Elimination of cracks in stainless steel casings via 3D printed sand molds with an internal topology structure

The important supporting component in a gas turbine is the casing,which has the characteristics of large size,complex structure,and thin wall.In the context of existing 3DP sand casting processes,casting crack defects are prone to occur.This leads to an increase in the scrap rate of casings,causing significant resource wastage.Additionally,the presence of cracks poses a significant safety hazard after the casings are put into service.The generation of different types of crack defects in stainless steel casings is closely related to casting stress and the high-temperature concession of the sand mold.Therefore,the types and causes of cracks in stainless steel casing products,based on their structural characteristics,were systematically analyzed.Various sand molds with different internal topology designs were printed using the 3DP technology to investigate the impact of sand mold structures on high-temperature concession.The optimal sand mold structure was used to cast casings,and the crack suppression effect was verified by analyzing its eddy current testing results.The experimental results indicate that the skeleton structure has an excellent effect on suppressing cracks in the casing.This research holds important theoretical and engineering significance in improving the quality of casing castings and reducing production costs.

Exploring the Potential to Uniquely Manufacture Curved VARTM Epoxy Composites Using Cost-Effective FDM Molds

The Resin Infusion or the VARTM (Vacuum Assisted Resin Transfer Molding) process has significant potential to be used to manufacture curved composites. Another way to produce curved or complex geometry is to use 3D printers. 3D or FDM (Fused Deposition Modelling) printers are now being used to produce relatively cheaper curved parts using thermoplastics such as PLA. However, the strength and mechanical performance of these parts is limited and can be enhanced if the polymer is reinforced with a type of fiber for instance. Research is being carried out to produce fiber rein-forced thermoplastic composites but that process is expected to be more expensive than the alternative methods such as injection or compression molding. Furthermore, to understand the manufacture of a hybrid composite using thermoplastics, fibers and epoxy resin, research and investigation need to be carried out. In this research, there are single-sided, double-sided, reusable, disposable and consumable molds. Most of the molds were created either using an FDM printer or manually. These molds were then used to manufacture flat and curved composite structures via the resin injection process, i.e. VARTM with epoxy resin system and glass/carbon/flax fiber reinforcement. By replacing the costly metallic molds by significantly cheaper molds, the cost of production was expected to further reduce. Furthermore, using double-sided PLA molds was not expected to be a threat to the overall cost of the composite part in question compared to double-sided matched molds used in compression molding. Shear strength, tensile strength and charpy impact strength of most of the manufactured composite parts were also investigated. The strengths were compared based on the method of mold usage. The results showed that this method is effective for a cheaper production of curved epoxy resin composites. However, the strength of the part will decrease as the curved profile gets more complicated unless the basic resin infusion process is altered.

Shrinkage Behaviour of Spheroidal Graphite Cast Iron in Green and Dry Sand Molds for the Benchmarking of Solidification Simulation

The effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroidal graphite cast iron have been studied, considering the parameters of carbon equivalent, inoculation, casting modulus, mold type (green or dry) and pouring temperature within specific ranges of these variables. Based on the orthogonal experiments, the metallurgical and processing parameters of the minimum casting shrinkage and the maximum casting shrinkage were obtained, and the effects of metallurgical and processing parameters on the formation of shrinkage cavities and porosities in spheroids graphite cast iron castings were discussed. Finally, two regression equations relating these variables to the formation of shrinkage porosity were derived based upon the orthogonal experiments conducted.

Potential Pathogens among Fungi Identified as Nonsporulating Molds from Blood Cultures

Twenty-eight molds were isolated from clinical blood cultures and were unidentifiable by cellular morphology using conventional microscopy. Using the utility of amplification and direct sequencing of internal transcribed spacer region of ribosomal RNA gene, 93% of these fungi were identified. Seventy-one percents of the molds were found to be associated with plants or soil with no or few published cases of human disease. These include species of basidiomycetes and ascomycetes such as Botryosphaeria dothidea, Phomopsis flavodonflavus, Inonotus pachyphloeus, Earlilella scabrosa, Calocybe indica, Athelia pellicularis, Tinctoporellus epimiltinus, Trametes lactinea, Coprinellus aureogranulat and Xylaria feejeensis. Some of the nonsporulating molds were identified as pathogen or potential pathogens in immunocompetent or immunocompromised hosts. These include Schizophylum commune and hyphomycetes such as Cladosporium cladosporoides, Aspergillus niger and Fusarium equiseti. Basidiomycetes and hyphomycetes identified in the current study are ubiquitous in the environment and are almost similar to the species of molds reported from cutaneous and respiratory samples suggesting that the fungi may represent contaminants rather than true fangaemia. Results of this study emphasize the need of an effort to minimise blood culture contamination and support the recommendation to incorporate clinical, radiologic findings and positive blood culture for molds in the diagnosis and management of invasive mycosis.

