Acoustical and optical determination of mechanical properties of inorganically-bound foundry core materials

Inorganically-bound sand cores are used in many light-metal foundries to form cavities in the cast part, which cannot be realised by the mould itself. To enable FEM simulations with core materials, their mechanical properties have to be measured. In this article, we adapt methods to determine the Young’s and shear modulus, the Poisson ratio and the fracture strain of sand cores. This allows us to fully parametrise an ideal brittle FEM model. We found that the Young’s and shear modulus can be obtained acoustically via the impulse excitation technique. The fracture strain was measured with a high-speed camera and a digital image correlation algorithm

Annual Report 1984-1985

It contains the statement of R&D works undertaken, achivement made and the expenditure by the laboratory during the financial year 1984-1985

Annual Report 1980-1981

It contains the statement of R&D works undertaken, achivement made and the expenditure by the laboratory during the financial year 1980-1981

Metalcasting Competitiveness Research. Final Report

This report comprises eleven separate reports: prediction of non- metallic particle distribution, electromagnetic separation of inclusions from molten Al alloy, clean steel castings, waste stream identification and treatment, elastic wave lithotripsy for removal of ceramic from investment castings, metal penetration in sand molds, mold-metal interface gas composition, improved Alloy 718, specifications for iron oxide additions to no-bake sands, criteria functions for defect prediction, and computer-aided cooling curve analysis

Annual Report 1981-1982

It contains the statement of R&D works undertaken, achivement made and the expenditure by the laboratory during the financial year 1981-1982

Annual Report 1974-1975

It contains the statement of R&D works undertaken, achivement made and the expenditure by the laboratory during the financial year 1974-1975

The processing and evaluation of an investment-cast magnesium–base alloy

Magnesium alloys are well known for their high affinity for oxygen and highly reactive characteristics. This has created difficulties in their processing. During melting, a protective film generated by chloride or fluoride based flux or an inert atmosphere created by a specific gas combination, is required to isolate the melt from the atmosphere in order to suppress any reaction. At the casting stage, reaction with some mould materials is likely to happen. This has caused a serious problem in the casting of magnesium, particularly with the investment casting process. The mould-metal interface reaction must be eliminated or minimized if the production of castings with close tolerances and good surface finish is to be achieved. [Continues.

Precision Casting via Advanced Simulation and Manufacturing

A two-year program was conducted to develop and commercially implement selected casting manufacturing technologies to enable significant reductions in the costs of castings, increase the complexity and dimensional accuracy of castings, and reduce the development times for delivery of high quality castings. The industry-led R&D project was cost shared with NASA's Aerospace Industry Technology Program (AITP). The Rocketdyne Division of Boeing North American, Inc. served as the team lead with participation from Lockheed Martin, Ford Motor Company, Howmet Corporation, PCC Airfoils, General Electric, UES, Inc., University of Alabama, Auburn University, Robinson, Inc., Aracor, and NASA-LeRC. The technical effort was organized into four distinct tasks. The accomplishments reported herein. Task 1.0 developed advanced simulation technology for core molding. Ford headed up this task. On this program, a specialized core machine was designed and built. Task 2.0 focused on intelligent process control for precision core molding. Howmet led this effort. The primary focus of these experimental efforts was to characterize the process parameters that have a strong impact on dimensional control issues of injection molded cores during their fabrication. Task 3.0 developed and applied rapid prototyping to produce near net shape castings. Rocketdyne was responsible for this task. CAD files were generated using reverse engineering, rapid prototype patterns were fabricated using SLS and SLA, and castings produced and evaluated. Task 4.0 was aimed at developing technology transfer. Rocketdyne coordinated this task. Casting related technology, explored and evaluated in the first three tasks of this program, was implemented into manufacturing processes

ESTABLISHING POSSIBLE MECHANISMS FORPRODUCING NANOPARTICLES OF TRONOH SILICA SAND VIA LOW SPEED MECHANICAL MILLING PROCESS

Silica sand is abundantly available in every part ofthe world and it is commonly used for production of ceramic matrix composites, construction of buildings, bridges, dams, roads and bricks as well as in production ofrefractory materials for high temperature furnaces. Some ofthe most important properties ofsilica sand are high hardness, high tensile and compressive strength, high chemical resistance, high temperature resistance, good insulation, high wear resistance and brittle in nature. Advanced uses of silica sand include in the production of engine, rotor, valve, bearings, sensors and thermal protection system. Natural silica sand is also found in Malaysia especially in Tronoh, Perak where previous tin mining activities were actively progressed 50 years ago