A life cycle inventory of aluminium die casting

As part of an ongoing project, a life cycle inventory (LCI) of aluminium high pressure die casting (HPDC) has been collected. This has been conducted from the view of an individual product and also the entire process. The objective of the study was to analyse the process and suggest changes to reduce environmental impacts. One modem aluminium high pressure die casting plant located in Victoria, Australia was evaluated and modelled. Site specific data on energy and materials was gathered and the process was modelled using a typical automotive component. The paper also presents our experience and methodology used in this inventory data collection process from the real industry for LCA purposes. The inventory data collected itself reveals that the HPDC process is energy intensive and as such the major emissions were from the use of natural gas fired furnaces and from the brown coal derived electricity. It is also found the large environmental benefits of using secondary aluminium over primary aluminium in the HPDC process. A detailed LCA is being cal1ied out based on the inventory obtained.

Magnesium alloy applications in automotive structures

The energy absorbed by magnesium alloys (high-pressure die-cast (HPDC) AM20, AM50, AM60, and extruded AZ31) in a buckling test was significantly greater than the aluminum alloy 6061 T6 and particularly mild steel of a similar weight, but was less than that of the aluminum alloy and steel for the same thickness (Figure 6).26 This indicates that mass savings can be achieved by the substitution with magnesium alloys to achieve similar energy-absorbing characteristics.

Numerical investigation of ramp and constant pressurization system during tube crushing process

The requirement for the automotive industry at present and even more so in the future is to simultaneously develop materials, economic forming processes and techniques for weight reduction of the component. To fulfil this need steel manufacturers have developed Advanced High Strength Steels which have high strength and good formability. Due to high strength, material thickness can be reduced without compromising the function of the component. High pressure hydro forming is one process that can be used to produce complex components from these materials. However, reduction in material thickness of these steels does not result in a large decrease of internal fluid pressure and die closing force during tube hydro forming and hence the higher strengths of these steels will require higher pressures. Tube crushing is a process in which the component can be formed with low pressures. In this paper numerical comparison of ramp and constant pressurization system during tube crushing for a TRIP steel is studied. It is proposed that ramp pressure is the best option to obtain a part with accurate geometrical shape from tube crushing with less die closing force. The stress and thickness distribution of the part during tube crushing were critically analysed.

Modified life cycle inventory of aluminium die casting

Aluminium die casting is a process used to transform molten aluminium material into automotive gearbox housings, wheels and electronic components, among many other uses. It is used because it is a very efficient method of achieving near net shape with the required mechanical properties. Life Cycle Assessment (LCA) is a technique used to determine the environmental impacts of a product or process. The Life Cycle Inventory (LCI) is the initial phase of an LCA and describes which emissions will occur and which raw materials are used during the life of a product or during a process. This study has improved the LCI technique by adding in manufacturing and other costs to the ISO standardised methods. Although this is not new, the novel application and allocation methods have been developed independently. The improved technique has then been applied to Aluminium High Pressure Die Casting. In applying the improved LCI to this process, the cost in monetary terms and environmental emissions have been determined for a particular component manufactured by this process. A model has been developed in association with an industry partner so this technique can be repeatedly applied and used in the prediction of costs and emissions. This has been tested with two different products. Following this, specialised LCA software modelling of the aluminium high pressure die casting process was conducted. The variations in the process have shown that each particular component will have different costs and emissions and it is not possible to generalise the process by modelling only one component. This study has concentrated on one process within die casting but the techniques developed can be used across any variations in the die casting process.

Towards a more holistic approach to quality improvements in aluminium die casting

This work evaluates the feasibility of using a holistic approach, based on dynamical system theory,
to reduce porosity defects in high pressure aluminum die casting. Quality improvements, from a
dynamical system perspective mean the ability to move the die casting process out of its natural
equilibrium to a more beneficial state and the ability to maintain this new process state. This more beneficial state may be achieved in several ways. One way is to increase the amount of forcing to overcome natural process resistance. This forcing approach is represented by typical continuous intervention policy, with modifications in die/part design and/or process parameters. An alternative approach is to reduce the amount of natural process resistance, in particular the amount of process disturbance, allowing the process to move out of its natural equilibrium with much less forcing. This alternative uses the self-regulating ability of dynamical systems thus decreasing the amount of human intervention required. In this respect, the influence of vacuum on time on chattering at the first stage of the casting shot was identified as a good process candidate for testing using dynamical system theory. A significant reduction in porosity defects was achieved, which also set the process on a path of slow but consistent self-improvement.

Formability and forming of advanced steels

The thesis identified how advanced high strength steels perform compared to conventional steels in terms of weight reduction and crash performance for automotive bodies. The novel production method of low pressure tube hydroforming was applied to form these advanced steels to reduce the press tonnage and fluid pressure compared to the conventional high pressure process. In addition analytical models were developed to predict the force and pressure in the low pressure process.

