Analysis of Causes of Porosity Change of Castings under the Influence of Variable Biscuit Height in the Filling Chamber

Quality properties of castings produced in a die casting process correlate with porosity that is conditioned by a number of factors, which range from input melt quality to setup of technological factors of the die casting, and through structural design of the gating system. One of the primary parameters conditioning the inner soundness of the casting is the liquid metal dose per single operation of die casting. This paper examines the issue of metal dose. The experiments are performed with casting a gate system of an electromotor flange. The gating system examined was die cast with a variable volume of metal dose per single operation. The metal dose was adjusted to reach the height of a biscuit of 10, 20, and 30 mm. The examination of the inner homogeneity of the castings of the individual variants of gating systems with variable height of the biscuit proved that decreasing biscuit height results in an increase of porosity share in the casting volume. The programme MagmaSoft 5.4 revealed the main causes of changes in porosity share. The simulations detected that the change in biscuit height and volume of liquid metal directly influence thermal conditions of the melt in the filling chamber, and in the mould by means of the period in which the holding pressure action is influenced. Simultaneously, the melt flow mode in the sprues and gas entrapment in the melt volume are affected as well. Correlation of the factors consequently influences the final porosity of castings.     

Shaping the Microstructure of High-Aluminum Cast Iron in Terms of the Phenomenon of Spontaneous Decomposition Generated by the Presence of Aluminum Carbide

A suitable aluminum additive in cast iron makes it resistant to heat in a variety of environments and increases the abrasion resistance of the cast iron. It should be noted that high-aluminum cast iron has the potential to become an important eco-material. The basic elements from which it is made—iron, aluminum and a small amount of carbon—are inexpensive components. This material can be made from contaminated aluminum scrap, which is increasingly found in metallurgical scrap. The idea is to produce iron castings with the highest possible proportion of aluminum. Such castings are heat-resistant and have good abrasive properties. The only problem to be solved is to prevent the activation of the phenomenon of spontaneous decomposition. This phenomenon is related to the Al₄C₃ hygroscopic aluminum carbide present in the structure of cast iron. Previous attempts to determine the causes of spontaneous disintegration by various researchers do not describe them comprehensively. In this article, the mechanism of the spontaneous disintegration of high-aluminum cast iron castings is defined. The main factor is the large relative geometric dimensions of Al₄C₃ carbide. In addition, methods for counteracting the phenomenon of spontaneous decay are developed, which is the main goal of the research. It is found that a reduction in the size of the Al₄C₃ carbide or its removal lead to the disappearance of the self-disintegration effect of high-aluminum cast iron. For this purpose, an increased cooling rate of the casting is used, as well as the addition of elements (Ti, B and Bi) to cast iron, supported in some cases by heat treatment. The tests are conducted on the cast iron with the addition of 34–36% mass aluminum. The molten metal is superheated to 1540 °C and then the cast iron samples are cast at 1420 °C. A molding sand with bentonite is used to produce casting molds.     

Use of casts in the necropsy diagnosis of fetal congenital heart disease

Objective—To evaluate a casting technique in the interpretation of fetal cardiac anatomy.

Design—In 32 fetuses, the echocardiographic and cast features were compared and correlated.

Patients—Three normal fetal heart specimens from spontaneous abortuses and 32 specimens from spontaneous or induced abortions with congenital heart malformation.

Results—There was close correlation between the echocardiographic and anatomical features in 32 abnormal fetuses studied. In some, additional features of diagnosis could be displayed on the cast and the relative sizes of the cardiac structures could be appreciated and defined.

Conclusions—With increasing echocardiographic detection of congenital heart disease in early prenatal life, an increasing number of fetal heart specimens of small size are dissected for pathological confirmation. The use of silicone rubber casts to reproduce the internal anatomy proved a useful addition to dissection, providing a three dimensional model of the cardiac defect.

