Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 35

Search results for: TNT casting

35 Design of a Mould System for Horizontal Continuous Casting of Bilayer Aluminium Strips

Authors: Ch. Nerl, M. Wimmer, P. Hofer, E. Kaschnitz

Abstract:

The present article deals with a composite casting process that allows to produce bilayer AlSn6-Al strips based on the technique of horizontal continuous casting. In the first part experimental investigations on the production of a single layer AlSn6 strip are described. Afterwards essential results of basic compound casting trials using simple test specimen are presented to define the thermal conditions required for a metallurgical compound between the alloy AlSn6 and pure aluminium. Subsequently, numerical analyses are described. A finite element model was used to examine a continuous composite casting process. As a result of the simulations the main influencing parameters concerning the thermal conditions within the composite casting region could be pointed out. Finally, basic guidance is given for the design of an appropriate composite mould system.

Keywords: Aluminium alloys, composite casting, compound casting, continuous casting, numerical simulation

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
34 Optimization of Process Parameters of Pressure Die Casting using Taguchi Methodology

Authors: Satish Kumar, Arun Kumar Gupta, Pankaj Chandna

Abstract:

The present work analyses different parameters of pressure die casting to minimize the casting defects. Pressure diecasting is usually applied for casting of aluminium alloys. Good surface finish with required tolerances and dimensional accuracy can be achieved by optimization of controllable process parameters such as solidification time, molten temperature, filling time, injection pressure and plunger velocity. Moreover, by selection of optimum process parameters the pressure die casting defects such as porosity, insufficient spread of molten material, flash etc. are also minimized. Therefore, a pressure die casting component, carburetor housing of aluminium alloy (Al2Si2O5) has been considered. The effects of selected process parameters on casting defects and subsequent setting of parameters with the levels have been accomplished by Taguchi-s parameter design approach. The experiments have been performed as per the combination of levels of different process parameters suggested by L18 orthogonal array. Analyses of variance have been performed for mean and signal-to-noise ratio to estimate the percent contribution of different process parameters. Confidence interval has also been estimated for 95% consistency level and three conformational experiments have been performed to validate the optimum level of different parameters. Overall 2.352% reduction in defects has been observed with the help of suggested optimum process parameters.

Keywords: Aluminium Casting, Pressure Die Casting, Taguchi Methodology, Design of Experiments

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
33 Casting Users- Perspectives on Foundries as Suppliers

Authors: T. Saarelainen, O. Piha, P. Makkonen, J. Orkas

Abstract:

Global competition is tightening and companies have to think how to remain competitive. The main aim of this paper is to discuss how Finnish foundries will remain competitive. To fulfil the aim, we conducted interviews in nine companies using castings and analysed buyer–supplier relationships, current competitive advantages of Finnish foundries and customer perspectives on how Finnish foundries remain competitive. We found that the customerfoundry relationship is still closer to traditional subcontracting than partnering and general image of foundries is negative. Current competitive advantages of Finnish foundries include designing cooperation, proximity and flexibility. Casting users state that Finnish foundries should sell their know-how and services instead of their capacity, concentrate on prototype, single and short series castings and supply ready-to-install cast components directly to customers- assembly lines.

Keywords: Buyer-supplier relationship, casting, competitiveadvantage, customer prespective.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
32 Synthesis of ZnO Nanostructures via Gel-casting Method

Authors: A.A.Rohani, A.Salehi, M.Tabrizi, S. A. Manafi, A. Fardafshari

Abstract:

In this study, ZnO nano rods and ZnO ultrafine particles were synthesized by Gel-casting method. The synthesized ZnO powder has a hexagonal zincite structure. The ZnO aggregates with rod-like morphology are typically 1.4 μm in length and 120 nm in diameter, which consist of many small nanocrystals with diameters of 10 nm. Longer wires connected by many hexahedral ZnO nanocrystals were obtained after calcinations at the temperature over 600° C.The crystalline structures and morphologies of the powder have been characterized by X-ray diffraction(XRD) and Scaning electron microscopy (SEM).The result shows that the different preparation conditions such as concentration H2O, calcinations time and calcinations temperature have a lot of influences upon the properties of nano ZnO powders, an increase in the temperature of the calcinations results in an increase of the grain size and also the increase of the calcinations time in high temperature makes the size of the grains bigger. The existences of extra watter prevent nano grains from improving like rod morphology. We have obtained the smallest grain size of ZnO powder by controlling the process conditions. Finally In a suitable condition, a novel nanostructure, namely bi-rod-like ZnO nano rods was found which is different from known ZnO nanostructures.