CAx Process Chain for Automated Laser Drilling of Tool Molds

Rotation sintering, also known as slush molding, is used to manufacture molded skins, such as dashboards or door interior panels for cars. At present, approximately 80% of such molded skins are manufactured using electroforms to achieve the complex free-form surfaces, and surface structures, such as leather graining that the industry demands. The manufacture of these electroforms is, however, time-consuming and expensive. This project aims to replace conventional electroforms with laser-drilled molds. Holes in tool molds should be drilled by using laser radiation as part of an automated process. The system consists of a robot with a fiber-laser beam source. A CAx （computer-aided x） process chain has been developed for this purpose in which the CAD （computer-aided design） data of the tool molds are processed, drill hole fields generated, and a machine-specific RC （robot control） program created. Process-specific fundamentals, such as suitable process windows and process control, have been devised to manufacture holes using fiber laser radiation The advantages of the new laser-drilled tool molds may result in substituting them for conventional electroforms, allowing old markets to be re-entered or additional markets to be created and targeted through new molds or lower costs.

Results and Analysis on Proficiency Testing and Measurement Audit for Molds and Yeast in Cosmetics

In order to improve and evaluate the proficiency testing of cosmetic microorganism detection laboratory,strengthen the control of cosmetic microbial detection quality.In 2019 and 2020,the laboratory of the author’s unit participated in the proficiency testing(NIFDC-PT-242)and measurement audit(NIFDC-MA-2020-148)for molds and yeasts in cosmetics organized by the National Institutes for Food and Drug Control,respectively.According to the operation instruction for counting molds and yeasts in cosmetics and the Safety and Technical Standards for Cosmetics,the results of the sample for proficiency testing numbered NIFDC-PT-242 were unsatisfactory,and the results of the sample for measurement audit numbered NIFDC-MA-2020-148 were satisfactory.In view of the unsatisfactory results,the laboratory analyzed and summarized from the aspects of“human,machine,material,method and environment”,providing reference for the laboratories participating in proficiency testing and measurement audit..

Reaction between Ti and boron nitride based investment shell molds used for casting titanium alloys

The aim of this paper was to study the reaction between a Ti-6Al-4V alloy and boron nitride based investment shell molds used for investment casting titanium. In BN based investment shell molds, the face coatings are made of pretreated hexagonal boron nitride （hBN） with a few yttria （Y2O3） and colloidal yttria as binder. The Ti-6Al-4V alloy was melted in a controlled atmosphere induction furnace with a segment water-cooled copper crucible. The cross-section of reaction interface between Ti alloys and shell mold was investigated by electron probe micro-analyzer （EPMA） and microhardness tester. The results show that the reaction is not serious, the thickness of the reacting layer is about 30-50 μm, and the thickness of α-case is about 180-200 pro. Moreover the α-case formation mechanism was also discussed.

Research progress on refractory composition and deformability of shell molds for TiAl alloy castings

At present, most TiAl components are produced by an investment casting process. Environmental and economic pressures have, however, resulted in a need for the industry to improve the current casting quality, reduce manufacturing costs and explore new markets for the process. Currently, the main problems for investment casting of TiAl alloys are cracks, porosities, and surface defects. To solve these problems, many studies have been conducted around the world, and it is found that casting defects can be reduced by improving composition and properties of the shell molds. It is important to make a summary for the related research progress for quality improvement of TiAl castings. So, the development on refractory composition of shell molds for TiAl alloy investment castings was reviewed, and research progress on deformability of shell mold for TiAl alloy castings both at home and abroad in recent years was introduced. The existing methods for deformability characterization and methods for improving the deformability of shell molds were summarized and discussed. The updated advancement in numerical simulation of TiAl alloy investment casting was presented, showing the necessity for considering the deformability of shell mold during simulation. Finally, possible research points for future studies on deformability of shell mold for TiAl alloy investment casting were proposed.

Effect of microstructure on the impact toughness of a bainitic steel bloom for large plastic molds

The correlation between the impact toughness and microstructural characteristics of a large bainitic steel bloom has been investigated. The study focuses on microcrack nucleation and propagation in the basic cleavage plane. To analyze the phase transformation during the wind-cooling process, the temperature field of the bloom was acquired by computer simulation, and a continuous cooling transformation experiment was conducted. The results show that compared with the surface of the bloom, the toughness of the bloom’s core is decreased by the increase in proeutectoid ferrite and the coarsening of tempered martensite–austenite constituents. The proeutectoid ferrite decreases the toughness via its effects on carbide precipitation, the formation of martensite–austenite constituents, and the bainite transformation. The relatively large tempered martensite–austenite constituents are conducive to microcrack nucleation and propagation.

