Development and Characterization of High Strength SiC Rotors

1991 ◽  
Author(s):  
R. W. Ohnsorg ◽  
G. V. Srinivasan
Keyword(s):  
Injection Molding ◽  
Gas Turbine ◽  
Slip Casting ◽  
High Strength ◽  
Cold Isostatic Pressing ◽  
General Motors ◽  
Injection Molding Process ◽  
Molding Process ◽  
Turbine Engine ◽  
Technology Applications

Sintered α-SiC (Hexoloy® SA*) turbine engine components have been fabricated by Carborundum for the Advanced Gas Turbine (AGT) Program and, more recently, for the Advanced Turbine Technology Applications Project (ATTAP) using three primary forming procedures — injection molding, cold isostatic pressing (CIP) followed by green machining, and slip casting. The near net-shape fabrication of injection molded AGT-100 radial rotors for the Allison Gas Turbine Division (AGTD) of General Motors Corporation and, more recently, AGT-5 axial rotors, has been demonstrated. The current emphasis at Carborundum is to refine the injection molding process, bringing it to a performance and reproducibility level sufficient for production needs. The process changes leading to increases in component strength from approximately 380 MPa (55 ksi) to 595 MPa (86 ksi) will be discussed, as well as investigation of the failure mechanism and proposed process modifications to enhance properties even further.

Development of Injection-Molded Gas Turbine Components: Investigation Into Toughening GTE PY6 Si3N4

1991 ◽  
Author(s):  
D. Sordelet ◽  
J. Neil ◽  
M. Mahoney ◽  
A. Hecker
Keyword(s):  
Gas Turbine ◽  
Process Development ◽  
General Motors ◽  
Injection Molding Process ◽  
Foreign Object ◽  
Molding Process ◽  
Foreign Object Damage ◽  
Research Activities ◽  
Injection Molded ◽  
Microstructural Control

GTE Laboratories has been supporting Allison Gas Turbine Division of General Motors under the current ATTAP program since early 1988. Injection-molding process development and component fabrication has been the emphasis of this effort, but material property enhancement studies have also been an important complement. Attempts to increase the resistance to foreign object damage have been made through parallel investigations of microstructural control and SiC whisker reinforcement. The research activities aimed at improving fracture toughness of GTE PY6 Si3N4 are discussed.

scholarly journals Insights into the Processing of Recycled Carbon Fibers via Injection Molding Compounding

2020 ◽  
Vol 4 (4) ◽  
pp. 161
Author(s):  
Jochen Wellekötter ◽  
Julia Resch ◽  
Stephan Baz ◽  
Götz Theo Gresser ◽  
Christian Bonten
Keyword(s):  
Injection Molding ◽  
Matrix Material ◽  
High Strength ◽  
High Volume ◽  
Injection Molding Process ◽  
Fiber Reinforced ◽  
Feed System ◽  
Molding Process ◽  
Reinforced Plastics ◽  
Recycled Fibers

Although fiber-reinforced plastics combine high strength and stiffness with being lightweight, major difficulties arise with high volume production and the return of manufactured parts back into the cycle of materials at the end of their lifecycles. In a novel approach, structural parts were produced from recycled material while utilizing the so-called injection molding compounding process. Recycled fibers and recycled polyamide matrix material were used by blending carbon and matrix fibers into a sliver before processing. Injection molding was then used to produce long fiber-reinforced parts through a direct fiber feed system. Recycled matrix granules were incorporated into the injection molding process by means of an injection molding compounder to investigate their influences on the mechanical properties of the parts. The findings show that the recycled fibers and matrix perform well in standardized tests, although fiber length and fiber content vary significantly and remain below expectations.

A Study on Injection Molding Analysis and Structural Analysis with Truck Brake Pedal

2013 ◽  
Vol 535-536 ◽  
pp. 430-433
Author(s):  
Chul Woo Park ◽  
Seong Ho Seo
Keyword(s):  
Injection Molding ◽  
High Efficiency ◽  
Low Cost ◽  
Fem Simulation ◽  
High Strength ◽  
Injection Molding Process ◽  
Brake Pedal ◽  
Molding Process ◽  
Molding Condition ◽  
Plastic Parts

Injection molding process one of the most important methods to produce plastic parts with high efficiency and low cost. Today, Injection molded parts have been increased dramatically the demand for high strength and quality applications. In this study, truck brake pedal is made of Cast iron and plastic materials to replace the frame for the optimization process that minimizes the runner and the gate dimension will determine the size and shape. Runner and gate dimensions of change based on availability of the product. I will discuss the injection molding. This report investigates that the optimum injection molding condition for minimum of runner and gate position. The FEM Simulation CAE tool, MOLDFLOW, is used for the analysis of injection molding process.

