Search Results (99)

The formation of hot tearing during direct chill casting of aluminum alloys, specifically AA6111, is a significant challenge in the production of ingots for industrial applications. This study investigates the role of hydrostatic pressure and tensile stress in the formation of hot tearing during direct chill casting of rectangular ingots. Combining experimental results and finite element modeling with ABAQUS/CAE 2022, the mechanical behavior of the semi-solid AA6111 alloy was analyzed under different cooling conditions. “Hot” (low water flow) and “Cold” (high water flow) conditions were the two types of cooling conditions that produced cracked and sound ingots, respectively. The outcomes indicate that high tensile stress and localized negative hydrostatic pressure in the hot condition are the main factors promoting the initiation and propagation of cracks in the mushy zone, whereas the improvement of the cooling conditions reduces these defects. Full article

The pore-throat structure of the extremely low-permeability sandstone reservoir in the Huachi area of the Ordos Basin is complex and highly heterogeneous. Currently, there are issues such as unclear understanding of the micro-pore-throat structural characteristics, primary controlling factors of reservoir quality, and classification boundaries of the reservoir in the study area, which seriously restricts the exploration and development effectiveness of the reservoir in this region. It is necessary to use a combination of various analytical techniques to comprehensively characterize the pore-throat structure and establish reservoir classification evaluation standards in order to better understand the reservoir. This study employs a suite of analytical and testing techniques, including cast thin sections (CTS), scanning electron microscopy (SEM), cathodoluminescence (CL), X-ray diffraction (XRD), as well as high-pressure mercury injection (HPMI) and constant-rate mercury injection (CRMI), and applies fractal theory for analysis. The research findings indicate that the extremely low-permeability sandstone reservoir of the Chang 3 section primarily consists of arkose and a minor amount of lithic arkose. The types of pore-throat are diverse, with intergranular pores, feldspar dissolution pores, and clay interstitial pores and microcracks being the most prevalent. The throat types are predominantly sheet-type, followed by pore shrinkage-type and tubular throats. The pore-throat network of low-permeability sandstone is primarily composed of nanopores (pore-throat radius r < 0.01 μm), micropores (0.01 < r < 0.1 μm), mesopores (0.1 < r < 1.0 μm), and macropores (r > 1.0 μm). The complexity of the reservoir pore-throat structure was quantitatively characterized by fractal theory. Nanopores do not exhibit ideal fractal characteristics. By splicing high-pressure mercury injection and constant-rate mercury injection at a pore-throat radius of 0.12 μm, a more detailed characterization of the full pore-throat size distribution can be achieved. The average fractal dimensions for micropores (Dh2), mesopores (Dc3), and macropores (Dc4) are 2.43, 2.75, and 2.95, respectively. This indicates that the larger the pore-throat size, the rougher the surface, and the more complex the structure. The degree of development and surface roughness of large pores significantly influence the heterogeneity and permeability of the reservoir in the study area. Dh2, Dc3, and Dc4 are primarily controlled by a combination of pore-throat structural parameters, sedimentary processes, and diagenetic processes. Underwater diversion channels and dissolution are key factors in the formation of effective storage space. Based on sedimentary processes, reservoir space types, pore-throat structural parameters, and the characteristics of mercury injection curves, the study area is divided into three categories. This classification provides a theoretical basis for predicting sweet spots in oil and gas exploration within the study area. Full article