Seasonal winds drive water temperature cycle and migration patterns of Southern Australian giant crab Pseudocarcinus gigas

The giant crab Pseudocarcinus gigas occurs along the continental shelf break of southern Australia. During the summer alongshore winds cause cooler water to upwell onto the shelf, and the crabs move from deeper water onto the shelf where there is more food. The combination of a preferred thermal niche and a depth-stratified food supply defines the favorable foraging environments that enhance the growth of P. gigas. Climate change is expected to cause a southerly shift of the austral subtropical high-pressure belt, and modelers have predicted more upwelling-favorable winds. The associated increase in the circulation of cooler water across the shelf is likely to provide P. gigas with an increased access to benthic food resources and their growth rate may increase in some regions.

Involvement of rootstocks and their hydraulic conductance in the drought resistance of grafted rubber trees

Improving drought resistance of rubber trees has become a pressing issue with the extension of rubber plantations and the prevalence of seasonal drought. Root system is vital to water and nutrients uptake of all plants, therefore, rootstocks could play decisive roles in drought resistance of grafted rubber trees on a specific scion clone. To investigate the responses of different clone rootstocks and their grafted trees to water stress and find applicable methods for selecting drought resistant rootstocks, seven related parameters and root hydraulic properties of both seeds originated and grafted saplings of PB86, PR107, RRIM600 and GT1 were measured to assess their drought resistance. It was shown that the rootstock drought resistance and root hydraulic conductance may improve the drought resistance of the grafted rubber trees. Among the four clone rootstocks, GT1, which demonstrated more resistant to drought and higher root hydraulic conductance, was comparatively resistant to drought both for the seed propagation seedlings and grafted saplings. In addition, studies on the grafted saplings with different root hydraulic conductance further validated the possibility of selecting drought resistant rootstocks on the basis of rootstock hydraulic conductance using a high-pressure flow meter.

Comparative studies of structural transition between AlN nanocrystals and nanowires

The structural transition of AIN nanocrystals and nanowires were investigated simultaneously under pressures up to 37.2 GPa by in situ angle dispersive high-pressure x-ray diffraction using synchrotron radiation source and a single diamond anvil cell. The size of hexagonal AIN nanocrystals and the diameter of nanowires are 45 nm on average. A pressure-induced wurtzite to rocksalt phase transition starts at 21.5 GPa and completes at 27.8 GPa for the nanocrystals and nanowires, respectively. The high-pressure behaviors of AlN nanocrystals the same as the AIN nanowires might arise from the similar size and diameter in nanocrystals and nanowires. Hexagonal AIN nanocrystals (45 nm) display an apparent volumetric contraction as compared to the AlN nanocrystals (10 nm) which might induce the difference of transition pressure.

Problems in seawater industrial desalination processes and potential sustainable solutions: a review

Seawater desalination has significantly developed towards membrane technology than phase change process during last decade. Seawater reverse osmosis (SWRO) in general is the most familiar process due to higher water recovery and lower energy consumption compared to other available desalination processes. Despite major advancements in SWRO technology, desalination industry is still facing significant amount of practical issues. Therefore, the potentials and problems faced by current SWRO industries and essential study areas are discussed in this review for the benefit of desalination industry. It is important to consider all the following five components in SWRO process i.e. (1) intake (2) pre-treatment (3) high pressure pumping (4) membrane separation (performance of membranes and brine disposal) and (5) product quality. Development of higher corrosion resistant piping materials or coating materials, valves, and pumps is believed to be in higher research demand. Furthermore, brine management, that includes brine disposal and resource recovery need further attention. Pre-treatment sludge management and reduced cleaning in place flush volume will reduce the capital costs associated with evaporation ponds and the maintenance costs associated with disposal and transportation reducing the unit cost of water. © 2013 Springer Science+Business Media Dordrecht.

Machining of titanium alloy (Ti-6Al-4V)-theory to application

This article correlates laboratory-based understanding in machining of titanium alloys with the industry based outputs and finds possible solutions to improve machining efficiency of titanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects of chip formation mechanism and practical issues faced by industries during titanium machining. This study also analyzed and linked the methods that effectively improve the machinability of titanium alloys. It is found that the deformation mechanism during machining of titanium alloys is complex and causes basic challenges, such as sawtooth chips, high temperature, high stress on cutting tool, high tool wear and undercut parts. These challenges are correlated and affected by each other. Sawtooth chips cause variation in cutting forces which results in high cyclic stress on cutting tools. On the other hand, low thermal conductivity of titanium alloy causes high temperature. These cause a favorable environment for high tool wear. Thus, improvements in machining titanium alloy depend mainly on overcoming the complexities associated with the inherent properties of this alloy. Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhanced machining, hybrid machining and, use of high conductive cutting tool and tool holders improve the machinability of titanium alloy.