No. 2, Next will be Hydel Power of Pakistan, Finally ending in last 4 presentations at Solutions to energy crises to Pakistan.
This document discusses aluminum alloys, including their types, heat treatment, and common alloying elements. It covers casting and wrought alloys, with casting alloys further divided based on their alloying elements like copper, silicon, magnesium, zinc, and tin. Heat treatable alloys can be strengthened through heat treatment to form precipitates, while non-heat treatable alloys rely on solid solution strengthening. Common alloying elements are discussed along with their effects on properties and example commercial alloys.
Production of aluminum (emphasis on energy and materials requirements) Thanos Paraschos
This document summarizes the production of aluminum through primary and secondary processes. Primary production involves refining bauxite ore through the Bayer process to produce alumina, which is then reduced to aluminum using the Hall-Héroult electrolysis process. Secondary production recycles scrap aluminum, which requires only 5% of the energy of primary production. Globally in 2010, 41.1 million tons of aluminum were produced using 210 million tons of bauxite as input. The production processes are energy intensive, requiring around 15 kWh of electricity to produce 1 kg of aluminum, or about 3% of global electricity production.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
Hydroforming process aids to improve the manufacturing of automobile parts and reduce industrial waste, utilization of the product, increase the efficiency of a plant, recycling efficient disassembly etc.
The document describes the process for extracting aluminum from bauxite ore. It involves crushing and grinding the bauxite, mixing it with a caustic soda solution in digesters, cooling the slurry, settling out the impurities, precipitating out the aluminum hydroxide, and calcining it to remove water. The aluminum hydroxide is then smelted using the Hall-Heroult process, which involves dissolving alumina in a molten cryolite bath using an electric current passing between carbon anodes and cathodes to produce molten aluminum.
This document discusses various applications of aluminium alloys including electrical conductors, transport, packaging, building and architecture, and miscellaneous uses. It then provides more detailed information on specific aluminium alloys commonly used in marine applications such as 5052, 5059, 5083, 5086, 6061, and 6063 aluminium alloys and their material properties and typical uses. The advantages of aluminium alloys over steel for vessels include lighter weight and better corrosion resistance, while disadvantages are more difficult welding and lower strength.
This document discusses the process of steel making. It begins by introducing steel and its types, which are classified based on carbon percentage as carbon steel, stainless steel, and alloy steel. It then describes the main steel making methods. The basic oxygen furnace uses carbon-rich pig iron and oxygen to produce low-carbon steel. The electric arc furnace produces specialty steels by heating scrap metal with an electric arc. Secondary steelmaking processes such as argon oxygen decarburization further refine the steel through decarburization, desulphurization, and alloying.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
Carburzing and Different Types of CarburzingMelwin Dmello
This Presentation covers the Basic concepts of Carburzing and Different Types of Carburzing in a easy version. For more information, please refer the books mentioned in the references slide.... Thank you
Heat Treatment Defects and their RemediesMiraj Patel
The document discusses heat treatment defects that can occur in bearing steels. It describes the common heat treatment processes used for bearings, including spheroidized annealing, quenching, tempering, and induction hardening. Potential heat treatment defects are outlined, such as surface decarburization, quenching cracks, soft spots, and microstructural defects. Remedial measures are provided to address issues like heat treatment deformation, ovality, decarburization, and quenching cracks through process control and design modifications. The document references heat treatment standards and concludes that setting suitable process parameters can decrease defects and improve bearing performance.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
The blast furnace is an important industrial process used to extract iron from its ore. Raw materials like iron ore, limestone, and coke are input into the blast furnace where a blast of hot air helps coke burn and generates high temperatures to remove oxygen from the iron ore, leaving behind iron. The extracted iron contains impurities that are later removed in the basic oxygen furnace to produce steel.
Dr. Shagufta Khan presented on understanding end grain corrosion in austenitic stainless steels. End grain corrosion occurs preferentially at grain boundaries and is caused by segregation of elements like silicon and phosphorus along the boundaries. It is a problem in nuclear reprocessing plants where stainless steel tubing is exposed to highly oxidizing nitric acid. Laser remelting and weld overlays can be used to control end grain corrosion by modifying the microstructure and masking susceptible material, while solution annealing homogenizes the material's structure.
This document provides information on how to read the standard for boring bars.
It is organized by product series, with each series listing specifications like insert type, geometry, stock dimensions, and recommended minimum diameters.
Pictures and diagrams are used to illustrate the available machining applications and cutting edge angles for each boring bar type.
Specifications covered include insert number, dimensions, minimum standard diameters, cutting corner recommendations, clamp torques, and required wrenches.
TALAT Lecture 2101.01: Understanding aluminium as a materialCORE-Materials
This lecture is an introduction to aluminium alloys, fabrication methods and properties. It provides information about the classification of aluminium alloys, new alloys and composites; shaping processes, processing chains and component shapes; microstructure and the interaction between microstructure and properties. It promotes understanding of the fact that the correct choice of materials demands knowledge of alloys, shaping processes and microstructure and the interaction among them. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2100.
TALAT Lecture 3205: The Fluidity of Molten MetalsCORE-Materials
This document provides an overview of fluidity in molten metals and its influence on casting processes in 3 sentences:
Fluidity refers to the distance molten metal will flow in a test mold before solidifying, and is influenced by factors like alloy composition, section thickness, and heat transfer characteristics; short freezing range alloys solidify from the outside in, while long freezing range alloys form a slurry when the dendrite fraction reaches 25-50%; fluidity maps show how fluidity varies with composition, being highest for pure metals and eutectic compositions.
The document discusses multi response optimization of friction stir welding (FSW) parameters for aluminum alloy AA6105 using the Taguchi method. It first provides background on welding processes including FSW. It then discusses factors that affect FSW quality like rotational speed, welding speed, and tilt angle. The document proposes using an L9 orthogonal array experiment with three control factors and mechanical properties and microstructure as response variables. The methodology involves conducting experiments, applying Taguchi analysis and ANOVA to optimize parameters for properties like tensile strength and hardness. The research aims to minimize defects and improve joint quality of AA6105. Equipment for FSW and response testing is also detailed.
This 3 sentence summary provides the key details about the industrial training report:
The report describes Akbar's 4 week industrial training at the foundry shop of Indo Farm Equipment Limited in Baddi, Himachal Pradesh. The training involved learning the various processes used in the foundry shop such as core making, mold making, melting metals, and finishing casted parts. Akbar gained hands-on experience working in the core shop and observing the other processes like molding, melting, pouring, and fettling during his training.
This document provides an overview of Autokast Limited, an iron casting company located in Cherthala, Kerala, India. It discusses the company's production processes which include molding, melting, pouring, fettling, and inspection. Autokast produces grey iron and spheroidal graphite iron castings up to 8.5 metric tons for applications in automotive, pumps, valves, and machinery. The training report aims to study Autokast's operations and understand how its various departments work together to manufacture cast iron components.
This document provides an overview of the sintering process used in iron ore pellet production. It discusses the history and development of sintering technology, the key equipment and phases in the sintering process, raw materials used and their properties, reactions that occur during sintering, and quality requirements for the sinter product. The document outlines the full sintering process from proportioning materials through cooling and breaking of the sinter product.
This document discusses various non-destructive testing (NDT) methods used to detect defects in gas turbine components, including visual inspection, dye penetrant testing, magnetic particle testing, ultrasonic testing, eddy current testing, replication, radiography, and manual ultrasonic inspection. It provides examples of applying these methods to examine surfaces of gas turbine blades, detect impact damage and white deposits on turbine parts, and identify mid-span sidewall cracking and trailing edge damage.
Thar Coal, A Black Treasure OF Pakistan ( Series of Presentations, (No. 2/17)Malik Tariq Sarwar Awan
This is Series if Presentations, total 17 Presentations, this is No. 2, Next will be Hydel Power of Pakistan, Finally ending in last 4 presentations at Solutions to energy crises to Pakistan.
This document discusses aluminum alloys, including their types, heat treatment, and common alloying elements. It covers casting and wrought alloys, with casting alloys further divided based on their alloying elements like copper, silicon, magnesium, zinc, and tin. Heat treatable alloys can be strengthened through heat treatment to form precipitates, while non-heat treatable alloys rely on solid solution strengthening. Common alloying elements are discussed along with their effects on properties and example commercial alloys.
Production of aluminum (emphasis on energy and materials requirements) Thanos Paraschos
This document summarizes the production of aluminum through primary and secondary processes. Primary production involves refining bauxite ore through the Bayer process to produce alumina, which is then reduced to aluminum using the Hall-Héroult electrolysis process. Secondary production recycles scrap aluminum, which requires only 5% of the energy of primary production. Globally in 2010, 41.1 million tons of aluminum were produced using 210 million tons of bauxite as input. The production processes are energy intensive, requiring around 15 kWh of electricity to produce 1 kg of aluminum, or about 3% of global electricity production.
This document discusses welding defects and their causes. It outlines the four zones in a welded joint and how they appear on an iron-carbon phase diagram. The zones are the fusion zone, weld interface zone, heat affected zone, and base metal. Solidification can be epitaxial or non-epitaxial depending on whether filler metal is used. Common welding defects include cracks, porosity, inclusions, incomplete fusion, imperfect shape, and residual stresses. Various defect types like longitudinal cracks and underbead cracks are described in more detail.