Keywords: morphology, nano particles, ZnO, gel-Casting method.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
31 Simulation of Die Casting Process in an Industrial Helical Gearbox Flange Die

Authors: Mehdi Modabberifar, Behrouz Raad, Bahman Mirzakhani

Abstract:

Flanges are widely used for connecting valves, pipes and other industrial devices such as gearboxes. Method of producing a flange has a considerable impact on the manner of their involvement with the industrial engines and gearboxes. By Using die casting instead of sand casting and machining for manufacturing flanges, production speed and dimensional accuracy of the parts increases. Also, in die casting, obtained dimensions are close to final dimensions and hence the need for machining flanges after die casting process decreases which makes a significant savings in raw materials and improves the mechanical properties of flanges. In this paper, a typical die of an industrial helical gearbox flange (size ISO 50) was designed and die casting process for producing this type of flange was simulated using ProCAST software. The results of simulation were used for optimizing die design. Finally, using the results of the analysis, optimized die was built.

Keywords: Die casting, finite element, flange.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
30 Processing Design of Miniature Casting Incorporating Stereolithography Technologies

Authors: Pei-Hsing Huang, Wei-Ju Huang

Abstract:

Investment casting is commonly used in the production of metallic components with complex shapes, due to its high dimensional precision, good surface finish, and low cost. However, the process is cumbersome, and the period between trial casting and final production can be very long, thereby limiting business opportunities and competitiveness. In this study, we replaced conventional wax injection with stereolithography (SLA) 3D printing to speed up the trial process and reduce costs. We also used silicone molds to further reduce costs to avoid the high costs imposed by photosensitive resin.

Keywords: Investment casting, stereolithography, wax molding, 3D printing.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
29 Behavior of Generated Gas in Lost Foam Casting

Authors: M. Khodai, S. M. H. Mirbagheri

Abstract:

In the Lost Foam Casting process, melting point temperature of metal, as well as volume and rate of the foam degradation have significant effect on the mold filling pattern. Therefore, gas generation capacity and gas gap length are two important parameters for modeling of mold filling time of the lost foam casting processes. In this paper, the gas gap length at the liquidfoam interface for a low melting point (aluminum) alloy and a high melting point (Carbon-steel) alloy are investigated by the photography technique. Results of the photography technique indicated, that the gas gap length and the mold filling time are increased with increased coating thickness and density of the foam. The Gas gap lengths measured in aluminum and Carbon-steel, depend on the foam density, and were approximately 4-5 and 25-60 mm, respectively. By using a new system, the gas generation capacity for the aluminum and steel was measured. The gas generation capacity measurements indicated that gas generation in the Aluminum and Carbon-steel lost foam casting was about 50 CC/g and 3200 CC/g polystyrene, respectively.

Keywords: gas gap, lost foam casting, photographytechnique.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
28 Porosities Comparison between Production and Simulation in Motorcycle Fuel Caps of Aluminum High Pressure Die Casting

Authors: P. Meethum, C. Suvanjumrat

Abstract:

Many aluminum motorcycle parts produced by a high pressure die casting. Some parts such as fuel caps were a thin and complex shape. This part risked for porosities and blisters on surface if it only depended on an experience of mold makers for mold design. This research attempted to use CAST-DESIGNER software simulated the high pressure die casting process with the same process parameters of a motorcycle fuel cap production. The simulated results were compared with fuel cap products and expressed the same porosity and blister locations on cap surface. An average of absolute difference of simulated results was obtained 0.094 mm when compared the simulated porosity and blister defect sizes on the fuel cap surfaces with the experimental micro photography. This comparison confirmed an accuracy of software and will use the setting parameters to improve fuel cap molds in the further work.

Keywords: Aluminum, die casting, fuel cap, motorcycle.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
27 Numerical Simulation of Investment Casting of Gold Jewelry: Experiments and Validations

Authors: Marco Actis Grande, Somlak Wannarumon

Abstract:

This paper proposes the numerical simulation of the investment casting of gold jewelry. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which lead to predict and control casting defects such as gas porosity and shrinkage porosity. A finite difference method, computer simulation software FLOW-3D was used to simulate the jewelry casting process. The simplified model was designed for both numerical simulation and real casting production. A set of sensor acquisitions were allocated on the different positions of the wax tree of the model to detect filling times, while a set of thermocouples were allocated to detect the temperature during casting and cooling. Those detected data were applied to validate the results of the numerical simulation to the results of the real casting. The resulting comparisons signify that the numerical simulation can be used as an effective tool in investment-casting-process optimization and casting-defect prediction.

