1.0 Sand Casting 1484 Abstracts From 2016 To 2021 Scopus and SD Combine

Scopus
EXPORT DATE:27 Oct 2020
Sustainability assessment of rapid sand mould making using multi-criteria

decision-making mapping
.
https://www.scopus.com/inward/record.uri?eid=2-s2.0-
85091483209&doi=10.1007%2f978-981-15-8131-
1_31&partnerID=40&md5=0ab9225e1d6e091072dea803af2159d2
ABSTRACT: Capabilities of additive manufacturing (AM) for rapid tooling are
well known in recent times. Rapid sand moulds are advantageous over
traditional sand moulds in terms of cost, manufacturing time, flexibility,
etc. This paper identifies metrics related to mould manufacturing and
categorises them into four categories (cost, time, quality and
environmental sustainability). A methodology based on the deterministic
Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS)
multi-criteria decision-making algorithm is used to map at high resolution
the influence of such categories on to the decision-making space when
comparing AM with conventional sand mould making. Results show that AM is
almost always clearly advantageous overall (excluding some very limited
corner cases) for the examined case. © The Editor(s) (if applicable) and
The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd
2021.
Fatigue Validation of Iron Casting Components by Strain-Life Principle

.
85092793030&doi=10.1007%2f978-981-15-4779-
9_22&partnerID=40&md5=415d740101603ff3514974d8d83746fa
ABSTRACT: Air Disc Brake is a safety critical system in a heavy commercial
vehicle, and its components are subjected to various types of loads during
braking. Fatigue damage of brake components due to cyclic loading is the
most critical and common component failure among other failures. Fatigue is
the most widely recognized reason for failure in metal
components/structures, and the main aim of this study is to predict fatigue
life of casting components with Finite Element Method (FEM) simulation and
correlate/validate with experimental results. Fatigue analysis of Brake
Caliper of Air Disc Brake which is manufactured by sand casting is carried
out using strain-life method. This study considers only mechanical fatigue
of strain-life theory with plastic stress and strain. Softwares, ANSYS 18.2
and nCodeDesignLife, are used to calculate component fatigue life under
static loading condition. The influence of the various parameters like
Surface Roughness, different Mean Stress Correction Theories, Stress
Combination Method, and Stress Gradient on the simulated results were
studied in detail to correlate/validate with experimental results. It is
observed that fatigue life by nCode DesignLife strain base method gives
good result in comparison with experimental result. © 2021, Springer Nature
Singapore Pte Ltd.
Investigation of the efficacy of a water-cooled chill on enhancing heat

transfer at the casting-chill interface in a sand-cast A319 engine block
.
85087703291&doi=10.1016%2fj.jmatprotec.2020.116789&partnerID=40&md5=f15d012
bdb12afe300dfb6ad16f9e727
ABSTRACT: In the recent years, the automotive industry has increased the
production of small, high-power gas engines as part of several strategies
to attain the new “Corporate Average Fuel Economy” (CAFE) standards, while
meeting consumer demand for increased performance at the same time. This
trend necessitates an improvement in the thermal and mechanical fatigue
strength of the aluminium alloys used in manufacturing cylinder heads and
engine blocks in these engines. In the absence of changing alloy chemistry,
which potentially has important implications for downstream operations such
as heat treating and machining, one feasible way to improve fatigue life is
to reduce the length-scales of the microstructural constituents arising
from solidification that limit fatigue resistance. This, in turn, may be
accomplished by increasing the cooling rate during solidification (reducing
the solidification time). Conventionally, solid chills are employed in the
industry to achieve this goal. A potential tactic for improving the
efficacy of these chills is to incorporate water cooling. In order to
assess the effectiveness of this technique, a water-cooled chill was
designed and installed in a bonded-sand engine block mould package (quarter
section). Twelve experiments were conducted with a conventional solid chill
and a water-cooled chill (with and without delay in water cooling). The
moulds were instrumented with “Linear Variable Displacement Transducers”
(LVDTs) to measure the gap formation at the casting-chill interface, and
thermocouples to measure the evolution of temperature at key locations in
the casting and the chill. Overall, the results show that the adoption of
water-cooled chill technology, if implemented carefully, has the potential
to improve the cast microstructure, therefore, increase the fatigue
durability of the engine blocks. © 2020 Elsevier B.V.
Improvement of mechanical properties by means of titanium alloying to steel

teeth used in the excavator
.
85077707869&doi=10.1016%2fj.jestch.2019.12.003&partnerID=40&md5=8a9166c481d
215d72714b11a44b8d2f4
ABSTRACT: The effect of Ti addition (0.15 and 0.20 wt%) on mechanical
properties and wear resistance of steel excavator bucket teeth was
investigated. Teeth were produced by commercial sand casting technique.
After production normalizing, hardening, and tempering heat treatment
procedures were applied to the teeth. Lath martensitic microstructure was
observed and small amount of carbide particles were present in the
microstructures of Ti containing ones. In addition, small amount of hard
and brittle TiN particles were observed in the microstructure of 0.20 wt%
Ti containing teeth. The best mechanical properties were obtained for 0.15
wt% Ti containing teeth with considerably high abrasive wear resistance.
However, 0.20 wt% Ti containing teeth exhibited worst abrasive wear
resistance and limited ductility due to the formation of TiN particles. ©
2019 Karabuk University
Inquiry-based learning: Development of an introductory manufacturing

processes course based on a mobile inverted pendulum robot
.
85065430659&doi=10.1177%2f0306419019844257&partnerID=40&md5=6c5a7809f69ff2a
3bdd56ecc1fc7af26
ABSTRACT: This paper describes the development of an innovative
introductory manufacturing processes course designed to expose students to
a broad overview of fundamental concepts, methods, procedures, tools, and
equipment used in the manufacturing industry. Based on an educational
mobile inverted pendulum robot, students are introduced to product design
and prototyping by identifying an existing problem with a component in the
robot, redesigning the component using computer aided design software, and
then building a prototype using additive manufacturing methods.
Subsequently, a set of hypothetical design requirement changes is imposed,
and various design methods and manufacturing processes that can be used to
make components to satisfy these new requirements are discussed. Topics
covered include integrated product design, additive manufacturing
prototyping based on different technologies, plastic injection molding,
sand casting, and fundamentals of both computer aided manufacturing and
computer numerical control machining. Tools, fixtures, and accessories
required in these processes, as well as associated challenges, are also
discussed. This course adapts the inquiry-based learning active learning
pedagogical approach and focuses on the development of students’ ability to
conduct analytical analysis and to apply a knowledge of mathematics,
science, engineering, and technology to solve practical engineering
technology problems. As an introductory course designed to be offered to
freshman level students, this course engages students in engineering
technology related topics and stimulates their interest in manufacturing
related subjects. It helps with improving the engineering student retention
rate and serves as a pathway connecting students to more advanced
specialized manufacturing courses such as computer numerical control
machining technology. This paper presents course materials developed and
student feedback as well as their evaluation of the course effectiveness
based on a summative questionnaire-style survey from the first cohort of
students. © The Author(s) 2019.
Energy release and countermeasures for sand casting explosion accidents

.
85070442559&doi=10.1080%2f10807039.2019.1650327&partnerID=40&md5=4861e46f8d
adbfc73a5288cbdc7e7387
ABSTRACT: Sand casting explosion accidents seriously threaten employees'
lives and the harmony and stability of society, such as casualties,
equipment trouble and environmental pollution. The main purpose of this
study was to determine the water requirement for sand casting explosion
accidents, and then corresponding safety measures were proposed to prevent
such accidents. First, the relationship between the water condition and
temperature for such accidents was achieved based on an energy release
equation in compressed gas expansion and the ideal gas state equation. The
volume of vapor expanded rapidly as the temperature rises, which was also
the immediate cause of sand casting expansion accidents. Also, the water
requirement for the sand casting expansion accidents decreased rapidly as
the temperature rises. Then, a bow-tie model was adopted for preventing the
causes and consequences of sand casting explosion accidents. Three main
causes were identified, namely molten metal meeting ponding, failure of
cavity exhaust and low strength sand of sand mold, and 11 prevention safety
measures were adopted to prevent the causes of such accidents. In addition,
three consequences were identified, namely casualties, equipment trouble
and environment pollution, and ten mitigation safety measures were adopted
to mitigate the consequences of such accidents. © 2019 Taylor & Francis
Group, LLC.
Product Design & development of High-Pressure moulding machine and analysis

of various mould properties
.
85091963812&doi=10.1088%2f1757-899X
%2f912%2f3%2f032079&partnerID=40&md5=086946258231b969619298fa167e32de
ABSTRACT: Although there are many advanced technologies for metal casting,
green sand casting is one of the most commonly used casting processes today
due to its low cost of raw materials, and ability to produce a variety of
castings both in size and composition, and the ability to recycle the
moulding sand. The green sand-casting process is one of the most versatile
processes in manufacturing because it is used for most metals and alloys
even with high melting temperatures such as iron, copper, and nickel.
Understanding the conventional and modern green sand moulding method can
help redesign for manufacturability and utilize processes for modernization
of foundry; that meet specific requirements. The flexibility of moulding is
demonstrated by the number of moulding processes currently available. This
wide range of choices offers design engineers and component users' enormous
flexibility in their metal forming needs. Each process offers distinct
advantages and benefits when matched with the proper product application.
This project is to design a high-pressure moulding machine and study,
compare mould properties achieved by different moulding methods, that help
improve product quality. © Published under licence by IOP Publishing Ltd.
Simulation of temperature field of A356 aluminum alloy in freeze casting

.
85090499287&doi=10.1088%2f1742-
6596%2f1600%2f1%2f012045&partnerID=40&md5=0c1b9e827ea59f136f4085ee247daaca
ABSTRACT: In this paper, the temperature change curve of the casting and
frozen sand mould during the solidification process of the A356 aluminum
alloy in the frozen sand mould is tested. According to the actual
temperature change curve of the casting surface and the sand mould surface,
the interface heat transfer coefficient between the frozen sand mould and
the A356 aluminum alloy could be reversed analysis. The results show that
when the casting temperature is lower than 550 °C, the interface heat
transfer coefficient remains about 750 W.(m2.K)-1; When the casting
temperature is between 550 °C and 610 °C, the interface heat transfer
coefficient increases significantly; when the casting temperature is higher
than 610 °C, the interface heat transfer coefficient reaches the maximum
value, which is about 2300W. (m2.K) -1. At this time, this study simulates
the solidification temperature field of aluminum alloy hub parts in the
frozen sand mould according to the interface heat transfer coefficient
calculated by inverse analysis, and the temperature field of resin sand
mould casting was used as for comparison. The results show that: under the
same solidification time, the temperature field of A356 aluminum alloy hub
parts in frozen sand mould is lower than that of resin sand casting,
freezing casting can realize the high-speed solidification process of
different parts of complex castings. © Published under licence by IOP
Publishing Ltd.
The effects of Y on primary α-Al and precipitation of hypoeutectic Al-Si

alloy
.
85083026033&doi=10.1016%2fj.matlet.2020.127795&partnerID=40&md5=96aad471c8c
4322d16cc4c50e9c927c4
ABSTRACT: Under sand casting conditions, the effects of yttrium (Y) on the
primary α-Al and precipitation of A357 alloy were investigated. The results
showed that with Y addition, the primary α-Al nucleation was more
difficult, and the Tliquidus-Tsolidus decreased. Meanwhile, the number of
the dendritic primary α-Al grains increased, the primary dendrite arms
became longer and narrower, and the secondary dendrites had longer arms and
smaller arm spacing. Some other elements had the same phenomenon, like Si,
Sr, etc. As for precipitation, with Y addition, the number of β″ decreased.
Y did not affect the β″ habit plane and did not change the types or produce
new precipitation. © 2020 Elsevier B.V.
Comparison Study on Four Types Mathematical Model for Sand-Casting Process

.
85091067387&doi=10.1088%2f1757-899X
%2f864%2f1%2f012074&partnerID=40&md5=e84eb4ed36a3c16b73b623d7f1c48f0c
ABSTRACT: Modelling and optimisation of sand-casting process have been
widely studied in casting research. The present study was developed to
compare the four types of mathematical model and find the best model used
in the optimised process. The four types of mathematical model discussed in
this paper were multiple linear regression model, full factorial model,
fractional factorial model and response surface methodology model. The best
model will used for the optimized process using soft computing technique.
The input parameters of these models were silica sand, bentonite, water and
coal dust. Meanwhile, permeability was the model output. The four types of
mathematical model produced were statistically validated to test for model
adequacy by using ANOVA and coefficient of determination. Each model was
finally, validated by using mean square error (MSE) and root square error
(RMSE). The research findings proved that respond surface methodology model
was the best model as compared the other models, which was significant with
p-values of less than 0.05. The model also produced the smallest MSE. ©
Published under licence by IOP Publishing Ltd.
Microstructures and mechanical properties of 3D printing sand casting Al-

7Si-0.4Mg alloy [3D 打印砂型铸造 Al-7Si-0.4Mg 合金的组织和力学性能]
.
85089935945&doi=10.11817%2fj.ysxb.1004.0609.2020-
39608&partnerID=40&md5=9c995383eefcc1bef36fb0925337f7bd
ABSTRACT: ProCAST software was used to simulate the filling and
solidification process of step parts with different thicknesses (5-30 mm),
and the casting experiment was carried out in combination with the
simulation results, the effects of thickness on the microstructure and
mechanical properties of 3D printing sand casting Al-7Si-0.4Mg alloy were
studied. The results show that, as the wall thickness decreases, the
secondary dendrite arm spacing, eutectic silicon size, and Fe-containing
phase size of α(Al) in the alloy decrease, while the density and tensile
mechanical properties of the alloy increase significantly. In the T6 state,
the highest (thickness of 5 mm) tensile strength of the alloy is 279 MPa,
and the elongation after break is 2.13%. According to the analysis, as the
thickness decreases, the solidification cooling rate of the alloy
increases, the microstructure is refined, the density is increased, and the
strength and elongation of the alloy are improved. In addition, the
properties of 3D printings and casting aluminum are limited by the sand
mold binder content, and the elongation is low. © 2020, Science Press. All
right reserved.
Light-Weighting Technologies for High-Performance Ductile Iron Sand

Castings
.
85079466836&doi=10.1007%2fs40962-020-00423-
4&partnerID=40&md5=a2c07f48e82f9415c1019845431c6207
ABSTRACT: There have been recent advances with high-strength high-ductility
alloys and 3D (dimensional) sand printing additive manufacturing
technologies. These advances make for original equipment manufacturer
casting design engineers to come up with newer, innovative design
solutions. Similarly, light-weighting technologies coupled with integrated
computational materials engineering (ICME) tools and latest strain-life
fatigue data optimize the process of casting configurations. This paper
discusses thin-wall casting designs and optimization process with case
studies, including the effective use of the ICME tool, casting process
modelling, and toolingless 3D printed sand additive manufacturing
processes. The approach of taking current legacy cast parts while utilizing
thin-wall technologies is discussed within the case studies. Studies also
cover casting conversion opportunities for competing materials and
processes: steel fabrications, steel castings, forgings and aluminium
castings for high-performance applications. © 2020, American Foundry
Society.
Challenges and opportunities to integrate the oldest and newest

manufacturing processes: metal casting and additive manufacturing
.
85086170674&doi=10.1108%2fRPJ-10-2019-
0277&partnerID=40&md5=a9498566d4b5754e172f5219f5aa46ad
ABSTRACT: Purpose: This paper aims to investigate the current state,
technological challenges, economic opportunities and future directions in
the growing “indirect” hybrid manufacturing ecosystem, which integrates
traditional metal casting with the production of tooling via additive
manufacturing (AM) process including three-dimensional sand printing (3DSP)
and printed wax patterns. Design/methodology/approach: A survey was
conducted among 100 participants from foundries and AM service providers
across the USA to understand the current adoption of AM in metal casting as
a function of engineering specifications, production demand, volume and
cost metrics. In addition, current technological and logistical challenges
that are encountered by the foundries are identified to gather insight into
the future direction of this evolving supply chain. Findings: One of the
major findings from this study is that hard tooling costs (i.e.
patterns/core boxes) are the greatest challenge in low volume production
for foundries. Hence, AM and 3DSP offer the greatest cost-benefit for these
low volume production runs as it does not require the need for hard tooling
to produce much higher profit premium castings. It is evident that there
are major opportunities for the casting supply chain to benefit from an
advanced digital ecosystem that seamlessly integrates AM and 3DSP into
foundry operations. The critical challenges for adoption of 3DSP in current
foundry operations are categorized into as follows: capital cost of the
equipment, which cannot be justified due to limited demand for 3DSP
molds/cores by casting buyers, transportation of 3DSP molds and cores,
access to 3DSP, limited knowledge of 3DSP, limitations in current design
tools to integrate 3DSP design principles and long lead times to acquire
3DSP molds/cores. Practical implications: Based on the findings of this
study, indirect hybrid metal AM supply chains, i.e. 3DSP metal casting
supply chains is proposed, as 3DSP replaces traditional mold-making in the
sand casting process flow, no/limited additional costs and resources would
be required for qualification and certification of the cast parts made from
three-dimensional printed sand molds. Access to 3DSP resources can be
addressed by establishing a robust 3DSP metal casting supply chain, which
will also enable existing foundries to rapidly acquire new 3DSP-related
knowledge. Originality/value: This original survey from 100 small and
medium enterprises including foundries and AM service providers suggests
that establishing 3DSP hubs around original equipment manufacturers as a
shared resource to produce molds and cores would be beneficial. This
provides traditional foundries means to continue mass production of
castings using existing hard tooling while integrating 3DSP for new complex
low volume parts, replacement parts, legacy parts and prototyping. © 2020,
Emerald Publishing Limited.
Feasibility of calcium sulfate moulds made by inkjet 3D printing for rapid

casting of aluminium alloys
.
85086665429&doi=10.3390%2fmet10060802&partnerID=40&md5=bb848974463cd515396b
65bab48223cd
ABSTRACT: In this research, a comparative analysis has been carried out
between a traditional sand casting process and a modern mould obtained by
additive manufacturing (AM), in the context of aluminium parts production.
In this case of AM, an inkjet 3D printing (3DP) process allowed us to
create a ceramic mould. A numerical simulation was carried out to study the
filling and cooling rates of both parts. The design freedom typical of the
3DP technique allowed us to optimize the filling system. The results showed
that in sand moulding, the speed in the gate suddenly increased when the
liquid metal entered the part cavity, leading to severe turbulence due to
the fountain effect. The input of air is related to the speed in the gate.
Nevertheless, the results showed that when using the 3DP mould, the speed
in the gate remained constant and the filling process was homogenous. With
regard to the dimensional precision, while the staircase effect in the
surface of the 3DP mould is the most critical aspect to control, in the
sand casting mould the critical aspect is the dimensional precision of the
pattern. Microstructures of the cross-section of the moulded parts showed
folded shapes and air input in sand casting, which could be produced by the
severe turbulence and the oxide film present in the melt during the filling
process. On the other hand, the porosity found in parts produced with the
3DP mould corresponds to shrinkage; during the filling process, the
remaining binder is vaporized, creating nucleation points. In this way,
pores are formed by shrinkage and a mixture of shrinkage and gas
entrapment. With these considerations, it can be concluded that AM shows
feasibility and advantages as an alternative to the sand casting method for
aluminium alloys. © 2020 by the authors. Licensee MDPI, Basel, Switzerland.
Experimental study of the corona performance of aged sand-cast substation

connectors
.
85085930810&doi=10.3390%2fen13112785&partnerID=40&md5=4ad38be272256f0ee2efb
6292561f5ab
ABSTRACT: Substation connectors, like many other high-voltage products, are
tested once manufactured. However, the corona behavior of aged specimens
can differ from that exhibited by newer ones, thus generating detrimental
technical and environmental effects. Manufacturers need to know the long-
term corona behavior of substation connectors to offer their customers
maximum safety and transparency about such critical products. This paper
analyzes the ageing effect on the surface roughness and the visual corona
extinction voltage of sand-cast aluminum connectors, which were
artificially aged in a salt spray chamber for different periods. The
experimental results show an important variability of the surface roughness
and corona extinction voltage (CEV) among connectors with the same ageing
level due to the sand-casting manufacturing process. The results in this
paper also show a slight increase in the surface roughness with the ageing
period, although there is not a clear pattern between the applied ageing
level and the experimental CEV value. It is concluded that the inherent
variability among connectors due to the sand-cast process has more
influence than the ageing effect itself. © 2020 by the authors. Licensee
MDPI, Basel, Switzerland.
Effect of process parameters on flexure strength and gas permeability of 3D

printed sand molds
.
85083300624&doi=10.1016%2fj.jmapro.2020.02.043&partnerID=40&md5=8a57f1dfca0
2346b104d373c6adeb6d7
ABSTRACT: 3D printed sand molds for the casting industry play a vital role
in manufacturing intricate parts using a computer model. The possibility of
producing fairly significant structural castings using a small job-box 3D
sand mold printer is another advantage compared to the direct metal 3D
printing processes. It is important to identify the relationship between
the process parameters and the properties of the sand mold to produce a
mold with the required strength, permeability and stiffness; to reduce gas
emissions during casting and minimize the mass of combustible materials in
the mold. Hence, it is possible to create an excellent casting by improving
the design of such molds for liquid alloy filling and solidification. The
relationship between the printing parameters and the properties of the mold
can be a great tool for foundrymen, primarily to optimize the strength and
permeability properties of these molds and therefore to provide exact
boundary conditions for the solidification simulation prior to a casting
trial. This paper reports on a study of a basic outline to quantify the
role of the sand mold printing process parameters, particularly the
recoater speed and print resolution, on the mold strength and permeability,
and their impacts on the anisotropic behavior of the printed sand molds. ©
2020 The Society of Manufacturing Engineers
Study on using Casting Simulation Software for Design and Analysis of Riser
Shapes in a Solidifying Casting Component
.
85086369175&doi=10.1088%2f1742-
6596%2f1500%2f1%2f012036&partnerID=40&md5=36b22d855fa5e9e9d5e452829a97f6e9
ABSTRACT: Filling and solidification of molten metals are very complex and
difficult to simulate correctly by conservative methods. For a large
industrial application, it needs an alternate approach that is fast,
reliable and user-friendly. In current casting industries, product
development paradigm is shifting from traditional trial-and-error in the
workshop to computer-aided casting design and simulation package by a
computer(s). Computer-aided casting simulation plays an important role in
the paradigm of new product development by way of modeling entire casting
processes and reveals a dynamic behavior of casting scheme in working
conditions. This study, highlighting is given on using casting simulation
software which helps foundry industries to design and analysis the size and
shape of the riser. Intended for simulation simplification in this study,
grain size of mold green sand, casting material quality, casting process
parameters are deliberated identical for all design schemes. Only the shape
and dimensional variances of sprue/risers are taken into considerations for
defects analysis. It is found that defects such as micro and shrinkage
porosities, and improper solidification, are directly related to gating and
risers system. Casting simulation software is used for mold filling and
solidification analysis and it is observed that the proposed gating and
risers system design will improve casting results with small defects. From
this study, the conclusion can be stated that taper sprue design, also acts
as a riser, with an additional four small risers that will produce a small
fraction of porosity inside of the casting part. Validation of simulation,
in the future, will be proved through experimental trials in the foundry
shop. © 2020 IOP Publishing Ltd. All rights reserved.
Simulation Analysis of Sand Casting Process of Automobile Accessory Reducer

Cover [汽车减速器箱盖砂型铸造工艺模拟分析]
.
85090620726&partnerID=40&md5=7c711f89f7bdc2fd3b45acbe8f8f1fbd
ABSTRACT: Taking the AZ91D magnesium alloy automobile accessory reducer
cover as the object, the flow field and temperature field in the sand
gravity casting process were simulated by using ProCAST numerical
simulation software, and the probable area of occurrence of casting defects
(such as shrinkage hole and shrinkage porosity) was predicted. Based on the
simulation results, eight rectangle risers were added on the convex surface
of the casting to prolong the solidification time, thus transferring the
defects to the riser positions. By simulation and optimization for casting
process, the defects of castings are effectively controlled, which ensures
the quality and production efficiency of castings. © 2020, Chinese
Mechanical Engineering Society. All right reserved.
A fully-coupled thermal-stress model to predict the behavior of the

casting-chill interface in an engine block sand casting process
.
85080045726&doi=10.1016%2fj.ijheatmasstransfer.2020.119490&partnerID=40&md5
=d79b509ed5702e151985408417083bac
ABSTRACT: The sole use of light alloys in the production of automotive
parts might not be the best strategy to reduce the emission of CO2, as for
this purpose, one should consider the life-cycle of the final part. One way
to address this issue is to increase the in-service life of the components
by modifying the manufacturing process. In the first phase of this study,
we used a different chill format in the bonded sand casting process for the
production of engine blocks, and it was concluded that this method might
increase the fatigue life of the component by refining the microstructure.
However, to better understand the dynamics of the casting-chill interface,
the development of a thermal-stress model was necessary. This paper
summarizes the methodology used to develop a thermal-stress model that
predicts the evolution of temperature within the casting and the chill and
the evolution of gap and/or pressure at the casting-chill interface. The
work identified that the gap size between the H13 chill and the casting at
the bottom of the chill in the main bearing bulkhead could reach a maximum
of 0.17 mm. Additionally, it was found that the heat transfer coefficient
decreased from a peak value of 2500 W m−2 K−1 to 500 W m−2 K−1 at a gap
size of 0.2 mm. The numerical analysis uncovered a couple of important
factors that play a major role in the development of the gap at the
interface including the thermal contraction/deformation of the casting; the
thermal expansion/deformation of the chill; the constitutive behavior of
the casting; the constitutive behavior of the bonded sand mold cap; and,
the geometry of the casting-chill interface. Overall, the modeling results
show that the interface gap/pressure dynamics are complicated and play a
critical role in governing heat transport across the casting-chill
interface. © 2020 Elsevier Ltd
Probabilistic surface layer fatigue strength assessment of en ac-46200 sand

castings
.
85090253618&doi=10.3390%2fmet10050616&partnerID=40&md5=670c926e4b7e1fe72e4b
ee81dab2b945
ABSTRACT: The local fatigue strength within the aluminium cast surface
layer is affected strongly by surface layer porosity and cast surface
texture based notches. This article perpetuates the scientific methodology
of a previously published fatigue assessment model of sand cast aluminium
surface layers in T6 heat treatment condition. A new sampling position with
significantly different surface roughness is investigated and the model
exponents a1 and a2 are re-parametrised to be suited for a significantly
increased range of surface roughness values. Furthermore, the fatigue
assessment model of specimens in hot isostatic pressing (HIP) heat
treatment condition is studied for all sampling positions. The obtained
long life fatigue strength results are approximately 6% to 9% conservative,
thus proven valid within an range of 30 µm ≤ Sv ≤ 260 µm notch valley
depth. To enhance engineering feasibility even further, the local concept
is extended by a probabilistic approach invoking extreme value statistics.
A bivariate distribution enables an advanced probabilistic long life
fatigue strength of cast surface textures, based on statistically derived
parameters such as extremal valley depth Svi and equivalent notch root
radius ρi . Summing up, a statistically driven fatigue strength assessment
tool of sand cast aluminium surfaces has been developed and features an
engineering friendly design method. © 2020 by the authors.
3DP Printing Sand Casting Technology for High-graded Automobile Stamping

Die Casting Steel Parts [高端汽车冲压模铸钢件的 3DP 打印砂型铸造技术]
.
85087362766&doi=10.15980%2fj.tzzz.2020.04.010&partnerID=40&md5=46c38f3a11f0
853d10c242412fe8ef37
ABSTRACT: The application of 3DP process in the manufacture and production
of medium and large stamping die casting steel parts was nalyzed. The
tensile strength, gas permeability, gas generation and other properties of
the sand mold were measured, and sand mold was designed based on 3DP
process. The results show that the tensile strength of the sand mold by 3DP
technology can reach 1.70 MPa, and the gas permeability is more than 400
with the maximum gas generation of 14.6 mL/g, which can meet the
requirements of alloy steel casting. The 3DP process forming sand mold
(core) has the advantages of mold free, sand type and sand core integration
process, as well as improving the precision of the casting. Through the 3DP
sand design, the problem of the sharpness of the printed sand word was
solved by a special process. © 2020, Journal Office of Special Casting and
Nonferrous Alloys. All right reserved.
Low carbon, high efficiency and sustainable production of traditional

manufacturing methods through process design strategy: Improvement process
for sand casting defects
.
85078188281&doi=10.1016%2fj.jclepro.2019.119917&partnerID=40&md5=283fad2537
6a19e4ac4352a5bf58fc55
ABSTRACT: Energy saving and emission reduction in traditional manufacturing
can be achieved by reducing the occurrence of defective products. Most of
the existing optimization methods are obtained by referring to production
experience and technical manual, which are time-consuming and laborious.
Thus, a method of process selection and optimization for defective products
in the design phase is required. In this paper, a process design strategy
based on design parameters for eliminating sand casting defects is
proposed. Firstly, the technological process and hole-type defects of sand
casting are analyzed. The process design parameters are divided into three
categories to propose a process design strategy. Three specific
optimization schemes named OSP (structure parameters optimized process),
OGP (gating system parameters optimized process), and OPP (processing
parameters optimized process) are derived. Then a carbon emission
prediction model is established to evaluate the effect of these schemes,
and a sustainable manufacturing evaluation method with six indicators is
also raised. Finally, a case study illustrates that 21%–24% of process
carbon emission was saved after optimization on average. Among the
strategies, OSP has the best energy-saving performance of average carbon
emission, which is 4% lower than the others. OGP has the largest proportion
of recyclable resources while OPP has the highest process yield and lowest
adjustment cost. The results show that the proposed strategies can
effectively improve the process yield, quality of casting, and decrease
carbon emissions. The strategy raised in the paper supports the sustainable
development of traditional manufacturing methods. © 2019 Elsevier Ltd
Life cycle energy and environmental impact assessment of CRIMSON sand

casting on intake manifold production process
.
85084136879&doi=10.1063%2f5.0000498&partnerID=40&md5=872a8e44e5fd517c1e091d
38da704718
ABSTRACT: The simplification of manufacturing efficiency can drive the
great impact to the energy consumption. In foundry industry, CRIMSON
(Constrained Rapid Induction Melting Single Shot Up-Casting) usually used
to reduce the sequences of processes and energy consumption. The present
paper focuses to analyze the CRIMSON sand casting stages due to its energy
consumption and environmental impact. In this paper, CRIMSON sand casting
process is used to produce automotive component, intake manifold. The
environmental impact assessment obtained through simulation by considering
material and energy consumption while in manufacturing process. It is
proven that CRIMSON sand casting drive to higher energy efficiency.
However, the pollutant is still found in a quite large amount. © 2020
Author(s).
Enhancement quality of sand casting manufacturing product using Taguchi

method
.
85084121960&doi=10.1063%2f5.0000497&partnerID=40&md5=bd7f665ae5cc3118e9e67c
bb1341c6ce
ABSTRACT: Sand casting is the most widely used technique in foundry
industry. In manufacturing process, there are found a number of parameters
involved. The parameters should be controlled to improve the quality of
sand casting product. However, a number of barriers make the casting
process difficult to avoid a defect of casting. This aims of this study is
to reduce the number of defect, especially on surfac e roughness. Taguchi
method was used to evaluate the sensitivity of several independent
parameters. Orthogonal array is used for experimental purpose. Several
control parameters; such as sand particle size, permeability and melting
temperature were selected as control parameters. By using Design of
Experiments, this study proposed a new design of operations process based
on independent parameters. The design proposed is 165 AFS of particle size,
50 nu of permeability and 710° for melting temperature. © 2020 Author(s).
Control Technology of Segregation Defects in ZL205A Alloy Large Cylinder

Castings [ZL205A 合金大型筒体类铸件偏析缺陷控制技术研究]
.
85089098060&partnerID=40&md5=b5ce857031537a93cce70ecd3de9f69c
ABSTRACT: The location and formation reason of segregation defect in the
ZL205A Alloy large cylinder castings were studied. The effect of casting
process on the segregation defect of casting was studied by using numerical
simulation technology and casting pouring test. The results show that the
segregation defect of casting can be reduced significantly by using low
pressure casting process. Furthermore, resin bonded sand core with the
better deformability was used to release the residual thermal stress at the
end of solidification and avoid high thermal internal stress in the hot
spots, which effectively reduce the segregation defects of castings. ©
2020, Chinese Mechanical Engineering Society. All right reserved.
Effectiveness analysis of resources consumption, environmental impact and

production efficiency in traditional manufacturing using new technologies:
Case from sand casting
.
85081260752&doi=10.1016%2fj.enconman.2020.112671&partnerID=40&md5=ee6e4c3b9
bd243d8943ca75da21f30e7
ABSTRACT: The emergence of new technologies has accelerated the process of
sustainable development, gradually moving traditional manufacturing away
from labor-intensive low-end towards high value-added and high-quality
production. In order to study the application effectiveness of new
technologies, the production of single or small batch castings in the
traditional foundry industry is taken as the analysis object by using
traditional manufacturing method, additive manufacturing (ink-jet bonding
3D printing) and subtractive manufacturing (sand mold milling), from the
aspects of resources consumption, environmental impact and production
efficiency. Among them, the resources consumption takes material, energy,
and human resources into comprehensive consideration, while the
environmental impact takes carbon emission as the main evaluation index,
and the production efficiency is determined according to the actual casting
output of the enterprise, this evaluation method is applicable to most of
the traditional manufacturing industries. The results indicate that in the
production of this kind of castings, additive and subtractive manufacturing
have better resource utilization and significantly reduced the carbon
emission of sand casting process by about 20.78% and 4.82%, respectively.
Besides, the production efficiency of additive and subtractive
manufacturing are 92.66% and 91.39% respectively, which has superiority not
only in production capacity but also in economic benefits. According to the
research conclusion, reference of what or whether new technologies can be
used in traditional manufacturing to realize sustainability is provided,
which has certain practical significance. © 2020 Elsevier Ltd
Prediction of the residual state of stress in a superduplex stainless steel

produced by sand casting (using a coupled thermo-mechanical approach)
.
85084151414&doi=10.1007%2fs00170-020-05213-
0&partnerID=40&md5=c30f958c46447a874de785a3706b562b
ABSTRACT: The present work aims at investigating the effect, in terms of
residual stress prediction, determined by the adoption of different
material constitutive models in the Finite Element simulation of the
casting process of a superduplex stainless steel benchmark, from the
cooling after the pouring phase to the subsequent heat treatment (heating
and water quenching). A 3D thermo-mechanical Finite Element (FE) model was
created with the commercial code Abaqus: the preliminary thermal problem,
i.e. the determination of the heat transfer coefficients during both the
mould cooling and the quenching, was solved by means of an inverse analysis
approach by minimizing the difference between the numerical evolution of
temperature and the experimental acquisition coming from real casting test.
Two separate routes were followed according to the adopted constitutive
equations: modelling the material as (i) elasto-plastic or (ii) elasto-
viscoplastic. The numerical prediction of the residual state of stress in
terms of casting relaxation was compared with the experimental data after
the cut of the casting using an electro-discharge machine. The analysis
revealed that when the elasto-viscoplastic modelling was adopted, the
simulations underestimated the relaxation with an error larger than 50%; on
the other hand, the elasto-plastic model leads to an overestimation with an
error of about 30%. © 2020, Springer-Verlag London Ltd., part of Springer
Nature.
Additively Manufactured Single-Use Molds and Reusable Patterns for Large

Automotive and Hydroelectric Components
.
85074711014&doi=10.1007%2fs40962-019-00379-
0&partnerID=40&md5=e0428e3df3ff8af4954ece145ad46a90
ABSTRACT: Additive manufacturing (AM) has the potential to reduce costs in
the casting industry, particularly for large parts (i.e., components with
any dimension > 12 in.). Here, pilot-scale production case studies of
hydroelectric and automotive parts were used to evaluate two AM-enabled
casting methods: the direct printing of sand molds by binder jet and
printing of reusable cope and drag patterns for sand casting. An additional
benefit was found when additively manufactured patterns were used in
combination with heat-treat free aluminum alloys, to produce castings of
complex hydrodynamic surfaces. These parts previously required production
via subtractive machining due to part distortion induced by the quench step
of heat treatments. The machine types used for the three case studies are
sand-binder jet, high-resolution polymer fused deposition modeling (FDM),
and big area additive manufacturing (BAAM) FDM in combination with CNC
machining. Each method demonstrated distinct advantages over traditional
casting practices in particular use cases. Single-use molds show great
reductions in start-up cost to produce one-off or legacy parts, and
additively manufactured impression patterns show promise for innovating the
tooling design process for complex geometry and large castings. © 2019,
American Foundry Society.
Design and Optimization of Casting Process for Automobile Cushion Block [汽

车垫块铸造工艺设计与优化]
.
85084657877&partnerID=40&md5=b7814702b825eb2025121d07c07aecac
ABSTRACT: According to the structural characteristics of the automobile
cushion block, the sand casting process of the bottom pouring and lap
gating system was designed. For the portions that cannot be directly formed
on the casting, the sand core with block design is used for forming, and
the positioning and core head are set between the sand cores, effectively
avoiding the mold dislocation. By using AnyCasting software numerical
simulation analysis is carried out on the casting. Aiming at the defects of
the casting, the riser and chills are designed, effectively controlling the
sequential solidification of the casting. The precision of the final
casting is high, the quality can be guaranteed and meet the work
requirements. © 2020, Chinese Mechanical Engineering Society. All right
reserved.
Design of Mg[sbnd]Zn[sbnd]Si[sbnd]Ca casting magnesium alloy with high

thermal conductivity
.
85078437773&doi=10.1016%2fj.jma.2019.11.008&partnerID=40&md5=b9060019d219de
7fb01c696e95a34f1a
ABSTRACT: Magnesium alloys are commonly used to produce lightweight parts.
While most magnesium alloys exhibit low thermal conductivities, high
thermal conductivities are needed for electronic devices. In this study, we
attempted to develop new magnesium casting alloys with high thermal
conductivities. The Mg[sbnd]Zn[sbnd]Si[sbnd]Ca alloy compositions were
chosen using CALPHAD (CALculation of PHAse Diagrams) calculations, and
alloy samples were prepared. The fluidity and hot-tearing resistance were
measured. The results indicated that these properties were similar to those
of AZ91 alloy. Tensile tests showed that high-pressure die casting could
produce Mg[sbnd]Zn[sbnd]Si[sbnd]Ca alloys possessing mechanical properties
1.5–3 times higher than those produced via sand casting. The alloy thermal
conductivity was 126 W/mK at room temperature. The corrosion rates of the
as-cast samples in NaCl/water solutions were two times higher than that of
AZ91. © 2020
Thermo-elasto-plastic finite element analysis of warping deformation during

casting of gray cast iron
.
85073563626&doi=10.1016%2fj.jmatprotec.2019.116454&partnerID=40&md5=29ea612
87ac11b717c5c9d7509dbac64
ABSTRACT: Warpage defect is a crucially important difficulty, especially
for large or long iron castings. Thermal stress analysis via computer aided
engineering (CAE) is an effective means of predicting warpage defect.
Nevertheless, no report of the relevant literature has described a study
investigating the mechanism of warping deformation by comparison of in-situ
measurements of warpage deformation in an iron casting during cooling with
results of thermo-elastic-plastic analysis. This study measured warping
deformation of a gray cast iron casting composed of thick and thin parts
during sand casting. Then the deformation process was elucidated
experimentally. Subsequently, based on the experiment results, this study
used thermo-elasto-plastic analysis and simulated warping deformation in
iron casting. Then the simulation results were compared with actual
measurements, which revealed that the analytically obtained results agreed
qualitatively with the experimentally obtained measurements of warping
deformation. Results demonstrated that the warping deformation of the
casting can be predicted with error of not more than 26%. The temperature
difference that existed when the whole casting had haven strength caused
different thermal contraction of thick and thin parts during cooling, which
produced warping deformation of the iron casting. © 2019 Elsevier B.V.
Rapid Sand Casting Process of Aluminium Alloy Piping Joints [铝合金管接头的快

速砂铸工艺]
.
85084637654&partnerID=40&md5=30303d46cf4ef1302b2c3234bbfa827c
ABSTRACT: Normally, aluminium alloy piping joints are manufactured using
investment casting process due to the demand of high surface finish. In
order to decrease the production cost and shorten the manufacturing lead
time as well as expand the scope of its application, rapid sand mold
casting of piping joints was investigated in the present study. Casting
simulation software ProCAST was used to simulate the filling process and
predict shrinkage defects.Sound castings could be obtained by using sand
mold/core prepared by SLS (Selective Laser Sintering) method. However, the
surface roughness values of the cast joints were high due to the presence
of the”step effect”in rapid prototyping sand mold. Combined with coating
process and polishing treatment for sand mold cavity, the “step effect” was
eliminated. As a result, the surface quality was significantly improved. ©
Forming Process of Squeeze Casting Aluminum Alloy Engine Mounting Bracket

[铝合金发动机悬置支架挤压铸造工艺研究]
.
85084674684&partnerID=40&md5=6f5100ed116e2ecd9c1c3a07f41eae13
ABSTRACT: The engine mounting bracket is an important load-bearing
structure part in automobile mounting system. It is usually made of nodular
cast iron and manufactured by sand casting process. In the present study,
light metal aluminum alloy are used for the reduction of auto-weight, and
the forming process was investigated by using squeeze casting based on the
structure and performance requirements of the engine mounting bracket. The
results are in satisfactory and the performance indexes of squeeze cast
engine mounting brackets all meet the design requirements when the
extrusion specific pressure is 100 MPa, the extrusion speed is adjusted by
sections, that is, the punch speed is set to 180 mm/s in the first section,
to 80 mm/s in the second section, to 50 mm/s in the third section, and the
pouring temperature, mold temperature and holding time are about 700 ℃,
200 ℃, 75 s, respectively. © 2020, Chinese Mechanical Engineering Society.
All right reserved.
Minimising defect formation in sand casting of sheet lead: A DoE approach

.
85079862068&doi=10.3390%2fmet10020252&partnerID=40&md5=8c0344079e89bc4282b4
d99a1f84c913
ABSTRACT: Sand casting of lead sheet is a traditional manufacturing process
used up to the present due to the special features of sand cast sheet such
as their attractive sheen. Similarly to any casting process, sand casting
of lead sheet suffers from the presence of surface defects. In this study,
a surface defect type, hereby referred to as ‘grooves’, has been
investigated. The focus has been laid on the identification of the main
factors affecting defect formation in this process. Based on a set of
screening experiments performed using Scanning Electron Microscopy (SEM) as
well as the existing literature, a number of factors affecting the
formation of such defects was identified and their corresponding
significance was estimated using the Analysis of Variance (ANOVA)
technique. The obtained results suggest that the most significant factor
affecting defect formation in sand casting of lead sheet is the composition
of the moulding mixture. Defect formation was also proven to be dependent
on the sand grain fineness, the quality of the melt and some of the
interactions between the aforementioned process parameters. Finally, an
optimal set of process parameters leading to the minimisation of surface
defects was identified. © 2020 by the authors. Licensee MDPI, Basel,
Switzerland.
Modelling the mechanical attributes (roughness, strength, and hardness) of

Al-alloy A356 during sand casting
.
85079695799&doi=10.3390%2fma13030598&partnerID=40&md5=b79b0d362c55f1bf3f431
f3dec533e82
ABSTRACT: Sand-casting is a well established primary process for
manufacturing various parts of A356 alloy. However, the quality of the
casting is adversely affected by the change in the magnitude of the control
variables. For instance, a larger magnitude of pouring velocity induces a
drop effect and a lower velocity increases the likelihood of cold-shut and
mis-run types of defects. Similarly, a high pouring temperature causes the
formation of hot tears, whereas a low temperature is a source of premature
solidification. Likewise, a higher moisture content yields microcracks (due
to gas shrinkages) in the casting and a lower moisture content results in
the poor strength of the mold. Therefore, the appropriate selection of
control variables is essential to ensure quality manufactured products. The
empirical relations could provide valuable guidance in this regard.
Additionally, although the casting process was optimized for A356 alloy, it
was mostly done for a single response. Therefore, this paper aimed to
formulate empirical relations for the contradictory responses, i.e.,
hardness, ultimate tensile strength and surface roughness, using the
response surface methodology. The experimental results were comprehensively
analyzed using statistical and scanning electron microscopic analyses.
Optimized parameters were proposed and validated to achieve castings with
high hardness (84.5 HB) and strength (153.5 MPa) with minimum roughness
(5.8 μm). © 2020 by the authors.
Casting design, simulation and manufacturing validation of air compressor

fan blade
.
85084823242&partnerID=40&md5=2270f2d71edd8bf2e05398bd44bcb924
ABSTRACT: The objectives of this study were to design and simulate an
aluminum sand casting process of air compressor fan blade, which had thin
disc and fins. The finite difference analysis (FDA) was conducted to
predict the fluid flow and defect during cast process. The experimental
work in a commercial foundry was used to validated the FEA results. This
study was conducted in three phases. It started from design, simulation,
and experimental validation. SOLIDCast software was selected for designing
the mold and rigging system as well as defining the mesh. The software
adopted a finite difference method as the basis of calculation. From FDA,
it showed that a 10mm diameter of down sprue was able to flow the molten
aluminum and fill in 100% of the cavity within 3 seconds without premature
solidification. The output criteria of solidification time and critical
fraction solid time had confirmed good directional solidification without
any isolated pool. The material density criteria displayed 30% porosity
around the disc surface. In the experimental work, the casting process
completed in approximately 2.5 seconds. The casted fan blade was then cut
into pieces at the location where the simulation identified potential
defects for defect analysis under Photo Micro. The simulation results were
found to be in good confirmation when compared with the experimental trial.
The defects could be predicted during the simulation, and hence
optimization could be done before the actual casting in foundry. © February
2020 IJENS.
Optimization of sand usage for metal casting process – a sustainable

manufacturing approach
.
85079619583&partnerID=40&md5=a3417e363352fadc0bb3a69992fe6436
ABSTRACT: Sand casting, also known as sand moulded casting, is a metal
casting process characterized by using sand as the mould material. Over 60%
of all metal castings are produced via sand casting process. Sand control
is the key to good foundry sand practice. It is very important to note that
almost 70% of total casting defects occur due to an improper quality of
sand mould. Hence, many industries want to use the fresh sand for the
moulding purpose. However, due to environmental concerns there is a need to
investigate the applicability of return sand for sand moulding. This paper
investigates the possibility of using 'used‘ or 'return‘ sand for the mould
preparation. Several combinations of return sand and other additives have
been experimentally investigated for moisture content, compressive
strength, hardness, and permeability and the optimum combination has been
selected. The results have shown that up to 80% of return sand could be
used with optimum combination of other additives giving relatively high
compressive strength and permeability. This would give significant
reduction in sand cost and also better utility of return sand as a step
towards sustainable manufacturing. © IJSTR 2020.
Review of microstructures and properties of zinc alloys

.
85079699643&doi=10.3390%2fmet10020253&partnerID=40&md5=233bcb162fc8b084f217
222e33276d03
ABSTRACT: According to market data, about 15% of world zinc consumption is
devoted to the production of zinc-base alloys that are used for
manufacturing automotive parts, electronic/electrical systems and also,
water taps and sanitary fittings, household articles, fashion goods, etc.
These alloys are characterized by low melting points and high fluidity that
make them suitable for foundry applications. Typically, they are processed
by hot chamber high-pressure die-casting where can be cast to thicknesses
as low as 0.13 mm. The die-cast zinc alloys possess an attractive
combination of mechanical properties, permitting them to be applied in a
wide variety of functional applications. However, depending on the alloying
elements and purposes, some zinc alloys can be processed also by cold
chamber die-casting, gravity, or sand casting as well as spin casting and
slush casting. In this paper, a detailed overview of the current knowledge
in the relationships between processing, microstructure and mechanical
properties of zinc-base alloys will be described. In detail, the evolution
of the microstructure, the dimensional stability and aging phenomena are
described. Furthermore, a thorough discussion on mechanical properties, as
such as hardness, tensile, creep, and wear properties of zinc-base alloys
is presented. © 2020 by the authors. Licensee MDPI, Basel, Switzerland.
Investigations of microstructure and mechanical properties of brass alloys

produced by sand casting method at different casting temperatures
.
85079042109&doi=10.1088%2f1757-899X
%2f726%2f1%2f012018&partnerID=40&md5=4d2580c438b45e73d33d57877bec80f3
ABSTRACT: Brass, which is an alloy of copper and zinc, is of historical and
lasting importance due to its hardness and workability. Indeed, to make
this metal alloy, ancient metalworkers around the Mediterranean Sea were
able to melt copper with zinc as early as 3000 B.C. Brass is stronger and
harder than copper. The amount of copper varies between 55% and 95% by
weight, depending on the type of brass and its intended use. It is easy to
form into various shapes, it is a good conductor of heat and generally
resistant to corrosion from salt water. It can be used to make pipes and
tubes, weather-stripping and other architectural trim pieces, screws,
radiators, musical instruments, and cartridge casings for firearms. The
manufacturing process involves combining the appropriate raw materials into
a molten metal, which is allowed to solidify. The shape and properties of
the solidified metal are altered through series of carefully controlled
operations to produce the desired brass alloy. Temperature used in the
process is one of the parameter to affect the product properties. In this
study, the brass alloys were produced by a sand casting method at different
casting temperatures. Structural and mechanical properties were observed.
Optical microscope, XRD and the SEM analysis were performed for the
microstructure and phase analysis of the material. Charpy impact test and
tensile test were applied to consider the mechanical properties of the
samples. As a main purpose of this study, the results were evaluated and
then the optimum temperature for the brass material production was
determined. © Published under licence by IOP Publishing Ltd.
Design and Casting Process of Foundry Shop for the Production of Special
Steel Castings with an Annual Output of 10 000 Tonnes [年产 1 万吨特种钢铸件生
产车间设计]
.
85084671780&partnerID=40&md5=d32d2bdc421bd41be541f9aece126003
ABSTRACT: According to the market's demand for special steel wear-resistant
castings in the coal-based machinery manufacturing industry in Ordos, a
foundry shop for the production of special steel castings, with an annual
output of about 10 000 t, was designed and built. The foundry shop covers
an area of 11 500 m 2, with five workshops of molding, melting, heat
treatment, cleaning and painting, and the melting workshop installs a 5-t
electric arc furnace, a LF ladle refining furnace and a 3-t medium
frequency induction furnace. For different wear-resistant casting products,
the production lines of EPC process and sand casting process can be
applied. Moreover, the molding workshop is also equipped with the shakeout
equipment, intermittent combustion roaster and other some equipment, so the
treatment and recovery of used sand can be realized by using dry heat
combined regeneration process. The castings are cleaned by pneumatic shot
blasting machine and heat treated by two trolley type electrical resistance
furnaces. The processed castings are finally inspected by non destructive
testing and then painted. In the design, the some factors such as energy
saving and consumption reduction, environmental protection, fire protection
and occupational health are fully considered, so as to realize the clean
and healthy production requirements of the workshop. © 2020, Chinese
Cost of Quality Optimization in Sand Casting Operations

.
85078996293&doi=10.1088%2f1742-
6596%2f1430%2f1%2f012044&partnerID=40&md5=9286e43da40ed1d88ee1c5e12bcd6ed6
ABSTRACT: Sand casting is one of the oldest methods applied in foundries
industry. However, this method has several disadvantages such as high
consumptions of energy. It has an impact on total cost production per
pieces. In other side, the problem of cost of quality need an appropriate
approach to reduce this cost immediately. This study proposed the
alternative sand casting process, CRIMSON (Constrained Rapid Induction
Melting Single Shot Up-Casting), to investigate the differences between
this methods. The result of this study was indicate clearly that CRIMSON
sand casting has a lower total cost per pieces which is the result of lower
energy consumption and no cost in sortation and rework because the process
was in statistical control. © Published under licence by IOP Publishing
Ltd.
Manufacturing of the Oloid. CAD/CAM Workflow

.
85078083829&doi=10.1088%2f1742-
6596%2f1425%2f1%2f012106&partnerID=40&md5=f58d1bf28cb3d963f0ffb1663df69ee9
ABSTRACT: This paper considers the manufacturing process of the Oloid by
means of numerical control machining. Firstly, the requirements of the end
part were studied, and it was decided to manufacture the Oloid via gravity
die casting, and its necessary mold to be produced by CNC machining. In
order to do so, the gating system and mold had to be designed and tested
using sand casting methods. When the test results were optimal the die was
machined and the part cast. During this process the CAD/CAM workflow was
object of observation and study, which allowed for insight and conclusions
on the design process. © 2020 Published under licence by IOP Publishing
Ltd.
Clay Cracking: A Natural Process Guiding a Design-to-Fabrication Method for

Cast Aluminum Panels
.
85083526084&doi=10.1080%2f24751448.2020.1705722&partnerID=40&md5=78f4c1df7d
50093db04cfc0f4f204547
ABSTRACT: Clay cracking, a natural process often associated with material
failure, can be leveraged by designers to generate unique forms. When clay
dries, a crack pattern emerges that is dependent on factors such as the
clay’s water content, thickness, and boundary conditions. This paper
presents a method for designing and fabricating cast aluminum architectural
panels using naturally formed cracked clay patterns. Casting unique panels
with clay has the potential to use less material and energy than
traditional sand casting uses. The authors used this methodology to develop
and fabricate panels for the Cast & Place pavilion (2017) in New York City.
© 2020, © 2020 Association of Collegiate Schools of Architecture.
With specifically adapted CAD/CAM software Harke & Paulig develops casting
models: Sand casting models with the highest standards [Sandgussmodelle mit
höchstem anspruch]
.
85085529548&partnerID=40&md5=f78fb04edc0e94655e7ac957bfa57be1
ABSTRACT: Sand casting is still one of the most important manufacturing
processes, because cast materials have some interesting properties that are
desirable in many areas of application. Thereby, sand casting requires a
great deal of experience, what particularly becomes apparent in the design
and manufacture of model equipment. Dirk Harke of the company Harke &
Paulig puts into practice his years of experience with the CAD/CAM system
"Creo" in casting models.
Mechanical properties and reliability of sand casting 3D printing materials

.
85084408439&doi=10.3740%2fMRSK.2020.30.1.38&partnerID=40&md5=a24e10f42bcb0b
db8bd442fcac2fd70b
ABSTRACT: Sand casting 3D printing uses a binder jetting method to produce
a mold having complicated shape by spraying a binder on sand coated with
activator. Appropriate heat treatment process in sand mold fabrication can
increase the degree of polymerization to improve flexural strength.
However, long heat treatment of over 24 hours decreases flexural strength
and reliability due to chemical bond decomposition through thermal
degradation. The main role of the activator is to control the reaction rate
between the polymer chains. As a result, when the activator composition is
increased from 0.15 wt% to 0.25 wt%, the flexural strength is increased by
218 N/cm2. However, excess activator (0.40 wt%) has been shown to decrease
reliability without increasing flexural strength. The main role of the
binder is to control the flexural strength of the specimen. As the binder
composition is increased from 2.00 wt% to 4.00 wt%, the flexural strength
increases to about 255 N/cm2, indicating the maximum flexural strength
increase. Finally, the reliability of the flexural strength of the
fabricated specimens is evaluated by a Weibull plot. Weibull modulus
calculations are used to evaluate the flexural strength reliability of the
specimens, and maximum reliability value of 11.7 is obtained at 0.20 wt%
activator composition. Therefore, it is confirmed that this composition has
maximum flexural strength reliability. © Materials Research Society of
Korea.
Investigation of Shrinkage related leakage in CI sand casting — study and

control using simulation and experimental validation
.
85088692253&doi=10.1615%2fNanoSciTechnolIntJ.2020031261&partnerID=40&md5=8d
f3f9654dcb81d46ea206e426e6ba2e
ABSTRACT: The purpose of this study is to investigate various parameters
causing shrinkage and leakage in heavy castings like engine cylinder heads.
Due to intricate shape and extreme functional requirements, engine cylinder
heads and blocks are made through casting and need to be free from
shrinkage and leakage defects to avoid seizures. However, green sand
casting is prone to defects, namely, shrinkage porosity, cold shuts, and
sand inclusion. Therefore, balancing needs to be done in related casting
parameters like gating and feeding system, chemical composition, part
geometry, pouring temperatures, etc. In the current research, an
optimization of gating and feeding parameters was made to control the
shrinkage and leakage in the casting. Consequently, further the effect of
input parameters on defects was also studied. On the basis of Pareto
analysis of existing defects, experiments were planned for parameters like
size and location of feeders, casting modulus, and venting area. A total of
7 experiments were done and the results were simulated through MAGMAS
software to modify the casting and feeder modulus, venting area and
localized chill application. The experimental validation was done over a
batch of 1100 castings in a foundry. It was observed from the experimental
results that the leakage cases are reduced from 5.5% to 0.7%, with a
savings of 20,000 USD over a span of 4 months. Implication of this study
involves identification and optimization of critical parameters like feeder
modulus, venting area, and casting geometry for different models of
cylinder heads. © 2020 Begell House, Inc.
Dimensional Variation and Wear Analysis of 3D Printed Pattern for Sand

Casting
.
85086223931&doi=10.1007%2f978-981-15-2647-
3_41&partnerID=40&md5=8882124e6f6d7734ccfc89f2019607b7
ABSTRACT: Additive manufacturing (AM) technology has proven its importance
in the field of foundry technology by means of its use for master pattern
preparation and investment casting pattern (lost PLA). Huge research has
been reported for the strength of the 3D printed part and its use as
functional part for different applications. 3D printed sand casting pattern
shows its potential where components of complex shapes are required to be
sand cast in batch quantity if it is in development stage or on breakage of
pattern during ongoing production of castings. 3D printing by using Fused
Deposition Modeling (FDM) is a fast process, so till the complete repair of
the broken pattern 3D printed pattern can be used. This study emphasis on
dimensional variation and wear analysis of FDM printed pattern for sand
casting. For this investigation, materials are tested against pneumatic
ramming for the abrasive wear and strength required for the sand casting
pattern. Also, to improve the life of 3D printed sand casting pattern,
attempts of post-processing are made by two different methods, namely
electroplating and abrasive resistant coating. © 2020, Springer Nature
Singapore Pte Ltd.
Simulation and experimental validation for defect reduction in geometry

varied aluminium plates casted using sand casting
.
85087793561&doi=10.1016%2fj.matpr.2020.02.788&partnerID=40&md5=85d780b13a7b
3f95fa1cb5dabe83c943
ABSTRACT: Casting is a manufacturing process for making complex types of
metal materials. Sand casting is one of the widely used casting processes
due to its inherent advantage of no size and shape constraint with low
costs. The main problem with sand casting is defect and yield. Optimization
of process parameters and gating system design can solve these problems.
The configuration of the gating or riser mechanism plays a very significant
role in enhancing casting efficiency. Several researchers reported that 90
percent of casting defects are only obtained due to improper gating and
feeding system design. Simulation can help in this matter a lot to optimize
the various process parameters to get sound casting. In the present work,
the behavior of metal filling and solidification was examined using
AUTOCAST – X1 casting simulation software and flowplus module. Aluminum
alloy AlSi5Cu3 was selected due to its excellent properties and a wide
range of commercial applications in automobile and aerospace. The sand mold
is selected as mold material and defect identification has been carried out
and confirmed by comparing the simulation results with the experimental
one. © 2019 Elsevier Ltd. All rights reserved.
Effect of different gating systems and sand mold binder on the castquality
of bicycle frame produced through sand casting method
.
85090802223&doi=10.4028%2fwww.scientific.net
%2fDDF.402.100&partnerID=40&md5=085235eb4d9c33e883d0ba3560d7a888
ABSTRACT: The bicycle frame produced through the metal casting process by
recycling aluminum alloys can be an environmentally friendly alternative
solution. Mold types and gating systems used generally affects the quality
of the casting product. In this experiment, the effect of gating number and
riser type variations (for sand binder) observed on casting defects,
hardness, and impact value. Subsequently, chemical composition and
microstructure of recycled aluminum metal from bicycle frames produced
through sand mold casting are also evaluated. Three types of risers are
bentonite, water glass, and furan resin. The results indicate that mold
with two gating system has a low porosity as casting defects. The cast-bike
frame produced using furan resin reaches the highest hardness value of 46
HRB compared to water glass and bentonite as the binder of sand-molds. The
impact test observes 3.9 J carried out by the ASTM E23 sample at room
temperature. © 2020 Trans Tech Publications Ltd, Switzerland.
Defect investigation of sand casted aluminum cooling fan

.
%2fMSF.991.30&partnerID=40&md5=80d887e5c905c7fc1b7e0a3313cb0a78
ABSTRACT: Sand casting is one of manufacturing processes that still exists
today. Numerous products are produced by sand casting to serve industrial
and domestic use. Defect could lead to product performance, and
unfortunately it is inevitable in a casting process. This paper aims to
investigate typical defect resulted from sand casting process. An aluminum
cooling fan was selected as the model since it has complicated shape with
different thicknesses. The casted fan was investigated under photo micro
for defect analysis. Porosity, gas inclusion, pinhole, and shrinkage were
found as the common defects occured at different parts of the fan. © 2020
Trans Tech Publications Ltd, Switzerland.
Evaluation of Fracture Mechanisms in Al-Si Metal Matrix Nanocomposites

Produced by Three Methods of Gravity Sand Casting, Squeeze Casting and
Compo Casting in Semi-Solid State
.
85078487473&doi=10.1007%2fs12633-020-00390-
9&partnerID=40&md5=8bd3c56f22cb3ca4baf3cd20cc7fd548
ABSTRACT: Magnetic stirring is considered to be the most useful stirring
method in semi-solid casting processes which doesn’t have the restrictions
of the mechanical stirring. In this research, fracture mechanisms of
aluminum-Al2O3 nanocomposites produced by three methods of gravity sand
casting, squeeze casting and compo casting in semi-solid state using
electromagnetic stirring were studied and discussed. For this purpose,
microstructure and fracture surfaces obtained from broken tensile test
samples were analyzed using optical and scanning electron microscopies. On
the fracture surfaces of all the samples, dimples were observed, which are
the sign of ductile fracture. It was revealed that the dimples on the
samples produced by the compo casting method are smaller, more spherical
and uniformly distributed in the metal matrix in comparison with the ones
from sand and squeeze casting. It also investigated that on the fracture
surfaces of compo casting samples less cleavage planes, dendritic fracture
and particles agglomeration were observed in comparison with the ones from
the sand and squeeze casting processes. © 2020, Springer Nature B.V.
Novel Approach to Thermal Processing Development for Precision Sand Casting

Process (PSCP) of Aluminum Engine Blocks
.
85092566334&doi=10.1007%2fs40962-020-00526-
y&partnerID=40&md5=57aafd7896c2f6cce767e0606dc2e327
ABSTRACT: The latest generation of high-performance engine blocks are
produced with the precision sand casting process (PSCP). Their enhanced
mechanical properties are provided by an integrated cast iron chill in the
bulkhead section and thus result in large variations in secondary dendrite
arm spacing (λ2) throughout the whole casting, providing unique challenges
in both heat treat (T7 temper) development and compliance to the CQI-9
protocol. This research examines the influence of chemistry, controlled
solution/quench, residence time between quench and the start of artificial
age and artificial age temperature, on the mechanical properties and
cryogenic testing observations on PSCP engine blocks. The results are
obtained from large population engine block castings (n = 204), heat
treated within an industrial plant environment with strict control over
furnace temperature gradients. The results indicated that age temperature
differences of as little as 4 °C (within CQI-9 for furnace temperature
specification of ± 5 °C) can alter yield strength and elongation
significantly, which in turn changes crack susceptibility (warranty
issues). In addition to the above analysis, it was found that extending the
time between the solution/quench operation and the start of artificial age
results in a continual drop in yield strength due to the influence of
natural aging. © 2020, American Foundry Society.
Investigating the effects of gating design on mechanical properties of

aluminum alloy in sand casting process
.
85082533951&doi=10.1016%2fj.jksues.2020.03.004&partnerID=40&md5=fd1e98a6d58
6a28b7d2871e1611e7834
ABSTRACT: This research aims to analyze the effects of bottom and top
gating configurations on mechanical properties of aluminum alloy 6063-T5 in
sand casting process. The influence of three most effective process
parameters including pouring temperature, runner area and ingate area have
been investigated. Empirical models for both bottom and top gating
configurations have been developed using response surface methodology
(RSM). Analysis of variance (ANOVA) and confirmatory experiments have been
used to measure adequacy and validity of developed models respectively.
Bottom gating was observed as better configuration as compared to top
gating configuration with 4.08%–18.78% higher ultimate tensile strength
(UTS) and 5.98%–20.60% higher percentage elongation. This resulted due to
splashes generated by top gating configuration which severely affected the
fluidity of the melt with consequent effects on mechanical properties.
Pouring temperature and ingate area have been identified as the most
significant process parameters affecting ultimate tensile strength and
percentage elongation. Ingate area, on the other hand influences the flow
pressure and speed of melt which is required for mold filling. Micro-
hardness of the specimens has also been investigated to clarify the effects
of gating configuration and input parameters on mechanical properties. To
have a deeper insight of the findings, microstructural analysis of casted
parts has also been carried out. The findings of this research will provide
better insight of bottom and top gated sand casted parts and their effect
on mechanical properties. © 2020 The Authors
Metallurgical and Technological Investigation with Experimental

Archaeometallurgical Reproduction of a Lombard Bronze Buckle from North
Italy
.
85091057677&doi=10.1007%2fs40962-020-00518-
y&partnerID=40&md5=c68a2862d186d29c5cc9ee24945523d4
ABSTRACT: Abstract: A metallurgical and technological characterization of a
seventh century bronze buckle coming from the Lombard necropolis of Monte
San Zeno in Montichiari (Brescia, northern Italy) was performed to
understand the manufacturing techniques. At first, a careful inspection was
carried out to highlight the existence of any type of details, which would
indicate an intentional design activity or typical casting defects. To
avoid destructive measures on the ancient artifact, the buckle was
successively characterized only via scanning electron microscopy coupled
with energy-dispersive X-ray spectroscopy. This investigation was supported
by an accurate study on the chemical composition of the matrix. The results
suggest that the buckle was produced by sand casting, although the use of
this technique in Europe dates back to the fifteenth century. Finally,
based on the results obtained, a faithful archaeometallurgical reproduction
of the buckle is proposed. Graphic Abstract: [Figure not available: see
fulltext.] © 2020, The Author(s).
Sand casting of sheet lead: numerical simulation of metal flow and

solidification
.
85075351897&doi=10.1007%2fs00170-019-04522-
3&partnerID=40&md5=d80b0ca1ba965f4606d770ea7680a86e
ABSTRACT: Sandcast lead sheets are characterised by their superior
aesthetic performance and mottled surface. Lead sheet casting is widely
used in the construction industry for roofing and flashing applications,
while the roots of this process can be tracked back to the Roman times. In
this study, two-dimensional computational fluid dynamics (CFD) simulations
have been performed to simulate the melt flow and solidification stages of
the lead sandcasting process. The effects of process parameters such as
pouring temperature, screed velocity and clearance between the screed and
the sandbed on the final quality of the lead sheet are investigated. Lead
sheet quality has been quantified by measuring the variance and the average
value of the final sheet thickness over the sandbed length. The developed
CFD model has been validated against experimental results by comparing the
time evolution of the lead-sandbed interface temperature against data
collected by thermocouples during the real-time process. The numerical
results show that all of the aforementioned parameters affect the final
quality of the cast product and suggest that superior quality lead sheets
can be produced for a range of relatively low values of the pouring
temperature and slow strickle motion. © 2019, Springer-Verlag London Ltd.,
part of Springer Nature.
Case Studies on Integrating 3D Sand-Printing Technology into the Production

Portfolio of a Sand-Casting Foundry
.
85066614692&doi=10.1007%2fs40962-019-00340-
1&partnerID=40&md5=0485f3a7347f896d5a9f70c13995a274
ABSTRACT: Metal casting foundries all across USA are increasingly adopting
the recent development in additive manufacturing including 3D sand printing
(3DSP) due to its unique ability to fabricate molds and cores without any
tooling requirement such as patterns, cores, core boxes, flasks among
others. This new method of rapid mold fabrication can accelerate process
cycle times, reduce shrinkage defects, offer part consolidation, functional
integration and customization that could facilitate the growth of foundry
industries. This study demonstrates how the adoption of 3DSP technology has
contributed to a conventional ferrous metal casting foundry that
specializes in manufacturing impellers, turbine housings and other mining
equipment. Four industrial case studies are presented to illustrate novel
opportunities via 3DSP. These case studies validate that 3DSP has the
ability to (1) reduce shrinkage by allowing casting in optimal orientation
without hard-tooling requirements, (2) reduce lead time through rapid mold
fabrication by easier facilitation of nesting multiple parts into a single
mold, (3) allow hybrid molding by integrating 3DSP with conventional mold
making and (4) fabricate tooling-less complex castings, respectively.
Findings from this study would help foundries rethink their design process
from traditional pattern-drawing to a new and radical freeform-based design
process via 3DSP. © 2019, American Foundry Society.
THE IMPACT of COMPOSITION and the DENSIFICATION LEVEL of FURAN MOLDING

COMPOUNDS on the STRENGTH of LARGE-SIZE CASTING MOLDS
.
85091019104&doi=10.24425%2famm.2020.133710&partnerID=40&md5=0b29516910f5e5a
d08db505464d201fb
ABSTRACT: The paper presents the test results of molding compounds, sand
casting molds and their analysis. The subject of testing was compound
containing furan resins prepared according to the following recipe: matrix
– regenerate 90% + fresh sand – 10%, furan resin – 1.10% by weight,
hardener – 0.40% by weight. The impact of adhesive type and its quantity
(Quan = 0.90, 1.1 and 1.5%) on the strength indexes of molding compound
subject to densification was analyzed. The publication presents the test
results: tensile strength Rm, compressive strength Rc and flexural strength
Rg, as well as compound permeability as function of its density. The
analysis also covers the impact of density level on mold strength and the
distribution of density level along the mold height. Based on the test
results, it was found that the best method to obtain high strength molds
made from compounds with chemical adhesives was to densify it by vibrating
the system: match plate – molding flask – compound filling the mold. The
effectiveness of this densification method depends on the amplitude and
frequency of vibrations. © 2020 Polish Academy of Sciences. All rights
reserved.
Sustainability-Based Evaluation of Casting Gating Systems: A Multi-Criteria

Decision-Making Approach
.
85088522050&doi=10.1016%2fj.promfg.2020.02.117&partnerID=40&md5=094293ea8ae
d491f06f89d92ccc7eee1
ABSTRACT: The selection of the most appropriate casting gating system
design is one of the most critical decision-making tasks in foundries as it
is closely associated to the amount of air inclusions and surface defect
concentration, which should be minimal in the final casting product to
ensure superior quality and enhanced mechanical properties. Moreover, the
design of the gating system influences the material and energy usage and
consequently the cost of the sand casting manufacturing process. Therefore,
its design should be thoughtfully considered and planned. In this
investigation, Multi-Criteria Decision-Making (MCDM) is being coupled with
Computational Fluid Dynamics (CFD) simulations in order to select the
optimal gating system design with respect to the sustainability of the
process. Besides process energy, three additional criteria were used for
the evaluation of the gating system performance, namely: air entrainment,
surface defect concentration and mould cost. CFD simulations were performed
to evaluate each one of the 6 gating system designs considered against each
one the aforementioned criteria. The selection of the most appropriate
gating system was performed using the Technique for Order of Preference by
Similarity to Ideal Solution (TOPSIS). © 2020 The Authors. Published by
Elsevier B.V.
Regeneration of used sand with sodium silicate binder by wet method and
their core manufacturing
.
85090792608&doi=10.1007%2fs10163-020-01103-
5&partnerID=40&md5=80dc1f08bbcd6e6bac74bf7172fde460
ABSTRACT: Organic binders that are used in sand casting emit high amounts
of hazardous pollutants and volatile organic compounds during the casting
process. Inorganic binders do not emit harmful gases and are widely used in
aluminum casting processes. However, there is a paucity of studies on the
reuse of waste sand using inorganic binders in casting processes. In the
study, waste sands using an inorganic binder and a powder were recycled via
wet regeneration and the effects of residual powder on regenerated sand
were analyzed. The wet regeneration of molding and casting sands was
performed by cleaning, followed by grinding in a 0.2-M KOH solution and
then removing the residual binder using water. The molding sand was
regenerated to the same level as the raw sand via the 0.2-M KOH solution
followed by water cleaning twice. The casting sand removed most of the
binder via additional water cleaning for the regeneration condition of the
molding sand. Although the powder was completely removed from the
regenerated molding sand, the regenerated casting sand remained used
powder; the residual powder had a 78% performance. Thus, the regenerated
casting sand was reusable only when adding binder without powder. © 2020,
Springer Japan KK, part of Springer Nature.
Investigation of the Foundry Properties of the Locally Available Sands for

Metal Casting
.
85090245996&doi=10.1007%2fs12633-020-00677-
x&partnerID=40&md5=1c0c57f59b2b25b937a65adf2e0de2a4
ABSTRACT: Utilization of locally available sands for building moulds for
sand casting will reduce the production cost and time as compared to
procured sands. In the present study, the foundry properties of the locally
available sands namely, mined silica river and beach sands have been
investigated to check their suitability for metal casting. Different
physical and mechanical tests were conducted on the chosen sand samples.
Aluminium alloy was cast in all mould types and its cast properties such as
volumetric porosity and surface roughness (SR) i.e. Ra value were
determined for comparison. The foundry test results showed that the beach
sand was the finest possessing highest grain fineness number (GFN) of 64
and the mined silica sand was the roughest, possessing lowest GFN of 44
among all sand samples. The pH value of all the sands was more than 7 which
represents their good bonding ability with the binder. The mould’s
permeability and strengths was found to decrease and increase with rise of
5–30% clay content in all cases. The mined silica sand mould demonstrated
highest permeability in contrast to other sand moulds. The Al-Si alloy
castings obtained from the mined sand mould exhibited minimum porosity with
acceptable surface roughness. © 2020, Springer Nature B.V.
Casting manufacturing of cylindrical preforms made of low alloy steels

.
85085493508&doi=10.1016%2fj.promfg.2020.04.333&partnerID=40&md5=b55487b5393
4ab59f2d10a4ef364ea8d
ABSTRACT: The manufacturing of complex drivetrain components made of steel
requires multi-stage manufacturing processes, resulting in long processing
times and high costs. Forged parts get their final geometry after multi-
stage forming operations. One approach to shorten such process chains is
close contour casting of steel preforms and a single subsequent forming
step to achieve high strength properties similar to those of multi-stage
forged parts. Since the application of precision forging using cast steel
preforms has been studied insufficiently up to now, the manufacturing of
cylindrical preforms made of the low-alloy heat-treatable steel G42CrMo4 by
sand casting was investigated. Using casting simulations, suitable casting
parameters for the finished casting systems were identified and nearly
pore-free preforms were achieved. Depending on the casting system,
metallographic investigations revealed different fractions of bainite in
the microstructure of the casted preforms. Subsequently, the cylinders were
deformed in upsetting experiments by which the remaining porosity could be
eliminated. The numerical casting simulation was combined with a forming
simulation to model the reduction in porosity and to allow the prediction
of the densification behavior in further research employing more complex
geometries. © 2020 The Authors. Published by Elsevier Ltd. This is an open
access article under the CC BY-NC-ND license
(https://creativecommons.org/licenses/by-nc-nd/4.0/) Peer-review under
responsibility of the scientific committee of the 23rd International
Conference on Material Forming.
Economies of complexity of 3D printed sand molds for casting

.
85084948661&partnerID=40&md5=fa62b45bdb53f8201d9b6a28ec849832
ABSTRACT: Additive Manufacturing (more commonly referred to as 3D printing)
is resulting in a metamorphosis of the sand casting industry as 3D printed
sand molds enable castings of unmatched geometric complexity. The manifold
benefits of these molds include: (1) the integration of structural elements
such as periodic lattices in order to optimize weight versus strength; (2)
the structural inclusion of unique features such as embossed part numbers
and/or other details of the production history; and (3) complex geometries
that generate new casting applications not possible previously. Additive
Manufacturing is often described as providing “complexity for free”, which
may not be entirely precise but generally holds true and the identification
of castings that are sufficiently complex to benefit from 3D printing is
generally left to the intuition of the designer or foundry. New software
tools are necessary for foundries to discover opportunities in which the
additional costs of 3D printing are compensated by the benefits of
increased structural complexity. This paper describes a complexity
evaluation tool that scores CAD models to determine the most economical
casting approach based on slicing and 2D geometry evaluation. The three
potential outcomes include (1) traditional sand casting, (2) AMenabled sand
casting and (3) a hybrid of the two with 3D printed cores in traditional
casting flasks. Several case studies are described and evaluated. © Solid
Freeform Fabrication 2018: Proceedings of the 29th Annual International
Solid Freeform Fabrication Symposium - An Additive Manufacturing
Conference, SFF 2018. All Rights Reserved.
How to Prevent Gas Porosity Defects in Castings of Stator Housing in Grey

Cast Iron
.
85081395158&doi=10.1007%2f978-3-030-36296-
6_106&partnerID=40&md5=908e4106c1fe2671dcc8ebfea5680f6f
ABSTRACT: Grey cast iron is one of the easiest metals to cast in a foundry,
and of ferrous metals, it has the lowest pouring temperature, high
fluidity, and very low shrinkage during the transformation from the liquid
to solid phase. One of the disadvantages of this grade of cast iron is the
presence of the different types of defects produced in green sand casting.
Cast defects are, at a higher proportion, caused by evolution of gases.
Pinholes and blowholes are major casting defects caused by gases. This
experimental work has focused on reducing gas defects on casting component,
stator housing, at a production scale using the green sand casting process.
The casting component produced was strongly affected by gas defects. A
series of simulations were performed using the casting simulation program
MAGMASOFT® in order to investigate the solidification characteristics as
well as the porosity formation in the casting component. © 2020, The
Minerals, Metals & Materials Society.
Shallow Cryogenic Treatment (SCT) Effects on the Mechanical Properties of

High Cr Cast Iron: Low-Carbon Cast Steel Bimetallic Casting
.
85092772879&doi=10.1007%2fs40962-020-00532-
0&partnerID=40&md5=0ca72c3d368c68daa7634840bfd9bc64
ABSTRACT: The shallow cryogenic (subzero) treatment (SCT) effect on the
mechanical properties of the bimetallic casting used in the crushing
industry has been investigated. Examination methods include sand casting,
heat treatment and SCT, Charpy impact test, optical microscope, scanning
electron microscope, microanalysis of the chemical composition (energy
dispersive spectroscopy—EDS), x-ray diffraction, and hardness measurement.
Two bimetallic castings (single casting containing two layers, one of low-
carbon cast steel-LCCS-back up part and other high Cr cast iron-HCCI-
working part) have been prepared by the sand casting method. They have been
subjected to diffusion annealing at 1040 °C for 5 h. One of them was
quenched in pressurized air till 100 °C and was tempered at 270 °C for 3 h
and, and the other one has been subjected to SCT at − 84 °C for 24 h and
then tempered at 270 °C for 3 h. The impact toughness values before and
after SCT are determined five Charpy specimens per point. Hardness values
and metallography of samples have been analyzed and compared. A remarkable
change was observed in hardness and impact energy/toughness before and
after SCT. © 2020, American Foundry Society.
An Integrated Fuzzy-Based Methodology for Selection of Casting Pattern

Material
.
85081380067&doi=10.1007%2f978-981-15-0751-
9_27&partnerID=40&md5=4e32bbc5b184f6a74f513e0c26b8f96b
ABSTRACT: Casting is a manufacturing process that is used for mass
production of complex metal shapes. Sand casting is one of the variations
of casting process which is also known as sand molded casting. The success
of the final product depends to a great extent on the patterns used in the
process which is a replica of the final product to be produced. Pattern is
used to prepare cavity into which the molten material is poured. Material
of the pattern used in its construction and its design are the important
primary considerations for achieving the best possible shapes from the sand
casting process. The present work proposes a novel fuzzy-based multi-
criteria decision making (MCDM) approach for selecting the best material
for the pattern. The integrated framework integrates fuzzy decision making
with the least explored Tomada de Decisão Interativa Multicritério (TODIM)
MCDM method. Material selection has been done considering five material
alternatives, i.e., wood, aluminum, steel, plastic, and cast iron; and
seven criteria, i.e., machinability, wear resistance, strength, weight,
reparability, resistance to corrosion, and resistance to swelling. It was
established that aluminum is the best-ranked material alternative. © 2020,
Springer Nature Singapore Pte Ltd.
Assessment and Comparison of Various MCDM Approaches in the Selection of

Manufacturing Process
.
85084089006&doi=10.1155%2f2020%2f4039253&partnerID=40&md5=b29688d541090bf25
0b30c6ef7872e53
ABSTRACT: The selection of manufacturing processes for a given application
is a complex problem of multicriteria decision-making although there have
been several different approaches that can be utilized to select a suitable
alternative. However, identifying appropriate multicriteria decision-making
approach from the list of available methods for a given application is a
difficult task. This work suggests a methodology to assess different
selection approaches, which are the technique for order of preference by
similarity to ideal solution (TOPSIS), analytic hierarchy process (AHP),
and VIKOR: Stepwise procedure. This valuation was done depending on the
following factors: Number of alternative processes and criteria, agility
through the process of decision-making, computational complexity, adequacy
in supporting a group decision, and addition or removal of a criterion. A
case study in this study was presented to analyse the evaluation
methodology. The criteria used to evaluate and identify the best
manufacturing process were categorized into productivity, accuracy,
complexity, flexibility, material utilization, quality, and operation cost.
Five manufacturing processes were considered, including gravity die
casting, investment casting, pressure die casting, sand casting, and
additive manufacturing. The results showed that each approach was suitable
for the problems of manufacturing process selection, in particular toward
the support of group decision-making and uncertainty modelling.
Manufacturing processes were ranked based on their respective weights for
AHP, TOPSIS, and VIKOR, and sand casting is the best. In terms of
computational complexity, the VIKOR method performed better than TOPSIS and
AHP. Moreover, the VIKOR and TOPSIS methods were better convenient to the
selection of manufacturing processes for agility during the process of
decision-making, the number of alternative processes and criteria, adequacy
in supporting a group decision, and addition or removal of a criterion. ©
2020 Atef M. Ghaleb et al.
Mechanical properties of thin wall ductile iron: Experimental correlation

using ANOVA and DOE
.
%2fKEM.835.171&partnerID=40&md5=34cc5d2d9f9001d449de0dc9531cf7d8
ABSTRACT: The present study was undertaken to investigate the effect of
different metallurgical parameters such as casting techniques, wall
thickness, inoculant technique, carbon equivalent, nodule count, ferrite
and pearlite percent on the mechanical properties of thin wall ductile iron
castings (TWDI). Understanding of the effect of chemistry, casting
techniques, melting and molten treatment on the mechanical properties and
microstructural features of TWDI castings would help in selecting
conditions required to achieve optimum mechanical properties and alloy high
strength to weight ratio. The use of the design of experiment (DOE) and the
analysis of variance (ANOVA) can be a useful methodology to reach this
objective. The analysis of the effects of each variable and their
interaction on the mechanical properties of TWDI castings using green sand,
green sand with insulation and investment casting techniques plays a key
role in improved materials performance. The results indicate that nodule
count, pearlite content and the interaction between carbon equivalent,
nodule count and pearlite content have a significant effect on the tensile
strength of TWDI castings. The impact toughness values decrease with
smaller section thickness and increased nodule count. Using investment
casting technique, decreasing the pearlite percent and nodule count, and
increasing the wall thickness and ferrite percent reduce the values of
ultimate tensile strength and yield strength. The results of percent
elongation and impact toughness show a reverse trend compared with those of
ultimate tensile strength and yield strength in terms with different
metallurgical parameters. © 2020 Trans Tech Publications Ltd, Switzerland.
The Efficacy of Replacing Metallic Cerium in Aluminum–Cerium Alloys with

LREE Mischmetal
.
85079615770&doi=10.1007%2f978-3-030-36408-
3_30&partnerID=40&md5=cf5d0aebfa97816f40b7ddda7d9475ec
ABSTRACT: The ongoing development of aluminum–cerium alloys has produced
materials exhibiting elevated temperature mechanical property retention,
long term microstructural stability, and flexible processability compared
to traditional aluminum alloys, accommodating the growing demand for high
temperature aluminum alloys not requiring the use of high-cost elements
like scandium. To date, reported Al–Ce alloy compositions contain large
amounts of elemental cerium. Mischmetal (MM), a mixture of lanthanum,
cerium, and other light rare earth elements (LREE) is less expensive and
more available than pure cerium. The chemical similarity of the LREEs means
there is possibility to use MM as the primary alloy addition, lowering
alloy cost. This talk will report the effect of using MM instead of cerium
in a 12 wt% binary alloy on mechanical properties, phase constituency,
thermal stability, and load sharing. Results will show that MM can be
substituted completely for cerium with a mostly positive impact on alloy
performance. © 2020, The Minerals, Metals & Materials Society.
Quantification of Influence of Casting Variables for Minimizing Hot Spot
Area in T Junction by ANOVA and Taguchi Method
.
85069677533&doi=10.1007%2f978-981-13-8196-
6_69&partnerID=40&md5=a83bd819c17fbeacaa64886ccebfbee5
ABSTRACT: Shrinkage porosity is common defect found at casting junctions.
Slowly, cooling of molten metal causes hot spot area generation at the
junction that is the cause of defect such as shrinkage porosity. Location
of riser above the junction may be the one design change for minimization
of defects. The hot spot area size and its extent depend on geometrical
complexity like thickness, fillet radii, and the angle between walls.
Alternatively, junction modification is one of the optimum solutions to
minimize such hot areas before solidification. Pro Engineering was used for
modeling and through STL, files format data exchange to AutoCAST. Taguchi
and ANOVA methods were employed to evaluate the influence of parameters on
hot spot area in casting junctions. Area of hot spot was selected as the
response variable. It is concluded that upper thickness makes the maximum
contribution, and lower thickness, radius, and angle followed upper
thickness. © Springer Nature Singapore Pte Ltd. 2020.
Hydroxymethylfurfural and its Derivatives: Potential Key Reactants in

Adhesives
.
85089897888&doi=10.1002%2fcssc.202001539&partnerID=40&md5=8f96c5e4bd9ed0ddf
2d539702a6fa86e
ABSTRACT: 5-Hydroxymethylfurfural (HMF) is a promising bio-derived platform
chemical with a broad scope of application, for example, in the production
of solvents, fuels, polymers, or adhesives. The wood and foundry industries
are among the largest adhesive users and currently both rely to a large
extent on the use of fossil-based binders, such as by using formaldehyde as
a crosslinker in many commercial adhesive systems. The industry is thus
looking for suitable alternatives to replace fossil-based chemicals. HMF
and its derivatives are considered to be key renewable reactants in
adhesive systems. The core of this Review is the critical evaluation of the
potential of HMF and its derivatives in adhesive systems. The technological
performance was assessed in the fields of wood-based materials, sand
casting and composites. As an overall conclusion, HMF and its derivatives
have a high application potential in alternative adhesives. Clearly,
further research is needed to improve the performance and produce
economically competitive adhesives. © 2020 The Authors. Published by Wiley-
VCH GmbH
Comprehensive utilization of foundry dust: Coal powder and clay minerals

separation by ultrasonic-assisted flotation
.
85092897563&doi=10.1016%2fj.jhazmat.2020.124124&partnerID=40&md5=669838f39f
7f946a978495cb9b0e6703
ABSTRACT: Clay sand casting generates a large amount of foundry dust (FD),
and the presence of coal powder in the FD makes it difficult to recycle and
utilize. The landfill of the FD creates a serious environmental pollution
and wastes a valuable resource. To improve the above situation, the FD was
analyzed and characterized by X-ray fluorescence spectrometer (XRF), X-ray
diffraction (XRD) and electron probe microanalyzer (EPMA). An ultrasonic-
assisted flotation process was developed for the comprehensive utilization
of the FD, and the effects of ultrasonic time on the flotation performance
and flotation kinetics were investigated. In addition, the two-stage
flotation of the FD was conducted. Obtained results showed that the FD
mainly consisted of coal powder and clay minerals, and the coal powder was
covered by clay minerals. The separation efficiency of the coal powder and
clay minerals can be significantly enhanced by ultrasonic pretreatment, and
the optimal ultrasonic time was 30 min. The flotation kinetics analysis
results indicated that the first-order model with rectangular distribution
was more reasonable for the data fitting of the ultrasonic-assisted
flotation. Furthermore, the concentrate and tailings obtained by the two-
stage flotation had achieved an acceptable result, favoring the
comprehensive utilization of the FD. © 2020 Elsevier B.V.
Thermal Decomposition Behaviour of Foundry Sand for Cast Steel in Nitrogen

and Air Atmospheres
.
85087544664&doi=10.1155%2f2020%2f8121276&partnerID=40&md5=c7efb41b4a6eb4b08
e1fd5d69ab9faa5
ABSTRACT: Sand casting is the most widely used casting technique, known for
ages, even since ancient times. The main goal of this study was to
determine the thermal decomposition behaviour of foundry sand for cast
steel. We first tested the basic properties of foundry sand, including its
proximate analysis, chemical composition, and particle size
characteristics; we next monitored the thermal decomposition behaviour of
foundry sand for cast steel via simultaneous thermal analysis. We focused
on the mass loss of foundry sand for cast steel at different heating rates
in nitrogen and air atmospheres. We adopted a novel method to calculate the
volatile release characteristic index of foundry sand. The volatile content
of foundry sand for cast steel was very low, so the volatile release
characteristic index of the sand could not be strictly calculated according
to this concept. We calculated the thermal decomposition kinetics
parameters of foundry sand, namely, the activation energy and
preexponential factor, under kinetics theory. To thoroughly test the
fitting effect, we conducted a single-factor analysis of variance on the
source of error. The results showed that the independent variable has a
significant influence on the dependent variable and that the fitting
equation we selected is feasible and effective. © 2020 Shoukun Chen et al.
Critical Quenching Rates After Solution Annealing: Peculiarities of

Aluminum–Silicon Alloys Fabricated by Laser Powder-Bed Fusion
.
85081363150&doi=10.1007%2f978-3-030-36296-
6_32&partnerID=40&md5=3f313007cfc376511b5a152510bc6c74
ABSTRACT: Hot isostatic pressing is commonly used to reduce the porosity of
(sand-)cast age-hardenable Al-alloys in order to meet the high quality
requirements defined by aircraft and automotive industries. In order to
establish additive manufacturing methods, such as laser powder-bed fusion
(L-PBF), hot isostatic pressing can be utilized to reduce the anisotropic
mechanical properties in as-built condition and at the same time eliminate
porosity. For the cast aluminum alloy A356, a gas pressure of 75 MPa during
hot isostatic pressing lowers the critical cooling rate required to achieve
an oversaturated solid solution to about 1 K/s, which is significantly
lower than the required quenchingrate at atmospheric pressure (2–4 K/s).
Thus, an oversaturated state of dissolved magnesium and silicon atoms
within the aluminum matrix of cast alloys can easily be achieved in modern
hot isostatic presses, thereby avoiding the necessity of a separate
solution annealing step. In this work, we applied hot isostatic pressing
followed by rapid quenching and direct aging to age-hardenable aluminum
alloys processed by both sand casting and laser powder-bed fusion. It was
shown that the proposed process of direct aging could be utilized for post-
heat treatment of additively manufactured age-hardenable aluminum alloys to
open up new fields of applications, for which components have to possess a
high fatigue resistance. © 2020, The Minerals, Metals & Materials Society.
Numerical simulation and evaluation of campbell running and gating systems
.
85077530514&doi=10.3390%2fmet10010068&partnerID=40&md5=e233e6770335d2bce14e
f2c0f76cf202
ABSTRACT: The most common problems encountered in sand casting foundries
are related to sand inclusions, air, and oxide films entrainment. These
issues can be addressed to a good extent or eliminated by designing proper
running systems. The design of a good running system should be based on
John Campbell’s “10 casting rules”; it should hinder laminar and turbulent
entrainment of the surface film on the liquid, as well as bubble
entrainment. These rules have led to the establishment of a group of
components such as high and low placed filters (HPF/LPF) and standard gate
designs such as the trident gate (TG) and vortex gate (VG) which are
incorporated in well-performing running system designs. In this study, the
potential of the aforementioned running system designs to eliminate air
entrainment and surface defects has been investigated via means of
computational fluid dynamics (CFD) simulations. The obtained results
suggest that the use of filters significantly enhances the quality of the
final cast product; moreover, all of the gating system designs appear to
perform better than the basic running system (BRS). Finally, the five in
total running and gating system designs have been evaluated with respect to
their ability to produce good quality cast products (reduced air
entrainment and surface defects) and their sustainability component (runner
scrap mass). © 2020 by the authors. Licensee MDPI, Basel, Switzerland.
Study and application status of additive manufacturing of typical inorganic

non-metallic materials
.
85074894219&doi=10.5755%2fj01.ms.26.1.18880&partnerID=40&md5=bdf900cadd1504
26879b7a70529f3c0b
ABSTRACT: Additive manufacturing is a rapid manufacturing based on discrete
accumulation to achieve prototypes or parts of products. Inorganic non-
metallic materials, as one of the three major materials, have incomparable
application prospect in medical, aerospace, automotive, construction, arts
and crafts, as well as many other fields. In order to rapidly create
devices with arbitrarily complex shapes, additive manufacturing of
inorganic non-metallic materials is becoming a hot spot of current
research. In view of the technical types, materials and other aspects, this
article introduced research status and development of additive
manufacturing in inorganic non-metallic materials at home and abroad.
Several common inorganic non-metallic materials are compared and analyzed,
such as Al2O3, Si3N4 SiO2, ZrO2, etc. The forming characteristics and the
problems of several popular ceramic materials and sand–casting materials
are illustrated with emphases. The key problems existed in additive
manufacturing forming process of inorganic non-metallic material are
pointed out and urgent to be solved at present. Furthermore, the impacts of
the material handling process, three dimensional printing (3DP), Selective
Laser Sintering(SLS), Selective Laser Melting (SLM) three-dimensional
forming processes and post treatment process on the quality and performance
of the forming parts are analyzed. Finally, the prospects in SLS of the gem
material are put forward. © 2020, Kauno Technologijos Universitetas. All
rights reserved.
A Preliminary Study Upon the Applicability of the Direct Water Cooling with
the Lost Foam Casting Process
.
85079197714&doi=10.1007%2fs40962-020-00420-
7&partnerID=40&md5=3dd0987058294636d7498baf2f257871
ABSTRACT: Direct water cooling (DWC) application with the lost foam casting
(LFC) process was inspired by the ablation casting technique. Ablation
casting is designed to combine the controlled filling property of sand mold
casting and the rapid cooling of the high-pressure die casting. Briefly, in
this method, sand casting is followed by the removal of the mold by water
spray and cooling of the part within a short time. The use of special
water-soluble inorganic binders facilitates the mold breakdown. However,
due to no use of binder materials in the LFC method, the DWC process may
become more effective. In this study, similar cooling techniques were
applied to the lost foam castings of A356 alloy by two techniques. In the
first one, cooling was achieved by tipping the mold content over into a
container with a sufficient amount of water after the casting process. The
second process was carried out by pouring a sufficient amount of water onto
the mold following the casting process. These two developed methods were
named as “quench casting” and “splash casting,” respectively. It was seen
that both methods changed the traditional casting microstructure and
properties considerably. A serious decrement in secondary dendritic arm
spacing with accompanying modification of the eutectic silicon was observed
for the specimens produced via both methods. Hardness values increased
significantly, and the results indicate that splash casting is preferable
than quench casting because it exhibits better and more stable properties.
© 2020, American Foundry Society.
International Conference on Experimental and Computational Mechanic in

Engineering, ICECME 2019, held in Conjunction with 9th AIC 2019
.
85089770220&partnerID=40&md5=1ea51537e664d4b0f1a77ca252405238
ABSTRACT: The proceedings contain 20 papers. The special focus in this
conference is on Experimental and Computational Mechanic in Engineering.
The topics include: Effect of different gating systems and sand mold binder
on the castquality of bicycle frame produced through sand casting method;
the investigation of hole delamination in drilling kevlar composite panel
using hss drill tool; the preparation and characterization of Fe-ZnO
nanoparticles immobilized onto fiberglass cloth; the effect of spindle
speed and feed rate on hole diameter of high-speed micro-drilling for
micro-screen manufacture; preface; role of size of rubber particles on
failure mode and impact resistance characteristics of pc/abs blends and
their abs constituents with a higher rubber content; properties of high
strength concrete with calcined diatomaceous earth as cement replacement
under compression; investigation of meniscus effect on microbond test of
typha fiber/epoxy matrix; study on fracture failures of the super heater
water pipe boiler; thermal spray application on the dissimilar metals weld
between aluminum and steel; fatigue life assessments of the sae 5160 carbon
steel subjected to uphill and downhill roads strains; Fatigue life
assessments of the AISI 1513 carbon steel subjected to road surface
strains; Fatigue life assessments of the AISI 1513 carbon steel of a
vehicle lower arm subjected to clockwise and counter-clockwise road
strains; flexural and splitting tensile strength of high strength concrete
with diatomite micro particles as mineral additive; influence of forestry
and agriculture by-products as filler materials on thermal conductivity of
fiberboard panels applied for heat-conditioned building partition wall.
Effect of Solidification Time on Microstructure, Wettability, and Corrosion

Properties of A205-T7 Aluminum Alloys
.
85083202683&doi=10.1007%2fs40962-020-00457-
8&partnerID=40&md5=34578f3c40a7796679f3d26cb715925a
ABSTRACT: In the present study, the grain size, second-phase morphology,
hardness, water wetting behavior, and corrosion resistance of A205, as a
function of solidification time, were investigated. A205 is aluminum–copper
alloy that is described in the AA Pink Sheets as “Primarily used for making
metal matrix composites” (AA Registration Record Pink Sheets, ISSN: 2377-
6722, Footnote 13, Aluminum Association, 2018) and as defined by AMS as a
“dilute aluminum/TiB2 metal matrix composite” (AMS D Nonferrous Alloys
Committee in Cast aluminum alloy composite 4.6Cu–3.4Ti–1.4B–0.75Ag–0.27Mg
(205.0/TiB2/3p-T7P) investment cast, solution, and precipitation heat
treated, SAE International, 2014). To study the effect of solidification
time, a step sand casting, with varying section thickness, was made and
subjected to a modified T7 heat treatment. Optical microscopy, scanning
electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray
diffraction analysis were utilized to study microstructure, morphology,
elemental composition, and phases in the A205 samples, respectively.
Potentiodynamic polarization experiment was used to measure the corrosion
resistance of the A205 samples. The casting process was also simulated by
use of a commercial software. Conclusions drawn from the simulation process
show that larger thickness allows for higher solidification time and
greater microporosity. It was observed that solidification time has a
direct impact on grain size. The phase identification result shows that the
two main phases of the alloys are Al and TiB2, while a modified heat
treatment cycle makes a complete solution of copper in the grains. Wetting
study shows that surface chemistry is not a controlling factor on contact
angles, while corrosion result shows a relationship between solidification
time and corrosion resistance of the A205 samples. It was observed that
there is almost 70% decrease in corrosion rate from the sample with the
least section thickness to the sample with the largest section thickness. ©
2020, American Foundry Society.
Forging process on gamelan bar tin bronze Cu-25wt.%Sn post casting

deformation to changes in microstructure, density, hardness, and acoustic
properties
.
85078286945&doi=10.1088%2f1757-899X
%2f673%2f1%2f012127&partnerID=40&md5=fc7623ba26fff01ba203a83cfaa55de3
ABSTRACT: Casting and forging are a method of formation to produce gamelan
instruments. This study aims to determine the effect of forging deformation
on the as-cast gamelan bar to changes in the microstructure, hardness,
density, porosity, and acoustical properties of the gamelan instrument. The
research material was tin bronze Cu-25wt.%Sn. The casting process uses a
sand casting method with a pouring temperature of 1100°C. The forging
deformation process was done by reheating the as-cast gamelan bar at a
temperature of 600°C. The thickness of the as-cast gamelan bar is reduced
by 30% after the forging deformation process. The observations on the as-
cast gamelan bar show coarse microstructure with large grains, inclusions,
and increased porosity. The forged gamelan bar shows finer microstructure,
elongated grain, α lamellar, α phase like a plate, and decreased porosity.
The hardness of forged gamelan bar increased by an average of 30.3% VHN,
density increased by 9,56% and porosity decreased by 95% compared to the
as-cast gamelan bar. Acoustic properties show an increase in the natural
frequency between the as-cast gamelan bar and the forged gamelan bar are
712.5 Hz and 1058 Hz. © Published under licence by IOP Publishing Ltd.
Design and analysis of sand casting process of mill roller

.
85074559738&doi=10.1007%2fs00170-019-04270-
4&partnerID=40&md5=293c11c6e58dfcdb0f158a493ef22264
ABSTRACT: The quality characteristics of the mill roller in sand casting
has been affected by casting defects caused by in proper process parameter
usage and intern affects its proper function that lead to large number of
shop floor trials, high rate of rejection, and low casting yield. The
objective of this research is to design and analyze sand casting process of
mill roller. In this research work, methods like critical observation,
interview, discussion, numerical experimentation, and simulation have been
done. Solid modeling of mill roller component with all incorporating gating
system has been carried out by solidwork software and simulation process
has been carried out by using ProCAST software for the mold filling and
solidification analysis to reduce the level and intensities of shrinkage
porosities in cast mill roller. Taguchi method of numerical
experimentations has been carried out for parameter optimization and
analysis of variance (ANOVA) using Minitab software. The confirmatory test
with the optimal level of casting process parameters have been carried out.
The casting process parameters of the mill roller have been identified by
using cause and effect diagram. The parameters such as permeability,
pouring temperature, and moisture content have been taken into
consideration. Based on the numerical results, their interpretation and the
optimal values of the parameters have been determined to eliminate the
defects. The present research work has shown in the improvement of casting
yield. It has been found that the casting defects are minimized by 2.98%.
The results also reveal that sand sintering problem and porosity defects
occurred in the mill roller castings were due to the weak sintering
strength of fine mixed molding silica sand used in the process. Using
simulation software, shrinkage porosity has been observed in both gating
system and roller part. © 2019, Springer-Verlag London Ltd., part of
Springer Nature.
A State-of-the-Art Review on Manufacturing and Additive Influences on Sand-

Cast Components
.
85074351293&doi=10.1007%2fs13369-019-04139-
4&partnerID=40&md5=48c63d1c1079dde12a63669e02bb5f99
ABSTRACT: Sand casting is the one of the oldest fabrication techniques,
which has a number of important technological challenges with respect to
improving productivity and quality of the castings. It is essential for the
foundries to reduce or eliminate the casting defects if they need to
survive in this highly competitive global market. This review arises from a
strong industrial demand for understanding the physical and process
parameters to improve the quality and soundness of the sand-cast products.
The present article primarily reviews the investigations done by
researchers on the usability of locally available silica sands and clays
for casting both ferrous and non-ferrous alloys. The paper highlights the
application of artificial intelligence techniques in predicting the sand
mould quality and further optimizing the casting process parameters. This
article also analyses the potentials and feasibility of three-dimensional
printing in sand casting process. Further, the role of different additives
on sand mould composition and different trace elements or inoculants on
mechanical properties and microstructure of sand casting has been
discussed. Finally, elaborations have been made about various types of
hybrid sand casting processes along with metal matrix composites. © 2019,
King Fahd University of Petroleum & Minerals.
Prediction of Shrinkage Microporosity in Gravity-Cast and Low-Pressure

Sand-Cast Mg–6Gd–3Y–0.5Zr Magnesium Alloys
.
85074363025&doi=10.1002%2fadem.201900755&partnerID=40&md5=3c7cd3ac0906f7e19
9a83914f32c24df
ABSTRACT: The Niyama criterion and the dimensionless Niyama criterion are
used to predict shrinkage microporosity in Mg–6Gd–3Y–0.5Zr magnesium plates
processed by gravity casting and low-pressure sand casting. Instead of the
Niyama evaluation condition recommended by commercial ProCAST software and
precious studies, the most appropriate Niyama evaluation condition is
suggested as fraction solid of 0.7 for the investigated alloys. With
consideration of the actual distribution of shrinkage microporosity and the
definition of unsound samples (shrinkage microporosity volume fraction is
higher than 1% based on the tensile test), the corresponding threshold
Niyama values are qualitatively determined as 0.44 and 0.3 °C0.5 s0.5 mm−1
for gravity-cast and low-pressure sand-cast plates, respectively. It
indicates that exerting pressure contributes to the decrease in the
threshold Niyama value. In addition, exerting pressure can reduce the
amount of shrinkage microporosity. For the dimensionless Niyama criterion,
it is capable to quantitatively predict the shrinkage microporosity volume
fraction in low microporosity-containing regions, but not in high
microporosity-containing regions. © 2019 WILEY-VCH Verlag GmbH & Co. KGaA,
Weinheim
Comparison of Mechanical Properties of Zn-27A1 Alloy Using Various Casting

Techniques
.
85079345637&doi=10.1088%2f1742-
6596%2f1355%2f1%2f012039&partnerID=40&md5=341e9321ee418bcb62eaf4746a9bb96d
ABSTRACT: Zinc-aluminium alloys are cost effective substitute for wide
range of applications in the industrial purpose mainly as bearing
materials. Zn-27 Al is the material selected due to its good mechanical and
tribological properties. Casting is one of the methods which can be used to
fabricate the alloys. Sand casting and stir casting are used to develop Zn-
27 Al alloy. Both mechanical and wear properties were studied. Hardness,
tensile strength and impact strength is highest for the stir casted alloy
when compared to sand casted Zn-27 Al.. The composition of the prepared
alloys justifies the better properties of stir casted alloy and the
compositions are analysed by Energy Dispersive X-Ray (EDX) analysis. © 2019
IOP Publishing Ltd. All rights reserved.
Numerical investigation on solidification in casting using ProCAST

.
85075475794&doi=10.1088%2f1757-899X
%2f561%2f1%2f012049&partnerID=40&md5=ab12c176faca33c9d31ab0873b446f61
ABSTRACT: This work deals with elimination of defects in aluminium alloy
castings produced by gravity sand casting process. The main intention of
the work is to investigate the defectsand improve quality of a gravity sand
cast component using Computer Aided CastingSimulation Software. In this
study aluminium alloy gravity sand casting solidification hasbeen selected
as a subject of study. The mould filling process and solidification
weresimulated for detection of casting defects and hence optimization of
the casting process. Themajor defects in the components are identified to
be solidification shrinkage porosity defects.ProCAST simulation software is
used for simulating the solidification process of casting andvisualizing
outputs showing possible problematic areas or defects which may occur in
the castproduct. © 2019 IOP Publishing Ltd. All rights reserved.
Design of Pouring Cup Liquid Level Control System in Sand Casting

.
85080054962&doi=10.1109%2fCAC48633.2019.8997054&partnerID=40&md5=610bd68cc1
3d0c1e2d0ecd934778772c
ABSTRACT: In this paper, aiming at the low degree of automation of the sand
casting in gravity casting, the mathematical modeling and simulation of the
pouring part of the plug-in casting machine is carried out, and the control
of the bottom-injection casting machine based on machine vision is
designed. System - The closed-loop gating system controlled by PID is
obtained by obtaining the ratio of the area of high-temperature molten iron
in the sand-type pouring cup to the total area of the pouring cup. The
hardware platform was built, and the solution for automatic control of the
pouring cup liquid level in the sand casting was given, which greatly
reduced the labor of the workers and improved the production efficiency of
the sand casting. © 2019 IEEE.
Process parameter optimization in green sand casting using ANN

.
85075275464&partnerID=40&md5=14dd0b72eaec0b37945493d5f7c009bb
ABSTRACT: In the present work a neural network models and fuzzy logic are
developed for predicting the mould and chemical properties of green sand
casting. An attempt has been made to predict major casting defects like
porosity, hot tearing, blow holes, pin holes, cold shut, and shrinkage
using back propagation and perception from the neural network. The network
trained with input parameters like compatibility, permeability, moisture,
grain strength, melting temperature, clay content and chemical properties
charge as inputs presence/absence of defects as output. The results of
neural network models were compared with the results obtained from fuzzy
logic. © IJSTR 2019.
Fast hybrid casting method and investigation of the influences on surface

roughness [Fast-Hybrid-Casting-Verfahren und Untersuchung der Einflüsse auf
die Oberflächenrauheit]
.
85079189011&partnerID=40&md5=e43fdddbbec54a421b8edfe986bcbbef
ABSTRACT: At the foundry centre of the Fachhochschule Nordwestschweiz
(FHNW) in Brugg-Windisch (Switzerland), the Fast Hybrid Casting process was
developed and optimised for the production of moulds on a laboratory scale
using 3D-printed, melt-out plastic positives. Fast Hybrid Casting - FH-Cast
for short - is derived from the combination of sand casting and lost-wax
casting. The aim is to be able to produce one-piece casting moulds on a
laboratory scale with a high degree of geometric freedom, including
undercuts on the casting, involving little manpower and low infrastructure
costs. © 2019 GDMB Gesellschaft fur Bergbau, Metallurgie, Rohstoff- und
Umwelttechnik e.V.. All rights reserved.
Effect of heat treatment on microstructure and mechanical properties of

sand-cast Mg-4Sm-0.6Zn-0.4Zr alloy [热处理对砂型铸造 Mg-4Sm-0.6Zn-0.4Zr 合金显微
组织和力学性能的影响]
.
85079354511&doi=10.19476%2fj.ysxb.1004.0609.2019.11.07&partnerID=40&md5=b8e
94f74d849ec8f5367f404c5bfe789
ABSTRACT: In this work, the effects of heat treatment on microstructure and
mechanical properties of sand-cast Mg-4Sm-0.6Zn-0.4Zr alloy were
investigated through the microstructure analysis by optical microscopy(OM),
X-ray diffractometry(XRD), scanning electron microscopy(SEM) and
transmission electron microscopy(TEM) and mechanical properties testing.
The results indicate that the as-cast alloy is mainly comprised of α-Mg
matrix and eutectic Mg3Sm phase. After solution treatment, the coarse
second phases are almost dissolved into Mg matrix and the grains do not
grow significantly. The dominant precipitates of the alloy peak-aged at
250℃ are identified as basal γ″ phase. Also, the peak-aged alloy displays
the best mechanical properties with ultimate tensile strength of 210 MPa,
yield strength of 153 MPa, and elongation to failure of 4.0%. In addition,
the dominant strengthening effect in peak-aged alloy is considered as
precipitation strengthening induced by the dispersed fine γ″ precipitate
based on the quantitative analysis results of the strengthening mechanism.
The contribution of precipitation strengthening to yield strength is 120
MPa, accounting for about 80% of the total yield strength. © 2019, Science
Press. All right reserved.
The role of yttrium modifying A357 alloy with sand casting

.
85070437873&doi=10.1080%2f02670836.2019.1650442&partnerID=40&md5=f3615fd26c
c2a0aef3d9d496c965cd8e
ABSTRACT: The microstructure of A357 alloy modified by yttrium (Y) and its
modification mechanism was investigated. The results show that under a sand
casting condition, there was small or even no solution strengthening effect
of Y on the A357 alloy. Y did not change the morphology of eutectic silicon
but made it shorter, and Y increased the nucleation cores during its
nucleation processes rather than promoting the formation of twinning during
the growth processes. The solidification mode of many eutectic silicon
phases changed from nucleating on the dendrites to heterogeneous nucleation
of eutectic grains in the interdendritic liquid. The number and area of
eutectic silicon clusters increased with increasing Y. A bright Al2Si2Y
phase appeared even though Y was very low. © 2019, © 2019 Institute of
Materials, Minerals and Mining.
Comparison and Analysis of Three Kinds of Casting Processes Producing

Aluminum Shock Tower [铝合金减震塔的三种铸造工艺对比分析]
.
85076858922&partnerID=40&md5=ee7f9922a1bdfdce745d7b7c8b42f829
ABSTRACT: Three kinds of casting processes, investment casting, sand
casting, and high vacuum assisted high pressure casting, for the production
of aluminum shock tower were employed at the development stage. Differences
in the microstructure, mechanical properties, connection performance and Al
alloy materials for the shock towers produced respectively by three kinds
of casting processes are compared and analyzed. Finally, according to the
practical production and application results, the advantages and
disadvantages of three kinds of casting processes producing aluminum shock
towers are summarized. © 2019, Chinese Mechanical Engineering Society. All
right reserved.
Study and control of factors influencing casting shrinkage using DOE and
numerical simulation
.
85074917342&doi=10.1088%2f1757-899X
%2f624%2f1%2f012021&partnerID=40&md5=94f7937ebfb4b111a4134c9a35ec04fa
ABSTRACT: The purpose of this study is to predict the effect of various
factors like alloying elements, Inoculation and Carbon Equivalent (CEV) on
green sand casting shrinkage defect in gearbox housing, without changing
the casting methoding system. Foundries are prone to have defects related
to feeding and gating system, sand and process parameters. In some
engineering applications, it is very difficult to alter methoding system
due to specific casting geometry requirements. If not controlled during
development stage, the rejections may seriously affect the productivity.
This research work involves the optimization of various factors by DoE and
numerical simulation to reduce the shrinkage defect. Unlike the prototype
or sample lot trial, mass production of gearbox housing castings has been
done in a foundry to achieve the research purpose. Effect of these factors
on final casting hardness and tensile strength has also been studied and
found to be on positive side, as these parameters are important for
satisfactory performance under dynamic loading. Outcome was the reduction
in shrinkage porosity from 10.9% to 3.2% with overall saving of 41k USD
over the period of 4.5 months. Implication of this study involves
standardization of optimum range of alloy elements and inoculation for
different grades of grey cast iron. © 2019 IOP Publishing Ltd. All rights
reserved.
Measurement of metal velocity in sand casting during mold filling

.
85073626497&doi=10.3390%2fmet9101079&partnerID=40&md5=2ef5218252606d50c51b8
d71681a8725
ABSTRACT: Melt turbulence during mold filling is detrimental to the quality
of sand castings. In this research study, the authors present a novel
method of embedding Internet of Things (IoT) sensors to monitor real-time
melt flow velocity in sand molds during metal casting. Cavities are
incorporated in sand molds to position the sensors with precise
registration. Capacitive and magnetic sensors are embedded in the cavities
where melt flow velocity is calculated by using an oscillator, the
frequency of which is sensitive to changes in the close field permittivity,
and change in magnetic flux, respectively. Their efficiency is investigated
by integrating the sensors into 3D sand-printing (3DSP) molds for conical-
helix and straight sprue configurations to measure flow velocities for
aluminum alloy 319. Experimental melt flow velocities are within 5% of
estimations from computational simulations. A major benefit of 3DSP is the
geometrical freedom for complex gating systems necessary to reduce
turbulence and access to mold volume for sensor integration during 3DSP
processing. Findings from this study establish the opportunity of embedding
IoT sensors in sand molds to monitor metal velocity in order to validate
simulation results (2–5% error), compare gating systems performance, and
improve foundry practice of manual pouring as a quality control system. ©
2019 by the authors. Licensee MDPI, Basel, Switzerland.
Improvement in the hygroscopicity of inorganic binder through a dual

coating process
.
85067246691&doi=10.1016%2fj.porgcoat.2019.06.005&partnerID=40&md5=66eca30ea
d63161a1546f22aa805fb80
ABSTRACT: The use of an anti-absorbent is proposed in this work to reduce
the hygroscopicity of the inorganic binder in the casting mold, in which
the anti-absorbent is coated on the mold prepared with an inorganic binder.
Three types of polymers were used to select material with optimal water
resistance. Polystyrene (PS) and polyvinyl alcohol (PVA) were used as a
water-insoluble polymer and water-soluble polymer, respectively. In
addition, polyurethane (PU) prepolymer has intermediate properties between
PS and PVA. PVA and PU prepolymer were used for comparative testing with
PS. For this testing process, the prepared green body was dipped into a
solution of inorganic binder precursor mixed with tetraethyl orthosilicate
(TEOS, SiO2 precursor) and sodium methoxide (NaOMe, Na2O precursor), and
then dipped into a solution of coating reagent after a drying process.
Thus, these series of coating processes in a green body is called a dual
coating process. Finally the sample was heat-treated at 1000 °C to generate
a glass phase by an organic–inorganic conversion process. In the sample
prepared with PS, the highest contact angle and a high firing strength were
exhibited, independent of polymer concentration, while the sample coated
with PVA showed lower green and firing strengths. When prepolymer, PU, was
applied, the green strength was remarkably improved, showing lower firing
strength compared with that of PS. The green and firing strengths were
optimized through the dual coating process with PS. Moreover, the moisture-
proof effect of the dual coating process was verified through the moisture
steam test. © 2019 Elsevier B.V.
Effect of Vibration on Interdendritic Feeding of AL–5%CU–0.4%MN Alloy

.
85073245061&doi=10.1007%2fs40962-019-00319-
y&partnerID=40&md5=c7665a557d7e54008dcea481e08258a1
ABSTRACT: In this study, the effect of vibration on the interdendritic
feeding of Al–5%Cu–0.4%Mn alloy was investigated using vibration casting
experiments and physical simulation. The solidification characteristics of
the zinc-oxide paste (used as a mold coating to prevent sand burn during
casting) resulted in shrinkage and porosity defects. The experiments were
designed to show that vibration can improve feeding and reduce defects. The
aqueous solution of sodium carboxmethyl cellulose (CMC) with the same
rheological characteristic of metal melt was used in the physical
simulation. The seepage calculation model of semisolid fluid in porous
media under vibration was established, and the finite difference method and
dynamic mesh technique were used to solve the model numerically. The
casting results show that vibration can improve the feeding capacity and
reduce shrinkage defects of Al–5%Cu–0.4%Mn alloy in gravity sand casting.
The physical simulation results show that mechanical vibration can change
the blocked structure at the seepage entrance, improve the permeability of
porous media and reduce the resistance of interdendritic feeding.
Mechanical vibration with the smaller frequency combined with the larger
exciting force, or the larger vibration frequency combined with the smaller
exciting force, can promote the seepage flow. Meanwhile, the numerical
simulation of one-dimensional semisolid fluid seepage reveals that
vibration can form a wave field in the porous medium, which can reduce the
adhesion force between fluid and the capillary wall and destroy the
boundary layer of fluid, thus promoting the seepage velocity. © 2019,
Influence of multiphase microstructure evolution and Fe-rich phases on Cu

uphill diffusion in Al-Si-Cu-Mg alloys
.
85073753432&doi=10.1088%2f2053-
1591%2fab4490&partnerID=40&md5=1d69a6bedf33fb42d998db08fd67db14
ABSTRACT: The evolution of multiphase microstructures in Al-Si-Cu-Mg alloys
has been investigated by studying four types of alloys with different
compositions and solidification rates. The experiment has been conducted
with and without 0.6 wt% Zn addition by using the permanent mould and sand
mould. Scanning electron microscope with energy dispersive spectroscopy,
differential scanning calorimetry and metallographic statistics were
applied to determine the evolution of the multiphase microstructure in the
solution treatment. The texture and morphology of the Fe-rich phases on the
uphill diffusion of Cu atoms was revealed. The results indicate that the
existing forms of multiphase microstructures, especially the crystal
texture and morphology of Fe-rich phases, were different with Zn addition
and secondary dendrite arm spacing, which resulted from different
solidification processes. In sand casting, large-sized acicular β-Fe was
modified by Zn into short rod-like free β-Fe, while in the permanent mould,
many π-Fe phases were formed with Zn addition. Unlike the decomposition of
the π-Fe phase, the free β-Fe in the alloy 3DSZ can directly provide a low-
energy grain boundary for the uphill diffusion of Cu atoms, which shortens
the precipitation peak time of the Al2Cu. Two schematic diagrams were
developed to describe the effect of decomposition of the π-Fe and free β-Fe
phases on the uphill diffusion of Cu atoms. © 2019 IOP Publishing Ltd.
Application of Resin Coated Sand to Cast Steel Valves [覆膜砂在阀门铸钢件中的应

用]
.
85073873841&partnerID=40&md5=bbb47b1aaf9a58ffcc5fff437f888056
ABSTRACT: Steel castings produced by resin coated sand process have
accurate dimensions and smooth surfaces, which can save materials and time
in the machining process. Moreover, resin coated sand castings is a good
solution for machinery and automatic casting production line due to less
quantity of sand needed during the casting process and it is suitable for
the mass production of cast steel valves with high precision requirements.
© 2019, Chinese Mechanical Engineering Society. All right reserved.
Geometrical effects on filling dynamics in low pressure casting of light

alloys
.
85068579279&doi=10.1016%2fj.jmapro.2019.06.006&partnerID=40&md5=f8127a122f2
d4f74ab360f5d66947020
ABSTRACT: In aluminum low-pressure sand casting process, filling
oscillations are observed when the metal front reaches a section change in
a part. The effect of geometry on the filling oscillations is primary
considered experimentally, including both mold cavity and filling system
geometries. To highlight the geometric parameters impacting the
oscillations, the pressurized melt flow is secondly studied numerically and
analytically. A new analytical model of oscillation is developed to
quantitatively predict the oscillations. It links the resulting filling
velocity to both the low-pressure casting parameters and the mold cavity
geometry. Considering oxides inclusion criterion from casting literature,
new rules to avoid bi-films defects are recommended for making reliable
low-pressure castings. © 2019 The Society of Manufacturing Engineers
Performance evaluation of bar plates without a draft angle to improve

refining efficiency
.
85078900054&doi=10.7584%2fJKTAPPI.2019.10.51.5.84&partnerID=40&md5=8cf7f5d1
80822937a8c7579b5110705f
ABSTRACT: Most of the refiner plates currently in use are made via sand
casting, so a draft angle is given to prevent damage to the mold; in
addition, the draft angle can reduce the flow rate of the pulp stock and
sharpness of the bar edge. In this study, the effect of a bar plate without
a draft angle was compared by manufacturing the bar plate using lost-wax
casting technology. The vertical bar had a larger cutting edge load and
consumed less refining energy than the tapered bar until the target
freeness was reached. Instead, more fiber cutting by the vertical bar
caused more sacrifice of fiber length and more fines content, which
resulted in a faster reduction in the tear strength properties of the
paper. Moreover, the tensile and burst strength of the paper was more
developed by the vertical bar plate. The rectangular groove inlet of the
vertical bar had a larger surface area than the trapezoidal groove of the
tapered bar, so more throughput of pulp stock could be processed in a
certain period. In conclusion, the vertical bar-shaped plate is expected to
yield better results than the tapered bar-shaped plate in terms of energy
saving and refining effects on pulp fibers. © 2019 Korean Technical Assoc.
of the Pulp and Paper Industry. All rights reserved.
Oxidation and Ignition Behaviors of Molten Mg-Nd-Zr Alloy in Resin-Sand
Mold
.
85071298332&doi=10.1007%2fs11665-019-04181-
1&partnerID=40&md5=e42a79017edf3c71da7950b4cdf4ff7b
ABSTRACT: High-temperature oxidation behavior of molten Mg-Nd-Zr in the
pyrolysis atmosphere of resin-bind sand mold was investigated. The results
showed that pouring temperature higher than 1023 K would sharply increase
the ignition risk of melt in mold. The oxide formed on Mg-Nd-Zr melt below
973 K consists of two layers: mainly MgO for outer layer; mixture of MgO
and Nd2O3 for inner layer. The inner oxide mixture layer played an
essential role in the protection of Mg-Nd-Zr matrix. Based on the
experimental results and thermodynamic analysis, the oxidation process
containing three stages was proposed. Nd- and Zn-enriched zone was found at
the subsurface of oxide scale, without the enrichment of Zr. DICTRA
calculation results indicated that this phenomenon was caused by the
depletion of Mg and up-hill diffusion of Zr. Thus, Zr showed limited
protection to the melt in long-term oxidation. © 2019, ASM International.
Weibull analysis of fluidity and hardness of ultrasonically degassed

secondary Al7Si0.3Mg aluminum alloy
.
85073692813&doi=10.1007%2fs41230-019-9029-
2&partnerID=40&md5=2e400a4da832f5c5b1efa8957a2c5b30
ABSTRACT: The influence of ultrasonic degassing process on fluidity and
hardness of secondary Al7Si0.3Mg alloy castings was studied by Weibull
analysis. This work makes a contribution about fluidity and hardness
distribution of secondary aluminum alloys with ultrasonic degassing
phenomena using a two-parameter form of Weibull analysis. Results show that
both hardness and fluidity of alloy are improved after the ultrasonic
degassing process. Average efficiency of ultrasonic degassing on fluidity
measurements is 31.71%, whereas on hardness values is 8.48%. The Brinell
hardness of 45.7 and fluidity of 19.5 of Weibull modulus were achieved as
the most reliable and reproducible after 45 s ultrasonic degassing process
against 15 s and 30 s ultrasonic degassing processes. The value of 70.08 HB
is obtained from ultrosonic degassing, which is equivalent to sand casting
of primary Al7Si0.3Mg aluminum alloy, and the highest value of 56.4 cm for
45 s after ultrasonic degassing of fluidity was measured. © 2019, Foundry
Journal Agency and Springer Singapore.
Bridging additive manufacturing and sand casting: Utilizing foundry sand

.
85067430574&doi=10.1016%2fj.addma.2019.06.008&partnerID=40&md5=752059102577
f60ae047b09fc0c6657e
ABSTRACT: Although additive manufacturing technology is available for the
direct fabrication of metal parts, the process is still in a juvenile state
compared to older metal fabrication methods such as sand casting.
Therefore, limited standards are available stipulating the use of
additively-manufactured parts in critical service conditions such as
extreme environments or safety components. However, since sand casting is
suited for multiple units of parts, the time and resources needed to
produce a single part through sand casting is not ideal for a competitive
market. Although additive manufacturing or “3D printing” has been combined
with metal casting in the past through “rapid casting” to fabricate sand
molds directly, the sand used is stipulated by the 3D printer. The use of
specialized sand may result in changes to infrastructure and large amounts
of additional sand required to be stored on location. The main question we
sought to answer was if traditional foundry sand or “non-standard” sand
could be used within a 3D printing system? We report herein that the
although the increase in surface roughness may be tolerable, the use of
foundry sand within a 3D printer produces molds with less than optimal
results, mainly due to the absence of compaction. Binder bleeding via the
liquid binder jetting process also contributes to a loss in dimensional
quality. © 2019 Elsevier B.V.
Optimization of sand casting performance parameters and missing data

prediction
.
85070441707&doi=10.1098%2frsos.181860&partnerID=40&md5=ae4a6dfb0f2a0422ad06
9f2d5ddecb6d
ABSTRACT: Due to a wide range of applications, sand casting occupies an
important position in modern casting practice. The main purpose of this
study was to optimize the performance parameters of sand casting based on
grey relational analysis and predict the missing data using back
propagation (BP) neural network. First, the influence of human factors was
eliminated by adopting the objective entropy weight method, which also
saved manpower. The larger variation degree in the evaluation indicators,
indicating that the evaluated projects had good discrimination in this
regard, the larger weight should be given to these evaluation indicators.
Second, the performance parameters of sand casting were optimized based on
grey relational analysis, providing a reference for sand milling. The
larger the grey relational degree, the closer the evaluated project was to
the ideal project. Third, this paper provided a new method for determining
the number of hidden neurons in a network according to the mean square
error of training samples, and venting quality was predicted based on BP
neural network. The relevant theory was deduced before predicting missing
data, such that there will be a general understanding regarding the
prediction principle of BP neural network. Fourth, to demonstrate the
validity of BP neural network adopted in the process of missing data
prediction, grey system theory was applied to compare the result of missing
data prediction. © 2019 The Authors.
Morphological characterization, in vitro biomedical corrosion and corrosion

behaviour of As-Cast Cu-Zn-Al-FeMn alloys in selected intravenous and
industrial fluids
.
85070631482&doi=10.1088%2f2053-
1591%2fab309d&partnerID=40&md5=702dfbb0fdd35db46060f8d73fd1027f
ABSTRACT: Several research findings have been published on the influence of
grain size control additives on the structure-property relationship and
performance of Cu-Zn-Al Shape Memory Alloys. However, a wide knowledge gap
still exists between the findings on the ordinary Cu-Zn-Al alloys and their
shape memory counterparts. Herein lies a significant contribution that
addresses this issue. Cu-Zn-Al and FeMn-modified Cu-Zn-Al alloys of
preferred chemical compositions were developed by stir sand casting. The
alloys were prepared for and subjected to metallographical and corrosion
immersion tests in sulphate-containing, chloride-containing and designated
physiological environments. Experimental results showed FeMn to be an
effective inoculant for heterogeneous nucleation and crystal growth in Cu-
Zn-Al alloys. Modified grains with different sizes and morphologies were
observed. There also appeared to be a Hall-Petch kind of relationship
between corrosion resistance and grain size of the FeMn-modified alloys in
nearly all the corrosion media. Dezincification of the FeMn-modified alloys
was significantly facilitated with high Zn content and large grain size,
notably in the sulphate-containing environment. Nonetheless, the dramatic
difference in the corrosion behaviour of Cu-Zn-Al alloy and that of FeMn-
modified Cu-Zn-Al alloys in the corrosion media only occurred at the
initial stage of experiment. Thereafter, a stable corrosion behaviour was
observed for the FeMn-modified alloys. © 2019 IOP Publishing Ltd.
Enhancing the Permeability and Properties of Ceramic Shell in Investment

Casting Process Using ABS Powder and Needle Coke
.
85064265300&doi=10.1007%2fs40962-018-00297-
7&partnerID=40&md5=a4d303fcbf5671ccadf2a6e82230934e
ABSTRACT: In the investment casting process, initially, a wax pattern is
made, around which repeated slurry/stucco coatings are applied. The slurry
is made up of very fine ceramic ingredients like zircon flour, etc. Once
the ceramic slurry is dried out, a ceramic shell is formed around the wax
pattern. After drying out of the ceramic shell, the wax is drained out and
the shell is fired in an oven for inducing additional strength. Molten
metal is then poured into the ceramic shell. Because of the fine
ingredients of the ceramic shell, the investment casting gets a very fine
surface roughness, compared to a conventional sand casting. However, the
ceramic shell exhibits poor permeability, which often results in porosity
defects. Hence, in the present work, an attempt was made to enhance the
permeability of ceramic shell by mixing certain fillers like acrylonitrile–
butadiene–styrene (ABS) powder and needle coke to the ceramic slurry. Fine
ABS powder was added to the inner coat slurry in a very small proportion.
The ABS powder, upon heating, got burnt and left micropores inside the
inner coating of the shell. In a similar way, needle coke was added to the
outer coat slurry in a very small proportion. During the firing of the
shell, the needle coke got burnt and, consequently, macropores were created
in the outer coating of the shell, which would enable escape of undesirable
gases that may generate inside the shell. This ultimately would reduce the
porosity defects in the final cast parts. Tests conducted on the ceramic
shell modified with ABS powder and needle coke reveal that the modified
shell possesses higher permeability compared to the conventional one. The
modified shell also possesses adequate mechanical properties like flexural
strength, hot tensile strength, etc., and fair surface roughness. © 2019,
Quality Assessment of Al Castings Produced in Sand Molds Using Image and CT

Analyses
.
85065413262&doi=10.1007%2fs11665-019-04040-
z&partnerID=40&md5=aa6e86a1a802d276e410654fcbed92c1
ABSTRACT: Nowadays, the economic production of aluminum casts is becoming
increasingly important. Therefore, the decision of whether to use alloys
based on the primary aluminum (low Fe content, but high costs) or the
secondary aluminum (high Fe content, but reasonable costs) for a cast
product is a common problem. The main expected influence of higher iron
content is to increase porosity and decrease mechanical and fatigue
properties. Therefore, this work is focused on assessment of the higher Fe
content influence on porosity and iron-rich intermetallic phases formation
and, hence, changes in the mechanical properties, with simultaneously
keeping the production economical. The quality of castings was measured by
application of the 2D technology (image analysis) and the 3D technology (CT
analysis), as well. Results show that technologies of assessment are
comparable and length of the Fe-rich phases is not critical for mechanical
properties, but it is important for porosity formation in materials with
the higher amount of Fe. © 2019, ASM International.
Evaluating a Ceramic Resin-Coated Sand for Aluminum and Iron Castings

.
85067387715&doi=10.1007%2fs40962-018-0269-
5&partnerID=40&md5=7718d25d106a85da8ab80bb7e66c813e
ABSTRACT: Shell molding technology remains an important part of metal
casting technology because it permits precision sand castings. However,
there is a lack of information available on shell resin-coated sand (RCS)
produced with ceramics. This paper relates the physical, mechanical, and
thermo-mechanical properties of disc-shaped shell core specimens made from
either silica or ceramic sands. Gravity-filled disc-shaped shell core
specimens were fabricated with silica and ceramic sands. Specimens were
laboratory tested and evaluated in aluminum and iron casting trials.
Testing included density, abrasion, thermal distortion, hot permeability,
impact and retained strength. All tests were accomplished according to
newly adopted American Foundry Society standards. With a ceramic RCS, it is
possible to produce cores and molds having superior abrasion resistance,
strength, and thermal stability when compared to a silica RCS. Ceramic RCS
shell core specimens showed fewer casting surface issues when compared to
silica RCS shell core specimens in aluminum and iron casting trials. ©
2018, American Foundry Society.
Research on Coatings and Infiltration to Strengthen Ceramic Lost Cores Used

in High-Pressure Die Casting Processes
.
85067385473&doi=10.1007%2fs40962-018-00301-
0&partnerID=40&md5=889a0a45647313382bc458b5b3adfec1
ABSTRACT: Lost cores used to manufacture complex aluminium components
through high-pressure die casting (HPDC) processes need to withstand very
high injection velocities and pressures. The conventional sand cores used
in other casting processes, such as sand casting or low-pressure die
casting, do not support the aggressive process parameters of the HPDC, so
advanced ceramic cores must be used. These cores must be strong enough not
to get broken during the casting process, but, at the same time, they must
have a minimum porosity to be easily removed from the casting to obtain the
finished part. Due to this porosity, the aluminium penetrates the core
surface during the casting process. So, the criterion here is to find the
necessary compromise between strength and porosity and to protect the core
surface from the aluminium penetration. In this work, two research lines
have been followed to address these challenges. On the one hand, different
refractory coatings have been applied to the ceramic core surface with the
aim of sealing it. Amongst the coatings analysed, boron nitride-based one
has been found to be the most suitable and cost-effective solution to avoid
aluminium penetration. On the other hand, silica has been proved to be a
suitable infiltration agent to increase the strength of the core. © 2019,
The Author(s).
Comparative study on the microstructures and hardness of the AlSi10.6CuMg

alloy produced by sand casting and high pressure die casting
.
85064604721&doi=10.1080%2f13640461.2019.1603681&partnerID=40&md5=4169294fa3
a3aad1cdd2b143b5a8e0d1
ABSTRACT: This study compares the microstructures and hardness of an
AlSi10.6CuMg alloy obtained by sand casting and high pressure die casting
(HPDC). The results show that the morphology of HPDC dendrites was not
uniformly distributed as in sand casting. HPDC refines the morphology of
intermetallics and produces a modification of eutectic silicon. Chinese-
script is the dominant iron intermetallic in sand casting, while primary
polyhedral and secondary proeutectic particles are dominant in HPDC. The
results of the X-ray diffraction show the presence of high residual
stresses in the HPDC. Deep etching for HPDC samples reveals θ-Al2Cu phases
in very thin compact dendrites. No evidence of twin plane re-entrant edge
assistance was found in the growth of primary silicon. The primary silicon
plate-like becomes unstable in HPDC, resulting in smooth and rounded outer
surfaces. Hardness of HPDC alloy was about 11% higher than that of sand
casting alloy. © 2019, © 2019 Informa UK Limited, trading as Taylor &
Francis Group.
Development of a hybrid method for improved accuracy of mould filling

computational models for castings
.
85064493526&doi=10.1080%2f13640461.2019.1603434&partnerID=40&md5=991d1c7cda
817035989453666355e00e
ABSTRACT: Computational modelling of mould filling is a component of
paramount importance for the design of gating systems of castings. The main
methods are the body-fitted grid system and the Cartesian grid system.
While the former comes with high accuracy but high calculation times, the
latter is fast but less accurate. A hybrid method combining a three-
dimensional Cartesian cut-cell method and a porous media approach has been
further developed. The calculated filling patterns compared favourably with
high-speed video images of sand mould filling during pouring of ductile
iron, and with visual images recorded through an acrylic glass-water model
device simulating the gravity die casting process. In addition, numerical
experiments were conducted to demonstrate the improved filling accuracy of
the developed hybrid method. To this goal, three different symmetry tests
with and without sub-mesh were designed and evaluated. All tests
convincingly demonstrated the computational time and accuracy advantages of
the developed method. © 2019, © 2019 Informa UK Limited, trading as Taylor
& Francis Group.
Reduced consumption of materials and hazardous chemicals for energy

efficient production of metal parts through 3D printing of sand molds
.
85063492755&doi=10.1016%2fj.jclepro.2019.03.158&partnerID=40&md5=c32cbdf972
232dbecf271d54fd77fbf0
ABSTRACT: Metals remain essential structural materials for many demanding
engineering applications requiring high strength at elevated temperatures
and good performance in environments subjected to high thermal fluctuations
such as often encountered in the automotive, rail and aircraft industries.
The sand-casting process is one of the most preferred methods of producing
complex and intricate shaped components out of metals with good strength at
elevated temperatures. Unfortunately, the sand casting process also leads
to the direct and indirect production of carbon dioxide. Three-dimensional
sand mold printing has been revolutionizing traditional production methods
by reducing the unnecessary consumption of metal and chemicals when
manufacturing a part through sand casting. This paper explores the
opportunities that are emerging in the area of 3D printing of sand molds
and the positive impact that these new technologies and practices are
having on the environmental impact of current sand-casting processes. The
paper demonstrates that 3D printing of sand molds enables new manufacturing
strategies reducing the direct CO 2 emissions and reducing the amount of
metal required by enabling design optimization of both the component and
mold/core assembly. Further benefits will be realized through the
development of environmentally friendly binder systems. © 2019 Elsevier Ltd
Development of high strength sand cast Mg–Gd–Zn alloy by co-precipitation

of the prismatic β′ and β1 phases
.
85065404858&doi=10.1016%2fj.matchar.2019.04.036&partnerID=40&md5=68e27bad3e
117749744bae364361040d
ABSTRACT: In order to design a high strength sand cast Mg–Gd–Zn alloy, the
microstructures and mechanical properties of cast Mg–12Gd–xZn–0.4Zr (x = 0,
0.4, 0.8)(wt%, signed as GZ1200K, GZ1204K and GZ1208K)alloys were studied.
Zn addition changes the constitution of the strengthening phases in
Mg[sbnd]12Gd alloy. Small amount of Zn addition leads to the formation of
basal precipitates of γ″ and γ′, accelerated-precipitation of the β1 phases
and lower number density of the prismatic β′ phases, and modifies the
morphology of the prismatic β′ precipitates. Compared with the Zn-free
alloy, the Zn-containing alloys (GZ1204K & GZ1208K)having higher yield
strength in peak-aged and over-aged conditions are mainly due to the extra
prismatic β1 precipitates, which do not precipitate in the Zn-free alloy.
Under sand casting condition, GZ1208K alloy strengthened by the co-
precipitates of the prismatic β′ and β1 phase indicates a good combination
of strength and ductility at room temperature: yield strength of 270 MPa,
ultimate tensile strength of 348 MPa and elongation of 2.6%. © 2019
Elsevier Inc.
Optimization of vanadium content for achieving higher wear resistance and

hardness in high Cr-V white cast irons for ball tube mill liner application
.
85070760591&doi=10.3221%2fIGF-
ESIS.49.47&partnerID=40&md5=46493bbbe2bb5dd806c2a2ce4ad34e05
ABSTRACT: The liner materials in coal fired tube mills are less promising
due to lower combination of abrasion wear resistance, hardness and impact
toughness properties, thus giving service life of 25,000 to 35,000 hours.
In this study, focus was given to develop a high Cr-V cast iron of high
abrasion wear resistance with higher hardness and impact strength for ball
tube mill liner application. The developed liner possesses high abrasive
wear resistance and impact resistance simultaneously with expected service
life of 40,000 to 50,000 hours. This grade was made using induction melting
and sand casting method. The casting was heat treated in two stages to
achieve higher abrasion wear resistance and mechanical properties. Various
tests like chemical analysis, abrasion wear, hardness and impact tests were
conducted on the above developed material. Abrasion wear test results show
a low wear loss value (2.7 to 4.4 mg/min). Hardness and impact tests show a
high combination of hardness (57 to 64 HRC) and impact strength (44 to 57
J/cm2). Prototype tube mill liners were manufactured and tested in a tube
mill at 250MW site. Results obtained from site testing are also discussed
in this study. © 2019, Gruppo Italiano Frattura. All rights reserved.
Simulation of casting process: case study on the gating and feeding design
for outlet diaphragms of iron ore ball mill
.
85053816722&doi=10.1007%2fs00231-018-2447-
7&partnerID=40&md5=e358dc247adbf780427dbb4a4b645917
ABSTRACT: In this paper, the sand casting process was evaluated using
ProCAST simulating software and practical experience for manufacturing of
the high chromium stainless steel outlet diaphragms used in iron ore ball
mill. In the simulation practice, the effects of feeding and gating designs
on the liquid flow, heat transfer and solidification phenomenon were
evaluated to minimize the liquid surface turbulence during filling of the
mold cavity and the shrinkage porosity formation during the liquid
solidification in the mold. The effects of different gating ratios and
number of feeders were numerically studied using different indicators in
the software such as linear velocity, niyama criteria, fraction solid and
shrinkage porosity. Further, the optimal design obtained by simulating
process was empirically examined. The simulation results showed that the
1:3:4 gating ratio is the proper gating system that it obtains an
unpressurized fluid flow without any surface turbulent of the liquid steel
in the filling step. In addition, the simulation of solidification
phenomenon was indicated that four feeders are required to eliminate of the
shrinkage porosities. The empirical casting examination shown the optimal
design by the simulation is proper for manufacturing of the steel part
without critical defects. © 2018, Springer-Verlag GmbH Germany, part of
Springer Nature.
Effect of cooling rate on the porosity defect in the thick aluminum casting
by 3D computed tomography analysis
.
85067874437&doi=10.1088%2f1757-899X
%2f529%2f1%2f012057&partnerID=40&md5=95fd3495edd05538ed8e969fae3eedb9
ABSTRACT: In the present study, effect of cooling rate on the formation of
the porosity in the thick aluminum sand casting was investigated. Nowadays
large scale thick aluminum casting replaces steel frame for vacuum chamber
for semiconductor production, with the consideration of weight and cost
reduction. Several thick aluminum castings were manufactured using chill
with temperature measurements. The castings were inspected by using 3D
computed tomography in order to quantify the porosity defect density in the
castings. Effect of the thickness of the chill on the porosity defect
density were discussed. © Published under licence by IOP Publishing Ltd.
Integrating mind, hand, and heart: How students are transformed by hands-on
designing and making
.
85078781852&partnerID=40&md5=44302ec9ea2aa0438674c6bf4ab91dbc
ABSTRACT: Hands-on education - the integration of mind and hands - is often
believed to transform the way that students think and learn. How and how
much are students changed by hands-on education, and by what mechanisms do
such transformations occur? This exploratory study considers 75 students in
a 10-week engineering design and manufacturing course where, in many cases,
students design and build a physical product for the first time. Students
participate in labs through which they gain hands-on experience in milling,
turning, forming, welding, and sand casting, among other manufacturing
processes. Additionally, through several iterations of an individual
project, each student builds a functional, high-fidelity, well-finished
prototype of their own design. Drawing from Dewey alongside Lave and
Wenger's theories of learning through experience and participation in
communities of practice, we observe how students engage their mind, hands,
and heart in a makerspace environment and the subsequent changes that they
experience. We hypothesize that greater integration of students' mind,
hands, and heart is associated with increased engineering task self-
efficacy, innovation self-efficacy, engineering identity, and closeness of
connection to a maker community. To examine these hypotheses, pre- and
post-course surveys were administered in addition to written reflections
throughout the course. Pre-post comparisons are performed on quantitative
constructs and qualitative reflections contextualize the interpretation.
Findings suggest that participation in this hands-on learning course is
associated with large positive transformations in innovation self-efficacy,
engineering task self-efficacy, and perceived connection between the self
and maker community, and that these gains occur in all examined subgroups.
On average, students report large increases in perceived connection between
their “mind and hands” and “heart and hands,” with underrepresented
minority (URM) women and non-URM men experiencing the largest increases in
mind-hand-heart connection. Future research may examine how different
groups of students, e.g. URM women, approach designing and making in
academic makerspaces and how they come to perceive exceptional integration
of mind, hand, and heart. Our findings also point to the underexplored and
potentially substantial role of emotion in makerspace learning
environments. These findings have implications for our understanding and
support of designing and making in engineering education. © American
Society for Engineering Education, 2019.
On the rapid manufacturing process of functional 3D printed sand molds

.
85065242172&doi=10.1016%2fj.jmapro.2019.04.034&partnerID=40&md5=921aedbfabe
ee699e2612f0515ca7a11
ABSTRACT: 3D printing sand mold technology offers an opportunity for the
foundry industry to rethink old casting approaches and to revive the
manufacturing approach using computer models. One of the major concerns in
sand molding using 3D printing is the functional characterization of the 3D
printed molds as its mechanical and mass transport properties. This
research paper discusses the effects of binder content on the mechanical
strength and the permeability of 3DP sand molds at different curing
conditions. The local permeability of the 3DP specimen was measured as a
function of the injection flow rate in order to quantify the inertial
pressure effects. The mechanical strength of the 3DP sand molds was
characterized using traditional three-point bending strength measurements.
The results show that the mechanical strength of the printed molds is
deeply dependent on the amount of binder and the curing process. The 3PB
strength was found to increase when cured at 100 °C and decrease when cured
at 200 °C for all binder contents. The 3PB strength attains its maximum
when cured at 100 °C for 2 h for all binder content. In contrast, no
significant effect of the amount of binder on the initial permeability of
the samples before curing was observed within the functional range of
binder mass fraction (1.02–1.98 %). Maximum permeability is attained at the
same conditions as the 3PB strength. Therefore, the mechanical strength of
the sample can be optimized within the investigated range of binder
contents without resulting in any significant decrease in permeability. ©
Downstream impacts of the Ranganadi hydel project in Brahmaputra Basin,

India: Implications for design of future projects
.
85065163807&doi=10.1016%2fj.envdev.2019.04.005&partnerID=40&md5=2f32126eacb
9941b0d77dc8071f32c76
ABSTRACT: This study analyses the downstream hydrological, morphological,
and socio-economic impacts of the sole operating hydropower scheme -
Ranganadi Hydel Project Stage I in Arunachal Pradesh (India), the state
with the largest potential and the highest number of upcoming hydro schemes
in the country. The project has a large dam with inter-basin water
diversion for electricity generation, thereby affecting flow in two rivers
of the Brahmaputra Basin - Ranganadi and Dikrong. Flow alterations were
measured using Nature Conservancy's Indicators of Hydrological Alteration
model, while planform changes were studied using multi-temporal satellite
imagery and Geographical Information System. The results indicated
significant downstream flow alterations by the project in the post-dam
period. Post-dam median annual flows in the impounded and flow-deprived
river - Ranganadi, have decreased by 63%, but increased by 138% in the
recipient river - Dikrong. The former displayed channel narrowing and
decreased braiding, while the latter exhibited a wider and more braided
planform. Unexpected releases from the reservoir, flash floods, and sand
casting were the major problems cited by the downstream communities in the
Ranganadi sub-basin, which impacted upon agricultural lands and
livelihoods. This study recommends mitigation plans that could be followed
by both existing and future hydropower projects. © 2019 Elsevier B.V.
An investigation on wear behaviour of cnt reinforced Al-SiC metal matrix

composites
.
85066021958&doi=10.24247%2fijmperdjun201918&partnerID=40&md5=d774cfc994bdd3
454d3a1bf55ca54b10
ABSTRACT: The attractive physical and mechanical properties of Aluminium
Alloys and their light weight property (approximately 3 times lighter than
Steel), low cost of production (with sand casting technology), easy
machinability with good recycling possibilities (up to 95 %) makes them
attractive for many Commercial and Industrial applications. The major
problem of these alloys in Wear applications is their Low Wear Resistance.
In order to improve its wear characteristic many Particle reinforced
Aluminium Matrix Composites (PAMCs) were developed using Silicon Carbide
(SiC), Titanium Carbide (TiC), Boron Carbide (B 4 C), Titanium Diboride
(TiB 2 ) , Graphite (Gr), Molybdenum Di-Sulphide (MoS 2 ) , etc. as
reinforcement particles by different methods (Stir casting, Compo casting,
Powder Metallurgy, in-situ method using salts and spray deposition) and
their wear characteristics were also studied. In this work, a MMC of
Aluminium AA6061 reinforced with 4% SiC with 0.5% of Carbon Nano Tube (CNT)
was developed by Stir and its dry sliding wear characteristic were
investigated using Pin-on-Disc machine with disc material of EN32 steel (65
HRC) under the conditions: Applied Load varying from 5 N to 15 N, Sliding
Velocity varying from 0.5 m/s to 1.5 m/s and Sliding distance varying from
400 m to 600 m. The worn out surfaces were examined using Scanning Electron
Microscope. Experiments were carried according to Taguchi’s L27 Orthogonal
Array with Mass Loss and Co-Efficient of Friction as Responses. Grey
Relational Analysis was carried to found the Minimal Mass Loss and Co-
Efficient of Friction. © TJPRC Pvt. Ltd.
Experiments on spatial stress of foot blade during caisson sinking in water