Influence of submerged entry nozzle clogging on the behavior of molten steel in continuously cast slab molds

The influence of submerged entry nozzle clogging on the behavior of molten steel in continuously cast slab molds was studied using commercial code CFX4.3. The results indicate that clogging at the top part of the nozzle port not only increases the velocity of molten steel, but also enhances the wall shear stress, F number and heat flux. This clogging has the greatest effect on the behavior of molten steel. However, clogging at the top 1/3 of the nozzle only increases the velocity of molten steel and has little influence. Clogging at the bottom of the nozzle almost has no influence.

Properties of fiber reinforced plaster molds for investment casting

In order to improve the performance of plaster molds for investment casting,a diverse content of glass fiber and polypropylene(PP)fiber was incorporated into the slurry for the preparation of a fiber-reinforced mold.The green and fired bending strengths,thermal expansion properties,permeability,and thermal shock resistance of the mold were examined,and the scanning electron microscope(SEM)with energy dispersive spectrometer(EDS)was applied for the observation of fracture morphology.With appropriate content,the introduction of glass fiber was proved to increase the green bending strength and fired bending strength,restrain the thermal expansion and improve the thermal shock resistance of the mold,while the polypropylene fiber added was able to raise the green bending strength and the permeability,reduce the thermal expansion and heighten the thermal shock resistance as well,though the fired bending strength would be weakened slightly.Evenly distributed fibers were capable of enhancing the mechanical properties of the matrix,but agglomerations and bundles of fibers resulting from excessive addition had a negative impact.Meanwhile,it was also manifested that micropores left by ablative polypropylene fibers could improve the permeability and reduce the thermal expansion of the mold,and the fired bending strength would be decreased slightly by the deterioration of continuous structure.Three different ratios of hybrid fiber were employed in plaster molds,which can meet altered requirement of castings.The samples modified with hybrid fiber possessed lower thermal deformation,higher air permeability,and better resistance of thermal shock,while the mechanical strength was equal to the fiber free sample or slightly increased.

Flow and Temperature Fields in Slab Continuous Casting Molds

In order to develop super-board and super-thick slabs, the flow and temperatur fields were studied in slab continuous casting molds under different practical conditions, such as slab dimensions, with-drawing slab speed, design of nozzles, and superheat tempera-ture. The results showed that it is preferred to incline nozzle bores downwards and the submerged depth of the nozzles is best kept be-tween 250-300 mm. In addition, the solidified shell is thicker at the wide face than that at the narrow face, while the thin points alongthe wide face ekist both in the center and in the some area toward each respective end.

Progress in the application of cold gas dynamic spraying to repairing continuous casting molds

A new continuous casting mold repairing method--cold gas dynamic spraying （CGDS） is introduced. The study investigates the advantages of the CGDS process regarding repairing operation, such as convenient, in-situ repairation,little heat delivery, microstructural and dimensional stability and other special applications. Microstructure and mechanical properties of the copper alloy coating, nickel coating, ceramic composite coating, and their interface to the substrates ,which are usually used in repairing operation have been researched by means of optical microscopy （ OM）, scanning electron microscopy （SEM）, transmission electron microscopy （TEM） and micro-hardness tests. Experimental results have demonstrated the relative density of the copper alloy coating is as high as 98.7%, and that no obvious difference can be observed between the CrZrCu substrate and the Cu alloy coating in terms of microstructures; thus the interface is quite difficult to be identified. The bonding strength and micro-hardness of the Cu alloy coating reach up to 37 MPa and 310 HV0.2 ,respectively. The interface between the copper alloy coating and the nickel coating is either zigzag or wave shaped, and the cohesion is relatively good. As-sprayed nickel coating is dominated by severely deformed particles,and the relative density is up to 98.5%. Complete recrystallization occurred after annealing at 900℃ for one hour,while its micro-hardness remains as high as 124.1 HV02. All these results have indicated that CGDS is a promising technology for repairing the continuous casting mold and that its future development is prosperous as well.

Calculation of Cost-Effectiveness of Molds Made of Aluminum, MDF (Medium Density Fiberboard) and Steel

We implemented the process of producing a new Rib in three different ways, and we selected the process that was the most affordable and required the least labor, and we did it. This paper also considers the influence of the cost of the form from MDF, Alumina and Steel on the quality of the product.