Keywords: Computer fluid dynamic, Investment casting, Jewelry, Mould filling, Simulation.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
26 A Reproduction of Boundary Conditions in Three-Dimensional Continuous Casting Problem

Authors: Iwona Nowak, Jacek Smolka, Andrzej J. Nowak

Abstract:

The paper discusses a 3D numerical solution of the inverse boundary problem for a continuous casting process of alloy. The main goal of the analysis presented within the paper was to estimate heat fluxes along the external surface of the ingot. The verified information on these fluxes was crucial for a good design of a mould, effective cooling system and generally the whole caster. In the study an enthalpy-porosity technique implemented in Fluent package was used for modeling the solidification process. In this method, the phase change interface was determined on the basis of the liquid fraction approach. In inverse procedure the sensitivity analysis was applied for retrieving boundary conditions. A comparison of the measured and retrieved values showed a high accuracy of the computations. Additionally, the influence of the accuracy of measurements on the estimated heat fluxes was also investigated.

Keywords: Boundary inverse problem, sensitivity analysis, continuous casting, numerical simulation.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
25 Customer-Supplier Collaboration in Casting Industry: a Review on Organizational and Human Aspects

Authors: Taneli Eisto, Venlakaisa Hölttä

Abstract:

Customer-supplier collaboration enables firms to achieve greater success than acting independently. Nevertheless, not many firms have fully utilized the potential of collaboration. This paper presents organizational and human related success factors for collaboration in manufacturing supply chains in casting industry. Our research approach was a case study including multiple cases. Data was gathered by interviews and group discussions in two different research projects. In the first research project we studied seven firms and in the second five. It was found that the success factors are interrelated, in other words, organizational and human factors together enable success but not any of them alone. Some of the found success factors are a culture of following agreements, and a speed of informing the partner about changes affecting to the product or the delivery chain.

Keywords: Casting industry, collaboration success factors, customer-supplier collaboration, supply chain collaboration.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
24 Application of Metakaolin from Northeast of Thailand Used as Binder in Casting Process of Rice Polishing Cylinder

Authors: T. Boonkang, C. Santhaweesuk, N. Pianthong, P. Neeramon, A. Phimhlo, S. Bangphan

Abstract:

The objective of this research was to apply metakaolin from northeast of Thailand as a binder in the casting process of rice polishing cylinder in replacement of the imported calcined magnesite cement and to reduce the production cost of the cylinder. Metakaolin was obtained from three different regions (Udon Thani, Nakhon Phanom, and Ubon Ratchathani). The design of experiment analysis using the MINITAB Release 14 based on the compressive strength and tensile strength testing was conducted. According to the analysis results, it was found that the optimal proportions were calcined magnesite cement: metakaolin from Udon Thani, Nakhon Phanom and Ubon Ratchathani equal to 63:37, 71:29, and 100:0, respectively. When used this formula to cast the cylinder and test the rice milling, it was found that the average broken rice percent was 32.52 and 38.29 for the cylinder contained the metakaolin from Udon Thani and Nakhon Phanom, respectively, which implied that the cylinder which contained the metakaolin from Udon Thani has higher efficiency than the cylinder which contained the metakaolin from Nakhon Phanom at 0.05 level of statistical significance. Whereas, the average wear rate of cylinder from both resources were 7.27 and 6.53 g/h, respectively.

Keywords: Binder, casting, metakaolin, rice polishing cylinder.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
23 Early Supplier Involvement in New Product Development: A Casting-Network Collaboration Model

Authors: Taneli Eisto, Venlakaisa Hölttä, Katrine Mahlamäki, Janne Kollanus, Marko Nieminen

Abstract:

Early supplier involvement (ESI) benefits new product development projects several ways. Nevertheless, many castuser companies do not know the advantages of ESI and therefore do not utilize it. This paper presents reasons why to utilize ESI in casting industry and how that can be done. Further, this paper presents advantages and challenges related to ESI in casting industry, and introduces a Casting-Network Collaboration Model. The model presents practices for companies to build advantageous collaborative relationships. More detailed, the model describes three levels for company-network relationships in casting industry with different degrees of collaboration, and requirements for operating in each level. In our research, ESI was found to influence, for example, on project time, component cost, and quality. In addition, challenges related to ESI, such as, a lack of mutual trust and unawareness about the advantages were found. Our research approach was a case study including four cases.

