Journal articles: 'Casting powder'

1

Dević, Snezana, and R. Carli. "Effect of Wolastonite Mineral (CaO SiO₂) Content in Continuous Casting Powder to SEN Erosion." Key Engineering Materials 352 (August 2007): 107–10. http://dx.doi.org/10.4028/www.scientific.net/kem.352.107.

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The basic idea of the work was to analyze the effect of the wollastonite mineral CaO SiO2 content in the continuous casting powder related to the SEN erosion. In order to realize the research, experiments were conducted in the laboratory conditions. The research, experiment, was realized in the Magnohrom Kraljevo laboratory, and cryptonym furnace EV16 was used for refractory material behavior. Cut SEN pieces from the slag zone in the reduction atmosphere were treated in the furnace with three types of casting powder of different mixtures ratio of SRD1 (without wollastonite) and SRD2 (with wollastonite): Casting powder 1 - SRD1/SRD2 = 50/50 %, Casting powder 2 - SRD1/SRD2 = 25/75 % and Casting powder 3 - SRD1/SRD2 = 75/25 %. Temperature of the experiment was in the range of 15200C – 15400C, and treatment time was changed simulating the average casting time of the heat; one heat (45 min), two heats (90 min), and three heats (135 min). The experiment pointed out that the erosion of the SEN was reduced with the increased ratio of wollastonite in the casting powder. The erosion rate of the SEN exposed to the casting powder 2 in the laboratory conditions was 0.0055 mm/min, whilst the erosion rate of the SEN exposed to the casting powder 3 (with the least wollastonite content) was 0.0075 mm/min. Erosion rate of SEN exposed to the casting powder 2 was lower for the 26.27 % related to the casting powder 3, and 17.90% lower than the erosion rate of the casting powder 1 (the erosion rate of the casting powder 1 was 0.0067 mm/min). These laboratory experiments are very consistent with results obtained in the plant conditions [1,2,3]. At that time, results indicated that SRD1 casting powder without wollastonite has the erosion rate 46 % higher than SRD2 casting powder with wollastonite. On the basis of the laboratory researches and earlier plant conditions researches it could be concluded that wollastonite mineral content in the casting powders has significant effect on the SEN erosion, in the way that the SEN erosion rate was decreased with the increased wollastonite content in the casting powders.

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Sheleg, V. K., M. A. Levantsevich, Y. V. Pilipchuk, M. A. Kravchuk, I. A. Bogdanovich, and T. Ya Bogdanova. "Alloying the Melt of Sliding Bearings Based on Babbitt." Science & Technique 19, no. 6 (November 27, 2020): 475–79. http://dx.doi.org/10.21122/2227-1031-2020-19-6-475-479.

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Abstract. A device design is proposed that makes it possible to obtain composite castings of sliding bearings based on babbitt by mixing alloying additives from antifriction powders of solid lubricants (graphite, molybdenum disulfide, etc.) into the melt, having a density significantly lower than the density of babbitt itself. The principle of mixing is based on the use of numerous turbulent flows resulting from the rotation of a gating rod with a wire pile in the melt material, the packing density coefficient of which is not less than 0.1. Due to the suction effect of these flows, non-metallic particles of solid lubricant powder do not float to the surface of the melt and, after crystallization, remain in the body of the casting. The supply of alloying powder of solid lubricant is carried out simultaneously with the supply of the babbitt melt through the central and distribution gating channels made in a rotating rod. Under the action of centrifugal forces, powder particles and melt material flow through distribution channels to the walls of the mold (mold), passing through the rotation zone of the metal pile. In this case, intensive mixing of the powder particles with the melt material occurs due to the suction effect of turbulent flows arising behind the moving pile. In addition, as a result of the rotation of the wire pile, dendritic constituents are crushed in babbitt castings. Metallographic studies of the castings obtained on the developed device have shown that the structure of the casting obtained by traditional technology contains large quantities of solid crystals of intermetallic compounds SnSb and Cu3Sn, while in the structure of the casting obtained using the proposed device, along with the aforementioned intermetallic compounds, particles of solid lubricant C + MoS2 powder embedded in the crystallized melt are observed.

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Hariharan, Ashok, and Samir Kumar Mozumdar. "Evolution of Mould Fluxes." Advanced Materials Research 794 (September 2013): 75–89. http://dx.doi.org/10.4028/www.scientific.net/amr.794.75.

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Mould flux was invented for bottom poured ingots using fly ash as raw material. It transited subsequently to synthetic raw materials. As continuous casting of steel developed, Fluxes in fine powder form evolved culminating to the development of environment friendly fluxes in granular form. As continuous casting of stainless steel commenced different powders were developed for different Stainless qualities like austenitic, ferritic etc. Powders developed from interface with users were not only to satisfy demand of lubrication in the mould but also for adequate heat transfer and better surface quality. Shrinkage in mould, interplay of the elements in steel during casting with mould slag, tendency of the steel grades towards cracking or sticking and influence of various casting parameters determined mould powder development and usage. In-mould Powder performance dynamically reacts to changes in casting parameters and conditions and appropriate changes in powder chemistry can overcome or minimise detrimental effects of such changes. Future demands of overall cost control, better surface quality, minimal grinding, stable meniscus will guide powder research and development alongwith focus on environmental concerns.

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4

McKay, S., N. S. Hunter, A. S. Normanton, V. Ludlow, P. N. Hewitt, and B. Harris. "Continuous casting mould powder evaluation." Ironmaking & Steelmaking 29, no. 3 (June 2002): 185–90. http://dx.doi.org/10.1179/030192302225004142.

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5

Znamenskii, L. G., A. N. Franchuk, and A. A. Yuzhakova. "Nanostructured Materials in Preparation Casting Alloys." Materials Science Forum 946 (February 2019): 668–72. http://dx.doi.org/10.4028/www.scientific.net/msf.946.668.