Hydroforming process aids to improve the manufacturing of automobile parts and reduce industrial waste, utilization of the product, increase the efficiency of a plant, recycling efficient disassembly etc.
The document describes the process for extracting aluminum from bauxite ore. It involves crushing and grinding the bauxite, mixing it with a caustic soda solution in digesters, cooling the slurry, settling out the impurities, precipitating out the aluminum hydroxide, and calcining it to remove water. The aluminum hydroxide is then smelted using the Hall-Heroult process, which involves dissolving alumina in a molten cryolite bath using an electric current passing between carbon anodes and cathodes to produce molten aluminum.
This document discusses various applications of aluminium alloys including electrical conductors, transport, packaging, building and architecture, and miscellaneous uses. It then provides more detailed information on specific aluminium alloys commonly used in marine applications such as 5052, 5059, 5083, 5086, 6061, and 6063 aluminium alloys and their material properties and typical uses. The advantages of aluminium alloys over steel for vessels include lighter weight and better corrosion resistance, while disadvantages are more difficult welding and lower strength.
This document discusses the process of steel making. It begins by introducing steel and its types, which are classified based on carbon percentage as carbon steel, stainless steel, and alloy steel. It then describes the main steel making methods. The basic oxygen furnace uses carbon-rich pig iron and oxygen to produce low-carbon steel. The electric arc furnace produces specialty steels by heating scrap metal with an electric arc. Secondary steelmaking processes such as argon oxygen decarburization further refine the steel through decarburization, desulphurization, and alloying.
1) The document discusses various defects that can occur during steel ingot solidification such as pipe, columnar structure, blow holes, and segregation.
2) It provides remedies for preventing these defects, such as using a hot top feeder head to avoid pipe formation and soaking ingots to minimize segregation.
3) The document also covers the mechanisms of ingot solidification, describing how killed, rimmed, and semi-killed steels solidify into chill, columnar, and equiaxed zones within the ingot.
Carburzing and Different Types of CarburzingMelwin Dmello
This Presentation covers the Basic concepts of Carburzing and Different Types of Carburzing in a easy version. For more information, please refer the books mentioned in the references slide.... Thank you
Heat Treatment Defects and their RemediesMiraj Patel
The document discusses heat treatment defects that can occur in bearing steels. It describes the common heat treatment processes used for bearings, including spheroidized annealing, quenching, tempering, and induction hardening. Potential heat treatment defects are outlined, such as surface decarburization, quenching cracks, soft spots, and microstructural defects. Remedial measures are provided to address issues like heat treatment deformation, ovality, decarburization, and quenching cracks through process control and design modifications. The document references heat treatment standards and concludes that setting suitable process parameters can decrease defects and improve bearing performance.
The document discusses the benefits of exercise for mental health. Regular physical activity can help reduce anxiety and depression and improve mood and cognitive functioning. Exercise causes chemical changes in the brain that may help protect against mental illness and improve symptoms.
The blast furnace is an important industrial process used to extract iron from its ore. Raw materials like iron ore, limestone, and coke are input into the blast furnace where a blast of hot air helps coke burn and generates high temperatures to remove oxygen from the iron ore, leaving behind iron. The extracted iron contains impurities that are later removed in the basic oxygen furnace to produce steel.
Dr. Shagufta Khan presented on understanding end grain corrosion in austenitic stainless steels. End grain corrosion occurs preferentially at grain boundaries and is caused by segregation of elements like silicon and phosphorus along the boundaries. It is a problem in nuclear reprocessing plants where stainless steel tubing is exposed to highly oxidizing nitric acid. Laser remelting and weld overlays can be used to control end grain corrosion by modifying the microstructure and masking susceptible material, while solution annealing homogenizes the material's structure.
This document provides information on how to read the standard for boring bars.
It is organized by product series, with each series listing specifications like insert type, geometry, stock dimensions, and recommended minimum diameters.
Pictures and diagrams are used to illustrate the available machining applications and cutting edge angles for each boring bar type.
Specifications covered include insert number, dimensions, minimum standard diameters, cutting corner recommendations, clamp torques, and required wrenches.
TALAT Lecture 2101.01: Understanding aluminium as a materialCORE-Materials
This lecture is an introduction to aluminium alloys, fabrication methods and properties. It provides information about the classification of aluminium alloys, new alloys and composites; shaping processes, processing chains and component shapes; microstructure and the interaction between microstructure and properties. It promotes understanding of the fact that the correct choice of materials demands knowledge of alloys, shaping processes and microstructure and the interaction among them. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2100.
TALAT Lecture 3205: The Fluidity of Molten MetalsCORE-Materials
This document provides an overview of fluidity in molten metals and its influence on casting processes in 3 sentences:
Fluidity refers to the distance molten metal will flow in a test mold before solidifying, and is influenced by factors like alloy composition, section thickness, and heat transfer characteristics; short freezing range alloys solidify from the outside in, while long freezing range alloys form a slurry when the dendrite fraction reaches 25-50%; fluidity maps show how fluidity varies with composition, being highest for pure metals and eutectic compositions.
This document provides an introduction to techniques for compensating for solidification shrinkage in castings. It outlines seven rules for designing effective feeder systems:
1) The feeder must solidify at the same time or later than the casting (Chvorinov's rule).
2) The feeder must contain sufficient liquid to satisfy the volume contraction of the casting.
3) The junction between the casting and feeder must not create a hot or cold spot.
4) There must be a path for feed metal to reach all parts of the casting.
5) The feeder design must consider pressure requirements.
6) There must be an appropriate pressure gradient in the feed
TALAT Lecture 1100.01: Introduction: Aluminium, a Light MetalCORE-Materials
This lecture provides basic information about the history of aluminium, the principles behind the production of primary metal, environmental properties, potential applications, areas of application. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2100.
TALAT Lecture 1202: Metallography of Aluminium AlloysCORE-Materials
This lecture aims at providing a survey of the metallographic techniques available for the examination of aluminium and its alloys. The information must be sufficient to be sure that the students and the users are able to choose the most suitable technique to solve their problems in the examination of samples. The lecture should contain a direct understanding of the main problems in the metallography of the different classes of aluminium materials.
This lecture provides an introduction to solidification theory; it aims at achieving an essential background understanding of solidification and cast structures. Basic knowledge of the solidification of metals is assumed.
This lecture provides an introduction to some of the finer points in the production of high quality castings. The students will be able to understand the various processes for sealing porosity in badly made castings and to appreciate factors influencing the accuracy of castings, including a basic understanding of how to control and measure casting dimensions. Basic understanding of the foundry industry is assumed.
TALAT Lecture 2503: Calculation Methods for Fire DesignCORE-Materials
This lecture gives information on how to calculate the fire resistance of aluminium alloy structures with and without applied insulation. General engineering background and some familiarity with TALAT lectures 2501 and 2502 is assumed.
TALAT Lecture 2401: Fatigue Behaviour and AnalysisCORE-Materials
This lecture explains why, when and where fatigue problems may arise and the special significance to aluminium as structural material; it helps to understand the effects of material and loading parameters on fatigue; to appreciate the statistical nature of fatigue and its importance in data analysis, evaluation and use; it shows how to estimate fatigue life under service conditions of time-dependent, variable amplitude loading; how to estimate stresses acting in notches and welds with conceptual approaches other than nominal stress; it provides qualitative and quantitative information on the classification of welded details and allow for more sophisticated design procedures. Background in materials engineering, design and fatigue is required.
TALAT Lecture 1502: Criteria in Material SelectionCORE-Materials
This document provides an overview of criteria for material selection. It discusses the need for systematic material selection given the large number of available materials. The objectives are to understand pre-selection, discriminating selection, and optimization in material selection. Intuitive selection methods are highlighted, along with their drawbacks. Systematic selection involves specifying requirements, relating them to material properties, analyzing material groups and specific materials, and optimizing the choice. Material selection is an integral part of design that should be considered at the part level. General guidelines include acting systematically and considering material selection as part of both design and manufacturing.
TALAT Lecture 1501: Properties, Characteristics and Alloys of AluminiumCORE-Materials
This document provides a 60-page survey of aluminium alloys, their properties, and applications. It discusses the history and production of aluminium, important physical properties including density, conductivity, corrosion resistance, and melting temperature. It also describes the classification systems for wrought and cast aluminium alloys and provides information on common alloys and their mechanical properties and applications. The objectives are to provide information on available aluminium alloys and insights into choosing aluminium for applications.
The document describes several test geometries used to determine the failure strengths of composite materials, including the Double Cantilever Beam test for mode I failure, the End Notch Flexure test for mode II failure, and the Mixed-mode Interlaminar Fracture test for mixed mode I/II failure. It also lists the Single Cantilever Beam test for skin debonding energy in composite sandwiches, the Centre Notch Flexure test for thin skin debonding, and the Interlaminar Shear Strength test, a three point bend test to determine shear strength.
This lecture provides a view of types of joints in aluminium structures and how to design and calculate frequently used joints. Basic structural mechanics and knowledge of design philosophy, structural aluminium alloys and product forms is assumed.