[水中沉井下沉期间刃脚空间受力试验]
.
85070298304&doi=10.16285%2fj.rsm.2017.2540&partnerID=40&md5=380a956b066d11d
d41e9ffdb1ed6b81d
ABSTRACT: A sinking simulation test of deep and large caisson is designed
based on the caisson of Hutong Bridge. The undrained sucking sediment
sinking of the caisson in the water is simulated and spatial distribution
of the stress at the tread and oblique planes of the foot blade during the
sinking process of the caisson. It concludes that the maximum stress occurs
in corners of the caisson, the minimum stress occurs in the middle of long
side, and the average stress at the short side is larger than that of the
long side. Applying the reference stress at the midpoint of the long side,
the total cross-section stress coefficient of the foot blade with the
aspect ratio of 1.33 is calculated. In addition to be affected by spatial
position, the stress on the incline plane of the foot blade is also greatly
related with the mud surface height, and it changes contrary to the
stresses at the tread. When the mud surface height is determined, the cubic
function is used to determine its stress distribution. The influences of
inclination, sand-casting and sudden sinking on the stress of the foot
blade are also discussed and it is found that both can cause changes in
spatial distribution of the stress of blade foot. Stresses at the tread and
incline planes hydraulic gradient of the foot blade change significantly
before and after the sand-casting and sudden sinking of caisson. They occur
earlier than the sand-casting and sudden sinking of caisson and it is of
great significance to early warning of sand-casting and sudden sinking. ©
2019, Science Press. All right reserved.
Application of AnyCasting Virtual Simulation in Sand Casting and Defect
Analysis [AnyCasting 虚拟仿真在砂型铸造中的应用及缺陷分析]
.
85070524162&partnerID=40&md5=dbbd609b7244e493ef0b7b0ba4641c48
ABSTRACT: In this paper, the filling and solidification sequence, and
possible defects in sand mould casting process were simulated and predicted
using side pillow model of practical teaching case based on AnyCasting
virtual simulation software. After AnyPRE pretreatment, AnySOLVER
calculation solution and AnyPOST post-processing were conducted, filling
time, solidification time, temperature, pressure, entrainment gas and
horizontal eddy current were observed and analyzed. Using the result
merging function can find twodimensional or three-dimensional
solidification defects, and through analysis and improvement of the casting
process, the defects can be prevented. © 2019, Chinese Mechanical
Engineering Society. All right reserved.
Formation Causes of Pinholes in Aluminium Alloy High Voltage Switch

Housings and Prevention Measurements [铝合金高压开关壳体铸造针孔形成原因及解决措
施]
.
85070490489&partnerID=40&md5=9bd83af59f251be74a234b608011d62d
ABSTRACT: Aluminium alloy high voltage switch housings produced using low
pressure sand casting had pinholes defect at the end face. Through
experimental analysis, it was found that the pinholes defect at the end
face is related to the layout of ingates. The ingates at the end face
resulted in the low cooling rate at the end face region during the
solidification, which caused the hydrogen precipitation and the formation
of gas porosity. Placing chills near the defects position and decreasing
the size of ingates can quicken the cooling rate of the end face,
preventing hydrogen precipitation. Therefore, the pinhole defect could be
eliminated. © 2019, Chinese Mechanical Engineering Society. All right
reserved.
Mechanical and material properties of castings produced via 3D printed

molds
.
85062866743&doi=10.1016%2fj.addma.2019.03.004&partnerID=40&md5=fe7c23eef74d
c771f87320e384523878
ABSTRACT: Additive manufacture of sand molds via binder jetting enables the
casting of complex metal geometries. Various material systems have been
created for 3D printing of sand molds; however, a formal study of the
materials’ effects on cast products has not yet been conducted. In this
paper the authors investigate potential differences in material properties
(microstructure, porosity, mechanical strength) of A356 – T6 castings
resulting from two different commercially available 3D printing media. In
addition, the material properties of cast products from traditional “no-
bake” silica sand is used as a basis for comparison of castings produced by
the 3D printed molds. It was determined that resultant castings yielded
statistically equivalent results in four of the seven tests performed:
dendrite arm spacing, porosity, surface roughness, and tensile strength and
differed in sand tensile strength, hardness, and density. © 2019
The role of acoustic pressure during solidification of AlSi7Mg alloy in

sand mold casting
.
85068543984&doi=10.3390%2fmet9050490&partnerID=40&md5=beae3ecce1ba801f08a0d
2ece56b9ba6
ABSTRACT: New alloy processes have been developed and casting techniques
are continuously evolving. Such constant development implies a consequent
development and optimization of melt processing and treatment. The present
work proposes a method for studying the influence of acoustic pressure in
the overall refinement of sand cast aluminum alloys, using and correlating
experimental and numerical approaches. It is shown that the
refinement/modification of the α-Al matrix is a consequence of the acoustic
activation caused in the liquid metal directly below the face of the
acoustic radiator. Near the feeder, there is a clear homogeneity in the
morphology of the α-Al with respect to grain size and grain circularity.
However, the damping of acoustic pressure as the melt is moved away from
the feeder increases and the influence of ultrasound is reduced, even
though the higher cooling rate seems to compensate for this effect. © 2019,
MDPI AG. All rights reserved.
Process characterization in laser metal deposition of en AC-43000

.
85064856456&doi=10.2351%2f1.5096114&partnerID=40&md5=f451218ba06c17dee81989
aa011e4d5d
ABSTRACT: EN AC-43000 is a well-established cast material for the
production of parts, which are used in the automotive and optical
industries. Typical components like cylinder heads, control blocks for
automatic transmissions, or housing are manufactured via die or sand
casting. The casting process depends on a lot of influencing parameters and
is difficult to control. Reject rates up to 10% are the consequence. Those
parts are mostly characterized by defects like pores, blowholes, or surface
deviations. Such defects restrict the functionality of the component,
especially if they are located next to sealing surfaces or at mechanically
or thermally high strained areas. In general, defect components are
recycled by putting them back to the melt feeding of the casting process.
An alternate approach in the presented paper is the repair of the defect
components via powder-based laser metal deposition (LMD). EN AC-43000
represents a group of aluminum alloys that are characterized by a
restricted weldability. Difficult material properties like the affinity to
oxygen and the high thermal diffusivity cause porosity and high dilution.
Welding experiments are performed using a disc laser with a maximum output
power of 4 kW. The typical seam parameters, such as width, height, depth,
and cross-sectional area, are measured in order to characterize the LMD
process and to define process limits. Furthermore, the ways to optimize
dilution and porosity are presented. © 2019 Laser Institute of America.
Removal of Casting Defects in C90500 Alloy Cryogenic Pump [C90500 铜合金深冷

泵泵体铸造缺陷的消除]
.
85068126176&partnerID=40&md5=400953b5067750bf7649438c3ce16e06
ABSTRACT: This paper mainly introduces the casting defects in C90500 copper
alloy cryogenic pump body and the methods to eliminate them. In the process
of common sand casting C90500 copper alloy pump body, casting defects such
as shrinkage, dispersed shrinkage, blowhole and crack are often caused by
unreasonable casting process design, improper operation of melting process
and welding and repair process, etc. According to material characteristics
of C90500 alloy, structural feature of pump body and combined with
production experience, sand casting process of C90500 copper alloy
cryogenic pump body was designed. Practical production verified that
casting defects in C90500 alloy pump body could be eliminated by designing
reasonably gating and risering system, controlling strictly the melting
process, selecting proper riser cutting method and repair welding
technology. © 2019, Chinese Mechanical Engineering Society. All right
reserved.
Experimental study on side friction distribution of caissons during sinking

in water [水中沉井下沉期侧壁摩阻力分布试验研究]
.
85070512883&doi=10.11779%2fCJGE201904014&partnerID=40&md5=324ccc3eac66528ce
6a7ca3f3a6caa39
ABSTRACT: A sinking simulation experiment on a deep and large caisson is
carried out based on the main caisson of Shanghai-Nomtong Bridge. Through
the analysis of the whole dynamic sinking, it is determined that the
effective stress on the sidewall is affected by various factors such as
sinking rate, pressure relaxation, inclination, sand-casting and sudden
sinking. After stopping sand suction, the effective stress of the sidewall
changes from a dynamic distribution to a quasi-static one, the overall
trend is decreasing and shows the reduction of extreme points and recovery
of pressure relaxation zone. The arrangement of the step can reduce the
total side friction of the caisson, and the reduction mainly comes from the
vertical section of the caisson. It is found that the sidewall of stepped
caisson can be divided into linear zone, step zone, excess zone and
pressure relaxation zone. A model for calculating the side friction of the
caisson in vertical state is established based on the influences of the
step and verified by the on-site monitoring tests on No. 29 caisson of
Shanghai-Nantong Bridge. The inclination the of caisson causes a change in
the effective stress distribution of the sidewall, and the increased earth
pressure generated by the compaction is 3~4 times the active earth pressure
of the corresponding side. © 2019, Editorial Office of Chinese Journal of
Geotechnical Engineering. All right reserved.
Comprehensive modelling, analysis and optimization of furan resin-based

moulding sand system with sawdust as an additive
.
85063259256&doi=10.1007%2fs40430-019-1684-
0&partnerID=40&md5=7ffd1c1f4ced88fe1d1fd8174fcde747
ABSTRACT: Scarcity of high-cost silica sand, casting defect such as hot
tear in hard moulds and casting ejection problem after solidification are
the key industrial problems. Sawdust is a by-product of wood working
industries, and economic disposal of sawdust in these industries is a
growing concern to the wood industries. The present work utilized sawdust
as an additive in preparing mould cavity for casting applications. Sand
mould properties such as compression strength (CS), mould hardness (MH),
gas evolution (GE), permeability (P) and collapsibility (CP) will have good
impact on the quality of castings. The effect of variables, namely quantity
of resin, hardener, sawdust and setting time, on no-bake furan-bonded sand
system is studied in the present research work. The experiments are
conducted as per design of experiments, and the data are used to
investigate the effect of individual and combined parametric contributions
towards responses and establish nonlinear input–output relationships. All
nonlinear regression models (that is, input–output relationships) are found
to be statistically adequate. The input–output relations are analysed and
presented for each of the response with the help of surface plots. Further,
the models are found to predict the output close to the experiment (target
value). The grand average value in predicting responses is found to be
equal to 5.03%. The multi-objective optimization of responses with
conflicting nature (minimize: GE and CP; maximize: CS, P and MH) is carried
out with the help of global fitness function values determined using
genetic algorithm, particle swarm optimization, teacher–learner-based
optimization and JAYA algorithms. The optimized values of process
parameters that resulted in best set of responses are found to be equal to
60 min, 2.01%, 0.6% and 0.93% for setting time, quantity of resin, hardener
and sawdust, respectively. Two automobile coupling parts are cast by
pouring molten aluminium into the mould cavity with the optimized and non-
optimum sand mould conditions. Further, these two cast components are
tested for their quality characteristics, such as surface finish, yield
strength, hardness, density and secondary dendrite arm spacing. It has been
observed that the quality characteristics of castings produced in mould
with optimized parameters are found to be much better. © 2019, The
Brazilian Society of Mechanical Sciences and Engineering.
Design of Locating Device for Self-Hardening Sand Mold Assembling [自硬砂型

合箱定位装置的设计]
.
85068109245&partnerID=40&md5=6d2b40071b2ccdba190a0eee53794b33
ABSTRACT: Based on the shortcomings of existing self-hardening sand mold
assembling methods, a new locating device for self-hardening sand casting
mold assembling was designed. The locating device has high precision and
can effectively prevent the shift defects caused by the large positioning
error or failure of the upper and lower boxes in the process of casting
production. © 2019, Chinese Mechanical Engineering Society. All right
reserved.
Numerical simulation and experiment of cavitation performance on CAP1400

nuclear reactor coolant model pump [CAP1400 反应堆冷却剂模型泵空化性能数值模拟与试
验]
.
85065963152&doi=10.3969%2fj.issn.1674-
8530.16.0299&partnerID=40&md5=80205c533daca4be176943d03c6522b3
ABSTRACT: In order to investigate the cavitation performance of CAP1400
reactor coolant pump, the standard k-ε model and mixture model were applied
to simulate the cavitating flow in a 1:2.5 CAP1400 model pump. The
cavitation inception was reaveled and cavitation development in the
impeller and the blade loading characteristics on the middle stream line at
different NPSH were analyzed. Furthermore, the cavitation experiment was
carried out with sand casting guide vane combined with precision casting
aluminum alloy impeller and sand casting impeller respectively. The results
show that the relative position of the volute and impeller has a certain
effect on the vapor volume fraction distribution in the impeller and the
cavitation is more serious on the suction surface of blade near the outlet
of the volute. Blockage effect of cavitation changes the flow angle near
the leading edge of blade, which causes the cavitation arising on the
pressure surface near the leading edge. Blade loading is significantly
influenced by cavitation. Blade loading along the streamline has a maximum
value near the end of vapor on the suction surface. Uneven distribution of
the vapor in the impeller increases the difference of blade loading among
different blades. The manufacturing precision of the impeller has a great
impact on the cavitation performance of pump. © 2019, Editorial Department
of Journal of Drainage and Irrigation Machinery Engineering. All right
reserved.
Process Experiment on Pre-Embedded Oil Duct in Steel Casting [埋管铸造成形油

道孔的工艺试验]
.
85068003561&partnerID=40&md5=c1688677e87d53ed76fc87b8c8472181
ABSTRACT: It’s easy to cause blockage, core breaking, sintering and sand
cleaning problem in sand mold casting by using sand core to form slender
oil duct. In order to solve these problems, both casting processes were
attempted. One was that the elongated oil hole in steel casting was formed
by pre-embedded hollow oil duct, and the other was formed by the pre-
embedded oil duct with chromite sand filled inside. The research also
focused on studying the interface bonding between the pre-embedded oil duct
and casting, the factors affecting the fusion of oil duct and the
relationship between the pre-embedded oil duct weight and hot spot weight.
The results indicate that the casting process of the pre-embedded hollow
oil duct in sand mold can effectively solve the problem of core breaking
for the castings with weight range from 20 kg to 100 kg; the casting
process of the pre-embedded oil duct with chromite sand filled inside not
only solve the problem of melt-through of preembedded oil duct, but also
improve the quality of castings with weight range from 100 kg to 300 kg. ©
Re-Thinking Design Methodology for Castings: 3D Sand-Printing and Topology

Optimization
.
85059751052&doi=10.1007%2fs40962-018-0229-
0&partnerID=40&md5=abe30a933bbdf3218240f45f646f0b34
ABSTRACT: Additive manufacturing of sand molds and cores for metal
castings, often called 3D sand-printing (3DSP), is an efficient “freeform”
fabrication process that enables rapid production of sand metal castings.
The ability to create highly complex molds and cores for advanced metal
casting geometries via 3DSP provides unparalleled design freedom,
particularly for low-volume production. However, there is a need to
thoroughly understand the opportunities and restrictions of 3DSP in a
systematic approach similar to well-established design guidelines for
traditional sand casting. This study presents a knowledge-based design
framework for 3DSP with the goal of developing new part design guidelines
under such 3DSP framework. In particular, constrained topology optimization
approach for the part redesign is developed for 3DSP. The presented design
framework is compared with traditional sand-casting rules and validated
through a case study on an existing metal component. Advantages of the
developed 3DSP design framework are illustrated and validated through a
case study where a 30% improvement in factor of safety and a 50% reduction
in weight of a mechanical part is achieved. Other advantages, such as
reduced lead time and production cost, are also observed. This research
provides the first known investigation into systematic implementation of
simultaneous constraints of 3DSP sand-casting rules mechanical strength
through the integration of topology optimization and novel design rules to
castings via 3D-printed molds. 3DSP also eliminates multiple design
constraints in conventional mold-making and core-box fabrication. Findings
from this study can be applied for a wide range of alloy systems, part
geometries and loading conditions for sand castings in industrial
applications. © 2018, American Foundry Society.
Possibility of Elevation of Mechanical Properties of Sand-Cast Copper

Silumins
.
85062697496&doi=10.1007%2fs11041-019-00322-
4&partnerID=40&md5=68df1a84632794b97f2f25ed55bab036
ABSTRACT: The effect of heat treatment modes of copper silumins with 4% Cu
and different concentrations of silicon and magnesium crystallized in sand
molds on their microstructure and mechanical properties is studied. It is
shown that the level of the strength and ductility parameters of the copper
silumins after the treatment depends primarily on the degree of dissolution
of phase CuAl 2 and that the concentration of magnesium in copper silumins
with 4% Si + 4% Cu should not exceed 0.1 – 0.12%, which is sufficient for
raising the strength characteristics without noticeable degradation of the
ductility. The optimum mode for aging of alloy Al – 4% Si – 3.9% Cu – 0.13%
Mg (160°C, 8 h), which provides σ 0.2 = 330 MPa, σ r = 400 MPa and δ = 2%,
is determined by computation. © 2019, Springer Science+Business Media, LLC,
part of Springer Nature.
Comparative study of aluminum alloy casting obtained by sand casting method

and additive manufacturing technology
.
85084303497&partnerID=40&md5=e552160d569a4d1c9940b1486b16d0d5
ABSTRACT: In this research, a comparison between traditional sand casting
technique and additive manufacturing technology with InkJet 3D Printing
technique (3DP) was made, comparing the manufacturing time, cooling rate,
dimensional deviation, surface quality, surface porosity and defects. In
this way, feasibility and advantages of additive manufacturing was probed
to be a good alternative to non-ferrous alloys sand casting. © 2020 The
Authors.
Process knowledge for improving quality in sand casting foundries: A

literature review
.
85072397306&doi=10.1016%2fj.promfg.2019.05.052&partnerID=40&md5=f658770ea82
fedbf6067f4ac434388c8
ABSTRACT: Foundry operation has many interlinked and complex processes that
require skill and caution to ensure good quality of castings. The complex
production processes and variables in the foundry industry also imposes
quality limitation for final castings. Due to this, defect reduction still
remains the main objective in sand casting foundries. In this regard,
process knowledge is important in foundries to increase productivity by
reducing sand casting defects. Process knowledge is defined as the
identification of process variables. This includes the gathering approach,
conceptualisation system and analysis to determine the varying process
variables that are associated with product characterisation for final
products. The paper presents a literature review on process knowledge in
manufacturing focusing in sand casting method. It then explores possible
application of this methodology specifically to the metal casting industry
with the main aim of making it more competitive. © 2019 The Authors.
Published by Elsevier B.V.
Characterisation of lead sheet manufactured using traditional sand-casting

technique
.
85064062261&doi=10.1007%2f978-3-030-06034-
3_27&partnerID=40&md5=42645d08f6ecef223b00719b55e8a1ef
ABSTRACT: Lead sheet is widely used for roofing and flashing applications.
Continuous casting and rolling are the most common processes used for
manufacture of such sheet. Sand casting of lead sheet is a traditional
process used since the Romans. Sand cast lead sheet is presently used for
restoration of heritage buildings, churches and cathedrals. It possesses a
distinct texture due to the uniqueness of the manufacturing process and is
considered a premium product. In the present study, sand cast lead sheet
samples were collected and characterised. The observations are then
compared with characteristics of continuously cast lead sheet obtained from
the literature and are reported in this paper. © The Minerals, Metals &
Materials Society 2019.
Effect of cooling rate on microstructures and mechanical property of Al

1230 alloy in a sand casting process
.
85089016283&doi=10.1016%2fj.matpr.2020.02.372&partnerID=40&md5=352518454e63
b6a276a3f126b3156fd7
ABSTRACT: Sand casting is a widely used process for making various products
used in numerous industries such as medical, electrical, automotive etc.
However, the poor mechanical properties and microstructural defects are the
challenging concern to the foundry engineers for a last decade. In the
present work, the microstructural and mechanical assets of Al 1230 alloy
are investigated by slow and rapid cooling in a sand casting process. The
effect of cooling strategy is analyzed using a scanning electron microscope
(SEM) and ultimate tensile strength. Eventually, it is observed that the
rapid cooling is a more suitable technique, which enhances the
microstructural and mechanical properties of the cast component by inducing
of silicon particles during the process. Hence, the proposed work is very
useful to smart industries for achieving desired mechanical property while
fabricating sand cast components. © 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee
of the 10th International Conference of Materials Processing and
Characterization.
Effect of composition and pouring temperature of Cu(20-24)wt.%Sn by sand

casting on fluidity and mechanical properties
.
85079540905&doi=10.15282%2fjmes.13.4.2019.20.0476&partnerID=40&md5=fd033a4a
6e80c633d11ae3d713b9b328
ABSTRACT: The effect of tin composition and pouring temperature on the
length of fluidity, microstructure, density, hardness, tensile strength and
bending of Cu-Sn alloy with sand casting method has been investigated.
Cu(20-24)wt.%Sn were casted in two different pouring temperatures (1000 ºC
and 1100 ºC) in strip plate pattern sand mold. The sand mold has a length
of 400 mm, width of 10 mm with a thickness of the mold cavity varied from
1.5 to 5 mm. The results show that the increase in composition (20-22) wt.%
Sn decreases the length of fluidity while the composition (22-24) wt.% Sn
length fluidity increase again. Increase of the pouring temperature and
mold cavity thickness can increase the length of fluidity. Increasing tin
composition and pouring temperature can increase the phase of α structure,
porosity, hardness of the alloy and trigger the growth of dendrite columnar
and secondary dendrite (DAS) microstructure.While the density, tensile
strength and bending strength of the alloy tend to decrease. Increasing tin
composition and pouring temperature in Cu(20-24) wt.% Sn caused the alloy
to be more brittle. © Universiti Malaysia Pahang, Malaysia
Use of additive manufacturing on models for sand casting process

.
85065391152&doi=10.1007%2f978-3-030-12346-
8_35&partnerID=40&md5=b6c8de7feb582b24b94483684a05eaf9
ABSTRACT: Sand casting processes are simple and, generally, require a small
initial investment in machines and tools. These characteristics make this
manufacturing process very used in the metal industry for the manufacture
of small series of any size and complexity, where the dimensional and
surface quality requirements are not very demanding. Among the necessary
tools, it is worth mentioning the flasks and the patterns as the most
important elements. Patterns are usually reusable and manufactured with
polymeric materials. However, any change in the design or development of a
new product involves the manufacture of new patterns. In case of polymer
patterns obtained by injection, these product changes lead to the need of
manufacturing new matrix, which deduces into higher costs and time. In this
regard, the use of Additive Manufacturing techniques may help to solve
these problems. Thereby, a methodology for the design and manufacturing of
different patterns by using Fused Deposition Modeling techniques is exposed
in this work. The results have been compared with those obtained in
injection processes, from a functional and economical point of view. These
patterns will be used in the manufacturing of parts for educational
purposes. Nevertheless, with the appropriate scale and higher 3D printing
resolution, the methodology exposed could be implemented on industrial
applications © Springer Nature Switzerland AG 2019.
High-Cycle Fatigue of Mg–6Gd–3Y–0.5Zr Cast Magnesium Alloys

.
85062099747&doi=10.1007%2f978-981-13-5944-
6_51&partnerID=40&md5=510da62a7ba06fbec529737af8b8c8d9
ABSTRACT: This work studies the high-cycle fatigue of Mg–6Gd–3Y–0.5Zr cast
magnesium alloy in as-cast and T6 states based on low-pressure sand casting
and gravity permanent mold casting. The stress amplitude–number of cycle to
failure diagram (S-N diagram) and fatigue strength of the alloy were
obtained, and failure behavior of the alloy under cyclic loading was
analyzed by OM and SEM. The results show that fatigue strength of low-
pressure sand casting and gravity permanent mold casting is 105 and 95 MPa
in as-cast states, respectively, which are increased by 14.3 and 21.1%
after aging treatment. For the as-cast alloy, fatigue crack initiated from
single point on the surface and cyclic deformation were controlled by
twinning. However, for aged alloy, fatigue cracks originated from multi-
positions on the surface and cyclic deformation were controlled by slips. ©
2019, Springer Nature Singapore Pte Ltd.
Effect of degassing time and cooling rate on microstructure and porosity of

aluminum 6061 alloy using sand casting method
.
%2fMSF.964.124&partnerID=40&md5=0440cf9e993d4b53c2f7a72e1b75490b
ABSTRACT: This research is aimed to get a better understanding on the
effort of reducing the porosity level in aluminum alloys. The degassing
process (2, 5 and 8 minutes) is done to reduce the hydrogen content in
liquid aluminum and cooling rate modifications (13, 20 and 26o C / min) was
performed to reduce the porosity by reducing the size of Dendrite Arm
Spacing (DAS). The casting method used in this research is sand casting and
raw materials were melted using an electric furnace at 720oC. The
microstructural images showed the DAS size are decreased by size from 137.3
μm to 87.58 μm obtained from cooling rates of 13oC / min and 26oC / min
respectively. In the other hand, the level of porosity is also decreased
from 3.58% at 2 min degassing and the cooling rate of 13oC / min to 1.8% at
5 min degassing and 26oC / min cooling rate. Furthermore, the tensile test
results show that the value of tensile strength increases when the DAS size
and porosity level are smaller. The highest ultimate tensile strength value
is 105.9 and the lowest is 70.53 MPa. © 2019 Trans Tech Publications Ltd,
Switzerland.
A study on the S/W application for a riser design process for fabricating
axisymmetric large offshore structures by using a sand casting process
.
85053046275&doi=10.1016%2fj.ijnaoe.2018.08.003&partnerID=40&md5=12e968a13b7
470401f57b91369ea9261
ABSTRACT: The effects of the location and dimension of the gate, location,
and volume of the feeder, application of a chill, chill volume, and heating
method of the feeder with respect to the effect of the mold-designing
technologies on the defect status of the products are described. It is
possible to increase the solidification time of the feeder by heating
feeder. Furthermore, the pressure generated from the feeder is imposed on a
product, and this decreases the generation of shrinkage porosities. In this
study, two types of gating and feeding systems had been proposed: the
bottom L-type junctions and the top L-type junctions. Additionally,
solidification behaviors, such as solidification time, shrinkage
porosities, weight percentage of chill system to product, hot spot, and
solidification time ratio (=Solidification time of feeder/solidification
time of product), are extensively analyzed by using commercial casting
simulation software. Based on the solidification behaviors, reasonable mold
design, feeding system, critical feeder heating temperature, and
solidification time ratios are proposed in the sand casting process for the
fabrication of carrier housing in order to reduce the casting defects and
to increase the recovery rate. © 2018 Society of Naval Architects of Korea
Application of Taguchi-based Six Sigma method to reduce defects in green

sand casting process: A case study
.
85063745171&doi=10.1504%2fIJBSR.2019.098666&partnerID=40&md5=8960a9b65c94b3
7f226e6f1b1d3accbd
ABSTRACT: Six Sigma is a systematic method for process improvement. It
relies on statistical and scientific methods to reduce the defect rates and
achieve improved quality. A case study carried out for a green sand casting
manufacturing company. Here, Six Sigma methodology is used for the part:
bearing bracket 3809. Define-measure-analyse-improve-control (DMAIC)
methodology along with Taguchi method is used to minimise the defects in
the bearing bracket 3809. The major tools used in this work are the project
charter, process map, statistical graph and cause-and-effect diagram. Use
of design of experiment (DOE) and analysis of variance (ANOVA) techniques
are combined to determine statistically the correlation of defects with the
mould hardness, moisture content, green strength, permeability of sand,
pouring rate and pouring temperature and also to find their optimum values
needed to reduce/eliminate the defects. The experimental results were
statistically analysed and modelled through Taguchi analysis. Based on the
findings, the optimised process parameters are taken for experiment and
better performance obtained in the production process was confirmed. The
comparison between the existing and the proposed process has been attempted
in this paper and the results have been discussed in detail. © 2019
Inderscience Enterprises Ltd.
Modeling and experimental study of Al-Cu alloy sand casting for circuit
breaker
.
85068411262&doi=10.18517%2fijaseit.9.3.4902&partnerID=40&md5=89f7941027a3a4
03c54a86bac4c665d2
ABSTRACT: Aluminum is a light metal with good electrical conductivity and
widely applied for electrical devices. One of its application is the
circuit breaker component. The 2xxx series of aluminum alloy has a copper
alloying element which increases its mechanical properties and improves
quality of electrical conductivity. This research aims to obtain the best
gating system design of the circuit breaker mold by ANSYS modeling. This
research also is subject to measure the influence of Cu alloying to the
rate of electrical conductivity, strength, and hardness in aluminum alloys
for circuit breaker application by experimental working. Aluminum is
alloyed with variations of 1; 2; 3; 4; and 5% copper addition. Modeling of
thermal analysis and structural analysis was calculated by ANSYS Mechanical
APDL with a finite element method to find the best design for the sand
casting experiments. Chemical composition, metallography, brinnel hardness,
tensile, XRD, and electrical conductivity tests were conducted in this
study. The highest strength is 59.50 MPa was acquired on Al - 3% Cu while
the lowest strength is 37.43 MPa was on Al - 1% Cu alloy. The peak of
hardness 48.70 HBN could be drawn at Al - 4% Cu. In the other hand, the dip
of it was Al 1% Cu of 25.5 HBN. The last variable, conductivity, has the
highest amount as of Al-5C, alloys with a value of 12.88 S / M, which is
found on Al-1Cu with a value of 9.30 S/m. © 2019 International Journal on
Advanced Science Engineering Information Technology.
Casting quality enhancement using new binders on sand casting and high-
pressure rheo-die casting
.
85083313024&doi=10.15407%2fufm.20.03.396&partnerID=40&md5=53a46bd32926edba9
1b88a8f3224b8db
ABSTRACT: Casting quality is a perfection factor for measuring the success
of the metal casting. One of efforts to obtain high-quality casting product
is identifying the quality of sand moulding used. Identification of the
sand-moulding quality is defined by the hardness, shear strength, tensile,
and permeability. This article reviews the explanations of the strength of
sand moulding with composition variation of binder type: (1) sand moulding,
bentonite, fly ash, and water; (2) sand of mount Kelud eruption, bentonite,
and water; (3) sand of mount Kelud eruption, Sidoarjo mud, and water; (4)
sand of mount Kelud eruption, Portland cement, and water; (5) sand
moulding, volcanic ash, and water; (6) green sand, bentonite, fly ash, and
water; (7) sand of Malang, bentonite, tapioca flour, and sago flour; (8)
sand moulding, bentonite, Portland cement, and water. High-pressure rheo-
die casting commonly known in the literature as rheo-high-pressure die
casting (rheo-HPDC) is a novel casting technique in producing good-quality
cast products. Escalating market demand drives the development of new
technology, with which casts with excellent mechanical properties, good
microstructure, and minor casting defects can be produced. As an advanced
version of HPDC, rheo-HPDC can be regarded as a smart manufacture
technique, since it integrates the semi-solid metal technology that
considers the proper preparation of slurry. The slurry-making process has
been continuously developed, and the latest preparation method is the self-
inoculation method. This review article discusses the procedure, mechanism,
development, and product quality of sand casting with new binders as well
as rheo-HPDC technique.Keywords: diffusion, martensite, austenite,
radioisotope, dislocation, stack-ing fault defect. © P. PUSPITASARI, J.W.
DIKA, 2019.
The Influence of Different Casting Methods on the Corrosion Resistance of

Mg–Gd–Y Alloys
.
85062083365&doi=10.1007%2f978-981-13-5944-
6_25&partnerID=40&md5=0d38749500b3302d2e78ef35fe566498
ABSTRACT: The present work mainly studied the corrosion resistance and
corrosion process of Mg–Gd–Y alloys casted by low-pressure sand casting and
gravity die-casting methods. The results showed that the main corrosion
type of the Mg–Gd–Y alloys was galvanic corrosion, which were formed by α-
Mg matrix with Mg 3 (Gd, Y) or, Mg 5 (Gd, Y) particle phases. The particle
phases in the low pressure sand casting alloys were mainly Mg 5 (Gd, Y)
phases, but Mg 3 (Gd, Y) in the gravity die-casting alloys. The Mg 5 (Gd,
Y) phases dissolved into α-Mg matrix by solid solution treatment (T4), but
due to their high melting points the Mg 3 (Gd, Y) phases could not dissolve
efficiently. So after T4 treatment, the particles in the low-pressure sand
casting alloy decreased and then its corrosion resistance was greatly
improved. However, there were still lots of residual particles in the
gravity die-casting alloys after T4 treatment, so their corrosion
resistance did not change obviously. © 2019, Springer Nature Singapore Pte
Ltd.
3D printing sand molds for casting bespoke metal connections

.
85068366391&partnerID=40&md5=9e65e34bff2bf1422e3e94039825a961
ABSTRACT: Metal joints play a relevant role in space frame constructions,
being responsible for large amount of the overall material and fabrication
cost. Space frames which are constructed with standardized metal joints are
constrained to repetitive structures and topologies. For customized space
frames, the fabrication of individual metal joints still remains a
challenge. Traditional fabrication methods such as sand casting are labour
intensive, while direct 3D metal printing is too expensive and slow for the
large volumes needed in architecture.This research investigates the use of
Binder Jetting technology to 3D print sand molds for casting bespoke metal
joints in architecture. Using this approach, a large number of custom metal
joints can be fabricated economically in short time. By automating the
generation of the joint geometry and the corresponding mold system, an
efficient digital process chain from design to fabrication is established.
Several design studies for cast metal joints are presented. The approach is
successfully tested on the example of a full scale space frame structure
incorporating almost two hundred custom aluminum joints. © 2019 and
published by the Association for Computer-Aided Architectural Design
Research in Asia (CAADRIA), Hong Kong.
Vacuum helps reduce weight in pump impeller

.
85075680833&partnerID=40&md5=5dee591ce9bba0316cc4dec6107950be
ABSTRACT: A pump impeller was designed to pull water in and pressurize it
out the discharge. It met the standard as a sand casting, but by using a
vacuum-assisted filling casting process, the manufacturer was able to reap
additional benefits that improved performance and reduced cost. By
optimizing the design for vacuum-assisted semi-permanent mold casting, the
customer lowered its overall cost by reducing machining stock and scrap and
improving quality.
Aluminum matrix graphene-reinforced composite materials

.
85064065764&doi=10.1007%2f978-3-030-06034-
3_36&partnerID=40&md5=8dcd3632ce44ffef2bbe309bc4079ae6
ABSTRACT: In this study, due to the enhanced properties of graphene, it was
aimed to produce aluminum matrix composite by graphene reinforcement.
Several different methods were applied such as lost foam casting, sand
casting, die casting, ceramic mold casting and squeeze casting. The
incorporation of the graphene was established by only squeeze casting
method. Graphene was added by two methods: As layers and in aluminum foils.
The produced samples were subjected to bending tests, and it was found that
25% increase in bending strength was achieved by 0.1 wt% graphene addition
to A356 alloy. © The Minerals, Metals & Materials Society 2019.
Mechanical and tribological properties of aluminium matrix composite using

recycled waste beverage cans reinforced with CSA P , ZnO P , Fe P and B 4 C
P
.
85064461086&partnerID=40&md5=24ee5be094ec62846007b9c069c1744f
ABSTRACT: Beverage cans are manufactured from aluminium. Worldwide
production of beverage cans is huge. By recycling beverage cans they can be
reused for other purposes. In this Aluminium Matrix Composite (AMC),
aluminium forms a network that is matrix phase and ceramic or non-metallic
material used as reinforcement. Sand casting procedure is useful for
production of particulate reinforced metal matrix composites. AMC was
produced with the addition of different percentage of Coconut Shell Ash
(CSA), Zinc oxide (ZnO), Iron (Fe) and Boron Carbide (B 4 C). It is found
out that wear loss decreases and ultimate tensile strength increases with
the increase in weight percent of CSA, zinc oxide, boron carbide and iron.
But variation in percentage of elongation is less. This may be due to the
existence of non-metallic and ceramic materials which raise the hardness
and improve Tribological properties of AMC. © 2019, Scibulcom Ltd. All
rights reserved.
Relation between microstructure and tensile properties of V and B added Al-

7Si alloy
.
85064066169&doi=10.1007%2f978-3-030-06034-
3_30&partnerID=40&md5=5227eeb04a905e03be6555794f92f697
ABSTRACT: It is known that vanadium and boron elements are used as grain
refiners. In this study, it was aimed to increase the mechanical properties
of A356 by grain refinement. Boron and vanadium elements were added in an
amount of 0.05 wt% and 0.1 wt%. Al–10 V and Al–3B master alloys were used.
The melts were casted into sand and permanent molds at 730 °C. The cast
samples were investigated by several tests: Metallographic examination for
microstructure and porosity measurements, tensile tests, and hardness tests
for mechanical property characterization. Additionally, bifilm index was
examined by reduced pressure test (RPT). The effect of alloying elements on
the distribution, size, and shape of porosities has been determined.
Weibull analysis was used. In both V and B additions, sand castings with
larger grain size revealed higher and more reliable tensile values than
permanent castings. © The Minerals, Metals & Materials Society 2019.
Self-healing Al 6061 alloy reinforced with low melting point alloys

.
85065411439&doi=10.1007%2f978-981-13-6412-
9_53&partnerID=40&md5=6cdfe4325d1adf8f6f2556050051774e
ABSTRACT: Self-healing materials can recover/repair damage automatically
and autonomously with or without the external intervention. In recent
times, many researchers have developed competitive technologies to achieve
self-healing properties of materials. This paper presents a methodology to
develop self-healing concept in metal matrix composite. Aluminium 6061 has
been utilized as the base metal, and a low melting point metal filled into
it to develop samples using the injection moulding method. Sand casting has
also been used to cast the required sample of Al 6061. To demonstrate self-
healing behaviour in the developed composite, an artificial crack developed
in the sample using a lathe and drill machines. It has been observed that
the low melting point alloy gets filled in the crack with heat. This shows
the partially self-healing behaviour of composite. SEM and microstructural
test has been performed to find out the topological and morphological
characteristics of the matrix. © Springer Nature Singapore Pte Ltd. 2019.
An analysis of brass casting parameter process using sand casting mold [Un
análisis del proceso de parámetros de fundición de latón utilizando molde
de arena]
.
85071386446&partnerID=40&md5=bbd9129f34d6c5dd1470fde107f7f6f5
ABSTRACT: This research tried to analyze the existing casting process of
ganto recycled brass by varying the liquid pressure parameters of different
induction metals, followed by the pouring of liquid metal into the mold.
The method used in this research was descriptive qualitative with aesthetic
analysis. As a result, metal casting can be defined as the process of
molten metal, poured into a mold, then allowed to be cool and freeze. In
conclusion, Ganto is one of the objects of brass casting that continues to
produce the brass handicrafts in Jorong Kapalo Koto, especially the
production center of Zikri ganto. © 2019, Universidad del Zulia. All rights
reserved.
Experimental investigation in order to determine deviation of dimensions of

the sand casting moulds, which were printed with the help of the additive
devices, from the 3D-model depending on the drop dimension of the binding
agent, as well as depending on the granulometric composition of sand
.
85065147180&partnerID=40&md5=8e4af0be1a3348a70a3bfc888774167a
ABSTRACT: In our article we pursued the following goal: experimental
investigation in order to determine the dependence of the geometrical
accuracy of the casting mould, which is obtained with the help of the 3D-
printer in accordance with the "Binder jetting" method, upon the
granulometric composition of the used material, as well as upon the drop
dimension of the binding agent. We have manufactured special reference
models, which had certain geometrical characteristics and which required
proper investigation. These samples were printed on the basis of
utilisation of various sands (as concerns their granulometric composition),
as well as on the basis of utilisation of various dimensions of drops of
the introduced binding agent. We have performed measurements of the
manufactured samples. Results of these measurements are presented in
tabular form and in the graph form. The article presents results of
measurements of the details, which were manufactured in accordance with the
"Binder jetting" technology on the basis of utilisation of various
dimensions of drops of the binding agent, as well as various sand grades.
It was demonstrated that increase in the drop dimension, as well as
increase in the dimensions of the powder particles result in the increase
in the dimensional accuracy. Accuracy of the details, which were printed
along the X-axis, differs from accuracy of the samples, which were oriented
along the Y-axis. It was also demonstrated that various accuracy along
various axes is caused by the asymmetric distribution of drops of the
binding agent, while this asymmetric distribution is caused by the
technological characteristics of the manufacturing plant. In addition, it
was demonstrated that it is possible to increase accuracy of the
manufactured products at the certain combination of the printing parameters
(even in the case of increase in dimensions of the powder particles).
Constraints of the investigation are as follows: scope of this
investigation is limited by the specific materials and by equipment.
Practical consequences of this investigation are as follows: the data,
which we have obtained, can be used in the course of designing of the
casting moulds, which will be manufactured in accordance with the method of
the layered synthesis with the help of the 3D-printers. © 2019, Institute
of Advanced Scientific Research, Inc. All rights reserved.
Effects of Gd/Y Ratio on the Microstructures and Mechanical Properties of

Cast Mg–Gd–Y–Zr Alloys
.
85064646482&doi=10.1007%2f978-3-030-05789-
3_9&partnerID=40&md5=0e21c03f460124b29ddd6cd5264e5201
ABSTRACT: Three Mg–xGd–yY–0.5Zr (x + y=13, wt%) alloys were prepared by
sand casting to investigate the effects of Gd/Y ratio on the
microstructures and mechanical properties. The results show that Gd/Y ratio
had little influence on the grain size and the phase constitution of the
microstructures. However, the volume fraction of the second phase Mg24(Gd,
Y)5 in as-cast state increased, while that of the cubic phase (Y, Gd)H2 in
as-solutionized state almost unchanged with the decrease of Gd/Y ratio. The
uniaxial tension tests of the three alloys show that for both as-
solutionized and as-aged states, the yield strength was slightly increased
but the ductility was apparently decreased with the decrease of Gd/Y ratio
from 3.33 to 1.17. It was thought that Gd and Y atoms in Mg matrix have
approximate solute strengthening effect but different adverse effect on
ductility, which should be responsible for the mechanical properties
difference for the three alloys. © 2019, The Minerals, Metals & Materials
Society.
Insight to the potentials of sentinel-1 SAR data for embankment breach

assessment
.
85049777553&doi=10.1007%2f978-3-319-77276-
9_4&partnerID=40&md5=45ea22447b21fa5be4943358a883a939
ABSTRACT: Embankment breaching is one of the serious issues on the
innumerous streams of the Brahmaputra floodplains during the monsoon
season, which extends from May to October, leading to major agricultural
damages by inundation and sand casting. These floodplains are highly
fertile areas supporting a dense population largely dependent on
agriculture for livelihood. Therefore, continuous monitoring and management
is required so that the annual loss due to embankment breaching can be
minimized. Traditional on-site methods are laborious and time consuming.
The use of Synthetic Aperture Radar (SAR) data for this application is
recommended instead of commonly used optical remote sensing data due to its
all-weather capability and high sensitivity towards dielectric constant.
This study analyses the potentials of C-band dual polarized (VV + VH) SAR
data for embankment monitoring and breach assessment such as identification
of breach locations, length of breach and area affected due to inundation
after occurrence of breach. For the purpose of study, Solengi river, a
north bank tributary of the Brahmaputra in Assam is used as a case study.
Temporal Sentinel-1 data are continuously analyzed to monitor critical
points of embankments and develop a suitable methodology to operationalize
embankment breach monitoring. The initial analysis shows encouraging
results. This methodology, if successful, may be helpful to automate the
process of monitoring embankment breaches enabling better decision making.
© 2019, Springer International Publishing AG, part of Springer Nature.
Use of arc plasma in metal casting as a new approach towards energy

efficient manufacturing
.
85063262913&doi=10.5937%2ffmet1901036C&partnerID=40&md5=7f10306557fc4804ef8
26792664d00a5
ABSTRACT: Foundries constitute a segment that influences the supply chain
of a several industrial segments by defining the quality and cost of
manufacturing metallic primary products. Within this context, the
encouragement of seeking for energy efficient processes is extremely
encouraged, also to minimize the environmental collateral damage inferred
by foundries. The present article explains and demonstrates the elaboration
of a mechanism to compensate the temperature drop of the poured cast iron
by pre-heating the cast iron pouring channel with the heat transfer from an
arc plasma source placed above it. Besides requiring less energy to heat
the post-poured molten metal, which impact has been measure after one year
of operation of this innovative solution, it was possible to improve the
metallurgical quality of the cast alloys and reduce defects thanks to a
more accurate control of the molten metal temperature. The result obtained
regard the design and implementation of a pioneer solution of heater inside
a conventional sand casting foundry. © 2019, Faculty of Mechanical
Engineering, Belgrade.
Ливнице представљају сегмент који утиче на ланац снабдевања неколико
индустријских сегмената дефинисањем квалитета и трошкова производње
металних примарних производа. У том контексту, охрабрује потицање потражње
за енергетски ефикасним процесима изузетно је подстакнуто, а такође и
минимизирати колатерална штета животне средине која произилази из ливница.
Овај чланак објашњава и демонстрира израду механизма за надокнађивање
падова температуре ливеног гвожђа сагревањем предгријевањем канала за
ливење ливених гвожђа са преносом топлоте из извора пламенског лука
постављеног изнад њега. Осим што захтијева мање енергије за загревање
постољег стаљеног метала, чији је утјецај након једне године рада овог
иновативног рјешења, могуćе је побољшати металуршки квалитет ливених легура
и смањити недостатке захваљујуćи прецизнијој контроли температура
растопљеног метала. Добијени резултати односе се на дизајн и имплементацију
пионирског раствора грејача унутар конвенционалног ливијара за ливење
пијеска.
Numerical process modelling and simulation of campbell running systems

designs
.
85064063161&doi=10.1007%2f978-3-030-06034-
3_5&partnerID=40&md5=2db9f3502f48beff33e3639a237921c2
ABSTRACT: In the 1980s, John Campbell developed a new casting process from
his research in the industry over a number of years. The Cosworth process
was for delivering very high-quality aluminium components for the
automotive industry. The process was very capital-intensive and not very
flexible for smaller companies delivering lower volumes of product.
However, the principles behind the process have been taken and used to
develop a range of different so-called running systems to help improve the
quality of castings. Some of these designs have been published in ‘Castings
Handbook’ [1] authored by Campbell. This paper presents the results of an
MSc project during which a number of the proposed designs from Campbell’s
Mini Casting Handbook [2] for certain features in running systems have been
modelled using a validated CFD software. © The Minerals, Metals & Materials
Society 2019.
A computational framework towards energy efficient casting processes

.
85059074979&doi=10.1007%2f978-3-030-04290-
5_27&partnerID=40&md5=21dab3bfbde1dde61b6e4b25805e2a3c
ABSTRACT: Casting is one of the most widely used, challenging and energy
intensive manufacturing processes. Due to the complex engineering problems
associated with casting, foundry engineers are mainly concerned with the
quality of the final casting component. Consequently, energy efficiency is
often disregarded and huge amounts of energy are wasted in favor of high
quality casting parts. In this paper, a novel computational framework for
the constrained minimization of the pouring temperature is presented and
applied on the Constrained Rapid Induction Melting Single Shot Up-Casting
(CRIMSON) process. Minimizing the value of the pouring temperature can lead
to significant energy savings during the melting and holding processes as
well as to higher yield rate due to the resulting reduction of the
solidification time. Moreover, a multi-objective optimization component has
been integrated into our scheme to assist decision makers with estimating
the trade-off between process parameters. © Springer Nature Switzerland AG
2019.
Characterization of microstructure and shrinkage porosity of a semi-solid

metal slurry in gravity die casting
.
%2fSSP.285.161&partnerID=40&md5=a67ca19c5d9d1cc7983494328baddf99
ABSTRACT: Current aluminum automotive parts such as wheels, engine and
transmission components are produced by tilted gravity die casting for
control gas porosity. But, there are still problems resulting in
inefficient production: shrinkage porosity, microstructure size and
uniformity. Shrinkage porosity is one of the major issues which affects
mechanical properties such as strength and elongation in tilted pour
permanent mold. Recent work using slurry casting technique has shown
potential in gravity sand casting. Results show that the casting parts have
complete filling at low solid fractions and the casting yield is also
higher than conventional gravity sand casting. This paper extends important
work for potential industrial applications in gravity die casting:
microstructure size, uniformity, solid fraction control for micro shrinkage
level. © 2019 Trans Tech Publications, Switzerland.
Market valuation of the patent “mould for centrifugal end shaped castings
from refractory and chemically active alloys”
.
85078594796&doi=10.17580%2ftsm.2019.12.01&partnerID=40&md5=d2142407e6784d75
b8f232b32fc1c72d
ABSTRACT: This paper examines a manufacturing technology behind graphite
moulds designed for casting refractory and chemically active alloys
following the patent of the Russian Federation No. 2585604 “Mould for
centrifugal end shaped castings from refractory and chemically active
alloys”. The paper substantiates the possibility to implement this patented
technology and compares investment casting and green sand casting in
application to small-scale (single-part) manufacturing. A case study of a
cast central bushing made of the titanium alloy VT20L is considered. A
feasibility study has been prepared to justify the application of green
sand casting. A market analysis has been conducted and potential customers
for the patented process have been identified. The authors substantiate the
feasibility of using green sand casting to produce graphite moulds for
small-scale or single-part casting of refractory and chemically active
alloys, and perform a market valuation of the patent in view. A set of
necessary equipment has been selected to implement the production of
graphite moulds to match the employed process. A feasibility study has been
carried out to justify the production of graphite moulds for casting
refractory and chemically active alloys (per 2017 data). Thus, the required
capital investment and production cost have been estimated. The authors
also estimated a payback period, cost effectiveness and a market value of
the process (patent cost). This project was implemented under the Decree of
the Government of the Russian Federation No. 218.3 dated 9 April 2010,
State Contract No. 02.G25.31.0009. © 2019, "Ore and Metals" Publishing
house. All rights reserved.
Optimization of essential parameters in green sand process to minimize

persisting casting defects using taguchi approach
.
85076309734&doi=10.25103%2fjestr.125.15&partnerID=40&md5=206c0143c542d54280
19d54ba46b43f0
ABSTRACT: The main objective of the work presented in this paper is the
identification of most influential parameters of green sand casting process
that is responsible for the occurrences of the defects which are persisting
in complex gray iron components. The shrinkage porosity, blowholes, sand
inclusion and low hardness are the defects which are persisting in cylinder
head castings produced in gray iron by a green sand casting process. In
pursuing for the identification of most influential parameters for
respective defects, Taguchi's approach to parameter design is proposed. In
the first stage of the study, 19 potential parameters associated with
principal operations are selected and experiments are performed as per the
plan given by the suitable Taguchi array, L36 OA. In the second stage
optimal levels of the parameters are determined from the signal-to-noise
ratio calculations. Analysis of variance (ANOVA) is subsequently performed
to identify most influential parameters. Confirmation run of experiments is
performed with optimal settings of parameters to verify the results.
Outcome of confirmation experiments indicated that persisting defects in
cylinder head castings produced by a green sand process are sufficiently
reduced. © 2019 School of Science, IHU. All rights reserved.
Applications of Ceramic Sand in Shell Process [宝珠砂在壳型铸造工艺中的应用]

.
85064979326&doi=10.15980%2fj.tzzz.2019.01.017&partnerID=40&md5=19963179570a
9b11dad7df3f33e59821
ABSTRACT: Ceramic sand was used widely in resin sand casting as the
features of spherical grain shape, higher refractoriness, inert chemical
property, high strength and higher reuse rate. Subsequently, shell
investment casting with ceramic sand was used gradually. Now, ceramic sand
shell casting was used widely to produce cast iron and cast steel and so
on, which can partially replace investment casting. The dimensional
precision of the castings can reach CT7~CT6 with surface roughness of 12.5
μm, greatly improving the product yield and casting quality as well as
greatly decreasing casting cost and exhaustion of scrap. © 2019, Journal
Office of Special Casting and Nonferrous Alloys. All right reserved.
Inverse methodology for estimating the heat transfer coefficient in a

duplex stainless steel casting
.
85060208326&doi=10.1007%2f978-3-030-02257-
0_5&partnerID=40&md5=3aafce681e5fa18930a68262a64113e0
ABSTRACT: In sand casting of metallic alloys, the cooling rate is a key
parameter that affects the microstructure and the appearance of defects and
residual stresses in the end cast components. In this work, a numerical
model was developed to simulate the cooling of a duplex stainless steel
casting on a furan-bonded sand mold. The heat transfer coefficient (HTC) as
a function of temperature was determined by an inverse method. A good
agreement between experimental and numerical cooling curves was achieved,
showing the importance of estimating HTC as a function of temperature. On
the basis of these results, it is possible to calculate thermal residual
stresses and model the microstructure of duplex stainless steel castings
with complex geometries. © Springer Nature Switzerland AG 2019.
Influence of Copper Chills and Pouring Temperature on Mechanical Properties

of LM6 Castings
.
85052947017&doi=10.1007%2f978-981-13-1780-
4_21&partnerID=40&md5=352bd1c564961d95107f36d20444eb10
ABSTRACT: Aluminum silicon alloy castings are highly used in automobile
industries due to their excellent casting and machining ability, corrosion
resistance and high strength-to-weight ratio. The mechanical properties of
aluminum–silicon LM6 alloy are mostly dependent on solidification and
casting parameters. This paper presents an experimental investigation made
on aluminum–silicon (Al–Si) cast LM6 alloy using sand casting process. The
main objective of the research is to investigate the effect of chill
thickness and pouring temperature on LM6 sand castings. The casting
parameters such as pouring temperature and external copper chills are
considered for the experimental work. The simulation work has been carried
out with AutoCast-X1 software for obtaining appropriate design parameters.
The experimental work has been carried out in the foundry. The pouring
temperatures 730, 750 and 770 °C are considered for experiments along with
varying chill thickness. The use of end chills during casting not only
favors directional solidification but also enhances solidification. Rapid
cooling rate helps to get finer structures and improved mechanical
properties. In this work, an attempt has been made to obtain the better
cooling rate of LM6 castings using copper chills. The mechanical properties
such as hardness and ultimate tensile strength (UTS) are analyzed. It is
seen that the external chill has a significant influence on the properties
of the casting components. The design of experiment has been set up and
experiments were conducted as per full factorial array. Castings are made
under the constraint of the process and methodical parameters at three
different levels. The mathematical models of UTS and hardness have been
developed. The micrographs of microstructure of castings with and without
applications of copper chills have been compared using optical microscopy.
The better mechanical properties such as UTS and hardness were obtained by
proper combination of pouring temperature and application of external
copper chills. © 2019, Springer Nature Singapore Pte Ltd.
Aluminum alloy with high Mg content: Casting studies for microstructural

evolution, phase formation and thermophysical properties with different
alloying elements
.
85064066029&doi=10.1007%2f978-3-030-06034-
3_33&partnerID=40&md5=a40f18ea0ffec2e81d94e293e11112a4
ABSTRACT: Global strategy for material science in the automotive industry
is to use the lightweight material. In the present work, the casting of
aluminum alloy with high magnesium content has been performed with the
addition of B, Sr, Ti and Zr. Gravity sand casting and permanent mold
casting methods were used. Microstructural evolution has been studied along
with phase formations during solidification. Microstructural changes of
each alloying element have been observed via optical and SEM microscopy.
XRD analysis has been done for evaluation of phase formations. TGA analysis
has been done to evaluate thermos physical properties. The reduced pressure
test was carried out to quantify melt cleanliness and bi-film content.
Indentation tests were carried out, and a linear relationship was found
between mechanical test results and bi-film index. © The Minerals, Metals &
Materials Society 2019.
Selection of aluminum alloy for casting defectless thermoforming molds

using green sand foundry technology- An experimental approach
.
85060205652&doi=10.7449%2f2018%2fMST_2018_1132_1139&partnerID=40&md5=394e91
35c2e9b9f23f46867cb9b31452
ABSTRACT: Vacuum foaming and thermoforming molds have been used worldwide.
The quality of thousands of products depends on the surface finish of the
cast and machined molds. Also the cost and time required to make individual
molds affects the manufacturing line badly. Various aluminum casting alloys
exist for making the molds, and a successful choice adds value to the mold
versus diminishing the mold properties. Common aluminum casting alloys like
A356, A295, EN AB 21000, EN AC 46600, ADC12 etc. have been used
experimentally for few years and their properties have been observed for
defectless casting. It has been found that some alloys provide sound and
defectless casting but their property deteriorate during application. A356
alloy was found to create shrinkage defects at junction points although the
gating design was completed by simulation software. EN AC 46600 alloy is
found to contain porosity, blowholes and shrinkage. One alloy stands out,
A295 and has been selected in terms of defectless casting and post
machining applications. Copyright © 2018 MS&T18®
Automobile Parts Casting-Methods and Materials Used: A Review

.
85085561330&doi=10.1016%2fj.matpr.2020.03.381&partnerID=40&md5=acf642714405
9e68e88451e95697822e
ABSTRACT: Automobiles are becoming more and more sophisticated with every
passing year. Manufacturers have been trying their best to bring down the
kerb weight of their automobiles by using various materials with high
strength to weight ratio. The different parts of the automobile are being
made much stronger than before in order to comply with the high standards
set by NCAP. Hence, this pushes automobile makers to come up with new and
innovative methods to manufacture the parts of their automobiles. Our paper
addresses the various casting processes used to make automobile parts and
also touches on the various materials used to make the components. The
casting methods discussed are-Green sand casting, Centrifugal casting,
Lost-foam casting, Die casting and Squeeze casting. In the paper we discuss
about the most suited materials used for each component and briefly discuss
about the pros and cons of each process © 2019 Elsevier Ltd.
Effect of Casting Temperature on the Surface Finish of Grey Iron Castings

.
85064768814&doi=10.1007%2f978-3-030-05728-
2_8&partnerID=40&md5=37df0605670b3cf25467adc57ac71294
ABSTRACT: One of the most common surface defects in sand casting of grey
cast iron is caused by metal penetration into the sand mould. Metal
penetration is a surface condition in which metal or metal oxides have
filled the voids between sand grains to various depth without displacing
them, thus yielding a phase of sand grains surrounded by metal and
frequently by mould–metal reaction products. The penetration is often so
severe that casting components are beyond the point of economical rework
and must be scrapped. This experimental work has focused on reducing metal
penetration on casting component on a production scale. The casting
component produced has strongly affected by sand sintering metal
penetration. A series of simulations were performed with the casting
simulation program MagmaSoft® in order to investigate the solidification
characteristics as well as the porosity formation in the casting component.
© 2019, The Minerals, Metals & Materials Society.
A Comprehensive Review on Manufacturing Methods and Characterization of

Al6061 Composites
.
85085583066&doi=10.1016%2fj.matpr.2020.03.390&partnerID=40&md5=e54f4a616f17
0c64043070f129e3a2a6
ABSTRACT: Now a days the world moves from monolithic materials to composite
materials due to its good properties and low cost. In particular, these
composites are used in aerospace, automobile and transportation application
because of high strength to weight ratio, good wear and corrosion
resistance and better damping properties etc. Among various metal matrix
composites, aluminium based composites (Al6061) are used for such
applications. These composites are manufactured by using various
manufacturing techniques such as sand casting, stir casting, squeeze
casting and friction stir welding. Moreover, these composites are prepared
by reinforcing it with ceramic particles, hard metals and natural particles
to enhance its properties and also to suit for various engineering
applications. Hence, a complete understanding of the above is very much
essential for selecting appropriate composites for various applications and
also to prepare new composites with enhanced behavior. This paper reports
the various manufacturing techniques used for the preparation of Al6061
composites, reinforcements used and its various characterization studies ©
2019 Elsevier Ltd.
Experiemental studies on optimization of molding sand composition with

tamarind kernel powder as additive
.
85069499678&doi=10.24247%2fijmperdjun2019102&partnerID=40&md5=390131a75e8c4
bf0f6fcaff65365bb35
ABSTRACT: Among all the manufacturing processes, sand casting process still
remains as one of the most complex process as it involves heat transfer,
fluid flow and so many other things. As the properties of the green sand
mix influence the casting defects, the parameters affecting these
properties should be identified and controlled precisely. Since,
Traditional method of trial-and-error based methods have many disadvantages
such as being nonsystematic, time consuming, error-prone and requirement
for long durations of experimentation [1], statistical techniques are to be
employed. The process parameters that are being varied are clay, water and
additive. L-9 orthogonal array is used for experimental design and S/N
ratio, and ANOVA are employed to find the optimal process parameter levels
and to analyze the effect of these parameters on green compression
strength, green shear strength, dry compression strength, dry shear
strength, and permeability. Confirmation test with the optimal levels of
machining parameters was carried out. © TJPRC Pvt. Ltd.
An analysis of casting defects and quality improvement using QC tools

.
85063397242&partnerID=40&md5=35cd91e81cabc37be0ada6a84dd9abc8
ABSTRACT: Foundry industry is affected by poor quality and lower
productivity due to several factors such as process parameters, unskilled
labour and lack of automation. A variety of casting defects can be expected
to occur if the casting process is not properly controlled. The various
defects occurred are blowholes, shrinkage, sand drop, dent, etc.
Segregation of casting defects, according to their sources can provide a
viable solution in identifying the root causes. In our case study, a
foundry industry was taken into consideration to study the quality of sand
casting process and also analyse the root cause of the quality losses that
is due to the defects. It was identified through brainstorming that blow-
hole is the major problem that occurs frequently and affects the quality
level of the production process. The recommended action was taken by
reducing the pouring time and change in temperature. With the help of QC
tools, the defect percentage was reduced from 5.66 % to 2.5%. © TJPRC Pvt.
Ltd.
Correlation between microstructural characteristics and static and dynamic

mechanical properties in aluminum casting alloys [Correlazione fra
caratteristiche microstrutturali e proprietà meccaniche statiche e
dinamiche nelle leghe di alluminio da fonderia]
.
85065839215&partnerID=40&md5=a30618fd2eda0055a5e4199b4ebf87ab
ABSTRACT: In this paper a failure is discussed, occurred in the early
stages of the development of a new aluminum engine block, in AlSi7CuMg T7
alloy, obtained by sand casting process. To determine the root cause of the
failure, non-destructive X-Ray analysis was performed, which did not show
anything anomalous in terms of macro-porosity in the area around the crack.
Also microstructural analysis was carried out, which showed a high
percentage (equal to 1.1% on average) of microporosity, spread throughout
the breaking zone, with about 450 μm maximum dimensions of porosity, a
rather large value, even if still acceptable at a nondestructive X-Ray
test. These values were very high, even considering the type of casting
process used to obtain this component. On the basis of the results of the
microstructural analysis, modifications and optimizations of the casting
process were introduced, which allowed to improve the mechanical
characteristics in the critical areas. At the same time, acceptance limits
for microporosity percentage, not previously considered, were introduced in
the drawing. © 2019 Associazione Italiana di Metallurgia. All rights
reserved.
The effects of solidification cooling rates on the mechanical properties of

an aluminum inline-6 engine block
.
85064879234&doi=10.1007%2f978-3-030-05864-
7_65&partnerID=40&md5=89efdbb75c87105f4c4df2b73a8e74fe
ABSTRACT: A shift from ferrous to aluminum alloys for use in automotive
engine blocks has significantly reduced the weight of vehicles and has
consequently improved fuel economy while reducing harmful emissions. During
the casting process of aluminum engine blocks, chilling devices are
typically incorporated into the sand castings for faster cooling and to
allow for a more uniform cooling rate. The effects that chills have on the
alloys microstructure (i.e. size, morphology and SDAS) and mechanical
properties have been studied in this paper. This study characterizes the
microstructure throughout a modified 319 type aluminum inline-six engine
block using scanning electron microscopy, energy dispersive spectroscopy
and X-ray diffraction. In addition, mechanical testing (i.e. uniaxial
tensile testing) have been performed at various depths along the cylinder
web to determine the effects that varying microstructure has on the
mechanical properties of the alloy. The results from this study indicate
that the minor variation in cooling rates led to a fine and relatively
uniform microstructure; resulting in the observation of similar mechanical
properties throughout the entire cylinder bridge. © 2019, The Minerals,
Metals & Materials Society.
Optimization of hardness and wear parameters of Al-Cu-Si alloy using design

of experiments
.
85085568850&doi=10.1016%2fj.matpr.2020.03.401&partnerID=40&md5=8aa848b6914a
8e5ad9883b436f17da49
ABSTRACT: Aluminium-Copper-Silicon (Al-Cu-Si) alloy of composition Al-
1.5Cu-0.5Si alloy was successfully fabricated by sand casting process.
Homogenization treatment was done at different temperatures to achieve
uniform distribution of elements. The hardness was measured in different
regions (outer, middle and inner) and the peak hardness of the alloy was
obtained at 425 °C homogenization temperature in the outer region because
of low solidification time at that region. L9 Orthogonal array was used to
conduct the experiments and optimize the process parameters in the three
regions for Specific Wear Rate (SWR) and the influencing parameters such as
load, speed, homogenization temperature and sliding time were analyzed
using Taguchi techniques. From the Analysis of variance (ANOVA), it was
observed that for outer region, the sliding speed has the major effect on
SWR followed by load, sliding time and homogenization temperature. In case
of middle and inner regions, the influence of load on SWR was significant
followed by sliding speed. The confirmation test was carried with obtained
optimal process parameter. The surfaces wear mechanism behind Al-1.5Cu-
0.5Si was analysed using scanning electron microscope (SEM) image © 2019
Elsevier Ltd.
Plasma nitriding process of cast camshaft to improve wear resistance
.
85071199223&doi=10.12693%2fAPhysPolA.135.793&partnerID=40&md5=c4152292bcb9a
56ba218f2461930bf8f
ABSTRACT: The aim of this study was to investigate the effect of plasma
nitriding heat treatment on the microstructure, hardness and abrasion
resistance of the GG25 grade gray cast iron camshaft. For this purpose, in
the first stage, casting simulation was carried out by using NOVACAST
computer software program of GG25 grade gray cast iron camshaft to optimize
casting quality and production of camshaft with sand casting method.
Casting process was performed between at 1410–1420◦C and casting time was
between 14-16 s. Plasma nitriding was carried out for 120 minutes and 240
minutes for cast gray iron camshafts for each gas mixture at gas mixture
ratios of 80% H2 + 20% N2, 90% H2 + 10% N2, 94% H2 + 6% N2 at 500◦C. Plasma
nitrided camshafts were subjected to optical microscopy, SEM, XRD analyzes
and mechanical tests (hardness and wear). For the cas iron camshaft made
from GG25 grade, the optimum hardness (583 HV0.1) and the wear resistance
(1.90 mg/500 cycles), were obtained from the diffusion layer depth (603 µm)
and the white layer thickness (10 µm) reached 240 min. plasma nitriding of
the 94% H2 + 6% N2 gas mixture. © 2019 Polish Academy of Sciences. All
rights reserved.
Bespoke Cast Facade Design and Additive Manufacturing for Cast Aluminum
Facade Elements
.
85085727048&partnerID=40&md5=1274ecbc0ae746b9116ca0021102a863
ABSTRACT: This paper presents a computational design approach and a digital
fabrication method for a freeform aluminum facade made of prefabricated
bespoke elements. The fabrication of customized metal elements for
construction remains a challenge to this day. Traditional fabrication
methods, such as sand casting, are labor intensive, while direct metal 3D
printing has limitations for architecture where large-scale elements are
needed. Our research investigates the use of Binder Jetting technology to
3D print sand molds for casting bespoke facade elements in aluminum. Using
this approach, custom facade elements can be economically fabricated in a
short time. By automating the generation of mold design for each element,
an efficient digital process chain from design to fabrication was
established. In search of a computational method to integrate casting
constraints into the form generation and the design process, a differential
growth algorithm was used. The application of this fabrication method (3D
printed sand molds and casting) in architecture is demonstrated via the
design and fabrication of a freeform facade-screen. The paper articulates
the relationship between the fabrication process and the differential
growth algorithm with a parallel process of adaptive design tools and
fabrication tests to exhibit future potential of the method for
architectural practice. © Ubiquity and Autonomy - Paper Proceedings of the
39th Annual Conference of the Association for Computer Aided Design in
Architecture, ACADIA 2019. All rights reserved.
Hot forming of cast steel cylinders

.
85079363676&partnerID=40&md5=744a08263694529f428b6a22cf6e7804
ABSTRACT: Regarding tool wear and energy consumption when forging steel
parts, tailored preform geometries are beneficial. In particular, the
number of forging steps can be reduced, in comparison to conventionally
rolled cylindrical stock material, if preformed billets are used. In order
to assess the potential offered by cast preforms as semi-finished products
for a subsequent forging process, cylindrical steel billets (G42CrMo4) were
cast by sand casting and then upset with different degrees of deformation φ
(0.7-1.5), forging temperature (600-1200 °C) and ram speed (30-700 mm/s).
Forging of conventional rolled bar material under the same forming
conditions was used as a reference. After forming, the specimens were heat
treated and the mechanical properties were determined by tensile tests (DIN
EN ISO 6892-1) and notch impact tests (similar to DIN EN ISO 148-1). The
microstructures were examined by metallographic analysis. For the
investigated process variables, no significant influences on the tensile
strengths or impact energies of the cast and forged specimens were found.
While the tensile strengths of the cast and forged specimens meet the
values of conventionally rolled and forged specimens, the impact energies
of the cast and forged specimens surpass those of the reference. This is
attributed to compressed pores, which were incompletely closed during
forging. A criterion for the design of a die forging process of cast
preforms will be derived based on the obtained results. © 2019 TANGER Ltd.,
Ostrava.
Experimental investigation of wear behaviour of A356-TiB2 metal matrix

composites
.
85069519791&doi=10.24247%2fijmperdjun2019141&partnerID=40&md5=b507fc3949a65
66c13a1bcffe9fa0c0f
ABSTRACT: Aluminium-Silicon (Al-Si) alloys have attractive physical and
mechanical properties. They are light weight (app. 3x lighter than gray
cast iron and steel), low cost of production (with sand casting
technology), easy to machine and have satisfactory mechanical properties
with good recycling possibilities (up to 95 %). Nevertheless, one of the
major drawbacks of these alloys is their low wear resistance. In order to
improve its wear characteristic many Particle reinforced Aluminium Matrix
Composites (PAMCs) were developed using SiC, TiC, B4C, TiB2, Gr, MoS2, and
fly ash as reinforcement particles by different methods (Stir casting,
Compo casting, Powder Metallurgy, in-situ method using salts and spray
deposition) and their wear characteristics were also studied But there is
no research work done on wear characteristics of semisolid processed PAMCs.
So a MMC of aluminium A356 reinforced with 5%TiB2 was developed by semi
solid process and its dry sliding wear characteristic were studied using
pin on disc machine with disc material of EN31 steel (55-60 HRC) under the
condition at sliding velocity varies from 1m/s to 3m/s and applied load
varies from 10N to 30N at constant sliding distance 3000m. A comparative
study was done between A356 alloy, A356-5%TiB2 in-situ composite and
Semisolid processed alloy, composite it was found that semisolid processed
alloy and composite shows more wear than commercial alloy and in-situ
composite. © TJPRC Pvt. Ltd.
Evaluation of castings surface quality made in 3D printed sand moulds using

3DP technology
.
85066122653&doi=10.1007%2f978-3-030-16943-
5_18&partnerID=40&md5=6815a1aa40c5169f7c727afc9ed086d7
ABSTRACT: The article presents the process of making castings in sand
moulds printed in 3DP technology. The moulds were printed using sands of
different graininess – quartz sand FS001 and FS003 of the grain size of
0.28 mm and 0.38 mm, respectively, and synthetic moulding sand FS053, used
in the production of cores of low thermal expansion. In total, four series
of prints were made, with five moulds in each series. Four types of binder
were used: FURAN – a standard binder used in traditional sand casting
methods, which does not require baking process, PHENOL – a binder with high
heat resistance, ANORGANIK – an inorganic eco-friendly binder, and CHP - a
cold-cured phenol. The objective of the research was to assess the casting
surface for different combinations of sands and binders. The following
alloys were selected for the tests: AlSi 11 aluminum alloy, CuSn10P copper
alloy, GJL 250 cast iron and X 5 Cr Ni 18-10 cast steel. The moulds were
poured with the alloys and cleaned. Surface roughness tests of castings
were executed using the contact method on the Hommel-Etamic T8000 RC
profilometer. The results are presented in graphs and summarized in the
tabular form. Based on an analysis of the results, it can be concluded that
the type of binder and size of sand grains used in the printed moulds have
a significant impact on the surface roughness of individual casting alloys.
© Springer Nature Switzerland AG 2019.
Novel sprue designs in metal casting via 3D sand-printing

.
85058708229&doi=10.1016%2fj.addma.2018.12.009&partnerID=40&md5=a11227c13edb
c9a49e20fa6d9348ad68
ABSTRACT: The opportunity to improve the quality of metal castings by
enabling fabrication of complex gating systems via 3D Sand-Printing (3DSP)
has been recently established. Among the different components of a gating
system (often called rigging), sprue design offers a major opportunity to
exploit the unlimited geometric freedom offered by 3DSP process. In this
study, conventional principles of casting hydrodynamics is advanced by
validated novel numerical models for novel sprue designs to improve melt
flow control. Computational flow simulations demonstrate that conical-helix
sprue satisfy the critical velocity condition by reducing the ingate
velocity below 0.5 m/s. Multiple approaches to integrate 3DSP into
conventional manufacturing to fabricate complex gating systems through
“Hybrid Molding” are presented. 3DSP molds featuring two optimized sprue
profiles and a benchmark straight sprue are fabricated to pour 17-4
stainless steel. Computed tomography scans (CT) shows that parabolic sprue
casting (PSC) and conical-helix sprue casting (CHSC) reduced overall
casting defects by 56% and 99.5% respectively when compared to straight
sprue casting (SSC). Scanning electron microscopy (SEM) analysis confirms
the presence of globular oxide inclusions and that PSC and CHSC exhibits
21% and 35% reduced inclusion when compared to the SSC. Three point
flexural testing reveals that CHSC and PSC exhibits an increase of 8.4% and
4.1% respectively in average ultimate flexural strength than SSC. The
findings from this study demonstrate that numerically optimized gating
systems that can only be fabricated via 3DSP have the potential to
significantly improve both mechanical and metallurgical performance of sand
castings. © 2018 The Authors
On the additive manufacturing of an energy storage device from recycled

material
.
85052636636&doi=10.1016%2fj.compositesb.2018.08.080&partnerID=40&md5=69595f
a5dd8384efc5ec902685231b7b
ABSTRACT: The disposal/recycling of plastic materials are one of the
biggest challenges of 21st century. Some studies have been reported in
recent past on recycling of thermoplastics via three-dimensional (3D)
printing as a novel technique under primary and secondary recycling. But
hitherto no work has been reported on use of recycled/virgin thermoplastics
for use as energy storage devices (ESD). In this paper an effort has been
made to develop in house ESD in form of dry cell by printing with low cost
fused deposition modeling (FDM) based commercial open source 3D printer.
The feed stock filament of FDM has been prepared by twin screw extrusion
(TSE) comprising of advanced composite materials (thermoplastic:
acrylonitrile butadiene styrene (ABS) matrix, reinforced with different
proportions of chemicals/salts namely: MnO2, ZnCl2, NH4Cl and graphite),
which has been used to print dry cell for energy storage applications. The
commercial dry cell consists of four zones/sections and feed stock
filaments for three zones have been prepared separately on TSE (with
different proportions of ABS and reinforcement of chemical/salts) and
fourth zone (of Zn metal) has been casted with conventional sand casting
route. Finally, all four zones have been assembled in series to develop
fully functional prototype of ESD. This study highlights that with the
proposed methodology, dry cell comprising of minimum 40% by weight recycled
thermoplastics can be prepared successfully having voltage potential at par
with commercial dry cell. Another major advantage of using this novel route
is that the ESD prepared is more thermally stable (confirmed by
differential scanning calorimetry (DSC) analysis) and can operate up to 95
°C temperature. Along with this the ESD so prepared has better rheological,
mechanical properties (tensile, surface hardness) ensuring it to be useable
under severe loading conditions. The results are also supported by
photomicrographs. © 2018 Elsevier Ltd
Comparative Analysis of Mechanical Properties and Cold Resistance of Metal

of Steel Castings from the Special Alloyed Steel
.
85060060892&doi=10.1088%2f1757-899X
%2f463%2f3%2f032061&partnerID=40&md5=ba3f27b83ff0cd5e5d02730f346f6ca8
ABSTRACT: In this paper, the experimental observation of influence of
casting conditions on steel alloy quality is presented. We studied the
casted steel samples obtained with the following methods: sand casting mold
(as a reference sample), thin-wall mold with height-adjusted ceramic layer
and forced water-air mixture cooling, same as above but with micro-cooling
channels used during liquid steel casting. We showed that the steel density
as well as typical distribution of non-metallic inclusions and mechanical
properties are dependent on casting technology been used. We present the
figures of impact toughness, crack growth energy and filamentation ratio
with respect to the test temperature. We observed that the impact toughness
of the samples is higher than for the reference one within the entire test
temperature range. In particular, the impact toughness exhibits a smooth
dependence versus temperature as opposed to its abrupt decrease for a
reference sample. We showed, that the samples obtained according to the new
technology are less fragile and have better cold resistance, similar
results were obtained after crack filamentation ratio analysis. © Published
under licence by IOP Publishing Ltd.
Microstructure and properties of 42CrMo steel ring for construction

machinery after heat treatment [工程机械用 42CrMo 钢环件热处理后的组织与性能]
.
85064317546&doi=10.13251%2fj.issn.0254-
6051.2018.12.041&partnerID=40&md5=69c26515e3955b4c356d5d40b1fa4bb5
ABSTRACT: The influence of quenching and tempering heat treatment on
microstructure evolution and mechanical properties was studied for 42CrMo
steel rings manufactured by sand casting and centrifugal casting followed
by hot rolling with different feed speeds. The results show that the
microstructure of sand cast 42CrMo steel ring is tempered sorbite after
tempering at 580 ℃ and 520 ℃, and more carbides can be precipitated in
solid solution at the same tempering temperature with higher feed speed,
and the carbide particles along the radial direction are finer, with their
precipitating positions gradually changing from the martensite lath
interface to both the lath interface and inside the lath. Compared with
sand casting steel ring, the carbides of centrifugal cast steel ring IV are
finer at the same quenching and tempering temperature, and the size of
carbide particles in outer layer, middle layer and inner layer has little
difference. The mechanical properties of sand cast steel rings are all in
accordance with the standard requirements when the tempering temperature is
520 ℃. The mechanical properties of centrifugal cast steel ring tempered
at 580 ℃ are also in accordance with standard requirements. © 2018,
Editorial Office of "Jinshu Rechuli". All right reserved.
Design and Optimization of Sand Casting Process for Aluminum Alloy Gearbox
Body [ZL101 齿轮箱箱体砂型铸造工艺优化]
.
85064159573&partnerID=40&md5=e4675c8a84b60edf0b5751ececbe30e6
ABSTRACT: Based on the structural characteristics and technical
requirements of the gearbox body, the sand casting process was chosen and
designed to produce the castings, in which the resin sand was selected as
the molding material. The filling and solidification processes of the
gearbox body were simulated by the software of View Cast, in order to
predict the location of casting defects. By analyzing the causes of defects
during the filling and solidification processes, the original casting
process scheme was optimized. Finally, for the optimized casting process
scheme, the stepped gating system was selected, the cross-sectional area
ratio of the sprue, runner and gate was set as 1:2:4. Meanwhile, the
thermal insulation riser was used and the pouring temperature was
determined to be 750℃.With the optimized casting process scheme, the
simulation and practical pouring tests were conducted, and the result shows
that there is almost no defect in the casting, which meets the actual
quality requirements of the gearbox bodies. © 2018, Chinese Mechanical
Determination of Interfacial Heat Transfer Coefficient during the Low

Pressure Sand Casting Process of Aluminum Alloy
.
85062826056&doi=10.15980%2fj.tzzz.2018.12.012&partnerID=40&md5=fce30a4ce2c1
bf7a3eb04c0a58edbcf7
ABSTRACT: Interfacial heat transfer coefficient(IHTC) between ZL114A
aluminum alloy and resin sand was obtained by a inverse heat conduction
problem (IHCP)method during the low pressure sand casting process of a
typical plate shape casting, and the relationship between IHTC and
temperature was analyzed. The results indicate that IHTC remains at an
approximately constant of 335W•m -2 •K -1 when temperature is above
liquidus value. Then the IHTC is decreased rapidly as the temperature is
inclined to 530~570℃. Finally, when the temperature is less than 530℃, the
IHTC is decreased gradually to an approximately value of 60W•m -2 •K -1 .
The empirical equation of IHTC as a function of temperature was established
by non-linear fiting. The reversely calculated IHTC was applied to the
temperature calculation of the casting with ProCAST software. The results
reveal that the calculated temperature agrees well with the experimental
temperature with the maximum deviation less than 12℃. © 2018, Journal
Office of Special Casting and Nonferrous Alloys. All right reserved.
On the Steel–Aluminum Hybrid Casting by Sand Casting

.
85056099867&doi=10.1007%2fs11665-018-3717-
8&partnerID=40&md5=02b5fa08f1baf926b30a2955348f2bbd
ABSTRACT: Hybrid casting is a well-known technology to join steel inserts
and aluminum. In order to achieve a high-performance material-based joining
between steel and aluminum, a new PVD Al-Si-(Fe) coating, which consists of
two sub-layers, has been successfully developed for high-pressure die
casting. This coating system has been investigated further in this work for
the sand casting process. By extending the sand casting process to the
plaster casting process with preheating possibilities for the coated steel
inserts, a material-based connection between steel and aluminum with a
tensile shear strength of 7.7 MPa could be created. The ductility of this
connection is decreased comparing with the connection manufactured by die
casting. SEM and EDS analysis and diffusion experiments show that the
difference of mechanical properties between plaster and die casting is
caused by the extensive diffusion and the corresponding layer growth at
plaster casting. The edge separation in plaster casting is a result of the
edge stresses due to the different thermal expansion of steel and aluminum
which can be suppressed at high-pressure die casting. To improve the
joining properties at sand casting, it is necessary to control the layer
diffusion by adding other alloy elements such as Mn into the Al-Si-(Fe)
coating layer. © 2018, ASM International.
Uphill filling system for a bar-like casting

.
85049459231&doi=10.1016%2fj.jmatprotec.2018.06.036&partnerID=40&md5=6404067
76890afa00c6ca00ef8dc80fb
ABSTRACT: Bar-like sand mould tilted angle reduced free surface
fluctuations. The primary and secondary reflected wave heights decreased
with the scaling of Re0.8 and Re0.55, respectively. These heights were
reduced by 54% and 51% when θ was increased from 0° to 5°. A larger tilted
angle was found to generate an air cavity in the cast, the size of which
was observed to vary with Reynolds number (Re). An optimised range of
tilted angle (2°–3°) was proposed as a compromise to reduce the free
surface fluctuations and maintain a perfect casting shape at the end of the
filling stage. © 2018
Manufacturing capability modeling and measurement model based on

manufacturing activity [基于制造活动的制造能力建模及其度量模型]
.
85062903400&doi=10.13196%2fj.cims.2018.12.012&partnerID=40&md5=74315d45622a
9dc67c9a2ccd727c1ceb
ABSTRACT: To solve the problem of constructing the manufacturing capability
effectively from the perspective of manufacturing activity, and to provide
the support effectively for the allocation of manufacturing capabilities in
manufacturing services, a manufacturing capability model based on
manufacturing activity was proposed. By employing manufacturing
organization and production cycle, the measurement model of manufacturing
capability based on manufacturing activity and manufacturing cycle was put
forward to study on the quantitative evaluation of manufacturing
capability. Manufacturing capability reflected the enterprise's ability to
create value to some extent, and the value-added measurement model of
manufacturing capability was presented on this basis to realize and measure
manufacturing capability quantificationally. The example of sand casting
enterprise was performed to illustrate the application of the model and
evaluation method. © 2018, Editorial Department of CIMS. All right
reserved.
Thermal decomposition characteristics of foundry sand for cast iron in

nitrogen atmosphere
.
85059680605&doi=10.1098%2frsos.181091&partnerID=40&md5=3a947e56e4bc03ae59b6
b9a07732f852
ABSTRACT: Sand casting, currently the most popular approach to the casting
production, has wide adaptability and low cost. The thermal decomposition
characteristics of foundry sand for cast iron were determined for the first
time in this study. Thermogravimetry was monitored by simultaneous thermal
analyser to find that there was no obvious oxidation or combustion reaction
in the foundry sand; the thermal decomposition degree increased as the
heating rate increased. There was an obvious endothermic peak at about 846
K due to the transition of quartz from β to α phase. A novel technique was
established to calculate the starting temperature of volatile emission in
determining the volatile release parameter of foundry sand for cast iron.
Foundry sand does not readily evaporate because its volatile content is
only about 2.68 wt% and its main components have high-temperature
stability. The thermal decomposition kinetics parameters of foundry sand,
namely activation energy and pre-exponential factor, were obtained under
kinetics theory. The activation energy of foundry sand for cast iron was
small, mainly due to the wide temperature range of thermal decomposition in
the foundry sand. © 2018 The Author(s) Published by the Royal Society.
Detection of size of manufactured sand particles based on digital image

processing
.
85058467246&doi=10.1371%2fjournal.pone.0206135&partnerID=40&md5=5d984745c60
6a09c78e0a9e4dfa47b09
ABSTRACT: The size distribution of manufactured sand particles has a
significant influence on the quality of concrete. To overcome the
shortcomings of the traditional vibration-sieving method, a manufactured
sand casting/dispersing system was developed, based on the characteristics
of the sand particle contours (as determined by backlit image acquisition)
and an extraction mechanism. Algorithms for eliminating particles from the
image that had be repeatedly captured, as well as for identifying
incomplete particles at the boundaries of the image, granular contour
segmentation, and the determination of an equivalent particle size, are
studied. The hardware and software for the image-based detection device
were developed. A particle size repeatability experiment was carried out on
the single-grade sands, grading the size fractions of the manufactured sand
over a range of 0.6–4.75 mm. A method of particle-size correction is
proposed to compensate for the difference in the results obtained by the
image-based method and those obtained by the sieving method. The
experimental results show that the maximum repeatability error of single-
grade fractions is 3.46% and the grading size fraction is 0.51%. After the
correction of the image method, the error between the grading size
fractions obtained by the two methods was reduced from 7.22%, 6.10% and 5%
to 1.47%, 1.65%, and 3.23%, respectively. The accuracy of the particle-size
detection can thus satisfy real-world measuring requirements. © 2018 Yang
et al. This is an open access article distributed under the terms of the
Creative Commons Attribution License, which permits unrestricted use,
distribution, and reproduction in any medium, provided the original author
and source are credited.
Identification, screening and optimization of significant parameters for

stir cast hybrid aluminium metal matrix composite
.
85057620841&doi=10.1016%2fj.heliyon.2018.e00988&partnerID=40&md5=77fe688721
6669b08d25f5b70f82d6c8
ABSTRACT: Different industries have explicit applications of Aluminum Metal
Matrix Composites (AMMCs). However, porosity, wettability and Ultimate
Tensile Strength (UTS) are important factors that need to consider while
fabricating AMMCs. This paper focuses on identification of the most
significant parameters for low porosity and high ultimate tensile strength
(UTS) of hybrid aluminium metal matrix composite. Significant as well as
non-significant factors were identified from the literature survey and
trial experiments. Without considering the significance of given responses,
identified factors were represented graphically by the fishbone diagram.
FMEA (Failure Mode and Effect Analysis) was used to find out significant
parameters from all the parameters that represented by fishbone diagram.
Afterwards, Plackett-Burman design was used to screen the most significant
parameters out of the significant parameters. Stirring speed, stirring
time, preheating temperature and reinforcement amount was found the most
significant parameters to attain high UTS and low porosity. However,
because of the unfavourable combination of parameters % porosity increased
beyond 7% during screening design based experiments. Subsequently, these
parameters were optimized by factorial design. The result shows optimized
parameters stirring speed 650 rpm and stirring time 12 minutes provides low
porosity and high UTS. UTS improved up to 310 MPa due to an optimized range
of stirring speeds and stirring time. However, porosity increased beyond 3%
due to excess stirring in cast composites during factorial design based
experiments. Moreover, studies were carried out to understand the effect of
stirring, fluxing, degassing and moulding methods on porosity, UTS,
clustering and surface finish of the cast composite. It was observed from a
supplementary study that permanent mould reduces surface roughness below
3μm, compared to the sand casting process. The porosity was reduced below
3% by degassing and fluxing. Low agglomeration was observed in specimen
prepared with automatic stirring process compared to the manually stirred
specimen. Compared to others, in specimen 4, UTS was improved beyond 150
MPa because of permanent mould, automatic stirring, degassing and fluxing.
© 2018
Deslgn and development of casted staln less steel Y-Tee jolnt for oll and
gas appllcatlon
.
85057321992&doi=10.1063%2f1.5075582&partnerID=40&md5=efafb0ae1a2e2f8c87cea1
8d005e7b7e
ABSTRACT: Pressure drop or head loss, occurs in all piping systems because
of elevation changes, turbulence caused by abrupt changes in direction, and
friction within the pipe and fittings. T-joint is commonly used in pipeline
or piping system to transport the liquid or gas from one place to another
places depending on the demand and application. A liquefied natural gas
(LNG) plant in Malaysia is taken a step forward in putting an effort to
replace some of Straight-T fitting component with new Y-Tee joint component
in their plant. The main purpose to implementing of Y-Tee is to reduce
vibration on the piping system. Y-Tee joint is an engineered fitting
component with some special characteristic to overcome some engineering
problem like pressure loss, vibration, flow efficiency etc. The design and
development of unlisted component, Y-Tee joint had been carried out for oil
and gas industry plant. This special item is considered as engineered pipe
fitting component with some special characteristic to overcome some
engineering problem such as pressure loss, flow efficiency etc.
Implementing of Y-Tee joint to the piping system will enhance the plant
efficiency and optimum the plant in operation. SIRIM BHD together with the
Group Technical Solutions (GTS) has been designing and developing the Y-Tee
stainless steel jointly adhering to the ASME standard code. By using the
facilities in SIRIM, three (3) numbers of Y-Tee were produced, tested and
installed at LNG plant successfully. © 2018 Author(s).
A review on additive manufacturing of sand molds by binder jetting and

selective laser sintering
.
85054885967&doi=10.1108%2fRPJ-10-2016-
0161&partnerID=40&md5=fc10239672e91ad1c877d4b285d37065
ABSTRACT: Purpose: The purpose of this paper is to analyze the current
state of the art manufacturing techniques using sand molds for the casting
industry by the means of additive manufacturing (AM). In particular, this
review will cover two families of 3D printing in regards to sand mold
fabrication. Design/methodology/approach: This paper will discuss the sand
casting manufacturing processes of AM by binder jetting (3D printing) and
selective laser sintering. Scientific articles, patents and case studies
are analyzed. Topics ranging from the technology types to the economic
implications are covered. Findings: The review investigates new factors and
methods for mold design, looking at mechanical properties and cost analysis
as influenced by material selection, thermal characteristics, topological
optimization and manufacturing procedure. Findings in this study suggest
that this topic lacks vigorous scientific research and that the case
studies by manufacturers thus far are not useful. Research
limitations/implications: As demonstrated by the limited data from previous
published studies, a more comprehensive and conclusive analysis is needed
due to the lack of interest and resources regarding the AM of sand molds.
Practical implications: This study is a useful tool for any researchers
with an interest in the field of AM of sand molds. Social implications: Key
perspectives are proposed. Originality/value: This review highlights
current gaps in this field. The review goes beyond the scientific articles
by curating patents and professional case studies. © 2018, Emerald
Publishing Limited.
EPC Process for Screens of Roller Type Coal Crushing Machine [滚轴碎煤筛选机
筛片的消失模铸造工艺]
.
85064177141&partnerID=40&md5=9cba8eacdc80b3950831b6809ca78b84
ABSTRACT: In order to improve the yield of the screens of roller type coal
crushing machines, the traditional sand mold casting process was replaced
by the evaporative pattern casting (EPC) process. The casting technology of
EPC process for the screens was introduced, including the design and
optimization of casting process parameters and heat treatment process. The
problems of blowhole, slag inclusion and burning-on defects were analyzed
and solved. The results show that the technological process of screens
produced by the EPC process is simple and the product yield is high; the
production efficiency of EPC process is 1.5 times that of the traditional
sand casting process, and the product yield is 1.25 times. © 2018, Chinese
Process Optimization for a Complex High Manganese Steel Casting [复杂高锰钢件

铸造工艺优化]
.
85064182855&partnerID=40&md5=0456dca73d3c4a3d76c30ed67cf5cdf0
ABSTRACT: Defects are easily formed in a high manganese steel casting due
to its complicated structure of inner chambers. Therefore, the initial
casting process of the complex high manganese steel casting was simulated
by the ADSTEFAN and ProCAST softwares, and the characteristics of
temperature field, the locations and causes of casting defects were
analyzed. Aiming at reducing the casting defects in the initial casting
process, an optimized casting process was proposed by changing the volume
of risers and adjusting the shape and location of chills. The simulated
results show that the optimized process can eliminate the dispersed
shrinkages in the area of the wheel rim, and greatly reduce the hot
cracking tendency of the casting. Then, the validity of the proposed
casting process was confirmed by the practical production. The predicted
positions of shrinkages, dispersed shrinkages and hot cracks are in good
agreement with the practical production results. © 2018, Chinese Mechanical
Reduction of casting defects and quality improvement by using Taguchi
technique
.
85058104024&partnerID=40&md5=63212403b40822f6f66739bc0c46c19f
ABSTRACT: This paper involves a process parameters of green sand castings,
which affect the quality of green sand castings production, an effort has
been made to optimal settings of casting process for improving performance,
yield and quality characteristic of the spheroidal graphite cast iron rigid
coupling. The parameters considered are moisture content, green strength,
pouring temperature, and mould hardness. Casting quality and their defects
are analyzed and optimal settings of parameters and their different levels
are selected by using Taguchi technique. The outcome result of this paper
indicates that the process parameters such as moisture content, green sand
strength and pouring temperature are highly significant on improving the
quality of casting products. The evaluation of the process parameters leads
to improve the performance and characteristics of green sand casting, and
thus to minimize casting defects. © IAEME Publication
Design optimisation of the feeding system of a novel counter-gravity

casting process
.
85055776267&doi=10.3390%2fmet8100817&partnerID=40&md5=d0bf6e7a40e89a9eb6915
fdf4b099204
ABSTRACT: The appropriate design of feeders in a rigging system is critical
for ensuring efficient compensation for solidification shrinkage, thus
eliminating (shrinkage-related) porosity and contributing to the production
of superior quality castings. In this study, a multi-objective optimisation
framework combined with Computational Fluid Dynamics (CFD) simulations has
been introduced to investigate the effect of the feeders’ geometry on
shrinkage porosity aiming to optimize casting quality and yield for a novel
counter-gravity casting process (CRIMSON). The weighted sum technique was
employed to convert this multi-objective optimisation problem to a single
objective one. Moreover, an evolutionary multi-objective optimisation
algorithm (NSGA-II) has been applied to estimate the trade-off between the
objective functions and support decision makers on selecting the optimum
solution based on the desired properties of the final casting product and
the process characteristics. This study is one of the first attempts to
combine CFD simulations with multi-objective optimisation techniques in
counter-gravity casting. The obtained results indicate the benefits of
applying multi-objective optimisation techniques to casting processes. ©
2018 by the authors. Licensee MDPI, Basel, Switzerland.
A low carbon process design method of sand casting based on process design
parameters
.
85052840986&doi=10.1016%2fj.jclepro.2018.06.285&partnerID=40&md5=9c619be480
c897eb8ed4be80b67ca020
ABSTRACT: The widespread use of sand casting technology has brought
tremendous pressure on the environment due to its energy consumption, waste
discharge, and process related carbon emissions. A plan should begin at the
design phase of the casting, in order to achieve low carbon sand castings
or sand castings with low greenhouse gas emissions. Accurate prediction of
carbon emission in sand casting is the basis for carbon emission reduction.
To calculate and reduce carbon emission of sand castings during the sand
casting process design phase, a low carbon process design method of sand
casting based on process design parameters is proposed. The process design
of sand casting includes various parameters. Three types of sand casting
carbon source model were built by three categories of process design
parameters analysis of sand mold casting. so as to predict the carbon
emission of sand mold casting. The feasibility of the proposed method to
estimating the carbon emission in the process design stage was validated by
using a practical example. Through the comparison of the two process design
schemes based on this method, it can be proved that carbon emissions have
decreased significantly. Moreover, we can know the amount of carbon
emissions from each type of carbon source can be predicted. A low carbon
sand casting process during the sand casting process design phase can be
created by this method. The optimization of process design parameters was
useful to the reduce carbon emissions of the sand casting and benefited to
achieve the aim of reach sustainable manufacturing. © 2018 Elsevier Ltd
Sand casting safety assessment for foundry enterprises: Fault tree

analysis, Heinrich accident triangle, HAZOP-LOPA, bow tie model
.
85056798111&doi=10.1098%2frsos.180915&partnerID=40&md5=1776b91ccfd88f659f53
8b862102da56
ABSTRACT: Sand casting operations, though commonplace, pose a significant
threat of explosion accidents. This paper presents a novel sand casting
safety assessment technique based on fault tree analysis, Heinrich accident
triangle, hazard and operability-layer of protection analysis (HAZOP-LOPA)
and bow tie model components. Minimal cut sets and minimal path sets are
first determined based on fault tree analysis, then the frequency of sand
casting explosion accidents is calculated based on the Heinrich accident
triangle. Third, the risk level of venting quality can be reduced by
adopting HAZOP-LOPA; the residual risk level of venting quality remains
excessive even after adopting two independent protective layers. The bow
tie model is then adopted to determine the causes and consequences of
venting quality. Five preventative measures are imposed to enhance the
venting quality of foundry sand accompanied by 16 mitigative safety
measures. Our results indicate that the risk attributable to low foundry
sand venting quality can be minimized via bow tie analysis. © 2018 The
Authors.
3D Printed Smart Molds for Sand Casting

.
85054840740&doi=10.1007%2fs40962-018-0211-
x&partnerID=40&md5=d07be005514813aaeb69bd578f76612e
ABSTRACT: Additive manufacturing, also commonly referred to as 3D printing,
stands to transform sand casting with binder jetting technology that can
create sand molds with unmatched geometric complexity. With printed sand
molds, castings can be optimized with regard to the strength-versus-weight
trade-off and structures such as periodic lattices are now available within
molds that are not possible with traditional casting technology. However,
an increase in design complexity invites more challenges in terms of
understanding and managing both the thermodynamics and physics of the
casting process. Simulations of castings are more important than ever, and
empirical in situ sensor data are required to validate high fidelity
computer modeling (e.g., MAGMASOFT®). One novel solution is to leverage the
design freedom of CAD-based solid modeling to introduce unique mold
features specifically for housing sensors (Internet of Things) within the
mold to enable the collection of a diversity of data at manifold locations:
temperature, pressure, moisture, gas chemistries, motion of the molds and
internal cores (shifting or rotation), and magnetic field. This report
describes a proof of concept in which unprecedented levels of process
monitoring were integrated—both wirelessly and wired—at strategic locations
throughout a printed mold and inside of internal cores. The collected data
were used to validate the quality of a casting in situ as well as to
provide feedback for optimizing the casting process, mold design, and
simulations. A trade-off was explored between sensor survivability and
disposability. © 2018, The Author(s).
Effects of Different Cooling Rate on Microstructure and Mechanical

Properties of Al-5.0Mg-0.6Mn-0.25Ce Alloys
.
85059734041&doi=10.15980%2fj.tzzz.2018.10.022&partnerID=40&md5=c0182b70ad6a
161ee038f7754d23f7c1
ABSTRACT: The microstructure and mechanical properties of the Al-5.0Mg-
0.6Mn-0.25Ce alloys prepared by sand casting, metal casting and die-casting
were investigated by OM, SEM, EDS and tensile testing. The results show
that with the increase of cooling rate, the α-Al dendrites in the casting
alloy are transformed into roundα-Al grains, and the second phase is
refined. With a lower cooling rate, the as-cast microstructure of sand
casting and metal casting alloy mainly consists of α-Al dendrite,
Al3Mg2phase, Al6(Fe, Mn)phase, Mg2Si phase. While with a higher cooling
rate, the die-casting alloy consists of small equiaxedα-Al grains and short
rod-shaped Mn-containing phases as well as needle-shaped Mg2Si phases
distributed around the grain boundaries. With the increase of the cooling
rate, the yield strength and tensile strength of the casting alloys are
gradually increased, while the elongation rate is increased firstly and
then decreased, which is mainly attributed to the microstructure of the
alloy and the casting defects such as shrinkage holes. When the cooling
rate increases, the microstructure of the casting alloys become finer, and
the more Mg and Mn are dissolved into the α-Al-based matrix, leading to the
higher strength of the alloys. However, in die-cast alloy, there exists gas
hole and needle Mg2Si phases, which is harmful to the plasticity of the
alloy. © 2018, Journal Office of Special Casting and Nonferrous Alloys. All
right reserved.
Non-destructive compositional and microstructural characterization of

Sardinian Bronze Age swords through Neutron Diffraction
.
85050676148&doi=10.1016%2fj.matchar.2018.07.035&partnerID=40&md5=33610c35da
e37a81a213d391338d457d
ABSTRACT: The Monte Sa Idda type swords belong to a well characterized
typological class, whose origin has long been debated and seems to coincide
with the Iberian Peninsula. The name comes from the site of the first
discovery of a hoard containing this type of swords, among other bronze
artefacts, namely Monte Sa Idda, Decimoputzu-Cagliari, Italy. The swords
were produced through fusion inside a casting mould. Such kind of casting
mould has not been found in Sardinia, and this may suggests that finished
objects were either imported or made using clay or sand casting mould.
Moreover, the discovery of these types of sword, in hoards and in votive
deposits, raises the problem of their functional use. It is unknown if the
blades were intended to be used as weapons, and therefore subjected to cold
working necessary for thinning and sharpening of the blade, or as
ceremonial objects. In order to answer to these questions, a neutron
diffraction experiment was performed on three swords belonging to the Monte
Sa Idda type. The results obtained are presented and discussed in the
paper. © 2018 Elsevier Inc.
Corrosion Behavior of B and Ti Grain-Refined Sr-Modified A356

.
85053941828&doi=10.1007%2fs11665-018-3657-
3&partnerID=40&md5=231c133a55cf5f43ffeff6b4990d8d9b
ABSTRACT: Corrosion behavior of A356 aluminum alloy with different grain
refiners was evaluated. For this purpose, the Sr-modified A356 alloy was
grain refined with Al5Ti1B and Al3B, and then, the corrosion
characteristics were determined. For the mechanical properties, impact and
Vickers hardness tests were carried out. To determine the corrosion
behavior, both the electrochemical impedance spectroscopy technique and by
potentiodynamic polarization plots were carried out in a 3.5 wt.% NaCl
solution at 25 °C. The corrosion resistance of A356 alloy was dramatically
improved in sequence with the following modifications compared to the
unmodified castings: Sr, Ti and B additions. This situation applies to both
different cooling rates, namely die and sand casting. The increase in
corrosion rate was more than 80% for all alterations of the microstructure.
Additionally, charge transfer resistance was increased ten times in die
cast samples, while this value was 2.5 for sand cast samples compared to
the unmodified alloy. It is important to note that sand casting of the
unmodified alloy was improved four times with regard to the die cast
unmodified A356. © 2018, ASM International.
Effects of Tace Cerium Addition on Microstructure and Properties of

Cu0.9%Cr Alloy [微量元素铈对 Cu0.9%Cr 合金组织与性能的影响]
.
85057877593&doi=10.11785%2fS1000-
4343.20180512&partnerID=40&md5=33380089d5003b57058a6cbe0bb73b61
ABSTRACT: Cu-0.9Cr and Cu-0.9Cr-0.05Ce were fabricated by graphite sand
casting. The studied alloy was treated by solution and aging with different
aging time. Effects of trace Ce additions on microstructure, tensile
strength, conductivity and frictional and wear property were investigated
by means of optical microscope (OM), scanning electron microscopy (SEM),
conductivity meter, MTS test works software and a to-and-fro wear test
apparatus. The results indicated that the trace addition of Ce can refine
primary Cu0.9%Cr microstructure and Cr particles uniformly distributed in
the alloy during earlier period of aging. The peak strength and electric
conductivity of Cu0.9Cr0.05Ce alloy occurs at about 450 ℃ for 4 h after
aging, which is 590 MPa and 83%IACS, respectively. It has better friction
and wear properties. During the posterior period aging treatment, the trace
addition of Ce declines tensile strength gradually, changes conductivity
smoothly and retards over-aging. © 2018, Editorial Office of Journal of the
Chinese Society of Rare Earths. All right reserved.
Analisys of casting defects and mechanical properties on Al-Si alloys using

Bangkalan local clays as sand casting binder
.
85054340338&doi=10.1051%2fmatecconf
%2f201820405014&partnerID=40&md5=fa9f1a3de19a70cfd24475bad3ed7383
ABSTRACT: This research is aimed to know the defect of castings, tensile
strength, and hardness of Al-Si alloy to the variation of binder. The
research method used is descriptive quantitative research method. This
beacuse the data is expressed in the form of numbers. This research uses
pre-experimental research design using one-shot case study model. Based on
the results of the study, it was found that most pinhole defects were owned
by specimens using 90% bentonite binder that is 59 defects. Whereas the
pinhole defect which is at least owned by the specimens using banngkalan
local clay binder 9% that is 31 defects. The most common open grain
structure defect is owned by metal casting specimens using a 9% bentonite
binder, which is 81 defects. Whereas the defect of open grain structure is
at least owned by the specimen result of casting of metal clad with
bangkalan local clay 3% which amounted to 40 defects. The result of the
research using bangkalan local clay binder of 9% has higher tensile
strength than other binder. This is because the characteristic of bangkalan
local clay which has a high content of calcium (Ca) is 92,81%. The value of
the tensile strength of the bangkalan local clay is 12,8712 (kg/mm2),
whereas the bentonite which is said to be the ideal binder for the mold has
a tensile strength of 10,1612 (kg/mm2). The highest hardness value is owned
by Al-Si alloy casting specimen with bend mixture variation of bangkalan
local clay 9% that is 128,033 HV. While the lowest hardness value is owned
by Al-Si alloy casting foundry with 9% bentonite binder 114,4 HV. © The
Authors, published by EDP Sciences, 2018.
Case studies in green sand casting

.
85054953284&partnerID=40&md5=d32d3cfa2ba3f5da7253393f6f53b35e
Design methodology for variable shell mould thickness and thermal

conductivity additively manufactured
.
85051433402&doi=10.1007%2fs40194-018-0598-
2&partnerID=40&md5=4fddd6cc7cc17d586bf53381ed4707d8
ABSTRACT: Additive manufacturing (AM) is said to be the fourth industrial
revolution disrupting the manufacturing industry. A focus on the foundry
industry’s need, more specifically the sand casting process, is done. The
usage of additive manufacturing in this field necessitates a different
mould design approach. Indeed, it is important to take advantage of AM and
the advantages of casting. The fabrication methodology of the mould is
binder jetting technique. The almost limitless design possibilities of
additive manufacturing are applied to sand moulds for metal casting. A new
methodology to optimise the design of sand moulds is proposed. This
optimisation reduces the amount of sand to the minimal need, which
corresponds to a shell. The shell is then parametrised to have a specific
cooling rate. In this case, the cooling speed can vary via a modification
of the coefficient of thermal conductivity and shell thickness. The cooling
speed is correlated to the dendrite arm spacing, which determines the
mechanical properties such as ultimate tensile strength and hardness.
Simulations of the cooling support the mould design methodology. © 2018,
International Institute of Welding.
Investigation to improve the sand molding formula of the ERG by

incorporating local materials
.
85050298251&doi=10.24247%2fijmperdaug201853&partnerID=40&md5=f338776c1c4d63
b8ac205d70c543ccc4
ABSTRACT: In the field of molding, the use of a large quantity of sand from
the beach causes an ecological problem for Algeria, plus its price which
keeps increasing in the Algerian market leads to the search for solutions,
to replace this type of sand which was nowadays among the first concerns of
the country. Thus the proposal to substitute beach sand by the sand of
Western ERG of Algeria gave satisfactory results presented on a first place
as a simple and effective solution, knowing that this type of sand is in
abundance and occupies nearly 6% of the surface of our country. The subject
on which this work focuses is part of the problematic associated with the
study of valorization of the sand of the ERG in the process of molding of
parts and the investigation to the improvement of the sand casting formula
of the ERG by incorporating local materials. However, the development of
ERG sand has an economic and ecological impact for Algeria. Among other
things, the addition of Bentonite in the molding formulation is an economic
problem because this type of material is very rare, very expensive and is
currently imported from abroad. Indeed, we want to improve the sand molding
formula of the ERG by adding materials that replace the Bentonite to
greatly reduce manufacturing costs in molding. The investigation in this
area is relevant to our country. © TJPRC Pvt. Ltd.
Design of a gate system and riser optimization for turbine housing and the
experimentation and simulation of a sand casting process
.
85053701531&doi=10.1177%2f1687814018795045&partnerID=40&md5=a11da9a0b8f7606
b98ca1e15dbfbc61e
ABSTRACT: The optimum gating system for manufacturing turbine housing is
designed in this study, and a heater as heat source is provided to the
riser, attempting to reduce its size. In the case where the runner is
divided into two branches, a symmetrical gating system is adopted so that
the two products could be produced in one process. Furthermore, cross-
sectional shapes of the sprue, runner, and gate are designed by setting the
sprue:runner:gate ratio at 1:0.9:0.6. A casting analysis is then conducted
to investigate the effects of shape of the riser, sleeve material,
temperature of the heater, and provision of insulation material at the top
of the riser. The conditions obtained from the analysis are applied to the
experiment. Hot spot defects calculated by casting simulation are reduced
when sand sleeve material, straight type riser, open top sleeve, and more
than 600°C of heater temperature are used. It is possible to produce a
casting with almost no surface defects by adopting a riser with a size of
10–20 mm and a heater of 600°C–700°C. A casting recovery rate of 80% is
achieved and, regarding mechanical properties, its tensile strength is 534
MPa, its elongation rate is 9%, and its Brinell hardness is 170 HB. © The
Author(s) 2018.
Non-conventional mold design for metal casting using 3D sand-printing

.
85048436728&doi=10.1016%2fj.jmapro.2018.03.049&partnerID=40&md5=b120dbca3a0
48cd66dc232fbfe1a8223
ABSTRACT: 3D Sand-Printing (3DSP) is a relatively new Additive
Manufacturing (AM) technology that enables direct digital manufacturing
(DDM) of complex sand molds and cores for sand casting applications. Ever-
growing interest in this indirect hybrid metal AM process is attributed to
its ability to rapidly produce tooling (i.e., cores and molds) for complex
metal castings that are otherwise impossible to manufacture using
conventional techniques. Knowledge-based design rules for this process is
currently very limited and is being progressively realized on an ad-hoc
basis to produce economicaly viable low-batch castings. In this research,
non-conventional design rules for gating and feeding (also known as
rigging) is developed to improve casting performance (i.e., filling,
feeding and solidification). Several case studies are presented to
illustrate the improved casting performance by systematically redesigning
each element of the rigging system. Computational simulations of the melt
flow are developed to evaluate the effectiveness of redesigned rigging
system. This research further illustrates the ability of 3DSP to not only
impact part performance, i.e., optimized metal casting designs via 3DSP but
also drastically improves the casting performance which could potentially
transform the industry of sand casting to produce high quality castings. ©
Tackling Key Quality Problems for Steering-Knuckle Cover Production [转向节

端盖产品质量攻关]
.
85063297824&partnerID=40&md5=76b316a4a150d6ff58e21db7116f5be4
ABSTRACT: The size of the steering knuckle cover casting produced by manual
operation using the process of the furan resin ceramsite sand casting is
unstable, and there are defects in the products after the processing.
According to the technical and practical requirements of the steering
knuckle cover, the production was optimized from casting process design,
site operation and die design, and the quality problems of the castings in
mass production were solved. The production process isintroduced based on
the technical management, quality management and production management
aspects. In order to maintain the stability and further improvement of
product quality, much attention must be paid to onsite meticulous
management, process control, training and quality control awareness of
onsite operators. © 2018, Chinese Mechanical Engineering Society. All right
reserved.
Direct observation of hot tearing of Al-7%Si-0.35%Mg alloy

.
85064004966&doi=10.1080%2f2374068X.2018.1463137&partnerID=40&md5=b13f927945
bd7a1435aa2f4c827412cb
ABSTRACT: Hot tearing of an Al-7%Si-0.35%Mg alloy T-shaped specimen was
analyzed by direct observation of cracking and a finite element method
(FEM) stress simulation. The semi-solid state during cooling enables direct
observation of corner surface cracks. Crack opening appears to begin before
the solid fraction reaches 0.3. However, a liquid phase infiltrates and
disturbs the crack opening process. After the onset of the eutectic
reaction, crack opening resumes and is detected as hot tearing. The FEM
stress analysis revealed that tensile stress concentrates at the corners of
the T-shaped specimen. The tensile stress increases with time at the
initial stage of solidification, peaks at around 170 s, and then decreases.
Microstructural observation of cooled and quenched specimens reveals that
if the inter-dendritic liquid phase is adequate and has high fluidity, then
healing of the crack occurs. © 2018, © 2018 Informa UK Limited, trading as
Taylor & Francis Group.
A comparative study of fabrication of sand casting mold using additive

manufacturing and conventional process
.
85045767719&doi=10.1007%2fs00170-018-2020-
z&partnerID=40&md5=b385cc4b660c31879bf07a5b56948957
ABSTRACT: In this study, two processes to fabricate casting mold,
conventional sand casting process and additive manufacturing or 3D printing
process, are comparatively investigated. The two processes were compared in
terms of their weight saving, surface finish, design allowance, and
fettling work. The results show that there are significant advantages in
using additive manufacturing in the production of mold. The 3D printed
molds provide substantial saving of sand used, design allowances, and
fettling work. The mechanical properties of 3D printed molds are also
higher than the conventional ones due to good bonding strength during 3D
printing. © 2018, Springer-Verlag London Ltd., part of Springer Nature.
Counter-Gravity Sand Casting of Steel with Pressurization During

Solidification
.
85049340676&doi=10.1007%2fs40962-017-0200-
5&partnerID=40&md5=47e82e21f44808d6e785ff5e0f138c8f
ABSTRACT: Counter-gravity filling and pressurization during solidification
have been separately shown to improve casting quality in sand cast steel.
Studies and industry practice show that counter-gravity filling increases
the yield and reduces reoxidation inclusions. Other studies show
pressurization during solidification has the potential to increase the
feeding effectivity of risers, which leads to a reduction in centerline
shrinkage. In the present study, a method for sand casting steel is
developed that combines both practices. Casting simulations are used to
determine key events during the process. Counter-gravity filling of a sand
mold with liquid steel is performed by linearly decreasing pressure to a
value of 0.053 MPa and holding this pressure for 40 s. After the vacuum
pressure is released, the entire system is pressurized to a maximum
pressure of 0.35 MPa, 220 s after the start of the filling process. The
casting method is applied to cylindrical bar castings. Radiographic and dye
penetrant inspection of the bars shows no detectable centerline porosity
forms when the casting system is pressurized, unlike the gravity-poured
control castings. © 2017, American Foundry Society.
Numerical Simulation and Process Optimization of Sand Casting Aluminum

Alloy Box
.
85055204830&doi=10.15980%2fj.tzzz.2018.07.007&partnerID=40&md5=2f95f192c75a
bde36a869bf22b6ba0ec
ABSTRACT: The structure and technological characteristics of aluminum alloy
box were analyzed. The gating system of sand casting was designed. The
casting process of aluminum alloy box body was simulated by AnyCasting
software, and the position and reason of casting defect were visualized.
Based on the simulated results, process scheme was modified by improving
gating system, setting cold iron and riser reasonably to reduce the casting
defects. Finally, an optimized casting process scheme was designed
successfully. © 2018, Journal Office of Special Casting and Nonferrous
Alloys. All right reserved.
MAGMASOFT Simulation of Sand Casting Process with EV31A Magnesium Alloy

.
85041931913&doi=10.1115%2f1.4039108&partnerID=40&md5=97b915d3981618ce1eb7bc
dc3f8bb1d7
ABSTRACT: Magnesium alloys with rare earth (RE) elements addition, modified
with zirconium are used for cast, light-weight solutions for components
applied at temperature up to 250-300 °C. Computational methods are often
used by the foundries to decrease the cost of a new product start-up. The
commercially available magmasoft software is widely used to simulate a
casting process. Nevertheless, its database does not contain complete data
for modern alloys. We present the results of our investigations on the
thermo-physical properties of a EV31A magnesium alloy and the simulation of
a sand casting process with applied data. We compared the simulation and
technological trials, recognized problems occurring during the simulation,
and applied corrections. Our final simulations gave acceptable results. The
differences between the technological tests and the simulation were caused
by factors that are difficult to model in the simulation, such as the
presence of nonmetallic inclusions and the degree of modification of the
liquid alloy. Copyright © 2018 by ASME.
Effect of Mould Coatings and Pouring Temperature on the Fluidity of

Different Thin Cross-Sections of A206 Alloy by Sand Casting
.
85044579837&doi=10.1007%2fs12666-018-1311-
2&partnerID=40&md5=e41a81310a9bafd63803c0bee751ceb0
ABSTRACT: Thin-wall castings of the A206 alloy can pose a manufacturing
problem associated with mould filling which results in fluidity defect. The
mould coating generates a smooth surface, and reduces the friction between
the melt and mould contact, thus reducing the heat-transfer coefficient,
which in turn leads to enhancement of fluidity and mechanical properties.
The fluidity of A206 alloy was observed in various cross-sections of the
thin channels at three altered pouring temperatures i.e. 700, 750 and
780 °C for uncoated and coated green sand moulds. The Graphite and
Soapstone powder coatings were used as sand mould coatings in the present
investigation. It was found that the fluidity of aforesaid alloy was
significantly increased with the Soapstone powder mould coating at pouring
temperature of 750 °C. The characterization of the coating materials was
performed by the X-ray diffraction analysis and scanning electron
microscope test with EDAX. © 2018, The Indian Institute of Metals - IIM.
Archaeometallurgical investigation of metal wares from the medieval Iranian

world (10th-15th centuries): The ISLAMETAL project
.
85046698987&doi=10.1016%2fj.jas.2018.04.008&partnerID=40&md5=aa0b6d094dc05b
9f33538abc58519af6
ABSTRACT: The ISLAMETAL project (2013–2017) was jointly conducted by the
Département des Arts de l'Islam (DAI), Musée du Louvre, and the Centre de
Recherche et de Restauration des Musées de France (C2RMF) and kindly
supported by the Roshan Cultural Heritage Institute (RCHI). The project
deals with the detailed technological investigation of copper-based metal
wares (10th to late 15th centuries CE) from the Iranian world at the Louvre
Islamic Art collection, comprising mostly household and domestic objects
such as candlesticks, lamps, ewers, plates, and bowls. Amongst the
collection characteristic qualities of production and decoration can be
discerned. High status objects were decorated with sophisticated patterns
including exquisite chasing, engraving, champlevé, and especially copper,
silver and gold inlays. Results of the technological investigation of some
169 objects (particle induced X-ray emission, inductively coupled plasma
atomic emission spectroscopy, digital microscopy, X-radiography) showed a
range of distinct alloy types employed and a correlation between artefact
typology, fabrication technique, status and alloys. Decoration techniques
showed a clear change spanning the 10th and 15th centuries with the notable
introduction of precious metal inlays during the 12th century and new
inlaying techniques before the mid-13th century. Lost-wax casting was the
preferred manufacturing method even for mass produced objects where sand
casting would seem a more suitable choice. Specific production centres in
the region of Khorasan, such as that of Herat and Ghazna, were possible to
be technologically identified. Detailed investigation of this comprehensive
corpus provided for the first time key technical references for further
comparison, particularly with neighbouring Near Eastern workshops. © 2018
Elsevier Ltd
The effect of ageing process on three-point bending strength and

permeability of 3D printed sand molds
.
85045851520&doi=10.1007%2fs00170-018-2024-
8&partnerID=40&md5=904fcff9eeaf089582ce0ec1e5d88a02
ABSTRACT: The objective of this paper was to investigate the effects of
curing parameters (i.e., temperature and time), on the permeability and
mechanical strength of the printed molds. Several sets of samples were
hence produced with a state-of-the-art 3D printer using well-characterized
silica sand and furan resin binder. Then, experiments were performed in
which the evolution over time of the three-point bending (3 PB) strength
and permeability of the samples were monitored at three different curing
temperatures. From these measurements, both the individual and combined
effects of curing temperature and time on the functionality of the 3D
printed molds were assessed. Moreover, loss-on-ignition (LOI) tests were
also performed in order to relate the loss of binder mass to the variation
in permeability and mechanical strength of the samples. The results showed
that the printed molds can be stored at room temperature for a long time
before being used, roughly preserving the initial properties. No
significant change in 3 PB strength was observed when curing at 100 °C. In
contrast, the permeability was shown to decrease with increasing curing
temperature. © 2018, Springer-Verlag London Ltd., part of Springer Nature.
In-situ investigation of incipient melting in a 319 type Al alloy using

laser scanning confocal microscopy
.
85046783696&doi=10.1016%2fj.matchar.2018.05.012&partnerID=40&md5=08d7bc1c08
0f07a2844720a150d81125
ABSTRACT: The modified 319 Al alloy system has been used extensively in
precision sand casting of automotive powertrain applications such as engine
blocks and cylinder heads, with significant improvement in vehicle fuel
efficiency. However, a concern in elevated temperature processing of Al
alloys, such as heat treatment and hot working processes, is incipient
melting of secondary phases, which is deleterious to mechanical properties.
In this study, the laser scanning confocal microscopy (LSCM) technique was
used in the analysis of in-situ changes in microstructure as a result of
incipient melting. Microstructural analysis was carried out prior to and
following elevated temperature exposure in the LSCM using optical
microscopy, SEM and EDX. The results suggest that incipient melting of the
Al-Al2Cu-Al5Mg8Cu2Si6 ternary eutectic clusters was initiated by the
formation of a liquid film which propagated rapidly from the eutectic
clusters, coating the Al dendrites in regions adjacent to the eutectic
clusters. Following film formation, the ternary eutectic clusters melted
completely. Incipient melting also resulted in a localized change in
composition in the interdendritic channels as supported by a change in
cluster morphology from eutectic to a combination of coarse blocky Al-Cu-Ni
and Si particles, and ultra-fine eutectic. © 2018 Elsevier Inc.
A Review on Influence of Various Technological Processes on Mechanical

Properties of Aluminum Alloys
.
85049907209&doi=10.1088%2f1757-899X
%2f376%2f1%2f012043&partnerID=40&md5=be5c4f66ea2891ac2ea155f00acff6fb
ABSTRACT: Aluminum alloys are alloys in which aluminium (Al) is the
predominant metal. The typical alloying elements are copper, magnesium,
manganese, silicon, tin and zinc.Aluminum alloys are widely used in
engineering structures and components where light weight or corrosion
resistance is required. Selecting the right alloy for a given application
entails considerations of its tensile strength, yield strength, fatigue
strength, ductility, microhardness, weldability and corrosion resistance.
The processes such as shot peening, age hardening, hydrostatic extrusion,
friction stir welding, tungsten inert gas welding, quenching,sand
casting,gas metal arc welding effect the various above mentioned mechanical
properties of alloys. This paper gives a brief review on various processes
used for improvising the mechanical properties of Aluminium alloys. ©
An Experimental Study of Use of Fly Ash (Type-C & Type-F) for Shell
Moulding
.
85049907481&doi=10.1088%2f1757-899X
%2f376%2f1%2f012113&partnerID=40&md5=454b6cae65b3cac84fe2b8f362899e40
ABSTRACT: Usage of fly ash in foundry has long been established for casting
processes like sand casting & ceramic shell moulding. However, no effort
was made if fly ash can be a successful replacement for shell moulding.
Shell moulding is a thin-walled shell created from applying a sand-resin
mixture around a pattern. Shell moulding- finds vast application in
automobile, automotive and locomotive industries owing to its versatility,
accuracy and surface finish. This paper presents by comparison the effect
of fly ash on various moulding properties like strength, permeability,
hardness and surface finish. The properties of various weight percentages
of fly ash and shell sand reveal rule out of fly ash as a complete
substitute for shell sand but can be a partial substitute for shell sand
contributing to the cost reduction in procurement of shell sand. The
castings obtained were checked for quality and the weight percentage of fly
ash to shell sand established. © Published under licence by IOP Publishing
Ltd.
Sand Casting Process for Double Suction Centrifugal Pump Body Made of Tin
Bronze [锡青铜双吸式离心泵体的砂型铸造工艺]
.
85061383790&partnerID=40&md5=98a7a773d9ffe163bd7a91cb34ccd789
ABSTRACT: Double suction centrifugal pump body is made of tin bronze
ZCuSn3Zn8Pb6Ni1, and it has a complicated structure.For the centrifugal
pump body, leakage is not allowed under the pressure of 3.5 MPa for 5 min
in the hydraulic test. In the paper, based on the casting properties of tin
bronze and the structural characteristics of the body, the casting defects
such as dispersed shrinkages, shrinkage cracks and pores were analyzed, and
the technology of sand casting process with horizontally molding and
vertically pouring adopted at the earlystage of production was introduced.
In the recent production ofthe pump body, the casting process has been
improved, and the sand casting process with horizontally molding and
pouring was adopted, which has remarkable advantages: the casting quality
is good. Although the yield ofthe improved process is slightlylower than
that of the casting process with horizontally molding and vertically
pouring, the rate of the pump leakage is reduced, and the molding operation
is simple and convenient, furthermore, there are no special requirements on
the sandboxes.So the production efficiency is greatly improved. © 2018,
Chinese Mechanical Engineering Society. All right reserved.
Influence of the vertical slot gate system on the filling process of low
pressure sand casting plate castings
.
85048887638&doi=10.1063%2f1.5041107&partnerID=40&md5=0f588b8a24216924198ca6
6dfe7a1294
ABSTRACT: Tn this paper, the effects of the vertical slot-gate system on
the filling process for low pressure casting are studied. The statistical
simulations results show that there are two filling zones, one is the
parallel flow zone and the other is the vortex zone. The width of the gap
runner in the vertical slot gate system is the main influencing factor
during filling process. The length of the gap runner and the diameter of
the vertical runner also have influences on the metal flow. For different
thickness plate castings, there are different critical velocities; the
velocity increases with the increasing width of the gap runner and the
diameter of the vertical runner and decreasing length of the gap runner. Tf
the actual velocity is greater than the critical velocity, the metal flow
tends to fill the mold in turbulence, and this will decline the performance
of products. © 2018 Author(s).
AIP Conference Proceedings

.
85048876868&partnerID=40&md5=34b0a4b0ca2025eadfd8aae33ab9ab48
ABSTRACT: The proceedings contain 116 papers. The topics discussed include:
the substitution of aluminum for cobalt in nanostructured bainitic steels;
study on ultrasonic assisted mechanism of ring opening polymerization of
octamethylcyclotetrasiloxane (D4); the tapered tellurite microstructure
optical fiber for the super-continuum generation; synthesis and
characterization of boron nitride powder; design of a metamaterial absorber
based on resistive film structure; development of temperature calculation
model for strip in hot rolled strip; and influence of the vertical slot
gate system on the filling process of low pressure sand casting plate
castings.
Investigation of optimum gating system design of fused deposition modeling

pattern for sand casting
.
85047737069&partnerID=40&md5=04ae1d915d0e52d378b66ff273b53941
ABSTRACT: Sand casting is one of the major processes in manufacturing
industries today. Inappropriate sand casting mould design have led to
casting defects and increased the rejection counts. Therefore, this paper
examines the feasibility of producing sand casting pattern with Fused
Deposition Modeling (FDM) system. FDM is one of additive manufacturing
processes that enable the fast, flexible and cost-effective production of
sand casting pattern. However, one of the important factors for a good
casting quality is the gating system design. Hence, three concepts of
gating system were CAD-designed and analysed in this research in order to
obtain the optimum design of sand casting mould. The first concept was
designed with sprue and riser at both opposite sides, second concept with
sprue at the side while riser was placed at the middle top and third
concept with sprue and riser both at the middle top. In order to select the
best design concept, ANSYS software was chosen. From the simulation result,
Concept 1b was selected as the optimum design of gating system design with
the highest ranking score based on the criteria; static pressure, density,
velocity magnitude, total temperature, internal energy, turbulent
viscosity, wall shear stress and velocity streamline. Lastly, an actual
sand casting process produced a hand wheel pattern and the results were
validated. A comparison made was based on the highest score Concept 1b
(sprue/30mm and riser/30mm opposite side) and lowest score Concept 3c
(sprue inlet/30mm, sprue outlet/10mm and riser/10mm at middle top) and It
showed that Concept 1b provides a better quality in terms of dimensional
accuracy and surface finish compared to the other concepts. © 2018 Faculty
of Mechanical Engineering, Universiti Teknologi MARA (UiTM), Malaysia.
Compressive strength of open cell AL-SI12FE foam produced through sand

casting method
.
85049691414&partnerID=40&md5=aba6ed703086c733ac733120cc7fd0e3
ABSTRACT: In the modern engineering world, the demand for novel materials
is always high. The aluminium foam is the one of the widely used material.
The researchers are concentrated to prepare the foam material with better
cost effectiveness. The low density aluminium foam is produced using sand
balls which are arranged in matrix form. The sand balls are made with used
mould sand and clay with the ratio of 1:1. The three different sizes of
sand balls are prepared with the diameter of 3mm, 5mm and 7mm. The foams
are prepared with different pore size of 3-4mm, 5-6mm and 7-8mm. The
percentage of porosity of the aluminium foam is estimated. Also, the foams
are tested under compressive load in Universal Testing Machine. The yield
and ultimate compressive strength was measured and plotted as a graph. The
result revealed that the increasing porosity of the foam resulted in better
yield and ultimate compressive strength. © IAEME Publication.
Casting Process and Control of Second-generation Plus CPR1000 Primary Pump

Shell
.
85053720958&doi=10.15980%2fj.tzzz.2018.06.019&partnerID=40&md5=251b07ed06e9
ae4a41036ca37eb83e91
ABSTRACT: CPR1000 primary pump shell was manufactured with austenite duplex
stainless steel contained 12% to 20% ferrite by sand casting. The self-
hardening sand was adopted to fabricate sand mold, and bottom-back rapidly
pouring with Ar protection was designed. Through using one steel ladle
pouring with diameter of ladle of 2×φ110mm and diameter of runner of
2×φ140mm as well as diameter of ingates of 4×φ100mm, the CPR1000 primary
pump shell was produced successfully with lifting velocity of 12~20mm/s at
1 520~1 550℃ for 120~150s. © 2018, Journal Office of Special Casting and
Influence of gating design on microstructure and fluidity of thin sections

AA320.0 cast hypo-eutectic Al-Si alloy
.
85047834827&doi=10.1063%2f1.5038699&partnerID=40&md5=bd613e3770d10dec32d702
8e6f076349
ABSTRACT: Influence of gating design especially number of ingrates on
microstructure and fluidity of thin sections of 2, 4, 6 mm AA320.0 cast
hypo-eutectic Al-Si alloy was evaluated for sand casting molding technique.
Increasing the number of ingates improves the microstructe to be fine and
more globular. About 87 μm of α-Al grain size, 0.6 α-Al grain sphericity
and 37 μm dendrite arm spacing DAS are achieved by using 4 ingates in
gating system. Increasing the number of ingates up to 3 increases hardness,
filling area and related fluditiy of all cast samples. The minimum
thickness of 2.5 mm for each ingate should be considered in order to
successfully production of high quality light weight thin sections castings
in sand mold. © 2018 Author(s).
Sand Casting Process Designing for Single-Stage Single-Suction Centrifugal

Pump Body of Tin Bronze [锡青铜单级单吸式离心泵体砂型铸造工艺设计]
.
85063194816&partnerID=40&md5=2faf80b43b501eb9edbfbcddb9becf4b
ABSTRACT: The marine single-stage single-suction centrifugal pump is made
of tin bronze ZCuSn 10 Zn 2 , and it has to meet the requirement of the
pump pressure test. Based on the casting characteristics of bronze and the
structural characteristics of the pump, the possible casting defects were
analyzed. In addition, the sand casting process of pump body has been
designed. In the designed casting process, the defects such as gas content,
shrinkage and shrinkage crack, which are caused by castings, can be
prevented. The leakage of the pump body is effectively prevented, and the
quality of the casting is improved, so the requirement of mass production
can be satisfied. © 2018, Chinese Mechanical Engineering Society. All right
reserved.
Lot Sizing and Scheduling Model and Solution Method for Melting in Sand
Casting Enterprise [砂型铸造企业熔炼批量计划与调度模型及求解方法]
.
85063233693&partnerID=40&md5=3e4f4a8ab5ee7108b1a1c0bc43a7eb53
ABSTRACT: To solve the problem of inefficiency, difficult allocation of
resources, and low utilization of production capacity caused by the
artificial lot sizing and scheduling for melting in foundries, an integer
programming model was constructed by taking casting delivery date,
utilization rate of smelting furnace and conversion of furnace alloys into
consideration. According to the characteristics of the model, a heuristic
strategy was proposed to decompose the problem into two related sub-
problems: (1) lot sizing division of castings pouring with molten metal in
the same furnace; (2) the furnace scheduling of melting alloys, which are
carried out by dynamic programming and genetic algorithm, respectively.
Finally, the effectiveness and superiority of the model and solution method
were verified based on the simulation data and real data of a sand casting
enterprise, respectively. © 2018, Chinese Mechanical Engineering Society.
All right reserved.
Effect of Sr/P Modification on Microstructure and Mechanical Properties of

Squeeze Casting Al-17.5Si Alloy [Sr/P 变质处理对挤压铸造 Al- 17.5Si 合金组织与性能
的影响]
.
85063234559&partnerID=40&md5=17edf97df95a011402e573835685b406
ABSTRACT: The effects of Sr and P modification on the microstructure and
mechanical properties of the Al-17.5Si alloy were mainly studied in this
paper. The results show that the microstructure of the alloy is
significantly changed by the squeeze casting process, and the mechanical
properties of the alloy are improved remarkably. After being modified by
Sr, the eutectic Si phase in the squeeze cast Al-17.5Si alloy is changed
into the tiny fibrous microstructure, and compared with the conventional
sand casting, the tensile strength and elongation of the squeeze cast Al-
17.5Si alloy are improved 59%and 328.7%, respectively. However, with the
addition of P in the squeeze cast Al-17.5Si alloy, large amounts of coarse
primary Si phase particles emerges in the microstructure of the alloy, and
then the tensile strength and elongation of the alloy decrease obviously.
So it is concluded that the best modification agent for the squeeze casting
hypereutectic Al-Si alloy is Sr rather than P addition. © 2018, Chinese
Design and Optimization of Casting Process for Large Water Valve

.
85050995035&doi=10.15980%2fj.tzzz.2018.05.012&partnerID=40&md5=57cb3c64b295
32e9bfddbf197266d29e
ABSTRACT: The large-scale water valve belongs to a small batch production
of nodular cast iron parts. Through a comprehensive analysis of its
structure and production technology, sand casting was determined to produce
the valve body. The core box precision assembling core was adopted to mold,
and double-step ladle gating system was selected to pour with "full riser
design". Meanwhile, by adding cold iron, the internal defects in the water
valve body was eliminated. By using Anycasting simulation and actual
production verification, the correctness and feasibility of the designed
scheme were confirmed. © 2018, Journal Office of Special Casting and
Flow behaviour of a feeder at dendrite coherency point in metal castings

.
85047058690&partnerID=40&md5=d0be3d01c658c32bf42b9db5d5664de1
ABSTRACT: This study applied heat transfer and fluid flow in numerical
simulation of metal casting solidification in order to investigate the
solidification behaviour of the metal casting as it reaches dendrite
coherency point. The goal is to explore and gain insight about the ability
of a given feeder design to feed the casting section to obtain a shrinkage-
defectfree casting. The mathematical model of the casting solidification
was solved using the finite volume method (FVM). Various feeder designs for
a step casting of aluminium alloys were studied. The relationship of the
flow characteristic and the soundness of the casting is explored. The
objective is to gain insight on how the metal flow behaviour at dendrite
coherency may influence the casting performance. The scope of this study is
limited to lost-foam sand casting of aluminium-silicon alloys. © 2018
Penerbit Akademia Baru.
Comparative study of manufacturing condyle implant using rapid prototyping

and CNC machining
.
85047789373&doi=10.1088%2f1757-899X
%2f346%2f1%2f012061&partnerID=40&md5=1bbf278fef3be38fe1fb784837176be9
ABSTRACT: Injuries to the cranio-maxillofacial area caused by road traffic
accidents (RTAs), fall from heights, birth defects, metabolic disorders and
tumors affect a rising number of patients in the United Arab Emirates
(UAE), and require maxillofacial surgery. Mandibular reconstruction poses a
specific challenge in both functionality and aesthetics, and involves
replacement of the damaged bone by a custom made implant. Due to material,
design cycle time and manufacturing process time, such implants are in many
instances not affordable to patients. In this paper, the feasibility of
designing and manufacturing low-cost, custom made condyle implant is
assessed using two different approaches, consisting of rapid prototyping
and three-axis computer numerically controlled (CNC) machining. Two
candidate rapid prototyping techniques are considered, namely fused
deposition modeling (FDM) and three-dimensional printing followed by sand
casting The feasibility of the proposed manufacturing processes is
evaluated based on manufacturing time, cost, quality, and reliability. ©
Effects of aluminum and copper chill on mechanical properties and

microstructures of Cu-Zn-Al alloys with sand casting
.
85045619875&doi=10.1063%2f1.5030248&partnerID=40&md5=5e225b876a2472da11532d
1efda17248
ABSTRACT: Cu-Zn-Al alloy is one type of brass, which has high strength and
high corrosion resistant. It has been applied on ship propellers and marine
equipment. In this research, the addition of aluminum (Al) with variation
of 1, 2, 3, 4% aluminum to know the effect on mechanical properties and
micro structure at casting process using a copper chill and without copper
chill. This alloy is melted using furnace in 1100°C without holding. Then,
the molten metal is poured into the mold with copper chill and without
copper chill. The speciment of Cu-Zn-Al alloy were chracterized by using
Optical Emission Spectroscopy (OES), Metallography Test, X-Ray Diffraction
(XRD), Hardness Test of Rockwell B and Charpy Impact Test. The result is
the addition of aluminum and the use of copper chill on the molds can
reduce the grain size, increases the value of hardness and impact. © 2018
Author(s).
The effect of silver (Ag) addition to mechanical and electrical properties

of copper alloy (Cu) casting product
.
85045690157&doi=10.1063%2f1.5030297&partnerID=40&md5=f3b9b66b7e0f21fb876773
f1ab62e705
ABSTRACT: Copper have good mechanical properties and good electrical
conductivities. Therefore, copper usually used as electrical components.
Silver have better electrical conductivities than copper. Female contact
resistor is one of the electrical component used in circuit breaker. This
study aims to analyze the effect of silver addition to hardness, strength,
and electric conductivity properties of copper alloy. This study uses
variation of 0; 0.035; 0.07; 0.1 wt. % Ag (silver) addition to determine
the effect on mechanical properties and electrical properties of copper
alloy through sand casting process. Modelling of thermal analysis and
structural analysis was calculated to find the best design for the sand
casting experiments. The result of Cu-Ag alloy as cast will be
characterized by OES test, metallography test, Brinell hardness test,
tensile test, and LCR meter test. The result of this study showed that the
addition of silver increase mechanical properties of Cu-Ag. The maximum
hardness value of this alloy is 83.1 HRB which is Cu-0.01 Ag and the lowest
is 52.26 HRB which is pure Cu. The maximum strength value is 153.2 MPa
which is Cu-0.07 Ag and the lowest is 94.6 MPa which is pure Cu. Silver
addition decrease electrical properties of this alloy. The highest electric
conductivity is 438.98 S/m which is pure Cu and the lowest is 52.61 S.m
which is Cu-0.1 Ag. © 2018 Author(s).
The effect of zinc (Zn) content to cell potential value and efficiency
aluminium sacrificial anode in 0.2 M sulphuric acid environment
.
85045627328&doi=10.1063%2f1.5030285&partnerID=40&md5=c3a2195c2c52be9796a63f
42ec529340
ABSTRACT: Sacrificial anode is sacirifial component that used to protect
steel from corrosion. Generally, the component are made of aluminium and
zinc in water environment. Sacrificial anode change the protected metal
structure become cathodic with giving current. The advantages of aluminium
is corrosion resistance, non toxicity and easy forming. Zinc generally used
for coating in steel to prevent steel from corrosion. This research was
conducted to analyze the effect of zinc content to the value of cell
potential and efficiency aluminium sacrificial anode with sand casting
method in 0.2 M sulphuric acid environment. The sacrificial anode
fabrication made with alloying aluminium and zinc metals with variation
composition of alloy with pure Al, Al-3Zn, Al-6Zn, and Al-9Zn with open die
sand casting process. The component installed with ASTM A36 steel. After
the research has been done the result showed that addition of zinc content
increase the cell potential, protection efficiency, and anode efficiency
from steel plate. Cell potential value measurement and weight loss
measurement showed that addition of zinc content increase the cell
potential value into more positive that can protected the ASTM A36 steel
more efficiently that showed in weight loss measurement where the
protection efficiency and anodic efficiency of Al-9Zn sacrificial anode is
better than protection efficiency and anodic efficiency of pure Al. The
highest protection efficiency gotten by Al-9Zn alloy. © 2018 Author(s).
Effect of Coating Layer of Sand Casting Mold in Thin-Walled Ductile Iron

Casting: Reducing the Skin Effect Formation
.
85044389345&doi=10.1007%2fs40962-017-0173-
4&partnerID=40&md5=f35ee8c6a39b39c8e839ac60df26233c
ABSTRACT: The effect of various coating layers on the skin effect formation
in thin-walled ductile iron casting with glass wool heat insulator has been
investigated. Graphite, MgO, Zr, Zr + graphite, MgO + graphite coating
layers have been used. We observed that the different coating layers can be
used to control cooling rate. Higher heat conductivity coating layer yields
lower cooling rate, while lower heat conductivity yields higher cooling
rate. The use of double layer can further increase cooling rate which was
observed for Zr + graphite and MgO + graphite double coating layers. These
may only be applicable in our system. Higher cooling rate system produces a
casting product that has thinner skin effect. The use of MgO layer yields
lower skin effect thickness which stood at 52.27 µm. © 2017, American
Foundry Society.
The Effect of Manganese Sulfide Inclusions and Zirconium Additions on the

Mechanical Properties of Heavy Section Cast Steel
.
85044397046&doi=10.1007%2fs40962-017-0175-
2&partnerID=40&md5=e1ae9c55fcca358cf04088d744732cc2
ABSTRACT: The aim of this study is to evaluate the effect of the addition
of zirconium (Zr) as an inoculant to the microstructure and to examine the
mechanical properties of test coupons and heavy section cast steel via a
conventional sand casting method. The microstructural and mechanical
properties of cast steel and Zr-added steel specimens have been studied in
detail. Optical and scanning electron microscopes have been used to
identify the inclusion morphology and microstructural changes. Tensile and
Charpy V-notch impact test was carried out to determine the mechanical
properties of test coupons and heavy section cast steel. The results show
that the Charpy V-notch impact energy and elongation were improved by
adding Zr. Fractographic studies show that the Type III manganese sulfide
inclusions located on the dendrite arms evolve to Type I with the addition
of Zr. © 2017, American Foundry Society.
Life cycle assessment of wire + arc additive manufacturing compared to

green sand casting and CNC milling in stainless steel
.
85041140505&doi=10.1016%2fj.jclepro.2017.12.148&partnerID=40&md5=88114cf5f7
93b00e1df21654bbef0077
ABSTRACT: Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing
technique based on robotic welding. This technique yields potential in
decreasing material consumption due to its high material efficiency and
freedom of shape. Empirical measurements of WAAM, using a deposition rate
of 1 kg/h, were performed on site of MX3D. The measured power consumption
per kg stainless steel is 2.72 kW, of which 1.74 is consumed by the welder,
0.44 by the robotic arm, and 0.54 by the ventilation. The material loss was
1.1%. A 98% argon 2% CO2 welding gas was used with a flow of 12 l/min. A
cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this
assessment context, green sand casting and CNC milling were additionally
assessed, through literature and databases. The purpose of this study is to
develop insight into the environmental impact of WAAM. Results indicate
that, in terms of total ReCiPe endpoints, the environmental impact of
producing a kg of stainless steel 308 l product using WAAM is comparable to
green sand casting. It equals CNC milling with a material utilization
fraction of 0.75. Stainless steel is the main cause of environmental damage
in all three techniques, emphasizing the importance of WAAM's mass
reduction potential. When environmentally comparing the three techniques
for fulfilling a certain function, optimized designs should be introduced
for each manufacturing technique. Results can vary significantly based on
product shape, function, materials, and process settings. © 2017 Elsevier
Ltd
Optimization of green sand mould system using Taguchi based grey relational
analysis
.
85051220512&doi=10.1007%2fs41230-018-7188-
1&partnerID=40&md5=86a54da507e8715a08e98f77f53c4acf
ABSTRACT: The strength of the mould cavity in sand casting is very much
significant to attain high-quality castings. Optimization of green sand
process parameters plays a vital role in minimizing casting defects. In the
present research work, the effect of process parameters such as AFS grain
fineness number, water, molasses, bentonite, fly ash, and ramming, and
their levels on the resultant mould properties were investigated and
optimized using Taguchi based grey relational analysis. The Taguchi L18
orthogonal array and analysis of variance (ANOVA) were used. The quality
characteristics viz., green compression strength, permeability, bulk
density, mould hardness and shatter index of green sand mould were
optimized using grey relational grade, based on the experiments designed
using Taguchi's Design of Experiments. ANOVA analysis indicated that water
content is the most influential parameter followed by bentonite, and degree
of ramming that contributes to the quality characteristics. The results are
confirmed by calculating confidence intervals, which lies within the
interval limits. Finally, microstructure observations and X-ray diffraction
analysis have been performed for the optimal sand parametric combination.
Results show that presence of maximum amount of Si02, which might be the
reason for enhancement of the physical properties of the sand. © 2018,
Foundry Journal Agency and Springer Nature Singapore Pte Ltd.
Optimization of green sand casting parameters using taguchi method to

improve the surface quality of white cast iron grinding plates - A case
study
.
85045272817&doi=10.1109%2fIEEM.2017.8290186&partnerID=40&md5=c8d67d84923d33
6ceedbd3d8436ac26b
ABSTRACT: This research focuses on the optimization of parameters in green
sand casting process; specifically to improve the surface quality of white
cast iron grinding plates using statistical design of experiments
techniques. Four controllable factors; Bentonite (A), charcoal (B), water
content (C), sand mixing time (D) and one noise factor; pattern (E) were
considered as the influential factors which have an impact on surface
quality of the cast grinding plate. Taguchi method was used as the
experimental method to conduct the experiments. The analysis of the
experiment shows that main factors A (p = 0.061), D (p = 0.021), B (p =
0.180) and AB (p = 0.060) two way interaction have a significant impact (at
10% significance level) on surface quality of grinding plates. Finally, the
results obtained through the confirmation run verified the optimum
parameter settings produced by the Taguchi method gives robust solutions to
improve the surface quality of grinding plates successfully. © 2017 IEEE.
Simulation Research of Riser Effective Feeding Distance of WE54 Magnesium

Alloy Castings
.
85047133064&doi=10.15980%2fj.tzzz.2018.02.006&partnerID=40&md5=fc17776499b1
6286455bc1fb199d2b3a
ABSTRACT: Casting simulation method to predicting shrinkage porosities in
WE54 magnesium alloy castings was evaluated through comparison between
casting experiment and simulation, and the riser effective feeding distance
was calculated by simulation software. The results reveal that the
distribution of shrinkage porosities in WE54 magnesium alloy castings can
be predicted reliably with casting simulation method. At the same
thickness, the riser effective feeding distance of WE54 alloy is increased
with increasing in width-to-thickness ratio. And with constant width-to-
thickness ratio, the feeding distance is decreased with the casting
thickness decrease. The results can realize calculation of riser quantity
needed to feed a WE54 alloy casting, and the riser designing method for
WE54 alloy castings is optimized. © 2018, Journal Office of Special Casting
and Nonferrous Alloys. All right reserved.
Casting Process Design and Optimization of Turbine Runner Body [水轮机转轮体

铸造工艺设计与优化]
.
85061316874&partnerID=40&md5=1fec1d57d4283ff83f06d56617f7d8cf
ABSTRACT: The process characteristics of low alloy steel turbine runner
body by sodium silicated-bonded sand arestudied;the castingprocess is
designed and optimized. The casting is modeled by SolidWorks software, and
the flow field and temperature field of the casting filling process are
simulated by AnyCasting software.The final casting process is determined,
and verified by experiments.The results show that adopting stepwise pouring
way can ensure the melt being filled smoothly and completely. The shrinkage
and dispersed shrinkage of the casting can be efficiently eliminated by
using of riser and chill. With optimal process scheme, the casting of low
alloy steel turbine runner body is totally shaped and has a legible
contour, and there are notobvious casting defects in the casting. © 2018,
Anti-carburizing Coating for Resin Sand Casting of Low Carbon Steel Based
on Composite Silicate Powder Containing Zirconium
.
85040680602&doi=10.1051%2fmatecconf
%2f201714203007&partnerID=40&md5=001d3eb8fd8d6fe172a056cf9ee7f2a7
ABSTRACT: This paper studied the structure and properties of
anticarburizing coating based on composite silicate powder containing
zirconium by X-ray diffraction analyzer, thermal expansion tester, digital
microscope and other equipment. It is introduced that the application
example of the coating in the resin-sand casting of ZG1Cr18Ni9Ti stainless
steel impeller. The anti-carburizing effect of the coating on the surface
layer of the cast is studied by using direct reading spectrometer and
spectrum analyzer. The change of the micro-structure of the coating after
casting and cooling is observed by scanning electron microscope. The
analysis of anti-carburizing mechanism of the coating is presented. The
results indicate that the coating possesses excellent suspension property,
brush ability, permeability, levelling property and crackresistance. The
coating exhibits high strength and low gas evolution. Most of the coating
could be automatically stripped off flakily when the casting was shaken
out. The casting possesses excellent surface finish and antimetal
penetration effect. The carburizing layer thickness of the stainless steel
impeller casting with respect to allowable upper limit of carbon content is
about 1mm and maximum carburizing rate is 23.6%. The anticarburizing effect
of casting surface is greatly improved than that of zircon powder coating
whose maximum carburizing rate is 67.9% and the carburizing layer thickness
with respect to allowable upper limit of carbon content is greater than
2mm. The composite silicate powder containing zirconium coating
substantially reduces the zircon powder which is expensive and radioactive
and mainly dependent on imports. The coating can be used instead of pure
zircon powder coating to effectively prevent metal-penetration and
carburizing of resin-sand-casting surface of low carbon steel,
significantly improve the foundry production environment and reduce the
production costs. © 2018 The Authors, published by EDP Sciences.
Biodegradability of polyvinyl alcohol in sand for resin bonded sand casting

process
.
85056459610&partnerID=40&md5=e4adb63ddcfa1b89299ff20c070f7de5
ABSTRACT: Resin bonded sand casting is widely used for manufacturing
automotive parts, especially those made of aluminium alloys. In general,
resin bonded sand casting use alkaline resin as binding agent. Typically,
they are from non-biodegradable materials that have issues on reclamation
and disposal of the sand as well as cause hazard to the environment.
Therefore, a biodegradable resin consisting of Polyvinyl Alcohol (PVA) as
one of the solution contents was developed to substitute the non-
environmental friendly resin. The purpose of this investigation is to
attest that PVA is a biodegradable material under natural environment.
Weight loss quantification was used as a method to study the
biodegradability of PVA and Fourier transform infrared spectroscopy (FTIR)
and Raman spectroscopy were used to examine the molecular bonding as well
as the morphological structure of the resin after biodegradation. The
degradation process was evaluated by the weight loss and molecular
structure of the PVA. At the end of this study, the weight loss of PVA is
insignificant to show the biodegradation process. However, further
investigation using FTIR and Raman spectroscopy methods; it is observed
that there is a significant change in molecular and morphological structure
of PVA. © 2016 Journal of Advanced Manufacturing Technology.
Optimization of moulding composition for quality improvement of sand

casting
.
85049246484&partnerID=40&md5=61ea5fbd16ad04d57c59427d34db8f68
ABSTRACT: Sand casting is a versatile and commonly used manufacturing
process in the metal casting industry. This method can be used in almost
all types of metal and the sand is recyclable. However, the defects in
casting production such as blowholes, pinholes, shrinkage, and porosity
cause imperfection in green sand moulding. The aim of this project is to
optimise the composition of silica sand, bentonite, water, and coal dust in
green sand to reduce the defects in the casting products using the 24-
factorial experiment design method, which can produce a total of 16 runs
for experiment to investigate the ratio of the four parameters. Then the
experiment results of compression strength are collected and the
composition effect of green sand was investigated. The results shows value
of the adjusted R-square indicated that 86.92% of the total variability was
explained by the model and the model predicted and actual fitted well with
the experiment data. An analysis using the Design Expert software
identified that bentonite and water are the main interaction effects in all
of the experiments. The optimal settings for green sand composition are 95g
silica sand, 24g bentonite, 8g water, and 8g coal dust. This composition
has an effect of compression strength 35kN/m2. © Journal of Advanced
Manufacturing Technology.
Morphology of aluminium with nickel addition on sand casting process

.
85047893742&doi=10.5604%2f01.3001.0012.0734&partnerID=40&md5=22684483a4f1e2
2d2a529836f57c1d64
ABSTRACT: Purpose: his research aimed to examine the morphology, elemental
changes, and phase in the aluminium cast alloys with variations in nickel
addition of 1%, 2% and 3%. Design/methodology/approach: Aluminium 98% was
melted in sand casting process. The sand casting process was operated at
7000C and atmospheric pressure. The addition of nickel contain of 92.19% of
its element. Specimens consist of 4 pieces Al-Ni with the size of 1 × 1 ×
0.5 cm for morphological testing, while for phase identification testing
consist of 4 pieces Al-Ni with the size of 1 × 1 × 2 cm. The morphological
testing was performed using FEI Inspect S50 Scanning Electron Microscope
(SEM) and the phase characterisation was conducted using Nikon ME5 Optical
Microscope. Findings: The results showed that the addition of 1% nickel in
the aluminium cast product could affect the morphology in granular shape
with as similar size, at 2% nickel addition also has granular shape, while
at 3% of nickel addition, the morphology of Al-Ni was in elongated shape.
Phase identification of Al-Ni cast alloy shows that there were Al matrix
with nickel that spread in grain boundary of Al. By increasing the
percentage of nickel, it shows that the nickel dominated the grain boundary
of Al. These results shows that Al-Ni alloy can be produced at simple route
on sand casting process. Research limitations/implications: Sand casting
process with 80% silica sand, 10% bentonite, 5% water. Raw material of
aluminium contains of 92-99% of purity. Nickel as addition element contain
of 90-92% purity. Practical implications: The addition of nickel should be
prepared wisely in term of the calculation of alloying treatment because it
will effect the mechanical properties of Al alloy itself. This research can
be improved by varying the temperature of casting process, variation of
nickel percentage, and observation of mechanical properties of Al-Ni alloy.
Originality/value: Simple route of making Al-Ni alloy using sand casting
method in laboratory and also the observation of nickel addition in
aluminium matrix as the result of casting product. © International OCSCO
World Press. All rights reserved. 2018.
The effect of palm oil fly ash reinforcement on recycle aluminium via sand
casting
.
85058419019&doi=10.14419%2fijet.v7i4.27.22508&partnerID=40&md5=033f75f14c36
f7b37e746b7b5465a4ca
ABSTRACT: Recycle aluminium has been mixed with palm oil fly ash based on
fraction weight of overall weight of palm oil fly ashes to aluminium
recycle. The ratios discussed on this paper are 0%, 3% 6%, 9%, 12% and 15%.
The samples have been developed via sand casting method. The result shows
that the best composition has been achieved when we added 3% of palm oil
fly ashes, with the new composite aluminum have a highest hardness with the
value of 119.7HV, with the Modulus of raptured of 7.71Mkg/m2. © 2018
Authors.
Mastering of the filling stage in low pressure sand casting process

.
%2fMSF.941.2306&partnerID=40&md5=d67b9559f4decc9c355ad1a4840a9f42
ABSTRACT: In Low Pressure Casting (LPC), the counter gravity filling at low
velocity and the protective gas atmosphere above the metal can potentially
reduce gas and oxides entrapment in the metal. However, the relationship
between the imposed gas pressure evolution and the melt filling dynamics
cannot be analytically determined as it is geometry-dependent. This issue
is the missing link to master and automate the filling step in LPC process.
In this work, the filling dynamics is numerically investigated for
different mold geometries and pressure ramps. The simulation, carried out
using ANSYS Fluent® simulation software, is combined with an analytical
model. As the results are quantitatively predictive of the filling flow, it
permits to develop a numerical study, considering different sudden or
progressive section changes and pressure ramps. The impact of the different
process parameters on the flow dynamics is analyzed, particularly the
transition smoothing impact. © 2018 Trans Tech Publications, Switzerland.
A six sigma framework for eliminating defects in sand casting foundries

.
85062275957&partnerID=40&md5=d1d89f7ee50bb7313b993582f1d93937
Design and Simulation of LM 25 Sand Casting for Defect Minimization

.
85045154923&doi=10.1016%2fj.matpr.2017.12.018&partnerID=40&md5=02e73c2e16e5
08ca1ad517e7dab36a31
ABSTRACT: The most critical step in casting process is the solidification
of molten metal in prepared mould cavity, because this is time where the
defects like volumetric shrinkage, porosity, blowholes occurs and affects
the quality of casting. These defects come into picture when the part is
completely manufactured and went for testing. In traditional casting
process to overcome these defects, again we have to redesign feeder, gating
system, etc, and repeat the casting, so this will directly affect the rate
of production. If these defects can be address before casting then it will
really help casting industry to improve their production rate and revenue.
These problems can be address using smart methoding and advance simulation
using casting software. In this paper the study has been made to improve
design and manufacture a defect free casting in particular volumetric
shrinkage defect and yield. The part taken for study is Contact wheel from
one of casting company in Aurangabad, Maharashtra. The company suffers from
casting defects like shrinkage, blowhole and pinhole. Casting
solidification is quickly simulated to view the progress of cooling from
casting surface to interior, and to predict the location of shrinkage
defects such as porosity and cracks.This helps in verifying and optimizing
the design of feeders, which can be verified by advanced simulation. This
simulation result was compared with the experimental trial and the
comparison result was found to be good. © 2017 Elsevier Ltd.
Optimization of green sand casting process parameter using response surface

methodology
.
85069678114&partnerID=40&md5=515e519c173e67b0d95a1b14e62bb891
ABSTRACT: This study demonstrates the optimization of the green sand
casting process parameter to generate the optimum quality characteristics
of the grey cast iron castings for a sand related defect. Firstly, the
planning of experiment is done based on response surface methodology using
Box-Behnken design. Analysis of various critical process parameters and the
interaction among them is carried out with the help of Design expert
software. The process parameters considered are permeability number,
volatile content (%) and moisture (%). The response variable is the defect
percentage and the analysis is done with the smaller the better-quality
characteristics. All the process parameters are considered for three levels
with a total of 17 runs and based on the fit analysis 2 Factored
Interaction (2FI) analysis was used as it had a better-adjusted R squared
value in competition with a linear and quadratic equation. Analysis of
variance (ANNOVA) is used to analyze the significance of each factor. It is
found that the volatile content has a significant effect on the sand
related defects. The results are optimized and to make the analysis more
precise contour plots and surface plots are used to study the effect of
each parameter on sand related defects. It was found that moisture content
of 3.3%, volatile matter content of 2.8% and permeability number of 150 is
the optimum solution with a rejection rate of 5.7%. The mathematical model
adequacy is verified in the foundry and it was found satisfactory with a
maximum error of 7%. © TJPRC Pvt. Ltd.
Innovative foundry technology and material using fused deposition modeling

and polylactic acid material in sand casing
.
85049779933&doi=10.24425%2f122504&partnerID=40&md5=c342a82a986155c459b8fc3a
3b1d5b62
ABSTRACT: In sand casting, Fused Deposition Modeling (FDM) printing by
using Poly Lactic Acid (PLA) filament is one of the innovative foundry
technologies being adopted to substitute traditional pattern making.
Several literatures have reported the influence of process parameters such
as raster angle and print speed on some mechanical properties of FDM-
printed, PLA-prototypes used in other applications. This study investigated
the effects of interior fill, top solid layer, and layer height on the
compressive strength of rapid patterns for sand casting application.
Different values of the process parameters were used to print the pre-
defined samples of the PLA-specimens and a compression test was performed
on them. The coupled effects of the process parameters on compressive
strength were investigated and the optimum values were determined. Interior
fill of 36%, layer height of 0.21 mm and top solid layer of 4 were found to
produce a FDM-printed, PLA-pattern that sustained a compaction pressure of
0.61 MPa. A simulation analysis with ANSYS® to compare failure modes of
both experiment and model shows a similarity of buckling failure that
occurred close to the base of each specimen. © 2018 Polish Academy of
Sciences. All Rights Reserved.
Effects of Welding Repair on Performance of Sand Mmold Casting Aluminum

Alloy Castings
.
85046721540&doi=10.15980%2fj.tzzz.2018.01.025&partnerID=40&md5=1b5c1cec3510
ed9f5aaf2adf0445f31d
ABSTRACT: Effects of the argon arc welding repairing on the properties of
ZL114A alloy sand castings were investigated by tensile testing and fatigue
testing. The results reveal that the argon arc welding repairing has the
ingored effect on properties of the ZL114A alloy sand castings, where the
tensile strength and yield strength are decreased by about 5% and the
elongation is decreased by about 15%. The high temperature of welding
process can result in Mg element burn-loss, so the strengthening phase
Mg2Si in the ZL114A alloy is reduced, leading to the decrease of properties
of the welding zone. The difference of hole and pore geometry and number
between the weld zone and un-welded zone can be observed, so fatigue life
of full-welded specimen is lower than that of half-welded and un-welded
ones at high stress condition, while fatigue life of half-welded specimens
is higher greatly than that of un-welded and full-welded ones. © 2018,
Journal Office of Special Casting and Nonferrous Alloys. All right
reserved.
Bayesian inference based optimization of process parameters for chemically

bonded molding system
.
85062301790&partnerID=40&md5=bcfd265f2f76ce47bf38717e217af274
ABSTRACT: Introduction of chemically bonded process is considered to be one
of the key improvements in molding of sand casting process. This further
leads to improved surface finish and better dimensional accuracy in
castings. However, quality of chemically bonded mold is primarily driven by
different process parameters including Grain Fineness Number (GFN), Binder
(%) and curing time. These process parameters affect different mold
characteristics (mold compressive strength, shear strength, mold shrinkage
and core hardness). In this work, the effect of different process
parameters on the characteristics of the mold has been studied. Three-part
binder system (one of chemically bonded molding system) has been taken for
the study, as it is widely accepted in most metal casting foundries. The
process parameters mentioned above varied in three levels, and experiments
were performed. The experimental results were then optimized using Bayesian
inference based tool. The Bayesian inference method is essentially based on
probabilistic approach. This tool is developed in such a way that it takes
input in the form of a spreadsheet, and provides an optimized range of
values for each input parameter. It was observed that GFN (no.) with 40-48;
Binder (%) with 2.20-2.40; curing time with 2-2.4 (hr) are optimized values
to achieve higher strength while optimum range of values for minimum core
shrinkage are found to be GFN: 70-80, Binder (%): 1.80-2.00; Curing Time:
1.75-2.50. Bayesian inference based tool is proven to be very effective in
the optimization of different characteristics of chemically bonded mold. ©
73rd World Foundry Congress "Creative Foundry", WFC 2018 - Proceedings.All
Rights Reserved.
Determination of critical cooling rate for minimization of porosity in the
large aluminum casting
.
85062284780&partnerID=40&md5=d4c5aed89c2992ae7e6ec56ab694eb26
ABSTRACT: In the present study, effect of cooling rate on the formation of
the porosity in the thick aluminum sand casting was investigated. Nowadays
large scale thick aluminum casting replaces steel frame for vacuum chamber
for semiconductor production, with the consideration of weight and cost
reduction. Several thick aluminum castings were manufactured using chill
with temperature measurements. The castings were inspected by using 3D
computed tomography in order to quantify the porosity defect density in the
castings. Effect of the thickness of the chill on the porosity defect
density were discussed. © 73rd World Foundry Congress "Creative Foundry",
WFC 2018 - Proceedings.All Rights Reserved.
Microstructural characterization and mechanical properties of sand cast and

investment cast alloy 625 for HP/IP casing applications for advanced fossil
fired power plants
.
85060439806&doi=10.1016%2fj.matpr.2018.09.019&partnerID=40&md5=20cccc474ca5
715a27c458cc505a9a6b
ABSTRACT: Alloy 625 is a candidate material for high temperature sections
of High Pressure (HP)/ Intermediate Pressure (IP) turbine casings for
Advanced Ultra Super Critical (AUSC) power plants. This material is
expected to operate at steam temperature of 710°C approx. and pressure of
300 ata approx. After carrying out a detailed literature survey, it was
observed that microstructural information and mechanical properties data on
Alloy 625 cast material is limited. Hence, this study was undertaken for
obtaining of mechanical properties and microstructures at room temperature
through two manufacturing techniques namely, conventional sand casting and
investment casting. Mechanical properties data includes tensile testing and
impact testing. The data obtained from this study is essential for design
of casings. The details of the study and results obtained are discussed and
presented in this work. © 2018 Elsevier Ltd.
Microstructure effects of Y2O3 addition to A356 alloy

.
85062273264&partnerID=40&md5=b408114a6e357f03806307bc1f5b8b5d
ABSTRACT: Aluminum alloys are the major lightweight alloys used in the
automotive industry. [9]. Improving the mechanical properties of these
alloys via microstructure control has been the target of many research
works. In the foundry industry, microstructure is controlled mainly through
modification and grain refinement processes. The present work investigates
the effect of dispersing Y2O3 powder in the molten 356 cast alloy on the
grain size of α-aluminum. A series of sand casting experiments were carried
out with Y2O3 addition ranges from 0.0 to 2.5 wt%. The microstructure was
investigated and the hardness was evaluated and related to the
microstructure of the cast samples. It was observed that addition of can
partially refine α-Al grains; however, the amount of addition should be
optimized to avoid the possible adverse effects on the microstructure. ©
73rd World Foundry Congress "Creative Foundry", WFC 2018 - Proceedings.All
Rights Reserved.
Challenges in gravity sand casting of Ze41 Mg alloy

.
85062303212&partnerID=40&md5=f9d62dc88c3a13080185b2df03dc50ab
Optimization of parameters effecting the heat recovery from a sand casting
process
.
85055709686&doi=10.21533%2fpen.v6i2.181&partnerID=40&md5=caa105bf1a25d7dbc8
52212505deb49b
ABSTRACT: Energy crises has gripped the world to a large extent.
Researchers are experimenting on newer and newer avenues to produce energy
efficiently, economically. Energy saved is actually twice produced. Energy
conservation is the need of the hour. Keeping this in mind the authors of
the paper have developed a method to harness the heat that gets wasted
during the casting process. Casting is basically one of the manufacturing
processes were molten metal is poured into mould and then solidified. The
solidifying metal takes the shape of the mould. Huge amount of energy is
required for the melting of the raw material. When the metal solidifies it
gives way the heat. In the present work the mould is modified such that the
raw material that will be used for subsequent process gets pre heated by
the heat that emanates due to the solidification process. A number of
factors influence the amount of heat that is recovered. Here attempt is
made to find out the factors that influence the pre heat of raw material
and also using Particle swarm optimization technique the factors are
optimized so that the heat recovered is maximised. The implementation of
the process is simple and the gains are enormous in terms of the energy
that is going to be saved. © 2018 International University of Sarajevo.
Implementing advanced technologies in the sand casting supply chain

.
85054486410&partnerID=40&md5=da69ec56b29076d039d4850e6e23e6cc
ABSTRACT: How many castings should be poured before getting a useable part?
The ideal answer may be one, but the reality is that the ideal is
infrequently realized. What alloy is the part? What is its size? What is
the complexity? How is the part complex: many interior cores, many thick to
thin section transitions, very thin walls, or something else entirely? No
two part geometries will be exactly the same, so the challenges and
expectations for each part will be different. At Sikorsky, our sand cast
components only seem to be getting more complex, with more demanding
dimensional and metallurgical requirements. All of these factors makes the
casting of these parts more challenging. This also coincides with a time
where lead times and costs to develop a new casting are being scrutinized.
Casting technologies have been tested on development programs at Sikorsky,
including the use of simulation of the pour, digitally produced mold and
low pressure casting. These technologies have shown dramatic improvements
in lead time and reduced the number of pours to yield a useable part.
However, there is still hesitation in promoting the use of these
technologies for production parts. An engineering specification has been
released that creates a process for using these new technologies for
casting manufacturing. In addition to changing our own internal processes,
Sikorsky is also driving change into the foundry industry as an outsider.
While we have found that the use of simulation, additive manufacturing of
the molds, and low pressure casting has greatly increased yields, the
foundry industry has been slow to adopt these technologies. Identifying
ways to influence change at existing suppliers and cultivate relationships
with new suppliers has been paramount to the success of these projects.
This paper explores this phenomena of cultivating change within our own
company's processes and procedures and influencing change in the greater
industry. We will also present reasons why programs are not buying in to
using these technologies, as well as a strategy to mitigate the
disinterest. Copyright © 2017 by AHS International, Inc. All rights
reserved.
Characterization of mechanical properties and corrosion behaviours of Mn
and Al Bronze Castings [Charakterisierung der mechanischen Eigenschaften
und des Korrosionsverhaltens von Gussteilen aus Mn-und Al-Bronze]
.
85042542413&doi=10.3139%2f147.110470&partnerID=40&md5=8ec0bab6ebdc40ea3450f
cf286273e13
ABSTRACT: From ancient times to the present, copper alloys, brasses and
bronzes are used for marine applications due to their high resistance to
sea water. In time, numerous of copper alloys have been developed and
manganese (Mn) and aluminium (Al) bronzes are the well-known members of
this large family. They have superior properties and are used to produce
some critical components of boats. These alloys are in competition with
each other. For this reason, C86500 Mn bronze and C95800 Al bronze were
evaluated in this study. Mechanical and corrosion tests were carried out on
specimens which were taken from sand castings. Tensile, impact and hardness
tests were applied to determine mechanical properties. Corrosion behaviour
of the alloys was characterized in HCl, NaCl, and H2SO4 solutions.
Additionally, microstructure observations and a definition of phases were
realized. According to mechanical tests results, Al bronze has better
properties than Mn bronze. Moreover, Mn bronze provides lower corrosion
rates in HCl solution as Al bronze in H2SO4. Intergranular corrosion was
detected in HCl solutions. Moreover, some micro shrinkage zones were seen
on an Al bronze specimen after corrosion tests. © Carl Hanser Verlag,
München.
Waste and discharge sand use of foundry for the manufacture of concrete
tiles
.
%2fKEM.759.3&partnerID=40&md5=de166e84292a8b548655f1ad0e303294
ABSTRACT: The progress in the world industrial sector, together with new
technologies increases solid waste generation and the consequent concern
with the correct management of them. One of the biggest problems in the
foundry sector is the generation of solid waste, consisting mainly of waste
sands or discarded sand castings (ADF). Proper waste disposal is a
challenge for industries, which are increasingly concerned about the need
to preserve the environment and seeking for sustainable development. In
Brazil, fused production in 2008 exceeded three million tons, generating
approximately one ton of waste for each ton of metal produced. The main
destination of this waste is industrial disposal landfills, which have high
cost and is an increasing environmental concern for companies. Therefore,
the aim of this research was to solve this problem, that is, it was
proposed a methodology to reuse these solid wastes, testing our methodology
by using concrete slabs with incorporation of foundry sand in different
concentrations, in an increasing order of 5%, where natural sand was
replaced by founding sand. The viability for the use of casting sand in
relation to the resistance was significant in the traces 30% and 35%. ©
2018 Trans Tech Publications, Switzerland.
Dynamic measurement of constraining force from green sand and casting

contraction of gray cast iron during cooling
.
85047756167&doi=10.2320%2fmatertrans.F-
M2018817&partnerID=40&md5=56b36a512414959ddfc0724cf19ad367
ABSTRACT: This study investigated the effects of the restraint from green
sand mold for cast iron during cooling process. Gray cast iron (JIS FC300,
almost identical to ASTM 45) was cast in a green sand mold, and the
constraining force to the casting from the sand mold and the contraction of
the casting were measured dynamically from the beginning of solidification
to 200°C. The measurement results obtained using the green sand mold were
compared with those using the furan sand mold. The maximum constraining
force in the green sand mold case was lower than that in the furan mold
case. The contraction in the green sand mold at 200°C was greater than that
in the furan sand mold. The results showed that the green sand mold
restrains the casting less than the furan sand mold during cooling process.
© 2018 The Japan Institute of Metals and Materials.
A study of inclusions in aluminum and titanium deoxidized 4130

.
85046734629&doi=10.24425%2f118825&partnerID=40&md5=be0c52f30a638d118df9cdc3
6cef49cf
ABSTRACT: In this paper, the authors investigated the size distribution of
titanium oxide (TiO2), titanium nitride (TiN) and titanium carbide (TiC)
inclusions in a titanium deoxidized 4130 steel and compared it with the
4130 base alloy composition inclusions. TiN and TiC inclusions are of
particular interest due to their role as heterogeneous nuclei for various
phase reactions in steels. Two types of samples were prepared, a polished
sample and a filtered sample. Electrolytic dissolution was employed to make
the filter paper samples. The size range of titanium inclusions was found
to be more than that of the non-metallic inclusions from 4130 base alloy
heat. Titanium inclusions from the filter and polished samples were round
in shape. TiC and TiN inclusions were not found in the electrolytic
extraction samples. Inclusions and their chemistries were analyzed using
scanning electron microscope and energy dispersive spectrometer. The
inclusion size range was larger for the titanium deoxidized samples than
the base alloy. However, in both steels the majority of inclusions had a
size smaller than 10 μm. © 2018 De Gruyter Open Ltd. All rights reserved.
Study on Cold Metal defect in Pump Mounting Flange using Taguchi Approach
.
85058419437&doi=10.1016%2fj.matpr.2018.10.323&partnerID=40&md5=c2a620c4e92d
932ffaac502532feff34
ABSTRACT: Sand casting is a process of producing complex shape castings
which cannot produce by other processes. Production of defect free casting
is a challenging task in a foundry. The quality of component produced by
sand casting is affected due to uncontrollable process parameters. Until
controlling such parameters, it is difficult to achieve defect free
casting. Keeping this in mind, a study is carried out in a jobbing foundry
in South Tamil Nadu. From the six months rejection data, it is identified
that the Pump Mounting Flange is mostly rejected due to cold metal defect.
In order to overcome the cold metal defect the process parameters mold
hardness, moisture, time and temperature of pouring are investigated using
the Taguchi approach the optimized values are arrived. The regression
analysis confirmed that the optimized values are acceptable. The values are
recommended to foundry for the production process. By six sigma methodology
(DMAIC), the quality tools Data Chart and Histogram are used to select
defected casting. From the Cause and effect diagram the root cause of the
cold metal defect is identified. © 2018 Elsevier Ltd.
Durable, flexible, superhydrophobic and blood-repelling surfaces for use in

medical blood pumps
.
85054875195&doi=10.1039%2fC8TB01547C&partnerID=40&md5=7eb0c89a8ab7015cb522c
ae52333f6a5
ABSTRACT: Extracorporeal blood pumps expose blood to high stresses and can
cause blood damage or clotting, leading to serious complications and death.
One possible solution is to use superhydrophobic (SHP) surfaces to reduce
blood stresses via slip flow. However, current SHP surfaces have the
durability problem, or are difficult to customize into complex 3D shapes.
Here, we report a novel sand-casting technique to prepare a SHP and blood-
repelling surface made of silicone and functionalized SiO2 nanoparticles,
which is durable, flexible, and customizable into complex 3D shapes with
relative ease. Compared to plain silicone surfaces, the casted surface can
reduce the water drag force by up to 72%. The casted item is mechanically
durable, maintaining its SHP properties after repeated tape peeling and
alcohol swab rubbing, high-speed (9.7 m s−1) water impacting, and high-
pressure sandpaper abrasion. Its flexibility is also demonstrated by
retention of its superhydrophobicity after repeated bending. Moreover, the
material is SHP as prepared. This allows the material to be shape-
customizable, simply by preparing molds of specific 3D geometries for sand-
casting, which will be useful on surfaces of complex 3D shapes. This SHP
material can be used on rigid blood pump surfaces or on flexible tubings of
roller pumps. © The Royal Society of Chemistry.
Research on coatings and infiltration to strengthen ceramic lost cores used

in high pressure die casting processes
.
85062273744&partnerID=40&md5=f85bdc01eb238ca017422aa9a94e7647
ABSTRACT: Lost cores used to manufacture complex aluminium components
through High Pressure Die Casting (HPDC) processes need to withstand very
high pressures. Conventional sand cores used in other casting processes,
such as sand casting or low pressure die casting, do not support these
pressures, so advanced ceramic cores must be used. These cores must be
strong enough to withstand the casting process and, at the same time, have
enough porosity to be easily removed to obtain the finished part. Due to
this porosity, aluminium penetrates the core surface during the casting
process. In this work, two research lines have been followed to address
this problem: application of coatings to seal the surface and infiltration
with silica. © 73rd World Foundry Congress "Creative Foundry", WFC 2018 -
Proceedings.All Rights Reserved.
Manufacture of biomaterials
.
85078646875&doi=10.1016%2fB978-0-12-801238-3.11027-
X&partnerID=40&md5=8f857860868a6d6ba84708620d3e05c8
ABSTRACT: Biomedical materials are biocompatible metals, polymers, ceramics
(including glasses and glass-ceramics), and composites. They are used in
the biomedical field in various forms: particles, fibers, thin films,
coatings, dense and non-porous, porous, etc. The size of implants and
medical devices ranges from tens of nanometers to tens of centimeters and
their shapes and geometries vary tremendously. Many biomedical materials
also require surface modification for achieving desired biological
responses. Therefore, numerous techniques have been investigated and
developed for the fabrication of biomedical devices from different types of
biomedical materials. This article gives a comprehensive coverage of major
manufacturing technologies for all types of biomedical materials. © 2019
Elsevier Inc. All rights reserved.
Optimization of casting parameters using taguchi method

.
85063436991&doi=10.24247%2fIJMPERDAUG201892&partnerID=40&md5=a456e28463dbaf
d7cf99ea7d2d6eee4a
ABSTRACT: Casting is a manufacturing process used in industries for mass
production in which materials in molten state are poured in a mold cavity
to solidify. A foundry’s performance should be high in terms of production
with minimum defects. Systematic analysis and identification of sources of
defects are essential for successful manufacturing. Various casting
parameters like moisture content, permeability, pouring temperature, green
compressive strength, mold hardness number and clay percentage affect the
casting quality. This paper discusses the influence of various casting
parameters on the quality of casting. The prominent parameters (moisture
percentage, green compressive strength, mold hardness number) were selected
on the basis of comparative study of research papers. Weight percentage was
selected as the response variable to obtain best results with minimum
possible cost of experimentation. To optimize the selected parameters,
Taguchi optimization technique was used by implementing L9 orthogonal array
and optimum values of parameters were obtained by Minitab software
analysis. The results show that weight percentage is minimal at certain
levels and these were verified practically by implementing in foundry,
which resulted in significant improvement in quality of casting. © 2018,
Transstellar Journal Publications and Research Consultancy Private Limited
(TJPRC). All rights reserved.
Quality assessment of Al castings produced in sand moulds using image and

CT analysis
.
85062303471&partnerID=40&md5=2f2cb3eddd67306d5af2b95ee636eac8
Combining mold milling and 3D sand printing to optimize casting design

.
85062292260&partnerID=40&md5=3af2cf980e555ebdf73aa29d8dfd0a79
Effect of Nd content on structures and mechanical properties of Mg-Gd

alloys cast into sand molds
.
85062269651&partnerID=40&md5=62ca3886a387ea04ba60f6808de29201
Using of 3D printed permanent patterns for mass production of castings on

„green sand” moulding lines
.
85062268585&partnerID=40&md5=7a5b0f62fa8067f20d066eb47cc98807
Dynamic measurement and FEM analysis of restraint force from mold on gray
cast iron castings and contraction of castings during cooling in green sand
mold
.
85062259011&partnerID=40&md5=ced38ef33970245d8a435a69c9da523e
Analysis of Filling in Thin Section by FEM Based Simulation for LM6

Material
.
85045145779&doi=10.1016%2fj.matpr.2017.12.196&partnerID=40&md5=37821ce760e3
315064035f8dc5822227
ABSTRACT: This paper deals with the cooling characteristics of LM6 alloy
used as a pouring material for manufacturing of thin hollow rectangular
section during the solidification process inside the mold. For purpose of
an accurate mathematical modeling, it is essential to establish appropriate
gating design and pouring temperature. Here simulation experimental study
is carried out by using Pro CAST 2009.0 for LM6 alloy. In this
investigation pouring is done on thin rectangular section at different
pouring temperature and sprue height. Finally a comprehensive analysis
result shows that for efficient casting, pouring temperature is more
significant parameter as compared to sprue height. © 2017 Elsevier Ltd.
Energy and material efficiency metrics in foundries

.
85049203210&doi=10.1016%2fj.promfg.2018.02.140&partnerID=40&md5=f955a6802e5
a6e3cfde7d40307a26434
ABSTRACT: Most of the current foundry processes are based on well-developed
and established practices typical of mature technologies. Contemporary
economic, environmental and societal developments have concurrently changed
at an unprecedented rate the context where traditional metal casting
methodologies have not really developed much over time. Consequently,
significant challenges and opportunities arise. This work will present the
founding metrics of a novel approach to metal casting with the development
of a new philosophy (called "Small is Beautiful") aimed at tackling the
current pressures on the industry with a focus on energy and materials'
efficiencies and flexible production. Traditional and well-established
parameters are presented and compared to new metrics defined from first
principles and thermodynamic properties. All metrics are validated using
industrial and scientific literature data of five sand casting plants
melting different ferrous and non-ferrous alloys. © 2018 Elsevier B.V. All
rights reserved.
A novel measurement method to study the themral aspects of moulding mixture

decomposition
.
85062275328&partnerID=40&md5=73bbc9d9887fdf2eddf4738ba844a41e
ABSTRACT: A wide variety of moulding mixtures are extensively used in the
process of sand casting of metal components. The sector is continuously
developing in production volume, moreover the expectations from the
customers are increasing on monthly basis, also from the quality point of
view. Even though mould and core manufacturing are well-organized processes
in most foundries, technological problems still appear which may lead to
casting defects. These trends are forcing metal casters to come up with
fitting strategies to solve their daily production challenges, while their
suppliers are expected to keep up the continuous development of their
existing foundry products and to find innovative solutions. Research on
moulding materials and their properties must also take the step forward
accordingly to generate the necessary new knowledge. This paper summarizes
the latest results of a novel measurement method suitable for studying the
degradation characteristics of different moulding materials from a new
perspective. The fundamentals of the method are based on thermal analysis,
focusing on the heat absorption behaviour of sand mixtures regardless of
binder type/amount or manufacturing process. © 73rd World Foundry Congress
"Creative Foundry", WFC 2018 - Proceedings.All Rights Reserved.
The effects of 0.16 % Chromium + 1.32 % Nickel addition on austempered

ductile iron for mechanical properties and slurry erosion
.
85052585346&partnerID=40&md5=7c5f5082d988da5eb8bf94b965591268
ABSTRACT: The effects of mechanical properties and slurry erosive wear
behaviour on combination of Chromium and Nickel Alloyed Ductile Iron before
and after austempering process were investigated in this study. Specimens
of pure ductile iron and addition of 0.16 % Cr+ 1.3 2% Ni alloyed ductile
iron were produced through conventional CO2 sand casting method. The
specimens were then austenitized at 900 °C before being tempered at 300 °C
for 40 minutes. The slurry erosion of newly developed material were
obtained by means of slurry erosive wear and the mechanical testing
involved tensile test (TS 138 EN1002-1), Vickers hardness test and Charpy
Impact test (ASTM E23). Roughness tests as well as SEM observations were
also done to Cr-Ni alloyed ductile iron samples. All the testing was done
to both as cast and austempered specimens. Austempering process heat
treatment of Cr-Ni alloyed ductile iron has shown an increase in slurry
wear and mechanical properties compared to as cast due to solid
strengthening effect of Chromium and Nickel. Meanwhile, the austempering
process does improve the hardness of alloyed ductile iron. © 2016 Faculty
of Mechanical Engineering, Universiti Teknologi MARA (UiTM), Malaysia.
Experimental and simulation tests on the impact of the conditions of

casting solidification from AlSi9Cu3 alloy on their structure and
mechanical properties
.
85046808885&doi=10.24425%2f118832&partnerID=40&md5=1c47bd071d70af004932d53f
b6b05f52
ABSTRACT: The impact of casting conditions on microstructure a and
mechanical properties was described, especially for cast products from
AlSi9Cu3 alloy. Particular attention was paid to the parameters of
dendritic structure: DAS 1 and DAS 2. Selected mechanical properties (by
static tension test) of test castings made using basic technologies of
casting: GSC - gravity sand casting, GDC - gravity die-casting and HPDC -
high-pressure die-casting, are presented for cast-on test bars and cast
separately. Casts were made of the same alloy AlSi9Cu3. Fractures and the
zone near the fracture (after static tension test) was subjected to VT -
visual tests, PT - penetration tests and metallographic tests. The
condition of porosity (fracture zone) was also assessed. The analysis of
virtual results was performed using the NovaFlow & Solid system together
with the database and they were compared to experimental tests. This way of
validation was applied in order to assess the correlation between the local
rate of cooling and the size of DAS for GSC, GDC and HPDC technologies.
Finally, the correlation between the parameters of structure and mechanical
properties with regard to the impact of porosity was signalized. © 2018 De
Gruyter Open Ltd. All rights reserved.
Studies on porosity of Al-4.5%Cu-2.5pTiB2 In Situ composites

.
%2fMSF.928.51&partnerID=40&md5=50397d8803e9c5a14c39fb5eb9ac14fc
ABSTRACT: In the present paper, experimental investigation as well as
computer assisted casting simulation technique is used to analyse the
effect of different parameters like properties of sand and molding methods
to predict defects in green sand casting. An attempt has been made to
obtain the optimal settings of the moulding sand and mould related process
parameters for the casting of Al-4.5%Cu-2.5TiB2 composites. The green sand
related process parameters considered in the study are moisture content,
green compressive strength, permeability of moulding sand and mould
hardness. In the fabrication of composites, porosity is greatly influenced
due to improper gating/riser system design. The analysis of porosity is
performed using Auto-CAST simulation technique by the introduction of a new
gating system designed and the solid model was developed for sand mould
cavity. A number of iterations using Auto-CAST simulation software were
performed for mould filling and solidification analysis to reduce the level
and intensities of porosities in cast Al-4.5%Cu-2.5TiB2 composite. With new
gating and feeding system design, reduction in porosity and improvement in
yield is observed. The simulation results were found to be in good
agreement when compared with the experimental trial. © 2018 Trans Tech
Publications, Switzerland.
Experimental study and investigation on wear characteristics of aluminium-

nano boron carbide (AL-B4C) metal matrix
.
85052736003&partnerID=40&md5=959ed68723e67d32185c7ed89b9cf5a4
ABSTRACT: In this study, fabrication and characterization of bulk Al–B4C
Nano composites were investigated. B4C nanoparticles were mixed with pure
Al (LM 24) by ball milling and Hybrid technique of Stir followed by sand
Casting to produce Al–B4C MMC. Al–B4C MMC containing different amounts of
B4C (5, 7.5 and 10 wt.%) were subsequently to produce bulk Nano composite
samples, due to low cost and good Physical and Mechanical Properties, Boron
Carbide particulate is selected as Reinforcement. Boron carbide Nano
particles were produced using commercially available boron carbide powder
(6•8 μm). Mechanical milling was used to synthesize B4Cnanostructured
powder in a planetary ball-mill under argon atmosphere up to 40 h. The
better distribution of reinforcement throughout the matrix would increase
hardness of the MMC. Wear test was planned to carry out with the help of
Pin on Disc Apparatus on the prepared Specimen, The wear resistance of the
Nano composites increased significantly by increasing the B4C content.
Dominant wear mechanisms for Al–B4C nano composites were determined.
Scanning electron microscopic studies showed the average size of B4C
particles was 200 nm, ranging from 50 nm to 350 nm. Thereby, Scanning
Electron Microscopy was used for the Analysis of Nano Structural AMC. ©
TJPRC Pvt. Ltd.
Influence of carbon nanotubes on mechanical properties of cast aluminum,

grade A5
.
85060950360&doi=10.1134%2fS2075113318020028&partnerID=40&md5=b70b762c4f8f66
763ed3e6569cc9fa23
ABSTRACT: Composite materials on the basis of A5 aluminum containing 0.01–
0.1 wt % of carbon nanotubes (CNT) were obtained. The composite materials
were fabricated by sand casting. Carbon nanotubes were added to the
aluminum melt in the form of powdered mixture preliminarily produced using
an AGO2S planetary ball mill. It was demonstrated that the CNT additions
improved the ultimate tensile strength and yield strength of cast metal by
9 and 32%, respectively. The improvement of metal strength properties even
at such a minor amount of nanotubes is determined not only by the
inoculating effect but also by dispersion, dislocation, and, to a lesser
extent, by reinforcing mechanisms of strengthening. For CNT content in
aluminum equal to 0.01 wt %, the calculated yield strength agrees well with
experimental values, whereas for CNT content equal to 0.05 and 0.1 wt %,
the obtained strengthening is significantly lower than calculations, which
can be attributed to agglomeration of nanotubes. The degree of conversion
of carbon nanotubes into aluminum carbide as a consequence of interaction
with aluminum melt is analyzed. It is demonstrated that less than 50% of
carbon nanotubes are transformed into aluminum carbide during melting at
700–800°C. The fact that CNTs are not completely converted into carbide can
be attributed to the fact that CNTs are arranged into bundles and only top
layer of CNTs is in contact with the melt. © A.V. Alekseev, D.Yu. Dubov,
M.R. Predtechenskiy, 2017 and Pleiades Publishing, Ltd., 2018.
An experimental investigation of Cu-Ni-Sn alloy on microstructure, hardness

and wear parameters optimization using DOE
.
85048231514&doi=10.24874%2fti.2018.40.01.15&partnerID=40&md5=0ddca0339ef34b
b626d487d88b7e7e5d
ABSTRACT: Copper-Nickel-Tin (Cu-Ni-Sn) spinodally decomposable alloy of
composition Cu-7Ni-4Sn was prepared by using sand casting process. The
specimens required for microscopic examination, micro-hardness and wear
tests were prepared from heat treated (homogenization, solution and ageing)
cast rods. The microscopic examination results revealed that the as-cast
dendrite structure was disappeared during the homogenization, solution and
ageing processes and forms grains of various sizes with respect to ageing
time. The hardness of the alloy was increased from 206 HV at solution
treated condition to 235 HV at four hours of ageing. By using pin-on-disc
wear tester in dry sliding condition an adhesive wear test was conducted as
per L9 orthogonal array by taking parameters of applied load, sliding speed
and ageing time. An optimum level of parameter for each case was determined
through S/N ratio investigation by considering "smaller-the-better". From
this investigation, it was found that the parameter ageing time was the
dominant as compared to other two parameters. The significant parameter
that affect the response was indicated by the results obtained from ANOVA
and these results were agreed with S/N analysis. The developed linear
regression equation was validated through confirmation experiments. The
wear mechanism was observed on worn out surfaces by selecting appropriate
specimens considering applied load and sliding speed for both normal and
optimum parameter specimens using scanning electron microscope (SEM). ©
2018 Published by Faculty of Engineering.
A Study of Microstructure and Tribological Properties of Al 5083 MMC

Processed by Direct Extrusion
.
85045969841&doi=10.1016%2fj.matpr.2017.11.513&partnerID=40&md5=7a20348f4ebf
43507a6420a3c761f210
ABSTRACT: In this study, investigations are done on commercially available
aluminum-magnesium (Al 5083) alloy. Aluminum 5083 alloy was first cast by
using sand casting technique and then subjected to severe plastic
deformation (SPD) through a direct extrusion process. To improve properties
of the material, severe plastic deformation technique has been widely used
over the last two decades. Present numerous experimental techniques of
metal forming are available that can apply great strains on materials for
better grain refinement, in that SPD is the best technique. To observe the
outcome of direct extrusion on Al 5083 alloy, microstructure and mechanical
properties of the cast alloy and extruded alloy were examined. Along the
transverse planes of the extruded alloy microstructural investigations were
carried out using an optical microscope and it discovered that the coarse
microstructure of the alloy was refined to a considerable amount. Hardness
and tensile strength of the alloy are improved by 10.33% and 9.8%
respectively after direct extrusion. Wear resistance of the aluminum 5083
alloy was determined by Pin-on-Disc test apparatus. The grain size of the
material is determined by using Olympus microscope. The wear properties of
the alloy after direct extrusion were improved considerably along with
improvement in hardness and tensile strength. Because of the highly refined
grains imparted by direct extrusion process the mechanical properties of
the alloy were improved to a certain extent and it makes the alloy to be
used in various engineering claims requiring high strength. © 2017 Elsevier
Ltd.
Comparison of SIF solutions obtained by XFEM and conventional FEM for

cracks in complex geometries like valve body
.
85064667591&doi=10.1016%2fj.prostr.2018.12.200&partnerID=40&md5=1d93495afef
dd2cc824189cca6420706
ABSTRACT: Globe valve is a type of industrial valve used to obstruct or
regulate flow of the fluid in pipelines via linear motion of the plug. The
main component of the valve, the valve body, is the carrier of the internal
and often variable pressure. The body itself is usually made by sand
casting which may result in impurities and metallurgic or shrinkage
defects. The above-mentioned, coupled with the relatively geometrically
complex shape of the valve bodies, makes the accurate determination of the
crack formation and growth often challenging. Additionally, formation of
the cracks in a pressure vessel such as globe valves usually leads to one
of the two outcomes. If the crack reaches its critical size under specified
loading conditions, a catastrophic failure may occur. On the other hand,
the preferred option of stable crack growth can lead to the effect known as
leak-before-break. Therefore, it is necessary to accurately determine
stress intensity factors (SIF) for cracks in such geometry. This
determination is usually made by classical finite element method, and it is
very hard to do on complex shape. In addition, it is possible to determine
SIF using eXtended Finite Element Method (X-FEM) which is proved on simple
geometry. In this paper, the verification of the X-FEM has been conducted
by comparison of results obtained by this method and by the classical
method on valve body. Presented computational model suggest the possibility
of accurately determining fracture mechanics parameters for cracks in
geometrically complex components such as those of valve bodies. © 2018 The
Authors.
The effect of slurry erosion wear on boronized alloyed ductile iron (0.019
% Niobium and 0.145 % Vanadium)
.
85052561738&partnerID=40&md5=131728ef36565f54bb6a5396f0038845
ABSTRACT: In this study, the effect on microstructure, hardness and slurry
erosion wear of alloyed ductile iron (DI) with addition of 0.019 % of
Niobium and 0.145 % of Vanadium before and after boronizing process will be
discussed. The specimens of ductile iron (DI) and Nb-V alloyed DI were
produced through CO2 sand casting method. Specimens were fully coated with
boronizing paste in estimation about 3-5mm thickness and heated using
Carbolite furnace at 850 °C and 900 °C for 8 hours holding time. The
observations of Microstructures were conducted by using Olympus BX 41M
Optical Microscope. Vickers Micro Hardness Tester was used to determine the
hardness of the specimens while Slurry erosion wear test was conducted to
measure the weight loss of each specimen. Diffusing boron into the iron
crystalline lattice leads to the formation of two kinds of iron borides
(FeB and Fe2B). The thickest boride layer was detected at sample with
temperature of 900 °C. The samples of 900 °C give higher hardness than
temperature of 850 °C which are 2500 HV and 2209 HV respectively. Referring
to slurry erosion test, samples boronized at 900 °C had greater wear
resistance compared to sample boronized at 850 °C and as cast. This was
attributed by the value of weight losses and surface roughness for the
materials. This study had proven that, by increasing the boronizing
temperature from 850 °C to 900 °C at 8 hours holding time has a
significance effect to the boride layer thickness, hardness and wear
resistance of alloyed ductile iron. © 2016 Faculty of Mechanical
Engineering, Universiti Teknologi MARA (UiTM), Malaysia.
Enhancing the permeability and properties of ceramic shell in investment

casting process using ABS powder and needle coke
.
85062286218&partnerID=40&md5=49db9b56fb5fafbfa4b968d3c9666706
ABSTRACT: In the investment casting process, initially, a wax pattern is
made, around which repeated slurry/stucco coatings are given. The slurry is
made up of very fine ceramic ingredients like zircon flour, etc. Once the
ceramic slurry is dried out, a ceramic shell is formed around the wax
pattern. After drying out of the ceramic shell, the wax is drained out and
the shell is fired in an oven for inducing additional strength. Molten
metal is then poured into the ceramic shell. Because of the fine
ingredients of the ceramic shell, the investment casting gets a very fine
surface roughness, compared to a conventional sand casting. However, the
ceramic shell exhibits poor permeability, which often results in porosity
defects. Hence, in the present work, an attempt is made to enhance the
permeability of ceramic shell by mixing certain fillers like ABS
(Acrylonitrile Butadiene Styrene) powder and needle coke to the ceramic
slurry. Fine ABS powder is added to the inner coat slurry in a very small
proportion. The ABS powder, upon heating, got burnt and left micro pores
inside the inner coating of the shell. In a similar way, needle coke is
added to the outer coat slurry in a very small proportion. During the
firing of the shell, the needle coke got burnt and, consequently, pores are
created inside the shell, which would enable escape of undesirable gases
that may generate inside the shell. This ultimately would reduce the
porosity defects in the investment castings. Tests conducted on the ceramic
shell modified with ABS powder and needle coke reveal that the modified
shell possesses higher permeability compared to the conventional one. The
modified shell also possesses adequate mechanical properties like flexural
strength, hot tensile strength, etc., and fair surface roughness. © 73rd
World Foundry Congress "Creative Foundry", WFC 2018 - Proceedings.All
Rights Reserved.
Thermal reclamation of foundry sands using repurposed sand dryer equipment

.
85060373501&doi=10.24425%2fafe.2018.125176&partnerID=40&md5=2a56af6827b2828
cb87d4b761d9e9886
ABSTRACT: One of the biggest problems for sand casting foundries must be
the waste produced from disposable molds. Stricter environmental
regulations make it harder to dispose of waste sand, so a truly competitive
foundry does no longer only make great products, but also concentrates on a
sustainable casting process. While methods for repurposing waste foundry
sand are still limited, the internal circulation of such sands proves
significant possibilities. This paper will focus on thermal reclamation of
foundry sands in a special rotating drum furnace in a central facility to
serve several foundries. Thermal reclamation is a process for handling
foundry sands in elevated temperatures to combust unwanted substances from
reusable base sand. The introduction focuses on background of the Finnish
foundry business, the most common sand systems in Finland and their reclaim
properties. The experimental part features presentation of the new
reclamation plant process and the conducted test runs. The samples
collected from each test run have been laboratory tested to assure proper
sand quality. The results of this work showed that the reclamation of
alkaline phenolic no-bake sands was excellent. Reclamation of green sands
did not provide satisfactory results as expected and the reclamation of
furan no-bake sands provided mixed results, as the raw material was
imperfect to begin with. The most important result of this work is still
the successful initiation of a centralized thermal reclamation plant, with
the ability to reclaim sands of several foundries. With this all of
industrial symbiosis, circular economy and sustainability advanced in
Finland, and the future development of this plant provides even further
opportunities and a possibility to spread the ideas on a global scale. ©
2018 Polish Academy of Sciences. All rights reserved.
Development of carbon anode for cathodic protection of mild steel in
chloride environment
.
85042880047&doi=10.1108%2fACMM-07-2017-
1817&partnerID=40&md5=8c6edf862362ab709a7e4001d0e3f617
ABSTRACT: Purpose: The purpose of this paper is to develop technically
efficient and economically effective sacrificial anodes that can be used
for cathodic protection (CP) of pipelines in marine environment and fill
the knowledge gap in the use of carbon anodes for CP.
Design/methodology/approach: A sacrificial anode was produced via sand
casting by adding varying weight-percent of coal and ferrosilicon to a
constant weight-percent of grey cast iron. The hardness of the produced
anodes was evaluated using a Rockwell hardness tester. The microstructure
of the anodes was observed with scanning electron microscope/energy-
dispersive spectroscopy (SEM/EDS). X-ray diffraction (XRD) was used to
study the phases present. A potentiostat was used to assess the corrosion
behaviour of the produced anodes and mild steel in 3.5 Wt.% NaCl solution.
Findings: The SEM results showed that some anodes had interdendritic
graphite formation, while others had pronounced graphite flakes. The EDS
analysis showed carbon and iron to be the prominent elements in the anode.
Anodes Bc, B2 and B5 with a corrosion rate of two order of magnitudes were
observed to have similar dendritic structures. Anode B4 is the most
electronegative with an Ecorr of −670.274 mV Ag/AgCl and a corrosion rate
of 0.052475 mmpy. The produced anodes can be used to protect mild steel in
the same environment owing to their lower Ecorr values compared to that of
mild steel −540.907 mV Ag/AgCl. Originality/value: Alloying has been
majorly used to improve the efficiency of sacrificial anodes and to
alleviate its setbacks. However, development of more technically efficient
and economically effective sacrificial anodes via production of composite
has not been exhaustively considered. Hence, this research focuses on the
development of a carbon based anode by adding natural occurring coal and
ferrosilicon to grey cast iron. The corrosion behaviour of the produced
anode was evaluated and compared to that of mild steel in marine
environment. © 2018, Emerald Publishing Limited.
New possibilities with improved green sand testing equipment

.
%2fMSF.925.504&partnerID=40&md5=549f62dd28792450d3296d19b6735e59
ABSTRACT: Background. The quality of green sand moulds is paramount for the
casting quality and reduction of surface defects. The general knowledge
within foundries on green sand properties and its influence on casting
defect behaviour has significantly decreased as a result of outsourced
external sand testing and dependence on external consultants. Moreover,
academic R&D activities targeting studies on green sand properties could
not attract significant funding and have hence been limited to small
extents. It cannot be stressed enough that in sand casting the majority of
casting defects can be related to an insufficient green sand management.
Recent research and development has been only supported by suppliers of the
foundry industry, however, with a major emphasis on anorganic water glass
binder systems and the reduction of phenolic binders in organic binders to
reduce emission and unpleasant smells while simultaneously increasing e.g.
fluidity or strength [1, 4]. In most industrial environments hand-operated
sand testing machines, whose basic concepts of operation were developed in
the middle of the last century, are still used. While these old fashioned
apparatuses can help to maintain quality in a foundry they are not suited
to provide additional information on the green sand quality. Therefore, any
developments on different mould materials were mainly performed with very
old fashioned manually operated sand testing equipment and a significant
aspect of the development of more accurate modern sand testing equipment
was neglected. Nevertheless, these manually operated sand testing
apparatuses represent the current state-of-the-art of sand testing
equipment. In order to improve green sand properties and gain additional
knowledge it is essential to develop new testing methods. This paper will
give information on the development of novel green sand testing equipment
for compaction, pressure, as well as wet strength testing development at
the ÖGI and gives comparison to values obtained by manually operated
machines. The main advantage of modern electronical testing machines is a
higher accuracy of measurement in general and the possibility of recording
stress-strain-curves. This work shows characteristic stress-strain-curves
for all mechanical green sand testing methods as well as the influence of
water content on the progression of mechanical properties. As a result the
area with the best handling properties of green sand is shown. Furthermore
negative influences of defective sand specimens and marginal deviations in
the testing process on the testing result have been investigated. © 2018
Trans Tech Publications, Switzerland.
Research on Reduction of Casting Residual Stress for Aluminum Alloy

Cylinder by Coated Sand Casting
.
85044675370&doi=10.16339%2fj.cnki.hdxbzkb.2017.12.001&partnerID=40&md5=9e7a
2e89ac65a78c76a200a7513bd920
ABSTRACT: In order to study the influence of coated sand thickness on
casting residual stress and solidification cooling process,the casting
residual stress of ZL205A aluminum alloy cylinder with different sand
thickness was measured by drilling method,and the solidification curves
were collected.The paper has carried out finite element simulation of
coated sand casting processes for ZL205A aluminum alloy specimen by
adopting Von Mises mold and Mohr-Coulomb mold.The results show that the
residual stress of castings can be reduced by about 62%,when the sand
thickness reaches 7 mm.The residual stress changes a little with the
sustained increasing of sand thickness.To provide a reliable process
reference,the relationship between sand thickness and solidification
cooling rate,grain size and eutectic temperature was established by
analyzing and comparing the temperature curve measured in coated sand
casting process.The simulation results show that the calculated results of
the two models are basically consistent with the experimental trend.But we
also need to take into account the applicability of the two models under
different sand thickness. © 2017, Editorial Department of Journal of Hunan
University. All right reserved.
Self-evaluation model of sand casting process and its application based on

AHP and data mining [基于层次分析法与数据挖掘的砂铸工艺自评价模型及应用]
.
85051584371&partnerID=40&md5=b5954dd6225b7fcd7c9f4560cf9e2994
ABSTRACT: A self-evaluation model of sand casting process based on analytic
hierarchy process and data mining is established, which can automatically
score the process version according to the actual data such as production
and quality of each process version, and provide scientific basis for the
process version upgrades. Firstly, the evaluation index of the process is
established by AHP to determine weight of the sub-evaluation index.
Secondly, the data mining method is used to obtain the data of all the
indexes in the enterprise ERP system, and the fuzzy comprehensive
evaluation method is used to automatically score the different versions of
the casting process. Finally, the model is applied to a sand casting
business, application effect shows that it can guide the foundry business
process improvement or change version, and effectively improve product
quality and comprehensive benefit of the business. The study can provide a
reference for automatic evaluation of process based on actual data. © 2017,
Performance of resin bonded sand for magnesium alloy casting

.
85030666920&doi=10.1016%2fj.jmapro.2017.10.002&partnerID=40&md5=6877bf5edc5
f01c729f25640fb3f4c7c
ABSTRACT: The factors which affect performance of no-bake resin bonded sand
(NBRBS) were investigated, including furan resin, curing agent and boric
acid content and kinds of collapsibility agents and base sand. The results
show that when the furan resin addition is 1.6 wt% of base sand content and
the curing agent addition is 50 wt% of furan resin content, the
comprehensive performance of NBRBS achieves optimization. The use of boric
acid increases the curing speed, retained strength and gas evolution. The
use of KI reduces the retained strength with a good tensile strength. When
ceramacore being used as base sand, furan resin addition decreases greatly,
and the tensile strength increases, gas evolution and retained strength
both decrease, which can improve collapsibility of NBRBS. The SEM analysis
demonstrates that the ceramacore particle is round, appeares standard
sphere, and the ceramacore can form complete bonding film and bridge. ©
Research and application of quality control model of serial-parallel

tracking in sand casting enterprises [砂型铸造企业串并联式质量追责追踪模型研究与应
用]
.
85051483379&partnerID=40&md5=46ea9e7a7355c27d2c67b736968c6733
ABSTRACT: Quality is difficult to trace in sand casting enterprises
currently because of the missing or weakness of responsibility claim and
batch tracking, as well as the neglect of multi-dimensional analysis in the
process of tracking and disposal. To resolve this issue, a series-parallel
quality control model is proposed. As a complete quality tracking chain, a
series circuit is formed between product defect diagnose, responsibility
claim, batch tracking and batch disposal. Responsibility claim and batch
tracking are analyzed in parallel from the production, process and
materials aspects, while batch is disposed in parallel according to
different states such as in production, in storage and delivered also.
Combining with the HZERP System, a MES for casting enterprises, the model
was applied to a typical sanding casting enterprise. As a result, the model
solves the problems such as the difficulty of batch tracking and disposal,
the weakness of responsibility claim of defects. This provides a reference
for casting enterprises to strengthen quality tacking management. © 2017,
Research on Optimum Structure Design of 3D Printed Sand Moulds

.
85040183626&doi=10.3901%2fJME.2017.21.158&partnerID=40&md5=fc1846e7cede563f
ec998db3f59dab06
ABSTRACT: As a novel rapid prototyping sand casting method, 3D-printing is
capable of producing any complex mould, which makes further structure
optimization of the sand mould possible. Because of the connection between
the production speed of 3D-printing and the structure of mould, it is
necessary to optimize structure of 3D printed sand mould. In this
situation, an optimum design method of the 3D printed sand mould is
established, and the design process is introduced. Based on the mechanical
property requirements, the thickness of the sand mould is taken as the
optimization parameter, and the optimum design model is established. In the
end, the optimum design of the casting sample is completed. Results show
that the volume of the sand mould is reduced by 42.6% after optimum
structure design, thus the efficiency of production is raised, and the cost
of the resin-bonded sand is reduced. © 2017 Journal of Mechanical
Engineering.
New Mode of Rapid Sand Casting Based on 3D Technology

.
85042158554&doi=10.15980%2fj.tzzz.2017.11.019&partnerID=40&md5=00ab2e0e6e26
131aa445aca737194759
ABSTRACT: A new mode of rapid sand casting based on 3D technology was
presented, which could realize the 3D design, production and detection of
whole casting process. Compared with those of conventional casting modes,
the new mode can shorten effectively the production time and improve the
dimension presicion and internal quality of the components. The mode can be
applied for the production of single part and small production-volume
production. © 2017, Journal Office of Special Casting and Nonferrous
Cavity prediction in sand mould production applying the DISAMATIC process

.
85027522657&doi=10.1016%2fj.powtec.2017.08.037&partnerID=40&md5=f5474bed570
c50dd0ed21b3f70a6a1de
ABSTRACT: The sand shot in the DISAMATIC process is simulated by the
discrete element method (DEM) taking into account the influence and
coupling of the airflow with computational fluid dynamics (CFD). The DEM
model is calibrated by a ring shear test, a sand pile experiment and a
slump test. Subsequently, the DEM model is used to model the propagation of
the green sand inside the mold chamber and the results are compared to
experimental video footage. The chamber contains two cavities designed to
quantify the deposited mass of green sand. The deposition of green sand in
these two cavities is investigated with three cases of different air vent
settings which control the ventilation of the chamber. These settings
resulted in different air- and particle-velocities as well as different
accumulated masses in the cavities, which were successfully simulated by
the model. © 2017
Squeeze Casting and Strengthening Mechanism of High-strength Al-Ni Cast

Aluminum Alloys
.
85049895488&partnerID=40&md5=858c8a68571bb32de88ce3ac9f19771c
ABSTRACT: In order to develop new high-strength cast aluminum alloys,
AlZn6Ni4Mg2Cu cast aluminum alloys based on Al-Ni eutectic system were
prepared by sand casting, permanent-mold casting and squeeze casting
processes. The influence of Ni element, casting process and heat treatment
on the microstructure and mechanical properties was studied. The results
indicate 4% Ni (mass fraction) forms a great deal of eutectic structure (α-
Al+Al3Ni) in the aluminum alloy. Al3Ni improves casting properties and
mechanical properties of the alloy and plays a role of eutectic
strengthening. Solution and aging treatment cause globalization of Al3Ni
phases and aging precipitation of MgZn2 and Al2Cu phases; as a result, the
strength of AlZn6Ni4Mg2Cu cast aluminum alloy is increased. Compared to the
samples by sand casting and permanent-mold casting, the sample by squeeze
casting possesses the finest grain and Al3Ni phase, as well as the optimum
mechanical properties, whose tensile strength is 586 MPa, and the
elongation percent is 3.5%. It is concluded that the strengthening
mechanism of AlZn6Ni4Mg2Cu cast aluminum alloy is aging strengthening of
η(MgZn2) phases and dispersion strengthening of Al3Ni phases. The
mechanical properties reach their highest values by squeeze casting and T6
heat treatment. © 2017, Science Press. All right reserved.
The Effect of Sr Modifier Additions on Double Oxide Film Defects in 2L99

Alloy Castings
.
85029520741&doi=10.1007%2fs11661-017-4310-
8&partnerID=40&md5=333e69c6f515506111ccc8e6a3268a18
ABSTRACT: In this paper, Sr modifier (300 ppm) was added to 2L99 alloy sand
castings to investigate its effect on bifilm defects in the castings. Two
different sand molds were used in this study, with good and bad running
system designs, to introduce different amounts of bifilm defects into the
castings. The mechanical properties of the modified 2L99 castings were
compared to the properties of unmodified castings and showed that with high
bifilm defect contents (H) the Sr addition reduced the Weibull modulus of
the UTS by 67 pct and the Position Parameter by 5 pct, and introduced a
bimodal distribution into the Weibull plot of the pct Elongation. However,
for castings with low bifilm defect content (L), the Weibull moduli of both
the UTS and pct Elongation were significantly improved (by 78 and 73 pct,
respectively) with the addition of Sr. The Position Parameter of the
pct Elongation was improved by 135 pct. The results suggested that a
desirable modification effect can only be achieved while the bifilm defect
content in a casting was low. © 2017, The Author(s).
Sand casting process of special-shaped triple valve body [异形三通阀体砂型铸造

工艺]
.
85051531894&partnerID=40&md5=4024729789e98af0039bde5a08635972
ABSTRACT: The triple valve body is a part of ship, there is a great
difference in casting wall thickness, and the hydraulic test requirement of
4.5MPa is required. The original design material of the triple valve body
is the tin bronze ZCuSn10Zn2, the pump leakage rate has reached more than
60%%. This paper analyses the structure of the triple valve body, and the
ZCuSn10Zn2 tin bronze and silicon brass ZCuZn16Si4 in seawater corrosion
resistance were compared. The result shows that under the sand casting
conditions, silicon brass ZCuZn16Si4 is more suitable for the thickness
wall triple valve body than tin bronze ZCuSn10Zn2, can meet higher pump
pressure requirements. The sand casting process of silicon brass triple
body was discussed, and the mass production was successfully carried out,
and the leakage rate was less than8%. © 2017, Chinese Mechanical
Rapid sand casting process for tractor complex casting [拖拉机复杂铸件的快速砂

型铸造方法]
.
85051508547&partnerID=40&md5=3f56baf16dff94bd265d59af68589cdd
ABSTRACT: Rapidsand castingprocess for tractor complex castingwas
studiedbecause of problems, such as long cycle,high cost and technical
backwardness. Aiming at these difficulties, rapid casting process, parting
surface design methods and dieless forming method were analyzed. Additive
and subtractive hybrid manufacturing method was used to direct forming sand
mould and core, and the casting was poured, tractor complex castings were
manufactured by rapid sand casting. The results show that, the method can
be used to rapid manufacture tractor rapid castings, without anymold
designand development. © 2017, Chinese Mechanical Engineering Society. All
right reserved.
Numerical Simulation and Process Optimization of Sand Casting Aluminum
Alloy Cover
.
85038003850&doi=10.15980%2fj.tzzz.2017.10.005&partnerID=40&md5=0371b12818be
af12dfee350eef88a070
ABSTRACT: The sand casting process of aluminum alloy cover was simulated by
AnyCasting, and origination of defects was analyzed. Aiming at the casting
defects in the sand casting process, by modifying gating system, setting
the cold iron and riser reasonably, and increasing the casting speed, the
casting defects can be reduced greatly, and the casting quality can be
improved. © 2017, Journal Office of Special Casting and Nonferrous Alloys.
All right reserved.
3D printing for rapid sand casting—A review

.
85028365810&doi=10.1016%2fj.jmapro.2017.07.017&partnerID=40&md5=49e3ebf1913
63a60961d0b2221186319
ABSTRACT: There are many 3D printing technologies available, and each
technology has its strength and weakness. The 3D printing of sand moulds,
by binder jetting technology for rapid casting, plays a vital role in
providing a better value for the more than 5000 years old casting industry
by producing quality and economic sand moulds. The parts of the mould
assembly can be manufactured by precisely controlling the process
parameters and the gas producible materials within the printed mould. A
functional mould can be manufactured with the required gas permeability,
strength, and heat absorption characteristics, and hence the process
ensures a high success rate of quality castings with an optimised design
for weight reduction. It overcomes many of the limitations in traditional
mould design with a very limited number of parts in the mould assembly. A
variety of powders, of different particle size or shape, and bonding
materials can be used to change the thermal and physical properties of the
mould and hence provide possibilities for casting a broad range of alloys.
Limited studies have been carried out to understand the relationship
between the characteristics of the printed mould, the materials used, and
the processing parameters for making the mould. These deficiencies need to
be addressed to support the numerical simulation of a designed part, to
optimise the success rate and for economic as well as environmental
reasons. Commonly used binders in this process, e.g. furan resins, are
carcinogenic or hazardous, and hence there is a vital need for developing
new or improved bonding materials. © 2017 The Society of Manufacturing
Engineers
Process Improvement of Air Leakage in the Aluminum Alloy Shell Castings

.
85037986823&doi=10.15980%2fj.tzzz.2017.10.027&partnerID=40&md5=109ac990506b
d1e74b47b8840a8c607d
ABSTRACT: Aimed at solving the air leakage problem (under the pressure of
the 0.2 MPa) in the aluminum alloy shell castings, based on analysis of the
structure and process of the castings, resin sand casting technique was
adopted. In addition, with the help of the Anycasting software, the casting
process was optimized. After improvement of the casting technique, the
gualified rate of the air tightness of the aluminum alloy shell castings
was improved from 14.3% to 71%. © 2017, Journal Office of Special Casting
and Nonferrous Alloys. All right reserved.
Communication: Characterization of spatial distribution of graphite nodules

in cast iron
.
85034061297&doi=10.1007%2fs40962-016-0128-
1&partnerID=40&md5=325913b4fd219fcfae6a733801749dff
ABSTRACT: Important properties of cast iron, such as fatigue strength, wear
resistance, and low-temperature toughness, relate to spatial distribution
of graphite nodules. Characterization of spatial distribution can also
provide insight into the solidification sequence in casting. An automated
SEM/EDX analysis was utilized to distinguish graphite nodules from other
structural features (pores and inclusions). The twodimensional near-
neighbor distance (NND) between nodule centers was calculated for three
equal sets of nodule diameters (small, medium, and large) in each cast
iron. Comparison of measured spatial distributions and ideal random
distribution was executed by plotting the mean and variance ratios of NND
on a spatial distribution quadrant. This method was used to clarify
clustering or ordering tendencies of graphite nodules in studied cast
irons. The suggested procedure was used to verify the effects of
inoculation and the cooling rate on spatial distribution of graphite
nodules. Inoculation of sand casting increased nodule counts, decreased
mean NND, and eliminated clustering of small graphite nodules precipitated
at the solidification end. Intensive surface cooling of a continuously cast
bar significantly increased nodule count near the external surface and
decreased NND without changing spatial distribution. The suggested analysis
can be used as a tool for cast iron quality control and process
development. © 2017 American Foundry Society.
Prediction of Shrinkage Porosity Defect in Sand Casting Process of LM25

.
85030322669&doi=10.1088%2f1757-899X
%2f225%2f1%2f012237&partnerID=40&md5=94e23f3c6c131d7686e02b833d4ed726
ABSTRACT: In the present worldwide and aggressive environment, foundry
commercial enterprises need to perform productively with least number of
rejections and create casting parts in shortest lead time. It has become
extremely difficult for foundry industries to meet demands of defects free
casting and meet strict delivery schedules. The process of casting
solidification is complex in nature. Prediction of shrinkage defect in
metal casting is one of the critical concern in foundries and is one of the
potential research areas in casting. Due to increasing pressure to improve
quality and to reduce cost, it is very essential to upgrade the level of
current methodology used in foundries. In the present research work,
prediction methodology of shrinkage porosity defect in sand casting process
of LM25 using experimentation and ANSYS is proposed. The objectives
successfully achieved are prediction of shrinkage porosity distribution in
Al-Si casting and determining effectiveness of investigated function for
predicting shrinkage porosity by correlating results of simulating studies
to those obtained experimentally. The real-time application of the research
reflects from the fact that experimentation is performed on 9 different Y
junctions at foundry industry and practical data obtained from
experimentation are used for simulation. © Published under licence by IOP
Publishing Ltd.
Effect of Binder and Mold parameters on Collapsibility and Surface Finish

of Gray Cast Iron No-bake Sand Molds
.
85030312494&doi=10.1088%2f1757-899X
%2f225%2f1%2f012246&partnerID=40&md5=8ab21808d0a0b67d47e341609ab1f2ca
ABSTRACT: Chemically bonded no-bake molds and cores have good mechanical
properties and produce dimensionally accurate castings compared to green
sand molds. Poor collapsibility property of CO2 hardened sodium silicate
bonded sand mold and phenolic urethane no-bake (PUN) binder system, made
the reclamation of the sands more important. In the present work fine
silica sand is mixed with phenolic urethane no-bake binder and the sand
sets in a very short time within few minutes. In this paper it is focused
on optimizing the process parameters of PUN binder based sand castings for
better collapsibility and surface finish of gray cast iron using Taguchi
design. The findings were successfully verified through experiments. ©
Effect of sand dilation on distortions and pattern allowances during steel

sand casting
.
85012909033&doi=10.1080%2f13640461.2017.1290909&partnerID=40&md5=01f2df81d4
84230f08c11d17ac9f93e6
ABSTRACT: Mechanical interactions between the sand mold and casting have a
great impact on pattern allowances. In this study, the effect of core
expansion on distortions during steel casting is investigated. A hollow
steel cylinder is cast using silica and zircon sand cores. The evolution of
the cylinder’s inner diameter is measured in situ using LVDTs. During
solidification, core expansion is found to distort the inner diameter into
a barrel-shaped profile, generating the largest expansion at the mid-
height. The experiments are simulated using a sequential thermo-mechanical
coupling. In the stress analysis, the steel and sand are modeled using an
elasto-visco-plastic constitutive law and the Drucker–Prager Cap model,
respectively. The simulations reveal that sand dilation due to shear
stresses, as opposed to thermal expansion, accounts for the majority of the
increase in the inner diameter. The measured and predicted pattern
allowances are found to be in excellent agreement. © 2017 Informa UK
Limited, trading as Taylor & Francis Group.
Investigation of optimum gating system design of fused deposition modelling

pattern for sand casting
.
85041799641&doi=10.15282%2fjmes.11.2.2017.3.0235&partnerID=40&md5=59ed21460
e3d3075c03bb01603daf028
ABSTRACT: Sand casting is a process of pouring molten metal into a mould.
The quality of the casting highly depends on the pattern and mould
involving the gating system design. Inappropriate gating system design
leads to casting defects. Moreover, conventional sand casting pattern
production is time consuming, expensive and unable to produce complex
patterns. This research therefore studies the feasibility of using the
Fused Deposition Modelling system as a rapid tooling process to produce a
sand casting pattern. To do this, three concepts of the gating system
designated by the location and size of sprue and riser were generated using
the CAD software. In order to select the optimum gating system design,
ANSYS software was employed to analyse the filling process based on eight
ranking criteria which included static pressure, density all, velocity
magnitude, total temperature, internal energy, turbulent viscosity, wall
shear stress and velocity streamline. Based on the simulation results, the
concept that comprised of the sprue and riser measured 20 mm diameter and
designed on both sides of the hand wheel was selected as the optimum design
of the gating system since it scored the highest mark in the eight ranking
criteria. Then, the actual casting of the hand wheel was produced. In order
to validate the results of the simulation, surface roughness and dimension
accuracy were done. The sprue and riser that measured 20 mm in diameter
showed smoother texture and this dimension was the closest to the ideal
dimension. The results also showed that the sprue and riser located on the
top of the connector of the hand wheel demonstrated the worst surface
finish and dimensional accuracy due to imbalance between molten metal flow
through the sprue and riser. © 2017 Universiti Malaysia Pahang, Malaysia.
Investigating surface roughness of ZE41 magnesium alloy cast by low-
pressure sand casting process
.
85015941463&doi=10.1007%2fs00170-017-0283-
4&partnerID=40&md5=083afac4dc8bac6e5231ba1938199f16
ABSTRACT: The sand mold 3D printing technologies enable the manufacturing
of molds with great dimensional accuracy. However, the roughness of as-cast
components is higher when cast in a 3D printed mold rather than in a
traditional sand mold. Coating the inner cavity is an efficient solution
but can be costly and, in the narrowest cavities, not achievable. Finding a
procedure to reduce the as-cast roughness without coating would ease the
casting procedures. In the present work, surface analysis of ZE41 magnesium
alloy is presented after being cast in 3D printed furan sand molds without
coating using the low-pressure casting process. The molten metal
temperature was measured during casting at different positions along the
cast cavity. The as-cast surface roughness was correlated to the molten
metal temperature and solid fraction at the time of contact against the
sand mold surface. © 2017, Springer-Verlag London.
Effects of Silica Sol Infiltration on Surface Quality of Selected Laser

Sintering (SLS) Coated Sand
.
85037134902&doi=10.15980%2fj.tzzz.2017.09.015&partnerID=40&md5=f310ec3a5b7e
ce7ee9c9906a1c2f1b4e
ABSTRACT: The effects of infiltrating silica sol process on mould surface
roughness of SLS coated sand were investigated by infiltrating silica sol
and post-processing into green part of SLS coated sand. The results reveal
that, with the increase of the temperature and time of the silica sol
infiltration, the surface roughness of the SLS coated sand mold is reduced
firstly and then increased. With the silica sol infiltration at 30℃ for 15
h, the surface roughness of coated sand casting reaches the maximum value
(Ra) of 11.48 μm. With the increase of curing temperature and time of
coated sand, surface roughness of SLS coated sand mould are decreased
firstly and then increased. With the coated sand after curing temperature
at 30℃ for 15 h, the minimum surface roughness of coated sand casting
reaches(Ra) 13.96 μm. © 2017, Journal Office of Special Casting and
Modelling the effect of coating on the stresses and microstructure

evolution in chill casting of wind turbine main shafts
.
85019141062&doi=10.1002%2fwe.2114&partnerID=40&md5=ab9faca737bce87c449058e8
8dfc004b
ABSTRACT: The purpose of the present work is to quantify the effect of the
inside coating on chills for casting of large wind turbine main shafts with
respect to the evolution of internal stresses. These are known to affect
the lifetime of the chills, and this is a major cost for the foundries
today. Simulations of the casting process are performed with four different
heat transfer coefficients (HTCs) between the casting and the chill, and
the resulting transient stress fields are reported in the chill. The
microstructural evolution in the casting in terms of the nodule count is
also modelled in the simulations. The outcome is validated by comparisons
with samples taken out from a critical region of main shafts cast in sand
and in chills. The results reveal minor reductions in the maximum principal
stresses on the inner and outer surfaces of the chill of 3.1% and 18.5%,
respectively, from changing the HTC from 2000 to 500 W m−2 K−1. These
results indicate that the lifetime of the chill will not be significantly
improved by adding a thicker layer of coating. The microstructure evolution
is not very much affected by the HTC value with a maximum reduction in
nodule count of 6.5%. Therefore, it is concluded that the material quality
obtained from casting the main shafts in chills (and hence the performance
of the part) is still much better than for sand casting, even though a very
thick layer of coating is applied. Copyright © 2017 John Wiley & Sons,
Ltd. Copyright © 2017 John Wiley & Sons, Ltd.
Material properties of CMT—metal additive manufactured duplex stainless

steel blade-like geometries
.
85027709806&doi=10.1007%2fs40194-017-0474-
5&partnerID=40&md5=b54343d127d512a24e97ef8ea583febc
ABSTRACT: Impeller blades are often individual and complex-shaped
components made of challenging metals. As the manufacturing of such blades
is highly sophisticated, only a few companies worldwide possess the
necessary processing knowledge and that is why long production times have
to be accepted by customers. To overcome this economic disadvantage,
manufacturing technologies are permanent under supervision and it seems
that metal additive manufacturing could thereby play an important role in
future. In this paper, wire arc additive manufacturing (WAAM) based on gas
metal arc welding (GMAW) is considered. Shape-giving GMAW is well known in
industrial manufacturing, but its application is limited due to
restrictions by the welding process itself: For thinner wall thicknesses, a
significant reduction of the weld process energy is required which
increases the risk of process instabilities and spatter formation.
Extensive welding process-related efforts have been undertaken to overcome
this fact and a new GMAW process, called CMT (Cold Metal Transfer) was
introduced. CMT is based on a high-frequency forward and backward movement
of the welding wire electrode and provides an almost spatter-free and
absolute precise, periodic detachment of accurately defined droplets from
the filler wire at very low process energies. In combination with an
accurate robotic movement of the CMT welding torch, geometries with minimum
thicknesses in the range of 2–4 mm can be build up layer by layer.
Additionally, a broad range of different, well established and third party-
approved GMAW filler metals for joining is available. In this work, an
impeller blade-like geometry out of duplex stainless steel has been
manufactured by CMT using a filler wire type G 22 9 3 N L. The
investigations have shown that the achieved surface roughness is comparable
to sand casting and the microstructure is without any evidence for porosity
and lack of fusion. Furthermore, an austenite/δ-ferrite weld microstructure
with partly preferred grain orientations and a δ-ferrite content of around
30FN exists. The measured mechanical properties, especially strength and
toughness, are comparable to data provided by the filler metal data sheet.
© 2017, International Institute of Welding.
Simulation of Filling and Solidification of Rapid Sand Casting Engine

Cylinder Head
.
85029319890&doi=10.15980%2fj.tzzz.2017.07.009&partnerID=40&md5=75f9f7c86829
51650f4fc051dd951864
ABSTRACT: Based on introduction of the processing procedure of rapid sand
casting engine cylinder head and its casting process design, filling and
solidification of liquid aluminium alloy were visualized by the ProCAST
software. The simulated results reveal that the smooth filling can be
realized by one-side bottom gating system. During the solidification
process, the outer wall of cylinder head is solidified ahead, and then the
inner casting. Satisfied feeding effect of risers on large thick parts of
upper part of work-piece wall and ingates on bottom part of workpiece wall
can be realzied, respectively. Absence of isolated liquid region in the
casting can be observed. The inner cylinder head has only the uniformly
dispersed shrinkage porosity (hole), and the porosity is less than 10%,
exhibiting excellent casting quality. © 2017, Journal Office of Special
Casting and Nonferrous Alloys. All right reserved.
Study on Technology of Hardener for Furan Resin Sand Casting

.
85035345910&partnerID=40&md5=f8b62978177c9def01e36ecafd7a35e3
ABSTRACT: The sulfonation process of concentrated sulfuric acid was
studied. The hardener for furan resin casting was prepared by using xylene
sulfonic acid and sulfuric acid ester as the main effective components. The
factors affecting the curing of furan resin sand were analyzed. The
hardener has the advantages of long working time, fast curing speed, high
strength of molding sand and low sulfur content. The hardener has formed a
mass production, stable application in casting production. © 2017, Chinese
Experimental investigation to produce thin-walled sand casting using

combination of casting simulation and additive manufacturing techniques
.
84994496322&doi=10.1007%2fs00170-016-9653-
6&partnerID=40&md5=87b020a1dc65b67e908d69f9c388eef6
ABSTRACT: Sand casting process is used by man from olden days to
manufacture metallic components. Due to various problems of sand, mold and
filling, the process is considered not suitable to produce small intricate
castings having thin geometries. Only huge castings are preferred and
sophisticated components are completely ruled out of the process. However,
the cost-effectiveness of the process is very attractive. The present work
is taken up to investigate the possibility of sand mold casting process to
produce intricate components having thin sections like automobile cylinder
head castings. The project uses additive layer manufacturing technique for
pattern development and computer-aided casting simulation technique to
analyze mold filling and solidification aspects. Simulations are performed
by varying pouring temperature and gating system design which also reduces
shop floor trials and lead time. Based on simulation results, experiments
are design and conducted using three types of sand, namely air-set sand,
dry sand, and sodium-silicate sand. The produced castings are tested for
various parameters and found successful. Results obtained from simulation
are validated experimentally proving the methodology adopted is very
helpful in producing intricate castings economically. © 2016, Springer-
Verlag London.
Predicting the Formation of Intermetallic Phases in the Al-Si-Fe System

with Mn Additions
.
85017162596&doi=10.1007%2fs11669-017-0542-
y&partnerID=40&md5=d3a6dccb301f407e9e6d8839da495a32
ABSTRACT: Phase formation was investigated via thermodynamic calculations
of the Al-Si-Fe system within the range of commercial compositions with
additions of Mn as a quaternary element. The calculations were performed
using a commercial aluminum thermodynamic database and were compared with
experimental data on sand casting from the literature. Both equilibrium and
Scheil–Gulliver models were analyzed. The results showed that by adding Mn
to the alloy it was possible to favor the formation of the Chinese script
α-Al15(Fe,Mn)3Si2 intermetallic instead of the harmful platelet-shaped β-
Al5SiFe. Furthermore, the calculations indicated that with higher amounts
of Mn, the β-Al5SiFe intermetallic can be formed via a solid-state
reaction, while α-Al15(Fe,Mn)3Si2 becomes the primary phase to form from
the melt (also known as “sludge” in the aluminum foundry industry). A
relationship between Fe and Mn contents was identified that can prevent the
formation of the β-Al5SiFe intermetallic. © 2017, ASM International.
Optimization of permeability for quality improvement by using factorial

design
.
85019677387&doi=10.1063%2f1.4982861&partnerID=40&md5=47ef4effa0916faec5c2e6
900b3e175a
ABSTRACT: Sand castings are used worldwide by the manufacturing process in
Metal Casting Industry, whereby the green sand are the commonly used sand
mould type in the industry of sand casting. The defects on the surface of
casting product is one of the problems in the industry of sand casting. The
problems that relates to the defect composition of green sand are such as
blowholes, pinholes shrinkage and porosity. Our objective is to optimize
the best composition of green sand in order to minimize the occurrence of
defects. Sand specimen of difference parameters (Bentonite, Green Sand,
Cold dust and water) were design and prepared to undergo permeability test.
The 24 factorial design experiment with four factors at difference
composition were runs, and the total of 16 runs experiment were conducted.
The developed models based on the experimental design necessary models were
obtained. The model with a high coefficient of determination (R2=0.9841)
and model for predicted and actual fitted well with the experimental data.
Using the Analysis of Design Expert software, we identified that bentonite
and water are the main interaction effect in the experiments. The optimal
settings for green sand composition are 100g silica sand, 21g bentonite,
6.5 g water and 6g coal dust. This composition gives an effect of
permeability number 598.3GP. © 2017 Author(s).
Prediction of distortions and pattern allowances during sand casting of a

steel bracket
.
85006129715&doi=10.1080%2f13640461.2016.1262984&partnerID=40&md5=d111dbfa3e
6e40041a57be49f9fa1522
ABSTRACT: Mechanical interactions between the casting and mould generate
unwanted distortions and lead to dimensional inaccuracies. In this study,
the effects of mould expansion and mould restraint are investigated through
sand casting experiments involving a U-shaped steel bracket. Distortions
are quantified by in situ measurements of the evolution of the gap opening
between the bracket legs. Mould expansion is observed immediately after
filling. Outer mould restraint prevents distortions in the bracket legs
until the time of mould fracture, after which the legs are pushed outward.
The experiments are simulated using a sequential thermo-mechanical
coupling. The steel and bonded sand are modelled using previously
calibrated elasto-visco-plastic and Drucker–Prager Cap constitutive laws,
respectively. Excellent agreement between measured and predicted pattern
allowances (PA) is obtained. Distortions are greatly under-predicted unless
mould fracture is considered. Variations in the packing density of the
moulds are also shown to have an impact on PA. © 2016 Informa UK Limited,
trading as Taylor & Francis Group.
Experimental investigation and optimization of hardness in sand casting

process by using the design of experiments approach
.
85018429340&doi=10.18576%2famis
%2f110334&partnerID=40&md5=4b0169cdd2a6abe08571a88aa4bcb980
ABSTRACT: Casting is one of the most important process in manufacturing
environment to develop a product for the customer needs and satisfaction.
There is lot of casting process available in industrial world. Among
various casting process, sand casting is one of the important process
generally used for both ferrous and non ferrous materials. The
solidification range of molten metal plays a vital role in sand casting
process to decide the quality of the product. During solidification
process, the results of casting defects such as shrinkage, porosity and hot
tears are eliminated and a standard casting design system is essential
which can be achieved by an experimental investigation. Recently, Aluminum
(6063) plays a major role in automobile, manufacturing, nuclear and marine
industries. In this experimental investigation, crucible furnace is used to
melt the material and develop the product through sand casting methods. The
important input process parameters such as vent hole angle and vent hole
diameter are selected and studied at three different levels according to
the recommendation of Design of Experiments Approach. The main objective of
this experimental investigation is to find the optimum level of hardness in
sand casting process by using Aluminum (6063) material. The hardness
quality of test specimen is measured by using the Brinell hardness tester.
This experimental results shows that, vent hole diameter plays a crucial
role in hardness of sand casting process and the optimum level is
recommended for further research. © 2017. NSP Natural Sciences Publishing
Cor.
Processing design and optimization of sand casting aluminum alloy bracket

.
85021720647&doi=10.15980%2fj.tzzz.2017.05.028&partnerID=40&md5=aa824b892f3a
fa8e773f02fd9ed6d052
ABSTRACT: According to thin-walled bracket structural characteristics and
quality requirement, the design of sand casting process for the thin-walled
aluminum alloy bracket was carried out. The View Cast software was used for
the filling and solidification process. The simulated results show that a
large number of shrinkage cavity and shrinkage defects appear in the
solidification process as a result of the failure to completely fill the
mold because of the thin wall thickness of the bracket. Origination of the
defects was described, and the gating system was optimized. Through
selecting the position of the riser and the cold iron, designing the size
of the riser and the cold iron, the simulated results reveal that the
optimized casting process can eliminate the casting defects and meet the
requirement of the casting production. © 2017, Journal Office of Special
Construction and analysis of dynamic solidification curves for non-

equilibrium solidification process in lost-foam casting hypoeutectic gray
cast iron
.
85021316378&doi=10.1007%2fs41230-017-7040-
z&partnerID=40&md5=bf7f5d90b5e074b5c2ae95038442e0c3
ABSTRACT: Most lost-foam casting processes involve non-equilibrium
solidification dominated by kinetic factors, while construction of a common
dynamic solidification curve is based on pure thermodynamics, not
applicable for analyses and research of non-equilibrium macro-
solidification processes, and the construction mode can not be applied to
nonequilibrium solidification process. In this study, the construction of
the dynamic solidification curve (DSC) for the nonequilibrium macro-
solidification process included: a modified method to determine the start
temperature of primary austenite precipitation (TAL) and the start
temperature of eutectic solidification (TES); double curves method to
determine the temperature of the dendrite coherency point of primary
austenite (TAC) and the temperature of eutectic cells collision point
(TEC); the “technical solidus” method to determine the end temperature of
eutectic reaction (TEN). For this purpose, a comparative testing of the
non-equilibrium solidification temperature fields in lost-foam casting and
green sand mold casting hypoeutectic gray iron was carried out. The thermal
analysis results were used to construct the DSCs of both these casting
methods under non-equilibrium solidification conditions. The results show
that the transformation rate of non-equilibrium solidification in
hypoeutectic gray cast iron is greater than that of equilibrium
solidification. The eutectic solidification region presents a typical mushy
solidification mode. The results also indicate that the primary austenite
precipitation zone of lost-foam casting is slightly larger than that of
green sand casting. At the same time, the solid fraction (fs) of the
dendrite coherency points in lost-foam casting is greater than that in the
green sand casting. Therefore, from these two points, lost-foam casting is
more preferable for reduction of shrinkage and mechanical burntin sand
tendency of the hypoeutectic gray cast iron. Due to the fact that the
solidification process (from the surface to center) at primary austenite
growth area in the lost-foam cylinder sample lags behind that in the green
sand casting, the mushy solidification tendency of lost-foam casting is
greater and the solidification time is longer. © 2017, Foundry Journal
Agency and Springer Nature Singapore Pte Ltd.
Interfacial Reaction of Zirconium Sand Mold with Titanium Alloy Castings

Based on SLS Method
.
85021777886&doi=10.15980%2fj.tzzz.2017.05.017&partnerID=40&md5=a70fe42519d0
6614f271d0886c4b2d78
ABSTRACT: Through selecting zircon sand as raw materials of sand, yttrium
oxide (Y2O3) and phenolic resin as filler and binder, coated zircon sand
was prepared by thermal method, and zirconium sand mold was prepared by
selective laser sintering (SLS) to pour pure titanium castings by rapid
prototyping process. The interfacial reaction between titanium alloy and
mould was analyzed. The results show that the titanium castings with clear
profile and clean surface and interface reaction layer only about 3 μm can
be fabricated successfully by SLS coated zircon sand casting with Y2O3
coating. Oxidation products in casting surface are composed of TinO2n-1 and
TiO2. The thickness of O diffusion enrichment solution layer is about 1 μm,
which is TiO2. © 2017, Journal Office of Special Casting and Nonferrous
Process improvement through six sigma - A case study of Agra foundry

.
85020213309&doi=10.1109%2fR10-
HTC.2016.7906806&partnerID=40&md5=6299d4738b2e93a642384e3863ba4b3d
ABSTRACT: The present paper is an exploration of six sigma in foundry adopt
for the refinement of green sand casting process by decreasing the defects
for getting sufficiently good casting improvement. An approach based on
case study is applied for reducing defects by implementing six sigma
techniques. Proposed technique is used for optimizing the various factors
which are responsible for controlling quality, stability & process. © 2016
IEEE.
Study on Large Thin-Wall Aluminum Alloy Damping Tower Sand Casting

Technology
.
85028352435&partnerID=40&md5=a6aaa803c9c7680bae37365a91e8a04e
ABSTRACT: Based on the characteristics of damping tower structure, the
damping tower casting process key points were analyzed. By A357 alloy
composition, size and quality control, melt purification and grain
refinement, the thin-wall casting filling full, the isotropy and excellent
mechanical properly A357 alloy damping tower casting was gained. The
foundry by using of precision sand adjusted pressure casting method,
optimized gating system, and chill in rod handover thick wall area, high
degree of super-heat pouring, while combined with thermal insulation
coatings and reinforced sand mold venting, the filling full, fine internal
quality of damping tower casting was obtained, meet the design
requirements. In addition, through die design and optimization, overall
outside sand mold and inner core parting surface cooperate with ladder
dentate, positioning pin and locating sleeve inlays fixed way, and combined
with heat treatment tooling and deformation control, the size of casting
meet the design requirements. © 2017, Chinese Mechanical Engineering
Society. All right reserved.
Heating system for riser size minimizing in sand casting process and its
experimental verification
.
85018495288&doi=10.3390%2fmet7040130&partnerID=40&md5=ef49e949a0f12abe0ae03
d60d36e620f
ABSTRACT: In the conventional sand casting process, the size of the riser
is made larger than that of the cavity (product part) in order for the
molten metal in the riser to solidify at a later stage than the molten
metal in the cavity. In this study, a continuous heating method is
developed and applied to the riser, using a cylindrical heater, to minimize
the size of the riser. A mold having four cavities is designed for casting
turbine housings. The height and diameter of the riser are chosen to be 80
mm and 20 mm, respectively. Solidification analysis results, using the
analysis program MAGMA soft for casting simulation, showed that when the
heater is implemented, the riser is the last to solidify. However, without
the heater, the riser solidifies before the cavity, thus causing the riser
to function improperly. Moreover, misruns are generated in the casted
product if the heater is not implemented, as opposed to the case of a solid
product without any defects, with the heater attached in the riser. © 2017
by the authors. Licensee MDPI, Basel, Switzerland.
Optimization of the gating system for sand casting using genetic algorithm
.
85017618234&doi=10.1007%2fs40962-016-0040-
8&partnerID=40&md5=b14ecc576ee1c87283987c7e2ad52ced
ABSTRACT: The paper presents a methodology of optimization of the gating
system for sand casting using the genetic algorithm. Software package for
computer-Aided design/computer-aided manufacturing (CAD/CAM) was used as
the support to the design and verification of the optimized gating system.
The geometry of the gating system of sand casting in excavator tooth holder
was the subject of optimization. The objective was to maximize filling rate
given the constraints posed by both the ingate module and Reynolds number.
Mold filling time has been presented as a function of the ingate cross
section and casting height. Given the conditions above, as the result of
the optimization, a complete geometry of the gating system has been
defined. Numerical simulation (software MAGMA5) has been used to verify the
validity of the optimized geometry of the gating system. Copyright © 2016
Imaging of silica sand to evaluate its quality to use it as foundry core

sand
.
85017618767&doi=10.1007%2fs40962-016-0063-
1&partnerID=40&md5=d76e769ccd2d373d03c36527220275c9
ABSTRACT: Silica sand is a major mineral commodity for foundries,
specifically for sand casting. Suppliers of foundry sand located near
consumers would keep costs low production. Gray cast iron in Mexico demands
large amounts of silica sand for the manufacture of core molds, currently
supplied by the USA. This sand must meet industrial specifications for core
sand to reach adequate strength, such as grain shape, grain size
distribution, pH and ADV. In the last years, a high demand for silica sand
for fracking in the USA has obligated Mexican foundries to search for new
sources of this commodity. In this research, seven samples of silica sand
from different areas Northeast and Southeast in Mexico were analyzed by
microscopy imaging using metallography microscopy and SEM, to compare with
core commercial sands. Also, semi-qualitative chemical composition by
energy dispersive X-ray spectroscopy was analyzed. Surprisingly, results
showed some silica sands from Mexico have textural surface and chemical
composition similar to samples from the USA. A source of silica sand
located in Mexico could be developed to meet local demand. © 2016 American
Foundry Society.
The Effect of Iron Content on Microstructure and Mechanical Properties of

A356 Cast Alloy
.
85009291126&doi=10.1007%2fs11663-016-0909-
1&partnerID=40&md5=05b1650b5f89409a6d8ab039f5665fa3
ABSTRACT: In the present study, microstructure and mechanical properties of
A356 alloy including various amounts (0.2 to 1.2 wt pct) of iron were
investigated. The alloys were produced by conventional gravity sand casting
method. In order to determine the effect of iron addition to A356, optical
and scanning electron microscopes (SEM/EDS) were used for microstructural
examinations, and X-ray diffraction (XRD) analysis was carried out for
phase characterization. Tensile tests were also conducted in order to
determine effect of the Fe content on mechanical properties. It was found
that as the Fe content of A356 was increased, the secondary dendrite arm
spacing (SDAS) was decreased and the morphology of Al-Si eutectic became
finer. From XRD examinations, different iron-based intermetallic compounds
(β-Al5FeSi and α-Al8Fe2Si) formations were observed. It was also observed
that as iron content increased, α-Al8Fe2Si intermetallic was transformed
into β-Al5FeSi intermetallic. The tensile test results revealed that
tensile strength and elongation values were reduced by increasing Fe
content. It was also determined that β-Al5FeSi intermetallics were more
negatively effective on tensile strength than α-Al8Fe2Si intermetallics. ©
2017, The Minerals, Metals & Materials Society and ASM International.
Low Density and Temperature Tolerant Alloys for Automotive Applications

.
85018371455&doi=10.4271%2f2017-01-
1666&partnerID=40&md5=c6dd20acabded227f277f33692db0ca1
ABSTRACT: Aluminum alloys containing cerium have excellent castability and
retain a substantial fraction of their room temperature strength at
temperatures of 200°C and above. High temperature strength is maintained
through a thermodynamically trapped, high surface energy intermetallic.
Dynamic load partitioning between the aluminum and the intermetallic
increases mechanical response. Complex castings have been produced in both
permanent mold and sand castings. This versatile alloy system, using an
abundant and inexpensive co-product of rare earth mining, is suitable for
parts that need to maintain good properties when exposed to temperatures
between 200 and 315°C. © 2017 SAE International.
Design of the Vent System of Sand Casting
.
85028363194&partnerID=40&md5=497930e3d435f35a2c56b1c633995ca2
ABSTRACT: The design of the vent system is one of the important parts in
the design of the casting process, which greatly affects the casting
quality. The optimal vent system can effectively prevent the casting
defects such as blowhole, burning-on, boiling, blowhole shrinkage, etc. and
improve the mold-filling capacity of the melt. The different vent system
designs of the sand casting were introduced, including sand core venting
and mold cavity venting, such as venting holes, exhaust rope, venting
channel and venting plug; air exhaust, venting riser, over flow exhaust
riser, ignition venting etc. which can provide valuable experiences and
references for the peers in the foundry industry. © 2017, Chinese
A comparative study of hot deformation behaviors for sand casting and

centrifugal casting Q235B flange blanks
.
85014078790&doi=10.1515%2fhtmp-2015-
0209&partnerID=40&md5=7601df093999375c63b1b0058f466cc8
ABSTRACT: Hot compression tests of sand casting and centrifugal casting
Q235B flange blanks were performed at strain rate range of 0.01-5 s-1 and
temperature range of 850-1,150°C. The evolutions of microstructure and
texture were revealed. The constitutive models based on Arrhenius
constitutive modeling were proposed by considering the effects of strain on
material constants. The results show that recrystallization in centrifugal
casting Q235B is more apparent than that in sand casting, resulting in the
finer grains and lower flow stress for centrifugal casting Q235B. The
intensities of textures slightly weaken with the increase of temperature.
At 1,050°C and 5 s-1, the textures of sand casting are characterized by
strong {001}<100> and {001}<110>, which are related with severe
deformation, while the textures of centrifugal casting are composed of
{110}<110> and {111}<112>, which are related with dynamic
recovery and shear deformation. A good agreement between the predicted and
experimental flow stress is achieved and demonstrates that the proposed
constitutive models are reliable. © by De Gruyter 2017.
Effect of heat treatment on the impact toughness of ‘high-chromium cast

iron – Low alloy steel’ bimetal components
.
85014518345&doi=10.1007%2fs11041-017-0088-
y&partnerID=40&md5=4514d8704270ef65f8b29a638f33462f
ABSTRACT: A bimetallic ‘low-alloy steel – high-chromium cast iron’
composite obtained by successive sand casting is studied and shown to have
good cohesion on the interface and no casting defects. The hardness and the
impact toughness of the bimetal increase simultaneously. The microstructure
is more homogeneous after diffusion annealing at 1040°C, rapid cooling, and
3-h tempering at 270°C. © 2017 Springer Science + Business Media New York.
Effect of copper addition to aluminium alloys on surface roughness in terms

of turning operation
.
85018672408&doi=10.12693%2fAPhysPolA.131.467&partnerID=40&md5=9eb045620d829
34c4dabdc91bed1faff
ABSTRACT: Aluminium alloys have found usage in numerous industries due to
some superior properties, such as high strength-to-weight ratios and high
oxidation resistance. Aluminum alloys can be strengthened by some
techniques. One of them, the most practical one, is precipitation hardening
in aluminum alloys. By adding Cu, aluminum gains strength and hardness. In
this work the machinability of unalloyed aluminum and aluminum alloyed with
4% and 8% of Cu have been investigated. Machinability assessment was
executed in terms of surface roughness during turning operation. Specimens
were manufactured by sand casting method, which is a commonly utilized
casting operation. In machinability experiments, three different cutting
tool materials were employed. Three different cutting speeds and three
different feed rates have been used. Effect of these feeds, speeds and
cutting tool materials on surface roughness has been studied. In addition,
effect of Cu addition to aluminum alloys on surface roughness has been
examined. © 2017, Polish Academy of Sciences. All rights reserved.
Prediction of Shrinkage Porosity and Processing Optimization of Casting Die

Inserts
.
85033406464&doi=10.15980%2fj.tzzz.2017.03.007&partnerID=40&md5=6bcd88933363
d0ec8118848c9b10eb00
ABSTRACT: To predict shrinkage porosity formed in the process of casting
die inserts, the solidification process of the original casting was
simulated by the ProCAST software and compared with experimental results.
The results indicate that three kinds of methods predicting shrinkage
porosity have a certain limitation under the condition of the process.
Moreover, a comprehensive method of the qualitative method combined with
shrinkage porosity critical value method can predict the defects of
shrinkage porosity accurately. Based on the simulation and analysis, the
casting process was optimized, and the shrinkage porosity defects were
reduced effectively. © 2017, Journal Office of Special Casting and
Casting Technique Design of Quarter Part of a Large Gear

.
85028318605&partnerID=40&md5=a81625e0930cf1acb7ac69152338eb48
ABSTRACT: The casting defects of quarter part of large gear such as
shrinkage, dispersed shrinkage and distortion etc were analyzed, especially
the joint position of the casting. The feeding system was designed by
modulus method, and optimized measures were adopted as follow: chill,
improved gating system, allowance riser at joint position of the casting.
And the casting process was verified by ProCAST casting simulation
software. After the process improvement, the production rate of casting was
improved obviously, the dispersed shrinkage and shrinkage and distortion
were eliminated, and the high-quality casting was obtained. © 2017, Chinese
Optimizing gate location to reduce metal wastage: Co–Cr–W alloy filling

simulation
.
84995608812&doi=10.1016%2fj.jmatprotec.2016.09.027&partnerID=40&md5=4c89a55
76c23bfeef8a7d13cffd15c71
ABSTRACT: This research aimed at reveal the reasons for the extra Co–Cr–W
alloy wastage in the risers in sand casting. The alloy filling behaviour in
both the original and modified moulds was investigated numerically. The
alloy–air interface was captured by using volume of fraction method. For
the original mould, an unfilled volume in the vicinity of the runner bar
top was apparent and it was refilled by a back flow, originated from the
risers in the late stage of filling. The back flow behaviour required a
higher level of the liquid alloy in the risers, which resulted in excessive
wastage, and it was essential to form the required shape of the cast. For
the modified mould, the unfilled volume was eliminated and the cast part
shaping time was reduced to around 10 s from 90 s. The alloy wastage in the
risers was reduced by 11%. © 2016 Elsevier B.V.
Improvement on Casting Process of Aluminum Alloy Sub-Frame for Car

.
85019436136&partnerID=40&md5=5cc60f1a909d2416eafad256cb05c928
ABSTRACT: It is very difficult to cast the aluminum alloy sub-frame casting
for its larger size, complex structure, and nonuniform wall thickness. The
causes of casting defects of the sub-frame in sand casting were analyzed
and the casting process was optimized and improved. Test results show that
dispersed shrinkage and blowhole casting defects etc. were eliminated, and
qualified castings were produced by optimization of gating system and
increasing refining degassing time. © 2017, Chinese Mechanical Engineering
The Common Design Mistakes and Countermeasures of Pouring System for Cast
Iron Casting
.
85019471294&partnerID=40&md5=b65b2b11bf30bff96523f20b46bfa3d3
ABSTRACT: The usual design mistakes in common gating system of cast iron
casting during the production were analyzed. In order to improve the
product quality, the author analyzed these mistakes by using of the
theories of casting formation, fluid mechanics and the other basic theories
and proposed the countermeasures. © 2017, Chinese Mechanical Engineering
Determination of the interfacial heat transfer coefficient at the metal-

sand mold interface in low pressure sand casting
.
85022202414&doi=10.1016%2fj.expthermflusci.2017.07.002&partnerID=40&md5=a16
17ccd0a83d9f328d27cffda013086
ABSTRACT: The interfacial heat transfer coefficient (IHTC) at the metal-
sand mold interface was determined by applying a nonlinear inverse
estimation method during the low pressure sand casting (LPSC) process.
Experiments were conducted using plate shape castings with different
thicknesses for both ZL205A and ZL114A aluminum alloys. A specific
temperature sensor unit was developed to measure accurately the temperature
evolution inside the sand mold, based on which the IHTC was estimated.
Results showed that the time-dependent IHTC during the LPSC mainly
comprised two stages, i.e., rapid increasing stage and maintain stage, and
the second stage could be further divided into two parts based on the plate
thickness. Besides, the IHTC was found to be also highly dependent on the
casting material, especially the maximum value. Further analysis also
revealed that the estimation accuracy of the inverse method was increased
by 50% if the temperature dependence of the thermo-physical parameters was
considered, rather than normally constant treatment or simple linear
interpolation versus temperature. © 2017 Elsevier Inc.
Compression strength of open-cell aluminum foam produced by green sand

casting using the energy conservation lost-foam technique
.
85058593328&doi=10.1201%2f9781315207322&partnerID=40&md5=73047ce6ec6f02ec3f
b6afa2cf8dd01b
ABSTRACT: The purposes of this study were to determine the mechanical
behavior of aluminum foam by compression test and the porosity percentage
of the three different types of aluminum foam produced by energy
conservation lost foam method. Commercial polystyrene usually used for
packaging was chosen as a template and the desired templates were produced
and filled with sand, which was then embedded in green sand casting
(recycle material). The mold subsequently poured with a molten aluminum
based on reusing and the samples was then undergoing blasting process to
remove the sand. It was followed by a machining process to remove surface
imperfections during casting. The mechanical behavior was investigated
under uniaxial compression with solid aluminum and three different
arrangements of pore structure with equal size samples of Al Foam 4, Al
Foam 9 and Al Foam 14. As a result, the aluminum foams’ mechanical behavior
differs with different pore size and porosity. The higher its density will
resultant higher ability to absorb energy. © 2018 by Apple Academic Press,
Inc.
Effect of Wall Thickness on the Quality of 1060 Aluminum Produced by Sand

Casting
.
85010377907&doi=10.1016%2fj.promfg.2016.12.015&partnerID=40&md5=081ebbe9757
5dc2e491b9649f50c17f6
ABSTRACT: The demand for thin walled sections in the industry is
continuously increasing due to their light weight. However, the production
of thin wall sections (<2 mm) using sand casting process present a huge
challenge in the foundry industry. This paper will investigate the filling
defects which are associated with thin walled sections, thus affecting the
quality of 1060 aluminium casting using sand casting process as a
manufacturing process. The results showed quick solidification of thin
walled section (1mm-2.5 mm) before the metal completely filled the mould
cavity. Some of the important factors which contributed to this quick
solidification were wall thickness, backpressure and presence of junctions.
The higher the number of junctions the higher the backpressure and the
lower the fillability. A small increase in wall thickness reduced the
backpressure which increased the metal flow. The temperature of the molten
metal remained constant at different places for all different test samples.
A slight increase in wall thickness yielded a minimum of 12.5% and a
maximum of 32% increase in fillability. It was observed that as the wall
thickness increases, so does the fillability. © 2016 The Authors
Design and optimization of rapid sand casting aluminum alloy cylinder head
.
85018630348&doi=10.15980%2fj.tzzz.2017.01.010&partnerID=40&md5=a3932a872d26
2ee7c89f50fe701edeb4
ABSTRACT: The rapid sand casting aluminum alloy cylinder head of the engine
was conducted. According to the characteristics of cylinder head, the top
pouring and bottom pouring gating were taken into account. Through the UG
NX 3D modeling, two kinds of gating systems were simulated by the ProCAST
software to optimize the pouring parameters. The results reveal that
through designing the gating system with single side-bottom pouring at
690℃ and 0.22 m/s, the satisfied aluminum alloy cylinder head can be
produced, meeting the requirements. © 2017, Journal Office of Special
Mechanical Characterization and Microstructure analysis of Al C355.0 by

Sand Casting, Die Casting and Centrifugal Casting Techniques.
.
85031782164&doi=10.1016%2fj.matpr.2017.08.056&partnerID=40&md5=23f45656d19f
9993e1a8efa6b4309ea4
ABSTRACT: In this study, mechanical properties of aluminium alloy C355.0
was investigated for Sand Casting, Die Casting and Centrifugal Casting
Technique. Mechanical properties like tensile test was performed using
PC2000 software, and Brinell hardness test was performed. Die casting was
observed to have good tensile and hardness properties compared to sand and
centrifugal castings Microstructure analysis was done by Nikon Microscope
LV150with Clemax Image Analyser. From the observation die casting had
uniform distribution of silicon. Wear behavior of the alloy studied using
sliding wear test. Good wear specific wear rate was found in all the
casting but the best was observed in die casting at 20N load. © 2017
Elsevier Ltd.
Design and development of FDM pattern for sand casting process

.
85029044383&partnerID=40&md5=e48e3c2e85d3a1ae422440dee170c424
ABSTRACT: This paper presents study of Rapid Prototype pattern directly
used in Sand casting. Sand mold preparation procedures including CAD
pattern designing, RP pattern formation, pattern surface finish and
sealing, Geometrical effects such as bulk solid and thin wall are studied.
For the process to be successful, the preparation should start as early as
CAD design stage. For bulk solid geometrics, "Shell" function in CAD and
"Sparse web" options are proved very effective and should be applied in
combination. Rapid prototyping is one of the most emerging fields of modern
industry. It is one of the most time saving methods for production of
physical parts or prototypes according to the required scale. Metal Casting
is one of the most widely used methods for production of components.
Casting in addition with the rapid prototyping process reduces the time
taken to produce a component or part along with an increase in the quality
of component. Use of rapid prototype for manufacturing the tailor-made
product is one of the important areas of research today. This has lot of
significance in automobile industries and aeronautical industries for
manufacturing mechanical components.
Effect of inclusions on mechanical properties of Nb stabilized austenitic

stainless steels (316Nb) with centrifugal and sand casting techniques
.
85040237139&doi=10.1051%2fmattech
%2f2017035&partnerID=40&md5=dcb0956db6969676ec4ab8874ea7304a
ABSTRACT: In this study, 316Nb stabilized austenitic stainless steel pieces
were produced via sand and centrifugal casting method in order to be
investigated. Heat treatments were done in two stages, and cooling was made
in various quenching mediums. As-cast parts and the parts with only the
highest and the lowest tensile strength were investigated. Metallographical
analyses were made and the content of non-metallic inclusions was examined.
Various types of carbides in microstructures were determined by means of
SEM-EDX analysis. The sand casting samples had more non-metallic inclusions
than the centrifugal casting ones. After the tensile tests, it was seen
that these inclusions had significant effect on the mechanical properties.
The tensile strength, the yield strength, the elongation and the hardness
values of the centrifugal casting samples were higher than the sand casting
ones. Investigating the SEM-EDX analyses, it was determined that the sand
cast samples had chromium carbides in small quantities, in addition to
niobium carbides. Centrifugal cast parts had niobium carbides. © EDP
Sciences, 2017.
Intelligent Machine Vision Based Modeling and Positioning System in Sand

Casting Process
.
85013468501&doi=10.1155%2f2017%2f3192672&partnerID=40&md5=84c8a16c70553a55b
724770efbf887c1
ABSTRACT: Advanced vision solutions enable manufacturers in the technology
sector to reconcile both competitive and regulatory concerns and address
the need for immaculate fault detection and quality assurance. The modern
manufacturing has completely shifted from the manual inspections to the
machine assisted vision inspection methodology. Furthermore, the research
outcomes in industrial automation have revolutionized the whole product
development strategy. The purpose of this research paper is to introduce a
new scheme of automation in the sand casting process by means of machine
vision based technology for mold positioning. Automation has been achieved
by developing a novel system in which casting molds of different sizes,
having different pouring cup location and radius, position themselves in
front of the induction furnace such that the center of pouring cup comes
directly beneath the pouring point of furnace. The coordinates of the
center of pouring cup are found by using computer vision algorithms. The
output is then transferred to a microcontroller which controls the
alignment mechanism on which the mold is placed at the optimum location. ©
2017 Shahid Ikramullah Butt et al.
Optimisation of Additive Manufactured Sand Printed Mould Material for

Aluminium Castings
.
85029829110&doi=10.1016%2fj.promfg.2017.07.136&partnerID=40&md5=8016f860b78
2fb58e274aea8b8ee3843
ABSTRACT: The sand casting process is utilised for over 70% of all
castings, the traditional this process requires a disposable sand mould, A
pattern the shape of the product to be manufactured, plus manufacturing
features is used to create the cavity. Additive Manufacturing processes
have been used to generate the sand mould tools directly without patterns,
hence reducing the lead time and manufacturing design constraints. This
paper focuses on optimising the characteristics of the 3D Sand Printing
process to traditional produced Furan mould tools, cumulating with an
automotive turbo charger case study, to validate the build parameters
optimisation process. © 2017
Characterisation of direct 3D sand printing process for the production of

sand cast mould tools
.
85013177883&doi=10.1108%2fRPJ-08-2014-
0101&partnerID=40&md5=b5576ad8f38183263bac2f32c60b7ed6
ABSTRACT: Purpose - Metal casting industry is in recovery phase after the
crisis in 2008; customer demand continues to increase, with 98.6 million
metric tons cast in 2011. Traditional ferrous and non-ferrous casting
techniques require one shot or permanent moulds which require tooling to
produce. Tooling particularly for developmental projects can be costly and
take valuable time to produce. Additive manufacturing (AM) has been used to
manufacture sand patterns for metal sand casting using laser sintering and
sand bonding. This research aims to focus on characterising the sand-bonded
process developed by ExOne GmbhH Germany. Design/methodology/approach - The
approach taken in this research is to evaluate characteristics of parts
built in the build volume for dimensional accuracy, tensile and compressive
crush strength, density, impact strength and high temperature resistance.
These properties are required to compare the 3D sand printing (3DSP)
process to direct laser sand sintering (DLSS) and traditional Furan-based
casting sand mixtures. The samples were taken from a production machine
over a period of 30 days to ensure consistency. Findings - The 3DSP process
has the capability to manufacture sand patterns to an accuracy of ±0.5 mm
or error less than 0.3 per cent; it has also demonstrated the best build
position to achieve accurate parts. The research has demonstrated the 3DSP
patterns are comparable to traditional methods for important casting
material characteristics such as tensile, compression and impact strength.
It has been shown that the 3DSP process is capable manufacturing
significantly larger parts, with build production rates up to 30 times
higher compared to similar parts manufactured via the DLSS process.
Research limitations/implications - As they has been very few 3DSP machines
sold in Europe and particular UK, they has been little research into this
new technique, and, therefore, they is a reliance on machine manufactures
data for assessment. This research into 3DSP has increased the knowledge of
this process significantly. Practical implications - This research would be
of interest to designers and manufacturing engineers wishing to take
advantage of the implications of having new design freedom, tool less
manufacturing with short lead times in a wide range of materials using
fundamentally tried and tested century's old casting techniques.
Originality/value - The research for this paper revealed very little
published academic research in this area; therefore, this work will
increase the body of knowledge for this niche AM process. © Emerald
Publishing Limited.
The effect of surface treatment on 0.16% Chromium and 1.32% Nickel Alloyed
Ductile Iron (Di) through boronizing process
.
%2fKEM.740.70&partnerID=40&md5=b30c812c02b92296770ec95404f8bdd7
ABSTRACT: This paper aim to investigate the effect on microstructure,
hardness and wear (slurry erosion) of alloyed ductile iron (DI) with
addition of 0.16% Chromium and 1.32% Nickel before and after boronizing
process. The specimens were prepared by melting the Ductile Iron
compositions through CO2 sand casting method. Specimens were fully coated
with boronizing paste and heated at 8500C and 9000C for 8 hours holding
time. Microstructures of the specimens were observed under Olympus BX 41M
Optical Microscope. Vickers Micro Hardness Tester was used to determine the
hardness of the specimens while Wear Test (Slurry Erosion) to measure the
wear volume of each specimen. After boronizing process, the boron element
diffused into the specimens which make the surface harden. The thickest
boride layer was detected at sample with temperature 9000C. The samples of
900°C give higher hardness than temperature 8500C which is 2909 HV and 1395
HV respectively. Referring to surface roughness test, samples boronized at
900°C had high wear resistance compared to sample boronized at 850°C and as
cast. The selection temperature in boronizing treatment can prevent the
rate of wear thus can identify the hardness of surface in order to prolong
the equipment and application or even structure. © 2017 Trans Tech
Effect of Modifier on Mechanical Properties of Aluminium Silicon Carbide

(Al-SiC) Composites
.
85020037941&doi=10.1016%2fj.proeng.2017.04.156&partnerID=40&md5=32a12aa46fd
bda8efbc303c1d2e6970b
ABSTRACT: The silicon carbide particle reinforced aluminum matrix
composites are expected to have many applications in aerospace, aircraft,
automobile and electronic industries. Aluminium Silicon Carbide (Al-SiC) is
also used for Advanced Microelectronic Packages. In this study, effect of
different weight percentage of strontium on microstructure and mechanical
properties of Al-SiC composite and Al-12Si (LM6) was investigated. In this
research, scanning electron microscope equipped with EDS was used to define
how modifier effect on microstructure. To fabricate Al-SiC composite, 10 wt
% silicon carbide and different percentages (0.02, 0.5) Wt % of Al-10Sr was
added to Al-11.6Si (LM6) by using vortex method for mixing the particles.
The influence of adding different amount of Al-10Sr (0.01, 0.02, 0.5) Wt%
on mechanical behavior of aluminum was also examined. The results found
that UTS for aluminum increased by adding SiC and Sr. It was observed that
the tensile for the composite did not increase dramatically. It was
concluded the weak interface between particles and matrix, decreased the
UTS. On the other hand strong interface between particles or fibers in the
matrix showed high stiffness and strength but typically a low resistance to
fracture. © 2017 The Authors.
PLASTER MOLD PROCESS - ITS PLACE IN THE DIE CASTING INDUSTRY.

.
85040270621&partnerID=40&md5=c279dbf55687d628d22fcd8a8a5d0854
ABSTRACT: The basic technology of the plaster mold process in producing
precision aluminum or zinc castings at minimum cost is outlined, with
emphasis on how this expendable mold process helps the die caster satisfy
his customer. It is shown that the plaster mold process shares the
advantages of short lead time and low tooling costs with sand casting, plus
the precision and repeatability of die casting. There are virtually no
limitations as to what part sizes and configurations can be cast in plaster
molds.
Optimized production process of a supporting plate as an improvement of the

product sustainability
.
85018406403&doi=10.1007%2f978-3-319-57078-
5_23&partnerID=40&md5=ec01014b39975a0c4dc25ba13ea0d045
ABSTRACT: The main goal of the described activity is the verification of an
innovative production process of a steel supporting plate by using
numerical simulation. The normal production process consists of different
phases and processes: the laser cutting of blanks, welding, stress
relieving, heat treatment and machining. The studied alternative is a sand
casting process in order to directly obtain the final supporting plate.
Numerical simulations were used to investigate the impact behavior of
complex products in order to define the best production solution. The new
design chain represents an important simplification in order to reach a
simpler, less expensive and more sustainable manufacturing process and
these aspects were confirmed performing a Life Cycle Assessment. © Springer
International Publishing AG 2017.
Features of formation of microstructure, elemental and phase compositions,

and properties of the 1.7%C- 14%Cr-3%Mn-3%Si-1%Ni-0.6%V-1.2%B Steel under
casting and pulsed plasma Deposition
.
85028878822&doi=10.15407%2fmfint.39.04.0491&partnerID=40&md5=3ae50e9e29a1c2
deac7efdcc0e7c7b6e
ABSTRACT: This article describes the microstructure features,
microhardness, and elemental phase distribution in ledeburitic 1.7%C-14%Cr-
3%Mn-3%Si- 1%Ni-0.6%V-1.2%B steel fabricated by pulsed plasma deposition in
comparison with conventional sand casting. An electrothermal axial plasma
accelerator is used as plasma source with following processing parameters:
voltage is of 4.0 kV, the discharge current amplitude is up to 18 kA, the
working environment is air, the working pressure is atmospheric, the
cathode is the 1.7%C-14%Cr-3%Mn-3%Si-1%Ni-0.6%V-1.2%B steel. The work is
carried out using the optical and scanning microscopies, EDS, XRD, and
microhardness measurements. As found after sand casting, the steel contains
in the structure large (10-40 μm) primary (Fe3.8Cr2.9Mn0.3)7C3 carbide,
(Fe1.4Cr0.6Mn0.1)2(C,B) and (Fe3.3Cr1.5Mn0.2)5(C,B2)3 carboborides as well
as 'austenite M7+3' and 'austenite M7+3 Mx(C,B)y' eutectics. The volume
fraction of carbides and carboborides is of 44%. Pulsed plasma treatment
leads to formation of steel coating of oversaturated solid solution with
the microhardness of 643-932 HV. Post-plasma heat treatment (quenching from
900°C) results in solid-state reaction of the (M7C3) carbide and (M2(C,B),
M5(C,B)3) carboborides' precipitation from the solid solution. This one
leads to formation of large amount of dispersed precipitates of mean size
of 0.7 μm reflecting substantial (ten folds) refinement of carbide and
carboborides in comparison with the sand cast steel. Pulsed plasma
deposition is accompanied with the saturation of steel by carbon due to the
erosion of dielectric chamber walls (bakelite-paper composite) under high-
current discharge. This one causes the increase of the carbides and
carboborides volume fraction by 10.5% relative to convention casting. Post-
plasma heat treatment provides the increase of microhardness up to 885-1100
HV.
Casting improvement based on metaheuristic optimization and numerical

simulation
.
85037676975&doi=10.22190%2fFUME170505022R&partnerID=40&md5=8dd362445e07d94e
e71fd2424445a104
ABSTRACT: This paper presents the use of metaheuristic optimization
techniques to support the improvement of casting process. Genetic algorithm
(GA), Ant Colony Optimization (ACO), Simulated annealing (SA) and Particle
Swarm Optimization (PSO) have been considered as optimization tools to
define the geometry of the casting part’s feeder. The proposed methodology
has been demonstrated in the design of the feeder for casting Pelton
turbine bucket. The results of the optimization are dimensional
characteristics of the feeder, and the best result from all the implemented
optimization processes has been adopted. Numerical simulation has been used
to verify the validity of the presented design methodology and the feeding
system optimization in the casting system of the Pelton turbine bucket. ©
2017 by University of Niš, Serbia.
Determination of heat transfer coefficient between az91 magnesium alloy

casting and no-bake mold
.
85029542021&doi=10.17580%2ftsm.2017.08.14&partnerID=40&md5=7eaa93826aee7892
b29f87d0f8835421
ABSTRACT: It is necessary to know the interface heat transfer coefficient
(iHTC) between the casting and the mold for the simulation of casting
filling and solidification processes in the casting simulation software
systems. This study demonstrates the way we determined the heat transfer
coefficient h between the cylindrical casting of 50-56 mm in diameter and
150 mm in height of the AZ91 magnesium alloy and no-bake mold on synthetic
resin binder. The temperature field in the mold and the temperature of the
alloy were determined using twelve thermocouples installed in the mold and
mold cavity. Their temperature data were recorded when pouring,
solidification and cooling of the casting. The ProCast software used for
the simulation of filling and solidification of castings. Then the cooling
curves were obtained for the points in the model corresponding to the
position of thermocouples during the experimental casting. We used the
thermal properties of the mold available in the literature and the thermal
properties of the alloy calculated using the ProCast thermodynamic
database. Simulation and recording of temperature measurements were carried
out to 1500 s. To determine the heat transfer coefficient the error
function was used. It indicates the difference between the experimental and
calculated values of the temperature in the casting and mold. The value of
heat transfer coefficient was set as temperature dependence. The value of
the heat transfer coefficient in the range hL = 600-1300 W/(m2.K) in every
100 W/(m2.K) was set above the liquidus temperature (610 °C) of the alloy.
The heat transfer coefficient hS = 500-700 W/(m2.K) was set below the
solidus temperature of the alloy (415 °C). We tried to find a value of heat
transfer coefficient at which the error function was minimized, and hence
the difference between the calculated and experimental temperature field in
the casting and mold has also been minimal. The obtained values of the heat
transfer coefficient between the casting and mold are hL = 1100 W/(m2.K)
above the liquidus temperature and hS = 600 W/(m2.K) below the solidus
temperature. Such heat transfer coefficient values give the error function
not more than 20 °C. This work was carried out with the support of the
Russian Federation President's Grant to the young scientists and post-
graduate students, carrying out the prospective scientific investigations
and developments on priority ways of modernization of Russian economics
(contest of 2016-2018).
Mechanical properties of Al2O3 particle-reinforced A356 composite produced

by a multi-step process regime
.
85017563028&doi=10.12982%2fcmujns.2017.0009&partnerID=40&md5=49747843af24ca
2b98e396a640420768
ABSTRACT: The aim of this study was to produce a composite material of A356
aluminum alloy reinforced with 250 μm alumina (Al2O3) powder. A multi-step
process regime was developed. Strain was induced via milling in production
of A356 chips. The chips were dry mixed with Al2O3 at 5, 10, and 15 wt% and
cold pressed, followed by sintering at 600°C for 20 min. Then the molten
composite was sand casted into a cylinder with a diameter of 20 mm and
length of 50 mm. Afterward, all cast specimens were heat treated by
solution treatment at 527°C for 12 h, quenched in water, and naturally aged
at room temperature for 10 h; then artificially aged at 177°C for 12 h and
furnace cooled. Specimens were subjected to hardness and wear tests. The
results of hardness testing of the 'as received' A356 and casted A356-5,
10, and 15 wt% Al2O3 were 23.5 HRB, 41.3 HRC, 44.0 HRC, and 46.0 HRC,
respectively, and the average hardness values after heat treatment were
46.0 HRB, 46.3 HRC, 48.0 HRC, and 51.1 HRC, respectively. The percentage of
Al2O3 was a significant factor based on statistical analysis. The hardness
values increased significantly after heat treatment. In addition, heat-
treated A356-5, 10, and 15 wt% Al2O3 exhibited average wear rates of
0.00387, 0.00375, and 0.00350 mm3/m, respectively. Increasing the amount of
alumina reduced the wear rate, but the difference was not statistically
significant. The cross-section micrographs revealed that the alumina
powders were uniformly dispersed in A356 matrix.
Diagnosis of a natural gas energy system of casting and heat treatment

process
.
85057553328&partnerID=40&md5=4a3ff71edc28e8a4add01376fc574343
ABSTRACT: A study based on the diagnosis of a natural gas energy
performance of the casting and the heat treatment processes of a Brazilian
company was developed. The company has an infrastructure composed of sand
casting machines, induction and voltaic arc furnaces, thermal treatment
processes of annealing and normalization, quenching and tempering in oven
chamber, machining processes and quality control. For 10 yr, the company
has improved natural gas as an alternative energy source in order to
replace LPG, oil, and electricity over their processes to reduce cost and
improve efficiency. However, the resulting efficiency was never noticed due
to the lack of monitoring and control data of the gas converted machinery.
Therefore, a diagnosis study about its energy efficiency was developed.
This study was conducted by SCGAS Company with the cooperation of SOCIESC
Institute through visits and evaluation of one induction furnace and one
steel ladle from casting and heat treatment process machinery.
Recent development in the characteristics of Alloy 625 for A-USC steam

turbine casting
.
85042440115&doi=10.1007%2f978-3-319-52333-
0_20&partnerID=40&md5=2e32fb8dde8781cef6038f252c90dd66
ABSTRACT: Raising the operating temperature and pressure of the steam
turbine can improve the thermal efficiency in order to reduce the fossil
fuel consuming and CO2 emissions. Alloy 625 is a solution strengthened Ni-
base superalloy and has been considered as one possible candidate for A-USC
steam turbine castings. In this research, we investigate the chemical
composition, microstructure, tensile and creep behavior, and long-term
thermal stability of an Alloy 625 step block, which was produced by sand
casting. Nb segregation has been observed in the thick section. Segregation
can influence the mechanical properties and cause defects in large casings
and valves. The alloy exhibits excellent creep properties and thermal
stability, however, the ductility of Alloy 625 casting decreased
significantly after 1000 h at 700 °C. Alloy 625 can meet the design
requirements of A-USC steam turbine, but also need further research on the
production process. © 2017, The Minerals, Metals & Materials Society.
Mathematical modelling of raw material preheating by energy recycling

method in metal casting process
.
85039981094&partnerID=40&md5=6af90968dda7f30ab383090b96037411
ABSTRACT: Modern economic development programs critically depend on
reliable supply of energy. Energy conservation has become the need of the
hour. Metal casting industry in one among the many industries which uses a
lot of energy for its production. This paper presents a novel method of
energy recycling in the sand casting process, which readily translates into
substantial energy conservation in foundries. The heat that is being wasted
into sand during the solidification process is used to preheat the raw
material that is melted, for the subsequent pouring. The influence of the
casting parameters such as, offset distance, moisture content in the
molding sand, and the insulator thickness on the temperature gain by the
raw material, have been analyzed. A mathematical model was developed via
statistical analysis of the experimental data, to predict the amount of
heat recovered from the solidifying molten metal, for any specific
combination of values for the experimental parameters. The predicted values
are in good agreement with the experimental values. Copyright © EM
International.
To Study the Cooling Rate and Influence of Boron Carbide on Mechanical

Properties of Aluminium LM13 Matrix B4C Reinforced Composites
.
85032277540&doi=10.1016%2fj.matpr.2017.07.047&partnerID=40&md5=5c01ad6bda26
5fc674e642feed5e32b3
ABSTRACT: Aluminium Metal Matrix Composites are one of the advanced
engineering materials that have been widely used in aerospace and
automotive industries due to their excellent mechanical properties. In
Aluminium Metal Matrix Composite, aluminium matrix is strengthened by
reinforcing it with hard ceramic particles like Sic, Al2O3, and B4C etc.
Aluminium Metal Matrix Composite was manufactured by sand casting process
with Aluminium-LM13 grade as base metal and boron carbide as reinforcement.
This study investigates the cooling rate and influence of boron carbide on
mechanical properties of Aluminium Metal Matrix Composites. Experiments
were performed by casting of Aluminium Metal Matrix Composites with varying
the weight Percentage of boron carbide from 3% to 9% and cooling rate is
measured using k type thermocouple at point 1mm away from the mold
cavity.In order to investigate the influence of boron carbide on mechanical
properties microstructure analysis, tensile tests, hardness tests were
conducted. Results showed that mechanical properties of Aluminium Metal
Matrix Composite were improved with Percentage of boron carbide. © 2017
Elsevier Ltd.
Geometric analysis to automate design for supply chain

.
85030999184&partnerID=40&md5=515bc475518a04eddf288665623dccca
ABSTRACT: This paper presents a method for using geometric algorithms to
characterize CAD models for the purpose of automated design for supply
chain. Improvements in computing allow for fast manufacturability analysis
of the 3D geometry found in CAD files. For example, designers can determine
the percentage of a 3D model that can be machined, or how many cores would
be required to produce a sand casting of the model. Traditionally, this
kind of information has been used for process planning or reducing cost via
design for manufacture. However, market pressures and product complexity
cause firms to outsource fabrication to external suppliers. It is therefore
necessary to understand how early design decisions will impact the
sourceability of a design, which encompasses cost, quality, and lead time
in the supply chain. The goal of this research is to use geometric
characterizations and production requirements of a conceptual design to
automatically predict sourceability, and provide feedback that enables
proactive design changes. This paper works toward this goal by providing a
correlation analysis of geometry-based metrics of models classified by
manufacturing process.
Effect of aluminium particles on mechanical and morphological properties of

epoxy nanocomposites
.
85038378468&doi=10.2298%2fAPT1748025B&partnerID=40&md5=02f6b4acd9e2be30666d
e7ea5eb16208
ABSTRACT: Bumper is a front or rear part of automobiles. It is designed and
shaped to be impact absorbing and protecting automobiles from damage in low
impact collisions. Initially, they were made from heavy steels, increasing
the weight of automobiles and fuel consumption. Also, high impacts of steel
bumpers on pedestrians during accidental collision cause fatalities and or
disabilities. An effort to enhance fuel efficiency, safety, freedom of
design and shape detailing, heavy alloys for automobile applications are
now being replaced with polymeric composites. Aluminium micro particles and
nanoparticles were prepared from aluminium cans through sand casting, lathe
machine spinning, and ball milling techniques. Both types of aluminium
particles were incorporated into a mixture of diglycidyl ether of bisphenol
A (DGEBA, epoxy resin) cured with amine base hardener (ABH). Phases of the
epoxy polymer and composites were identified using Xray Diffraction (XRD).
Spatial arrangement of the phases within the matrix and their elemental
composition were examined using Scanning Electron Microscope with attached
energy dispersive X-ray spectroscopy (SEM/EDX). Tensile, impact and micro
hardness tests were conducted on the prepared epoxy/aluminium composites.
Results of the XRD showed the presence of aluminium compounds/phases due to
chemical reactions between aluminium particles and DGEBA/ABH system. SEM
confirmed a homogeneous distribution of the phases within the epoxy matrix,
and that there is a strong adhesion between the epoxy matrix and aluminium
particles. Correlation between the mechanical properties of the prepared
nanocomposite and the procured bumper materials exhibited a fair
suitability of the prepared nanocomposites for automobile applications.
Protectiveness of different silane coatings on patinated ancient and modern

bronzes: Part 2
.
85052289796&partnerID=40&md5=a28261e5f2032606054ce88286a7c1de
ABSTRACT: The safeguard of artistic and cultural heritage is of great
importance for the conservation of the historical and cultural background
of a society. The works of art in bronze are an important part of this
heritage and the production of effective surface protective treatments with
a low environmental impact is a central and still unresolved issue. The
effectiveness of protective treatments depends on the nature of the
substrate including both the characteristics of bronze and of the surface
patina actually present at the time of coating application. For this
reason, within the M-ERA.NET project named B-IMPACT, two bronze alloys were
produced by sand casting and properly patinated to obtain substrates
representative of monuments exposed outdoors on which different silane-
based coatings were tested. In particular, a quaternary Cu-Sn-Zn-Pb bronze
was artificially aged in the laboratory by dropping synthetic acid rain to
reproduce the surface of more ancient sculptures. Moreover, a modern
silicon bronze was treated by an aqueous solution of potassium sulfide
(K2S), as traditionally done in artworks of the 19th century. These
substrates were treated by some silane-based coatings characterized by
different functional groups, such as amino, thiol, and tetrasulfide groups
or long aliphatic chains. The most promising coatings were evaluated
considering the visual aspect (colour measurement), the adherence, the UV-
resistance (test in climatic chamber with an UV lamp), the resistance to
run-off or stagnant exposure to synthetic acid rain (artificial ageing
tests by dropping and Wet&Dry, with related characterisation of the
ageing solutions and samples during and at the end of the tests). The
achieved results were compared to those obtained by applying a standard
benzotriazole-based acrylic coating, still the most widely used by
restorers. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim. All rights
reserved.
A novel composite material of A356 aluminum alloy reinforced with alumina

(Al2O3) powder for automobile construction industries
.
85035035523&partnerID=40&md5=8c0ce1843668e0c552a046ec8c2b0798
ABSTRACT: This study aims to manufacture a composite material of A356
aluminum alloy reinforced with 250 μm of micro-scale (>100 μm) Alumina
(Al2O3) particulates. The major problem often encounters when fabricating
Aluminium-Metal Matrix Composite (Al MMC) is the difficulty of
incorporating the ceramics reinforcing particles in micro-scale into the
molten Al alloy. To overcome this, casting process of multiple step has
been developed including milling, compressing, sintering and sand casting.
Strain induced chips are produced by milling, dry mixed with Al2O3 in
weight fraction of 5%, 10% and 15%. Admixture of individual fraction is
hydraulic compressed into a disk and is sintered at 600 °C for 20 min.,
then rapidly heated and melted at 1,350 °C. After short holding time of 5
mins, the molten composite is a green sand mould casted into a cylinder
with a diameter of 20 mm and of 50 mm in length. Afterwards, all casted
samples are T6 heat treated by a solid solution at 527 °C for 12 hours,
water quenched, natural aged at ambient temperature for 10 hours, then
artificial aged at 177°C for 12 hours and slowly cooled in the furnace. T6-
composites are subjected to the hardness test, microstructure examination
and Pin on Disk wear test. The hardness values of as casted A356-0 wt%,
A356-5 wt%, A356-10 wt% and A-356-15 wt% Al2O3 are 23.5 HRB, 41.3 HRB, 44
HRB and 46 HRB respectively and the hardness values of T6 composite
increases as 46 HRB, 66.3 HRB, 68 HRB and 71.1 HRB respectively. In
addition, A356 with 5%, 10% and 15 wt% Al2O3 via T6 aging have low wear
rate of 0.00387, 0.00375 and 0.00350 mm3/m respectively. Microstructures of
cross sections of composites reveal that Al2O3 particles are evenly
dispersed in a sound A356 matrix without any defects (porosities,
agglomeration of particulates, cracks). © 2017 Taylor & Francis Group,
London.
Development of a high-temperature mold process for sand casting with a thin

wall and complex shape
.
84992401730&doi=10.1016%2fj.tsf.2016.08.069&partnerID=40&md5=17b9f6464c6099
a7af9cb43d834c0a71
ABSTRACT: A new process has been developed for preparing a mold that can be
sustained at a heat treatment of 1000 °C, resulting in fabricating cast
product having a thin-wall and complex shape. In the new mold process, an
inorganic binder composed of tetraethyl orthosilicate and sodium methoxide,
and bead powder with a high heat resistance and a low thermal expansion to
molten metal were used. The mold sample prepared through the resin-coated
sand process using the bead powder showed higher green strength than those
through the CO2 process using the chamotte sand, while the firing strengths
were improved and showed similar values by applying the new mold process
using the inorganic binder. In particular, the glassification behavior of
the inorganic binder and its phase were not changed even in the mold sample
prepared with the recycled bead powder. The thermal expansion of the mold
sample was linear and about 0.23% up to 1000 °C, indicating that the mold
has a superior thermal stability. The actual product, an impeller, was well
cast in the mold prepared by the new mold process, indicating that the new
mold process is efficient method in improving mold strength. © 2016
Elsevier B.V.
Numerical simulation and processing optimization of steel casting beam by

sand casting
.
85016009207&doi=10.15980%2fj.tzzz.2016.12.008&partnerID=40&md5=414dc52ded2a
e35872c0a2dc702d11d4
ABSTRACT: The initial casting process of steel casting beam was designed by
conventional method. The solidification process of initial casting was
simulated by the View Cast software. The location and origination of
shrinkage porosities in the initial casting process were analyzed. Based on
the above analysis, through adding chilling iron and using insulating
riser, the casting process was optimized and simulated again. The results
show that the optimized process can fill smoothly and orderly, realizing
sequential solidification and eliminating shrinkage and porosity mostly.
According to the optimized process for actual production, the casting
quality is improved greatly, and microstructure and mechanical properties
meet the requirement. © 2016, Journal Office of Special Casting and
Simulating the DISAMATIC process using the discrete element method — a

dynamical study of granular flow
.
84991080795&doi=10.1016%2fj.powtec.2016.09.039&partnerID=40&md5=974d209b955
952152087c79b9c726510
ABSTRACT: The discrete element method (DEM) is applied to simulate the
dynamics of the flow of green sand while filling a mould using the
DISAMATIC process. The focus is to identify relevant physical experiments
that can be used to characterize the material properties of green sand in
the numerical model. The DEM parameters describing the static friction
coefficients are obtained using a ring shear tester and the rolling
resistance and cohesion value is subsequently calibrated with a sand pile
experiment. The calibrated DEM model is used to model the sand shot in the
DISAMATIC process for three different sand particle flow rates as captured
on the corresponding video footage of the interior of the chamber. A mould
chamber with three ribs mounted on the fixed pattern plate forming four
cavities is chosen as a reference geometry to investigate the conditions
found in the real moulding process. The geometry of the cast part and the
casting system can make the moulding process complicated due to obstacles
such as ribs that deflect the sand flow causing “shadows effects” around
the cavities of the mould. These dynamic effects are investigated by the
qualitative flow dynamics and quantitative mould filling times captured in
the video footage and simulated by the calibrated DEM model. Both two- and
three-dimensional DEM models are considered and found to produce results in
good agreements with the video footage of the DISAMATIC process. © 2016
Elsevier B.V.
On the making of copper oxhide ingots: evidence from metallography and

casting experiments
.
85003811092&doi=10.1007%2fs12520-015-0255-
2&partnerID=40&md5=ea7a17ae2a28592ed897712d85f7fda5
ABSTRACT: We report on the texture, phase content and on the making of Late
Bronze Age copper oxhide ingots as excavated from the shipwreck of
Uluburun. This type of ingot represented the “world market” bulk metal in
the Mediterranean and beyond. The ingots are characterized by a high
porosity, by inclusions of slag fragments and cuprite which result from
casting raw copper smelted before from ores. The ingots were cast from
several batches of copper. The shape of the oxhide ingots was never fully
understood, and the way of casting was uncertain due to the absence of
casting moulds. It is the aim of this paper to discuss the making of these
ingots. We will present an alternative model on how to cast such ingots
using four crucibles. The experiments will show that the texture of the
ingots is created by gases such as hydrogen, carbon monoxide and water
vapour. The high porosity is shown to be advantageous for breaking the
ingots into fragments. © 2015, Springer-Verlag Berlin Heidelberg.
Improvements in energy consumption and environmental impact by novel single

shot melting process for casting
.
84991017422&doi=10.1016%2fj.jclepro.2016.06.165&partnerID=40&md5=8c3743ec1a
e896b449ab631e6aa9b0eb
ABSTRACT: The CRIMSON (Constrained Rapid Induction Melting Single Shot Up-
Casting) method uses a rapid induction furnace to melt just enough metal
for a single mould rather than bulk melting used in traditional casting
process. The molten metal is then transferred to a computer – controlled
platform to complete the counter-gravity up filling. The highly controlled
metal flow is pushed into the mould to finish the pouring and
solidification. In the present paper the energy saving capability of
CRIMSON approach is compared with conventional sand casting process. The
paper focuses on the energy and resource efficiency optimization of casting
stages through simulation and life cycle assessment analysis simulation for
proposing alternative means for the better performance of such processes.
It is proven that the CRIMSON process can produce high quality castings
with higher energy efficiency and lower environmental impact. © 2016 The
Authors
Enhancement of Anisotropic Strength of Fused Deposited ABS Parts by Genetic
Algorithm
.
84986237622&doi=10.1080%2f10426914.2015.1127949&partnerID=40&md5=f1135f2c41
2d195ed76991f7f4e2c598
ABSTRACT: Fused Deposited Modeling (FDM) is one of the Rapid Prototyping
(RP) processes that use thermoplastics to fabricate parts layer by layer.
The parts built using ABS M30 plastics using FDM shows anisotropic
property. This direction-dependent failure criterion results in parts with
strength lesser than the maximum possible available strength. Also the
orientation for building the parts is selected by the proprietary software
based on minimum fabrication time and material consumption. When it comes
to sand casting patterns, tensile strength and density play a major role in
determining its service life and load bearing capacity. So in this paper an
attempt has been made to study the dependency of process parameters
(orientation, raster angle, raster width and air gap) on tensile strength
and density. The design of the experiment is formulated based on Face
Centered Central Composite Design (FCCCD). Response plots are plotted to
study how the levels of process parameters influence each other in the
resulting response. Scanning Electron Microscope (SEM) images are taken to
study the fracture surface of the specimen. The multi-objective
optimization of tensile strength and density is performed by using Non-
Dominated Sorting Genetic Algorithm (NSGA-2). © 2016, Copyright © Taylor &
Francis Group, LLC.
Study and application status of additive manufacturing of typical inorganic

non-metallic materials
.
85046233763&doi=10.11896%2fj.issn.1005-
023X.2016.21.018&partnerID=40&md5=01514ff8ec0848f5c085fa9ae37a96ba
ABSTRACT: Additive manufacturing is a rapid manufacturing based on discrete
accumulation to achieve prototypes or parts of products. Inorganic non-
metallic materials, as one of the three major materials, have incomparable
application prospect in medical, aerospace, automotive, construction, arts
and crafts, as well as many other fields. In order to rapidly create
devices with arbitrarily complex shapes, additive manufacturing of
inorganic non-metallic materials is becoming a hot spot of current
research. In view of the technical types, materials and other aspects, this
article introduced research status and development of additive
manufacturing in inorganic non-metallic materials at home and abroad.
Several common inorganic non-metallic materials are compared and analyzed.
The forming characteristics and the problems of several popular ceramic
materials and sand-casting materials are illustrated with emphases. The key
problems existed in additive manufacturing forming process of inorganic
non-metallic material are pointed out and urgent to be solved at present.
Furthermore, the impacts of the material handling process, 3DP/SLS/SLM
three-dimensional forming processes and post treatment process on the
quality and performance of the forming parts are analyzed. Finally, the
prospects in additive manufacturing of the gem material are put forward. ©
2016, Materials Review Magazine. All right reserved.
High Performance Aluminum Casting Alloys for Engine Applications