Keywords: Casting Industry, Collaboration Model, EarlySupplier Involvement, New Product Development.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
22 The Temperature Range in the Simulation of Residual Stress and Hot Tearing During Investment Casting

Authors: Saeid Norouzi, Ali Shams, Hassan Farhangi, Alireza Darvish

Abstract:

Hot tear cracking and residual stress are two different consequences of thermal stress both of which can be considered as casting problem. The purpose of the present study is simulation of the effect of casting shape characteristic on hot tearing and residual stress. This study shows that the temperature range for simulation of hot tearing and residual stress are different. In this study, in order to study the development of thermal stress and to predict the hot tearing and residual stress of shaped casting, MAGMASOFT simulation program was used. The strategy of this research was the prediction of hot tear location using pinpointing hot spot and thermal stress concentration zones. The results shows that existing of stress concentration zone increases the hot tearing probability and consequently reduces the amount of remaining residual stress in casting parts.

Keywords: Hot tearing, residual stress, simulation, investment casting.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
21 Development of a Robot Assisted Centrifugal Casting Machine for Manufacturing Multi-Layer Journal Bearing and High-Tech Machine Components

Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

Abstract:

Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: Casting, cylinder liners, journal bearing, robot.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
20 Characterization of Aluminium Alloy 6063 Hybrid Metal Matrix Composite by Using Stir Casting Method

Authors: Balwinder Singh

Abstract:

The present research is a paper on the characterization of aluminum alloy-6063 hybrid metal matrix composites using three different reinforcement materials (SiC, red mud, and fly ash) through stir casting method. The red mud was used in solid form, and particle size range varies between 103-150 µm. During this investigation, fly ash is received from Guru Nanak Dev Thermal Plant (GNDTP), Bathinda. The study has been done by using Taguchi’s L9 orthogonal array by taking fraction wt.% (SiC 5%, 7.5%, and 10% and Red Mud and Fly Ash 2%, 4%, and 6%) as input parameters with their respective levels. The study of the mechanical properties (tensile strength, impact strength, and microhardness) has been done by using Analysis of Variance (ANOVA) with the help of MINITAB 17 software. It is revealed that silicon carbide is the most significant parameter followed by red mud and fly ash affecting the mechanical properties, respectively. The fractured surface morphology of the composites using Field Emission Scanning Electron Microscope (FESEM) shows that there is a good mixing of reinforcement particles in the matrix. Energy-dispersive X-ray spectroscopy (EDS) was performed to know the presence of the phases of the reinforced material.

Keywords: Reinforcement, silicon carbide, fly ash, red mud.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
19 Issues in Procurement of Castings

Authors: T. Saarelainen, O. Piha, J. Orkas, P. E. Makkonen

Abstract:

The aim of this paper is to present current and future procedures in castings procurement. Differences in procurement are highlighted. The supplier selection criteria used in practice is compared to literature findings. Different trends related to supply chains are presented and it is described how they are reflected in reality to castings procurement. To fulfil the aim, interviews were conducted in nine companies using castings. It was found that largest casting users have the most subcontractor foundries and it is more typical that they have multiple suppliers for the same parts. Currently only two companies out of nine purchase castings outside Europe, but the others are also progressing in the same direction. The main reason is the need to lower purchasing costs. Another trend is that all companies want to buy cast components or sub-assemblies instead of raw castings from foundries. It was found that price is a main supplier selection criterion. All companies use competitive bidding in supplier selection.

Keywords: Casting, interview study, procurement, supplytrends.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
18 Efficient CT Image Volume Rendering for Diagnosis

Authors: HaeNa Lee, Sun K. Yoo

Abstract:

Volume rendering is widely used in medical CT image visualization. Applying 3D image visualization to diagnosis application can require accurate volume rendering with high resolution. Interpolation is important in medical image processing applications such as image compression or volume resampling. However, it can distort the original image data because of edge blurring or blocking effects when image enhancement procedures were applied. In this paper, we proposed adaptive tension control method exploiting gradient information to achieve high resolution medical image enhancement in volume visualization, where restored images are similar to original images as much as possible. The experimental results show that the proposed method can improve image quality associated with the adaptive tension control efficacy.