This lecture helps to understand the basic principles of die forging and the characteristic features of special aluminium die forging processes. It aims at learning about the basic design of dies in order to obtain optimum part qualities and tool life. General understanding of metallurgy and deformation processes is assumed.
This document summarizes a presentation on snap fit design. It discusses what a snap fit is, the different types of snap fits, and their applications. It then covers key design features for snap fits, including theoretical considerations, design guidelines, and material selection. Specifically, it discusses factors like strain limits, stress concentrations, friction, and lead and return angles that influence mating and separation forces. The document provides equations for calculating deflection and forces. It also discusses design of cantilever and tapered beam styles and choosing thermoplastics as ideal materials. Finally, it lists some modifications to consider for snap fits.
Disrupting Tech With Diversity and Inclusion Wayne Sutton
Wayne Sutton (http://socialwayne.com/about ) Disrupting Tech With Diversity and Inclusion presentation at Dropbox Austin for Black History Month http://dbxblackmatters.eventbrite.com / #dbxblackmatters
Series of powerpoint slides showing three different drawing processes used in the manufacture of wires, rod, tubes and drinks cans. The slides are adapted from the University of Liverpool "Materials Processing" lectures [MATS214] by Dr J. Wilcox.
Cyber Tech Israel 2016: Get Your Head in the CloudSymantec
The document is a presentation about enterprise cloud security. It argues that giving up control is the main challenge of cloud computing, as cloud services provide benefits like agility and low cost by taking control away from the enterprise. However, control can be regained by establishing "control points" like securing endpoints consistently across systems, using a cloud security broker to monitor SaaS applications, and allowing these systems to share security information. With control points working together intelligently through a cloud-powered security operations center, enterprises can better harness the power of the cloud while maintaining control over security, compliance, and data protection.
Creating an Interactive Content Strategy that Works with Technologyion interactive
Scott Brinker's presentation from 2016 ContentTech Virtual Event:
Designing Interactive Content to Power Your Marketing Data Strategy
Interactive content—things such as quizzes, assessments, calculators, and configurators—is qualitatively different than the passive content that audiences simply read, watch, or listen to. Interactive content experiences are essentially miniature software programs, or web apps, which have logic and user experience wrapped into their design and operation. Most importantly, they give marketers the ability to collect and leverage a rich set of data that is explicitly volunteered by participants.
Marketers can design interactive content with this data in mind to develop a broader marketing data strategy. This presentation covers frameworks for both the user-facing options that marketers
can apply, to solicit the right kind of data from prospects at different stages of the buyer's journey, and the back-office management of this data through different marketing automation platforms (MAP) and CRM systems.
Topics include:
- Managing explicit "digital dialogue" data vs. implicit "digital body language"
- Applying advanced progressive profiling tactics in interactive content
- Pipelining richer data profiles from marketing to sales through your marketing stack
- Understanding scenarios for programmatic data vs. human-consumable data
TALAT Lecture 5105: Surface Treatment of AluminiumCORE-Materials
This lecture helps to understand the general principles, methods, properties and applications of plating on aluminium. Some knowledge in general electrochemistry is assumed.
TALAT Lecture 2102.04: A Compressed Air Tank for a Lorry, Special Studies: Ro...CORE-Materials
This lecture offers an example of product development. It imparts knowledge about rolling aluminium; deep-drawing aluminium; welding aluminium (MIG and TIG) and choice of alloy - rolling/deep-drawing/welding. It provides insight into how to develop a product using the general specifications and the interaction between form, material and processing chain; the importance of being thoroughly familiar with the different design materials, their processing possibilities and properties. The lecture is recommended for those situations, where a brief, general background information about aluminium is needed as an introduction of other subject areas of aluminium application technologies. This lecture is part of the self-contained course "Aluminium in Product Development", which is treated under TALAT lectures 2101 and 2102.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research(IJCER) is an intentional online Journal in English monthly publishing journal. This Journal publish original research work that contributes significantly to further the scientific knowledge in engineering and Technology
TALAT Lecture 3503: Finishing and other Supplementary OperationsCORE-Materials
This lecture describes supplementary fabrication measures for impact extruded parts and gives some examples of finished impacts. Basic knowledge about the formability of metals and background in mechanical engineering is assumed.
This document provides an overview of continuous casting of aluminium, specifically focusing on strip casting and wire bar casting technologies. It describes the basic principles of continuous casting, including key features like using rotating drums or belts to form a mould for molten aluminium. It discusses different types of casters like twin drum casters, single drum casters, and those using belts or blocks. It also addresses properties of continuously cast products and their behavior in further processing like rolling. The document aims to give readers an understanding of the possibilities and limitations of continuous casting aluminium.
The document discusses the design modification and analysis of a V6 engine mounting bracket. It begins by introducing the purpose and functions of an engine mounting bracket. It then discusses sources of engine vibrations and the objectives of modifying the existing bracket design. The existing and modified bracket designs, which includes adding ribs, are modeled using CAD software. Various analyses including structural, thermal, and modal are performed on the original and modified bracket designs using different materials like aluminum alloy, magnesium alloy, and aluminum silicon carbide. The results of the analyses show that the modified bracket design with aluminum silicon carbide material performs better in reducing deformation, stress, heat flux, and increasing natural frequencies.
The document discusses finishing processes for castings including rectifying leaks, ensuring accuracy, and heat treating. It describes testing castings for leaks by pressurizing them with air or liquid and looking for bubbles or pressure drops. Methods to repair leaks include remaking the casting, removing the defect and welding, or sealing pores using impregnation techniques like vacuum impregnation with resins. The document provides an overview of factors that influence casting quality and finishing steps.
TALAT Lecture 2402: Design Recommendations for fatigue loaded structuresCORE-Materials
This lecture presents calculation of design stresses for variable stress ratios in practice, explanation on the background of design recommendations; it demonstrates the concept of partial safety factors and supply appropriate background information for aluminium; it enables the designer to evaluate service behavior of structural details on a more sophisticated level applying the same principles as in current design recommendations; it provides understanding of the fatigue design procedure according to current recommendations. Background knowledge in engineering, materials and fatigue as well as some knowledge in statistics is required.
Prism surface coatings pvt ltd is one of the largest Turnkey suppliers of Painting and Powder Coatings plants, lines and has installed over 500 coating lines/plants worldwide. We have also worked for various customers over 25 years across Europe, USA, Asia, Africa and The Middle East for a wide range of industries. We supply to a wide range of Industries such as Automotive Components, Aerospace, Elevators, Aluminum Extrusion & Architectural Components, Valves, Steel / Wood Furniture, Electric Control Panels, Transformer, HHP Engines, Construction Machinery, Wind Mills, Railways, Rail coach / Wagons, Scooter / Motor cycle components, tractors,water boilers,cookwares. Agricultural Machinery, Trucks, Bus Body ,Drums, Cellular Phones...etc
Prism recently has taken over OMT technologies which is a 50 year old German company to form prism group of companies.
Our turnkey plants includes equipment like Shot Blasting Systems,Robotic blasting systems ,Dip and Spray Chemical Pre-treatment plants, Powder Coating Booths and recovery Systems, Dry and Wet type Paint booths/ Spray Booths, Paint Sludge separation and removal Systems, Conveyors, Paint shop -Automation, Ovens,shower tester booths,Teflon coating lines ,enamel coating lines and Effluent Treatment Plants.
This document provides an overview of forging processes and technology. It discusses the history of forging dating back 6000 years and how steam and water power replaced manual forging in the 18th-19th centuries. It also outlines key modern forging processes like drop forging, describes common forging materials like various grades of steel, and explains factors that influence the accuracy of forged parts.
MINIATURIZED CYLINDER HEAD PRODUCTION BY RAPID PROTOTYPINGRodrigo Melo
Abstract. This work shows the development of the design and manufacturing of a very small engine, namely its head.
The engine works under the 4-stroke cycle, therefore having a very complex cylinder head, housing the camshaft,
valves and its auxiliaries (seats, guides, springs), spark plug, inlet and exhaust passages and a coolant chamber. The
geometries, both inner and outer are highly intricate which makes the production of such a part a very difficult job. In
addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore
making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core
removal problem due to reduced accessibility, imposing casting limitations. The cores place also a problem of air and
gas removal during metal filling and solidification. Rapid prototyping may be the only solution to build the cores, and
may help in the design and manufacturing phases of the casting tools. 3D printing with a plaster based material as a
rapid prototyping technique presents itself as a tool to drastically reduce the design-development-casting process effort
and time cycle. This technique enables the designer to obtain new moulds for castings on the shortest time possible,
following redesign and new casting simulations. This paper illustrates the various tasks involved in the design and
development stages leading to the production of a running prototype of the cylinder head for this small engine.
Lefebvre Engineering is an integrated service provider in engineering, fabrication, machining and equipment building in the region. Incorporated in 2006 as a Free Zone company in Hamriyah Free Zone, Sharjah, United Arab Emirates was originally founded in 1914 in Montreal, Canada as Lefebvre Freres. Lefebvre was at that time specialized in automobile industry. Over the years the company diversified as fabricators and manufacturers of custom build machinery for use in aluminium, steel, Power and Oil & Gas industry.