     

Influence of the Die Height on the Density of the Briquette Produced from Shredded Logging Residues

An alternative to plant biomass of various origins are forest logging residues. They differ significantly from other, previously used plant materials. This difference is due to the heterogeneous composition and relatively large size of individual particles. This research on the compaction of this type of shredded material was aimed at determining the influence of the die height on the density and relaxation of briquettes. This parameter is crucial for the proper construction of compaction devices. The measurements were carried out for the same fractional composition of the shredded logging residues, with variable input parameters of the material and process. It was found that the briquette density and relaxation are influenced by the die height, as well as the material moisture content and process temperature. The highest density at maximum compaction pressure (1.40 g·cm^–3) was obtained at a moisture content of 16%, temperature of 80 °C, and the lowest die height (195 mm). In the case of the briquette density after ejection from the die, the best results were obtained at the same temperature and die height but at a moisture content of 9%. The tests confirmed that, regardless of the process temperature and material moisture, the briquette density increases as the die height is reduced. The relaxation coefficient of compacted logging residues ranges from 21.7% to 50.1% and depends mainly on the material moisture content and the temperature of the process. The lowest value of the relaxation coefficient (21.7 ± 1.61) was obtained at 9% moisture content, 60 °C temperature, and 220 mm die height.     

Left atrial volume assessed by transthoracic three dimensional echocardiography and magnetic resonance imaging: dynamic changes during the heart cycle in children

OBJECTIVE—To assess the dynamic changes in left atrial volume by transthoracic three dimensional echocardiography and compare the results with those obtained by magnetic resonance imaging (MRI).
DESIGN AND PATIENTS—30 healthy children (15 boys and 15 girls, aged 8 to 13 years) underwent examination by three dimensional echocardiography and MRI.
METHODS—Three dimensional echocardiography of the left atrium was performed using rotational acquisition of planes at 18° intervals from the parasternal window with ECG gating and without respiratory gating. Volume estimation by MRI was performed with a slice thickness of 4-8 mm and ECG triggering during breath holding in deep inspiration. A left atrial time-volume curve was reconstructed in each child.
RESULTS—Left atrial maximum and minimum volumes averaged 24.0 ml/m² and 7.6 ml/m² by three dimensional echocardiography, and 22.1 ml/m² and 11.9 ml/m² by MRI. The greater left atrial minimum volume in the latter was at least in part a result of breath holding. Dynamic changes in left atrial volume during the heart cycle were detectable by both methods. The higher temporal resolution of three dimensional echocardiography allowed a more precise evaluation of different phases.
CONCLUSIONS—Three dimensional echocardiography and MRI were both useful methods for studying the physiological volume changes in the left atrium in children. These methods may be used for further study of the systolic and diastolic function of the heart.


Keywords: three dimensional echocardiography; magnetic resonance imaging; left atrial volume; children     

Influence of power and aerobic exercise training on haemostatic factors after coronary artery surgery

Objectives—To determine the effects of aerobic and power exercise training on haemostatic factors after coronary artery surgery and to compare the effect of the two exercise programmes.Design—A prospective randomised controlled study of six months aerobic and power exercise training in men after coronary artery surgery.Setting—Exercise rehabilitation classes in a teaching hospital in Glasgow.Patients—55 men within 12 months of coronary artery surgery recruited from surgical centres and medical clinics and asked to participate in the study.Interventions—Assessments, including a treadmill test, measurements of haemoglobin, platelet, fibrinogen, factor VIIc, and fibrinopeptide A concentrations, and packed cell volume, done at baseline, three months, and six months. Patients in the two exercise groups attended training sessions three times weekly for six months. Control patients had no formal exercise training but continued with their leisure time activities.Main outcome measures—Exercise performance on a treadmill, haematology, and haemostatic factor assays at baseline, three months, and six months.Results—In the aerobic trained group exercise performance increased significantly over baseline at three months (interval change 146·7, 95% confidence interval (95% CI) 52·5 to 240·9 s, p = 0·003) and was maintained at six months (interval change 172·1, 95% CI 63·3 to 280·9 s, p = 0·002). In the power trained groups significant improvement in exercise performance was delayed until six months (interval change 99·9 s, 95% CI 20·3 to 170·5 s, p = 0·01). Exercise performance in the control did not change significantly. Haemoglobin, concentration, packed cell volume, and platelet counts did not change significantly at any time. Fibrinogen concentration was significantly lower in the aerobic group than the other two groups at three months (2·96 g/dl compared with 3·3 g/dl and 3·87 g/dl in the power and control groups, p = 0·01). The power group had a lower fibrinogen concentration than the control group (p = 0·04). The lower fibrinogen concentration in the aerobic group was maintained at six months. There was a gradual rise in factor VIIc concentrations in the aerobic and control groups compared with a small fall in the power group. Fibrinopeptide A concentrations showed no consistent changes.Conclusions—Aerobic exercise training after coronary artery surgery causes an early favourable change in treadmill performance and in fibrinogen concentrations, that is maintained with further training. Power exercise training causes delayed benefit in treadmill performance. It also causes a small fall in fibrinogen concentrations. These changes may be relevant in reducing cardiovascular morbidity from graft failure and occurrence of myocardial infarction after coronary artery surgery.     

