APPENDIX D. GLOSSARY

AAP St. Marys Corp.

A U.S. operation of Hitachi Metals that produces wheels, located in Wisconsin.

ADCAST

A new process for casting titanium alloys developed at Tohoku University.

Aludelta^TM

Thermal analysis equipment sold by MPT products; used to monitor the level of grain refinement.

APE pins

Corepins that extend into the casting during solidification: they help to eliminate solidification shrinkage.

ANAPROD

Software program developed by CTIF to analyze the downtime causes in die casting machines. It is a Windows-based system and allows corrective measure, predictive maintenance planning and provides the statistics for each machine, each part, or die, and each worker.

ANGLE

Software developed by CTIF to calculate gating of die cast dies.

AOD

A steel refining treatment used to control the carbon content of the steel.

austempering

A heat treatment given ferrous alloys, such as steel and ductile iron, which refines their structure and imparts excellent mechanical properties. It permits ductile iron castings to be made with mechanical properties comparable to that of steel.

CADIC convert mold

A process that converts resin-bonded cores to silicate-bonded cores suitable for use in preheated molds. In the convert mold process, conventional resin-bonded molds and cores are immersed in a sodium silicate solution, which is allowed to fully penetrate the sand body. Then the mold is fired at an elevated temperature, burning out the resin and setting the silicate bond. The core or mold can be poured immediately, at elevated temperatures. This allows the pouring of ferrous alloys in thin sections or under conditions where the cooling rate can be slowed to improve casting characteristics.

captive producer

A production operation for which the product is used within the company rather than for outside sales.

cermets

Ceramic/metal materials.

chill surface

A mold or mold surface having a very high heat transfer capability, such as a water-cooled metal plate.

cold isostatic pressing (CIP)

₃

₄

CLA and CLV

Counter gravity mold filling processes in which the metal is introduced into the sand mold from a bath beneath the mold, instead of being poured into the mold from above. The processes significantly reduce oxide inclusion formation, decrease finishing costs, and decrease the amount of gates and sprues that must be remelted. The A designates air melt, and the V designates vacuum melt.

Clearpor

A lost foam pattern material developed by Mitsubishi Yuka Badische, a Japanese joint venture of Mitsubishi Chemical of Japan and Badische of Germany and used extensively by Morikawa.

CMM machines

Coordinate measurement machines.

DIADEM

An expert system developed by CTIF for the diagnosis of defects.

The Dream Process

A name which Morikawa gives to a variation on the lost foam process, in which vapors from the decomposing foam are burned off above the mold. This serves the dual purpose of combusting the vapors, and it also draws a vacuum on the mold, increasing its integrity during pouring.

Eutectic Al-Si

The aluminum-rich alloy of silicon in aluminum which solidifies in the eutectic structure (about 11.6% Si). The eutectic structure is a unique metallurgical structure in which two phases are intimately intermingled.

+fcc Fe structure

Face-centered cubic crystal structural forms of iron.

FDM

Finite difference model, a numerical method of determining numerical answers to problems defined by differential equations.

Georg Fischer treatment

A method of adding pure magnesium to molten iron in a reaction chamber to produce nodular iron.

H-Alloy

A trade name for the composite casting of two different alloys.

HIBASE

A trade name for cast product to support buildings.

HISPLIT

A trade name for a cast product to join beams in the construction of buildings.

HIPAC-11

A casting technique developed by Hitachi Metals that uses high pressure to avoid creating fins at parting lines.

HMRAC

A casting technique developed by Hitachi Metals that uses pressure below atmosphere to enhance casting thin sections of both steel and iron. The reduced pressure (vacuum) is applied during the gravity pouring process.

hot isostatic pressing (HIP)

Process using high hydrostatic pressure and high temperature to compress fine particles into coherent parts (used by Kubota, for example, to produce skid buttons from a chromium matrix alloy); also used to densify castings.

Hypereutectic Al-Si

An aluminum-rich alloy of silicon in aluminum which has a silicon content higher than 11.6%.

A silicon nitride ceramic developed by Kubota Corp. used to make transfer ladles, transfer tubes, riser stalks, heater element tubes, thermocouple protection tubes, and nozzles.

LAIS

A test used to monitor inclusions in the melt; based on a metallographic technique.

LIMCA

A test used to monitor inclusions in the melt; based on a coulter counter technique.

Magmasoft^TM

A German solidification simulation model which predicts mold filling and solidification patterns for casting.

magnetostriction

The dependence of the state of strain (dimensions) of a ferromagnetic sample on the direction and extent of its magnetization.

A composite material developed by Kubota Corp. consisting of a titanium matrix containing ceramic particulates distributed throughout the matrix.

MHD

Magnetohydrodynamics, a process which uses magnets to affect the flow of liquids, particularly water and metal.

Misch metal

An alloy consisting of a crude mixture of cerium, lanathanum, and other rare-earth metals obtained by electrolysis of the mixed chlorides of the metals dissolved in fused sodium chloride: used in making aluminum alloys, in some steels and irons, and in coating the cathodes of glow-type voltage regulator tubes.

NSHR-F steel

A stainless steel alloy for auto exhaust systems.

PASOP

Reaction process to remove air used by Ahresty Corp.

PODFA

A test used to monitor inclusions in the melt; based on a metallographic technique.

Qualiflash

An apparatus designed by CTIF to test the inclusion quantity in an aluminum bath.

RIC

Sand cores with a special resin coating that prevents liquid metal from impregnating into the core.

RX 1000

Ryobi's name for its metal matrix composite materials used in die casting.

SCAST

A computer-aided engineering software program developed by Hitachi Metals that determines the solidification time and direction in casting.

SIMULOR

A solidification simulation model that predicts mold filling and solidification patterns for castings - developed by Pechiney.

soft contact solidification

A continuous sheet casting process whereby the solidifying metal barely makes contact with the surfaces of the casting nozzle, thereby yielding an as-cast surface of sufficient quality to eliminate scarfing prior to rolling. The use of magnetic fields to constrain molten metal permits solidification to occur with no physical mold/metal contact.

source code

The term given to the computer code in which a program is written, including the original instruction commands. This code is normally not visible to the user of the program.

SYSTAPRE

A software program developed by CTIF to calculate gating of die casting dies.

TDP

Total differential pressure (as in TDP aluminum cylinder block, Toyota).

thixocasting

Semi-solid forming of a pre-solidified non-dendritic billet (e.g., made by Alumax, Pechiney, and others.)

V-process

A molding process, developed in Japan, in which the mold is formed by stretching a sheet of mylar plastic over a heated metal pattern so that it conforms to the shape of the pattern. A box of loose sand is placed over the pattern, and a vacuum is applied to the sand, which then conforms to the shape of the mylar film. Thus supported, the sand-backed film is removed from the pattern and is used as one part of mold. When the metal is poured, the vacuum is released, and the loose sand falls away from the casting.

Flow 3D

A commercial solidification software code available in the United States and Europe.

Published: March 1997; WTEC Hyper-Librarian