For close to a century, Lefebvre has built pressure vessels, Heat exchangers, steel and aluminium weldments, specialized equipment and machinery for Hydro carbon, Power, aluminium and Oil & Gas Industry.
The engine block is a critical component that houses the internal parts of an engine. It is typically made of cast iron or aluminum alloys due to their ability to withstand high stresses and temperatures. The manufacturing process involves pattern making, casting, and machining. Patterns are used to create molds for casting the block. The block is then machined to final specifications. Proper material selection and manufacturing processes are needed to produce an engine block that can withstand combustion pressures and temperatures for the life of the vehicle.
The document discusses applications of aluminum metal matrix composites for the Department of Defense, including their use in lightweight track shoes for the Bradley Fighting Vehicle, seeker support structures for missiles, and pistons for military vehicles. It also outlines the manufacturing process of squeeze casting used to produce metal matrix composites and its advantages over other methods in achieving close tolerances, superior mechanical properties, and internal integrity. Current and potential applications within the DOD are highlighted along with the properties and benefits of silicon carbide whiskers as a reinforcement.
Lakwoo Industry Co., Ltd. is a South Korean company established in 1968 that produces aircraft parts, tools, and fixtures as well as ceramic products. The company has divisions for aviation and ceramics. The aviation division supplies parts and tools to major customers like Korea Aerospace Industries and produces aircraft components, semiconductor manufacturing equipment, and titanium chemical milling. Lakwoo aims to diversify its industries and lead business growth in aviation and eco-friendly paint.
IRJET-Split Casing Open Differential without Cross Pin and it’s Comparison wi...IRJET Journal
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Casting is a manufacturing process where liquid material is poured into a mold and solidifies. Advantages include low cost for complex parts and reduced weight. Vacancies in casting include shortage of skilled technicians and need for more capable simulation software. Simulation software allows for predicting cast structure, properties, defects and reducing costs. Aluminum and magnesium alloys are increasingly used in automotive parts like suspension parts and dashboards. New developments in casting include squeeze casting and lost foam casting. Shell molding uses sand and resin to form thin shells. Counter gravity casting and differential pressure casting produce parts like camshafts and crankcases. Flaskless molding avoids flask transport and repair. Freeze casting forms ice patterns for casting. Semisolid
1) The document discusses using advanced manufacturing techniques like electron beam melting (EBM) to fabricate missile components from lightweight materials like gamma titanium aluminide (TiAl) lattice block structures (LBS).
2) EBM allows for net or near-net shape manufacturing without tooling, enabling rapid design changes and production of complex, integrated single-piece components.
3) Using gamma TiAl LBS fabricated by EBM could reduce missile component weight and costs while improving stiffness and flutter resistance over current nickel-base alloy designs.
Lefebvre Engineering FZC is a fabrication company that has been in business since 1914. It has facilities in the UAE, Oman, and Bahrain equipped for heavy machining, fabrication, and aluminum casting. The company targets markets in the GCC like oil and gas, construction, and marine. It has a 70,000 square foot facility in the UAE with machinery like CNC mills and over 125 welding machines. The company specializes in aluminum bus bars, steel structures, equipment fabrication, and automation projects for industries like aluminum smelting. Lefebvre believes in quality work and timely deliveries to its customers across the GCC.
The document is a collection of project descriptions and illustrations for various clients of a design firm called Zoltun. It includes projects for clients like Eaton Corporation, Pittsburgh CLO Guild, Berry Metal Company, MSA, UPMC, SPX, Calgon Carbon, and Friends of the Riverfront. The projects involve graphic design work like illustrations, icons, diagrams, and infographics for purposes like invitations, newsletters, websites, presentations, catalogs, and reports.
VLSI technology development nowadays is mostly focused on the downsizing of semiconductor devices, which is significantly reliant on advancements in complementary metal-oxide-semiconductor technology. Due to capacitance, shorter channel length, body biassing, faster-switching transistor, limited variability, and faster running transistor, Silicon-on-Insulator technology has seen a lot of changes. In comparison to traditional bulk technology, Silicon on Insulator offers intriguing new possibilities. The recent stalling of advancement in CMOS technology has been noticed. A fully depleted silicon on the insulator provides additional performance. Power usage and communication speed are two areas where performance can be improved. Silicon on insulator technology has the potential to reduce power consumption by nearly half while increasing speed by about 40%. Using the Atlas module of the SILVACO software, the research presents a comprehensive analysis of silicon on insulator-based nano metal oxide semiconductor field-effect transistors. Atlas is used to virtually construct a 20 nm silicon on insulator MOSFET. The gate metals employed are Aluminum, N. poly, W (Tungsten), and WSi2 (Tungsten Silicide), and their respective characteristics are obtained and compared. Finally, WSi2 was chosen as the final gate metal because it has the desired band offset, resulting in a positive threshold voltage without the need for any further implants in the channel region. Other metrics are collected, such as the variation of ID vs. VGS features at various values. There is also a fluctuation in drain current as a function of drain to source voltage.
Similar to TALAT Lecture 3201: Introduction to Casting Technology (20)
The document describes several common composite manufacturing techniques including wet lay-up, vacuum bagging, compression moulding, filament winding, pultrusion, and resin transfer moulding. Each technique involves different processes for combining fibres and resin such as applying layers by hand, using pressure and heat, winding fibres onto a rotating mandrel, pulling fibres through a resin bath, or injecting resin into a mould containing dry fibres. The techniques are suited for different part geometries and production volumes.
The role of technology in sporting performanceCORE-Materials
The lecture answers the questions of how much effect does engineering technology have on sport, is technology only used to increase performance and what are the "new technologies" being introduced. Courtesy of Prof Claire Davies, School of Metallurgy and Materials, University of Birmingham.
The chapter describes principles of the chemical analysis in the SEM and TEM. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the scanning electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives insight into the transmission electron microscope technique. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
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Electrons and their interaction with the specimenCORE-Materials
The chapter explains the behaviour of electrons within a specimen and shows how they interact with the atoms of the sample. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the comparison of electron microscopy with other imaging and analysis techniques. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
The chapter gives the basic principles of microscopy. From "Electron Microscopy and Analysis" textbook by Peter J. Goodhew, John Humphreys and Richard Beanland. Courtesy of Taylor and Francis Books UK.
TALAT Lecture 5301: The Surface Treatment and Coil Coating of AluminiumCORE-Materials
This lecture describes the continuous coil coating processes for aluminium in sufficient detail in order to understand the industrial coating technology and its application potential. General background in materials engineering and familiarity with the subject matter covered in TALAT This lectures 5100 and 5200 is assumed.
This lecture describes the processes of electroless, electrolytic, as well as physical and chemical vapour deposition of metals on the aluminium surface in order to achieve variations in its surface properties for functional and decorative purposes. Some knowledge of the surface properties of metals, metallurgy and electrochemistry of aluminium and familiarity with the subject matter covered in TALAT This lectures 5101, 5102, 5105 is assumed.
This lecture describes the process of anodic oxidation of aluminium, which is one of the most unique and commonly used surface treatment techniques for aluminium; it illustrates the weathering behaviour of anodized surfaces. Some familiarity with the subject matter covered in TALAT This lectures 5101- 5104 is assumed.
This lecture describes the key factors associated with conversion coatings on aluminium can be appreciated, such as general and local behaviour of the aluminium surface, range of conversion coatings and interrelationships, requirements of conversion coating, tailor-making of coatings, current and future issues. Some familiarity with the subject matter covered in TALAT This lectures 5101, 5102, 5201 is assumed.
TALAT Lecture 5104: Basic Approaches to Prevent Corrosion of AluminiumCORE-Materials
This lecture describes important measures for the prevention of corrosion of unprotected, bare
aluminium. Basic knowledge of corrosion behaviour of aluminium and some knowledge of the electrochemical nature of corrosion is assumed
TALAT Lecture 5103: Corrosion Control of Aluminium - Forms of Corrosion and P...CORE-Materials
This document discusses various forms of corrosion that can affect aluminium and aluminium alloys. It describes general corrosion that can occur in acid and neutral solutions. It also covers localized corrosion such as pitting, crevice, filiform, and biological corrosion. Factors influencing galvanic and intergranular corrosion are presented. The document also discusses mechanically assisted degradation like erosion, fretting corrosion, and corrosion fatigue. It concludes with descriptions of stress corrosion cracking and hydrogen embrittlement.
TALAT Lecture 5102: Reactivity of the Aluminium Surface in Aqueous SolutionsCORE-Materials
This lecture provides better understanding of the electrochemistry of aluminium; it gives an introduction to the other lectures. Some knowledge in aluminium metallurgy, simple chemistry (thermodynamics and kinetics), electricity and general electrochemistry is assumed.
TALAT Lecture 5101: Surface Characteristics of Aluminium and Aluminium AlloysCORE-Materials
This lecture provides a realistic view of the aluminium surface in order to understand the need for "effective" surface treatment. Some knowledge in aluminium metallurgy is assumed.
This lecture describes the factors important for the quality assurance of adhesive joining; it gives information about the destructive and non-destructive testing methods for the quality control of adhesive joining. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
TALAT Lecture 4704: Surface Preparation and Application ProceduresCORE-Materials
This lecture describes the important aspects of surface preparation and pretreatments for adhesive joining of aluminium parts; it illustrates the methods and equipment necessary to obtain good adhesive bonds. General background in production engineering and material science, some knowledge of mechanics and polymer science is assumed.
বাংলাদেশের অর্থনৈতিক সমীক্ষা ২০২৪ [Bangladesh Economic Review 2024 Bangla.pdf] কম্পিউটার , ট্যাব ও স্মার্ট ফোন ভার্সন সহ সম্পূর্ণ বাংলা ই-বুক বা pdf বই " সুচিপত্র ...বুকমার্ক মেনু 🔖 ও হাইপার লিংক মেনু 📝👆 যুক্ত ..
আমাদের সবার জন্য খুব খুব গুরুত্বপূর্ণ একটি বই ..বিসিএস, ব্যাংক, ইউনিভার্সিটি ভর্তি ও যে কোন প্রতিযোগিতা মূলক পরীক্ষার জন্য এর খুব ইম্পরট্যান্ট একটি বিষয় ...তাছাড়া বাংলাদেশের সাম্প্রতিক যে কোন ডাটা বা তথ্য এই বইতে পাবেন ...
তাই একজন নাগরিক হিসাবে এই তথ্য গুলো আপনার জানা প্রয়োজন ...।
বিসিএস ও ব্যাংক এর লিখিত পরীক্ষা ...+এছাড়া মাধ্যমিক ও উচ্চমাধ্যমিকের স্টুডেন্টদের জন্য অনেক কাজে আসবে ...
How to Make a Field Mandatory in Odoo 17Celine George
In Odoo, making a field required can be done through both Python code and XML views. When you set the required attribute to True in Python code, it makes the field required across all views where it's used. Conversely, when you set the required attribute in XML views, it makes the field required only in the context of that particular view.
Philippine Edukasyong Pantahanan at Pangkabuhayan (EPP) CurriculumMJDuyan
(𝐓𝐋𝐄 𝟏𝟎𝟎) (𝐋𝐞𝐬𝐬𝐨𝐧 𝟏)-𝐏𝐫𝐞𝐥𝐢𝐦𝐬
𝐃𝐢𝐬𝐜𝐮𝐬𝐬 𝐭𝐡𝐞 𝐄𝐏𝐏 𝐂𝐮𝐫𝐫𝐢𝐜𝐮𝐥𝐮𝐦 𝐢𝐧 𝐭𝐡𝐞 𝐏𝐡𝐢𝐥𝐢𝐩𝐩𝐢𝐧𝐞𝐬:
- Understand the goals and objectives of the Edukasyong Pantahanan at Pangkabuhayan (EPP) curriculum, recognizing its importance in fostering practical life skills and values among students. Students will also be able to identify the key components and subjects covered, such as agriculture, home economics, industrial arts, and information and communication technology.
𝐄𝐱𝐩𝐥𝐚𝐢𝐧 𝐭𝐡𝐞 𝐍𝐚𝐭𝐮𝐫𝐞 𝐚𝐧𝐝 𝐒𝐜𝐨𝐩𝐞 𝐨𝐟 𝐚𝐧 𝐄𝐧𝐭𝐫𝐞𝐩𝐫𝐞𝐧𝐞𝐮𝐫:
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Walmart Business+ and Spark Good for Nonprofits.pdfTechSoup
"Learn about all the ways Walmart supports nonprofit organizations.
You will hear from Liz Willett, the Head of Nonprofits, and hear about what Walmart is doing to help nonprofits, including Walmart Business and Spark Good. Walmart Business+ is a new offer for nonprofits that offers discounts and also streamlines nonprofits order and expense tracking, saving time and money.
The webinar may also give some examples on how nonprofits can best leverage Walmart Business+.
The event will cover the following::
Walmart Business + (https://business.walmart.com/plus) is a new shopping experience for nonprofits, schools, and local business customers that connects an exclusive online shopping experience to stores. Benefits include free delivery and shipping, a 'Spend Analytics” feature, special discounts, deals and tax-exempt shopping.
Special TechSoup offer for a free 180 days membership, and up to $150 in discounts on eligible orders.
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Answers about how you can do more with Walmart!"
Gender and Mental Health - Counselling and Family Therapy Applications and In...PsychoTech Services
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Chapter wise All Notes of First year Basic Civil Engineering.pptxDenish Jangid
Chapter wise All Notes of First year Basic Civil Engineering
Syllabus
Chapter-1
Introduction to objective, scope and outcome the subject
Chapter 2
Introduction: Scope and Specialization of Civil Engineering, Role of civil Engineer in Society, Impact of infrastructural development on economy of country.
Chapter 3
Surveying: Object Principles & Types of Surveying; Site Plans, Plans & Maps; Scales & Unit of different Measurements.
Linear Measurements: Instruments used. Linear Measurement by Tape, Ranging out Survey Lines and overcoming Obstructions; Measurements on sloping ground; Tape corrections, conventional symbols. Angular Measurements: Instruments used; Introduction to Compass Surveying, Bearings and Longitude & Latitude of a Line, Introduction to total station.
Levelling: Instrument used Object of levelling, Methods of levelling in brief, and Contour maps.
Chapter 4
Buildings: Selection of site for Buildings, Layout of Building Plan, Types of buildings, Plinth area, carpet area, floor space index, Introduction to building byelaws, concept of sun light & ventilation. Components of Buildings & their functions, Basic concept of R.C.C., Introduction to types of foundation
Chapter 5
Transportation: Introduction to Transportation Engineering; Traffic and Road Safety: Types and Characteristics of Various Modes of Transportation; Various Road Traffic Signs, Causes of Accidents and Road Safety Measures.
Chapter 6
Environmental Engineering: Environmental Pollution, Environmental Acts and Regulations, Functional Concepts of Ecology, Basics of Species, Biodiversity, Ecosystem, Hydrological Cycle; Chemical Cycles: Carbon, Nitrogen & Phosphorus; Energy Flow in Ecosystems.
Water Pollution: Water Quality standards, Introduction to Treatment & Disposal of Waste Water. Reuse and Saving of Water, Rain Water Harvesting. Solid Waste Management: Classification of Solid Waste, Collection, Transportation and Disposal of Solid. Recycling of Solid Waste: Energy Recovery, Sanitary Landfill, On-Site Sanitation. Air & Noise Pollution: Primary and Secondary air pollutants, Harmful effects of Air Pollution, Control of Air Pollution. . Noise Pollution Harmful Effects of noise pollution, control of noise pollution, Global warming & Climate Change, Ozone depletion, Greenhouse effect
Text Books:
1. Palancharmy, Basic Civil Engineering, McGraw Hill publishers.
2. Satheesh Gopi, Basic Civil Engineering, Pearson Publishers.
3. Ketki Rangwala Dalal, Essentials of Civil Engineering, Charotar Publishing House.
4. BCP, Surveying volume 1
Communicating effectively and consistently with students can help them feel at ease during their learning experience and provide the instructor with a communication trail to track the course's progress. This workshop will take you through constructing an engaging course container to facilitate effective communication.
RHEOLOGY Physical pharmaceutics-II notes for B.pharm 4th sem students
TALAT Lecture 3201: Introduction to Casting Technology
1. TALAT Lecture 3201
Introduction to Casting Technology
29 pages, 44 figures
Basic Level
prepared by John Campbell and Richard A. Harding, IRC in Materials,
The University of Birmingham
Objectives:
− To provide an introduction to the techniques used to produce castings and to the
range of castings produced
− To gain an appreciation of the production and application of castings
Prerequisites:
− No prior knowledge is assumed.
Date of Issue: 1994
EAA - European Aluminium Association
2. 3201 Introduction to Casting Technology
Table of Contents
3201 Introduction to Casting Technology ......................................................2
Introduction..................................................................................................................2
Low pressure sand casting method (LPS)....................................................................3
Pressure die casting process.........................................................................................6
Pattern for sand castings ..............................................................................................7
Example of cast component .........................................................................................8
Cores and moulds.........................................................................................................9
The Cosworht Process................................................................................................13
Examples of sand cast components............................................................................14
Squeeze Casting Process............................................................................................16
Investment Casting.....................................................................................................18
Cast Metal Production ...............................................................................................22
Die Casting Processes ................................................................................................22
Sand Casting Processes..............................................................................................25
Investment Casting Processes ....................................................................................26
Literature....................................................................................................................27
List of Figures ............................................................................................................28
Introduction
This lecture is to set the scene. It plans to answer the questions: what are castings and
what does the industry look like? It is worth while spending some time on these initial
questions.
The first series of figures will give us an overview of the many varieties of castings
which are produced.
Figure 3201.00.01 may be your image of the casting industry - rough iron castings from
a foundry under a railway arch. It is true that some of the industry is still like this, as in
many sections of the engineering profession. However, elsewhere, the industry has
entered the twentieth century, and is already preparing for the twenty-first!
TALAT 3201 2
3. alu
Training in Aluminium Application Technologies
Image from the "Dark Age" of the Casting Industry 3201.00.01
Low pressure sand casting method (LPS)
Much modern casting design starts here, on the computer. The series of the following
figures (Figure 3201.00.02, Figure 3201.00.03, Figure 3201.00.04, Figure 3201.00.05
and Figure 3201.00.06) shows how the design is built up for an inlet manifold. This
was for Rover’s highly successful K series engine, based almost entirely on lightweight
aluminium alloy castings produced on their Low Pressure Sand (LPS) casting method.
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Modern Computer Design of Castings: Air Inlet Manifold
(Rover), Low Pressure Sand Casting (1) 3201.00.02
Training in Aluminium Application Technologies
TALAT 3201 3
4. Modern Computer Design of Castings: Air Inlet Manifold
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3201.00.03
Training in Aluminium Application Technologies (Rover), Low Pressure Sand Castings (2)
Modern Computer Design of Castings: Air Inlet Manifold
(Rover), Low Pressure Sand Casting (1)
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Modern Computer Design of Castings: Air Inlet Manifold
Training in Aluminium Application Technologies (Rover), Low Pressure Sand Casting (3) 3201.00.04
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Modern Computer Design of Castings: Air Inlet Manifold
Training in Aluminium Application Technologies (Rover), Low Pressure Sand Casting (4) 3201.00.05
TALAT 3201 4
5. alu Modern Computer Design of Castings: Air Inlet Manifold
Training in Aluminium Application Technologies (Rover), Low Pressure Sand Casting (5) 3201.00.06
This was the first inlet manifold which they had designed with a wall thickness of 3
mm. Figure 3201.00.07 shows the solid model generated on the computer.
alu Air Inlet Manifold (Rover), Solid Model
Training in Aluminium Application Technologies Generated by Computer 3201.00.07
The final casting which the designer received three months later is shown in Figure
3201.00.08. It can be commented that three months was a good achievement for a
casting having high technical requirements - the competitors did not succeed even after
15 months.
TALAT 3201 5
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Training in Aluminium Application Technologies
Final Casting Shipped 3 Months after Receipt of Orders 3201.00.08
Pressure die casting process
And now for something completely different! Approximately half of all light alloy
castings are made by the pressure die casting process, in which the liquid metal is
injected at high speed and high pressure into a metal mould which is usually called the
die. The principle of the pressure die casting process is shown in Figure 3201.00.09.
High Pressure Die Casting
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Training in Aluminium Application Technologies
Principle of the Pressure Die Casting Process 3201.00.09
Figure 3201.00.10 shows a simple gear for an instrument application and is a pressure
die casting. It is characterised by a good quality surface finish which often means that
machining is not required. However, we need to take care with pressure die castings
because, although the product in this case seems to be perfectly well suited to its
application, the lack of internal unsoundness is a cause for concern in other applications
where strength and possibly leak tightness are required properties. As we will see in
later lectures, turbulence and air bubble entrapment often cause an Aero Chocolate
structure which has poor metallurgical properties and causes leaks in many castings.
TALAT 3201 6
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Example of High-Pressure Die Casting (Gear) 3201.00.10
Training in Aluminium Application Technologies
Pattern for sand castings
I would now like to return to sand castings which, in contrast to pressure die castings,
can be made sound and leak tight. The pattern is the starting point for making a mould
and Figure 3201.00.11 illustrates a simple pattern which will form the lower half of a
sump casting for a racing engine.
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Pattern for a Racing Engine Sump (Sand Casting) 3201.00.11
Training in Aluminium Application Technologies
Figure 3201.00.12 shows the lower half-mould which now also contains a number of
cores which will form some of the waterways and oil passageways in the sump. It
should be noticed that one of the cores is painted with a white ceramic wash. This is an
oil passageway core and the customer was insistent that no grains of sand remain in this
TALAT 3201 7
8. interior part of the casting which is difficult to clean. The upper half of the mould can
also be seen assembled ready to be closed over. Other cylinder heads are discernible in
the distance.
Half-Mould with Cores (White Core for Oil Passageway);
alu
3201.00.12
Training in Aluminium Application Technologies Upper Half-Mould in Back
Example of cast component
Figure 3201.00.13 is a view of the finished casting. This was the lower crankcase for
the Cosworth DFV Formula 1 engine.
alu Finished Casting (lower Crankcase of the Cosworth DFV 3201.00.13
Training in Aluminium Application Technologies Formula 1 Engine)
TALAT 3201 8
9. Cores and moulds
You remember that it is necessary to start with a pattern to make a mould and we shall
see some examples of patterns in the next slides. However, you should also remember
that the hollow inside part of a casting is formed by a core - this can be remembered by
analogy with an apple core. Such shapes in sand are formed in a special sort of pattern
called a core box. We shall see some examples of cores being produced from core boxes
in this section. As a final note before we start these slides, you should notice in places
that the distinction between moulds and cores becomes hazy in the core assembly
process, in which large blocks of sand are formed in boxes, as a core, but are assembled
together to form a mould.
The making of sand shapes in hard, chemically-bonded sands is an important area of
foundry technology. In Figure 3201.00.14 we see here a core-making machine in the
Caterpillar Foundry in Peoria, Illinois, using the Ashland Isoset process. This allows
core sand (silica sand mixed with a two-part binder consisting of a phenol formaldehyde
resin and a reactive isocyanate) to be blown into a core box and then hardened by
passing an amine catalyst in a carrier gas through it. Thus the core is more-or-less fully
hardened by the time it is ejected from the box. This provides high productivity and high
accuracy.
Core-Making Machine Using the Ashland Isoset
alu
3201.00.14
Training in Aluminium Application Technologies Process (Courtesy: Caterpillar Foundry, Preoria, Illinois)
Figure 3201.00.15 gives another view of large cores being assembled to make a mould.
TALAT 3201 9
10. alu
Assembly of Large Cores to Form a Mould 3201.00.15
Training in Aluminium Application Technologies
The production of large mould halves in chemically-bonded self-setting sand at the
Pryor Foundry, Oklahoma, showing the superb engineering required to turn moulds of
this size (Figure 3201.00.16).
alu
Machine for Turning Over Large Moulds 3201.00.16
Training in Aluminium Application Technologies
Figure 3201.00.17 shows a process where no binder is used to bond together the sand.
The mould is sealed on its front face with a thin film of plastic and a vacuum used to
hold the sand grains in place. The mould has just been stripped off the pattern, which
can be seen coloured red below. The vacuum moulding process, normally abbreviated to
TALAT 3201 10
11. the V-process, is not widely used in Europe, but is popular in Japan where it was
invented. The high quality and smoothness of the mould face can just be seen in this
view.
alu
Vacuum Moulding Process (Japan) 3201.00.17
Training in Aluminium Application Technologies
A close-up of the V-process mould is shown in Figure 3201.00.18 which clearly
demonstrates that sand can be used to make complicated shapes.
alu
Sand Mould Made by the V - Process 3201.00.18
Training in Aluminium Application Technologies
Figure 3201.00.19 shows a set of chemically-bonded sand cores ready for assembly to
make a cylinder head mould for the Rover K series engine. The high quality of the cores
TALAT 3201 11
12. is clear and the technique allows the construction of extremely precise moulds. The
technique is known as the Core Assembly Process.
alu Set of Chemically Bonded Sand Cores for Cylinder
3201.00.19
Training in Aluminium Application Technologies Head Mould (Rover, Longbridge)
Figure 3201.00.20 shows a similar set of cores for the assembly of the cylinder block
for the K series engine, again in the Rover foundry in Longbridge.
alu Set of Chemically Bonded Sand Cores for Cylinder 3201.00.20
Training in Aluminium Application Technologies Block (Rover, Longbridge)
TALAT 3201 12
13. The Cosworht Process
The Cosworth Process is a modern development designed specifically for the high
volume production of high quality automotive castings. The process illustrates the fact
that liquid metal need not be poured to make a casting. In this case, it is pumped uphill
against gravity and this enables control to be maintained over the process of filling the
mould. The large reservoir of liquid metal in the holding furnace allows time for
impurities to sink or float, and the electromagnetic pump (which contains no moving
parts) displaces the best quality metal from the mid-depth of the holding furnace up and
into the mould, displacing the air ahead of it as it goes (Figure 3201.00.21).
Cosworth Process
(Low Pressure Sand Casting)
Melting Furnace
Zircon
Sand Mould
Electro-Magnetic
Pump
Holding
Furnace
alu
Schematic of the Cosworth Process 3201.00.21
Training in Aluminium Application Technologies
The process is capable of a great degree of sophistication with the pump being
programmable to fill each type of casting with an optimum filling program. In the latest
variant of this process - the Mark II - the metal is introduced through the side wall of the
mould which is then rolled over and detached from the filling system. This enables the
throughput of moulds to be increased since it is no longer necessary to wait for the metal
in one mould to solidify before the next mould is indexed into position at the pouring
station.
This process is being adopted by Ford in the USA and Rover have used a similar
approach in their LPS Process shown earlier.
Figure 3201.00.22 shows the Cosworth Foundry in Worcester, UK, showing the
lightweight engineering approach to the design of the plant, and is in marked contrast to
the common image of foundries under the railway arches.
