Metallurgy Commons^™

Riser Design For Green Sand And Ductile Iron Castings, K. Michael Kuebler

Graduate Research Papers

Shrinkage defects in ductile iron riser contacts has long been one of the most frustrating defects to eliminate for the foundry engineer. While process variation can definitively contribute to the occurrence of these defects most can be prevented if the risers are properly designed and/or applied to the castings to be fed. There are several proven methods for the designing risers some of which go back over 40 years ago. There are also new methods available today with the advancements of simulation software. Four of these riser design methods were evaluated for their ability to produce an internally sound casting …

Comparison Study Of Cooling Fins And Chills Effectiveness In Aluminum Sand Mold Casting, Vladimir E. Kouznetsov

Graduate Research Papers

Besides proper design of gating and risering systems, there are several methods used to control and modify solidification behavior of cast alloys. Within these methods, the most widely used are local cooling aids employing cooling fins (thin segments attached to problematic areas of casting) or external chills (metal inserts placed into mold walls to accelerate heat withdrawing from potential hot spot). The later helps to promote directional solidification when traditional methods are not possible to use due to limitations related to the casting design. Despite relatively wide application in aluminum foundries, there are no specific recommendations on cooling aids parameters …

Relationship Between Cost Of Technical Training And Cost Reduction Of Internal Defects At John Deere Waterloo Foundry, John Brackin

Graduate Research Papers

Can the cost of technical training at John Deere Waterloo Foundry pay for itself in the reduction of internal defects? This research compared training costs to the savings from reduced internal defects on Molding Unit 801 located in the John Deere Waterloo Foundry. Training was the independent variable of this research. The results of this research identified a correlation between training costs ( operational definition on page 10) and defect reduction costs. A correlation between these two established a break even point for training dollars spent.

The dependent variable was the dollar savings based on reduction of internal defects. There …

A Fluid Flow Analysis Of Aluminum 356.0 In The Vacuum Assisted Countergravity Method, John Launstein

Graduate Research Papers

The purpose of this study is to determine the fluid flow pattern obtained through the use of the countergravitaional process. The physical fluid flow model assists design engineers in their casting design of parts utilizing the LS-Vac technology thereby reducing tooling costs and time losses.

An Analysis Of The Disposition Of Used Foundry Sand With Thermal Reclamation, Douglas Miller

Graduate Research Papers

The purpose of this study was to identify the economic and environmental concerns for the disposal, reuse, or reclamation of used foundry sand and show how foundries have developed options to landfills. The sand type and the reclamation processes available are the factors to use in determining whether disposal, reuse, or reclamation is appropriate. The continued use of landfills for disposal of used sand strongly indicates that reclamation and reuse techniques were either not understood or not as economical as disposal. Public concerns and new environmental laws demand that alternate means of disposal for used foundry sand should be developed …

Development Of A Gating System For The "H" Process Of Metal Casting, Dean A. Boyce

Graduate Research Papers

The "H" Process of metal casting uses a unique gating system that controls the flow of molten metal during the casting process. A feeder/runner bar serving each casting is the vital element in the "H" Process. Available information on the "H" Process is not very specific about the runner system configuration. This study will develop a gating system for use with the "H" Process using the available information and principles of conventional gating practice.

Desirable Combinations Of Electrode And Flux For Submerged Arc Welding Of Low Carbon Steel, James A. Husmann

Graduate Research Papers

The major purpose of this study was to provide information about desirable combinations of welding electrode and appropriate fluxes for submerged arc welding of low carbon steel. Other purposes were to:

1. Test a variety of combinations of available submerged arc welding electrodes and fluxes in welding low carbon steel.

a. Prepare specimens for tensile tests.

b. Conduct tensile tests.

c. Calculate tensile strength, yield point, break point, percent of elongation, and percent reduction of area.

2. Determine the most desirable combinations of electrode and flux for companies presently using or planning to use submerged arc welding for low carbon …

Computerized Twist Drill Selection For Cast Iron And Steel, Clinton K. Orth

Graduate Research Papers

The science of hole making can hardly be considered new to modern day industry. Evidence of drilling dates back as early as 4000 B.C. However, computers are considered relatively new to industry and their use is growing rapidly. One of the major concerns of industry is to identify a consistent method of selecting the proper drill when given a set of variables. The problem is to identify the sets of variables and select a drill that will give consistent results.

Numerical Control Milling, Roger Schroeder

Graduate Research Papers

This research paper centers on two general problems:

1) Development of machine angles on the point-to-point NC mill by utilizing different combinations of feed rates on the X and Y axes.

2) Developing a learning activity package which includes a product to be produced by students on the numerical control milling machine that is safe, fast and inexpensive. The experiences gained in this activity will give the students a good working knowledge of numerical control principles.

Powder Metallurgy, Harold L. Street

Graduate Research Papers

The purpose of the study is (1) to investigate pertinent literature and industries for the purpose of learning how the powder metallurgy process is carried out; (2) to construct a set of dies to press metal powder; (3) to use this equipment to press and sinter specimens; (4) to develop a unit of study on powder metallurgy suitable for use in an introductory metal class.

Photo Chemical Milling, Terry R. Smith

Graduate Research Papers

This study is concerned with the techniques used in the production of metal parts by the use of photofabrication. Included will be a research of the historical background of the industry, and the production processes used by the photofabrication industry that apply to this project. Information will include careers, education, current status of the industry, as well as methods for implementing the processes into the industrial arts curriculum.