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The article deals with technologies of refining and inoculating casting alloys with the use of nanostructured diamond powder, as well as stimulation technique on molten metal including processing of the liquid alloy with nanosecond electromagnetic pulses. The developed method of cast iron inoculation allows to eliminate the flare and to increase the physical and mechanical properties of the castings through the grain refining and the decrease of chilling tendency during crystallization of the liquid alloy. Inoculating of aluminium alloys by high-melting particles of a nanostructured diamond powder leads to the grinding of structural constituents, including conditions for dispersing hardening intermetallics during postbaking of such castings. As a result, foundry and physicomechanical properties of castings are significantly improved.

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6

Kim, Woo Chang, and Jong Kook Lee. "Effect of Powder Characteristics on Slip Casting Fabrication of Dental Zirconia Implants." Journal of Nanoscience and Nanotechnology 20, no. 9 (September 1, 2020): 5385–89. http://dx.doi.org/10.1166/jnn.2020.17610.

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Dense zirconia compacts were fabricated by slip casting and sintering of nanoscale zirconia powders, and the effect of the powder characteristics (crystallite size, specific surface area, yttria content, and agglomeration) on the slurry and sintered properties was investigated. Three types of commercial 3 mol% yttria-stabilized tetragonal zirconia polycrystals powders were used as the starting powders after the powder characteristic analysis. A zirconia slurry for slip casting was prepared by mixing zirconia powder (solid loading of 60, 65, and 70 wt.%), distilled water, and a dispersant of Darvan C. The green compacts obtained from slip casting were cold isostatic pressed to enhance the close packing and densified by sintering at 1450 °C for 2 h. Highly dense zirconia compacts with a relative density of 99.5% and grain size of 350 nm were obtained based on the powder type and solid loading in the slurry. The microstructure and mechanical hardness of the sintered specimen after slip casting were dependent on the yttria content in the 3 mol% yttria-stabilized tetragonal zirconia polycrystal powder and the solid loading within the slurry.

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7

Ardelean, Marius, Alina Lăscuțoni, Erika Ardelean, and Ana Socalici. "Optimization of Synthetic Slag Additions Used in Continuous Casting of Steel." Solid State Phenomena 254 (August 2016): 176–81. http://dx.doi.org/10.4028/www.scientific.net/ssp.254.176.

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The appropriate use and in adequate quantities of synthetic slags in continuous casting process (insulating coating powder in tundish and respectively lubricant molding powder in crystallizer) gives a good quality of continuous castings products. The paper presents two methods of determining the necessary of slags: using dispersion analysis software Minitab.v17 and optimization of heat transfer in tundish, depending on powder coating thickness, performed with a program made in Mathcad14 and respectively optimization of the molding powder thickness, using an own simulation program. Both methods are based on the properties of steel grade which is casted (in particular the liquidus temperature of the steel) and they can be adapted to the specifics of the continuous steel casting machines.

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8

Stobierski, Ludosław, Jerzy Lis, and Agnieszka Gubernat. "SiC Powder for Casting from Aqueous Suspension." Advances in Science and Technology 45 (October 2006): 297–302. http://dx.doi.org/10.4028/www.scientific.net/ast.45.297.

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The activation of silicon carbide by boron and carbon is required to obtain dense monophase sintered body from SiC powder. The presence of carbon renders casting from aqueous suspension impossible. The SiC powders with boron and extra carbon were prepared by combustion method (SHS), where carbon was bound to SiC particles in a stable way. The experiments showed that this powder could be used for processing by casting of aqueous suspension. Finally nearly dense polycrystals were obtained by pressureless sintering.

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9

Singh, Satnam, Dheeraj Gupta, and Vivek Jain. "Microwave melting and processing of metal–ceramic composite castings." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 232, no. 7 (September 1, 2016): 1235–43. http://dx.doi.org/10.1177/0954405416666900.

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Applications of metal–ceramic composites are increasing in advanced materials field; however, efficient utilization of these materials depends on the cost involved in processing and structure–properties correlations. Processing of materials through microwave energy has already been accepted as a well-established route for many materials. In this work, composites of nickel-based metallic powder (matrix) and SiC powder (reinforcement) were successfully casted by microwave heating. The mechanism for the development of composite castings using microwaves is discussed with proper illustrations. The results of microstructure analysis of the developed cast revealed that uniform equiaxed grain growth with uniform dispersion of reinforcement. The results of X-ray diffraction analysis revealed that during microwave heating some metallurgical changes took place, which led to higher microhardness of cast. Micowave processed casting revealed lower defects (~1.75% porosity) and average Vickers microhardness of 920 ± 208 HV. This work reports the successful applications of microwaves in manufacturing, in the form of melting and casting of metallic powders.

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10

Xu, Ying, and Li Guang Zhu. "Study and Application on Crystallization Temperature of Mould Powder for High-Speed Continuous Casting." Advanced Materials Research 197-198 (February 2011): 677–81. http://dx.doi.org/10.4028/www.scientific.net/amr.197-198.677.

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Crystallization rule of mould powder for high-speed continuous casting was studied and the suitable composition powder was done. The analysis of experiment shows: in the given range, the influencing order of different fluxing agents for the crystallization temperature is: Li2O> BaO> B2O3> Na2O> CaF2> MgO. According to different solidification characteristics of steel and the requirements to the performance of mould power, component design of mould powder for high-speed continuous casting was done from the perspective of the crystallization characteristics.

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11

Ludlow, V., B. Harris, S. Riaz, and A. Normanton. "Continuous casting mould powder and casting process interaction: why powders do not always work as expected." Ironmaking & Steelmaking 32, no. 2 (April 2005): 120–26. http://dx.doi.org/10.1179/174328105x15850.

