Search Results (160)

3D printing represents a promising fabrication technology for silica-based ceramic cores, which are essential components in the casting of turbine blades, but it is faced with poor high-temperature dimensional stability. Herein, alumina nanopowder was utilized as a modifier agent in digital light processing (DLP) 3D printing of silica-based ceramic cores, and systematic investigations were conducted on the microstructure and properties of ceramic cores throughout sintering and casting dependent on the content of alumina nanopowder (0–1.0 wt.%). Alumina nanopowder increased the sintering barrier of fused silica, significantly reducing the shrinkage in sintering and simulated casting, while improving high-temperature dimensional stability. Even though the alumina nanopowder led to decreased room-temperature and high-temperature flexural strengths attributed to inhibited densification and crystallization, the strengths met investment casting requirements after PVA solution strengthening. Excessive alumina nanopowder (0.8–1.0 wt.%) resulted in poor interlayer bonding and particle spalling, unfavorable to the structural integrity in casting. The optimal alumina content was 0.6 wt.%, which balanced sintering shrinkage of 1.86%, shrinkage of 4.41% after simulated casting, room-temperature flexural strength of 11.13 MPa, high-temperature flexural strength of 31.29 MPa, high-temperature creep deformation of 0.55 mm, and surface roughness of 1.815 μm. This research proposes an effective strategy for the optimization of 3D-printed silica-based ceramic cores in the manufacture of complex hollow turbine blades. Full article

The brittleness of 18-karat purple gold originates from the AuAl₂ intermetallic compound. This study investigates the microstructural modification of the AuAl₂ intermetallic compound by adding silicon (Si) and cobalt (Co) and by rapid solidification in copper molds. The samples with alloy additions from a traditional investment casting were compared with copper mold casting for grain boundary characteristics using SEM, EBSD, and TEM. SEM micrographs showed a reduction in grain size of copper mold casting from approximately within 150–200 μm to within 12–20 μm. EBSD showed a narrow grain size distribution in the Si–Co-modified alloy than in the Si-modified alloy, using the copper mold casting technique. TEM observations show that grain boundaries were closely packed, with ~80 nm-sized voids. XRD confirmed that all alloys retained the AuAl₂ intermetallic phase, with peak broadening in the modified and fast-cooling samples indicating crystallographic refinement. These results confirm that Si-Co additions with a fast cooling rate effectively refine the microstructure of the AuAl₂ intermetallic compound, making the alloy less brittle while preserving the purple gold color. Full article

Solar energy plays a fundamental role in achieving decarbonization in the construction sector, and therefore, a detailed assessment of solar potential at the urban scale is a key tool in supporting this process. Within this framework, the present study focuses on the high-resolution evaluation of photovoltaic (PV) potential in urban environments, specifically targeting the city of Milan, Italy, where two representative study areas are selected. In detail, 3D city models are developed using Rhino3D 7 software, and a solar radiation analysis was performed using Ladybug components. The solar radiation received by the surfaces that comprise the roofs and facades of buildings is estimated for each floor and orientation, taking into account local climate conditions and shadows cast by surrounding buildings. To define the economic viability of PV system deployment, two threshold criteria were introduced: one concerning the size (area) of the PV system and the other the minimum annual solar radiation level that each surface receives. Based on the obtained data, it is found that approximately 28% of roof surfaces and 5% of facades meet these cost-effective thresholds for PV integration. Further analysis indicates that the balcony self-shading can be considered negligible in the high-density urban context analyzed. The results are beneficial for urban energy management, considering energy savings and investment approaches, and the possibility to transform existing buildings into zero-carbon buildings powered by renewables. Full article