Keywords: Tension control, Interpolation, Ray-casting, Medical imaging analysis.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
17 Babbitt Casting and Babbitt Spraying Processes Case Study

Authors: M. Jalali Azizpour, S.Norouzi H. Mohammadi Majd

Abstract:

In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis such as SEM, EDS and wet chemical analysis has been made in the Babbitt alloys and worn surfaces. Two type of babbitt materials: tinbase and lead-base babbitt was used. The benefits of thermally sprayed babbitt layers are completely clear especially in large bearings.

Keywords: Thermal spray, Babbitting, Bonding, Bearing, BFP, CWP

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
16 The Significance of the Radiography Technique in the Non-Destructive Evaluation of the Integrity and Reliability of Cast Interconnects

Authors: Keshav Pujeri, Pranesh Jain, Krutibas Panda

Abstract:

Significant changes in oil and gas drilling have emphasized the need to verify the integrity and reliability of drill stem components. Defects are inevitable in cast components, regardless of application; but if these defects go undetected, any severe defect could cause down-hole failure. One such defect is shrinkage porosity. Castings with lower level shrinkage porosity (CB levels 1 and 2) have scattered pores and do not occupy large volumes; so pressure testing and helium leak testing (HLT) are sufficient for qualifying the castings. However, castings with shrinkage porosity of CB level 3 and higher, behave erratically under pressure testing and HLT making these techniques insufficient for evaluating the castings- integrity. This paper presents a case study to highlight how the radiography technique is much more effective than pressure testing and HLT.

Keywords: Casting Defects, Interconnects, Leak Check, Pressure Test, Radiography.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
15 Mechanical Properties of Die-Cast Nonflammable Mg Alloy

Authors: Myoung-Gon Yoon, Jung-Ho Moon, Tae Kwon Ha

Abstract:

Tensile specimens of nonflammable AZ91D Mg alloy were fabricated in this study via cold chamber die-casting process. Dimensions of tensile specimens were 25mm in length, 4mm in width, and 0.8 or 3.0mm in thickness. Microstructure observation was conducted before and after tensile tests at room temperature. In the die casting process, various injection distances from 150 to 260mm were employed to obtain optimum process conditions. Distribution of Al12Mg17 phase was the key factor to determine the mechanical properties of die-cast Mg alloy. Specimens with 3mm of thickness showed superior mechanical properties to those with 0.8mm of thickness. Closed networking of Al12Mg17 phase along grain boundary was found to be detrimental to mechanical properties of die-cast Mg alloy.

Keywords: Non-flammable magnesium alloy, AZ91D, die-casting, microstructure, mechanical properties.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
14 Neuroblasts Micropatterning on Nanostructural Modified Chitosan Membranes

Authors: Chun-Yen Sung, Chung-Yao Yang, Tzu-Chun Liao, Wen-Shiang Chen, Chao-Min Cheng, J. Andrew Yeh

Abstract:

The study describes chitosan membrane platform modified with nanostructure pattern which using nanotechnology to fabricate. The cell-substrate interaction between neuro-2a neuroblasts cell lines and chitosan membrane (flat, nanostructure and nanostructure pattern types) was investigated. The adhered morphology of neuro-2a cells depends on the topography of chitosan surface. We have found that neuro-2a showed different morphogenesis when cells adhered on flat and nanostructure chitosan membrane. The cell projected area of neuro-2a on flat chitosan membrane is larger than on nanostructure chitosan membrane. In addition, neuro-2a cells preferred to adhere on flat chitosan surface region than on nanostructure chitosan membrane to immobilize and differentiation. The experiment suggests surface topography can be used as a critical mechanism to isolate group of neuro-2a to a particular rectangle area on chitosan membrane. Our finding will provide a platform to take patch clamp to record electrophysiological behavior about neurons in vitro in the future.

