A Method for Characterising the Influence of Casting Parameters on the Metallurgical Bonding of Copper and Steel Bimetals.

Traditional casting technology offers two mayor drawbacks towards research activities. On the one hand, time and resources needed for every casting are rather high. The mould has to be able to withstand the high temperatures introduced by the melt and provide cooling for the cast part. Preparation and installation of measuring equipment therefore takes time. Additionally, due to the high mass of the mould when compared to the cast part, parameter variations are rather limited in their resulting effect on the temperature-time profile being one of the most prominent factors regarding cast quality. Especially when pouring by hand, variations in casting times and rates superimpose effects created intentionally. Therefore, a different process was advanced and evaluated, allowing to minimise some of the drawbacks mentioned before. The key idea is to drastically reduce casting size to the dimensions of one specimen and to apply a highly automated production route. As such, a mirror furnace was modified as to allow the processing of melt. Due to the specimens size, an adaption of mechanical testing equipment was performed and evaluated. As an example, copper-iron bimetal specimens were examined by light microscopy, micro hardness testing, nanoindentation as well as tensile and torsion testing. As the results were consistent, the newly introduced method can be applied successfully in casting research. This allows for highly reproducible results, reducing the uncertainty of temperature measurements of a specimen due to the distance between them. The possibility of separating influencing variables like maximum temperature and cooling rate allows an analysis of the casting process, which would require different moulds to do so in traditional casting methods. The next steps will be directed at a broader variety of metals processed and at a direct comparison between the new process route and traditional casting technology.

Influence of Salt Support Structures on Material Jetted Aluminum Parts.

Like most additive manufacturing processes for metals, material jetting processes require support structures in order to attain full 3D capability. The support structures have to be removed in subsequent operations, which increases costs and slows down the manufacturing process. One approach to this issue is the use of water-soluble support structures made from salts that allow a fast and economic support removal. In this paper, we analyze the influence of salt support structures on material jetted aluminum parts. The salt is applied in its molten state, and because molten salts are typically corrosive substances, it is important to investigate the interaction between support and build material. Other characteristic properties of salts are high melting temperatures and low thermal conductivity, which could potentially lead to remelting of already printed structures and might influence the microstructure of aluminum that is printed on top of the salt due to low cooling rates. Three different sample geometries have been examined using optical microscopy, confocal laser scanning microscopy, energy-dispersive X-ray spectroscopy and micro-hardness testing. The results indicate that there is no distinct influence on the process with respect to remelting, micro-hardness and chemical reactions. However, a larger dendrite arm spacing is observed in aluminum that is printed on salt.

A Plane Stress Failure Criterion for Inorganically-Bound Core Materials.

Inorganically-bound core materials are used in foundries in high quantities. However, there is no validated mechanical failure criterion, which allows performing finite-element calculations on the core geometries, yet. With finite-element simulations, the cores could be optimised for various production processes from robotic core handling to the decoring process after the casting. To identify a failure criterion, we propose testing methods, that enable us to investigate the fracture behaviour of inorganically-bound core materials. These novel testing methods induce multiple bi-axial stress states into the specimens and are developed for cohesive frictional materials in general and for sand cores in particular. This allows validating failure criteria in principal stress space. We found that a Mohr-Coulomb model describes the fracture of inorganic core materials in a plane stress state quite accurately and adapted it to a failure criterion, which combines the Mohr-Coulomb model with the Weakest-Link theory in one consistent mechanical material model. This novel material model has been successfully utilised to predict the fracture force of a Brazilian test. This prediction is based on the stress fields of a finite element method (FEM) calculation.

Acoustical and Optical Determination of Mechanical Properties of Inorganically-Bound Foundry Core Materials.

Inorganically-bound sand cores are used in many light-metal foundries to form cavities in the cast part, which cannot be realised by the mould itself. To enable FEM simulations with core materials, their mechanical properties have to be measured. In this article, we adapt methods to determine the Young's and shear modulus, the Poisson ratio and the fracture strain of sand cores. This allows us to fully parametrise an ideal brittle FEM model. We found that the Young's and shear modulus can be obtained acoustically via the impulse excitation technique. The fracture strain was measured with a high-speed camera and a digital image correlation algorithm.

Fracture Statistics for Inorganically-Bound Core Materials.

In this article, we study the fracture characteristics of inorganically-bound foundry cores. It will be shown that the fracture stress of inorganic cores follows Weibull's strength distribution function for brittle materials. Using three-point and four-point-bending experiments, the volume dependence of the bending fracture stress is analyzed and a Weibull model fitted. Furthermore, the fracture stress of arbitrary bending experiments can be calculated based on the Weibull parameters found.

Effect of whole-body vibration and insulin-like growth factor-I on muscle paralysis-induced bone degeneration after botulinum toxin injection in mice.

Botulinum toxin A (BTX)-induced muscle paralysis results in pronounced bone degradation with substantial bone loss. We hypothesized that whole-body vibration (WBV) and insulin-like growth factor-I (IGF-I) treatment can counteract paralysis-induced bone degradation following BTX injections by activation of the protein kinase B (Akt) signaling pathway. Female C57BL/6 mice (n = 60, 16 weeks) were assigned into six groups (n = 10 each): SHAM, BTX, BTX+WBV, BTX+IGF-I, BTX+WBV+IGF-I, and a baseline group, which was killed at the beginning of the study. Mice received a BTX (1.0 U/0.1 mL) or saline (SHAM) injection in the right hind limb. The BTX+IGF-I and BTX+WBV+IGF-I groups obtained daily subcutaneous injections of human IGF-I (1 µg/day). The BTX+WBV and BTX+WBV+IGF-I groups underwent WBV (25 Hz, 2.1 g, 0.83 mm) for 30 min/day, 5 days/week for 4 weeks. Femora were scanned by pQCT, and mechanical properties were determined. On tibial sections TRAP staining, static histomorphometry, and immunohistochemical staining against Akt, phospho-Akt, IGF-IR (IGF-I receptor), and phospho-IGF-IR were conducted. BTX injection decreased trabecular and cortical bone mineral density. The WBV and WBV+IGF-I groups showed no difference in trabecular bone mineral density compared to the SHAM group. The phospho-IGF-IR and phospho-Akt stainings were not differentially altered in the injected hind limbs between groups. We found that high-frequency, low-magnitude WBV can counteract paralysis-induced bone loss following BTX injections, while we could not detect any effect of treatment with IGF-I.