Impellers are critical components in industrial applications, requiring smooth surfaces and precise dimensions. Traditional investment casting methods are often time-consuming and costly. Fused filament fabrication (FFF), an additive manufacturing (AM) technology, offers a faster, more cost-effective alternative. FFF produces 3D-printed sacrificial patterns directly from a CAD file, making it ideal for low-volume and complex patterns. Unlike wax patterns, which can shrink or distort, 3D-printed patterns offer precise tolerances and allow for thin-walled geometries. FFF also eliminates the need for tooling, reducing capital investment. However, achieving the desired surface finish and accuracy remains a challenge. In this study, a semi-open, single-shrouded centrifugal pump impeller was fabricated using FFF with acrylonitrile butadiene styrene (ABS). A Taguchi L9 (3³) design of experiments was employed to investigate the influence of layer thickness (0.08–0.24 mm), extrusion temperature (260–280 °C), and infill density (30–70%) on dimensional accuracy and surface roughness. Dimensional deviations were evaluated for critical features, including outer diameter (OD), inner diameter (ID), blade thickness (BT), shroud thickness (ST), and blade height (BH). Results show that small and thin features (BT, ST, BH) exhibited deviations with standard deviations below 0.08 mm, whereas OD was the most affected feature with a maximum standard deviation of 0.362 mm due to dominant shrinkage effects. The optimal parameter combination for minimum dimensional deviation was identified as 0.08 mm layer thickness, 280 °C extrusion temperature, and 70% infill density. Surface roughness analysis revealed that layer thickness was the most significant factor, with Ra values ranging from 4 to 7 µm, which falls within acceptable limits for investment casting. Surfaces parallel to the XY plane demonstrated superior surface quality compared with XZ/YZ planes, highlighting the feasibility of FFF-printed ABS patterns for investment casting of complex impellers. Full article

The addition of Cu or La plays an important role in microstructure and property manipulation of 4xxx series Al-Si alloys. However, the effects of Cu-La hybrid modification on the microstructure and properties of Al-5Si alloys and welding performance remain unclear. In this paper, the influence of Cu-La addition on the strength and elongation of one commercial Al-5Si alloy and the welding joint characterization are investigated. The results show that the addition of Cu-La can refine α-(Al) and Fe-rich phase and improve the fluidity. Meanwhile, the elongation can be improved by Cu-La microalloying, which is beneficial for the manufacturing filler wire. The uniform distribution of Cu in the alloy but not segregation at grain boundaries due to La addition is the key factor to adjust the mechanical properties. Moreover, the filler materials were used to conduct metal inert gas welding on 6061 alloy. It reveals that, with Cu-La addition, the weld pool width increases and porosity defect decreases significantly. This is ascribed to Cu-La co-addition enhancing wettability and fluidity, which improves the welding performance. Our results offer an effective strategy for manufacturing and optimizing welding performance of welding wires. Full article

Foreign direct investment (FDI) has often been cast as a straightforward engine of growth, yet its record across Central and Eastern Europe tells a more tangled story where outcomes hinge on the interplay of education, governance, and the timing of external shocks. This study embeds fixed effects panel econometrics within a systems framework, treating FDI as a subsystem of socio-economic dynamics. Using a long-run panel of eleven economies from 2000 to 2023, the analysis models path dependence and regime shifts through interaction terms and period-specific dummies set against a systems-thinking backdrop. The analysis shows that for the average CEE economy, FDI’s contribution has waxed and waned: it dragged on growth during the early transition years (2000–2007), settled into a neutral role after the global financial crisis, and proved unpredictable in the pandemic era. Romania stands out, however, with a marked “FDI premium” quantified as approximately 0.7 pp of growth per pp of FDI that seems to stem from reinforcing loops between rising tertiary enrolment and productivity spillovers. Mapping these feedbacks brings to light virtuous circles where human capital and resilience make or break the benefits of foreign capital. The policy message is plain: nurture the positive loops through investment in skills and firm linkages, keep institutions nimble enough to adapt, and watch for early warning signs of systemic strain. Full article

Investment casting of aluminum alloys is widely used in the aeronautical and automotive sectors for manufacturing complex components. However, conventional alloys lack sufficient mechanical strength and high-temperature resistance, prompting the need for enhanced materials. This study investigated the addition of submicron TiC particles, introduced via stir casting process, to an AlSi7Mg0.3 alloy for investment casting. Chemical analysis confirmed the incorporation of up to 0.1 wt.% TiC, but no significant improvement in tensile properties was observed. High Resolution Scanning Electron Microscopy (HRSEM) and Transmission Electron Microscopy (TEM) revealed a complex microstructure with few TiC particles and needle-shaped intermetallic phases containing titanium, iron, silicon, or aluminum. The high mold temperature (700 °C) and slow solidification rate likely caused partial TiC dissolution and intermetallic precipitation, which may have offset strengthening mechanisms like the Hall–Petch effect. Notably, the partial dissolution of TiC particles in investment casting has not been previously reported in similar alloys. These findings highlight the challenges of using particle-reinforced alloys in this process and emphasize the need for further research into process–microstructure relationships. Full article