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12

Kania, H., and K. Nowacki. "Optimization of Chemical Composition of the Mould Powder for Casting Ø 170 mm Billets from C45 Steel." Archives of Metallurgy and Materials 61, no. 4 (December 1, 2016): 2083–90. http://dx.doi.org/10.1515/amm-2016-0335.

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Abstract Physico-chemical properties of mould powders and assumed casting parameters for the particular steel grade influence the way of lubricating the surface of the skin of concast billets formed in the mould, as well as heat transfer along its circumference. The paper presents research which main aim was to improve the surface quality of continuous casting round billets (Ø 170 mm) cast from C45 steel. Improvement of the surface quality can be obtained by designing the chemical composition of mould powder for local casting conditions and the technical and technological parameters of CC equipment. Based on the experimental casting from C45 medium carbon steel it was found that there are relationships between the physicochemical properties of mould powder and intensity of skin lubrication and heat transmission to the mould wall.

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13

Wang, Lei, Yi Xiang Cai, Xin Liu, Huan Wen Xie, and Xin Tong. "The Spherical Casting WC Powder and its Application in Laser Surface Alloying Treatment." Advanced Materials Research 785-786 (September 2013): 910–13. http://dx.doi.org/10.4028/www.scientific.net/amr.785-786.910.

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The spherical casting WC powder is a kind of new potential wear-resistance ceramic material. In this paper, its chemical composition, surface morphology, microstructure, phase, microhardness and some powder characteristics were investigated, and then the powders were applied in laser surface alloying treatment on medium carbon steel. The results indicate that the spherical WC powder consists of (wt.%) 94.06 W, 4.03 C and 1.91 other elements including Fe, V, Cr and Nb. Most of powder particles have regular spherical shape and smooth surface, and the microstructure is acicular eutectic of WC and W2C, which leads to high microhardness of 2812 HV. The fluidity of powders is 5.97 s/50g, and the apparent density of powders is 10.1 g/cm3. The laser alloyed layer is characterized by dendritic primary phase, ledeburite microstructure and some residual WC particles. The laser surface alloying treatment with adding material of spherical casting WC powder can enhanc the abrasive wear resistance of medium carbon steel by over 200%.

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14

Tashima, Shunzo, Hiroyuki Suzuki, and Hidenori Kuroki. "Pressure Slip Casting of Submicron Alumina Powder." Journal of the Japan Society of Powder and Powder Metallurgy 40, no. 1 (1993): 3–7. http://dx.doi.org/10.2497/jjspm.40.3.

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15

NAGAE, Hajime, Akio ITO, Motohiro TORIYAMA, Kaoru SOBATA, and Seiji KIRIYAMA. "Centrifugal Casting of Alumina-Zirconia Mixed Powder." Journal of the Ceramic Society of Japan 102, no. 1184 (1994): 346–49. http://dx.doi.org/10.2109/jcersj.102.346.

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16

Kromhout, J. A., A. A. Kamperman, M. Kick, and J. Trouw. "Mould powder selection for thin slab casting." Ironmaking & Steelmaking 32, no. 2 (April 2005): 127–32. http://dx.doi.org/10.1179/174328105x15869.

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17

Kromhout, J. A., C. Liebske, S. Melzer, A. A. Kamperman, and R. Boom. "Mould powder investigations for high speed casting." Ironmaking & Steelmaking 36, no. 4 (May 2009): 291–99. http://dx.doi.org/10.1179/174328109x407130.

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18

Kawamoto, M., T. Murakami, M. Hanao, H. Kikuchi, and T. Watanabe. "Mould powder consumption of continuous casting operations." Ironmaking & Steelmaking 29, no. 3 (June 2002): 199–202. http://dx.doi.org/10.1179/030192302225004151.

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19

Kromhout, J. A., S. Melzer, E. W. Zinngrebe, A. A. Kamperman, and R. Boom. "Mould Powder Requirements for High-speed Casting." steel research international 79, no. 2 (February 2008): 143–48. http://dx.doi.org/10.1002/srin.200806329.

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20

GANESH, IBRAM. "Aqueous slip casting of MgAl2O4 spinel powder." Bulletin of Materials Science 34, no. 2 (April 2011): 327–35. http://dx.doi.org/10.1007/s12034-011-0073-9.

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21

Meier, Lorenz P., Lukas Urech, and Ludwig J. Gauckler. "Tape casting of nanocrystalline ceria gadolinia powder." Journal of the European Ceramic Society 24, no. 15-16 (December 2004): 3753–58. http://dx.doi.org/10.1016/j.jeurceramsoc.2004.01.002.

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22

Sumpena, Sumpena. "Pengaruh Paduan Serbuk Fe12% pada Aluminium terhadap Porositas dan Struktur Mikro dengan Metode Gravity Casting." Jurnal Engine: Energi, Manufaktur, dan Material 1, no. 1 (May 31, 2017): 20. http://dx.doi.org/10.30588/jeemm.v1i1.225.

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<em>The purpose of this research is to know the effect of Fe12% powder alloy on aluminum to porosity and micro structure by gravity casting method. Metal Matrix Composite (MMC) is an engineering material formed from the combination of two or more materials to obtain new materials with better properties. Making of composite material with aluminum matrix or metal matrix composite (MMC) can be done by casting method. The composite forming elements are called boosters (fibers or particles) and binders (matrices). In the process of casting metal can occur porosity In the casting process with sand molds usually occur porosity, causing the mechanical properties of casting objects decreased. Porosity is caused by bubbles of gas, gas released by the core when exposed to metal liquid heat, resulting in pores or perforated defects.The process of smelting was carried out at the metal foundry laboratory of Mechanical Engineering UP 45 Yogyakarta. The smelting process uses a krusible furnace with coke fuel, on which it is placed kowi to place aluminum and iron powder to be melted. Aluminum and 12% iron powder are weighed in accordance with the volume of the pattern, so that the melt does not suffer from metal deficiency. Observation of porosity is done by looking visually on each side of the outer part of the casting object. Observation of microstructure using optical microscope is done by taking three samples of specimen castings that have been in the preparation of polishing machine and etching. The effect of Fe 12% alloys on porosity is the average porosity occurring on specimens A, B and C of 2,766 gr / cm3. The effect of Fe 12% alloys on micro structure is the spreading of Fe, Si and Mg elements evenly, but for the C specimens of Fe and Si bersenyawa, while the Al and Mg elements are separate.</em>

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23

Wu, Guo Rong. "Control of Surface Quality of if Steel Sheet." Advanced Materials Research 415-417 (December 2011): 1651–55. http://dx.doi.org/10.4028/www.scientific.net/amr.415-417.1651.

