Metal-Casting Processes and Equipment
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Troubleshooting Decorative Electroplating Installations, Part 5
Troubleshooting Decorative Electroplating Installations, Part 5: Plating Problems Caused Article By Heat & Bath Temperature Fluctuations by N.V. Mandich, CEF, AESF Fellow Technical Technical In previous parts of this series, emphasis was given The fast-machining steels must then be carburized to troubleshooting of the sequences for pre-plating or case-hardened to obtain a surface with the hardness and electroplating over metals, Parts 1 and 2;1 required to support the top chromium electroplate. the causes, symptoms and troubleshooting for Case hardening is the generic term covering several pores, pits, stains, blistering and “spotting-out” processes applicable to steel or ferrous alloys. It changes phenomena, Part 3;2 and troubleshooting plating on the surface composition of the top layer, or case, by plastic systems, Part 4.3 Here in Part 5, causes and adsorption of carbon, nitrogen or a mixture of the two. some typical examples of problems that occur in By diffusion, a concentration gradient is created. The electroplating as a result of a) thermal, mechanical heat-treatments and the composition of the steel are surface treatments, b) the metallurgy of the part to additional variables that should be addressed and taken be plated or c) effects of plating bath temperature into account in the electroplating procedure. on plating variables and quality of the deposits When discussing the effect of heat-treatment on are discussed. subsequent electroplating processes it is necessary to zero in on the type of heat-treatment involved. We Nearly every plater has at one time or another had the can defi ne the heat-treatment process as changing the experience of trying to plate parts that simply would characteristics of the parts by heating above a certain not plate. -
Precision Investment Casting Solutions
PRECISION INVESTMENT CASTING SOLUTIONS One stop MEDICAL/DENTAL APPLICATIONS for your Precision SPOKANE INDUSTRIES has been supplying quality precision investment castings to the medical and dental industry for over 10 Investment years. We utilize a state-of-the-art investment casting process to casting needs produce high quality, precision parts tailored for the application. Typical • Castings from 3g to 45Kg alloys poured at Spokane Industries include all stainless and carbon steel grades, in addition to low alloy materials. • Full In-House • Engineering Our experienced engineering team will • Metallurgy work with you on new designs, to assess • Design/Development existing parts or production problems, • Non-Destructive Test or identify casting conversions from • Physical Test weldments, fabrications and assemblies. • Finishing We can help optimize the design to take full advantage of the • Industry Leading Quality benefits of investment casting • On-Time Delivery and recommend solutions that reduce production complexity and cost, and increase reliability and quality. Please contact us for more information and quotes: (800) 541-3601 X110 • www.SpokaneIndustries.com • [email protected] Copyright© 2011 • Spokane Industries, Inc. Spokane Precision Castings Services • Capabilities Production Capabilities From a few grams up to 45kg Thousands of units per week Commonly Poured Alloys Carbon Steels Cobalt Based Materials Industries Low Alloy Steels Supported Lead-free Copper Based Alloys Nickel Based Alloys Include: Tool Steels -
Low-Pressure Casting of Aluminium Alsi7mg03 (A356) in Sand and Permanent Molds
MATEC Web of Conferences 326, 06001 (2020) https://doi.org/10.1051/matecconf/202032606001 ICAA17 Low-Pressure Casting of Aluminium AlSi7Mg03 (A356) in Sand and Permanent Molds Franco Chiesa1*, Bernard Duchesne2, and Gheorghe Marin1 1Centre de Métallurgie du Québec, 3095 Westinghouse, Trois-Rivières, Qc, Canada G9A 5E1 2Collège de Trois-Rivières, 3500 de Courval, Trois-Rivières, Qc, Canada, G9A 5E6 Abstract. Aluminium A356 (AlSi7Mg03) is the most common foundry alloy poured in sand and permanent molds or lost-wax shells. Because of its magnesium content, this alloy responds to a precipitation hardening treatment. The strength and ductility combination of the alloy can be varied at will by changing the temper treatment that follows the solutionizing and quenching of the part. By feeding the mold from the bottom, the low-pressure process provides a tranquil filling of the cavity. A perfect control of the liquid metal stream is provided by programming the pressure rise applied on the melt surface. It compares favorably to the more common gravity casting where a turbulent filling is governed by the geometry of the gating system. 1 The low-pressure permanent 2) The very efficient feeding achieved via the mold process bottom feeder tube by applying a pressure of up to one atmosphere to the melt; the resulting yield is very high, typically 80-90% versus 50-60% for The low-pressure permanent mold casting gravity casting. However, the low-pressure (LPPM) [1], schematized in Figure 1a and shown process cannot pour any casting geometries. in Figure 1b and 1c, is a common process Low-pressure sand casting (LPS) is much less producing high quality castings resulting from common than LPPM; the sand mold rests on top two main characteristics: of the pressurized enclosure as shown in Figure 1) The perfectly controlled quiescent filling 1d. -
Mold Making for Glass Art
Mold Making for Glass Art a tutorial by Dan Jenkins When Dan Jenkins retired he did not originally intend to make tools and molds for glass artists. However, his wife and friends who work in fused glass were constantly calling on the skills he developed during 30 years as a marine engineer in the Canada Navy to produce items that were needed but unavailable. He began his career on steam driven ships for which it was impossible to get parts. The engineers had to fabricate their own parts out of whatever was available to them. Dan has drawn on his knowledge of woodworking, metalworking, design, engineering and making something out of nothing. He discovered that he enjoys the challenge of designing new tools that are practical economical, and easy to use. Dan has always enjoyed teaching and spent much of his time in the navy as an instructor both at sea and onshore. Dan currently lives in Victoria B.C. with his wife, two cats, and 3 dogs. Mold Making For Glass Art by Dan Jenkins Choosing a Prototype The first projects you wish to tackle should be fairly simple because failure the first few times is Making molds for your own use or for not only possible it is probably inevitable. The reproduction is fairly easy to do and very first objects I tried to cast were self-produced satisfying. Making your own molds frees you wood blocks in the form of squares and from relying on molds made by others and triangles, simple shapes which should have allows you to tailor your mold for your own taste. -
Application of Investment Casting: a Review Paper
Pramana Research Journal ISSN NO: 2249-2976 Application of Investment Casting: A Review paper 1Rahul Ojha, 2Gourav, 3Rohit Goyal 1,2 B.E, student, Mech. Engg. Department, Chandigarh University, Mohali, India 3Assistant Professor, Department of Mechanical Engineering Department [email protected] [email protected] [email protected] Abstract Investment casting process is a type casting process of producing clear net shape, high- dimensional accuracy and intricate design. Consistent research effort has been made by various researchers from all over the world with an objective to explore the world of investment casting. This article highlights the advancements made and proposed at each step of investment casting and its applications in practical world . Investment casting is being used from years to manufacture parts such as weapons, jewellery item, idols and statues of god and goddess; this article reviews the present and future applications of the investment casting. The aim of this review article is to present state of art review of applications of investment casting since 3200 BC. This article is organized as follows: in section ‘Introduction’, introduction to investment casting and process is given ; in section ‘Application in Aerospace Industries’, background is given on the application of investment casting in aerospace and related industries; section ‘Biomedical applications of investment casting’ presents the medicine or biomedical applications of investment casting; section ‘Conclusion’ closes the article by offering conclusions. Keywords: investment casting, biomedical application and aerospace industry application. Introduction Investment casting is a manufacturing process that can be traced back over 5,000 years to ancient Egypt and China. It is utilized to cast a wide variety of items, including high- quality, high-performance industrial parts. -
OVERVIEW of FOUNDRY PROCESSES Contents 1
Cleaner Production Manual for the Queensland Foundry Industry November 1999 PART 5: OVERVIEW OF FOUNDRY PROCESSES Contents 1. Overview of Casting Processes...................................................................... 3 2. Casting Processes.......................................................................................... 6 2.1 Sand Casting ............................................................................................ 6 2.1.1 Pattern Making ................................................................................... 7 2.1.2 Mould Making ..................................................................................... 7 2.1.3 Melting and Pouring ........................................................................... 8 2.1.4 Cooling and Shakeout ........................................................................ 9 2.1.5 Sand Reclamation .............................................................................. 9 2.1.6 Fettling, Cleaning and Finishing....................................................... 10 2.1.7 Advantages of Sand Casting............................................................ 10 2.1.8 Limitations ........................................................................................ 10 2.1.9 By-products Generated .................................................................... 10 2.2 Shell Moulding ........................................................................................ 13 2.2.1 Advantages...................................................................................... -
Boilermaker Health & Safety Manual
Boilermakers Health & Safety Manual ihsa.ca Boilermakers Health & Safety Manual Infrastructure Health & Safety Association 5110 Creekbank Road, Suite 400 Mississauga, Ontario L4W 0A1 Canada 1-800-263-5024 ihsa.ca 1 Boilermakers Health & Safety Manual IHSA has additional information on this and other topics. Visit ihsa.ca or call Customer Service at 1-800-263-5024. The contents of this publication are for general information only. This publication should not be regarded or relied upon as a definitive guide to government regulations or to safety practices and procedures. The contents of this publication were, to the best of our knowledge, current at the time of printing. However, no representations of any kind are made with regard to the accuracy, completeness, or sufficiency of the contents. The appropriate regulations and statutes should be consulted. Readers should not act on the information contained herein without seeking specific independent legal advice on their specific circumstance. The Infrastructure Health & Safety Association is pleased to answer individual requests for counselling and advice. This manual was developed, reviewed, and endorsed by the Boilermakers Labour-Management Health and Safety Committee in association with IHSA. Manual IHSA editor: Lori-Lynn Bonnell, design and illustrations: Philippa Giancontieri; project manager: Mike Russo. The Infrastructure Health & Safety Association would like to thank the members of the working group for contributing their knowledge, experience, and time to produce a health and safety manual that will benefit both labour and management in the boilermaker sector. The working group included representatives from the Boilermaker Contractors’ Association (BCA) as well as: · Marty Albright – Alstom Power Canada Inc. -
Interchange Modification Report
I-26 / Naval Base Terminal Access Road Interchange INTERCHANGE MODIFICATION REPORT CHARLESTON COUNTY, SOUTH CAROLINA Prepared for: South Carolina Department of Transportation Prepared by: Parsons Brinckerhoff, Inc. May 2012 I-26ȀPortAccessRoadInterchangeModificationReport TABLEOFCONTENTS EXECUTIVE SUMMARY ............................................................................................................................................ 1 1. INTRODUCTION .............................................................................................................................................. 3 Project Location.................................................................................................................................................. 3 Project History.................................................................................................................................................... 3 Project Description ............................................................................................................................................. 7 Project Purpose and Need .................................................................................................................................. 9 Project Conceptual Design ................................................................................................................................ 11 Interchange Modification Report (IMR) Scope.................................................................................................. -
Implementation of Metal Casting Best Practices
Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof. -
Electroforming of Copper Canisters
Mineralogical Magazine, November 2015, Vol. 79(6), pp. 1521–1528 OPEN ACCESS Manufacturing technology for implementing geological disposal: electroforming of copper canisters 1,2,3,* 1,3 1,4 2 2 T. H ERNANDEZ-SELVA ,D.L.ENGELBERG ,F.SCENINI ,D.FOX AND A. MCCLUSKY 1 Materials Performance Centre, School of Materials, The University of Manchester, Manchester M13 9PL, UK 2 BEP Surface Technologies Ltd, Eton Hill Road, Radcliffe, Manchester M26 2XT, UK 3 Research Centre for Radwaste and Decommissioning, The University of Manchester, Manchester M13 9PL, UK 4 Nuclear Advanced Manufacturing Centre, The University of Manchester, Manchester M13 9PL, UK ABSTRACT The existing capability and current development needs for implementing electroforming as a viable manufacturing process to produce copper cylinders with dimensions comparable to the Swedish KBS-3 design are discussed. Large freestanding copper cylinders can be produced readily, but there is a need to address challenges associated with controlling the electro-deposition process to conform to compositional and mechanical requirements of the copper layers produced. The methodology to optimize the manufacturing process, based on a study of key parameters, such as the effects of electrolyte additives on grain size and the chemical composition of electroformed layers, is described here. Possible ways to introduce a robust manufacturing route are also presented. K EYWORDS: nuclear wastes, deep geological repository, KBS-3 copper canister, electroforming, electroplating. Introduction Institute, 2006; ARAO, 2009), whereas the Nuclear Waste Management Organization (NWMO) of THE concept for the UK’s inventory of high-level Canada is focusing its research on thick-walled radioactive waste (HLW) is to implement deep steel containers coated with 3 mm of electroplated geological disposal (Department of Energy & copper (Keech et al., 2014). -
Investment Casting Or the Lost Wax Process
Investment Casting or The Lost Wax Process Apecs Investment Castings was founded in 1963 and is now situated in the Melbourne suburb of Burwood where we have been since we outgrew our Canterbury factory in August 1987. The company name (APECS), stands for Anthony Philip Eccles Casting Service. Investment is a type of plaster that we use in our process of reproducing multiple copies of an original master pattern which is usually supplied to us by our customers. This is a classic 18ct yellow gold emerald and diamond ring taken from the Apecs catalogue. The next series of photos will show the steps involved in producing multiple copies of this ring. An original master pattern is designed and fabricated by our customers and supplied to us to reproduce in the quantities and metals of their choice. It is important to ensure that the master is made as accurately as possible and to pay particular attention to the finish of the master pattern. The better the quality of the master pattern the better the casting result. The finished master pattern ready for the caster. A picture of the master pattern is drawn and a mould number is allocated for identification. When the customer wants to reorder he quotes the mould number for the pattern he wants. A sprue is soldered onto the pattern. This sprue enables the pattern to be easily located in the mould and will provide the path for the wax to be injected into the rubber mould. To make a mould the master pattern is placed between sheets of uncured vulcanising rubber. -
Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting
applied sciences Article Fabrication of Ceramic Moulds Using Recycled Shell Powder and Sand with Geopolymer Technology in Investment Casting Wei-Hao Lee, Yi-Fong Wu, Yung-Chin Ding and Ta-Wui Cheng * Institute of Mineral Resources Engineering, National Taipei University of Technology, Taipei 10608, Taiwan; [email protected] (W.-H.L.); [email protected] (Y.-F.W.); [email protected] (Y.-C.D.) * Correspondence: [email protected] Received: 1 June 2020; Accepted: 29 June 2020; Published: 1 July 2020 Abstract: Lost-wax casting, also called precision casting, is the process of casting a duplicate metal sculpture cast an original sculpture. The ceramic shell mould used in lost-wax casting usually consists of several layers formed with fine zircon and granular mullite particles using silica gel as a binder. However, it is a complicated and time-consuming process. Large amounts of waste moulds that need to be disposed and recycled become an environmental concern. In this study, waste shell sand from the recycled mould and calcium carbonate/metakaolin were used as raw materials to prepare geopolymer slurry and coating. The influence of mixing ratio and the SiO2/K2O modulus of the alkali solution on the setting time and green/fired strength were evaluated. Ceramic shells with one to four layers of geopolymer slurry and waste sand sprinkling were fabricated and tested for their permeability and green/fired strength. It was found that geopolymer shells had higher green/fired strength and better permeability than the original zircon/mullite shell. For foundry practice, metal casts were fabricated using recycled ceramic shell moulds with one to four layers of geopolymer coating.