The Effect of Combined Processing on Residual Stresses in the Surface Layer of Power Plant Parts

The purpose of this research was to analyze the change in residual stresses in the surface layer of steel samples taking into account the technological heredity effect on the value and sign of residual stresses. An installation of combined processing was developed. Combined processing consists of sequentially performing electromechanical processing and diamond smoothing. All areas of the samples were studied—after machining (i.e., in the initial state), after electromechanical processing, and after diamond smoothing. The research shows that the sign and value of residual stresses are significantly affected by the combined processing modes. The main parameters of the surface layer are formed at the final stage of the combined processing–diamond smoothing. This paper gives recommendations on the use of combined processing for power plant parts.     

Influence of the volume of osteonecrosis on the outcome of core decompression of the femoral head

OBJECTIVES—To assess the outcome of core decompression in the treatment of osteonecrosis of the femoral head related to the volume of necrotic bone measured according to a previously reported method.
METHODS—Twenty hips corresponding to strictly Ficat stage II underwent magnetic resonance imaging and the volume of necrotic bone was expressed as a percentage of the volume of the entire head measured on each slice. All hips underwent core decompression and the outcome was evaluated at 24 months. The primary evaluation criterion was radiological appearance: the outcome was considered as good if the hip remained stage II and poor if the disease progressed.
RESULTS—Twenty four months after core decompression, half the cases remained stable and in half the disease had progressed. Outcome seemed to be related to the volume of necrotic bone (average 22% in the good outcome group versus 45% in the poor outcome group (p = 0.0051)) and was independent of risk factors, age, and histological type.
CONCLUSIONS—The volume of necrotic bone should be taken into account in the evaluation of any treatment, bearing in mind that in more than one third of cases this volume will probably decrease, especially at the beginning of the disease process.

     

The Influence of the Deformation Method on the Microstructure and Properties of Magnesium Alloy Mg-Y-RE-Zr

This article presents the influence of the applied extrusion method on the microstructure and mechanical properties of the WE43 magnesium alloy. The materials for tests were ingots made from magnesium alloy, with dimensions of 40 × 90 mm, marked with the symbol WE43. Two extrusion methods were used: the classic one—concurrent extrusion, and the complex one—concurrent extrusion with a reversible die (KoBo). As a result of the application of deformation processes, rods were obtained. The implemented deformation methods made it possible to determine the influence of the deformation process parameters on changes in the structure and properties of the WE43 alloy. In addition, compression tests were performed to determine the values of the yield stress and to analyze changes in the microstructure after plastic deformation. The hot plastic deformation activation energy and the process parameters, for which the course of plastic flow is affected by the presence of twins in the microstructure, were determined for the WE43 alloy. The effects of superplastic flow at 350 °C (250% elongation) and microstructure refinement (d = 1 µm) were demonstrated after applying the KoBo method. The results will be useful in the development of forming technology of selected construction elements, which serve as light substitutes for currently used materials.     

