A new technology to produce lightweight metal castings with stronger dissimilar reinforcement inserts has been developed. The new technology is a cast-on process that detaches oxides and bubbles from the surfaces of the insert and enhances the metallurgical interaction of the casting with the reinforcement metal. No gap is formed at the casting/insert interface. The bonding strength of the dissimilar metals is 5 times stronger than that produced by conventional cast-on method.

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The specimens after being push-out tested: (L) made using the traditional caston method, and (R) made using the new method. Corrosion occurred on the steel surface of the specimen produced using the traditional cast-on method.

A new technology, USV-GRTM, has been developed for producing metal ingots of ultrafine grains without the use of foreign particles or grain refiners. This new USVGRTM technology can produce metal and alloy products with grain size much smaller than that obtainable using the best commercial grain refiners.

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The grain size of the ingot using Tibor grain refiner.

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The grain size of the ingot processed using our new technology was at least one magnitude smaller than that in ingots with commercial grain refiners.

 

An advanced technology for dispersing nanoparticles (<50 nm) in molten metal, and for mass production of aluminum matrix nanocomposites has been developed. The resultant nanocomposites have superior mechanical properties, especially tensile strength, fatigue resistance, and creep resistance at elevated temperatures.

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Individual nano-sized SiC particles that have been dispersed into molten alloy using our new processing route.