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Energy Saving Melting and Revert Reduction Technology (Energy-SMARRT): Surface/Near Surface Indication - Characterization of Surface Anomalies from Magnetic Particle and Liquid Penetrant Indications

Description: The systematic study and characterization of surface indications has never been conducted. Producers and users of castings do not have any data on which they can reliably communicate the nature of these indications or their effect on the performance of parts. Clearly, the ultimate intent of any work in this area is to eliminate indications that do in fact degrade properties. However, it may be impractical physically and/or financially to eliminate all surface imperfections. This project focused on the ones that actually degrade properties. The initial work was to identify those that degrade properties. Accurate numerical simulations of casting service performance allow designers to use the geometric flexibility of castings and the superior properties of steel to produce lighter weight and more energy efficient components for transportation systems (cars and trucks), construction, and mining. Accurate simulations increase the net melting energy efficiency by improving casting yield and reducing rework and scrap. Conservatively assuming a 10% improvement in yield, approximately 1.33 x 1012 BTU/year can be saved with this technology. In addition, CO2 emissions will be reduced by approximately 117,050 tons per year.
Date: February 20, 2014
Creator: Griffin, John
Partner: UNT Libraries Government Documents Department

Energy-Saving Melting and Revert Reduction (E-SMARRT): Energy Efficiency Instrumentation

Description: As with any manufacturing operation, the metalcasting processes have several sources of variation. Additionally, the metalcasting industry routinely produces a wide variety of complex shaped components, which often exacerbates the problem of determining the source of variation. The goals of this project were to develop better tools and strategies to collect and manage process and product information. Based on industry feedback, five areas were selected based on the amount of variation caused by this source or the potential for improvement in terms of energy, emissions and competitiveness. These five areas were: 1. Heat Treatment Control Strategies 2. Semi-Automated Grinding 3. Surface Mapping Software 4. Study of Impact of Repairs via Weld Gouges 5. Rapid Pattern Making Machine This project collectively looked at areas of the steel casting production process which could help reduce the rework, scrap and energy consumption required. Through these efforts, casting producers are better equipped to control their processes and specify processes that better meet their customers’ needs.
Date: December 31, 2013
Creator: Peters, Frank & Frank, Matthew
Partner: UNT Libraries Government Documents Department