Mrs. DostalikScience

10/29/2008

1. Scientists and Engineers2. Materials in Everyday Life3. Materials Companies in Beaver County

1. Metalwerks2. NF&M3. Rome Metals4. Allegheny Ludlum / Technologies5. Nova Chemical / BASF6. Zinc Corp

Vacuum Induction Melter

Load Metal and Molds1.Must know density!2.Different melt temperatures

INDUCTION SKULL MELTER1.Mainly Titanium and Zirconium2.Uses water cooled copper for a melting container

proprietary CHARGE CALCULATION PROCEDURE confidential

Alloy Name=   1058

procedure Heat number=    

PC-627 Charge weight=   505.00 density 0.297

SET UP = 6 x 65, NO HT

Element   C Cr Ni Fe Ti Mn Si Co Nb Mo Al   P Be S  

  Min   19.00 15.00     1.50   39.00   6.75            

  Max 0.15 21.00 16.00 bal   2.00 1.00 41.00   7.50     0.015 0.001 0.015  

  Aim % 0.04 20.10 15.50 15.28   1.98 0.10 40.00   7.00     100.00        

  weight 0.20 101.51 78.28 77.16 0.00 10.00 0.51 202.00 0.00 35.35 0.00 0.00        

TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE

weight

Scrap 1 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 2 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 3 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

Scrap 4 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 5 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 6 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 7 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 8 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 9 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 10 %                         0.00%

    0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000  

Scrap 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00  

Balance virgin 504.50 0.202 101.505 78.275 77.164 ###### 9.999   202.000 0.000 35.350 0.000 0.000

    0.040% 20.100% ###### ####### ###### 1.980% ##### 40.000% 0.000% 7.000% 0.000% 0.000% 0.000%

Total= 504.50

1. Metals – Alloys – Organic Materials – Gassesa. Pass around metalsb. questions

2. Melting Metals – Production of Polymers3. Welding vs Glue4. Why Vacuum?5. Demonstration - Reactive Metals / Reactivity6. Lab: Density – theoretical vs actual7. Demonstration: LN2, sensitivity of materials to

temperature8. Demonstration – Shape Memory9. Applications – Materials in Life / biomechanical

engineering

Observe the materials as they come around.◦ Weight vs size: what is this called?◦ Locate the element on the periodic table. Note the

atomic weight, theoretical density◦ Melting points◦ Properties of Metals – crystals!◦ Polymers – Chains!◦ Properties of liquids / gasses – absolute chaos!

Structure Reactivity Density

http://www.gordonengland.co.uk/conversion/density.htm

http://www.handymath.com/cgi-bin/density.cgi

Examples of Melt Points Physical States at Room Temp.

Melting Points W = 6,192F Al = 1,220F Re = 5,767F Sn = 449F Hg = -39F

Locate the melting points of some of the metals on the periodic table◦ Tungsten, rhenium, tin, lead◦ Applications?◦ Density while melting◦ Metal gasses, sputtering◦ Polymeric reactions

Popular polymers? Strings of polymers Carbon fiber

Welding is a specialized process where two sections of metal melted together◦ Heat◦ Explosion◦ Diffusion◦ Friction

Glue◦ Reactive polymers◦ Strong bonds◦ Boeing 787, stealth fighter

Absence of reactive gasses Reduced contamination of metal

◦ “regular” vacuum◦ Medium Vacuum◦ Deep vacuum

Melting by Induction – Electromagnetic Field Melting by Arc – Electrical / Plasma cloud Melting by Electron Beam – Focused Beam

of Electrons

Reaction Uses

Titanium, not solid but in small particles

Surface area Oxygen in atmosphere Ti + 2O = TiO2

Exothermic

Ti Oxide◦ Coloring – white◦ Toothpaste◦ Deodorant◦ Paint

Jewelry Anodized aluminum

Ductile to brittle transition Demo – Liquid nitrogen Video – forging

Nickel and Titanium alloy

“stretches” like a polymer

Can be deformed and snap back to a shape because of the crystal structure

Skeletal repairs Blood vessel strengthening Artificial limbs Mobility enhancements