Keywords: Chitosan membrane, neuro-2a, wet chemical etching, solvent casting.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
13 Improving TNT Curing Process by Using Infrared Camera

Authors: O. Srihakulung, Y. Soongsumal

Abstract:

Among the chemicals used for ammunition production, TNT (Trinitrotoluene) play a significant role since World War I and II. Various types of military weapon utilize TNT in casting process. However, the TNT casting process for warhead is difficult to control the cooling rate of the liquid TNT. This problem occurs because the casting process lacks the equipment to detect the temperature during the casting procedure This study presents the temperature detected by infrared camera to illustrate the cooling rate and cooling zone of curing, and demonstrates the optimization of TNT condition to reduce the risk of air gap occurred in the warhead which can result in the destruction afterward. Premature initiation of explosive-filled projectiles in response to set-back forces during gunfiring cause by casting defects. Finally the study can help improving the process of the TNT casting. The operators can control the curing of TNT inside the case by rising up the heating rod at the proper time. Consequently this can reduce tremendous time of rework if the air gaps occur and increase strength to lower elastic modulus. Therefore, it can be clearly concluded that the use of Infrared Cameras in this process is another method to improve the casting procedure.

Keywords: Infrared camera, TNT casting, warhead, curing.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
12 Defect Cause Modeling with Decision Tree and Regression Analysis

Authors: B. Bakır, İ. Batmaz, F. A. Güntürkün, İ. A. İpekçi, G. Köksal, N. E. Özdemirel

Abstract:

The main aim of this study is to identify the most influential variables that cause defects on the items produced by a casting company located in Turkey. To this end, one of the items produced by the company with high defective percentage rates is selected. Two approaches-the regression analysis and decision treesare used to model the relationship between process parameters and defect types. Although logistic regression models failed, decision tree model gives meaningful results. Based on these results, it can be claimed that the decision tree approach is a promising technique for determining the most important process variables.

Keywords: Casting industry, decision tree algorithm C5.0, logistic regression, quality improvement.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
11 An Aggregate Production Planning Model for Brass Casting Industry in Fuzzy Environment

Authors: Ömer Faruk Baykoç, Ümit Sami Sakalli

Abstract:

In this paper, we propose a fuzzy aggregate production planning (APP) model for blending problem in a brass factory which is the problem of computing optimal amounts of raw materials for the total production of several types of brass in a period. The model has deterministic and imprecise parameters which follows triangular possibility distributions. The brass casting APP model can not always be solved by using common approaches used in the literature. Therefore a mathematical model is presented for solving this problem. In the proposed model, the Lai and Hwang-s fuzzy ranking concept is relaxed by using one constraint instead of three constraints. An application of the brass casting APP model in a brass factory shows that the proposed model successfully solves the multi-blend problem in casting process and determines the optimal raw material purchasing policies.

Keywords: Aggregate production planning, Blending, brasscasting, possibilistic programming.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
10 Evaluation of Corrosion Property of Aluminium-Zirconium Dioxide (AlZrO2) Nanocomposites

Authors: M. Ramachandra, G. Dilip Maruthi, R. Rashmi

Abstract:

This paper aims to study the corrosion property of aluminum matrix nanocomposite of an aluminum alloy (Al-6061) reinforced with zirconium dioxide (ZrO2) particles. The zirconium dioxide particles are synthesized by solution combustion method. The nanocomposite materials are prepared by mechanical stir casting method, varying the percentage of n-ZrO2 (2.5%, 5% and 7.5% by weight). The corrosion behavior of base metal (Al-6061) and Al/ZrO2 nanocomposite in seawater (3.5% NaCl solution) is measured using the potential control method. The corrosion rate is evaluated by Tafel extrapolation technique. The corrosion potential increases with the increase in wt.% of n-ZrO2 in the nanocomposite which means the decrease in corrosion rate. It is found that on addition of n-ZrO2 particles to the aluminum matrix, the corrosion rate has decreased compared to the base metal.

Keywords: Al6061 alloy, corrosion, solution combustion, stir casting, Potentiostat, Zirconium Dioxide.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
9 Fabrication of High Aluminum Content Mg alloys using a Horizontal Twin Roll Caster

Authors: H. Harada, S. Nishida, T. Nagumo, M. Endo, H. Watari

Abstract:

This study was aimed for investigating of manufacturing high aluminum content Mg alloys using a horizontal twin roll caster. Recently, weight saving has been key issues for lighter transport equipments as well as electronic component parts. As alternative materials to aluminum alloys, developing magnesium alloy with higher strength has been expected. Normally high Aluminum content Mg alloy has poor ductility and is difficult to be rolled because of its high strength. However, twin roll casting process is suitable for manufacturing wrought Mg alloys because materials can be cast directly from molten metal. In this study, manufacturing of high aluminum content magnesium alloy sheet using the roll casting process has been carried out. Effects of manufacturing parameter, such as roll velocity, pouring temperature and roll gap, on casting was investigated. A microscopic observation of the crystals of cross section of as cast strip as well as rolled strip was conducted.

