Importance of Metal Casting - Assignment Example

MATERIAL Student’s Name Course Professor’s Name University City Date Material Question One Metal casting involves pouring a metal that has been heated into a liquid state into another which has a cavity of the desired shape. Metal smelting has been used in history for renovation of different objects. The process has effects on various properties of the material, especially the grain and the structure. Recycling of aluminum has continually increased all over the world. There has however been discovered that the foundry of metal is affected by the development of the new products. The metal design has also been altered with to the greatest extent while dealing with metal casting. There are a number of factors that lead to alteration of the shape and structure of the metal that is being cast. These include; the microstructure of the metal, the chemical make-up of the metal as well as heat treatment. Additionally, the metal surface deposition and the extrusion are drivers that lead to the alteration of the structure of the metal once it is metal casted[BCa03]. The microstructure of the metal is usually altered by the amount of heat that is subjected to the metal during the recycling process. The metal is usually stipulated so as to get the desired shape and also manipulated to serve the intended purpose. For example, in a case where a metal alloy for a vehicle is required, the aluminium quality is fostered in controlled conditions. The temperatures are controlled as well as the permeability of the sand involved in the casting of the aluminium metal. The product is used as a master part in hydraulic brakes. Furthermore, the process of solidification highly affects the material of the metal product of the whole process. Finally, the material of the metal is highly dependent on the temperature and the method that was employed in the cooling process. The properties of the metal that are manipulated during the metal casting are reflected in the shape and the appearance of the product. The durability of the product is also an indicator of the metal product that is produced by the selective mix of conditions to give the desired product. The mechanical strength is also a determinant of the molding of a certain product. The hardness of the product is determined by the amount of air that is trapped in the mold of the sand during the casting of the metal. Metal casting is meant to be economical and therefore, the smelters should apply pressure so as to make light but strong products. The ductility of the metal alloy that is produced is also a determining factor of the pressure that was involved in the reformation of the material. This changes the appearance of the metal and more importantly the surface of the product is totally different from the original process. The reformation of aluminium for reusing is advantageous as it leads to the reduction of the amount of energy that is required to make the original material by up to 5%. The strength of a material that has been cast depends on the controlled conditions at which the material is made[KOb12]. Question Two The castings that are often produced by the use of sand mold are found to have significant microstructure. The structure is dependent on the distribution of the sand along the alloy and the conditions in which the alloy is made. For instance, the level of oxygen and pressure that is employed in the casting of engine blocks determines the property of the product. The surface of the alloy is especially determined by the amount of metal that is used as well as the chemical composition. Initially, the cast alloys of iron have been used to make the engine blocks through reforming the iron metal trough in the smelting industries. Due to advancement in technology, engines have also changed continually. The weight of the iron engine blocks was heavy and unsustainable, according to the new models of the motor vehicles. The engines have been made in a more sophisticated design and require lighter metals. This calls for the creativity of the metal reforming industries such as smelters and the engineers to come up with a lighter engine block that is sufficient and efficient for the engines. Aluminium metal was used to substitute the iron alloy as it is lighter than iron. The metal alloys that were made of aluminium have been efficiently used due to the strength, the ductility and the microstructure of the metal. Iron and aluminium were used interchangeably to facilitate the engines. The technology is dynamic and the engineers need to be swift to keep the pace. The motor manufacturing industries continued to produce sophisticated models of cars with engines that could not work in a sustainable manner with the aluminum and iron alloys. Magnesium allows was hence introduced to facilitate the performance of the engines in the vehicles. Gray cast iron continued to be disregarded, especially with the invention of a graphite cast, which is as strong as magnesium and has a lower weight than both aluminium and iron alloys used in making engine blocks[Hie05]. Prosthetic hip replacement is an advancement in medical engineering that embraces the use of the new technology to fix the fractures. Materials are always in the environment and are almost unavoidable as they revolve around humanity. Several materials can be chosen by the doctor who is a specialist in bones so as to work as the normal hip bone. The prosthesis is comprised of a metal ball which is usually attached to a rod which is also metallic. The major alloys that are used to make the prosthesis includes; the chrome, titanium and cobalt as well as the stainless steel. Various alloys have been failing when used as prosthetic. The Ti-alloy is, however, continually improved as it is known for its mechanical strength and most importantly the resistance to corrosion hence health friendly. The Ti-alloy has no adverse in the body regarding the cytotoxicity and bio processes. The material is therefore continually used in medical integrated engineering to save the lives of the people. Sand casting which is used to make the Ti-alloys is a sustainable product in the metal casting and strengthening of material[Yvo16]. Question Three Aluminium foil has the highest percentage of a maximum of 99%. The foil is an alloy that has been used for many purposes, including use in thermos flask as it is made from different size of the width and its strength is used in various utilities. The foil is used in the construction industry, in electric transformers and a wide range of electronics such as radio and televisions. The availability of the raw material used for manufacturing of the foil makes it popularly used in the world. The qualities of the aluminium foil include, grease and oil proof, durability cheap and affordable price. When used in the electronics, it prevents damage that through shielding the electricity and non-magnetic. The foil can also be used in lunch box due to its ability to block oxygen, light and its availability globally at a cheap price. The raw material used for production of aluminium foil is aluminium[Jav16]. The first step involved in the production of aluminum foil is refining also known as the Bayer process. There are a number of processes that take place in the Bayer process, including the digestion of aluminium, clarification of the raw material to remove the impurities, precipitation and finally, the calcinations process[Mut16]. During the first process of digestion, the aluminium (bauxite) is broken down and ground and is passed over sodium hydroxide after which, the mixture is pressurized. The ore is broken down to a sodium aluminate solution and the contaminants settle at the bottom. Clarification is then done and then the mixture is precipitated. Additionally, in the Bayer process, aluminium is introduced into high temperature to dehydrate the mixture, and then a white powder is collected as the residue[Mut16]. The fifth step of the aluminium foil production is smelting where pure aluminium is collected after being reduced through the use of electrolyte. The sixth step involves using an electric current to dissolve alumina using electrolytes. The pure aluminium is received at the bottom of the chamber. The seventh step is whereby; the collected aluminium is put into crucible dishes and is transferred into the furnace where the heat is set so as to make the aluminium foils. There eighth step is rolling off the aluminum foil. The stock of the foil is made first, and then the width is reduced to make the foils. Rolling mills and work rolls are used to make the right size of the aluminium foil. The lubricant is added to the foil to make it roll easily on the work roll. The process is maintained at controlled heat. The ninth step is shaping of the razors as well as trimming the edges so as to have a controlled width[Yuc13]. Finally, the foils are coated with a desired material according to the purpose that it serves. For example, the material used for coating the aluminium foil may be decorative. The foil can also be laminated. After the final process, the foil is packaged and delivered to the customers. The quality should be highly controlled through use of optimum temperature and controlled pressure[Yuc13]. . Bibliographies BCa03: , (Cantor, 2003, p. 9), KOb12: , (Obieka, 2012, p. 3663), Hie05: , (Nguyen, 2005, p. 3), Yvo16: , (Kirmanidou, 2016), Jav16: , (Butt, 2016), Mut16: , (Manikandan, 2016, p. 32405), Mut16: , (Manikandan, 2016, p. 32413), Yuc13: , (Birol, 2013, p. 82), Yuc13: , (Birol, 2013, p. 89), Read More

The mechanical strength is also a determinant of the molding of a certain product. The hardness of the product is determined by the amount of air that is trapped in the mold of the sand during the casting of the metal. Metal casting is meant to be economical and therefore, the smelters should apply pressure so as to make light but strong products. The ductility of the metal alloy that is produced is also a determining factor of the pressure that was involved in the reformation of the material.

This changes the appearance of the metal and more importantly the surface of the product is totally different from the original process. The reformation of aluminium for reusing is advantageous as it leads to the reduction of the amount of energy that is required to make the original material by up to 5%. The strength of a material that has been cast depends on the controlled conditions at which the material is made[KOb12]. Question Two The castings that are often produced by the use of sand mold are found to have significant microstructure.

The structure is dependent on the distribution of the sand along the alloy and the conditions in which the alloy is made. For instance, the level of oxygen and pressure that is employed in the casting of engine blocks determines the property of the product. The surface of the alloy is especially determined by the amount of metal that is used as well as the chemical composition. Initially, the cast alloys of iron have been used to make the engine blocks through reforming the iron metal trough in the smelting industries.

Due to advancement in technology, engines have also changed continually. The weight of the iron engine blocks was heavy and unsustainable, according to the new models of the motor vehicles. The engines have been made in a more sophisticated design and require lighter metals. This calls for the creativity of the metal reforming industries such as smelters and the engineers to come up with a lighter engine block that is sufficient and efficient for the engines. Aluminium metal was used to substitute the iron alloy as it is lighter than iron.

The metal alloys that were made of aluminium have been efficiently used due to the strength, the ductility and the microstructure of the metal. Iron and aluminium were used interchangeably to facilitate the engines. The technology is dynamic and the engineers need to be swift to keep the pace. The motor manufacturing industries continued to produce sophisticated models of cars with engines that could not work in a sustainable manner with the aluminum and iron alloys. Magnesium allows was hence introduced to facilitate the performance of the engines in the vehicles.

Gray cast iron continued to be disregarded, especially with the invention of a graphite cast, which is as strong as magnesium and has a lower weight than both aluminium and iron alloys used in making engine blocks[Hie05]. Prosthetic hip replacement is an advancement in medical engineering that embraces the use of the new technology to fix the fractures. Materials are always in the environment and are almost unavoidable as they revolve around humanity. Several materials can be chosen by the doctor who is a specialist in bones so as to work as the normal hip bone.

The prosthesis is comprised of a metal ball which is usually attached to a rod which is also metallic. The major alloys that are used to make the prosthesis includes; the chrome, titanium and cobalt as well as the stainless steel. Various alloys have been failing when used as prosthetic. The Ti-alloy is, however, continually improved as it is known for its mechanical strength and most importantly the resistance to corrosion hence health friendly. The Ti-alloy has no adverse in the body regarding the cytotoxicity and bio processes.

The material is therefore continually used in medical integrated engineering to save the lives of the people. Sand casting which is used to make the Ti-alloys is a sustainable product in the metal casting and strengthening of material[Yvo16].

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