metalcasting technology - worcester polytechnic instituteearly melting and casting in mesopotamia,...
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Metals Conservation
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MetalcastingMetalcasting TechnologyTechnology
A brief historical perspectiveA brief historical perspective
Ralph E. NapolitanoRalph E. Napolitano
Department of Materials Science & EngineeringDepartment of Materials Science & EngineeringIowa State University Iowa State University
Ames, IowaAmes, Iowa
Metals Conservation Summer InstituteMetals Conservation Summer InstituteJune 1, 2005June 1, 2005
IOWA STATE UNIVERSITYMaterials Science & Engineering
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Metalcasting
Casting is an important method for reliable and reproducible production of net-shape metallic components of very intricate geometry.
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Early melting and casting
In mesopotamia, the melting and casting of copper began some time around 4000 BC and was followed by the casting of bronze and the introduction of the lost-wax process. By virtue of the well crafted products that resulted, the methods developed here spread rapidly through both east and west. With the development of smelting technology, the world was ready for the explosion of metalcasting.
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Eastern masters of clay molding
Chinese bronze vesselShang dynasty1000-1100 BCFreer Gallery of ArtWashington, DC
With very little evidence of an “incubation time”, Chinese casting emerges from about 1600 BC, with techniques much different from those used in the west.
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Cast iron giants
A better understanding of furnace bellows and control of heat permitted eastern artisans to work with cast iron, and they produced numerous monumental castings.
One of four cast-iron warriors guarding the 'Depository of Ancient Spirits' (Gu shen ku) of the Zhongyue Temple in Dengfeng, Henan (A.D. 1064).
The 'Eastern Iron Pagoda' of the Guangxiao Temple in Guangzhou, Guangdong (A.D. 967).
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The emergence of metalcasting methods
While simple cast copper objects date back as early as 4000 BC, it wasn’t until the 1600th century AD when melting of metals became a widely applied practice.
Significant Milestones
- open groove molds (clay or stone)-lost-wax molding (3000 BC)-Bivalve mold (cope and drag)-bivalve cored mold- piece molding- integral cast-on methods (700 BC)- casting and joining- sand casting (1500 AD)
- Guns, money, bells, and the press
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Bivalve castings
Appearing, perhaps, early in Egyptian castings,
cope and drag methods permitted more complex shapes than open molds, but was still restricted by convexity requirements.
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Casting with cores
Positioning of cores is critical, and incorporation of chaplets logically leads to integral cast-on methods.
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Piece-molds
Chinese bronze chiaChou dynastyBoston MFA
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Piece-molds
Large relief integrated into pattern for mold impression.
Fine detail carved directly into the accessible mold.
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Replication
Chou dynastyFreer GalleryWashington DC
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Lost-wax castings
BronzeTell Judeideh, Syria2900 BCBoston MFA
BronzeBenin, Nigeria1500-1700 BCBrooklyn Museum
GoldColumbiaMuseo del Oro(Bogota Colombia)
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Lost-wax castings
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Lost-foam process
Alfred Duca1960
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An advanced application
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Jet engine turbine blades
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Investment casting of single crystal parts
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Perhaps the most sophisticated castings ever made
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A challenge of scale
Turbines for power generation
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Novel casting methods
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Laser melting and cladding
X--Y Positioning Stage
Laser and Powder Delivery Nozzle
X
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Laser Engineered Net Shaping (LENS™)
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Localized alloying
12 mm
0% Cu 20% Cu
40% Cu 60% Cu 80% Cu 100% Cu
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Simulations
Simulation of laser welding
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Laser clad microstructure
50 µm
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Gas atomization
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Levitation melting
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Free-jet melt-spinning
Melt
Cu wheel(30 cm dia.)Extracted
ribbon
Melt pool
Chamber with controlled atmosphere
CCD Camera
Quartz crucible
Spinningdirection
Orifice(0.8 mm)
Free-jetmelt stream
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10 µm
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10 µm
(a)
10 µm
(a)