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In order to solve the problem of mold powder entrapment which is one of the affecting factors on faint-sliver defect in IF cold-rolled steel sheet in casting process, continuous casting process is optimized. Based on the analysis of the defect, the composition of mold powder is optimized. Otherwise, surface tension and viscosity of mold powder are raised. With theses countermeasures, mold powder entrapment and casting subcutaneous slag is decreased obviously. In addition, the rate of faint-sliver defect in cold-rolled IF steel sheet has been reduced from 5.21% to below 1.0%.

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24

LI, Xiaodong, Lei WANG, Mikio IWASA, and Motozo HAYAKAWA. "Effect of Powder Characteristics on Centrifugal Slip Casting of Alumina Powders." Journal of the Ceramic Society of Japan 111, no. 1296 (2003): 594–99. http://dx.doi.org/10.2109/jcersj.111.594.

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25

Sorek, A., and Z. Kudliński. "The Influence of the Near-Meniscus Zone in Continuous Casting Mold on the Surface Quality of the Continuous Casting Ingots." Archives of Metallurgy and Materials 57, no. 1 (March 1, 2012): 371–77. http://dx.doi.org/10.2478/v10172-012-0036-1.

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The Influence of the Near-Meniscus Zone in Continuous Casting Mold on the Surface Quality of the Continuous Casting IngotsThe physical, chemical and mechanical phenomena which take place in the near-meniscus zone of continuous casting mold are the significant factors influencing the quality of CC ingot and especially the quality of its surface. Such phenomena consist of the following processes: lubrication of the ingot surface by the liquid slag-forming phase of mold powder, creation of meniscus, formation of the specific kind of galvanic cell and connected with this cell ions migration of liquid mold powder. Application of the mold powders is the commonly used lubrication method of the surface of CC ingots in mold (in near-meniscus zone). According to the ionic structure theory of the liquid metallurgical slags the following thesis can be formulated: the liquid slag-forming phase of mold powder is the ionic liquid. The ionic liquid occurs between two metals: the copper wall of mold and the steel surface of ingot can create a specific kind of galvanic cell in the upper part of mold (the near-meniscus zone of mold). The paper presents results of industrial research of low-carbon steel continuous casting. The electromotive force of galvanic cell situated in the upper (near-meniscus) part of CC mold was measured. Moreover, the influence of applied powders with different alkalinity on the character of oscillatory marks forming on the ingot surface was considered. The galvanic cell, which is created in the upper part of mold in the near-meniscus zone, can cause the essential change of the chemical composition of electrolyte (liquid phase of mold powder) in the near-electrodes zones. So in the process the condition of lubrication and character of obtained oscillatory mark can also be changed.

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Martyushev, Nikita. "Alignment of the Microstructure of Castings from the Heterophase Lead Bronzes." Advanced Materials Research 880 (January 2014): 163–67. http://dx.doi.org/10.4028/www.scientific.net/amr.880.163.

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This paper reports on the use of nanopowders in the coating composition forms in casting blanks from lead bronzes for the petrochemical industry. Influence of composition of used protective separating coating of casting mold on the microstructure castings was investigated. For experimental investigations following coating were selected [1]: the mixture of zirconium dioxide nanopowder with industrial oil and the same composition as it’s, but on the basis of aluminum oxide nanopowder. As the test material multicomponent and lead bronzes were selected. The cooling curves castings using coatings of different compositions by means the developed device thermograph were constructed using techniques developed by the authors. The study results showed that the greatest reduction in the cooling rate at the time of crystallization bronze corresponds to coating casting mold based on powder of zirconium dioxide (45 °C/c). The cooling rate is reduced only to 65 °C/c when coating based on aluminum oxide. Decrease the cooling rate of castings using these coatings can change the shape and size of lead inclusions and align the casting structure in section. Form inclusions lead is becoming more spherical and their interfacial surface is leveled. The greatest changes occur in the surface layers of castings. Is shown that the multicomponent bronzes decreased speed the cooling due to the use plasters leads not only to changes in the morphology of inclusions but also to lead the change in the phase composition. Decrease of cooling rate leads to increasing the amount of eutectoid and growth of hardness casting.

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Ma, Li, Xingping Lai, Jianguo Zhang, Shuangshuang Xiao, Leiming Zhang, and Yuhang Tu. "Blast-Casting Mechanism and Parameter Optimization of a Benched Deep-Hole in an Opencast Coal Mine." Shock and Vibration 2020 (February 18, 2020): 1–11. http://dx.doi.org/10.1155/2020/1396483.

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During the research on bench deep-hole blast casting, the blast-casting parameters are directly related to the blast-casting results, so it could reveal the mechanism for improving the effect thereof. Based on the principle of the plane charge method, both the stress wave and detonation gas were considered to affect rock fragmentation and casting, a model of overburden fragmentation and casting process around the blasting hole was established, and bench deep-hole blast-casting behaviours were elucidated. By using the Factor Analysis Method (FAM), a correlation analysis model of factors influencing blast-casting results was built. The results proved that powder factor (or specific charge) ranked first in terms of its influence, followed by hole spacing, minimum resistance line, burden, and bench height. The formulae for calculating the limit powder factor value and the spacing of blasting holes were derived for different rock properties. The results showed that the optimum hole spacing was no more than 12.49 m and the powder factor was no more than 0.75 kg/m3, and it proved that an effective casting percentage (ECP) of 34% could be realized.