.
85019623211&doi=10.4271%2f2016-32-
0019&partnerID=40&md5=e93f4581e9a9234bcb76eebc5d4f1702
ABSTRACT: In the early 1980's, some promising research and development
efforts focused on powder metallurgy revealed that aluminum alloys
containing 4 wt% cerium exhibit high temperature mechanical properties
exceeding those of the best commercial aluminum casting alloys currently in
production. Cerium oxide is an abundant rare earth oxide that is often
discarded during the refining of more valuable rare earths such as Nd and
Dy. Therefore, the economics are compelling for cerium as an alloy
additive. In this paper, we report select results obtained during an
investigation of the castability of aluminum-cerium alloys and determine
compositional modifications that may be required to ensure the
compatibility of the alloy with near net shape casting methods such as
advanced sand casting, die casting, permanent mold casting and squeeze
casting. Al-Ce alloys were cast in binary composition of 6-16 wt% Ce.
Commercially pure aluminum ingots were melted and held at approximately
785°C. Ternary and quaternary alloys with Si and Mg additions were also
investigated. Test bars were cast to establish mechanical properties and
step plates and hot tear molds were used to determine sensitivity to
solidification conditions and hot tearing sensitivity respectively.
Finally, air cooled engine cylinder heads were cast in sand molds to get a
sense of castability in complicated shape castings. Copyright © 2016 SAE
International.
Using a complexity factor to calculate cost benefits of 3-D sand printing

.
85002168901&partnerID=40&md5=ca9dc25610f169f7713b75dc5b0f6385
ABSTRACT: Three-dimensional sand printing provides a means to fabricate
molds and cores without the need to make patterns and coreboxes.
Metalcasters and end-users would benefit from learning more about when to
use this evolving advanced technology over conventional patternmaking.
Researchers examined the cost of molds and cores as a function of part
design complexity quantified by a complexity factor. Additive manufacturing
in the form of 3-D sand printing is complementary to the traditional
approach of moldmaking in sand casting. 3-D sand printers can directly
print a mold from computer-aided design (CAD) models of the desired part
design in a matter of a few hours without the need for patterns or
coreboxes. 3 -D sand printing provides unique advantages in moldmaking such
as significantly reduced lead-time and flexibility without the need for
tooling. It also offers additional geometric freedom to produce complex
designs not otherwise feasible or affordable using the traditional
approach.
Measurement of the variation of mechanical properties with aging

temperatures for sand cast Cu-5Ni-5Sn alloy
.
84994607338&partnerID=40&md5=0c23984bf67f62a42df472a5b4b2de0f
ABSTRACT: The purpose of the investigation is to study the mechanical
properties of copper-nickel-tin spinodal alloy and its effect with respect
to aging temperatures using sand casting process without cold work. An
alloy of Cu-5Ni-5Sn was melted in a crucible furnace under argon atmosphere
and cast into sand moulds. Homogenized and solution treated specimens were
aged at 300 °C, 350 °C, and 400 °C for different period of time. Specimens
were tested for its mechanical properties such as micro-hardness, yield
stress, tensile stress and percent elongation. It was found that the peak
hardness increases with aging temperatures up to 400 °C. Yield and tensile
stresses are proportional to hardness of the alloy. Percent elongation
decreases with increase in hardness and stresses. Incremental yield stress
increases with increase in aging temperature of the alloy. Also, the yield
stress of the alloy is found to increase two times than that of traditional
cast bronze alloys. © School of Engineering, Taylor’s University.
Dynamic measurements of the load on gray cast iron castings and contraction
of castings during cooling in furan sand molds
.
84973868081&doi=10.1016%2fj.jmatprotec.2016.05.012&partnerID=40&md5=bab3d94
4ded0d891dacb5b11669f813b
ABSTRACT: After JIS FC300 (almost identical to ASTM 45) gray cast iron was
cast in a furan sand mold, both the load on the casting from the sand mold
and contraction of the casting were measured dynamically from the beginning
of solidification to 200 °C. During solidification, the cast iron casting
received compressive load from the sand mold attributable to expansion of
the casting. After solidification, the load on the casting and the
contraction of the casting increased linearly with cooling. During A1
transformation, the load on the casting was relieved because of the casting
expansion. After the A1 transformation, the load on the casting and the
contraction of the casting increased linearly with cooling again. When the
load on the casting reached approximately 13 kN, the load stayed constant,
probably because of the sand mold fracture. © 2016 Elsevier B.V. All rights
reserved.
Optimization of connector part structure and die casting process based on

the MAGMASOFT
.
84995482272&doi=10.15980%2fj.tzzz.2016.10.016&partnerID=40&md5=e7b4a0e18eea
744cbafd60f0769f1455
ABSTRACT: Casting internal defects such as shrinkage porosity, entrapped
gas are mainly decided by the part structure and forming process. The
solidification temperature field and hot spot distribution in connector
were analyzed by the MAGMASOFT. Through reducing the wall thickness and
adding the ribs, above mentioned defects in the optimized casting structure
can be eliminated. Aluminum alloy was adopted to conduct die casting
instead of cast iron to sand casting by optimizing connector structure.
Based on calculating pouring, cooling and exhausting system of die casting
process, rational die casting scheme was designed. The results reveal that
the casting's internal and external quality as well as tightness test meet
the technology requirement. © 2016, Journal Office of Special Casting and
Investigation of design and manufacture in hot stamping tools with

conformal cooling channels based on simulation and 3d-printing technology
.
84994330115&doi=10.3901%2fJME.2016.19.180&partnerID=40&md5=565a1d7ea1b4310f
54c889114dbc8ce9
ABSTRACT: To against the uneven cooling of traditional hot stamping tool
with opposite deep-hole drilling cooling system, a new design method of hot
stamping tool with conformal cooling channels is put forward, which is
based on multi-field couplings in heat transfer theory and simulated by
Star-ccm+. By taking the insert of a B-pillar tool on the self-developed
rainbow electric car as the research object and comparing the cooling
effects of traditional hole drilling and some newly proposed cooling
designs, a new optimization strategy for B-pillar tool insert with
longitudinal conformal cooling channel arrangement is applied and the
temperature distribution of work surface before and after optimization has
been analyzed. Hot stamping tool with conformal cooling channels is
fabricated by means of combining 3D printing technique of precoated sand
with traditional sand casting. This hot stamping tool with optimized
longitudinal conformal design overcome the cooling limitations of parallel
conformal designs, such as maximum temperature of work surface decreases by
47.4%, average temperature decreases by 40.9% and temperature uniformity
improves by 1.8%. According to the design process of longitudinal conformal
cooling channel, the parameters of channel shape and location such as R, H,
r are set as optimization variables and the surface temperature field will
serve as the optimization object. The optimization result shows that the
maximum temperature of work surface decreases by 49.8%, and the average
temperature decreases by 46.8%, and the temperature standard deviation
decreases by 67.5%, while the temperature uniformity increases by 1.9%. It
is found that this hot stamping tool with conformal cooling channels
upgrades production efficiency and prolongs service life-span, furthermore,
the uniformity of mechanical properties of hot stamping parts is improved.
© 2016 Journal of Mechanical Engineering.
Effects of Si on microstructure and phase transformation at elevated

temperatures in ferritic white cast irons
.
84984945107&doi=10.1016%2fj.matchar.2016.08.025&partnerID=40&md5=f05bff6016
39a71eef6df63fbf5977b6
ABSTRACT: The effects of Si on microstructure and phase transformation at
elevated temperature of ferritic 31wt.%Cr-1.1wt.%C white cast irons with up
to 3wt.%Si have been studied. Applications of these irons include parts
requiring heat resistance at elevated temperature. The irons were produced
by sand casting. The microstructure in as-cast condition and after being
subjected to high temperature (700 to 1000 °C) was investigated by light
microscopy, X-ray diffraction, and electron microscopy. The results
revealed that the as-cast microstructure consisted mainly of primary
ferrite dendrites and eutectic (ferrite + M7C3). Si promotes M7C3-to-M23C6
transformation in the irons subjected to transformation at elevated
temperature, but no sigma phase was found. The extent of M7C3-to-M23C6
transformation increases proportional to the increasing transformation
temperature, holding time and Si content in the irons. For the iron with
1.0wt.%Si content after holding at elevated temperatures, martensite was
also found, which could be attributed to carbon accretion effects in
eutectic ferrite. Si was incorporated in M23C6 such that M23C6 containing
Si can show darker contrast under SEM-BEI as compared to M7C3; this is the
opposite to what has been observed for the cases of typical M23C6 and M23C6
containing Mo or W. The results obtained are important to understand the
change in properties of ferritic, high chromium irons containing Si
subjected to elevated temperature. © 2016 Elsevier Inc.
Numerical simulation of sand casting diffuser

.
84990048045&doi=10.15980%2fj.tzzz.2016.09.006&partnerID=40&md5=8d13ba1ba107
051a3cccdbeeb665e7ad
ABSTRACT: The casting process of sand casting diffuser as the key part of
underwater device was simulated by the ProCAST software, and feasibility of
casing process was verified. Through calculation of temperature field, the
time before the casting solidification completion and a lot of brittle σ
phase precipitation was determined. Shakeout operation was implemented at
this time from pouring completion to the casing cooling in the actual
production, eliminating the stress caused by contraction of the blade. So
the crack defects were eliminated, and quality of the casting was improved.
© 2016, Journal Office of Special Casting and Nonferrous Alloys. All right
reserved.
Effect of coating process on property of furan resin sand

.
84995938191&partnerID=40&md5=76d021b5007e867e8cc51eaa00a4ac55
ABSTRACT: Coating plays important role in casting technology. High-
performance coatings and the correct coating process is indispensable
condition to obtain high-quality resin sand casting. By test design, the
effects of sand mold drying after stripping, coating, standing time of
coating, coating time were analyzed. The results show that to guarantee
high-temperature performance of sand mold is the key to obtain high quality
castings. After production trial, with the optimal coating process obtained
by test, casting quality and yield are improved. © 2016, Chinese Mechanical
An investigation of preload relaxation behaviour of three zinc-aluminum

alloys
.
84990196738&doi=10.1088%2f1757-899X
%2f146%2f1%2f012042&partnerID=40&md5=9ec58055a4cb2f90898aa731fb760fe2
ABSTRACT: Zinc alloy castings are usually assembled together or mounted by
screwed steel fasteners, and are tightened to a predetermined torque to
develop the required tensile preload in the fastener. Due to relaxation
processes in the castings, creep may cause a partial preload loss at an
elevated temperature. The equipment used for load relaxation tests consists
of a loadmonitoring device, an oil bath, and a data-acquisition system. A
load cell monitoring device is used to monitor the load loss in an ISO-
metric M6∗1 steel screw set into sand castings made from alloys No. 3, No.
5 and No. 2 and tightened to produce an initial preload of 6 kN. The
castings were held at constant temperature in the range 80 - 120°C in an
oil bath. The oil bath maintains the desired test temperature throughout
the experiment. All tests were conducted for periods of up to 160 h. For
all alloys, the initial load loss was high, decreasing gradually with time,
but not ceasing. The load loss increased rapidly with test temperature, and
almost all of the relaxation curves approximated to a logarithmic decay of
load with time. Alloy No. 2 had the best resistance to load loss, with No.
5 next and No. 3 worst at all temperatures. The lower resistance to
relaxation of alloy No. 3 was mainly due to the lower relaxation strength
of copper-free primary dendrites, whereas in alloys No. 5 and No. 2, the
higher copper contents contribute greatly to their relaxation strength in
the form of second-phase particles. © Published under licence by IOP
Publishing Ltd.
Improving strength in casting mold by control of starting material and

process
.
85011589849&doi=10.4191%2fkcers.2016.53.5.541&partnerID=40&md5=b7122f22ef18
31dca3ba29513bc8fd2c
ABSTRACT: In developing high temperature molds with advantages of the sand
and precision (investment) castings, mechanical properties of the mold were
improved through homogeneous coating of starting powders with an inorganic
binder and improvement of fabrication process. Beads with mullite
composition were employed for properties of the mold under high
temperature, which was compared with artificial sands. Precursors of silica
and sodium oxide were used as starting materials for an inorganic binder to
achieve homogeneous coating on the starting powders. Strength was enhanced
by the glass phase converted from the inorganic binder through heat
treatment process. Also, two kinds of process, wet and dry processes, were
incorporated to prepare mold specimens. Consequently, fabrication process
of the mold with superior strength and high temperature applicability,
compared with the previous molds for sand casting, could be suggested
through control of the starting material and enhancement of the
vitrification efficiency.
Influence of different casting processes on high cycle fatigue behavior of

Mg-10Gd-3Y-0.5Zr alloy
.
84976325959&doi=10.1557%2fjmr.2016.221&partnerID=40&md5=ada01860a59c13fc9d7
15bf7c716a146
ABSTRACT: In this present study, the influence of different casting
processes on high cycle fatigue behavior of Mg-10Gd-3Y-0.5Zr magnesium
alloy was investigated by using porosity-free low-pressure sand-casting
(LPS) bars and gravity permanent mold casting (GPM) ingots. The results
show that the fatigue properties of both LPS and GPM Mg-10Gd-3Y-0.5Zr alloy
in as-cast condition are determined by Mg matrix and eutectic phase.
However, the fatigue property improvement for LPS alloy by T6 heat
treatment is significantly superior to that of GPM alloy. The different
degree of enhancement of fatigue properties for two conditions of the alloy
is related to different crack initiation mechanism. The fatigue crack of
the LPS alloy initiates from the free surface of the sample, while the
crack of the GPM alloy initiates from porosities or inclusions near the
surface of the sample. Meanwhile, the crack of slip band has a crucial
effect on the fatigue crack initiation of both as-cast and T6 conditions
for LPS alloy. © Copyright Materials Research Society 2016.
Rapid sand casting process CAD/CAE system based on SLA prototype

.
84988420983&partnerID=40&md5=8d74fafa8708a50322b2a5e791a32866
ABSTRACT: Casting process CAD/CAE system for rapid sand casting based on
SLA prototype was developed by utilizing Pro/E4.0, Pro/Toolkit and VC+
+2005. The functions of each module of the CAD/CAE system were designed
according to the theory and standards in the casting process manual with
the exception of draft angles and linear shrinkage rates which were re-
determined according to the characteristics of SLA prototype. Practical
application results indicate that with the aid of the CAD/CAE system, both
casting process design efficiency and new product development efficiency
have been dramatically improved. © 2016, Chinese Mechanical Engineering
CAD/CAM design and the genetic optimization of feeders for sand casting
process
.
84982947745&doi=10.22190%2ffume1602147d&partnerID=40&md5=195ff0cc6a509654b3
9df85937429d51
ABSTRACT: The paper proposes methodology of feeder design and optimization
for sand casting process. Casting part is a part of excavator buckets, i.e.
holder of the cutting tooth. Process of design and optimization is based on
the application of the rules, which are the result of many years of work
researchers in the field of metal casting. Computer Aided Design (CAD) is
used as a methodology in the design of feeders. Genetic Algorithm (GA) as
an artificial intelligence technique is used in the optimization process of
the feeder geometry. Computer Aided Manufacturing (CAM) is used as
methodology that involves numerical simulation of the casting process.
Numerical simulation is used to verify the validity of the optimized
geometry of the feeding system. © 2016, Facta Universitatis, Series:
Mechanical Engineering. All rights reserved.
Effect of double-quenching heat treatment process on microconstituent and

XRD of Ductile iron
.
84988442787&partnerID=40&md5=42b9495e770d9d6030432f9b42e21035
ABSTRACT: Heat treatment is one of the preferred methods in altering
material characteristic. In this present study, the effect of austenitizing
temperature in double-quenching heat treatment process was studied on
microstructure as well as exploring the phase constituents of ductile iron
through x-ray diffraction (XRD)analysis.Ductile iron produced through
conventional CO2 sand casting method. Ductile iron was heat treated by
using the double-quenching method. The sample was annealed at 673K for 1.8
ks and subsequently oil quenched before austenitized at 3 different
temperatures which those are 1123K, 1173K and 1223K for 3.6 ks
respectively. Standard metallographic observation nodule and XRD analysis
were done to characterize the microstructure and the constituents
respectively. It is found that austenitizing process transforms the
microstructure from pearlitic-ferritic matrix structure, which presented in
annealing condition into martens tic. Marten site morphology becomes
coarser and the nodularity of graphite nodule decreases as austenitizing
temperature increases. But, austenitizing process seemingly gives no
significant effect to the graphite nodule size. The presence of BCT marten
site is validated by the presence of high-intensity (110) and (101) planes
verified at 43° to 44° 2θ angles. Austenitizing sub-process of double-
quenching heat treatment process does influence the marten site and
graphite nodule morphologies. It transforms ferritic-pearlitic structure in
as annealed ductile iron to martens tic matrix structure. The presence of
Marten site and austenite can be validated by using XRD method with
specific plane. © 2006-2016 Asian Research Publishing Network (ARPN). All
rights reserved.
Evolution of grain orientation and texture of ring shaped blank induced by

hot compression during casting-rolling process
.
84983042668&doi=10.11901%2f1005.3093.2015.185&partnerID=40&md5=d2be1ce6e552
3be3152cf8e81a6840b0
ABSTRACT: The characteristics for the evolution of grain orientation and
texture of ring shaped blanks of sand- and centrifugal-casting Q235B
respectively were investigated by electron backscatter diffraction (EBSD)
technique, while the blanks have been subjected to hot compression with a
strain rate of 0.1 s-1 at different temperatures. The results show that the
grain size of the blanks after hot compression at 1000℃ becomes smaller in
the deformed microstructure, but a few grains maintains as in cast state.
The mechanisms of the microstructure evolution may be ascribed to dynamic
recovery and large strain geometric dynamic recrystallization. For
centrifugal cast ones, the percentage of high- angle boundary in 20°-50° is
22%, but after hot compression at 1100℃ it shows a homogenous
microstructure with equiaxed grains because of sufficient
recrystallization, while the mis-orientation distribution of grain
boundaries still presents a typical characteristic of double- peaks and the
proportion of the high- angle boundaries reaches to 60%- 75%. The textures
of sand casting Q235B are a small amount cube texture {001}<100> and
{001}<110> along <001>//ND at 1000℃, while the main textures
are Goss texture {110} <001> and r- cube texture {110}<001> at
1100℃. For centrifugal casting ones at 1000℃, {110}<110> and Cu
texture {112}<111> distributes along ε orientation; at 1100℃ the
types of texture including {001}<110> and {111}<110>
transformed from {111}<112>alongg orientation. The orientation
density is higher due to the high extent of recrystallization. © All right
reserved.
Improvement and effect of sand casting flexible specialization production

line
.
84988373930&partnerID=40&md5=c6d3a7a241568a31ce7b683f680e7eec
ABSTRACT: To adapt to market changes, sand casting professional production
line was flexibly improved, the necessity of flexibility improvement and
the principle need to follow were introduced. Taking bolster and side frame
sand casting professional production line as an example, the molding,
melting, cleaning in each process of production line were flexibly improved
and good results were achieved, which meet the needs of variety, different
batch production. © 2016, Chinese Mechanical Engineering Society. All right
reserved.
Quantifying the role of part design complexity in using 3d sand printing

for molds and cores
.
84978162131&doi=10.1007%2fs40962-016-0027-
5&partnerID=40&md5=a0f0803f16561f1bb6f3d277a12f2027
ABSTRACT: 3D sand printing provides a means to fabricate molds and cores
without the need to fabricate patterns and core boxes. It is desirable to
understand when to use this evolving advanced technology versus
conventional pattern making. This analysis evaluates this question by
examining the cost of molds and cores as a function of part design
complexity quantified by a complexity factor. Two case studies are
presented where the complexity of the castings is systematically varied by
changing the geometry and number of cores. Tooling costs and fabrication
costs are estimated for both 3D sand printing and conventional pattern
making. The breakeven points are identified, and it is shown that 3D sand
printing is cost-effective for castings with complexity factor values
greater than that of the breakeven points. For low volume production of
these castings, 3D sand printing is shown to be cost-effective for low
quantities (\45 parts) of castings with lower complexity. However, it can
also be very cost-effective for casting with higher complexity even at
quantities of 1000 units. Since breakeven point is sensitive to the cost of
3D sand printing, lowering the materials and operations costs can
significantly improve the cost-effectiveness of 3D sand printing for varied
production volume and part design complexity. © 2016 The Author(s). This
article is published with open access at Springerlink.com.
Method for automating digital fixture-setups that are optimal for machining
castings to minimize scrap
.
84971631319&doi=10.1016%2fj.jmsy.2016.05.004&partnerID=40&md5=f0b45b495b57b
198ffac59526de9ff58
ABSTRACT: The motivation for this paper is to describe a method for
lowering the cost of finishing large castings that have machined surfaces
for attaching other components. Considerable time is required to set-up
each cast part on a machine-tool, sometimes taking longer than the
machining itself, and errors in set-up can result in scrapping expensive
parts or attempts to salvage them by rework. Although the focus of the
paper is to demonstrate a new technology and software for set-up prior to
the machining of iron/aluminum/steel sand castings, the same technology
also is applicable to large welded assemblies on which finished machining
occurs. In this paper, we outline a method, currently being implemented,
that can predictively, and off-line, identify the adjustments needed to
position and orient each part in its fixture before machining operations
begin so that, after machining, all finished features will lie in their
tolerance zones. Computer models first simulate all the to-be-machined
(TBM) surfaces and any contact points with the fixture by feature-fitting
point clouds taken from selective scanning of the raw casting. The
locations of these features are compared with their locations on the CAD
model of the part. Then, by using the T-Map model for tolerances, all
possible locations of the part in its machining fixture are identified so
that all TBM faces lie in their tolerance-zones. An optimum location may
then be chosen. © 2016 The Society of Manufacturing Engineers
Use of casting simulation and rapid prototyping in an undergraduate course

in manufacturing processes
.
84983289189&partnerID=40&md5=62e43b883264de29217f997fd4b0218b
ABSTRACT: Mechanical Engineering students at Milwaukee School of
Engineering (MSOE) study manufacturing processes in the junior year. Part
of their study in this course is a project to create an original casting.
This project encompasses several steps. First is to design the part and the
associated mold system (gates & risers) for sand-casting the part. Next,
students analyze performance of their mold layout through the use of
SolidCast casting simulation software and make improvements to the initial
mold layout. A final version of the casting design is submitted to the MSOE
rapid prototyping center for fabrication of the casting patterns. The last
step is to make an aluminum sand-cast part, in a small-scale foundry in
MSOE's labs. The project emphasizes the basic premise of the course; a
manufactured part must be designed within the limitations and capabilities
of the manufacturing process. Successful completion of the project covers
several key course outcomes, including: 1) understand the steps involved in
basic green-sand casting process along with its capabilities and
limitations, 2) apply this knowledge to design a component and mold layout,
3) understand the characteristics of a good versus poor mold layout, 4)
apply modern computing methods as a means to do design of an effective mold
for sand casting. With the successful implementation of SolidCast™ and
rapid prototyping methods into this project, students learn course outcomes
at a much higher level. In the past, the lab was an informative exercise
where students made sand cast parts. Now it is a true engineering design
experience for the students. They are able to approach mold design as a
fluids problem, a heat transfer problem, and a manufacturing quality and
cost problem. © American Society for Engineering Education, 2016.
Effect of trace addition of Zn and Nd on microstructure and mechanical

properties of sand casting Mg-5Gd-4Y-0.5Zr alloy
.
85008873211&partnerID=40&md5=33fd1f6c915489a923e2d652a920a44b
ABSTRACT: :Effect of trace addition of Zn and Nd on microstructure, age
hardening response and mechanical properties of sand casting Mg-5Gd-4Y-Zr
magnesium alloys was investigated. The results show that the trace addition
of Zn and Nd obviously refines the grain size and changes the kinds,
morphology and quantities of the precipitation phase of the as-cast Mg-5Gd-
4Y-Zr alloy, and improves its tensile mechanical properties at room
temperature. The solution treatments of the alloys are optimized based on
experiments, and it is found that the grains near the surface of the
casting tensile bar grow up for the Mg-5Gd-4Y-0.8Nb-Zr alloy after two
stage solid solution treatment, which can be avoided by single stage solid
solution treatment. Moreover, the trace addition of Zn and Nd can
significantly improve the aging hardening response of the Mg-5Gd-4Y-0.5Zr
alloy as well as its strength at ambient and elevated temperature, and the
strengthing effect of Nd addition is better than that of Zn. The ultimate
tensile strength, yield strength and elongation of the Mg-5Gd-4Y-0.8Nd-Zr
alloy are 303 MPa, 215 MPa and 1.2% at room temperature and 283 MPa, 200
MPa and 7.2% at elevated temperature, respectively. © 2016, Editorial
Office of Transactions of Materials and Heat Treatment. All right reserved.
Performance comparison for aluminium, copper and steel shots in waste heat
recovery and scrap preheating from solidifying molten metal
.
84968765174&partnerID=40&md5=56bb506a43880ccffa3ca89a9ac58d22
ABSTRACT: During solidification of molten metal in sand casting, the
sensible, latent and superheat are lost to the sand. This research article
focuses on waste heat recovery from solidifying molten metal and scrap
preheating using the recovered heat. This is done by incorporating an
intermediate heat transfer medium such as aluminium, copper and steel shots
in green sand mould. These intermediate heat transfer media absorb the heat
from the solidifying metal in the mold cavity; the heated shots are
separated from the mold and allowed to transfer their heat energy to the
metal scrap by conduction, convection and radiation. The experiments prove
that 8.4 % of heat recovery is achievable by introducing copper shots with
the green sand mold, compared to aluminium shots, which generates 3.7 % and
steel shots achieving 3 %. This method has the potential to be instrumental
in reducing the enormous amount of energy spent to melt the metal in
foundries. The experiments reveal that about 84 kWh of energy can be saved
by using copper shots for melting one ton of metal. Cumulative effect of
this novel energy conservation method on energy costs and global warming
mitigation is found to be very convincing for industrial implementation,
particularly for countries such as India. © 2006-2016 Asian Research
Publishing Network (ARPN). All rights reserved.
Fused Deposition Modeling Design Rules for Building Large, Complex

Components
.
84959232325&doi=10.1080%2f16864360.2015.1114393&partnerID=40&md5=16812652d7
507e892532122d5686a35f
ABSTRACT: The Fused Deposition Modeling (FDM) process is a bead deposition
based additive manufacturing (AM) process that builds a product from thin
layers of molten thermoplastic filaments. The ongoing goal of this research
is to develop methodologies for designing and fabricating large complex
parts such as complex beta testing prototypes, or sand casting patterns.
The unique capabilities of the FDM process are leveraged when designing
components and assemblies. Complex geometry can be readily manufactured
allowing designers to incorporate non-standard component features, and
consider unique solutions; however, there are size, surface finish, and
accuracy limitations. Rules are developed to leverage the process
characteristics and address the observed limitations. Case studies are
presented to highlight the benefits and challenges when using the FDM
process. © 2016 CAD Solutions, LLC.
Energy optimization of high-energy pumps

.
85026400369&partnerID=40&md5=56c437a3ba0dc4bb65be80135a9ee73a
ABSTRACT: As energy costs continue to escalate, finding ways to reduce
energy consumption is becoming a means of survival. This is placing a
greater interest in methods to reduce energy consumptions, with pumping
systems being one of the greatest sources for potential savings. With
reverse engineering, laser digitizing equipment, CFD software and rapid
prototyping coupled with the ability to print 3D foundry molds directly
from CAD/CAM software, the end user achieves great savings. Field flow
measurements as well as real-time data acquisition allows for a complete
reassessment of the service water system. Using the latest state-of-the-art
3D foundry sand printers and casting simulation software drastically
reduces the lead time and overhead normally associated with pattern/core
box sand casting processes. In addition, the improved surface finishes
geometric accuracy obtainable with 3D-printed molds can offer as much as 3–
5% improved pump efficiencies.
Mn segregation dependence of damping capacity of as-cast M2052 alloy
.
84959317502&doi=10.1016%2fj.msea.2016.02.084&partnerID=40&md5=9772a2323cf8e
86789c130de878713bd
ABSTRACT: In this paper, three types of sand-casting M2052 alloys subjected
to different heat treatments have been designed and prepared in order to
investigate the relationship between Mn segregation and damping capacity
using dynamic mechanical analysis, optical microscopy, X-ray diffraction,
scanning electron microscopy, and energy dispersive spectroscopy. The
results show that damping capacity has a crucial dependence on the Mn
segregation in as-cast M2052 alloy. The original as-cast alloy without
subsequent heat treatment shows its internal friction (Q-1) is 1.52×10-2 at
a strain amplitude of γ=2×10-4, while a remarkable enhancement (2.6×10-2)
of Q-1 can be obtained by ageing of the as-cast alloy at 435 °C for 4 h.
This is mainly ascribed to the further formation of nanoscale Mn
segregation in the Mn dendrites (so-called Mn macrosegregation) by spinodal
decomposition during the ageing. On the contrary, performing the additional
homogenization treatment at 850 °C for 24 h prior to the ageing at 435 °C
for 4 h for the as-cast M2052 alloy can result in the obvious reduction of
damping capacity (only 6.5×10-3 for Q-1), which is closely associated with
the distinct decrement of lattice distortion of γ'-Mn during f.c.c-f.c.t
phase transformation caused by weakening of Mn segregation at the
macro/nano-scale. © 2016 Elsevier B.V..
Optimization design of a gating system for sand casting aluminium A356

using a Taguchi method and multi-objective culture-based QPSO algorithm
.
84966929630&doi=10.1177%2f1687814016641293&partnerID=40&md5=df90263485185f4
0dab423d219b19369
ABSTRACT: This article combined Taguchi method and analysis of variance
with the culture-based quantum-behaved particle swarm optimization to
determine the optimal models of gating system for aluminium (Al) A356 sand
casting part. First, the Taguchi method and analysis of variance were,
respectively, applied to establish an L27(38) orthogonal array and
determine significant process parameters, including riser diameter, pouring
temperature, pouring speed, riser position and gating diameter.
Subsequently, a response surface methodology was used to construct a
second-order regression model, including filling time, solidification time
and oxide ratio. Finally, the culture-based quantum-behaved particle swarm
optimization was used to determine the multi-objective Pareto optimal
solutions and identify corresponding process conditions. The results showed
that the proposed method, compared with initial casting model, enabled
reducing the filling time, solidification time and oxide ratio by 68.14%,
50.56% and 20.20%, respectively. A confirmation experiment was verified to
be able to effectively reduce the defect of casting and improve the casting
quality. © The Author(s) 2016.
Effect of molding parameters on chemically bonded sand mold properties

.
84962299209&doi=10.1016%2fj.jmapro.2016.03.007&partnerID=40&md5=09ea4333746
d5a15be66268f2e3bc34e
ABSTRACT: Chemically bonded sand molds and cores have better mechanical
properties and produce more dimensionally accurate castings, compared to
green sand molds, and hence are being increasingly preferred for near net
shape metal parts. While it is well known that the properties and quality
of a mold depend on its material composition and molding process, this has
not been investigated well for chemically bonded molds. In this work, the
effect of sand grain size, binder percentage and curing time (each varied
in three levels) on the mechanical properties (compression strength, shear
strength and core hardness) as well as dimensional changes (shrinkage) of
no-bake chemically-bonded molds and cores was studied through lab
experiments. Their mechanical properties were found to increase with an
increase in binder content and curing time; and decrease with increasing
grain fineness number. The shrinkage was found to increase with an increase
in all three process parameters. The results are explained in terms of
bonding and curing phenomena of binders, and evaporation of solvent. These
are also supported by SEM analysis of crosslinked resin bridges between
sand grains. The findings were incorporated into a multi-objective
optimization model to obtain the desired combination of mold properties,
which is solved as a linear programming problem. The model and its results
were successfully verified through experiments. This work paves the way for
automatic optimization of molding parameters of chemically-bonded sand
molds and cores, to achieve the desired quality. © 2016 The Society of
Manufacturing Engineers.
Study on the performance of YunXi environment friendly molding sand

.
84965053129&doi=10.3901%2fJME.2016.06.092&partnerID=40&md5=5a3fe31802d56ce8
b6f9e6d676f4eca3
ABSTRACT: YunXi environment friendly molding sand has been successfully
used in sand casting process, it can effectively reduce burning-on, scab,
sand inclusion, blowhole and other defects. It helps to improve the
internal quality and visual quality of casting. YunXi environment friendly
molding sand casting process has comprehensive advantages of environment
friendly, economic, high-quality and high-efficient. A series of
experiments are carried out, which helps to further understand the
characteristics of YunXi environment friendly molding sand and the effects
of molding sand performance on the casting defects and casting quality. The
wet compressive strength, permeability, hot wet tensile strength, gas
evolution, thermal expansion, hot pressing strength, high temperature form
transformation, differential scanning calorimetry-Thermogravimetric
analysis (DSC-TG) curve of YunXi environment friendly molding sand are
systematically studied, and which are compared with that of the
conventional coal sand. The result shows that the wet compressive strength,
permeability, thermal expansion of YunXi environment friendly molding sand
are similar with coal sand, but the hot wet tensile strength, hot pressing
strength, gas evolution of YunXi environment friendly molding sand are far
superior to that of coal sand. These advantages can effectively reduce the
casting defects, and ensure the quality of the casting. Research work can
helps to further improve the casting quality and further promote the
production process of green casting. © 2016 Journal of Mechanical
Engineering.
Low pressure sand casting of ultrasonically degassed AlSi7Mg0.3 alloy:

Modelling and experimental validation of mould filling
.
84958063556&doi=10.1016%2fj.matdes.2016.01.059&partnerID=40&md5=169a95745ef
da067ec57e1e74169e301
ABSTRACT: The effect of combining smooth mould cavity filling and
ultrasonic degassing by using a low pressure sand casting process with US
melt treatment on the microstructure and mechanical properties of
AlSi7Mg0.3 alloy was investigated. Computational fluid dynamics (CFD)
modelling and experimental validation was used to study the liquid metal
flow behaviour and oxide film defect distribution for different filling
rates, using two pressurization curves (p-t). The effect of ultrasonic
degassing on the resultant microstructure (morphology and presence of
porosities and inclusions) was studied for 650 and 700 °C melt degassing
temperatures. Results show that ultrasonic degassing and mould filling
velocities below 0.5 m/s improve the alloy microstructure and lead to high
mechanical properties. © 2016 Elsevier Ltd.
Semi-Solid Processing by Electric Current during Sand Casting of Aluminium

Alloys
.
84971668208&doi=10.1088%2f1757-899X
%2f115%2f1%2f012005&partnerID=40&md5=ae1ff40d8af1a0ade4cdb7069f296b13
ABSTRACT: This study reports the effect of DC and 50Hz AC treatment (ECT)
on aluminium or aluminium alloys during solidification in sand moulds i.e.,
at their semisolid state. Castings, with different geometry, were made in
open or closed sand moulds. It is observed that ECT (a) reduces dissolved
gas, (b) reduces internal shrinkage and (c) metal mould reactions in
castings. It is also observed that the AC treatment is more effective
compared to DC treatment. ECT changes the movement of solidification front.
The optical microstructures of ECT samples are quite similar to the samples
treated in other semisolid processing methods. © Published under licence by
IOP Publishing Ltd.
IOP Conference Series: Materials Science and Engineering

.
84971601439&partnerID=40&md5=c78d3ab370ec9e78ea83dc46e29b7acf
cellular automata modeling of decarburization of metal droplets in basic
oxygen steelmaking; impact resistance and hardness modeling of aluminum
alloy welds using squareheaded friction-stir welding tool; dielectric
properties of epoxy resin fly ash composite; semi-solid processing by
electric current during sand casting of aluminum alloys; epoxy matrix
composites filled with micro-sized LD sludge: wear characterization and
analysis; studies on effective elastic properties of CNT/nano-clay
reinforced polymer hybrid composite; effect of nanosize yittria and
tungsten addition to duplex stainless steel during high energy planetary
milling; application of hydrogen for the reduction of bauxite mineral;
effect of delamination on vibration behavior of woven glass/epoxy composite
plate-an experimental study; and an experimental investigation on the
effect of particle size on the thermal properties and void content of solid
glass microsphere filled epoxy composites.
Correlating shrinkage microporosity with the mechanical properties of sand-

cast superduplex stainless steel using a numerical/experimental approach
.
84957802396&doi=10.1016%2fj.matdes.2015.12.088&partnerID=40&md5=65e09a8b00e
763e7166e50b84da442b6
ABSTRACT: In this work, the Niyama criterion for the prediction of
shrinkage microporosity in a superduplex stainless steel (ASTM A890 Gr. 5A)
end-risered plate produced by sand-casting is adopted. To validate
numerical results obtained using the commercial software MAGMASoft,
experimental castings were produced, and both the shrinkage microporosity
and its effect on the material behaviour was evaluated. Metallographic
techniques were used to quantify the microporosity and evaluate its
distribution; the effect of the shrinkage microporosity on the sand cast
material was measured through tensile tests on miniaturised specimens
extracted along the longitudinal direction of the plate.Image analyses
allowed estimation of the threshold Niyama value for microporosity in the
investigated material. An analogous threshold for the Niyama parameter was
determined from the mechanical data arising from tensile tests in which
specific microporosity levels (and Niyama values) were identified that
corresponded to minimum required levels of yield stress, UTS and elongation
after fracture as specified by the ASTM standard. Mechanical data were
found to be well correlated to the Niyama value, thus allowing to
effectively use the purely thermal parameter Niyama to predict the sand
cast material behaviour. © 2015 Elsevier Ltd.
Reduction of reworks in green sand casting process: A six sigma prospective

.
84964077803&partnerID=40&md5=8e841fe56dd7524a97bcb4f49a410a3b
ABSTRACT: In this paper, a case study of Indian foundry industry has been
presented to explore the success of six sigma methodology. The DMAIC
(Define-Measure-Analyse-Improve-Control) approach of six sigma has been
followed here to reduce the rejection rate in the green sand casting
process. In addition, response surface methodology is been employed in
‘Improve phase’, to develop an empirical model which correlates the casting
process variables with the desired quality characteristics. The developed
model is further utilised to optimise the process parameters to minimise
the casting rejection. The results show that after the implementation of
six sigma, the rejection rate is reduced by 25.44%. © Research India
Publications.
Effect of as-solidified microstructure on subsequent solution-treatment

process for A356 Al alloy
.
84977669807&doi=10.1016%2fS1003-6326%2816%2964152-
3&partnerID=40&md5=127b76497e29ef5e624aa0e80e59a43e
ABSTRACT: For the compromise of mechanical properties and product cost, the
end-chilled sand casting technique was applied to studying the
microstructure evolution of A356 Al alloy with cooling rate and the effect
of different as-cast microstructures on the subsequent solution-treatment
process. The experimental results show that the secondary dendrite arm
spacing (SDAS) of primary α(Al), the size of eutectic Si and the volume
fraction of Al–Si eutectic are reduced with increasing the cooling rate.
Eutectic Si, subjected to solution treatment at 540 °C for 1 h followed by
water quenching to room temperature, is completely spheroidized at cooling
rate of 2.6 K/s; is partially spheroidized at cooling rate of 0.6 K/s; and
is only edge-rounded at cooling rates of 0.22 and 0.12 K/s. Whilst the
microhardness is also the maximum at cooling rate of 2.6 K/s. It
consequently suggests that subjected to modification by high cooling rate,
the eutectic Si is more readily modified, thus shortening the necessary
solution time at given solution temperature, i.e., reducing the product
cost. © 2016 The Nonferrous Metals Society of China
A review on the effects of casting quality, microstructure and mechanical

properties of cast Al-Si-0.3Mg alloy
.
84964711759&partnerID=40&md5=b6be7676a683df80cd0e59398e376a1a
ABSTRACT: This paper investigates a study on the effects of heat treatment
on the microstructure, quality of casting and mechanical properties of Al-
7Si-0.3Mg (LM25) alloy. The large reputation of Al-7Si-0.3Mg (LM25) alloy
in automobile industry stems from its light weight (density of about 2.68
g/cc), high strength to weight ratio, excellent casting characteristics,
high corrosion resistance, low coefficient of thermal expansion, good
thermal & electrical conductivity and good mechanical properties including
high machinability and workability. The microstructure of this alloy
depends strongly on its composition and solidification rate. The slow-
cooling rates encountered in sand castings lead to acicular silicon phase.
The silicon phase in the form of large plates with sharp sides and edges
act as internal stress risers in the microstructure and provide easy paths
for fracture leading to inferior mechanical properties. The applications of
this alloy demand several techniques and research methodologies to modify
the microstructure and there by improve mechanical properties. Alloying,
chemical modification, mould vibration during solidification and heat
treatment were found to be effective in modifying the microstructure. In
this view, this article presents the information's about the influences of
all such techniques which modify the microstructure and increase the
quality of casting and mechanical properties. © Totem Publisher.
Deformation behavior at elevated temperature and processing maps of flange

blanks on casting-rolling compound forming technology
.
84962776129&doi=10.3901%2fJME.2016.04.045&partnerID=40&md5=32b2508c5aa5634c
a2d667b5f07a6f6e
ABSTRACT: Casting-rolling compound forming technology of ring-shaped parts
has significant advantages such as shortening production process,
efficient, saving materials and energy. The deformation behavior and
microstructure evolution mechanism are studied for as-cast ring billet
during casting-rolling compound forming, and has becoming the key to
realize forming and performance of the materials. The compression tests of
Q235B flange blanks from sand casting and centrifugal casting are conducted
under different conditions. The variation of flow stresses is analyzed and
the constitutive equations are derived. The processing maps are constructed
by considering the effects of temperature and strain rate on microstructure
and performance based on dynamic materials model. The experimental results
show that the flow stress of these two materials increases with increasing
strain rate and decreasing temperature. The level of the stress of flange
billet for centrifugal casting is low and the dynamic recrystallization is
easy to occur. Both the value and the variation of efficiency of power
dissipation for centrifugal casting are higher than that of sand casting.
It indicates the severe microstructure change and sufficient evolution in
centrifugal casting billet. The rolling parameters are achieved by combined
with the processing maps and the microstructure of typical areas identified
from these maps. The centrifugal casting can provide high-quality materials
for casting-rolling compound forming technology. © 2016 Journal of
Mechanical Engineering.
Microstructure and mechanical properties of sand casting Mg-9Gd-4Y-0.5Zr

alloy
.
84964057733&partnerID=40&md5=e1b59247469bb51a1f2546c24fc3dad8
ABSTRACT: The microstructure and mechanical properties of sand casting Mg-
9Gd-4Y-0.5Zr alloy were investigated systematically byoptical
microscopy(OM), scanning electron microscopy(SEM), energy dispersive
spectrometer(EDS), Micro Vickers hardness and tensile tests. The results
showthat the microstructure of as-cast GW94 Mg alloy was mainly composed of
equiaxed dendrite of α-Mg solid solution, coarse eutectic phases of Mg24
(Gd, Y)5 at the grain boundaries and a few of square particles of Mg5(Gd,
Y). The solution treatment was 525 ℃×6 h after optimization. The
microstructure of solutionizing GW94 Mg alloy was mainly composed of
supersaturated α-Mg solid solution, residual phases of Mg5(Gd, Y) as well
as cuboid-shaped phases formed during solid treatment. The GW94 Mg alloy
exhibited remarkable age-hardening response. The peak-hardness of HV 122
was obtained by aging at 250 ℃ for 18 h. The ultimate tensile strength,
yield strength and elongation-to-failure of the peak-aged alloy at room
temperature were 300 MPa, 247 MPa and 0.9%, respectively. Meanwhile, the
ultimate tensile strength within 250 ℃ was still higher than 300 MPa, and
it showed an abnormal behavior that the ultimate tensile strength increased
with the increase of temperature. This was due to the interaction between β
′ phases and dislocations. The fracture modes of the peak-aged alloys
trans-formedfromtransgranular fracture at roomtemperature to intergranular
fracture at elevated temperature. © 2016, Chinese Mechanical Engineering
Carbon efficiency validity model for sand casting based on self-advantage

.
84961695998&doi=10.13196%2fj.cims.2016.02.028&partnerID=40&md5=44c252a0af01
3775eef187e0cab2bf84
ABSTRACT: To evaluate validity of the carbon efficiency scientifically,
carbon efficiency validity model based on self-advantage for sand casting
was established. Through summary the feature of sand casting, process
carbon sources and carbon efficiency of sand casting were built. With
analyzing process of sand casting, five process carbon sources and four-
dimensional carbon efficiency were proposed. The validity level
quantification method of carbon efficiency based on self-advantage was
introduced by analyzing process carbon sources. Thus the validity
evaluation of sand casting technical improvement was implemented. The
validity as well as the practicality of the proposed methodology was
demonstrated with the technical remolding solution of sand casting. © 2016,
CIMS. All right reserved.
Processing technology of removing sand chip in machining sand mold with

hollow end mill for patternless casting
.
84964078856&partnerID=40&md5=30db4c4c1c21ea609a7cadbcb58e1f65
ABSTRACT: To solve the problem of removing sand chips with the new hollow
end mill during patternless sand casting and machine sand mold efficiently,
the processing technology of aerodynamically assisted removing sand chip
with hollow end mill was researched. The critical wind velocity of removing
sand chips is 3.3 m/s, derived with pneumatic conveying principle. The
simulation show that when milling sand mold with hollow end mill, in the
sand mold cavity, from the bottom to the top outlet, the average gas
pressure increases and the average gas velocity decreases and the sand
chips can be removed when the average gas velocity of sand mold cavity
outlet is equal or greater than the critical wind velocity for removing
sand. The simulations, experiments and the application show that the gas
pressure supplied for hollow end mill can be adjusted on the basis of sand
mold cavity depth. The method can not only guarantee the removing sand
chip, but also avoid wasting resources. © 2016, Chinese Mechanical
Investigation of water pollution in China's sand molding foundry industry

.
84964048552&partnerID=40&md5=6894b7c1a309bcf62433ab1a9f7aeadb
ABSTRACT: This study comprehensively and systematically investigated the
wastewater quality in China's foundry industry. It was found that the
wastewater of lost wax casting was heavily polluted with NH4+-N (up to 37
008 mg/L) for which a combined physical and chemical treatment was
required. In the rest samples, only some of electric furnace cooling water
and heat treatment cooling water were found exceeded national wastewater
standards (pH and COD not meet), which should be noticed. The wastewater
from wet reclamation of sodium silicate used sand was also heavily polluted
with the average pH value 11.01, SS 984 mg/L and TP 3.26 mg/L. For such
wastewater adding acid followed by coagulation and sedimentation treatment
was required. Sodium silicate sand castings usually use carbon dioxide
process or ester cured process. Wastewater from wet reclamation of the
later one showed high Chemical Oxygen Demand up to 10 703 mg/L, thus a
biochemical treatment after coagulation and sedimentation process was
required. Meanwhile for carbon dioxide process the COD was only 60 mg/L.
Wastewater treatment facilities were found in some foundry companies, but
the wastewater quality does not improve significantly. The all wastewater
was tested in the study, none of the total Cr concentrations exceeded 0.1
mg/L. © 2016, Chinese Mechanical Engineering Society. All right reserved.
Assessment of a controlled solidification aluminium investment casting

technique for use in helicopter gearboxes
.
84946601286&doi=10.1016%2fj.msea.2015.10.028&partnerID=40&md5=53dc0e0ec141d
f5bf408fa3866c20363
ABSTRACT: By using a combination of cast plates and a helicopter gearbox
casting, the superiority of a controlled solidification investment casting
process in terms of strength, ductility and fatigue resistance was
observed, when compared to three sand casting processes (conventional, low
pressure and low pressure with chills) and a conventional investment
casting process was observed. The most important factors responsible for
the high levels of tensile strength and ductility and fatigue life were a
refined grain size, a fine distribution of particles, a low level of
porosity and a reduction in the level of bifilm formation. When porosity
levels were low, i.e. less than 0.6%, a refined grain size and
microstructure have been shown to be the most important factors influencing
strength and ductility. Further improvements in the fatigue life within the
'as-cast' controlled solidification investment process can be achieved by
the use of hot isostatic pressing (HIPping). No statistically significant
difference in the fatigue life between the 'as-cast' and machined surfaces
was observed.A higher degree of mechanical property scatter, as measured by
Weibull Modulus and the Coefficient of Variance (CV), was observed between
the TGB casting and the cast plates inferring the design of the filling
system used by the foundry had not been optimised resulting in higher metal
flow and surface turbulence and a greater likelihood of bifilms occurring
within the casting. © 2015 Elsevier B.V.
A case for low pressure sand casting of aluminum: Less common than gravity
sand casting and low pressure permanent mold casting, low pressure sand
molding holds a distinct combination of advantages for large aluminum
castings
.
84958980403&partnerID=40&md5=00da8e3209d508d827ff13ad7c8ccc8a
ABSTRACT: A majority of aluminum castings are produced via sand or
permanent mold casting, but for large precision components, another viable
option is low pressure sand casting, which uses principles from both low
pressure permanent mold (LPPM) and gravity pour sand casting. LPPM casting
is a common process producing high quality castings due to tranquil filling
of the mold and the application of pressure to fill the mold efficiently
and cleanly. Compared to gravity sand casting, the low pressure sand
molding process simplifies the filling of the mold. A single operator can
repeatedly fill the mold for a 600-lb. casting at the push of a button,
compared to the manpower necessary to fill the mold by gravity through
multiple sprues. The filling metal is also cleaner. Solidification times
are typically five times longer in sand casting than in permanent mold.
This is why the low pressure sand molding is no match to LPPM when castings
are small enough to be produced on a LPPM press.
Grain refiner for aluminium-silicon sand casting aloys

.
85015899126&doi=10.1007%2f978-3-319-48179-
1_59&partnerID=40&md5=fbf6f7f03b9f606bba4549b4964f1817
ABSTRACT: Al-Si alloys exhibit large grain structure when Al-Si alloy melt
is solidified in sand moulds due to low cooling rate provided by the mould.
Ti-based grain refiner (Al-Ti-B) is known to be less-effective to refine
grain structure of Al-Si alloys due to formation of Ti-Si phase. Recently,
we have developed an effective novel grain refiner (NGR) for aluminium-
silicon sand casting alloys. Effectiveness of grain size under slow cooling
conditions has been investigated. For comparative purposes, a range of sand
casting alloys with NGR addition have been produced. The results show that
the addition of novel grain refiner reduces the grain and eutectic size
significantly for all these alloys at lower cooling rate <0.5°C/s. As a
result of fine primary Al grains, the porosity and elongation in the
solidified alloys is notably improved. © 2016 by The Minerals. Metals &
Materials Society.
Application of sand casting to recycle aluminum alloy for motorcycle brake

handle
.
%2fKEM.705.357&partnerID=40&md5=5097803f9cdf41501d1e71af73da9a20
ABSTRACT: The development of the automotive industry brings impact of
increasing use of aluminum for vehicle components that will ultimately
produce more aluminum waste. If it is not addressed properly, it will be a
serious problem for the environment. One of the solutions is to recycle the
waste of drum brake to be a raw material for motorcycle accessories brake
handle. The process of making motorcycle brake handle using the sand
casting method can be done by varying the temperatures of casting molten
metal which are at temperatures of 650°C, 700°C and 750°C. Furthermore, the
testing of the mechanical properties and microstructure of the resulted
product is done. The result shows that motorcycle brake handle required
high impact strength in which the highest impact strength was 0.011 Nm/mm2
that was obtained when temperature of casting was 700°C. © 2016 Trans Tech
Optimisation of green sand casting process parameters for enhancing quality

of mild steel castings
.
84957053891&doi=10.1504%2fIJPQM.2016.074446&partnerID=40&md5=829132bae8731e
44fbcd7ec005ef5f2b
ABSTRACT: In this paper, an attempt has been made to obtain an optimal
parameter setting of green sand casting process to enhance the quality of
mild steel castings by reducing the percentage of casting defects. Taguchi
method of parameter design is used to set the optimal process parameters.
Minimisation of casting defects is set as quality target. Analysis of
variance (ANOVA) is then performed on the signal-to-noise ratio to find the
optimal parameter levels and to identify the statistical significance and
contribution of each factor on the casting defects. Finally, a confirmation
test is performed using the optimal parameter setting, which shows that the
casting defects can be minimised, effectively, by using the method proposed
in the study. Copyright © 2016 Inderscience Enterprises Ltd.
Modeling of distortion of a steel bracket sand casting

.
84974728185&doi=10.1002%2f9781119274865.ch6&partnerID=40&md5=b6a9ea870b701a
f5efc0f2e9bb85801b
ABSTRACT: Modeling the thermo-mechanical behavior of bonded sand is
essential for predicting casting distortions. In this study, steel casting
experiments involving a steel U-shaped bracket are performed to investigate
the effect of core restraint. The gap opening between the bracket legs is
measured in-situ using LVDTs (Linear Variable Differential Transformers)
that are attached to quartz rods embedded into the bottom of each leg.
During cooling, the core restrains thermal contractions of the steel and
pushes the legs outward, generating distortions. To simulate the
experiments, calculated transient temperature fields are input into a
finite element stress analysis code. The steel is modeled using an elasto-
visco-plastic constitutive law, while the core employs the Drucker Prager
Cap model. After adjustments to the high-temperature core sand properties,
the observed distortions are accurately predicted.
A coupled thermal-stress model of A319 alloy chilled sand casting

.
84974667185&doi=10.1002%2f9781119274865.ch24&partnerID=40&md5=a4dbbf071e230
6362a20f0790e0ef214
ABSTRACT: Fatigue properties of cast parts are strongly influenced by their
microstructures. One practical way to improve fatigue performance of any
given alloy is to reduce the length scales of the microstructural features
arising from solidification. Conventionally, solid chills are employed tp
achieve this. A potential means of improving the effectiveness of chills is
by incorporating water cooling. To assess the efficacy of this method, a
solid and a water-cooled chill were designed and installed in bonded-sand
mould packages, which were instrumented with thermocouples. A coupled
thermal-stress mathematical model was developed in "ABAQUS CAE 6.13" to
assess the casting/chill interface heat transfer behaviour and predict gap
size. Overall, the experimental and modelling results show that this
approach has the potential to improve the cast microstructure farther into
casting.
Development of large sand casting of Haynes® 282® for A-USC turbine

.
85018448729&partnerID=40&md5=5a7691f92ed1c3da16712700d5d00d23
ABSTRACT: The United States Department of Energy Office of Fossil Energy
and the Ohio Coal Development Office (OCDO) have led a U.S. consortium
tasked with development of the materials technology necessary to build an
advanced-ultra-Supercritical (A-USC) steam boiler and turbine with steam
temperatures up to 760°C (1400°F). Part of this effort has focused on the
need for higher temperature capable materials for steam turbine components,
specifically cast nickel-base superalloys such as Haynes® 282® alloy. As
the size of the needed components is much larger than is capable of being
produced by vacuum casting methods typically used for these alloys, an
alternative casting process has been developed to produce the required
component sizes in Haynes® 282® alloy. The development effort has
progressed from production of sub-scale sand castings to full size sand and
centrifugal castings. The aim of this work was to characterize the
microstructure and properties of a nickel alloy 282 casting with section
size and casting weights consistent with a full sized component. A 2720 kg
(6000 lbs.) nickel alloy 282 sand casting was produced and heat treated at
MetalTek International. The casting was a half valve body configuration
with a gating system simulated and optimized to be consistent with a full
sized part. Following casting, heat treatment and NDE inspections, the half
valve body was sectioned and tested. Tensile and high temperature creep was
performed on material from different casting section thicknesses. Further
analysis of the microstructure was carried out using light microscopy (LM),
scanning electron microscopy (SEM), and X-ray spectroscopy (EDS). The paper
also presents the mechanical properties obtained from the various sections
of the large casting. Copyrighl © 2016 Electric Power Research Institute,
Inc.
Prediction of the effectiveness of the feeding system of carbon steel sand

castings using the solid fraction criterion. Application to square bars
.
84969902720&doi=10.1504%2fIJMPT.2016.076370&partnerID=40&md5=822fc66b796a23
8e1da09aca30ba6de2
ABSTRACT: This work analyses the dimensioning of a gating-risering system
for a particular piece that consists in a low carbon steel square bar.
Empirical rules are considered and a simple gating system is designed.
Several variations about the distance between risers and their location in
the mould are submitted to simulation, for which the VULCAN software (ATZ
Quantech) is employed. To evaluate gating-risering system action, the solid
fraction criterion is considered. The results show good agreement between
the simulation results and the empirical solution. Onset of porosity takes
place only for a longer distance at the end of the bar than the end effect,
which corresponds to the empirical solution. Empirical rules allow us to
optimise the distance between risers, although longer distances are allowed
for the coldest part of the piece. This work provides a better
understanding of sand casting processes and how to analyse the related
simulation results. Copyright © 2016 Inderscience Enterprises Ltd.
The influence of two different casting moulds on the fatigue properties of

the Al–Si–Cu cast alloy
.
84991817720&doi=10.1007%2f978-981-10-1082-
8_6&partnerID=40&md5=2e8ceffe199f69bd7947979944423a09
ABSTRACT: The most widely used technologies for founding Al castings are
sand casting and die casting (gravity casting; high pressure die casting;
low pressure die casting; vacuum die casting; squeeze casting or squeeze
forming). The lower cooling rate setting used for casting into a sand mould
(sand casting) causes a coarse granular structure and lower values of
mechanical properties. Higher cooling rate settings used for casting into a
metallic mould (chill casting) causes fine-grained structures and higher
values of mechanical properties. The present study provides information
about the effect of casting into two different moulds on the fatigue
properties of the heat treated AlSi9Cu3 cast alloy. Fatigue fracture
surfaces were observed using a scanning electron microscope (SEM) after the
fatigue test. The results show that the existence of casting defects and
different morphologies of structural parameters (especially eutectic Si
particles and Fe-rich intermetallic phases) has considerable influence on
fatigue properties in both types of experimental materials. The results
show that the fatigue lifetime is longer for samples casted into a metallic
mould (chill casting) (average fatigue lifetime for 107 of cycles = 68 MPa)
compared to casting the same materials into a sand mould (sand casting)
(average fatigue lifetime for 107 cycles = 39 MPa). © Springer
Science+Business Media Singapore 2016.
Dynamic measurements of the load on GCI castings and the contraction of

castings during cooling in green sand molds
.
85016568054&partnerID=40&md5=da0d3979b994789851dee5f4e4a5a295
ABSTRACT: For cylinder head of diesel engine and bed of machine tools which
are made of sand casting, residual stress and deformation are serious
problems. These defects are known to be due to the restraint by sand mold
of heat shrinkage during casting. In previous studies, Motoyama et al. [1-
4] conducted dynamic measurement of the aluminum alloy casting the
resulting sand mold reaction force and the casting shrinkage, but studies
in iron castings has not been performed so far. A continuous measuring
device of sand mold reaction force and casting shrinkage of the green sand
was newly developed. In this study, using the newly developed device, the
authors conduct continuous measurement of the sand mold reaction force and
casting shrinkage that occur in iron casting in green sand mold. The
measured results provide valuable information to produce high quality
casting. © 2016, The WFO (The World Foundry Organization Ltd). All rights
reserved.
Characterization and evaluation of incorporation the casting sand in mortar

.
85028843617&doi=10.1007%2f978-3-319-48191-
3_64&partnerID=40&md5=c798ce919dc8d671aa87b7c90a2e6de9
ABSTRACT: The process of casting metals and alloys occurs through the
fusion of this metal and its subsequent casting into a mold with the
dimensions and geometry close to the final piece. Most foundries use sand
casting molds for making you. This work aims to characterize and evaluate
the foundry sand to allow its use in segments of Civil Engineering,
creating a viable destination for a residue is that discarded. The
following characterization tests were performer: particle size, chemical
analysis, X-ray Diffraction and Density Real grain. For the execution of
the test specimens was used to 1: 3 cement and sand, and the incorporation
of 10% and 20% of the total mass replacing the sand, and the trace
reference. The results show that best results in compression and bending
tests were obtained by replacing 10 % of common sand for sand casting. ©
2016 by The Minerals, Metals & Materials Society.
Identification of casting conditions influence on the structure and

properties of Al-Si-X alloy castings by experimental and virtual way
.
%2fDDF.367.110&partnerID=40&md5=82e4075dfb0777844f14e6128a9e908b
ABSTRACT: The paper describes influence of the structure type and its
parameters on the mechanical properties of cast products (not subjected to
plastic forming), made out of Al-Si-X alloys. The special attention has
been focused on the dendritic structure parameters: dendritic arms spacing
of the first order (DAS 1) and the second order (DAS 2). The results of
investigations of mechanical properties of the test castings made using
three basic casting technologies: gravity sand casting (GSC), gravity die
casting (GDC) and high pressure die casting (HPDC), are presented. All the
castings were made out of the same AlSi9Cu3 alloy. The test castings
(adherent samples and separately cast samples) were subjected to a static
tensile test and their mechanical properties were determined. In the next
stage, the samples fractures and zones near the fractures (metallographic
specimen) were subjected to visual testing, penetrating testing - PT and
metallographic microscopic tests. The microstructure, including the size of
the DAS 2, was determined. Evaluation of the porosity state was also
undertaken. A customer casting was also manufactured and subjected to the
metallographic, tomographic (CT) and strength tests. The castings
solidification simulation tests were performed for all the three casting
technologies (GSC, GDC and HPDC) using the Nova Flow &Solid system. The
results were used for estimation of the correlation between the cooling
rate of the particular casting solidifying in the above mentioned mould
types and for the DAS size. The coupled influence of the structure
parameters on the mechanical properties, regarding the occurrence of
porosity, was also analyzed. © 2016 Trans Tech Publications, Switzerland
Experimental investigation on mechanical behaviour of sand cast Al 6061-
SiCp metal matrix composites
.
84994164642&partnerID=40&md5=24e8bbafc1bbbfe585ace19c789b8a6d
ABSTRACT: Al 6061-SiCp metal matrix composites were synthesized
successfully using sand casting processes. The effects of volume fractions
of reinforcements on the composite properties were investigated. Vortex
method was used to add the reinforcement particles with the Al 6061 alloy.
The sand mould was prepared to make the composite castings. The
microstructural characterization studies revealed the uniform distribution
of SiC particles in the aluminium matrix and particle clustering in some
places. The results of mechanical characterization revealed that the
density, hardness and impact energy of composites increased on increasing
the volume fractions of SiC particles.
Effect of heat treatment on corrosion behavior of low pressure sand cast

Mg-10Gd-3Y-0.5Zr alloys
.
84983740847&doi=10.1007%2fs41230-016-6012-
z&partnerID=40&md5=884e827e81ab120253552216048766d2
ABSTRACT: The corrosion behaviors of low-pressure sand cast Mg-10Gd-3Y-
0.5Zr (wt.%) alloys in as-cast, solution treated (T4) and aged (T6)
conditions were studied by means of immersion test and electrochemical
measurements in 5wt.% NaCl solution saturated with Mg(OH)2. It was observed
that the corrosion rate in the T4 condition was lower than that of the as-
cast and T6 conditions by both sand casting and permanent mold casting with
the same order of as-cast>T6>T4; while the corrosion resistance of
the permanent mold casting is superior to the sand casting. The
morphologies of the corrosion products are similar porous structures
consisting of tiny erect flakes perpendicular to the corroded surface of
the alloy, irrespective of the heat treatment conditions. Especially, the
corrosion film in T4 condition is more compact than that in the other two
conditions. In addition, the severer corrosion happening to the as-cast
condition is correlated with the galvanic corrosion between the matrix and
the eutectic compounds; while improved corrosion resistance for the T4 and
T6 conditions is ascribed to the dissolution of the secondary eutectic
compounds. The measured corrosion current densities of Mg-10Gd-3Y-0.5Zr
alloys in as-cast, T4, and T6 conditions are 36 µA•cm-2, 10 µA•cm-2, and 33
µA•cm-2, respectively. The proposed equivalent circuit
[Rs(CPE1(Rt(RfCPE2))] by Zview software matches well with the tested
electrochemical impedance spectra (EIS) data. © 2016, Foundry Journal
Agency. All rights reserved.
Design quality cost system through fault tree analysis (FTA) for fnb cast
iron foundry industry
.
%2fJERA.24.165&partnerID=40&md5=f3b523d4a2e83e2ef3f7bc4f42cd3a3c
ABSTRACT: The approach taken by this paper is expected to motivate the
Furan No Bake (FNB) sand casting foundries to use a standardized system of
classification to show unwanted casting defects for highly effective
failure analysis. It will also motivate foundries to develop new systems to
quantify process parameters relating to the defects. Any reduction in the
scrap and rework also highly influences the impact on environment of
industry. This paper covers the various aspects of a systematic approach
for understanding and quality cost system development in cast iron
foundries through Fault Tree Analysis (FTA). © 2016 Trans Tech
Rheological characterization of green sand flow
.
85021655300&doi=10.1115%2fIMECE2016-
66469&partnerID=40&md5=af1ea0d07bc584cc502a90c194c9976e
ABSTRACT: The main aim of this paper is to characterize experimentally the
flow behaviour of the green sand that is used for casting of sand moulds.
After the sand casting process is performed, the sand moulds are used for
metal castings. The rheological properties of the green sand is important
to quantify as they can be used to evaluate whether the casting process
will be successful. In addition, the properties can potentially be
implemented in a computational fluid dynamics model which can be used as a
tool to optimize the process. The rheological experiments are carried out
on a MCR 502 rheometer with a new module for characterizing granular
materials. The new module enables viscosity measurements of the green sand
as function of the shear rate at different flow rates, i.e. 0, 2, 4, 6, 8,
10, 12 and 15 L=min. The results show generally that the viscosity
decreases with both the shear- and flow rate. In addition, the measurements
show that the green sand flow follows a shear-thinning behaviour even after
the full fluidization point. Copyright © 2016 by ASME.
Metal-ceramic composite lattice structures using 3D printed sand molds and

cores
.
85018395917&partnerID=40&md5=a81506b8da7481c42fa4995bddd5332a
ABSTRACT: Binder Jetting of sand molds for metal casting provides a
scalable and efficient means of fabricating large metal parts with complex
geometric features made possible only by Additive Manufacturing. For
example, in earlier work, the authors demonstrated the use of Binder
Jetting to fabricate complex mold structures for casting large-scale,
lightweight metallic lattice structures and sandwich panels that could not
be made through either traditional sand casting or through other direct
metal AM techniques. In this paper, the authors demonstrate the fabrication
of metal-ceramic composite lattice structures via embedding ceramic tiles
into the printed mold package. The addition of ceramic tiles can add
resistance to penetrators and/or radiation shielding to the lightweight
lattice structures, which can be tailored for energy absorbing performance.
3D printed mold and core designs for metal and metal-ceramic composite
lattice castings are described along with 3D printed mold designs for
encapsulating individual metal or ceramic tiles. © 2016 The Department of
Energy’s Kansas City National Security Campus is operated and managed by
Honeywell Federal Manufacturing Technologies, LLC under contract number DE-
NA0002839.
Suitability of a South African silica sand for three-dimensional printing

of foundry moulds and cores
.
84996606690&doi=10.7166%2f27-3-
1662&partnerID=40&md5=bb3e19c826acf8c810603141801d812f
ABSTRACT: Applications of three-dimensional printing (3DP) to metal casting
include, among other things, the direct manufacturing of foundry moulds and
cores in refractory materials such as silica sand. The main properties of
silica sand that are essentially related to the traditional moulding and
core-making processes are: size distribution, clay content, pH, acid
demand, and refractoriness. The silica sand used for 3DP must also be
appropriately selected for the layer-based manufacturing process involved
in 3DP. Properties such as grain size distribution, grain surface
morphology, angularity, flowability, and recoating abilities have a
particular importance when determining sand suitability. Because of these
extra requirements, only a limited range of available foundry silica sands
can be used for 3DP processes. The latter situation explains the scarcity
and high cost of suitable silica sands, thus contributing to the relatively
high operational costs of the 3DP processes for the production of sand
moulds and cores. This research paper investigates the suitability of a
locally-available silica sand for use in a Voxeljet VX1000 3DP machine. The
local silica sand was assessed and compared with an imported silica sand
recommended by the manufacturer of 3DP equipment in terms of foundry
characteristics and recoating behaviour. The study shows that, despite the
differences between the characteristics of the two silica sands, the local
sand could be considered a suitable alternative to imported sand for rapid
sand casting applications. © 2016, South African Institute of Industrial
Engineering. All rights reserved.
Effect of silicon content and solutionizing temperature on the mechanical

properties in a sand molded aluminum 206 casting
.
85048319194&partnerID=40&md5=821e10d4590c3b01ec1f6a13cc842566
ABSTRACT: Aluminium A206 (AlCu4) is one of the strongest aluminium casting
alloys with tensile properties approaching those of ferritic ductile iron.
If the specification on the silicon content (< 0.05%) is easy to achieve
during alloy ingot production, it is not the case in a foundry, where
returns are used which are not perfectly cleaned from the silicate
containing molding sand (Olivine). In alloy A206, the Si content is
controlled in order to avoid the formation of a low melting point
intermetallic phase (such as phase Q Al5Cu2Si6Mg2); these phases will melt
during the solutionizing heat treatment to which alloy A206 must be
subjected to develop its outstanding mechanical properties. This incipient
melting may deteriorate the mechanical properties of Alloy A206 if the
solutionizing treatment is applied at the standard temperature of 530°C. In
the present study, a lower temperature solutionizing (520°C) was applied to
a high Si content 206 alloy in order to reduce or eliminate the possible
incipient melting. This was carried out on a complex shape industrial
casting weighing 14 kg (31 lb) and 560x410x250 mm (22x16x10”) in size
poured in aluminum 206 with a high silicon content (0.22% vs 0.05% max for
alloy A206). Twenty ASTM E8 subsize tensile specimens were excised from two
locations in the casting in order to compare the tensile properties for the
two solutionizing temperature used (530 and 520°C). Optical and SEM
microscopy allowed to investigate the causes of the differences in the
properties observed between the 2 zones of the casting studied for 3
different heat treatments. © 2016 TAPPI Press. All rights reserved.
Thermophysical properties and performance of riser sleeves for steel

castings
.
84992539209&doi=10.1007%2fs40962-016-0041-
7&partnerID=40&md5=67e1bb5c48e07cb63a05b1b5238c06d5
ABSTRACT: Riser sleeves are a popular feeding aid used in the metal casting
industry. Reliable simulation of the performance of riser sleeves requires
accurate temperature-dependent thermophysical properties. Unfortunately,
there are little or no property data available in the open literature. A
procedure for developing thermophysical properties of riser sleeves for
steel castings is presented here along with its results. Analyses are
performed using these sleeve properties to investigate optimal sleeve use.
The modulus extension factor (MEF), which quantifies sleeve performance, is
calculated for sleeve materials. Regardless of casting size studied here,
the MEF determines casting yield improvement when using riser sleeves, and
exothermic reactions do not necessarily increase yield unless they increase
the MEF. Analyzing the effect of sleeve thickness on casting yield, it is
found that the thicknesses of most commercially available riser sleeves are
too small to maximize casting yield, particularly for risers of 8 in.
diameter and larger. Copyright © 2016 American Foundry Society.
Influence of the chemical composition on electrical conductivity and

mechanical properties of the hypoeutectic Al-Si-Mg alloys
.
84960471979&doi=10.1515%2famm-2016-
0065&partnerID=40&md5=121b178d723b49ef6cbe974e8126a2d0
ABSTRACT: Due to low density and good mechanical properties, aluminium
alloys are widely applied in transportation industry. Moreover, they are
characterized by the specific physical properties, such as high electrical
conductivity. This led to application of the hypoeutectic Al-Si-Mg alloys
in the power generation industry. Proper selection of the alloys chemical
composition is an important stage in achievement of the demanded
properties. The following paper presents results of the research on the
influence of alloys chemical composition on their properties. It has been
revealed that Si and Ti addition decreases electrical conductivity of the
Al-Si-Mg alloys, while Na addition increases it. The mechanical properties
of the investigated alloys are decreased by both silicon and iron presence.
Sodium addition increases ductility of the Al-Si-Mg alloys.
Optimization of sand mould type and melting parameters to reduce porosity

in Al-Si alloy castings
.
84990857376&partnerID=40&md5=bcb8f4a81552e11f01bd2924e7eb892c
ABSTRACT: Sand mould casting remains one of the most widely used casting
process because of its ability to produce wide variety of low cost
components. From among the total metal casting production, over 60% of
metal castings are processed by sand casting process alone and the rest is
shared by all other casting processes. As a process sand casting involves
many parameters which are even interdependent, if not controlled properly
they may lead to defects which eventually affects the quality of the
components. In this study an attempt has been made to optimize sand mould
type and melting parameters and to study the influence of these parameters
on the defect porosity of Al-Si alloy castings. The parameters selected are
sand mould type, pouring temperature, amount of degasser and holding time
at three levels each. Experiments are designed using Taguchi’s Orthogonal
Array to identify the optimum level of process parameters. Analysis of
Variance technique is used make out the significant factors and their
percentage contribution. The results reveal that the amount of degasser is
the most significant factor among the selected factors. Confirmation test
conducted based on optimum level of process parameters shows that the
porosity in the produced casting is reduced from 4.664% to 1.158%, and this
value is found to be within the confidence interval. © 2016,
AcademicDirect. All rights reserved.
Application of casting technologies to Sikorsky development programs

.
85001842879&partnerID=40&md5=d9cfcb96b39c75d615642c2aa8de1add
ABSTRACT: Sikorsky Aircraft Corporation recently demonstrated new casting
technologies in two if its latest development programs, the S-97 RAIDERTM
aircraft and Future Advanced Rotorcraft Drive System (FARDS), to improve
casting quality and speed to market. The development of new sand castings
for rotorcraft gearbox housings can frequently take years to complete.
Using modeling and simulation, additive manufacturing of the mold, and low
pressure casting, Sikorsky has shown that the lead time and number of pours
to yield a usable casting has been reduced by at least ten times compared
to using traditional casting methods. These technologies also reduce the
amount of weld repair required. Ultimately this will allow for new and
improved gearbox designs with better speed to the market. © 2016 by the
American Helicopter Society International, Inc. All rights reserved.
Crankshaft mould CNC machining based on CAD/CAM technique

.
%2fKEM.693.1704&partnerID=40&md5=56bf73bb5b7f6c1fe57c22dbdba83e87
ABSTRACT: Taking the CY4105 crankshaft mould as the research target, this
paper introduced the CNC machining method based on CAD/CAM technique. At
first, structure of the mould was introduced. Then, machining method was
introduced, including blank setting method, cutting tool selection,
machining method selection and technological parameters setting method.
After that, generation method of the mould machining programs was
introduced, including tool path and G codes generation. At last, the mould
was machined by a vertical machining center, and the results show that the
machining accuracy is high. © 2016 Trans Tech Publications, Switzerland.
TMS Annual Meeting

.
84974694673&partnerID=40&md5=c820f7af21ea6832f5c317bbe52370a9
bifilms and hot tearing of Al-Si alloys; the unidirectional solidification
of Ti-46Al-8Nb alloy with BaZrO3 coated Al2O3 mould; analytical model of
filling fine features and sharp corners in investment casting of CMSX-4;
real-time radiography and modeling of porosity formation in an A356
aluminum alloy wedge casting; modeling of distortion of a steel bracket
sand casting; SiC particle reinforced Al matrix composite by SIMA;
evolution of primary Fe-rich compounds in secondary Al-Si-Cu alloys;
methods of reducing materials' waste and saving energy in investment
casting; quality assessment of A356 ingots from different suppliers in
wheel production; on the relationship between quality index and fatigue
life distributions in B201 and D357 alloy aerospace castings; and the
reliability of ductile casting iron dependent on runner system design: an
example of support bracket of brake caliper.
Enhancement of Productivity of Traditional Brass Manufacturing Industry

Using Sustainable Manufacturing Concept
.
84966473442&doi=10.1016%2fj.procir.2016.01.134&partnerID=40&md5=923955575cd
381650e50eeb4aceb28bb
ABSTRACT: The Sri Lankan Brass manufacturing industry has evolved through
centuries. Since then, this industry has been operated as family business,
there are many gaps compared to modern manufacturing industries. Hence it
faces sever threats from different aspects including escalation of raw
material prices, proper reverse logistic mechanism to collect scarp brass
material, lack of competencies to adapt new technology. This research is
carried out to investigate the adaptation of appropriate technology to
replace traditional sand casting process and manual sheet metal carving
process. As a secondary measure, a methodology is developed to introduce
appropriate technology to marginalized community as University - Industry
partnership. This is paramount important since they do not have required
level of technical competencies to use CAD, CAM. Outcomes reveal that there
are number of productivity enhancements in terms of product quality,
material efficiency and process standardization. © 2016 The Authors.
Published by Elsevier B.V.
Challenges in assessing the sustainability of wire + arc additive
manufacturing for large structures
.
85041104396&partnerID=40&md5=ef75cadc4c682d8f8a22470d4503772c
ABSTRACT: Additive manufacturing is known as a disruptive technology, in
enabling freedom in shape and on-demand production with little human
intervention. At present, large-scale digital manufacturing means are being
developed, such as Wire & Arc Additive Manufacturing (WAAM). These could be
beneficial in aerospace, automotive and construction industries. However,
while the technology is rapidly developing, little is known on the
sustainability aspects. This article explores how such environmental
effects could be assessed for a novel technology, and the production of
large-scale products by means of a Life Cycle Assessment (LCA). Forerunning
results show possible gains in material usage when compared to traditional
manufacturing technologies, and in power consumption when compared to
different additive manufacturing technologies. Future research will focus
benchmarking WAAM against alternative manufacturing techniques, including
green sand casting and CNC milling. © 2016 The Department of Energy’s
Kansas City National Security Campus is operated and managed by Honeywell
Federal Manufacturing Technologies, LLC under contract number DE-NA0002839.
On friction stir welding of Mg-Zn-RE-Zr alloy using threaded tools for

aerospace application
.
85014990736&doi=10.1007%2f978-3-319-48108-
1_24&partnerID=40&md5=08068de3ede57c1c0c61fa9dc0904eb7
ABSTRACT: Magnesium alloys are widely used for manufacturing aerospace
engineering components due to their light weight, excellent high
temperature properties and corrosion resistance. In the present
investigation, Friction Stir Welding (FSW) has been investigated as a solid
state joining method for Mg-Zn-RE-Zr cast alloy. The Mg-Zn-RE-Zr alloy
(commonly known as RZ-5) of 6 mm thickness was fabricated by sand casting
method in an aeronautical engineering component manufacturing environment.
The cast Mg-Zn-RE-Zr alloy plates were then joined using FSW process by
utilizing in-house developed tools with cylindrical threaded pin profiles
and shoulder surface geometries. The effects of FSW process parameters such
as rotational speed and welding traverse speed on the cast Mg-Zn-RE-Zr
alloy welds were investigated. The tensile strength, percentage elongation,
hardness and microstructure of the cast Mg-Zn-RE-Zr alloy welds were also
investigated. © 2016 by The Minerals, Metals & Materials Society.
A low cost, light weight cenosphere-aluminium composite for brake disc

application
.
84959294836&doi=10.1007%2fs12034-015-1134-
2&partnerID=40&md5=8b8a62ad9158cf3e36c97afb20550326
ABSTRACT: The commonly used composite material for brake rotor consists of
silicon carbide (SiC) or aluminium oxide (Al2O3) particles which are more
expensive. The weight of conventionally used composite is more compared to
base alloy. The aim of this paper is to develop a light weight material for
brake disc applications thereby substituting base alloy and conventional
composite. This analysis led to 10 vol% cenosphere reinforced aluminium
alloy (AA) 6063 composite as the most appropriate material for brake disc.
To ensure the manufacturability of composite, composite brake rotor was
casted using the sand casting technique and was machined to achieve the
final component. Thermal capability of brake disc was ensured by studying
temperature variation through vehicle testing procedure of disc brake. Cost
reduction is one of the important benefit acquired using cenosphere
reinforced composite. This was ensured by cost estimation and analysis. The
cost estimated to manufacture the AA6063 brake disc was compared with
composite cost. © 2016 Indian Academy of Sciences.
Failure investigations of helicopter tail rotor gearbox casings at

Agustawestland Limited
.
84943163852&doi=10.1016%2fB978-0-12-800950-5.00006-
5&partnerID=40&md5=07ec0163fd5eaf0c28f63b48924e203b
ABSTRACT: This chapter outlines a number of failure investigations of tail
rotor gearbox center housings from a medium-lift helicopter. These housings
are manufactured from magnesium alloy sand castings which are susceptible
to corrosion if surface-protective coatings become damaged; hence they
sometimes fail to achieve their design life. However, approximately 15
years ago these housings also started to experience cases of fatigue
cracking, leading to even higher scrap rates.Geometrical modifications were
made to reduce fatigue stresses and a more corrosion-resistant material was
introduced, however, cracking was still observed.A number of investigations
into casting quality and fatigue strength were undertaken to determine the
cause of cracking and during these, a simple method of determining the
extent of fatigue cracking in certain light alloys was developed and has
been described herein.The chapter concludes that the failures were due to a
combination of high stresses and damaging casting defects. © 2016
AgustaWestland Published by Elsevier Ltd All rights reserved.
A study on relationship between casting geometric modulus and feeding

distance of ductile iron bar-shaped castings
.
84992612746&doi=10.1007%2fs40962-016-0056-
0&partnerID=40&md5=e3e9a1f93a346f13b765788369c1a128
ABSTRACT: Ductile iron is an engineering material gaining its popularity
for its versatility in making complex engineered components. Ductile iron,
also known as nodular iron or SG iron, has graphite in the form of
spheroids. The solidification phenomena of ductile iron are complex since
it has long freezing range and the formation of thin flexible skin where
the metal comes in contact with the mold or core. Ductile iron
microstructure is more sensitive to solidification due to the presence of
magnesium which influences the thermo-physical properties of the material
such as surface tension, viscosity and thermal conductivity. Formation of
non-metallic oxides, silicates and sulfides during nodularization treatment
makes solidification more complex. Various attempts have been made to
understand the effect of solidification behavior on the feeding distance.
Very little work has been done on the feeding distance of ductile iron
casting shapes. In this paper, an attempt is made by conducting series of
experiments to find out the maximum feeding distance in the bar-shaped
ductile iron sand castings as a function of the geometric modulus.
Copyright © 2016 American Foundry Society.
The influence of binder variation using eruption kelud sand on sand mold'
strength, quality and fluidity results on Al-Si metal casting
.
84957894473&partnerID=40&md5=284f796e6fa6f247a22a23bffe4f96cc
ABSTRACT: Sand casting carried by medium and large scale industries
typically uses commercial silica sand. Natural disaster on Mount Kelud
eruption has introduced a new breakthrough in the form of ideas to use
volcanic sand foundry sand as a base material for aluminum silica based
products. This study, meanwhile, used the experimental method in which,
prior to be given the treatment, the specimens were analyzed on the
strength of molding sand, disability and ability to cast the metal flow
(fluidity), and the quality of Al-Si as casting product. In addition, to
observe the defects, tests on surface hardness and microstructure of Al-Si
using Optical Microscope and Scanning Electron Microscope (SEM) were
conducted. The results showed the best fluidity owned by the eruption of
Mount Kelud sand specimens with a variety of bentonite 10% and hardness
value at 129.71 HV. The data obtained from the microstructure result
revealed that the eruption of Mount Kelud sand specimens with 10% portland
cement variations have the pinhole defect size of most small amounting to ±
7 pieces and open grain structure defects ± 117 pieces. In other words,
sand Kelud eruption molding sand can be an alternative to the metal casting
industry. © 2006-2016 Asian Research Publishing Network (ARPN).
Failure of steel couplings used in railway transport

.
84943185885&doi=10.1016%2fB978-0-12-800950-5.00020-
X&partnerID=40&md5=bdff0c3f9db167b24d92ad1a4b00c61b
ABSTRACT: A significant number of failures have occurred in mechanical
components (named couplings) of the coal freight trains which led to
disruption of service and economic losses. Fortunately, there weren't life
losses. The cracks detected, exhibit the classical mechanisms of fatigue
cracks under dynamic loads. The coal is loaded in electric freight trains
of 22 wagons with 2 locomotives, corresponding to a total of 2154. tons.
These trains make two journeys of about 334. km each, during 300 days for
year, which includes one way in the South to North direction, fully loaded,
and the return empty in the North to South direction. The couplings were
obtained by sand casting process, with the specification in ASTM A148 90-60
and the owner is a multinational thermoelectric company. In this chapter is
present the procedure followed to determine the damage predict of this
components. Thereby, is made the description of material characterization,
manufacturing process, and geometry of the railway coupling, followed by a
study of the intrinsic casting defects inherent to manufacturing process.
Fatigue tests procedure and microscopy analysis of the specimens is
presented. And life fatigue curves for different reliabilities were study.
Is given a particular emphasis to the experimental procedure, since service
acquisition until service data treatment. Life prediction approaches one
using the Palmgren-Miner Rule modified by Haibach and the other using
Palmgren-Miner Rule and Goodman relation were used, analyzed, and
discussed. © 2016 Elsevier Ltd. All rights reserved.
Non-standard tests for process control in chemically bonded sands

.
84958535031&doi=10.1007%2fs41230-016-5118-
7&partnerID=40&md5=f68ab9e03d29153cf04732d26a7171a4
ABSTRACT: Chemically bonded sand cores and molds are more commonly referred
to as precision sand systems in the high production automotive powertrain
sector. Their behavior in contact with molten metal can lead to casting
defects. Consequently, the interaction is of great interest and an
important part of metal casting technology. The American Foundry Society
(AFS) sand testing is based on physical, mechanical, thermal and chemical
properties of the sand system. Foundry engineers have long known that
certain AFS sand tests provide limited information regarding control of
molding and casting quality. The inadequacy is due to the fact that sand
casting processes are inherently thermo-mechanical, thermo-chemical and
thermo-physical. Non-standard foundry sand testing has proven useful for
laboratory measurement of these characteristics in foundry sand using a
disc-shaped specimen. Similarly, the equivalent disc-shaped specimens are
used for casting trials. In order to accomplish near-net-shape casting with
minimal defects, it is necessary to understand both the properties of the
sand system, as well as the interface of molten metal when different
binders, additives and/or refractory coatings are used. The methodology for
the following non-standard chemically bonded sand tests is described: (1)
disc transverse; (2) impact; (3) modified permeability; (4) abrasion; (5)
thermal distortion; (6) quick loss on ignition. The data related to the
non-standard sand tests were analyzed and interpreted. The test results
indicate that there is relatively lower test-to-test variability with the
disc-shaped specimens. The non-standard tests were able to discriminate
between the chemically bonded polyurethane cold box sand specimens. Further
studies should be conducted on various other sand and binder systems as
well as on different specimen thicknesses. © 2016, Foundry Journal Agency.
All rights reserved.
A modified cellular automation model with hybrid simulated annealing and

particle swarm optimization procedure for evaluation of the dendritic
nucleation and growth during alloys solidification
.
85007414010&partnerID=40&md5=66d6220962cbf6ed8e52464ba58b6985
ABSTRACT: The new 2D algorithm was developed to further accelerate alloys
development. A modified cellular automation (CA) model is used to simulate
and evaluate competitive dendritic structure evolution and growth during
solidification. Classical CA model considers only temperature field.
Presented algorithm taking into account solutal, thermal, curvature,
kinetic, and pressure undercooling. It allows to evaluate micro-structure
development in wider solidification ranges, which will cover fast
solidification of the alloy during laser welding, thin wall high pressure
structural die casting, and relatively slow solidifying sand castings.
Nucleation sites and preferred grain growth orientation are randomly
selected when metal reaches an appropriate undercooling temperature.
Neighboring computational cells are evaluated in order to determine the
best condition for a grain nucleation using swarm optimization approach
with the simulated annealing procedure. It improves the accuracy of the
traditional probabilistic Monte Carlo approach to a nucleation problem.
Implementation of the heuristic algorithms with dynamically adjusted
inertia weight parameter was implemented to allow both exploration and
exploitation of the computational domain. The position of the newly
nucleated grain was adjusted based on a finding of a Pareto optimal
solution. Dendrite growth velocity was evaluated based on the KGT (Kurz–
Giovanola–Trivedi) model. Finite volume model was coupled with CA model and
used to evaluate temperature and solute distribution field in the
computational domain. Gaussian distribution model was used in the presented
algorithm and covers mold-liquid metal interface, transition zone, and
solidification in a bulk metal. The model was coupled with the commercial
software FLOW3D®. It allowed increasing the accuracy of the results by
including temperature evaluation during the entire manufacturing process,
such as; melting during laser welding, or metal flow and solidification
during casting processes. Results of the grain size and distribution obtain
from modified CA-SA_PSO model was compared with the once obtained
experimentally. Numerical results are found to be in good agreement with
the experiment. © 2016, American Institute of Aeronautics and Astronautics
Inc, AIAA. All Rights Reserved.
Konstantinos Salonitis, Mark Jolly, Binxu Zeng,
Simulation Based Energy and Resource Efficient Casting Process Chain Selection: A Case Study,
Procedia Manufacturing,
Volume 8,
2017,
Pages 67-74,
ISSN 2351-9789,
https://doi.org/10.1016/j.promfg.2017.02.008.
(http://www.sciencedirect.com/science/article/pii/S2351978917300124)
Abstract: Casting processes are among the most energy intensive manufacturing processes. A typical
modern casting process contains different stages, classified as melting-alloying, moulding, pouring,
solidification, fettling, machining and finishing respectively. At each stage, large amounts of energy
are consumed. Since a number of different casting processes exist, it is not always straightforward
which process chain to select among the available ones. Up to now the selection is based on cost
criteria. This paper focuses on the different criteria that needs to be considered and how they can be
simulated focusing especially on the energy and resource efficiency of casting stages. A disruptive
technology that uses a rapid induction furnace to melt just enough metal for a single mould rather
than bulk melting used in traditional processing is proposed and validated.
Keywords: Casting; Simulation; Energy efficiency
Shun Yang, Hui Liu, Yue Zhang, Tobias Arndt, Constantin Hofmann, Benjamin Häfner, Gisela Lanza,
A Data-Driven Approach for Quality Analytics of Screwing Processes in a Global Learning Factory,
Volume 45,
2020,
Pages 454-459,
ISSN 2351-9789,
(http://www.sciencedirect.com/science/article/pii/S235197892031091X)
Abstract: Quality problems of screwing processes in assembly systems, which are an important issue
for operation excellence, needs to be quickly analyzed and solved. A network can be very beneficial
for root cause analysis due to different data from various factories. Nevertheless, it is difficult to
obtain reliable and consistent data. In this context, this paper aims to develop a method for data-
driven oriented quality analytics of screwing processes considering a global production network.
Firstly, the overview of data structure is introduced. Further, the data transformation is modelled for
edge- and cloud-based analytics across the global production network. Lastly, the rules for analyzing
are identified. A joint case study based on Learning Factory Global Production (LF) in Germany and
I4.0 Innovation Centre and Artificial Intelligence Innovation Factory (IC&AIIF) in China is used to
validate the proposed approach, which is also a new teaching method for quality analysis in the
framework of learning factory.
Keywords: learning factory; quality analytics; data-driven; edge; cloud analytics
Brian K. Paul, Patrick McNeff,
A Pedagogical Framework for Manufacturing Process Design,
Volume 26,
2018,
Pages 1388-1397,
ISSN 2351-9789,
Abstract: In recent years, federal economists have argued that manufacturing is a vital part of the
U.S. economy, providing a disproportionate share of engineering jobs, research and patents. At the
center of these arguments is an understanding that manufacturing research and development is
important to the innovation and competitiveness of manufacturing firms. As a result, federal
agencies have made significant investments in public-private partnerships stimulating industry-
directed research and development on university campuses. At the same time, state and federal
agencies have increasingly encouraged the commercialization of university research for regional
economic development. Combined, these investments have increased the amount of manufacturing
engineering activity at U.S. universities providing opportunities to advance manufacturing
engineering practice. This paper discusses efforts at Oregon State University to teach manufacturing
process design based on twenty years of findings from efforts to translate microchannel process
technology into the marketplace.
Keywords: Manufacturing Education; Manufacturing Process Design; Microchannel Process

Technology
Ram Prabhu T,
Effect of synthetic graphite and activated charcoal addition on the mechanical, microstructure and
wear properties of AZ 81 Mg alloys,
Journal of Materials Research and Technology,
Volume 5, Issue 3,
2016,
Pages 259-267,
ISSN 2238-7854,
https://doi.org/10.1016/j.jmrt.2015.12.001.
Abstract: In the present study, the grain refinement effects of carbon on AZ 81 (Mg–8%Al) alloys
were investigated through the addition of synthetic graphite and activated charcoal inoculants. The
mechanical and dry sliding wear properties of AZ 81 (Mg–8%Al) alloys with and without grain
refiners were studied. The composition, microstructure and wear surface of the cast alloys were
analyzed with the aid of atomic absorption spectroscopy, optical and scanning electron microscopes.
The wear test was conducted at a speed of 5.37m/s and two loading (20N and 30N) conditions in a
pin on disc wear apparatus. The mean grain size of the alloy is significantly reduced from about 185
to 32μm when the carbon content is increased to 0.98% C. Both tensile strength and ductility
increase with increasing carbon content. Also, the wear rate decreases with the increase of carbon
content in the alloy. The activated charcoal with 0.98wt% C is found to be a better grain refiner in
improving the properties of tensile behaviour and wear resistance. The fracture surface morphology
shows the brittle intergranular fracture. Analyses of wear surface morphology show that abrasive
and delamination wear mechanisms are responsible for the wear loss in the AZ 81 alloy.
Keywords: Mg alloys; Wear; Microstructure; Mechanical properties; Scanning electron microscopy
B.R. Powell, P.E. Krajewski, A.A. Luo,
Chapter 4 - Magnesium alloys for lightweight powertrains and automotive structures,
Editor(s): P.K. Mallick,
In Woodhead Publishing in Materials,
Materials, Design and Manufacturing for Lightweight Vehicles (Second Edition),
Woodhead Publishing,
2021,
Pages 125-186,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00004-5.
(http://www.sciencedirect.com/science/article/pii/B9780128187128000045)
Abstract: This chapter introduces magnesium, the lightest of the structural automotive metals. It
provides an overview of alloy nomenclature and properties and the major casting, sheet forming,
and extrusion processes. Descriptions of automotive magnesium applications produced by each
process are provided and there is a summary that describes the challenges in alloy and process
development that need to be overcome if the magnesium content in automotive subsystem
applications is to be increased.
Keywords: Magnesium; casting; sheet forming; extrusion; hydroforming; automotive
Swarndeep Singh, Rupinder Singh, Simranpreet S. Gill,
Experimental Investigations for Development of Aluminum MMC With Hybrid Reinforcement and
Vacuum Molding,
Editor(s): Saleem Hashmi, Imtiaz Ahmed Choudhury,
Encyclopedia of Renewable and Sustainable Materials,
Elsevier,
2020,
Pages 301-311,
ISBN 9780128131961,
https://doi.org/10.1016/B978-0-12-803581-8.11304-9.
Abstract: This article highlights the detailed procedure for development of aluminium (Al) based
metal matrix composite (MMC) with hybrid reinforcement (of Al2O3 and SiC) through synergistic
combination of fused deposition modeling (FDM), vacuum moulding (VM) and stir casting (SC)
processes. The functional prototypes prepared with combined/hybrid processes have been checked
for various performance characteristics (namely: wear, micro hardness, dimensional accuracy).
Finally to understand whether the combined process is statistically controlled, process capability
indices (Cp and Cpk) has been calculated to ensure that the combined/ hybrid process is statistically
controlled. The results of this study are useful for field engineers in form of technology transfer
involved in process hybridization as the Cp and Cpk values are greater than 1 (which ensures that the
combined/hybrid process is statistically controlled).
Keywords: Combined processes; Hybrid reinforcement; MMC; Process capability
E. Hovad, J. Spangenberg, P. Larsen, J.H. Walther, J. Thorborg, J.H. Hattel,
Simulating the DISAMATIC process using the discrete element method — a dynamical study of
granular flow,
Powder Technology,
Volume 303,
2016,
Pages 228-240,
ISSN 0032-5910,
https://doi.org/10.1016/j.powtec.2016.09.039.
Abstract: The discrete element method (DEM) is applied to simulate the dynamics of the flow of
green sand while filling a mould using the DISAMATIC process. The focus is to identify relevant
physical experiments that can be used to characterize the material properties of green sand in the
numerical model. The DEM parameters describing the static friction coefficients are obtained using a
ring shear tester and the rolling resistance and cohesion value is subsequently calibrated with a sand
pile experiment. The calibrated DEM model is used to model the sand shot in the DISAMATIC
process for three different sand particle flow rates as captured on the corresponding video footage
of the interior of the chamber. A mould chamber with three ribs mounted on the fixed pattern plate
forming four cavities is chosen as a reference geometry to investigate the conditions found in the
real moulding process. The geometry of the cast part and the casting system can make the moulding
process complicated due to obstacles such as ribs that deflect the sand flow causing “shadows
effects” around the cavities of the mould. These dynamic effects are investigated by the qualitative
flow dynamics and quantitative mould filling times captured in the video footage and simulated by
the calibrated DEM model. Both two- and three-dimensional DEM models are considered and found
to produce results in good agreements with the video footage of the DISAMATIC process.
Keywords: Sand casting; Green sand; Granular flow; Discrete element method; DISAMATIC process
M. Viquar Mohiuddin, A. Krishnaiah, S. Ferhathullah Hussainy, P. Laxminarayana,
Influence of process parameters on quality of Al7SiMg alloy casting using statistical techniques,
Materials Today: Proceedings,
Volume 3, Issue 10, Part B,
2016,
Pages 3726-3733,
ISSN 2214-7853,
https://doi.org/10.1016/j.matpr.2016.11.020.
Abstract: Manufacturing industry is considered to be the backbone of the economy of a country. As

a result of globalization, there is a stiff competition in the industry for producing quality products
with reduced cost. The key element for achieving high quality and low cost product is parameter
design. Through parameter design, optimum level of process parameters are obtained and
controlled to improve the quality of both the process and the product. Sand mould casting process is
considered to be the most unpredictable manufacturing process as it is associated with huge
number of inter-dependant process parameters. In this study Taguchi’s method of design of
experiments is applied to investigate the effect of process parameters on Al7SiMg alloy casting. The
influence of three types of sand mould viz. dry sand, sodium silicate sand and air set sand along with
pouring temperature, amount of degasser and holding time are studied. Experimental result
revealed that amount of degasser is the most significant factor for improving density and quality
index in Al7SiMg alloy castings. Based on the experimental results recommendations are made to
help producing low cost quality castings.
Keywords: Sand moulds; Al7SiMg alloy; Quality; Taguchi technique; ANOVA analysis
Yuichi Motoyama, Hitoshi Tokunaga, Makoto Yoshida, Toru Maruyama, Toshimitsu Okane,
Measuring the interfacial heat transfer coefficient between flowing molten alloy and sand mold
using fluidity tests,
Journal of Materials Processing Technology,

Volume 276,
2020,
116394,
ISSN 0924-0136,
https://doi.org/10.1016/j.jmatprotec.2019.116394.
Abstract: This study specifically examined a method using fluidity test results to measure the
interfacial heat transfer coefficient (IHTC) between a molten alloy and a mold during flow. Review of
earlier studies revealed that conventional methods require the choking area length to calculate the
IHTC during flow, but one earlier study used an assumed choking area length. Details of its length
remain unclear. Using an arbitrarily chosen choking area length leads to inaccurate acquisition of the
IHTC. For this study, we observed the microstructures and macrostructures around a fluidity test
specimen tip to ascertain the choking area length. This value led to calculation of the IHTC between
the flowing bronze melt and the shell sand mold as 1521 W/m2•K. This study also found a new
method requiring no choking area length to ascertain the IHTC between the flowing melt and the
sand mold. The IHTC obtained using this method was 1406 W/m2•K, representing a difference of
about 8% from the value obtained using a conventional method. This study assessed experimental
conditions under which the new method can produce accurate IHTC values.
Keywords: Casting; Copper alloy; Fluidity; Interfacial heat transfer coefficient (IHTC); Sand mold
Digitalisation key to rapid repairs,
World Pumps,
Volume 2019, Issue 1,
2019,
Pages 24-26,
ISSN 0262-1762,
https://doi.org/10.1016/S0262-1762(18)30418-8.
Abstract: Repairing critical equipment can be a time-consuming task, especially if original parts are
difficult to source. Sulzer's US Parts Manufacturing Centre in West Virginia re-engineers and
produces new castings for rotating equipment by using additive manufacturing.
L. Arnberg,
Solidification of Light Metals (Non-Ferrous)☆,

Reference Module in Materials Science and Materials Engineering,
Elsevier,
2017,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.03372-5.
Abstract: This chapter covers the solidification of nonferrous light metals (eg, aluminum,
magnesium). The nucleation and grain refinement of aluminum and magnesium are discussed along
with the dendrite and eutectic growth on these two light metals.
Keywords: Aluminum; Dendrite growth; Eutectic growth; Grain refinement; Magnesium; Nucleation
Michael V. Glazoff, Alexandra V. Khvan, Vadim S. Zolotorevsky, Nikolai A. Belov, Alan T. Dinsdale,
Introduction to the Second Edition,
Editor(s): Michael V. Glazoff, Alexandra V. Khvan, Vadim S. Zolotorevsky, Nikolai A. Belov, Alan T.
Dinsdale,
Casting Aluminum Alloys (Second Edition),
Butterworth-Heinemann,
2019,
Pages xi-xiii,
ISBN 9780128118054,
https://doi.org/10.1016/B978-0-12-811805-4.00011-0.
Lorraine F. Francis,
Chapter 3 - Melt Processes,
Editor(s): Lorraine F. Francis,
Materials Processing,
Academic Press,
2016,
Pages 105-249,
ISBN 9780123851321,
https://doi.org/10.1016/B978-0-12-385132-1.00003-3.
Abstract: This chapter covers the processing of metals, ceramic glasses, and thermoplastic polymers
from the melt. The fundamentals section explores melt structure, surface tension and rheology, and
then goes on to provide an introduction to the principles of liquid flow, heat transfer, and
solidification. The first process discussed is shape casting, a process used to make complex metal
shapes. The next is sheet casting of glasses. Polymer extrusion and injection molding are then
discussed, along with blow molding of polymers and glasses. The chapter concludes with fused
deposition modeling, an additive process used to make complex polymer shapes. For all processes,
principles of liquid flow and solidification are applied to develop an understanding of factors that
control the process and final products.
Keywords: Liquid structure; rheology; fluid flow; solidification; heat transfer; sand casting; die
casting; float glass process; polymer extrusion; polymer injection molding; blow molding; fused
deposition modeling
L. Bolzoni, U. Joshi, R. Alain, D. Garetto, N. Hari Babu,
Refinement of Mg alloys crystal structure via Nb-based heterogeneous substrates for improved
performances,
Materials Science and Engineering: A,
Volume 723,
2018,
Pages 70-78,
ISSN 0921-5093,
https://doi.org/10.1016/j.msea.2018.03.005.
Abstract: Lightness and high specific strength make magnesium alloys ideal materials for the
transportation industry, especially the automotive sector that is struggling to cope with the everyday
more stringent regulations on emission of carbon dioxide. Wrought magnesium alloys are difficult to
deform because of the few active slip systems characteristic of their hexagonal close-packed lattice.
Consequently, most of the commercially available magnesium alloys are alloys based on the Mg-Al
binary system used in casting processes. The improvement of the mechanical properties of these
alloys cannot be achieved by means of grain refinement using Zr due to the formation of Zr
aluminides. In this study we propose a novel chemical composition that can refine all types of Mg
alloys as proved in the Al-containing AM50 Mg alloy. We demonstrate that Nb-B inoculation of Mg
alloys promotes the formation of heterogeneously nucleated primary α-Mg grains leading to the
reduction of the grain size and this is obtained over a wide range of cooling rates. We also show that
the grain refinement achieved leads to the improvement of the properties of high pressure die cast
Mg automotive components and has the potential to enhance the mechanical properties of cast Mg
alloys.
Keywords: Magnesium alloys; Casting methods; Grains and interfaces; Grain refinement; Mechanical
behaviour
I. Narasimha Murthy, J. Babu Rao,
Non Destructive Evaluation of A356 alloy Castings made in Sand and Granulated Blast Furnace Slag
Moulds,
Volume 5, Issue 1, Part 1,
2018,
Pages 168-174,
ISSN 2214-7853,
Abstract: Silica sand is traditionally used in foundry applications as a moulding material. Due to the
depletion of natural materials, there is a need to find suitable alternative material, which will replace
the conventional materials. In view of the large quantity of blast furnace slag availability, having
similar physical and chemical properties with silica sand present investigations are focused to
evaluate the suitability of GBF slag as an alternative mould material in foundries. In the present
investigation three types of moulds were made with slag, silica sand individually and combination of
these two. Sodium Silicate-CO2 process was used for making the necessary moulds. Two types of
commonly used automobile parts like Gear wheel and Connecting rod was selected for casting the
same. A356 (Al-7.5% Si) alloy castings were performed on these newly developed slag and sand
moulds. The cast products were investigated for its quality evaluation by non destructive methods;
in this investigation Visual inspection, Liquid penetrant, Ultrasonic and Radiographic tests was used.
Results reveal that the castings were performed successfully in GBF slag and sand moulds. The cast
products show good surface finish with dimensional accuracy. NDE results evident that both sand
and slag mould cast products had a sound castings with neither surface, subsurface defects nor
internal defects.
Keywords: Silica Sand; GBF Slag; Visual inspection; Liquid Penetrant testing; Ultrasonic and
Radiography testing
Li-jun JING, Ye PAN, Tao LU, Jin-hong PI, Teng-fei GU,
Nucleation potency prediction of LaB6 with E2EM model and its influence on microstructure and
tensile properties of Al-7Si-0.3Mg alloy,
Transactions of Nonferrous Metals Society of China,
Volume 28, Issue 9,
2018,
Pages 1687-1694,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64812-5.
Abstract: The edge-to-edge matching (E2EM) crystallographic model was used to predict the
orientation relationships (ORs) between LaB6 and Al. Three different possible ORs can be predicted
between LaB6 and Al, which are (100)Al‖(100)LaB6, [001]Al‖[001]LaB6; (110)Al‖(110)LaB6,
[001]Al‖[001]LaB6; and (111)Al‖(111)LaB6, [011¯]Al‖[011¯]LaB6. The prediction results are perfectly
confirmed through TEM analysis and prove the nucleation potency of LaB6. The refining efficacy of
Al-2La-1B refiner and its influence on the tensile properties were investigated in the as-cast Al-7Si-
0.3Mg alloy. According to the results, LaB6 has higher nucleation potency than TiB2, leading to
better grain refining efficacy of Al-2La-1B refiner in the as-cast Al-7Si-0.3Mg alloy. Regarding the
mechanical performances, tensile properties of the as-cast Al-7Si-0.3Mg casting alloy are
prominently improved after addition of Al-2La-1B refiner, due to the refined microstructures.
Keywords: edge-to-edge matching; orientation relationship; casting aluminum alloy; grain

refinement; tensile properties
Guoling Mao, Zhigang Wu, Shanguang Liu, Liwei Zhong, Wenli Gao,
The fluidity of A357 alloy with scandium (Sc) and zirconium (Zr) addition,
Volume 9, Issue 6,
2020,
Pages 13570-13574,
ISSN 2238-7854,
Abstract: The effect of Sc and Zr on the fluidity of A357 alloy was investigated using spiral fluidity
resin sand molds. The results showed that the order of the fluidity was A357+Zr > A357+Sc > A357 >
A357+Zr+Sc. The TDCP and the solidification temperature range were also discussed. With Sc and Zr
addition, the TDCP and the solidification temperature range of the alloy were changed, which led to
the changes of the fluidity. The order of TDCP was A357+Zr < A357+Sc < A357 < A357+Zr+Sc and the
order of the solidification temperature range was A357+Zr < A357+Sc < A357 < A357+Zr +Sc. What’s
more, △T2 (△T2=TP-TDCP, TP was pouring temperature) and △T1 (△T1=TN-TDCP, TN was α-Al
nucleation temperature) were compared, and △T2 was better suited for fluidity investigation than
△T1.
Keywords: Fluidity; Scandium (Sc); Zirconium (Zr); Cast; Metal and alloys
M.D. Vijayakumar, V. Dhinakaran, T. Sathish, G. Muthu, P.M. Bupathi ram,
Experimental study of chemical composition of aluminium alloys,
2020,
ISSN 2214-7853,
Abstract: The Aluminium has been popular in the recent years due to the necessity to produce light
weight components in the aircraft and automobile industries. These have been used in the
manufacture of producing light weight transmission cables, heat exchangers, evaporators,
automotive cylinder heads and radiators. These materials have excellent mechanical properties such
as high tensile strength, high strength to weight ratio, corrosion resistance, ductility, formability,
recyclability, etc. For these reasons, Aluminium alloys have been used in most of the applications. In
this work the characteristics of aluminium alloys are studied and a new alloy with a different
chemical composition is studied through experimental tests such as tensile test, hardness test and
chemical test. The results were obtained from the experiments and were analyzed and conclusions
were drawn.
Keywords: Aluminium alloy; Tensile test; Hardness test; Chemical composition; Aerospace industries
Guan-yi CHEN, Zhuan LI, Peng XIAO, Xi OUYANG, Wen-jie MA, Peng-tao LI, Jin-wei LI, Yang LI,
Tribological properties and thermal-stress analysis of C/C-SiC composites during braking,
Volume 29, Issue 1,
2019,
Pages 123-131,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64921-0.
Abstract: The tribological properties and thermal-stress behaviors of C/C-SiC composites during
braking were investigated aiming to simulate braking tests of high-speed trains. The temperature
and structural fields of C/C-SiC composites during braking were fully coupled and simulated with
ANSYS software. The results of tribological tests indicated that the C/C-SiC composites showed
excellent static friction coefficient (0.68) and dynamic friction coefficient (average value of 0.36). The
highest temperature on friction surface was 445 °C. The simulated temperature field showed that
the highest temperature which appeared on the friction surface during braking was about 463 °C.
Analysis regarding thermal-stress field showed that the highest thermal-stress on friction surface
was 11.5 MPa. The temperature and thermal-stress distributions on friction surface during braking
showed the same tendency.
Keywords: C/C-SiC composites; brake; tribological behavior; temperature field; thermal-stress field
Suttipong Sriintharasut, Bovornchok Poopat, Isaratat Phung-on,
The effects of different types of welding current on the characteristics of nickel aluminum bronze
using gas metal arc welding,
2018,
Pages 9535-9542,
ISSN 2214-7853,
Abstract: This study aims to investigate the effects of different types of welding current on the
characteristics of Nickel Aluminum Bronze Alloy (NAB) such as microstructure, hardness,
depth/width ratio and dilution by using Gas Metal Arc Welding (GMAW). The mechanized GMAW
was employed for the bead on plate welding of NAB using 3 levels of heat input, 500-600 J/mm, 700-
800 J/mm. and 800-900 J/mm with 2 types of welding current: standard and pulsed. The AWS.A5.7
ERCuNiAl solid wire and 100% argon shielding gas were applied. The results indicated that welding
current types did not significantly affect the microstructures in the weld area and heat affected zone
(HAZ).The hardness of welding from both welding current types were comparable with the average
hardness of 160-180 HV in weld metal and 200-240 HV in the HAZ. Nevertheless the more heat per
unit length (HI) was the higher depth/width ratio was. However, for pulsed current, the metal was
transfer form solid wire to the NAB during the peak current of pulsed current resulting in deeper
penetration but with higher dilution ratio compared to standard current. This could indicate that the
pulsed current could be more appropriated for groove welding while the standard current for the
built-up overlay welding.
Keywords: Nickel aluminum bronze; Standard current; Pulsed current
Yajun Yin, Tong Wang, Zhixian Wang, Zhiwei Huang, Xu Shen, Jianxin Zhou,
Research and Development of Casting Process CAD System for Steel Casting based on OpenCASCADE
and wxWidgets,
Volume 37,
2019,
Pages 348-352,
ISSN 2351-9789,
Abstract: With the development of computer technology, the casting process CAD system has
become the main way of casting process design for process designers. Most of these systems are
developed based on second development tools of commercial 3D CAD systems. Due to the version
escalation of commercial 3D CAD systems and confidentiality and consistency of data in foundry
enterprises, the application of casting process CAD systems are greatly limited. To handle these
problems, this paper puts forward the casting process CAD system for steel casting based on
OpenCASCADE and wxWidgets. The framework of casting CAD system is constructed by the 3D
geometric modeling kernel (OpenCASCADE) and the interface design platform (wxWidgets). The
system has the function of practical casting process design and modeling, including part information
extraction, gating system, chill system and riser system and so forth. Finally, taking the articulation
piece for example, the casting can be designed by the system. It shows that the system resolves the
above difficulties and improves the speed of casting process design and the ability of casting
information exchange.
Keywords: Casting process; CAD system; OpenCASCADE; wxWidgets; Steel Casting
Ian Polmear, David StJohn, Jian-Feng Nie, Ma Qian,
5 - Cast Aluminium Alloys,
Editor(s): Ian Polmear, David StJohn, Jian-Feng Nie, Ma Qian,
Light Alloys (Fifth Edition),
2017,
Pages 265-286,
ISBN 9780080994314,
https://doi.org/10.1016/B978-0-08-099431-4.00005-1.
Abstract: Aluminum is the most versatile of the common foundry metals with about 50% by weight
being cast from recycled secondary alloys. This chapter describes the attributes of Al–Si, Al–Si–Mg,
Al–Si–Cu, Al–Cu, Al–Mg, and Al–Zn–Mg alloys in terms of mechanical properties and their limitations
from a manufacturing perspective. Apart from light weight, the attributes are the relatively low
melting temperatures, often good fluidity, negligible solubility for all gases except hydrogen, and the
good surface finish of final products. One of the limitations highlighted is the relatively high
shrinkage that occurs in most aluminum alloys during solidification leading to porosity and hot
tearing of the casting. Because the eutectic phase of the commercially important Al–Si alloys
contains brittle flake-like silicon and constitutes a large proportion of the microstructure, the
methods and possible mechanisms of the modification of silicon to a fibrous morphology to enhance
ductility, are presented.
Keywords: Aluminum casting alloys; Al–Si casting alloys; foundry alloys; alloy designations; eutectic;
silicon modification; heat treatment; mechanical properties
Min Wang, Lin Guo, Haoran Sun,
Manufacture of Biomaterials,
Editor(s): Roger Narayan,
Encyclopedia of Biomedical Engineering,
Elsevier,
2019,
Pages 116-134,
ISBN 9780128051443,
https://doi.org/10.1016/B978-0-12-801238-3.11027-X.
(http://www.sciencedirect.com/science/article/pii/B978012801238311027X)
Abstract: Biomedical materials are biocompatible metals, polymers, ceramics (including glasses and
glass-ceramics), and composites. They are used in the biomedical field in various forms: particles,
fibers, thin films, coatings, dense and non-porous, porous, etc. The size of implants and medical
devices ranges from tens of nanometers to tens of centimeters and their shapes and geometries
vary tremendously. Many biomedical materials also require surface modification for achieving
desired biological responses. Therefore, numerous techniques have been investigated and
developed for the fabrication of biomedical devices from different types of biomedical materials.
This article gives a comprehensive coverage of major manufacturing technologies for all types of
biomedical materials.
Keywords: 3D printing; Addition polymerization; Annealing; Autoclaving; Biomimetic deposition;

Blending; Blow molding; Chemical vapor deposition; Compacting; Compression molding;
Copolymerization; Cross-linking; Crystallization; Drawing; Double emulsion; Electrospinning;
Emulsion; Extrusion; Filament winding; Forging; Good manufacturing practice; Grafting; Grain
growth; Heat treatment; Hot isostatic pressing; Hot pressing; Injection molding; Investment casting;
Ion beam assisted deposition; Layer-by-layer deposition; Laminating; Liquid-phase sintering;
Machining; Melt quenching; Phase separation; Plasma spraying; Pressureless sintering; Plasma
treatment; Porogen leaching; Physical entrapment; Powder metallurgy; Pultrusion; Re-
crystallization; Rolling; Sand casting; Self-assembly; Sol-gel; Solvent-casting; Solid-state sintering;
Step-growth polymerization; Surface modification; Transfer molding; Welding
A. Sanitas, M. Bedel, M. El Mansori,
Experimental and numerical study of section restriction effects on filling behavior in low-pressure
aluminum casting,
Volume 254,
2018,
Pages 124-134,
ISSN 0924-0136,
https://doi.org/10.1016/j.jmatprotec.2017.11.013.
Abstract: The molten metal flow under low-pressure filling was investigated both experimentally and
numerically inside sand molds with different cross sections and different pressure ramps. The
proposed fluid dynamics simulation predicts quantitatively the observed filling oscillations. An
analytical model is developed to link the over-height with the geometrical restriction and the
pressure ramp. The calculated over-height is proportional to the ramp and non-linearly impacted by
the section change as confirmed by the experimental results.
Adrian Pocola, Alexandru Serban, Mugur Balan,
Complex and Efficient Waste Heat Recovery System in Aluminum Foundry,
Energy Procedia,
Volume 112,
2017,
Pages 504-509,
ISSN 1876-6102,
https://doi.org/10.1016/j.egypro.2017.03.1134.
Abstract: The study presents the evaluation of a heat recovery system in a Romanian aluminum
foundry. The study was based on a thermal power balance that revealed on one side that the
components of the balance is in good agreement with similar results presented in the literature and
revealed on the other side the heat recovery potential from the available waste represented by
exhaust gases. The proposed heat recovery from waste is capable to recover more than 25% of the
total thermal power of the burners, equivalent with more than 60% of the available waste.
Keywords: phase change material; sphere; air conditioning
G. Thiyagesan, S. Vigneshwaran, S. Beer Mohammed, S.A. Srinivasan, B. Thirumaran, S.P. Kumaresh

Babu,
Investigation on the erosive wear resistance of squeeze cast AA7150 under slurry conditions,
Volume 27, Part 3,
2020,
Pages 2529-2532,
ISSN 2214-7853,
Abstract: An investigation has been performed on the slurry erosion behavior of squeeze cast
AA7150 aluminium alloy – a potential structural alloy in as cast condition. The tests were conducted
at room temperature varying the service factors using quarts silica sand. The cast samples were
examined for its metallurgical and mechanical factors followed by investigation on erosive wear
behavior. The results showed the ductile nature of mechanism undergone and greater influence was
seen with respect to the angle of impingement. The erodent flow rate also significantly affects the
performance of the material. The surface morphologies of the wear tested specimens were
examined using SEM for better understanding on the mechanism of failure. Severe plastic
deformation is seen in all the cases as the strain energy exceeded the elastic strain rate.
Keywords: AA7150; Slurry erosion; Squeeze cast; Mechanistic studies; SEM and XRD
K. Vamsi, M. Krishnakumar, R. Saravanan,
Effect of preheating temperatures on distribution of FeTiO3 on A 360 aluminium alloy by stirring,
Volume 27, Part 3,
2020,
Pages 2412-2417,
ISSN 2214-7853,
Abstract: An investigation on distribution of 5 wt% of natural mineral called ilmenite (FeTiO3) an

extract from iron ore particles in A 360 aluminium metal matrix composite (MMC) by manual
stirring. In preparing the MMC, the FeTiO3 was preheated at different temperatures, namely at
200 °C, 400 °C, 600 °C, and 800 °C and then added to the MMC in an equal interval of time and the
5 wt% of FeTiO3 was evenly distributed. Microstructure of the MMC was observed using a
metallurgical microscope. The deposition of FeTiO3 on eutectic Si was revealed during the
microscopic observation. Composition of the cast MMC was analyzed using EDS. The result of the
EDS analysis confirmed the presence of FeTiO3 content on the MMC compared to the substrate.
Further the compositions of intermetallic phases were obtained during the EDS analysis. The XRD
spectrum confirms the presence of intermetallic phases. The hardness and tensile strength of the
MMC reinforced with FeTiO3 preheated at various temperatures was found to be increased when
compared to the MMC.
Keywords: Aluminium – 12%silicon; Mineral; Stir casting; Microstructure; Hardness; Wear rate
Abid Haleem, Pawan Gupta, Shashi Bahl, Mohd Javaid, Lalit Kumar,
3D scanning of a carburetor body using COMET 3D scanner supported by COLIN 3D software: Issues
and solutions,
2020,
ISSN 2214-7853,
Abstract: Nowadays, the industry uses 3D Scanners for reverse engineering, new product design,
rapid manufacturing, multimedia, architecture, inspection, and quality control. The scanning process
converts a real object into a digital format. This paper's essential purpose is to show the use of a 3D
blue light Scanner/COMET 3D to redesign a carburetor body. The paper identifies different issues
involved in the processes to help future users. COMET 3D does scanning of the carburetor body by
which COLIN 3D software is used for measurements, editing, and analyzing of the acquired point
clouds data. This paper also identifies the necessary steps to undertake 3D Scanning and part
dimensioning for a carburetor body. It also discusses the error/problems that occurred during the
process. The applications of non-contact blue light 3D Scanners are many as they can be innovatively
used to redesign an existing part, architecture designing, and reducing production cycle time,
biomedical and associated applications. This paper's contribution lies in achieving a step-by-step
procedure of scanning any three-dimensional object as this helps in understanding the 3D scanning
hardware and support software. It provides good knowledge of how to resolve the issues that can
cause an error during the measurement of the surfaces and scan objects.
Keywords: COMET 3D scanner; Colin3D; Point clouds; Reverse engineering; Triangulation
Denisa Závodská, Lenka Kuchariková, Eva Tillová, Mario Guagliano, Mária Chalupová, Milan Uhríčik,
Juraj Belan,
The Fatigue lifetime of AlZn10Si8Mg cast alloy with different percentage of iron,
Procedia Structural Integrity,
Volume 13,
2018,
Pages 1554-1559,
ISSN 2452-3216,
https://doi.org/10.1016/j.prostr.2018.12.317.
Abstract: To increase the proportion of Al-cast alloys in a variety of industrial applications, it appears
useful to control their fatigue behavior. In general, that behavior is affected by many factors, such as
chemical composition, heat treatment, inclusions etc. The problem with utilization of the Al-scrap as
a material for casting the Al-Si alloys lies in the fact that the scrap, unfortunately as a rule, is
contaminated with iron. The Fe-rich intermetallics, formed during the solidification process, appear
in a great variety of shapes and sizes. The most important are platelets or needles Al5FeSi, because
they greatly decrease mechanical and corrosion properties of Al-cast alloys. The effect of the brittle
Fe-rich phases on the fatigue properties in the secondary self-hardening AlZn10Si8Mg cast alloys
with different percentage of iron (0.150 and 0.559 wt. %) was studied. Microstructure of alloys and
the 3D-morphology of phases were analyzed by the optical and SEM microscopy. Rotating bending
fatigue tests were realized for a defined number of cycles 3 x 106. The results show that with
increasing the content of Fe, the area proportion and the average length of Al5FeSi phases increased
a significant influenced on the fatigue life and pores formation.
Keywords: secondary cast aluminum alloys; iron intermetallic phases; fatigue properties
I. Narasimha Murthy, N. Arun Babu, J. Babu Rao,
Microstructure and Mechanical properties of A356 alloy Castings made in Sand and Granulated Blast
Furnace Slag Moulds,
2018,
Pages 161-167,
ISSN 2214-7853,
Abstract: Investigations were focused on structure property evaluation of castings made through
Granulated blast furnace (GBF) slag and silica sand moulds. Sodium Silicate-CO2 process was used
for making the necessary moulds. Three types of moulds were made with slag, silica sand
individually and combination of these two. A356 alloy castings were performed on these newly
developed slag moulds. Results reveal that the castings were performed successfully in all the
moulds. Cast products with good surface finish, no surface defects and without porosity were
produced by slag moulds. Faster heat transfer in slag moulds enabled the obtained castings with
enhanced metallurgical and mechanical properties. Consistent and uniform hardness on the cross
section of the specimen was obtained in all the materials made through sand, slag and mixed
moulds. Improved hardness, compression, tensile and impact properties were observed in all the
materials made through GBF slag moulds. Based on these present investigations can conclude that
GBF Slag moulds can make a way for producing the castings with improved surface finish and
enhanced properties while reduced operational costs.
Keywords: Silica sand; GBF slag; A356 alloy castings; Optical & SEM studies; Mechanical properties
Roger N. Lumley,
Chapter 3 - How to Design and Buy Aluminium Castings,
Editor(s): Roger N. Lumley,
In Woodhead Publishing Series in Metals and Surface Engineering,
Fundamentals of Aluminium Metallurgy,
2018,
Pages 93-122,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.00003-5.
Abstract: A product development process is a sequence of activities that a company employs to

bring an idea to the marketplace. Today, with the increased use of computer aided drawing
programmes and rapidly decreasing innovation cycles, the design process itself has been largely
taken out of the designer's realm and into that of the general engineering community. This has
brought with it both challenges and opportunities for the foundry industry. Whereas in the past the
link between the design and manufacturing process was reasonably well understood, the reality is
that today most component designer's experience of foundries and castings is limited to what they
see in a short visit. Similarly, procurement or supply chain engineers in large organizations do not
necessarily understand what a foundry does, nor what is important in the manufacturing process.
Many also do not realize that there are often simple steps to reduce cost through consultation with
the personnel at the foundry that is going to manufacture the parts. As the demand for lighter and
radically new designs with newer materials and alloys has increased, the pressure on the entire
supply chain to be profitable and efficient continues to build. What is clear is that most of the
committed costs of a product development cycle are realized in the design phase, well before
production begins. It is therefore pertinent to provide guidance for the design of castings so that
procurement and manufacture is a simple process.
Keywords: Casting; Design; Design for manufacture; Design for casting; Safety factor; Casting factor
P. Suresh, P. Arunagiri, A.P. Arun Pravin,
Experimental analysis of aluminium alloy LM25 with carbon in composite material,
2020,
ISSN 2214-7853,
Abstract: This paper considers the potential use of Aluminium alloy LM25 with carbon in metal
matrix composite with reference to the automobile industry. MMC of Aluminum alloy with carbon is
done by appropriate casting process. This Work helps to explore the importance of Aluminium LM25
with carbon in automobile, aerospace industries. Mechanical and Microstructure properties are
observed to improve the strength of the Aluminium alloy composite material.
Keywords: Aluminium alloy LM25; Brinell hardness; Microphotography; Composite material; Impact
test
M.M. Mehrabinejad, A. Najafi, A. Hajighadery, M. Saraei, N. Izadi, Z.B. Alemohammad,
Association of sleep characteristics and respiratory symptoms at a smelting factory,
Sleep Medicine,
Volume 64, Supplement 1,
2019,
Page S335,
ISSN 1389-9457,
https://doi.org/10.1016/j.sleep.2019.11.935.
Contents,
2021,
Pages v-xi,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00014-8.
Yanan Wang, Tao Peng, Yi Zhu, Yang Yang, Renzhong Tang,
A comparative life cycle assessment of a selective-laser-melting-produced hydraulic valve body using

design for Property,
Procedia CIRP,
Volume 90,
2020,
Pages 220-225,
ISSN 2212-8271,
https://doi.org/10.1016/j.procir.2020.01.095.
Abstract: Selective laser melting (SLM) is known to be potentially sustainable, enabled

manufacturing with complex parts with high flexible design. Existing studies have explored the
environmental sustainability of SLMed parts, but there is not yet a consolidated conclusion. In this
paper, industrial hydraulic valve body was taken as an example. Its part design, material preparation,
and part manufacturing were included in the comparative analysis for SLM and conventional
manufacturing (CM). A redesigned part using Design for Property (DfP) method was fabricated using
SLM. Then, a cradle-to-gate comparative LCA study of these SLMed and CMed parts was performed,
with the data from our experiments, enterprise, literature, and databases. The environmental
impact of the SLMed hydraulic valve body was found to be 37.42% lower, and the SLMed optimal
design can further reduce the environmental impacts 16.84%. Powder preparation is the highest
stage of unit impact. For heavier valve body, with the increase of the potentials of lightweight, the
environmental impacts of SLM process will become the main phrase during life cycle. Electricity is
the main reason of SLM environmental impact. Therefore, to improve environmental performance,
collective efforts from both designer and manufacturer are important.
Keywords: Selective laser melting; Life cycle assessment; Hydraulic valve body; Design for property;
Lightweight; ReCiPe
Ozen Gursoy, Giulio Timelli,
Lanthanides: a focused review of eutectic modification in hypoeutectic Al–Si alloys,
Volume 9, Issue 4,
2020,
Pages 8652-8666,
ISSN 2238-7854,
Abstract: A modified fibrous-like eutectic structure strongly improves the final mechanical properties
of Al–Si foundry alloys, especially ductility. Beside widely used commercial eutectic modifiers such as
Sr and Na, lanthanides appear to be a possible alternative in the eutectic Si modification process for
hypoeutectic Al–Si casting alloys. All lanthanides have similar physical and chemical properties, such
as density, melting point, and fading phenomena, which have been compared in the present review.
They also show atomic radii close to the optimal atomic radius for a modifying agent. However, the
microstructural evolution of eutectic Si is strictly related to the specific element and content of
lanthanides, whose abundance, reserve, mining, production and market situations have been
preliminary evaluated in this paper. The eutectic modification mechanisms induced by lanthanides
are not well-discussed and clarified yet. The advantages and disadvantages of individual addition of
lanthanides for chemical modification of hypoeutectic Al–Si alloys have been here critically
reviewed. The use of lanthanides for eutectic Si modification in Al–Si alloys has been discussed from
both effectiveness and economical point of views. Nowadays, the actual cost and their efficiency
seem to make lanthanides still far to be used in foundry industry for commercial and large-scale
applications.
Keywords: Lanthanides; Rare earth; Eutectic modification; Silicon morphology; Aluminium alloy
Mohsen Ziaee, Nathan B. Crane,
Binder jetting: A review of process, materials, and methods,
Additive Manufacturing,
Volume 28,
2019,
Pages 781-801,
ISSN 2214-8604,
https://doi.org/10.1016/j.addma.2019.05.031.
Abstract: Binder Jet printing is an additive manufacturing technique that dispenses liquid binding
agent on powder to form a two-dimensional pattern on a layer. The layers are stacked to build a
physical article. Binder Jetting (BJ) can be adapted to almost any powder with high production rates
and the BJ process utilizes a broad range of technologies including printing tehniques, powder
deposition, dynamic binder/powder interaction, and post-processing methods. A wide variety of
materials including polymers, metals, and ceramics have been processed successfully with Binder
Jet. However, developing printing and post-processing methods that maximize part performance is a
remaining challenge. This article presents a broad review of technologies and approaches that have
been applied in Binder Jet printing and points towards opportunities for future advancement.
Keywords: Binder jetting; Powder deposition; Wetting; Post-processing; Sintering; Materials
Haohao Zhang, Jianfeng Fan, Liang Zhang, Guohua Wu, Wencai Liu, Wendong Cui, Shi Feng,
Effect of heat treatment on microstructure, mechanical properties and fracture behaviors of sand-
cast Mg-4Y-3Nd-1Gd-0.2Zn-0.5Zr alloy,
Volume 677,
2016,
Pages 411-420,
ISSN 0921-5093,
Abstract: Microstructure, mechanical properties and fracture behaviors of sand-cast Mg-4Y-3Nd-

1Gd-0.2Zn-0.5Zr (wt%) alloy in different thermal conditions were investigated. The as-cast alloy was
comprised of α-Mg matrix, Mg24Y5, Mg41Nd5 and β1 phases. After solution treatment at 525°C for
6h, the eutectics dissolved into α-Mg matrix, leading to a huge improvement of plasticity. Alloys
peak-aged at 200°C and 225°C exhibit high strength due to fine dense β″ and β′ precipitates. Aged at
250°C for 10h, the precipitates in the alloy are coarse sparse coupled β1/β′ phases. A desirable
combination of strength and ductility was obtained with 198MPa in yield strength, 276MPa in
ultimate tensile strength and 7.6% in elongation when over-aged at 250°C for 10h. Alloys under
different thermal conditions show different fracture behaviors, which are closely linked to the
structures of both inner grains and grain boundaries.
Keywords: Magnesium alloy; Heat treatment; Microstructure; Mechanical property; Fracture

behavior
Yanlei Li, Guohua Wu, Antao Chen, Wencai Liu, Yingxin Wang, Liang Zhang,
Effects of processing parameters and addition of flame-retardant into moulding sand on the
microstructure and fluidity of sand-cast magnesium alloy Mg-10Gd-3Y-0.5Zr,
Journal of Materials Science & Technology,
Volume 33, Issue 6,
2017,
Pages 558-566,
ISSN 1005-0302,
https://doi.org/10.1016/j.jmst.2017.01.013.
Abstract: In this study, the effects of processing parameters (such as pouring temperature and
mould pre-heating temperature) and flame-retardant content on the microstructure and fluidity of
sand-cast magnesium (Mg) alloy Mg-10Gd-3Y-0.5Zr (GW103K) were systematically investigated. It
was found that the increase of pouring temperature leads to coarsened microstructure and
decreased fluidity of sand-cast GW103K alloy. Increase of mould pre-heating temperature incurs
coarsening of as-cast microstructure and increase of fluidity. The addition of flame-retardant into
moulding sand has a negligible influence on the microstructure of sand-cast GW103K alloy. With the
increase in flame-retardant content, fluidity of the alloy initially increases and then decreases. The
optimized process parameters and flame-retardant addition were obtained to be pouring
temperature of 750°C, mould temperature of 110°C, and flame-retardant addition of 1%. The fire
retardant mechanism of moulding sand was determined.
Keywords: Magnesium alloy; Fluidity; Microstructure; Flame retardant; Fire retardant mechanism
G. Sathishkumar, S. Saravanan, G. Navaneethakrishan, N. Parkunam, R. Yokeshwaran,
Microstructural and wear behaviour of heat treated Cu-11Ni-6Sn alloy,
Volume 21, Part 1,
2020,
Pages 89-92,
ISSN 2214-7853,
Abstract: Cu-11Ni-6Sn alloy used bearing material in aerospace and mining industries, Casting is one
of the famous metal additive process in which it is able to produce complex shape for engineering
applications. Heat Treatment is the controlled heating and cooling of metals to modify their physical
and mechanical properties. In the present study, to investigate the microstructural and wear
behaviour of heat treated Cu-11Ni-6Sn alloys. During the aging process, the hardness of the alloy
increased, which is due to microstructural changes. The wear rate is a function of hardness of the
alloy decreased and it follows the adhesion theory of wear.
Keywords: Copper; Nickel; Casting; Hardness; Wear rate; Coefficient of friction
Chen Wu, Mingyang Li, Peng Jia, Rongxue Liu, Shujing Cui, Haoran Geng,
Solidification of immiscible Al75Bi9Sn16 alloy with different cooling rates,
Journal of Alloys and Compounds,
Volume 688, Part A,
2016,
Pages 18-22,
ISSN 0925-8388,
https://doi.org/10.1016/j.jallcom.2016.06.275.
Abstract: In this paper, the impact of cooling rate on solidification microstructures of Al75Bi9Sn16
alloy was studied for obtaining AlBiSn core-shell organizations by SEM under normal casting
conditions. The results show that the core-shell structure is composed of SnBi-rich core and Al-rich
shell and outermost thin layer of SnBi phase when Al75Bi9Sn16 alloy melt is cast in a copper mold;
when Al75Bi9Sn16 alloy melt is cast in sand mold, alloy does not form the typical core-shell
structure.
Keywords: Al-Bi-Sn alloy; Immiscible alloys; Cooling rate; Core-shell structure; Liquid-liquid phase
separation
Denisa Závodská, Lenka Kuchariková, Eva Tillová, Mario Guagliano, Mária Chalupová, Milan Uhríčik,
Juraj Belan,
The effect of iron content on fatigue lifetime of AlZn10Si8Mg cast alloy,
International Journal of Fatigue,
Volume 128,
2019,
105189,
ISSN 0142-1123,
https://doi.org/10.1016/j.ijfatigue.2019.105189.
Abstract: The problem with utilization of the Al-scrap as a material for casting the Al-Si alloys lies in
the fact that the scrap, unfortunately as a rule, is contaminated with iron. The current study presents
an investigation of the effect of different iron contents (0.150 and 0.559 wt%) on microstructure,
porosity and bending fatigue properties in the secondary (recycled) self-hardening AlZn10Si8Mg cast
alloy. Rotating bending fatigue tests were realized for a defined number of cycles 3 × 106 with a
stress asymmetry ratio R = −1 at room temperature. Observation by the optical and SEM microscopy
using deep etching and image analysis highlight the role of the plate/needle-like Fe-rich intermetallic
(Al5FeSi phase), formed during the solidification process. The quantitative metallography and CT
scan was used to quantify the amount of pores. The results show that Al5FeSi phases play an
important role in the low cycle region. The higher amounts of needle/plate like Fe-rich particles
(Al5FeSi) with increased porosity degraded fatigue lifetime in the short and medium life-time regime
(<106 cycles) and there was no effect or slight increases the fatigue lifetime for long life-time regime
(≫106 cycles). In the high cycle’s region are the pores more detrimental than Fe-rich phases to the
fatigue strength. Fracture surface of the fatigue specimens were analysed by SEM to characterize the
micromechanism and the initiation fracture local.
Keywords: Aluminium alloys; Fatigue limit; S-N curves; Fractography; Intermetallics
KunduruSrinivasulu Reddy,
Effect of Catalyst and Mold parameters on Collapsibility of Phenolic Urethane No-bake Sand Molds,
Volume 16, Part 2,

2019,
Pages 284-289,
ISSN 2214-7853,
Abstract: Chemically bonded no-bake molds and cores have good mechanical properties and
produce dimensionally accurate castings compared to green sand molds. Poor collapsibility property
of CO2 hardened sodium silicate bonded sand mold and phenolic urethane no-bake (PUN) binder
system, made the reclamation of the sands more important. In the present work fine silica sand is
mixed with phenolic urethane no-bake binder and the sand sets in a very short time within few
minutes. In this paper, it is focused on optimizing the process parameters of PUN binder based sand
molds like amount of catalyst, number of strokes and GFN of sand for better collapsibility using
Taguchi design. The findings were successfully verified through experiments.
Keywords: Phenolic urethane no-bake binder; Collapsibility; Reclamation
J.H. Jeon, D.H. Bae,
Effect of cooling rate on the thermal and electrical conductivities of an A356 sand cast alloy,
Volume 808,
2019,
151756,
ISSN 0925-8388,
https://doi.org/10.1016/j.jallcom.2019.151756.
Abstract: This study evaluates the effect of cooling rate on the microstructures and conduction
properties of an A356 sand cast alloy. To evaluate effect of cooling rate, computer recordable sand
mold with four step-thickness (5 mm– 20 mm) was used and microstructures of T6 heat treated
specimens with different cooling rates were observed. It was found that with increasing cooling rate,
eutectic reaction temperature shifted to lower temperature and the supercooling also increased.
Based on the coarsening model via solute diffusion, when the cooling rate increase, secondary
dendrite arm spacing decreases, providing the enhanced thermal and electrical conductivities.
Keywords: Metals and alloys; Electrical transport; Heat conduction; Microstructure
Sergey Yu. Kondrat’ev, Ekaterina V. Sviatysheva, Grigoriy P. Anastasiadi, Sergey N. Petrov,
Fragmented structure of niobium carbide particles in as-cast modified HP alloys,
Acta Materialia,
Volume 127,
2017,
Pages 267-276,
ISSN 1359-6454,
https://doi.org/10.1016/j.actamat.2017.01.043.
Abstract: The structure of niobium carbide particles in as-cast heat resistant modified HP40NbTi
alloy have been studied by light and electron microscopy, electron microprobe and X-ray diffraction.
The niobium carbide particles in the structure of the HP40NbTi alloys are a multiphase polycrystal
clusters with inhomogeneous chemical composition and crystallographic form. The boundaries
between the crystals of the carbide particle are large-angle; the disorientation angle between
crystals is 30–60°. Polycrystalline character of carbides is, probably, connected with the high thermal
stress arising at interphase boundaries in the alloy structure at primary cooling of an ingot. The
explanation of the polymorphic character of a niobium carbide cluster requires an independent
analysis on the basis of a structural and geometrical crystallography.
Keywords: Niobium carbide; Heat-resistant cast Fe-Cr-Ni-based alloys; Microstructure; Morphology

of carbide; Phase composition; Analytical electron microscopy
Dinesh Kumar, Rakesh Kumar Phanden, Lalit Thakur,
A review on environment friendly and lightweight Magnesium-Based metal matrix composites and
alloys,
2020,
ISSN 2214-7853,
Abstract: Magnesium is the lightest metal known on earth has a great potential to be used as a
structural alloy. The lightweight alloy and composite property attract the automobile and aerospace
companies and provide an alternative to replace the denser metals such as steel, cast iron, zinc
alloys and even aluminium alloys. In the present scenario of global warming and increased CO2
content, the introduction of limiting emission legislation has triggered the fascinate in magnesium
alloys and its composites. Owing to lowest density, the usage of magnesium has been increased in
the last decade and several programs related with processing, development, improvement in design
and production field are going on to minimize the emission threat over the environment. This paper
aims to discuss briefly followed by examples, the future trends, increasing use of magnesium alloys
and composites and its good environmental impacts. So, it was concluded that the overall weight
reduction of vehicle by using magnesium-based MMCs and its alloys elucidate the drastic
enhancement in its performance in terms of mechanical and tribological behavior which
consequently creates a potential for its usage in advanced manufacturing technology for automobile
and aerospace sector.
Keywords: Magnesium; Metal matrix composite; Dispersion; Automotive; Lightweight
Samir Chakravarti, Swarnendu Sen, Asish Bandyopadhyay,
A Study On Solidification Of Large Iron Casting In A Thin Water Cooled Copper Mould,
2018,
Pages 4149-4155,
ISSN 2214-7853,
Abstract: The paper presents a one dimensional transient heat transfer model of casting to
determine the temperature distribution as a function of time using FORTRAN software. Casting is
considered to be semi-infinite. In the present work, the calculation of temperatures at any point
within the casting is performed by calculating the error function. The solidification time and length of
metal solidified at different times have also been determined. It can be concluded that this
presented approach is computationally more efficient and faster.
Keywords: Casting; Solidification; Temperature distribution
Konstantinos Salonitis, Binxu Zeng, Hamid Ahmad Mehrabi, Mark Jolly,
The Challenges for Energy Efficient Casting Processes,
Procedia CIRP,
Volume 40,
2016,
Pages 24-29,
ISSN 2212-8271,
Abstract: Casting is one of the oldest, most challenging and energy intensive manufacturing
processes. A typical modern casting process contains six different stages, which are classified as
melting, alloying, moulding, pouring, solidification and finishing respectively. At each stage, high
level and precision of process control is required. The energy efficiency of casting process can be
improved by using novel alterations, such as the Constrained Rapid Induction Melting Single Shot
Up-casting process. Within the present study the energy consumption of casting processes is
analyzed and areas were great savings can be achieved are discussed. Lean thinking is used to
identify waste and to analyse the energy saving potential for casting industry.
Keywords: Energy efficiency; casting; Value Stream Mapping
Quan Wang, Lv Xiao, Wencai Liu, Haohao Zhang, Wendong Cui, Zhongquan Li, Guohua Wu,
Effect of heat treatment on tensile properties, impact toughness and plane-strain fracture toughness
of sand-cast Mg-6Gd-3Y-0.5Zr magnesium alloy,
Volume 705,
2017,
Pages 402-410,
ISSN 0921-5093,
Abstract: The tensile properties, impact toughness and plane-strain fracture toughness of sand-cast
Mg-6Gd-3Y-0.5Zr magnesium alloy were studied in different thermal conditions, including as-cast,
as-quenched and isothermal aging states. The results show that optimum heat treatment is
solutionized at 490℃ for 12h, and then aged at 212℃ for 100h. Tensile test exhibits that as-
quenched GW63 alloy shows high elongation but low tensile strength, nevertheless, aged alloy
shows higher strength but worse ductility. Impact values of GW63 alloy are 34.6, 50.9 and 20.3J/cm2
in the as-cast, as-quenched and aged states, respectively. Room temperature impact toughness is
more closely related to material ductility than strength for the studied alloy. The plane-strain
fracture toughness values of the as-cast, as-quenched and aged alloy are 16.2, 17.7 and
19.5MPam½, respectively, i.e., the improvement of 20.4% has been achieved by aging precipitation
strengthening in contrast with slight improvement of 9.3% by solid solution strengthening. In
addition, fractured characteristics after impact and fracture toughness tests were also investigated
by fracture analysis.
Keywords: Mg-Gd-Y-Zr; Heat treatment; Impact toughness; Fracture toughness; Cast magnesium
alloy
Hyun-Hee Choi, Eun-Hee Kim, Hye-Yeong Park, Geun-Ho Cho, Yeon-Gil Jung, Jing Zhang,
Application of dual coating process and 3D printing technology in sand mold fabrication,
Surface and Coatings Technology,
Volume 332,
2017,
Pages 522-526,
ISSN 0257-8972,
https://doi.org/10.1016/j.surfcoat.2017.07.035.
Abstract: A new dual coating process has been developed for complex sand mold casting using
three-dimensional (3D) printing technique. In the dual coating process, two types of polyvinyl
alcohols (PVAs) with different decomposition points were applied, unlike conventional casting
methods that use just one organic binder. Mullite bead (~200μm), mullite powder (~16μm), and
zircon flour (~43μm) were used as starting materials, which were coated with PVA aqueous solution
and then recoated with an inorganic binder. The coated powders were heat-treated at 1000°C for
1h, followed by a 3D printing process. The sample was heat-treated at 250°C for 4h to burn out the
PVA with a lower decomposition point. The heat-treated sample was dipped into the solution of the
inorganic binder composed of tetraethyl orthosilicate and sodium methoxide, which are the silica
and sodium oxide precursors, respectively. After drying at 80°C for 1h, the final heat treatment was
conducted at 1000°C for 1h to produce an organic–inorganic conversion reaction. In the case of the
starting materials composed with the same composition, as the particle size became smaller, higher
surface roughness and strength were obtained. The highest green and firing strength could be
obtained in the samples with zircon flour and mullite bead, respectively. These results confirm the
feasibility of combining a new coating process with 3D printing technology.
Keywords: Sand mold; Casting; Organic binder; Inorganic binder; Coating; 3D printing; Strength
Alfredo Anglani, Massimo Pacella,
Logistic Regression and Response Surface Design for Statistical Modeling of Investment Casting
Process in Metal Foam Production,
Procedia CIRP,
Volume 67,
2018,
Pages 504-509,
ISSN 2212-8271,
Abstract: A metal foam represents a promising material since it keeps the high mechanical
properties of the metal while reducing the weight up to 90%. Among several manufacturing
processes, the investment casting is a foundry process flexible enough to be suitable both for
stochastic and for regular foams. This paper presents an experimental determination of the
manufacturing process of metal regular foams by investment casting. The goal is to derive
experimentally an actual formability map. The use of logistic regression and response surface design
is proposed as an effective tool for determining a statistical model of the metal foam casting process.
Keywords: Metal foams; Logistic regression; Generalized linear models; Design of Experiments (DoE)
Francesco Di Benedetto, Elena Gazzano, Maura Tomatis, Francesco Turci, Luca A. Pardi, Simona
Bronco, Gabriele Fornaciai, Massimo Innocenti, Giordano Montegrossi, Maurizio Muniz Miranda,
Alfonso Zoleo, Fabio Capacci, Bice Fubini, Dario Ghigo, Maurizio Romanelli,
Physico-chemical properties of quartz from industrial manufacturing and its cytotoxic effects on
alveolar macrophages: The case of green sand mould casting for iron production,
Journal of Hazardous Materials,
Volume 312,
2016,
Pages 18-27,
ISSN 0304-3894,
https://doi.org/10.1016/j.jhazmat.2016.03.016.
Abstract: Industrial processing of materials containing quartz induces physico-chemical modifications

that contribute to the variability of quartz hazard in different plants. Here, modifications affecting a
quartz-rich sand during cast iron production, have been investigated. Composition, morphology,
presence of radicals associated to quartz and reactivity in free radical generation were studied on a
raw sand and on a dust recovered after mould dismantling. Additionally, cytotoxicity of the
processed dust and ROS and NO generation were evaluated on MH-S macrophages. Particle
morphology and size were marginally affected by casting processing, which caused only a slight
increase of the amount of respirable fraction. The raw sand was able to catalyze OH and CO2−
generation in cell-free test, even if in a lesser extent than the reference quartz (Min-U-Sil), and
shows hAl radicals, conventionally found in any quartz-bearing raw materials. Enrichment in iron and
extensive coverage with amorphous carbon were observed during processing. They likely
contributed, respectively, to increasing the ability of processed dust to release CO2− and to
suppressing OH generation respect to the raw sand. Carbon coverage and repeated thermal
treatments during industrial processing also caused annealing of radiogenic hAl defects. Finally, no
cellular responses were observed with the respirable fraction of the processed powder.
Keywords: Quartz; Hole and Al centres; EPR/ESEEM; Free radicals; Cytotoxicity; ROS; NO;
Macrophages; Health effects; Carbon coating
Martin Leary,
Chapter 13 - Binder jetting,
Editor(s): Martin Leary,
In Additive Manufacturing Materials and Technologies,