Alpha-case formation, originating from interfacial reactions between molten titanium and oxide molds, remains a critical issue limiting the surface integrity and mechanical performance of titanium castings. In this study, the effect of aluminum content (0–52 at%) on alpha-case formation was systematically investigated using plasma arc melting and drop casting with alumina-based molds. The reaction kinetics between titanium melts and alumina molds were evaluated through cooling rate measurements and thermodynamic modeling. Microstructural and compositional analyses using optical microscopy, hardness testing, and electron probe microanalysis revealed that increasing aluminum content effectively suppressed alpha-case development. No distinct reaction layer was observed when the aluminum concentration exceeded 30 at%. The alpha-case consisted primarily of Ti₃Al, TiO₂, and Ti₅Si₃ phases, indicating that the molten titanium reacted with both alumina and silica constituents of the mold. Oxygen was identified as the dominant element controlling the reaction depth, consistent with its diffusion behavior across titanium phases. Calculated alpha-case thicknesses showed excellent agreement with experimental measurements, confirming that the reduction in alpha-case depth with increasing aluminum content results from decreased oxygen diffusivity, shorter reaction time, and lower interfacial temperature. These findings establish aluminum addition as a key strategy for minimizing interfacial reactions during titanium investment casting, thereby improving dimensional accuracy and surface quality in high-temperature components. Full article

Cracks were found at the gate of the 430Cb ferritic stainless steel exhaust system jet base produced by investment casting. In this paper, the cracks of failed stainless steel castings were comprehensively analyzed by means of macroscopic inspection, laser confocal microscopy, field emission scanning electron microscopy, electron backscatter diffraction, X-ray diffractometer, ProCAST (version 2018, ESI Group, Paris, France) simulation and Thermo-Calc (TCFE10 database, 2022a, Thermo-Calc Software AB, Solna, Sweden) thermodynamic calculation. It can be concluded that all the cracks originate from the gate on the surface of the casting, and the fracture surface shows brittle intergranular characteristics, which can be determined as cold cracks. The formation of cold cracks can be attributed to the fact that the local stress generated during cooling after the casting solidifies exceeds the strength limit of the material itself. As the gate is the final solidification zone, shrinkage is limited and stress is concentrated. The grains are coarse, and the microstructure defects such as shrinkage porosity, pores and needle-like NbC further weaken the plasticity of the grain boundaries, promoting the crack to propagate along the direction of the maximum principal stress. The uneven cooling rate and shell constraint during the investment casting process make it difficult to release stress, and the existence of microstructure defects are the fundamental causes of crack generation. Full article

As manufacturing industries pursue net-zero emission (NZE) goals, hybrid manufacturing processes that integrate additive manufacturing (AM) with traditional casting techniques are gaining traction for their sustainability potential across the globe. Therefore, this work presents a “gate-to-gate” life cycle assessment (LCA) comparing AM-assisted sand casting (AM-SC) and AM-assisted investment casting (AM-IC), for Al-Si5-Cu3 alloy as a case material, under various energy scenarios including a conventional grid mix and renewable sources (wind, solar, hydro, and biomass). This study compares multiple environmental impact categories based on the CML 2001 methodology. The outcomes show that AM-SC consistently outperforms AM-IC in most impact categories. Under the grid mix scenario, AM-SC achieves 31.57% lower GWP, 19.28% lower AP, and 21.15% lower EP compared to AM-IC. AM-SC exhibits a 90.5% reduction in “Terrestrial Ecotoxicity Potential” and 75.73% in “Marine Ecotoxicity Potential”. Wind energy delivers the most significant emission reduction across both processes, reducing GWP by up to 98.3%, while AM-IC performs slightly better in HTP. These outcomes of the study offer site-specific empirical insights that support strategic decision-making for process selection and energy optimisation in casting. By quantifying environmental trade-offs aligned with India’s current energy mix and future renewable targets, the study provides a practical benchmark for tracking incremental gains toward the NZE goal. This work followed international standards (ISO 14040 and 14044), and the data were validated with both foundry records and field measurements; this study ensures reliable methods. The findings provide practical applications for making sustainable choices in the manufacturing process and show that the AM-assisted conventional manufacturing process is a promising route toward net-zero goals. Full article

Since mechanical processing can introduce stress in the sample, electrochemical dissolution has been utilized to attain shape accuracy in certain materials. However, this technique is rarely applied to laser-repaired Ni-based single-crystal superalloys. In this work, the transpassive dissolution behaviors of an additive manufacturing-repaired Ni-based single crystal superalloy in a 10% NaNO₃ solution were investigated by comparison with the substrate. A significant disparity in dissolution rates was found between the dendritic and interdendritic regions of the substrate, resulting in a rough surface. Conversely, the dissolution of the dendritic and interdendritic regions in the cladding structure occurred nearly simultaneously, leading to a high-quality, smooth surface. This behavior was attributed to the differences in phase dissolution preferences between the substrate and the cladding structure. It indicates that electrochemical dissolution is a promising method for achieving shape accuracy in laser-clad Ni-based single-crystal superalloys. Full article

Throughout history, cultural heritage has accumulated, and is often embodied in monuments, structures, and notable figures. Cultural heritage preservation and management also include digitalization, allowing tangible monuments to be managed as digital inventory with “digital twins”. This provides innovative ways to experience and interact with the real world, in particular by using modern mobile devices. The digitalization of monuments opens new ways to produce decorative items based on the shape of the monuments. Usually, decorative items are produced by craft businesses, family-run for generations, with specialized skills in metal and stone processing. We developed and tested a methodological proposal for frugal innovation: how to produce decorative items with minimal costs based on digital twins, which are particularly in demand in tourism-driven countries like Croatia. A micro-business with three employees, specializing in “metal art,” aims to innovate and expand by producing small-scale replicas of cultural heritage objects, such as busts, statues, monuments, or profiles. A method has been developed to create replicas in the desired material and at a desired scale, faithfully reproducing the original—whether based on a physical object, 3D model, or photograph. The results demonstrate that this sustainable frugal innovation can be successfully implemented using affordable tools and licenses. Full article

To address the sustainability challenges faced by the machinery manufacturing industry, this study establishes an emergy-based evaluation framework that integrates four dimensions—economic, social, ecological, and sustainability—to comprehensively assess the sustainability of mechanical manufacturing systems. An empirical study was conducted on the balance shaft housing manufacturing system of AH Axle Co., Ltd. Results reveal that the system exhibits a relatively low net emergy yield ratio (NEYR), with an emergy investment ratio (EIR) of 2.27 and an improved emergy sustainable index (IESI) of 0.44, indicating poor social benefits and weak long-term sustainability. However, through the optimization of finishing and casting processes, the emergy waste rate (EWR) decreased from 12.96% to 9.86%, substantially enhancing overall sustainability. This study not only provides a novel perspective and practical tool for sustainability assessment in mechanical manufacturing systems but also offers significant theoretical and practical implications for promoting green transformation and sustainable development across the industry. Full article

Two types of spherical mold samples—designated PW1 (reference) and PW2 (modified) were prepared using the dip-and-sprinkle method. Both samples consisted of seven layers, but PW2 was differentiated by the incorporation of 5 wt.% ground walnut shell chips into the fifth layer of its structure. The aim of this modification was to assess the feasibility of employing biodegradable organic additives to generate controlled porosity after thermal decomposition, thereby enhancing gas transport through the mold structure. The gas permeability of the samples was determined across a broad temperature range from 25 to 950 °C using a dedicated, custom-built test rig developed for elevated-temperature permeability assessments. The results revealed that the inclusion of walnut shell chips significantly increased the gas permeability of the molds by approximately 42% at ambient temperature and 36% at 950 °C, attributable to the formation of stochastically distributed macro-voids upon burnout of the organic additive. The study demonstrates that selective layer modification using natural waste materials can be a viable method for tailoring functional properties of ceramic molds, offering a cost-effective, sustainable, and easily scalable alternative to conventional pore-forming strategies. Full article

This study aimed to optimize the grain structure of complex thin-walled nickel-based superalloy castings by investigating the influence of key casting parameters using both cellular automaton–finite element (CAFE) simulations and experimental validation. The main problem addressed was the inhomogeneous grain morphology arising from complex mold geometries and uneven thermal conditions during investment casting. The solidification process was simulated using the ProCAST software, incorporating the CAFE method to model temperature fields and grain growth dynamics. The results revealed that the molten metal flow pattern during mold filling significantly affected the local temperature field and subsequent grain formation. Specifically, simultaneous bidirectional filling minimized thermal gradients and suppressed coarse columnar grain formation, promoting finer, more uniform equiaxed grains. Lowering the pouring temperature (to 1430 °C) in combination with reduced shell temperature (600–800 °C) enhanced nucleation and improved grain uniformity in thin-walled regions. Higher cooling rates also refined the grain structure by increasing undercooling and limiting grain growth. Experimental castings confirmed these simulation outcomes, demonstrating that the proposed optimization strategies can significantly improve grain homogeneity in critical structural areas. These findings provide a practical approach for controlling microstructure in large, intricate superalloy components through targeted process parameter tuning. Full article