Metal casting: An essential process in modern manufacturing

Welcome back to the Mechanical newsletter. Join us in this week's Engineering Spotlight as we explore the age-old art and science of metal casting. Discover the latest innovations in material science, explore cutting-edge advancements, and meet the pioneers of protein self-assembly.

Lastly, we have also included a list of books to inspire our engineering enthusiasts.

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INDUSTRY UPDATES

🔋 US: Sakuu and SK On join hands to mass-produce 3D-printed EV batteries
Sakuu’s innovations in dry-process manufacturing and electrodes enable cost-effective, high-performance batteries.

🌊 Prysmian: World’s deepest subsea cable installed at record-breaking 7,054 feet
Non-metallic armored cable made from High-Modulus Synthetic Fibres installed 2150 meters deep underwater.

⚡️ China: Game changer solid electrolyte cuts solid-state battery price by 90%
Revolutionary battery design utilizes a new sulphide solid electrolyte called LPSO without lithium sulfide.

🫁 Self-Steering Robotic Needle for More Accurate Lung Biopsies
A flexible, self-controlled needle robot can effectively treat lung cancer by accessing and retrieving hard-to-reach lung tissue.

🤖 New Approach May Make More Reliable and Safe Robots
MaxDiffRL approach is a robot control mechanism capable of generating truly random data to prepare the system for effective machine learning.

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SPOTLIGHT

Understanding Metal Casting in an Industrial Context

Metal casting is a foundational manufacturing process that involves melting metals and pouring them into molds to create various shapes and objects. This technique dates back over 7000 years and has significantly evolved to enable the production of complex parts that would otherwise be immensely challenging to manufacture. Metal casting has become indispensable across various industries, from automotive to fine arts. 

The Basics of Metal Casting

Metal casting works by heating metals beyond their melting point and pouring the molten metal into molds. Once the metal cools and solidifies, it retains the mold’s shape. This process is more than just filling a mold. It also involves careful temperature and flow control to guarantee high-quality output without defects like porosity and inclusions.

Types of Metal Casting Processes

The versatility of metal casting is evident in the variety of its methods. Each method is suited for different production needs and material types. Expendable mold casting and non-expendable mold casting are the two primary categories. Expendable mold casting involves using temporary molds made from materials like sand or plaster. These molds are usually destroyed to retrieve the cast part. On the other hand, non-expendable mold casting uses permanent molds. These molds are suitable for high-volume production as they can withstand numerous casting cycles.

Expendable Mold Casting Techniques

Sand casting is the most common form of expendable mold casting. Suitable for both small batches and large parts, It uses sand to form the mold. Sand casting is a favored method for its adaptability and cost-effectiveness. Other techniques like shell molding and investment casting offer higher accuracy and better surface finish, ideal for more complex designs.

Non-Expendable Mold Casting Methods

Die casting and centrifugal casting are non-expendable mold techniques. This method is suitable for large-scale production and uses reusable metal molds, perfect for accurately and quickly creating detailed parts. Centrifugal casting, used to produce cylindrical parts like pipes, utilizes rotational forces to fill molds evenly and achieve a dense, high-quality structure.

Innovations and Advancements

Modern advancements in metal casting and the integration of automation and control technologies have helped achieve higher precision and efficiency than traditional casting processes. Innovations such as 3D-printing molds from sand or other materials also allow for quicker prototype development and greater flexibility in design changes.

Metal casting is critical to manufacturing processes. It is used to produce everything from basic industrial components to detailed art pieces. Its evolution in response to industrial needs underscores its enduring importance.

MechTech Innovations

Innovative Computational Model Redefines Protein Self-Assembly 

Through extensive study, researchers from the University of Massachusetts Amherst, Brandeis University, and the Technical University of Munich developed a groundbreaking computational model. It is meant to optimize the design of nano-sized self-assembling protein materials. The team has explored new geometrical configurations beyond traditional spherical forms, leveraging principles of symmetry discovered by biologists Donald Caspar and Aaron Klug. The researchers are trying to explore structures with saddle-like curvature, similar to natural architectures found in bird feathers and butterfly wings, which contribute to their structural color.

With this approach, we will not only effectively mimic biological efficiency but also find a way to create materials with minimal use of resources by optimizing the arrangement and symmetry of biological building blocks. The self-assembling structures hold potential for a variety of applications. These applications range from photonic coatings to more efficient material production. The next steps in this discovery involve experimental validation and refining the assembly process to enhance precision and reduce potential defects. By focusing on these steps, researchers are moving closer to practical applications in various engineering fields.

BOOK RECOMMENDATIONS

👩🏽‍🚀 An Astronaut's Guide to Life on Earth by Chris Hadfield 
Astronaut Chris Hadfield tells us about his life in space, sharing sharp observations about the leadership, teamwork, and problem-solving skills that have served him well in his adventures.

🔬 The Alchemy of Us: How Humans and Matter Transformed One Another by Ainissa Ramirez 
This book explores eight inventions and how they have shaped the human experience. It blends history, science, and storytelling to engage readers interested in the intersections of technology and society.

🖥️ The Glass Cage: How Our Computers Are Changing Us" by Nicholas Carr 
The Glass Cage discusses the impact of automation and digital technology on human skills and the nature of work. This book is highly relevant to those interested in moral debates on robotics and AI in mechanical engineering.

⚙️ Gears and Gear Cutting by Ivan Law 
This is a practical handbook for those interested in gear technology, providing a solid foundation in mechanical design and manufacturing.

🔩 Thing Explainer: Complicated Stuff in Simple Words by Randall Munroe 
This book uses simple language and detailed illustrations to explain complex engineering and scientific concepts, which is ideal for breaking down complicated mechanical systems.