One of the most effective methods of improving the properties of aluminium alloys is grain refining using Al-Ti-B master alloys. In contrast, zirconium is a key alloying element, used mainly in 2xxx and 7xxx series aluminium alloys, where it contributes to dispersion enhancement and reduces the rate of dynamic recrystallisation. However, even trace amounts of zirconium—just a few hundredths of ppm—significantly reduce the performance of Al-Ti-B grain refiners, a phenomenon known as ‘Zr poisoning’. This study investigates the impact of holding time and the level of Al-5Ti-1B addition on the microstructure and properties of an AlMgSi(Cu) alloy containing 0.15 wt.% Zr, cast as 7-inch DC billets. The structure and phase distribution were characterised using optical microscopy (OM), scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Grain size and morphology were evaluated through macrostructure analysis (etched cross-sections and polarised light microscopy), while chemical and elemental distributions were analysed via SEM-EDS and STEM-EDS mapping. Additionally, Brinell hardness measurements were conducted across the billet diameter to assess the correlation between grain size and mechanical properties. The results show that reducing holding time and increasing the Al-5Ti-1B addition improves grain refinement efficiency despite the presence of Zr. The finest grain structure (150–170 μm) and most homogeneous hardness distribution were achieved when the grain refiner was continuously fed during casting at 80 ppm B. These findings are supported by the literature and contribute to a deeper understanding of the Zr poisoning effect and its mitigation through optimized casting practice. Full article

Investment casting is a precision casting technology that can produce complex shapes from various materials, particularly difficult-to-cast and difficult-to-machine metallic alloys. Meanwhile, electrical discharge machining (EDM) is a well-known technique for producing ultra-precise mechanical parts, and electrode quality is crucial. Few studies have explored how rapid prototyping (RP) pattern generation and investment casting influence the final product’s shape, dimensions, and surface roughness. This study investigates EDM electrode fabrication using investment casting and RP-generated epoxy resin patterns. We examine the effects of electrode materials (CuZn5, CuZn30, and FeCr24) on surface roughness, alongside the impact of ceramic shell thickness and RP pattern shrinkage on electrode quality. The EDM electrodes have a shrinkage of 0.8–1.9% and a surface roughness of 3.20–6.35 μm, depending on the material selections. Additionally, the probability of shell cracking decreases with increasing shell thickness, achieving stability at 16.00 mm. This research also applies investment casting electrodes to process DC53 steel. The results indicate that the surface roughness of the workpiece after EDM machining with different electrode materials is in the range of 4.71 µm to 9.88 µm. The result expands the use of investment casting in electrode fabrication, enabling the production of high-precision electrodes with complex profiles and challenging materials, potentially reducing both time and cost. Full article

Objective: To evaluate mandibular kinematics in an orthodontic population using the Modjaw^® optical jaw tracking system. Materials and methods: A total of 154 orthodontic patients underwent mandibular kinematic analysis using the Modjaw^® system. ANB values determined skeletal classification, while dental classification was assessed on digital casts. The Modjaw^® records were taken as instructed by the manufacturer, and data collected from the readings included the discrepancy between centric occlusion and maximum intercuspation, maximum opening, Bennett angles, and sagittal condylar guidance. The presence or absence of temporomandibular disorders was determined by the DC-TMD questionnaires. Non-parametric tests and Spearman correlations were applied for the statistical analysis. Results: Significant differences in mandibular kinematics were observed between skeletal classes, particularly in CO-MI discrepancies, Bennett angles, and maximum opening (p < 0.05). TMD symptoms were associated with higher absolute CO-MI discrepancies but did not significantly alter other kinematic parameters. Weak correlations were found between sagittal condylar guidance and anterior guidance variables. Conclusions: Mandibular kinematics differ by skeletal classification, with Class III patients demonstrating distinct patterns. While TMD symptoms impact CO-MI discrepancies, overall mandibular dynamics remain consistent. Full article

To create an orthodontic bracket material combining the favourable properties of ceramic and polymer while minimising their limitations, graded porous ceramic scaffolds were created using unidirectional gelation-freeze casting, following which the pores were infiltrated with polymer. Two processing parameters were investigated: (1) sedimentation times of 0, 8, and 24 h, with ceramic solid loading of 20 vol.% and 2.5 wt.% gelatine concentration, and (2) ceramic solid loadings of 15, 20, and 25 vol.% with a fixed 2.5 wt.% gelatine concentration and an 8 h sedimentation time. The graded ceramic structures demonstrated porosity gradients ranging from 9.86 to 63.84 vol.%, except those with 25 vol.% ceramic solid loading at 8 h sedimentation. The Al₂O₃-UDMA/TEGDMA composites had compressive strengths of 60.25 to 120.92 MPa, modulus of elasticity of 19.84 to 35.29 GPa, and fracture toughness of 0.78 to 1.78 MPa·m^1/2. The values observed were between those of dense ceramic and pure polymer. Statistical analysis was conducted using Excel^® 2019 (Microsoft^®, Washington, DC, USA). Means, standard deviations, and 95% confidence intervals (CI) were calculated at a significance level of α = 0.05, alongside polynomial regression to evaluate relationships between variables. Composites with 20 vol.% ceramic solid loading at 8 h sedimentation displayed promising potential for further clinical validation. Full article