Influence of Column Axial Load and Heat Affected Zone on the Strength of Aluminium Column Web in Tension

The component method for aluminium joints has been recently introduced in some codes and guidelines. Nevertheless, it is still in need of some development and improvement, as in some cases it was obtained by adapting the existing formulations that are valid for steel. The current paper presents the main outcomes of a parametric analysis carried out by means of finite element (FE) numerical models for determining the influence of both column axial load and heat affected zone—in the case of welded details—on the structural response of the column web in a tension component. The proposed study integrates previous research carried out by the authors, where the influence of the assumed alloy was investigated and interpreted by corrective parameters expressed as a function of both the material strain hardening and ductility.     

Structural Factors Inducing Cracking of Brass Fittings

Cu–Zn–Pb brasses are popular materials, from which numerous industrially and commercially used components are fabricated. These alloys are typically subjected to multiple-step processing—involving casting, extrusion, hot forming, and machining—which can introduce various defects to the final product. The present study focuses on the detailed characterization of the structure of a brass fitting—i.e., a pre-shaped medical gas valve, produced by hot die forging—and attempts to assess the factors beyond local cracking occurring during processing. The analyses involved characterization of plastic flow via optical microscopy, and investigations of the phenomena in the vicinity of the crack, for which we used scanning and transmission electron microscopy. Numerical simulation was implemented not only to characterize the plastic flow more in detail, but primarily to investigate the probability of the occurrence of cracking based on the presence of stress. Last, but not least, microhardness in specific locations of the fitting were examined. The results reveal that the cracking occurring in the location with the highest probability of the occurrence of defects was most likely induced by differences in the chemical composition; the location the crack in which developed exhibited local changes not only in chemical composition—which manifested as the presence of brittle precipitates—but also in beta phase depletion. Moreover, as a result of the presence of oxidic precipitates and the hard and brittle alpha phase, the vicinity of the crack exhibited an increase in microhardness, which contributed to local brittleness.     

Fluidity Investigation of Pure Al and Al-Si Alloys

Fluidity tests of pure aluminum 1070 and Al-Si alloys with Si contents of up to 25% were conducted using a die cast machine equipped with a spiral die. The effects of the channel gap, die temperature, and injection speed on the fluidity were investigated. When the channel gap was small (0.5 mm), the flow length of the 1070 was minimized, and the fluidity increased monotonically at a gradual rate with increasing Si content. In contrast, larger gaps yielded convex fluidity–Si content curves. Additionally, heating the die had less of an influence on the fluidity of the 1070 than on that of the Al-Si alloy. These results are discussed in the context of the peeling of the solidification layer from the die based on the thicknesses of foils and strips cast by melt spinning and roll casting, respectively. At lower Si contents, heat shrinkage was greater and the latent heat was lower. When the heat shrinkage was greater, the solidification layer began to peel earlier, and the heat transfer between the solidification layer and the die became smaller. As a result, the fluidity of the 1070 was greatest when the channel gap was 0.8 mm.     

Determination of the Influence of Hydraulic Additives on the Foaming Process and Stability of the Produced Geopolymer Foams

The research described in this article was aimed at determining the influence of hydraulic additives on the foaming process and the stability of the produced geopolymer foams. These foams can be used as insulation materials to replace the currently commonly used insulations such as expanded polystyrene or polyurethane foams. Geopolymers have low thermal conductivity, excellent fire- and heat-resistant properties, and have fairly good mechanical properties. Research on foamed materials shows that they have the highest class of fire resistance; therefore, they are most often used as insulation products in construction. Geopolymer foams were made of aluminosilicate materials (fly ash) and foaming agents (H₂O₂ and Al powder), and the stabilizers were gypsum and portland cement. Additionally, surfactants were also used. It was found that better foaming effects were obtained for H₂O₂—it is a better foaming agent for geopolymers than Al powder. When using a hydraulic additive—a stabilizer in the form of cement—lower densities and better insulation parameters were obtained than when using gypsum. Portland cement is a better stabilizer than gypsum (calcium sulfates), although the effect may change due to the addition of surfactants, for example.     