TALAT 3201 13
14. alu Cosworth Foundry in Worcester, UK, Showing the 3201.00.22
Training in Aluminium Application Technologies Lightweight Foundry Equipment Design
Examples of sand cast components
Figure 3201.00.23 is a housing for a rotary engine developed by Norton Engineering for
motorbikes and has both thick (15 mm) and thin (2 mm outer shroud) sections. This is a
sand casting, but filled under gravity, showing that simple filling systems can be made
to work well for many castings and that an uphill filling system is not always necessary
(even though it would nearly always produce a good casting).
alu Rotary Engine Housing with Thick (15 mm) 3201.00.23
Training in Aluminium Application Technologies and Thin (2 mm) Sections
TALAT 3201 14
15. In Figure 3201.00.24 we now have a series of three sand castings used by the aerospace
industry. This is a lightweight space frame for a pilot’s ejector seat.
alu
Aerospace Sand Casting: Pilot`s Ejector Seat Frame 3201.00.24
Training in Aluminium Application Technologies
Figure 3201.00.25 shows an air intake for the Rolls Royce Gem engine which powers
the Lynx helicopter, and Figure 3201.00.26 an even more complex air intake for an
aerospace engine produced in France.
Aerospace Sand Casting: Air Intake for a
alu
3201.00.25
Training in Aluminium Application Technologies Turbo-Engine (Rolls Royce)
TALAT 3201 15
16. Aerospace Sand Casting: Air Intake for a
alu
3201.00.26
Training in Aluminium Application Technologies Turbo-Engine (France)
Squeeze Casting Process
We shall now turn to a completely different kind of casting technology. You will recall
that we introduced the current topic with a picture of a pressure die casting, but with a
warning of its probable unsoundness. The Squeeze Casting Process was developed to
counter unsoundness in die castings and is shown in the next slide (Figure 3201.00.27).
alu Schematic of the Squeeze Casting Process
3201.00.27
Training in Aluminium Application Technologies (Sometimes Also Called Squeeze Forming)
Metal is introduced into an open die, just as in a closed die forging process. The dies are
then closed. During the final stages of closure, the liquid is displaced into the further
parts of the die. No great fluidity requirements are demanded of the liquid, since the
TALAT 3201 16
17. displacements are small. Thus forging alloys, which generally have poor fluidities which
normally precludes the casting route, can be cast by this process. This is a unique
advantage enjoyed by Squeeze Casting. For this reason, it is sometimes known as
Squeeze Forming, to emphasize its similarity to forging processes. The other great
advantage of Squeeze Casting is of course the potential of the process to produce
products which are effectively perfectly sound. In practice this is not always so easy, but
the process has to be recognised as having unique potential in this respect.
Figure 3201.00.28 shows the massive presses at GKN Sankey, Telford, UK on which
the Squeeze Casting dies are mounted. This is very much heavy engineering and the
high costs of the castings produced by this process reflect this.
alu
Training in Aluminium Application Technologies
GKN Sankey Squeeze Casting Machine (Telford, UK) 3201.00.28
Typical products produced by Squeeze Casting are necessarily simple, produced if
possible from simple two-part dies (Figure 3201.00.29). This is the usual geometrical
limitation of all of the die casting processes. However, although side pulls can be used
on die casting moulds to produce cored holes, they are especially vulnerable to being
sheared off in a Squeeze Casting press!
TALAT 3201 17
18. alu
Typical Examples of Squeeze Casting Product Forms 3201.00.29
Training in Aluminium Application Technologies
Investment Casting
I would now like to turn to yet another totally different area of foundry technology:
investment casting. This is of course widely known as lost wax casting, because of the
use of wax patterns which are coated with a refractory (i.e. the patterns are invested in
alternate layers of slurry and stucco), with the wax patterns subsequently melted out to
leave a hollow shell into which the metal is cast.
The elegant die from Deritend Precision Castings, Droitwich, UK makes impeller
patterns in wax (Figure 3201.00.30). The centre is made from steel, with bronze being
used for the sliding inserts.
alu
Investment (Lost Wax) Casting: Die Assembly for
3201.00.30
Training in Aluminium Application Technologies Production of Wax Patterns (here: Impeller Wheels)
TALAT 3201 18
19. In Figure 3201.00.31 a series of wax patterns is assembled onto a common running
system known as a tree and dipped by hand into the ceramic slurry.
A "Tree" of Wax Patterns being Coated with
alu
3201.00.31
Training in Aluminium Application Technologies Ceramic Slurry
Figure 3201.00.32: the coated pattern is removed, coated in refractory stucco and
allowed to dry. The dipping process is repeated many times until a shell of sufficient
thickness is built up, typically a minimum of ~7 mm. Until recently, the size of
investment castings was limited by the size of shell which could be manhandled.
alu
Dipping Process is Repeated until Sufficient Coating
3201.00.32
Training in Aluminium Application Technologies Thickness is Achieved (~7 mm)
An overall view of a modern facility for making ceramic shells is shown in Figure
3201.00.33. A series of slurry tanks and fluidised beds for the stucco are arranged
around a robot. The increased weight carrying capacity offered by a robot has
TALAT 3201 19
20. revolutionised the investment casting industry, since castings can now be made with
overall dimensions of a metre or more.
alu
Overall View of a Modern Ceramic Coating Plant 3201.00.33
Training in Aluminium Application Technologies
Figure 3201.00.34 shows a steel investment casting being cast.
alu
Training in Aluminium Application Technologies
A Steel Investment being Cast 3201.00.34
The shell has to be removed from the casting which is then cut off from its running and
feeding system (Figure 3201.00.35).
TALAT 3201 20
21. alu
Cutting off Runners and Feeders from the Casting 3201.00.35
Training in Aluminium Application Technologies
In Figure 3201.00.36 lost wax castings have noticeably different forms from other cast
shapes. Clearly, the process is versatile in the complexity of shapes which can be
formed.
alu
Examples for Lost Wax Castings: Versatility of Form 3201.00.36
Training in Aluminium Application Technologies
TALAT 3201 21
22. Cast Metal Production
I would now like to move on to give you an overview of the light metals casting
industry.
The table in Figure 3201.00.37 shows the world-wide annual production of castings,
from which it can be seen that ferrous castings remain a long way ahead of non-ferrous
metals. The majority of non-ferrous castings are made in a wide variety of aluminium
alloys and this is followed in importance by zinc alloys. Only relatively limited tonnages
of castings are made in magnesium alloys because of their cost. We shall concentrate on
the aluminium alloys. These are mainly produced using die casting, sand casting and
investment casting, with smaller tonnages being cast using squeeze casting and the lost
foam process. We shall look at each of these in turn.
World production of castings 1990
Metal Production
Millions of metric tonnes
Cast irons 54.6
Steels 5.0
Copper-base 0.8
Aluminium 3.4
Magnesium 0.3
Zinc 0.4
Other 0.1
Total 64.6
alu
World Production of Castings 1990 3201.00.37
Training in Aluminium Application Technologies
Die Casting Processes
There are a number of die casting processes, as summarised in Figure 3201.00.38. High
pressure die casting is the most widely used, representing about 50% of all light alloy
casting production. Low pressure die casting currently accounts for about 20% of
production and its use is increasing, mainly because it is being favoured by the Japanese
car companies that have recently been expanding. Gravity die casting accounts for the
rest, with the exception of a small but growing contribution from the recently introduced
squeeze casting process.
TALAT 3201 22
23. Die casting processes
High pressure Low pressure Gravity Squeeze
die casting die casting die casting casting
~ 50% ~ 20%
alu
Die Casting Processes 3201.00.38
Training in Aluminium Application Technologies
High pressure die casting is carried out using a large, expensive piece of equipment
shown schematically in Figure 3201.00.39. It consists of two vertical platens on which
bolsters are located which hold the die halves. One platen is fixed and the other can
move so that the die can be opened and closed. A measured amount of metal is poured
into the shot sleeve and then introduced into the mould cavity using a hydraulically-
driven piston. Once the metal has solidified, the die is opened and the casting removed.
Schematic view of high pressure die casting machine
Fixed platen
Die
Bolster
Moving platen
Casting
Ejectors Shot sleeve
Gate
Piston
alu
Training in Aluminium Application Technologies
Schematic View of High Pressure Die Casting Machine 3201.00.39
Low pressure die casting differs in two significant ways (Figure 3201.00.40). Firstly,
the machine is vertically oriented which gives a horizontal die-parting line. The molten
metal is held in a sealed vessel which is then pressurised by gas (usually air) so that
metal is displaced ‘’up-hill’’ into the die cavity. In theory, this should be beneficial since
it should lead to the controlled filling of the mould. However, in practice, there is often
poor control with the result that metal fills the mould in a turbulent manner. This
process is mainly used for producing automotive wheels and it is interesting to note that
every wheel is X-rayed since these are safety-critical parts.
