Additive Manufacturing for Rapid Sand Casting: Mechanical and Microstructural Investigation of Aluminum Alloy Automotive Prototypes

The automotive industry is undergoing a rapid evolution to meet today's challenges; therefore, continuous innovation and product development are needed. Validation tests on prototypes play a crucial role in moving new components into industrial production. There is also a pressing need for faster prototyping processes. In this context, rapid sand casting (RSC), based on additive manufacturing technology, offers a promising solution for a quick production of sand molds. While this technology is already employed in the industry, the need to deepen the general understanding of its impact on the casting properties is still a relevant item. In this study, different geometries of automotive prototypes made of aluminum EN AC 42100-T6 alloy were experimentally analyzed. Microstructural examinations, tensile tests, and fractography and porosity analyses were conducted. The findings demonstrate the considerable potential of RSC, giving, in general, high mechanical properties. A comparative analysis with prototypes produced through traditional sand casting revealed similar results, with RSC exhibiting superior yield strength and stress at brake. However, both technologies revealed a reduced elongation percentage, as expected. Future efforts will focus on standardizing the RSC process to enhance ductility levels

parameters identification for scroll expander semi empirical model by using genetic algorithm

Abstract In this paper a small Organic Rankine Cycle (ORC) plant was tested under different operating conditions and by using refrigerants (R245fa) as working fluids. In particular, attention was posed towards the scroll expander of the power plant in order to identify experimental parameters to use in its predictive semi-empirical model. Experimental results obtained by imposing different operating conditions at the expander inlet section (i.e. temperature, pressure, mass flow rate) and different temperature at the condensation section, were used to validate the mathematical model. An in-house code (MatLab®/Scilab® based) using CoolProp® library for the accurate evaluation of fluid properties, was optimized by using a genetic algorithm implemented in modeFrontier® software. Thus, the validated model was used in predictive mode to evaluate the machine performances

Steel slag as a low-impact filler in rubber compounds for environmental sustainability

This study investigates the use of electric arc furnace (EAF) slag, as a substitute for conventional filler, such as calcium carbonate, in nitrile-butadiene rubber (NBR) composites in different volume fraction. The results demonstrate that slag exhibits morphological traits comparable to calcium carbonate when used as a filler, moreover their processability and mechanical properties are similar. Specifically, at 20% v/v, slag-flled NBR exhibits slightly longer scorch times but unchanged vulcanization times. Both fillers at 20% v/v show comparable hardness, compression strength, and elastic modulus. Tensile properties are also comparable, except for the strain at break, where slag-filled NBR shows a 40% higher tensile strain at break. The environmental impact of this innovative slag application has been evaluated through a comparative life cycle assessment. All assessed impact categories demonstrate a reduction of at least 89%. The study suggests that the use of EAF slag has the potential to promote sustainable waste management

Effect of kolsterising treatment on surface properties of a duplex stainless steel

In recent years, attempts of engineering the surface of duplex stainless steels were made in order to enhance their hardness and tribological properties, without affecting their corrosion resistance. A possibility of improving these properties is provided by a family of processes developed by Prof. B.H. Kolster in the Netherlands in the late 1980’s. These processes (usually referred to as Kolsterising® treatments) consist in a low temperature surface carburizing, which involves the diffusion of large quantities of carbon atoms (up to 6-7 wt.%) into the steel at a diffusion temperature below 450 °C. In the present paper a characterization of the surface layer of Kolsterised duplex SAF 2205 stainless steel was carried out to study the effects of this treatment on surface properties. The characterization includes optical metallographic examination, microhardness tests and SEM-EDS investigation on the Kolsterised steel in the as treated condition and after annealing treatments at 200, 250, 300 350 and 400°C for 10 hours, to evaluate the stability of Kolsterised layer’s properties with a moderate increase in temperature. Moreover, complying with ASTM G48-03 Method E Standard, in order to evaluate the effect of the Kolsterising® treatment on steel pitting resistance, the critical pitting temperature was obtained for Kolsterised duplex SAF 2205 stainless steel compared with the base metal

On the crack path of rolling contact fatigue cracks in a railway wheel steel

The objective of the present paper is to give some preliminary results obtained in the frame of a more wide investigation on the rolling contact fatigue (RCF) behavior of a railway wheel steel. The effect of different test parameters on the RCF fatigue strength of the railway wheel steel was evaluated. RCF tests were conducted using two cylindrical contact specimens under different Po/k ratio (where Po is the maximum Hertzian pressure, k is the yield stress in shear of the material), under dry contact conditions or with water lubrication, and at varying slip ratio. In the present study crack initiation location and crack growth direction were carefully investigated; microscopic examination showed that the cracks were initiated at the surface, propagated obliquely in the depth direction and then occasionally branched into two directions. Usually multiple cracks are initiated, at the rolling contact surface, caused by the accumulation of shear deformation due to repeated rolling–sliding contact loading. Subsequent crack growth has been found to occur along specific sloped directions. The influence of Po/k ratio, dry or wet contact, and slip ratio on crack slope angle to the radial direction and the depths at which slope changes occur has been investigated. Observed crack slopes and slope change position have been discussed according to crack path prediction criteria in the literature

heat exchanger design and optimization by using genetic algorithm for externally fired micro turbine

Abstract In this study, a new configuration where syngas produced by downdraft gasifier is feed directly in an externally fired air turbine is discussed. Attention was posed towards the critical component of this configuration: the heat exchanger. To achieve acceptable electrical efficiencies, high temperature of the air at the inlet turbine section was imposed. A code for heat exchanger design was built by using Matlab®, while the geometrical optimization was performed by using modeFRONTIER® by imposing a multi-objective function to maximize the overall heat transfer coefficient and minimize both costs and pressure drops across the equipment

Evolution of prototyping in automotive engineering: a comprehensive study on the reliability of Additive Manufacturing for advanced powertrain components

Additive manufacturing (AM) could be used to reduce the production times of prototypes; however, further research is required to address metals structural parts. To obtain the correct properties, some relevant factors to be considered are the build volume, shape factor, and the need for specific heat treatments. This study aims to evaluate the reliability of AM prototypes applied at a new powertrain system developed to reduce vehicle emissions. Firstly, it was investigated the mechanical behavior, microstructure, and the effect of sample size and heat treatments on both specimens and prototypes made of AM 17-4PH steel. Finite Element Analysis (FEA) was performed to evaluate the structural resistance. Finally, the prototypes were produced, analyzed, and tested on a functional engine test bench to evaluate their reliability. The mechanical properties decreased with an increase in the sample volume. After heat treatment, the yield strength increased, due to the transformation of δ-ferrite in martensite and the reduction of retained austenite. The engine test bench was successfully completed. The conclusions set the basis for similar future applications of time-effective prototypes that can be dimensioned owing to appositely developed postprocesses that guarantee the required resistance

Effect of a spectrometer magnet on the beam-beam interaction

The presence of experimental apparatus in the interaction regions of an intersecting beam accelerator changes the configuration of the crossing beams. This changes the space-charge forces with respect to the standard, magnet-free crossing. The question is: what is the maximum allowable perturbation caused by the spectrometer magnet that can be tolerated from the point of view of the beam dynamics. This paper is limited to the perturbations that the curved trajectories cause the beam-beam space charge nonlinearities. The question has arisen of how one defines the strength of the perturbation. The only solution is to compute the strength of the most important nonlinear resources. In what follows, the computational method used in calculating these resonances is described, and compared with those induced by random orbit errors

Analysis of particle size distribution in municipal wastewaters

Innovative membrane filtration plants for municipal wastewaters are being developed and need the support of reliable filtration models in the designing phase. In the past, semi-empirical filtration models for membrane processes have been proposed. At present, the most prominent works point out the importance of particle poly-dispersity in the development of reliable models but fail into the implementation of probability density functions (PDFs) capable of an accurate fitting of the experimental particle size distribution (PSD). We report the experimental PSDs of two different municipal wastewater samples, obtained through the laser diffraction technique. The experimental results show that the laser diffraction technique can characterize wastewater particle dimensions both in the colloidal and supra-colloidal regions. The experimental study is complemented by a comparative analysis in which many PDFs are used to fit the experimental PSDs through a least-squares approach. Some of these PDFs are proposed here for the first time to fit experimental wastewater PSDs. Among the PDFs considered for the statistical modeling, the three-parameter lognormal and the Burr PDFs are demonstrated to provide satisfactory fitting, whereas the other considered functions fail. This result is confirmed by the analysis of both the available wastewater samples