Development and Optimization of Tin/Flux Mixture for Direct Tinning and Interfacial Bonding in Aluminum/Steel Bimetallic Compound Casting

Interfacial bonding highly affects the quality of bimetallic bearing materials, which primarily depend upon the surface quality of a solid metal substrate in liquid–solid compound casting. In many cases, an intermediate thin metallic layer is deposited on the solid substrate before depositing the liquid metal, which improves the interfacial bonding of the opposing materials. The present work aims to develop and optimize the tinning process of a solid carbon steel substrate after incorporating flux constituents with the tin powder. Five ratios of tin-to-flux—i.e., 1:1, 1:5, 1:10, 1:15, and 1:20—were used for tinning process of carbon steel solid substrate. Furthermore, the effect of volume ratios of liquid Al-based bearing alloy to solid steel substrate were also varied—i.e., 5:1, 6.5:1 and 8.5:1—to optimize the microstructural and mechanical performance, which were evaluated by interfacial microstructural investigation, bonding area determination, hardness and interfacial strength measurements. It was found that a tin-to-flux ratio of 1:10 offered the optimum performance in AlSn12Si4Cu1/steel bimetallic materials, showing a homogenous and continuous interfacial layer structure, while tinned steels using other percentages showed discontinuous and thin layers, as in 1:5 and 1:15, respectively. Furthermore, bimetallic interfacial bonding area and hardness increased by increasing the volume ratio of liquid Al alloy to solid steel substrate. A complete interface bonding area was achieved by using the volume ratio of liquid Al alloy to solid steel substrate of ≥8.5.     

Determination of prestenotic flow volume using an automated method based on colour Doppler imaging for evaluating orifice area by the continuity equation: validation in a pulsatile flow model

Objective—To evaluate, in a pulsatile flow model simulating flow conditions in valvar stenoses, whether accurate determination of orifice area can be achieved by the continuity equation using automated determination of flow volumes based on spatiotemporal integration of digital colour Doppler flow velocities.
Methods—A method for automated determination of flow volumes which takes into account the velocity distribution across a region of interest was examined using flow through a tube and various restrictive outlet orifices with areas ranging between 0.2 and 3.1 cm². The sampling rectangle of the Doppler method was positioned proximal to the obstructions within the flow convergence zone for evaluating prestenotic flow volume. Stenotic jet velocities were recorded by continuous wave Doppler to obtain the integral under the velocity curve. Prestenotic flow volume was then divided by the velocity integral to calculate functional orifice area according to the continuity equation.
Results—The presence of parabolically shaped velocity profiles across the prestenotic region was demonstrated by the Doppler method. Excellent agreement was found between prestenotic flow volumes measured by the Doppler technique and actual values (r = 0.99, SEE = 1.35 ml, y = 0.99x−0.24). Use of the continuity equation led to a close correlation, with a systematic underestimation of geometric orifice sizes. Correction of Doppler data for flow contraction yielded an excellent agreement with actual orifice areas.
Conclusions—The study validated the accuracy of a Doppler method for automated determination of flow volumes for quantifying orifice area by the continuity equation. Prestenotic flow volume and functional orifice area could be evaluated reliably in the presence of non-flat velocity profiles. Thus the method contributes to the non-invasive assessment of valvar stenoses.

Keywords: Doppler echocardiography;  automated flow volume determination;  valvar stenoses;  pulsatile flow model     

Magnetic resonance imaging of the coronary arteries: clinical results from three dimensional evaluation of a respiratory gated technique

