Entrained defects and mechanical properties of aluminium castings

The presence of entrained double oxide films, known as bifilms, has been identified as a contributing factor to the variability in mechanical properties observed in aluminium castings. These bifilms consist of folded-over oxide films containing gas-filled crevices and are formed due to turbulence on the liquid metal's surface during handling and pouring. Additionally, it has been suggested that hydrogen dissolved in the aluminium melt can permeate these defects, causing them to expand and leading to the formation of hydrogen porosity. This, in turn, exacerbates the detrimental effects on the mechanical properties of the castings. In this study, the ultimate tensile strength (UTS) and percentage elongation of sand cast bars were compared under various casting conditions. These parameters were chosen as indicators of casting reliability, which was expected to be influenced by the presence of oxide films. The results indicated that incorporating filters in the gating system and reducing the runner height led to a noticeable improvement in tensile strength and elongation. This improvement was attributed to enhanced mold filling conditions, which reduced the likelihood of oxide film entrainment. The findings of this research provide valuable insights into the factors that affect the properties of light metal alloy castings. By understanding these influences, it becomes possible to develop improved practices that result in healthier castings with enhanced mechanical properties

Influence of bifilm defects generated during mould filling on the tensile properties of Al–Si–Mg cast alloys

Entrapped double oxide film defects are known to be the most detrimental defects during the casting of aluminium alloys. In addition, hydrogen dissolved in the aluminium melt was suggested to pass into the defects to expand them and cause hydrogen porosity. In this work, the effect of two important casting parameters (the filtration and hydrogen content) on the properties of Al–7 Si–0.3 Mg alloy castings was studied using a full factorial design of experiments approach. Casting properties such as the Weibull modulus and position parameter of the elongation and the tensile strength were considered as response parameters. The results suggested that adopting 10 PPI filters in the gating system resulted in a considerable boost of the Weibull moduli of the tensile strength and elongation due to the enhanced mould filling conditions that minimised the possibility of oxide film entrainment. In addition, the results showed that reducing the hydrogen content in the castings samples from 0.257 to 0.132 cm3/100 g Al was associated with a noticeable decrease in the size of bifilm defects with a corresponding improvement in the mechanical properties. Such significant effect of the process parameters studied on the casting properties suggests that the more careful and quiescent mould filling practice and the lower the hydrogen level of the casting, the higher the quality and reliability of the castings produced

Effect of runner thickness and hydrogen content on the mechanical properties of A356 alloy castings

Earlier studies demonstrated the detrimental effect of entrained bifilm defects on aluminum cast alloys’ tensile and fatigue properties. It was suggested that hydrogen has a contributing role as it diffuses into the bifilms and swells them out to form hydrogen porosity. In this study, the effect of the runner height and hydrogen content on the properties of A356 alloy castings was investigated using a two-level full factorial design of experiments. Four responses, the Weibull modulus and position parameter of both the ultimate tensile strength (UTS) and % elongation, were assessed. The results suggested that decreasing the runner height and adopting procedures intended to decrease the hydrogen content of the casting caused a considerable enhancement of the Weibull moduli and position parameters of the UTS and % elongation. This was reasoned to the more quiescent practice during mold filling, eliminating the possibility of bifilm formation as well as the decreased hydrogen level that eliminated the amount of hydrogen diffused into the bifilms and accordingly decreased the size of the entrained defects. This, in turn, would allow the production of A356 cast alloys with better and more reproducible properties

Effect of high-fat diet-induced obesity on thyroid gland structure in female rats and the possible ameliorating effect of metformin therapy

Background: Obesity is known to induce a state of lipotoxicity that affects the different organs of the body. Metformin is an antidiabetic drug commonly used in obesity treatment. It was known to improve thyroid function and its regulating hormones. Structural changes in the thyroid gland associated with obesity have not been well investigated. So, the aim of the present study is to detect structural changes in thyroid gland induced by obesity and to investigate the possible protective role of metformin therapy. Materials and methods: Thirty adult female albino rats were divided into three groups (10 rats each). Group I (control group), group II (rats fed with a high-fat diet), and group III (rats fed with a high-fat diet and treated with metformin therapy). After 12 weeks, rats from all groups were sacrificed. Blood samples were taken for measurement of lipid profile, thyroid stimulating hormone (TSH), free T3 and free T4. Thyroid glands were extracted and processed for histological and ultrastructural study. Morphometric measurements for the colloid area of thyroid follicles and height of the follicular cells were done. Results: Group I displayed normal biochemical parameters and architecture of the thyroid gland. Group II revealed disordered lipid profile, high TSH, free T3 and T4. Microscopically, large thyroid follicles with excessive colloid accumulation and decreased follicular cells height were seen. Some follicular cells showed pyknotic nuclei, vacuolated cytoplasm and disrupted basement membrane with mast cell infiltration of the thyroid tissue. Ultrastructurally, group II follicular cells showed loss of apical microvilli, dense shrunken nuclei, dilated endoplasmic reticulum, swollen damaged mitochondria with large intracellular vacuoles and colloid droplets. In group III, the biochemical parameters and structure of thyroid follicles were improved, and they had a near-normal appearance. Conclusions: Obesity induced by high-fat diet in female rats structurally and functionally changed the thyroid gland in a way that may explain hypothyroidism associated with obesity. These changes were improved by metformin therapy

A mechanical behavior law for the numerical simulation of the mushy zone in welding

The aim of this work is to propose a mechanical behavior law dedicated to the mushy zone located between the solid phase and the weld pool in welding. The objective is to take into account of the influence of the mushy zone in the simulation of welding in order to improve the computation of induced effects such as residual stresses

Design optimisation of additively manufactured titanium lattice structures for biomedical implants

A key advantage of additive manufacturing (AM) is that it allows the fabrication of lattice structures for customised biomedical implants with high performance. This paper presents the use of statistical approaches in design optimisation of additively manufactured titanium lattice structures for biomedical implants. Design of experiments using response surface and analysis of variance were carried out to study the effect design parameters on the properties of the AM lattice structures such as ultimate compression strength, specific compressive strength, elastic modulus, and porosity. In addition, the lattice dimensions were optimized to fabricate a diamond cellular structure with properties that match human bones. The study found that the length of a diamond-shaped unit cell strut is the most significant design parameter. In particular, the porosity of the unit cell increases as the strut length increases, while it had a significant reverse effect on the specific compressive strength, elastic modulus and ultimate compression strength. On the other hands, increasing the orientation angle was found to reduce both the specific compressive strength and modulus of elasticity of the lattice structure. An optimised lattice structure with strut diameter of 0.84 mm, length of 3.29 mm and orientation angle of 47° was shown to have specific compressive strength, elastic modulus, ultimate compression strength and porosity of 37.8 kN.m/kg, 1 GPa, 49.5 MPa and 85.7%, respectively. A cellular structure with the obtained properties could be effectively applied for trabecular bones replacement surgeries