Keywords: AZ91, AZ111, AZ121, Magnesium alloys, Twin roll casting

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
8 Homogeneity of Microstructure and Mechanical Properties in Horizontal Continuous Cast Billet

Authors: V. Arbabi , I. Ebrahimzadeh, H. Ghanbari, M.M. Kaykha

Abstract:

Horizontal continuous casting is widely used to produce semi-finished non-Ferrous products. Homogeneity in the metallurgical characteristics and mechanical properties for this product is vital for industrial application. In the present work, the microstructure and mechanical properties of a horizontal continuous cast two-phase brass billet have been studied. Impact strength and hardness variations were examined and the phase composition and porosity studied with image analysis software. Distinct differences in mechanical properties were observed between the upper, middle and lower parts of the billet, which are explained in terms of the morphology and size of the phase in the microstructure. Hardness variation in the length of billet is higher in upper area but impact strength is higher in lower areas.

Keywords: Horizontal Continuous Casting, Two-phase brasses, CuZn40Al1 alloy, Microstructure, Impact Strength.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
7 Preparation and Characterization of Pectin Based Proton Exchange Membranes Derived by Solution Casting Method for Direct Methanol Fuel Cells

Authors: Mohanapriya Subramanian, V. Raj

Abstract:

Direct methanol fuel cells (DMFCs) are considered to be one of the most promising candidates for portable and stationary applications in the view of their advantages such as high energy density, easy manipulation, high efficiency and they operate with liquid fuel which could be used without requiring any fuel-processing units. Electrolyte membrane of DMFC plays a key role as a proton conductor as well as a separator between electrodes. Increasing concern over environmental protection, biopolymers gain tremendous interest owing to their eco-friendly bio-degradable nature. Pectin is a natural anionic polysaccharide which plays an essential part in regulating mechanical behavior of plant cell wall and it is extracted from outer cells of most of the plants. The aim of this study is to develop and demonstrate pectin based polymer composite membranes as methanol impermeable polymer electrolyte membranes for DMFCs. Pectin based nanocomposites membranes are prepared by solution-casting technique wherein pectin is blended with chitosan followed by the addition of optimal amount of sulphonic acid modified Titanium dioxide nanoparticle (S-TiO2). Nanocomposite membranes are characterized by Fourier Transform-Infra Red spectroscopy, Scanning electron microscopy, and Energy dispersive spectroscopy analyses. Proton conductivity and methanol permeability are determined into order to evaluate their suitability for DMFC application. Pectin-chitosan blends endow with a flexible polymeric network which is appropriate to disperse rigid S-TiO2 nanoparticles. Resulting nanocomposite membranes possess adequate thermo-mechanical stabilities as well as high charge-density per unit volume. Pectin-chitosan natural polymeric nanocomposite comprising optimal S-TiO2 exhibits good electrochemical selectivity and therefore desirable for DMFC application.

Keywords: Biopolymers, fuel cells, nanocomposite, methanol crossover.

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF
6 Internal Structure Formation in High Strength Fiber Concrete during Casting

Authors: Olga Kononova, Andrejs Krasnikovs , Videvuds Lapsa, Jurijs Kalinka, Angelina Galushchak

Abstract:

Post cracking behavior and load –bearing capacity of the steel fiber reinforced high-strength concrete (SFRHSC) are dependent on the number of fibers are crossing the weakest crack (bridged the crack) and their orientation to the crack surface. Filling the mould by SFRHSC, fibers are moving and rotating with the concrete matrix flow till the motion stops in each internal point of the concrete body. Filling the same mould from the different ends SFRHSC samples with the different internal structures (and different strength) can be obtained. Numerical flow simulations (using Newton and Bingham flow models) were realized, as well as single fiber planar motion and rotation numerical and experimental investigation (in viscous flow) was performed. X-ray pictures for prismatic samples were obtained and internal fiber positions and orientations were analyzed. Similarly fiber positions and orientations in cracked cross-section were recognized and were compared with numerically simulated. Structural SFRHSC fracture model was created based on single fiber pull-out laws, which were determined experimentally. Model predictions were validated by 15x15x60cm prisms 4 point bending tests.

Keywords: fibers, orientation, high strength concrete, flow

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF