Hot tearing occurs primarily in the casting mold and can be attributed to thermally induced tensile stresses which occur as the molten metal cools and begins to contract. There are a number of studies available which investigate the behavior and effects of hot tearing but the prevention of this phenomenon is not so simple. Continue reading
Grain refinement is an established technique which basically reduces the grain size of the material with the direct intention to improve its finished properties or characteristics.
The addition of boron specifically in aluminum castings, which are well known for their poor mechanical properties, can improve these characteristics to expand the potential use of the castings to a multitude of other applications. Continue reading
In typical EAF systems around 45% of input energy is lost through slag or off gas, the latter representing 70% of the complete loss of input energy. The expert furnace system optimization process attempts to tackle this issue by allowing a real time assessment of the energy lost through off gas and to allow plants to react quickly and therefore keep this loss to a minimum.
Sheet metal forming is one of the most significant manufacturing processes in industry today and is of particular importance in the automotive industry to drive advances in material technology and weight saving. There are numerous forms of SMF including bending, stretch forming, and deep drawing. Continue reading
Aluminum strip casting is a key contributor to weight saving possibilities, particularly in the automotive industry and although strip casting has been established for over 50 years, it continues to increase in popularity. Casting speeds can be limited by several factors including the type of alloy being cast and the desired sheet thickness required. Continue reading
The Continuous Rheoconversion Process (CRP) is designed to be flexible allowing both thixocasting and rheocasting to be achieved by mixing two melts together at near liquidus temperatures to achieve smaller grain sizes and more globular structures. Key advantages of the CRP include continuous conversion of liquid to slurry, can be used with different alloys, benefits in simplified re-cycling. Continue reading
Boriding is an established surface treatment process which helps tackle the common issue of extending the general life of moving bearing applications and especially in dusty, corrosive environments. There are several advantages of the boriding surface treatment process including a prolonged hardness at high temperatures, flexibility in its applications with different material types and more. Continue reading
The explosive bonding of materials uses the substantial energy of a detonation to bond similar or dissimilar materials together. The technique has several key associated benefits besides the flexibility of joining different materials together including high strength, resistance to abrasion and corrosion, and increased toughness. Continue reading
In the Low Frequency Electromagnetic Casting process the mold is surrounded by a coil powered by an alternating current to endue an electromagnetic field. One of the biggest advantages of using the LFEC process in comparison to conventional casting processes is a distinct improvement in the microstructure with LFEC ingots producing a very fine equiaxed grain structure. Continue reading
The DMLS process is an additive melting technology which has been used in many years as a key method for prototyping in medical and aerospace applications. Because an extremely high level of flexibility DMLS also appears in several other unexpected industries such as automotive, energy, textile industry and many more. Continue reading