Interface reactions between TiAl alloys and diacetatozirconic acid-yttria molds differentiated by ammonium metatungstate addition

Two types of diacetatozirconic acid-yttria molds which were labeled as ZYW mold(diacetatozirconic acidyttria mold with traces of ammoium metatungstate in the slurry) and ZY mold(diacetatozirconic acid-yttria mold without ammonium metatungstate) were prepared by traditional investment casting.The ZYW and ZY molds were sintered in a carbon-reducing atmosphere and in air,respectively,at 1550℃ for 4 h.Interactions between Ti-47Al-2Cr-2Nb(at%) alloys and the molds at 1650℃ for 30 min were studied.The microstructures of the metalmold interfaces and the presence of inclusions and oxygen contamination in the TiAl bulk alloy were analyzed,and the influences of ammonium metatungstate were discussed.The results indicate that WO_(3)releases O into the TiAl melt,introducing tungsten metal into the alloy matrix.The TiAl alloy ingots cast in the ZY molds had the fewest inclusions and the lowest oxygen contamination.

Rapid Manufacturing of Sand Molds by Direct Milling

Direct milling of sand molds is an important development in rapid manufacturing of sand molds. Direct milling is an effective method for manufacturing single or small batches of cast parts. This paper describes experimental investigations to find sand blocks with the appropriate strength, to describe wear patterns of different tools (high-speed steel (HSS), carbide, and polycrystalline diamond (PCD) tools), and to analyze sand mold cutting mechanisms. The results show that the PCD tool outperformes the other tools in terms of tool life. Average flank wear and micro-tipping are the dominant tool failure modes in the sand mold milling process. With a flank wear limit of 0.3 mm, the PCD tool works continuously for about 70 h under the experimental conditions. The experimental results show that the cutting mechanism for direct milling sand molds differs from metal cutting.

Irregular initial solidification by mold thermal monitoring in the continuous casting of steels:A review

Occasional irregular initial solidification phenomena,including stickers,deep oscillation marks,depressions,and surface cracks of strand shells in continuous casting molds,are important limitations for developing the high-efficiency continuous casting of steels.The application of mold thermal monitoring(MTM) systems,which use thermocouples to detect and respond to temperature variations in molds,has become an effective method to address irregular initial solidification phenomena.Such systems are widely applied in numerous steel companies for sticker breakout prediction.However,monitoring the surface defects of strands remains immature.Hence,indepth research is necessary to utilize the potential advantages and comprehensive monitoring of MTM systems.This paper summarizes what is included in the irregular initial solidification phenomena and systematically reviews the current state of research on these phenomena by the MTM systems.Furthermore,the influences of mold slag behavior on monitoring these phenomena are analyzed.Finally,the remaining problems of the formation mechanisms and investigations of irregular initial solidification phenomena are discussed,and future research directions are proposed.

Effects of the Water-Cement Ratio and the Molding Temperature on the Hydration Heat of Cement

The effects of the water-cement ratio and the molding temperature on the hydration heat of cement were investigated with semi-adiabatic calorimetry.The specimens were prepared with water-cement ratios of 0.31,0.38,and 0.45,and the molding temperature was specified at 10 and 20℃.The experimental results show that,as the water-binder ratio increases,the value of the second temperature peak on the temperature curve of the cement paste decreases,and the age at which the peak appears is delayed.The higher the water-cement ratio,the higher the hydration heat release in the early period of cement hydration,but this trend reverses in the late period.There are intersection points of the total hydration heat curve of the cement pastes under the influence of the water-cement ratio,and this law can be observed at both molding temperatures.With the increase in the molding temperature,the age of the second temperature peak on the temperature curve of the cement paste will advance,but the temperature peak will decrease.The higher the molding temperature,the earlier the acceleration period of the cement hydration began,and the larger the hydration heat of the cement in the early stage,but the smaller the total heat in the late period.A subsection function calculation model of the hydration heat,which was based on the existing models,was proposed in order to predict the heat of the hydration of the concrete.

Investigation of bubbles escape behavior from low basicity mold flux for high-Mn high-Al steels using 3D X-ray microscope

During the continuous casting process of high-Mn high-Al steels,various types of gases such as Ar need to escape through the top of the mold.In which,the behavior of bubbles traversing the liquid slag serves as a restrictive link,closely associated with viscosity and the thickness of liquid slag.In contrast to two-dimensional surface observation,three-dimensional(3D)analysis method can offer a more intuitive,accurate,and comprehensive information.Therefore,this study employs a 3D X-ray microscope(3D-XRM)to obtained spatial distribution and 3D morphological characteristics of residual bubbles in mold flux under different basicity of liquid slag,different temperatures,and different holding times.The results indicate that as basicity of slag increases from 0.52 to 1.03,temperature increases from 1423 to 1573 K,the viscosity of slag decreases,the floating rate of bubbles increases.In addition,when holding time increases from 10 to 30 s,the bubbles floating distance increases,and the volume fraction and average equivalent sphere diameter of the bubbles solidified in the mold flux gradually decreases.In one word,increasing the basicity,temperature,and holding time leading to an increase in the removal rate of bubbles especially for the large.These findings of bubbles escape behavior provide valuable insights into optimizing low basicity mold flux for high-Mn high-Al steels.