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Ortega-Jimenez, Cesar Humberto, Giovany David Luque Andino, Walter Alfonso Amador Segura, Gerardo Efraín Villalobos Andino, Carlos Eduardo Díaz Pavón, Selvin Alejandro Baca Valladares, Herbert Daniel Chavarría Donaire, Luis Fernando Chandias Flores, and Carlos Humberto Aguilar Padilla. "Systematic Review of Powder Metallurgy: Current Overview of Manufactured Materials and Challenges for Future Research." Materials Science Forum 1015 (November 2020): 36–42. http://dx.doi.org/10.4028/www.scientific.net/msf.1015.36.

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The journey toward foundry and the increasing implementation of Powder Metallurgy are evoking replacing traditional Sand Casting, thus, creating new challenges and opportunities. To take advantage of these opportunities and deal with the challenges, we must gain a holistic understanding of the emerging technical interactions and apply new approaches and methods when introducing new technologies and designing Powder Metallurgy. In this paper, we present the findings of a systematic literature review, consisting of quantitative and qualitative data, focusing on investigating Powder Metallurgy, as an alternative to traditional Sand Casting, by comparing certain characteristics of either process to synthesize the existing information of each method and to present an overview of manufactured materials. Although results indicate an increasing current trend in research publications, showing Powder Metallurgy with many advantages over traditional casting, the latter continues to be implemented as the preferred option in industries with low-level casting production. Given that the studies indicate greater advances in Powder Metallurgy methods over traditional casting, we identified the need for more research on the former under different contexts and therefore recommend it as an approach for future studies of metal casting. This review both reorganizes the available knowledge on Powder Metallurgy, as well as it makes an important methodological contribution by applying a review in Materials science, where there is little to no systematic research, which often means failure to provide sufficient help to implement Powder Metallurgy. Based on these findings, we point to future research needs, highlighting the need for further empirical evidence and improved collaboration between the topics of Mechanical Engineering, Manufacturing Processes, and Materials science, as well as with practitioners.

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Luo, Yi Lan, Shi Gen Zhu, Zheng Gang Yang, and Rui Zhang. "Study on the Mechanism of the Strippable Sintering Layer of the Natural Yellow Clay-Bonded Sand for Iron Casting." Applied Mechanics and Materials 66-68 (July 2011): 1622–27. http://dx.doi.org/10.4028/www.scientific.net/amm.66-68.1622.

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The distinguished characteristic of casting process of natural yellow clay-bonded green sand is a strippable sintering layer formed at the interface of casting and mould. Hot shake-out can be realized because this sintering layer can firmly attach to the casting surfaces to protect castings at elevated temperature. Better surface quality of castings is achieved after the sintering layer easily shed from the casting surface at room temperature. In this study, a series of tests were carried out to reveal the characteristic of this sintering layer. First, thermal gravimetric/differential thermal analysis (TG/DTA) method was used for detailed analysis the thermal property of natural yellow clay-bonded green sand. And, X-ray diffraction (XRD) analysis was employed to define the phase composition at variable temperatures. Then, sintering experiments were carried out on mixtures of natural yellow clay-bonded sand with iron powder or iron oxides under different conditions. Finally, the mechanical performances of sinter layer of natural yellow clay-bonded sand at elevated and room temperatures were investigated. The result revealed that natural yellow clay-bonded green sand is a kind of low grade molding sand, and iron oxides participate in the forming of sintering layer. The sintering layer of natural yellow clay-bonded sand were proved both excellent plastic at elevated temperature and brittle at room temperature, which coincides with its behavior in the casting process.

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Pineda Huitron, Rosa Maria, Pavel Ernesto Ramírez López, Esa Vuorinen, Pooria Nazen Jalali, Leonardo Pelcastre, and Maija Kärkkäinen. "Scale Formation on HSLA Steel during Continuous Casting Part II: The Effect of Surface Conditions." Metals 10, no. 9 (September 16, 2020): 1245. http://dx.doi.org/10.3390/met10091245.

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The present research addresses the effect of surface condition on oxide scale formation at high temperatures such as those experienced during secondary cooling in Continuous Casting. Tests were carried out in clean, as-cast and surfaces covered with casting powder to replicate the oxidation/re-oxidation after the mould. Specimens oxidized at 1000, 1100 and 1200 °C under dry air and water-vapour conditions revealed that the oxide scale formation is strongly influenced by temperature, environmental and surface conditions. The oxide scale thickness increases with temperature alterations in the surface (e.g., as-cast and covered with powder) where oxides and carbonates from the casting powder accelerate oxidation kinetics leading to thick and unstable scales. A high amount of carbon is present on surfaces covered with casting powder where it diffuses through the oxide scale forming CO and CO2 which lead to stress accumulation that makes scales prone to defects such as pores, voids and micro-cracks. Ultimately, if wüstite remains attached to the steel surface or inside oscillation marks, it may disturb heat transfer during secondary cooling which has deep industrial implications for crack formation and overall casting yield. Therefore, accurate insights on scale type and growth mechanisms could lead to accurate control of its formation during casting.

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da Costa, Cesar Edil, Walter Contreras Zapata, and Moisés Luiz Parucker. "Characterization of casting iron powder from recycled swarf." Journal of Materials Processing Technology 143-144 (December 2003): 138–43. http://dx.doi.org/10.1016/s0924-0136(03)00394-7.

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TSUTSUMI, Koichi, Hiroshi MURAKAMI, Shin-ichi NISHIOKA, Mitsuhiro TADA, Masayuki NAKADA, and Masami KOMATSU. "Estimation of Mold Powder Consumption in Continuous Casting." Tetsu-to-Hagane 84, no. 9 (1998): 617–24. http://dx.doi.org/10.2355/tetsutohagane1955.84.9_617.

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Ohta,, H., K. Watanabe,, K. Nakajima,, and Y. Waseda,. "Absorption Coefficient of Continuous Casting Powder for Steel." High Temperature Materials and Processes 12, no. 3 (September 1993): 139–44. http://dx.doi.org/10.1515/htmp.1993.12.3.139.

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Kromhout, J. A. "Mould Powder Development for Continuous Casting of Steel." Transactions of the Indian Institute of Metals 66, no. 5-6 (July 3, 2013): 587–96. http://dx.doi.org/10.1007/s12666-013-0296-0.

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Martyushev, Nikita, Ilya V. Semenkov, and Yuriy N. Petrenko. "Impact of Protective Release Coatings with Nanopowders on the Quality of Bronze Castings Surface." Advanced Materials Research 872 (December 2013): 112–17. http://dx.doi.org/10.4028/www.scientific.net/amr.872.112.

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In work are submitted data of casting mold coverings with nanopowders application for molding lead bronze. Influence of a structure of used protective - separating coating of a foundry core on a microstructure of castings was investigated. For experimental work following coverings (the patent No 2297300) a mix dioxide zirconium nanopowder with industrial oil, and the same structure, but already on a basis on oxide aluminum nanopowder have been chosen. It is shown that these coverings application leads to decrease in quantity of surface defects, the roughness of a cast surface decreases. At the same time penetration of particles of a powder from a foundry covering in casting doesn't occur.

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Giorleo, Luca, and Michele Bonaventi. "Casting of complex structures in aluminum using gypsum molds produced via binder jetting." Rapid Prototyping Journal 27, no. 11 (July 14, 2021): 13–23. http://dx.doi.org/10.1108/rpj-03-2020-0048.

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Purpose The purpose of present paper is to enlarge the knowledge about the performance of gypsum powder to realize complex molds or cores for aluminum casting. Design/methodology/approach The research was divided into two activities: simple; and complex-part production capability. In the simple-part step, the performance of gypsum powder and the minimum mold thickness that would withstand the casting process. In the complex-part step, the authors first investigated the powder removability as a function of geometry complexity and then binder jetting performance was evaluated for the case of lattice-structure fabrication. Findings All the geometries tested withstand the casting process demonstrating the benefits in terms of complexity part design; however, the process suffers of all the typical defect of casting as misrun, porosity and cold shut. Originality/value The results found in this research improve the benefits related to additive manufacturing application in industrial environment and in particular to the binder jetting technology and the rapid casting approach.

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Löber, Lukas, Denis Klemm, Uta Kühn, and Jürgen Eckert. "Rapid Manufacturing of Cellular Structures of Steel or Titaniumalumide." Materials Science Forum 690 (June 2011): 103–6. http://dx.doi.org/10.4028/www.scientific.net/msf.690.103.

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The Selective Laser Melting (SLM) technique is used to produce different cellular structures. Regular unit cells are placed in tensile bars to determine the mechanical performance of different lattice structures. The mechanical properties of the tensile bars with lattice structures are compared to fully dense tensile bars. Tensile bars are produced by conventional casting to compare the mechanical properties between SLM and casting. To exclude other influences, the whole process chain starting from the powder to the finished part is characterized. The different powders, namely 1.4404 steel powder and a titaniumaluminde (Ti-48Al-2Cr-2Nb [TiAl]) powder are characterized via scanning electron microscopy (SEM), energy disperse x-ray spectroscopy (EDS), chemical analysis and light microscopy (LM). In addition measurements of the particle size distribution are conducted. Detailed experimental conditions of the SLM-process are given.

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Li, Zhi Wei, Kai Yong Jiang, Fei Wang, and Ji Liang Zhang. "Behavior of Microwave Heating of 316 Stainless Steel Green Body." Advanced Materials Research 936 (June 2014): 1694–700. http://dx.doi.org/10.4028/www.scientific.net/amr.936.1694.

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This paper mainly introduces the mechanism of microwave heating: electric conduction loss, eddy current loss and arc discharge. The microwave heating behavior of 316 stainless steel powder body which made by gel casting was investigated in the paper. Experiments on different microwave power, powder particle size, and the content of auxiliary heating material showed that the smaller the powder particle size, the larger microwave power and auxiliary heating materials help 316 stainless steel body for sintering.

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Wu, Guo Rong. "Effect of Mold Powder on Faint-Sliver Defect in if Cold-Rolled Steel Sheet." Advanced Materials Research 339 (September 2011): 134–39. http://dx.doi.org/10.4028/www.scientific.net/amr.339.134.

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Mold powder entrapment is one of the affecting factors on faint-sliver defect in IF cold-rolled steel sheet in casting process. Based on the analysis of the defect, the composition of mold powder is adjusted. Otherwise, surface tension and viscosity of mold powder are raised. After taking these measures, mold powder entrapment and casting subcutaneous slag is decreased obviously. In addition, the rate of faint-sliver defect in cold-rolled IF steel sheet has been reduced from 5.21% to below 1.0%.

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Wang, Shuo Ming, Yan Wang, and Ruo Si Wang. "Analysis of Large Inclusions in Q195 Steel." Advanced Materials Research 997 (August 2014): 522–25. http://dx.doi.org/10.4028/www.scientific.net/amr.997.522.

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Aimed at the Q195 steel strip inclusion defects in a steel mill, using tracer analysis make system analysis to casting of large inclusions content. Large inclusions in casting containing ladle slag accounted for about 39% of the total number of test, containing tundish covering agent accounts for about 42.2%, while containing protection slag accounted for 45%. Shows that large inclusions in the billet is mainly comes from the crystallizer mold powder entrapment, secondly is the tundish slag and the ladle slag powder entrapment. When transient casting large inclusions content is steady casting several times, increasing the stability of operation on transient casting, controlling the stability of cast-on and ladle changing, stabilizing the liquid level of tundish and mould can improve the quality of the steel.

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Anca, Denisa, Mihai Chisamera, Stelian Stan, Iuliana Stan, and Iulian Riposan. "Sulfur and Oxygen Effects on High-Si Ductile Iron Casting Skin Formation." Coatings 10, no. 7 (June 29, 2020): 618. http://dx.doi.org/10.3390/coatings10070618.

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The main objective of the present paper is to evaluate by thermal (cooling curve) analysis the solidification pattern and the occurrence of the layer of degenerate graphite at the surface of ductile iron castings (3.15% Si, typically as 450-18 grade, ISO 1563/2011), with or without a mold coating, including S or O, and different agents (carbonic material, iron powder), supposed to act to block their diffusion into the iron melt. It is found that the mold coating materials temperately influence the parameters of the solidification cooling curves and, more visibly, the occurrence and the thickness of the undesired skin layer. Different graphite morphologies comparable to the casting body are present, at a large range of thicknesses, from 50 up to 200 µm. The sulfur presence in the mold coating will promote a higher skin thickness compared to oxygen (up to 50% by oxygen and 2.5–3.3 times for sulfur action), despite the fact that in the casting body, the graphite nodularity undergoes a limited decrease (from 85% up to 82%–83% level). Carbonic material or iron powder supplementary addition decreases these undesired effects, but the solidification undercooling compared to the equilibrium system is increased. It is found that carbonic material is more efficient at limiting oxygen than iron powder is at limiting the negative effects of sulfur on the casting skin thickness. More experiments are necessary to quantify their capacity to block the oxygen or sulfur transfer into the iron melt.

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Wu, Haihua, Kui Chen, Yafeng Li, Chaoqun Ren, Yu Sun, and Caihua Huang. "Fabrication of Natural Flake Graphite/Ceramic Composite Parts with Low Thermal Conductivity and High Strength by Selective Laser Sintering." Applied Sciences 10, no. 4 (February 14, 2020): 1314. http://dx.doi.org/10.3390/app10041314.

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The 3D graphite/ceramic composite prototyping parts directly prepared by selective laser sintering (SLS) were porous, which led to poor strength and low thermal conductivity. In order to obtain low thermal conductivity and high strength, its thermal conductivity and compressive strength were adjusted by changing the mixture powder composition and adding post-processing. The result showed that the addition of silicon powder in the mixture powder could significantly improve the compressive strength and thermal conductivity. The addition of expanded graphite was beneficial to the formation of the closed pores in the matrix, which slightly reduced the compressive strength but significantly reduced the thermal conductivity. The 3D graphite/ceramic composite part showed an order of magnitude improvement in compressive strength (from 1.25 to 13.87 MPa) but relatively small change in thermal conductivity (from 1.40 to 2.12 W·m−1K−1) and density (from 0.53 to 1.13 g·cm−3) by post-processing. Reasonable mixture powder composition and post-processing were determined and realized the possibility of fabricating a 3D graphite/ceramic composite part with low thermal conductivity but high compressive strength. Furthermore, it could be used for the repeated casting of steel castings, and through the comparative analysis of casting defects, the prepared graphite/ceramic composite part was expected to replace water glass sand mold.

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Zhan, Chunyi, Shengshan Feng, Shuzhong Xie, Chunjing Liu, Yunhua Gao, and Jiahao Liang. "Anti-carburizing Coating for Resin Sand Casting of Low Carbon Steel Based on Composite Silicate Powder Containing Zirconium." MATEC Web of Conferences 142 (2018): 03007. http://dx.doi.org/10.1051/matecconf/201814203007.

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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.

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Geffroy, Pierre Marie, Jean François Silvain, and Thierry Chartier. "Elaboration by Tape Casting and Hot Rolling of Copper/Silicon Carbide Composite Thin Films for Microelectronic Applications." Materials Science Forum 534-536 (January 2007): 881–84. http://dx.doi.org/10.4028/www.scientific.net/msf.534-536.881.

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During the last decade, the use of metal matrix composites (MMCs) materials such as Al/SiC or CuW for microelectronic devices have made powder modules more reliable. Today, due to the continuous increasing complexity, miniaturization and high density of components in modern devices, high power microelectronic industries are looking for new adaptive thin films with high thermal conductivity, low coefficient thermal expansion, and good machinability. This paper presents an original and new elaboration method (tape casting and hot rolling) which has been optimized in order to elaborate copper/silicon carbide thin film composite materials. The first part presents the optimization of the tape casting parameters used (powder mixing; optimization of the nature and concentration of organic additives; tape casting, debinding and pre-sintering conditions). In the second part, the main characteristics of thin film obtained are discussed, such as thermomechanical properties of the composite Cu/SiC thin films.

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Liu, Liangwen, Mu Zhang, Xing’an Wang, and Xudong Sun. "Preparation of MgO–Y2O3 Composite Ceramic by Aqueous Gel Casting." Journal of Nanoelectronics and Optoelectronics 16, no. 3 (March 1, 2021): 444–51. http://dx.doi.org/10.1166/jno.2021.2940.

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MgO–Y2O3 composite ceramics were prepared by gel-casting technology. The surface of MgO powder is passivated with H3PO4 ethanol solution. The treated powder can be dispersed in water with a dispersant. The powder surface modification process was verified by pH, Zeta potentials, Fourier transmission infrared absorption spectroscopy (FT-IR), the absorbance of suspension and rheological properties. The obtained stable suspensions were gel cast, dried, and sintered at 1400 °C for 30 min under 35 MPa. As a comparison, the powder was compressed by die pressing and sintered at the same temperature and pressure. After sintering, the MgO–Y2O3 composite ceramic with a theoretical density of 97.29% can be prepared by aqueous gel casting process. The properties of MgO–Y2O3 composite ceramic fabricated by gel casting are better than die pressing.

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Ko, Seh Yun, Bo Young Kim, Yong In Kim, Taeh Yeong Kim, Ki Tae Kim, Brian J. McKay, and Je Sik Shin. "Manufacture of CNTs-Al Powder Precursors for Casting of CNTs-Al Matrix Composites." Materials Science Forum 765 (July 2013): 353–57. http://dx.doi.org/10.4028/www.scientific.net/msf.765.353.

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CNTs-Al matrix composites are considered to be promising heat dissipating materials because thermal conductivity can potentially be improved whilst their density is reduced. Although casting has many advantages in the fabrication of large, complex components, this process cannot be easily employed when manufacturing CNTs-Al composites. In order to produce CNTs-Al matrix composites by casting a CNTs-Al powder precursor was manufactured using mechanical milling and electroless plating processes. Aluminium powder with CNTs of 10 wt.% and 20 wt.% were mixed and ball milled using a horizontal mill. After milling for 3 hrs., the milled powder exhibits a flattened morphology with a band-type distribution of CNT clusters observed within the aluminium particles. Prolonged milling of up to 24 hrs. introduces an equiaxed particle shape for the milled powders with a uniform distribution of CNTs within the aluminium particles. However, as milling time increases, the CNTs become fractured by ball-to-ball collisions. There was no reaction evident between the aluminium and the CNTs at milling times up to 24 hrs. In order to improve the wettability between the CNTs-Al powder precursor and Al melt during the casting process, electroless Ni plating was performed. The processing time for the Ni-plating affects the uniformity of the coating layer. For a uniform coating condition, the average thickness of the coating was ~1.87 μm, with no evidence of gaps between the milled powders and coatings observed.

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Rohani, A. A., M. Tabrizi, S. Manafi, and H. Badiei. "Synthesis and Optimization of TiO₂ Nano Crystals by Gel-Casting Method." Journal of Nano Research 11 (May 2010): 73–77. http://dx.doi.org/10.4028/www.scientific.net/jnanor.11.73.

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In this study, titania (TiO2) nano powders were synthesized by a new method. TiO2 nano-sized powders were prepared by a gel-casting method. Crystalline structure, morphology and mineral phase analysis of TiO2 powder have been characterized by X-ray diffraction (XRD) and Scanning Electron Microscopy (SEM). Results show that different preparation conditions of gel such as reactants concentration, accelerator, starter concentration, time and temperature of calcination have a large influence on the properties of the produced powder. Calcination time and temperature can improve the crystallization of TiO2 powders and can be an accelerator factor for converting amorphous phase to anatase or rutile phase. The results obtained show that the anatase to rutile transformation is started at about 750oC and the best size of produced powder grain is 20-25 nm.

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Liu, Li Na, Xiu Li Han, Chang Cun Li, and Hui Ping Yang. "Effect of Mold Flux for Casting on Microstructe of Mould Powder." Advanced Materials Research 194-196 (February 2011): 287–91. http://dx.doi.org/10.4028/www.scientific.net/amr.194-196.287.

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The microstructe of mold fluxes of low-carbon steel and mould powders were researched by means of polarizing microscope. The result shows that the mineral compositions of the mould fluxes primarily are glass phase, wollastonite, quartz, melilite, pyroxene and feldspar. The main mineral compositions of mould powders is melilite. The quartz, pyroxene and glass phase are helpful to reduce the crystalline portion of mould powder, but the melilite, wollastonite help to improve the crystalline portion and promote crystallization of melilite. It is good for the crystalline portion when the casting speed droop.

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Marwah., O. M. F., S. Sharif, M. A. Zainol, M. Ibrahim, and Elmy Johana Mohamad. "3D Printer Patterns Evaluation for Direct Investment Casting." Applied Mechanics and Materials 465-466 (December 2013): 1400–1403. http://dx.doi.org/10.4028/www.scientific.net/amm.465-466.1400.

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The term direct investment casting represents the employment of pattern fabricated by rapid prototyping technique have been reduce the cost and production lead time. The non-wax materials having robust ability on producing pattern in accuracy stability and clean burnout. However 3D printer (3DP) parts are powder based materials and not easily burnout during firing process. The purpose of this investigation were to evaluate the ZP150 powder materials as a sacrificial pattern to be used in investment casting (IC) process. Result shows powder based patterns of 3DP process failed to disintegrate completely even at high temperature during collapsibility investigations. However the pattern become brittle and easily remove by water pressure. Therefore the ceramic mould can be used for metal casting.

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Miwa, Yasunari, Shinichiro Kawada, Masahiko Kimura, Yukio Higuchi, Hiroshi Takagi, Tohru Suzuki, Tetsuo Uchikoshi, and Yoshio Sakka. "Textured PbTiO₃ Based Ceramics Fabricated by Slip Casting in a High Magnetic Field." Key Engineering Materials 421-422 (December 2009): 395–98. http://dx.doi.org/10.4028/www.scientific.net/kem.421-422.395.

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Textured PbTiO3 (PT) ceramics were fabricated by slip casting in a high magnetic field of 12 T. The sample obtained from the powder calcined at 1100 °C was (100), (010), and (001)-oriented, and the orientation factor was 90 %. On the other hand, the sample obtained from the powder calcined at 900 °C was not oriented. Aggregability and crystallinity of powder are an important factor when textured ceramics are fabricated by slip casting in a high magnetic field.

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Journal articles on the topic 'Casting powder'

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