Sintering metal injection molding parts of tungsten-based steel using microwave and conventional heating methods

2018 ◽  
Vol 233 (11) ◽  
pp. 2138-2146 ◽  
Author(s):  
Veeresh Nayak C ◽  
Ramesh MR ◽  
Vijay Desai ◽  
Sudip Kumar Samanta
Keyword(s):  
Injection Molding ◽  
Microwave Sintering ◽  
Weight Ratio ◽  
High Strength ◽  
Conventional Heating ◽  
Metal Injection Molding ◽  
Injection Molding Process ◽  
Molding Process ◽  
Homogeneous Microstructure ◽  
Microwave Assisted

In recent years, the near net shape metal injection molding process combines desirable features of plastic injection molding and powder metallurgy processes to gain high strength-to-weight ratio for manufacturing complex-shaped parts. The metal injection molding process consists of mixing, molding, debinding, and sintering. Microwave processing has attracted much attention in global research because of its unique features such as its ability to heat and sinter a wide variety of metals and its significant advantages in energy efficiency, processing speed, and compatibility. Also, it presents few environmental risks and can produce refined microstructures. The injected samples to be sintered are composed of fine tool steel metal powder and binders, stearic acid, paraffin wax, low-density polyethylene, and polyethylene glycol (600). In recent years, microwave-assisted post-treatment is considered a novel method for processing green parts. In this work, the green parts are subjected to high-intensity microwave fields which operate at a frequency of 2.45 GHz. Metal injection molding compacts were sintered using multi-mode microwave radiation. The sintering of a metal injection molding compact by microwaves has hardly been reported. The metal injection molding compact showed better results than those produced by sintering with conventional heating. This study evaluates the effect of conventional sintering and microwave sintering on mechanical properties. By optimizing the sintering process, increased sintered hardness, a more homogeneous microstructure, and greater shrinkage were obtained using microwave-assisted sintering.

Filling Behavior of Polymer Material into Sub-^|^mu;m Structure in Injection Molding Process

2013 ◽  
Vol 133 (4) ◽  
pp. 105-111
Author(s):  
Chisato Yoshimura ◽  
Hiroyuki Hosokawa ◽  
Koji Shimojima ◽  
Fumihiro Itoigawa
Keyword(s):  
Injection Molding ◽  
Polymer Material ◽  
Injection Molding Process ◽  
Molding Process

scholarly journals Study on External Gas-Assisted Mold Temperature Control with the Assistance of a Flow Focusing Device in the Injection Molding Process

Materials ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 965 ◽  
Author(s):  
Nguyen Truong Giang ◽  
Pham Son Minh ◽  
Tran Anh Son ◽  
Tran Minh The Uyen ◽  
Thanh-Hai Nguyen ◽  
...  
Keyword(s):  
Injection Molding ◽  
Temperature Control ◽  
Mold Temperature ◽  
Injection Molding Process ◽  
Melt Flow ◽  
Flow Focusing ◽  
Molding Process ◽  
Heating Efficiency ◽  
Flow Length ◽  
Insert Plate

In the injection molding field, the flow of plastic material is one of the most important issues, especially regarding the ability of melted plastic to fill the thin walls of products. To improve the melt flow length, a high mold temperature was applied with pre-heating of the cavity surface. In this paper, we present our research on the injection molding process with pre-heating by external gas-assisted mold temperature control. After this, we observed an improvement in the melt flow length into thin-walled products due to the high mold temperature during the filling step. In addition, to develop the heating efficiency, a flow focusing device (FFD) was applied and verified. The simulations and experiments were carried out within an air temperature of 400 °C and heating time of 20 s to investigate a flow focusing device to assist with external gas-assisted mold temperature control (Ex-GMTC), with the application of various FFD types for the temperature distribution of the insert plate. The heating process was applied for a simple insert model with dimensions of 50 mm × 50 mm × 2 mm, in order to verify the influence of the FFD geometry on the heating result. After that, Ex-GMTC with the assistance of FFD was carried out for a mold-reading process, and the FFD influence was estimated by the mold heating result and the improvement of the melt flow length using acrylonitrile butadiene styrene (ABS). The results show that the air sprue gap (h) significantly affects the temperature of the insert and an air sprue gap of 3 mm gives the best heating rate, with the highest temperature being 321.2 °C. Likewise, the actual results show that the height of the flow focusing device (V) also influences the temperature of the insert plate and that a 5 mm high FFD gives the best results with a maximum temperature of 332.3 °C. Moreover, the heating efficiency when using FFD is always higher than without FFD. After examining the effect of FFD, its application was considered, in order to improve the melt flow length in injection molding, which increased from 38.6 to 170 mm, while the balance of the melt filling was also clearly improved.

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