Design for Additive Manufacturing,
Elsevier,
2020,
Pages 335-339,
ISBN 9780128167212,
https://doi.org/10.1016/B978-0-12-816721-2.00013-0.
Abstract: Binder jetting provides a unique AM technology platform for the inexpensive fabrication of
high-value product with high-geometric complexity. Emerging developments in BJT technologies are
enabling the fabrication of structurally robust metallic structures; novel materials for pharmaceutical
and biological applications; and the potential to fabricate ceramics and other materials that are
potentially challenging for alternative AM technologies. Although the commercial applicability of BJT
to these material systems has matured significantly in recent years, there remains a need for
commercially focussed DFAM research teams to generate the fundamental data required for the
robust implementation of this technology. This chapter reviews these emerging opportunities and
DFAM requirements including the nascent opportunities for the application of BJT systems to
generative design applications.
Keywords: Binder jetting (MJT); Biomaterials; Ceramics; DFAM; Functional gradient; GD&T; Metals;
Polymers
Eva Tillova, Maria Chalupova, Lenka Kucharikova, Denisa Zavodska, Juraj Belan,
Effect of the laser surface treatment on structure and mechanical properties of AlZn10Si8Mg cast
alloy,
2017,
Pages 5973-5978,
ISSN 2214-7853,
Abstract: The laser surface melting/hardening is method which provides increasing mechanical
properties of secondary (recycled) Al-Si cast alloys for automotive industry. Improvement of
mechanical properties and structure of secondary aluminium alloys can often significantly increase
the lifetime of casting and reduce costs for fuel and reduction of environmental loading. Self-
hardening Al-alloys (Al-Zn-Si-Mg alloys) introduce an innovative class of light Al-alloys. AlZn10Si8Mg
alloy is used for engine and vehicle constructions, hydraulic unit and mould making without the need
of heat treatment because this alloy is self-hardened. For this study, a laser beam of Nd: YAG laser,
BLS 720, with laser power 50 and 80 W, was used. The final microstructure of Al- alloys depend on
the laser process parameters. The laser beam action on the surface of the experimental alloy has
changed the microstructure of the material. Melting area is alpha-phase with much fine columnar
dendrites morphology without the presence of Si-particles and intermetallic phases. In the transition
area, grain refinement of eutectic Si (finer and rounder Si particles) as the modify action of the laser
was observed. By increasing the laser power the microhardness of surface layers decreases. In the
surface layer (after the 80 W laser beam action), cracks due to uneven heat transfer of the material
were observed.
Keywords: AlZn10Si8Mg cast aluminium alloy; Laser hardening; Microstructure; Mechanical

properties
S. Hafenstein, E. Werner,
Direct aging of a hot isostatically pressed A356 aluminum cast alloy,
Volume 768,
2019,
138417,
ISSN 0921-5093,
https://doi.org/10.1016/j.msea.2019.138417.
Abstract: In continuation of [1], the proposed route of combined hot isostatic pressing and direct
aging for age-hardenable aluminum cast alloys does not only offer shorter processing time, but also
leads to outstanding mechanical properties. The favorable mechanical properties result from a
modified clustering behavior of magnesium and silicon atoms during pre-aging.
Keywords: Hot isostatic pressing; Direct aging; A356; Fatigue resistance; Critical cooling rate
Sandeep Nair, R. Sellamuthu, R. Saravanan,
Effect of Nickel content on hardness and wear rate of surface modified cast aluminum bronze alloy,
2018,
Pages 6617-6625,
ISSN 2214-7853,
Abstract: An investigation was carried out to study the variation of nickel content on the
microstructure, the hardness and the wear rate of surface modified cast aluminium bronze alloy. The
heat source used was gas tungsten arc for modification of the surface. The nickel was coated by
using electroplating technique on the cast aluminium bronze alloy by varying the coating thickness.
The hardness increases and the wear rate decreases for the surface modified specimen. EDAX results
confirms the presence of AlNi3 and AlNi intermetallic compounds. The result obtained by this
investigation are compared with the earlier literature.
Keywords: Cast aluminum bronze; Surface modification; Heat source; Nickel profile; Phase
formation; Functionally graded material
S. Hafenstein, E. Werner,
Pressure dependence of age-hardenability of aluminum cast alloys and coarsening of precipitates

during hot isostatic pressing,
Volume 757,
2019,
Pages 62-69,
ISSN 0921-5093,
Abstract: The application of hot isostatic pressing is often mandatory to improve the fatigue
resistance of aluminum cast alloys in order to meet the high quality requirements defined by
automotive and aircraft industries. A pressure difference of 75 MPa between heat treatment and hot
isostatic pressing affects the diffusivity and the precipitation kinetics. It is shown that the coarsening
of precipitates during hot isostatic pressing is slower compared to the coarsening of precipitates
during heat treatment. It is supposed that the high pressure within this densification process reduces
the density of vacancies and therefore decreases the diffusivity of silicon and magnesium atoms,
resulting in a lower critical cooling rate at which an oversaturated condition of dissolved silicon and
magnesium atoms within the aluminum matrix can be achieved. Thus, quenching following hot
isostatic pressing can be performed in slightly modified standard hot isostatic presses at lower
cooling rates than quenching during standard heat treatment and even then does result in high age-
hardenability of the alloy. It becomes possible to combine hot isostatic pressing and solution
annealing within a single process step.
Keywords: Hot isostatic pressing; HIP; Pressure dependent diffusivity; Aluminum castings; A356;
Fatigue resistance
Francis Froes,
19 - Combining additive manufacturing with conventional casting and reduced density materials to
greatly reduce the weight of airplane components such as passenger seat frames,
Editor(s): Francis Froes, Rodney Boyer,
Additive Manufacturing for the Aerospace Industry,
Elsevier,
2019,
Pages 419-425,
ISBN 9780128140628,
https://doi.org/10.1016/B978-0-12-814062-8.00021-2.
Abstract: Two technologies, conventional casting and additive manufacturing (AM), are combined
together in an innovative approach to result in a reduced weight component; as an example; the
passenger seat in an airliner. A complex precursor plastic assembly, produced by AM, is converted
using the lost wax process, to a metal assembly with weight lower than the conventional part. The
weight of the component can be reduced further by using a nonflammable low density magnesium
alloy. The latter alloy has already been qualified for use in the interior of commercial aircraft.
Keywords: Conventional casting; additive manufacturing; combined processes; airliner passenger

seats; lost wax process; reduced weight parts; magnesium alloys; nonburning
Michael F. Ashby, Elicia M.A. Maine,
4.23 Design Aspects of Metal Matrix Composite Usage,
Editor(s): Peter W.R. Beaumont, Carl H. Zweben,
Comprehensive Composite Materials II,
Elsevier,
2018,
Pages 554-572,
ISBN 9780081005347,
https://doi.org/10.1016/B978-0-12-803581-8.09980-X.
Abstract: Metal matrix composites (MMCs) have attractive mechanical and thermal properties
(illustrated here with material property charts) but they can be expensive. When does it make sense
to use them? This chapter examines ways to identify applications for which MMCs are well suited,
meaning that their performance is seen to have sufficient value to justify their cost. There are three
steps: and analysis of performance, an estimate of cost, and an examination of the trade-off
between the two involving a metric of value. The performance analysis leads to a set of material
indices (metrics of excellence) that can be plotted onto the material property charts, enabling
material selection. The method is illustrated by case-studies, using a contemporary compilation of
data for the mechanical and thermal properties of MMCs.
Keywords: Cost modeling; Design; Light-weight design; Material indices; Material property charts;
Material selection; Metal matrix composites; Penalty functions; Technical modeling; Trade-off
methods; Value assessment
Sunil Dutta, Suresh Kumar Reddy Narala,
Alloying criteria and investigations on the properties of novel AM series alloy fabricated using stir
casting,
2020,
ISSN 2214-7853,
Abstract: Magnesium alloys are being used in different sectors for several applications. The low
density and high strength to weight ratio have made them indispensable. However, it is observed
that Mg alloys are less preferred for the fabrication of critical and complex parts. The inferior
mechanical and corrosive properties, along with high inflammability, limit their usage for several
applications. The mechanical and physical properties can be enhanced by varying the weight
percentage of alloying elements along with an appropriate process for its development. The paper
discusses an approach for selection of the alloying elements and their weight percentage with the
help of phase diagrams, vital inputs from past literature and properties of commercially available Mg
alloys. The developed AM series alloy (Mg-7 wt%Al-0.9 wt%Mn) has shown improvement in the
mechanical properties vis-a-vis the existing AM series alloys. The elastic modulus and hardness were
observed 24.3% and 16.21% higher than the maximum values of existing AM alloys. For the
development of alloy, a systemized stir casting setup was used, which ensured uniform mixing of
alloying elements and essentially played an active role in enhancing the mechanical properties.
Keywords: Magnesium; AM alloy; Phase diagrams; Stir casting; Mechanical properties
Hüseyin Özdeş, Murat Tiryakioğlu,
On estimating high-cycle fatigue life of cast Al-Si-Mg-(Cu) alloys from tensile test results,
Volume 688,
2017,
Pages 9-15,
ISSN 0921-5093,
Abstract: Five methods to estimate fatigue life from tensile data have been compared by using four
datasets from cast Al-Si-Mg-(Cu) alloys in the literature. Results have shown that none of the five
methods provide reliable results. A new method to estimate the S-N curve from tensile data has
been developed by using the Basquin parameters from seventy-two S-N curves collected from the
literature. Analysis has shown a distinct relationship between the Basquin exponent and the ratio of
tensile elongation to ductility potential, i.e., quality index, QT. Moreover, the ratio of the Basquin
strength coefficient to tensile strength expected in castings with no casting defects has been found
to increase linearly with QT. Based on these findings, a step-by-step procedure has been introduced
to estimate the S-N curve of cast Al-Si-Mg-(Cu) alloys. The Basquin parameters estimated by using
the new method have provided more reliable fits to the same datasets tested for the five methods.
These results support the hypothesis that the minimum elongation requirement in industrial
specifications is a de facto fatigue life requirement.
Keywords: Basquin law; Fatigue life prediction; Quality index
W.A. Butler, G. Timelli, E. Battaglia, F. Bonollo,
Die Casting (Permanent Mold),
Elsevier,
2016,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.03555-4.
Abstract: The die casting process is a name given to metal casting processes that utilize metal molds
or permanent dies. There are really several distinct processes included under the general name. The
die casting process actually has three main sub-processes. These are: (1) permanent mold casting,
also called gravity die casting, (2) low-pressure die casting, and (3) high-pressure die casting. The
three processes differ mainly in the amount of pressure that is used to force the molten metal into
the die. The advantages of such a process include high production rates, exceptional dimensional
repeatability, low part costs, and less machining due to reduced casting finish stock. The great heat
transfer rate obtained by means of metal molds can further refine and improve the final cast
structure, and therefore the mechanical properties, of the castings. The disadvantages are design
limitations due to metal dies, higher initial die cost, and longer lead time for die construction and for
changes to the die caused by a casting design change.
Keywords: Foundry; Gravity die casting; High-pressure die casting; Innovative foundry processes;
Low-pressure die casting; Permanent mold
Ganesh P. Borikar, Sandip T. Chavan,

Optimization of Casting Yield in Multi-cavity Sand Moulds of Al-alloy Components,
Volume 28, Part 2,
2020,
Pages 819-824,
ISSN 2214-7853,
Abstract: To produce casting with efficient use of material, energy, lead time and manpower is very
essential to sustain in foundry industry. Mould with dense cast cavities or less number of cavities
may lead to more solidification time, poor mechanical properties and defects like shrinkage, misrun
and cold shut. It is proposed to design mould layout with selection of suitable combination of mould
size and multiple number of cavities based on temperature distribution and solidification time which
results in optimization of casting yield. Casting simulations are carried out for casting mould with
single cavity based on mould size and variation of cavity –wall distance for Al-alloy component in
green sand mould result in finding of minimum cavity wall gap. Double and multiple cavities moulds
are simulated based on cavity-wall distance value and variation of cavity-cavity distance along with
temperature distribution, solidification time and defects if any in cast part results in computing
minimum cavity-cavity distance. Applying this in mould layout design, it leads into optimum mould
layout and casting yield. AutoCAST-X1 simulation results are validated by experimentation for LM4
alloy cast in sand mould allocated with thermocouples and data acquisition system.
Keywords: Mould layout; Multicavity; Sand mould; Casting simulations; Casting yield
R. Kumar, S. Madhu, K. Aravindh, V. Jayakumar, G. Bharathiraja, A. Muniappan,
Casting design and simulation of gating system in rotary adaptor using procast software for defect
minimization,
Volume 22, Part 3,
2020,
Pages 799-805,
ISSN 2214-7853,
Abstract: This work gives an idea of creating gating system for investment casting with the help of
fascinating advancements in the casting field. In this study, advanced techniques are utilized for
creating a part named rotary adapter. This part has a complex shaped profile and needs a high
surface finish with stringent dimensional tolerance. Hence investment casting has been chosen for
fabricating. Unigraphics software was used for modelling the part and the gate system as per the
given dimensions. Then the part is imported to the Pro-CAST software for simulation. In this work
different real time parameters were given as input and the simulation was carried out. The
simulation results were analysed and the defects were identified. Different gating system has been
implemented for eliminating the defects. The process was repeated in the software and the
efficiency was proved with defect free casting.
Keywords: Investment Casting; Gating system; Computer aided design; Unigraphics; Pro-Cast
Raymond J. Donahue, Roger N. Lumley,
Chapter 6 - New Hypoeutectic/Hypereutectic Die-Casting Alloys and New Permanent Mould Casting
Alloys That Rely on Strontium for Their Die Soldering Resistance,
2018,
Pages 173-215,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.00006-0.
Abstract: This chapter provides an overview of a range of new aluminium alloy compositions for
high-pressure die casting and permanent mould casting that contain strontium (Sr) to impart
enhanced processability and mechanical properties. The Sr works to reduce or eliminate die
soldering in high-pressure die-cast alloys, such as 367, 368, B360, and F380. Similarly, Sr is
advantageous in the preparation of permanent mould castings because the coating on the moulds is
not adversely influenced by the molten metal. The findings suggest the coating may be able to be
eliminated altogether. Here we highlight the newly proposed and registered alloy compositions with
explanations for the efficacy of Sr in the various alloys developed. Examples of application to
structural die castings are provided and future directions for increasing competitiveness
demonstrated.
Keywords: High-pressure die casting; Die casting; Permanent mould casting; Strontium; Structural
die castings; Mercalloy; A367; A368; B360; F380
R. Singh, M. Chhabra,
Three-Dimensional Printing,
Elsevier,
2017,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.04167-9.
Abstract: Among the additive manufacturing techniques, three-dimensional printing (3DP) is a

relatively new technique that offers the ability to produce a variety of part geometries using
different powder materials and binders. A novel rapid casting (RC) solution based on the 3DP process
has been developed by ZCorp for direct printing of pattern-less complex shell molds with a
proprietary mold material (ZCast501 powder) and binder (Zb56) for casting of nonferrous materials.
The process is known as ZCast Direct Metal Casting. The literature survey conducted reveals that the
ZCast RC solution is effective in obtaining cast technological prototypes in relatively short times and
with low cost, as compared to other pattern-less RC solutions, with dimensional tolerances that are
completely consistent with metal casting processes. ZCast501 powder is a patented casting material
of ZCorp and the recommended shell mold wall thickness range is a minimum of 12 mm and a
maximum of 25.4 mm for producing castings. Although ZCast RC solution is a proprietary technology
of ZCorp, high cost is involved in making the shells even up to the minimum recommended 12-mm
thickness. The cost factor is one of the major barriers to enhancing the application domain of ZCast
into traditional casting methods, especially in small-scale foundries. The aim of this study is to
explore the means for generating RCs using the ZCast process.
Keywords: Hardness; Three-dimensional printing; Z cast process
Denisa Závodská, Eva Tillová, Ivana Švecová, Lenka Kuchariková, Mária Chalupová,
Secondary cast Al-alloys with higher content of iron,
2018,
Pages 26680-26686,
ISSN 2214-7853,
Abstract: The use of secondary aluminium cast alloys can reduce significantly the production costs of
a casting, are cheaper and their production requires much less energy and generates less CO2
emissions. But secondary Al-alloys (produced from Al-scrap) contain higher background Fe levels
than the primary metal. The article describes the evaluation of Fe-rich phases in secondary
AlSi7Mg0.3 cast alloys with amount 0.12; 0.45 and 0.65 wt. % of Fe. Higher content, as 0.3-0.5 wt. %
of Fe, causes first of all formation of Fe- phases (needle-like Al5FeSi and skeleton-like
Al15(FeMg)3Si2). First of all long and brittle Fe-platelets (needles as they appear in the
microstructure) have influence on the formation of porosity and increase the dimensions of the
casting defects. In experimental material was observed, as the iron content increases, the volume
fraction of Fe-rich intermetallic phase’s increases too. A higher percentage of iron occurred to the
progressive lengthening of a needle-like Fe-phase, Al15(FeMg)3Si2 phases was transformed into
Al5FeSi phase; average pore sizes gently decreased, but maximal pore size increased.
Keywords: Secondary aluminium cast alloy; Microstructure; Porosity; Fe-rich intermetallic phases
H.S. Jiang, M.Y. Zheng, X.G. Qiao, K. Wu, Q.Y. Peng, S.H. Yang, Y.H. Yuan, J.H. Luo,
Microstructure and mechanical properties of WE43 magnesium alloy fabricated by direct-chill

casting,
Volume 684,
2017,
Pages 158-164,
ISSN 0921-5093,
Abstract: High quality WE43 magnesium alloy ingots with diameter of 500mm are successfully
fabricated by direct-chill (DC) casting. The alloying elements distributed almost homogeneously
across the large ingot. With the average grain size decreasing from the center to the edge of the
ingot, the mechanical properties are improved gradually. After solution treatment at 525°C for 8h,
the Mg14Nd2Y phases distributing along the grain boundaries are well dissolved into matrix. The
direct-chill (DC) casting ingot exhibits remarkable age-hardening response from 85Hv to 117Hv after
T6 treatment at 250°C. The T6 peak-aged sample exhibits ultimate tensile strength of 274MPa, yield
strength of 215MPa and elongation to failure of 3.4%, which are higher than those of sand-cast and
permanent mold cast WE43 alloys. The large amount of nano prismatic β′ and β1 phases
precipitated during T6 treatment contribute to improved strength of the WE43 alloy.
Keywords: WE43 alloy; Direct-chill casting; Microstructures; Mechanical properties; Age-hardening
Arnob Bormudoi, Masahiko Nagai,
Perception of risk and coping capacity: A study in Jiadhal Basin, India,
International Journal of Disaster Risk Reduction,
Volume 21,
2017,
Pages 376-383,
ISSN 2212-4209,
https://doi.org/10.1016/j.ijdrr.2017.01.015.
Abstract: The River Jiadhal in North East India experiences huge siltation due to a process of
landslides and erosion coupled with heavy rainfall. This normal phenomenon is translated into a
disaster when the river breaches the embankments and the villages in the floodplains of the lower
basin experience floods. These floods carry highly silted waters and when they leave the floodplains,
the agricultural lands remain dumped with sterile sands which prevent the farmers to practice their
annual farming activities. The two major communities living in the lower basin have to force
themselves to live with this new disaster. This paper investigates the role of perception in their
ability to cope with the disaster. Questions were asked about the primary cause of the disaster they
perceived to be and this was related to their ability to cope. It was found that when the respondents
perceived the cause as understandable and visible, their coping was better. On the other hand when
they perceived the cause to be invisible and hidden from their realm of understanding, their coping
was low.
Keywords: Risk perception; Coping capacity; Floods
Eva Anglada, Antton Meléndez, Iban Vicario, Jon Kepa Idoiaga, Aitz Mugarza, Ernesto Arratibel,
Prediction and validation of shape distortions in the simulation of high pressure die casting,
Journal of Manufacturing Processes,
Volume 33,
2018,
Pages 228-237,
ISSN 1526-6125,
https://doi.org/10.1016/j.jmapro.2018.05.019.
Abstract: The use of the thermomechanical simulation is very infrequent in the metal casting
industry although the associated results are really useful for the manufacturing process. The main
reasons are the complexity, the long calculation times and the difficulties to interpret the results.
The parts manufactured by metal casting processes cool from its filling temperature to ambient,
which causes a certain stress-strain state. Although the stress levels might be significant, the main
worry of the foundrymen is usually the shape distortion. That is, the mismatches between the
desired dimensions and the real ones. The problem is that the results obtained from numerical
simulation are not directly useful to cover this industrial necessity. This work presents the prediction
obtained using the thermomechanical simulation for the final dimensions of a component
manufactured in aluminium alloy by high pressure die casting (HPDC) and its validation with the final
dimensions of the manufactured component. The methodology established to forecast the
mismatches with the reference geometry is also detailed, as it may be useful to encourage the use of
this type of simulation in the metal casting industry.
Keywords: Numerical simulation; Finite elements; Thermal stress; Shape distortion; HPDC; Aluminum
alloy
Xue Han, Zhenpu Zhang, Yuming Pan, Gary C. Barber, Hongyu Yang, Feng Qiu,
Sliding Wear Behavior of Laser Surface Hardened Austempered Ductile Iron,
2020,
ISSN 2238-7854,
Abstract: This study describes the laser surface hardening process effect on microstructures
produced and their wear behavior. Ductile iron samples were austempered at three different
austempering temperatures: 232°C/288°C/398°C respectively. Then, the laser surface hardening
process was applied on each sample. Different laser gaps were designed: 1.5mm/3mm/4mm. The
microstructures were observed using optical microscopy and tribo-tests were run using a UMT-3
tribo tester. A Rockwell hardness tester was used to measure the hardness after heat-treatment.
Optical microscopy and SEM were used to observe the different microstructures and their
distribution on the worn surface. The results showed that the laser processing generated ledeburite,
martensite, tempered bainite, or bainite microstructures. Vickers hardness tests were carried out on
these microstructures. The original needle-like microstructures were observed on the samples with
4mm laser gap but not with 1.5mm or 3mm laser gap. This is because part of the 4mm laser gap is
beyond the laser heat effected zone. Generally, severe ploughing wear and smearing wear were
observed on the tempered bainite zone but not the bainite zone. Debris was generated during the
tribo-tests and led to three body abrasive wear which not only resulted in higher wear loss, but also
polished the worn surface.
Keywords: Laser surface hardening; Austempering process; Wear behavior; Debris
Jiangwei Liu, Sindo Kou,
Crack susceptibility of binary aluminum alloys during solidification,
Acta Materialia,
Volume 110,
2016,
Pages 84-94,
ISSN 1359-6454,
Abstract: Cracking can occur during solidification in welding and casting. The present study
attempted to deal with some fundamental questions regarding the susceptibility to cracking during
solidification. How does the phase diagram affect the crack susceptibility? Can back diffusion occur
in welding? How is the dihedral angle related to bridging between grains? To help answer the
questions, the maximum |dT/d(fS)1/2| (T is temperature and fS fraction solid) was calculated,
whose validity as the crack susceptibility index was verified recently. To deal with curved solidus and
liquidus lines (i.e., variable equilibrium segregation coefficient k), fS was calculated as a function of T
by numerical integration instead of by a simple analytical equation for constant k. Based on the
secondary dendrite arm spacing λ2 in common Al arc welds and the λ2−tf data of Al alloys (tf is local
solidification time), it was shown that back diffusion can occur in Al arc welding. Binary Al alloy
systems were investigated over wide ranges of the eutectic temperature TE (229–548 °C) and k
(about 0–0.87 at TE). It was shown that with a very low TE the crack susceptibility can still be
relatively low if k is very high at TE to increase the effect of back diffusion on crack susceptibility
reduction, consistent with the lower crack susceptibility of Al-Mg and even Al-Zn than Al-Cu. With
both a very low TE and a very low k at TE, however, the crack susceptibility can be very high,
consistent with the severe crack susceptibility of Al-Sn. The effect of the curvature of the liquidus
and solidus lines on the crack susceptibility was shown. A possible link between the dihedral angle
and bridging between grains was also shown.
Keywords: Solidification cracking; Hot tearing; Aluminum alloys; Welding; Back diffusion; Casting; Al-
Cu; Al-Mg; Al-Zn; Al-Sn; Dihedral angle; Dendrite arm spacing
Guangyu Li, Wenming Jiang, Feng Guan, Junwen Zhu, Haixiao Jiang, Zitian Fan,
Effect of insert materials on microstructure and mechanical properties of Al/Mg bimetal produced by
a novel solid-liquid compound process,
Volume 47,
2019,
Pages 62-73,
ISSN 1526-6125,
Abstract: A novel lost foam casting solid-liquid compound method was developed for the
preparation of the A356 aluminum alloy/AZ91D magnesium alloy bimetal (Al/Mg bimetal), and the
effect of insert materials on microstructure and mechanical properties of the Al/Mg bimetal was
studied in this paper. Obtained results indicated that the insert materials played a great role in the
bonding of the Al/Mg bimetal. The Al/Mg bimetal with a defect-free and uniform metallurgical
interface was achieved by use of the A356 aluminum alloy solid insert. With an optimized parameter
in the condition of the AZ91D magnesium alloy solid insert, the Al/Mg bimetal also obtained a
metallurgical bonding. Nevertheless, the crack defects were always found in the interfaces of the
bimetallic samples produced with the AZ91D solid insert. The formation mechanism of the crack
were proposed by stress distribution, thermodynamics and intermetallic compounds (IMCs)
analyses. The microstructures exhibited that the interfaces of the bimetallic samples prepared with
different insert materials were constituted by Al3Mg2+Mg2Si layer, Al12Mg17+Mg2Si layer as well
as Al12Mg17+δ-Mg eutectic layer. The Al/Mg bimetal produced with the A356 solid insert possessed
a much higher bonding strength compared to the bimetal obtained with the AZ91D solid insert,
whereas their hardnesses were basically same. The fractured samples produced with different insert
materials showed brittle fracture morphologies, and the fractures primarily occurred between the
Al3Mg2+Mg2Si layer and Al12Mg17+δ-Mg eutectic layer.
Keywords: Compound casting; Al/Mg bimetal; Insert materials; Microstructure; Mechanical

properties; Crack
Akira Matsushita, Tomoaki Nakazawa, Toshimitsu Okane, Makoto Yoshida,
Crack prediction for a partially solidified lead-free bronze casting using thermal stress analysis,
Volume 249,
2017,
Pages 46-56,
ISSN 0924-0136,
Abstract: For crack prediction in permanent mold casting of lead-free bronze, elasto-viscoplastic and
elasto-plastic thermal stress analyses were performed and compared with the casting tests. The
elastoviscoplastic model was constructed by the method which enables to determine rheological
properties without steady state stress in experiments. Maximum deviatoric principal (only by the
elastoviscoplastic analysis) and hydrostatic stress were in reasonable agreement with the locations
of cold cracking and hot tearing in the casting tests, respectively. It was suggested that considering
the rheological properties of semi-solid alloys was important especially to predict cracks during and
after solidification
Keywords: Casting; Cold cracking; Copper; Hot tearing; Semi-solid; Solidification
Karthick Srinivasan, C.S.K. Siddharth, L.V. Arun Kaarthic, M. Thenarasu,
Evaluation of Mechanical Properties, Economic and Environmental Benefits of Partially Replacing

Silica Sand with Biomass Ash for Aluminium Casting,
2018,
Pages 12984-12992,
ISSN 2214-7853,
Abstract: Green sand molding for metal casting makes up around 70% of the total castings produced
worldwide. Silica sand mining and its transportation to foundries harm the ecosystem, rendering this
metal casting process environmentally unsustainable. This research paper introduces a novel
method of partially replacing the silica sand with biomass ash - a waste product of combustion in
various processes such as domestic and commercial cooking. Suitable experiments were conducted
to measure the effects of mixing progressively higher proportions of biomass ash (from 9% to 30%)
in conventional green sand mold. The molds then underwent tests for the evaluation of
technological properties such as green compression strength, green shear strength, permeability and
compaction. After suitable pattern making, the molds were tested for casting using LM 24
Aluminium Alloy. The obtained Aluminium Alloy castsings underwent micro hardness tests and micro
structure study. The results obtained for biomass ash molding sand were compared with the
corresponding tests results for conventional sand mold casting and the results were satisfactory.
Keywords: Biomass ash; Green sand mold
Alok Ranjan Pradhan, Sarojrani Pattnaik, Mihir Kumar Sutar,
Improving the Filling System for a Defect Free Casting: A Review,
Volume 18, Part 7,
2019,
Pages 2887-2892,
ISSN 2214-7853,
Abstract: With the evolution of modern technologies, now a day’s, it is very convenient to find out
the primary causes of casting defects. Before going to actual practice, the flow behaviour can be
simulated with the help of computer and input parameters can be optimized for obtaining defect
free castings. The major defects in casting leading to early failure are due to air porosity and surface
turbulence caused by the flow velocity and nature of flow of molten metal. Thus, it is needed to
modify the gating system to get the optimised velocity and no surface fluctuations. In this review
article, the flow behaviour of some improved gating systems such as submerged gating, uphill filling
and trident gating systems have been reviewed and they were found to be turbulent free and the
defects due to the surface turbulence have been considerably reduced.
Keywords: Gating system; Surface turbulence; Submerged gating system; Uphill filling system;
Trident gating system
Merton C. Flemings,
MIT studies on dendritic solidification from 1950 to 1970,
Journal of Crystal Growth,
Volume 530,
2020,
125246,
ISSN 0022-0248,
https://doi.org/10.1016/j.jcrysgro.2019.125246.
Abstract: A number of circumstances combined in the years following the Second World War to
bring about much increased interest in solidification from both engineering and science
perspectives. These included the advent of new casting processes such as continuous casting,
superalloy casting for engine parts, silicon crystal growing for the electronics, and new basic
understandings including the advent of constitutional supercooling. This paper recalls developments
in solidification processing during the two decades following 1950, focusing primarily on work at MIT
in those years.
Keywords: A1. Solidification; A1. Segregation; A1. Dendrites; A1. Heat transfer; A1. Characterization
Denisa Medvecká, Eva Tillová, Mária Chalupová, Lenka Kuchariková, Denisa Zavodská,
Mechanical properties of self-hardening Al-Zn-Si cast alloy with higher content of Fe,
2020,
ISSN 2214-7853,
Abstract: Recycled (scrap-based) aluminium alloys are commonly referred to as secondary. In cast
aluminium components, brittle and needle/plate-like Fe-rich particles are common constituents that
normally degrade the mechanical properties. Secondary Al-alloys contain higher background Fe
levels than the primary metal and is currently no economical way of removing Fe. Therefore, it is
important to gain knowledge on the effect of Fe-rich particles on mechanical properties in order to
expand the use of more environmental friendly secondary alloys. Present study examines the effect
of iron phases Al5FeSi in secondary self-hardening AlZn10Si8Mg cast alloys A (0.15 wt% Fe) and B
(0.56 wt% Fe) on microstructure, mechanical properties (UTS, YTS, ductility and Brinell hardness) and
fracture surfaces. For observation and identification of microstructural components as Si and Fe-
phases standard (0.5% HF) and deep etching (HCl) were utilized. The results showed that the eutectic
silicon in alloy B has a slightly finer structure (probably due to slightly higher cooling rate used); with
increasing of the Fe content, the length and number of Al5FeSi phases increased too; mechanical
properties slightly decreased (YTS from 175 MPa to 166 MPa and UTS from 187 MPa to 178 MPa).
The fracture surface of experimental samples mainly consists of transcrystalline ductile fracture (the
transcrystalline cleavage fracture was not detected as much). In alloy A dominant is the
transcrystalline ductile fracture in the eutectic and on the α-matrix and in alloy B is dominant the
transcrystalline cleavage fracture.
Keywords: Secondary aluminium cast alloys; Fe-rich intermetallic phases; Fracture; Mechanical
properties; Microstructure
R.U. Lomte, S.P. Bhosle, P.M. Ambad, R.A. Gaikwad,
Reliability Improvement for TSR Machine of Banburry Mixer using Plant Optimization Process,
Volume 20,
2018,
Pages 440-445,
ISSN 2351-9789,
Abstract: This paper is presented on project work carried out on critical machine Twin Screw Roller
Die which is part of Banbury Mixer. To identify the failures, machine deterioration and reduce
change over time, plant optimization technique is implemented to restore equipment to its proper
condition as well as proper training was given to operators about the technique The main objective
of the paper is to improve key performance indicator by increasing MTBF and decreasing MTTR using
Reliability Excellence pillar of plant optimization. Repeated breakdown were identified and analyzed
along with critical parts. The root cause of machine part breakdown were identified and analyzed by
method of why-why analysis. This turn helped to develop new preventive maintenance checklist for
machine. Root cause analysis method is used to prevent failure of equipment before occurs.
Keywords: Breakdown; downtime; Preventive Maintenance; Lubrication checklist; Root Cause

analysis; why-why analysis
H. Westengen, H.M.M.A. Rashed,
Magnesium Alloys: Properties and Applications,
Elsevier,
2016,
,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.02568-6.
Abstract: Being the lightest structural material, the scope of use of magnesium and its alloys has
increased several-fold over the last decade. New alloys are being prototyped in cast and wrought
form. These alloys are used in civil aircraft industries, motor vehicles and as well as in military
applications. Recent trend in light-weight electronic gadgets had helped magnesium alloys to receive
positive comeback and are now used as housings for notebooks, cameras, etc. Use of magnesium
has invoked a potential interest even in biomedical applications.
Keywords: Alloy development; Cast alloys; Magnesium alloys; Magnesium alloy applications;
Wrought alloys
Index,
2017,
Pages 517-525,
ISBN 9780080994314,
https://doi.org/10.1016/B978-0-08-099431-4.00022-1.
Gabor Takacs,
Three inventions shaping the future of ESP technology,
Journal of Petroleum Science and Engineering,
Volume 182,
2019,
106330,
ISSN 0920-4105,
https://doi.org/10.1016/j.petrol.2019.106330.
Abstract: This paper presents a review of the three most significant inventions that will enable future
ESP installations to be more efficient and use less power while handling extreme well conditions
better than today's systems. It will be shown how these revolutionary ideas will expand the
application ranges of future ESP systems and why they soon become part of the daily routine. The
novel method of making pump stages using powder metallurgy techniques, instead of the universally
used sand molded casting, allows producing pump stages with more complex geometries, improved
tolerances, and surface finishes. Such stages provide higher pump efficiencies and are dynamically
more balanced as well. The conventional ESP motor is a 3-Phase AC induction motor; the permanent
magnet motor introduced recently provides 3–4 times greater power in a shorter constructional
length. With motor efficiencies above 90% and extremely high power factors, PMMs develop much
lower heat. If driving ESP pumps, the required number of pump stages is much reduced and the use
of as smaller downhole cables is possible. Therefore, PMMs will surely be the future prime movers
for ESP installations providing greater system efficiencies than the AC motors currently used. The
recently patented V-Pump can replace the ESP centrifugal pump; it is a helico-axial pump whose
rotor and stator are fitted with an extremely big gap. The produced fluid spirals upward in the rotor
channels while a fluid seal is created in the radial gap between the rotor and stator. Pump efficiency
is not affected by the size of the gap and the pump can easily handle the most detrimental
conditions for conventional ESP pumps: high fluid viscosities, extremely high solid concentrations,
and high gas-liquid ratios. Having these desirable features, it can be predicted that usage of the V-
Pump will become more and more popular in the future.
Keywords: ESP; Inventions; Electrical submersible pumping; Latest developments; Oil well;
Production
J. Jensin Joshua, A. Abraham Eben Andrews,
Design of experiments to optimize casting process of aluminum alloy 7075 in addition of TiO2 using
Taguchi method,
2020,
ISSN 2214-7853,
Abstract: Design of Experiments is the design of any task that aims to describe the variation of data
under conditions that are hypothesized to reflect the variation. In this research, we analyzed various
significant process parameters of the casting of aluminium alloy 7075 with TiO2 addition. An
experiment was made to obtain an optimal setting for casting parameters to yield the optimum
casting of aluminium alloy 7075. The process parameters are considered as melting temperature,
filling time of the mould and the solidification time. The effect of selected parameters of casting
towards the optimum cast of aluminium alloy 7075 will be accomplished using the Taguchi method.
The purpose of adding titanium dioxide is to further enhance the physical properties like the
hardness and its wear resistance of aluminium alloy 7075. The Taguchi method is used here to bring
out the best settings possible for casting that depends on the above parameters. Minitab software is
used to apply the Taguchi method.
P.D. Ingle, B.E. Narkhede,
A Literature Survey Of Methods To Study And Analyze The Gating System Design For Its Effect On
Casting Quality,
2018,
Pages 5421-5429,
ISSN 2214-7853,
Abstract: For the optimum design of gating system, the study of filling process is of great significance
since it directly affects casting quality. The goal of proper mould filing cannot be achieved without
proper gating design which influences the flow pattern, further affects the temperature distribution
and modifies the progression of solidification. But it is not only expensive but difficult to observe the
molten metal flow in the mould directly due to the opacity of sand mould.For the study and analysis
of flow of molten metal through the gating system and into the mould cavity, many researchers have
tried various techniques which can be broadly classified as direct observation method and through
modelling the process by water analogy or by computational modelling.To get accurate and
dependable prediction of the subtle transient events, one has to make a judicious combination of
both methods for casting with an alloy system. Many researchers attempted to use numerical
simulation techniques to analyse the molten flow through the gating system, which has an
advantage to accurately predict subtle transient events and gain more profound information about
the behaviour of metal stream. Considerable materials are available in literature to understand the
influence of gating system design on mould filling using various techniques of direct observation
validating the given design of gating system by using real time X-ray radiography to observe the flow
of molten metal in a sand mould, or by using contact wire sensing method along with computerized
data acquisition, or by using water analogy method to observe the flow of water in a transparent
mould.Also few researchers attempted optimization of gating system in casting to control defects
and maximize the effective yield of the cast products. This paper comprehensively review the
available literature for various techniques to study, analyse and predict the flow behaviour of the
melt in order to minimize the related defects arising due to melt flow and also increasing the
effective yield of the casting with minimum effect on its quality.
Keywords: Gating Design; Flow Analysis; Numerical Simulation; Water Modelling; Direct Observation;
Contact time Method; Optimization Techniques
Janko Slavič, Matjaž Mršnik, Martin Česnik, Jaka Javh, Miha Boltežar,
Chapter 9 - Harmonic vs. random excitation,
Editor(s): Janko Slavič, Matjaž Mršnik, Martin Česnik, Jaka Javh, Miha Boltežar,
Vibration Fatigue by Spectral Methods,
Elsevier,
2021,
Pages 155-161,
ISBN 9780128221907,
https://doi.org/10.1016/B978-0-12-822190-7.00017-7.
Abstract: Ch. 9 presents an experimental approach accelerated vibration fatigue testing with random
and harmonic excitation. A comparison of experimental and numerical results is also given.
Keywords: experiment; harmonic excitation; random excitation; Y-sample
G.T. Kridli, P.A. Friedman, J.M. Boileau,
Chapter 7 - Manufacturing processes for light alloys**Updated by J.M. Boileau and P.K. Mallick.,
2021,
Pages 267-320,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00007-0.
Abstract: This chapter highlights the manufacturing processes used to fabricate lightweight
automotive parts. The chapter provides an overview of aluminum and magnesium alloys, describes
design issues and manufacturing challenges for light alloys, and highlights commonly used metal
forming and casting processes. It also identifies enablers required to significantly increase the use of
light alloys in the production of automotive parts and describes some of the promising metal
forming technologies for light alloys.
Keywords: Light alloys; metal forming processes; metal casting processes
R. Venkata Rao, Dhiraj P. Rai,

Optimization of Selected Casting Processes Using Jaya algorithm,
Volume 4, Issue 10,
2017,
Pages 11056-11067,
ISSN 2214-7853,
Abstract: The performance of casting processes depends upon a number of input parameters. To
produce a defect free casting with high productivity it is important to select the best combinations if
process parameters. Therefore, the objective of this work is to improve the performance of squeeze
casting process, continuous casting process and die casting process through process parameter
optimization using Jaya algorithm. In addition, a variant of Jaya algorithm with quasi oppositional-
based-learning is proposed. The optimization problems for each of the above mentioned casting
processes are formulated and solved using Jaya algorithm and QO-Jaya algorithm and the results are
compared with the results of GA, SA, PSO and TLBO algorithms.
Keywords: Optimization; casting processes; oppositional-based-learning; Jaya algorithm
Anupam Das,
Multivariate statistical monitoring strategy for an automotive manufacturing part facility,
Volume 27, Part 3,
2020,
Pages 2914-2917,
ISSN 2214-7853,
Abstract: In this article an attempt has been made to devise a statistical monitoring strategy based
on multivariate projection based method. The projection based method that was employed for
development for the strategy was Principle Component Analysis (PCA) which is primarily used as a
dimension reduction technique. The strategy thus devised was applied to a connecting rod
manufacturing facility. Connecting rods are primarily produced via hot forging process accompanied
by a litany of other finishing processes. Each process in turn is characterized by their own set of
process characteristics which requires simultaneous monitoring so as to produce good quality end
product. Simultaneous monitoring of characteristics and moreover correlated characteristics can be
achieved via the employment of multivariate statistical control technique. Projection based
techniques viz., PCA and partial least squares regression fall under special category MSPC techniques
owning to their ability to deal with highly correlated and ill-conditioned data. The PCA based
monitoring strategy thus devised in this article was found to be efficient in detection of faults
indicated by out-of-control observations and thus aiding in producing good quality connecting rods.
Keywords: Multivariate projection based method; Principal Component Analysis; Multivariate

statistical processes control; Connecting rod; Monitoring strategy
Wilson R. Nyemba, Ranganai T. Moyo, Charles Mbohwa,
Optimization of the casting technology and sustainable manufacture of 100mm grinding balls for the
mining Sector in Zimbabwe,
Volume 21,
2018,
Pages 68-75,
ISSN 2351-9789,
Abstract: Excess waste is common in foundry die-casting processes due to a number of factors.
These include sizes of runners and gates, heat and pressure that may result in expanded sizes of
runners and oversized products that require more time for fettling after solidifying and removal from
moulds. The gating system, runners and handling of the molten metal play critical roles in the
efficiency and productivity of casting processes. This research was prompted and motivated by one
of Zimbabwe’s largest foundries’ desire to reduce product costs brought on by drops in sales caused
by more affordable imports. The research focused on the company’s major challenges such as excess
waste and the long hours spent in manual fettling. This was done by optimizing the casting
technology through the redesign of the gating systems for the sustainable manufacture of 100 mm
grinding balls for the mining sector. The conventional casting approach, which is often unsystematic,
was optimized using computational fluid dynamics and resizing of the gating system for the efficient
and sustainable production of grinding media. Reductions in waste from 37% to 24% were
anticipated based on the redesign, thus marginal reductions in the cost of grinding balls.
Keywords: Die-casting; foundry; fettling; gating system; mould; optimization; sustainable production
D.M. Wankhede, B.E. Narkhede, S.K. Mahajan, C.M. Choudhari,
Influence of pouring temperature and external chills on mechanical properties of aluminum silicon
alloy castings,
2018,
Pages 17627-17635,
ISSN 2214-7853,
Abstract: To produce a sound casting it is necessary to control a heat transfer rate, which induces
directional solidification. The proper design of gating system, placement of riser and application of
external chill helps to obtain a higher solidification rate. The simulation work has been carried out
with AutoCast-X1 software for obtaining correct design parameters. Experimental work has been
carried out in the foundry. The casting and methoding parameters such as pouring temperature and
chill thickness are considered for the experimental work. Use of end chills during casting not only
favours directional solidification but also accelerates solidification. Faster cooling rates give rise to
finer structures and improved mechanical properties. In this work, attempts have been made to
obtain the cooling rate of aluminum-silicon alloy casting using mild steel as a material for external
chills. It has been observed that chill has a significant impact on properties of the cast specimens.
The finer grain structure and better mechanical properties were observed by controlling pouring
temperatures and varying the chill sizes. The scheme for design of experiment has been set up and
experiments were conducted at three different levels. Results were evaluated to optimize the
casting parameters. This investigation has help in improving ultimate tensile strength and hardness
of castings with an application of external mild steel chills
Keywords: Pouring temperature; Chills; Mechanical properties; Cooling rate; Aluminum silicon alloy
casting
Seungmun Jung, Changwoo Jeon, Yong Hee Jo, Won-Mi Choi, Byeong-Joo Lee, Yong-Jun Oh, Seongsik
Jang, Sunghak Lee,
Effects of tungsten and molybdenum on high-temperature tensile properties of five heat-resistant

austenitic stainless steels,
Volume 656,
2016,
Pages 190-199,
ISSN 0921-5093,
Abstract: Heat-resistant austenitic stainless steels have been intensively used worldwide for turbo-
chargers requiring excellent high-temperature properties to sustain their structures at very high
exhaust gas temperatures. Five heat-resistant austenitic stainless steels were fabricated by varying
contents of W and Mo, and their high-temperature tensile properties were investigated by analyzing
phases (liquid, austenite, ferrite, and carbides) existing at high temperatures. Effects of replacement
of expensive alloying element, W, by Mo or reduction in W were also examined. The increase in
contents of W and Mo resulted in linearly increased volume fractions of M7C3 and total carbides,
while the volume fraction of MC carbide hardly showed any relation, and showed a good
correspondence with high-temperature yield and tensile strengths. The steel where 2wt% of W was
replaced by 2wt% of Mo showed the best 900°C-tensile properties, thereby confirming the
successful achievement of partly replacement of W by Mo. In addition, the low-W-containing steels
showed excellent 900°C-tensile properties, which also indicated that the reduction in 1–2wt% of W
was accepted for saving costs of alloying elements.
Keywords: Austenitic stainless steel; High-temperature tensile properties; Carbide; Tungsten

equivalent; Equilibrium phase diagram; Thermodynamic calculation
Chintan Morsiya, Mayur Sutaria, Sandip Patel,
Influence of the heat treatment on the surface bioactivity of investment cast SS 316L,
2020,
ISSN 2214-7853,
Abstract: In present paper, an attempt has been made to assess the effect of solution annealing on
investment cast stainless steel 316L (Low carbon) material’s tensile strength, microstructure and also
to assess surface bioactivity of heat treated SS 316L. Solution annealing at 1020 °C dissolved sigma
phase into austenite matrix and also reduces ferrite phase by 83.36%, which result into negligible
magnetism. Further investigation has been carried out by in-vitro testing, to assess surface
bioactivity. It has been observed from SEM and EDX analysis that heat treated SS 316L has apatite
formation ability, a compatibility with body fluid.
Keywords: Investment casting; Biomaterial; SS 316L; Solution annealing; In-vitro treatment
F.H. (Sam) Froes,
Additive manufacturing of titanium components: An up-date,
Metal Powder Report,
Volume 73, Issue 6,
2018,
Pages 329-337,
ISSN 0026-0657,
https://doi.org/10.1016/j.mprp.2018.10.001.
Abstract: This paper is an up-date of a paper published in Metal Powder Report almost two years
ago (Dutta and (Sam) Froes, 2017). The present paper presents the various methods which have
been developed for the production of AM components, emphasizing those which have been used for
titanium parts. This is followed by a presentation of recently developed processes for the production
of spherical powder feed-stock for Additive Manufacturing including an innovative low cost non-melt
approach. Consideration is then given to the effects of surface roughness and defects of AM parts. A
summary of some of the titanium parts which have been fabricated by AM in the past few years in a
variety of segments of the economy is then discussed.
Zhiyu Chang, Yujuan Wu, Xiangwen Heng, Ning Su, Yu Zhang, Baoyi Yu, Li Zheng, Xiaohong Shao,
Liming Peng,
Characterization of microstructure and nanoscale phase in Mg-15Gd-1Zn (wt.%) alloy fabricated by

rotating magnetic field casting,
Materials Characterization,
Volume 170,
2020,
110660,
ISSN 1044-5803,
https://doi.org/10.1016/j.matchar.2020.110660.
Abstract: An Mg-15Gd-1Zn (GZ151, wt.%) alloy was fabricated by rotating magnetic field (RMF)
casting, and the microstructures were compared with those produced by conventional gravity
casting (CGC). The results show that the RMF can cause significant dendritic fragmentation and
resultant grain refinement of the as-cast alloy. Compared with the CGC, the RMF makes the
distribution of secondary eutectic phase-(Mg, Zn)3Gd more uniform, but does not affect the phase
types. Furthermore, the RMF contributes to the formations of kinks of long-period stacking ordered
(LPSO) structures and < c + a > dislocations, which originate from the stress and strain caused by
Lorenz force. Under the solution-treated condition, the RMF casting alloy presents higher content
and larger size of X phases than those of CGC alloy. Interestingly, for the first time, some curved
chain-like structures consisting of short rod-like nanoscale phases were found in the grains. The
short rod-like nanoscale phase is composed of many γ' precipitates confined in an elliptical domain.
Keywords: Mg-Gd-Zn alloy; Rotating magnetic field (RMF); Microstructure; Long-period stacking
order (LPSO) structures; Dislocation; γ' precipitate
Hrishikesh Shastri, A.K. Mondal, K. Dutta, H. Dieringa, S. Kumar,
Microstructural correlation with tensile and creep properties of AZ91 alloy in three casting
techniques,

Volume 57,
2020,
Pages 566-573,
ISSN 1526-6125,
Abstract: The relationships among microstructure, tensile and creep behaviour of the AZ91 Mg alloy
produced by three different casting techniques have been investigated. All the as-cast alloys consist
of primary Mg (α-Mg) and β-Mg17Al12 phases. The volume fraction of β-Mg17Al12 phase is the
highest in the gravity casting (GC), intermediate in the squeeze-casting (SC) and the lowest in the
high-pressure die-casting (HPDC). The best tensile properties are exhibited by the SC alloy at all the
temperatures employed in the present investigation owing to the presence of negligible porosity and
relatively finer grain size. Fracture surfaces of the broken tensile specimens reveal the quasi-
cleavage fracture. The best and the worst creep resistance are exhibited by the SC and HPDC alloys
respectively with the GC alloy exhibiting the intermediate creep resistance. The inferior creep
resistance of the HPDC alloy is attributed to the presence of a higher amount of porosity that allows
easy crack initiation and growth during creep tests. On the contrary, the negligible porosity and
continuous network of eutectic phase contributes to the superior creep resistance of the SC alloy.
Keywords: AZ91 Mg alloy; Casting technique; Microstructure; Tensile; Creep
Mudda Nirish, R. Rajendra,
Suitability of metal additive manufacturing processes for part topology optimization – A comparative
study,
Volume 27, Part 2,
2020,
Pages 1601-1607,
ISSN 2214-7853,
Abstract: Additive Manufacturing (AM) has the main benefits of freedom of design, mass
customization, waste minimization and the ability to manufacture complex shape. AM is the process
of making 3D object from computer model data by depositing of material layer by layer. This paper is
discussions of a concept of 3D metal printing of Direct Metal Laser Sintering, Selective Laser
Sintering and Electron Beam Melting with application and compares processes with respect to
material, process and parameter. It explores the metal 3D printing processes for topological
optimization of parts. Topology optimization is iterative modify the shape and optimize material
within a given designs space for load, boundary condition thus leading to weight reduction of
components. Thus form lightweight components which have great advantage where energy
consumption is minimal. Topology optimization is used for structural optimization is dealing with
optimal design load carrying mechanical structures. This optimization is very useful to design and
application engineers.
Keywords: Additive manufacturing (AM); 3D printing; Direct Metal Laser Sintering (DMLS); Selective
Laser Melting (SLM); Electron Beam Melting (EBM); Topology optimization (TO)
N.D.Malleswararao.K, I.N.Niranjan Kumar,
Investigation of tribological behaviour of DLC coating on hyper-eutectic Al-Si alloys, a review,
Volume 18, Part 7,
2019,
Pages 2581-2589,
ISSN 2214-7853,
Abstract: Diamond-like Carbon (DLC) coatings are used significantly in modern industries because of
their outstanding tribological performance. The objective of this review is to explore the wide range
of deposition methods and wear performance of DLC coatings. Earlier DLC coatings are broadly used
in various industrial applications like electronics, shaving and optical. Whereas due to rapidly
changing automobile performance such as standard production and racing engine vehicles the DLC
coatings are used well as surface coatings for pistons, piston rings, ball bearings, and cylinder liners
etc. Moreover, due to high wear resistance, adhesive protection and low coefficient of friction
properties the coatings are used extensively in tribological applications.
Wenbo Liu, Ning Li, Zhenyu Zhong, Jiazhen Yan, Dong Li, Ying Liu, Xiuchen Zhao, Sanqiang Shi,
Novel cast-aged MnCuNiFeZnAl alloy with good damping capacity and high usage temperature
toward engineering application,
Materials & Design,
Volume 106,
2016,
Pages 45-50,
ISSN 0264-1275,
https://doi.org/10.1016/j.matdes.2016.05.098.
Abstract: Novel cast-aged Mn-26.0Cu-2.0Ni-2.0Fe-2.0Zn-3.0Al (wt.%) alloy with good damping
capacity and high usage temperature has been well designed and developed in this work, which can
act as a promising candidate toward engineering applications. The microstructure, damping capacity
and usage temperature were investigated systematically by X-ray diffraction, optical microscopy,
scanning electron microscopy, energy dispersive spectroscopy, and dynamic mechanical analyzer.
The results show that heat treatment has a significant influence on the damping capacity and usage
temperature of as-cast MnCuNiFeZnAl alloy. Compared to the original as-cast alloy with internal
friction (Q−1) of 3.0×10−2 at a strain amplitude ε=2×10−4 and usage temperature of 43°C, the
largest Q−1 (5.0×10−2) and highest usage temperature (70°C) can be obtained simultaneously by
ageing treatment at 435°C for 2h, while homogenization-ageing, solution-ageing and overageing can
just result in the limited improvement of damping capacity and usage temperature. This is because
the highest nanoscale Mn segregation in Mn dendrites can be formed by spinodal decomposition
during ageing, while carrying out the homogenization or solution treatment prior to the ageing, as
well as overageing treatment can cause the weakening of Mn segregation at the macro/nano-scale
and even the precipitation of α-Mn, thus leading to the undesirable damping capacity and usage
temperature.
Keywords: Mn-Cu based damping alloys; Casting; Internal friction; Usage temperature; Heat
treatment; Phase transformation
Christian Vargel,
Chapter A.3 - The advantages of aluminium,
Editor(s): Christian Vargel,
Corrosion of Aluminium (Second Edition),
Elsevier,
2020,
Pages 9-16,
ISBN 9780080999258,
https://doi.org/10.1016/B978-0-08-099925-8.00003-X.
Abstract: With an annual world consumption of 59 million tons in 2016, aluminium is the leader in
the metallurgy of nonferrous metals. The development of applications for aluminium and its alloys,
as well as the sustained rise in consumption, can be attributed to several of its properties, which are
decisive criteria in users’ choice of metals, especially in the fields of transport, building, electrical
engineering and packaging. These advantageous properties include the following: lightness, thermal
conductivity, electrical conductivity, suitability for surface treatments, corrosion resistance, diversity
of aluminium alloys, diversity of semi-products, functional advantages of extruded and cast semi-
products, ease with which aluminium can be formed, ease of recycling.
Keywords: 1XXX series; 2XXX series; 3XXX series; 5XXX series; 6XXX series; 7XXX series; 8XXX series;
Aluminium lithium alloys; Blackening; Casting alloys; Density; Desalination of seawater; Electrical
conductivity; Extrusion alloys; Heat exchangers; Lightness; Melting point; Pitting corrosion;
Recycling; Solar energy; Space applications; Surface treatments; Thermal conductivity
Kartik Singh, Ramesh Kumar Nayak, Diptikanta Das, Sushant kumar Sahoo,
Improvement of Hardness of Short Fork (6082 Alloy)-A Case Study,
Volume 18, Part 7,
2019,
Pages 2515-2519,
ISSN 2214-7853,
Abstract: The short fork is made of 6082 Aluminium alloy and used in propeller shaft of small or mini
trucks. The objective of the current investigation is to find the influence of t-6 heat treatment on the
hardness of short fork (yoke). The effect of aging time on hardness and Microstructural changes is
investigated. The test samples of the 6082-aluminum alloy were initially forged into the short fork at
temperature 450°C and then solutionizing at 540°C for 15 min followed by water quenching.
Furthermore, it was artificially aged at 190°C for 60-240 minutes. Rockwell hardness test was
performed to find out the relationship between hardness and aging time. The optical microscope
was used to investigate the Microstructural changes of the Aluminium alloy with different aging
time. The result revealed that the change in grain size and microstructure during solutionizing heat
treatment and artificial aging process are responsible for the change in hardness of the alloy. Aging
at 190°C for 240 minutes gives the desired hardness of the component. These process parameters
will be helpful to achieve maximum hardness of short fork and will be useful to other gorging
industries.
Keywords: Short fork; Aluminum Alloy; Heattreatment; Automotive
Alex Ellery,
Sustainable in-situ resource utilization on the moon,
Planetary and Space Science,
Volume 184,
2020,
104870,
ISSN 0032-0633,
https://doi.org/10.1016/j.pss.2020.104870.
Abstract: We propose that current in-situ resource utilization schemes based on mining of water
resources on the Moon is unnecessary and unsustainable. Life support systems are capable of
recycling with high efficiency. Burning of hydrogen propellant and oxygen is akin to the burning of
fossil fuels. The value of in-situ resources will be in exploiting the resources that are abundant,
husbanding of resources that are not and recycling as much as possible to minimise waste. We
propose that a closed loop industrial ecology must be implemented with extensive recycling loops as
a sustainable approach to in-situ resource utilization on the Moon. We must build in sustainability
into our forays from Earth in order not to continue to make the same mistakes as we have on Earth.
Keywords: Lunar in-situ resource utilization; Metalysis FFC process; 3D printing; Lunar industrial
ecology
John Campbell,
Chapter 2 - Fracture in the liquid/solid state,
Editor(s): John Campbell,
The Mechanisms of Metallurgical Failure,
2020,
Pages 167-191,
ISBN 9780128224113,
https://doi.org/10.1016/B978-0-12-822411-3.00002-2.
Abstract: The mechanical properties of the liquid/solid regime during the freezing of metals have
been studied repeatedly, but, in general, without the knowledge of the presence of bifilms. (The
oxide cracks are introduced into the metal by turbulence during casting processes.) The flow of
liquid through the “pasty zone” has been simulated in theoretical models, which, at this time,
appears far removed from reality as a result of the blockage of flow channels by bifilms. The opening
of “hot tears” is seen to be the opening of bifilms. In addition, the elimination of hot tears is seen to
be by the elimination of bifilms, particularly bifilms formed during the final pour of the liquid metal.
It is predicted, and demonstrated, that even in a highly hot tear prone alloy subjected to freezing in a
mold designed to encourage maximum tearing, that tears will not form if bifilms are absent. Thus, in
the partly solidified condition, the occurrence of fracture is controlled by bifilms.
Keywords: Bifilm; Fracture; Hot tearing; Oxide film; Pasty zone; Semisolid
Wei Wang, Cheng Fang, Yiyi Chen, Mingxing Wang,
Seismic performance of steel H-beam to SHS-column cast modular panel zone joints,
Engineering Structures,
Volume 117,
2016,
Pages 145-160,
ISSN 0141-0296,
https://doi.org/10.1016/j.engstruct.2016.03.006.
Abstract: This paper sheds considerable light on the potential of using cast steel technology for
seismic-resistant H-beam to tubular column joints. The considered cast modular joint was an integral
assembly of joint zone, beam linking zone, and column linking zone, and the joint geometry was
carefully designed to overcome some fracture-related issues that conventional joints may have. The
research commenced with a set of tensile and cyclic coupon tests for a comprehensive
understanding of the material properties of the entire cast modular joint at different key locations,
where the material generally showed sufficient ductility, pronounced strain hardening, consistent
yield and ultimate strengths, and plump hysteretic response. The following sub-frame tests covered
two types of cast modular joints (Type-A and Type-B) with two column load ratios for each joint
type. Each specimen represented a typical sub-frame consisting of a cast modular joint and
connecting beams and columns. All the specimens exhibited good ductility and energy dissipation
ability. No facture was observed at the welding zone which was relocated away from the column
face, and as a result, ductile fracture was delayed to occur within the cast modular joint at very large
drifts. Moreover, the shear deformation of the panel zone was sufficiently mobilised, and the energy
dissipation mechanism of the sub-frame was featured by a combined action of panel zone in shear
and beam section in flexural yielding. The codified design expressions for the strength and stiffness
of the specimens were also revisited, and design comments were finally made.
Keywords: Cast modular joint; Steel casting; Tubular column; Seismic performance; Experiments
Rajesh Kumar,
Flood hazard assessment of 2014 floods in Sonawari sub-district of Bandipore district

(Jammu&Kashmir): An application of geoinformatics,
Remote Sensing Applications: Society and Environment,
Volume 4,
2016,
Pages 188-203,
ISSN 2352-9385,
https://doi.org/10.1016/j.rsase.2016.10.002.
Abstract: Massive flooding in the Kashmir valley was induced by heavy rainfall due to combined
effects of western disturbances and Indian summer monsoon during September 04–10, 2014. The
populous Sonawari sub-district was severely affected by flood waves that caused complete damage
to standing crops and disrupted man-made linear structures (embankment, canal, and road
network). High value land use classes (cropped land, built-up and plantation), which encroached on
swamps and wetlands between 1972 and 2014, were badly damaged. The main aim of this study is
to assess flood hazard at village level in the sub-district. Village-wise standardised flood hazard
indicators were flood affected areas, mean turbidity, mean flood depth and duration. These
indicators were derived from the Landsat 7 ETM+, Landsat 8 OLI-TIRS images and SRTM (30m) DEM.
Linear combination of these standardised indicators in GIS environment formulated Flood Hazard
Index (FHI). Furthermore, the computed FHI values were divided into four flood hazard zones. Low,
moderate, high and very high flood hazard zones occupied 16, 32, 34 and 19% of the total area,
respectively. Further, these zones accounted for 21, 23, 33 and 23% of the total number of villages
and towns (43), respectively. FHI was validated with overall changes in NDVI values with the help of
linear regression model that showed a fair association between village-wise FHI and changes in
mean NDVI values as the coefficient of determination (R2) was 0.75 with a least standard error of
0.05. Village-wise flood hazard assessment has immense importance to plan future land use and to
implement flood management strategies during pre and post- floods in the sub-district.
Keywords: Landsat 8 OLI-TIRS; SRTM (30m); Kashmir valley; Flood hazard index; MNDWI; RMSE
Heinz P. Bloch,
Subject Category 22 - Non-OEM Repairs Combine Effective Upgrade Strategies,
Editor(s): Heinz P. Bloch,
Petrochemical Machinery Insights,
2017,
Pages 301-337,
ISBN 9780128092729,
https://doi.org/10.1016/B978-0-12-809272-9.00022-0.
Abstract: There are many reasons why non-original equipment manufacturer (non-OEM) equipment
rebuilders exist and compete for the equipment users' business. Starting in the late 1980s,
considerable consolidation and reshuffling has affected the pump industry. What used to be big
names among the manufacturers have vanished from the scene. In the 100kW and larger size pump
categories, the loss of legacy brand experience makes itself felt. Some OEMs are no longer staffed
with predominantly experienced personnel, and the loss has repercussions. At times, the now often
less knowledgeable OEM employees are ill-equipped to work with the owner-operator of these
pumps. Timely scheduling of work execution and delivery can be difficult for OEMs, and repairs are
sometimes offered as restoration to as designed, but not restoration and upgrading to state-of-the-
art performance. It is for these reasons that this text chapter deals extensively with non-OEM
capabilities. The chapter singles out competent pump repair shops (which we chose to abbreviate as
“CPRS” facilities) that excel in the market place. Working toward close CPRS-owner/CPRS-user
cooperation and interaction is valuable and will be of benefit to all parties. Essential non-OEM
capabilities in defining prerepair and postrepair mechanical reliability and hydraulic efficiency
achievements must be discussed and guidance mapped out. In return, the results will often exceed
expectations.
Keywords: Upgrade repairs; Sand printing; Performance testing laboratory; CPRS; Three-dimensional
printing; Sand casting; Cast iron; Repurposing; RCFFR; Wear materials
Palash Poddar, Sumanta Bagui, K. Ashok, A.P. Murugesan,
Experimental investigation on microstructure and mechanical properties of gravity-die-cast

magnesium alloys,
Volume 695,
2017,
Pages 895-908,
ISSN 0925-8388,
Abstract: The influence of various alloying elements (i.e., Sn, Al, Si, Mm, Sc) with different quantities
on the microstructure and mechanical properties of gravity die cast magnesium alloys are
investigated. Experimental evidences show that the secondary dendrite arm spacing is increasing
with the increase in Sn content from 5% to 8% in Magnesium alloy. Misch Metal (Mm) addition in
Mg-5%Sn causes grain refinement (∼30%) and the shape of interdendritic second phase particles
changes from rod/irregular geometry to feathery shape. In Mg-8%Sn-3%Al-1%Si alloy, α-Mg, Mg2Sn,
Mg17Al12 and Mg2Si phases are identified. Addition of Al-Sc master alloy refines the grain size
(∼12%) of Mg-8%Sn alloy. Solution heat treatment at 520 °C for 48–72 h leads to complete
dissolution of Mg2Sn intermetallic for Mg-Sn alloys. During ageing of Mg-Sn alloys at 200 °C,
discontinuous precipitation of Mg2Sn occurs at grain boundaries and their triple junctions at the
initial stage and later they become coarse in nature. Tensile properties (i.e., YS, UTS and %EL) are
improved after 100 h of aging for all alloys used compared with the cast alloys of same composition.
Cast Mg-8%Sn-3%Al-1%Si alloy exhibits superior tensile properties as compared to cast Mg-5%Sn,
Mg-8%Sn,Mg-5%Sn-2%Mm,Mg-8%Sn-3%(Al-Sc) alloys.
Keywords: Magnesium alloy; Ageing; Gravity die casting; Tensile properties
Quhao Li, Wenjiong Chen, Shutian Liu, Huiru Fan,
Topology optimization design of cast parts based on virtual temperature method,
Computer-Aided Design,
Volume 94,
2018,
Pages 28-40,
ISSN 0010-4485,
https://doi.org/10.1016/j.cad.2017.08.002.
Abstract: Topology optimization has been widely used in industry for its powerful innovation ability
to obtain the concept designs, which are generally unintuitive. But due to the limitation of the
manufacturing processes or costs, some of these designs cannot be manufactured directly, so
considering manufacturing process constraints in topology optimization becomes increasingly
important. This paper presents a new method for structural topology optimization design
considering the molding constraint which requires the absence of interior voids and undercuts in the
cast parts. A virtual thermal diffusion problem is appropriately defined and a global thermal
constraint is added into the optimization model to guarantee the cast-ability of the structural shape.
The parting directions, unidirectional or multi-directional, are modeled by modifying heat dissipation
boundaries and material properties. This method does not require an optimization process to start
from a feasible initialization and can be applied to almost any topology optimization problems. Finite
volume method is used to solve a steady-state heat equation and a parametric formulation of the
conductive coefficient is given. Several examples of topology optimization of cast parts are provided
to illustrate the validity and the effectiveness of the proposed method.
Keywords: Topology optimization; Virtual temperature method; Molding constraint; Parting

direction; Finite volume method
Paul Schüler, Robert Frank, David Uebel, Sebastian F. Fischer, Andreas Bührig-Polaczek, Claudia
Fleck,
Influence of heat treatments on the microstructure and mechanical behaviour of open cell
AlSi7Mg0.3 foams on different lengthscales,
Acta Materialia,
Volume 109,
2016,
Pages 32-45,
ISSN 1359-6454,
Abstract: This paper reports about the influence of different heat treatments such as solution
annealing (W) and solution annealing plus ageing (T6, T7) on the microstructure of AlSi7Mg0.3 open
cell foams and their effect on the mechanical properties. The mechanical properties and the local
failure mechanisms of individual struts and foam specimens have been evaluated by micro-hardness
measurements and micro-tensile testing of struts as well as in-situ compression tests on foam
samples, combined with scanning and transmission electron microscopic evaluation of the
microstructure. Contrary to published results for the bulk material, we only found a weak influence
of the heat treatments on the struts' and foams' mechanical properties. We assume that this is
mainly due to the inhomogeneous microstructure of the struts with coarse plate-shaped Si phases,
leading to a subordinate effect of the precipitates formed during the heat treatments. The
morphology of the coarse Si and intermetallic phases is only slightly influenced by the heat
treatments, but profoundly determines the deformation, cracking and failure behaviour of the struts
and thus of the entire foam.
Keywords: Aluminium foam; Heat treatment; Microstructure; Mechanical properties; Micro-tensile

testing
S.M. Sapuan,
Chapter 4 - Concurrent Engineering in Design and Development of Composite Products,
Editor(s): S.M. Sapuan,
Composite Materials,
2017,
Pages 95-139,
ISBN 9780128025079,
https://doi.org/10.1016/B978-0-12-802507-9.00004-0.
Abstract: In this chapter, the use of concurrent engineering (CE) in the development of composite
products is presented. It emphasizes on the importance of integrated information technology (IT)
tools, as well as procedure-based tools in the design for manufacture of composite products. Review
of selected work on the research of CE in composite product development was carried out. The
industrial application of CE in composite product development in several international companies is
presented. Author’s own works with his coworkers are also reviewed and several flowcharts and
models are presented and discussed.
Keywords: integration of IT tools; design for manufacture; polymer composites; composite

fabrication; composite manufacturing process
Andreas Gebhardt, Jan-Steffen Hötter,
3 - Machines for Rapid Prototyping, Direct Tooling, and Direct Manufacturing,
Editor(s): Andreas Gebhardt, Jan-Steffen Hötter,
Hanser,
2016,
Pages 93-290,
ISBN 9781569905821,
https://doi.org/10.3139/9781569905838.003.
Krishnan K. Sankaran, Rajiv S. Mishra,
Chapter 7 - Magnesium Alloys,
Editor(s): Krishnan K. Sankaran, Rajiv S. Mishra,
Metallurgy and Design of Alloys with Hierarchical Microstructures,
Elsevier,
2017,
Pages 345-383,
ISBN 9780128120682,
https://doi.org/10.1016/B978-0-12-812068-2.00007-2.
Abstract: Magnesium is the lightest element among the candidates for structural applications.
Compared to the mainstream aluminum, titanium, and iron alloys covered in Chapters 4–6Chapter
4Chapter 5Chapter 6, whereas magnesium alloys have the potential to transition into airframe
applications because of their weight advantage, they suffer from some limiting attributes that are
the focus of ongoing research. The primary argument for considering magnesium alloys is built on
specific properties. However, to have real opportunities for insertion, it is important that the
combination of properties become competitive with aluminum alloys, as highlighted in this chapter
through some examples. Concepts of microstructural efficiency and alloying efficiency are
introduced. These concepts allow discussion of pathways for development of hierarchical
microstructure in cost-effective magnesium alloys. Appropriate selection of alloying elements can
promote synergy between microstructural and alloying efficiency.
Keywords: Alloying efficiency; Critical grain size; Magnesium alloys; Microstructural efficiency;
Nonbasal slip; Twinning
John Campbell,
Chapter 1 - The fracture of liquids,
Editor(s): John Campbell,
The Mechanisms of Metallurgical Failure,
2020,
Pages 1-165,
ISBN 9780128224113,
https://doi.org/10.1016/B978-0-12-822411-3.00001-0.
Abstract: The fundamental process of the consolidation of metals ensures bifilms are created and
are widespread in engineering metals. The bifilm is a crack resulting from the impingement of two
oxide films. The impingement of oxides on powder particles during the consolidation of powders to
make powder metallurgical products is easily understood, but results in relatively harmless and
controlled dispersions of cracks. Bifilms formed during the casting of liquid metals are quite
different, ranging in sizes from submicrometer to fractions of meters. The many phenomena
associated with their creation and their morphological changes with temperature and time are
presented. The behaviors of the light metals and the higher temperature metals, particularly irons,
steels, and Ni-based alloys, are contrasted. Techniques for the avoidance of bifilm formation are
outlined. The macroscopic bifilm cracks, fundamental to current vacuum arc remelted steels, are a
special danger, which are highlighted.
Keywords: Bifilms; Defects; Entrainment; ESR; Fracture; Oxide films; Turbulence; VAR
Ze-Xian Low, Yen Thien Chua, Brian Michael Ray, Davide Mattia, Ian Saxley Metcalfe, Darrell Alec
Patterson,
Perspective on 3D printing of separation membranes and comparison to related unconventional

fabrication techniques,
Journal of Membrane Science,
Volume 523,
2017,
Pages 596-613,
ISSN 0376-7388,
https://doi.org/10.1016/j.memsci.2016.10.006.
Abstract: Additive manufacturing, likewise known as 3-dimensional (3D) printing and rapid
prototyping, has the ability to create almost any geometrically complex shape or feature in a range
of materials across different scales. It has found its applications in various areas, such as medicine
(bioprinting), art, manufacturing and engineering. On the other hand, its use in separation
membrane engineering is relatively new. The use of additive manufacturing techniques could
provide more control towards the design of separation membrane systems and offers novel
membrane preparation techniques that are able to produce membranes of different shapes, types
and designs which cannot be made using conventional techniques such as phase inversion or
sintering. Here we provide key background information on 3D printing technologies and applications
in membrane engineering; a discussion of the potential and limitations of current 3D printing
technologies for membrane engineering and future aspects of the technology. Due to the potential
benefits of 3D printing in membrane manufacturing, in particular the unprecedented control over
membrane architecture the technique could allow, the use of 3D printing in membrane systems
should see significant growth in the near future.
Keywords: 3D printing; Additive manufacturing; Subtractive manufacturing; Membrane; Separation;

Rapid prototyping
Mohammadhasan Hedayati, Megan J. Neufeld, Melissa M. Reynolds, Matt J. Kipper,
The quest for blood-compatible materials: Recent advances and future technologies,
Materials Science and Engineering: R: Reports,
Volume 138,
2019,
Pages 118-152,
ISSN 0927-796X,
https://doi.org/10.1016/j.mser.2019.06.002.
(http://www.sciencedirect.com/science/article/pii/S0927796X19300415)
Abstract: The development of blood-compatible materials represents a grand challenge in

biomaterials science. Blood is a complex fluid containing many types of living cells, functional
proteins, and other signaling molecules, which work together to protect the circulatory system from
injury, pathogens, and foreign materials. Blood-contacting biomaterials include the components of
cardiovascular implants (such as stents, shunts, and valves) and extracorporeal circuit components
(such as tubing, membranes, and pumps). The engineered materials used in these applications are
distinctly unlike the biological tissues that make up the cardiovascular system in their physical,
chemical, and biological properties, leading to undesirable—and sometimes catastrophic—blood-
material interactions. The pursuit of blood-compatible materials challenges nearly every aspect of
materials design, including composition, mechanical properties, structure across multiple length
scales, tribology, surface physical-chemistry, and biochemical functionalization. Materials have been
designed to bind or reject specific blood proteins, interact favorably with specific cell types, or to
interact with particular biochemical pathways in blood. This review summarizes the important
blood-material interactions that regulate blood compatibility, organizes recent developments in this
field from a materials perspective, and recommends areas for future research.
Keywords: Blood-compatibility; Thrombosis; Inflammation; Protein adsorption; Biomimetic;

Bioinspired; Polymer brush; Zwitterionic; Nitric oxide
M Ravikumar, H.N Reddappa, R. Suresh,
Aluminium Composites Fabrication Technique and Effect of Improvement in Their Mechanical

Properties – A Review,

2018,
Pages 23796-23805,
ISSN 2214-7853,
Abstract: Aluminium metal matrix composites are extensively used in automobile industries and
aerospace. Aluminium metal matrix composites (AMMCs) reinforced by firm ceramic particulates
which provide expressively improved mechanical properties by the addition of ceramics particles
into the matrix. The ceramic particles dissolve into aluminium matrix, which helps to produce a high
bonding strength among the particles and matrix materials. The adding of reinforcement particles
into the AMMCs increases the specific strength, stiffness, wear rate, fatigue and creep properties
when it is compared with conventional engineering resources. The main aim of this paper is to
review the benefits of using MMCs over other Al/Al alloy with respect to mechanical properties. It is
possible to optimize the wt. % of reinforcement in to metal matrix by using the proper proportion
and combination of different particle as reinforcement
Keywords: MMCs; Reinforcements; Aging temperature; Mechanical properties
Sebastien Dezecot, Matthieu Rambaudon, Alain Koster, Fabien Szmytka, Vincent Maurel, Jean-Yves
Buffiere,
Fatigue crack growth under large scale yielding condition in a cast automotive aluminum alloy,
Volume 743,
2019,
Pages 87-97,
ISSN 0921-5093,
Abstract: Low Cycle Fatigue crack growth tests have been performed at 250 °C in order to study
fatigue crack growth under large scale yielding conditions in a material widely used at high
temperature by the automotive industry for cylinder head applications. The studied material was a
cast aluminum alloy AlSi7Cu3Mg (close to A319) produced by Lost Foam Casting. Two different
microstructures were investigated: one containing large natural pores and another where pores
have been removed by Hot Isostatic Pressing (HIP). Fatigue Crack Growth Rates (FCGR) have been
measured by in situ surface optical microscopy for different loading conditions all inducing
generalized plasticity and compared to assess the influence of pores on the FCGR. In situ
observations coupled to post mortem analysis revealed strong crack interactions with both pores
and large hard particles on specimen surfaces and in the bulk. FCGR ranging between 10−6 and
10−4 m/cycle appear to be mainly sensitive to applied strain amplitudes. Although pores promoted
secondary crack initiations and crack coalescences, they seemed to have a limited effect on steady-
state FCGR which has been analytically modeled using energy densities.
Keywords: Low Cycle Fatigue; Cast aluminum alloy; Fatigue crack growth; Large scale yielding; High
temperature
K.Ch. APPARAO, Anil Kumar BIRRU,
QFD-Taguchi based hybrid approach in die casting process optimization,
2017,
Pages 2345-2356,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(17)60260-7.
Abstract: Abstract
The present research work emphasized on identifying and optimizing various significant process
parameters of high pressure die casting by using QFD-Taguchi based hybrid approach in order to
yield the optimum casting density of the A380 alloy. Identification of critical process parameters,
selection of appropriate orthogonal array, analysis of means and analysis of variance are employed
to study the performance characteristic of the die casting process. The most critical process
parameters identified and optimized by QFD-Taguchi based hybrid approach, such as the injection
pressure, the molten metal temperature, the plunger velocity (first and second stage) and the die
temperature were explored in the experimental work. The results show that injection pressure is the
most significant factor among the selected parameters. The contribution of the injection pressure to
the variation of mean casting density is around 61.483%. Confidence interval (CI) has also been
estimated as 0.000718 for 95% consistency level to validate the predicted range of optimum casting
density of aforesaid alloy.
Keywords: high pressure die casting; A380 alloy; QFD technique; Taguchi method; casting density
Alireza Nouri, Antonella Sola,
8 - Electron beam melting in biomedical manufacturing,
Editor(s): Cuie Wen,
In Woodhead Publishing Series in Biomaterials,
Metallic Biomaterials Processing and Medical Device Manufacturing,
2020,
Pages 271-314,
ISBN 9780081029657,
https://doi.org/10.1016/B978-0-08-102965-7.00008-4.
Abstract: Electron beam melting (EBM) is an additive manufacturing technique that uses an electron
beam to selectively fuse and consolidate the metal powder. The final object is built up layer-by-layer
according to a computer-aided design or, in case of customized biomedical implants, according to a
computed tomography of the patient. This chapter introduces the basic concepts of EBM and the
advantages and limitations of applying this technique in biomedical manufacturing. Subsequently,
the chapter is describing the processing steps of EBM, the consolidation mechanisms, and the
potential microstructural defects of the finished parts. A thorough discussion is provided about the
EBM capability of producing cellular structures, dental implants, and orthopedic prostheses, with an
emphasis on customized parts. The chapter closes with a survey of the challenges and the future
developments of EBM to fabricate biomedical devices.
Keywords: Electron beam melting; additive manufacturing; metal powder; titanium alloys; scaffolds;
dental; orthopedic; bone; implants
Washington L.R. Santos, Bismarck L. Silva, Felipe Bertelli, José E. Spinelli, Noé Cheung, Amauri Garcia,
An alternative thermal approach to evaluate the wettability of solder alloys,
Applied Thermal Engineering,
Volume 107,
2016,
Pages 431-440,
ISSN 1359-4311,
https://doi.org/10.1016/j.applthermaleng.2016.06.177.
Abstract: The aim of the work is to propose an alternative method to qualitatively evaluate the
wettability of different alloys of a particular alloy system. The technique is based on a thermal
approach supported by experimental/theoretical methodologies involving a directional solidification
procedure and numerical simulations based on the solution of the inverse heat conduction problem
(IHCP). The wettability strongly affects the heat ability to flow across the alloy/substrate interface
during solidification, which is construed as a heat transfer coefficient (hg). Particularly, for the alloys
used in soldering processes, the wettability plays an important role in the integrity of solder
junctions, being a fundamental parameter for selecting the most appropriate solder composition.
The experiments were carried out with high temperature Zn-Sn solder alloys (10, 20, 30 and 40wt
%Sn) in a solidification device in which heat is extracted only through a water-cooled steel bottom.
Experimental thermal profiles collected during solidification are used as input data to solve the IHCP
and determine expressions hg vs. time for each alloy examined, permitting a tendency of wettability
to be established. In order to validate the wetting behavior indicated by the hg values,
alloy/substrate contact angles (θ) were measured on a steel substrate using a goniometer. It is
shown that both hg and θ indicate improvements in wettability with the decrease in the alloy Sn
content.
Keywords: Zn-Sn solder alloys; Solidification; Wettability; Interfacial heat transfer coefficient
M. ARJMAND, S.M. ABBASI, A. KARIMI TAHERI, A. MOMENI,
Hot workability of cast and wrought Ni–42Cu alloy through hot tensile and compression tests,
Volume 26, Issue 6,
2016,
Pages 1589-1597,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(16)64264-4.
Abstract: In order to analyze the flow behavior and workability of Ni–42Cu in cast and wrought
conditions, hot deformation tests were performed at temperatures and strain rates within the
ranges of 900–1150 °C and 0.001–1 s−1, respectively. Tensile tests showed a “hot ductility trough” at
950 °C for both alloys. The drop in hot ductility was more considerable in the cast alloy because of
the sluggish dynamic recrystallization. The hot ductility drop and grain boundary cracking,
particularly in the cast alloy, were attributed to the segregation of detrimental atoms to the
boundaries. It was shown that the hot ductility of the wrought alloy could be improved with
increasing strain rate. It was associated with increasing the fraction of dynamic recrystallization at
higher strain rates. This finding corroborated the change in the mechanism of dynamic
recrystallization with strain rate. The strain rate sensitivity and instability parameters calculated for
the wrought alloy showed that the material is prone to strain localization at low temperatures, i.e.,
950–1050 °C, and high strain rates of 0.1 and 1 s−1. Based on the tensile and compression tests, the
best temperature range for a desirable hot workability was introduced as 1050–1150 °C.
Keywords: Ni–Cu alloy; hot ductility; mechanical properties; dynamic recrystallization; hot
compression; formability
N.R. Overman, S.A. Whalen, M.E. Bowden, M.J. Olszta, K. Kruska, T. Clark, E.L. Stevens, J.T. Darsell,
V.V. Joshi, X. Jiang, K.F. Mattlin, S.N. Mathaudhu,
Homogenization and texture development in rapidly solidified AZ91E consolidated by Shear Assisted
Processing and Extrusion (ShAPE),
Volume 701,
2017,
Pages 56-68,
ISSN 0921-5093,
Abstract: Shear Assisted Processing and Extrusion (ShAPE) -a novel processing route that combines
high shear and extrusion conditions- was evaluated as a processing method to densify melt spun
magnesium alloy (AZ91E) flake materials. This study illustrates the microstructural regimes and
transitions in crystallographic texture that occur as a result of applying simultaneous linear and
rotational shear during extrusion. Characterization of the flake precursor and extruded tube was
performed using scanning and transmission electron microscopy, x-ray diffraction and
microindentation techniques. Results show a unique transition in the orientation of basal texture
development. Despite the high temperatures involved during processing, uniform grain refinement
and material homogenization are observed. These results forecast the ability to implement the
ShAPE processing approach for a broader range of materials with novel microstructures and high
performance.
Keywords: Rapid solidification; Magnesium alloy; Microstructure; ShAPE; Friction consolidation

extrusion; EBSD
N.Yu. Bobrov, S.S. Krylov, E.Yu. Antonov, A.N. Shein, N.P. Smilevets,
Physical and mathematical modeling of transient electromagnetic soundings over salt-dome

structures,
Russian Geology and Geophysics,
Volume 58, Issue 2,
2017,
Pages 266-274,
ISSN 1068-7971,
https://doi.org/10.1016/j.rgg.2016.03.017.
Abstract: This paper presents the results of physical and mathematical modeling performed to
evaluate the potential of transient electromagnetic sounding in areas of salt-dome tectonics. Two
geoelectric arrays are considered: an array with an inductive source (a horizontal loop) and an array
with a mixed-type source (a horizontal current line). It is shown that the transient electromagnetic
method provides important information on the relief of the top of salt deposits.
Keywords: physical modeling; mathematical modeling; electromagnetic soundings; transient

electromagnetic method; salt-dome structures
Gabor Takacs,
Chapter 3 - Electrical Submersible Pump Components and Their Operational Features,
Editor(s): Gabor Takacs,
Electrical Submersible Pumps Manual (Second Edition),
Gulf Professional Publishing,
2018,
Pages 55-152,
ISBN 9780128145708,
https://doi.org/10.1016/B978-0-12-814570-8.00003-9.
Abstract: This chapter discusses the construction and operation of the individual components of the
electrical submersible pumping (ESP) installation. The basic constructional and operational features
of submersible centrifugal pumps are presented along with details of their performance curves. The
two kinds of electric motors used in ESP service (induction and permanent magnet motors) are
introduced; their constructional and operational features are discussed in detail. Motor temperature
calculations are presented. The use of induction and permanent magnet motors in ESP service is
compared based on their power efficiencies and published case studies. The main functions of
protectors (seal sections) are introduced and their different parts, including the latest innovations,
are thoroughly described. Gravitational gas separators are fully described; the properties of electric
cable are detailed. The chapter concludes with a full description of ancillary downhole and surface
equipment used in ESP installations.
Keywords: Ancillary downhole/surface equipment; Centrifugal pump; ESP cable; ESP protector; Fixed
impeller pump; Floating impeller pump; Gravitational gas separator; Induction motor; Isolation
chamber; Motor comparison; Motor controller; Motor startup; Motor temperature; Permanent
magnet motor; Pump performance curves; Thrust bearing
I. McBean,
16 - Manufacturing technologies for key steam turbine parts,
Editor(s): Tadashi Tanuma,
Advances in Steam Turbines for Modern Power Plants,
2017,
Pages 381-393,
ISBN 9780081003145,
https://doi.org/10.1016/B978-0-08-100314-5.00016-6.
Abstract: The manufacturing of steam turbines has some unique aspects related specifically to steam
turbine design. The manufacturing technologies required are, to some extent, dependent on the
technology type employed by the manufacturer. The biggest differences are found in the blading
fixations and the rotor technology. The geometric or design differences in other components tend to
be smaller, or lead to less difference in the manufacturing methods employed.
Keywords: manufacturing; blade; rotor
Heng Rao, Stephanie Giet, Kun Yang, Xinhua Wu, Chris H.J. Davies,
The influence of processing parameters on aluminium alloy A357 manufactured by Selective Laser
Melting,
Materials & Design,
Volume 109,
2016,
Pages 334-346,
ISSN 0264-1275,
Abstract: The aim of this work is to investigate the effects of Selective Laser Melting (SLM) on the
microstructure and mechanical properties of A357 aluminium alloys. The SLM processing parameters
were optimised to achieve maximum density, corresponding to an extremely fine microstructure
with very few pores. This translates to differences in mechanical properties compared to
conventional cast alloy. Porosity in SLMed A357 Al samples was analysed based on relative density
versus laser parameter and energy input curves. Substrate temperatures and the combination of
laser parameters influence the mechanical properties via changes in melt pool morphology and
eutectic Si cell characteristics. The anisotropy of SLMed Al samples is explained in relation to the
directionality of the microstructure based on differences in the deformation response of horizontal
and vertical tensile samples. Fractographic studies have been performed to understand tensile
properties by comparing fracture surfaces of tensile samples with microstructural features in
different planes. This has led to an explanation of why the tensile properties are better for the
horizontal test samples than for the vertical ones in an as-SLMed material.
Keywords: Selective Laser Melting; Al–Si alloys; Microstructure; Porosity; Mechanical properties
Junfeng Ma, James D. Harstvedt, Daniel Dunaway, Linkan Bian, Raed Jaradat,
An exploratory investigation of Additively Manufactured Product life cycle sustainability assessment,
Journal of Cleaner Production,
Volume 192,
2018,
Pages 55-70,
ISSN 0959-6526,
https://doi.org/10.1016/j.jclepro.2018.04.249.
Abstract: Additive manufacturing (AM) refers to a group of manufacturing techniques that produce
components in a layer-by-layer fashion. By virtue of its capability to produce parts with complex
geometry and functionally graded materials, AM has been introduced and used in multiple industrial
sectors and is leading the way into the “third industrial revolution”. One of the key considerations in
Additively Manufactured Products (AMP) is the issue of sustainability which attracts increasing
attention as modern society becomes more aware of environmental concerns. As a response to the
growing requirement for sustainability, industries and customers are inclined to assess products and
services through the perspective of life cycle sustainability. The integration of life cycle sustainability
and AMP is still an open question and is the primary motivation for this study. Since the eventual
goal of all advanced technologies is to serve and satisfy human society, social sustainability must be
an essential part of all decisions regarding AMP. Limited studies that integrate social sustainability
into AMP life cycle analysis is a current research gap in the body of the literature, and thus this paper
will address it. The primary merit of this paper is developing a suitable full-dimension sustainability
life cycle assessment framework to obtain a fundamental understanding of the performance of AMP
life cycle sustainability. The proposed framework applies a more systemic AMP life span including
AMP design, AM, usage, and end-of-life (EOL) handling. An AM produced gear is used as an example
to illustrate the life cycle sustainability assessment framework. The results show that the AM stage
has the highest influence on economic and environmental dimensions of sustainability and the EOL
stage has the highest social impact. The results also indicate that AM mass production can
significantly reduce the impact of sustainability.
Keywords: Additive manufacturing; Life cycle assessment; Sustainability assessment; Energy

consumption; Social sustainability assessment
P.K. Mallick,
Chapter 1 - Overview,
2021,
Pages 1-36,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00001-X.
Abstract: With increasing demand for fuel economy improvement and emission control, there is a
great deal of interest in finding alternative solutions for producing lighter vehicles through material
substitution, design modification, and efficient manufacturing. The materials available today include
many new steels, such as advanced high-strength steels, light nonferrous alloys, such as aluminum
and magnesium alloys, and a variety of polymer matrix composites, such as carbon fiber-reinforced
epoxy. This chapter gives an overview of these materials and their current and future applications in
automobiles. It also provides general guidelines that need to be considered in selecting these
materials for lightweight vehicles.
Keywords: Lightweight vehicles; steel; aluminum; magnesium; titanium; stainless steel; cast iron;
thermoplastic polymers; composites; glazing; multimaterial design
Michael Molitch-Hou,
1 - Overview of additive manufacturing process,
Editor(s): Jing Zhang, Yeon-Gil Jung,
2018,
Pages 1-38,
ISBN 9780128121559,
https://doi.org/10.1016/B978-0-12-812155-9.00001-3.
Abstract: This chapter provides an overview of AM (additive manufacturing), which is also known as
“3D printing.” The chapter at first elaborates on the roots of the technology and then breaks down
the various types of processes that fall under the umbrella of AM. Emerging 3D printing technologies
are also discussed. A series of homework questions is included for introductory students.
Keywords: additive manufacturing; 3D printing; 3D printing basics; 3D printing overview; laser

sintering; metal 3D printing; metal additive manufacturing
E.E.T. ELSawy, M.R. EL-Hebeary, I.S.E. El Mahallawi,
Effect of manganese, silicon and chromium additions on microstructure and wear characteristics of
grey cast iron for sugar industries applications,
Wear,
Volumes 390–391,
2017,
Pages 113-124,
ISSN 0043-1648,
https://doi.org/10.1016/j.wear.2017.07.007.
Abstract: Mill roller shells are amongst the most important manufacturing-line elements in the sugar
production process. They are carefully designed according to many surface criteria amongst which
wear resistance is the most important. To increase the life of the mill roller shells, the resistance of
the surface to failure by abrasion should be increased. In this investigation, a series of sixty-six cast
iron samples with varied contents of chromium, manganese and silicon were prepared. The
microstructure and the mechanical properties were studied. Hence, the wear of all the specimens
was evaluated using the pin-on-disc test, with a high-speed steel disc. The accumulated weight loss
was measured and the wear rates were determined at constant normal test load of 20N and
constant pin velocity of 1.28m/s during the pin-on-disc test. The accumulated weight loss was
measured as a function of the number of revolutions. From test results, it was found that the wear
rate, for all conditions under investigation, decreases with the increase of manganese and chromium
additions at constant silicon additions. The wear rate obtained for the samples containing 3%
manganese and 2.02% silicon was equal to 1.2267mg/s, and the minimum wear rate was obtained
for the samples containing 3% manganese, 2.11% silicon, and 2.11% chromium (equal to
0.3400mg/s). The enhancement in the wear resistance of the chromium alloyed samples was
attributed to the increase in the chromium carbides volume fraction.
Keywords: Wear resistance; Mill roller shells; Microstructure; Grey cast iron
Viet-Duc Le, Franck Morel, Daniel Bellett, Nicolas Saintier, Pierre Osmond,
Multiaxial high cycle fatigue damage mechanisms associated with the different microstructural
heterogeneities of cast aluminium alloys,
Volume 649,
2016,
Pages 426-440,
ISSN 0921-5093,
Abstract: This paper is dedicated to the high cycle fatigue (HCF) behaviour of cast Al–Si alloys. In
particular, three similar alloys with different microstructural characteristics are investigated. The
result of an experimental campaign is presented, in order to characterise the fatigue behaviour, and
more specifically the fatigue damage mechanisms related to the different microstructural
heterogeneities (i.e. casting porosity, dendrite size, SDAS, non-metallic inclusions and silicon
particles), observed under different multiaxial loading conditions: pure tension, plane bending, pure
torsion and combined tension–torsion with a load ratio R=−1. It is shown that casting porosity has a
very detrimental influence on the uniaxial and combined tension–torsion fatigue strengths.
However, a much lower influence is observed for the torsional fatigue strength. For the porosity-free
alloy, it is observed that the formation of persistent slip bands (PSB) in the aluminium matrix is the
major fatigue crack initiation mechanism regardless of the loading modes, at a load ratio of R=−1. It
is also shown that the aluminium matrix has a large role in the formation of PSB and that the Si
particles facilitate the formation of PSB.
Keywords: EBSD; Aluminium alloys; Casting; Fatigue; SDAS; Defect
Index,
Editor(s): Kapil Gupta, Neelesh Kumar Jain, Rudolph Laubscher,
Advanced Gear Manufacturing and Finishing,
Academic Press,
2017,
Pages 219-230,
ISBN 9780128044605,
https://doi.org/10.1016/B978-0-12-804460-5.00022-5.
Kaushik Jayasayee, Ponce de León, Mari Juel,
Chapter 4 - Alternative chemistries in primary metal-air batteries,
Editor(s): Hajime Arai, Jürgen Garche, Luis Colmenares,
Electrochemical Power Sources: Fundamentals, Systems, and Applications,
Elsevier,
2021,
Pages 47-79,
ISBN 9780444643339,
https://doi.org/10.1016/B978-0-444-64333-9.00004-7.
Abstract: Primary metal-air batteries (PMABs) with metal anodes such as Zn, Mg, Al, Li, Fe, Si, Na, Ca
have the advantage of high specific energy, low cost, safety, abundance, and high recyclability of
materials. With the ability to build compact lightweight and modular designs, PMABs are suited for
niche applications that require energy independence such as remote and military
telecommunication systems, short-range aircraft, reserve power sources, unmanned aerial vehicles,
low-power consumer electronics, etc. By mechanically replacing the spent anodes, PMABs are
contemplated to play a significant role in electric transportation as range extenders and powering
logistic vehicles in industries. The current chapter starts with offering an overview of MABs with a
focus on electrode reactions, general corrosion processes, electrolyte types and cathode catalysts.
This is followed by more detailed sections on major PMAB chemistries such as Mg-air, Al-air, and Si-
air. Current challenges faced by the PMABs and future perspectives cover the last part of the
chapter.
Keywords: Al-air; Aluminum-air; Electrodes; Energy storage; Magnesium-air; Primary batteries;

Primary metal-air
H. Özkan Gülsoy, Özgür Özgün, Sezer Bilketay,
Powder injection molding of Stellite 6 powder: Sintering, microstructural and mechanical properties,
Volume 651,
2016,
Pages 914-924,
ISSN 0921-5093,
Abstract: The purpose of this study was to produce Co-based Stellite 6 superalloy components by
using the method of Powder Injection Molding (PIM) and to characterize the microstructural and
mechanical properties of the produced components. The experimental studies were started through
the formation of feedstock by mixing Stellite 6 powder with a multicomponent binder system.
Prepared feedstock was formed by utilizing powder injection molding technique. Then the molded
samples were subjected to the solvent and thermal debinding processes. Different sintering cycles
were applied to the raw components for the purpose of determining the optimum sintering
conditions. The densities of the sintered components were determined in accordance with the
Archimedes' principle. The microstructural characterization was performed through scanning
electron microscope (SEM) analysis, energy dispersive spectrometry (EDS) analyses, and X-ray
diffraction (XRD) analysis. Hardness measurement and tensile test were conducted in order to
determine the mechanical properties. The results illustrated that the injection molded Stellite 6
components were composed of fine and equiaxed grains, plenty of carbide precipitates exhibiting
homogenous distribution throughout the microstructure formed at the grain boundaries and thus
the mechanical properties were considerably high.
Keywords: Powder injection molding; Stellite 6; Microstructure; Mechanical properties
Dhrub Prasad, Sanatan Ratna,
Decision support systems in the metal casting industry: An academic review of research articles,

2018,
Pages 1298-1312,
ISSN 2214-7853,
Abstract: This article offers a complete review of the research articles that are related to the
application of decision support and intelligent system with specific reference to metal/dry casting.
Data was obtained from 89 articles that were published from 2000 to 2015 in 47 journals. The
articles are categorized based upon three different categories based on numbers of impressions,
material poured and pressureapplication. They are further classified into 10 subsections. A
widespread list of journal articles is identified in this present study that provides relevant
information/references for both practitioners and researchers on the application of decision support
and intelligent systems to various stages of metal/die casting. In light of the developed classification
framework, we identify gaps in extending the use of the decision support and artificial intelligent
systems in the industry and suggest potential and applicable research areas for further consideration
in this subject area.
Keywords: Metal casting; Decision support system; Die casting; Artificial intelligence system
Rajkumar Velu, Felix Raspall, Sarat Singamneni,
Chapter 8 - 3D printing technologies and composite materials for structural applications,
Editor(s): Georgios Koronis, Arlindo Silva,
In Woodhead Publishing Series in Composites Science and Engineering,
Green Composites for Automotive Applications,
2019,
Pages 171-196,
ISBN 9780081021774,
https://doi.org/10.1016/B978-0-08-102177-4.00008-2.
Abstract: Additive manufacturing, also known as 3D printing, is a new and emergent manufacturing
technology for rapid tooling which promises to disrupt the fabrication of highly sophisticated parts
directly from computer-aided designs. These printed parts can achieve lightweight structures with
high dimensional accuracy and at a lower cost for customized geometries. Over the past few years,
the intrinsic limitations of neat polymers, metals, and ceramics have propelled toward better
alternative composite materials to enhance mechanical and other essential properties; nowadays,
3D printing research follows a similar direction from neat to composite materials. This chapter
presents an overview of additive manufacturing techniques for composite materials, their
properties, performance, and potential applications. The focus is on structural applications and
technologies such as vat polymerization, material jetting, powder bed fusion, material extrusion,
binder jetting, direct energy deposition, and sheet lamination. Based on sustainability benefits of
natural fibers like wood, vegetable, and animal fibers we provide motivation for future research on
green composites 3D printing, and thereafter we discuss the advantages, weaknesses, and
limitations of these composites.
Keywords: 3D printing; Additive manufacturing; Composite materials; Conventional manufacturing;

Green composites; Manufacturing strategies; Structural applications
G. Masi, J. Esvan, C. Josse, C. Chiavari, E. Bernardi, C. Martini, M.C. Bignozzi, N. Gartner, T. Kosec, L.
Robbiola,
Characterization of typical patinas simulating bronze corrosion in outdoor conditions,
Materials Chemistry and Physics,
Volume 200,
2017,
Pages 308-321,
ISSN 0254-0584,
https://doi.org/10.1016/j.matchemphys.2017.07.091.
Abstract: In order to bring the treatment of historical bronze monuments in line with proper
engineering practice and cultural heritage regulations, the standardisation of artificially aged
surfaces that are comparable with natural ones is still to take place. In this aim, this investigation
reports a comparative study of corroded quaternary bronze samples produced by accelerated ageing
tests, simulating the unsheltered and sheltered exposure conditions mainly affecting outdoor bronze
monuments. The effects of run off in a dropping test (unsheltered simulation) and the exposure to
stagnant acid rain in a wet & dry test (sheltered simulation) on a bronze surface were studied. A
multi-analytical approach was performed including conventional analytical methods, such as a
microscopy examination coupled with elemental and structural analyses of the surface. In addition, a
focused ion beam (FIB) was used to produce cross-sections in the size range up to a few tens of
nanometres. It is evidenced that the corrosion layers, forming a nano-porous structure, are linked to
a decuprification process marked by the preferential dissolution of Cu and Zn and the formation of a
SnO species network within the barrier layer. A correlation between the tin content of the alloy and
the corrosion amplitude is shown: the anodic areas are related to the lowest tin-content part of the
alpha phase (in the centre of the dendrite), while the eutectoid areas (including the delta phase) are
cathodic and therefore not attacked. The corroded samples artificially aged are well representative
of natural corrosion structures observed on outdoor bronzes.
Keywords: Bronze; Artificial ageing; Atmospheric corrosion; FIB; Nano-porous corrosion layer
Jinghuai Zhang, Shujuan Liu, Ruizhi Wu, Legan Hou, Milin Zhang,
Recent developments in high-strength Mg-RE-based alloys: Focusing on Mg-Gd and Mg-Y systems,
Journal of Magnesium and Alloys,
Volume 6, Issue 3,
2018,
Pages 277-291,
ISSN 2213-9567,
https://doi.org/10.1016/j.jma.2018.08.001.
Abstract: Higher strength is always the goal pursued by researchers for the structural materials,
especially for the lightweight magnesium (Mg) alloys which generally have relatively low strength at
present. From this aspect, the present paper reviews the recent reports of a kind of Mg alloys, i.e.
Mg-RE (RE: rare earths, mainly Gd or Y) casting and wrought alloys, which have been able to achieve
high strength compared with common or commercial Mg alloys, from the viewpoint and content of
the alloy system, alloying constitution, preparation process, tensile strength and each of the main
strengthening mechanisms. This review of recent research and developments in high-strength Mg-
RE alloys is beneficial for the further design of Mg alloys with higher strength as well as excellent
comprehensive performance.
Keywords: Mg alloys; High strength; Rare earths (RE); Strengthening mechanism
Faisal Kiani, Cuie Wen, Yuncang Li,
Prospects and strategies for magnesium alloys as biodegradable implants from crystalline to bulk
metallic glasses and composites—A review,
Acta Biomaterialia,
Volume 103,
2020,
Pages 1-23,
ISSN 1742-7061,
https://doi.org/10.1016/j.actbio.2019.12.023.
Abstract: As a biodegradable metal (BM), alloys of magnesium (Mg) offer great potential as an
alternative to the permanent metallic implants currently being used for fracture repairs and tissue-
healing processes. These alloys exhibit superior biocompatibility and appropriate mechanical
strength and dissolution behavior in the physiological environment, essential prerequisites for a BM.
However, rapid and generally non-uniform corrosion has been the major drawback of Mg alloys.
Abrupt deterioration in mechanical strength is experienced due to the inhomogeneous corrosion,
which is also considered detrimental to the surface passivation process. This review has analyzed a
variety of strategies that can be adopted to address the core challenges with Mg alloy biomaterials.
In addition, the review provides fundamental understanding of the mechanisms associated with
these challenging problems, including discussion of crystalline and bulk metallic glasses (BMGs) and
composites. Comparison among the properties and mechanisms observed in other metal alloy
systems, including zinc (Zn) and iron (Fe) alloys and prominent BMGs, are also presented for analysis
in order to provide new approaches to resolving the critical issues of Mg alloys.
Statement of Significance
The effects of alloying elements, microstructure, heat treatment and deformation on the mechanical
and corrosion properties of biodegradable metals such as Mg-based alloys and bulk metal glasses
(BMGs) are identified. Theoretical models and experimental findings are comprehensively analyzed
to corroborate the actual corrosion and deformation mechanisms observed in biodegradable metals
(BMs). This work also provides an in-depth comparison of mechanical and corrosion properties
among the prominent biodegradable metal alloy systems, illustrating a clear outlook on their
potentials. The proposed strategies to address the current challenges in BMs are substantiated with
fundamental theories and experimental evidence.
Keywords: Biodegradable metals; Bulk metallic glasses; Corrosion mechanisms; Magnesium alloys;
Mechanical properties
H. Rojacz, I.A. Neacşu, L. Widder, M. Varga, J. Heiss,
Thermal effects on wear and material degradation of slag pots operating in steel production,
Wear,
Volumes 350–351,
2016,
Pages 35-45,
ISSN 0043-1648,
Abstract: Slag pots are commonly used for the transportation of liquid slag from steel mills to slag
dumps. A detailed failure analysis of slag pots is required to determine effects limiting their lifetime.
Temperature measurements were implemented throughout an ongoing operation to quantify
thermal loading. Different microscopy methods, cross sectional analyses and hardness
measurements were performed on a slag pot after prolonged usage. Material degradation
mechanisms, wear and deformations found during and after slag pot operation were compared to
performed finite element simulations of the transport cycle. Special focus was placed on weaknesses
of the current design. This study addresses thermal effects on wear, failure and degradation
mechanisms present at slag pots. Additionally, attempts for specific solutions will be proposed.
Results indicate that thermal shocks and oxidation lead to material degradation, which alongside the
thermally induced deformation of the pot shape reduce the overall lifetime. Layers of solidified slag
inside the pots further cause severe abrasive wear on the inner pot walls during the discharging
procedure.
Keywords: High temperature; Abrasive wear; Thermal effects; Tribology; Finite element modelling;
Surface analysis
Xiangru Chen, Jie Xu, Henry Hu, Hardy Mohrbacher, Ming Kang, Wei Zhang, Aimin Guo, Qijie Zhai,
Effects of niobium addition on microstructure and tensile behavior of as-cast ductile iron,
Volume 688,
2017,
Pages 416-428,
ISSN 0921-5093,
Abstract: The effects of niobium addition up to 0.11wt% on the microstructure and tensile properties
of as-cast ductile iron (ACDI) were investigated. Metallographic analyses by both optical microscopy
(OM) and scanning electron microscopy (SEM) indicated that niobium (Nb) promoted the formation
of pearlite, reduced pearlite lamellar spacing and decreased the extent of graphitization taking place
in the Nb-alloyed ACDI. The nodularity and nodule counts of graphite changed insignificantly when
the Nb content was less than 0.08wt% in the ACDI. The analysis of precipitates by transmission
electron microscopy (TEM) revealed that nano and micro sized (Nb, Ti)C carbides acted as nucleation
site for graphites, and promoted the formation of large graphite nodules with low roundnesses as
Nb content rose above 0.08wt%. The results of tensile testing showed that the yield strength,
ultimate tensile strength and elongation of the ACDI with 0.08wt% Nb increased by 12.1%, 11.2%
and 14.3% over those of the Nb-free ACDI, respectively. The optimum values of the yield strength,
tensile strength and elongation of the Nb-alloyed ACDI were found to be 418MPa, 746.0MPa and
8.0%, respectively, at the Nb content of 0.08wt%. The high strain hardening rates of the Nb-
containing ACDIs implied that they were capable of spontaneously strengthening itself increasingly
to a large extent, in response to a slight plastic deformation after yielding.
Keywords: As-cast ductile iron; Niobium; Microstructure; (Nb, Ti) C nano precipitate; Tensile
behavior; Fracture
Mark T. MacLean-Blevins,
4 - What tooling will be required?,
Editor(s): Mark T. MacLean-Blevins,
In Plastics Design Library,
Designing Successful Products with Plastics,
William Andrew Publishing,
2018,
Pages 79-97,
ISBN 9780323445016,
https://doi.org/10.1016/B978-0-323-44501-6.00004-0.
Abstract: Selecting and specifying the tooling for a product or part made from plastics is discussed as
a function of the material(s) selected and the process selected for the product or part. Tooling is
vastly different for different plastics manufacturing processes and the design teams need to fully
understand the tooling required for the process and material(s) chosen. Optimum part performance
is achieved when the design of the part will facilitate the design and implementation of the proper
tooling (molds, dies, forms, etc.) to manufacture the part in the selected process. Some rudimentary
background and experience in tooling requirements, and methods is necessary for the design team
before they embark on the detail part design for a given plastics process; some consider tooling
knowledge and experience as an absolute necessity for optimum part design and development.
Keywords: plastics tooling; injection mold; tooling for plastics; thermoforming die; blow mold;
stretch blow mold; extrusion blow mold; high-capacity tooling; multicavity plastics molds; tooling
quality for part quality; prototype tooling; short-run plastics tooling
Giulio Timelli, Daniele Caliari, Jovid Rakhmonov,
Influence of Process Parameters and Sr Addition on the Microstructure and Casting Defects of LPDC
A356 Alloy for Engine Blocks,
Volume 32, Issue 6,
2016,
Pages 515-523,
ISSN 1005-0302,
Abstract: The effects of Sr addition and pressure increase on the microstructure and casting defects
of a low-pressure die cast (LPDC) AlSi7Mg0.3 alloy have been studied. Metallographic and image
analysis techniques have been used to quantitatively examine the microstructural changes and the
amount of porosity occurring at different Sr levels and pressure parameters. The results indicate that
an increase in the filling pressure induces lower heat dissipation of the liquid close to the die/core
surfaces, with the formation of slightly greater dendrite arms and coarser eutectic Si particles. On
the other hand, the increase in the Sr level leads to finer microstructural scale and eutectic Si. The
analysed variables, within the experimental conditions, do not affect the morphology of eutectic Si
particles. Higher applied pressure and Sr content generate castings with lower amount of porosity.
However, as the filling pressure increases the flow of metal inside the die cavity is more turbulent,
leading to the formation of oxide films and cold shots. In the analysed range of experimental
conditions, the design of experiment methodology and the analysis of variance have been used to
develop statistical models that accurately predict the average size of secondary dendrite arm spacing
and the amount of porosity in the low-pressure die cast AlSi7Mg0.3 alloy.
Keywords: Aluminium alloys; Engine block; Microstructure; Casting defects; Sr addition; Process
parameters
Hoda Dini, Ales Svoboda, Nils-Eric Andersson, Ehsan Ghassemali, Lars-Erik Lindgren, Anders E.W.
Jarfors,
Optimization and validation of a dislocation density based constitutive model for as-cast Mg-9%Al-
1%Zn,
Volume 710,
2018,
Pages 17-26,
ISSN 0921-5093,
Abstract: A dislocation density-based constitutive model, including effects of microstructure scale

and temperature, was calibrated to predict flow stress of an as-cast AZ91D (Mg-9%Al-1%Zn) alloy.
Tensile stress-strain data, for strain rates from 10-4 up to 10-1s-1 and temperatures from room
temperature up to 190°C were used for model calibration. The used model accounts for the
interaction of various microstructure features with dislocations and thereby on the plastic
properties. It was shown that the Secondary Dendrite Arm Spacing (SDAS) size was appropriate as an
initial characteristic microstructural scale input to the model. However, as strain increased the
influence of subcells size and total dislocation density dominated the flow stress. The calibrated
temperature-dependent parameters were validated through a correlation between microstructure
and the physics of the deforming alloy. The model was validated by comparison with dislocation
density obtained by using Electron Backscattered Diffraction (EBSD) technique.
Keywords: Characterization; Magnesium alloy; Casting methods; Plasticity; Physically-based model;

Optimization
Peter R.N. Childs,
19 - Tolerancing and precision engineering,
Editor(s): Peter R.N. Childs,
Mechanical Design Engineering Handbook (Second Edition),
2019,
Pages 875-918,
ISBN 9780081023679,
https://doi.org/10.1016/B978-0-08-102367-9.00019-6.
Abstract: The aims of this chapter are to introduce the concepts of component and process
variability and the allocation of component tolerances. The selection of suitable tolerances for the
assembly of components is a key requirement in the development of a machine design for given
functionality, and this requires an understanding of process capability as well as careful attention to
the detailing of the allowable variability component dimensions. The principles of engineering
tolerancing can also be applied to model the variability of a process or function.
Keywords: Tolerances; Tolerancing; Standard; Fits; Interference; Geometric; Statistical; Quality;

Assurance; Selection
Yun Ling, Jianxin Zhou, Hai Nan, Yajun Yin, Xu Shen,
A shrinkage cavity prediction model for gravity castings based on pressure distribution: A casting
steel case,
Volume 26,
2017,
Pages 433-445,
ISSN 1526-6125,
Abstract: Numerical simulation of casting solidification process is of great importance for producing
of gravity casting part. In the paper, two key points of evolution of isolated liquid areas and
shrinkage location in each isolated liquid area in the shrinkage prediction are discussed. The
boundary criterion used in isolated liquid areas searching algorithm and rule of shrinkage
distribution based on the principle of minimum potential energy is derived. The pressure plays a key
role in both points. Then we discussed the detail of the workflow and solution of shrinkage cavities
prediction model. Finally, a group of U-type casting experiments are simulated and implemented in
order to test and verify effectiveness of the proposed model. An excellent agreement is indicated for
the numerical simulation result and the experiment results.
Keywords: Numerical simulation; Gravity castings; Shrinkage prediction; Isolated liquid area;
Pressure
Federico Campi, Claudio Favi, Marco Mandolini, Michele Germani,

Using design geometrical features to develop an analytical cost estimation method for axisymmetric
components in open-die forging,
Procedia CIRP,
Volume 84,
2019,
Pages 656-661,
ISSN 2212-8271,
Abstract: Hot forging is an industrial process where a metal piece is formed through a series of dies
which permanently change the shape of the part. Open-die forging is a particular type of hot forging
in which the used dies are generally flat and the part to be formed has a simple shape.
Manufacturing cost estimation is a well-debated topic, especially for traditional manufacturing
technologies. However, only few models are available in scientific literature for the open-die forging
process. This lack is due to the complexity of the process, characterized by a low level of automation
and a high degree of expertise required to develop the process. The paper proposes an analytical
model for the cost estimation of axisymmetric components realized using open die-forging. The
model uses as input the geometrical features of the part (e.g. dimensions, shape, material and
tolerances), and gives as output: (i) the time required for the process development, (ii) the amount
of material needed for the part processing and, (iii) the forging machine size/type, from the cutting
of the billet to the piece deformation. Two cylindrical discs have been analysed for validating the
proposed cost estimation model. The case studies show that the cost models give an accurate result
in terms of cost breakdown, allowing the designer a quick calculation of process costs.
Keywords: hot forging; cost estimation; open-die forging; analytical cost model; design features
Andreas Gebhardt, Julia Kessler, Laura Thurn,
2 - Additive Manufacturing Processes/3D Printing,
Editor(s): Andreas Gebhardt, Julia Kessler, Laura Thurn,
3D Printing (Second Edition),
Hanser,
2019,
Pages 33-70,
ISBN 9781569907023,
https://doi.org/10.3139/9781569907030.002.
Jozef Mitterpach, Emília Hroncová, Juraj Ladomerský, Karol Balco,
Environmental evaluation of grey cast iron via life cycle assessment,
Volume 148,
2017,
Pages 324-335,
ISSN 0959-6526,
Abstract: The metallurgy industry significantly influences the quality of its surrounding environment.
This paper, therefore, focuses on creating a model of life cycle assessment (LCA) for a foundry
producing grey cast-iron castings. The principles of a LCA are given in ISO 14040: 2006 and ISO
14044: 2006. The environmental impact of the production of one ton of ready grey cast-iron castings
was quantified, and the significant components of the LCA model were identified. The Hronec
foundry model is situated in Slovakia, and its average annual production is 6000 tons of grey cast-
iron castings. The production consists of typical processes for melting metal in cupolas, including
production of castings by pouring molten metal into single-use sand moulds and final finishing
before dispatch. The SimaPro 8 and ReCiPe Endpoint (quality of ecosystem, human health and
consumption of resources) methods were used to assess the environmental impact of the castings.
The greatest overall negative environmental impact (74.1%) is caused by processes related to
melting metal in the smeltery, with the greatest negative impact on the consumption of resources.
An important component of the LCA and the company's contribution is the identification of recycled
metal waste (iron and steel waste sort 258.598 kg/t, backspacing scarp 82.88 kg/t and metallic
packaging waste 0.952 kg/t), which in the melting process, reduces the impact of smelting by 9.52%.
The next important component of the LCA and the company's contribution is the recycling of waste
cores (1204.92 kg/t) during the manufacture of moulds, which reduces the impact of moulding by
1.65%. The overall impact of the other main foundry processes on environmental quality was
minimised using environmental measures in the foundry, particularly its technological methods.
These methods focused on reducing the demand for raw materials and other materials, energy
consumption, release of emissions to the atmosphere, water use, and creation and production of
solid waste as well as increasing the quality of drained water. These findings directly indicate the
importance of the environmental measures that are used in foundry production processes. This
“cradle-to-gate” LCA study can therefore form the basis for further environmental analyses that will
help to reduce the negative environmental impact of foundry production.
Keywords: LCA; Environment; Foundry; Waste; Recycling
Hamdy Ibrahim, Sajedeh Nasr Esfahani, Behrang Poorganji, David Dean, Mohammad Elahinia,
Resorbable bone fixation alloys, forming, and post-fabrication treatments,
Materials Science and Engineering: C,

Volume 70, Part 1,
2017,
Pages 870-888,
ISSN 0928-4931,
https://doi.org/10.1016/j.msec.2016.09.069.
Abstract: Metallic alloys have been introduced as biodegradable metals for various biomedical
applications over the last decade owing to their gradual corrosion in the body, biocompatibility and
superior strength compared to biodegradable polymers. Mg alloys possess advantageous properties
that make them the most extensively studied biodegradable metallic material for orthopedic
applications such as their low density, modulus of elasticity, close to that of the bone, and
resorbability. Early resorption (i.e., <3months) and relatively inadequate strength are the main
challenges that hinder the use of Mg alloys for bone fixation applications. The development of
resorbable Mg-based bone fixation hardware with superior mechanical and corrosion performance
requires a thorough understanding of the physical and mechanical properties of Mg alloys. This
paper discusses the characteristics of successful Mg-based skeletal fixation hardware and the
possible ways to improve its properties using different methods such as mechanical and heat
treatment processes. We also review the most recent work pertaining to Mg alloys and surface
coatings. To this end, this paper covers (i) the properties and development of Mg alloys and coatings
with an emphasis on the Mg-Zn-Ca-based alloys; (ii) Mg alloys fabrication techniques; and (iii)
strategies towards achieving Mg-based, resorbable, skeletal fixation devices.
Keywords: Biodegradable metals; Corrosion; Magnesium alloys; Heat treatment; Additive

manufacturing; Bone fixation hardware
Jorge Santos, Ronny M. Gouveia, F.J.G. Silva,
Designing a new sustainable approach to the change for lightweight materials in structural
components used in truck industry,
Volume 164,
2017,
Pages 115-123,
ISSN 0959-6526,
Abstract: Reducing emissions and improving fuel economy are very important concerns for the
heavy-duty transportation industry. Removing weight from vehicles increases performance and
efficiency; this consequently lowers produced emissions and improves fuel consumption. For
commercial vehicle manufacturers, the introduction of cost-competitive lightweight materials
provides great potential to achieve these objectives. Ferrous cast materials, due to their high specific
strength per cost ratio and flexibility to be used with casting processes are good alternatives to
produce structural components, as weight savings can be achieved. Numerous parts used in heavy-
duty transportation vehicles need to be redesigned to fully take advantage of the increasing
developments of metallic alloys. These materials with higher strength allow the reduction of part
thickness while maintaining similar mechanical resistance properties. However, there are no
established procedures that can help designers to reassess their previous projects and aid them in
making new design decisions in order to achieve weight savings on heavy-duty vehicles. Vehicles of
such nature are intensively used in ground transportation and are responsible for a considerable
amount of emissions. This work intends to create a novel procedure to help select and change the
materials used for structural components of commercial vehicles, being certainly useful to alert and
aid designers in updating their preexisting designs. Due to the complex geometry of the components
utilized on cars, trucks and similar vehicles and regarding the strength requirements usually
demanded by customers, casting processes assume a relevant status when considering the selection
of the material/process combo to be used. Thus, a flow diagram was created containing relevant
questions and answer paths, allowing the designer to easily re-think about the materials currently in
use and bring to the discussion new materials and manufacturing processes. By introducing
lightweight components in a more efficient way through well-selected materials alongside with
contemplation of the manufacturing processes to be used, design engineers simultaneously enhance
weight reduction; promote time savings, decrease energy consumption and achieve emission gains.
As a case study, this work presents lightweight ferrous cast materials as a good weight reducing
alternatives, as well as the procedure for materials selection for heavy-duty structural components.
Keywords: Emissions reduction; Fuel efficiency; High strength materials; Cast ferrous alloys;
Austempered ductile iron; SiboDur®; Ausferritic steel
Zhiyi Ding, Zengbao Jiao,
Metallic Materials for Making Multi-Scaled Metallic Parts and Structures,
Elsevier,
2020,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-819726-4.00007-7.
Abstract: Metallic materials are important for making multi-scale parts and structures because of
their excellent mechanical properties and good formability. This article reviews several types of
classic metallic materials for multi-scale structural applications, including aluminum alloys,
magnesium alloys, copper alloys, titanium alloys, carbon steels, nanoprecipitation-strengthened
steels, metallic glasses, and high-entropy alloys. Particular emphasis is placed on the alloy
characteristics, microstructure, mechanical properties, processability, formability, and applications
of these materials, aiming at providing a reference tool for material selection in multi-scale structure
design and development.
Keywords: Aluminum; Copper; Formability; High-entropy alloy; Magnesium; Mechanical property;

Metallic glass; Metallic material; Microstructure; Multi-scale application; Steel; Titanium
R. Singh, S. Singh,
Development of Functionally Graded Material Through the Fused Deposition Modeling-Assisted

Investment Casting Process: A Case Study,
Elsevier,
2016,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.04169-2.
Abstract: Aluminum matrix composites (AMCs) are one of the most demanding engineering
materials in the category of metal matrix composites (MMCs) due to their light weight and excellent
mechanical and tribological properties. The main objective of the present research work was to
develop Al–Al2O3 composites through the fused deposition modelling-assisted investment casting
(FDMAIC) process by using reinforced fused deposition modeling (FDM) feedstock filament as a
novel method. Initially, experimentation was performed using the melt flow indexer (MFIer) to select
the appropriate proportions of nylon-6, Al powder, and Al2O3 powder for obtaining the same melt
flow index (MFI) as the commercial Acrylonitrile-Butadiene-Styrene (ABS) has. During the second
stage, the fabricated FDM filaments were used for the manufacturing of investment casting
sacrificial patterns on the existing FDM system. Barrel finishing (BF) was used to improve the surface
finish of the sacrificial patterns prior to ceramic molding. Taguchi L18 orthogonal array was used for
designing the control log of experimentation, and the signal-to-noise (S/N) ratio has been analyzed
to determine the effect of input process parameters (such as filament proportion, volume of FDM
pattern, density of FDM pattern, BF cycle time, BF media weight, and number of slurry layers) of the
properties (such as surface roughness, dimensional accuracy, hardness, and wear) of the castings
developed. Characterization of the castings was performed by using an optical microscope, scanning
electron microscopy, energy dispersive spectrometry, and X-ray diffraction analysis. It has been
found that the distribution of Al2O3 particles was limited to the outer surface of the castings and the
core was not reinforced; therefore, the composites developed can be considered functionally graded
material (FDM). The castings developed were found to be acceptable as UNI-EN-20286-i (1995), and
the process was statistically controlled for batch production.
Keywords: Additive manufacturing; Barrel finishing; Composite; Design of experimentation;

Dimensional accuracy; Energy dispersive; Functionally graded material; Fused deposition modeling;
Hardness; Investment casting; Melt flow indexer; Nylon-6; Process capability; Scanning electron
microscopy; Spectroscopy; Surface roughness; Taguchi; Tolerance grade; Wear; X-ray diffraction
D. Krewerth, T. Lippmann, A. Weidner, H. Biermann,
Influence of non-metallic inclusions on fatigue life in the very high cycle fatigue regime,
Volume 84,
2016,
Pages 40-52,
ISSN 0142-1123,
https://doi.org/10.1016/j.ijfatigue.2015.11.001.
Abstract: The present paper deals with the influence of non-metallic inclusions on fatigue life in the
high cycle fatigue and the very high cycle fatigue regime. For that purpose, several castings of steel
42CrMo4 (AISI 4140, DIN EN 1.7225) were produced by using recently developed novel metal-melt
filters. The specimens were tested in hot-isostatically pressed and heat treated condition. After
fatigue failure every fracture surface was intensively investigated by scanning electron microscopy in
order to define the type, the size, the chemical composition, the morphology and the location of the
crack initiating discontinuity. Subsequently, Murakami’s √area model was used for the evaluation of
the influence of non-metallic inclusions on the fatigue life. In the present investigation four common
types of chemical compositions of crack initiating discontinuities were identified. Furthermore, four
different internal failure types and their influence on the fatigue life in cast steel were investigated
and described. Thus, the present contribution proposes a basic correlation determined from fatigue
lives in case of various internal crack initiation types. The key parameters for fatigue life prediction in
case of internal fatigue failure in the very high cycle fatigue regime are (i) the size of the crack
initiating discontinuity, (ii) the inclusion depth and (iii) the crack initiating failure type.
Keywords: Very high cycle fatigue; Internal crack initiation; Non-metallic inclusions; AISI 4140
N. Tamiloli, J. Venkatesan, B. Vijaya Ramnath,
A grey-fuzzy modeling for evaluating surface roughness and material removal rate of coated end
milling insert,
Measurement,
Volume 84,
2016,
Pages 68-82,
ISSN 0263-2241,
https://doi.org/10.1016/j.measurement.2016.02.008.
Abstract: The prime factor for selecting equipment is its performance capability and reliability
without compromising on quality. Materials for aerospace application such as aluminum and its
alloys have limited applications because of their complications in machining, effectively and
economically. There is no further development in raising the effectiveness above the optimal level in
cutting tool materials. The surface roughness influences the determination of the quality of the
product. The present study focuses on finding optimal end milling process parameters by
considering multiple performance characteristics using grey fuzzy approach. In this work, Aluminum
Alloy 6082T6 (AA6082T6) is used as workpiece material which was end milled using Aluminum
Chromo Nitride (AP3) coated milling insert. Three process performance parameters namely Centre
Line Average Roughness (Ra), Root Mean Square Roughness (Rq) and Material Removal Rate (MRR)
were optimized. The grey output is fuzzified into five membership functions and also with twenty-
seven rules. Grey Fuzzy Reasoning Grade (GFRG) is developed and the optimal values were found
out from the Grey relational grade. The result of the Analysis of Variances (ANOVA) shows that the
maximum contribution in the depth cut is (31.785%) followed by feed (28.212%). Moreover,
Adaptive Neuro-Fuzzy Inference System (ANFIS) model has been developed with the help of the
same input values compared to the performance of the fuzzy logic model. With the help of detailed
analysis, it has been found that the fuzzy logic based model gives more reasonable results when
compared to ANFIS model.
Keywords: Grey-fuzzy model; Adaptive Neuro-Fuzzy Inference System; End milling; Coated insert;
Optimization; Aluminum alloy
Ron Palgrave,
Chapter 4 - Pump basics; part 2,
Editor(s): Ron Palgrave,
Troubleshooting Centrifugal Pumps and their Systems (Second Edition),
2020,
Pages 61-95,
ISBN 9780081025031,
https://doi.org/10.1016/B978-0-08-102503-1.00004-9.
Abstract: Centrifugal pumps are very simple machines. They consist of a few basic parts. However
these parts will differ generically in detail, sometimes significantly. Furthermore, these basic
components can be configured in a variety of different ways. This variety helps to substantially
extend the range of centrifugal pump application. This Chapter attempts to outline why some of the
popular configurations exist. It describes their principal features.
Keywords: Single entry impeller; Double entry impeller; Multistage; Stacked rotor; Back-to-back
rotor; Andersons' area ratio
Index,
Editor(s): Gabor Takacs,
Electrical Submersible Pumps Manual (Second Edition),
2018,
Pages 545-564,
ISBN 9780128145708,
https://doi.org/10.1016/B978-0-12-814570-8.18001-8.
Index,
Elsevier,
2020,
Pages 797-813,
ISBN 9780080999258,
https://doi.org/10.1016/B978-0-08-099925-8.20001-X.
M. Mödlinger, E. Godfrey, W. Kockelmann,
Neutron diffraction analyses of Bronze Age swords from the Alpine region: Benchmarking neutron
diffraction against laboratory methods,
Journal of Archaeological Science: Reports,
Volume 20,
2018,
Pages 423-433,
ISSN 2352-409X,
https://doi.org/10.1016/j.jasrep.2018.05.017.
Abstract: Bronze Age swords represent the peak of craftsmanship in terms of prehistoric weapon
production. Following an extensive study on the manufacture and usage of Bronze Age swords from
the Alpine region, we have used non-destructive time-of-flight neutron diffraction to analyse a
selection of bronze swords. The diffraction patterns were used to determine the phase compositions
and crystallographic textures of the copper tin alloys, in order to reveal information about the
working treatment at different parts of the sword blades. Neutron diffraction analyses are
benchmarked against results from reference bronze samples, as well as against X-ray fluorescence
and metallographic analyses applied to the same objects. Comparing different working intensities of
cold working in various areas of the sword blades can lead to information about the usage of the
swords as mainly thrusting or as cut-and-thrust used weapons.
Keywords: Bronze Age; Swords; Neutron diffraction; Structure and texture analysis; Manufacture
and usage
Peter Schwarzmann, Adolf Illig,
21 - Thermoforming tools,
Editor(s): Adolf Illig, Peter Schwarzmann,
Thermoforming (Second Edition),
Hanser,
2019,
Pages 337-409,
ISBN 9781569907085,
https://doi.org/10.3139/9781569907092.021.
Mohammad Jahedi, Brandon A. McWilliams, Franklin R. Kellogg, Irene J. Beyerlein, Marko Knezevic,
Rate and temperature dependent deformation behavior of as-cast WE43 magnesium-rare earth alloy
manufactured by direct-chill casting,
Volume 712,
2018,
Pages 50-64,
ISSN 0921-5093,
Abstract: In this work, we study the deformation behavior of a direct chill cast WE43 Mg alloy. This
material initially has equiaxed grains approximately 40µm in diameter and a random texture. The
room temperature, quasi-static response exhibits little plastic anisotropy when evaluated parallel to
and normal to the solidification direction and no initial yield tension-compression asymmetry. The
deformation at room temperature is accompanied by significant basal texture development and
formation of three types of deformation twins: {101̅2}〈1̅011〉, {101̅1}〈1012̅〉, and {112̅1}
〈1̅1̅26〉 as well as double twins {101̅1}〈1012̅〉-{101̅2}〈1̅011〉, although each in small amounts
< 10% up to failure. We find that in the elevated 250°C ± 20°C regime, the material exhibits a
negative strain rate sensitivity, with a decreasing flow stress as the strain rate increases. In most of
the high-temperature, 250°C to 350°C, and high-strain-rate, 0.01/s to 10/s, tests, the material failed
at moderate compression strains, 0.35–0.45. Subsequent fracture analyses find that the material
fractures transgranularly by a typical shear fracture, often with the presence of additional arrested
cracks. At elevated temperatures and under strain rates sufficiently low (i.e., 275°C and 0.01/s,
300°C and 0.1/s, 350°C and 1/s, 375°C and 10/s) or at a temperature of 400°C deformation
conditions, the material exhibited pseudo-super plastic behavior, experiencing relatively high
deformation strains (> 1.0 true strain) without fracturing.
Keywords: Rare earth magnesium alloys; Crystallographic texture; Deformation twinning; Strain
hardening; Anisotropy
Ivette Arroyo, Johnny Åstrand,
User involvement in housing recovery after typhoon Haiyan from a capability perspective,
International Journal of Disaster Risk Reduction,
Volume 38,
2019,
101158,
ISSN 2212-4209,
https://doi.org/10.1016/j.ijdrr.2019.101158.
Abstract: Typhoon Haiyan hit the Philippines on 8th November 2013 destroying more than 1 million
houses and affecting mostly the poor. This paper discusses user involvement in housing recovery
from a capability perspective. The paper also analyses possibilities for extension of the housing
solutions. Based on the Sphere handbook and the theoretical framework, a Model for user
involvement in evolutionary housing recovery has been developed and applied to analyse empirical
data from two qualitative case studies in the cities of Tanauan and Ormoc. Prospective users that
have attained different opportunities and choices through the projects whilst being actively involved
in some stages of the process seem to have enhanced capacities such as self-construction skills, self-
esteem, leadership and community organizing. Users were not involved or only consulted during the
planning and design stage, which derived in generic housing lacking qualities for extension. The
findings from both case studies support the theoretical construct underlying the model. The
implications of the model is that it can be applied to design, carry out or assess housing recovery
processes in other developing contexts.
Keywords: Housing recovery; User involvement; Capability approach; Evolutionary housing; The
Philippines; Typhoon Haiyan
Chapter 2 - Structure and Microstructure of Aluminum Alloys in As-Cast State,
Dinsdale,
2019,
Pages 133-234,
ISBN 9780128118054,
https://doi.org/10.1016/B978-0-12-811805-4.00002-X.
Abstract: This chapter is devoted to establishing relatioships among phase diagrams, thermodynamic
properties of alloys, and their microstructure. A systematic review of the classical Gibbsian
thermodynamics was performed, followed by its extension to equilibrium concentrationally
nonuniform systems given by Cahn, Hilliard, and Allen. The generalization of their early approach by
Khachaturian and Chen allowed to develop a powerful group of microstructure evolution modeling
techniques called “phase-field” approach. The most recent developments in phase field simulations
were reviewed along with the available software for microstructure evolution of aluminum alloys. A
systematic review of the quantitative methods of microstructure characterization was offered in
Section 2.4, including the software available for microstructure analysis, segmentation, and feature
extraction (Image J; MorphoHawk© etc.). This section is devoted to nonequilibrium solidification of
foundry aluminum alloys has been updated and includes two new sections titled “Formation of
Metastable Phases and suppression of Stable Phases during Solidification” and “Solidification Paths
in Systems with a Miscibility Gap in the Liquid State.” The former section provides interesting
illustrations using thermodynamic and first-principles calculations for the Al–Mn and Al–Zr systems,
including the description of such metastable “phases” as Al31Zr, Al107Zr, and Al255Zr. This chapter
is concluded by discussing the interplay of phase and defect microstructures in cast aluminum alloys,
that is, the role of dislocation structures upon phase microstructure; and by describing the
decomposition of (Al) solid solutions during cooling after solidification.
Keywords: aluminum alloy thermodynamics; CALPHAD; nonequilibrium solidification; phase and

defect microstructures; phase diagrams; phase-field modeling; stable and metastable Al-bearing
phases
Jipeng Pan, Penghuai Fu, Liming Peng, Bin Hu, Haiming Zhang, Alan A. Luo,
Basal slip dominant fatigue damage behavior in a cast Mg-8Gd-3Y-Zr alloy,

Volume 118,
2019,
Pages 104-116,
ISSN 0142-1123,
Abstract: Low fatigue strength has been a major barrier for structural applications of cast
magnesium alloys. It is important to understand the fatigue mechanisms and improve the fatigue
lives of these alloys. Stress-controlled high-cycle fatigue behaviors of cast Mg-8Gd-3Y-Zr (wt.%) alloy
in as-cast, solution treated (T4) and aged (T6) conditions were studied at room temperature, and the
fatigue damage morphologies were carefully characterized. During high-cycle fatigue, only basal slips
were observed on the surface of fatigue samples under different stress amplitudes, which suggests
that basal slip is the dominant fatigue damage mechanism. The T4 and T6 alloys show distinguishing
different damage morphologies at grain interiors: there are serried PSMs in the T4 alloy and only
sparse PSMs in the T6 alloy. Basal slip deformation can be transferred among basal planes in the
“soft” T4 alloy, while only limited on several PSBs in the “hard” T6 alloy. In the T4 alloy, a great
number of basal slip planes in a single grain and most of the grains participate in the fatigue
deformation, resulting higher fatigue strength (80 MPa, for 107 cycles). For T6 alloy, the fatigue
deformation only happens in several PSBs and most of the grains have no plastic deformation,
resulting lower fatigue strength (70 MPa).
Keywords: Magnesium alloy; High cycle fatigue; Fatigue morphology; Basal slip; Deformation transfer
Nagendra Kumar Maurya, Vikas Rastogi, Pushpendra Singh,
An overview of mechanical properties and form error for rapid prototyping,
CIRP Journal of Manufacturing Science and Technology,
Volume 29, Part A,
2020,
Pages 53-70,
ISSN 1755-5817,
https://doi.org/10.1016/j.cirpj.2020.02.003.
Abstract: Rapid prototyping (RP) is one of the most imperative advanced manufacturing techniques.
RP has attracted attention in the prototyping community due to its capability of reducing the lead
time of the product development. It has emerged as an alternative method to fabricate component.
RP has recently shown a wide range of engineering as well as medical applications. However,
dimensional accuracy, surface roughness and part strength of the component fabricated by RP
technology are poorer compared to that of traditional manufacturing process. The main emphasis of
authors in this research work is to describe the methodology adopted by researchers. The novelty of
this work lies in the fact that it provides a systematic approach to enable potential for persons from
industry as well academic users to select suitable process parameters for fabricating the component.
Keywords: Rapid prototyping; Dimensional accuracy; Surface roughness; Mechanical properties;

