Twin roll casting is a relatively short single step casting process which is primarily used for thin, mm gauge aluminum sheets. In comparison to the more traditional direct chill casting process TRC provides and number of attractive economic and quality advantages. Continue reading
Grain refinement using inoculents such as boron increase the nucleation sites within the material and there for lead to improvements in the overall durability of the material.
As well as reducing quality issues such as hot tearing, boron also provides enhancements to some key properties such as electrical and heat conductivity. Continue reading
Vanadium forged steels have found their place in industry sectors such as automotive to help combat some specific problems related to the quenching process of medium carbon steels.
Alloying with vanadium has meant that advantageous properties such as tensile strength and yield stress can be achieved through air cooling of the material. Continue reading
Compacted graphite iron (CGI) along with lamellar graphite iron and spheroidal graphite iron define the three main classes of cast iron according to morphology.
CGI displays very useful properties for a range of engineering applications with the tensile strength and elastic modulus being considerably higher than grey cast irons (75% and 35% respectively). Continue reading
Hot tearing occurs primarily in the casting mold and can be attributed to thermally induced tensile stresses which occur as the molten metal cools and begins to contract. There are a number of studies available which investigate the behavior and effects of hot tearing but the prevention of this phenomenon is not so simple. Continue reading
Grain refinement is an established technique which basically reduces the grain size of the material with the direct intention to improve its finished properties or characteristics.
The addition of boron specifically in aluminum castings, which are well known for their poor mechanical properties, can improve these characteristics to expand the potential use of the castings to a multitude of other applications. Continue reading
In typical EAF systems around 45% of input energy is lost through slag or off gas, the latter representing 70% of the complete loss of input energy. The expert furnace system optimization process attempts to tackle this issue by allowing a real time assessment of the energy lost through off gas and to allow plants to react quickly and therefore keep this loss to a minimum.
Sheet metal forming is one of the most significant manufacturing processes in industry today and is of particular importance in the automotive industry to drive advances in material technology and weight saving. There are numerous forms of SMF including bending, stretch forming, and deep drawing. Continue reading
Aluminum strip casting is a key contributor to weight saving possibilities, particularly in the automotive industry and although strip casting has been established for over 50 years, it continues to increase in popularity. Casting speeds can be limited by several factors including the type of alloy being cast and the desired sheet thickness required. Continue reading
The Continuous Rheoconversion Process (CRP) is designed to be flexible allowing both thixocasting and rheocasting to be achieved by mixing two melts together at near liquidus temperatures to achieve smaller grain sizes and more globular structures. Key advantages of the CRP include continuous conversion of liquid to slurry, can be used with different alloys, benefits in simplified re-cycling. Continue reading