BACKGROUND—Magnetic resonance coronary angiography is challenging because of the motion of the vessels during cardiac contraction and respiration. Additional challenges are the small calibre of the arteries and their complex three dimensional course. Respiratory gating, turboflash acquisition, and volume rendering techniques may meet the necessary requirements for appropriate visualisation.
OBJECTIVE—To determine the diagnostic accuracy of respiratory gated magnetic resonance imaging (MRI) for the detection of significant coronary artery stenoses evaluated with three dimensional postprocessing software.
METHODS—32 patients referred for elective coronary angiography were studied with a retrospective respiratory gated three dimensional gradient echo MRI technique. Resolution was 1.9 × 1.25 × 2 mm. After manual segmentation three dimensional evaluation was performed with a volume rendering technique.
RESULTS—Overall 74% (range 50% to 90%) of the proximal and mid coronary artery segments were visualised with an image quality suitable for further analysis. Sensitivity and specificity for the detection of significant stenoses were 50% and 91%, respectively.
CONCLUSIONS—Volume rendering of respiratory gated MRI techniques allows adequate visualisation of the coronary arteries in patients with a regular breathing pattern. Significant lesions in the major coronary artery branches can be identified with a moderate sensitivity and a high specificity.


Keywords: magnetic resonance imaging; coronary artery disease; coronary angiography; computer assisted image processing     

A multiscale model linking ion-channel molecular dynamics and electrostatics to the cardiac action potential

Ion-channel function is determined by its gating movement. Yet, molecular dynamics and electrophysiological simulations were never combined to link molecular structure to function. We performed multiscale molecular dynamics and continuum electrostatics calculations to simulate a cardiac K⁺ channel (I_Ks) gating and its alteration by mutations that cause arrhythmias and sudden death. An all-atom model of the I_Ks α-subunit KCNQ1, based on the recent Kv1.2 structure, is used to calculate electrostatic energies during gating. Simulations are compared with experiments where varying degrees of positive charge—added via point mutation—progressively reduce current. Whole-cell simulations show that mutations cause action potential and ECG QT interval prolongation, consistent with clinical phenotypes. This framework allows integration of multiscale observations to study the molecular basis of excitation and its alteration by disease.     

Are the returns to technological change in health care declining?

Whether the U.S. health care system supports too much technological change—so that new technologies of low value are adopted, or worthwhile technologies become overused—is a controversial question. This paper analyzes the marginal value of technological change for elderly heart attack patients in 1984–1990. It estimates the additional benefits and costs of treatment by hospitals that are likely to adopt new technologies first or use them most intensively. If the overall value of the additional treatments is declining, then the benefits of treatment by such intensive hospitals relative to other hospitals should decline, and the additional costs of treatment by such hospitals should rise. To account for unmeasured changes in patient mix across hospitals that might bias the results, instrumental–variables methods are used to estimate the incremental mortality benefits and costs. The results do not support the view that the returns to technological change are declining. However, the incremental value of treatment by intensive hospitals is low throughout the study period, supporting the view that new technologies are overused.     

Effect of Returnable Material in Batch on Hot Tearing Tendency of AlSi9Cu3 Alloy

The main reason for the use of returnable material, or recycled alloys, is a cost reduction while maintaining the final properties of the casting. The casting resulting quality is directly related to the correct ratio of commercial grade alloy and alloy made by remelting the returnable material in the batch. The casting quality is also affected by the purity of the secondary raw materials used, the shape complexity and the use of the casting itself. The presented article focuses on the effect of increasing the returnable material content in the batch on the hot tearing susceptibility of AlSi9Cu3 alloy. Hot tears are a complex phenomenon that combines metallurgical and thermo-mechanical interactions of the cast metal. Hot tearing susceptibility was evaluated on the basis of quantitative (HTS—hot tearing susceptibility index) and qualitative evaluation. The negative effect of returnable material in the batch was already manifested at a 20% content in the batch. The critical proportion of the returnable alloy in the batch can be stated as 50%. The alloy with a 50% returnable material content manifested insufficient results of the HTS index and qualitative evaluation, which means increased sensitivity to tearing. The negative effect of returnable material and the increased sensitivity were also confirmed in the evaluation of the fracture surface and hot tear profile. The microstructure of alloys with 50% and higher proportion of returnable material was characterized by a higher amount of iron phases (mainly Al₅FeSi), whose sharp ends acted as critical regions of hot tearing and subsequent hot tear propagation, which had a major impact on the increase in hot tearing susceptibility.