Form error
Purnendu Kumar Mandal, P.S. Robi,
Influence of micro-alloying with silver on microstructure and mechanical properties of Al-Cu alloy,
Volume 722,
2018,
Pages 99-111,
ISSN 0921-5093,
Abstract: The present study aims to investigate the microstructure and mechanical properties of Al-
Cu-Zn-Fe-Ti-Mg alloy (≈ 2219 Al-alloy), micro-alloyed with silver (Ag in the range 0 − 0.1 wt%), under
different thermo-mechanical process conditions. Investigation of the microstructure of cast alloys
revealed the presence of intermetallic CuAl2 and metastable Al-Cu-Fe-Zn-Si-Mn phases at the grain
boundary regions. The as-cast dendritic structure was eliminated by heat treatment and subsequent
rolling process resulting in improved mechanical properties. The strength and hardness increased
with the increase in silver content up to 0.07 wt% in combination with reasonable ductility.
Maximum strength for the alloy was achieved in the rolled and age hardened condition.
Fractographic studies revealed brittle failure in as-cast alloys, whereas the heat treated alloys
exhibited features typical of ductile failure.
Keywords: 2219 Al-alloy; Micro-alloying; Silver; Microstructure; Mechanical properties
Ojas Satbhai, Subhransu Roy, Sudipto Ghosh,
A parametric multi-scale, multiphysics numerical investigation in a casting process for Al-Si alloy and
a macroscopic approach for prediction of ECT and CET events,
Applied Thermal Engineering,
Volume 113,
2017,
Pages 386-412,
ISSN 1359-4311,
https://doi.org/10.1016/j.applthermaleng.2016.11.003.
Abstract: Understanding of columnar-to-equiaxed transition (CET) and equiaxed-to-columnar

transition (ECT) is difficult not only due to the involvement of multiple factors like advection of
equiaxed grains, fragmentation of dendrites, etc. but also due to its complex relationship with
temperature gradient (G), solidification velocity (R), and cooling rate (Ṫ) at the solidification front
over a broad range of solidification conditions. Parametric multi-scale, multiphysics grain structure
simulations were performed to develop the relationship between process-parameters and grain
structure for the casting process over a wide range of process parameters. The effect of interfacial
heat transfer coefficient, superheat, and nucleation site density on the grain structure is studied
using a coupled finite-volume-method-cellular-automaton (FVM-CA) multi-scale, multiphysics
solidification model. A numerical averaging strategy at the solidification front is proposed for
monitoring the occurrence of CET and ECT. We attempt to study the grain structure evolution
obtained from the multi-scale model with the transient macroscopic average thermal parameters.
Unlike the previous attempts here we evolve criteria independently from the macro-model that
obeys the phase diagram. It was found that the temperature field has the imbibed signatures for the
occurrence of CET and ECT.
Keywords: Multi-physics and multi-scale solidification modelling; Grain structure simulation; FVM-
CA; Process-grainstructure relationship; CET and ECT
Sang-Hoon Kim, Jong Un Lee, Ye Jin Kim, Jun Ho Bae, Bong Sun You, Sung Hyuk Park,
Accelerated precipitation behavior of cast Mg-Al-Zn alloy by grain refinement,
Volume 34, Issue 2,
2018,
Pages 265-276,
ISSN 1005-0302,
Abstract: This study demonstrates that the precipitation behavior of β-Mg17Al12 phase during aging
and the resultant variation in hardness and mechanical properties of cast Mg-Al-Zn alloy are strongly
dependent on initial grain size. Grain size reduction accelerates discontinuous precipitation at the
early stage of aging treatment by increasing the area fraction of grain boundaries that can act as
nucleation sites for discontinuous precipitates (DP), but it does not influence DP growth rate. Grain
refinement also prematurely terminates continuous precipitation because the formation of a large
number of DP reduces the amount of Al dissolved in the matrix, which is required for the formation
of continuous precipitates (CP). This promotion of DP formation and early termination of CP
formation significantly decrease the peak-aging time to one-third. The enhanced precipitation
behavior also leads to an additional hardness improvement in the aged alloy, along with an increase
in hardness owing to grain boundary strengthening by grain refinement. The amount of increase in
hardness changes with aging time, which is determined by the variation of three variables with aging
time: DP fraction difference between refined and nonrefined alloys, hardness difference between DP
and matrix, and matrix hardness difference between the two alloys. Grain refinement improves both
tensile strength and ductility of the homogenized alloy owing to grain boundary strengthening and
suppression of twinning activation, respectively. However, the loss of ductility after peak-aging
treatment is greater in the refined alloy because of the larger amount of DP acting as a crack source
in this alloy.
Keywords: Magnesium; Grain refinement; Aging; Precipitation; Tensile properties
Hala A. Hassan, John J. Lewandowski,
4.4 Fracture Toughness and Fatigue of Particulate Metal Matrix Composites,
Editor(s): Peter W.R. Beaumont, Carl H. Zweben,
Comprehensive Composite Materials II,
Elsevier,
2018,
Pages 86-136,
ISBN 9780081005347,
https://doi.org/10.1016/B978-0-12-803581-8.09964-1.
Abstract: The addition of high modulus fibers, particles, or whiskers to conventional metallic alloys
can produce favorable changes in strength, elastic modulus, wear resistance, creep resistance,
coefficient of thermal expansion, and fatigue life. These are some of the benefits of producing metal
matrix composites (MMCs). Although there are many types of MMCs available, the economical
production of silicon carbide whiskers, SiCw, and particles, SiCp, has produced considerable interest
in Al-alloys reinforced with SiC. There is a preponderance of published work on the properties of
discontinuously reinforced aluminum (DRA) and MMCs, discontinuously reinforced metal matrix
composites (DRMMCs) available in the open literature, with more recent work on damage tolerance
of nano-structured composites and laminated metal composites (LMCs). The effects of discontinuous
reinforcement (including nano-sized) on the properties of MMCs are presented, followed by the
benefits of creating LMCs for both toughness enhancement and fatigue resistance. This chapter
begins with a discussion of the current and potential applications of MMC’s, followed by detailed
summaries of various properties.
Keywords: Fatigue; Fatigue crack growth; Fracture toughness; Laminated metal composites; Metal
matrix composites
Luo-yi WU, Hao-tian LI, Zhong YANG,
Microstructure evolution during heat treatment of Mg–Gd–Y–Zn–Zr alloy and its low-cycle fatigue
behavior at 573 K,
Volume 27, Issue 5,
2017,
Pages 1026-1035,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(17)60120-1.
Abstract: In as-cast Mg–2.1Gd–1.1Y–0.82Zn–0.11Zr (mole fraction, %) alloy, lamellar microstructures

that extend from grain boundaries to the interior of α-Mg grains are identified as clusters of γ′ using
a scanning transmission electron microscope equipped with a high-angle annular dark-field detector.
Under a total strain-controlled low-cyclic loading at 573 K, the mechanical response and failure
mechanism of Mg–2.1Gd–1.1Y–0.82Zn–0.11Zr alloy (T6 peak-aging heat treatment) were
investigated. Results show that the alloy exhibits cyclic softening response at diverse total strain
amplitudes and 573 K. The experimental observations using scanning electron microscopy show that
the micro-cracks initiate preferentially at the interface between long-period stacking order
structures and α-Mg matrix and extend along the basal plane of α-Mg. The massive long-period
stacking order structures distributed at grain boundaries impede the transgranular propagation of
cracks.
Keywords: Mg–Gd–Y–Zn–Zr alloy; long-period stacking order structure; low-cycle fatigue at high
temperature; crack initiation and propagation
F. Brownlie, C. Anene, T. Hodgkiess, A. Pearson, A.M. Galloway,
Comparison of Hot Wire TIG Stellite 6 weld cladding and lost wax cast Stellite 6 under corrosive wear
conditions,
Wear,
Volumes 404–405,
2018,
Pages 71-81,
ISSN 0043-1648,
Abstract: This study compares Hot Wire Tungsten Inert Gas Stellite 6 weld cladding on a low carbon
steel substrate with a lost wax cast Stellite 6 in impingement erosion-corrosion conditions. Austenitic
stainless steel samples were used as a reference material. Tests were conducted in a closed loop
impinged slurry vessel with a jet velocity of 18 m/s with 3.5%NaCl aqueous solution containing
500 µm spherical silica sand particles (0.5 g/l sand concentration). The testing temperature was
40 °C. Mass loss measurements and a volumetric analysis as well as microstructural evaluation were
used as post-test analysis techniques. Results showed that weld cladding and lost wax cast Stellite 6
performed better than the stainless steel, with the weld cladding marginally outperforming the lost
wax cast technique.
R.M. German,
1 - Metal powder injection molding (MIM): Key trends and markets,
Editor(s): Donald F. Heaney,
Handbook of Metal Injection Molding (Second Edition),
2019,
Pages 1-21,
ISBN 9780081021521,
https://doi.org/10.1016/B978-0-08-102152-1.00001-5.
Abstract: Metal powder injection molding (MIM) has been in production since the 1970s. During that
time, the market has expanded enormously to include a broad array of applications; the initial
successes were in dental orthodontic brackets, watch cases, and firearms, but recently the
technology has moved into higher performance, life-critical applications in dental implants, artificial
joints, heart pacemakers, and aerospace jet engines. This chapter provides a statistical overview of
MIM, its applications, growth, financial performance, and growth prospects.
Keywords: Markets; Productivity; Sales; Applications; Production statistics; Capacity; Financial
Eric Neiva, Michele Chiumenti, Miguel Cervera, Emilio Salsi, Gabriele Piscopo, Santiago Badia,
Alberto F. Martín, Zhuoer Chen, Caroline Lee, Christopher Davies,
Numerical modelling of heat transfer and experimental validation in powder-bed fusion with the
virtual domain approximation,
Finite Elements in Analysis and Design,
Volume 168,
2020,
103343,
ISSN 0168-874X,
https://doi.org/10.1016/j.finel.2019.103343.
Abstract: Among metal additive manufacturing technologies, powder-bed fusion features very thin
layers and rapid solidification rates, leading to long build jobs and a highly localized process. Many
efforts are being devoted to accelerate simulation times for practical industrial applications. The new
approach suggested here, the virtual domain approximation, is a physics-based rationale for spatial
reduction of the domain in the thermal finite-element analysis at the part scale. Computational
experiments address, among others, validation against a large physical experiment of 17.5 [cm3] of
deposited volume in 647 layers. For fast and automatic parameter estimation at such level of
complexity, a high-performance computing framework is employed. It couples FEMPAR-AM, a
specialized parallel finite-element software, with Dakota, for the parametric exploration. Compared
to previous state-of-the-art, this formulation provides higher accuracy at the same computational
cost. This sets the path to a fully virtualized model, considering an upwards-moving domain covering
the last printed layers.
Keywords: Additive manufacturing (AM); Powder-bed fusion (PBF); Selective laser melting (SLM);
Finite elements (FE); Thermal analysis; High performance computing (HPC)
I. Narasimha Murthy, N. Arun Babu, J. Babu Rao,
High Carbon Ferro Chrome Slag – Alternative Mould Material for Foundry Industry,
Procedia Environmental Sciences,
Volume 35,
2016,
Pages 597-609,
ISSN 1878-0296,
https://doi.org/10.1016/j.proenv.2016.07.046.
Abstract: High silica sand is commonly used in foundry industry for sand moulds making. Various
efforts are being made to use the industrial wastes as an alternate molding material in foundry to
conserve the natural resources; and effective utilization of the industrial waste to sustain the
industrialization. Ferro chrome (Fe-Cr) slag has many of the same attributes of the sand. In this paper
investigations were carried out on comparative mould and casting properties of high silica sand and
Fe-Cr slag for foundry applications. A series of sand tests were carried out on silica sand, Fe-Cr slag
individually and various combinations of these two. The process parameters considered for this
investigation were % of Sodium silicate, CO2 gassing time, and mould setting time. Two types of
moulds were made with 100%Fe-Cr Slag and 100% Silica Sand individually with 8%Sodium Silicate
and 15Seconds CO2 gassing time. AA2024 Aluminium alloy cylindrical castings were made through
these two moulds; castings were investigated for its microstructure and hardness studies. Results
reveal that standard samples with Fe-Cr slag can be prepared; these shows smooth surface finish
and accurate dimensions on par with the sand samples. The mould permeability, compression and
shear strength results showed Fe-Cr Slag will be a suitable candidate for either partial or full
replacement of molding sand. Enhanced mould properties were observed for Fe-Cr slag than silica
sand. Good surface finish castings with enhanced mechanical properties and fine grain
microstructures were produced by Fe-Cr slag moulds.
Keywords: Silica sand; Fe-Cr slag; CO2 process; Mould properties; AA2024 Castings ;
Wojciech Kasprzak, Hirotaka Kurita, Gabriel Birsan, Babak Shalchi Amirkhiz,
Hardness control of Al–Si HPDC casting alloy via microstructure refinement and tempering
parameters,
Materials & Design,
Volume 103,
2016,
Pages 365-376,
ISSN 0264-1275,
Abstract: Analysis of the effect of microstructure refinement, water quenching, natural ageing as
well as T5 and T6 tempers on macro-hardness development of the hypereutectic HPDC Al–Si based
alloy was performed. Duration of casting holding at room temperature after its removal from the
die, and prior to subsequent temper operation had a measurable effect on casting macro-hardness.
Such finding underlined the need for tighter control of parts handling between casting and heat
treatment operations. Water quenching after casting de-molding operation increased alloy macro-
hardness in naturally aged as well as T5 temper conditions but did not have any effect on macro-
hardness after T6 treatment. T5 temper carried out after casting de-molding and water quenching
from 380°C enabled on average approximately 9 to 19% macro-hardness increase as compared to
the T1 condition. Microstructure refinement had a minor effect on macro-hardness increase but the
measurements of the α-Al matrix micro-hardness needed to be used to demonstrate this effect.
Compared with T6, the T5 temper offered up to approximately 20 to 60% shorter process duration
and could offer potential cost reduction gains achieved at the expense of lower macro-hardness.
Microstructure refinement did not have the effect on T6 casting macro-hardness.
Keywords: Hypereutectic Al–17%Si–4.5%Cu–0.5%Mg alloy; High pressure die casting; Microstructure

refinement; Solidification rate; Hardness; Heat treatment
Alessandro Averardi, Corrado Cola, Steven Eric Zeltmann, Nikhil Gupta,
Effect of particle size distribution on the packing of powder beds: A critical discussion relevant to
additive manufacturing,
Materials Today Communications,
Volume 24,
2020,
100964,
ISSN 2352-4928,
https://doi.org/10.1016/j.mtcomm.2020.100964.
Abstract: Several additive manufacturing (AM) methods use powder feed materials. Selective laser
sintering is an example of a versatile AM method, using feed material in powder form, capable of
producing polymer and metallic parts. In the variations of this technique, a laser spot or an electron
beam is used to locally sinter or melt a packed powder bed. After the completion of sintering on
each layer, further powder is added on top of the existing bed so that the next layer may be joined.
A major challenge in this method is controlling the porosity of the powder bed so that the final part
has uniform and maximum density. Uniformity in the packing of bed from one layer to the other is
important for optimizing the processing parameters. This review is focused on considering the
packing characteristics of polydisperse hard particle beds and the determination of the expected
density achievable for a given particle size and shape distribution. Models are presented for discrete
mixtures as well as continuous distributions. The effect of the initial configuration of a particle bed
on its ability to form a highly dense packing is also discussed. Blending of different particle sizes and
shapes can be used to substantially increase the packing density, but can also lead to separation or
segregation of the bed. Through appropriate control of the particle shape and use of wide
distributions, packing densities close to 100 % can theoretically be achieved, but practicality and
various effects that appear at small size scales prevent from achieving such high packing densities.
Recent advancements have reduced the dependence of AM part quality on the density of the
packed particle bed but the packing is still important for considerations such as thermal conductivity
of the bed and absorption of laser power in the bed. Improved knowledge of packed bed
characteristics can be helpful in developing AM methods for novel material systems.
Keywords: Additive manufacturing; 3D printing; Selective laser sintering Selective laser melting;
Electron beam additive manufacturing; Particle packing
G.N. Karimi, M.J. Carrington, J. Thomas, P.H. Shipway, D.A. Stewart, T. Hussain,
The role of microstructural development in the hydrothermal corrosion of cast and HIPed Stellite 6
analogues in simulated PWR conditions,
Corrosion Science,
Volume 159,
2019,
108141,
ISSN 0010-938X,
https://doi.org/10.1016/j.corsci.2019.108141.
Abstract: The corrosion behaviour of cast and HIPed Stellite 6 analogue materials in PWR-simulating
conditions was investigated. The cast alloy exhibited localised corrosion at the boundary between
the matrix and the M7C3 carbides, with this being attributed to chromium depletion in the matrix
associated with the carbide growth. In contrast, the HIPed alloy exhibited no localised corrosion. The
carbon content of the cast Stellite 6 analogue was right at the top end of the range indicated in the
Stellite 6 specification: this results in a high fraction of carbides and a general depletion of the
chromium content of the matrix.
Keywords: Stellite 6; Corrosion behaviour; PWR conditions; Chromium depletion; Preferential

oxidation
Peng Cao, Muhammad Dilawer Hayat,
Chapter 1 - Reactive powder metal injection molding,
Editor(s): Peng Cao, Muhammad Dilawer Hayat,
Feedstock Technology for Reactive Metal Injection Molding,
Elsevier,
2020,
Pages 1-42,
ISBN 9780128175019,
https://doi.org/10.1016/B978-0-12-817501-9.00001-6.
Abstract: This chapter briefly introduces each step involved in metal injection molding. It also
introduces the evolution of metal injection molding technologies, opportunities, applications, and
some constraints.
Keywords: Metal injection molding; applications; MIM products
Shafaqat Siddique, Muhammad Imran, Frank Walther,
Very high cycle fatigue and fatigue crack propagation behavior of selective laser melted AlSi12 alloy,
Volume 94, Part 2,
2017,
Pages 246-254,
ISSN 0142-1123,
Abstract: Selective laser melting is a maturing additive manufacturing process which has been
studied in the recent years for processing different alloys. The focus, however, remained on the
processibility, design considerations and static or quasistatic mechanical properties. For the
application of the process for functional components, it is required that the process parts perform
well in cyclic applications as well. The influence of processing parameters on the resulting part
parameters and the corresponding fatigue behavior remains unaddressed. This study investigates
the influence of base plate heating and post-process stress-relief on part properties like process-
incited defects, which are critical for fatigue loading, for AlSi12 alloy. Investigations have been made
for very high cycle fatigue as well as fatigue crack growth. To understand the fatigue phenomenon,
characterization of basic material properties is also carried out. Results show that the material
defects as well as microstructure is influenced by these parameters. The corresponding fatigue and
crack growth behavior is improved by base plate heating which changes the fatigue crack initiation
mechanisms as well. Relatively reduced thermal gradients by base plate heating helps improving the
fatigue reliability by reducing the fatigue crack initiation from material defects.
Keywords: Selective laser melting (SLM); AlSi12 alloy; Computed tomography (CT); Very high cycle
fatigue (VHCF); Crack propagation rate (da/dN)
Humayun Kabir, Khurram Munir, Cuie Wen, Yuncang Li,
Recent research and progress of biodegradable zinc alloys and composites for biomedical
applications: Biomechanical and biocorrosion perspectives,
Bioactive Materials,
Volume 6, Issue 3,
2021,
Pages 836-879,
ISSN 2452-199X,
https://doi.org/10.1016/j.bioactmat.2020.09.013.
Abstract: Biodegradable metals (BMs) gradually degrade in vivo by releasing corrosion products once
exposed to the physiological environment in the body. Complete dissolution of biodegradable
implants assists tissue healing, with no implant residues in the surrounding tissues. In recent years,
three classes of BMs have been extensively investigated, including magnesium (Mg)-based, iron (Fe)-
based, and zinc (Zn)-based BMs. Among these three BMs, Mg-based materials have undergone the
most clinical trials. However, Mg-based BMs generally exhibit faster degradation rates, which may
not match the healing periods for bone tissue, whereas Fe-based BMs exhibit slower and less
complete in vivo degradation. Zn-based BMs are now considered a new class of BMs due to their
intermediate degradation rates, which fall between those of Mg-based BMs and Fe-based BMs, thus
requiring extensive research to validate their suitability for biomedical applications. In the present
study, recent research and development on Zn-based BMs are reviewed in conjunction with
discussion of their advantages and limitations in relation to existing BMs. The underlying roles of
alloy composition, microstructure, and processing technique on the mechanical and corrosion
properties of Zn-based BMs are also discussed.
Keywords: Biocorrosion; Biodegradable metals; Tissue engineering; Zinc-based alloys and

composites
Uzair Khaleeq uz Zaman, Mickael Rivette, Ali Siadat, Seyed Meysam Mousavi,
Integrated product-process design: Material and manufacturing process selection for additive
manufacturing using multi-criteria decision making,
Robotics and Computer-Integrated Manufacturing,
Volume 51,
2018,
Pages 169-180,
ISSN 0736-5845,
https://doi.org/10.1016/j.rcim.2017.12.005.
Abstract: Market dynamics of today are constantly evolving in the presence of emerging
technologies such as Additive Manufacturing (AM). Drivers such as mass customization strategies,
high part-complexity needs, shorter product development cycles, a large pool of materials to choose
from, abundant manufacturing processes, diverse streams of applications (e.g. aerospace, motor
vehicles, and health care) and high cost incurred due to manufacturability of the part have made it
essential to choose the right compromise of materials, manufacturing processes and associated
machines in early stages of design considering the Design for Additive Manufacturing guidelines.
There exists a complex relationship between AM products and their process data. However, the
literature to-date shows very less studies targeting this integration. As several criteria, material
attributes and process functionality requirements are involved for decision making in the industries,
this paper introduces a generic decision methodology, based on multi-criteria decision-making tools,
that will not only provide a set of compromised AM materials, processes and machines but will also
act as a guideline for designers to achieve a strong foothold in the AM industry by providing practical
solutions containing design oriented and feasible material-machine combinations from a current
database of 38 renowned AM vendors in the world. An industrial case study, related to aerospace,
has also been tested in detail via the proposed methodology.
Keywords: Additive manufacturing; Concurrent engineering; Design for additive manufacturing;

Integrated product-process design; Material and process selection; Multi-criteria decision making
Index,
2017,
Pages 711-726,
ISBN 9780128092729,
https://doi.org/10.1016/B978-0-12-809272-9.09981-3.
Ramesh Singh,
Chapter 2 - Codes, Specifications, and Standards,
Editor(s): Ramesh Singh,
Applied Welding Engineering (Second Edition),
2016,
Pages 383-400,
ISBN 9780128041765,
https://doi.org/10.1016/B978-0-12-804176-5.00032-3.
Abstract: The Welding industry has developed over the years, the quality and inspection bodies
world over have tried to layout basic minimum requirements in design and workmanship to ensure
the product are safe for people and environment. This chapter tries to list some of the most
common codes, specifications and standards that address welding related matters.
Keywords: Codes; Standards; Specifications; ASME; ASTM; ANSI; API; CSA; National Board; EN; ISO;
DNV
Honglei Liu, Baotong Li, Wenhao Tang,
Manufacturing oriented topology optimization of 3D structures for carbon emission reduction in

casting process,
Volume 225,
2019,
Pages 755-770,
ISSN 0959-6526,
Abstract: Low-carbon casting for box-beams is achieved by using an explicit topology optimization
method that provides an optimized stiffener layout with fewer carbon emissions. First, a life-cycle
assessment of carbon generated during casting stage is presented in detail. Considering the carbon
assessment is formulated in an explicit form, an explicit topology optimization method is applied,
where stiffeners are explicitly described with geometric parameters. Additionally, the stiffeners are
able to move freely without background mesh constraints. This trait is achieved by an interpolation
algorithm that spreads the stiffness of the stiffeners to adjacent background nodes. To illustrate this
method, a press slide is investigated, and the optimized design shows a 17.6% reduction in carbon
emissions with no reduction of stiffness.
Keywords: Low-carbon casting; Box-beam; Topology optimization
Heinz P. Bloch,
Subject Category 32 - Reliable Plants and Machines Benefit From MQA,
2017,
Pages 513-537,
ISBN 9780128092729,
https://doi.org/10.1016/B978-0-12-809272-9.00032-3.
Abstract: Reliable plants require forethought. Before such a facility is built, the cost (and benefit) of
reliability is factored into all the planning. Up-front investment is budgeted; it implies that only
competent vendors are invited to bid on a project. Thoughtful specifications covering entire assets
and important components are sent to these bidders, and a thorough evaluation of their bids will be
done. One of the owner's engineers is designated to follow up by conducting audits and periodic
compliance reviews. Work processes and procedures are either already in place or being developed
before the assets are being delivered to the installation site. Procedures and work processes are
being issued. Engineers involved in the above (and other personnel in related job functions) are
trained in equipment engineering. We know them as machinery quality assessment (MQA)
professionals. They have the requisite background and experience to monitor the design
contractor's work, verifying that none of the purchaser's specification clauses are either overlooked
or misunderstood. To engage in this work, engineers have lots of practical and analytic experience.
They are resourceful individuals who know what to question and what guidance to give on matters
such as equipment selection based on life-cycle costs, to name just one.
Keywords: Up-front investment; Machinery quality assessment (MQA); Deposition testimony; RCFA;
TapRooT; Cost-benefit
Ankush Anand, Raof Ahmad Khan, Mohd. Farooq Wani,
Development of a sustainability risk assessment index of a mechanical system at conceptual design

stage,

Volume 139,
2016,
Pages 258-266,
ISSN 0959-6526,
Abstract: The increasing environmental concerns owing to the use of various engineering gadgets
worldwide have posed a greater challenge for product designers, manufacturers, risk analysts and
environmentalists in the design and development of various systems. In a system design
environment, where sustainability risk assessment is the focus of the designer, the systematic
consideration of sustainability risk during the conceptual design stage is a function of environmental
impact of a system. This research paper presents a framework for sustainability risk assessment of a
mechanical system at conceptual design stage. The system parameters are identified. These
parameters are referred as Sustainability Risk Assessment parameters. Based on the parameters
identified, the relationships among these parameters are also identified. These relationships are
represented by means of a sustainability risk assessment graph. To avoid complexity of the graph
while analyzing the system, it is represented by a matrix, which helps in developing the sustainability
risk assessment expression. For analytical assessment, permanent risk function is obtained. Finally,
an index is developed for evaluating various mechanical design systems from risk consideration. This
framework will help designers while developing mechanical systems at conceptual design stage
considering risk through sustainability. The proposed approach has been applied to a material
selection case study. The relationships among various sustainability risk assessment parameters are
established. Finally graph theory and matrix approach is applied for ranking of various design
alternatives from sustainability risk assessment point of view.
Keywords: Sustainability; Risk assessment; Conceptual design stage; Graph theory; Multi attribute
decision making; Environment; Sustainability risk assessment index (SRA-I); Disposability;
Recyclability
Sarogini Grace Pease, Russell Trueman, Callum Davies, Jude Grosberg, Kai Hin Yau, Navjot Kaur, Paul
Conway, Andrew West,
An intelligent real-time cyber-physical toolset for energy and process prediction and optimisation in
the future industrial Internet of Things,
Future Generation Computer Systems,
Volume 79, Part 3,
2018,
Pages 815-829,
ISSN 0167-739X,
https://doi.org/10.1016/j.future.2017.09.026.
(http://www.sciencedirect.com/science/article/pii/S0167739X1630382X)
Abstract: Energy waste significantly contributes to increased costs in the automotive manufacturing
industry, which is subject to energy usage restrictions and taxation from national and international
policy makers and restrictions and charges from national energy providers. For example, the UK
Climate Change Levy, charged to businesses at 0.554 p/kWh equates to 7.28% of a manufacturing
business’s energy bill based on an average total usage rate of 7.61 p/kWh. Internet of Things (IoT)
energy monitoring systems are being developed, however, there has been limited consideration of
services for efficient energy-use and minimisation of production costs in industry. This paper
presents the design, development and validation of a novel, adaptive Cyber-Physical Toolset to
optimise cumulative plant energy consumption through characterisation and prediction of the active
and reactive power of three-phase industrial machine processes. Extensive validation has been
conducted in automotive manufacture production lines with industrial three-phase Hurco VM1
computer numerical control (CNC) machines.
Keywords: Wireless networks; Real-time systems; Energy efficiency; Energy management; Process
planning
6 - Materials and Design,
Hanser,
2019,
Pages 167-193,
ISBN 9781569907023,
https://doi.org/10.3139/9781569907030.006.
Geoffry Scamans, Hu-Tian Li, Jaime Lazaro Nebreda, Jayesh Patel, Ian Stone, Yun Wang, Xinliang
Yang, Zhongyun Fan,
Chapter 8 - Advanced Casting Technologies Using High Shear Melt Conditioning,
2018,
Pages 249-277,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.00008-4.
Abstract: In recent years BCAST has developed the high shear melt conditioning (HSMC) process for
controlling solidification. HSMC is now an emerging technology to manipulate the solidification
process by intensive shearing to control both the cast microstructure and defect formation. The high
shear is applied to the melt using a simple rotor stator which has been demonstrated to disperse
oxide films to provide a high density of oxide particles to enhance nucleation. The high-shear device
has been successfully applied directly in the sump during DC casting up to the industrial scale to
provide both significant grain refinement and uniform microstructure with reduced segregation and
defects. It produces a DC casting sump with uniform chemical composition, uniform temperature,
and a significantly increased temperature gradient at the solidification front. The sump temperature
can be controlled by appropriate selection of the rotation speed. This provides the opportunity to
control the cast microstructure, for example, to produce fine and uniformly dispersed second phase
particles to improve mechanical properties. The high-shear device can also be used to degas alloys to
unprecedentedly low hydrogen levels and has also been successfully applied to remove iron from
casting alloys in which the iron containing particles are the primary solidification phase.
Keywords: High shear melt conditioning; Nucleation control; Microstructure control; Rotor stator;
Dispersed oxide films
Yue Li, Hongxiang Li, Laurens Katgerman, Qiang Du, Jishan Zhang, Linzhong Zhuang,
Recent advances in hot tearing during casting of aluminium alloys,
Progress in Materials Science,
2020,
100741,
ISSN 0079-6425,
https://doi.org/10.1016/j.pmatsci.2020.100741.
Abstract: Hot tearing is one of the most severe and irreversible casting defects for many metallic
materials. In 2004, Eskin et al. published a review paper in which the development of hot tearing of
aluminium alloys was evaluated (Eskin and Suyitno, 2004). Sixteen years have passed and this
domain has undergone considerable development. Nevertheless, an updated systematic description
of this field has not been presented. Therefore, this article presents the latest research status of the
hot tearing during the casting of aluminium alloys. The first part explains the hot tearing
phenomenon and its occurrence mechanism. The second part presents a detailed description and
analysis of the characterisation methods of the mushy zone mechanical properties and hot tearing
susceptibility. The third part presents considerable data pertaining to the mushy zone behaviour,
including those of the linear contraction and load behaviour during solidification, semi-solid strength
and ductility, and characteristic points related to hot tearing. The fourth part examines the effect of
the composition and casting process parameters on the hot tearing susceptibility of aluminium
alloys. The fifth part describes the hot tearing simulations and the associated criteria and
mechanisms. Finally, recommendations for the further development of hot tearing research are
presented.
Keywords: Aluminium alloys; Hot tearing; Casting; Mushy zone; Compositions; Process parameters
Henri Van Damme,
Concrete material science: Past, present, and future innovations,
Cement and Concrete Research,
Volume 112,
2018,
Pages 5-24,
ISSN 0008-8846,
https://doi.org/10.1016/j.cemconres.2018.05.002.
Abstract: Concrete is flying off, but it is simultaneously facing tremendous challenges in terms of
environmental impact, financial needs, societal acceptance and image. Based on an historical
approach of the science of concrete and reinforced concrete in particular, this paper calls for the
exploration of radical changes in three key aspects of concrete use: reinforcement, binder content,
and implementation methods. More precisely, it is suggested that, in parallel to the introduction of
robotic fabrication methods, digital technologies may be key for the introduction several innovations
like (i) rebar-free reinforcement using non-convex granular media; (ii) compression-optimized
concrete structures, using topology optimization, architectural geometry, and 3D-printing or
origami-patterned formworks; (iii) truly digital concrete through the coupling of massive data
collection and deep learning.
A.B. Stefaniak, A.R. Johnson, S. du Preez, D.R. Hammond, J.R. Wells, J.E. Ham, R.F. LeBouf, K.W.
Menchaca, S.B. Martin, M.G. Duling, L.N. Bowers, A.K. Knepp, F.C. Su, D.J. de Beer, J.L. du Plessis,
Evaluation of emissions and exposures at workplaces using desktop 3-dimensional printers,
Journal of Chemical Health and Safety,
Volume 26, Issue 2,
2019,
Pages 19-30,
ISSN 1871-5532,
https://doi.org/10.1016/j.jchas.2018.11.001.
Abstract: There is a paucity of data on additive manufacturing process emissions and personal
exposures in real-world workplaces. Hence, we evaluated atmospheres in four workplaces utilizing
desktop “3-dimensional” (3-d) printers [fused filament fabrication (FFF) and sheer] for production,
prototyping, or research. Airborne particle diameter and number concentration and total volatile
organic compound concentrations were measured using real-time instruments. Airborne particles
and volatile organic compounds were collected using time-integrated sampling techniques for off-
line analysis. Personal exposures for metals and volatile organic compounds were measured in the
breathing zone of operators. All 3-d printers that were monitored released ultrafine and fine
particles and organic vapors into workplace air. Particle number-based emission rates (#/min)
ranged from 9.4×109 to 4.4×1011 (n=9 samples) for FFF 3-d printers and from 1.9 to 3.8×109 (n=2
samples) for a sheer 3-d printer. The large variability in emission rate values reflected variability
from the printers as well as differences in printer design, operating conditions, and feedstock
materials among printers. A custom-built ventilated enclosure evaluated at one facility was capable
of reducing particle number and total organic chemical concentrations by 99.7% and 53.2%,
respectively. Carbonyl compounds were detected in room air; however, none were specifically
attributed to the 3-d printing process. Personal exposure to metals (aluminum, iron) and 12 different
organic chemicals were all below applicable NIOSH Recommended Exposure Limit values, but results
are not reflective of all possible exposure scenarios. More research is needed to understand 3-d
printer emissions, exposures, and efficacy of engineering controls in occupational settings.
Elena Cischino, Francesca Di Paolo, Enrico Mangino, Daniele Pullini, Cristina Elizetxea, César Maestro,
Estibaliz Alcalde, Jesper deClaville Christiansen,
An Advanced Technological Lightweighted Solution for a Body in White,
Transportation Research Procedia,
Volume 14,
2016,
Pages 1021-1030,
ISSN 2352-1465,
https://doi.org/10.1016/j.trpro.2016.05.082.
Abstract: Funded by the EC FP7 Program, EVolution project is using the Pininfarina Nido concept car
as a baseline for its activities, with the goal to demonstrate the sustainable production of a full
electric 600kg vehicle (FEV). The project has to be finalized by the end of 2016. The existing Body in
White (BiW) has been completely reviewed through a design strategy aiming to reduce the number
of parts and using innovative lightweight materials and technologies. The considered Al technologies
applied on high performances Al alloys provide the opportunities to obtain components with
complex geometries and low thickness, merging different parts into one unique element. Besides, it
is possible to process a variable thickness element with a single operation. A “green sand mold”
technique allows co-casted joints among elements produced with different Al manufacturing
processes. The potential cost reduction and process simplification in terms of time and assembly are
promising: current state-of-the-art, based on traditional moulds, does not allow these opportunities.
The BiW has been hybridized in certain areas of the underbody with a composite material of the PA
family, reinforced with GF. This material has been obtained improving existing ones and developing
a production process suitable for scaling to commercial requirements, throughout an advanced
sheet thermoforming and 3D-injection method (CaproCAST process). Novel polypropylene
nanocomposites (PNC) based on silicate and glass fiber layers demonstrate improved toughness and
stiffness and have been selected for crash cross beam and side door. Polyurethane foams based on
recycled polymers are explored as sustainable energy-absorbing filling in cross beam sections.
Structural epoxy adhesives have been considered to join the BiW parts and welding points are
reduced in number: in certain areas spot-welds have been used only to tack the parts during
polymerization. In addition to the previous results, current weight of the BiW is 115kg versus 160kg
of the baseline car. An FE-analysis on the virtual full vehicle indicates a good structural behavior,
considering EU standards of crash homologation and global static and dynamic performances. The
developed architecture and the integration of lightweight materials will ensure that the EU
maintains its competitiveness against the Asian and United States automobile industries. This topic is
focused on the results obtained on the BiW in terms of design strategies, Al and composite materials
innovative technologies and joining methods.
Keywords: Lightweight; electric vehicle; aluminium processing; composite; design; Body in White
Yahia Ali, C.D. Garcia-Mendoza, J.D. Gates,
Effects of ‘impact’ and abrasive particle size on the performance of white cast irons relative to low-
alloy steels in laboratory ball mills,
Wear,
Volumes 426–427, Part A,
2019,
Pages 83-100,
ISSN 0043-1648,
Abstract: In mineral grinding mills, media and liners are consumed by abrasion, corrosion, and
fracture-related damage mechanisms. White cast irons (carbide-reinforced composites) can provide
substantially greater wear life than martensitic steels of comparable bulk hardness, but the
magnitude of benefit depends on abrasive mineral characteristics. Their performance might also be
influenced by mill operating parameters. Since increasing mill rotation speed increases the
proportion of high-angle impingement compared to sliding, and since ‘impact’ is commonly expected
to promote fracture-related damage mechanisms in brittle materials, it might be assumed that
increasing speed will degrade white cast iron performance. However, such assumptions require
scrutiny. Using the laboratory ball mill abrasion test (BMAT), the effects of impact severity on
relative performance of white cast irons were quantified. Contrary to intuitive expectations,
increasing impact severity appeared to improve white iron relative performance. Micro-fracture is
known to be influenced by the abrasive's mineral constitution; but the results demonstrate an
influence from abrasive particle size — fine particles being less capable of damaging the eutectic
carbide network. The observed effects of mill operating parameters were all explicable in terms of
their effect on particle size; hence were manifestations of simple abrasive wear processes, not
impact-related damage mechanisms.
Keywords: Abrasion; Micro-fracture; White cast iron; Low alloy steel; Ball mill
Richard O'Hegarty, Oliver Kinnane,
Review of precast concrete sandwich panels and their innovations,
Construction and Building Materials,
Volume 233,
2020,
117145,
ISSN 0950-0618,
https://doi.org/10.1016/j.conbuildmat.2019.117145.
Abstract: Precast concrete cladding is experiencing a resurgence in popularity as a means of building

cladding. Precast concrete sandwich panels are a specific type of precast cladding, characterised by
high thermal resistance provided by a layer of insulation which is sandwiched between two concrete
wythes and fixed together with mechanical connectors. Hence, they have the potential to offer a
thermally efficient cladding solution for new buildings and as replacement cladding in the case of
renovation. Due to this thermal efficiency potential, and the resurgent popularity of precast concrete
generally, considerable innovation in sandwich panel design has occurred in recent years. New high-
performance concrete, with novel means of reinforcement, have enabled lighter and thinner
concrete wythes. Numerous new fibre reinforced polymer connectors have been developed and
tested that facilitate shear load transfer across the layers while also minimising localised heat loss.
State-of-the-art low-conductivity insulation technologies allow for remarkably low U-values for thin
wall build-ups. All these innovations are increasing the applicability of sandwich panels for a wider
range of building typologies and are augmenting the inherent benefits of precast cladding. A review
of precast sandwich panels is therefore timely to evaluate the body of research undertaken and
analyse proposed design-solutions and test-results to identify future research focuses. This review
determines particular advancements in the development of high strength concretes with no steel
but that achieve high flexural strengths. It reviews the considerable number of studies focused on
the structural performance of sandwich panels but highlights a need for further thermal validation of
novel sandwich panel designs and further testing of different connector types.
Keywords: Precast concrete; Cladding; Sandwich panel; Thermal efficiency; Composite action
Bavita Bhardwaj, Pardeep Kumar,
Waste foundry sand in concrete: A review,
Volume 156,
2017,
Pages 661-674,
ISSN 0950-0618,
https://doi.org/10.1016/j.conbuildmat.2017.09.010.
Abstract: Concrete is the most extensively used construction material in the world, second to water.
Increasing rate of urbanization and industrialization has lead to over exploitation of natural
resources such as river sand and gravels, which is giving rise to sustainability issues. It has now
become imperative to look for alternatives of constituent materials of concrete. Waste foundry
sand, a by-product of ferrous and non ferrous metal casting industries is one such promising material
which can be used as an alternative to natural sand in concrete. In last few decades, several studies
have been conducted to investigate the effect of addition of waste foundry sand as partial and
complete replacement of regular sand in concrete. It has been found suitable to be used as partial
replacement of sand in structural grade concrete. A number of properties have been reviewed in the
current paper, the results observed from the various studies depict that replacement of foundry
sand to a certain extent enhance the durability as well as strength properties of the concrete but
simultaneously decreases the slump value with the increase of replacement level of waste foundry
sand.
Keywords: Waste foundry sand; Concrete; Geopolymer concrete; Strength; Permeability
Chapter 1 - Introduction to Materials Processing,
Academic Press,
2016,
Pages 1-20,
ISBN 9780123851321,
https://doi.org/10.1016/B978-0-12-385132-1.00001-X.
Abstract: This chapter defines the field of materials processing and the scope of the text overall.
Materials processing is the series of steps that converts a starting material into a useful form with
controlled structural features and properties. The importance of materials processing to the
discipline of materials science and engineering is described. Three approaches to materials
processing are introduced: forming processes (creating shapes using dies, molds and forces),
additive processes (creating shapes layer-by-layer using a computer file containing the details of the
part shape), and subtractive processes (removing material from a block to leave behind the shape of
interest). The chapters and the book focus on forming and additive processes. Examples of these
approaches across metals, ceramics, and polymers are given.
Keywords: Materials processing; materials science and engineering; forming processes; additive
manufacturing
H.M.M.A. Rashed, A.K.M. Bazlur Rashid,
2.12 Heat Treatment of Aluminum Alloys,
Editor(s): MSJ Hashmi,
Comprehensive Materials Finishing,
Elsevier,
2017,
Pages 337-371,
ISBN 9780128032497,
https://doi.org/10.1016/B978-0-12-803581-8.09194-3.
Abstract: Aluminum has been the material of choice in the transportation sector, including
automotive and aerospace industries, for more than 80 years. Pure aluminum is quite soft, and it is
made usable for different service conditions by alloying, heat treatment, or working. Except for a few
nonheat-treatable alloys, aluminum alloys are hardened by solution treatment and quenching,
followed by natural or artificial aging. In addition, annealing treatment is sometimes used to soften
work-hardened products. Quenching media and rate, solution treatment, and aging responses are
discussed in this chapter, with highlights of schedules of heat treatment for different wrought and
cast aluminum alloys.
Keywords: Age hardening; Alloy classification; Alloy designation system; Aluminum alloy;
Dimensional stability; Heat treatment; Precipitation hardening; Quenched-in vacancies; Quenching;
Solution heat treatment; Strengthening mechanisms; Temper designation
Kun V. Yang, Paul Rometsch, C.H.J. Davies, Aijun Huang, Xinhua Wu,
Effect of heat treatment on the microstructure and anisotropy in mechanical properties of A357
alloy produced by selective laser melting,
Materials & Design,
Volume 154,
2018,
Pages 275-290,
ISSN 0264-1275,
Abstract: A357 alloy was manufactured by selective laser melting (SLM) and subjected to different
heat treatments, by considering the stress relief step as critical, to establish the microstructure-
mechanical property relationship and model the yield strength. For the as-SLM processed condition,
the imposed fast cooling rate refines and limits the amount of Fe-rich intermetallic and eutectic
Mg2Si phases, and enables a higher level of supersaturation of solutes. The latter leads to significant
yield strength contributions from solid solution strengthening and natural ageing. The inter-cellular
Si network within the columnar grains remains unchanged but small Si-rich particles appear within
cells after direct ageing. The Si network breaks up during stress relieving, leading to high ductility.
The lower ductility for the vertically-built samples under as-SLM processed, directly aged, and stress
relieved conditions is due mainly to the finer Si networks brittle nature. Porosity resulting from
trapped hydrogen gas enlarges significantly with solutionisation, deteriorating the ductility. Grain
growth is not obviously observed with heat treatment. Si particles coarsen preferentially at grain
boundaries initially, however, they distribute more evenly by coarsening within the grains as well
during prolonged solutionisation. Anisotropy in both yield strength and ductility subsequently
disappears when a more homogeneous microstructure is obtained.
Keywords: Aluminium alloys; Selective laser melting; Elongation to fracture; Strengthening

mechanism; Anisotropy
Zhiyu Chang, Ning Su, Yujuan Wu, Qiao Lan, Liming Peng, Wenjiang Ding,
Semisolid rheoforming of magnesium alloys: A review,
Materials & Design,
Volume 195,
2020,
108990,
ISSN 0264-1275,
https://doi.org/10.1016/j.matdes.2020.108990.
Abstract: A reflection upon the recent developments of semisolid rheoforming techniques of

magnesium (Mg) alloys is vital for successfully shaping the future landscape of lightweight and high-
performance metal materials. In our paper, formation mechanisms of non-dendritic structure were
firstly reviewed, and slurry preparation methods as well as rheoforming processes of Mg alloys were
then summarized. Afterwards, microstructures and mechanical properties of semisolid Mg alloys
were elaborated. The various formation mechanisms of non-dendritic structures provide theoretical
bases for understanding the microstructure evolution of semisolid metal slurries. Despite the
abundant slurry preparation methods to date, inexpensive industrial solutions for producing high-
quality Mg alloy slurries are still scarce, which is constituting one of many key challenges in the
future. In the case of rheoforming processes, high pressure die casting (HPDC) and squeeze casting
are the most promising processes for mass production of semisolid Mg alloys. At present, researches
on semisolid Mg alloys are mainly focused on AZ and AM series alloys. To develop high-performance
semisolid Mg alloys, the slurry preparation and rheoforming technology of Mg-RE alloys are worthy
of further investigation.
Keywords: Semisolid; Magnesium alloy; Rheoforming; Slurry; Non-dendritic structure
5 - Rapid Tooling,
Hanser,
2016,
Pages 353-394,
ISBN 9781569905821,
https://doi.org/10.3139/9781569905838.005.
Baiwei Zhu, Salem Seifeddine, Per O.Å. Persson, Anders E.W. Jarfors, Peter Leisner, Caterina Zanella,
A study of formation and growth of the anodised surface layer on cast Al-Si alloys based on different
analytical techniques,
Materials & Design,
Volume 101,
2016,
Pages 254-262,
ISSN 0264-1275,
Abstract: This paper aims to investigate the mechanisms of formation and growth of the anodised
surface layer on Al-Si castings by applying different analytical techniques such as optical microscopy,
scanning electron microscopy (SEM), scanning transmission electron microscopy (STEM), and X-ray
computer tomography (X-ray CT) scanning. Three different Al alloys with various Si content (2.43%,
3.53% and 5.45%) were investigated. Si particle morphological modification by Sr addition, as well as
directional solidification, was used to vary the microstructural coarseness in a controlled manner to
study the influence of these parameters on the growth behaviour of the oxide layer. This study
observed residual unanodised Al phases trapped beneath or between Si particles in the oxide layer.
It was found, depending on the geometry and morphology of Si particles, that Al can be shielded by
Si particles and prevented from oxidising.
Keywords: Al-Si cast alloys; Anodising; Oxide layers; Silicon
Ravikumar Saranu, Ratnam Chanamala, Srinivasa Rao Putti,
Processing, micro structures and mechanical properties of AZ91E, Sic and fly ash composites: A
review,
Volume 26, Part 2,
2020,
Pages 2629-2635,
ISSN 2214-7853,
Abstract: The Mg alloy based composites have a lower density, highest strength, stiffness, best
damping capacity, and highest ability which are used in industries. These materials were reinforced
with other ceramic particles to create the Metal Matrix Compounds (MMCs). The lightweight
materials like Aluminium (Al) and Magnesium (Mg) through hard particles creates metal matrix
composites. Moreover, hybrid MMCs are manufactured using a stir casting approach, friction stir
processing and examined by Scanning Electron Microscopy (SEM), Optical Microscopy (OM), and
Electron Backscattered Drawing (EBSD). These composites are called hybrid metal composites that
are reinforced with materials such as nitrides, carbides, and oxides. In this paper, enhancing the
consequence of heat treatment and mechanical, microstructure properties of hybrid composites like
AZ91E, Silicon Carbide (Sic), and Fly ash are reviewed. Finally, it concludes that hybrid composites
parameters are high strength, hardness, low weight, and greatest wear resistance and fatigue than
the conventional composites.
Keywords: Metal matrix composites; Fly ash; Sic; Heat treatment; Stir casting; Hardness
Sefiu Adekunle Bello, Isiaka Ayobi Raheem, Nasir Kolawole Raji,
Study of tensile properties, fractography and morphology of aluminium (1xxx)/coconut shell micro
particle composites,
Journal of King Saud University - Engineering Sciences,
Volume 29, Issue 3,
2017,
Pages 269-277,
ISSN 1018-3639,
https://doi.org/10.1016/j.jksues.2015.10.001.
Abstract: Aluminium (1xxx)/coconut shell micro particle (Al/CMP) composites have been developed
using a compo cast technique. Coconut shells (CSs) were processed with the aid of mortar/pestle
and disc grinder and then classified with a set of sieves vibrated with a sine shaker. The CMP
additions increased from 2% to 10% at 2% interval. Microstructural/chemical composition analyses
were carried out with the aid of scanning electron microscopes (ASPEX 3020) with attached energy
dispersive X-ray spectroscopy. Phases were identified using an X-ray diffractometer (XRD). The
tensile properties and mode of fracture were studied using Instron extensometer and Avery Denison
Impact Testing Machine respectively. Results revealed 99.3% purity of aluminium matrix. The
presence of new phases in the aluminium matrix is attributable to chemical interaction between Al
and CMPs. The fine grained structure of Al/CMPs composites was confirmed by SEM and optical
micrographs. The enhancement in the tensile properties is attributable to the presence of hard
phases in the Al matrix and good interfacing bonding between Al matrix and CMP reinforcements.
The cone and cup surface appearance with fibrous, dull, dimple and goose grain microstructure of
the fracture surfaces of the composites is an indication of ductile fracture. Hence low cost metal
matrix aluminium based composites have been developed.
Keywords: Fractography; Aluminium (1xxx); Tensile property; Enhancement; Ductility; Coconut shell
C. Dharmendra, A. Hadadzadeh, B.S. Amirkhiz, G.D. Janaki Ram, M. Mohammadi,
Microstructural evolution and mechanical behavior of nickel aluminum bronze Cu-9Al-4Fe-4Ni-1Mn

fabricated through wire-arc additive manufacturing,
Volume 30,
2019,
100872,
ISSN 2214-8604,
https://doi.org/10.1016/j.addma.2019.100872.
Abstract: As a step forward toward the development of the next generation of nickel aluminum
bronze (NAB) components using wire-arc additive manufacturing (WAAM), square bars were printed
in the vertical direction. The as-built microstructure was characterized using multi-scale electron
microscopy techniques, where the differences in phase formation were compared to the reference
cast-NAB based on the solidification characteristics. The as-cast microstructure typically consists of
Cu-rich α-matrix, and four types of intermetallic particles referred to as κ-phases. In the WAAM-NAB,
the formation of κI was suppressed due to high cooling rates. The microstructure was finer and the
volume fraction of intermetallic particles was significantly lower than that of the cast-NAB. Based on
energy dispersive spectroscopy (EDS) technique and diffraction pattern analysis using transmission
electron microscopy (TEM), the phases formed in the interdendritic regions were identified as κII
(globular Fe3Al) and κIII (lamellar NiAl), whereas numerous fine (5–10 nm) Fe-rich κIV particles were
precipitated uniformly within the α-matrix. Electron backscatter diffraction analysis revealed weak
texture on both parallel and perpendicular planes to the building direction with (100) poles rotated
away from the build direction. The WAAM-NAB sample exhibited considerably higher yield strength
(˜88 MPa) and elongation (˜10%) than the cast-NAB, but the gain in the ultimate tensile strength
was marginal.
Keywords: Nickel Aluminum Bronze (NAB); Wire-arc additive manufacturing (WAAM); Electron
microscopy; κ-Phases; Mechanical properties
Qiang Li, Kezhun He, Ni Wu, Jianmin Zeng,
Purification of Aluminum melt in Crucibles by Bubble Flotation,
Volume 37,
2019,
Pages 438-442,
ISSN 2351-9789,
Abstract: According to the principle of bubble floatation, purification of A356 aluminum casting alloy
has been studied by purging nitrogen gas into the A356 alloy melt through a patented porous
sprayer which is immerged in the molten aluminum and can generate a large quantity of dispersed
micro bubbles to absorb the hydrogen and carry the nonmetallic inclusions in the melt to the surface
of the melt. The experiments have been carried out in different capacity of crucibles for the
assessment of the evaluation of effectiveness. 5 samples were taken at 0 min, 2 min, 4 min, 6 min, 8
min and 10 min, respectively, to measure the hydrogen content through HYSCAN Ⅱ hydrogen tester
in the temperature of 720C. The experiments results show that the removing effects of hydrogen
and oxide inclusion are remarkable. The hydrogen contents reach the minimum when purging lasts
10, 8 and 4 minutes for the 280kg, 160kg and 40kg, respectively. The inclusions are also removed
along with the removal of hydrogen.
Keywords: :Aluminum cast alloy; purification; bubble floatation; A356 alloy
H. Jiryaei Sharahi, M. Pouranvari, M. Movahedi,
Enhanced resistance to liquation cracking during fusion welding of cast magnesium alloys:
Microstructure tailoring via friction stir processing pre-weld treatment,
Volume 798,
2020,
140142,
ISSN 0921-5093,
Abstract: Magnesium alloys provide critical opportunities for energy and lightweight-materials
challenges. The alloy design approach based on utilizing the second phase strengthening mechanism
plays an essential role in producing low-density high strength Mg-based alloys. However, the second
phase in the microstructure (e.g., Mg17Al12 phase in Mg–Al–Zn alloys) can deleteriously affect the
weldability of the metallic materials by promoting the liquation and liquation cracking during fusion
welding. The lack of sufficient weldability of Mg-based alloys is a crucial barrier to their potential use
in safety-critical applications. In this paper, it is shown that the severe plastic deformation induced
by friction stir processing, as an effective pathway to microstructure refinement, before fusion
welding enables tailoring the initial microstructure of an Mg–Al–Zn cast alloy for enhancing its
resistance to liquation cracking. The formation of ultra-fine sub-micron Mg17Al12 particles in friction
stir treated base metal translates the liquation mechanism from sub-solvus constitutional liquation
to super-solvus melting alloy, reducing the size of susceptible partial liquation zone to cracking.
Moreover, the higher grain boundary density induced by dynamic recrystallization phenomena
during friction stir processing can enhance the resistance to liquation cracking of the alloy. It is
shown that this pre-welding strategy enables a significant enhancement in the weld mechanical
properties compared to the conventionally produced welds. The joint efficiency, defined as the ratio
of the joint tensile strength to the as-cast material tensile strength, was changed from 0.74 in case of
welds made on cast base metal to 1.4 in case of welds made on friction stir processed base metal.
This simple modification to the fusion welding process can be used as a practical pathway to
enhance the weldability of liquation-sensitive second phase-strengthened alloys.
Keywords: Welding; Liquation cracking; Mg alloys; Microstructure; Friction stir-processing; Strength
Index,
2021,
Pages 471-488,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00015-X.
Tao Liu, Mikko Karkkainen, Laurentiu Nastac, Vish Arvikar, Ilya Levin, Luke N. Brewer,
Iron-rich intermetallics in high pressure die cast A383 aluminum alloys,
Intermetallics,
Volume 126,
2020,
106814,
ISSN 0966-9795,
https://doi.org/10.1016/j.intermet.2020.106814.
Abstract: This work describes the composition and crystal structure of Fe-rich intermetallics that
form during the high pressure die casting (HPDC) process of alloy A383. Engine castings were
produced using the HPDC process with A383 material with a nominal iron content of 1 wt %.
Quantitative energy dispersive X-ray spectroscopy (EDS) was used to measure the chemical
composition of Fe-rich intermetallics that formed during the process, and electron backscattered
diffraction (EBSD) was used to identify their corresponding crystal structures and space groups. The
results revealed that there were two types of Fe-rich intermetallics: sludge particles with a polygonal
morphology and α-Fe with a Chinese-script shape. No needle-like β-Fe intermetallics were observed.
Sludge and α-Fe had the same crystal structures, indexed as body-center cubic (bcc) with the same
space group of Im3¯(No. 204). Sludge contained more Mn and Cr than α-Fe, whereas there was a
larger concentration of Cu in α-Fe than sludge. ThermoCalc software was used to estimate the
formation temperature of Fe-rich intermetallics, and the results suggested that α-Fe (Al8Fe2Si) with
the bcc crystal structure and sludge were the same phase but formed at different temperatures
during solidification process.
Kun V. Yang, Yunjia Shi, Frank Palm, Xinhua Wu, Paul Rometsch,
Columnar to equiaxed transition in Al-Mg(-Sc)-Zr alloys produced by selective laser melting,
Scripta Materialia,
Volume 145,
2018,
Pages 113-117,
ISSN 1359-6462,
https://doi.org/10.1016/j.scriptamat.2017.10.021.
Abstract: The addition of 1.08wt% Sc to an Al-Mg-Zr alloy produced by selective laser melting
modifies the highly coarse columnar grain structure to significantly refined columnar grains
separated by sub-micron equiaxed grains at the melt pool boundaries. The latter nucleate mainly
from the Al3Sc particles in the remelting zone. An almost fully equiaxed grain structure was achieved
by increasing the applied volumetric energy density from 77.1J/mm3 to 154.2J/mm3 and the
platform temperature from 35°C to 200°C, due to the combined effects of potent nuclei, increased
remelting zone volumes and reduced thermal gradients.
Keywords: Selective laser melting; Columnar to equiaxed transition; Aluminium-scandium alloys;

Thermal gradients; Grain refinement
Guangyu Li, Wenming Jiang, Feng Guan, Junwen Zhu, Zheng Zhang, Zitian Fan,
Microstructure, mechanical properties and corrosion resistance of A356 aluminum/AZ91D

magnesium bimetal prepared by a compound casting combined with a novel Ni-Cu composite
interlayer,
Volume 288,
2021,
116874,
ISSN 0924-0136,
Abstract: In the present work, a novel Ni-Cu composite interlayer was prepared on the surface of
A356 aluminum alloy solid insert using the chemical nickel-plating and electro-coppering technology,
in order to restrain the generation of brittle phases and enhance the shear strength of A356
aluminum/AZ91D magnesium bimetal manufactured using a compound casting. The effect of the Ni-
Cu composite interlayer on the microstructure, mechanical properties and corrosion resistance of
the bimetal was studied. The results show that the Ni-Cu composite interlayer effectively restrained
the generation of the brittle and hard Al-Mg intermetallic compounds (IMCs). The interface layer of
the A356/AZ91D bimetal without Ni-Cu composite interlayer was composed of Al3Mg2, Al12Mg17,
δ-Mg and Mg2Si phases, while the interfacial reactants of the A356/AZ91D bimetal with Ni-Cu
composite interlayer were mainly Al3Ni, Ni (Cu), Cu (Ni), Mg2Cu and Al7Cu3Mg6 phases. With the
application of the Ni-Cu composite interlayer, the thickness of the interface of the A356/AZ91D
bimetal remarkably decreased from 1400 μm of the sample without Ni-Cu composite interlayer to
40 μm. The shear strength of the A356/AZ91D bimetal using Ni-Cu composite interlayer increased by
20.3 % compared with that of the bimetal without Ni-Cu composite interlayer. The fractures of the
A356/AZ91D bimetals with and without Ni-Cu composite interlayers belonged to a brittle rupture
mode. The breakage of the bimetal with Ni-Cu composite interlayer mainly took place between the
Ni-Cu layer and AZ91D matrix, while the rupture of the A356/AZ91D bimetal without Ni-Cu
composite interlayer was located in the interface layer. The Cu(Ni) and Ni(Cu) layers had a lower
nano-hardness than the Al-Mg IMCs, and the elasticity modulus for the Cu(Ni), Ni(Cu) and Al3Ni
phases were higher compared to those of the Al-Mg IMCs. The results of corrosion test exhibited
that the Ni-Cu composite interlayer had little influence on the corrosion resistance of the
A356/AZ91D bimetal.
Keywords: A356/AZ91D bimetal; Ni-Cu composite interlayer; Compound casting; Microstructure;

Mechanical properties; Corrosion resistance
Chen-Yi Ma, Cheng Wang, Zhen-Ming Hua, Peng-Yue Wang, Jin-Guo Wang, Hui-Yuan Wang,
A high-performance Mg-Al-Sn-Zn-Bi alloy fabricated by combining sub-rapid solidification and hot

rolling,
Volume 169,
2020,
110580,
ISSN 1044-5803,
Abstract: The development of wrought Mg alloys with high alloying contents is greatly restricted by
the negative influence of coarse aggregative second phases originating from the casting process. In
the present work, we reported a high-performance Mg-5Al-2Sn-2Zn-0.5Bi (wt%, ATZB5220) alloy
fabricated by combining sub-rapid solidification (SRS) and controlled hot rolling. The microstructure
of the as-cast alloy was greatly refined by the SRS with a high cooling rate (~350 °C/s). The micro-
segregation of different alloying elements was also alleviated by the SRS to varying degrees. The
improvement degrees of micro-segregation for Al and Sn solutes were much higher compared with
Zn and Bi. The SRS sample obtained more uniform and finer (~3 μm) grains than the conventional
solidified counterpart after hot rolling (a reduction of ~70%) and annealing treatment, which mainly
benefited from the finer as-cast microstructure under the SRS. Eventually, the high-alloyed
ATZB5220 sample following the SRS route showed a good combination of strength and ductility,
exhibiting an ultimate tensile strength (UTS) of ~356 MPa, yield strength (YS) of ~267 MPa, and
elongation to failure (δf) of ~13%. This work provides a novel strategy to fabricate high-performance
Mg alloy sheets with high alloying contents.
Keywords: Mg alloys; Sub-rapid solidification; Micro-segregation; Microstructure heredity; Hot

rolling; Tensile properties
Sohil Parsana, Nishil Radadia, Mohak Sheth, Nisarg Sheth, Vimal Savsani, N. Eswara Prasad, T.
Ramprabhu,
Machining parameter optimization for EDM machining of Mg–RE–Zn–Zr alloy using multi-objective
Passing Vehicle Search algorithm,
Archives of Civil and Mechanical Engineering,
Volume 18, Issue 3,
2018,
Pages 799-817,
ISSN 1644-9665,
https://doi.org/10.1016/j.acme.2017.12.007.
Abstract: Mg alloys are known for their specific strength, stiffness, damping capacity, EMI shielding.
Particularly, Rare earths added Mg alloys find applications in the gear box casing, transmission
housing, engine mount, ribs, frames, instrument panels due to their improved corrosion resistance,
pressure tightness, specific strength and creep strength. Reemergence of Mg alloys in the aircraft
structural applications demands for advanced machining processes such as EDM to fabricate
complex geometry parts. In this study, parametric multi-objective optimization of EDM on Mg–RE–
Zn–Zr alloy is carried out using the novel meta-heuristic algorithm – Passing Vehicle Search (PVS).
The input parameters considered are pulse-on (Ton), pulse-off (Toff) and peak current (A). Response
surface method (RSM) is implemented through the Box–Behnken design to formulate a
mathematical model for Material Removal Rate (MRR), Tool Wear Rate (TWR) and Roundness of
holes. The accuracy of theoretical model has been established using the confirmation runs. Using the
weighted sum method, the multi-objective PVS calculated optimal solutions for different weights to
generate 2-D and surface pareto fronts. These pareto fronts were evaluated for performance
determination of PVS using novel and established metrics such as spacing, spreading, hypervolume
and pure diversity. The values of performance metrics indicate acceptable nature of the graphs and
such analysis would facilitate better comparisons of solutions to select algorithms for optimization.
Finally, decision making is illustrated with the help of level diagrams to draw up practical inferences
for designing production plans and providing the best choice of machining parameters according to
their preferences.
Keywords: Mg–RE alloys; Electric discharge machining; Passing Vehicle Search algorithm; Response
surface method; Machining parameters optimization
Kapil Gupta, Neelesh Kumar Jain, Rudolph Laubscher,
Chapter 2 - Conventional Manufacturing of Cylindrical Gears,
Academic Press,
2017,
Pages 35-51,
ISBN 9780128044605,
https://doi.org/10.1016/B978-0-12-804460-5.00002-X.
Abstract: This chapter provides a brief introduction to certain conventional processes that are used
to manufacture cylindrical gears. These processes belong to three main classes, namely material
removal processes, forming processes, and additive processes. Material removal processes include
form-cutting and generative processing to manufacture gears. Gear milling, broaching, gear cutting
by shaper, and shear cutting are form-cutting type material removal processes; while gear hobbing,
shaping and planning are generative type material removal processes. In the forming category,
stamping, extrusion, and gear rolling are introduced. The chapter is concluded with an introduction
of selected additive processes, including gear casting, powder metallurgy, and injection molding.
Keywords: Broaching; Extrusion; Gear Hobbing; Gear shaping; Gear milling; Injection molding;
Stamping
Mathias Liewald, Celalettin Karadogan, Benjamin Lindemann, Nasser Jazdi, Michael Weyrich,
On the tracking of individual workpieces in hot forging plants,
Volume 22,
2018,
Pages 116-120,
ISSN 1755-5817,
Abstract: Tracking each workpiece provides two major advantages in forging technology. First, the
matching of physical workpiece with the monitored process information facilitates root-cause
analysis for product quality. Second, the following process steps can be adapted according to the
incoming workpiece properties to improve the robustness of hot forging process chain. The paper
presents a general tracking methodology and tagging experiments on aluminium and steel forgings
for harsh drop-forging technology. Furthermore, a framework for streaming and processing large
amounts of real-time data as well as a multidimensional approach to model and analyse the
workpiece information for individual and batch-tracking are presented.
Keywords: Forging; Digital manufacturing system; Knowledge management
Chengyang Deng, Jinwu Kang, Haolong Shangguan, Yongyi Hu, Tao Huang, Zhiyong Liu,
Effects of hollow structures in sand mold manufactured using 3D printing technology,
Volume 255,
2018,
Pages 516-523,
ISSN 0924-0136,
Abstract: The performance of 3D printed sand molds with internal hollow structures was studied.
The influence of the internal hollow structures (a single layer air cavity or multilayer air cavities) on
heat flux was theoretically analyzed and numerically simulated using COMSOL software. Better
insulation effect was achieved by reducing the cavity spacing, and multilayer air cavities performed
better than a single layer air cavity. 3D printed sand molds with these hollow structures for a stress-
frame casting and a bar-shaped casting were designed and poured with aluminum alloy A356 melt.
The solidification time of the riser surrounded by three layers of air cavities was prolonged by over
30%, and its feeding function during solidification was significantly improved. The temperature
difference within the stress-frame casting was decreased using three layers of air cavities
surrounding its thin rods, resulting in a 40% reduction of the residual stress in the thin rods. Open air
cavity structure was used for air blowing during the solidification process to increase the cooling rate
of one thin rod of the cast specimen, and its secondary dendrite arm spacing was narrowed.
Keywords: Sand mold; 3D printing technology; Hollow structure; Controlled cooling; Insulation
Joseph K. Adu, Dzakadzie Fafanyo, Emmanuel Orman, Isaac Ayensu, Cedric D.K. Amengor, Samuel
Kwofie,
Assessing metal contaminants in milled maize products available on the Ghanaian market with
Atomic Absorption Spectrometry and Instrumental Neutron Activation Analyser techniques,
Food Control,
Volume 109,
2020,
106912,
ISSN 0956-7135,
https://doi.org/10.1016/j.foodcont.2019.106912.
Abstract: The study is undertaken as a quality assurance exercise, to investigate the quality of milling
plates available on the market by evaluating the metals released from them into food products in
contact with them during comminution. Two locally manufactured and one imported milling plates
were used in both dry and wet milling of maize samples collected from different geographical
locations in the country (N = 12). Atomic Absorption Spectrometry and Instrumental Neutron
Activation Analyser techniques were used to detect and quantify the metals present as contaminant
in the flour samples over a seven-week period. While Na, Fe, Zn, Mn, Mg, Ca and Al were detected,
As, Cd, Cu, Co, Pb and Ni were either absent or below detection limits. The concentrations of the
metals were observed to decline with continuous use of milling plates, with Mg recording the
highest of concentrations in each week and Mn, the vice versa. The results showed that the quality
of the milling plates contributed to the levels of metals seen in the samples. In terms of the extent of
contamination, the imported plate was deemed best of the three milling plates used whiles the two
locally manufactured plates were comparable. Wet milling process was touted as better than dry
milling in contributing to metal contamination of milled food products. Also, the maize samples
collected from different places were shown to exhibit varying metal concentrations. The sample
from Ejura-Sekyere Dumase was showed to be more contaminated than from other sources. When
the flours were used to produce consumable foods, porridge and kenkey, the metal concentrations
in them were comparable. The outcomes of the study show that education on sources of food
contamination should be organized for stakeholders in the maize cultivation and processing industry
and regulatory systems should also be strengthened to safeguard consumers’ health.
Keywords: Food contamination; Atomic absorption spectroscopy; Instrumental neutron activation

analysis; Heavy metals; Corn milling plate; Ghana Research Reactor-1
I. Bacaicoa, M. Wicke, M. Luetje, F. Zeismann, A. Brueckner-Foit, A. Geisert, M. Fehlbier,
Characterization of casting defects in a Fe-rich Al-Si-Cu alloy by microtomography and finite element
analysis,
Engineering Fracture Mechanics,
Volume 183,
2017,
Pages 159-169,
ISSN 0013-7944,
https://doi.org/10.1016/j.engfracmech.2017.03.015.
Abstract: The casting defects from a Fe-rich Al-Si-Cu alloy were characterized by micro tomography
and Finite Element Analysis. The specimens were analyzed in a high resolution computed-
tomography scan and the 3D geometry of the casting defects were segmented in a rendering
software. Shrinkage pores of various shapes as well as large plate-like ß-Al5FeSi inclusions were
identified and their 3D volumetric model was imported into a FE software tool in order to calculate
the stress concentration factors caused by these defects. In the case of the shrinkage pores,
maximum Kt factors ranging from 4.73 and 14.56 were obtained located at the holes and dendritic
arms of the shrinkage pores. For the ß-Al5FeSi particles, the highest stress concentration factors
were located at the edge and the protuberances of the inclusions and ranged between 1.74 and
3.46. Large clusters of these ß-phases were observed, in which micro-pores were retained. After
heat treatment, a significant fragmentation and dissolution of the ß-Al5FeSi inclusions was found
together with an increase in the ductility and ultimate strength of the alloy.
Keywords: Al-Si-Cu alloys; X-ray tomography; Porosity; ß-Al5FeSi; Finite element analysis
Krzysztof Bryła,
Microstructure and mechanical characterisation of ECAP-ed ZE41A alloy,
Volume 772,
2020,
138750,
ISSN 0921-5093,
Abstract: The ZE41A magnesium alloy is used mainly for aerospace and automotive applications
owing to its moderate strength up to 150 °C. However, it shows reduced strength and ductility at
ambient temperature as a consequence of formation of stable ternary compound on grain
boundaries. Therefore, obtaining improved mechanical properties by grain refinement and changing
the distribution and size of ternary phase using equal-channel angular pressing constitute the
objectives of the present work. The microstructure after four passes of ECAP is characterised by
bimodal grain distribution, with parts of ultrafine grains or subgrains below 1 μm, and elongated
larger ones, even above 20 μm. The significant change in distribution and size of ternary phase
occurred after ECAP. In addition, the Zn22Zr particles of approximately 50 nm in diameter and less
were determined. These precipitates were not previously identified in the EZ41A alloy. The grain
refinement, as well as the redistribution and the fragmentation of the ternary phase particles
through a ECAP process is accompanied by an increase in mechanical properties. The hardness is
almost two times higher after 4 passes of ECAP compared to as-cast condition. The tensile strength,
as well as the compression strength approximately doubles and the ductility is enhanced.
Keywords: Magnesium alloy; Equal-channel angular pressing; Grain refinement
Rui Chen, Qingyan Xu, Huiting Guo, Zhiyuan Xia, Qinfang Wu, Baicheng Liu,
Correlation of solidification microstructure refining scale, Mg composition and heat treatment

conditions with mechanical properties in Al-7Si-Mg cast aluminum alloys,
Volume 685,
2017,
Pages 391-402,
ISSN 0921-5093,
Abstract: Analysis of solidification conditions, compositions and heat treatment parameters and
their mutual interaction on the microstructure evolution is of great importance for designing
components with desired mechanical properties. The present paper aims at widening the knowledge
on the correlation of solidification microstructure refining scale, Mg composition and heat treatment
parameters with the mechanical properties in Al-7Si-Mg cast aluminum alloys. The results reveal
that the advantage of fine solidification microstructure can be inherited after heat treatment, with
the finer microstructure being characterized by higher tensile properties. Furthermore, with the
solidification microstructure refining, the fracture mode transforms from quasi-cleavage to dimple
and fracture path transforms from transgranular to intergranular. With the increase of Mg
composition, both yield strength and ultimate tensile strength increase, while the elongation
decreases. Higher artificial aging temperature can decrease the peak strength. Different solution
treatment can produce the different tensile properties because of the different microstructures and
composition. A yield strength model using an experiment-based term ∆σ0 to account the effect of
solidification and solution treatment is proposed, and the relationship between yield strength and
ultimate tensile strength is described using an empirical equation.
Keywords: Al-7Si-Mg cast alloys; Solidification microstructure; Heat treatment; Precipitation

hardening; Tensile properties
Tobias Fiegl, Martin Franke, Carolin Körner,
Impact of build envelope on the properties of additive manufactured parts from AlSi10Mg,
Optics & Laser Technology,
Volume 111,
2019,
Pages 51-57,
ISSN 0030-3992,
https://doi.org/10.1016/j.optlastec.2018.08.050.
Abstract: The selective laser melting (SLM) process is well established in the construction of
prototypes and in the low volume production. With increasing build-up rates the next step to serial
production is possible. Multi laser systems and larger build envelopes make the process cost-
efficient. Enlarged systems enable not only the manufacturing of numerous smaller parts in one
build job but also bigger parts for the automotive and aerospace industry. A modified metal laser
melting machine X LINE 2000R equipped with a dual laser system and an enlarged build envelope is
used to investigate the position-dependent properties of parts made from AlSi10Mg. The impact on
porosity and mechanical properties is shown for different spatial directions. The results are an
important contribution to process design, component layout and further improvements of larger
SLM machines.
Keywords: Additive manufacturing; Selective laser melting; AlSi10Mg; Large-scaled parts; Position-
dependent properties
Poonam Sundriyal, P.L. Sah,
Enhancement of Mechanical Properties of Graphite Particulate Aluminum Metal Matrix Composites

by Magnesium Addition,
Volume 4, Issue 9,
2017,
Pages 9481-9486,
ISSN 2214-7853,
Abstract: In the present work effect of 1% Magnesium (Mg) addition on Graphite (Gr) particulate
Aluminum metal matrix composites (AMMCs) has been studied. Achieving good wettability and
uniform distribution of particles in the metal matrix are major challenges for the fabrication of metal
matrix composites and this problem can be overcome by two step-mixing stir casting method.
Literature suggests that Mg is a strong surface agent which removes oxygen from the dispersoids
surface so gas layers (which are responsible for the poor wettability) will be reduced hence
wettability between the reinforcement particles and metal melt will be improved. So to obtain good
wettability of solid particles with Aluminum (Al) melt 1% Mg was added in the Gr particles. AMMCs
were prepared by varying Gr content as 2, 4 and 6 weight percentage of Al with and without
addition of Mg. By comparing both of the composites, it was observed that Gr-1 wt.% Mg admixture
reinforced composites have better mechanical properties, better conductivity and better thermal
stability than the unreinforced Mg composites and best results were obtained for 4 wt% of Gr-1 wt.
% Mg admixture composite.
Keywords: Aluminium metal matrix composites; Stir casting; Magnesium; Graphite; Mechanical
properties
Index,
Academic Press,
2016,
Pages 591-597,
ISBN 9780123851321,
https://doi.org/10.1016/B978-0-12-385132-1.00020-3.
Denisa Zavodska, Eva Tillova, Mario Guagliano, Lenka Kucharikova, Maria Chalupova,
Fatigue Resistance of Self-hardening Aluminium Cast Alloy,
2017,
Pages 6001-6006,
ISSN 2214-7853,
Abstract: Cast aluminium alloys are widely used in fatigue critical structural applications, such as
engine blocks, cylinder heads, chassis and suspension components, to improve automotive fuel
economy. However, it may be difficult to use these alloys for parts that require a high fatigue
strength and high reliability because of a large number of casting defects as porosity and
microshrinkages exist in them. Fatigue properties of cast aluminium components are controlled by
maximum defect size in the material. The larger maximum defect size, the lower the fatigue strength
and life. Self-hardening Al-alloys (Al-Zn-Si-Mg alloys) introduce an innovative class of light Al-alloys.
Fatigue properties of AlZn10Si8Mg cast alloy in the high cycle region were tested by rotating bending
fatigue loading in a high cycle region with the used of parameters - frequency f = 40 Hz, temperature
T = 20 ± 5 °C and stress ratio R = -1. Because of that large pores are near or at specimeńs surface and
its dominant reason of fatigue crack initiation and propagation.
Keywords: AlZn10Si8Mg cast aluminium alloy; Fatigue lifetime; Casting defects
Jae-Hyun Yu, Yoon-Suk Choi, Do-Sik Shim, Sang-Hu Park,
Repairing casting part using laser assisted additive metal-layer deposition and its mechanical
properties,
Optics & Laser Technology,
Volume 106,
2018,
Pages 87-93,
ISSN 0030-3992,
https://doi.org/10.1016/j.optlastec.2018.04.007.
Abstract: Generally, it is known that a welding technology is not suitable for repairing casting parts
due to metallurgical issues and high carbon contents. So, the repairing of cast iron by welding has
not been satisfactorily realized yet, resulting in microstructure changes in the welding area, which
greatly impacts on crack initiation and growth as well as Martensite formation in the repaired area
and heat affected zone (HAZ). In this study, we evaluated how the HAZ affected the mechanical
properties of gray cast iron after it was repaired by the traditional welding process (shielded metal
arc welding) and by the additive metal-layer deposition (AMD) process using a laser. The results
indicated that the ultimate strength of each repaired part reduced by up to 16% when compared to
that of the original specimen composed of only cast iron, FC300. However, the elongations of the
specimens varied according to the repair methods. In the case of repair welding, the elongation
decreased by approximately 20%. However, in the case of repairing by AMD, the elongation
increased dramatically to approximately 60%. Hence, the proposed repairing method based on AMD
appears to be a promising method for repairing castings.
Keywords: Welding; Additive metal-layer deposition (AMD); Gray cast iron; Heat-affected zone
(HAZ); Local brittle zone (LBZ); Remanufacturing
Yeon-Gil Jung, Erdenechuluun Tumenbayar, Hyeun-Hee Choi, Hye-Young Park, Eun-Hee Kim, Jing
Zhang,
Effects of alumina precursor species in a ternary-phase binder system on the strength of sand mold,
Ceramics International,
Volume 44, Issue 2,
2018,
Pages 2223-2230,
ISSN 0272-8842,
https://doi.org/10.1016/j.ceramint.2017.10.179.
Abstract: A new ternary-phase binder system incorporating alumina (Al2O3) precursors was
successfully developed through process control to improve the sand mold's strength for casting of
large objects. Three types of Al2O3 precursors with different molecular structures, such as Al(OH)3,
Al(OEt)3, and Al(NO3)3 were employed in the ternary-phase binder system. A dual-dipping process
was developed. The first dipping includes the ternary-phase binder composition and heat treatment
at 1000 or 1200°C. The second dipping uses a binary-phase binder composed of TEOS and NaOMe
and heat treatment at 1000°C. The results show that sodium aluminosilicate was synthesized in the
ternary-phase binder at both temperatures, and amorphous silica was formed only in the ternary
composition of TEOS/NaOMe/Al(OEt)3. In contrast, sodium silicate was formed in the binary-phase
binder. The strength of the mold prepared with precursor Al(OEt)3 was higher than those with
Al(OH)3 and Al(NO3)3, due to its improved glassification efficiency of Al(OEt)3. Additionally, the
mold strength was increased with increasing content of TEOS in the ternary-phase binder
composition. Finally, the optimal highest strength was obtained with the ternary-phase binder
composition of TEOS/NaOMe/Al(OEt)3 in the mole ratio of 5:1:1.
Keywords: Inorganic binder; Precursor; Ternary-phase composition; Aluminum compound; Strength
Nirav Mehta, A.V. Gohil, K.G. Dave, V.B. Patel,
Development of casting defect analysis module through integrated approach for small and medium
scale industries,
2020,
ISSN 2214-7853,
Abstract: Casting process carries a threat of deficiency occurrence during stages of manufacturing
because of the involvementof a large number of manufacturing parameters starting from design,
pattern making through molding, melting, pouring, etc. to the last stage of shakeout and heat
treatment. The solution tocountless casting problem requires empirical knowledge and proficiency
cultivated over the many years. In particular, small and medium and scale industries often
experienceimmense problems in acquiring and sustaining the scenario. The present research
focused to assist medium and small scale industries for defect analysis of casting products to drive
them self-sustain. The research outlines the defect diagnostic tasks in determining the cause of
defects in casting and suggests remedies to rectify the casting defect based on database structure
for defect analysis prepared by combining both expertize from industrial and theoretical literature
exist. The computer-assisted interactive integrated module operable through skilled or unskilled
persons is developed for enhancing quality control in casting industries precisely small and medium
scale industries. The developed integrated module consists of defect identification and rectification
steps. The identification of defects is carried out based on visual characteristics. The verification of
an integrated module is also realized in coordination with industry by performing a defect
identification and diagnosis generated in casting products.
Keywords: Casting; Defect diagnosis; Defect analysis module; Expert system; Casting software
Ron Palgrave,
Chapter 11 - Does the pump continue to operate well?,
Editor(s): Ron Palgrave,
Troubleshooting Centrifugal Pumps and their Systems (Second Edition),
2020,
Pages 301-343,
ISBN 9780081025031,
https://doi.org/10.1016/B978-0-08-102503-1.00011-6.
Abstract: The content of this section leans unashamedly towards aspects of pump and system
interaction. It does so because, in the writer's experience, this aspect is most often misunderstood.
In contrast, many of the mechanical aspects of pump design are not unique to that industry. A wider
body of experience exists to solve such problems, which in any case are often intuitive.
Keywords: Site test results analysis; Corrosion of wetted surfaces; Protective coatings; Efficiency
improvement
L. Di Angelo, P. Di Stefano, A.E. Morabito,
Fillets, rounds, grooves and sharp edges segmentation from 3D scanned surfaces,
Computer-Aided Design,
Volume 110,
2019,
Pages 78-91,
ISSN 0010-4485,
https://doi.org/10.1016/j.cad.2019.01.003.
Abstract: Fillets, rounds, chamfers and grooves are secondary features which are typically present in
real manufactured mechanical components to satisfy some manufacturing and functional
requirements. Despite the broad array of research conducted on feature recognition, the
investigation of secondary features is a relatively new topic. All of the pertinent studies have been
focusedonly on the recognition of secondary features from B-Rep models. The recognition and
segmentation of secondary features from a discrete model is a non-trivial problem due to the same
geometric descriptors that may be applied to both primary and secondary features. Moreover,
although in real-world mechanical parts primary features are planes, cylinders or cones, the
secondary features may be non-analytical and complex-shaped geometries. Further sources of
uncertainty are the measurement errors and non-ideal geometries of the real objects to which the
method is applied. To overcome these problems, a new and original method to segment secondary
features of tessellated geometric models is proposed. The method is based on the analysis of
geometric-differential properties and provides specific strategies that reduce its sensitivity to all of
the above-mentioned uncertainties without affecting its selectivity. The proposed method, described
in detail in this paper, is tested in some very critical cases, and the results are presented and
discussed.
Keywords: Blending features; Features recognition; 3D mesh segmentation; STL; 3D scanning; Fuzzy
logic
Suming Zhu, Charlotte Wong, Mark J. Styles, Trevor B. Abbott, Jian-Feng Nie, Mark A. Easton,
Revisiting the intermetallic phases in high-pressure die-cast Mg–4Al–4Ce and Mg–4Al–4La alloys,
Volume 156,
2019,
109839,
ISSN 1044-5803,
Abstract: Mg–Al–RE based alloys such as AE42 (Mg–4Al–2RE) and AE44 (Mg–4Al–4RE) are commonly
known to contain A111RE3 and Al2RE intermetallic phases, with the former being predominant.
However, it was found recently that the predominant intermetallic phase in a gravity-cast Mg–4.5Al–
6.3La alloy is not A111La3 but a new ternary phase with the composition of (Al,Mg)3La. In this work,
the intermetallic phases in high-pressure die-cast Mg–4Al–4Ce and Mg–4Al–4La alloys are thus re-
examined by X-ray diffraction (XRD), scanning electron microscopy (SEM) and transmission electron
microscopy (TEM). It is shown that the predominant intermetallic phase is A111Ce3 in the die-cast
Mg–4Al–4Ce alloy but (Al,Mg)3La in the die-cast Mg–4Al–4La alloy. Both A111Ce3 and (Al,Mg)3La
remain thermally stable upon annealing at 500 °C for 100 h and are most likely equilibrium phases in
each alloy. This study provides strong evidence that the formation of intermetallic phases in Mg–Al–
RE alloys is affected by the choice of individual RE elements.
Keywords: Mg–Al–La alloy; Mg–Al–Ce alloy; Microstructure characterization; Intermetallic phase;

High-pressure die-casting
Xian Du, Wenbo Du, Zhaohui Wang, Ke Liu, Shubo Li,
Simultaneously improved mechanical and thermal properties of Mg-Zn-Zr alloy reinforced by ultra-
low content of graphene nanoplatelets,
Applied Surface Science,
Volume 536,
2021,
147791,
ISSN 0169-4332,
https://doi.org/10.1016/j.apsusc.2020.147791.
Abstract: Mg-Zn-Zr (ZK60) alloys reinforced by ultra-low content (<0.1 wt%) of graphene

nanoplatelets (GNPs) were fabricated via stirring cast and extrusion processes. In composites, GNPs
thoroughly dispersed and continuously combined with Mg matrix at the interface, beneficial for the
load and heat transfer of composites. The static and dynamic mechanical properties of GNP/ZK60
composite were investigated and respectively compared with those of ZK60 alloy. With only 0.04 wt
% addition, GNP nanofillers improved the impact toughness twice that of ZK60 matrix up to 17 J cm-
2. In tensile test, GNP(0.04)/ZK60 composite performed enhanced tensile yield strength of 256 MPa,
improved by 62% than ZK60 alloy. Although grain boundary is commonly considered as defect to
deteriorate transport property, GNP(0.04)/ZK60 composite with largely refined grain size conducted
superior thermal conductivity of 139.4 W·(mK)-1 than ZK60 alloy (132.2 W·(mK)-1) at room
temperature. The dispersed GNPs in matrix provide beneficial networks for efficient load and heat
transfer. This work explores that graphene reinforcement is an effective way to simultaneously
improve the mechanical and thermal properties of Mg alloys for enlarged applications.
Keywords: Graphene; Magnesium; Interface; Mechanical property; Impact toughness; Thermal

conductivity
Hong-mei YANG, Wen-bo YU, Yong-you CAO, Xiao-bo LI, Zhi-peng GUO, Shou-mei XIONG,
Effect of different processing parameters on interfacial heat-transfer behavior in high-pressure die-
casting process,
2018,
Pages 2599-2606,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64907-6.
Abstract: Vacuum die casting can reduce the “air entrapment” phenomenon during casting process.
Based on the temperature measurements at metal–die interface with different processing
parameters, such as slow shot speed (VL), high shot speed (VH), pouring temperature (Tp) and initial
die temperature (Tm), inverse method was developed to determine the interfacial heat transfer
coefficient (IHTC). The results indicate that a closer contact between the casting and die could be
achieved when the vacuum system is used. It is found that the vacuum could strongly increase the
values of IHTC and decrease the grain size in castings. The IHTC could have a higher peak value with
increasing the Tp from 680 to 720 °C or the VL from 0.1 to 0.4 m/s. In addition, the influence of the
VH and Tm on IHTC could be negligible.
Keywords: vacuum die casting; interfacial heat transfer behavior; metal–die interface; externally
solidified crystals
Shaik Mozammil, Jimmy Karloopia, P.K. Jha,
Investigation of porosity in Al casting,
2018,
Pages 17270-17276,
ISSN 2214-7853,
Abstract: Porosity is one of the serious problems observed in foundries. In the present study pure
aluminium (99.85%) is used as a cast material. For both simulation and experimental work, it has
been seen that due to the pouring temperature, pouring time and different types of gating system
design, porosity in the casting is greatly influenced. Here optimization of pouring temperature,
pouring time and gating design is done by using Auto-CAST simulation technique. Finally,
experimental results are validated with Auto-CAST simulation results and improvements are
suggested in terms of optimisation of gating system by modelling and simulation technique. Non-
destructive method of testing like dye-penetrant test has been used for checking the surface defects
and ultrosonic method of testing has been used for evaluating the presence of subsurface defects.
Keywords: Porosity; pouring temperature; gating system; Auto-CAST
M.R. MIRZADEH RAHNI, B. BEIDOKHTI, M. HADDAD-SABZEVAR,
Effect of filler metal on microstructure and mechanical properties of manganese–aluminum bronze

repair welds,
Volume 27, Issue 3,
2017,
Pages 507-513,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(17)60057-8.
Abstract: The repair welding of UNS C95700 manganese–aluminum bronze plates was done using
different filler metals. The microstructure and mechanical properties of welds were studied. The
main microstructural constituents were α, β and κ phases with different morphologies. The addition
of manganese decreased the percentage of α phase in the microstructure of weldments from 80%
(Mn-free weld) to 57% (12.5% Mn weld, mass fraction). The morphology of κ phase was lamellar in
high nickel specimens and it was changed to a globular morphology for high manganese welds.
Although the application of high manganese filler metal yielded the higher tensile and bending
strengths of weldment compared with the weld using high nickel filler material, the optimum
mechanical properties of repair welds were obtained using a non-alloy filler material (ERCuAl-A2) for
the underlay and high manganese filler metal (ERCuMnNiAl) for filling passes. This weld presented
an increase of 39% in tensile strength compared with the base metal, and no cracking was observed
after bending test.
Keywords: manganese–aluminum bronze; welding; filler metal; microstructure; mechanical

properties
Gabriele Piscopo, Eleonora Atzeni, Flaviana Calignano, Manuela Galati, Luca Iuliano, Paolo Minetola,
Alessandro Salmi,
Machining induced residual stresses in AlSi10Mg component produced by Laser Powder Bed Fusion
(L-PBF),
Procedia CIRP,
Volume 79,
2019,
Pages 101-106,
ISSN 2212-8271,
Abstract: The adoption of metal powder-based laser process (L-PBF) for industrial applications
continues to widen, due to an increasing knowledge on additive processes and the availability of
new systems for industrial production. The use of L-PBF processes requires a deeper investigation
and comparison on mechanical properties of conventional and additive parts. For instance, metal
parts produced by L-PBF could require additional machining operations, which alter the stress state
of additive components. In this work, the effect of machining operations on the residual stress state
of an AlSi10Mg component produced by L-PBF is investigated by means of the semi destructive hole-
drilling method.
Keywords: Residual stresses; Laser Powder Bed Fusion; AlSi10Mg; Hole-drilling method; Machining
Xingrui Chen, Yonghui Jia, Qichi Le, Shaochen Ning, Xiaoqiang Li, Fuxiao Yu,
The interaction between in situ grain refiner and ultrasonic treatment and its influence on the
mechanical properties of Mg–Sm–Al magnesium alloy,
Volume 9, Issue 4,
2020,
Pages 9262-9270,
ISSN 2238-7854,
Abstract: This work investigated the interaction between in situ grain refiner and ultrasonic
treatment (UT) and its influence on the mechanical properties of Mg–Sm–Al magnesium alloy. The
grain size is reduced with the increasing of Al content, which is attributed to the enhancement of
heterogeneous nucleation by Al2Sm particles. The ultrasonic melt treatment also refines grains via
increasing the number of nucleation sites by ultrasonic cavitation. There is a maximum grain
refinement efficiency on a certain solidification circumstance. The alloying method (generation the in
situ grain refiner) and UT have a positive interaction, which increases the number of potential
nucleation particles in melt, while the number of activated nucleation particles is decided by
solidification condition. The increase of Al content and UT improve both yield strength and ultimate
tensile strength due to grain refinement strengthening and the second phase strengthening. The UT
significantly improves the elongation of each alloy with an increasing range of up to 312%. The de-
agglomeration of second particles and increased diversity of grain orientation respond to such
improvement.
Keywords: Magnesium alloy; Grain refinement; Ultrasonic treatment; Grain refiner; Intermetallics;
Ahmad Mayyas, Margaret Mann,
Emerging Manufacturing Technologies for Fuel Cells and Electrolyzers,
Volume 33,
2019,
Pages 508-515,
ISSN 2351-9789,
Abstract: Fuel cells have emerged as viable solutions in areas such as stationary and backup power
systems, material handling equipment (MHE), and fuel cell electric vehicles (FCEV). Persistent
challenges for fuel cells and electrolyzers include high initial cost and the availability of hydrogen
infrastructure to support FCEV and MHE fleets. Cost of fuel cells are still high compared to other
power generation systems such as diesel and natural gas generators. This, however, can be linked to
two facts: first is low production volumes generally and second is emerging manufacturing
technologies currently in R&D that need to be scaled up to factory production volumes. This study
investigates current manufacturing processes used in production of fuel cells (e.g., spray coating and
manual assembly) and emerging manufacturing technologies (e.g., roll-to-roll catalyst coating) to
investigate key cost drivers and potential cost reductions in manufacturing of fuel cells and
electrolyzers. In particular, we focus on how cost reductions for advance manufacturing technologies
may be more significant at scale than existing technologies.
Keywords: Cost; Electrolyzer; Fuel Cells; Manufacturing
Zhenming Li, Alan A. Luo, Qigui Wang, Hui Zou, Jichun Dai, Liming Peng,
Fatigue characteristics of sand-cast AZ91D magnesium alloy,
Volume 5, Issue 1,
2017,
Pages 1-12,
ISSN 2213-9567,
Abstract: The fatigue characteristics of the AZ91D-T6 alloy samples taken from engine blocks have
been investigated at 20 °C and elevated temperature (150 °C). The fatigue strength and cyclic stress
amplitude of the alloy significantly decrease with the increase of the test temperature, although
cyclic hardening occurs continuously until failure for both temperatures. With the increase of the
temperature, the decreased fatigue life of the alloy tested at the same stress amplitude is mainly
attributed to the decreased matrix strength and the increased hysteresis energies. Fatigue failure of
the engine blocks made of AZ91D-T6 alloy is mainly controlled by casting defects. For the defect-free
specimens, the crack initiation behavior is determined by the single-slip (20 °C) and by environment-
assisted cyclic slip (150 °C) during fatigue, respectively. The low-cycle fatigue lives of the alloy can be
predicted using the Coffin-Manson relation and Basquin laws, the three-parameter equation and the
energy-based concepts, while the high-cycle fatigue lives of the alloy fitted well with the developed
long crack life model and MSF life models.
Keywords: Magnesium alloy; Engine blocks; Fatigue properties; Cyclic deformation behavior;
Temperature; Fatigue life prediction
Kh. Abd El-Aziz, D. Saber,
Mechanical and microstructure characteristics of heat-treated of high-Cr WI and AISI4140 steel

bimetal beams,
Volume 9, Issue 4,
2020,
Pages 7926-7936,
ISSN 2238-7854,
Abstract: Heat treatments are considered as one of the most important methods used to make
significant changes in the microstructure of the metallic materials and their alloys, which makes it
possible to change the external behavior and properties of these materials. The effect of heat
treatment at 900°C on the microstructure, hardness and flexural behavior of bimetal beams has
been studied in the present work. The bimetal beams composed of a high-Cr WCI as a wear-resistant
part and an AISI4140 steel as a ductile part were fabricated. The two parts of bimetal castings are
joined together by means of dovetail joint and/or connector pins. The present experimental and
numerical results revealed that all bimetal beams exhibited flexural strength, toughness and
maximum deflection higher than those of high-Cr WI specimen and lower than those of AISI4140
specimen in heat treated conditions. Heat treatment of the bimetal casting beams produced
significant improvements in both hardness and flexural strength of high-Cr WI and AISI4140 steel.
This is due to the formation of secondary carbides in the martensitic matrix surrounded by a
network of M7C3 carbides in high-Cr WI, and formation of fine pearlite with proeutectoid α at grain
boundaries for AISI4140 steel as revealed by SEM and an optical metallography. Bimetal beam with
12-connector pins (BI12CONN) as a mechanical joint exhibited the highest flexural strength and
toughness compared with the other bimetal beams after heat treatment.
Keywords: High-Cr WI; AISI4140 steel; Bimetal casting beams; Microstructure; Heat treatment;
Flexural strength
P. Paulraj, R. Harichandran,
The tribological behavior of hybrid aluminum alloy nanocomposites at High temperature: Role of
nanoparticles,
Volume 9, Issue 5,
2020,
Pages 11517-11530,
ISSN 2238-7854,
Abstract: The influence of the addition of hexagonal boron nitride nanoparticles and silicon carbide
nanoparticles on dry sliding tribological properties of the AA2024-SiC-h-BN hybrid nanocomposites
was evaluated at high-temperature environment using pin- on- disc wear testing machine at 30, 100,
200 and 300 °C under an applied load of 10, 20, and 30 N. The aluminium alloy 2024 matrix shows
mild to rigorous wear at and above 100 °C under an applied load of 10, 20, and 30 N. AA2024–
1.5 wt. % of SiC–2 wt. % of h-BN (H3), and AA2024–2 wt. % of SiC–1.5 wt. % of h-BN (H4) hybrid
nanocomposites exhibit severe wear only at a 30 °C chamber temperature environment under an
applied load of 30 N. The absence of severe wear phenomena in AA2024-SiC-h-BN hybrid
nanocomposites is attributed to the formation of thin lubricant film, oxidation layer, and mechanical
mixed layer on the pin surface. Abrasive, adhesive, and fracture wear are the main mode of wear
mechanism for AA2024-SiC-h-BN hybrid nanocomposites in a high-temperature environmental
chamber at 30, 100, 200 and 300 °C under an applied load of 10, 20, and 30 N.
Keywords: AA2024-SiC-h-BN hybrid nanocomposites; Mechanical stirrer; Ultrasonic casting; High-

Temperature environmental chamber tribological properties.
Wolfgang Bauer, Jürgen Dorn,
System Design of E-Markets for IPSS Purchasing,
Procedia CIRP,
Volume 64,
2017,
Pages 211-216,
ISSN 2212-8271,
Abstract: The production of labor cost intense goods in industrial countries becomes increasingly
unprofitable, unless add-on values can be delivered by supporting services. Research in Industrial
Product Service Systems (IPSS) – a marketable set of products and services - focuses on all aspects of
IPSS and supports the conversion of industrial countries towards a service society. This fundamental
change in paradigm sometimes described as the ‘servizitation of manufacturing’ could be seen as
survival strategy against low labor costs within a global market. However, industrial procurement
perceives IPSS as more difficult to assess than product offers. Buying departments are challenged to
compare values of different IPSS on an international market. Information asymmetry between
expert seller and consumer, hidden information or outcome uncertainties are some of the reasons,
that buyers perceive risks at IPSS purchasing. The complexity of working systems that support
nowadays purchasing environments increased. Until now, no standardized systems such as e-
markets are suitable to support buyers to find and compare available IPSS. This paper describes
design guidelines for a system that supports the search, discovery and comparison of IPSS.
Keywords: IPSS purchasing; IPS2; service procurement; IPSS e-marketplace; service description; e-
markets for service buyer
Shantanu Shahane, Narayana Aluru, Placid Ferreira, Shiv G Kapoor, Surya Pratap Vanka,
Finite volume simulation framework for die casting with uncertainty quantification,
Applied Mathematical Modelling,
Volume 74,
2019,
Pages 132-150,
ISSN 0307-904X,
https://doi.org/10.1016/j.apm.2019.04.045.
Abstract: The present paper describes the development of a novel and comprehensive
computational framework to simulate solidification problems in materials processing, specifically
casting processes. Heat transfer, solidification and fluid flow due to natural convection are modeled.
Empirical relations are used to estimate the microstructure parameters and mechanical properties.
The fractional step algorithm is modified to deal with the numerical aspects of solidification by
suitably altering the coefficients in the discretized equation to simulate selectively only in the liquid
and mushy zones. This brings significant computational speed up as the simulation proceeds.
Complex domains are represented by unstructured hexahedral elements. The algebraic multigrid
method, blended with a Krylov subspace solver is used to accelerate convergence. State of the art
uncertainty quantification technique is included in the framework to incorporate the effects of
stochastic variations in the input parameters. Rigorous validation is presented using published
experimental results of a solidification problem.
Keywords: Solidification; Unstructured grid; Finite volume method; Validation; Uncertainty

quantification; Casting
G. Masi, C. Josse, J. Esvan, C. Chiavari, E. Bernardi, C. Martini, M.C. Bignozzi, C. Monticelli, F. Zanotto,
A. Balbo, E. Svara Fabjan, T. Kosec, L. Robbiola,
Evaluation of the protectiveness of an organosilane coating on patinated Cu-Si-Mn bronze for

contemporary art,
Progress in Organic Coatings,
Volume 127,
2019,
Pages 286-299,
ISSN 0300-9440,
https://doi.org/10.1016/j.porgcoat.2018.11.027.
Abstract: A 3-mercapto-propyl-trimethoxysilane coating (PropS-SH) applied on Cu-Si-Mn bronze,

patinated by “liver of sulphur”, was investigated as a non-toxic alternative to Incralac®, usually
applied on outdoor artistic bronzes. Electrochemical testing was performed in synthetic acid rain.
Exposure to temperature/UV cycles and accelerated corrosion test simulating unsheltered exposure
to rainwater was also carried out. The exposed samples were characterised by FEG-SEM coupled
with EDS on FIB cross-sections and XPS on free surfaces. The black patina without protective coating
was scarcely protective against bronze corrosion and easily transformed into cuprous oxide. PropS-
SH coating fully preserved the black patina microstructure and phase constituents (cuprous oxide
and cuprous sulphide). The PropS-SH coating also resulted more protective than Incralac® when
aged under run-off conditions. Selective dissolution of copper from the silicon bronze alloy was
observed on both uncoated and Incralac®-coated bronze, leading to the formation of an internal Si-
rich corrosion layer.
Keywords: Organic coating; Bronze; Atmospheric corrosion; UV degradation; Electrochemical

techniques; XPS
Jingying Sun, Qichi Le, Li Fu, Jing Bai, Johannes Tretter, Klaus Herbold, Hongwei Huo,
Gas entrainment behavior of aluminum alloy engine crankcases during the low-pressure-die-casting
process,
Volume 266,
2019,
Pages 274-282,
ISSN 0924-0136,
Abstract: Gas pores on the top face of engine crankcases which are produced by Low Pressure Die
Casting (LPDC) have been studied. Micrographic analysis has been conducted to investigate the
evolution of such kind of casting defects. Results show that the surface of such casting defects have
meandering shapes and random sizes. Microstructures of the cross section of the defects displayed
folded feather shapes, which can be produced by the folded oxide film into the melt during the filling
process. Oxide inclusions have been found below the filter at the ingate area. Thus, it is confirmed
that the folded oxide films came from turbulence of the metal in the die cavity. Numerical simulation
has been carried out to study the filling behavior of the crankcase. Results show that gating velocity
suddenly increased when the liquid metal got into the waterfall structure and led to the turbulence.
Moreover, the air entrained behavior is related with the gating velocity. With increasing gating
velocity, turbulence happened when metal confluences, and became more intensely in the middle of
the casting due to its waterfall structure. Finally, this kind of casting defect was confirmed as gas
entrainment.
Keywords: Gas entrainment; Bifilm; Gating velocity; Turbulence; Waterfall
Wencai Liu, Beiping Zhou, Guohua Wu, Liang Zhang, Xiang Peng, Liang Cao,
High temperature mechanical behavior of low-pressure sand-cast Mg–Gd–Y–Zr magnesium alloy,
Volume 7, Issue 4,
2019,
Pages 597-604,
ISSN 2213-9567,
Abstract: The aim of this work is firstly to optimize T6 heat-treatment of low-pressure sand-cast Mg–
10Gd–3Y–0.5Zr alloy, and then systematically investigate the mechanical behavior of the T6-treated
alloy from room temperature to 300 °C. It turned out that the optimum T6 heat-treatments for the
tested alloy are 525 °C × 12 h + 225 °C × 14 h and 525 °C × 12 h + 250 °C × 12 h which integrated age-
hardening and tensile properties into account, respectively. The strength of the T6-treated alloy
indicates obvious anomalous temperature dependence from room temperature to 300 °C, namely
both ultimate tensile strength and yield strength of the tested alloy firstly increase with tensile
temperature, and then decrease as temperature increases further. Elongation increased with
temperature monotonously. The tensile fracture mode of the tested alloy changes from
transgranular fracture to intergranular fracture with the increasing of test temperature.
Keywords: Mg–Gd–Y–Zr; Heat treatment; High temperature tensile property; Anomalous

temperature dependence
Li Li, Dejiang Li, Xiaoqin Zeng, Alan A. Luo, Bin Hu, Anil K. Sachdev, Liangliang Gu, Wenjiang Ding,
Microstructural evolution of Mg-Al-Re alloy reinforced with alumina fibers,

Volume 8, Issue 3,
2020,
Pages 565-577,
ISSN 2213-9567,
Abstract: Few studies were reported on the phases’ relationships of AE44 (Mg-4.0Al-4.1RE-0.3Mn,
wt.%) and its composites. In this work, AE44 alloy and Saffil (δ-Al2O3)/AE44 Metal matrix composite
(MMC) were both prepared by slow shot high pressure die casting (SS-HPDC) technology and their
phase constitutions were all studied in detail using experimental techniques combined with
CALPHAD (Calculation of Phase Diagram) modeling. The results revealed that the alloy consists of the
α-Mg matrix, Al11RE3 intermetallic phase, and one trace phase Al3RE, while the composite contains
five major phases: α-Mg, δ-Al2O3, Al3RE, MgO and Mg2Si, and two trace phases of Al2RE and
Al11RE3, respectively. Al11RE3 is partly derived from Al2RE, while Al3RE is a product of the
peritectoid reaction between the two precipitates. The presence of MgO and Mg2Si is due to the
interfacial reaction between the SiO2 binder in the fiber preforms and the molten magnesium during
infiltration. The use of SiO2 binder in the preform manufacturing was limited/minimized to reduce
the MgO formation in the MMC casting process, which can be detrimental to the fatigue
performance of the MMC materials.
Keywords: Mg-Al-RE; Magnesium composite; Slow shot high pressure die casting; Microstructure;
CALPHAD; AlxREy
C. Bermudo, S. Martín-Béjar, F.J. Trujillo, G. Castillo, L. Sevilla,
Material flow analysis in indentation process by 3D Digital Image Correlation,
Volume 41,
2019,
Pages 26-33,
ISSN 2351-9789,
Abstract: Focusing on the application of the 3D Digital Image Correlation technique, this work
proposes a material flow analysis of an indentation process. The study establishes the methodology
for the calibration and implementation of the 3D image sensing technology for deformation
measurements. The purpose is to continue with the validation of DIC application on the indentation
processes, where a deep penetration is achieved and extensive material flow is produced. With the
3D DIC technique is possible to perform accurate deformation measurements in non planar
specimens and study the material emerging towards the exterior of the tested specimen, which is
not possible with the 2D DIC technique. Although previous 2D studies were efficient detecting the
flow field and von Mises strains on the specimens tested, the bulge emerging under the punch on
the front surface (dead zone) could not be studied due to its predominantly 3D character. Therefore,
present work implements a 3D methodology that carries out a complete deformation study,
including the material flow that occurs on the Z axis, towards the exterior of the tested specimen,
optimizing previous analyses.
Keywords: Dgital Image Correlation; experimental methodology; incremental forming; indentation
Erheng chen, Huajun Cao, Qinyi He, Jiahao Yan, Salman Jafar,
An IoT based framework for energy monitoring and analysis of die casting workshop,
Procedia CIRP,
Volume 80,
2019,
Pages 693-698,
ISSN 2212-8271,
Abstract: In order to reduce the impact on resource shortage and environmental pollution caused by
the massive use of energy, meeting the requirements of the fierce market competition,
manufacturing enterprises must strengthen the awareness of the energy utilization in the workshop.
As a widely distributed manufacturing system, die casting workshop consumes lots of energy with
low efficiency. Due to the dynamic and complicated of energy usage, an effective energy monitoring
and analysis method is still lacked in die casting workshop. This paper divides the die casting
workshop into die casting machine level, die casting task level, and die casting workshop level and it
proposes an energy monitoring and analysis system including data acquisition layer, data
transmission layer, data storage layer, data processing layer, and data display layer based on
Internet of Things (IoT) technology. A set of indicators, such as energy per process in die casting
workshop, energy per part in die casting task, and energy per part in die casting machine, and so on,
were calculated to interpret the energy data and evaluate the performance of a die casting
workshop through data mining. With the application of the proposed system in a die casting
workshop, enterprise managers can easily find potential opportunities for energy consumption
reduction, and energy efficiency improvement, and propose ways to reduce energy consumption
cost. The feasibility and practicability of the developed energy monitoring and analysis system was
verified through a case study.
Keywords: Energy monitoring; Energy analysis; Die casting workshop; Internet of Things; Data mining
Preface,
Academic Press,
2016,
Pages xiii-xiv,
ISBN 9780123851321,
https://doi.org/10.1016/B978-0-12-385132-1.00011-2.
Gianni Campatelli, Davide Campanella, Antonio Barcellona, Livan Fratini, Niccolò Grossi, Giuseppe
Ingarao,
Microstructural, mechanical and energy demand characterization of alternative WAAM techniques

for Al-alloy parts production,
2020,
ISSN 1755-5817,
Abstract: Additive manufacturing (AM) processes are gathering momentum as an alternative to

conventional manufacturing processes. A research effort is being made worldwide to identify the
most promising AM approaches. Within this category, wire arc additive manufacturing (WAAM) is
among the most interesting, especially when large parts must be manufactured. In this paper, two
different WAAM deposition techniques suitable for the deposition of Aluminum alloys, Cold Metal
Transfer (CMT) and CMT mix drive, are analyzed and compared. With the aim of obtaining a clear
picture concerning the two different techniques, microstructural analyses, mechanical property
evaluation and electrical energy demand characterizations were conducted. The results revealed
that both techniques allowed sound components to be manufactured and no significant differences
were observed in terms of their microstructural and mechanical properties, while CMT was also
found to provide a relevant energy saving. This allows the selection of the best technology taking
into account not only the geometrical characteristic of the part but also the environmental impact
associated to each technique.
Keywords: Additive manufacturing; WAAM; Mechanical properties; Energy efficiency
Sarafadeen Azeez, Madindwa Mashinini, Esther Akinlabi,

Road map to sustainability of friction stir welded Al-Si-Mg joints using bivariate weibull analysis,
Volume 33,
2019,
Pages 35-42,
ISSN 2351-9789,
Abstract: Welding is a crucial joining technique that is generally embraced in the fabrication industry.
The integrity of weld joints is of great importance because of its safety and economic importance. In
this paper, the concept of reliability as it applies to FSW was introduced to reduce repair and
maintenance cost. The Friction stir welding (FSW) of Al-Si-Mg alloy was examined. The response of
welding parameters on joints integrity was assessed through Weibull analysis of weld strengths. The
analysis revealed that the Weibull modulus increases with FSW parameters and 120mm/min welding
speed gave the highest value while the 90mm/min speed gave the least. Meanwhile, the reliability of
welds was observed to reduce by approximately 30% as the traverse speed increases by 25%. This
was due to the presence of defects and recrystallization of the grain morphology. The higher the
weld joint reliability the better the sustainability.
Keywords: Bivariate; Fabrication; Friction stir welding; Probabilistic; Reliability; Weibull modulus
Maria Cristina Tanzi, Silvia Farè, Gabriele Candiani,
Chapter 3 - Manufacturing Technologies,
Editor(s): Maria Cristina Tanzi, Silvia Farè, Gabriele Candiani,
Foundations of Biomaterials Engineering,
Academic Press,
2019,
Pages 137-196,
ISBN 9780081010341,
https://doi.org/10.1016/B978-0-08-101034-1.00003-7.
Abstract: The manufacture of an object or a device is a very important stage for the success of a
project. For this reason, this chapter is entirely dedicated to processing techniques of the different
classes of materials. For each type of material class, the basic principles of the main processing
techniques are presented, highlighting advantages and disadvantages when useful. Due to the
peculiar properties of each material class, manufacturing techniques are listed following the
sequence already used in the preceding chapters: polymers, metals, ceramics and carbons,
composites, and distinguishing the traditional processing methods from peculiar or advanced ones.
Examples of some biomedical devices production are also provided, namely heart valve and hip
prostheses components. In the last part of this chapter, emerging advanced techniques and their
working principles are presented.
Keywords: Raw materials; Finished products; Cohesion; Molding; Casting; Extrusion; Injection;
Thermoforming; Rolling; Machining; Foams; Polystyrene; Polyurethanes; Fibers; Spinning; Filament
winding; Electrospinning; Powder metallurgy; Plastic deformation; Junction operations; Surface
finishing; Drawing; Electroerosion; PVD; CVD; Ion implantation; Nondestructive tests; Powders
production; Forming; Green; Sintering; Pyrolytic carbon; Graphite; Isotropic carbon; LTI; ULTI;
Carbon fibers; PAN; Composites; Open mold processing; Closed mold processing; RTM; RIM; VARTM;
SMC; Poltrusion; Rapid prototyping; Additive manufacturing; 3D printing; Powder bed fusion; Bonder
jet; Materials jetting; Selective laser melting; Electron beam melting; Stereolithography; Selective
laser sintering; Fused deposition modeling; Laminated object manufacturing
Eric Kadaj, Rolando Bosleman,
Chapter 11 - Energy Recovery Devices in Membrane Desalination Processes,
Editor(s): Veera Gnaneswar Gude,
Renewable Energy Powered Desalination Handbook,
2018,
Pages 415-444,
ISBN 9780128152447,
https://doi.org/10.1016/B978-0-12-815244-7.00011-8.
Abstract: The use of energy recovery devices (ERDs) continues to be more common, as the cost of
power continues to increase throughout the world. More frequently, system designers are being
asked to minimize the specific energy consumption (SEC) even in areas where the cost of power is
relatively low. By far, the largest contributor to the decrease in SEC over the past three decades has
been the advancements made in energy recovery technologies. All ERDs used in the water treatment
industry reduce power by harnessing the energy in the concentrate (or brine) waste stream and
transferring it to the feed side via various methods.
Keywords: Energy recovery; ERDs; Energy Recovery Inc.; Desalination; Reverse osmosis
T. Liu, S. Morales, M. Karkkainen, L. Nastac, V. Arvikar, I. Levin, L.N. Brewer,
The combined effects of Sr additions and heat treatment on the microstructure and mechanical
properties of high pressure die cast A383 alloy,

Volume 756,
2019,
Pages 373-380,
ISSN 0921-5093,
Abstract: The microstructures and mechanical properties of high pressure die cast A383 alloys under
four conditions (with and without Sr additions and heat treatment) were investigated. Sr addition is
responsible for the increase in the elongation of high pressure die cast A383 alloys by refining the
eutectic Si particles from long, needle-like morphologies to fine, fibrous ones. High cooling rates, as
generated in the high pressure die casting process, also significantly contribute to the
microstructural refinement of the eutectic Si particles. However, there was almost no relationship
between the morphologies (size and roundness) of the eutectic Si particles and the yield strength of
high pressure die cast A383 alloys. Heat treatment (aging without solution treatment) increased the
yield strength of high pressure die cast A383 alloys. Sr addition combined with heat treatment was
found to refine the size of aging precipitates and therefore improve the yield strength beyond the
levels observed for heat treatment alone. The sludge characteristics (size, roundness and fraction)
were not affected by the different heat treatments and Sr additions and had no discernible effect on
the change in mechanical properties.
Keywords: High pressure die casting; Aluminum alloys; Mechanical properties; Microstructrues; Heat
treatment
Qiang Tong, Kaihua Xue, Tingli Wang, Shan Yao,
Laser sintering and invalidating composite scan for improving tensile strength and accuracy of SLS
parts,
Volume 56, Part A,
2020,
Pages 1-11,
ISSN 1526-6125,
Abstract: The laser scanning method is one of the key factors in the process of selective laser
sintering. Laser sintering and invalidating composite (LSIC) scanning method, which is composed of
high tensile strength sintering scanning with large-spot and high accuracy invalidating scanning with
small-spot, is able to improve the tensile strength, accuracy and fabrication efficiency of SLS parts. In
this paper, the principle and implementation of this method were presented, and in order to prove
the effectiveness of the method, the conventional scanning method was used to carry out the
sintering forming experiments of the coated ceramics, and the relationship between the energy
density, the tensile strength and accuracy of the parts was explored. Then based on the conclusion
of this experiment, the composite scanning method is used for comparative sintering experiments.
The results show that when the sintering process is carried out using the process parameters
corresponding to the high tensile strength, a substantial amount of secondary sintered bodies is
generated on the surface of the part and the accuracy is destroyed. The conventional scanning
method cannot achieve high accuracy forming under this process condition. However, the composite
scanning method can effectively eliminate the adverse influence of secondary sintering on accuracy,
and achieve high tensile strength and high accuracy parts. Moreover, the method can also improve
the fabrication efficiency. Therefore, this method is of great significance to realize high quality sand
mould additive manufacturing and enrich the scanning method of SLS.
Keywords: Selective laser sintering; Composite scan; Coated ceramsite; Varying spot size; High
tensile strength; High accuracy
Albert Shih, Bruce Tai, Roland Chen, Lei Chen, Yihao Zheng, Yancheng Wang,
Video Enriched Pedagogy in Manufacturing Processes,
Volume 5,
2016,
Pages 1154-1167,
ISSN 2351-9789,
Abstract: This paper presents an effective video-assisted pedagogy in manufacturing processes

courses. Teaching manufacturing processes is fundamental to manufacturing education. However,
the dynamic and complex concepts and phenomenon in manufacturing processes are difficult to
teach and comprehend using stationary pictures and verbal explanation. In this paper, we
systematically select and prepare video clips for teaching the concepts and demonstrating
applications in manufacturing process courses. Four aspects of this pedagogy are discussed,
including lengths of video and interruption for comments, timing for playing video, video selection,
and student engagement. The effectiveness of utilizing video clips is demonstrated by three case
studies: 1) ME482 Machining Processes at the University of Michigan, 2) MEEN 360 Materials and
Manufacturing Selection in Design at Texas A&M University, and 3) ME61120240 Manufacturing
Process and Engineering at Zhejiang University (China). To facilitate this pedagogy, a cloud-based
video library for manufacturing processes has been established. Other issues related to
implementing this pedagogy including adoption in distance education, the credibility of the video,
and copyrights are discussed.
Keywords: Manufacturing education; video enriched teaching; pedagogy

Maria Teresa Di Giovanni, João T. O. de Menezes, Emanuela Cerri, Enrique M. Castrodeza,
Influence of microstructure and porosity on the fracture toughness of Al-Si-Mg alloy,
Volume 9, Issue 2,
2020,
Pages 1286-1295,
ISSN 2238-7854,
Abstract: With improving molten metal quality and foundry technology, cast alloys are expected to
be used more commonly in critical applications. The demands for improved damage tolerance of
cast aluminum alloys have increased the importance of fracture-related properties. In this
perspective, the present study aims to evaluate the effect of four different aging treatments on
fracture toughness of a die cast A356 Al alloy with and without Cu addition. Crack growth resistance
curves (J-R curves) were experimentally evaluated using the ASTM E1820-17 standard procedure on
25 mm thick compact tension C(T) specimens. The influence of microstructure and porosity in
hardness and fracture toughness (JIc) is discussed. In addition, microstructural observations were
carried out to endorse the fracture mechanisms.
Keywords: A356 aluminum alloy; Fracture toughness; J-R curves; Porosity; Microstructure; Hardness.
Wolfgang Bauer, Jürgen Dorn,
Requirements for Product-service Description at e-marketplaces in the Manufacturing Domain,
Procedia CIRP,
Volume 47,
2016,
Pages 406-411,
ISSN 2212-8271,
Abstract: Industrial procurement is exposed to an increased service-oriented supplier market.

However, industrial e-marketplaces for product-services that are accepted by buying experts are
rare. Possible buyer benefits of e-markets such as access to a wider range of markets, accumulation
of required information, and increase of market transparency cannot be utilized. Currently, product-
services are at best traded within closed silos that offer mainly manual search and comparison
capabilities through a web storefront. A lack of existing “generic” industry-sector-specific concepts
for service description is a main problem that the potential of e-commerce is not utilized for
product-services. This article analyzes the requirements for service representation at e-markets
regarding the manufacturing domain. State-of-the-art concepts of business service description are
considered at the beginning of this research. Because of the heterogeneity of product-services, a
case study was conducted in order to identify relevant product-services in the manufacturing
domain. In order to study a real case scenario, a “first-tier supplier” in the automotive industry was
used in this research study. This company is specialized in systems engineering and systems serial
assembly. Typical product-services of this company source are manufactured products needed for
serial production, for example, casting, milling, turning, or injecting molding parts, alongside a wide
range of services. Investigating the professional purchasing department was necessary to analyze
the requirements in service description throughout the complete buying process, commencing with
the conceptual product design stage until the serial product delivery.
Keywords: product-service description; product-service advertisements; manufacturing services;

service capability description; manufacturing service; USDL; service marketplace; electronic
marketplace
Emanuele Pagone, Mark Jolly, Konstantinos Salonitis,
The Development of a Tool to Promote Sustainability in Casting Processes,
Procedia CIRP,
Volume 55,
2016,
Pages 53-58,
ISSN 2212-8271,
Abstract: The drive of the manufacturing industry towards productivity, quality and profitability has
been supported in the last century by the availability of relatively cheap and abundant energy
sources with limited focus on the minimisation of energy and material waste. However, in the last
decades, more and more stringent regulations aimed at reducing pollution and consumption of
resources have been introduced worldwide and in particular in Europe. Consequently, a highly
mature and competitive industry like foundry is expecting challenges that an endeavour towards
sustainability can turn into significant opportunities for the future. A tool to undertake a systematic
analysis of energy and material flows in the casting process is being developed. An overview of the
computer program architecture is presented and its output has been validated against real-world
data collected from foundries.
Keywords: Energy efficiency; Sustainable development; Casting
Penchal Reddy Matli, Vyasaraj Manakari, Gururaj Parande, Manoj. Gupta,
Tensile Response of Al-Based Nanocomposites,

Elsevier,
2021,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-819724-0.00003-3.
Abstract: In recent years, aluminum matrix nanocomposites have gained increased importance
compared to conventional aluminum-based alloys owing to their better mechanical, thermal, and
tribological properties. High tensile strength properties are considered to be an important criterion
in the selection of materials for automotive, aerospace, military, and other lightweight applications.
The tensile properties of the aluminum-based nanocomposite are governed by several factors
including the type of processing technology, amount of reinforcement, microstructural features, and
so on. Accordingly, this article discusses the recent advancements in the fabrication of aluminum
matrix nanocomposites with low volume addition of ceramics nanoparticles. Firstly, the importance
of the powder metallurgy technique on the synthesis of aluminum matrix nanocomposites is
discussed. Thereafter, the influence of microstructural influences of the nanoparticles on the tensile
properties of the aluminum matrix composite system is outlined. Strengthening mechanisms
responsible for the enhancement in the tensile yield strength properties are also discussed. The
relationship between the hardness and tensile strength properties of the nanocomposites is
established. The tensile strength properties of different Al matrix nanocomposites relationship is
summarized. Finally, a comparison is made between the recently reported Al matrix nanocomposites
systems to gain insight on the effect of hardness and particle size on the tensile strength properties.
Keywords: Aluminum; Fractography; Hot extrusion; Metal matrix nanocomposites; Microwave

sintering; Nanoreinforcements; Tensile behavior
Jiayi Wang, Santosh Reddy Sama, Paul C. Lynch, Guha Manogharan,
Design and Topology Optimization of 3D-Printed Wax Patterns for Rapid Investment Casting,
Volume 34,
2019,
Pages 683-694,
ISSN 2351-9789,
Abstract: Traditional investment casting (IC), also known as lost-wax casting, suffers from high
tooling cost and long lead-time during fabrication of wax patterns. In recent years, rapid investment
casting (RIC) based on AM has become widely accepted in casting foundries due to rapid production
of patterns without any tooling requirements. Direct AM production of wax patterns is not only cost-
efficient for low volume production but also capable of creating freeform and highly complex
geometries that are otherwise extremely difficult or too expensive to cast conventionally. Such
advantages provide unlimited opportunities in the cast part design and enable the use of advanced
design tools especially advanced optimization tools like topology optimization (TO). In this study,
knowledge-based design guidelines for rapid investment casting are developed through streamlined
integration of TO with design for investment casting and design for AM principles. Specifically, TO
routine based on Solid Isotropic Material with Penalization (SIMP) method using Abaqus Topology
Optimization Module (ATOM) has been developed for both material extrusion and investment
casting constraints. Part design optimization is demonstrated for this new technique and is validated
by a case study using heat-treated ASTM A216 WCB cast carbon steel parts. AM patterns for
investment casting are produced using commercially available wax filaments. Wax material extrusion
parameters are identified for optimal AM accuracy and surface finish.
Keywords: Topology Optimization; Design for Additive Manufacturing; Investment Casting; Pattern
Design; Wax Filament; Material Extrustion
4 - Applications of Additive Manufacturing,
Hanser,
2019,
Pages 101-136,
ISBN 9781569907023,
https://doi.org/10.3139/9781569907030.004.
Xiao-li Shi, Ye-hua Jiang,
Analysis of morphological, thermodynamic, and mechanical properties of typical hard phase Fe–5Cr–
1.5B–0.45C alloy,
Volume 816,
2020,
152681,
ISSN 0925-8388,
Abstract: Fe–5Cr–1.5B–0.45C alloys exhibit excellent balance of hardness and toughness. The hard
phase of boron carbide in the Fe–Cr–B–C alloy system of high-boron iron-based alloys plays a key
role in various properties of the system. Therefore, in this study, several typical hard phase
morphological and crystalline structures are analyzed in detail. Use of first-principle methods for
calculating the thermodynamic and mechanical properties of the hard phase in Fe–5Cr–1.5B–0.45C
alloys shows that the incorporation of alloying elements can further improve the properties of the
alloys and the improvement of hardness can enhance the wear resistance properties.
Keywords: Hard phase; Eutectic borocarbide; Crystalline structures
K.T. Akhil, Jerry Varghese, K. Vinoj, K Shunmugesh, Sanjivi Arul, R. Sellamuthu,
Influence of heat Treatment and aging process on LM13 Aluminium Alloy Cast Sections: An
Experimental Study,
Volume 4, Issue 8,
2017,
Pages 7194-7201,
ISSN 2214-7853,
Abstract: LM13 Aluminium alloy of variable section sizes have been extensively used in the
automotive and aerospace industry. This paper reports the influence of heat Treatment and aging
process on the microstructure, mechanical properties of LM13 aluminium alloy sections. Experiment
is performed by melting of Aluminium ingot using heat treatment furnace and poured into sand
mould cavity of varying section sizes. Microstructure, mechanical properties like hardness, tensile
strength and impact strength were measured during as-cast, heat treated and aged condition. ASTM
standard B917-01 was followed for heat treatment of LM13 Aluminium Alloy. Cast section was kept
at 537°C for 12 hrs for heat treatment, followed by aging at a temperature of 155°C for 5 hrs. The
result obtained indicates that at as-cast condition, microstructure changes from coarse to fine with
decrease in section size. It was also observed that, mechanical properties also improve with
decrease in section size. At heat treated and aged condition, it was observed that almost similar
microstructure was observed. Further, the mechanical properties were improved when compared to
as-cast condition and variation is irrespective to section size.
Keywords: heat treatment; Mechanical properties; Aluminium-LM13; Cast section
Lihui Wang, Albert J. Shih,
Challenges in smart manufacturing,

Journal of Manufacturing Systems,
Volume 40, Part 2,
2016,
Page 1,
ISSN 0278-6125,
https://doi.org/10.1016/j.jmsy.2016.05.005.
G. Eisaabadi B., GY Yeom, Murat Tiryakioğlu, Nelson Netto, R. Beygi, M.Z. Mehrizi, SK Kim,
The effect of solution treatment time on the microstructure and ductility of naturally-aged A383
alloy die castings,
Volume 722,
2018,
Pages 1-7,
ISSN 0921-5093,
Abstract: A383 aluminum alloy high pressure die castings were solution treated at 490 °C for six
duration ranging between 15 and 180 min, subsequently quenched in water and naturally aged for 4
days. The effects of solution treatment time on the evolution of microstructure and tensile
properties were determined. As expected, Si particles became larger and rounder with increasing
solution treatment time. In all cases, the size and aspect ratio of the Si particles followed the
lognormal distribution. Moreover, the coarsening of Si particles during solution treatment was found
to follow the Lifshitz –Slyozov-Wagner model. A new equation was developed for the evolution of
the aspect ratio during solution treatment of Al-Si-Mg alloys. Analysis of tensile properties showed
that elongation and quality index increased steadily with increasing Si particle size, a result that is in
contrast with the widely accepted notion that large Si particles impairs the ductility of cast Al-Si-Mg
alloys. The positive correlation between Si particle size and quality index was interpreted to be due
to partial healing of oxide bifilms entrained in the castings.
Keywords: Heat treatment; Homogenization; ADC12 alloy; Aspect ratio; Coarsening
Narinder Singh, Rupinder Singh, Inderpreet S. Ahuja,
Investigations for Metal Matrix Composites Prepared by Using Waste Polymer-Based Sacrificial Rapid
Pattern in Investment Casting,
Editor(s): Saleem Hashmi, Imtiaz Ahmed Choudhury,

Encyclopedia of Renewable and Sustainable Materials,
Elsevier,
2018,
Pages 376-384,
ISBN 9780128131961,
https://doi.org/10.1016/B978-0-12-803581-8.10400-X.
Abstract: In this article a step by step procedure for the preparation of metal matrix composite from
waste polymer-based sacrificial rapid pattern via investment casting route has been outlined as a
case study of aluminum matrix reinforced with SiC and Al2O3 particles. Also in this article various
other processing techniques have been discussed that are necessary for controlling the surface
properties for field engineers.
Keywords: Al2O3 particles; FDM; Filament; Investment casting; Metal matrix composites; SiC; Waste
polymers
M. Maldonado, A. Pinto, L. Magne, C.O. Gomez, J.A. Finch,
Gas holdup estimation using Maxwell equation in flotation systems: Revisited,
Minerals Engineering,
Volume 98,
2016,
Pages 9-13,
ISSN 0892-6875,
https://doi.org/10.1016/j.mineng.2016.04.005.
Abstract: Estimation of gas holdup from electrical conductivity measurements has been used in lab
and industrial installations. The approach is based on the application of Maxwell’s model, which
relates the concentration of a dispersed phase in a continuous medium to measurements of the
electrical conductivity of the dispersed phase, continuous medium and the resulting mixture
(dispersion). When applied to inferring the collection zone gas holdup in a three phase system and to
facilitate real-time on-line measurement, the slurry is assumed to behave as the continuous medium
and gas bubbles as a non-conducting dispersed phase. This article derives an equation for estimating
gas holdup in a three phase system, eliminating the assumption that the slurry behaves as a
continuous medium but rather as a dispersion of non-conducting solid particles in water. In this
formulation only water behaves as the continuous medium in the sense of Maxwell, and gas holdup
in a three phase system is then calculated from the application of the Maxwell model twice: (1) to
determine solid content in a two-phase system, and (2) to determine solid plus gas holdup in a three
phase system. To validate the new equation and quantify the errors incurred by assuming slurry is
the continuous phase a laboratory flotation cell was instrumented to continuously measure the
conductivity of two and three phase dispersions with known solids contents. As the amount of gas in
a lab flotation machine is difficult to measure directly or by another indirect technique such as using
pressure signals, 2.5mm dielectric plastic spheres having a density of ca. 1.3g/cm3 were used instead
of air bubbles for validation. Experimental results demonstrated that the continuous medium
assumption underestimates gas holdup and that the resulting bias error increases linearly with the
solid content and decreases with the magnitude of gas holdup.
Keywords: Flotation; Gas holdup; Measurement
G. Abhijith, R. Abhishek, S. Adithyan, P. Adwaith, K. Sivaselvi,
Reinforcement of Bitumen Using Low Density Polyethylene and Green Sand,
Volume 18, Part 7,
2019,
Pages 5057-5062,
ISSN 2214-7853,
Abstract: Plastics are the non-biodegradable materials which create significant economic and
environmental problem. Nowadays, plastic wastes are used in the construction of roads along with
bitumen to improve the strength. This process helps us to reduce the waste plastics in our
environment and the overall use of bitumen. Low density Polyethylene is light weight material, cost
effectiveness and good strength. Green sand is a type of foundry sand, which contains a high quality
silica, bentonite clay, pulverized coal and water and used as a fine aggregate. In our work, apart from
the use of low density polyethylene, green sand is also used as filler for aggregate for public road
works. These mixture which helps to increase the permeability and refractoriness of the overall
compound. This will help in binds the aggregates to enhance the cohesion to mass and water-
proofing nature to the mixture.
Keywords: LDPE; green sand; dry process; softening point; penetration point; stripping test
Index,
Editor(s): Berend Denkena, Tobias Mörke,
Cyber-Physical and Gentelligent Systems in Manufacturing and Life Cycle,
Academic Press,
2017,
Pages 471-480,
ISBN 9780128119396,
https://doi.org/10.1016/B978-0-12-811939-6.09994-5.
Anil Kumar, Santosh Kumar, N.K. Mukhopadhyay,
Introduction to magnesium alloy processing technology and development of low-cost stir casting
process for magnesium alloy and its composites,
Volume 6, Issue 3,
2018,
Pages 245-254,
ISSN 2213-9567,
Abstract: This paper presents the processing of magnesium alloys and its composite through
different stir casting technologies. Design and development of stir casting technology that is suitable
for processing of magnesium alloys has been done in this study. The low-cost stir casting processing
of magnesium alloy and its composite with flux and without flux has been explained. The magnesium
alloy and its composite have been fabricated by both the stir casting process. The micro structural
characterization and mechanical properties of the developed composites has been evaluated. The
optical emission spectroscopy of the developed alloy and factography of the developed alloy as well
as composite was also examined.
Keywords: Metal matrix composite; Magnesium alloys; Stir casting; Composite
B. Anand Ronald, C. Arun Prakash, M. Suba Karthik, K.V.J. Arun,
Influence of steel shot size on the permeability of mould,
Perspectives in Science,
Volume 8,
2016,
Pages 444-446,
ISSN 2213-0209,
https://doi.org/10.1016/j.pisc.2016.04.100.
Abstract: Summary
Casting is one of the commonly used techniques in industries for the manufacturing of metal
products. Although sand is used as a mould material for casting, its permeability and thermal
conductivity are very low and hence affects the microstructure and mechanical properties of the cast
product. Therefore using alternate material for the mould may result in better permeability, heat
transfer rate and thereby better properties. In the present work, steel balls are used as mould
material and the effect of grain size on the permeability of the mould material is studied. Steel balls
of different diameters namely 0.18mm, 0.6mm and 1mm which are commercially available were
used. From the experiments conducted, it is confirmed that coarser steel balls showed more
permeability and thereby can help in easy escape of hot gases (from the molten metal and mould
material) during pouring of molten metal into the mould.
Keywords: Permeability; Grain size; Steel ball; Casting
L. Bolzoni, M. Nowak, N. Hari Babu,
Nb-based heterogeneous nuclei for enhanced α-Mg nucleation in Mg(-Al) alloys,
Materials Letters,
Volume 169,
2016,
Pages 207-209,
ISSN 0167-577X,
https://doi.org/10.1016/j.matlet.2016.01.121.
Abstract: The effect of the introduction of in-situ formed Nb-based compounds on Al-including Mg
alloys has been investigated. It is found that grain refinement is consistently achieved. Nb-based
intermetallic particles are responsible of the effective heterogeneous nucleation of Al-including Mg
alloys. The refining mechanism is discussed on the base of crystallography.
Keywords: Cast; Crystal structure; Metals and alloys; Microstructure; Solidification; Thermal analysis
Wang Mingguang, Pu Yong,
Numerical Simulation and Analysis of Hot Cracking in the Casting of Fork,
Rare Metal Materials and Engineering,
Volume 46, Issue 4,
2017,
Pages 946-950,
ISSN 1875-5372,
https://doi.org/10.1016/S1875-5372(17)30127-3.
Abstract: In the investment casting of shifting fork, hot cracking is a common defect. In order to
analyze the hot cracking in the investment casting, the ProCAST software was adopted, and the
investment casting process was simulated, The filling field, temperature field and stress field were
analyzed, and the cause of crack was predicted. Results show that as the local area receives larger
tensile stress from around, the shrinkage cavity appears; as a result, hot cracking occurs. By
decreasing the pouring temperature, increasing preheating temperature of the shell, or chamfer
angle of the fork, the casting stress can be reduced, and thus the crack will be avoided.
Keywords: hot cracking; fork; numerical simulation
Tao Peng, Yanan Wang, Yi Zhu, Yang Yang, Yiran Yang, Renzhong Tang,
Life cycle assessment of selective-laser-melting-produced hydraulic valve body with integrated

design and manufacturing optimization: A cradle-to-gate study,
Volume 36,
2020,
101530,
ISSN 2214-8604,
Abstract: Selective laser melting (SLM), a relatively advanced additive manufacturing (AM)
technique, enables high design flexibility and manufacturing complexity; therefore, it can facilitate
improvement in the environmental performance of a complex component throughout its life cycle.
However, existing studies have been unable to conclusively determine whether the environmental
impacts of parts produced via AM are lower than those of conventionally manufactured parts.
Moreover, few studies have investigated industrially applicable parts with complex inner shapes
fabricated via SLM whilst simultaneously considering the design and manufacturing optimization
involved thereof. In this study, an industrial hydraulic valve body was investigated in consideration of
the part design, material preparation, and part fabrication with respect to their influence on the life-
cycle impacts of SLM and conventional manufacturing (CM). The part was first re-designed to
achieve a lightweight structure and optimized process parameters. Subsequently, an optimized and
a non-optimized sample part were fabricated via SLM. A cradle-to-gate study of this part was
conducted, involving a comparison employing life cycle assessment (LCA) for the case of CM. The
life-cycle inventory data were obtained from the relevant enterprise, literature, databases, and our
experiments. According to our results, the environmental impact of SLM without optimization was
37.42% lower than that of CM with respect to a hydraulic valve body, and the SLM-optimized design
can lead to a 10–23% reduction in environmental impacts. Of all the life-cycle stages, the powder
preparation stage was observed to exert the highest impact per part. Moreover, the electricity
requirement for SLM is the main reason for environmental damage. With the optimization of the
valve body design, the proportion of environmental impact caused by SLM processing increases. This
indicates that when a part has a high lightweight potential, the SLM process will have a more
significant cradle-to-gate environmental impact. In this case, manufacturing optimization will play a
more important role. The results can be used to guide AM practitioners to improve the life-cycle
environmental performance of AM-fabricated industrial parts through integrated design and
manufacturing optimization.
Keywords: Metal additive manufacturing; Selective laser melting; Life cycle assessment; Hydraulic
valve; Cradle-to-gate; Environmental impact
Rosang Pongen, Anil Kumar Birru, P. Parthiban,
Study of microstructure and mechanical properties of A713 aluminium alloy having an addition of
grain refiners Al-3.5 Ti-1.5C and Al-3Cobalt,
Results in Physics,
Volume 13,
2019,
102105,
ISSN 2211-3797,
https://doi.org/10.1016/j.rinp.2019.02.041.
Abstract: Aluminium die casting manufacturing is a prominent for mass production with economical,
which is also a challenging with many casting defects which are influenced by many process
parameters. The mechanical and microstructural properties of the die cast parts contributes
significantly in determining the final quality of the die cast alloy. In the present research work,
tensile and hardness test are carried out to study the influences on the mechanical properties of an
A713 alloy without and with Al-3.5 Ti-1.5C and Al-3Cobalt as grain refiners. Mechanical properties
such as tensile strength and micro hardness were observed which has shown an increase in the case
of A713 alloy where grain refiners such as Al-3.5Ti-1.5C and Al-3Cobalt were added as compared to
that of without grain refinement. In addition of 0.1 wt% of Al-3.5Ti-1.5C to A713 alloy there was a
transition from coarser grains to finer grain structure with an average grain size of 16.6 µm. The
finest grain structure was obtained with an addition of 1.0 wt% Al-3.5Ti-1.5C having an average grain
size of 15.0 µm. From the SEM it was established that due to the absence of Al-3.5Ti-1.5C the image
shows coarser columnar α-Al dentritic like arrangements with non-modified platelets. The addition
of 0.1 wt% Al-3.5Ti-1.5C and 1.0 wt% Al-3.5Ti-1.5C with the A713 alloy the grain structure of the
alloy shows transition from coarse to fine equiaxed grains.
Keywords: A713 alloy; Die casting; Grain refinement; Mechanical properties; Microstructural analysis
Gustavo J.L. Coppio, Maryangela Geimba de Lima, Julia W. Lencioni, Luciana S. Cividanes, Paulo
P.O.L. Dyer, Silvelene A. Silva,
Surface electrical resistivity and compressive strength of concrete with the use of waste foundry
sand as aggregate,
Volume 212,
2019,
Pages 514-521,
ISSN 0950-0618,
https://doi.org/10.1016/j.conbuildmat.2019.03.297.
Abstract: The steel industry generates large amounts of waste foundry sand (WFS) in landfills.
Studies on the viability of using this residue as a fine aggregate have been carried out for asphalt
mixtures. However, studies are still scarce in relation to their use in concrete. In this sense, the
present work analysed the effects of the use of WFS as fine aggregate in Portland cement concrete,
in the electrical resistivity and compressive strength. The results showed that the behaviour of the
electrical resistivity varies according to the characteristic of the WFS, whereas the compressive
strength tends to be smaller.
Keywords: Waste foundry sand; Portland cement concrete; Compressive strength; Surface electrical
resistivity
Khalid A. Al-Ghamdi,
Sustainable FDM additive manufacturing of ABS components with emphasis on energy minimized
and time efficient lightweight construction,
International Journal of Lightweight Materials and Manufacture,
Volume 2, Issue 4,
2019,
Pages 338-345,
ISSN 2588-8404,
https://doi.org/10.1016/j.ijlmm.2019.05.004.
Abstract: Fused Deposition Modeling (FDM) is a widely used additive manufacturing process with
applications in rapid prototyping and rapid manufacturing. In view of increasing trend of sustainable
manufacturing, the present study was focused on analyzing the process sustainability with an
objective to ensure lightweight construction with minimized energy consumption and printing time.
Having extensive applications in industry and being an amenable printing material, Acrylonitrile
Butadiene Styrene (ABS) was used as the test material. A Design of Experiments (DoE) composed of
46 tests was conducted by varying four different printing parameters namely layer thickness, fill
density, feed rate and shell thickness. Three important measures of sustainable manufacturing
(specific energy, specific mass and specific time) were measured during experimentation. The
statistical variance analysis was performed on the DoE results, which revealed that the considered
printing parameters had significant influence on the mentioned sustainability measures with an
exception that the feed rate did not affect the specific mass. The values of these measures were
observed to decrease with a decrease in the fill density and shell thickness, and an increase in the
layer thickness and feed rate: feed rate, however, did not affect the specific mass. The degree of
these effects was observed to depend on the companion printing parameters thereby showing
strong interactive and complex effects of parameters. This suggests that the printing parameters
should be chosen judiciously in order to achieve sustainable printing, for which results presented in
this study can be greatly helpful. Regression analysis was performed to devise prediction models
with a purpose to estimate considered sustainability measures for FDM printing of ABS material.
Finally, optimum printing conditions are proposed in order to ensure sustainable printing in the FDM
process.
Keywords: Additive manufacturing; FDM; Sustainable; Parameters; Analysis; Optimization
P. Ajay Kumar, H.C. Madhu, Abhishek Pariyar, Chandra S. Perugu, Satish V. Kailas, Uma Garg,
Pradeep Rohatgi,
Friction stir processing of squeeze cast A356 with surface compacted graphene nanoplatelets (GNPs)
for the synthesis of metal matrix composites,
Volume 769,
2020,
138517,
ISSN 0921-5093,
Abstract: Friction stir processing (FSP) was applied to graphene nanoplatelets (GNPs) physically
compacted on the surface of squeeze cast A356 alloy to incorporate GNPs within the matrix and to
improve its mechanical properties. Squeeze casting resulted in finer size silicon and intermetallic
compounds in cast microstructure, and subsequently FSP further refined the microstructure of
squeeze cast A356 alloy, and GNP reinforced A356 alloy. The finer Si particles, intermetallics and
graphene dispersed in the matrix increased the yield and ultimate tensile strength of FSP squeeze
cast A356 alloy compared to the results reported in prior literature for FSP A356 alloy. Eutectic Si
needles have been converted to fine spherical particles during FSP and were uniformly distributed
within the nugget zone. The crystallite size of GNPs which were physically adhered to the surface of
squeeze cast alloy prior to FSP decreased after FSP as a result of deformation. Thus, a combination of
squeeze casting, and friction stir processing and incorporation of GNPs reinforcement in the A356
matrix is a promising route to further improve its mechanical properties.
Keywords: Metal-matrix composites (MMCs); Graphene; Mechanical properties; Microstructures;

Fractography
L. Xue,
Chapter 16 - Laser Consolidation—A Rapid Manufacturing Process for Making Net-Shape Functional
Components,
Editor(s): Jonathan Lawrence,
In Woodhead Publishing Series in Welding and Other Joining Technologies,
Advances in Laser Materials Processing (Second Edition),
2018,
Pages 461-505,
ISBN 9780081012529,
https://doi.org/10.1016/B978-0-08-101252-9.00016-9.
Abstract: Laser consolidation is a novel computer-aided manufacturing process being developed by

the National Research Council of Canada at its London facility (NRC-London). This rapid
manufacturing process produces net-shape functional metallic parts layer by layer directly from a
CAD model by using a laser beam to melt the injected powder and re-solidifying it on the substrate
or previous layer. As an alternative to the conventional machining process, this novel manufacturing
process builds net-shape functional parts or features on an existing part by adding instead of
removing material. In this chapter, NRC-London's progress on laser consolidation research is
reviewed. The functional properties of laser consolidated materials (including Ni-, Ti-, Co-, Al-alloys,
stainless, and tool steels) are reported, while the observation of the unique microstructure of the
laser consolidated materials is discussed. The examples of the laser consolidation process for making
net-shape functional components for various industrial applications (such as a space robotic arm,
sonar, tooling, gas turbines, and rocket engines) are presented.
Keywords: Laser consolidation; Rapid manufacturing; Rapid prototyping; Net-shape; Functional

component; IN-625; IN-718; IN-738; Waspaloy; 316L; CPM-9V; H13; Ti-6Al-4V; Al 4047; Stellite 6
Chapter 5 - Industrial and Perspective Casting Alloys,
Dinsdale,
2019,
Pages 405-510,
ISBN 9780128118054,
https://doi.org/10.1016/B978-0-12-811805-4.00005-5.
Abstract: This is a completely new chapter that, in a sense, combines Chapters 5 and 6 of the first
edition of ‘Casting Aluminium Alloys’. It describes both the existing industrial foundry alloys and
some new perspective materials. Almost 90% of all existing alloys belong to the Al–Si group, so the
general characterisation of industrial alloys of this type is given first. Examples considered in this
section include Cu-free alloy (such as 356/357 and the 413 type), Cu-bearing Al–Si foundry alloys
(354, 355 types and so on) and the relatively new Ni bearing alloys such as 434. In section 2, alloys of
the 2xx and 5xx series are discussed (Al–Cu and Al–Mg, respectively). Finally, in the last section of
this chapter a broad overview of some novel foundry aluminium alloys is offered. It is based on the
original approach to alloying for eutectic multicomponent alloys developed by the authors. Examples
include high strength alloys on the basis of the Al–Zn–Mg matrix, alloys for high temperature service
(with additions of Zr and Sc), and a new class of alloys of the Al–Ca type. In the latter case such
systems as Al–C a–Sc were considered. Some of the supporting thermodynamic/phase equilibria
calculations in this chapter were done using ThermoCalc AB software and the excellent light alloy
database COST507 (in the public domain; developed with participation of one of the authors, Prof.
Dinsdale).
Keywords: principles of alloying; eutectic systems; new foundry aluminium alloys; thermocalc
calculations; industrial casting alloys
Liujie Xu, Fangfang Wang, Yucheng Zhou, Xi Wang, Chong Chen, Shizhong Wei,
Fabrication and wear property of in-situ micro-nano dual-scale vanadium carbide ceramics
strengthened wear-resistant composite layers,
Ceramics International,
2020,
ISSN 0272-8842,
https://doi.org/10.1016/j.ceramint.2020.08.209.
Abstract: This study fabricates wear-resistant composite layers (WRCLs) strengthened with in situ
vanadium carbide (VC) ceramics on the surface of carbon steel via casting infiltration technology.
The abrasive and impact wear properties are evaluated accordingly. The action mechanism of VC
ceramics of different scales in the wear process is clarified. The VC ceramics used in WRCLs include
microscale primary VC and nanoscale secondary VC. Vanadium content exerts a considerable effect
on the wear resistance of composite layers. The optimal vanadium contents for resisting abrasive
and impact wear are 5.5 wt% and 5.1 wt%, respectively. The abrasive and impact wear resistance of
the WRCLs are 2.5 and 1.9 times that of Cr20 cast iron as the vanadium content reaches the optimal
amount. The improved wear resistance of the WRCLs is attributed to the synergy of the dual-scale
VC ceramics. The microscale VC ceramics resist scratch efficiently while the nanoscale VC ceramics
strengthen the matrix. Therefore, dual-scale VC ceramics work synergistically to reduce wear.
Keywords: VC ceramics; Micro-nano dual scale; Wear-resistant composite layers (WRCLs); Casting
infiltration; Wear resistance
Xiang-dong WANG, Qing-lin PAN, Shang-wu XIONG, Li-li LIU, Yuan-wei SUN, Wei-yi WANG,
Prediction on hot deformation behavior of spray-formed 7055 aluminum alloy via phenomenological
models,
Volume 28, Issue 8,
2018,
Pages 1484-1494,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64789-2.
Abstract: Hot compression tests in the temperature range of 340–450 °C and strain rate range of
0.001–1 s−1 of spray-formed 7055 aluminum alloy were carried out to study its hot deformation
behavior. Three phenomenological models including Johnson–Cook, modified Fields–Backofen and
Arrhenius-type were introduced to predict the flow stresses during the compression process. And
then, a comparative predictability of the phenomenological models was estimated in terms of the
relative errors, correlation coefficient (R), and average absolute relative error (AARE). The results
indicate that Johnson–Cook model and modified Fields–Backofen model cannot well predict the hot
deformation behavior due to the large deviation in the process of line regression fitting. Arrhenius-
type model obtains the best fit through combining the effect of strain rate and temperature.
Keywords: spray-formed 7055 aluminum alloy; hot deformation behavior; phenomenological

models; statistical analyses
Petra Tschakert, Partha Jyoti Das, Neera Shrestha Pradhan, Mario Machado, Armando Lamadrid,
Mandira Buragohain, Masfique Alam Hazarika,
Micropolitics in collective learning spaces for adaptive decision making,
Global Environmental Change,
Volume 40,
2016,
Pages 182-194,
ISSN 0959-3780,
https://doi.org/10.1016/j.gloenvcha.2016.07.004.
Abstract: Recent advances on power, politics, and pathways in climate change adaptation aim to re-
frame decision-making processes from development-as-usual to openings for transformational
adaptation. This paper offers empirical insights regarding decision-making politics in the context of
collective learning through participatory scenario building and flexible flood management and
planning in the Eastern Brahmaputra Basin of Assam, India. By foregrounding intergroup and
intragroup power dynamics in such collective learning spaces and how they intersect with existing
micropolitics of adaptation on the ground, we examine opportunities for and limitations to
challenging entrenched authority and subjectivities. Our results suggest that emancipatory agency
can indeed emerge but is likely to be fluid and multifaceted. Community actors who are best
positioned to resist higher-level domination may well be imbricated in oppression at home. While
participatory co-learning as embraced here might open some spaces for transformation, others close
down or remain shut.
Keywords: Power; Politics of adaptation; Co-learning; Flood management; Participatory scenarios;

Assam
Xianna Meng, Datong Zhang, Weiwen Zhang, Cheng Qiu, Guangxing Liang, Junjie Chen,
Microstructure and mechanical properties of a high-Zn aluminum alloy prepared by melt spinning
and extrusion,
Volume 819,
2020,
152990,
ISSN 0925-8388,
Abstract: High-Zn aluminum casting alloys usually contain coarse dendrites, network eutectoid
structure and casting defects which deteriorate the mechanical properties seriously. In order to
overcome these problems, the combination of melt spinning and extrusion was explored for
microstructure modification in this work. A high-Zn aluminum alloy (Al–27Zn-1.5Mg-1.2Cu-0.08Zr)
was prepared by melt spinning and extrusion. The results show that the melt spun alloy mainly
consists of micro-sized network-like grain boundary (GB) η-MgZn2 structure (η phase) and disc-like
precipitates (GP-zone, η′-phase and η-precursor) embedded into fine α-Al grains with high solute
atomic concentration. After extrusion, the grain size of α-Al is further refined due to the
recrystallization, and primary network GB η-phase structures are transformed to granular η particles.
Moreover, the extrusion induces the precipitation of nano-sized η′-phase, η-precursor and Zn
phases. As a result, the alloy exhibits a high tensile strength of 485 MPa and a reasonable elongation
of 5.2%. The contributions of grain boundary, dislocation, solid solution and precipitate
strengthening to the yield strength are calculated according to the microstructure analysis, and it is
found that precipitation strengthening is the main strengthening mechanism in this alloy. Fracture
analysis shows that micro-cracks preferentially occur at α-Al/η phase interfaces due to interfacial de-
cohesion, and propagate along the GBs.
Keywords: Al-Zn alloy; Melt spinning; Extrusion; Microstructure; Mechanical property
Ivica Galić, Krešimir Vučković, Zdenko Tonković, Ivan Čular,
Numerical simulation of initiation and crack growth on cast valve body,
Engineering Failure Analysis,
Volume 117,
2020,
104793,
ISSN 1350-6307,
https://doi.org/10.1016/j.engfailanal.2020.104793.
Abstract: Global industry depends of the different type of valves, such as globe valves which are
used for precise flow regulation. Since most of the power plants rely on performance of globe valves,
it is necessary that valves function without interruption. In this paper, the main part of the globe
valve, valve body, is investigated. Simulation of crack initiation and its growth in a wall of valve body
is carried out. Required number of cycles for crack initiation is estimated according to Basquin-
Coffin-Manson equation. Afterwards, stress intensity factor is estimated through eXtended Finite
Element Method (XFEM) and required number of cycles for crack growth across the valve body
thickness is calculated according to Paris’ law. The aforementioned method is validated on the
results from the available literature by employing relatively simple shapes such as steel pipe with
integrated flaw. Subsequently, the method is used on a relatively complex geometry, as is the valve
body. The obtained results indicate lack of brittle fracture in a valve body. In other words, the results
imply occurrence of Leakage Before Brake (LBB). This is utterly important for power plant industries,
since it ensures the proper reaction of the user and possibly avoids possible catastrophic
consequences for personnel and the equipment located in the proximity of the valve.
Keywords: Initiation; Crack growth; XFEM; Valve body; Stress intensity factor
C. Dharmendra, S. Shakerin, G.D. Janaki Ram, M. Mohammadi,
Wire-arc additive manufacturing of nickel aluminum bronze/stainless steel hybrid parts – Interfacial
characterization, prospects, and problems,
Materialia,
Volume 13,
2020,
100834,
ISSN 2589-1529,
https://doi.org/10.1016/j.mtla.2020.100834.
Abstract: Hybrid parts of nickel aluminum bronze (NAB) and 316L stainless steel were fabricated
using a commercially available wire-arc additive manufacturing (WAAM) technology to evaluate the
feasibility and cracking tendency. Focused Ion beam (FIB) based Scanning Electron Microscopy
(SEM), Energy Dispersive Spectroscopy (EDS), Electron Backscatter Diffraction (EBSD), and
Transmission Electron Microscopy (TEM) were used to characterize the built (NAB)-substrate (SS)
interfacial characteristics. FIB extracted a selected region of the interface, and the spatial
distribution of the interface across several sections was characterized by using the state-of-the-art
technique for 3D EBSD mapping. A metallurgically bonded interface without any pores and cracks,
with the inter-diffusion region in a thickness of 2 μm, was formed, which was further confirmed by a
video with the results of 3D reconstructed EBSD maps. The interface did not exhibit any strong
texture orientation owing to the control of the thermal gradient as NAB is more conductive than
316L. EDS elemental mapping confirmed that Fe3Al intermetallic was formed at the NAB/SS
bimetallic-joint interface. Occasional liquation cracks on the grain boundaries in the heat-affected
zone (HAZ) of 316L substrate were observed. Fe-Al based intermetallic formation, along with the
penetration of copper along the HAZ cracks, was noticed. The problems associated were highlighted,
and remedial measures were suggested to open up the possibilities of additive manufacturing to
fabricate NAB-Stainless steel hybrid parts for industrial repair and maintenance applications.
Keywords: Nickel aluminum bronze (NAB); Stainless steel; Wire-arc additive manufacturing (WAAM);
Interface; Liquation cracking; 3D characterization
Tianxiang Zhang, Xueting Zhao, Jiahao Liu, Ruijie Zhang, Xianfei Wang, Yong Yuan, Zhongquan Li,
Zhiqiang Han,
The microstructure, fracture mechanism and their correlation with the mechanical properties of as-
cast Mg-Nd-Zn-Zr alloy under the effect of cooling rate,
Volume 801,
2021,
140382,
ISSN 0921-5093,
Abstract: The microstructure, fracture mechanism and their correlation with the mechanical
properties of as-cast Mg-Nd-Zn-Zr alloy were studied, in which the effect of cooling rate on the
microstructure and the mechanical properties were taken into account. The results showed that the
microstructure of the alloy is composed of primary phase (α-Mg) and eutectic compounds. With the
increase of the cooling rate in the range of 0.4–2.4 °C/s, the grain size of the alloy decreases from
66 μm to 44 μm, while the volume fraction of the eutectic compounds increases from 3% to 6.1%.
The decrease of the grain size tends to improve the yield strength, ultimate tensile strength and
elongation of the alloy. The eutectic compounds have complicated effects on the mechanical
properties. It is found that the increase of the volume fraction of the eutectic compounds leads to
the decrease of the yield strength while the network-like eutectic compounds formed at higher
cooling rates decreases the ultimate tensile strength. The fracture pattern of the alloy changes from
intergranular to quasi-cleavage fracture and then to a mixed fracture of intergranular and
transgranular fracture with the increase of cooling rate.
Keywords: Cooling rate; Mg-Nd-Zn-Zr alloy; Microstructure; Fracture mechanism
Veronica Negrelli,
CRP Group’s technology supporting the first Italian high performance electric motorcycle:
Development and construction of the Energica Ego motor housing and dashboard,
Reinforced Plastics,
Volume 63, Issue 5,
2019,
Pages 251-256,
ISSN 0034-3617,
https://doi.org/10.1016/j.repl.2018.12.072.
Jinhua Lin, Lin Ma, Yu Yao,
Segmentation of casting defect regions for the extraction of microstructural properties,
Engineering Applications of Artificial Intelligence,
Volume 85,
2019,
Pages 150-163,
ISSN 0952-1976,
https://doi.org/10.1016/j.engappai.2019.06.007.
Abstract: Extracting microstructural properties of casting defect regions plays an important role in
quality control efforts for casting production. However, it is not easy to extract microstructural
properties via the existing extraction strategies because the microstructures of casting defect
regions are extremely complex and irregular. In this paper, a 3D convolutional neural network, a
nonlinear topological dimension parameter and an empirical model are proposed for extracting the
microstructural properties of casting defect regions efficiently. First, taking the 3D region proposal
network (RPN), the instance segmentation network (ISN) and the 3D RoIAlign layer as three
subnetworks, a 3D convolutional neural network is constructed for the initial segmentation of
casting defect regions, and the geometric features of casting defect regions are further characterized
according to the nonlinear topological dimension parameter. In the end, based on the nonlinear
topological dimension parameter, an empirical model is established for extracting four important
microstructural properties of casting defect regions. The experimental results demonstrate that
microstructural properties of casting defect regions can be extracted via this method.
Keywords: Microstructural properties; Casting defect region; Convolutional neural network
M. Buzzoni, E. Mucchi, G. Dalpiaz,
A CWT-based methodology for piston slap experimental characterization,
Mechanical Systems and Signal Processing,
Volume 86, Part A,
2017,
Pages 16-28,
ISSN 0888-3270,
https://doi.org/10.1016/j.ymssp.2016.10.005.
Abstract: Noise and vibration control in mechanical systems has become ever more significant for
automotive industry where the comfort of the passenger compartment represents a challenging
issue for car manufacturers. The reduction of piston slap noise is pivotal for a good design of IC
engines. In this scenario, a methodology has been developed for the vibro-acoustic assessment of IC
diesel engines by means of design changes in piston to cylinder bore clearance. Vibration signals
have been analysed by means of advanced signal processing techniques taking advantage of
cyclostationarity theory. The procedure departs from the analysis of the Continuous Wavelet
Transform (CWT) in order to identify a representative frequency band of piston slap phenomenon.
Such a frequency band has been exploited as the input data in the further signal processing analysis
that involves the envelope analysis of the second order cyclostationary component of the signal. The
second order harmonic component has been used as the benchmark parameter of piston slap noise.
An experimental procedure of vibrational benchmarking is proposed and verified at different
operational conditions in real IC engines actually equipped on cars. This study clearly underlines the
crucial role of the transducer positioning when differences among real piston-to-cylinder clearances
are considered. In particular, the proposed methodology is effective for the sensors placed on the
outer cylinder wall in all the tested conditions.
Keywords: Piston slap; Signal processing; Cyclostationarity; Vibration
Giampaolo Campana, Mattia Mele, Barbara Cimatti,
Sustainable Optimisation of a Carousel for Foundry Processes,

Volume 43,
2020,
Pages 650-657,
ISSN 2351-9789,
Abstract: Foundry technology includes a family of processes that traditionally consume high
amounts of energy. It is fundamental to apply the principles of Sustainable Manufacturing to
increase the energy efficiency of these processes. This paper describes the research activity carried
out to improve the efficiency of a carousel, which allows the automatisation of aluminium gravity die
casting process, consisting of different phases: die preparation, filling with molten aluminium alloy,
solidification time, die opening, and part extraction. It is demonstrated that the efficiency is a
function of the disposition of the dies mounted on the carousel, due to the solidification time (which
is the limiting process parameter), and different cycle times depending on the realised product. The
authors propose an optimised layout, which reduces the cycle time while maintaining the same level
of the casting final quality. This reduction in the cycle time significantly improves the sustainability of
the foundry process.
Keywords: Aluminium Alloy; Gravity Die Casting; Sustainable Manufacturing; Reduce
E. Riedel, I. Horn, N. Stein, H. Stein, R. Bähr, S. Scharf,
Ultrasonic treatment: a clean technology that supports sustainability in casting processes,
Procedia CIRP,
Volume 80,
2019,
Pages 101-107,
ISSN 2212-8271,
Abstract: The casting process is one of the most important steps in the production and supply chain
of metallic components. Certain aspects, such as a clean melt, a finely clustered microstructure, and
homogeneous solidification, are the basic requirements for making high-quality components and
therefore influence all subsequent production stages. Current procedures to fulfill these
requirements are the use of additional chemical substrates and stirring units, as well as energy-
intensive technologies for cooling and tempering the molds. The goals of this work can be
summarized as the development and investigation of a new ultrasonic treatment (UST) applied
during the solidification of the aluminum casting alloy A356. The main idea is to expand the well-
known physical effects of UST by exploiting the possibility of influencing microstructure formation
during solidification. From the viewpoint of industrial applicability, the contribution of this work is
the presentation of a new simulation tool that allows for making comprehensive predictions of UST
processes. The presented results confirm the huge potential of the proposed treatment for
increasing strength, reducing wall thicknesses, and saving valuable resources, such as materials and
energy.
Keywords: Energy efficiency; casting processes; plant technology; aluminum; ultrasonic treatment;
acoustic streaming; CFD simulation
Kapil Gupta, Neelesh Kumar Jain, Rudolph Laubscher,
Chapter 1 - Introduction to Gear Engineering,
Academic Press,
2017,
Pages 1-33,
ISBN 9780128044605,
https://doi.org/10.1016/B978-0-12-804460-5.00001-8.
Abstract: Gears are basic mechanical components used to transmit motion and/or power and are
responsible for the smooth functioning of a significant number of machines, instruments, and
equipments employed in most major industrial, scientific, and domestic applications. The purpose of
this chapter is to present a basic introduction to gears, their use, and manufacture. The chapter
commences with an introduction to gears along with a brief history. A classification scheme is then
presented based on the gear-shaft axis orientation and corresponding gear types with their unique
features and applications. The applicable gear terminology and nomenclature along with the most
important gear materials, their properties, and application areas are presented next. The chapter is
concluded with a brief introduction into gear manufacture comprising both conventional and
advanced types along with the relevant finishing processes.
Keywords: Bevel gear; involute; gear hobbing; noncircular gear; spline; spur gear; worm wheel
Darshan Raju, Aswin Ramaswamy Govindan, Jisnu Subramanian, Saravanan Ramachandran, Sandeep
Nair,
Surface alloying of aluminium bronze with chromium: Processing, testing, and characterization,
Volume 27, Part 3,
2020,
Pages 2191-2199,
ISSN 2214-7853,
Abstract: Gas Tungsten Arc (GTA) surface alloying has been carried out on an aluminium bronze alloy
electroplated with Cr at two different heat inputs (currents of 160 A and 180 A) in an argon
environment. The microstructural changes have been studied using an optical microscope (OM),
scanning electron microscope (SEM), and X-ray diffraction (XRD) analysis. In addition, the influence
of Cr content on hardness, wear resistance, coefficient of friction, and corrosion behaviour has been
examined. Moreover, it is observed that the Cr modification leads to enhanced heat transfer on the
substrate, resulting in improved hardness, depth of penetration and decreased wear rate.
Microstructure and X-ray diffraction analyses showed grain refinement due to the surface
modification process (SMP). Further, it was seen that the formation of intermediate phases was
confirmed through characterisation techniques (EDS, XRD). Surface hardness improved from 210 HV
to 688 for 160 A Cr modified specimen (960 KJ/mm) and 732 HV for 180 A Cr modified specimen (at
1080 KJ/mm). The depth of penetration increased with increased heat input and was higher for
180 A Cr modified specimen than 160 A Cr modified specimen. Wear loss and wear rate is inversely
proportional to the hardness and decreased significantly with higher heat input and for Cr
modification. The coefficient of friction remains constant with irrespective of hardness. Corrosion
behaviour of the alloys was studied in a saline environment (3.5 wt% NaCl) by Tafel polarisation and
showed an improvement in the corrosion resistance for the surface modified specimens.
Keywords: Gas Tungsten Arc (GTA); Surface modification process; Scanning electron microscope;
Dilution rate; X-ray diffraction; Tafel polarisation
Fusheng Pan, Mingbo Yang, Xianhua Chen,
A Review on Casting Magnesium Alloys: Modification of Commercial Alloys and Development of New
Alloys,
2016,
Pages 1211-1221,
ISSN 1005-0302,
Abstract: The research and development status of casting magnesium alloys including the
commercial casting alloys and the new types casting alloys are reviewed, with more attention to
microstructure and mechanical properties of modified-AZ91, AM60 and WE43 alloys with various
additions, and new types of low cost casting alloys and high strength casting alloys. The modification
and/or refinement of Mg2Si phase in Mg–Al–Si based casting alloys by various additions are
discussed and new purifying technologies for casting magnesium alloys are introduced to improve
the performance. The modified AZ81 alloy with reduced impurities is found to have the tensile
strength of 280 ± 6 MPa and elongation of 16% ± 0.7%. The fatigue strength of AZ91D alloy could be
obviously improved by addition of Ce and Nd. The Mg–16Gd–2Ag–0.3Zr alloy exhibits very high
tensile and yield strengths (UTS: 423 MPa and YS: 328 MPa); however, its elongation still needs to be
improved.
Keywords: Casting magnesium alloys; Microstructure; Mechanical properties; Corrosion; Purification;

Alloying elements
Johannes G. Schaper, Martin Wolff, Björn Wiese, Thomas Ebel, Regine Willumeit-Römer,
Powder metal injection moulding and heat treatment of AZ81 Mg alloy,
Volume 267,
2019,
Pages 241-246,
ISSN 0924-0136,
Abstract: Ongoing research has proven that Mg alloys can be introduced into the metal injection
moulding process for the production of small parts in high quantities and of complex shape for
medical as well as lightweight applications. Previously, development studies have been conducted
using Mg and Mg-Ca alloys intended for medical application. However, progress towards the
implementation of a process for technical and lightweight applications alloys with higher strength is
needed. Therefore, in this study processing of conventional AZ81 alloy by MIM was successfully
developed. Using this alloy, a yield strength of approximately 120 MPa and an ultimate tensile
strength of approximately 255 MPa with elongation at fracture of approximately 7% was achieved.
T4 heat treatment at 420 °C for 10 h does not reveal a positive influence on the mechanical
properties this could be caused by an observed grain growth effect. This is in contrast to
conventional material for example as cast, where T4 heat treatment is known to improve the
mechanical properties especially elongation at fracture.
Keywords: Magnesium; Sintering; Mechanical properties; Grain growth; Liquid phase
F.M. Mwema, T.O. Mbuya, E.T. Akinlabi, P.A.S. Reed, J.O. Obiko,
Data on the effect of high-pressure torsion processing on secondary cast Al–10%Si– Cu piston alloy:
Methods, microstructure and mechanical characterizations,
Data in Brief,
Volume 25,
2019,
104160,
ISSN 2352-3409,
https://doi.org/10.1016/j.dib.2019.104160.
Abstract: The dataset presented here shows the microstructure and mechanical properties of
secondary (recycled) cast aluminum-silicon (Al–Si) piston alloys processed through severe plastic
deformation technique, known as high-pressure torsion (HPT). The HPT processing was undertaken
for 1/4, 1/2, 1 and 10 turns of the lower anvil (rotating at constant speed of 1rpm) while the upper
anvil maintained at a normal pressure of 3.0 GPa. The data on microstructural evolution obtained at
the central region and edge of the circular (disk) HPT sample were obtained using optical and
scanning electron microscopy and these data are presented here. The data on the analysis of the
particle shape, sizes and distribution from the micrographs using ImageJ software are also
presented. Data on mechanical properties characterized using Vickers microhardness measurement
across the surface of HPT sample are also shown. Pictures depicting the microhardness
measurement scheme, high-pressure torsion facility and sample nomenclature are presented.
Keywords: Aluminum alloys; High-pressure torsion (HPT); Severe plastic deformation (SPD); Grain
refinement; Microhardness
Gang Li, Tingchao Ji,
Severe accidental water vapour explosions in a foundry in China in 2012,
Journal of Loss Prevention in the Process Industries,
Volume 41,
2016,
Pages 55-59,
ISSN 0950-4230,
https://doi.org/10.1016/j.jlp.2016.03.001.
Abstract: On 20th February 2012 a severe water vapour explosion occurred in China. The site of the
explosion was an in-door molding pit of the Steel Casting Plant of the Heavy Machinery Co. Ltd., a
part of the Anshan Iron and Steel Group in the Liaoning Province in north–east China. The pit,
located inside a large factory building, had been in use for a number of years. When the pit was first
made years ago, a large hole of square cross section was dug out of the ground and lined with a
whole-welded steel box of 10 mm wall thickness. Then the inside of the steel box was lined with a
0.7 m thick water-proof concrete layer. The completed pit was 4.5 m deep and the side-wall lengths
were about 12 m. When the explosion occurred, a conical stainless-steel ring weighing about 90
tonnes and intended to be the foundation of a water turbine was being cast in a sand mold. The
ground water level was about 2 m below the ground level at the location of the pit. Hence, the
bottom of the pit was 2.5 m below the ground water level. Due to a holiday break during the
preparation of the sand mold in the pit ground water sept into the sand at the bottom and corners
of the pit via eroded holes in the steel lining and cracks in the concrete layer. When the completed
sand mold received the molten stainless steel the sand was exposed to a substantial heat flux from
the hot metal. The heat was conducted downwards and side-ways into to the regions of the sand in
the pit containing water. The water evaporated and highly pressurized water vapour was gradually
generated throughout the sand bed below the mold. Pouring of the molten stainless steel into the
mold continued without any observable problems for about 30 min before the violent water vapour
explosion occurred. Then the entire sand mold, with its content of molten stainless steel, was
suddenly lifted at 5 m up in the air, just as by a piston, and shattered all around, killing 13 workers
and injuring another 17.
Keywords: Metal casting industry; Seeping of ground water; Water vapour explosion; Accidental
explosion; Quantitative analysis
Deping Zhang, Qiang Yang, Dongdong Zhang, Kai Guan, Fanqiang Bu, Hong Zhou, Jian Meng,
Effects of substitution of Nd in a sand-cast Mg-2.5Nd-0.6Zn-0.5Zr alloy with x wt.% Sm (x = 2.5, 4,

and 6),
Journal of Rare Earths,
2017,
Pages 1261-1267,
ISSN 1002-0721,
https://doi.org/10.1016/j.jre.2017.03.002.
Abstract: The microstructures and mechanical properties of a series of sand-cast Mg-Sm-Zn-Zr alloys
under as-cast, solution-treated and peak-aged states were thoroughly investigated. The OM, XRD,
SEM and HRTEM were employed to characterize the microstructural evolution. The results indicate
that substitution Nd in the conventional Mg-2.5Nd-0.6Zn-0.5Zr alloy with different contents of Sm
has comparative grain refinement effect and will fully change the dominant intermetallic phase. In
addition, the substituted alloys perform clearly higher strength with comparative ductility at both as-
cast and peak-aged conditions and much greater aging hardening response than the referential alloy.
It is obvious that the strength increments of this alloy are attributed to the changes of the eutectic
intermetallic particles on grain boundaries.
Keywords: Mg-Sm-Zn-Zr; Sand-cast; Heat treatment; Microstructure; Mechanical property
Xin Dong, Yanan Zhou, Qi Sun, Yuntao Qu, Haojiang Shi, Wenbo Liu, Huabei Peng, Biao Zhang, Sheng
Xu, Jiazhen Yan, Ning Li,
Fatigue behavior of biomedical Co–Cr–Mo–W alloy fabricated by selective laser melting,

Volume 795,
2020,
140000,
ISSN 0921-5093,
Abstract: Co–Cr–Mo based alloy was widely used biomaterials for metallic implants fields. Recently,
selective lase melting (SLM), one of the additive manufacturing technologies, is broadly studied
because it can produce metallic implants with complex geometries and high degree of
personalization. However, the possibility of mechanical failure must be avoided during the working
period of SLM produced biomaterials. Therefore, in this paper we investigated the fatigue behaviors
of the SLM Co–Cr–Mo–W alloy and their corresponding microstructure and fracture morphology.
The sand mold casting fabricated (Cast) Co–Cr–Mo–W alloys with the same chemical composition as
SLM specimens were also investigated and compared. The results showed that the SLM Co–Cr–Mo–
W alloy exhibits higher fatigue life, tensile strength, and ductility than Cast Co–Cr–Mo–W alloy. The
high fraction of Σ3 boundaries and precipitates in SLM Co–Cr–Mo–W alloy lead to secondary cracks
and deflected fatigue crack path, which can alleviate the stress concentrations of the main fatigue
cracks and decrease the fatigue crack growth rate. However, the dendritic structure of Cast Co–Cr–
Mo–W alloy cause cleavage fracture mode and the large island-like precipitates can generate stress
concentration, which result in lower fatigue life. We believed that the results of this work can
provide a new perspective towards microstructure regulation for additive manufacturing technology
and paved way for in-depth application of SLM fabricated biomedical alloy.
Keywords: Co-Cr-Mo-W alloy; Selective laser melting; Fatigue behavior; Biomedical metals
J. Vernet, G. Ghiara, P. Piccardo,
Are tin oxides inclusions in early archaeological bronzes a marker of metal recycling?,
Volume 24,
2019,
Pages 655-662,
ISSN 2352-409X,
Abstract: Bronze artifacts from Early Bronze Age in Europe often contain white inclusions in the
metallic matrix, that are identified as tin oxides (SnO2 or Cassiterite). These inclusions are
interpreted as un-smelted residues coming from the copper ore and are generally mixed with more
complex oxidized inclusions, which contain sulfur, antimony, arsenic, silver, nickel and cobalt. The
nature, shape and distribution of these partially smelted tin inclusions give information on the
alloying process. Depending on the technological context and the geographical areas, the presence
of such inclusions might indicate that the material has been produced by selecting and
supplementing of raw materials containing SnO2 (e.g. co-smelting). In order to understand the role
of tin oxide inclusions in the production of bronzes and possible recycling procedures, a crosscutting
investigation has been carried out, based on experimental researches. The results show that tin
oxides do not completely reduce after four re-melting cycles (recycling) and such a fact is deeply
related to the oxygen availability and the dwell time that influences the kinetics of the reaction.
Keywords: Bronze production; Tin oxide; Recycling; Casting
Pantcho Stoyanov, Kalissa Andre, Paul Prichard, Matthew Yao, Christoph Gey,
Microstructural and Mechanical Characterization of Mo-containing Stellite Alloys Produced by three

Dimensional Printing,
Procedia CIRP,
Volume 45,
2016,
Pages 167-170,
ISSN 2212-8271,
Abstract: Stellite materials are widely used in demanding conditions such as corrosion and high- load
wear components. The ability to develop cobalt-chrome based components by means of three-
dimensional printing may increase their performance as well as enable the use of these wear-
resistant materials in new applications. In this study, we use the binder jetting method to
manufacture cobalt-chrome based articles using powders with various characteristics. The final
components showed theoretical densities above critical limits, which correlated well with the
microstructural characterization and mechanical properties. In addition, abrasion experiments
showed higher wear resistance for the 3D printed parts compared to as-cast components, which was
attributed to differences in the microstructure.
Keywords: Stellite; Additive Manufacturing; Binder Jetting; Wear
Hanxue Cao, Qicai Sun, Qingqing Pu, Luhan Wang, Mengtao Huang, Ziwei Luo, Junqi Che,
Effect of vacuum degree and T6 treatment on the microstructure and mechanical properties of Al–
Si–Cu alloy die castings,
Vacuum,
Volume 172,
2020,
109063,
ISSN 0042-207X,
https://doi.org/10.1016/j.vacuum.2019.109063.
Abstract: This study investigated the effect of T6 treatment on the microstructure and mechanical
properties of a die-cast Al–Si–Cu alloy at three vacuum degrees: 1013, 200, and 100 mbar.
Corresponding microstructure and mechanical properties were performed. At the as-cast state, the
eutectic Si sizes increased unexpectedly with increasing vacuum degree because oxides can act as
heterogeneous nucleation sites for the eutectic Si at atmospheric pressure. Also, the increasing
vacuum level from 1013 mbar to 100 mbar decreased pore size and porosity, which was the main
reason for 12% and 55% increases in tensile strength and elongation, respectively. After T6
treatment, the decreasing pore size and porosity prevented the formation of blister. In addition,
numerous θ′ phases were precipitated to strengthen the α-Al grains, evidently improving the tensile
strength. The fractography of alloys under 1013 mbar revealed transgranular fractures because the
spheroidized eutectic Si reduced the stress concentration at the grain boundaries. In contrast, the
fractography of the alloys under 200 and 100 mbar showed coexistence of transgranular fractures
and intergranular fractures due to the eutectic Si phase with coarse morphology presented at the
grain boundaries.
Keywords: Al–Si–Cu alloy; Die casting; Vacuum degree; Heterogeneous nucleation; Eutectic Si
C. Hardes, F. Pöhl, A. Röttger, M. Thiele, W. Theisen, C. Esen,
Cavitation erosion resistance of 316L austenitic steel processed by selective laser melting (SLM),
Volume 29,
2019,
100786,
ISSN 2214-8604,
Abstract: Every SLM-fabricated component typically possesses a process-specific microstructure that

fundamentally differs from any conventionally fabricated specimen. This publication addresses the
evaluation of microstructure-related influencing factors on the resistance against cavitation erosion.
We exemplarily compared the findings to a cast and hot rolled reference sample. Due to careful
adjustment of the process parameters, the overall cavitation erosion resistance of both SLM-
processed and conventionally fabricated 316L are very much alike in the investigated case. The
incubation period of intact surface areas is improved by the greater hardness and yield strength of
the SLM specimen, which is attributable to an increased dislocation density and a smaller grain size.
Nevertheless, processing and powder feeding during SLM-fabrication occasionally results in
microstructural defects, at which pronounced mass loss during cavitation was registered. X-ray
measurements of the residual stresses reveal the development of severe compressive stresses that
emerge after a few seconds of cavitation. This compressive stress state delays the immediate
propagation of SLM-inherent micro cracks. Moreover, investigations of the microstructure in
combination with examination of the ongoing surface deformation highlighted the emergence of
coarse grains that grew towards the temperature gradient. This effect leads to a temporarily high
surface roughness, local stress concentrations and an increased probability of cavitation impacts.
Furthermore, parallel cracks appear perpendicular to the scan tracks that are traced back to formerly
protruded slip bands.
Keywords: Additive manufacturing; Laser powder bed fusion; Selective laser melting (SLM);
Cavitation erosion resistance; Residual stresses
Ivan Todaro, Rosario Squatrito, Shai Essel, Henning Zeidler,
High conductive aluminium metal matrix composites with carbon inserts obtained by casting
processes,
Volume 10, Part 2,
2019,
Pages 277-287,
ISSN 2214-7853,
Abstract: This work focuses on the production of high conductive Aluminum based MMC or co-cast
components obtained by casting processes. The activity started from the “reinforcement” materials
to be used for the MMC fabrication. Carbon based materials were chosen and their characterization
under the thermal point of view was carried out. Several arrangements for matrix-reinforcement
and matrix-insert couples were evaluated and their potential performances were estimated via
numerical simulation. Aluminum-Diamond, Aluminum-Reduced Graphene Oxide and Aluminum-
Thermal Pyrolytic Graphite components were produced and their performances were experimentally
evaluated. Finally, demonstrator utilizing the novel materials were produced and tested in their
relevant working condition.
Keywords: Metal Matrix composites; high conductive; Aluminum; Carbon; Pyrolitic Graphite
Ghulam Abbas Gohar, Tareq Manzoor, Asad Naeem Shah,
Investigation of thermal and mechanical properties of Cu-Al alloys with silver addition prepared by
powder metallurgy,

Volume 735,
2018,
Pages 802-812,
ISSN 0925-8388,
Abstract: In this study, Cu-10 wt.% Al-X wt.% Ag alloys (X = 0.0, 2.0, 2.5, 3.0, 4.0, 5.0, 5.5, 6.0) were
synthesized through Powder Metallurgy. The effect of silver addition on microstructural, thermal
and mechanical properties of the prepared alloys were investigated by using Scanning Electron
Microscopy (SEM), Energy Dispersion Spectroscopy (EDS), X-rays Diffractometry (XRD), Transient
Plane Source method (TPS), Rockwell hardness tester and Universal testing Machines. The XRD result
of raw materials such as pure copper, pure aluminum, pure silver were qualified through JCPDS
cards, and subsequently quantified. The microstructural analysis of all samples was carried out, with
heating rate of 5 C ̊ /min and annealed at room temperature. The results indicated that presence of
silver in Cu-Al alloy offered better hardness up-to 3%Ag and compression strength increases up to
2%Ag in Cu-10 wt. %Al alloys which shows intermetallic structure in XRD analysis. Thermal
conductivity and thermal diffusivity of the prepared alloys are investigated with help of TPS method
in this work. It is observed that both thermal conductivity and thermal diffusivity increased with the
increase of silver contents in the alloys owing to higher conductive behavior of silver.
Keywords: Powder metallurgy; Silver; Aluminum bronze; Thermal and mechanical properties
Philip Dirisu, Ganguly Supriyo, Filomeno Martina, Xiangfang Xu, Stewart Williams,
Wire plus arc additive manufactured functional steel surfaces enhanced by rolling,
Volume 130,
2020,
105237,
ISSN 0142-1123,
Abstract: Surface waviness (SW) is one of the major problems confronting the economical use of as-
deposited components made with the wire plus arc additive manufactured (WAAM) process. The SW
acts as a stress raiser, thereby reducing the tensile properties and fatigue life of the component. In
this study, the effect of compressive residual stress on the mechanical and fatigue behaviour of the
as-deposited WAAM mild steel component was carried out using a process which combines
deposition and rolling on the WAAM component surface. The fractured faces and microstructure
were characterised by a scanning electron and optical microscope. The microstructural changes
were characterised by X-ray diffraction techniques. The results revealed that an increase in the notch
radius and compressive stress induced by rolling on the as-deposited condition reduced the SW from
0.18 to 0.08 mm with a reduction of stress concentration, consequently reducing crack initiation and
propagation and improving fatigue life. This work shows that rolling has a dual effect on as-
deposited WAAM mild steel components with a new functional surface.
Keywords: Functional surfaces; Fatigue life; Tensile strength; WAAM; Rolling
Shyamprasad Karagadde, Pradip Dutta,
A comparison of time-scales governing the interaction and growth of hydrogen bubbles with a
solidifying front,
International Communications in Heat and Mass Transfer,
Volume 79,
2016,
Pages 16-20,
ISSN 0735-1933,
https://doi.org/10.1016/j.icheatmasstransfer.2016.10.014.
Abstract: Elongated hydrogen porosity appears in aluminum based cast components and can lead to
crack initiation. In this study, a comparison between the growth rates of hydrogen bubbles and the
solidifying front during the process of engulfment is presented. Extending upon a previously
developed order estimate for the ratio of growth rates of the two interfaces, it is found that
dimensionless grouping leads to two distinct time scales that correspond to solidification and
hydrogen diffusion. The analysis proves the hypothesized thought-experiment and explains the
mechanism of hydrogen bubble elongation. The scaling prediction is also validated with available
experimental studies, and shows that the rate of elongation varies directly with the pore radii and
inversely with the cooling rates.
Keywords: Engulfment; Bubble elongation; Microporosity; Scaling; Solidification
Thomas Wei Jie Kwok, Wei Zhai, Wee Yang Peh, Manoj Gupta, Ming Wang Fu, Beng Wah Chua,
Squeeze Casting for the Production of Metallic Parts and Structures,
Elsevier,
2020,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-819726-4.00038-7.
Abstract: Squeeze casting, or liquid forging, is a near-net shape casting process that combines the
flexibility of casting and the strength of forging. By applying pressure during solidification, many
casting defects can be eliminated and even wrought alloys can be cast by this method. This article
introduces the process and fundamental principles of squeeze casting as well as mechanical
properties and microstructures of squeeze cast components. Several case studies are also presented
to offer a practical perspective.
Keywords: Alloys and composites; Defect control; Heat treatment; Liquid forging; Mechanical
properties; Melt temperature; Microstructures; Pressure; Semi solid casting; Solidification; Squeeze
casting
Peter Futáš, Alena Pribulová, Gabriel Fedorko, Vieroslav Molnár, Andrea Junáková, Vlastislav
Laskovský,
Failure analysis of a railway brake disc with the use of casting process simulation,
Volume 95,
2019,
Pages 226-238,
ISSN 1350-6307,
https://doi.org/10.1016/j.engfailanal.2018.09.005.
Abstract: Software for modelling of industry processes is an integral part of production involving
many segments of industry. The use of simulation software in foundry industry is perceived as a tool
for visualization of ongoing processes in casting production. These tools eliminate defects and
imperfections within the process before the production even begins which has a subsequent positive
effect on quality increase and reduction of financial costs in product manufacturing. The paper deals
with a solution of formation and occurrence of foundry defects such as shrinkage in the casting
produced from ductile iron with the use of simulation software. The casting of railway brake disc and
its 3D model were used in the experiments. The goal of the study was evaluation of simulation
results with regard to casting quality increase and decrease of shrinkage formation, as well as
decrease in manufacturing costs during casting production. The paper focuses on a possibility of
improving the utilization of liquid metal in the solidification of castings with the help of simulation
that compares basic as well as adjusted parameters of casting. Computer simulation of casting
uncovered the gating system elements' adjustments and technological modifications effect on the
entire casting and on reduction or elimination of shrinkages incidence along with the increase of
liquid metal utilization during casting. These imply the reduction of financial costs and increased
efficiency in production of castings. The paper presents the results of the simulation casting of the
railway brake disc. Based on the results of these simulations, the shape of gating system and position
of casting in mould was modified and the number of feeders has been reduced from 6 to 1. This
technology modification saves the liquid metal and the casting has been without shrinkages.
Keywords: Failure analysis; Computer simulation; Ductile iron; Shrinkage; Gravity casting;
Unidirectional freezing
Shantanu Shahane, Narayana Aluru, Placid Ferreira, Shiv G. Kapoor, Surya Pratap Vanka,
Optimization of solidification in die casting using numerical simulations and machine learning,
Volume 51,
2020,
Pages 130-141,
ISSN 1526-6125,
Abstract: In this paper, we demonstrate the combination of machine learning and three dimensional
numerical simulations for multi-objective optimization of low pressure die casting. The cooling of
molten metal inside the mold is achieved typically by passing water through the cooling lines in the
die. Depending on the cooling line location, coolant flow rate and die geometry, nonuniform
temperatures are imposed on the molten metal at the mold wall. This boundary condition along
with the initial molten metal temperature affect the product quality quantified in terms of micro-
structure parameters and yield strength. A finite volume based numerical solver is used to
determine the temperature-time history and correlate the inputs to outputs. The objective of this
research is to develop and demonstrate a procedure to obtain the initial and wall temperatures so as
to optimize the product quality. The non-dominated sorting genetic algorithm (NSGA-II) is used for
multi-objective optimization in this work. The number of function evaluations required for NSGA-II
can be of the order of millions and hence, the finite volume solver cannot be used directly for
optimization. Therefore, a multilayer perceptron feed-forward neural network is first trained using
the results from the numerical solution of the fluid flow and energy equations and is subsequently
used as a surrogate model. As an assessment, simplified versions of the actual problem are designed
to first verify results of the genetic algorithm. An innovative local sensitivity based approach is then
used to rank the final Pareto optimal solutions and select a single best design.
Keywords: Die casting; Deep neural networks; Multi-objective optimization
Lorella Ceschini, Alessandro Morri, Stefania Toschi, Salem Seifeddine,
Room and high temperature fatigue behaviour of the A354 and C355 (Al–Si–Cu–Mg) alloys: Role of
microstructure and heat treatment,
Volume 653,
2016,
Pages 129-138,
ISSN 0921-5093,
Abstract: Al–Si–Mg alloys are widely used in the automotive industry for the production of engine
components. Due to the new stringent emissions standards, these components undergo higher
temperatures than in the past; as a result, alloys with higher thermal stability, such as the Al–Si–Cu–
Mg, are currently under investigation. The present paper aims at widening the knowledge on the
relationship between room temperature (RT) and high temperature fatigue behaviour of A354 and
C355 alloys and their microstructural features, in particular, secondary dendrite arm spacing (SDAS)
and intermetallic compounds. Samples for fatigue characterization were hot isostatic pressed,
aiming to avoid the effect of solidification defects. The results of microstructural analyses and
rotating bending fatigue tests highlighted that (i) SDAS influences room temperature fatigue
behaviour of the peak-aged A354 and C355 alloys, while its effect on the overaged alloys at high
temperature is negligible; (ii) fatigue cracks nucleated mostly from large intermetallic compounds;
(iii) at room temperature, C355 alloy is characterized by higher fatigue strength (151 and 135MPa for
fine and coarse SDAS, respectively) in comparison to A354 alloy (133 and 113MPa); after overaging
and testing at high temperature, the behaviour of the two alloys is comparable. A good correlation
between ultimate tensile strength and fatigue resistance was found, independent of microstructure
and aging condition.
Keywords: Casting aluminium alloys; A354; C355; Overaging; High temperature fatigue
M. Wicke, M. Luetje, I. Bacaicoa, A. Brueckner-Foit,
Characterization of Casting Pores in Fe-rich Al-Si-Cu Alloys by Microtomography and Finite Element
Analysis,
Volume 2,
2016,
Pages 2643-2649,
ISSN 2452-3216,
Abstract: An accurate methodology has been developed to identify local stress concentration on the
contour of casting pores in high Fe-content Al-Si-Cu alloys. It relies on the 3D reconstruction of the
pore morphology by micro-computed tomography (μ-CT), which was converted into a 3D volumetric
model to be used as an input for linear finite element analysis (FEA) with the aim of investigating the
structural influence of these defect. In combination with an appropriate visualization of the results,
this treatment allowed localizing highly stressed regions. Results indicate that particularly holes in
the shape of shrinkage pores act as stress concentrators and can thus be identified as hot spots.
Keywords: Al-Si-Cu alloys; X-ray tomography; Porosity; Finite element analysis
Daniel G.H. Sorensen, Thomas Ditlev Brunoe, Kjeld Nielsen,
A classification scheme for production system processes,
Procedia CIRP,
Volume 72,
2018,
Pages 609-614,
ISSN 2212-8271,
Abstract: Manufacturing companies often have difficulties developing production platforms, partly
due to the complexity of many production systems and difficulty determining which processes
constitute a platform. Understanding production processes is an important step to identifying
candidate processes for a production platform based on existing production systems. Reviewing a
number of existing classifications and taxonomies, a consolidated classification scheme for processes
in production of discrete products has been outlined. The classification scheme helps ensure
consistency during mapping of existing production systems, and assists in providing an overview of
when, where and how fundamental functions of a production system are realised.
Keywords: processes; production; manufacturing; handling; classification; ontology; taxonomy
Alejandro Graf,
Chapter 3 - Aluminum alloys for lightweight automotive structures,
2021,
Pages 97-123,
ISBN 9780128187128,
https://doi.org/10.1016/B978-0-12-818712-8.00003-3.
Abstract: An overview of automotive aluminum alloys and their applications as sheet, extrusions,
and castings. Rather than to inform, the emphasis of the chapter is to lead the reader through the
process of selecting aluminum for a specific application, and a specific alloy or form (wrought vs cast,
extrusion vs sheet). The reader is encouraged to supplement this chapter with many sources listed in
the references for exact alloy characteristics.
Keywords: Body in white structure; aluminum; design; manufacturing; aluminum sheet; aluminum
extrusion; aluminum casting
Fei Shen, Joshua Tarbutton,
A Voxel Based Automatic Tool Path Planning Approach Using Scanned Data as the Stock,
Volume 34,
2019,
Pages 26-32,
ISSN 2351-9789,
Abstract: This paper presents a novel automatic tool path planning approach which employs the
scanned data as the stock. Using the scan data as the stock allows a new geometrical approach to
measure the difference between the stock model and desired final geometry. This approach employs
a voxel model as the underlying geometric representation, which enables an efficient parallel tool
path planning algorithm based on a general-purpose graphics processing unit (GPGPU) approach.
The approach is composed of two stages: first, to identify the excess material to be cut and reduce
the required GPU memory, a novel voxelization algorithm for machining was developed to voxelize
the scanned data and the model of the part in a single 3D grid. Second, slice-by-slice contour parallel
tool paths for roughing and 3D contour parallel tool paths for finishing were generated directly
based on the voxel model. The proposed approach has been successfully implemented to machine a
part representative of the welded blade tip and a part representative of a cast workpiece with a
freeform surface into parts with desired final geometry. The experiment results show that the
proposed approach is efficient and feasible in generating tool paths when scanned data was used as
the stock.
Keywords: Tool Path Generation; Voxel Model; 3D Scanning; Stock
Alok Manas Dubey, Ajay Kumar, Ashok Kumar Yadav,
Wear behaviour of friction stir weld joint of cast Al (4–10%) Cu alloy welded at different operating
parameters,
Volume 240,
2017,
Pages 87-97,
ISSN 0924-0136,
Abstract: The effect of Friction stir welding on microstructure, hardness and wear rate of Al-Cu alloy
was measured in this study. Wear tests for cast aluminium alloy joint were conducted on a pin disc
machine for different loads of 2–4kg at constant sliding velocity. The pins were prepared from cast
aluminium billets of 4×4mm2 cross-sections worn on En31 steel as counter body. Wear behavior and
hardness for welded and unwelded portion were determined for the joint. The highest hardness
value occurs in the centre of the welded zone followed by a gradual decrease across the TMAZ and
HAZ until reaching the hardness value of the base material. Hardness of each sample was co-related
with the friction and wear behavior of cast aluminium alloy of FSW. Microstructure of FSW was also
obtained for weld zone (fusion zone) boundary (between weld zone & HAZ), heat affected zone and
base metal region.
Keywords: Friction stir welding (FSW); Cast aluminium alloy; Wear behavior; Dry sliding
Shuai DAI, Feng WANG, De-zhi MA, Zhi WANG, Zheng LIU, Ping-li MAO,
Enhanced strengthening by two-step progressive solution and aging treatment in AM50−4%(Zn,Y)

magnesium alloy,
2018,
Pages 2419-2426,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64888-5.
Abstract: AM50−4%(Zn,Y) alloy with a Zn/Y mole ratio of 6:1 was subjected to thermal analysis, and
the results were used for designing a two-step progressive solution treatment process. The effects of
solution and aging treatments on the microstructure and mechanical properties of the AM50−4%
(Zn,Y) alloy were investigated using OM, XRD, SEM/EDS, TEM, tensile test and hardness test. The
experimental results demonstrated that the two-step progressive solution treatment could make the
Φ and β phases sufficiently dissolve into the matrix which possessed higher supersaturated degree
of the dissolved solute compared with the one-step solution treatment. This resulted in a certain
enhancement of the precipitation strengthening effect during the subsequent aging process. The
precipitation of the Ф phase had a greater impact on the comprehensive mechanical properties of
the alloy than β phase precipitation when the aging treatment was performed at 180 °C. The peak
aging strength of the AM50−4%(Zn,Y) alloy which was subjected to the two-step progressive solution
treatment process (345 °C for 16 h and 375 °C for 6 h) was obtained after the aging treatment at 180
°C for 12 h.
Keywords: AM50−4%(Zn,Y) alloy; thermal analysis; solution; aging treatment; microstructure;
strengthening mechanism
Yijie Zhang, Shouxun Ji, Geoff Scamans, Zhongyun Fan,
Interfacial characterisation of overcasting a cast Al-Si-Mg (A356) alloy on a wrought Al-Mg-Si

(AA6060) alloy,
Volume 243,
2017,
Pages 197-204,
ISSN 0924-0136,
Abstract: The microstructure and tensile properties of hybrid Al-Si-Mg (A356) and Al-Mg-Si (AA6060)
materials were investigated through overcasting. The solid bonding at AA6060/A356 interface was
obtained under as-cast condition and T7 heat-treated condition. The oxide film on the surface of the
AA6060 inserts was successfully removed by properly designed casting structure and optimised
overcasting process. Fine equiaxed primary α-Al grains could be formed at the bonding interface,
during which the primary α-Al grains in the A356 alloy were grown up on the primary α-Al grains in
the solid inserts of AA6060 alloy. EBSD results revealed that these two types of primary α-Al grains
exhibited the same orientation, indicating the cast A356 alloy and the wrought AA6060 alloy shared
one primary α-Al grain at the interface. The interfacial bonding strength was measured at a level of
180MPa. Heat-affected zone was not significant in the overcast structure because the decrease of
the ultimate tensile strength of overcast arts was only 3–5% in comparison with the properties of the
original AA6060 alloys under aged condition.
Keywords: Aluminium alloys; Bonding; Microstructure; Mechanical properties; Overcasting;

Interfaces
Guanfei Xiao, Jufu Jiang, Yingze Liu, Ying Wang, Baoyong Guo,
Recrystallization and microstructure evolution of hot extruded 7075 aluminum alloy during semi-
solid isothermal treatment,
Volume 156,
2019,
109874,
ISSN 1044-5803,
Abstract: In this paper, semi-solid isothermal treatment of hot extruded aluminum alloy (SSITHEAA)
method was used to fabricate semi-solid billets of 7075 aluminum alloys. It contains continuous
temperature rising stage and temperature holding stage during semi-solid isothermal treatment. The
effect of heating temperature from 480 °C to 580 °C on recrystallization and texture of hot extruded
7075 Al alloy was investigated in the continuous temperature rising stage. The effects of isothermal
temperature and soaking time on microstructure evolution of 7075 Al alloy were investigated in the
temperature range of 580 °C to 615 °C for 5–25 min. The results indicated that recrystallization
occurred in the continuous temperature rising stage, and the recrystallization degree increased with
the increase of heating temperature. When heating temperature increased to 580 °C, the
recrystallization was essentially completed, and the elongated grains were completely transformed
into equiaxed grains. The isothermal temperature and soaking time had significant effects on
average grain size and shape factor of 7075 Al alloy semi-solid billets. The results showed that the
optimum condition was in the isothermal heating temperature range of 600 °C to 610 °C for 10–
15 min. The coarsening rate of 7075 Al alloy increased with the increase of isothermal temperature
from 580 °C to 610 °C, and decreased at 615 °C. The intermediate phases and eutectic phases were
observed at the grain boundaries of 7075 Al alloy during semi-solid isothermal treatment.
Keywords: Semi-solid; Isothermal treatment; Microstructure; Recrystallization; 7075 aluminum alloy
Annissa Fanya, Esa Haruman, Mohammad S. Adenan,
Optimization of Multi-Objective Taguchi Method for Hybrid Thermochemical Treatment Applied to

AISI 316LVM Biological Grade Stainless Steel,
Elsevier,
2019,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.11165-8.
Abstract: A method was developed to obtain AISI 316LVM stainless steel with consistent quality
characteristic through hybrid thermochemical treatment in a gaseous tube furnace by determining
combinations of optimum parameters such as the gas composition, holding time, and treatment
temperature. The investigation makes use of the multi-objective Taguchi method to determine the
optimum process parameters. Two process of analysis were used in the present study which include
with and without interaction effect of process parameters. The Taguchi orthogonal array table was
utilized for designing the L8 experiments and data analysis. The normalization by applying the ratio
between the quality loss values of the observed experiments was also performed. Analysis of
variance (ANOVA) was used in order to identify the contribution of each parameter for achieving a
multiple S/N ratio value associated with the quality of the material. Based on the current work, the
optimum process parameters are determined to be a gas composition of 75% NH3, 5% CH4, and 20%
N2, with a treatment temperature of 425°C and a holding time of 12 h. This study suggests that
adapting the interaction effect of process parameters in the calculation process produced more
consistent quality characteristics compared to the optimization without interaction effect. Based on
the ANOVA calculation the work also concluded that the interaction between the treatment
temperature and holding time is the most influential parameter for achieving predetermined
properties of a resultant layer that is ~10 µm in thickness, with a minimum surface hardness of 600
VHN and surface roughness below 3 µm. This influential parameter is followed by the holding time
and the interaction between the gas composition and holding time.
Keywords: Hybrid thermochemical treatment; Multi-objective taguchi method; Optimization;

Stainless steel AISI 316 LVM
János Gábor Tarbay, Boglárka Maróti, Zoltán Kis,
Introducing the spear project: The tale of the Late Bronze Age spearhead with wooden shaft from
the Marshland of Kikinda, Serbia,
Volume 21,
2018,
Pages 268-274,
ISSN 2352-409X,
Abstract: The study discusses a Late Bronze Age (Br D-Ha A) spearhead with wooden shaft from the
territory of Serbia (Kikinda, Vojvodina Province). This rare find was analyzed by different non-
destructive analytical methods (PGAA, XRF, Neutron imaging, X-ray imaging) for documenting and
characterizing its wooden and metal parts.
Keywords: Late Bronze Age (Br D-Ha A); Spearhead; Wooden shafts; PGAA; XRF; Neutron imaging; X-
ray imaging
E. Olejnik, Ł. Szymański, P. Batóg, T. Tokarski, P. Kurtyka,
TiC-FeCr local composite reinforcements obtained in situ in steel casting,
Volume 275,
2020,
116157,
ISSN 0924-0136,
Abstract: A method of the in situ fabrication of TiC-FeCr local composite reinforcements (LCR) in a
cast steel matrix was discussed. The synthesis of a reinforcing phase was performed by placing the
substrates of the reaction of TiC formation in the form of compressed packets in a mold cavity. In
order to restrict the fragmentation of the composite zones resulting from the reactive infiltration
phenomenon, the addition of 30, 50, 70, and 90 wt.% of a moderator was introduced into the initial
powder mixture. The moderator was a powder mixture showing the composition of high-chromium
cast iron. The presented macrostructure of a composite casting made it possible to determine the
influence of the moderator addition on the stabilization of LCR. The dimensional stability and
homogeneity of the LCR increased with increasing percentages of the moderator added to the initial
powder mixture. The samples taken from the LCR region were analyzed, considering their structure,
microstructure, mechanical properties, and wear resistance. The investigations carried out with the
application of phase analysis and scanning electron microscopy (SEM) confirmed the occurrence of
TiC-type phases in the structure of the composite zones. With increasing percentages of the
moderator addition, a higher fraction of Cr7C3-type chromium carbides was observed in the LCR
structure. The hardness of the composite zones ranged at average levels from 776 to 878 HV1
depending on the percentage of the moderator addition and pure substrates of the TiC formation.
Keywords: Local reinforcement; TiC; In situ; Wear resistance; Hardness; SHS
Ajay Ratna Bajracharya, Sagar Ratna Bajracharya, Arun Bhakta Shrestha, Sudan Bikash Maharjan,
Climate change impact assessment on the hydrological regime of the Kaligandaki Basin, Nepal,
Science of The Total Environment,
Volume 625,
2018,
Pages 837-848,
ISSN 0048-9697,
https://doi.org/10.1016/j.scitotenv.2017.12.332.
Abstract: The Hindu Kush-Himalayan region is an important global freshwater resource. The
hydrological regime of the region is vulnerable to climatic variations, especially precipitation and
temperature. In our study, we modelled the impact of climate change on the water balance and
hydrological regime of the snow dominated Kaligandaki Basin. The Soil and Water Assessment Tool
(SWAT) was used for a future projection of changes in the hydrological regime of the Kaligandaki
basin based on Representative Concentration Pathways Scenarios (RCP 4.5 and RCP 8.5) of ensemble
downscaled Coupled Model Intercomparison Project's (CMIP5) General Circulation Model (GCM)
outputs. It is predicted to be a rise in the average annual temperature of over 4°C, and an increase in
the average annual precipitation of over 26% by the end of the 21st century under RCP 8.5 scenario.
Modeling results show these will lead to significant changes in the basin's water balance and
hydrological regime. In particular, a 50% increase in discharge is expected at the outlet of the basin.
Snowmelt contribution will largely be affected by climate change, and it is projected to increase by
90% by 2090.Water availability in the basin is not likely to decrease during the 21st century. The
study demonstrates that the important water balance components of snowmelt, evapotranspiration,
and water yield at higher elevations in the upper and middle sub-basins of the Kaligandaki Basin will
be most affected by the increasing temperatures and precipitation.
Keywords: Climate change; CMIP5; Hydrology; Kaligandaki; RCP; Snowmelt; SWAT
Zuhaib Nissar, Azharuddin Kazi, Mir Safiulla, Muhammad Faisal,
A Thorough Study: In-Situ Aluminium LM6 Metal Matrix Composites Reinforced with Iron Oxide and
MWCNTs,
2017,
Pages 11999-12006,
ISSN 2214-7853,
Abstract: This paper aims on synthesis and characterization of Aluminium LM6 composites,
discontinuously reinforced with iron oxide (γ-Fe2O3) particles and MWCNTs under different
compositions using stir casting method. An investigation of carried out to determine physical,
mechanical and electromagnetic properties of LM6 composites. Alumina particles were produced in-
situ by reaction with iron oxide reduced by aluminium. Morphological studies were carried out to
reveal the surface morphology and chemical composition of the prepared sample. EMI shielding
effectiveness was measured using transmission line waveguide technique in the X-band.
Observations yield that the presence of iron oxide particles and MWCNTs in Aluminium matrix
affects EMI shielding property of the composite in X-band (8-12 GHz) frequency range. The reflection
and absorption coefficients have shown reflection dominated electromagnetic energy attenuation of
the composite samples, which was tailored by incorporation of iron oxide and MWCNTs.
Simultaneous Thermal Analysis (STA) technique was performed for uniform ramp and purging rates
to analyse the thermal stabilities of composites. The hardness, impact strength and wear rate of
both composites increases while the compression strength was compromised. Furthermore,
incorporating MWCNT along with iron oxide had reducing effect on the density of composite. The
effect of dispersants on the distribution of reinforcements and the controlled distribution of MWCNT
is further to more research and discussion.
Keywords: MMC; In-situ; Al LM6; γ-Fe2O3; MWCNT; BHN; SEM-EDS; EMI SE; STA
Bijayani Panda, C.A. Niranjan, A.D. Vishwanatha, P. Harisha, K.R. Chandan, Rakesh Kumar,
Development of Novel Stir Cast Aluminium Composite with modified Coconut Shell Ash Filler,
Volume 22, Part 4,
2020,
Pages 2715-2724,
ISSN 2214-7853,
Abstract: Coconut shell is a bio-degradable agro-waste obtained from the coconut processing
industry and is found abundantly in India. Due to its low density, suitable chemical composition, ease
of availability and cost effectiveness, coconut shell ash (CSA) is a suitable candidate as reinforcement
for metal-matrix composites for automotive and aerospace applications. In the present work,
coconut shell powder was initially burnt at 700°C in air to form ash. The ash was further treated at
650°C in an inert atmosphere with magnesium and graphite. The composition and morphology of
initial and modified CSA was studied using X-ray diffraction (XRD) technique and scanning electron
microscopy (SEM) along with energy dispersive spectroscopy (EDS). The density of the particles was
also determined. The composite was prepared by compo-casting route by melting AA 1200
aluminium in a stir casting furnace and adding 2, 4 and 8 wt. % (weight percentage) of the modified
CSA. The microstructure of the as-cast composite was studied using optical microscopy and SEM.
The density of the composite was also determined and related to the amount of filler. Hardness and
wear behaviour of the composite were determined using Brinell hardness test and dry sliding pin-on
disc wear test at room temperature, respectively
Keywords: Aluminium matrix composite; Modified coconut shell ash; Density; Microscopy; Hardness;
Wear
Yu Sun, Sen Yu, Gui Wang,
3 - General manufacturing route for medical devices,
Editor(s): Cuie Wen,
In Woodhead Publishing Series in Biomaterials,
Metallic Biomaterials Processing and Medical Device Manufacturing,
2020,
Pages 97-135,
ISBN 9780081029657,
https://doi.org/10.1016/B978-0-08-102965-7.00003-5.
Abstract: To reach the full potential in the cost-saving and complex performance, it is essential to
understand the manufacturing route of medical devices. Manufacturing is about forming or shaping
materials, which may include: (1) producing a part that generally is at or near the final desired shape
through casting, forging, or stamping processes; (2) the operations such as rolling, extrusion, and
drawing processes that produce long continuous semifinishing products, including plates, sheets,
tubing, and bars with various cross sections. The initial raw material used in forming and shaping
metals is usually molten metal, which is cast into individual ingots or continuously cast into slabs.
Heat treatment is the process of heating and cooling metals to change their microstructure and to
bring out the physical and mechanical characteristics that make metals more desirable by controlling
the temperatures metals are heated to, and the rate of cooling after heat treatment. It is a critical
process used either to improve the formability of the metal during the forming operation or to
enhance the properties of the final product. Welding joins metals by using heat to melt the parts
together and allowing them to cool causing fusion. This chapter covers the basic principles of each of
aforementioned processes: the relative advantages, limitations, and capabilities of the process. A
detailed primary manufacturing processing for titanium alloys has been also illustrated as an
example.
Keywords: Thermomechanical processing; metallic materials; titanium
Haiguang Liao, Penghuai Fu, Liming Peng, Jia Li, Shuquan Zhang, Guoqi Hu, Wenjiang Ding,
Microstructure and mechanical properties of laser melting deposited GW103K Mg-RE alloy,
Volume 687,
2017,
Pages 281-287,
ISSN 0921-5093,
Abstract: Mg-10Gd-3Y-0.4Zr (wt%) (GW103K) Mg-RE based alloy was manufactured in Laser melting
deposition (LMD) process and its microstructure and mechanical properties were studied in as-
fabricated and T6-treated conditions. As-fabricated LMDed GW103K alloy consists of equiaxed grains
about 19µm in size and Mg3Gd, GdH2 particles. Under conventional solution and aging treatment
parameters, grains of LMDed alloy coarsen significantly, from 19 to 158µm. Plenty of GdH2 particles
can be observed after solution treatment. Yield strength (YS), ultimate tensile strength (UTS) and
elongation of as-fabricated and T6-treated LMDed GW103K alloy at room temperature are 118–
232MPa-13.9% and 191–298MPa-8.9%, respectively. Compared with sand cast alloy, as-fabricated
LMDed GW103K alloy has comparable YS (−5MPa), much higher UTS (+51MPa) and elongation
(+12.1%). Unfortunately, after T6 treatment under conventional heat treatment parameters, YS and
UTS were about 40MPa lower than those of sand cast alloy, with relatively higher elongation
(+5.8%). Reduction of Gd, Y content during LMD process, grain growth and formation of GdH2
particles during heat treatment are believed to be the main reasons of the reduced YS and UTS.
Keywords: Laser melting deposition; Mg rare earth alloy; Microstructure; Mechanical property; Grain
coarsening; GdH2
Radu Eugen Breaz, Octavian Bologa, Sever Gabriel Racz,
Selecting between CNC milling, robot milling and DMLS processes using a combined AHP and fuzzy
approach,
Procedia Computer Science,
Volume 122,
2017,
Pages 796-803,
ISSN 1877-0509,
https://doi.org/10.1016/j.procs.2017.11.439.
Abstract: Recent advancements in manufacturing technology allow now a much wider selection of
machining processes. Milling with industrial robots or additive manufacturing could now replace
traditional milling performed on CNC machine-tools, for certain applications. This work presents a
decision-making process for selecting between CNC milling, robot milling and a process of additive
manufacturing (DMLS) for a certain class of parts. The AHP method was used for selecting between
the three variants of manufacturing processes. The criteria used for AHP were divided into crisp ones
and criteria described by linguistic variables. For the last ones, fuzzy inference systems were built to
extract measurable information to be used for AHP. Finally, the proposed method was applied for a
specific part.
Keywords: AHP; CNC milling; DMLS; fuzzy approach; robot milling
Moshe Nahmany, Yoav Hadad, Eli Aghion, Adin Stern, Nachum Frage,
Microstructural assessment and mechanical properties of electron beam welding of AlSi10Mg

specimens fabricated by selective laser melting,
Volume 270,
2019,
Pages 228-240,
ISSN 0924-0136,
Abstract: Electron beam bead on plate and butt-welded specimens (˜5 mm in thickness) built in the
X and Z directions were investigated. The microstructure of welds in both bead on plate and
electron-beam-welded specimens revealed a eutectic morphology with a very thin heat-affected
zone. Increasing heat input resulted in reduced porosity of the joint and subsequent improvement of
the mechanical properties. The yield strength and tensile strength of the joint region are similar to
those of the base metal, i.e., 206 vs. 207.5 MPa and 310 vs. 322 MPa, respectively. The elongation of
the welded metals was slightly reduced, as compared to that of the base metal. Fractography
analysis revealed that for samples welded under optimal welding parameters, failure mostly
occurred at the base metal. The results of a simulation of temperature distribution within the joint
region were in a good agreement with observed macrostructural characteristics. Electron beam
welding can be successfully used for joining AlSi10Mg parts fabricated by selective laser melting.
Keywords: AlSi10Mg; Additive manufacturing; Electron beam welding; Mechanical properties;

Microstructure; Selective laser melting
Wentao Yu, Qitang Hao, Li Fan, Jiehua Li,
Eutectic solidification microstructure of an Al-4Ni-2Mn alloy,
Volume 688, Part B,
2016,
Pages 798-803,
ISSN 0925-8388,
Abstract: Eutectic solidification microstructure of an Al-4Ni-2Mn alloy has been investigated by

Scannig Electronic Microscopy (SEM), Transmission Electron Microscopy (TEM) and X-ray Diffraction
(XRD). In contrast to the predicted α-Al and Al3Ni eutectic solidification microstructure, a α-A1 and
Al9(Mn, Ni)2 eutectic solidification microstructure was observed. The Al9(Mn, Ni)2 phase is present
with rob-like morphology, which is believed to be grown along the primary α-Al. The Al9(Mn, Ni)2
phase can be indexed to be of Al9Co2-type structure with a monoclinic cell with a = 0.8565(3) nm;
b = 0.6266(2) nm, c = 0.6196(2) nm and β = 94.60(3)°. The formation of Al9(Mn, Ni)2 phase can be
attributed to the partitioning of Mn into the Al9(Mn, Ni)2 phase during solidification. This
investigation provides a better understanding on the formation mechanism of Al-Ni eutectic
solidification microstructure in Al alloys.
Keywords: Al alloys; Eutectic microstructure; Transmission electron microscopy; Solidification
Sebastian Pomberger, Martin Leitner, Michael Stoschka,
Evaluation of surface roughness parameters and their impact on fatigue strength of Al-Si cast
material,
Volume 12, Part 2,
2019,
Pages 225-234,
ISSN 2214-7853,
Abstract: Sand-cast aluminium components enable complex component designs whose surface is
partly machined subsequently. Thus, the fatigue strength is affected both by volumetric shrinkage
porosity as well as by surface roughness. For as-cast surface characterisation, utilization of area-
based roughness parameters is essential. Fatigue tests covering T6 and HIP heat treatment as well as
machined versus as-cast surface conditions are performed, whereat a change of up to fifteen
percent in fatigue strength is observable. The results of this study reveal, that the mean values of the
area-based surface roughness parameters Sa and St correlate well with the fatigue strength if no
micro-porosity exists within the surface layer
Keywords: Cast aluminium; As-cast surface; Surface roughness; Surface topography; Fatigue
strength; HIP
K. Satish Prakash, T. Nancharaih, V.V. Subba Rao,
Additive Manufacturing Techniques in Manufacturing -An Overview,
2018,
Pages 3873-3882,
ISSN 2214-7853,
Abstract: Research projects have been taken up on additive manufacturing (AM) technology and has
been getting developed for more than 25 years, but without removing or replacing materials, AM
processes are useful to produce 3D parts directly from CAD models by joining materials layer by
layer which offers beneficial ability to build parts with geometric and material complexities that
could not be formed by subtractive manufacturing processes. Through intensive research over the
past two decades, significant progress has been achieved in the development and commercialization
of new and innovative AM processes, and the applications in automotive, energy sectors, aerospace,
biomedical, and other fields as well. This paper reviews the main processes, materials and
applications of the current AM technology.
Keywords: Additive Manufacturing (AM); AM processes; AM materials; AM applications

E. Zaretsky, A. Stern, N. Frage,
Dynamic response of AlSi10Mg alloy fabricated by selective laser melting,
Volume 688,
2017,
Pages 364-370,
ISSN 0921-5093,
Abstract: The dynamic response of selective laser melting (SLM)-processed and sand cast Al10SiMg
samples were studied in a series of planar impact experiments. It was found that the dynamic
response of SLM-processed alloys is virtually independent of the processing orientation. The
dynamic yield strength and tensile (spall) strengths of SLM-processed material exceeds those of the
cast alloy by factors of two and four, respectively. It was found that with increase in the tensile strain
rate ε̇t, the fracture mode of SLM-processed material changes from apparently ductile at strain rates
below ε̇t≈5×103s−1 to evidently brittle above this threshold. At approximately the same strain rate
and at shear stress greater than 65MPa, the mechanism governing the compressive (yield) strength
of the SLM-processed alloy also changes from thermally-activated passage of obstacles by moving
dislocations to dislocation over-barrier glide controlled by phonon viscous drag.
Keywords: Dynamic response; Selective laser melting; AlSi10Mg alloy
Roger N. Lumley,
Introduction: Aluminium, the Strategic Material,
2018,
Pages xvii-xxx,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.10000-1.
Rui Chen, Qingyan Xu, Huiting Guo, Zhiyuan Xia, Qinfang Wu, Baicheng Liu,
Modeling the precipitation kinetics and tensile properties in Al-7Si-Mg cast aluminum alloys,
Volume 685,
2017,
Pages 403-416,
ISSN 0921-5093,
Abstract: The extensive application of Al-7Si-Mg cast aluminum alloys in the automotive and
aerospace industries raises the need to better understand the relationship between microstructures
and properties. In present work, an integrated precipitation/strengthening/strain-hardening
numerical model is developed in order to model the precipitation kinetics and tensile properties in
Al-7Si-Mg alloys. The influence of solidification and solution treatment conditions on yield strength is
reflected by a term ∆σ0. The strain hardening model takes into account the effect of Orowan loops
on the dislocation storage and recovery as well as kinematic contributions. Application of this
integrated model to various aging treatments of Al-7Si-Mg alloys is conducted and the predictions
both for precipitate microstructure and yield strength are compared well with experimental results.
The influence of aging temperature, solution treatment temperature as well as Mg concentration on
yield strength is investigated. Using the strain hardening model, the stress-strain curves are
predicted and the influence of aging treatment on k1 and k20 parameters as well as the strain
hardening behavior is analyzed. Through combining with the empirical expression
(σUTS−σYS)=m·σYS+n+f(Tss), the ultimate tensile strength and elongation for the samples in Al-7Si-
Mg alloys aged at 160°C and 180°C are predicted. Finally, the limitations of present model and the
factors influencing the prediction precision of tensile properties are discussed.
Keywords: Al-7Si-Mg alloys; Heat treatment; Precipitation; Solidification microstructure; Tensile

property; Modeling
Shaik Mozammil, Raviraj Verma, Jimmy Karloopia, Pradeep Kumar Jha,
Investigation and measurement of porosity in Al+4.5Cu/6wt%TiB2 in situ composite: optimization

and statistical modelling,
Volume 9, Issue 4,
2020,
Pages 8041-8057,
ISSN 2238-7854,
Abstract: Present work investigates the adequacy of stir casting technique using mixed salt route
method to fabricate in situ Al-4.5Cu-6wt%TiB2 composites and further the variation of porosity
present in cast composite with varying pouring temperature, pouring time and different types of
gating systems. The casting was found to be effective and economical for top gating system amongst
rest of the gating design. The microstructural analysis of cast composite was carried out to
determine the physical morphology and distribution of the TiB2 and Al2Cu phases in the matrix with
the help of scanning electron microscopy (SEM). X-ray diffraction (XRD) analysis of cast composite
shows the formation of TiB2 particles in the absence of intermetallic, hard and brittle compound
Al3Ti. Microstructural characterization was tandem with optical and high-resolution transmission
electron microscopy (HR-TEM) results. These castings were checked for surface defects or sub-
surface cracks using dye penetrant and ultrasound test. The amount of porosities present in all the
castings was then determine precisely using Archimedes’ Principle of buoyancy. The experimental
results thus found were validated with the simulation results obtained by AutoCAST simulation tool
and improvements were incorporated by optimization of gating systems using modelling and
simulation technique.
Keywords: Al-4.5%Cu-6%TiB2 composite; Porosity; Microstructural characterization; AutoCAST

simulation; Gating design optimization; Solidification
Roger N. Lumley,
Chapter 4 - Aluminium Investment Casting and Rapid Prototyping for Aerospace Applications,
2018,
Pages 123-158,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.00004-7.
Abstract: Investment cast aluminium has been used extensively for aerospace products for many
years, but recently, two major innovations have become particularly important. The first of these is
an appreciation of what is routinely achievable with respect to advances in casting quality, and the
second of these is related to advances in the rapid prototyping of resin or plastic patterns via 3D
printing routes, which may be used for tool-less production. This now allows designers an
unprecedented opportunity to develop premium investment castings in numbers from one, all the
way up to production volumes in the several thousands. Smooth surface finish, high tolerances and
high integrity are achievable for aerospace components, which may previously have been machined
from billet aluminium. Investment casting therefore finds widely expanded opportunities in the
aerospace sector.
Keywords: Investment casting; Aerospace; 3D printing; Rapid prototyping; Premium casting
Florian Summer, Michael Pusterhofer, Florian Grün, István Gódor,
Tribological investigations with near eutectic AlSi alloys found in engine vane pumps –
Characterization of the material tribo-functionalities,
Tribology International,
Volume 146,
2020,
106236,
ISSN 0301-679X,
https://doi.org/10.1016/j.triboint.2020.106236.
Abstract: This paper gives attention to wear and friction processes of sliding contacts with cover
parts of variable displacement engine vane pumps. Two near eutectic aluminium-silicon alloys for
different casting processes were characterized by tribological investigations. This was done with the
aid of specifically designed test methods on model scale as well as by damage analysis of real life
parts from engine tests. The latter was additionally used as a validation measure for the model tests,
which proved transferability of damage events from model tests to the engine parts. The results
emphasize significance of the material structure of near eutectic AlSi materials on the wear
performance. A pronounced load bearing structure of eutectic Si is able to provide high wear
resistance.
Keywords: Engine vane pump; Wear; AlSi; Tribometer
Alice Cervellon, Luciana Maria Bortoluci Ormastroni, Zéline Hervier, Tresa M. Pollock, Fernando
Pedraza, Jonathan Cormier,
Damage mechanisms during very high cycle fatigue of a coated and grit-blasted Ni-based single-
crystal superalloy,
Volume 142,
2021,
105962,
ISSN 0142-1123,
Abstract: The very high cycle fatigue properties of the Ni-based single-crystal superalloy CMSX-4
coated with an MCrAlY type coating and grit-blasted were studied at 1000 °C, 20 kHz and R = -1. A
recrystallized layer thicker than the size of the larger casting pores (>50 μm) drastically reduces the
fatigue life without environmental influence. The recrystallized layer and roughness introduced by
grit-blasting degrades the environmental resistance of the alloy and the resultant fatigue life. The
fatigue life of the coated specimens is also greatly reduced from damage accumulation in the
interdiffusion zone by grain boundary cracking, oxidation and internal nitridation.
Keywords: Very high cycle fatigue; Single-crystal superalloy; Recrystallization; Coating; Oxidation
C. Kannan, R. Ramanujam,
Advanced liquid state processing techniques for ex-situ discontinuous particle reinforced
nanocomposites: A review,
Science and Technology of Materials,
Volume 30, Issue 2,
2018,
Pages 109-119,
ISSN 2603-6363,
https://doi.org/10.1016/j.stmat.2018.05.005.
Abstract: Recent times, metal matrix composites (MMC) are considered as candidate materials for
numerous applications such as aerospace, automotive and military industries due to improved
properties over the conventional metals and alloys. Out of the different categories of metal matrix
composites, discontinuous particulate reinforced composites are preferred for industrial applications
due to low manufacturing cost. High fracture toughness, improved ductility and machinability
characteristics support the selection of metal matrix nanocomposites (MMnC) over conventional
composites for different applications. The majority of nanocomposites are produced through liquid
state processing due to faster processing time and economy. However, the conventional liquid
processing method leads to poor wetting of reinforced nanoparticles by molten metal that degrades
the quality of the fabricated nanocomposite. This paper reviews some of the advanced liquid state
processing techniques adopted for the improved wettable characteristics of nanoparticles and their
uniform distribution in the metal matrix.
Keywords: Nanocomposites; Ultrasonic assisted cavitation; Compocasting; Rheocasting; Squeeze

casting; Thixoforming
S. Roberts,
5 - Martensitic steels for cast components in ultra-supercritical power plants,
Editor(s): Augusto Di Gianfrancesco,

Materials for Ultra-Supercritical and Advanced Ultra-Supercritical Power Plants,
2017,
Pages 121-141,
ISBN 9780081005521,
https://doi.org/10.1016/B978-0-08-100552-1.00005-1.
Abstract: This chapter discusses specifically about castings utilized for high temperature application
steam turbine components for ultra-supercritical and potential advanced ultra-supercritical
applications. Casting remains by far the most cost-effective method for the manufacture of steam
turbine valve casings, turbine casings, and ancillary parts such as valve bonnets and covers. This
chapter provides an insight into the modern manufacturing techniques, parameters, and tools used
for the production of high-integrity castings, along with details of traditional power generation cast
material grades, new material developments of 9–10%Cr steel castings for up to 650°C plant
operation, and nickel alloy castings for potential operation up to 750°C.
Keywords: 9%Cr Steel; Alloy; Castings; CB2; Chemistry; Grades; Heat treatment; MarBN; Material
requirements; Weld repair
Yifan Wang, Yanli Lu, Jing Zhang, Wenchao Yang, Changlin Yang, Pan Wang, Xiaoqing Song, Zheng
Chen,
Investigation of the 12 orientations variants of nanoscale Al precipitates in eutectic Si of Al-7Si-

0.6Mg alloy,
Volume 67,
2021,
Pages 186-196,
ISSN 1005-0302,
Abstract: Various orientations and diffraction patterns from nanoscale Al precipitates in eutectic Si
were investigated by high-resolution transmission electron microscopy combined with transition
matrix and stereographic projection. It was found that the Al precipitates had 12 variants, all
orientation relationships can be expressed as: (001)Al//{111}Si, [110]Al//<1¯10>Si. Further, a new
diffraction pattern model from Al precipitates was established under [111]Si zone axis, which was in
good agreement with the experiment data. The microstructure, adhesion strength and electronic
structure of the interface between Al precipitate and Si matrix were studied by first-principles
calculation and experimental observation. The results show that the covalent bonds are formed
between interfacial Al and Si atoms, which play a key role in interfacial bind strength. Based on the
Griffith fracture theory, the cracks tend to form and expand in the interior of Al precipitates firstly,
and the interfaces can act as a protective layer to prevent crack propagation. Therefore, the
nanoscale Al precipitates will improve the toughness of eutectic Si particles by releasing part of
stress through lattice distortion. In addition, the stretched nanoscale Al precipitates can act as
effective heterogeneous nucleation sites for high density deformation nanotwins in eutectic Si
during deformation, which significantly improved the deformability of eutectic Si.
Keywords: Aluminum precipitates; Silicon particles; High-resolution transmission electron

microscopy; Strengthening mechanism; First-principles
Index,
Editor(s): Abdel Salam Hamdy Makhlouf, Mahmood Aliofkhazraei,
Handbook of Materials Failure Analysis with Case Studies from the Aerospace and Automotive
Industries,
2016,
Pages 493-503,
ISBN 9780128009505,
https://doi.org/10.1016/B978-0-12-800950-5.09993-2.
Mohsen K. Keshavarz, Sylvain Turenne, Ali Bonakdar,
Solidification behavior of inconel 713LC gas turbine blades during electron beam welding,
Volume 31,
2018,
Pages 232-239,
ISSN 1526-6125,
Abstract: In this study, a comprehensive microstructure analysis was carried out to determine the
solidification behavior of Inconel-713LC gas turbine blades under a variety of cooling conditions
during electron beam welding (EBW). An empirical correlation between the secondary dendrite arm
spacing (SDAS) in the fusion zone and cooling rate was established. Additionally, liquation was
observed in the heat affected zone (HAZ), which is induced by the segregation of elements at the
grain boundaries.
Keywords: Electron beam welding; Inconel-713LC; Solidification; Microstructure; Induced liquation;

Cooling rate
Jianjun Zhang, Jiachen Liu, Huimin Liao, Ming Zeng, Sude Ma,
A review on relationship between morphology of boride of Fe-B alloys and the wear/corrosion
resistant properties and mechanisms,
Volume 8, Issue 6,
2019,
Pages 6308-6320,
ISSN 2238-7854,
Abstract: Fe-B alloys have attracted much attention as a new kind of wear-resistant and corrosion-
resistant materials. It is interesting that the boride morphology of Fe-B alloys determines their
superior wear resistant or corrosion resistant property. The review of Fe-B alloys’ research and
development status claims more attention to controlling boride morphology that is net-like, broken
and oriented to design wear resistant or corrosion resistant alloy. Besides, this review focuses on the
relationship between boride morphology and wear/corrosion resistant properties and mechanisms.
Keywords: Fe-B alloys; Wear resistance; Corrosion resistance; Boride
Hanxue Cao, Mengtao Huang, Chengcheng Wang, Siyuan Long, Jili Zha, Guoqiang You,
Research status and prospects of melt refining and purification technology of magnesium alloys,
Volume 7, Issue 3,
2019,
Pages 370-380,
ISSN 2213-9567,
Abstract: Refining and purification is a significant way to obtain pure and high-quality magnesium
alloy melts. This paper summarizes the flux refining methods and non-flux purification methods
(blowing purification, filtration purification, electromagnetic purification and ultrasonic purification).
It also introduces the composite refining technologies that have been widely researched and applied
in recent years, including low-voltage pulse electromagnetic technology, ultrasonic argon
purification, self-purification technology and non-flux continuous purification technology. Among
them, the non-flux continuous purification technology integrates a variety of purification methods,
which can produce high-quality magnesium alloy continuously and steadily, realize environmental
protection production, and achieve remarkable technical and economic benefits.
Keywords: Magnesium alloy; Purification method; Inclusions; Mechanical properties
M.E. Toxopeus, W. Haanstra, M.R. van Gerrevink, R. van der Meide,
A Case Study on Industrial Collaboration to Close Material Loops for a Domestic Boiler,
Procedia CIRP,
Volume 61,
2017,
Pages 52-57,
ISSN 2212-8271,
Abstract: This paper presents a practical implementation of circular principles in a case study on
domestic boilers. The manufacturer and a recycling company collaborated by performing pilot
studies on closing the aluminium cycle. The case study proved economically viable and not limited by
technical or practical aspects. Additional benefits for both companies have been implemented and
additional insights on the circular economy were observed. The results indicate that this form of
sustainable manufacturing quickly transcends the boundaries of individual companies, which
confirms the necessity of close collaboration with stakeholders in the value chain.
Keywords: circular economy; closed material loop; industrial collaboration; case study; end of life
Dhaval B. Shah, K.M. Patel, Arvind I. Patel, Vishwajit Pariyal, Shashikant J. Joshi,
Experimental investigation on spring-back deformation during autoclave curing of parabolic antenna

reflectors,
Composites Part A: Applied Science and Manufacturing,
Volume 115,
2018,
Pages 134-146,
ISSN 1359-835X,
https://doi.org/10.1016/j.compositesa.2018.09.017.
Abstract: High dimensional fidelity is the primary challenge for the large size carbon fiber reinforced
polymer (CFRP) antenna reflectors used in space applications. Selection of crucial process
parameters governs dimensional control of a composite product. In this paper, the influence of the
mould materials, curing cycle, lay-up sequence and laminate thickness on spring-back deformation
during autoclave curing is investigated by fabricating a large number of parabolic reflectors using the
unidirectional prepreg system. The non-contact type accurate 3D scanning technique is used to
measure the dimensions of the parabolic antenna reflectors. In the present work, an experimental
approach is adopted for the determination of a combination of process parameters which gives
minimum spring-back deformation. The results reveal that the spring-back deformation of parabolic
reflectors is significantly affected by the mould material and laminate thickness, whereas the lay-up
sequence and curing cycle do not have a significant effect.
Keywords: A. Polymer-matrix composites; E. Prepreg; E. Autoclave curing; Spring-back deformation
L. Lattanzi, A. Fabrizi, A. Fortini, M. Merlin, G. Timelli,
Effects of microstructure and casting defects on the fatigue behavior of the high-pressure die-cast
AlSi9Cu3(Fe) alloy,
Volume 7,
2017,
Pages 505-512,
ISSN 2452-3216,
Abstract: High-pressure die-cast (HPDC) components are being increasingly used due to good
flexibility and high productivity. These aspects make HPDC suitable to produce several mass
components, especially for the automotive sector. Due to the rapid filling of the die and high cooling
rate, the process generally leads to the formation of a wide variety of defects, such as porosity and
oxide films. Such defects might act as starting points for fatigue cracks and thus deteriorating the
fatigue behavior of the casting. To this respect, the fatigue behavior of die cast aluminum alloys is an
important aspect to consider when assessing the performance of complex castings for automotive
applications. In the light of these aspects, the goal of this work is to describe how the microstructure
affects the fatigue crack initiation and propagation. Die cast AlSi9Cu3(Fe) specimens were produced
by means of a specifically designed die and the microstructure was preliminary characterized.
Uniaxial fatigue tests were performed at load control with a stress ratio of R = 0.1 and at a single
level of stress amplitude. After the fatigue tests, the samples were investigated to assess the
propagation of the fatigue cracks; the starting points of cracks were specifically identified and the
obtained data suggested how defects strongly influence the damage mechanism of the material.
Keywords: die cast aluminum alloy; casting defects; microstructure

Denisa Závodská, Eva Tillová, Mario Guagliano, Mária Chalupová, Lenka Kuchariková,
Effects of Porosity on the Fatigue Behaviour of AlZn10Si8Mg Casting Alloys in a High Cycle Region,
Procedia Engineering,
Volume 192,
2017,
Pages 988-993,
ISSN 1877-7058,
https://doi.org/10.1016/j.proeng.2017.06.170.
Abstract: The fatigue behaviour of AlZn10Si8Mg cast alloy used in an automotive industry and
consequently effect of porosity was investigated for present study. The study was exploring for a
lifetimes as long as 106 cycles using rotating bending fatigue device operating at 30Hz, at a room
temperature 20±5 °C. The tested specimen's fracture surfaces and fracture profiles were observed
with the use of a scanning electron microscope (SEM) and optical microscope to determine the
fatigue crack initiation sites and porosity. A correlation was made between the sample fatigue life
and the distribution of the pores and Fe-rich needle-like phases which initiated the fatigue crack. It
was shown that fatigue life decreases as the surface pore size increases and that the crack initiation
site contains multiple pores or consists of a spongy structure. Main factor for decreasing the fatigue
life are these castings defects since 90% of the samples examined tended to fracture as a result of
the casting defects.
Keywords: AlZn10Si8Mg cast aluminium alloy; fatigue behaviour; surface porosity
Mingshan Zhang, Junsheng Wang, Jiaqiang Han, Huaiming Sui, Houbing Huang, Ke Jin, Feng Qian,
Optimization of heat treatment process of Al–Mg–Si cast alloys with Zn additions by simulation and
experimental investigations,
Calphad,
Volume 67,
2019,
101684,
ISSN 0364-5916,
https://doi.org/10.1016/j.calphad.2019.101684.
Abstract: With increasing demands of the high strength and light weight suspension components
from automotive industry, aluminum alloys with higher strength than traditional alloys must be
developed. In order to meet this requirement for cast Al alloys, higher solute concentration than
traditional A356 alloys is needed to enhance the solute and later precipitation strengthening effects.
Considering Zn as one of the alloying elements with high solubility in Al, we investigate the effects of
Zn addition and related heat treatment parameters on the mechanical properties of Al–Si–Mg alloys
by using a combination of experimental and thermodynamic methods. With the addition of Zn, the
yield strength (YS) and ultimate tensile strength (UTS) of Al–Si–Mg alloys are significantly improved
by up to 52.2% and 8.5% compared with those without Zn additions. After a proper heat treatment,
the YS and UTS of Al–Si–Mg–Zn alloys can be further increased by up to 35% and 28%, respectively,
compared to the as-cast state. Based on the study, optimal heat treatment parameters for Al–Si–Mg
alloys with different Zn contents are proposed.
Keywords: Al-Mg-Si-Zn; Thermodynamics; Solidification path; Solution heat treatment; Age

hardening
Ramesh Singh,
2 - Codes, specifications, and standards,
Editor(s): Ramesh Singh,
Applied Welding Engineering (Third Edition),
2020,
Pages 385-402,
ISBN 9780128213483,
https://doi.org/10.1016/B978-0-12-821348-3.00034-3.
Abstract: This chapter lists various agencies and regulatory bodies that develop and issue
specifications and codes for various fabrication, construction, maintenance, and inspection of
equipment and structures. The chapter has included a list of some specifications issued by these
bodies as an example.
Keywords: ASME; Power boilers; Pressure vessels; Piping; Materials; American Petroleum Institute;
DNV; CSA; International Standards Organization
Vincent Debut, Miguel Carvalho, Elin Figueiredo, José Antunes, Rui Silva,
The sound of bronze: Virtual resurrection of a broken medieval bell,
Journal of Cultural Heritage,
Volume 19,
2016,
Pages 544-554,
ISSN 1296-2074,
https://doi.org/10.1016/j.culher.2015.09.007.
Abstract: The bell from the church of S. Pedro de Coruche is one rare surviving example of early
bells, cast during the 13th century in Europe, which was exhumed from a crypt-ossuary in an
archaeological excavation carried out near Lisbon in Portugal. Of particular significance, it is believed
to belong to a time period during which bell's profile has evolved noticeably, leading to bells with
fine musical qualities and a well-defined sense of pitch. If the bell from Coruche was a tangible piece
of evidence for tracing the history of bell casting in Europe, it had however lost all trace of its original
sound: indeed the bell was found broken and incomplete and even if it has undergone a restoration
process since the archaeological discovery, the use of an adhesive during the reassembly has
changed somehow the vibrational properties of the bell structure. To bring back to life the sound of
this broken musical artefact, a methodology combining experimental and numerical techniques from
materials science and music acoustics is described in this paper. The general approach comprises
material characterisation, geometrical measurements, modal analysis and physics-based sound
synthesis techniques. By coupling a physical dynamical model of a bell impacted by a clapper with
the modal properties of the original bell computed by Finite Element Analysis, realistic time-domain
simulations of the Coruche bell dynamics were performed and realistic synthetic sounds were
produced. As the original clapper has not survived, parametric computations have been performed
to illustrate the changes in bell sounds associated with clappers of different mechanical properties.
The overall approach provides insight into the tuning of this medieval bell which can be compared to
the modern-type tuning, and reproduce the sound that the bell from Coruche might have had. The
strategy developed can be easily adapted to other musical instruments in poor/variable states of
preservation, therefore benefiting the importance of such non-renewable cultural resources.
Keywords: Medieval bell; Virtual restoration; Bronze alloy; Young modulus; Physical-based
modelling; Sound synthesis
Jingyu Han, Juan Chen, Liming Peng, Feiyan Zheng, Wei Rong, Yujuan Wu, Wenjiang Ding,
Influence of processing parameters on thermal field in Mg–Nd–Zn–Zr alloy during friction stir
processing,
Materials & Design,
Volume 94,
2016,
Pages 186-194,
ISSN 0264-1275,
Abstract: As-cast Mg–Nd–Zn–Zr (NZK) plates were subjected to friction stir processing (FSP) at a
variety of tool rotation rates as well as traverse speeds, while the plunge depth remained constant.
Thermocouples were placed systematically within each sheet to obtain the thermal history and
temperature distribution during friction stir processing of NZK alloy. The relationship among
processing parameters, heat input, microstructure and resulting mechanical properties were
investigated to get a better understanding of the microstructure evolution during friction stir
processing of NZK alloys. Cross sectional thermal distribution contour was built based on
experimental data. The thermal field was then used to describe the effect of revolutionary pitch on
materials flow (mainly focusing on onion rings), texture evolution, and grain structures. The results
suggest that the center of onion rings generally locates in the intersection between the processing
centerline and the 520°C peak temperature isothermal line. Transition zone of texture exists
between the shoulder driven zone and pin driven zone. The samples can be divided into two groups
according to the way the grain structure varies with revolutionary pitch. In addition, the detected
mechanical properties also demonstrate the effect of different pitches.
Keywords: Friction stir processing; Mg–Nd–Zn–Zr alloy; Revolutionary pitch; Thermal field; Texture
Dominik Rietzel, Martin Friedrich, Tim A. Osswald,
7 - Additive Manufacturing,
Editor(s): Tim A. Osswald,
Understanding Polymer Processing (Second Edition),
Hanser,
2017,
Pages 147-169,
ISBN 9781569906477,
https://doi.org/10.3139/9781569906484.007.
M. Jayanthi, S. Thirumurthy, M. Muralidhar, P. Ravichandran,
Impact of shrimp aquaculture development on important ecosystems in India,
Global Environmental Change,
Volume 52,
2018,
Pages 10-21,
ISSN 0959-3780,
https://doi.org/10.1016/j.gloenvcha.2018.05.005.
Abstract: The rapid growth of aquaculture has raised the environmental concern about the
conversion of ecologically important areas such as mangroves and agricultural lands. The study
explored the impact of shrimp aquaculture on land use change in India’s coastal wetlands using
Landsat satellite data, geographical information system techniques and field verification. From 1988
to 2013, the area under aquaculture has grown by 879 %, which brought the tremendous changes in
the coastal land use pattern. Mangrove and agriculture lands have been used for 5.04 % and 28.10 %
of the aquaculture growth. Mudflats, scrublands, saltpan, and waterbodies have contributed to
51.65 %, 1.76 %, 1.73 % and 2.37 % of the aquaculture area expansion respectively. Mangrove areas
have undergone severe changes due to gain and loss at different places. Environmental factors
influenced the changes in mangroves, and the overall extent of mangrove has increased by 13.44 %.
Construction activities and aquaculture have reduced the agricultural land by 3.52 % and 0.53 %
respectively. The variation between the actual area under shrimp aquaculture and the Coastal
Aquaculture Authority approved area indicate that the larger extent of shrimp farm operates
without approval. Implementation of an intensive monitoring program for strict adherence to
coastal aquaculture regulation laws will be helpful for the sustainability of coastal resources as well
as aquaculture.
Keywords: Aquaculture development; agriculture; mangroves; land use conversion; India; remote
sensing
P.A. McQuay, V.K. Sikka, Y.E. Khalfalla, K.Y. Benyounis,
Casting of Intermetallics,
Elsevier,
2016,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.03554-2.
Abstract: Despite of the significant effort has been dedicated to featuring the properties of elevated
temperature intermetallics, melting, and casting techniques for such materials have been slightly
developed. A mixture of methods may be applicable for the melt processing of intermetallics,
however, assigning the process will be according to various considerations associated to
solidification microstructure, sort of alloys, and melt cleanliness. In this review article, casting of
three different alloys (near-gamma titanium aluminide and two types of nickel aluminide) is
investigated. Advanced casting technologies are applied such as melt and casting technology, cast
microstructure, production readiness, exo-melt process, equiax casting, and DS casting technology.
Keywords: Casting; DS casting; Equiax casting; Exo-melt process; Intermetallic; Melting;

Microstructure
J.P. Shingledecker,
20 - The US DOE/OCDO A-USC materials technology R&D program,

2017,
Pages 689-713,
ISBN 9780081005521,
https://doi.org/10.1016/B978-0-08-100552-1.00020-8.
Abstract: A 14-year US Department of Energy (DOE) and Ohio Coal Development Office (OCDO)
program to develop the materials technology to build and operate an advanced ultra-supercritical
(A-USC) boiler and turbine with steam conditions up to 760°C (1400°F) and 35MPa (5000psi) has
been completed. This chapter addresses the research completed by this unique cost-sharing US
consortium of manufacturers and research organizations. The US DOE/OCDO A-USC Consortium has
had many successes, including demonstration of welding and fabrication of nickel-based alloys for an
A-USC plant, extensive successful fireside corrosion testing including in-plant operation of the
world's first 760°C (1400°F) steam-cooled corrosion test loop, development of casting techniques for
high-alloy age-hardenable alloys, new materials for rotor forgings, and code acceptance of Inconel
740H, which gives manufacturers, for the first time, an alloy with the requisite strength for a 760°C
(1400°F) plant. The chapter discusses the materials selection, research completed, and a view
toward the future for A-USC including a short discussion on advanced power cycles and the
development of a US component test facility (ComTest).
Keywords: Advanced materials; Boilers; Creep; Fireside corrosion; Oxidation; Steam turbines
Zailiang Jiang, Zitian Fan, Wenming Jiang, Guangyu Li, Yao Wu, Feng Guan, Haixiao Jiang,
Interfacial microstructures and mechanical properties of Mg/Al bimetal produced by a novel liquid-
liquid compound casting process,
Volume 261,
2018,
Pages 149-158,
ISSN 0924-0136,
Abstract: In the present work, a novel method was proposed to produce Mg/Al bimetal using the
lost foam casting (LFC) liquid-liquid compound process with a Zn interlayer, and the interfacial
microstructures and mechanical properties of the Mg/Al bimetal were investigated for the first time.
Obtained results reveal that a compact metallurgical interface was formed between the AZ91D
magnesium alloy substrate and the A356 aluminum alloy substrate. The metallurgical interface
included two reaction layers. The reaction layer adjacent to the AZ91D substrate was composed of
α-Mg, Al5Mg11Zn4 and MgZn phases, and the reaction layer adjacent to the A356 substrate
consisted of α-Al, Mg32(Al, Zn)49 and Mg2Si phases. The addition of the Zn interlayer not only
prevented different liquid metals from directly mixing, but also restrained the formation of Mg-Al
intermetallics. The microhardnesses of the reaction layers were much higher than those of the
substrates, and the reaction layer close to the A356 substrate had the highest microhardness. The
shear strength of the Mg/Al bimetal was about 10.91 MPa, and the fracture surface of the Mg/Al
bimetal exhibited a brittle fracture nature.
Keywords: Magnesium alloys; Aluminum alloys; Bimetal; Compound casting; Microstructures;

Guangyu Yang, Shifeng Luo, Shaojun Liu, Lei Xiao, Wanqi Jie,
Microstructural evolution, phase constitution and mechanical properties of directionally solidified

Mg-5.5Zn-xGd (x = 0.8, 2.0, and 4.0) alloys,
Volume 725,
2017,
Pages 145-154,
ISSN 0925-8388,
Abstract: The microstructural evolution, phase constitution and mechanical properties of

directionally solidified Mg-5.5Zn-xGd (x = 0.8, 2.0, and 4.0) alloys were firstly investigated under
G = 30 K/mm at a wide range of V (10 μm/s - 100 μm/s). It was confirmed that there existed
α(Mg) + I(Mg3Zn6Gd) in Mg-5.5Zn-0.8Gd alloy, and α(Mg) + I(Mg3Zn6Gd) + W(Mg3Zn3Gd2) in Mg-
5.5Zn-(2.0, 4.0)Gd alloys, respectively. The criterion growth rate for cellular-columnar dendrite
transition (CDT) for Mg-5.5Zn-xGd alloys decreased with the increase of Gd content. The
relationships between the microstructural parameters (λ1, λ2) and V for Mg-5.5Zn-xGd alloys were
established using a linear regression analysis. The values of λ1 and λ2 decreased exponentially with
the increase of V and the exponent values were found to be close to the theory values of 1/4 and
1/3, respectively. The tensile test showed that the room temperature ultimate tensile strength (UTS)
increased and the elongation decreased with the increase of the growth rate for a certain
composition of Mg-5.5Zn-xGd alloy. For a certain growth rate, UTS first increased from 0 wt % to
2.0 wt % of Gd content, and then decreased with the further increase of Gd content. The
directionally solidified Mg-5.5Zn-2.0Gd experimental alloy showed the maximum ultimate tensile
strength.
Keywords: Mg-5.5Zn-xGd alloys; Directional solidification; Microstructures; Microstructural

parameters; Mechanical properties
Corson L. Cramer, Peeyush Nandwana, Richard A. Lowden, Amy M. Elliott,
Infiltration studies of additive manufacture of WC with Co using binder jetting and pressureless melt
method,
Volume 28,
2019,
Pages 333-343,
ISSN 2214-8604,
Abstract: Additive manufacturing (AM) of tungsten carbide-cobalt (WC-Co) is explored starting with
WC preforms shaped with binder jet additive manufacturing (BJAM) followed by melt infiltration of
Co. The research objective is to demonstrate the ability to net-shape WC-Co composites through
BJAM of a WC preform followed by backfilling with cobalt via pressureless infiltration. This method
also has the potential to minimize shrinkage and grain growth compared to other AM techniques.
The effects of sintering, Co content, and infiltration time on the net shaping and properties of
processed composites are shown. The best shaped material had an average grain size of 5.1 μm, 32
vol.% Co, density of 98.54% theoretical, fracture toughness of 23.2 MPa m1/2, and hardness of 9.0
GPa. Data presented illustrates that the proposed approach results in favorable ceramic-metal
(cermet) properties and is viable for fabricating cermets of other material combinations. Successful
AM of cermets provides complex geometries, high throughout, and low costs.
Keywords: Binder jet additive manufacturing; Cermet composite; Pressureless melt infiltration
Adnan Mehmood, Masood Shah, Nadeem Ahmed Sheikh, Junaid Ahmad Qayyum, Shahab
Khushnood,
Grain refinement of ASTM A356 aluminum alloy using sloping plate process through gravity die
casting,
Alexandria Engineering Journal,
Volume 55, Issue 3,
2016,
Pages 2431-2438,
ISSN 1110-0168,
https://doi.org/10.1016/j.aej.2016.03.016.
Abstract: Sloping plate flow is used for enhancement of material properties through grain
refinement in gravity die casting of Aluminum alloy ASTM A356. The castings are prepared with
different slope angles of an 800mm long, naturally cooled stainless steel plate. The specimens
obtained are then tested for tensile strength and elongation. Microstructure of the cast specimens is
observed and conclusions drawn on the grain size and precipitate morphology as a function of angle
of sloping plate. Analysis is presented for the boundary layer created while the material flows over
the plate. An indication of the boundary layer thickness is determined by measuring the thickness of
the residual metal layer on the plate after casting. An analytical solution of the boundary layer
thickness is also presented. It is shown that the calculated boundary layer thickness and the
thickness of the layer of material left in the channel after casting are in good agreement. Moreover,
microstructure examination and tensile tests show that best properties are achieved with a 60°
sloping plate.
Keywords: Grain refinement; Sloping plate; Nucleation; Thermal boundary layer; Viscous boundary
layer
K.S. Boparai, R. Singh,
Advances in Fused Deposition Modeling,
Elsevier,
2017,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.04166-7.
Abstract: Fused deposition modeling (FDM) is one of the most commonly used additive
manufacturing techniques. A number of advancements have been made recently for improving the
capabilities of the FDM process. These advancements are primarily focused on the development of
FDM feedstock filament, process parametric optimization, and process hybridization. This article
highlights some of the advances in the FDM process and the role of various advanced postprocessing
techniques in surface finishing of FDM prints.
Keywords: Fused deposition modeling; Process optimization; Surface finish
Bin Zhang, Changlin Yang, Dongchen Zhao, Yunxia Sun, Xiaobo Wang, Feng Liu,
Microstructure characteristics and enhanced tensile properties of in-situ AlN/ AZ91 composites
prepared by liquid nitriding method,
Volume 725,
2018,
Pages 207-214,
ISSN 0921-5093,
Abstract: Nano-, submicron- and micron-sized AlN particles were in situ synthesized in AZ91 matrix
alloy by liquid nitriding method. According to thermodynamics calculation and experimental results,
the nitriding reactions of AlN particle formation were stably completed in the matrix AZ91 alloy melt.
And in situ formed AlN particles with the granular and rod-like shapes were uniformly distributed in
the matrix. Thus, the grain sizes of α-Mg were significantly refined, the amount and sizes of β-
Mg17Al12 phases were decreased, and a lot of dislocations trapping and the precipitation of γ-
Mg17Al12 phase were induced in the AZ91 matrix alloy. As results, higher ultimate tensile strength
(240 ± 10 MPa) and higher fracture elongation (20 ± 3%) were simultaneously improved for
AlN/AZ91 permanent mold casting composites.
Keywords: Particle-reinforcement; Metal-matrix composites (MMCs); Microstructures; Mechanical

Properties
Joaquin Montero, Pablo Vitale, Sebastian Weber, Matthias Bleckmann, Kristin Paetzold,
Indirect Additive Manufacturing of resin components using polyvinyl alcohol sacrificial moulds,
Procedia CIRP,
Volume 91,
2020,
Pages 388-395,
ISSN 2212-8271,
Abstract: Using additive manufacturing (AM) as aid to manufacture parts with traditional
manufacturing methods is one of the many applications of AM, yet one of the less investigated. In
this article, for the first time, a way to produce soluble AM customizable sacrificial moulds for resin
casting is explained. The moulds are produced through fused filament fabrication using polyvinyl
alcohol (PVA) as raw material. After curing, the moulds are dissolved in water leaving the solid resin
parts away. The results of indirect additively manufactured resin components in PVA moulds are
examined, supported by surface and dimension analysis on prism-like sample parts for different sets
of process parameters. Possible applications and limitations of the technique are exposed, as well as
recommendations for future works.
Keywords: Indirect Additive Manufacturing; Epoxy Resin; Fused Filament Fabrication
Shilan Meimandi, Nicolas Vanderesse, Denis Thibault, Philippe Bocher, Martin Viens,
Macro-defects characterization in cast CA-6NM martensitic stainless steel,

Volume 124,
2017,
Pages 31-39,
ISSN 1044-5803,
https://doi.org/10.1016/j.matchar.2016.11.040.
Abstract: Cast low carbon CA-6NM (13%Cr-4%Ni) martensitic stainless steel has been used for
hydraulic turbine runners manufacturing since the 60's owing to its high strength, toughness,
corrosion, and cavitation-erosion resistance. These castings contain several types of defects which
may have detrimental effects on the performance of the produced parts. Several aspects of the
casting defects in these steels have not been specifically studied in detail. It is common in industry to
evaluate the integrity of cast components by nondestructive testing such as X-ray radiography
before putting them in operation. However, tortuous and complex geometry of macro-shrinkage
porosities makes them difficult to be characterized precisely only by 2D radiographic results. In the
present study, the relation between radiography mapping and actual macro-defect morphologies
has been studied by the “salami” cross sectioning method in order to document the real shape and
morphology of defects. Furthermore, metallographic characterization of cast microstructure in CA-
6NM stainless steels has also been performed using several techniques to document both chemical
composition and microstructure around macro-defects. Briefly stated, the main purpose of the
investigation described herein is to study several severity levels of macro-defects in cast martensitic
stainless steels and investigate some characteristics of real defects which can impact on the fatigue
properties of cast parts at microstructural level.
Keywords: Hydraulic-turbine; Macro-shrinkage porosity; Cast martensitic stainless steel;

Characterization; Shape analysis
Bruna Moreira Freire, Camila Neves Lange, Tatiana Pedron, Lucilena Rebelo Monteiro, Livia Rentas
Sanches, Walter dos Reis Pedreira-Filho, Bruno Lemos Batista,
Occupational exposure of foundry workers assessed by the urinary concentrations of 18 elements

and arsenic species,
Journal of Trace Elements in Medicine and Biology,
Volume 62,
2020,
126593,
ISSN 0946-672X,
https://doi.org/10.1016/j.jtemb.2020.126593.
Abstract: Background
Some raw materials applied in Fe foundry industries may contain potentially toxic elements. Thus,
foundry worker’s occupational exposure is a constant health concern.
Method
In this study, 194 urine samples from foundry workers were analyzed by inductively coupled plasma
mass spectrometry for biomonitoring of Al, As, Ba, Cd, Co, Cr, Cs, Cu, Fe, I, Mn, Ni, Pb, Sb, Sn, Se, U
and Zn. Moreover, arsenic speciation was performed in representative samples of production sector
workers (group A) and administration sector workers (group B).
Results
Concentrations of As, Pb, Cd, Cu, Cs, I, Sb in urines from group A were higher than those found for
group B. Samples of group A presented Cs, Ni, Mn, Pb, U and Zn concentrations higher than values
reported for exposed workers assessed by other studies. Forty-four samples from group A exceed
As-reference limits. Group A had approximately seven times more inorganic As (as arsenite) and 14
times more organic As (as dimethyl As) than group B. A statistically significant difference was
observed in the elemental concentration in the workers' urine by the time in the function.
Moreover, alcohol consumption is probably influencing the urine concentration of As, Ba, Cd, Co, Cu,
Fe, I, Se and Zn.
Conclusion
The monitored foundry workers are exposed to potentially toxic elements and more attention must
be given to their health. Therefore, workplace safety conditions must be improved, and constant
biomonitoring is necessary to ensure workers' health.
Keywords: Biomonitoring; HPLC-ICP-MS; Arsenic speciation; Toxicological risk; Iron casting
Index,
2018,
Pages 553-562,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.09993-8.
Dirk Biermann, Tobias Bleckmann, Sebastian Schumann, Ivan Iovkov,

Advanced Simulation-based Design of High Performance Machining Processes,
Procedia CIRP,
Volume 46,
2016,
Pages 165-168,
ISSN 2212-8271,
Abstract: The development of high performance machining processes is a key aspect to achieve
higher productivity, efficiency and performance in modern production systems. In order to reduce
the corresponding effort and costs, simulation systems are one possibility to support the design and
the optimization of manufacturing processes. In this article, three different application examples
with respect to milling, grinding and deep-hole drilling operations are presented. In this context,
both finite-element and geometric-kinematic simulation approaches are applied to model the
different challenging issues of the corresponding machining process.
Keywords: High Performance Cutting; Simulation; Milling; Chatter; Deep hole drilling; Thermal error;
Straightness; Distortion correction; Grinding; Temperature; Thermal effects
Joakim Haraldsson, Maria T. Johansson,
Review of measures for improved energy efficiency in production-related processes in the

aluminium industry – From electrolysis to recycling,
Renewable and Sustainable Energy Reviews,
Volume 93,
2018,
Pages 525-548,
ISSN 1364-0321,
https://doi.org/10.1016/j.rser.2018.05.043.
Abstract: The aluminium industry is facing a challenge in meeting the goal of halved greenhouse gas
emissions by 2050, while the demand for aluminium is estimated to increase 2–3 times by the same
year. Energy efficiency will play an important part in achieving the goal. The paper's aim was to
investigate possible production-related energy efficiency measures in the aluminium industry.
Mining of bauxite and production of alumina from bauxite are not included in the study. In total, 52
measures were identified through a literature review. Electrolysis in primary aluminium production,
recycling and general measures constituted the majority of the 52 measures. This can be explained
by the high energy intensity of electrolysis, the relatively wide applicability of the general measures
and the fact that all aluminium passes through either electrolysis or recycling. Electrolysis shows a
higher number of emerging/novel measures compared to the other processes, which can also be
explained by its high energy intensity. Processing aluminium with extrusion, rolling, casting (shape-
casting and casting of ingots, slabs and billets), heat treatment and anodising will also benefit from
energy efficiency. However, these processes showed relatively fewer measures, which might be
explained by the fact that to some extent, these processes are not as energy demanding compared,
for example, to electrolysis. In many cases, the presented measures can be combined, which implies
that the best practice should be to combine the measures. There may also be a future prospect of
achieving carbon-neutral and coal-independent electrolysis. Secondary aluminium production will be
increasingly important for meeting the increasing demand for aluminium with respect to
environmental and economic concerns and strengthened competitiveness. Focusing on increased
production capacity, recovery yields and energy efficiency in secondary production will be pivotal.
Further research and development will be required for those measures designated as novel or
emerging.
Keywords: Aluminium industry; Aluminium production; Energy efficiency; Electrolysis; Recycling;

Efficiency measures
Jia-hua LIN, Hai-dong ZHAO, Jia-min HUANG,
Spatial interfacial heat transfer and surface characteristics during gravity casting of A356 alloy,
Volume 29, Issue 1,
2019,
Pages 43-50,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(18)64913-1.
Abstract: As one of the key boundary conditions during casting solidification process, the interfacial
heat transfer coefficient (IHTC) affects the temperature variation and distribution. Based on the
improved nonlinear estimation method (NEM), thermal measurements near both bottom and lateral
metal-mold interfaces throughout A356 gravity casting process were carried out and applied to
solving the inverse heat conduction problem (IHCP). Finite element method (FEM) is employed for
modeling transient thermal fields implementing a developed NEM interface program to quantify
transient IHTCs. It is found that IHTCs at the lateral interface become stable after the volumetric
shrinkage of casting while those of the bottom interface reach the steady period once a surface layer
has solidified. The stable value of bottom IHTCs is 750 W/(m2·°C), which is approximately 3 times
that at the lateral interface. Further analysis of the interplay between spatial IHTCs and observed
surface morphology reveals that spatial heat transfer across casting-mold interfaces is the direct
result of different interface evolution during solidification process.
Keywords: A356 alloy; solidification; interfacial heat transfer coefficient; inverse heat conduction
problem; surface characteristics
Lenka Kuchariková, Eva Tillová, Mária Chalupová,
The Si Particles Morphology in Hypoeutectic Al-Si Casts,
Volume 3, Issue 4,
2016,
Pages 1031-1036,
ISSN 2214-7853,
Abstract: The article deals with the Si particles morphology study of casts from hypoeutectic
aluminium alloys. The morphology, distribution and volume of Si particles in α-matrix influence
mechanical properties of casts. It is known that the wear resistance of AlSi surface is affected with
the hardness of the primary Si particles, too. Long and brittle Si particles have negative effect on
mechanical properties, but small, spherical and evenly distributed particles positive. The Si particles
in as cast state were observed in negative morphology and so the heat treatment and modification
were used for affecting the morphology of Si particles in hypoeutectic casts. The study shows that
the best morphology of Si particles was when hypoeutectic casts were heat treated.
Keywords: Si morphology; aluminium casts alloy; modification; heat treatment
H. Bakraouy, S. Souabi, K. Digua, O. Dkhissi, M. Sabar, M. Fadil,
Optimization of the treatment of an anaerobic pretreated landfill leachate by a coagulation–

flocculation process using experimental design methodology,
Process Safety and Environmental Protection,
Volume 109,
2017,
Pages 621-630,
ISSN 0957-5820,
https://doi.org/10.1016/j.psep.2017.04.017.
Abstract: Nowadays, landfill leachates are one of the most critical environmental issues faced by
countries around the world. They result from the percolation of rain water through layers of solid
waste, to which is added water from biochemical processes in waste’s cells and water that comes
from wastes themselves. They are therefore highly charged with organic and mineral matter, which
requires treatment before discharge to the receiving environment. In recent years, many techniques
have been developed for leachate treatment. In this study, landfill leachate selected comes from
Rabat city’s landfill. Landfill leachate is treated by anaerobic combined with coagulation flocculation
(CF) process, using ferric chloride as coagulant and a cationic polymer as flocculant. The leachate is
characterized by high COD and BOD5. The BOD5/COD ratio is equal to 0.58±0.01, revealing that it is
a young leachate with a very important biodegradability. The leachate was also loaded with phenolic
compounds whose concentration reached 341.6±21.3mg/L. The optimization of the doses of
coagulant and flocculant was performed using factorial design of experiments. Optimal dosages
obtained were: 4.4g/L of coagulant and 9.9mL/L of flocculant. Removal efficiencies reached: 89±6,
69±4.8, 94±1.3, 80±8.7 and 89±1.2% for phenol, turbidity, color, COD and absorbance at 254nm (Abs
254nm) respectively.
Keywords: Landfill leachate; Anaerobic pretreated; Coagulation flocculation; Factorial design of

experiments; Optimization; Dosages
Seungmun Jung, Seok Su Sohn, Yong Hee Jo, Won-Mi Choi, Byeong-Joo Lee, Yong-Jun Oh, Gi-Yong
Kim, Seongsik Jang, Sunghak Lee,
Effects of Cr and Nb addition on high-temperature tensile properties in austenitic cast steels used for
turbo-charger application,
Volume 677,
2016,
Pages 316-324,
ISSN 0921-5093,
Abstract: In automotive turbo-chargers, excellent high-temperature properties are needed for

retaining their structures at extremely high temperature of exhausted gas, and thus austenitic cast
steels have been actively developed. In this study, high-temperature tensile properties of austenitic
cast steels containing different W, Nb, and Cr were interpreted by deformation and fracture
mechanisms related with carbides and austenite matrix. Replacement effects of W by Nb or Cr were
also investigated because of expensive alloying cost of W. The high-temperature tensile test results
revealed that the Cr-added steel containing many M7C3 carbides showed the higher strength than
the Nb-added steel containing hard MC carbides. This was because the strength could be enhanced
by distributing carbides having slightly lower hardness such as M7C3 carbides in the strengthened
matrix as it could hold hard carbides, like in the Cr-added steel. The Cr-added steel (1wt% W) also
showed the higher strength and elongation at 900 °C than the basic-composition steel (2wt% W),
which indicated that the partly replacement of W by Cr was successfully achieved.
Keywords: Austenitic cast steel; Turbo-charger; Replacement of W by Nb or Cr; MC and M7C3

carbides
Sunpreet Singh, Rupinder Singh,
Investment Casting (Disposable Mold),

Elsevier,
2017,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.10518-1.
Abstract: In this article, various research possibilities to improve the investment cast mold’s
characteristics have been outlined for field applications. The reported literature highlights that
various input parameters like ingredients of the molding sand, dry strength, collapsibility, cavity
precision, surface finish, and heat transfer rate are some of the significant parameters for controlling
the mechanical/metallurgical properties of final cast component. The inclusion of organic and
inorganic fibers can further enhance the strength and dimensional stability along with reduction in
the cost and time associated with the fabrication. Furthermore, with the invention of additive
manufacturing technologies it is now possible to create a customized cavity directly from the
computer-aided design file, through a series of established process especially for batch production
activities.
Keywords: Additive manufacturing; CAD; Dimensional stability; Foundry; Heat transfer; Investment
casting; Organic fibers; Strength; Wax; 3D printed mold
S.-L. Zhang, X.-X. Shi, Y.-T. Zhao, B.-R. Zhang, Z.-P. Liang, H.-S. Yin, B.-Y. Dou, Q. Zhang, C.-X. Wang,
Preparation, microstructures and mechanical properties of in-situ (TiB2 + ZrB2)/AlSi9Cu3

composites,
Volume 673,
2016,
Pages 349-357,
ISSN 0925-8388,
Abstract: In this paper, the preparation, microstructures and mechanical properties of in-situ
(TiB2 + ZrB2)/AlSi9Cu3 composites are investigated by X-Ray diffraction (XRD), optical microscope
(OM), scanning electronic microscopy (SEM), energy dispersive spectrometer (EDS), transmission
electron microscope (TEM) and tensile testing. The composites are fabricated from Al–K2TiF6–
K2ZrF6–KBF4 system via melt in-situ reaction technology. The results reveal that the morphology of
TiB2 and ZrB2 particles is presented in rectangular and nearly hexagonal, and the size of 20–100 nm
in the synthesized composites. In addition, the particles are agglomerated as many of “Reinforced
Group”, which are distributed along the crystal boundary of the matrix. The silicon phase and
secondary dendrite arm spacing of AlSi9Cu3 alloy are obviously changed by the introduction of in-
situ particles. The morphology of the silicon phase is presented in rod-shape or needle-shape with
the size of about 3–10 μm. The particles affect the formation of dendrites and the size of the
secondary dendrite arm spacing is 9.8–20 μm, while it seems to not affect the morphology of the
CuAl2 phase. Tensile testing results show that the tensile strength and elongation clearly increase
with the introduction of in-situ particles. Moreover, the tensile strength and elongation reach
265 MPa and 14.8% respectively, with the best reaction time (30 min) and mass fraction of reactants
(20wt.%). The mechanical stirring also significantly affected the particles dispersion in the
composites.
Keywords: (ZrB2+TiB2) particles; AlSi9Cu3 alloy; In-situ reaction; Microstructure; Tensile properties
T. Dahmen, C.G. Klingaa, S. Baier-Stegmaier, A. Lapina, D.B. Pedersen, J.H. Hattel,
Characterization of channels made by laser powder bed fusion and binder jetting using X-ray CT and
image analysis,
Volume 36,
2020,
101445,
ISSN 2214-8604,
Abstract: Metal additive manufacturing is highly suited to enhance the performance of engineering
applications with sophisticated internal features and passageways. Laser Powder Bed Fusion (LPBF)
is commonly used or considered for fabrication in these applications, although the resulting channels
can show significant form and surface deviations, particularly due to dross-formation at overhang-
areas. Binder Jetting (BJ), another additive manufacturing method that can process metals does not
employ a heat source to fuse powder particles during build-up and therefore has the potential to
overcome these limitations. In this study, additively manufactured circular channels with a nominal
diameter of two millimeters are made by LPBF and BJ in seven different directions and are
extensively analyzed depending on their orientation. The test-artifacts are made by four different
state-of-the-art LPBF and BJ system manufacturers with standard parameters in 17−4PH stainless
steel and with similar layer thicknesses. A novel type of X-ray Computed Tomography (CT) image
analysis method for additively manufactured channels is applied in combination with commercial
image analysis software. Form deviations and surface texture are characterized in accordance with
ISO1101 and ISO 4287:1997. Results show a high level of precision, independently of build direction
for channels made by BJ when compared to LPBF. The accuracy of BJ-channels is strongly dependent
on the appropriate scaling before printing. Parallel to the build direction, LPBF-channels exhibit
superior characteristics. The channels investigated in this work are categorized into ISO tolerance
grades IT13−17 for LPBF and IT13−15 for BJ following ISO268−2. Based on the findings, design
considerations and characteristic attributes of each process to manufacture channels are discussed
within a broader context.
Keywords: Metal additive manufacturing; Cooling channels; X-ray computed tomography; Geometric
dimensioning and tolerancing; Roughness analysis
K. Chandra Mouli, S Arunkumar, B Satwik, S.Bhargava Ram, J. Rushi Tej, A.Sai Chaitanya,
Design of Reversible Plough Attachment,
2018,
Pages 23702-23709,
ISSN 2214-7853,
Abstract: In farming operations, tillage is the primary and energy consuming operation. The purpose
of the tilling the soil is to provide favorable soil conditions by cutting and inverting the soil for
seeding or transplanting. Advanced tillage equipments are available in the market. However, poor
farmers and the one with small farm size cannot afford them, as they are costly to buy and maintain.
This paper briefly reviews the different types of plows used for preparing the land. Three types of
simple reversible plow attachments have been designed. The materials and manufacturing processes
to prepare these plow attachments is also discussed. The tractive and the thrust forces for these
plow attachments are then estimated analytically.
Keywords: Reversible plough; Tillage; Moldboard; Chisel plough; Disc plough; Ridge plough
T.R. Prabhu,
Microstructure and mechanical properties of a thixoforged (semi solid state forged) Al–Cu–Mg alloy,
Archives of Civil and Mechanical Engineering,
Volume 16, Issue 3,
2016,
Pages 335-343,
ISSN 1644-9665,
https://doi.org/10.1016/j.acme.2016.01.003.
Abstract: Al–4.4%Cu–1.4%Mg–0.7%Mn (AA 2024 grade) wrought alloys are forged in a semi solid
state for 30% and 40% reductions at two increasing temperatures (525°C and 535°C). Additionally,
the alloy is forged in the solid state at 450°C for comparison purposes. The hardness and tensile
properties of the forgings were evaluated and compared. The microstructure characterization,
fracture morphology of the tensile failed samples of the forgings was performed with the aid of
optical and scanning electron microscopes (SEM). The key findings of the present investigation are:
(1) the microstructure of the thixoforged alloys shows a significant grain refinement with the grain
size range of 3.5–8.7μm through the recrystallization and partial remelting, thixotropic flow of liquid,
grain boundary sliding, rotation and deformation, (2) the tensile strength, hardness and ductility
properties of the thixoforged alloys are marginally higher than the solid state forged alloys, (3) the
condition of 535°C and 40% reduction is identified as the best thixoforging condition that gives the
average grain size of 3.5μm, and (4) the fractography of the thixoforged alloys shows spherical grain
morphology failed by the ductile rupture mechanism and the fracture mode is intergranular with no
evidences of solidification defects such as micro shrinkage pores and hot tearing.
Keywords: Al alloys; Thixoforging; Microstructure; Fractography; Tensile properties
Index,
Editor(s): Maria Cristina Tanzi, Silvia Farè, Gabriele Candiani,
Foundations of Biomaterials Engineering,
Academic Press,
2019,
Pages 547-561,
ISBN 9780081010341,
https://doi.org/10.1016/B978-0-08-101034-1.09994-1.
A. Basso, I. Toda-Caraballo, D. San-Martín, F.G. Caballero,
Influence of cast part size on macro- and microsegregation patterns in a high carbon high silicon
steel,
Volume 9, Issue 3,
2020,
Pages 3013-3025,
ISSN 2238-7854,
Abstract: In this work, the macro and microsegregation of Cr, Si and Mn have been investigated in a
high-carbon high-silicon cast steel using X-ray fluorescence (XRF) and electron probe microanalysis
(EPMA), respectively. Two different keel block sizes with leg thicknesses of 12.5 and 75 mm have
been compared. In each of the keel blocks, three different locations along the leg thickness have
been analyzed: A) zone near surface (≈1 mm); C) the central zone of the leg thickness and B) an
equidistant zone from A and C. After comparing the analysis performed by XRF in these three zones
no macrosegregation of the Cr, Mn and Si has been observed in any of the two keel blocks. However,
clear microsegregation patterns have been obtained by EPMA for these three elements;
interdendritic zones are enriched while dendrites are impoverished in these elements implying that
their partition coefficient is lower that the unity (k < 1). This coefficient has been estimated using the
EPMA measurements and Thermo-Calc calculations, finding good agreement between both
approaches for Si and Mn but not for Cr. Finally, for both keel block leg thicknesses, similar
microsegregation intensity, measured in terms of alloying element concentration has been
observed. This result suggests that the cast part size (or dimension) do not have a strong influence
on the microsegregation profiles. This it attributed to the back diffusion phenomena involving
redistribution of solute during the solidification process.
Keywords: Macro-microsegregation; High carbon-high silicon steel; Cast size; Electron probe
microanalysis; X-ray fluorescence
Aswin G. Nath, E. Sarath Krishnan, Sachin Cheriyan, P.S. Vishnu, A. Krishnan, Pramod Sreedharan,
Ganesha Udupa,
Design and Manufacture of Miniature Hydraulic Gear Pump for Bio-Medical Application,
2018,
Pages 25570-25580,
ISSN 2214-7853,
Abstract: A miniaturize hydraulic gear pump is used for pressure generation in the fluidic actuators
used in some of the medical and bio-medical devices such as blood pressure monitoring devices,
artificial heart pump and prosthetic hands. A large variety of sizes of hydraulic pumps is
commercially available. Proper design of the pump depends significantly on the application. Various
designs of miniature hydraulic pumps have been developed in the past. In this paper, a custom made
high pressure miniature hydraulic gear pump is designed and developed for bio medical application,
which is not commercially available. Various design and analysis tools such as SolidWorks and ANSYS
are used in developing the miniaturized gear pump. This paper aims at maximum pressure
generation along with reduction in size of the pump to specifically reduce the weight of the devices.
Comparative studies on different types of hydraulic pumps are carried out to select suitable pump
for manufacturing. The evaluation and verification of design parameters are followed in design
methodology. The analyses are carried out in ANSYS to study and understand deformation in gears.
The gear pump is manufactured using both EDM (electro discharge machining) and conventional
turning, milling and finally tested to verify its performance suitable for prosthetic hand application. A
novel asymmetric metallic bellow flexible actuators (AMBFA) as the bending joints of the fingers are
fabricated and tested using the developed pump. It is found that the pump is best suited for bending
of these type of actuators in the development of prosthetic hand.
Keywords: Hydraulic Gear Pump; Robotic Gripper Application; Bellow Actuator; Analysis; Fabrication;
Testing
Qing Liu, Maowen Liu, Cong Xu, Wenlong Xiao, Hiroshi Yamagata, Shenghui Xie, Chaoli Ma,
Effects of Sr, Ce and P on the microstructure and mechanical properties of rapidly solidified Al7Si
alloys,
Volume 140,
2018,
Pages 290-298,
ISSN 1044-5803,
Abstract: A series of Al7Si based alloys with trace addition of Sr, Ce or P were prepared using melt-
spinning at two different high cooling rates, and the microstructure as well as the hardness of the
ribbons was comprehensively studied. The results show that Sr or Ce induces the formation of
columnar transition zone and modifies the morphology of eutectic Si phase from dispersed particle
chains to fine fibers only at extremely high cooling rate. However, P has little effect on the
microstructure of either α-Al or eutectic Si. Compared with conventional casting, the Al7Si ribbons
exhibit extremely high hardness due to the fine dispersion of eutectic Si, the grain refinement and
the supersaturation of Si. The hardness is further enhanced by Sr or Ce addition at extremely high
cooling rate, especially for columnar and equiaxed zones, attributing to the modification effect on Si
phase.
Keywords: AlSi alloy; Melt spinning; Modification; Microstructure; High hardness
Jakob Olofsson, Kent Salomonsson, Joel Johansson, Kaveh Amouzgar,
A methodology for microstructure-based structural optimization of cast and injection moulded parts
using knowledge-based design automation,
Advances in Engineering Software,
Volume 109,
2017,
Pages 44-52,
ISSN 0965-9978,
https://doi.org/10.1016/j.advengsoft.2017.03.003.
Abstract: The local material behaviour of cast metal and injection moulded parts is highly related to
the geometrical design of the part as well as to a large number of process parameters. In order to
use structural optimization methods to find the geometry that gives the best possible performance,
both the geometry and the effect of the production process on the local material behaviour thus has
to be considered. In this work, a multidisciplinary methodology to consider local microstructure-
based material behaviour in optimizations of the design of engineering structures is presented. By
adopting a knowledge-based industrial product realisation perspective combined with a previously
presented simulation strategy for microstructure-based material behaviour in Finite Element
Analyses (FEA), the methodology integrates Computer Aided Design (CAD), casting and injection
moulding simulations, FEA, design automation and a multi-objective optimization scheme into a
novel structural optimization method for cast metal and injection moulded polymeric parts. The
different concepts and modules in the methodology are described, their implementation into a
prototype software is outlined, and the application and relevance of the methodology is discussed.
Keywords: Component casting; Injection moulding; Design automation; Knowledge based

engineering; Finite element analysis; Multi-objective optimization
İnal Kaan Duygun, Gökçe Hapçı Ağaoğlu, Derya Dispinar, Gökhan Orhan,
Time-dependent corrosion properties of Sr-modified AlSi9 alloy analyzed by electrochemical

techniques,
Volume 803,
2019,
Pages 786-794,
ISSN 0925-8388,
Abstract: The relation between time-dependent corrosion behaviors and microstructural

characteristics of Sr modified and unmodified AlSi9 alloy was studied. The melted alloys were cast
into the permanent mold at 700 °C casting temperature. The Effect of holding time in the furnace on
chemical compositions of alloys was determined. Sr content of the modified alloys was 200 ± 5 ppm
after 4 h and 50 ± 2 ppm after 17 h holding time. Microstructural properties were analyzed after
casting. The corrosion behavior of AlSi9 depending on Sr content was investigated by means of
electrochemical impedance spectroscopy technique and potentiodynamic polarization plots in
3.5 wt% NaCl solution at 25 °C. The effect of immersion time was examined at 1, 24, 72 and 120 h.
The results indicated that high Sr content in AlSi9 alloy contributes to the formation of a finer
eutectic phase and more stable corrosion behavior during immersion time.
Keywords: Al–Si casting alloys; Sr modification; Immersion time; Corrosion resistance; EIS
A.B. Stefaniak, A.R. Johnson, S. du Preez, D.R. Hammond, J.R. Wells, J.E. Ham, R.F. LeBouf, S.B.
Martin, M.G. Duling, L.N. Bowers, A.K. Knepp, D.J. de Beer, J.L. du Plessis,
Insights Into Emissions and Exposures From Use of Industrial-Scale Additive Manufacturing
Machines,
Safety and Health at Work,
Volume 10, Issue 2,
2019,
Pages 229-236,
ISSN 2093-7911,
https://doi.org/10.1016/j.shaw.2018.10.003.
Abstract: Background
Emerging reports suggest the potential for adverse health effects from exposure to emissions from
some additive manufacturing (AM) processes. There is a paucity of real-world data on emissions
from AM machines in industrial workplaces and personal exposures among AM operators.
Methods
Airborne particle and organic chemical emissions and personal exposures were characterized using
real-time and time-integrated sampling techniques in four manufacturing facilities using industrial-
scale material extrusion and material jetting AM processes.
Results
Using a condensation nuclei counter, number-based particle emission rates (ERs) (number/min) from
material extrusion AM machines ranged from 4.1 × 1010 (Ultem filament) to 2.2 × 1011 [acrylonitrile
butadiene styrene and polycarbonate filaments). For these same machines, total volatile organic
compound ERs (μg/min) ranged from 1.9 × 104 (acrylonitrile butadiene styrene and polycarbonate)
to 9.4 × 104 (Ultem). For the material jetting machines, the number-based particle ER was higher
when the lid was open (2.3 × 1010 number/min) than when the lid was closed (1.5–5.5 × 109
number/min); total volatile organic compound ERs were similar regardless of the lid position. Low
levels of acetone, benzene, toluene, and m,p-xylene were common to both AM processes. Carbonyl
compounds were detected; however, none were specifically attributed to the AM processes.
Personal exposures to metals (aluminum and iron) and eight volatile organic compounds were all
below National Institute for Occupational Safety and Health (NIOSH)-recommended exposure levels.
Conclusion
Industrial-scale AM machines using thermoplastics and resins released particles and organic vapors
into workplace air. More research is needed to understand factors influencing real-world industrial-
scale AM process emissions and exposures.
Keywords: Additive manufacturing; Material extrusion; Material jetting; Ultrafine particles; Volatile
organic compounds
Seungmun Jung, Yong Hee Jo, Changwoo Jeon, Won-Mi Choi, Byeong-Joo Lee, Yong-Jun Oh, Gi-Yong
Kim, Seongsik Jang, Sunghak. Lee,
Effects of Mn and Mo addition on high-temperature tensile properties in high-Ni-containing

austenitic cast steels used for turbo-charger application,
Volume 682,
2017,
Pages 147-155,
ISSN 0921-5093,
Abstract: Since turbo-chargers require more excellent high-temperature properties to maintain their
structures at further higher exhaust gas temperatures up to 1050°C, a 20wt%-Ni-containing
austenitic cast steel (N20 steel) has been suggested as a promising candidate cast steel. However,
this steel is very expensive because it contains a large amount of expensive Ni. In order to partly
replace expensive Ni by inexpensive Mn and to improve high-temperature tensile properties in the
N20 steel, three austenitic cast steels were fabricated by replacing 6wt% of Ni by 6.9wt% of Mn or
by adding 2–4wt% of Mo. Thermodynamically calculated fractions of equilibrium phases (austenite,
ferrite, and M7C3 carbide) were matched with experimentally measured fractions, although they
were somewhat overestimated. The N14 steel where 6wt% Ni was replaced by 6.9wt% of Mn did not
contain any ferrite, and showed comparable or more excellent high-temperature tensile properties
than those of the N20 steel, which indicated the successful replacement up to 6wt% Ni by Mn,
together with alloying cost reduction of 10%. The Mo addition also favorably affected high-
temperature properties because Mo worked for increasing both M7C3 fraction and austenite matrix
hardness. Simultaneously considering mechanical properties and alloying costs, therefore, these Mo-
containing N14 steels can be fully adopted for high-performance turbo-chargers requiring excellent
high-temperature properties.
Keywords: Austenitic cast steel; Turbo-charger; High-temperature tensile properties;

Thermodynamically calculated equilibrium phase diagram; Ferrite; M7C3 Carbide
Antonio Rotella, Yves Nadot, Mickaël Piellard, Rémi Augustin, Michel Fleuriot,
Fatigue limit of a cast Al-Si-Mg alloy (A357-T6) with natural casting shrinkages using ASTM standard
X-ray inspection,
Volume 114,
2018,
Pages 177-188,
ISSN 0142-1123,
Abstract: This work aims to quantify the effect of natural shrinkages on the fatigue limit of A357-T6
cast aluminum alloy. The main objective is to characterize the fatigue strength of the alloy following
the ASTM X-ray standard defect identification, by correlating a different ASTM indication to a fatigue
limit reduction. The analysis has been conducted on six customized castings with two defect types
(cavity and sponge shrinkages) and a different harmfulness ASTM grade as defined by Non
Destructive Testing (NDT) standard. The effect of the defect size has been correlated with the ASTM
grade and a Kitagawa-Takahashi diagram has been generated for surface defects. A micro
Computed-Tomography (μ-CT) analysis has been performed in order to compare the defect size
estimation using two equivalent parameters AREA1/2 and VOLUME1/3. A Defect Stress Gradient
(DSG) approach has been proposed to simulate the Kitagawa-Diagram obtained for surface defects.
Finally, the effect of the specimen surface has been investigated for the reference material (ASTM
grade < 1) by comparing the “as cast” surface to a machined surface finish.
Keywords: Cast aluminum alloys; Shrinkage defect; Kitagawa-Takahashi diagram; Micro-computed

tomography; Defect Stress Gradient
J. Fiocchi, A. Tuissi, P. Bassani, C.A. Biffi,
Low temperature annealing dedicated to AlSi10Mg selective laser melting products,
Volume 695,
2017,
Pages 3402-3409,
ISSN 0925-8388,
Abstract: In this work a new heat treatment specific for selective laser melted (SLM) AlSi10Mg
products is studied. Samples were analyzed by differential scanning calorimetry (DSC) and scanning
electron microscopy (SEM); two exothermic phenomena were recognized, kinetically analyzed and
associated to the precipitation of Mg2Si and to the rupture and spheroidization of the silicon
network, which is characteristic of SLM built parts. Thermal treatments, based on the results of
calorimetric analyses, were defined and applied to SLM built samples. The evolution of the silicon
network morphology was confirmed by SEM observations and corresponding hardness variations
were correlated to the treatment conditions. Dedicated thermal treatment is therefore proposed as
a lower temperature alternative to the usually applied post – building annealing.
Keywords: Metals and alloys; Laser processing; Powder metallurgy; Microstructure; Calorimetry;
Scanning electron microscopy
A. Kmita, C. Fischer, K. Hodor, M. Holtzer, A. Roczniak,
Thermal decomposition of foundry resins: A determination of organic products by

thermogravimetry–gas chromatography–mass spectrometry (TG–GC–MS),
Arabian Journal of Chemistry,
Volume 11, Issue 3,
2018,
Pages 380-387,
ISSN 1878-5352,
https://doi.org/10.1016/j.arabjc.2016.11.003.
Abstract: The article presents the results of research on thermal decomposition of Ester-Cured
Alkaline Phenolic No-Bake (ALPHASET) binders used in molding technology. In the ALPHASET system
phenol-formaldehyde resin of resole type is cured with a liquid mixture of esters. Under the
influence of the molten metal the thermal decomposition of the binder follows, resulting in the
evolution of gases, often harmful, e.g. from benzene, toluene, ethylbenzene and xylenes (BTEX) or
Polycyclic Aromatic Hydrocarbon (PAH) groups. The identification of gases evolved during the
pyrolysis of the binders was carried out and their decomposition temperatures were determined
using the Thermogravimetry–Gas Chromatography–Mass Spectrometry (TG–GC–MS) technique. The
tests were subjected to two types of binders from different manufacturers. Among the products of
pyrolysis there have been identified mainly benzene and its derivatives, and phenol and its
derivatives. Compounds identified in pyrolytic gas are largely considered to be harmful to humans
and the environment (some of the compounds are carcinogenic and mutagenic). The presented
results of the TG–GC–MS measurements show that the applied analytic methods are feasible to
perform a qualitative and also quantitative characterization of the binder samples.
Keywords: Resins; Decomposition; TG–GC–MS; Metal casting; Emission
V Divya Prasad, E Lalith Prakash, M Abishek, K Ushanth Dev, C.K. Sanjay Kiran,
Study on concrete containing Waste Foundry Sand, Fly Ash and Polypropylene fibre using Taguchi
Method,

2018,
Pages 23964-23973,
ISSN 2214-7853,
Abstract: With increase in quantities of industrial bi-products, solid waste management is of special
significance. Approximately two million tons of Waste Foundry Sand (WFS) is produced yearly in
India. Improper disposal of waste foundry sand impose environmental effects such as inhibition of
soil microbial activity and ground water toxication. Using WFS as a building materials can effectively
reduce the environmental effects and disposal concerns. Strength requirements and cost reduction
is achieved by partially replacing cement with fly ash. Polypropylene fibre increases the ductility of
the concrete. In this paper, work behaviour of M25 concrete was studied by replacing natural sand
with WFS (10%, 20% and 30%) by weight, cement with fly ash(20%, 25% and 30%) by weight and
polypropylene fibre was added (0.5%, 1% and 1.5%) by weight of cement. The mix proportion
parameters of the concrete were analysed using Taguchi method for optimal design of experiments.
Concrete mixtures were designed in L9 orthogonal array with three control factors namely WFS, fly
ash and polypropylene fibre. The mixtures were tested both in fresh and harden state, and the
optimized mixture was identified based on the test results using Signal to Noise ratio.
Keywords: Waste Foundry Sand (WFS); Fly Ash (FA); Polypropylene (PP) fibre; Taguchi Method;
Signal to Noise ratio (SNR)
Krishnendu Mukherjee, Søren Fæster, Niels Hansen, Anders Bjorholm Dahl, Carsten Gundlach, Jens
Ole Frandsen, Asger Sturlason,
Graphite nodules in fatigue-tested cast iron characterized in 2D and 3D,
Volume 129,
2017,
Pages 169-178,
ISSN 1044-5803,
Abstract: Thick-walled ductile iron casts have been studied by applying (i) cooling rate calculations by
FVM, (ii) microstructural characterization by 2D SEM and 3D X-ray tomography techniques and (iii)
fatigue testing of samples drawn from components cast in sand molds and metal molds. An analysis
has shown correlations between cooling rate, structure and fatigue strengths demonstrating the
benefit of 3D structural characterization to identify possible causes of premature fatigue failure of
ductile cast iron.
Keywords: Tomography; Casting; Fatigue

Mingzhou Jin, Renzhong Tang, Yangjian Ji, Fei Liu, Liang Gao, Donald Huisingh,
Impact of advanced manufacturing on sustainability: An overview of the special volume on advanced

manufacturing for sustainability and low fossil carbon emissions,
Volume 161,
2017,
Pages 69-74,
ISSN 0959-6526,
Abstract: Advanced manufacturing uses emerging technologies to critically enhance not only the
economic competitiveness of individual manufacturers but also the sustainability of the whole
industrial sector. New materials and technologies require new manufacturing processes and novel
analytical models for process controls and parameter optimization regarding cost, reliability, quality,
product flexibility, energy consumption, and fossil carbon emissions. The successful adoption of
advanced manufacturing for sustainability can only be realized by following a systematic approach
from concept development, product design and manufacturing to product delivery and service as
well as in forward and reverse supply chain management. This special volume reports on progress of
advanced manufacturing on sustainability improvements along the whole life cycle and covers the
six themes: 1. Design theory and methodology for sustainability with advanced manufacturing; 2.
Energy efficiency assessment and control of mechanical manufacturing systems; 3. Parameter
optimization for advanced manufacturing and remanufacturing; 4. Low fossil-carbon process
planning and production scheduling; 5. Integration of supply-chain innovations and advanced
manufacturing; 6. Sustainable innovation for product-service systems. In addition, this SV
introductory article, highlights future research directions, such as the need for energy consumption
and emission data for advanced manufacturing processes, optimization models and control
schemes, supply chain innovations, and product-service integration.
Keywords: Advanced manufacturing; Sustainability; Design theory and methodology; Energy

efficiency; Parameter optimization; Process planning and production scheduling; Supply chain
innovation; Product-service systems; Remanufacturing
Abdul Razaq, Yajun Yin, Jianxin Zhou, Xu Shen, Xiaoyuan Ji, Ismat Ullah,
Influence of Alloying Elements Sn and Ti on the Microstructure and Mechanical Properties of Gray
Cast Iron,
Volume 37,
2019,
Pages 353-359,
ISSN 2351-9789,
Abstract: The investigations are finalized after reviewing and observing the influence of mechanical
properties of the gray cast iron via adding pearlite promoting alloying elements such as Tin (Sn),
Titanium (Ti). The results indicated, the microstructure, Brinell hardness and Ultimate tensile
strength of the gray cast iron were significantly changed. Graphite and matrix evolution was
emphasized by scanning electron microscopy. It was observed, the Sn in experimental range reduces
graphite size, whereas, the pearlite quantity increased about 95% with the increasing of Sn and Ti.
The prepared samples showed A, B, D, E and F type-microstructures. Adding significant
concentration of Sn (0.492 wt%) and Ti (0.591 wt%) stimulate the Ultimate tensile strength and
impact toughness, showing the highest values of 314 MPa and 234, respectively. Yield strength was
plunged with the addition of Sn and Ti content because of the presence of more pearlite. Samples
containing excessive Sn and Ti experience sharp deterioration in mechanical properties due to brittle
cementite.
Keywords: Alloying Elements Sn; Ti; Gray cast iron; Microstructure; Mechanical properties
Qingchen Deng, Yujuan Wu, Yuanhang Luo, Ning Su, Xiaoyu Xue, Zhiyu Chang, Qianye Wu, Yanting
Xue, Liming Peng,
Fabrication of high-strength Mg-Gd-Zn-Zr alloy via selective laser melting,
Volume 165,
2020,
110377,
ISSN 1044-5803,
Abstract: A Mg-11.00Gd-1.77Zn-0.43Zr (wt.%) alloy named GZ112K was prepared by selective laser
melting (SLM) with different processing parameters. The formability, element vaporization,
microstructure and tensile properties of the SLMed samples at different scanning speed and hatch
spacing were characterized. The process map at a constant laser power of 80 W for the alloy has
been established. It shows that the optimum scanning speed and hatch spacing are 300–700 mm/s
and 100 μm respectively. The SLMed samples have fine grains of about 2 μm and dispersed eutectic
phase of β-(Mg,Zn)3Gd due to the very high cooling rate, high solid solubility of Gd and Zn elements
in ɑ-Mg matrix owing to the effect of solute trapping. The SLMed GZ112K alloy with scanning speed
of 300 mm/s and hatch spacing of 100 μm has yield strength (YS) of 325 MPa, ultimate tensile
strength (UTS) of 332 MPa and elongation of 4.0% at room temperature. Compared with as-cast
alloy, the SLMed GZ112K alloy has much higher YS (+162 MPa), UTS (+122 MPa) and comparable
elongation (+0.4%).
Keywords: Selective laser melting; Mg-Gd-Zn-Zr alloy; Formability; Element vaporization;

Microstructure; Tensile properties
Charlotte Wong, Kazuhiro Nogita, Mark J. Styles, Suming Zhu, Dong Qiu, Stuart D. McDonald, Mark A.
Gibson, Trevor B. Abbott, Mark A. Easton,
Solidification path and microstructure evolution of Mg-3Al-14La alloy: Implications for the Mg-rich
corner of the Mg-Al-La phase diagram,
Volume 784,
2019,
Pages 527-534,
ISSN 0925-8388,
Abstract: The solidification path and microstructure evolution in Mg-3Al-14La alloy have been
investigated by in-situ synchrotron radiography, thermal analysis and characterisation of the final
microstructure. It is shown that the solidification sequence begins with the precipitation of primary
Al5La2, followed by a eutectic with the products α-Mg+Al5La2, then a mono-variant binary eutectic
with the products α-Mg+Mg12La and lastly a ternary eutectic with the products α-Mg+Mg12La +
(Al,Mg)3La. This solidification sequence is found to be significantly different to the current Mg-Al-La
thermodynamic description. The two main discrepancies are: (i) with Al5La2 being the primary
phase, the Mg-3Al-14La alloy is a hyper-eutectic alloy rather than a hypo-eutectic alloy as currently
described and (ii) the (Al,Mg)3La phase, which was recently identified as a new phase in the Mg-Al-
La system, is also present in the Mg-3Al-14La alloy. The results from this study will be useful for the
improvement of the current thermodynamic description of the Mg-Al-La system.
Keywords: Metals and alloys; Solidification; Phase diagrams; Synchrotron radiation; X-ray diffraction;
Transmission electron microscopy (TEM)
Ignatio Madanhire, Charles Mbohwa,
Achieving Environmental Performance through Design for Environment (DFE) Process in Foundry
Operations,
Procedia CIRP,
Volume 40,
2016,
Pages 121-126,
ISSN 2212-8271,
Abstract: A detailed discussion is made on how to develop an implementation procedure for design
for environment (DFE) management program. A foundry manufacturing enterprise was chosen for
comprehensive assessment and recommendation in this research. The main thrust of this work was
to develop theory on how DFE could be comprehensively and consistently managed in daily business
situation of product development. It was realized that an integration of environmental management
systems, design for Environment, and integrated product development was necessary to achieve
this. It was found that an intersection existed where three areas needed to coexist. Hence, theory
and a model needed to be developed that explained and guided the management of DFE in the
industry. The use of DFE for foundry industry would go a long way in preserving the environment
and reducing costs for production hence create more profits.
Keywords: DFE; environmental; green; foundry; competitiveness; performance
Gerrit Dumstorff, Christoph Pille, Rico Tiedemann, Matthias Busse, Walter Lang,
Smart aluminum components: Printed sensors for integration into aluminum during high-pressure
casting,
Volume 26,
2017,
Pages 166-172,
ISSN 1526-6125,
Abstract: We present a new and innovative approach for the direct integration of sensors into
aluminum during casting to obtain strain and temperature data for the aluminum. This technology
will enable a variety of new applications in sensing technology such as sensing car parts in the
automotive industries (e.g., a suspension arm), innovative parts of an exoskeleton with integrated
sensors for feedback information, or sensing structural components of vehicles. Furthermore, these
sensors can result in more efficient quality assurance, are fully encapsulated against environmental
influence, provide an ideal connection between sensor and metal matrix due to integration in the
casting process, and enable engineers to place sensors directly at the place of interest without
limitations. To reach the goal of integrating sensors in aluminum, we first focus on silicon-based
sensors. We will show that sensor integration is possible, but the failure rate is high. This is analyzed
by evaluating sensor data during casting. Due to the high difference in coefficiency of thermal
expansion between aluminum and silicon, high thermal-induced compressive stress is generated in
the silicon and is destroyed in the casting process during solidification cooling. This is why we
convert in the second part of this paper to a new sensor concept, which is adapted to the conditions
of the casting process. A sensor and its electrical connections are printed on aluminum sheets and
integrated in aluminum in an industrial high-pressure casting process. As a result of these pre-tests,
more than three-quarters of the devices survived the process of integration. Finally, we show that
we obtain strain and temperature data from the cast part to develop smart components out of cast
aluminum and to enable new sensing technologies.
Keywords: Sensor integration in aluminum; Printed strain gauge; high-pressure die casting; material
integrated sensing
Weigang Hu, Zhiming Liu, Dekun Liu, Xue Hai,
Fatigue failure analysis of high speed train gearbox housings,
Volume 73,
2017,
Pages 57-71,
ISSN 1350-6307,
https://doi.org/10.1016/j.engfailanal.2016.12.008.
Abstract: The present work addresses the formation of fatigue cracks in gearbox housings of high
speed trains. Systematic studies of fracture analysis, finite element analysis, and field tests under
actual stress and acceleration conditions are employed. Time domain, frequency domain, and time-
frequency domain analyses indicate that the first two natural vibration modes are excited by out-of-
round wheels and rail-track irregularities, and the superposition of these vibration modes results in
the occurrence of the beat phenomenon, where the amplitude of the vibration modulates
periodically, which increases the likelihood of exceeding fatigue limits, and produces greater
structural damage. Analyses reveal that the fatigue strength of the failure region is reduced by the
casting process, which eventually leads to the formation of fatigue cracks. Our findings suggest that
the gearbox housing casting process should be improved to reduce casting porosity, and the housing
structure must be redesigned to avoid the resonance frequencies associated with wheel-rail
excitation at operational speeds.
Keywords: Time-frequency analysis; Crack failure; Beat vibration; Wheel-rail excitation
Amir Mostafaei, Amy M. Elliott, John E. Barnes, Fangzhou Li, Wenda Tan, Corson L. Cramer, Peeyush
Nandwana, Markus Chmielus,
Binder jet 3D printing – Process parameters, materials, properties, and challenges,
Progress in Materials Science,
2020,
100707,
ISSN 0079-6425,
https://doi.org/10.1016/j.pmatsci.2020.100707.
Abstract: As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP)
is a process where a liquid binder is jetted on layers of powdered materials, selectively joined and
then followed by densification process. Among AM technologies, binder jetting holds distinctive
promise due to possibility of rapid production of complex structures to achieve isotropic properties
in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines
can produce prototypes in which material properties and surface finish are similar to those attained
with traditional powder metallurgy. Various powdered materials have been 3D printed, however, a
typical challenge during BJ3DP is developing printing and post-processing methods that maximize
part performance. Therefore, a detailed review of the physical processes during 3D printing and the
fundamental science of densification after sintering and post heat treatment steps are provided to
understand the microstructural evolution and properties of binder jetted parts. Further, to
determine the effects of the binder jetting process on metallurgical properties, the role of powder
characteristics (e.g. morphology, mean size, and distribution), printing process parameters (e.g. layer
thickness, print orientation, binder saturation, print speed, and drying time), sintering (e.g.
temperature and holding time) and post-processing are discussed. With the development of AM
technologies and need for post-processing in 3D printed parts, it is necessary to understand the
microstructural evolution during densification process and here, processing steps are explained.
Finally, opportunities for future advancement are addressed.
Keywords: Additive manufacturing; Indirect 3D printing; Sintering; Infiltration; Powder bed; Powder
characteristics; Binder; Print processing parameters; Post-processing; Materials selection; Metal;
Ceramic; Composite
Chapter 2 - General Engineering and Science,
Editor(s): William C. Lyons, Gary J. Plisga, Michael D. Lorenz,
Standard Handbook of Petroleum and Natural Gas Engineering (Third Edition),
2016,
Pages 2-1-2-177,
ISBN 9780123838469,
https://doi.org/10.1016/B978-0-12-383846-9.00002-3.
Abstract: This chapter focuses on engineering design, chemistry, electricity, basic mechanics,
strength of materials, fluid mechanics, and geological engineering. Mechanics is the physical science
that deals with the effects of forces on the state of motion or rest of solid, liquid, or gaseous bodies.
The field may be divided into the mechanics of rigid bodies, the mechanics of deformable bodies,
and the mechanics of fluids. In fluid mechanics, the field is generally divided into hydrostatics and
hydrodynamics and further subdivided on the basis of compressibility. The principles of strength of
materials are applied to the design of structures to assure that the elements of the structures
operate reliably under a known set of loads. Thermodynamics involves terms and concepts that are
often used in a nontechnical setting. In thermodynamics, these terms are abstractions of the
ordinary concepts and have precise meanings that may differ drastically from everyday usage.
Geological engineering focuses on various technical details of the Earth, its internal and surface
composition, structure, and the processes that cause changes in its composition and structure. The
processes that form the sedimentary basins are discussed in some detail and their resulting pore and
fracture pressure gradients. Electricity deals with electrical charge, directions of flow, conductance,
inductance, resistivity, circuit elements, magnetism, and magnetic flux. Analogies exist between
electric and magnetic fields. The chapter also introduces basic chemistry, with emphasis on the
compounds found in petroleum and selected physical chemistry topics likely to arise in petroleum
engineering. The chapter also describes ideal gas laws. Engineering designs practiced by petroleum
engineers are a small part of the chapter and are significant in developing petroleum resources.
Keywords: immature basins; Mature basins; Asteroid 65 million years ago; Morphology
6 - Direct Manufacturing: Rapid Manufacturing,
Hanser,
2016,
Pages 395-450,
ISBN 9781569905821,
https://doi.org/10.3139/9781569905838.006.
Gunnar Engelmann, Johannes Ganster,
7 - Lignin Reinforcement in Thermosets Composites,
Editor(s): Omar Faruk, Mohini Sain,
Lignin in Polymer Composites,
William Andrew Publishing,
2016,
Pages 119-151,
ISBN 9780323355650,
https://doi.org/10.1016/B978-0-323-35565-0.00007-2.
Abstract: With its highly branched structure, its functional groups, and its free ring positions in the
aromatic monomers, lignin is a promising bio-based candidate for network formation in resin
formulations for thermosets and thermoset composites. Of particular interest are phenol-
formaldehyde, polyurethane, and epoxy systems which are reviewed in separate sections. Various
kinds of lignin are considered, including common kraft lignin and lignosulfonates but also the more
recent organosolv and enzymatic hydrolysis lignins. A few examples for the development of cross-
linked polymers with lignin which do not fall in the three categories are also given. It becomes clear
that with the right structure (molar mass, functional groups) and the right modification (e.g.,
purification, fractionation, chemical derivatization) lignin can play an important role in future
thermoset systems.
Keywords: Epoxy; Phenol-formaldehyde; Polyester; Polyurethane; Propargylether
Tassilo Moritz, Saeed Maleksaeedi,
4 - Additive manufacturing of ceramic components,
2018,
Pages 105-161,
ISBN 9780128121559,
https://doi.org/10.1016/B978-0-12-812155-9.00004-9.
Abstract: This chapter deals with the additive manufacturing (AM) of ceramic components. It shows
not only the chances of this shaping route in comparison to the conventional dry, (thermo)plastic, or
suspension-based shaping methods, but also the challenges AM is faced with in powder technology.
A variety of direct and indirect AM methods, either powder-based or feedstock-/suspension-based,
are introduced. Practical examples are given for chosen technologies, showing which AM method is
suitable for which ceramic material. The contribution explains why AM of ceramic components
differs from AM of metals or polymers. All ceramic AM processes are powder technological
processes and need subsequent debindering and sintering steps following the AM step. The chapter
gives a brief market survey and an outlook of the future development trends in this turbulent area.
Keywords: additive manufacturing; ceramic components; direct additive manufacturing; indirect

additive manufacturing; hybridization
2 - Sensors, data storage and communication technologies,
Editor(s): Berend Denkena, Tobias Mörke,
Cyber-Physical and Gentelligent Systems in Manufacturing and Life Cycle,
Academic Press,
2017,
Pages 7-278,
ISBN 9780128119396,
https://doi.org/10.1016/B978-0-12-811939-6.00002-9.
Michael Zenou, Lucy Grainger,
3 - Additive manufacturing of metallic materials,
2018,
Pages 53-103,
ISBN 9780128121559,
https://doi.org/10.1016/B978-0-12-812155-9.00003-7.
Abstract: Digital printing of metals is probably the most important element for “functional” additive
manufacturing. Printed structures made up of polymers usually lack the required mechanical,
electrical, and thermal properties for functional structures and devices. Metal deposition by
conventional methods, either by evaporation or by electrochemistry, is quite inadequate for fast
built-up, multilayered 3D structures. In this chapter, we describe methods and materials for additive
manufacturing of metal by classifying them into two categories. The first category deals with the
differences between 2D and 3D additive manufacturing of metal. The second category deals with the
metallic phase used for the manufacturing process. The metallic phase includes the following three
main phases: metallic particle, metallic complex, or molten metallic droplet.
Keywords: additive manufacturing; digital printing; laser sintering; laser induced forward transfer;
metallic materials; microdroplet; nanoparticle
Jiangfeng Song, Jia She, Daolun Chen, Fusheng Pan,
Latest research advances on magnesium and magnesium alloys worldwide,

Volume 8, Issue 1,
2020,
Pages 1-41,
ISSN 2213-9567,
Abstract: In the past two years, significant progresses have been achieved in high-performance cast
and wrought magnesium and magnesium alloys, magnesium-based composites, advanced cast
technologies, advanced processing technologies, and functional magnesium materials, such as Mg
ion batteries, hydrogen storage Mg materials, bio-magnesium alloys, etc. Great contributions to the
development of new magnesium alloys and their processing technologies have been made by
Chongqing University, Shanghai Jiaotong University, Chinese Academy of Sciences, Helmholtz
Zentrum Geesthacht, Queensland University, Brunel University, etc. This review paper is aimed to
summarize the latest important advances in cast magnesium alloys, wrought magnesium alloys and
functional magnesium materials worldwide in 2018–2019, including both the development of new
materials and the innovation of their processing technologies. Based on the issues and challenges
identified here, some future research directions are suggested, including further development of
high-performance magnesium alloys having high strength and superior plasticity together with high
corrosion resistance and low cost, and fundamental research on the phase diagram, diffusion,
precipitation, etc., as well as the development of advanced welding and joining technology.
Keywords: Cast magnesium alloys; Wrought magnesium alloys; Functional magnesium materials;
Cast and processing technologies; Corrosion and surface treatment; International standard
8 - Novel Materials and Processing Methods,
2017,
Pages 461-514,
ISBN 9780080994314,
https://doi.org/10.1016/B978-0-08-099431-4.00008-7.
Abstract: This chapter is concerned primarily with the role of light alloys in the development of novel
materials and new methods by which they can be produced. Examples of these novel materials are
fiber-reinforced laminates, metal–matrix composites, sandwich panels, and metallic foams. More
recent developments have been the production of amorphous and nanophase alloys that have been
produced by techniques such as rapid solidification, mechanical alloying, and consolidating
extremely fine powders produced in high-energy ball mills, or by subjecting alloys to extreme plastic
deformation by a technique known as equal channel angular pressing. Other topics in the chapter
are titanium-aluminide compounds that offer promise for reducing the weight of components
operating at high temperatures, and additive manufacturing by 3D printing which has been
successfully applied to manufacture complex-shaped components in a wide range materials
including aluminum, magnesium, and titanium alloys.
Keywords: Composites; metallic foams; amorphous alloys; nanophase alloys; quasicrystals; titanium
aluminides; rapid solidification processes; mechanical alloying; physical vapor deposition; equal
channel angular pressing; 3D printing
M.K. Banerjee,
2.1 Fundamentals of Heat Treating Metals and Alloys,
Editor(s): MSJ Hashmi,
Comprehensive Materials Finishing,
Elsevier,
2017,
Pages 1-49,
ISBN 9780128032497,
https://doi.org/10.1016/B978-0-12-803581-8.09185-2.
Abstract: The chapter has dealt with the fundamentals of heat treatment in reference to underlying
physical metallurgy principles. Discussion has been initiated with description of the purpose of heat
treatment of metals and alloys, the different stages of a heat treatment cycle, and the ways the
different metals and alloys can be responsive to the process of heat treatment as a whole. Attention
has been paid to enumerate the elements of heat treatment practice in a generalized fashion in
order that the readers are able to identify the principles of heat treatment as generic to metals and
alloys. Specificity is cited wherever it is required to make things clearer to the readers. Reference to
steel is invoked to make it easy for the readers to grasp the underlying scientific principles which
lead to changes in structure and property of materials undergoing heat treatment.
Keywords: Age hardening; Annealing; Austempering; Hardening and tempering; Martempering;

Martensite; Normalizing; Pearlite; Phase diagram; Quenching medium
Index,

2017,
Pages 847-875,
ISBN 9780081005521,
https://doi.org/10.1016/B978-0-08-100552-1.18001-7.
Chapter 4 - Dependence of Castability and Mechanical Properties on Composition and

Microstructure of Aluminum Alloys,
Dinsdale,
2019,
Pages 313-404,
ISBN 9780128118054,
https://doi.org/10.1016/B978-0-12-811805-4.00004-3.
Abstract: Chapter 4 deals with a very important issue of aluminium foundry alloy castability, its
experimental measurements, and dependence upon chemical and phase composition of foundry
aluminum alloys. It is important to justify the appearance of yet another book (and chapter) on
foundry aluminium alloys. The original first edition of ‘Casting Aluminum Alloys’ published in 2007, is
out of print now. As was pointed out above, during some 12+ years that had passed since the 1st
edition, many archival papers and several excellent monographs were published on this subject. One
of our goals was to provide the reader with an overview of this literature, As it was pointed out in all
other chapters of this book, the key distinction of this book from other publications as well as from
the 1st edition was to get the interested reader acquainted to the modern simulation and modeling
techniques that nowadays find widespread application both in industry and education related to
foundry aluminium alloys and their castability. To be able to make a good shaped casting, an
aluminium alloy needs to possess good castability. The term ‘good’ is explained: it assumes that a
homogeneous casting could be obtained, uniform in its composition without pores and cracks and
with the surfaces exactly reproducing the internal geometry of the mould used for the casting
process. The level of casting properties is determined by the alloy composition and the technological
aspects of the process. Among the most important casting properties, it is necessary to mention
liquid fluidity and shrinkage, and associated with them are hot cracking and tendency to the
formation of shrinkage porosity and macro-segregation. Therefore, all of these important issues
were described in detail, along with the review of the currently available literature and the emerging
mathematical modeling techniques.
Keywords: additive manufacturing; castability; computer simulation and modeling; foundry

aluminum alloys; hot pre-solidification cracking; macrosegregation; microstructure; molten metal
fluidity; phase composition; porosity; shrinkage
Chapter 4 - Solid Processes,
Academic Press,
2016,
Pages 251-342,
ISBN 9780123851321,
https://doi.org/10.1016/B978-0-12-385132-1.00004-5.
Abstract: In this chapter, materials processing routes that involve the deformation of solid
engineering materials are explored. The chapter begins with a fundamentals section that introduces
the principles of deformation and plastic flow under uniaxial and triaxial stresses, and the typical
mechanical responses of metals and thermoplastic polymers. The wire drawing process is covered in
detail and analyzed using a forced balance (slab) method. This section reveals how sequential
deformations lead to the final desired shape and how work hardening of the metal changes the
process requirements. Extrusion, forging and rolling are covered to show how different shapes are
processed from solids, and the importance of hot working. The last section is an introduction to
several forming operations that begin with metal or plastic sheets, including bending,
thermoforming, and superplastic forming.
Keywords: Deformation mechanics; wire drawing; extrusion; forging; rolling; thermoforming;

superplastic forming
Chapter 3 - Influence of Heat Treatment Upon Microstructure of Casting Aluminum Alloys,
Dinsdale,
2019,
Pages 235-312,
ISBN 9780128118054,
https://doi.org/10.1016/B978-0-12-811805-4.00003-1.
Abstract: Summary
Casting aluminum alloys can be subjected to different kinds of heat treatment (homogenizing to
remove residual stress, heterogenizing, solution heat treatment with subsequent quench, F and T5
tempers, etc.). Sometimes aging of castings can be conducted without prior quench (e.g., the T5
temper) using the effect of supersaturation of Al-based solid solution in the course of
nonequilibrium solidification. In certain cases (particularly often after casting under pressure),
aluminum alloys can be used without any heat treatment (i.e., in the F-temper). This is the
foundation of the so-called CTS (cast–trim–ship) production approach that becomes more and more
wide spread. In Chapter 3, an emphasis is made upon introducing the reader to the modern
techniques of computer modeling of the heat treatment operations described above. Advanced
experimental techniques that could be applied for studying different alloys and their microstructure
also receive the attention required for such an important issue. Also, 11 years have passed since the
first edition of this book had been published, and the authors tried to review the new literature and
capture the important trends in the development of the whole field of foundry aluminum alloys.
Keywords: aluminum foundry alloys; heat treatment; computer simulations; microstructure and its
evolution; microstructure–properties
I.G. Crouch, S.J. Cimpoeru, H. Li, D. Shanmugam,
2 - Armour steels,
Editor(s): Ian G. Crouch,
The Science of Armour Materials,
2017,
Pages 55-115,
ISBN 9780081010020,
https://doi.org/10.1016/B978-0-08-100704-4.00002-5.
Abstract: Armour steels are the most understood family of armour materials following more than a
century of research and development. They are also the material of choice for most ground-based,
military vehicle platforms. However, what grades of steel make the most effective armours? Are they
all capable of being used as structural armours? How do they fail? This chapter details the
metallurgical factors governing ballistic performance, from alloy chemistry to the effects of
possessing an orthotropic microstructure. High strain rate effects are also well covered, as are
fabricability, cost and availability. Specific armour failure mechanisms like adiabatic shear and brittle
fracture are detailed as well as a number of over-riding structural engineering requirements. The
chapter covers standardised grades for both cast and rolled steels, and provides tables of armour
specifications and ballistic standards. Current research grades like super bainitic steels, TWIP and
TRIP steels, are also included as well as the benefits of perforated armour steels.
Keywords: Armour specifications; Armour steels; Ballistic test standards; High strain rate properties;
Perforated armours; Steels
Index,
Editor(s): Roger Narayan,
Encyclopedia of Biomedical Engineering,
Elsevier,
2019,
Pages 523-568,
ISBN 9780128051443,
https://doi.org/10.1016/B978-0-12-804829-0.18001-0.
Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis, Mark Jolly,
Sustainability-Based Evaluation of Casting Gating Systems: a Multi-Criteria Decision-Making

Approach,
Volume 43,
2020,
Pages 704-711,
ISSN 2351-9789,
Abstract: The selection of the most appropriate casting gating system design is one of the most
critical decision-making tasks in foundries as it is closely associated to the amount of air inclusions
and surface defect concentration, which should be minimal in the final casting product to ensure
superior quality and enhanced mechanical properties. Moreover, the design of the gating system
influences the material and energy usage and consequently the cost of the sand casting
manufacturing process. Therefore, its design should be thoughtfully considered and planned. In this
investigation, Multi-Criteria Decision-Making (MCDM) is being coupled with Computational Fluid
Dynamics (CFD) simulations in order to select the optimal gating system design with respect to the
sustainability of the process. Besides process energy, three additional criteria were used for the
evaluation of the gating system performance, namely: air entrainment, surface defect concentration
and mould cost. CFD simulations were performed to evaluate each one of the 6 gating system
designs considered against each one the aforementioned criteria. The selection of the most
appropriate gating system was performed using the Technique for Order of Preference by Similarity
to Ideal Solution (TOPSIS).
Keywords: Multi-Criteria Decision-Making (MCDM); TOPSIS; Computational Fluid Dynamics (CFD);

Sand Casting; Gating System Design
Christian Vargel,
Chapter A.5 - Cast aluminium alloys,
Elsevier,
2020,
Pages 21-23,
ISBN 9780080999258,
https://doi.org/10.1016/B978-0-08-099925-8.00005-3.
Abstract: By optimizing the design of a part made with cast aluminium alloys, the finishing by
machining can be substantially reduced. By combining two advantages offered by casting (insertion
of functionalities and very limited finishing), this method is competitive with welded assemblies. Cast
aluminium alloys belong mainly to four systems based on aluminium-silicon, aluminium-copper,
aluminium-magnesium and aluminium-zinc. Casting techniques can be grouped into four categories,
each of which can have several variants: sand casting—casting by gravity in a sand mould;
investment casting—casting by gravity in a ceramic mould; permanent mould casting by gravity; and
pressure die-casting in a permanent metal mould. The choice of the casting technique has no
influence on the corrosion resistance of casting alloys. Aluminium-silicon-magnesium alloys and
aluminium-copper cast alloys can undergo precipitation hardening, as do wrought alloys of the 6XXX
series and 2XXX series.
Keywords: Age-hardenable alloys; Automotive industry; Cast aluminium alloys; Cast aluminium-
copper; Cast aluminium-magnesium; Cast aluminium-silicon; Cast aluminium-zinc; Electrical industry;
Investment casting; Machining; Marine atmosphere; Mechanical engineering; Permanent mould
casting; Primary aluminium; Precipitation hardening; Pressure die-casting; Recycling; Sand casting;
Secondary alloys; Ship superstructures; Temper F; Temper O; Temper T1; Temper T4; Temper T5;
Temper T6; Temper T7; Temper T64
C. Chelladurai, N.S. Mohan, D. Hariharashayee, S. Manikandan, P. Sivaperumal,
Analyzing the casting defects in small scale casting industry,
2020,
ISSN 2214-7853,
Abstract: In this current scenario of globalization, foundries play a key role for manufacturing
industries as they are the major source of castings. Casting has various processes like Pre casting
Processes, pattern making, core making, moulding and mould assembly making, Casting Processes,
furnace charging, melting, holding and pouring, and Post casting Processes, shakeout, inspection and
dispatch etc. In India there are many foundry have followed conventional and manual operations.
Today’s competitive environment has, lower manufacturing cost, more productivity in less time, high
quality product, defect free operation are required to follow to every foundry man. Mould shifting,
Crushing, Lower Surface finish, Shrinkage, Porosity, Cold shut and Extra material are common casting
defects due to these manual operations. These defects directly affect on productivity, profitability
and quality level of organization. In this paper all data presented is taken from one foundry. As a key
industry a foundry’s performance should be effectively high in terms of production with minimum
number of rejections. Castings are the major inputs for most industrial products hence foundry
industry is most indispensable. Casting is an integrated process considered as an artwork with
experienced professionals for high quality yield, even then in highly controlled environment defects
are dominant to take place leading to rejections, contrary to rejections a foundry’s key attempt is to
satisfy the demands neglecting quality levels. The challenges of casting defects are to be identified
and minimized for effective castings. This study provides an intense knowledge of critical casting
defects and their root cause analysis. In this paper efforts are made to achieve technically feasible
remedies for minimizing several casting defects and improving the quality of castings which will
serve as control measures for quality control professionals with zero defect concepts.
Keywords: Casting; Casting defects; Manual Metal Casting Activities; Pattern mismatching; Human
Errors; Casting process; Defects Analysis; Cause and remedies
Eugen Demler, Stanislav Götze, Sebastian Herbst, Florian Nürnberger, Hans Jürgen Maier, Jonathan
Ursinus, Christoph Büdenbender, Bernd-Arno Behrens,
Casting Manufacturing of Cylindrical Preforms Made of Low Alloy Steels,
Volume 47,
2020,
Pages 445-449,
ISSN 2351-9789,
Abstract: The manufacturing of complex drivetrain components made of steel requires multi-stage
manufacturing processes, resulting in long processing times and high costs. Forged parts get their
final geometry after multi-stage forming operations. One approach to shorten such process chains is
close contour casting of steel preforms and a single subsequent forming step to achieve high
strength properties similar to those of multi-stage forged parts. Since the application of precision
forging using cast steel preforms has been studied insufficiently up to now, the manufacturing of
cylindrical preforms made of the low-alloy heat-treatable steel G42CrMo4 by sand casting was
investigated. Using casting simulations, suitable casting parameters for the finished casting systems
were identified and nearly pore-free preforms were achieved. Depending on the casting system,
metallographic investigations revealed different fractions of bainite in the microstructure of the
casted preforms. Subsequently, the cylinders were deformed in upsetting experiments by which the
remaining porosity could be eliminated. The numerical casting simulation was combined with a
forming simulation to model the reduction in porosity and to allow the prediction of the
densification behavior in further research employing more complex geometries.
Keywords: sand casting; casting; forging simulation; G42CrMo4; reduction in porosity
M. Sengottuvelan, K. Sivakumar, M. Nandagopal,
Study on Cold Metal defect in Pump Mounting Flange using Taguchi Approach,
2018,
Pages 25212-25218,
ISSN 2214-7853,
Abstract: Sand casting is a process of producing complex shape castings which cannot produce by
other processes. Production of defect free casting is a challenging task in a foundry. The quality of
component produced by sand casting is affected due to uncontrollable process parameters. Until
controlling such parameters, it is difficult to achieve defect free casting. Keeping this in mind, a study
is carried out in a jobbing foundry in South Tamil Nadu. From the six months rejection data, it is
identified that the Pump Mounting Flange is mostly rejected due to cold metal defect. In order to
overcome the cold metal defect the process parameters mold hardness, moisture, time and
temperature of pouring are investigated using the Taguchi approach the optimized values are
arrived. The regression analysis confirmed that the optimized values are acceptable. The values are
recommended to foundry for the production process. By six sigma methodology (DMAIC), the quality
tools Data Chart and Histogram are used to select defected casting. From the Cause and effect
diagram the root cause of the cold metal defect is identified.
Keywords: Parameters; cold metal; Minitab; Taguchi; Six sigma; regression analysis; Control charts
Vana Orfanou, Annabelle Collinet, Ziad El Morr, David Bourgarit,
Archaeometallurgical investigation of metal wares from the medieval Iranian world (10th-15th
centuries): The ISLAMETAL project,
Journal of Archaeological Science,
Volume 95,
2018,
Pages 16-32,
ISSN 0305-4403,
https://doi.org/10.1016/j.jas.2018.04.008.
Abstract: The ISLAMETAL project (2013–2017) was jointly conducted by the Département des Arts
de l’Islam (DAI), Musée du Louvre, and the Centre de Recherche et de Restauration des Musées de
France (C2RMF) and kindly supported by the Roshan Cultural Heritage Institute (RCHI). The project
deals with the detailed technological investigation of copper-based metal wares (10th to late 15th
centuries CE) from the Iranian world at the Louvre Islamic Art collection, comprising mostly
household and domestic objects such as candlesticks, lamps, ewers, plates, and bowls. Amongst the
collection characteristic qualities of production and decoration can be discerned. High status objects
were decorated with sophisticated patterns including exquisite chasing, engraving, champlevé, and
especially copper, silver and gold inlays. Results of the technological investigation of some 169
objects (particle induced X-ray emission, inductively coupled plasma atomic emission spectroscopy,
digital microscopy, X-radiography) showed a range of distinct alloy types employed and a correlation
between artefact typology, fabrication technique, status and alloys. Decoration techniques showed a
clear change spanning the 10th and 15th centuries with the notable introduction of precious metal
inlays during the 12th century and new inlaying techniques before the mid-13th century. Lost-wax
casting was the preferred manufacturing method even for mass produced objects where sand
casting would seem a more suitable choice. Specific production centres in the region of Khorasan,
such as that of Herat and Ghazna, were possible to be technologically identified. Detailed
investigation of this comprehensive corpus provided for the first time key technical references for
further comparison, particularly with neighbouring Near Eastern workshops.
Keywords: Copper-based alloys; Islamic metalwork; Khorasan; Fars; Lost-wax casting; Sand casting;
Metal inlays
M. Shilpa, G.S. Prakash, M.R. Shivakumar,
A combinatorial approach to optimize the properties of green sand used in casting mould,
2020,
ISSN 2214-7853,
Abstract: The uses of cast iron have been well documented since the fifth century. Most of the
current small scale production of cast iron is carried out using the sand casting process. The present
study investigates the sand casting process parameters of green sand to determine the optimal
control factors on shear strength, compression strength and permeability with different
compositions of bentonite, dextrin, coal powder, and water. To determine the considerable effect on
three responses namely, shear strength, compression strength and permeability of green sand,
eighteen experimental runs, with two replications, have been conducted using L18 orthogonal array.
The experimental results were analyzed using Grey Relational Analysis (GRA); Grey Relational Grade
(GRG) was calculated to determine the rank and influence of the control parameters for the three
different responses. From the analysis of experimental results, it was observed that bentonite plays
a significant role in the green sand strength, when compared to coal powder, dextrin and water. The
results showed that elevated bentonite and coal powder in the sand could prominently improve the
shear strength, compression strength and permeability. The experimentation demonstrated that the
sand strength reduces as the amount of dextrin increases, within the range of specifications
considered.
Keywords: Sand Casting; Green Sand; Orthogonal Arrays; Grey Relational Analysis; Regression
Analysis
Guoling Mao, Shanguang Liu, Zhen Wu, Congcong Zhu, Wenli Gao,
The effects of Y on primary α-Al and precipitation of hypoeutectic Al-Si alloy,
Materials Letters,
Volume 271,
2020,
127795,
ISSN 0167-577X,
https://doi.org/10.1016/j.matlet.2020.127795.
Abstract: Under sand casting conditions, the effects of yttrium (Y) on the primary α-Al and
precipitation of A357 alloy were investigated. The results showed that with Y addition, the primary
α-Al nucleation was more difficult, and the Tliquidus-Tsolidus decreased. Meanwhile, the number of
the dendritic primary α-Al grains increased, the primary dendrite arms became longer and narrower,
and the secondary dendrites had longer arms and smaller arm spacing. Some other elements had
the same phenomenon, like Si, Sr, etc. As for precipitation, with Y addition, the number of β″
decreased. Y did not affect the β″ habit plane and did not change the types or produce new
precipitation.
Keywords: Cast; Metals and alloys; Microstructure; A357
A. Wiengmoon, J.T.H. Pearce, S. Nusen, T. Chairuangsri,
Effects of Si on microstructure and phase transformation at elevated temperatures in ferritic white

cast irons,
Volume 120,
2016,
Pages 159-167,
ISSN 1044-5803,
Abstract: The effects of Si on microstructure and phase transformation at elevated temperature of

ferritic 31wt.%Cr-1.1wt.%C white cast irons with up to 3wt.%Si have been studied. Applications of
these irons include parts requiring heat resistance at elevated temperature. The irons were
produced by sand casting. The microstructure in as-cast condition and after being subjected to high
temperature (700 to 1000°C) was investigated by light microscopy, X-ray diffraction, and electron
microscopy. The results revealed that the as-cast microstructure consisted mainly of primary ferrite
dendrites and eutectic (ferrite+M7C3). Si promotes M7C3-to-M23C6 transformation in the irons
subjected to transformation at elevated temperature, but no sigma phase was found. The extent of
M7C3-to-M23C6 transformation increases proportional to the increasing transformation
temperature, holding time and Si content in the irons. For the iron with 1.0wt.%Si content after
holding at elevated temperatures, martensite was also found, which could be attributed to carbon
accretion effects in eutectic ferrite. Si was incorporated in M23C6 such that M23C6 containing Si can
show darker contrast under SEM-BEI as compared to M7C3; this is the opposite to what has been
observed for the cases of typical M23C6 and M23C6 containing Mo or W. The results obtained are
important to understand the change in properties of ferritic, high chromium irons containing Si
subjected to elevated temperature.
Keywords: Ferritic white cast iron; Phase transformation; Electron microscopy; Silicon
E. Naveen, S. Ilangovan,
Optimization of hardness and wear parameters of Al-Cu-Si alloy using design of experiments,
Volume 22, Part 4,

2020,
Pages 2704-2714,
ISSN 2214-7853,
Abstract: Aluminium-Copper-Silicon (Al-Cu-Si) alloy of composition Al-1.5Cu-0.5Si alloy was

successfully fabricated by sand casting process. Homogenization treatment was done at different
temperatures to achieve uniform distribution of elements. The hardness was measured in different
regions (outer, middle and inner) and the peak hardness of the alloy was obtained at 425 °C
homogenization temperature in the outer region because of low solidification time at that region. L9
Orthogonal array was used to conduct the experiments and optimize the process parameters in the
three regions for Specific Wear Rate (SWR) and the influencing parameters such as load, speed,
homogenization temperature and sliding time were analyzed using Taguchi techniques. From the
Analysis of variance (ANOVA), it was observed that for outer region, the sliding speed has the major
effect on SWR followed by load, sliding time and homogenization temperature. In case of middle and
inner regions, the influence of load on SWR was significant followed by sliding speed. The
confirmation test was carried with obtained optimal process parameter. The surfaces wear
mechanism behind Al-1.5Cu-0.5Si was analysed using scanning electron microscope (SEM) image
Keywords: Al-Cu-Si alloys; homogenization; microhardness; specific wear rate; analysis of variance
Christian Demminger, Christian Klose, Hans Jürgen Maier,
Microstructure and Magnetic Properties of Cobalt and Zinc Containing Magnesium Alloys,
Procedia Technology,
Volume 26,
2016,
Pages 35-42,
ISSN 2212-0173,
https://doi.org/10.1016/j.protcy.2016.08.006.
Abstract: The magnetic properties of lightweight alloys based on magnesium and cobalt offer a novel
way to measure mechanical loads throughout the entire structural component using the
magnetoelastic effect. Since the solubility of cobalt in the magnesium matrix is negligible, the
magnetic properties mainly originate from Co-rich precipitates. Size and distribution of the Co-
containing phases within the alloy's microstructure can be influenced during the initial processing
method of the alloy. Specifically, the cooling rate in the casting processes has a major influence on
the resulting magnetic properties. In this study, Mg-Co-based alloys were produced by several
casting methods which feature substantially different cooling rates, i.e. gravity sand casting, gravity
die casting and high-pressure die casting. The differences between the manufactured alloys’ micro-
and phase structures are compared and the superior magnetic and mechanical properties of the
high-pressure die cast material are demonstrated.
Keywords: magnesium; cobalt; magnetic materials; load-sensitive materials; die-casting; sand-

casting; eddy-current measurements
Gianfranco Palumbo, Vito Piglionico, Donato Sorgente, Antonio Piccininni, Pasquale Guglielmi, Luigi
Tricarico,
Correlating shrinkage microporosity with the mechanical properties of sand-cast superduplex

stainless steel using a numerical/experimental approach,
Materials & Design,
Volume 93,
2016,
Pages 168-179,
ISSN 0264-1275,
Abstract: In this work, the Niyama criterion for the prediction of shrinkage microporosity in a
superduplex stainless steel (ASTM A890 Gr. 5A) end-risered plate produced by sand-casting is
adopted. To validate numerical results obtained using the commercial software MAGMASoft,
experimental castings were produced, and both the shrinkage microporosity and its effect on the
material behaviour was evaluated. Metallographic techniques were used to quantify the
microporosity and evaluate its distribution; the effect of the shrinkage microporosity on the sand
cast material was measured through tensile tests on miniaturised specimens extracted along the
longitudinal direction of the plate. Image analyses allowed estimation of the threshold Niyama value
for microporosity in the investigated material. An analogous threshold for the Niyama parameter
was determined from the mechanical data arising from tensile tests in which specific microporosity
levels (and Niyama values) were identified that corresponded to minimum required levels of yield
stress, UTS and elongation after fracture as specified by the ASTM standard. Mechanical data were
found to be well correlated to the Niyama value, thus allowing to effectively use the purely thermal
parameter Niyama to predict the sand cast material behaviour.
Keywords: Superduplex stainless steel (ASTM A890 Gr.5A); Sand-casting; MAGMASoft; Niyama
criterion; Shrinkage microporosity; Miniaturised tensile specimens
A. Zhang, S. Liang, Z. Guo, S. Xiong,
Determination of the interfacial heat transfer coefficient at the metal-sand mold interface in low
pressure sand casting,
Experimental Thermal and Fluid Science,
Volume 88,
2017,
Pages 472-482,
ISSN 0894-1777,
https://doi.org/10.1016/j.expthermflusci.2017.07.002.
Abstract: The interfacial heat transfer coefficient (IHTC) at the metal-sand mold interface was
determined by applying a nonlinear inverse estimation method during the low pressure sand casting
(LPSC) process. Experiments were conducted using plate shape castings with different thicknesses
for both ZL205A and ZL114A aluminum alloys. A specific temperature sensor unit was developed to
measure accurately the temperature evolution inside the sand mold, based on which the IHTC was
estimated. Results showed that the time-dependent IHTC during the LPSC mainly comprised two
stages, i.e., rapid increasing stage and maintain stage, and the second stage could be further divided
into two parts based on the plate thickness. Besides, the IHTC was found to be also highly dependent
on the casting material, especially the maximum value. Further analysis also revealed that the
estimation accuracy of the inverse method was increased by 50% if the temperature dependence of
the thermo-physical parameters was considered, rather than normally constant treatment or simple
linear interpolation versus temperature.
Keywords: Interfacial heat transfer coefficient (IHTC); Low pressure sand casting (LPSC); Thermo-
physical parameters; Inverse estimation method
Farzaneh Farhang Mehr, Steve Cockcroft, Daan Maijer,
A fully-coupled thermal-stress model to predict the behavior of the casting-chill interface in an

engine block sand casting process,
International Journal of Heat and Mass Transfer,
Volume 152,
2020,
119490,
ISSN 0017-9310,
https://doi.org/10.1016/j.ijheatmasstransfer.2020.119490.
Abstract: The sole use of light alloys in the production of automotive parts might not be the best
strategy to reduce the emission of CO2, as for this purpose, one should consider the life-cycle of the
final part. One way to address this issue is to increase the in-service life of the components by
modifying the manufacturing process. In the first phase of this study, we used a different chill format
in the bonded sand casting process for the production of engine blocks, and it was concluded that
this method might increase the fatigue life of the component by refining the microstructure.
However, to better understand the dynamics of the casting-chill interface, the development of a
thermal-stress model was necessary. This paper summarizes the methodology used to develop a
thermal-stress model that predicts the evolution of temperature within the casting and the chill and
the evolution of gap and/or pressure at the casting-chill interface. The work identified that the gap
size between the H13 chill and the casting at the bottom of the chill in the main bearing bulkhead
could reach a maximum of 0.17 mm. Additionally, it was found that the heat transfer coefficient
decreased from a peak value of 2500 W m−2 K−1 to 500 W m−2 K−1 at a gap size of 0.2 mm. The
numerical analysis uncovered a couple of important factors that play a major role in the
development of the gap at the interface including the thermal contraction/deformation of the
casting; the thermal expansion/deformation of the chill; the constitutive behavior of the casting; the
constitutive behavior of the bonded sand mold cap; and, the geometry of the casting-chill interface.
Overall, the modeling results show that the interface gap/pressure dynamics are complicated and
play a critical role in governing heat transport across the casting-chill interface.
Keywords: Engine block; Casting; Chill; Water cooled chill; Interface gap; Thermal-stress model; Heat
transfer; Mathematical modeling; Numerical analysis
Philip Hackney, Richard Wooldridge,
Optimisation of Additive Manufactured Sand Printed Mould Material for Aluminium Castings,
Volume 11,
2017,
Pages 457-465,
ISSN 2351-9789,
Abstract: The sand casting process is utilised for over 70% of all castings, the traditional this process
requires a disposable sand mould, A pattern the shape of the product to be manufactured, plus
manufacturing features is used to create the cavity. Additive Manufacturing processes have been
used to generate the sand mould tools directly without patterns, hence reducing the lead time and
manufacturing design constraints. This paper focuses on optimising the characteristics of the 3D
Sand Printing process to traditional produced Furan mould tools, cumulating with an automotive
turbo charger case study, to validate the build parameters optimisation process.
Keywords: Rapid Casting Technology; 3D Sand Printing; Sand Casting
M. Bedel, A. Sanitas, M. El Mansori,
Geometrical effects on filling dynamics in low pressure casting of light alloys,
Volume 45,
2019,
Pages 194-207,
ISSN 1526-6125,
Abstract: In aluminum low-pressure sand casting process, filling oscillations are observed when the
metal front reaches a section change in a part. The effect of geometry on the filling oscillations is
primary considered experimentally, including both mold cavity and filling system geometries. To
highlight the geometric parameters impacting the oscillations, the pressurized melt flow is secondly
studied numerically and analytically. A new analytical model of oscillation is developed to
quantitatively predict the oscillations. It links the resulting filling velocity to both the low-pressure
casting parameters and the mold cavity geometry. Considering oxides inclusion criterion from
casting literature, new rules to avoid bi-films defects are recommended for making reliable low-
pressure castings.
Keywords: Low pressure casting; Aluminum alloys; Mold filling; Fluid flow oscillations; Oxide
inclusions
H. Puga, J. Barbosa, T. Azevedo, S. Ribeiro, J.L. Alves,
Low pressure sand casting of ultrasonically degassed AlSi7Mg0.3 alloy: Modelling and experimental
validation of mould filling,
Materials & Design,
Volume 94,
2016,
Pages 384-391,
ISSN 0264-1275,
Abstract: The effect of combining smooth mould cavity filling and ultrasonic degassing by using a low
pressure sand casting process with US melt treatment on the microstructure and mechanical
properties of AlSi7Mg0.3 alloy was investigated. Computational fluid dynamics (CFD) modelling and
experimental validation was used to study the liquid metal flow behaviour and oxide film defect
distribution for different filling rates, using two pressurization curves (p–t). The effect of ultrasonic
degassing on the resultant microstructure (morphology and presence of porosities and inclusions)
was studied for 650 and 700°C melt degassing temperatures. Results show that ultrasonic degassing
and mould filling velocities below 0.5m/s improve the alloy microstructure and lead to high
mechanical properties.
Keywords: Simulation; Ultrasonic degassing; Low pressure sand casting; Mechanical properties;
Oxides
Swapnil Agrahari, Ishaan Panda, Faisal Moin Patel, Manoj Gupta, Chinmaya P. Mohanty,
Effect of cooling rate on microstructures and mechanical property of Al 1230 alloy in a sand casting
process,
Volume 26, Part 2,
2020,
Pages 1771-1775,
ISSN 2214-7853,
Abstract: Sand casting is a widely used process for making various products used in numerous
industries such as medical, electrical, automotive etc. However, the poor mechanical properties and
microstructural defects are the challenging concern to the foundry engineers for a last decade. In
the present work, the microstructural and mechanical assets of Al 1230 alloy are investigated by
slow and rapid cooling in a sand casting process. The effect of cooling strategy is analyzed using a
scanning electron microscope (SEM) and ultimate tensile strength. Eventually, it is observed that the
rapid cooling is a more suitable technique, which enhances the microstructural and mechanical
properties of the cast component by inducing of silicon particles during the process. Hence, the
proposed work is very useful to smart industries for achieving desired mechanical property while
fabricating sand cast components.
Keywords: Sand casting; Rapid cooling; Slow cooling; Microstructure; Tensile strength
R. Karuppasamy, Debabrata Barik,
Production methods of aluminium foam: A brief review,
2020,
ISSN 2214-7853,
Abstract: In recent years, developments of new materials are finding more importance in various
engineering applications the reason for this development is attributed to the needed for the lighter
and stronger materials. The major advantage of lighter and stronger materials is that, it improves the
efficiency of the parts made of materials without compromising on the strength of the part. Most of
the researchers are investing the development of aluminium foam production methods and its
characters and properties. In this paper discuss the production methods and applications of
aluminium foam. Different types of aluminium foams are closed and open cell structure. This can be
produced through stir casting, infiltration, powder metallurgy and sand casting methods are used.
Keywords: Aluminium foam; Stir casting; Sand casting; Infiltration; Space holder
G. Rajeshkumar, A.M. Harikrishna, S. Ajithkumar,
A Comprehensive Review on Manufacturing Methods and Characterization of Al6061 Composites,
Volume 22, Part 4,
2020,
Pages 2597-2605,
ISSN 2214-7853,
Abstract: Now a days the world moves from monolithic materials to composite materials due to its
good properties and low cost. In particular, these composites are used in aerospace, automobile and
transportation application because of high strength to weight ratio, good wear and corrosion
resistance and better damping properties etc. Among various metal matrix composites, aluminium
based composites (Al6061) are used for such applications. These composites are manufactured by
using various manufacturing techniques such as sand casting, stir casting, squeeze casting and
friction stir welding. Moreover, these composites are prepared by reinforcing it with ceramic
particles, hard metals and natural particles to enhance its properties and also to suit for various
engineering applications. Hence, a complete understanding of the above is very much essential for
selecting appropriate composites for various applications and also to prepare new composites with
enhanced behavior. This paper reports the various manufacturing techniques used for the
preparation of Al6061 composites, reinforcements used and its various characterization studies
Keywords: Al6061; metal matrix composites; reinforcements; manufacturing process
M. Sunil Kumar, N. Sathisha, Batluri Tilak Chandra,
A study on effect of chill casting on A356 reinforced with Hematite metal matrix composite,
2020,
ISSN 2214-7853,
Abstract: The Present scenario in industries has huge demand in high strength and lightweight
materials of aluminum alloy and its composites. In this paper an attempt is made to study the
influence of copper chills in Aluminum alloy metal matrix composites. A356-Hematite particulate
composites were fabricated through stir casting technique followed by sand moulds with and
without copper chills, by varying weight percentage of Hematite particulates from 0 wt%, to 12 wt%
in steps of 3 wt%. The test samples were prepared according to ASTM standards. The prepared
samples have undergone microstructure, hardness, tensile and compression tests. The
microstructure revealed that uniform distribution of Hematite particulates in the A356 matrix alloy
and the rapid cooling rate helped to get fine grained structure. The use of copper chill in turn
improved the hardness, tensile strength, and compressive strength of the chilled composite
specimen as compared to as-cast specimen.
Keywords: Metal matrix composite; Stir casting technique; With and without copper chill; Al-A356;
Hematite
Cindy Sithole, Kasongo Nyembwe, Peter Olubambi,
Process knowledge for improving quality in sand casting foundries: A literature review,
Volume 35,
2019,
Pages 356-360,
ISSN 2351-9789,
Abstract: Foundry operation has many interlinked and complex processes that require skill and
caution to ensure good quality of castings. The complex production processes and variables in the
foundry industry also imposes quality limitation for final castings. Due to this, defect reduction still
remains the main objective in sand casting foundries. In this regard, process knowledge is important
in foundries to increase productivity by reducing sand casting defects. Process knowledge is defined
as the identification of process variables. This includes the gathering approach, conceptualisation
system and analysis to determine the varying process variables that are associated with product
characterisation for final products. The paper presents a literature review on process knowledge in
manufacturing focusing in sand casting method. It then explores possible application of this
methodology specifically to the metal casting industry with the main aim of making it more
competitive.
Keywords: Defects; Foundry; Process-knowledge; Sand casting; Quality
Saptarshee Mitra, Antonio Rodríguez de Castro, Mohamed El Mansori,
On the rapid manufacturing process of functional 3D printed sand molds,

Volume 42,
2019,
Pages 202-212,
ISSN 1526-6125,
Abstract: 3D printing sand mold technology offers an opportunity for the foundry industry to rethink
old casting approaches and to revive the manufacturing approach using computer models. One of
the major concerns in sand molding using 3D printing is the functional characterization of the 3D
printed molds as its mechanical and mass transport properties. This research paper discusses the
effects of binder content on the mechanical strength and the permeability of 3DP sand molds at
different curing conditions. The local permeability of the 3DP specimen was measured as a function
of the injection flow rate in order to quantify the inertial pressure effects. The mechanical strength
of the 3DP sand molds was characterized using traditional three-point bending strength
measurements. The results show that the mechanical strength of the printed molds is deeply
dependent on the amount of binder and the curing process. The 3PB strength was found to increase
when cured at 100 °C and decrease when cured at 200 °C for all binder contents. The 3PB strength
attains its maximum when cured at 100 °C for 2 h for all binder content. In contrast, no significant
effect of the amount of binder on the initial permeability of the samples before curing was observed
within the functional range of binder mass fraction (1.02–1.98 %). Maximum permeability is attained
at the same conditions as the 3PB strength. Therefore, the mechanical strength of the sample can be
optimized within the investigated range of binder contents without resulting in any significant
decrease in permeability.
Keywords: Additive manufacturing; 3D printing; Mold characterization; Sand casting; Three-point

bending strength; Permeability
Gurmeet Singh,
Replace wooden pattern to polymer pattern by 3D printing,
2020,
ISSN 2214-7853,
Abstract: Purpose of this paper is replacing wooden pattern to the polymer by 3D printing, Plastic is
most common raw material for 3D printing for making any type of item from 3D printing the item
made with this procedure incorporate work area. Utensils, container and action figure accessible in
straightforward structure plastic fibre are sold on spool and has a matte and bright it is also available
in transparent form and bright colour. Sand casting is an ancient process of manufacturing it is
integrated through the 3D printing for making pattern, in conventional sand casting the component
make by pouring molten metal into moulds structure is made by compacting is around (for example -
set in a form of box) after the compaction pattern is pulled back from where liquid metal is poured
Pattern is making by wood because it available easily and machining, it has high compressive
strength to its grain that is suitable for compaction moulding there is less failure during the
operation. But it not reduces the environment effect that why we are use polymer. Polymer recycle
and reduce the environment effect which is occur from the polymeric waste 3D printers use that
west of raw materials into useful product.
Keywords: Polymer; 3D printing
M.V. Santosh, K.R. Suresh, S. Kiran Aithal,
Mechanical Characterization and Microstructure analysis of Al C355.0 by Sand Casting, Die Casting
and Centrifugal Casting Techniques.,
Volume 4, Issue 10,
2017,
Pages 10987-10993,
ISSN 2214-7853,
Abstract: In this study, mechanical properties of aluminium alloy C355.0 was investigated for Sand
Casting, Die Casting and Centrifugal Casting Technique. Mechanical properties like tensile test was
performed using PC2000 software, and Brinell hardness test was performed. Die casting was
observed to have good tensile and hardness properties compared to sand and centrifugal castings
Microstructure analysis was done by Nikon Microscope LV150with Clemax Image Analyser. From the
observation die casting had uniform distribution of silicon. Wear behavior of the alloy studied using
sliding wear test. Good wear specific wear rate was found in all the casting but the best was
observed in die casting at 20N load.
Keywords: Die casting; Sand casting; Centrifugal casting; Mechanical and sliding wear properties
Hudivhamudzimu Mugeri, Wallace Matizamhuka, Damilola Isaac Adebiyi, Jacobus Hendrik

Deppinnar,
Effect of Wall Thickness on the Quality of 1060 Aluminum Produced by Sand Casting,
Volume 7,
2017,
Pages 402-412,
ISSN 2351-9789,
Abstract: The demand for thin walled sections in the industry is continuously increasing due to their
light weight. However, the production of thin wall sections (<2 mm) using sand casting process
present a huge challenge in the foundry industry. This paper will investigate the filling defects which
are associated with thin walled sections, thus affecting the quality of 1060 aluminium casting using
sand casting process as a manufacturing process. The results showed quick solidification of thin
walled section (1mm-2.5 mm) before the metal completely filled the mould cavity. Some of the
important factors which contributed to this quick solidification were wall thickness, backpressure
and presence of junctions. The higher the number of junctions the higher the backpressure and the
lower the fillability. A small increase in wall thickness reduced the backpressure which increased the
metal flow. The temperature of the molten metal remained constant at different places for all
different test samples. A slight increase in wall thickness yielded a minimum of 12.5% and a
maximum of 32% increase in fillability. It was observed that as the wall thickness increases, so does
the fillability.
Keywords: fillability; sand casting process; mould cavity; backpressure; junctions and solidification
İsmail Öztürk, Gökçe Hapçı Ağaoğlu, Eray Erzi, Derya Dispinar, Gökhan Orhan,
Effects of strontium addition on the microstructure and corrosion behavior of A356 aluminum alloy,
Volume 763,
2018,
Pages 384-391,
ISSN 0925-8388,
Abstract: 3XX series Al–Si alloys are generally used in corrosive environments open for oxidation
such as rainwater and seawater. The dendrite size and characteristics of the eutectic Si are
important factors determining the properties of A356 alloy. In this study, the microstructure of Sr
modified A356 aluminum alloy and the changes in corrosion properties were investigated. The alloy
was cast into die and sand molds to examine the effect of cooling parameters on the microstructure.
Sr modification was carried out by adding four different weight percentages (0, 120, 170 and
250 ppm). Corrosion behavior of the produced alloys was investigated by two ways. One of them
was electrochemical impedance spectroscopy technique and the other is potentiodynamic
polarization plots that was carried out in 3.5 wt.% NaCl solution at 25 °C. The corrosion resistance of
the alloy was found to be increasing as Sr content was increased which modified the morphology of
the silicon in the alloy.
Keywords: Al–Si casting alloy; A356; Sr modification; Corrosion; EIS
Eun-Hee Kim, Guen-Ho Cho, Yoon-Suk Oh, Yeon-Gil Junga,
Development of a high-temperature mold process for sand casting with a thin wall and complex
shape,
Thin Solid Films,
Volume 620,
2016,
Pages 70-75,
ISSN 0040-6090,
https://doi.org/10.1016/j.tsf.2016.08.069.
Abstract: A new process has been developed for preparing a mold that can be sustained at a heat
treatment of 1000°C, resulting in fabricating cast product having a thin-wall and complex shape. In
the new mold process, an inorganic binder composed of tetraethyl orthosilicate and sodium
methoxide, and bead powder with a high heat resistance and a low thermal expansion to molten
metal were used. The mold sample prepared through the resin-coated sand process using the bead
powder showed higher green strength than those through the CO2 process using the chamotte sand,
while the firing strengths were improved and showed similar values by applying the new mold
process using the inorganic binder. In particular, the glassification behavior of the inorganic binder
and its phase were not changed even in the mold sample prepared with the recycled bead powder.
The thermal expansion of the mold sample was linear and about 0.23% up to 1000°C, indicating that
the mold has a superior thermal stability. The actual product, an impeller, was well cast in the mold
prepared by the new mold process, indicating that the new mold process is efficient method in
improving mold strength.
Keywords: Inorganic precursor; Sol-gel; Bead powder; Sand casting; Mold strength
Fiona Belben,
Chapter 6 - Failure investigations of helicopter tail rotor gearbox casings at Agustawestland Limited,
Industries,
2016,
Pages 117-140,
ISBN 9780128009505,
https://doi.org/10.1016/B978-0-12-800950-5.00006-5.
Abstract: This chapter outlines a number of failure investigations of tail rotor gearbox center
housings from a medium-lift helicopter. These housings are manufactured from magnesium alloy
sand castings which are susceptible to corrosion if surface-protective coatings become damaged;
hence they sometimes fail to achieve their design life. However, approximately 15 years ago these
housings also started to experience cases of fatigue cracking, leading to even higher scrap rates.
Geometrical modifications were made to reduce fatigue stresses and a more corrosion-resistant
material was introduced, however, cracking was still observed. A number of investigations into
casting quality and fatigue strength were undertaken to determine the cause of cracking and during
these, a simple method of determining the extent of fatigue cracking in certain light alloys was
developed and has been described herein. The chapter concludes that the failures were due to a
combination of high stresses and damaging casting defects.
Keywords: Magnesium alloy castings; ZE41A; WE43A; Fatigue cracks; Linear casting defects
V.E. Bazhenov, A.V. Koltygin, M.C. Sung, S.H. Park, A.Yu. Titov, V.A. Bautin, S.V. Matveev, M.V. Belov,
V.D. Belov, K.V. Malyutin,
Design of MgZnSiCa casting magnesium alloy with high thermal conductivity,
Volume 8, Issue 1,
2020,
Pages 184-191,
ISSN 2213-9567,
Abstract: Magnesium alloys are commonly used to produce lightweight parts. While most
magnesium alloys exhibit low thermal conductivities, high thermal conductivities are needed for
electronic devices. In this study, we attempted to develop new magnesium casting alloys with high
thermal conductivities. The MgZnSiCa alloy compositions were chosen using CALPHAD (CALculation
of PHAse Diagrams) calculations, and alloy samples were prepared. The fluidity and hot-tearing
resistance were measured. The results indicated that these properties were similar to those of AZ91
alloy. Tensile tests showed that high-pressure die casting could produce MgZnSiCa alloys possessing
mechanical properties 1.5–3 times higher than those produced via sand casting. The alloy thermal
conductivity was 126 W/mK at room temperature. The corrosion rates of the as-cast samples in
NaCl/water solutions were two times higher than that of AZ91.
Keywords: Magnesium alloy; Thermal conductivity; Phase composition; Corrosion rate; Sand casting;
High-pressure die casting
Muhammad Huzaifa Raza, Ahmad Wasim, Muhammad Sajid, Salman Hussain,
Investigating the effects of gating design on mechanical properties of aluminum alloy in sand casting
process,
Journal of King Saud University - Engineering Sciences,
2020,
ISSN 1018-3639,
https://doi.org/10.1016/j.jksues.2020.03.004.
Abstract: This research aims to analyze the effects of bottom and top gating configurations on
mechanical properties of aluminum alloy 6063-T5 in sand casting process. The influence of three
most effective process parameters including pouring temperature, runner area and ingate area have
been investigated. Empirical models for both bottom and top gating configurations have been
developed using response surface methodology (RSM). Analysis of variance (ANOVA) and
confirmatory experiments have been used to measure adequacy and validity of developed models
respectively. Bottom gating was observed as better configuration as compared to top gating
configuration with 4.08%–18.78% higher ultimate tensile strength (UTS) and 5.98%–20.60% higher
percentage elongation. This resulted due to splashes generated by top gating configuration which
severely affected the fluidity of the melt with consequent effects on mechanical properties. Pouring
temperature and ingate area have been identified as the most significant process parameters
affecting ultimate tensile strength and percentage elongation. Ingate area, on the other hand
influences the flow pressure and speed of melt which is required for mold filling. Micro-hardness of
the specimens has also been investigated to clarify the effects of gating configuration and input
parameters on mechanical properties. To have a deeper insight of the findings, microstructural
analysis of casted parts has also been carried out. The findings of this research will provide better
insight of bottom and top gated sand casted parts and their effect on mechanical properties.
Keywords: Gating configuration; UTS; Percentage elongation; Mechanical properties; RSM
Teresa L.M. Morgado,
Chapter 20 - Failure of steel couplings used in railway transport,
Industries,
2016,
Pages 449-470,
ISBN 9780128009505,
https://doi.org/10.1016/B978-0-12-800950-5.00020-X.
Abstract: A significant number of failures have occurred in mechanical components (named

couplings) of the coal freight trains which led to disruption of service and economic losses.
Fortunately, there weren’t life losses. The cracks detected, exhibit the classical mechanisms of
fatigue cracks under dynamic loads. The coal is loaded in electric freight trains of 22 wagons with 2
locomotives, corresponding to a total of 2154tons. These trains make two journeys of about 334km
each, during 300 days for year, which includes one way in the South to North direction, fully loaded,
and the return empty in the North to South direction. The couplings were obtained by sand casting
process, with the specification in ASTM A148 90-60 and the owner is a multinational thermoelectric
company. In this chapter is present the procedure followed to determine the damage predict of this
components. Thereby, is made the description of material characterization, manufacturing process,
and geometry of the railway coupling, followed by a study of the intrinsic casting defects inherent to
manufacturing process. Fatigue tests procedure and microscopy analysis of the specimens is
presented. And life fatigue curves for different reliabilities were study. Is given a particular emphasis
to the experimental procedure, since service acquisition until service data treatment. Life prediction
approaches one using the Palmgren-Miner Rule modified by Haibach and the other using Palmgren-
Miner Rule and Goodman relation were used, analyzed, and discussed.
Keywords: Fatigue; Failure; Structural durability; Damage; Life prediction
Jun Zheng, Xingjian Zhou, Yunge Yu, Jian Wu, Wei Ling, Hongping Ma,
Low carbon, high efficiency and sustainable production of traditional manufacturing methods
through process design strategy: Improvement process for sand casting defects,
Volume 253,
2020,
119917,
ISSN 0959-6526,
https://doi.org/10.1016/j.jclepro.2019.119917.
Abstract: Energy saving and emission reduction in traditional manufacturing can be achieved by
reducing the occurrence of defective products. Most of the existing optimization methods are
obtained by referring to production experience and technical manual, which are time-consuming
and laborious. Thus, a method of process selection and optimization for defective products in the
design phase is required. In this paper, a process design strategy based on design parameters for
eliminating sand casting defects is proposed. Firstly, the technological process and hole-type defects
of sand casting are analyzed. The process design parameters are divided into three categories to
propose a process design strategy. Three specific optimization schemes named OSP (structure
parameters optimized process), OGP (gating system parameters optimized process), and OPP
(processing parameters optimized process) are derived. Then a carbon emission prediction model is
established to evaluate the effect of these schemes, and a sustainable manufacturing evaluation
method with six indicators is also raised. Finally, a case study illustrates that 21%–24% of process
carbon emission was saved after optimization on average. Among the strategies, OSP has the best
energy-saving performance of average carbon emission, which is 4% lower than the others. OGP has
the largest proportion of recyclable resources while OPP has the highest process yield and lowest
adjustment cost. The results show that the proposed strategies can effectively improve the process
yield, quality of casting, and decrease carbon emissions. The strategy raised in the paper supports
the sustainable development of traditional manufacturing methods.
Keywords: Traditional manufacturing industry; Sustainable manufacturing; Process design strategy;

Sand casting
Kerem A. Guler, Serhat Acar,
Lost Foam Casting of Metallic Parts and Structures,
Elsevier,
2020,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-819726-4.00008-9.
Abstract: The lost foam casting is a unique casting method in which ceramic coated polymeric foams
are used as the pattern. Generally, loose silica sand is used as the mold material. The presence of the
foam pattern in the mold until the moment of casting is the most crucial feature that distinguishes
the method from other casting techniques, and therefore the technique is also referred to as the full
mold casting. Although the method employs sand as a molding material, it has very different
features than conventional sand casting methods. The lack of parting lines in the casts, no need for
the draft angle, the elimination of the core concept, and generally, no need for feeders are among
these. On the other hand, the LFC method is not entirely perfect. For instance, gaseous products
resulting from the decomposition of the foam during casting can cause back pressure and
contamination. But overall, with the investments made by major automotive manufacturers, this
casting method has reached an essential point in the industry. The technique has also been a subject
and foundation of numerous studies in the scientific area. The fact that the pattern does not need to
be removed from the mold is a significant challenge to the conventional casting methods, and this
feature will make the LFC method always attractive.
Keywords: Aluminum alloys; Bimetal structures; Cast irons; Cellular metals; Ceramic pattern coating;
EPMMA foam; EPS foam; Evaporative pattern casting; Expendable pattern casting; Full mold casting;
Lost foam casting; Magnesium alloys; Metal matrix composites (MMC); Molding silica sand; Replicast
Santosh Reddy Sama, Jiayi Wang, Guha Manogharan,
Non-conventional mold design for metal casting using 3D sand-printing,
Volume 34, Part B,
2018,
Pages 765-775,
ISSN 1526-6125,
Abstract: 3D Sand-Printing (3DSP) is a relatively new Additive Manufacturing (AM) technology that
enables direct digital manufacturing (DDM) of complex sand molds and cores for sand casting
applications. Ever-growing interest in this indirect hybrid metal AM process is attributed to its ability
to rapidly produce tooling (i.e., cores and molds) for complex metal castings that are otherwise
impossible to manufacture using conventional techniques. Knowledge-based design rules for this
process is currently very limited and is being progressively realized on an ad-hoc basis to produce
economicaly viable low-batch castings. In this research, non-conventional design rules for gating and
feeding (also known as rigging) is developed to improve casting performance (i.e., filling, feeding and
solidification). Several case studies are presented to illustrate the improved casting performance by
systematically redesigning each element of the rigging system. Computational simulations of the
melt flow are developed to evaluate the effectiveness of redesigned rigging system. This research
further illustrates the ability of 3DSP to not only impact part performance, i.e., optimized metal
casting designs via 3DSP but also drastically improves the casting performance which could
potentially transform the industry of sand casting to produce high quality castings.
Keywords: 3D sand-printing; Sand casting; Additive manufacturing; Metal casting; Feeding system;
Gating system; Risers
H.M.M.M Jayawickrama, M. Dharmawardana, A.K Kulatunga, K.G.S.P Karunarathna, S.A.U. Osadith,
Enhancement of Productivity of Traditional Brass Manufacturing Industry Using Sustainable

Manufacturing Concept,
Procedia CIRP,
Volume 40,
2016,
Pages 562-567,
ISSN 2212-8271,
Abstract: The Sri Lankan Brass manufacturing industry has evolved through centuries. Since then,
this industry has been operated as family business, there are many gaps compared to modern
manufacturing industries. Hence it faces sever threats from different aspects including escalation of
raw material prices, proper reverse logistic mechanism to collect scarp brass material, lack of
competencies to adapt new technology. This research is carried out to investigate the adaptation of
appropriate technology to replace traditional sand casting process and manual sheet metal carving
process. As a secondary measure, a methodology is developed to introduce appropriate technology
to marginalized community as University - Industry partnership. This is paramount important since
they do not have required level of technical competencies to use CAD, CAM. Outcomes reveal that
there are number of productivity enhancements in terms of product quality, material efficiency and
process standardization.
Keywords: Traditional Brass industry; CAD/CAM; prototyping; casting; sheet metal forming;
appropriate technology
Kevin J. Hodder, Richard J. Chalaturnyk,
Bridging additive manufacturing and sand casting: Utilizing foundry sand,
Volume 28,
2019,
Pages 649-660,
ISSN 2214-8604,
Abstract: Although additive manufacturing technology is available for the direct fabrication of metal
parts, the process is still in a juvenile state compared to older metal fabrication methods such as
sand casting. Therefore, limited standards are available stipulating the use of additively-
manufactured parts in critical service conditions such as extreme environments or safety
components. However, since sand casting is suited for multiple units of parts, the time and resources
needed to produce a single part through sand casting is not ideal for a competitive market. Although
additive manufacturing or “3D printing” has been combined with metal casting in the past through
“rapid casting” to fabricate sand molds directly, the sand used is stipulated by the 3D printer. The
use of specialized sand may result in changes to infrastructure and large amounts of additional sand
required to be stored on location. The main question we sought to answer was if traditional foundry
sand or “non-standard” sand could be used within a 3D printing system? We report herein that the
although the increase in surface roughness may be tolerable, the use of foundry sand within a 3D
printer produces molds with less than optimal results, mainly due to the absence of compaction.
Binder bleeding via the liquid binder jetting process also contributes to a loss in dimensional quality.
Keywords: Additive manufacturing; Sand casting; Binder jetting; Foundry; Surface roughness; Metal
casting
S. Sulaiman, Z. Marjom, M.I.S. Ismail, M.K.A. Ariffin, N. Ashrafi,
Effect of Modifier on Mechanical Properties of Aluminium Silicon Carbide (Al-SiC) Composites,
Procedia Engineering,
Volume 184,
2017,
Pages 773-777,
ISSN 1877-7058,
https://doi.org/10.1016/j.proeng.2017.04.156.
Abstract: The silicon carbide particle reinforced aluminum matrix composites are expected to have
many applications in aerospace, aircraft, automobile and electronic industries. Aluminium Silicon
Carbide (Al-SiC) is also used for Advanced Microelectronic Packages. In this study, effect of different
weight percentage of strontium on microstructure and mechanical properties of Al-SiC composite
and Al-12Si (LM6) was investigated. In this research, scanning electron microscope equipped with
EDS was used to define how modifier effect on microstructure. To fabricate Al-SiC composite, 10 wt
% silicon carbide and different percentages (0.02, 0.5) Wt % of Al-10Sr was added to Al-11.6Si (LM6)
by using vortex method for mixing the particles. The influence of adding different amount of Al-10Sr
(0.01, 0.02, 0.5) Wt% on mechanical behavior of aluminum was also examined. The results found
that UTS for aluminum increased by adding SiC and Sr. It was observed that the tensile for the
composite did not increase dramatically. It was concluded the weak interface between particles and
matrix, decreased the UTS. On the other hand strong interface between particles or fibers in the
matrix showed high stiffness and strength but typically a low resistance to fracture.
Keywords: AL-SiC composite; stir casting; sand casting; Modifier; LM6
S.A. Jawade, Rashmi.S. Joshi, S.B. Desai,
Comparative study of mechanical properties of additively manufactured aluminum alloy,
2020,
ISSN 2214-7853,
Abstract: Additive Manufacturing (AM) is rapidly growing manufacturing technique. Selective Laser
Melting (SLM) is most important method in an additive manufacturing. The aim of the research is to
analyze the mechanical properties of additively manufactured AlSi10Mg Aluminum alloy and
compared with conventional manufacturing. In this work the mechanical properties are investigated
of selective laser melting manufactured AlSi10Mg aluminum alloy and compared with sand and
gravity die cast AlSi10Mg parts. The results are validated using simufact additive manufacturing
software.
Keywords: Additive manufacturing; Selective laser melting (SLM); AlSi10Mg; Aluminum alloy;
Simufact additive manufacturing
D.P. Davies, S.L. Jenkins,
Assessment of a controlled solidification aluminium investment casting technique for use in

helicopter gearboxes,
Volume 651,
2016,
Pages 449-460,
ISSN 0921-5093,
Abstract: By using a combination of cast plates and a helicopter gearbox casting, the superiority of a
controlled solidification investment casting process in terms of strength, ductility and fatigue
resistance was observed, when compared to three sand casting processes (conventional, low
pressure and low pressure with chills) and a conventional investment casting process was observed.
The most important factors responsible for the high levels of tensile strength and ductility and
fatigue life were a refined grain size, a fine distribution of particles, a low level of porosity and a
reduction in the level of bifilm formation. When porosity levels were low, i.e. less than 0.6%, a
refined grain size and microstructure have been shown to be the most important factors influencing
strength and ductility. Further improvements in the fatigue life within the ‘as-cast’ controlled
solidification investment process can be achieved by the use of hot isostatic pressing (HIPping). No
statistically significant difference in the fatigue life between the ‘as-cast’ and machined surfaces was
observed. A higher degree of mechanical property scatter, as measured by Weibull Modulus and the
Coefficient of Variance (CV), was observed between the TGB casting and the cast plates inferring the
design of the filling system used by the foundry had not been optimised resulting in higher metal
flow and surface turbulence and a greater likelihood of bifilms occurring within the casting.
Keywords: Casting; Fatigue; Mechanical Strength; Al–10Si–Mg alloy
Lintao Zhang, Kenny W.Q. Low, Fawzi Belblidia, Johann Sienz,
Uphill filling system for a bar-like casting,
Volume 262,
2018,
Pages 269-276,
ISSN 0924-0136,
Abstract: Bar-like sand mould tilted angle reduced free surface fluctuations. The primary and
secondary reflected wave heights decreased with the scaling of Re0.8 and Re0.55, respectively.
These heights were reduced by 54% and 51% when θ was increased from 0° to 5°. A larger tilted
angle was found to generate an air cavity in the cast, the size of which was observed to vary with
Reynolds number (Re). An optimised range of tilted angle (2°–3°) was proposed as a compromise to
reduce the free surface fluctuations and maintain a perfect casting shape at the end of the filling
stage.
Keywords: Sand casting; Filling behaviour; Mould design; Computational fluid dynamics; Co–Cr–W
alloy
Ashish Kumar Srivastava, Rakesh Kumar Singh, Sanjay Kumar, Shashi Prakash Dwivedi, Nagendra
Kumar Maurya, Shivam Mishra,
Development of duralumin alloy and its microstructural characterization by using grain refiner,
Volume 25, Part 4,
2020,
Pages 877-880,
ISSN 2214-7853,
Abstract: In this paper, an attempt is made to characterize the in-house development of aluminium
copper alloy (duralumin). Further the investigation moves to examine the effect of grain refiner
process on microstructure of duralumin. The experimental process involves the casting process of
duralumin with pure aluminium and master alloy (Al-40 wt%Cu.). For grain refinement of the
duralumin, different fraction of Al-3Ti-0.15C grain refiner was added to the duralumin. The results
highlight that the grain refiner with addition of 0.6% Al-3Ti-0.15C will be resulted in the reduction of
grain size of duralumin.
Keywords: Duralumin; Grain refinement; Casting; Macroscopic image; Inter-dendritic network
Jonnro Erasmus, Irene Vanderfeesten, Konstantinos Traganos, Paul Grefen,
Using business process models for the specification of manufacturing operations,

Computers in Industry,
Volume 123,
2020,
103297,
ISSN 0166-3615,
https://doi.org/10.1016/j.compind.2020.103297.
Abstract: Business process management (BPM) is often employed as a driver of integration, by

articulating business processes that cross the boundaries of individual business functions. Business
process modelling as part of BPM has shown its potential in administrative environments, such as
banking and insurance organizations. However, business process modelling remains unproven for all
the processes encountered in manufacturing enterprises, including the physical operations
processes that transform input materials into the required product. These processes have physical
characteristics that make them essentially different from administrative processes with a highly
digital nature, like limited physical buffers for intermediate products and transportation times
between activities. In this paper, we present an approach to use business process models for the
specification of these physical operations processes. Our approach is based on a catalogue of
common process fragments that are adapted to the physical nature of manufacturing. These process
fragments serve as reusable building blocks for the specification of manufacturing processes. We use
the industry standard Business Process Model and Notation (BPMN) to represent both fragments
and processes. We demonstrate the use of our catalogue of fragments by modelling and enacting
the real-world processes of ten manufacturing organizations. The results show strong support for
the use of business process models for both representation and enactment of manufacturing
processes. This work closes part of the gap between the support for administrative processes and
physical industrial processes, thus contributing to the advent of the smart manufacturing concept in
the context of Industry 4.0.
Keywords: Manufacturing operations; Business process modelling; Cross-functional process

management
J. Senthil, M. Prabhahar, C. Thiagarajan, S. Prakash, Ramalingam Lakshmanan,
Studies on performance and process improvement of implementing novel vacuum process for new
age castings,
2020,
ISSN 2214-7853,
Abstract: In the Age of Modern Nonferrous Casting process, varieties of processes are being worked
out. Castings are integral part of many Industries and they occupy more than 25% of the metal
processes. As we look at this century, newer processes are evolving which contribute to the success
stories of many product profiles. One of the important characteristics of a Casting process is
aesthetics. With Aesthetics and development time, Sand Casting and Gravity Die casting are the
major two process adopted by the Industries. These two processes have been used by majority of
the Industries. However issues like poor finish due to improper hand pouring methodology and
environmental conditions prevailing, the products coming out of these processes are not giving the
requisite output, to say that mildly. Investment Castings are good but the cost of development and
operating costs are not economical for Industries to adopt. An observation was made from several
foundries and found V-process or Vacuum process could be deployed for same. As a pilot project
couple of Industries started adopting this process and found that the process is giving excellent yield
and excellent aesthetics with near net shape finish. As a result of newer process, the machining cost
is cut down drastically and the process is environmental friendly as well. Sequence of operations and
other finer aspects of V-process are dealt in detail.
Keywords: V-process; Casting process; L-type junctions; Foundry practices; Stereo lithography
Dan Wang, Penghuai Fu, Liming Peng, Yingxin Wang, Wenjiang Ding,
Development of high strength sand cast Mg–Gd–Zn alloy by co-precipitation of the prismatic β′ and
β1 phases,
Volume 153,
2019,
Pages 157-168,
ISSN 1044-5803,
Abstract: In order to design a high strength sand cast Mg–Gd–Zn alloy, the microstructures and
mechanical properties of cast Mg–12Gd–xZn–0.4Zr (x = 0, 0.4, 0.8) (wt%, signed as GZ1200K,
GZ1204K and GZ1208K) alloys were studied. Zn addition changes the constitution of the
strengthening phases in Mg12Gd alloy. Small amount of Zn addition leads to the formation of basal
precipitates of γ″ and γ′, accelerated-precipitation of the β1 phases and lower number density of the
prismatic β′ phases, and modifies the morphology of the prismatic β′ precipitates. Compared with
the Zn-free alloy, the Zn-containing alloys (GZ1204K & GZ1208K) having higher yield strength in
peak-aged and over-aged conditions are mainly due to the extra prismatic β1 precipitates, which do
not precipitate in the Zn-free alloy. Under sand casting condition, GZ1208K alloy strengthened by the
co-precipitates of the prismatic β′ and β1 phase indicates a good combination of strength and
ductility at room temperature: yield strength of 270 MPa, ultimate tensile strength of 348 MPa and
elongation of 2.6%.
Keywords: Mg alloy; Mg–Gd–Zn; Basal precipitate; Prismatic precipitate; Strengthening mechanism

3 - Casting of Light Alloys,
2017,
Pages 109-156,
ISBN 9780080994314,
https://doi.org/10.1016/B978-0-08-099431-4.00003-8.
Abstract: About 16 million tonnes of aluminum and 190,000 tonnes of magnesium alloys were
converted into cast products in 2014. Casting involves melting, alloying, pouring into a mold, and
solidification of the melt into a suitable microstructure to meet the performance requirements of
the cast components. The solidification of aluminum and magnesium alloys is described covering
nucleation and grain growth of both the primary and eutectic phases, and defect formation. Due to
its importance, special attention is given to grain refinement methods. The second part of the
chapter describes common casting methods such as sand casting, low- and high-pressure die casting,
and semisolid casting. In addition, recently developed casting technologies including T-Mag and
Ablation casting, and methods to further refine the grain size by the application of external fields,
e.g., melt conditioning, and ultrasonic and pulsed magnetic treatments are described.
Keywords: Casting; solidification; nucleation; grain refinement; casting defects; casting technologies
Jatin Sadarang, Ramesh Kumar Nayak, Isham Panigrahi,
Effect of binder and moisture content on compactibility and shear strength of river bed green sand
mould,
2020,
ISSN 2214-7853,
Abstract: Green sand mold casting process is an ancient manufacturing process where the
manufacturing cost is very low and can produce intricate shape casting for different industrial
applications. In recent years, the sand casting foundries are shifted from western countries to India
and other Asian countries due to easy availability of manpower and raw materials. However, in India
silica sand availability is decreasing gradually due to high production rate of sand casting products
and huge civil construction, leads to increase in the cost of production of sand casting products. The
current investigation aims to study the effect of binder and moisture percentage on local river bed
sand mould compactibility and shear strength. The sand mould cylindrical specimens are fabricated
as per American Foundry Society (AFS) to determine shear strength of the mould. The result shows
that the mould compactibility decreases and shear strength increases with the increase in binder
percentage. The optimum sand mould compactibility 52% and shear strength 0.56 kg/cm2 are
observed at 7% moisture and 14% bentonite. Furthermore, the compactibility and shear strength of
river bed sand mould and commercially used pure silica sand mould are compared and found local
river bed sand may be used as alternative silica sand in green sand mould casting.
Keywords: Sand mould casting; Compactibility; Shear strength; River bed sand; Sand mould
Ivica Galić, Ivan Čular, Krešimir Vučković, Zdenko Tonković,
Comparison of SIF solutions obtained by XFEM and conventional FEM for cracks in complex
geometries like valve body,
Volume 13,
2018,
Pages 2109-2113,
ISSN 2452-3216,
Abstract: Globe valve is a type of industrial valve used to obstruct or regulate flow of the fluid in
pipelines via linear motion of the plug. The main component of the valve, the valve body, is the
carrier of the internal and often variable pressure. The body itself is usually made by sand casting
which may result in impurities and metallurgic or shrinkage defects. The above-mentioned, coupled
with the relatively geometrically complex shape of the valve bodies, makes the accurate
determination of the crack formation and growth often challenging. Additionally, formation of the
cracks in a pressure vessel such as globe valves usually leads to one of the two outcomes. If the crack
reaches its critical size under specified loading conditions, a catastrophic failure may occur. On the
other hand, the preferred option of stable crack growth can lead to the effect known as leak-before-
break. Therefore, it is necessary to accurately determine stress intensity factors (SIF) for cracks in
such geometry. This determination is usually made by classical finite element method, and it is very
hard to do on complex shape. In addition, it is possible to determine SIF using eXtended Finite
Element Method (X-FEM) which is proved on simple geometry. In this paper, the verification of the
X-FEM has been conducted by comparison of results obtained by this method and by the classical
method on valve body. Presented computational model suggest the possibility of accurately
determining fracture mechanics parameters for cracks in geometrically complex components such as
those of valve bodies.
Keywords: Pressure valve; X-FEM; FEM; stress intensity factor; leak-before-break

Meet Upadhyay, Tharmalingam Sivarupan, Mohamed El Mansori,
3D printing for rapid sand casting—A review,
Volume 29,
2017,
Pages 211-220,
ISSN 1526-6125,
Abstract: There are many 3D printing technologies available, and each technology has its strength
and weakness. The 3D printing of sand moulds, by binder jetting technology for rapid casting, plays a
vital role in providing a better value for the more than 5000 years old casting industry by producing
quality and economic sand moulds. The parts of the mould assembly can be manufactured by
precisely controlling the process parameters and the gas producible materials within the printed
mould. A functional mould can be manufactured with the required gas permeability, strength, and
heat absorption characteristics, and hence the process ensures a high success rate of quality castings
with an optimised design for weight reduction. It overcomes many of the limitations in traditional
mould design with a very limited number of parts in the mould assembly. A variety of powders, of
different particle size or shape, and bonding materials can be used to change the thermal and
physical properties of the mould and hence provide possibilities for casting a broad range of alloys.
Limited studies have been carried out to understand the relationship between the characteristics of
the printed mould, the materials used, and the processing parameters for making the mould. These
deficiencies need to be addressed to support the numerical simulation of a designed part, to
optimise the success rate and for economic as well as environmental reasons. Commonly used
binders in this process, e.g. furan resins, are carcinogenic or hazardous, and hence there is a vital
need for developing new or improved bonding materials.
Keywords: Additive manufacturing; Sand casting; 3D printing; Sand molds; Rapid prototyping; Rapid
manufacturing; 3D sand moulds
Rupinder Singh, Harpreet Singh, Ilenia Farina, Francesco Colangelo, Fernando Fraternali,
On the additive manufacturing of an energy storage device from recycled material,
Composites Part B: Engineering,
Volume 156,
2019,
Pages 259-265,
ISSN 1359-8368,
https://doi.org/10.1016/j.compositesb.2018.08.080.
Abstract: The disposal/recycling of plastic materials are one of the biggest challenges of 21st
century. Some studies have been reported in recent past on recycling of thermoplastics via three-
dimensional (3D) printing as a novel technique under primary and secondary recycling. But hitherto
no work has been reported on use of recycled/virgin thermoplastics for use as energy storage
devices (ESD). In this paper an effort has been made to develop in house ESD in form of dry cell by
printing with low cost fused deposition modeling (FDM) based commercial open source 3D printer.
The feed stock filament of FDM has been prepared by twin screw extrusion (TSE) comprising of
advanced composite materials (thermoplastic: acrylonitrile butadiene styrene (ABS) matrix,
reinforced with different proportions of chemicals/salts namely: MnO2, ZnCl2, NH4Cl and graphite),
which has been used to print dry cell for energy storage applications. The commercial dry cell
consists of four zones/sections and feed stock filaments for three zones have been prepared
separately on TSE (with different proportions of ABS and reinforcement of chemical/salts) and fourth
zone (of Zn metal) has been casted with conventional sand casting route. Finally, all four zones have
been assembled in series to develop fully functional prototype of ESD. This study highlights that with
the proposed methodology, dry cell comprising of minimum 40% by weight recycled thermoplastics
can be prepared successfully having voltage potential at par with commercial dry cell. Another major
advantage of using this novel route is that the ESD prepared is more thermally stable (confirmed by
differential scanning calorimetry (DSC) analysis) and can operate up to 95 °C temperature. Along
with this the ESD so prepared has better rheological, mechanical properties (tensile, surface
hardness) ensuring it to be useable under severe loading conditions. The results are also supported
by photomicrographs.
Keywords: Energy storage devices; Dry cell; Additive manufacturing; Recycling
G.A. Hodbe, B.R. Shinde,
Design And Simulation Of LM 25 Sand Casting For Defect Minimization,
2018,
Pages 4489-4497,
ISSN 2214-7853,
Abstract: The most critical step in casting process is the solidification of molten metal in prepared
mould cavity, because this is time where the defects like volumetric shrinkage, porosity, blowholes
occurs and affects the quality of casting. These defects come into picture when the part is
completely manufactured and went for testing. In traditional casting process to overcome these
defects, again we have to redesign feeder, gating system, etc, and repeat the casting, so this will
directly affect the rate of production. If these defects can be address before casting then it will really
help casting industry to improve their production rate and revenue. These problems can be address
using smart methoding and advance simulation using casting software. In this paper the study has
been made to improve design and manufacture a defect free casting in particular volumetric
shrinkage defect and yield. The part taken for study is Contact wheel from one of casting company in
Aurangabad, Maharashtra. The company suffers from casting defects like shrinkage, blowhole and
pinhole. Casting solidification is quickly simulated to view the progress of cooling from casting
surface to interior, and to predict the location of shrinkage defects such as porosity and cracks .This
helps in verifying and optimizing the design of feeders, which can be verified by advanced
simulation. This simulation result was compared with the experimental trial and the comparison
result was found to be good.
Keywords: Simulation; Sand casting; Casting defects; Experimental validation
T.R. Sahroni, S. Sulaiman,
Application of Nonlinear Thermal Expansion Model for Casted Aluminium Silicon Carbide,
Elsevier,
2016,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.04130-8.
Abstract: This work presents the application of the nonlinear thermal expansion model for casted
aluminum silicon carbide. The thermal expansion model was developed during the filling process of
the aluminum silicon carbide casting process. The application of the nonlinear thermal expansion
model was successfully performed in sand casting, low-pressure die casting, and investment casting.
The coefficient of thermal expansion (CTE) of fiber-reinforced metal matrix composite material is
significantly influenced by the thermal stresses and interfaces between matrix and fibers. The
thermal expansion behavior of the SiC/Al fiber-reinforced composite relies on the thermal expansion
of the fibers and is influenced by the onset of interfacial strength and the residual stress state. The
change in internal stress of fiber in composite is positive and increases with the increasing
temperature. Applying the nonlinear thermal expansion model to the casting processes could reduce
casting defects. In addition, the nonlinear thermal expansion model can be applied as a reference for
the aluminum silicon carbide materials in casting processes.
Keywords: Aluminum silicon carbide; Application; Nonlinear; Thermal expansion model
David Weiss,
Chapter 5 - Advances in the Sand Casting of Aluminium Alloys,

2018,
Pages 159-171,
ISBN 9780081020630,
https://doi.org/10.1016/B978-0-08-102063-0.00005-9.
Abstract: The sand casting process is one of the oldest casting methods and has been used for
aluminium alloys since they became popular at the turn of the 20th century. This process uses
binder systems to hold together mineral or artificial aggregates so that metals can be poured into
moulds produced from these materials. The mould is then removed and not reused. Advancements
in the technology have concentrated on development of superior binder systems, new pouring
technologies, and gating systems that more effectively deliver metal to the mould-free of oxides and
other contaminants. The use of additively printed moulds and cores for sand casting has become
common for prototypes, low-volume production and the replacement of complicated core
assemblies with single cores.
Keywords: Sand casting; Binder systems; Ablation; Counter-gravity casting; Additive manufacturing
Jason M. Walker, Andrew Prokop, Charles Lynagh, Brian Vuksanovich, Brett Conner, Kirk Rogers,
Jerry Thiel, Eric MacDonald,
Real-time process monitoring of core shifts during metal casting with wireless sensing and 3D sand
printing,
Volume 27,
2019,
Pages 54-60,
ISSN 2214-8604,
Abstract: In this work, real-time in-process monitoring of core motion in metal castings is
demonstrated through the use of two emerging technologies. 3D sand printing (3DSP) is a binder
jetting additive manufacturing process that is quickly manifesting itself as a technological disrupter in
the metal casting industry. Based on its direct digital manufacturing principle, 3DSP enables complex
mold and core design freedom that has been previously unavailable to foundry engineers. In
addition, the miniaturization and affordability of electronics and sensing equipment is rapidly
accelerating. Here, these two shifting paradigms are leveraged together. An experimental casting
and mold were designed in this research to demonstrate and evaluate wireless sensing of core shifts.
With the use of 3D sand printing, precisely sized and located pockets were manufactured inside of
cores. Miniature wireless Bluetooth sensors capable of measuring acceleration and rotation were
then embedded inside the cores. From these, high fidelity data were captured wirelessly from the
sensors during the casting process. With strategically designed core prints designed to allow varying
levels of core motion, it is shown that core shifts can be measured and discriminated during casting
in real time.
Keywords: Wireless; Sensors; Process monitoring; Quality control; Metal casting; Additive
manufacturing
M.S. Ayar, V.S. Ayar, P.M. George,
Simulation and experimental validation for defect reduction in geometry varied aluminium plates
casted using sand casting,
Volume 27, Part 2,
2020,
Pages 1422-1430,
ISSN 2214-7853,
Abstract: Casting is a manufacturing process for making complex types of metal materials. Sand
casting is one of the widely used casting processes due to its inherent advantage of no size and
shape constraint with low costs. The main problem with sand casting is defect and yield.
Optimization of process parameters and gating system design can solve these problems.The
configuration of the gating or riser mechanism plays a very significant role in enhancing casting
efficiency.Several researchers reported that 90 percent of casting defects are only obtained due to
improper gating and feeding system design.Simulation can help in this matter a lot to optimize the
various process parameters to get sound casting. In the present work, the behavior of metal filling
and solidification was examined using AUTOCAST – X1 casting simulation software and flowplus
module. Aluminum alloy AlSi5Cu3 was selected due to its excellent properties and a wide range of
commercial applications in automobile and aerospace. The sand mold is selected as mold material
and defect identification has been carried out and confirmed by comparing the simulation results
with the experimental one.
Keywords: Aluminum; Autocast; Casting; Sand; Simulation
P. Rodríguez-González, A.I. Fernández-Abia, M.A. Castro-Sastre, P.E. Robles, J. Barreiro, P. Leo,
Comparative Study of Aluminum Alloy Casting obtained by Sand Casting Method and Additive
Manufacturing Technology,
Volume 41,
2019,
Pages 682-689,
ISSN 2351-9789,
Abstract: In this research, a comparison between traditional sand casting technique and additive
manufacturing technology with InkJet 3D Printing technique (3DP) was made, comparing the
manufacturing time, cooling rate, dimensional deviation, surface quality, surface porosity and
defects. In this way, feasibility and advantages of additive manufacturing was probed to be a good
alternative to non-ferrous alloys sand casting.
Keywords: Inkjet 3D printing; Sand casting; Aluminium Alloy
Hyung-Yoon Seo, Pan-Ki Seo, Chung-Gil Kang,
A study on the S/W application for a riser design process for fabricating axisymmetric large offshore
structures by using a sand casting process,
International Journal of Naval Architecture and Ocean Engineering,
Volume 11, Issue 1,
2019,
Pages 462-473,
ISSN 2092-6782,
https://doi.org/10.1016/j.ijnaoe.2018.08.003.
Abstract: The effects of the location and dimension of the gate, location, and volume of the feeder,
application of a chill, chill volume, and heating method of the feeder with respect to the effect of the
mold-designing technologies on the defect status of the products are described. It is possible to
increase the solidification time of the feeder by heating feeder. Furthermore, the pressure
generated from the feeder is imposed on a product, and this decreases the generation of shrinkage
porosities. In this study, two types of gating and feeding systems had been proposed: the bottom L-
type junctions and the top L-type junctions. Additionally, solidification behaviors, such as
solidification time, shrinkage porosities, weight percentage of chill system to product, hot spot, and
solidification time ratio (=Solidification time of feeder/solidification time of product), are extensively
analyzed by using commercial casting simulation software. Based on the solidification behaviors,
reasonable mold design, feeding system, critical feeder heating temperature, and solidification time
ratios are proposed in the sand casting process for the fabrication of carrier housing in order to
reduce the casting defects and to increase the recovery rate.
Keywords: Axisymmetric large offshore structures; Recovery rate; Feeding system; Chill system;
Solidification time ratio
Tharmalingam Sivarupan, Meet Upadhyay, Yahia Ali, Mohamed El Mansori, Matthew S. Dargusch,
Reduced consumption of materials and hazardous chemicals for energy efficient production of metal
parts through 3D printing of sand molds,
Volume 224,
2019,
Pages 411-420,
ISSN 0959-6526,
Abstract: Metals remain essential structural materials for many demanding engineering applications
requiring high strength at elevated temperatures and good performance in environments subjected
to high thermal fluctuations such as often encountered in the automotive, rail and aircraft industries.
The sand-casting process is one of the most preferred methods of producing complex and intricate
shaped components out of metals with good strength at elevated temperatures. Unfortunately, the
sand casting process also leads to the direct and indirect production of carbon dioxide. Three-
dimensional sand mold printing has been revolutionizing traditional production methods by reducing
the unnecessary consumption of metal and chemicals when manufacturing a part through sand
casting. This paper explores the opportunities that are emerging in the area of 3D printing of sand
molds and the positive impact that these new technologies and practices are having on the
environmental impact of current sand-casting processes. The paper demonstrates that 3D printing of
sand molds enables new manufacturing strategies reducing the direct CO2 emissions and reducing
the amount of metal required by enabling design optimization of both the component and
mold/core assembly. Further benefits will be realized through the development of environmentally
friendly binder systems.
Keywords: 3D sand mold printing; Casting; Carbon emission; Energy saving
M. Swamy, P. Laxminarayana, A.H.V. Pavan, M.C. Antony Harison, G. Jayaraman, K. Singh,
Microstructural characterization and mechanical properties of sand cast and investment cast alloy
625 for HP/IP casing applications for advanced fossil fired power plants,
2018,
Pages 27118-27122,
ISSN 2214-7853,
Abstract: Alloy 625 is a candidate material for high temperature sections of High Pressure (HP)/
Intermediate Pressure (IP) turbine casings for Advanced Ultra Super Critical (AUSC) power plants.
This material is expected to operate at steam temperature of 710°C approx. and pressure of 300 ata
approx. After carrying out a detailed literature survey, it was observed that microstructural
information and mechanical properties data on Alloy 625 cast material is limited. Hence, this study
was undertaken for obtaining of mechanical properties and microstructures at room temperature
through two manufacturing techniques namely, conventional sand casting and investment casting.
Mechanical properties data includes tensile testing and impact testing. The data obtained from this
study is essential for design of casings. The details of the study and results obtained are discussed
and presented in this work.
Keywords: Alloy 625; AUSC; Investment/ shell casting; Sand casting
Satish Kumar Verma, Ashish Mogra,
Analysis of Filling in Thin Section by FEM Based Simulation for LM6 Material,
2018,
Pages 5947-5954,
ISSN 2214-7853,
Abstract: This paper deals with the cooling characteristics of LM6 alloy used as a pouring material for
manufacturing of thin hollow rectangular section during the solidification process inside the mold.
For purpose of an accurate mathematical modeling, it is essential to establish appropriate gating
design and pouring temperature. Here simulation experimental study is carried out by using Pro
CAST 2009.0 for LM6 alloy. In this investigation pouring is done on thin rectangular section at
different pouring temperature and sprue height. Finally a comprehensive analysis result shows that
for efficient casting, pouring temperature is more significant parameter as compared to sprue
height.
Keywords: Sand castings; LM6; Mold filling; Solidification
Francesco Grazzi, Antonio Brunetti, Antonella Scherillo, Marco E. Minoja, Gianfranca Salis, Sergio
Orrù, Anna Depalmas,
Non-destructive compositional and microstructural characterization of Sardinian Bronze Age swords
through Neutron Diffraction,
Volume 144,
2018,
Pages 387-392,
ISSN 1044-5803,
Abstract: The Monte Sa Idda type swords belong to a well characterized typological class, whose
origin has long been debated and seems to coincide with the Iberian Peninsula. The name comes
from the site of the first discovery of a hoard containing this type of swords, among other bronze
artefacts, namely Monte Sa Idda, Decimoputzu-Cagliari, Italy. The swords were produced through
fusion inside a casting mould. Such kind of casting mould has not been found in Sardinia, and this
may suggests that finished objects were either imported or made using clay or sand casting mould.
Moreover, the discovery of these types of sword, in hoards and in votive deposits, raises the
problem of their functional use. It is unknown if the blades were intended to be used as weapons,
and therefore subjected to cold working necessary for thinning and sharpening of the blade, or as
ceremonial objects. In order to answer to these questions, a neutron diffraction experiment was
performed on three swords belonging to the Monte Sa Idda type. The results obtained are presented
and discussed in the paper.
Santosh Reddy Sama, Tony Badamo, Paul Lynch, Guha Manogharan,
Novel sprue designs in metal casting via 3D sand-printing,
Volume 25,
2019,
Pages 563-578,
ISSN 2214-8604,
Abstract: The opportunity to improve the quality of metal castings by enabling fabrication of
complex gating systems via 3D Sand-Printing (3DSP) has been recently established. Among the
different components of a gating system (often called rigging), sprue design offers a major
opportunity to exploit the unlimited geometric freedom offered by 3DSP process. In this study,
conventional principles of casting hydrodynamics is advanced by validated novel numerical models
for novel sprue designs to improve melt flow control. Computational flow simulations demonstrate
that conical-helix sprue satisfy the critical velocity condition by reducing the ingate velocity below
0.5 m/s. Multiple approaches to integrate 3DSP into conventional manufacturing to fabricate
complex gating systems through “Hybrid Molding” are presented. 3DSP molds featuring two
optimized sprue profiles and a benchmark straight sprue are fabricated to pour 17-4 stainless steel.
Computed tomography scans (CT) shows that parabolic sprue casting (PSC) and conical-helix sprue
casting (CHSC) reduced overall casting defects by 56% and 99.5% respectively when compared to
straight sprue casting (SSC). Scanning electron microscopy (SEM) analysis confirms the presence of
globular oxide inclusions and that PSC and CHSC exhibits 21% and 35% reduced inclusion when
compared to the SSC. Three point flexural testing reveals that CHSC and PSC exhibits an increase of
8.4% and 4.1% respectively in average ultimate flexural strength than SSC. The findings from this
study demonstrate that numerically optimized gating systems that can only be fabricated via 3DSP
have the potential to significantly improve both mechanical and metallurgical performance of sand
castings.
Keywords: 3D sand-printing; Metal casting hydrodynamics; Gating system; Sprue; Flow simulation;
Casting defects
Fuchu Liu, Li Yang, Ying Huang, Peng Jiang, Guang Li, Wenming Jiang, Xinwang Liu, Zitian Fan,
Performance of resin bonded sand for magnesium alloy casting,
Volume 30,
2017,
Pages 313-319,
ISSN 1526-6125,
Abstract: The factors which affect performance of no-bake resin bonded sand (NBRBS) were
investigated, including furan resin, curing agent and boric acid content and kinds of collapsibility
agents and base sand. The results show that when the furan resin addition is 1.6wt% of base sand
content and the curing agent addition is 50wt% of furan resin content, the comprehensive
performance of NBRBS achieves optimization. The use of boric acid increases the curing speed,
retained strength and gas evolution. The use of KI reduces the retained strength with a good tensile
strength. When ceramacore being used as base sand, furan resin addition decreases greatly, and the
tensile strength increases, gas evolution and retained strength both decrease, which can improve
collapsibility of NBRBS. The SEM analysis demonstrates that the ceramacore particle is round,
appeares standard sphere, and the ceramacore can form complete bonding film and bridge.
Keywords: Sand casting; Furan resin; Magnesium alloy casting; Collapsibility; Tensile strength; Gas
evolution
R.P. Barot, V.S. Ayar,

Casting simulation and defect identification of geometry varied plates with experimental validation,
Volume 26, Part 2,
2020,
Pages 2754-2762,
ISSN 2214-7853,
Abstract: This work mainly deals with the simulation of geometry varied plates subjected to
permanent mold gravity casting process. There are extensive demands of Aluminum and its alloys in
diverse industries owing to its better properties especially mechanical (good strength and stiffness
with low density). Aluminum alloy AlSi5Cu3 was chosen and the behavior of metal filling and
solidification was examined using AUTOCAST – XI software equipped with flow plus module. Three
rectangular plates with variation in thickness were selected as casting geometry with equal length
and width. Three feeders have been applied to each cavity at various locations with optimized
dimensions. The casting yield and casting quality were calculated for all casting geometry. The values
of casting yield for 8 mm, 12 mm and 16 mm thick plates were 91.20%, 91.5% and 92.05% while
casting quality were 95.20%, 94.05% and 93.68%, respectively. The temperature difference, the
velocity of melted metal and solidification time were analyzed for thickness varied plates. The front
velocity of the liquid metal was calculated and having values of 1.02 m/sec, 0.91 m/sec and
0.39 m/sec and solidification time was 23.56 sec, 31.56 sec and 37.35 sec for 8 mm, 12 mm and
16 mm thick plates, respectively. The cooling curves for different geometry were obtained by placing
virtual thermocouple at various locations. Shrinkage porosity defect identified and validated with
actual experimentation. The depth of shrinkage porosity was measured by simulation results and
calculated for actual casted plates. It showed a variation of shrinkage porosity depth by 10%, 5.88%
and 4.34% for 8 mm, 12 mm and 16 mm thick plates, respectively.
Keywords: AutoCAST; Casting; Defect; Geometry; Simulation; Solidification
A. Lombardi, W. Mu, C. Ravindran, N. Dogan, M. Barati,
In-situ investigation of incipient melting in a 319 type Al alloy using laser scanning confocal
microscopy,
Volume 141,
2018,
Pages 328-337,
ISSN 1044-5803,
Abstract: The modified 319 Al alloy system has been used extensively in precision sand casting of
automotive powertrain applications such as engine blocks and cylinder heads, with significant
improvement in vehicle fuel efficiency. However, a concern in elevated temperature processing of Al
alloys, such as heat treatment and hot working processes, is incipient melting of secondary phases,
which is deleterious to mechanical properties. In this study, the laser scanning confocal microscopy
(LSCM) technique was used in the analysis of in-situ changes in microstructure as a result of incipient
melting. Microstructural analysis was carried out prior to and following elevated temperature
exposure in the LSCM using optical microscopy, SEM and EDX. The results suggest that incipient
melting of the Al-Al2Cu-Al5Mg8Cu2Si6 ternary eutectic clusters was initiated by the formation of a
liquid film which propagated rapidly from the eutectic clusters, coating the Al dendrites in regions
adjacent to the eutectic clusters. Following film formation, the ternary eutectic clusters melted
completely. Incipient melting also resulted in a localized change in composition in the interdendritic
channels as supported by a change in cluster morphology from eutectic to a combination of coarse
blocky Al-Cu-Ni and Si particles, and ultra-fine eutectic.
Keywords: 319 Al alloy; Heat treatment; Elevated temperature processing; Incipient melting; Laser
scanning confocal microscopy
Xiaolong Gong, Wenming Jiang, Shengli Hu, Zhiyuan Yang, Xinwang Liu, Zitian Fan,
Comprehensive utilization of foundry dust: Coal powder and clay minerals separation by ultrasonic-
assisted flotation,
Journal of Hazardous Materials,
2020,
124124,
ISSN 0304-3894,
https://doi.org/10.1016/j.jhazmat.2020.124124.
Abstract: Clay sand casting generates a large amount of foundry dust (FD), and the presence of coal
powder in the FD makes it difficult to recycle and utilize. The landfill of the FD creates a serious
environmental pollution and wastes a valuable resource. To improve the above situation, the FD was
analyzed and characterized by X-ray fluorescence spectrometer (XRF), X-ray diffraction (XRD) and
electron probe microanalyzer (EPMA). An ultrasonic-assisted flotation process was developed for the
comprehensive utilization of the FD, and the effects of ultrasonic time on the flotation performance
and flotation kinetics were investigated. In addition, the two-stage flotation of the FD was
conducted. Obtained results showed that the FD mainly consisted of coal powder and clay minerals,
and the coal powder was covered by clay minerals. The separation efficiency of the coal powder and
clay minerals can be significantly enhanced by ultrasonic pretreatment, and the optimal ultrasonic
time was 30 min. The flotation kinetics analysis results indicated that the first-order model with
rectangular distribution was more reasonable for the data fitting of the ultrasonic-assisted flotation.
Furthermore, the concentrate and tailings obtained by the two-stage flotation had achieved an
acceptable result, favoring the comprehensive utilization of the FD.
Keywords: Foundry dust; Flotation performance; Recycling; Ultrasonic pretreatment; Flotation
kinetics
Payam Haghighi, Satchit Ramnath, Nathan Kalish, Jiten V. Shah, Jami J. Shah, Joseph K. Davidson,
Method for automating digital fixture-setups that are optimal for machining castings to minimize
scrap,
Journal of Manufacturing Systems,
Volume 40, Part 2,
2016,
Pages 15-24,
ISSN 0278-6125,
https://doi.org/10.1016/j.jmsy.2016.05.004.
Abstract: The motivation for this paper is to describe a method for lowering the cost of finishing
large castings that have machined surfaces for attaching other components. Considerable time is
required to set-up each cast part on a machine-tool, sometimes taking longer than the machining
itself, and errors in set-up can result in scrapping expensive parts or attempts to salvage them by
rework. Although the focus of the paper is to demonstrate a new technology and software for set-up
prior to the machining of iron/aluminum/steel sand castings, the same technology also is applicable
to large welded assemblies on which finished machining occurs. In this paper, we outline a method,
currently being implemented, that can predictively, and off-line, identify the adjustments needed to
position and orient each part in its fixture before machining operations begin so that, after
machining, all finished features will lie in their tolerance zones. Computer models first simulate all
the to-be-machined (TBM) surfaces and any contact points with the fixture by feature-fitting point
clouds taken from selective scanning of the raw casting. The locations of these features are
compared with their locations on the CAD model of the part. Then, by using the T-Map model for
tolerances, all possible locations of the part in its machining fixture are identified so that all TBM
faces lie in their tolerance-zones. An optimum location may then be chosen.
Keywords: Automation; Fixture adjustments; Casting; Machining; Manufacturing
Bo DANG, Cong-cong LIU, Feng LIU, Ying-zhuo LIU, Yuan-bing LI,
Effect of as-solidified microstructure on subsequent solution-treatment process for A356 Al alloy,
Volume 26, Issue 3,
2016,
Pages 634-642,
ISSN 1003-6326,
https://doi.org/10.1016/S1003-6326(16)64152-3.
Abstract: For the compromise of mechanical properties and product cost, the end-chilled sand
casting technique was applied to studying the microstructure evolution of A356 Al alloy with cooling
rate and the effect of different as-cast microstructures on the subsequent solution-treatment
process. The experimental results show that the secondary dendrite arm spacing (SDAS) of primary
α(Al), the size of eutectic Si and the volume fraction of Al–Si eutectic are reduced with increasing the
cooling rate. Eutectic Si, subjected to solution treatment at 540 °C for 1 h followed by water
quenching to room temperature, is completely spheroidized at cooling rate of 2.6 K/s; is partially
spheroidized at cooling rate of 0.6 K/s; and is only edge-rounded at cooling rates of 0.22 and 0.12
K/s. Whilst the microhardness is also the maximum at cooling rate of 2.6 K/s. It consequently
suggests that subjected to modification by high cooling rate, the eutectic Si is more readily modified,
thus shortening the necessary solution time at given solution temperature, i.e., reducing the product
cost.
Keywords: A356 Al alloy; solution heat treatment; cooling rate; eutectic silicon; modification
Dean A. Snelling, Christopher B. Williams, Alan P. Druschitz,
Mechanical and material properties of castings produced via 3D printed molds,
Volume 27,
2019,
Pages 199-207,
ISSN 2214-8604,
Abstract: Additive manufacture of sand molds via binder jetting enables the casting of complex
metal geometries. Various material systems have been created for 3D printing of sand molds;
however, a formal study of the materials’ effects on cast products has not yet been conducted. In
this paper the authors investigate potential differences in material properties (microstructure,
porosity, mechanical strength) of A356 – T6 castings resulting from two different commercially
available 3D printing media. In addition, the material properties of cast products from traditional
“no-bake” silica sand is used as a basis for comparison of castings produced by the 3D printed molds.
It was determined that resultant castings yielded statistically equivalent results in four of the seven
tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength and
differed in sand tensile strength, hardness, and density.
Keywords: Additive manufacturing; Binder jetting; Indirect 3D printing; Metal casting; Sand casting
Yuichi Motoyama, Shuhei Sekiguchi, Toshimitsu Okane, Makoto Yoshida,

Thermo-elasto-plastic finite element analysis of warping deformation during casting of gray cast iron,
Volume 277,
2020,
116454,
ISSN 0924-0136,
Abstract: Warpage defect is a crucially important difficulty, especially for large or long iron castings.
Thermal stress analysis via computer aided engineering (CAE) is an effective means of predicting
warpage defect. Nevertheless, no report of the relevant literature has described a study
investigating the mechanism of warping deformation by comparison of in-situ measurements of
warpage deformation in an iron casting during cooling with results of thermo-elastic-plastic analysis.
This study measured warping deformation of a gray cast iron casting composed of thick and thin
parts during sand casting. Then the deformation process was elucidated experimentally.
Subsequently, based on the experiment results, this study used thermo-elasto-plastic analysis and
simulated warping deformation in iron casting. Then the simulation results were compared with
actual measurements, which revealed that the analytically obtained results agreed qualitatively with
the experimentally obtained measurements of warping deformation. Results demonstrated that the
warping deformation of the casting can be predicted with error of not more than 26%. The
temperature difference that existed when the whole casting had haven strength caused different
thermal contraction of thick and thin parts during cooling, which produced warping deformation of
the iron casting.
Keywords: Casting; Constitutive equation; Finite element analysis; Thermal stress; Warpage
K.T. Akhil, Jerry Varghese, Arun Raphel, K. Vinoj, Frenosh K. Francis,
To Study the Cooling Rate and Influence of Boron Carbide on Mechanical Properties of Aluminium
LM13 Matrix B4C Reinforced Composites,
Volume 4, Issue 8,
2017,
Pages 7202-7207,
ISSN 2214-7853,
Abstract: Aluminium Metal Matrix Composites are one of the advanced engineering materials that
have been widely used in aerospace and automotive industries due to their excellent mechanical
properties. In Aluminium Metal Matrix Composite, aluminium matrix is strengthened by reinforcing
it with hard ceramic particles like Sic, Al2O3, and B4C etc. Aluminium Metal Matrix Composite was
manufactured by sand casting process with Aluminium-LM13 grade as base metal and boron carbide
as reinforcement. This study investigates the cooling rate and influence of boron carbide on
mechanical properties of Aluminium Metal Matrix Composites. Experiments were performed by
casting of Aluminium Metal Matrix Composites with varying the weight Percentage of boron carbide
from 3% to 9% and cooling rate is measured using k type thermocouple at point 1mm away from the
mold cavity.In order to investigate the influence of boron carbide on mechanical properties
microstructure analysis, tensile tests, hardness tests were conducted. Results showed that
mechanical properties of Aluminium Metal Matrix Composite were improved with Percentage of
boron carbide.
Keywords: Aluminium Metal Matrix Composites; Influence of boron carbide; Mechanical properties;
Aluminium-LM13
Madhav Goenka, Chico Nihal, Rahul Ramanathan, Pratyaksh Gupta, Aman Parashar, J. Joel,
Automobile Parts Casting-Methods and Materials Used: A Review,
Volume 22, Part 4,
2020,
Pages 2525-2531,
ISSN 2214-7853,
Abstract: Automobiles are becoming more and more sophisticated with every passing year.
Manufacturers have been trying their best to bring down the kerb weight of their automobiles by
using various materials with high strength to weight ratio. The different parts of the automobile are
being made much stronger than before in order to comply with the high standards set by NCAP.
Hence, this pushes automobile makers to come up with new and innovative methods to
manufacture the parts of their automobiles. Our paper addresses the various casting processes used
to make automobile parts and also touches on the various materials used to make the components.
The casting methods discussed are- Green sand casting, Centrifugal casting, Lost- foam casting, Die
casting and Squeeze casting. In the paper we discuss about the most suited materials used for each
component and briefly discuss about the pros and cons of each process
Keywords: Centrifugal Casting; Die Casting; Engine Block; Piston; Al-Si Alloys; CGI
Konstantinos Salonitis, Mark R. Jolly, Binxu Zeng, Hamid Mehrabi,
Improvements in energy consumption and environmental impact by novel single shot melting
process for casting,
Volume 137,
2016,
Pages 1532-1542,
ISSN 0959-6526,
Abstract: The CRIMSON (Constrained Rapid Induction Melting Single Shot Up-Casting) method uses a
rapid induction furnace to melt just enough metal for a single mould rather than bulk melting used
in traditional casting process. The molten metal is then transferred to a computer – controlled
platform to complete the counter-gravity up filling. The highly controlled metal flow is pushed into
the mould to finish the pouring and solidification. In the present paper the energy saving capability
of CRIMSON approach is compared with conventional sand casting process. The paper focuses on
the energy and resource efficiency optimization of casting stages through simulation and life cycle
assessment analysis simulation for proposing alternative means for the better performance of such
processes. It is proven that the CRIMSON process can produce high quality castings with higher
energy efficiency and lower environmental impact.
Keywords: Casting; Foundry sector; CRIMSON; Sand casting; LCA; Yield
Priyam L. Borgohain,
Downstream impacts of the Ranganadi hydel project in Brahmaputra Basin, India: Implications for
design of future projects,
Environmental Development,
Volume 30,
2019,
Pages 114-128,
ISSN 2211-4645,
https://doi.org/10.1016/j.envdev.2019.04.005.
Abstract: This study analyses the downstream hydrological, morphological, and socio-economic
impacts of the sole operating hydropower scheme - Ranganadi Hydel Project Stage I in Arunachal
Pradesh (India), the state with the largest potential and the highest number of upcoming hydro
schemes in the country. The project has a large dam with inter-basin water diversion for electricity
generation, thereby affecting flow in two rivers of the Brahmaputra Basin - Ranganadi and Dikrong.
Flow alterations were measured using Nature Conservancy's Indicators of Hydrological Alteration
model, while planform changes were studied using multi-temporal satellite imagery and
Geographical Information System. The results indicated significant downstream flow alterations by
the project in the post-dam period. Post-dam median annual flows in the impounded and flow-
deprived river - Ranganadi, have decreased by 63%, but increased by 138% in the recipient river -
Dikrong. The former displayed channel narrowing and decreased braiding, while the latter exhibited
a wider and more braided planform. Unexpected releases from the reservoir, flash floods, and sand
casting were the major problems cited by the downstream communities in the Ranganadi sub-basin,
which impacted upon agricultural lands and livelihoods. This study recommends mitigation plans
that could be followed by both existing and future hydropower projects.
Keywords: Brahmaputra basin; Hydropower development; Ranganadi; Flow alterations; Modified

planform; Socio-economic impacts
Hong Liu, Ting Lei, Cong Ma, Fan Peng,
Optimization of driven waveform of piezoelectric printhead for 3D sand-printing,
2020,
101627,
ISSN 2214-8604,
Abstract: Micro-droplet injection forming technology demonstrates considerable potential with

regard to additive manufacturing of complex casting sand molds. However, the influence of micro-
droplet injection characteristics on the forming accuracy and injection regulation strategies is
relatively weak during the process of promoting the industrialization of three-dimensional sand
printing. Moreover, the practical requirements of precision rapid prototyping of complex sand molds
have not been adequately addressed through investigations on the aforementioned influence. A
jetting experiment platform is developed herein to optimize the driving waveform of a piezoelectric
printhead. On the basis of theoretical simulations and experimental verification, the influence of the
printhead waveform on its jetting characteristics is discussed. A method for driving the waveform is
presented to improve and optimize the casting sand mold performance. Several case studies are
presented to illustrate the effectiveness of the optimized driving waveform for enhancing the casting
sand mold performance via systematic printing of a standard sand mold test block. Moreover, the
optimal driving waveform’s contribution to the forming accuracy and efficiency of a large-scale
casting sand mold is investigated through experiments using a three-dimensional sand printer. On
the basis thereof, the effectiveness of the optimal driving waveform is demonstrated to improve not
only the forming accuracy of the sand mold but also the production efficiency. This development can
transform the industry of sand casting to produce high-quality castings.
Keywords: 3D printing; Casting sand mold; Printhead; Micro-droplet injection; Forming accuracy
Farzaneh Farhang Mehr, Steve Cockcroft, Carl Reilly, Daan Maijer,

Investigation of the efficacy of a water-cooled chill on enhancing heat transfer at the casting-chill
interface in a sand-cast A319 engine block,
Volume 286,
2020,
116789,
ISSN 0924-0136,
Abstract: In the recent years, the automotive industry has increased the production of small, high-
power gas engines as part of several strategies to attain the new “Corporate Average Fuel Economy”
(CAFE) standards, while meeting consumer demand for increased performance at the same time.
This trend necessitates an improvement in the thermal and mechanical fatigue strength of the
aluminium alloys used in manufacturing cylinder heads and engine blocks in these engines. In the
absence of changing alloy chemistry, which potentially has important implications for downstream
operations such as heat treating and machining, one feasible way to improve fatigue life is to reduce
the length-scales of the microstructural constituents arising from solidification that limit fatigue
resistance. This, in turn, may be accomplished by increasing the cooling rate during solidification
(reducing the solidification time). Conventionally, solid chills are employed in the industry to achieve
this goal. A potential tactic for improving the efficacy of these chills is to incorporate water cooling.
In order to assess the effectiveness of this technique, a water-cooled chill was designed and installed
in a bonded-sand engine block mould package (quarter section). Twelve experiments were
conducted with a conventional solid chill and a water-cooled chill (with and without delay in water
cooling). The moulds were instrumented with “Linear Variable Displacement Transducers” (LVDTs) to
measure the gap formation at the casting-chill interface, and thermocouples to measure the
evolution of temperature at key locations in the casting and the chill. Overall, the results show that
the adoption of water-cooled chill technology, if implemented carefully, has the potential to improve
the cast microstructure, therefore, increase the fatigue durability of the engine blocks.
Keywords: Precision Sand Casting; Engine block casting; Chill; Water cooled chill; Microstructure;
Dendrite arm spacing; Solidification; Cooling rate; A319 alloy; Interface gap; Heat transfer; Interfacial
heat transfer
Jun Zheng, Ankai Chen, Wang Zheng, Xingjian Zhou, Bing Bai, Jian Wu, Wei Ling, Hongping Ma, Wei
Wang,
Effectiveness analysis of resources consumption, environmental impact and production efficiency in

traditional manufacturing using new technologies: Case from sand casting,
Energy Conversion and Management,
Volume 209,
2020,
112671,
ISSN 0196-8904,
https://doi.org/10.1016/j.enconman.2020.112671.
Abstract: The emergence of new technologies has accelerated the process of sustainable
development, gradually moving traditional manufacturing away from labor-intensive low-end
towards high value-added and high-quality production. In order to study the application
effectiveness of new technologies, the production of single or small batch castings in the traditional
foundry industry is taken as the analysis object by using traditional manufacturing method, additive
manufacturing (ink-jet bonding 3D printing) and subtractive manufacturing (sand mold milling), from
the aspects of resources consumption, environmental impact and production efficiency. Among
them, the resources consumption takes material, energy, and human resources into comprehensive
consideration, while the environmental impact takes carbon emission as the main evaluation index,
and the production efficiency is determined according to the actual casting output of the enterprise,
this evaluation method is applicable to most of the traditional manufacturing industries. The results
indicate that in the production of this kind of castings, additive and subtractive manufacturing have
better resource utilization and significantly reduced the carbon emission of sand casting process by
about 20.78% and 4.82%, respectively. Besides, the production efficiency of additive and subtractive
manufacturing are 92.66% and 91.39% respectively, which has superiority not only in production
capacity but also in economic benefits. According to the research conclusion, reference of what or
whether new technologies can be used in traditional manufacturing to realize sustainability is
provided, which has certain practical significance.
Keywords: Traditional manufacturing; New technologies; Sustainability; Resource utilization;

Effectiveness evaluation
Lintao Zhang, Fawzi Belblidia, Helen M. Davies, Nicholas P. Lavery, Stephen G.R. Brown, Dyfyr Davies,
Optimizing gate location to reduce metal wastage: Co–Cr–W alloy filling simulation,
Volume 240,
2017,
Pages 249-254,
ISSN 0924-0136,
Abstract: This research aimed at reveal the reasons for the extra Co–Cr–W alloy wastage in the risers
in sand casting. The alloy filling behaviour in both the original and modified moulds was investigated
numerically. The alloy–air interface was captured by using volume of fraction method. For the
original mould, an unfilled volume in the vicinity of the runner bar top was apparent and it was
refilled by a back flow, originated from the risers in the late stage of filling. The back flow behaviour
required a higher level of the liquid alloy in the risers, which resulted in excessive wastage, and it
was essential to form the required shape of the cast. For the modified mould, the unfilled volume
was eliminated and the cast part shaping time was reduced to around 10s from 90s. The alloy
wastage in the risers was reduced by 11%.
Keywords: Sand casting; Mould design; Co–Cr–W alloy; Computational fluid dynamics; Filling
behaviour
Anne C.M. Bekker, Jouke C. Verlinden,
Life cycle assessment of wire + arc additive manufacturing compared to green sand casting and CNC
milling in stainless steel,
Volume 177,
2018,
Pages 438-447,
ISSN 0959-6526,
Abstract: Wire and Arc Additive Manufacturing (WAAM) is a metal 3D printing technique based on
robotic welding. This technique yields potential in decreasing material consumption due to its high
material efficiency and freedom of shape. Empirical measurements of WAAM, using a deposition
rate of 1 kg/h, were performed on site of MX3D. The measured power consumption per kg stainless
steel is 2.72 kW, of which 1.74 is consumed by the welder, 0.44 by the robotic arm, and 0.54 by the
ventilation. The material loss was 1.1%. A 98% argon 2% CO2 welding gas was used with a flow of
12 l/min. A cradle-to-gate Life Cycle Assessment (LCA) was performed. To give this assessment
context, green sand casting and CNC milling were additionally assessed, through literature and
databases. The purpose of this study is to develop insight into the environmental impact of WAAM.
Results indicate that, in terms of total ReCiPe endpoints, the environmental impact of producing a kg
of stainless steel 308 l product using WAAM is comparable to green sand casting. It equals CNC
milling with a material utilization fraction of 0.75. Stainless steel is the main cause of environmental
damage in all three techniques, emphasizing the importance of WAAM's mass reduction potential.
When environmentally comparing the three techniques for fulfilling a certain function, optimized
designs should be introduced for each manufacturing technique. Results can vary significantly based
on product shape, function, materials, and process settings.
Keywords: LCA; Additive manufacturing; Wire + arc additive manufacturing; Metal 3D printing;
Environmental impact
Sascha Gerbe, Jochen Tenkamp, Steffen Scherbring, Kevin Bleicher, Ulrich Krupp, Wilhelm Michels,
Frank Walther,
Microstructural influences on the fatigue crack initiation and propagation mechanisms in hypo-
eutectic Al-Si cast alloys,
Volume 23,
2019,
Pages 511-516,
ISSN 2452-3216,
Abstract: Al-Si cast alloys are accompanied by different defects and microstructural heterogeneities
like porosity, varying secondary dendrite arm spacings (SDAS) and multiple appearances of the
eutectic. These issues are well known but technically difficult to prevent for the industry. To improve
the light weight performance of cast aluminum alloys the present work deals with influences on
crack initiation and propagation mechanisms of such heterogeneities in the high-cycle-fatigue (HCF)
and very-high-cycle-fatigue (VHCF) regime for the two hypo-eutectic cast aluminum alloys AlSi8Cu3
(in-series sand castings) and AlSi7Mg0.3 (laboratory gravity die castings). Furthermore, the
occurrence of facet-regions and their role in early and late state of fatigue damage evolution is
discussed by showing results from modified Kitagawa-Takahashi analysis and ex-situ computed
tomography investigation during intermitted HCF experiments. In the early HCF regime crack
initiation starts at multiple pores. Due to coalescence of these defects, shear-stress-controlled crack
propagation along slip bands leads to the occurrence of facets. In the VHCF regime, porosity
provides strong scattering of the number of cycles to failure. A reduction in SDAS increases the
fatigue strength significantly. However, in absence of porosity fatigue crack initiation and
propagation is controlled by shear stresses on facet-like slip-planes. Additionally, the barrier role
against dislocation movement of eutectic regions can be shown by means of these specimens.
Keywords: cast aluminum; fatigue; HCF; VHCF; porosity; SDAS; microstructural barrier; crack
propagation
C. Dharmendra, B.S. Amirkhiz, A. Lloyd, G.D. Janaki Ram, M. Mohammadi,
Wire-arc additive manufactured nickel aluminum bronze with enhanced mechanical properties using
heat treatments cycles,
Volume 36,
2020,
101510,
ISSN 2214-8604,
Abstract: Wire-arc additive manufacturing (WAAM) technique was used to develop nickel aluminum
bronze (NAB) components for naval applications. The microstructural changes were characterized
using scanning electron microscopy (SEM) and transmission electron microscopy (TEM) with energy
dispersive spectroscopy (EDS). As-built WAAM-NAB consists of κII (globular Fe3Al) and κIII (lamellar
NiAl) phases in the interdendritic regions and fine Fe-rich κIV particles in the Cu-matrix. Along the
build direction, the WAAM-NAB flat samples exhibited yield and ultimate tensile strength values of
380 and 708 MPa, respectively, and 34 % elongation. Furthermore, three different heat-treatments
were performed on the samples in a view to evaluating their effect on mechanical properties. When
heat-treated to 350 °C for 2 h (HT-1), there are no significant microstructural changes, and tensile
properties along the build direction are similar to the as-built WAAM-NAB. Heat-treatment at 550 °C
for 4 h (HT-2) produced a new needle-like κv phase in the α-matrix, coarsening of globular κII, partial
spheroidization of lamellar κIII, and reduced amount of κIV precipitation. As compared to the
WAAM-NAB, HT-2 samples exhibited a significant increase in yield strength (∼90 MPa), and ultimate
tensile strength (∼60 MPa); however, tensile ductility was observed to drop by 20 %. After heat-
treatment at 675 °C for 6 h (HT-3), globular κII and needle-like κv were coarsened, lamellar κIII was
completely spheroidized, and the amount of κIV was significantly reduced. HT-3 samples showed
better tensile strength (∼37 MPa) than the WAAM-NAB with marginal loss (6%) in the ductility.
Keywords: Nickel aluminum bronze (NAB); Wire-arc additive manufacturing (WAAM); Heat
treatment; Electron microscopy; κ-Phases; Tensile properties
C.R. Hasbrouck, Joseph W. Fisher, Manuel Rudy Villalpando, Paul C. Lynch,
A Comparative Study of Dimensional Tolerancing Capabilities and Microstructure Formation

between Binder Jet Additively Manufactured Sand Molds and Olivine Green Sand Molds for
Metalcasting of A356.0,
Volume 48,
2020,
Pages 338-348,
ISSN 2351-9789,
Abstract: The development of additive manufacturing in the 1980s led to a revolution in various
metalcasting processes as early as the 1990s, including the use of polymer 3D printing for the
manufacture of sand casting patterns. While additive manufacturing has entered many metalcasting
processes, including both expendable and permanent mold processes, this paper specifically
examines the sand casting process. ExOne’s development of binder jetting technology over the last
20 years has allowed designers in the sand casting field to directly 3D print sand molds for
metalcasting. Use of binder jet additively manufactured sand molds allows for quicker turnaround
time for testing prototypes, new gating designs, and for producing one-off parts. Additive
manufacturing of sand molds for metalcasting may implement any of the same foundry sands as
green sand processes, but uses a furan binder instead of the traditional mixture of bentonite clay
and water. The use of a chemical binder had led to questions about the resulting dimensional
capabilities and mechanical properties of the castings produced by the mold. This study investigated
the dimensional tolerancing capabilities, surface finish, mechanical properties, microstructure, and
defects present in identical castings made from both a traditional olivine green sand molding process
and a binder jet additively manufactured silica sand molding process. It was concluded that binder
jet additively manufactured sand molds are capable of either equal or better dimensional accuracy
and tolerance capabilities than traditional olivine green sand molds. The olivine green sand parts had
an average of approximately 1 μm better surface finish than the binder jet sand molds; however, it is
likely that both the addition of sea coal to the green sand and the difference in final part color
significantly affected this result. The mean hardness of the binder jet parts was 58.9 HBW with a
standard deviation of 5.6 HBW, compared to the mean of the green sand parts of 47.7 HBW with a
standard deviation of 7.2 HBW. The hardness findings were confirmed by the presence of a finer
microstructure in the binder jet parts than the green sand parts. While both types of molds
produced parts with defects, a greater variety of defects was evident in the olivine green sand
molds. Porosity tended to move toward the surface of the olivine green sand parts, but was
relatively evenly spread through the additively manufactured sand mold parts.
Keywords: Hybrid Manufacturing; Additive Manufacturing; Metalcasting; Binder Jetting; Metallurgy;

Tolerancing; Microstructure; Cooling Rate
Sachin L. Nimbulkar, Rajendra S. Dalu,
Design optimization of gating and feeding system through simulation technique for sand casting of
wear plate,
Perspectives in Science,
Volume 8,
2016,
Pages 39-42,
ISSN 2213-0209,
https://doi.org/10.1016/j.pisc.2016.03.001.
Abstract: Summary
Casting is a manufacturing process to make complex shapes of metal materials; during mass
production, we may experience many defects, such as gas porosity, pin holes, blow holes, shrinkages
and incomplete filling that may occur in sand casting. Porosity is one of the defects most frequently
encountered in ductile iron casting. Porosity impacts cost by scrap loss and limits the use of cast
parts in critical high strength applications. The amount of porosity is closely related to the parameter
of sand casting process. The gating/riser system design plays a very important role for improving
casting quality. Many researchers reported that 90% of the defects in casting are obtained only
because of improper design of gating and feeding system. The main objectives were to study the
existing design of gating and feeding system, to optimize the gating and feeding system using Auto-
CAST X1 casting simulation software, to prepare the sand mold and cast the part, to compare the
simulated result and experimental results, to reduce rejection rate and to enable the company to
again start the production.
Keywords: Design; Feeder and gating; Simulation; Sand casting
Jigar Suthar, Kaushik Patel,
Identification, screening and optimization of significant parameters for stir cast hybrid aluminium
metal matrix composite,
Heliyon,
Volume 4, Issue 12,
2018,
e00988,
ISSN 2405-8440,
https://doi.org/10.1016/j.heliyon.2018.e00988.
Abstract: Different industries have explicit applications of Aluminum Metal Matrix Composites
(AMMCs). However, porosity, wettability and Ultimate Tensile Strength (UTS) are important factors
that need to consider while fabricating AMMCs. This paper focuses on identification of the most
significant parameters for low porosity and high ultimate tensile strength (UTS) of hybrid aluminium
metal matrix composite. Significant as well as non-significant factors were identified from the
literature survey and trial experiments. Without considering the significance of given responses,
identified factors were represented graphically by the fishbone diagram. FMEA (Failure Mode and
Effect Analysis) was used to find out significant parameters from all the parameters that represented
by fishbone diagram. Afterwards, Plackett-Burman design was used to screen the most significant
parameters out of the significant parameters. Stirring speed, stirring time, preheating temperature
and reinforcement amount was found the most significant parameters to attain high UTS and low
porosity. However, because of the unfavourable combination of parameters % porosity increased
beyond 7% during screening design based experiments. Subsequently, these parameters were
optimized by factorial design. The result shows optimized parameters stirring speed 650 rpm and
stirring time 12 minutes provides low porosity and high UTS. UTS improved up to 310 MPa due to an
optimized range of stirring speeds and stirring time. However, porosity increased beyond 3% due to
excess stirring in cast composites during factorial design based experiments. Moreover, studies were
carried out to understand the effect of stirring, fluxing, degassing and moulding methods on
porosity, UTS, clustering and surface finish of the cast composite. It was observed from a
supplementary study that permanent mould reduces surface roughness below 3μm, compared to
the sand casting process. The porosity was reduced below 3% by degassing and fluxing. Low
agglomeration was observed in specimen prepared with automatic stirring process compared to the
manually stirred specimen. Compared to others, in specimen 4, UTS was improved beyond 150 MPa
because of permanent mould, automatic stirring, degassing and fluxing.
Keywords: Metallurgical engineering; Materials science; Mechanical engineering

Zhenyu Zhong, Wenbo Liu, Ning Li, Jiazhen Yan, Jinwu Xie, Dong Li, Ying Liu, Xiuchen Zhao, Sanqiang
Shi,
Mn segregation dependence of damping capacity of as-cast M2052 alloy,
Volume 660,
2016,
Pages 97-101,
ISSN 0921-5093,
Abstract: In this paper, three types of sand-casting M2052 alloys subjected to different heat
treatments have been designed and prepared in order to investigate the relationship between Mn
segregation and damping capacity using dynamic mechanical analysis, optical microscopy, X-ray
diffraction, scanning electron microscopy, and energy dispersive spectroscopy. The results show that
damping capacity has a crucial dependence on the Mn segregation in as-cast M2052 alloy. The
original as-cast alloy without subsequent heat treatment shows its internal friction (Q−1) is
1.52×10−2 at a strain amplitude of γ=2×10−4, while a remarkable enhancement (2.6×10−2) of Q−1
can be obtained by ageing of the as-cast alloy at 435°C for 4h. This is mainly ascribed to the further
formation of nanoscale Mn segregation in the Mn dendrites (so-called Mn macrosegregation) by
spinodal decomposition during the ageing. On the contrary, performing the additional
homogenization treatment at 850°C for 24h prior to the ageing at 435°C for 4h for the as-cast M2052
alloy can result in the obvious reduction of damping capacity (only 6.5×10−3 for Q−1), which is
closely associated with the distinct decrement of lattice distortion of γ′-Mn during f.c.c-f.c.t phase
transformation caused by weakening of Mn segregation at the macro/nano-scale.
Keywords: Non-ferrous alloys; Casting; Internal friction; Ageing; Spinodal decomposition; Phase
transformation
6 - Magnesium Alloys,
2017,
Pages 287-367,
ISBN 9780080994314,
https://doi.org/10.1016/B978-0-08-099431-4.00006-3.
Abstract: This chapter covers cast and wrought magnesium alloys and describes current trends in
their commercial applications. Solid solubilities of the commonly used alloying elements are
considered with respect to their effects on melting and casting with special reference to the
beneficial grain refinement that can result from the addition of small amounts of zirconium.
Emphasis is placed on how other alloying elements influence the as-cast microstructures, response
to age hardening, mechanical properties, and corrosion resistance of sand castings and high-
pressure die castings. Attention is then given to wrought magnesium alloys and how alloying
elements may also influence formability, extrudability, and mechanical properties. Fabrication of
products is discussed with particular reference to joining methods and the exceptional machinability
of magnesium alloys. Some current applications of both cast and wrought magnesium alloys are
then described in the aerospace, automobile, medical, and superconducting industries.
Keywords: Deformation; precipitation processes; age hardening; mechanical properties; creep;

sheet; texture; formability; extrudability; extrusion limit diagram; corrosion
R. Singh, S. Singh, M.S.J. Hashmi,
Vacuum Molding,
Elsevier,
2017,
ISBN 9780128035818,
https://doi.org/10.1016/B978-0-12-803581-8.04164-3.
Abstract: Vacuum molding (VM) process is distinctly different from other sand casting processes as
this process requires no binders for holding the sand grains together in the mold. Due to this, the
ceramic sand could be used again and again with negligible pre-/posttreatments. This characteristic
of VM makes it a strong candidate for green manufacturing process. As of today, not much
information is documented for VM process and its applications, however, some efforts have been
made by the authors for the development of different categories of castings (such as metal, alloy,
and composites). The present article is focused on discussing the manufacturing steps involved in
VM process, along with various case studies that are discussed to understand the importance of
process parameters for casting characteristics. The capabilities of VM process are vital and could be
increased through innovative ideas at various stages.
Keywords: Casting; Ceramic; Composite; Dimensional accuracy; Disk; Fiber; Fused deposition;
Hardness; Matrix; Metal; Modeling; Molding; Particle size; Pattern; Rapid prototyping; Roughness;
Signal/noise; Taguchi; Vacuum
Tharmalingam Sivarupan, Mohamed El Mansori, Nicolas Coniglio, Matthew Dargusch,

Effect of process parameters on flexure strength and gas permeability of 3D printed sand molds,
Volume 54,
2020,
Pages 420-437,
ISSN 1526-6125,
Abstract: 3D printed sand molds for the casting industry play a vital role in manufacturing intricate
parts using a computer model. The possibility of producing fairly significant structural castings using
a small job-box 3D sand mold printer is another advantage compared to the direct metal 3D printing
processes. It is important to identify the relationship between the process parameters and the
properties of the sand mold to produce a mold with the required strength, permeability and
stiffness; to reduce gas emissions during casting and minimize the mass of combustible materials in
the mold. Hence, it is possible to create an excellent casting by improving the design of such molds
for liquid alloy filling and solidification. The relationship between the printing parameters and the
properties of the mold can be a great tool for foundrymen, primarily to optimize the strength and
permeability properties of these molds and therefore to provide exact boundary conditions for the
solidification simulation prior to a casting trial. This paper reports on a study of a basic outline to
quantify the role of the sand mold printing process parameters, particularly the recoater speed and
print resolution, on the mold strength and permeability, and their impacts on the anisotropic
behavior of the printed sand molds.
Keywords: 3D printing; Sand mold; Granular materials; Additive manufacturing; Low-pressure sand
casting
Himanshu Khandelwal, B. Ravi,
Effect of molding parameters on chemically bonded sand mold properties,
Volume 22,
2016,
Pages 127-133,
ISSN 1526-6125,
Abstract: Chemically bonded sand molds and cores have better mechanical properties and produce
more dimensionally accurate castings, compared to green sand molds, and hence are being
increasingly preferred for near net shape metal parts. While it is well known that the properties and
quality of a mold depend on its material composition and molding process, this has not been
investigated well for chemically bonded molds. In this work, the effect of sand grain size, binder
percentage and curing time (each varied in three levels) on the mechanical properties (compression
strength, shear strength and core hardness) as well as dimensional changes (shrinkage) of no-bake
chemically-bonded molds and cores was studied through lab experiments. Their mechanical
properties were found to increase with an increase in binder content and curing time; and decrease
with increasing grain fineness number. The shrinkage was found to increase with an increase in all
three process parameters. The results are explained in terms of bonding and curing phenomena of
binders, and evaporation of solvent. These are also supported by SEM analysis of crosslinked resin
bridges between sand grains. The findings were incorporated into a multi-objective optimization
model to obtain the desired combination of mold properties, which is solved as a linear
programming problem. The model and its results were successfully verified through experiments.
This work paves the way for automatic optimization of molding parameters of chemically-bonded
sand molds and cores, to achieve the desired quality.
Keywords: Sand-casting; No-bake binder; Chemically bonded mold; Mechanical property; Shrinkage;
Optimization
P. Alen Thomas, P. Kavya Aahlada, N. Sai Kiran, Jayanth Ivvala,
A Review On Transition In The Manufacturing Of Mechanical Components From Conventional

Techniques To Rapid Casting Using Rapid Prototyping,
2018,
Pages 11990-12002,
ISSN 2214-7853,
Abstract: 3D printing has made its way from mere prototyping of mechanical components to its
manufacturing. Actual working mechanical components are directly printed and are used having no
relative difference. As a new manufacturing technology, 3D printing has gradually started attracting
interest in both the academic community and the business world.The first machine for 3D printing
was created less than 35 years ago, indicating great potential for future development in 3D printing.
However, the promising future of this technology also makes an impact on traditional industry
unpredictable. Gradual increase in the applications of rapid prototyping has paved its way to many
industries and its researchers to fabricate intricate components and replace conventional
manufacturing techniques such as casting. Rapid castingis an integration of
conventionalcastingwithrapid prototyping/3D printing. In this technique either mouldsor disposable
pattern used for forming moulds are created with 3D printing techniques like fused deposition
modelling (FDM), Solid ground curing, Ballistic particle manufacturing, Drop-on-drop deposition
inkjet printing technology,Selective laser sintering (SLS),Stereo lithography and laminated object
manufacturing(LOM). In this paper, the evolution of rapid casting is described and variations in its
process parameters are compared to conventional casting. The different types of rapid casting
techniques developed along with materials used in it, are studied. Recent advancements in rapid
casting along with its scope in the future is described .Various notable mechanical components
which have found their way to get Rapid casted are presented and assertions are made on their
technical details.
Keywords: Rapid casting; Rapid prototyping; Fused Deposition Modelling; Casting
Jun Zheng, Binbin Huang, Xingjian Zhou,
A low carbon process design method of sand casting based on process design parameters,
Volume 197, Part 1,
2018,
Pages 1408-1422,
ISSN 0959-6526,
Abstract: The widespread use of sand casting technology has brought tremendous pressure on the
environment due to its energy consumption, waste discharge, and process related carbon emissions.
A plan should begin at the design phase of the casting, in order to achieve low carbon sand castings
or sand castings with low greenhouse gas emissions. Accurate prediction of carbon emission in sand
casting is the basis for carbon emission reduction. To calculate and reduce carbon emission of sand
castings during the sand casting process design phase, a low carbon process design method of sand
casting based on process design parameters is proposed. The process design of sand casting includes
various parameters. Three types of sand casting carbon source model were built by three categories
of process design parameters analysis of sand mold casting. so as to predict the carbon emission of
sand mold casting. The feasibility of the proposed method to estimating the carbon emission in the
process design stage was validated by using a practical example. Through the comparison of the two
process design schemes based on this method, it can be proved that carbon emissions have
decreased significantly. Moreover, we can know the amount of carbon emissions from each type of
carbon source can be predicted. A low carbon sand casting process during the sand casting process
design phase can be created by this method. The optimization of process design parameters was
useful to the reduce carbon emissions of the sand casting and benefited to achieve the aim of reach
sustainable manufacturing.
Keywords: Design parameters; Carbon emissions calculation; Low carbon; Sand casting
N.D. Mehta, A.V. Gohil, Sachindra J. Doshi,
Innovative Support System for Casting Defect Analysis – A Need of Time,

2018,
Pages 4156-4161,
ISSN 2214-7853,
Abstract: Owing to the increasing demand for metal casting from the various sectors, foundry has
played a significant role in spurring the global foundry market’s growth prospects. Foundry Industry,
especially in India, has seen overwhelming growth in the past few years and to set up manufacturing
base abroad for both the low-cost and quality production of casting components, India is seen as a
potential hub for the global companies. Casting, a process in which various transformations involved
and it carries risk of failure occurrence and the failure in any of the process leads to produce defect
in casting which ultimately leads to rejection of casting product. Risk involved rightly starting from
material of pattern, material of sand, type of metal, pouring temperature of metal and so on. That
put forward the necessity of action required to be taken while manufacturing of cast product to
accomplish defect free parts. Different simulation software are also available and many
methodology were been presented by various researchers about remedies to be taken care to
produce defect casting previously but still defect are produced because of range of process
parameters involved during the actual production. Present paper highlights the gap between present
scenario in foundry and tools and techniques available to produce defect free casting.
Keywords: Casting Defects; Quality Control; Casting Simulatin Software; Expert system for casting
defect
Ali Keleş, Mehmet Yildirim,
Improvement of mechanical properties by means of titanium alloying to steel teeth used in the
excavator,
Engineering Science and Technology, an International Journal,
Volume 23, Issue 5,
2020,
Pages 1208-1213,
ISSN 2215-0986,
https://doi.org/10.1016/j.jestch.2019.12.003.
Abstract: The effect of Ti addition (0.15 and 0.20 wt%) on mechanical properties and wear resistance
of steel excavator bucket teeth was investigated. Teeth were produced by commercial sand casting
technique. After production normalizing, hardening, and tempering heat treatment procedures were
applied to the teeth. Lath martensitic microstructure was observed and small amount of carbide
particles were present in the microstructures of Ti containing ones. In addition, small amount of hard
and brittle TiN particles were observed in the microstructure of 0.20 wt% Ti containing teeth. The
best mechanical properties were obtained for 0.15 wt% Ti containing teeth with considerably high
abrasive wear resistance. However, 0.20 wt% Ti containing teeth exhibited worst abrasive wear
resistance and limited ductility due to the formation of TiN particles.
Keywords: Microstructure; Martensite; Mechanical properties; Wear
Naoya Marumoto, Haruki Kashimura, Kazuki Yoshida, Tsuneo Toyoda, Toshimitsu Okane, Makoto
Yoshida,
Dynamic measurements of the load on gray cast iron castings and contraction of castings during
cooling in furan sand molds,
Volume 237,
2016,
Pages 48-54,
ISSN 0924-0136,
Abstract: After JIS FC300 (almost identical to ASTM 45) gray cast iron was cast in a furan sand mold,
both the load on the casting from the sand mold and contraction of the casting were measured
dynamically from the beginning of solidification to 200°C. During solidification, the cast iron casting
received compressive load from the sand mold attributable to expansion of the casting. After
solidification, the load on the casting and the contraction of the casting increased linearly with
cooling. During A1 transformation, the load on the casting was relieved because of the casting
expansion. After the A1 transformation, the load on the casting and the contraction of the casting
increased linearly with cooling again. When the load on the casting reached approximately 13kN, the
load stayed constant, probably because of the sand mold fracture.
Keywords: Sand mold; Sand casting; Residual stress; Distortion; CAE; Gray cast iron
Emanuele Pagone, Konstantinos Salonitis, Mark Jolly,
Energy and material efficiency metrics in foundries,
Volume 21,
2018,
Pages 421-428,
ISSN 2351-9789,
Abstract: Most of the current foundry processes are based on well-developed and established
practices typical of mature technologies. Contemporary economic, environmental and societal
developments have concurrently changed at an unprecedented rate the context where traditional
metal casting methodologies have not really developed much over time. Consequently, significant
challenges and opportunities arise. This work will present the founding metrics of a novel approach
to metal casting with the development of a new philosophy (called “Small is Beautiful”) aimed at
tackling the current pressures on the industry with a focus on energy and materials’ efficiencies and
flexible production. Traditional and well-established parameters are presented and compared to
new metrics defined from first principles and thermodynamic properties. All metrics are validated
using industrial and scientific literature data of five sand casting plants melting different ferrous and
non-ferrous alloys.
Keywords: Energy efficiency; Casting; Sustainability
V. Jaya Prasad, N. Mohan Rao, S. Kamaluddin, KVP. Surya,
A Study of Microstructure and Tribological Properties of Al 5083 MMC Processed by Direct Extrusion,
2018,
Pages 8232-8240,
ISSN 2214-7853,
Abstract: In this study, investigations are done on commercially available aluminum-magnesium (Al
5083) alloy. Aluminum 5083 alloy was first cast by using sand casting technique and then subjected
to severe plastic deformation (SPD) through a direct extrusion process. To improve properties of the
material, severe plastic deformation technique has been widely used over the last two decades.
Present numerous experimental techniques of metal forming are available that can apply great
strains on materials for better grain refinement, in that SPD is the best technique. To observe the
outcome of direct extrusion on Al 5083 alloy, microstructure and mechanical properties of the cast
alloy and extruded alloy were examined. Along the transverse planes of the extruded alloy
microstructural investigations were carried out using an optical microscope and it discovered that
the coarse microstructure of the alloy was refined to a considerable amount. Hardness and tensile
strength of the alloy are improved by 10.33% and 9.8% respectively after direct extrusion. Wear
resistance of the aluminum 5083 alloy was determined by Pin-on-Disc test apparatus. The grain size
of the material is determined by using Olympus microscope. The wear properties of the alloy after
direct extrusion were improved considerably along with improvement in hardness and tensile
strength. Because of the highly refined grains imparted by direct extrusion process the mechanical
properties of the alloy were improved to a certain extent and it makes the alloy to be used in various
engineering claims requiring high strength.
Keywords: Aluminium SiC MMC; Grain Refinement; Optical microscope; Wear; Tensile; Hardness
Emil Hovad, Per Larsen, Jon Spangenberg, Jens H. Walther, Jesper Thorborg, Jesper H. Hattel,
Cavity prediction in sand mould production applying the DISAMATIC process,
Powder Technology,
Volume 321,
2017,
Pages 204-217,
ISSN 0032-5910,
https://doi.org/10.1016/j.powtec.2017.08.037.
Abstract: The sand shot in the DISAMATIC process is simulated by the discrete element method
(DEM) taking into account the influence and coupling of the airflow with computational fluid
dynamics (CFD). The DEM model is calibrated by a ring shear test, a sand pile experiment and a
slump test. Subsequently, the DEM model is used to model the propagation of the green sand inside
the mold chamber and the results are compared to experimental video footage. The chamber
contains two cavities designed to quantify the deposited mass of green sand. The deposition of
green sand in these two cavities is investigated with three cases of different air vent settings which
control the ventilation of the chamber. These settings resulted in different air- and particle-velocities
as well as different accumulated masses in the cavities, which were successfully simulated by the
model.
Keywords: DISAMATIC process; Sand casting; Green sand; Granular flow; Discrete element method
Hyun-Hee Choi, Eun-Hee Kim, Hye-Ju Lee, Bong-Gu Kim, Yeon-Gil Jung, Jing Zhang,
Improvement in the hygroscopicity of inorganic binder through a dual coating process,
Progress in Organic Coatings,
Volume 135,
2019,
Pages 306-312,
ISSN 0300-9440,
https://doi.org/10.1016/j.porgcoat.2019.06.005.
Abstract: The use of an anti-absorbent is proposed in this work to reduce the hygroscopicity of the
inorganic binder in the casting mold, in which the anti-absorbent is coated on the mold prepared
with an inorganic binder. Three types of polymers were used to select material with optimal water
resistance. Polystyrene (PS) and polyvinyl alcohol (PVA) were used as a water-insoluble polymer and
water-soluble polymer, respectively. In addition, polyurethane (PU) prepolymer has intermediate
properties between PS and PVA. PVA and PU prepolymer were used for comparative testing with PS.
For this testing process, the prepared green body was dipped into a solution of inorganic binder
precursor mixed with tetraethyl orthosilicate (TEOS, SiO2 precursor) and sodium methoxide
(NaOMe, Na2O precursor), and then dipped into a solution of coating reagent after a drying process.
Thus, these series of coating processes in a green body is called a dual coating process. Finally the
sample was heat-treated at 1000 °C to generate a glass phase by an organic–inorganic conversion
process. In the sample prepared with PS, the highest contact angle and a high firing strength were
exhibited, independent of polymer concentration, while the sample coated with PVA showed lower
green and firing strengths. When prepolymer, PU, was applied, the green strength was remarkably
improved, showing lower firing strength compared with that of PS. The green and firing strengths
were optimized through the dual coating process with PS. Moreover, the moisture-proof effect of
the dual coating process was verified through the moisture steam test.
Keywords: Sand casting; Inorganic binder; Hygroscopicity; Dual coating process
Puneet Bansal, Lokesh Upadhyay,
Effect of Turning Parameters on Tool Wear, Surface Roughness and Metal Removal Rate of Alumina
Reinforced Aluminum Composite,
Procedia Technology,
Volume 23,
2016,
Pages 304-310,
ISSN 2212-0173,
https://doi.org/10.1016/j.protcy.2016.03.031.
Abstract: Now a day's demand of light materials is increasing continuously and MMC of aluminum
playing a vital role to fulfill these demands due to their light weight, high strength and appreciable
hardness etc. This study deals with the manufacturing of Aluminum based MMC of Alumina. Three
samples were manufactured by sand casting with 2%, 4% and 6% of alumina by weight and
mechanical properties like tensile Strength and Hardness were tested. Investigation reveals that
mechanical properties enhanced in appreciable fashion as compared to pure aluminum. Turning on
MMCs were carried out using uncoated carbide tool and coated tool. Turning test were performed
at various speed, feed rate, depth of cut and percentage of alumina inclusion in MMCs. Furthermore
tool wear, surface roughness and metal removal rate were investigated. Purpose of the study is to
observe and understand the behavior of the turning parameters of composite materials under
various operating conditions.
Keywords: Metal Matrix Composite; Alumina; Tool Wear; MRR.; Hardness

P. Rodríguez-González, A.I. Fernández-Abia, M.A. Castro-Sastre, J. Barreiro,
Heat treatments for improved quality binder jetted molds for casting aluminum alloys,
Volume 36,
2020,
101524,
ISSN 2214-8604,
Abstract: The objective of this paper was to investigate the most suitable heat treatment for casting
molds manufactured by binder jetting. For this purpose, the printed molds were subjected to
different heat treatments and the properties of the molds were analyzed. Tests were performed at
different temperatures and times to investigate their effect on the water and volatile substances
content; the joining among particles; and the porosity, roughness, and compression strength of the
printed molds. Moreover, to relate the properties of the mold with the quality of the castings,
aluminum alloy specimens were cast and the dimensional accuracy, surface roughness, mechanical
strength, and porosity were evaluated. This research leads to the conclusion that the binder jetting
process, using calcium sulfate powder, is useful for manufacturing molds for casting aluminum alloy.
To improve the mold quality and, consequently, the casting quality, heat-treatment is necessary. The
best mold properties were obtained at 250 °C for 1.5 h.
Keywords: Additive manufacturing; Binder jetting; Aluminum casting; Mold properties; Calcium
sulfate

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