TALAT 3201 23
24. Schematic view of the low pressure die casting process
Moving platen
Dies
Pressurising gas
Metal fill
Fill stalk
Crucible
alu Schematic View of the Low Pressure 3201.00.40
Training in Aluminium Application Technologies Die Casting Process
Figure 3201.00.41: Gravity die casting is the simplest die-casting process. It enables
castings to be produced with only a very modest capital investment, although plenty of
hard physical work is required! However, it can also be automated with either
horizontally or vertically-parted dies. Good quality castings can be produced if sufficient
care is taken to design running and gating systems which minimise surface turbulence in
the metal as it flows into the die.
Schematic view of gravity die casting
Pouring basin Casting
Feeder
Metal core
Filling
system
Sand core
Gate
Die location Core Print
alu
Schematic View of Gravity Die Casting 3201.00.41
Training in Aluminium Application Technologies
The die casting processes are limited by their poor productivity since it is necessary to
wait for the metal to solidify before the die can be opened. [However, at considerable
expense, it is sometimes possible to overcome this restriction with gravity die casting by
mounting a number of dies on a carousel.] During the solidification time, the very
expensive plant is not being used and hence the capital investment is not being
recovered. As an example, the cycle time for producing a typical die-cast cylinder head
is about 5 - 7 minutes, although this can be as long as 15 minutes for larger variants,
such as a Jaguar cylinder head. Ideally, therefore, die casting should be restricted to thin-
walled components. The other limitations with all forms of die casting are the high cost
TALAT 3201 24
25. of the dies themselves and their limited lives as a result of thermal fatigue which causes
craze-cracking of the working faces.
Sand Casting Processes
In contrast to the long cycle times inherent in die casting, high production rates can be
achieved when casting into sand moulds (Figure 3201.00.42). This shows the family of
sand-casting processes and in each case, the rate-controlling step is the rate at which the
moulds can be produced. The technology has developed to the point where some
automatic greensand moulding machines can produce moulds at the very high rate of
one every 12 seconds. This process relies on the use of moist clay to bind together the
sand grains to produce a green (i.e. unfired) mould.
Sand casting processes
Clay-bonded Chemically-bonded Vacuum
(greensand) ('V'-process)
Heat Gas- Self-
cured hardened setting
alu
Sand Casting Processes 3201.00.42
Training in Aluminium Application Technologies
Most of the other sand moulding processes employ a chemical resin to bond together the
sand grains. The resin is subsequently cured by using heat or gas; alternatively a number
of self-setting resins are available. Although it typically takes 30 - 60 seconds to make a
mould and to cure it, this is nevertheless faster than most die casting cycles.
TALAT 3201 25
26. Investment Casting Processes
The steps in the investment casting process are shown in Figure 3201.00.43. It is an
extremely slow process and the production rate is governed by the time to make the
mould. The production of a wax pattern might take only 1 or 2 minutes but most
ceramic shell moulds require between 7 and 14 coats and take at least 24 hours and
sometimes as long as several days to complete. However, it is now normal practice to
make several hundred moulds automatically in one batch and, of course, each mould
may comprise several dozen or over a hundred small components.
Stages in investment (low wax) casting
! Make wax pattern in die
! Assemble patterns onto 'tree'
! Build up ceramic shell mould
! Dewax and fire shell
! Pour metal and allow to solidify
! Remove shell
! Separate castings from runner system and fettle
alu
Training in Aluminium Application Technologies
Stages in Investment (Low Wax) Casting 3201.00.43
Stages in the 'lost foam' process
! Produce expanded polystyrene pattern
! Assemble patterns onto runner system
! Coat with ceramic slurry and dry
! Embed in sand and vibrate to consolidate
! Pour metal
! Remove from sand
! Clean and fettle castings
alu
Training in Aluminium Application Technologies
Stages in the 'Lost Foam' Process 3201.00.44
The lost foam or expanded polystyrene or evaporative pattern casting process again
TALAT 3201 26
27. consists of a number of steps which prevent the achievement of high production rates
(Figure 3201.00.44):
Polystyrene beads are firstly injected into a metal die which is then heated with steam to
expand and fuse the beads. The die is subsequently water-cooled to remove the heat
before extracting the pattern. The overall cycle takes at least 1 minute. A number of
patterns are then assembled to form a tree which is then coated in a ceramic slurry. After
drying, the assembly is embedded in loose sand which is vibrated to consolidate it and
thereby form a rigid mould. The molten metal is poured onto the polystyrene which is
vaporised and replaced by the metal. Although considerable effort has been devoted to
this process over recent years, its adoption has been limited by the difficulties of
producing defect-free castings and of overcoming dimensional inconsistencies caused
by the distortion of the fragile patterns.
The remaining lectures in this course will concentrate on die and sand casting.
This brief view of some selected casting processes forms our introduction to the course.
In later lectures we shall see how the metal solidifies to give different metallurgical
structures and sometimes to cause defects and we shall see how to control both. The
course will conclude with the engineering problems of how casting manufacture can be
successfully integrated into an overall manufacturing operation. Thus we shall look into
the methods of designing patternwork, castings and machining operations so that they
are compatible, each handing over smoothly to the other in a professionally-run relay
race. If the baton is dropped, the race is lost whereas, if it is handed on successfully, it is
possible to win.
One can guarantee that the race will be exciting!
Literature
Campbell, J.: Castings, Butterworth Heinemann, 1991.
Clegg, A.J.: Precision Casting Processes:, Pergamon Press, 1991.
TALAT 3201 27
28. List of Figures
Figure No. Figure Title (Overhead)
3201.00.01 Image from the „Dark Age“ of the Casting Industry
3201.00.02 Modern Computer Design of Castings: Air Inlet Manifold (Rover), Low
Pressure Sand Casting (1)
3201.00.03 Modern Computer Design of Castings: Air Inlet Manifold (Rover), Low
Pressure Sand Casting (2)
3201.00.04 Modern Computer Design of Castings: Air Inlet Manifold (Rover), Low
Pressure Sand Casting (3)
3201.00.05 Modern Computer Design of Castings: Air Inlet Manifold (Rover), Low
Pressure Sand Casting (4)
3201.00.06 Modern Computer Design of Castings: Air Inlet Manifold (Rover), Low
Pressure Sand Casting (5)
3201.00.07 Air Inlet Manifold (Rover), Solid Model Generated by Computer
3201.00.08 Final Casting Shipped 3 Months after Receipt of Orders
3201.00.09 Principle of the Pressure Die Casting Process
3201.00.10 Example of High-Pressure Die Casting (Gear)
3201.00.11 Pattern for a Racing Engine Sump (Sand Casting)
3201.00.12 Half-Mould with Cores (White Core for Oil Passageway); Upper Half-
Mould in Back
3201.00.13 Finished Casting (Lower Crankcase of the Cosworth DFV Formula 1
Engine)
3201.00.14 Core-Making Machine Using the Ashland Isoset Process
(Courtesy: Caterpillar Foundry, Preoria, Illinois)
3201.00.15 Assembly of Large Cores to Form a Mould
3201.00.16 Machine for Turning Over Large Moulds
3201.00.17 Vacuum Moulding Process (Japan)
3201.00.18 Sand Mould Made by the V-Process
3201.00.19 Set of Chemically Bonded Sand Cores for Cylinder Head Mould (Rover,
Longbridge)
3201.00.20 Set of Chemically Bonded Sand Cores for Cylinder Block (Rover,
Longbridge)
3201.00.21 Schematic of the Cosworth Process
3201.00.22 Cosworth Foundry in Worcester, UK,
Showing the Lightweight Foundry Equipment Design
3201.00.23 Rotary Engine Housing with Thick (15mm) and Thin (2mm) Sections
3201.00.24 Aerospace Sand Casting: Pilot’s Ejector Seat Frame
3201.00.25 Aerospace Sand Casting: Air Intake for a Turbo-Engine (Rolls Royce)
3201.00.26 Aerospace Sand Casting: Air Intake for a Turbo-Engine (France)
3201.00.27 Schematic of the Squeeze Casting Process (sometimes also called Squeeze
Forming)
3201.00.28 GKN Sankey Squeeze Casting Machine (Telford, UK)
3201.00.29 Typical Examples of Squeeze Casting Product Forms
3201.00.30 Investment (Lost Wax) Casting: Die Assembly for Production of Wax
Patterns (here: Impeller Wheels)
TALAT 3201 28
29. Figure No. Figure Title (Overhead)
3201.00.31 A „Tree“ of Wax Patterns being Coated with Ceramic Slurry
3201.00.32 Dipping Process is Repeated until Sufficient Coating Thickness is
Achieved (∼ 7mm)
3201.00.33 Overall View of a Modern Ceramic Coating Plant
3201.00.34 A Steel Investment being Cast
3201.00.35 Cutting off Runners and Feeders from the Casting
3201.00.36 Examples for Lost Wax Castings: Versatility of Form
3201.00.37 World Production of Castings 1990
3201.00.38 Die Casting Processes
3201.00.39 Schematic View of High Pressure Die Casting Machine
3201.00.40 Schematic View of the Low Pressure Die Casting Process
3201.00.41 Schematic View of Gravity Die Casting
3201.00.42 Sand Casting Processes
3201.00.43 Stages in Investment (Lost Wax) Casting
3201.00.44 Stages in the “Lost Foam“ Process
TALAT 3201 29