The direct-chill (DC) casting of diameter of 300 mm 7050 aluminum alloy ingots under the impact of intense melt shearing and electromagnetic fields (combined fields) was simulated using the COMSOL software 6.2 to determine the temperature distribution and melt flow. The results indicated that the use of electromagnetic fields, intense melt shearing, and combined fields can all improve melt flow velocity, heat transfer efficiency, temperature field uniformity, and reduce sump depth when compared to conventional DC casting. However, the use of combined fields creates the shallowest sump and the most uniform temperature field. With the application of electromagnetic field, intensive melt shearing, and combined fields, the sump depth was decreased from 121 mm of DC casting to 118 mm, 112 mm, and 110 mm, respectively. Under the impact of the combined fields, the increase in the rotor rotation speed leads to the enhancement of overall flow velocity, the improvement of temperature distribution uniformity, and the reduction of melt temperature in the sump. The temperatures at reference points A and B dropped from 631.80 °C and 645.26 °C to 630.20 °C and 630.75 °C, respectively, as the rotor rotation speed increased from 1500 rpm to 6000 rpm. Additionally, the application of the combined fields resulted in a uniform microstructure distribution and notable grain refinement. Full article

Background/Objectives: Occlusion plays a crucial role in the long-term success and functionality of dental restorations. The purpose of this study was to investigate the changes in occlusal contacts upon the cementation of zirconia crowns with different cement spacer settings in computer-aided design and computer-aided manufacturing (CAD-CAM) software (3Shape Dental System version 2.102.1.0). Methods: A master model of a prepared abutment for a crown on the right maxillary first molar was scanned, and 30 sets of sample casts and zirconia crowns were fabricated with varying cement spaces (70 μm and 120 μm). These casts were mounted in maximal intercuspation (MIP) on a semi-adjustable articulator. Pre-cementation adjustments were made to fit the crowns and maintain the existing occlusion. Occlusal records were taken before and after cementation using polyvinyl siloxane impression material. These records were analyzed using a DC light box and image analyzer to measure changes in contact area, intensity, and patterns. Paired sample t-tests were used to compare pre- and post-cementation occlusal contact areas of each sample (α = 0.05). Results: Significant differences in occlusal contact areas were found between pre- and post-cementation in both groups (p < 0.001). The mean post-cementation contact surface area for the 70 μm group was 6281 ± 3310 μm², compared to 2339 ± 1206 μm² before cementation. For the 120 μm group, the post-cementation area was 5545 ± 3491 μm², compared to 2071 ± 909 μm² before cementation. An increase in contact intensity was also observed after cementation. Conclusions: This study demonstrates that cementation increases occlusal contact surface area and intensity in both cement space groups. Full article

This article investigates the application of eXtreme gradient boosting (XGBoost) and hybrid metaheuristics optimisation techniques to predict the axial load bearing capacity of fully grouted rock bolting systems. For this purpose, a comprehensive dataset of 72 pull-out tests was built, considering various influential parameters such as three water-to-grout (W/G) ratios, five ranges of curing time (CT), three different grout admixtures with two different fly ash (FA) contents, and two different diameter confinements (DCs). Additionally, to find out the effect of the mechanical behaviour of grouts on the performance of fully grouted rock bolting systems, seventy-two uniaxial compression strength (UCS) samples were cast and tested simultaneously with pull-out samples. The UCS samples were prepared with the same details as the pull-out samples to avoid any inconsistency. The results highlight that peak load values generally increase with longer curing times, lower W/G, and higher UCS and DC values. The main novelty of this paper lies in its data-driven approach, using various XGBoost models. This method offers a time-, cost-, and labour-efficient alternative to traditional experimental methods for predicting rock bolt performance. For this purpose, after building the dataset and dividing it randomly into two training and testing datasets, five different XGBoost models were developed: a standalone XGBoost model and four hybrid models incorporating Harris hawk optimisation (HHO), the jellyfish search optimiser (JSO), the dragonfly algorithm (DA), and the firefly algorithm (FA). These models were subsequently evaluated for their ability to predict peak load values. The results demonstrate that all models effectively predicted peak load values, but the XGBoost-JSO hybrid model demonstrated superior performance, achieving the highest R-squared coefficients of 0.987 and 0.988 for the training and testing datasets, respectively. Sensitivity analysis revealed that UCS values were the most influential parameter, while FA content had the least impact on the maximum peak load values of fully cementitious grouted rock bolts. Full article

This paper presents the results of an analysis of resistance to hydrogen embrittlement and offers solutions and technologies for manufacturing castings of components for critical applications, such as blades for gas turbine engines (GTEs). The values of the technological parameters for directional crystallization (DC) are determined, allowing the production of castings with a regular dendritic structure of the crystallization front in the range of 10 to 12 mm/min and a temperature gradient at the crystallization front in the range of 165–175 °C/cm. The technological process of making GTE blades has been improved by using a scheme for obtaining disposable models of complex profile castings with the use of 3D printing for the manufacture of ceramic molds. The ceramic mold is obtained through an environmentally friendly technology using water-based binders. Short-term tensile testing of the samples in gaseous hydrogen revealed high hydrogen resistance of the CM-88 alloy produced by directed crystallization technology: the relative elongation in hydrogen at a pressure of 30 MPa increased from 2% for the commercial alloy to 8% for the experimental single-crystal alloy. Full article

The large-scale ingot of the 7xxx-series aluminum alloys fabricated by direct chill (DC) casting often suffers from foundry defects such as cracks and cold shut due to the formidable challenges in the precise controlling of casting parameters. In this manuscript, by using the integrated computational method combining numerical simulations with machine learning, we systematically estimated the evolution of multi-physical fields and grain structures during the solidification processes. The numerical simulation results quantified the influences of key casting parameters including pouring temperature, casting speed, primary cooling intensity, and secondary cooling water flow rate on the shape of the mushy zone, heat transport, residual stress, and grain structure of DC casting ingots. Then, based on the data of numerical simulations, we established a novel model for the relationship between casting parameters and solidification characteristics through machine learning. By comparing it with experimental measurements, the model showed reasonable accuracy in predicting the sump profile, microstructure evolution, and solidification kinetics under the complicated influences of casting parameters. The integrated computational method and predicting model could be used to efficiently and accurately determine the DC casting parameters to decrease the casting defects. Full article

This study focusses on the energy efficiency of compressed air storage tanks (CASTs), which are used as small-scale compressed air energy storage (CAES) and renewable energy sources (RES). The objectives of this study are to develop a mathematical model of the CAST system and its original numerical solutions using experimental parameters that consider polytropic charging and discharging processes, changes in the time of the temperature, flow parameters of the inlet and outlet valves under choked and subsonic conditions, and the characteristics of the air motor. This model is used to select CAST as an energy storage system for compressed air generated by compressors and recycling, as well as an energy source to drive DC generators and a pneumatic propulsion system (PPS). A measuring test rig is built to verify the polytropic pressure and temperature variations during CAST charging and discharging obtained from numerical solutions. The topic of discussion is the functional model of a high-pressure air system (HPAS) that contains a CAST connected to an air motor coupled to a mechanical drive for a DC generator or PPS. Such a system is used in small-scale CASTs, which currently respond to socio-economic demands. The presented CAST energy efficiency indicators are used to justify the storage of compressed air energy on a small scale. Small-scale compressed air storage in CASTs is currently important and relevant due to the balance between peak electricity demand and the development of wind energy, photovoltaics, and other renewable energy sources. Full article

The paper reports on high voltage (HV)-isolated MEMS quad–solenoid transformers for compact isolated gate drivers and bias power supplies. The component is wafer-level fabricated via a novel MEMS micro-casting technique, where the tightly coupled quad–solenoid chip consists of monolithically integrated 3D inductive coils and an inserted ferrite magnetic core for high-efficiency isolated power transmission through electromagnetic coupling. The proposed HV-isolated transformer demonstrates a high inductance value of 743.2 nH, along with a small DC resistance of only 0.39 Ω in a compact footprint of 6 mm², making it achieve a very high inductance integration density (123.9 nH/mm²) and the ratio of L/R (1906 nH/Ω). More importantly, with embedded ultra-thick serpentine-shaped (S-shaped) SiO₂ isolation barriers that completely separate the primary and secondary windings, an over 2 kV breakdown voltage is obtained. In addition, the HV-isolated transformer chips exhibit a superior power transfer efficiency of over 80% and ultra-high dual-phase saturation current of 1.4 A, thereby covering most practical cases in isolated, integrated bias power supplies such as high-efficiency high-voltage-isolated gate driver solutions. Full article

Soft magnetic Fe-Al alloys have been a subject of research in the past. However, they never saw the same reception in technical applications as the Fe-Si or Fe-Ni alloys, which is, to some extent, due to a low ductility level and difficulties in manufacturing. Additive manufacturing (AM) technology could be a way to avoid issues in conventional manufacturing and produce soft magnetic components from these alloys, as has already been shown with similarly brittle Fe-Si alloys. While AM has already been applied to certain Fe-Al alloys, no magnetic properties of AM Fe-Al alloys have been reported in the literature so far. Therefore, in this work, a Fe-12Al alloy was additively manufactured through laser powder bed fusion (L-PBF) and characterized regarding its microstructure and magnetic properties. A comparison was made with the materials produced by casting and rolling, prepared from melts with an identical chemical composition. In order to improve the magnetic properties, a heat treatment at a higher temperature (1300 °C) than typically applied for conventionally manufactured materials (850–1150 °C) is proposed for the AM material. The specially heat-treated AM material reached values (H_C: 11.3 A/m; µ_max: 13.1 × 10³) that were close to the heat-treated cast material (H_C: 12.4 A/m; µ_max: 20.3 × 10³). While the DC magnetic values of hot- and cold-rolled materials (H_C: 3.2 to 4.1 A/m; µ_max: 36.6 to 40.4 × 10³) were not met, the AM material actually showed fewer losses than the rolled material under AC conditions. One explanation for this effect can be domain refinement effects. This study shows that it is possible to additively manufacture Fe-Al alloys with good soft magnetic behavior. With optimized manufacturing and post-processing, further improvements of the magnetic properties of AM L-PBF Fe-12Al may still be possible. Full article

Compared with electroplating, liquid casting enables the rapid formation of a three-dimensional solenoid coil with a narrower line width and greater thickness, which proves advantageous in enhancing the comprehensive performance of the micro-electromechanical system (MEMS) fluxgate sensor. For this reason, a MEMS fluxgate sensor based on liquid casting with a closed-loop Fe-based amorphous alloy core is proposed. Based on the process parameters of liquid casting, the structure of the MEMS fluxgate sensor was designed. Utilizing MagNet to build the simulation model, the optimal excitation conditions and sensitivity were obtained. According to the simulation model, a highly sensitive MEMS fluxgate sensor based on liquid casting was fabricated. The resulting sensor exhibits a sensitivity of 2847 V/T, a noise of 306 pT/√Hz@1 Hz, a bandwidth of DC-10.5 kHz, and a power consumption of 43.9 mW, which shows high sensitivity and low power consumption compared with other MEMS fluxgates in similar size. Full article