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Mark R. Jolly
Cranfield University, Cranfield, UK

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Journal article
Published: 28 May 2021 in Progress in Materials Science
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Over the last 4 decades, remarkable progress has been made in the modelling of casting processes. The development of casting models is well reflected in the proceedings of the 15 Modelling of Casting, Welding and Advanced Solidification Processes (MCWASP) conferences that have been held since 1980. Computer simulations have enabled a better understanding of the physical phenomena involved during solidification. Modelling gives the opportunity to uncouple the physical processes. Furthermore, quantities that are difficult or impossible to measure experimentally can be calculated using computer simulations e.g. flow patterns and recalescence. However, when it comes to accurately predicting casting performance and in particular, the occurrence of defects like cracks, segregation and porosity there is certainly some way to go. In this paper, the current understanding of the main mechanisms of defect formation during shape and DC casting processes will be reviewed and requirements will be discussed to give a direction to making casting models more predictive and quantitative.

ACS Style

Mark Jolly; Laurens Katgerman. Modelling of Defects in Aluminium Cast Products. Progress in Materials Science 2021, 100824 .

AMA Style

Mark Jolly, Laurens Katgerman. Modelling of Defects in Aluminium Cast Products. Progress in Materials Science. 2021; ():100824.

Chicago/Turabian Style

Mark Jolly; Laurens Katgerman. 2021. "Modelling of Defects in Aluminium Cast Products." Progress in Materials Science , no. : 100824.

Conference paper
Published: 11 September 2020 in Blockchain Technology and Innovations in Business Processes
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Capabilities of additive manufacturing (AM) for rapid tooling are well known in recent times. Rapid sand moulds are advantageous over traditional sand moulds in terms of cost, manufacturing time, flexibility, etc. This paper identifies metrics related to mould manufacturing and categorises them into four categories (cost, time, quality and environmental sustainability). A methodology based on the deterministic Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) multi-criteria decision-making algorithm is used to map at high resolution the influence of such categories on to the decision-making space when comparing AM with conventional sand mould making. Results show that AM is almost always clearly advantageous overall (excluding some very limited corner cases) for the examined case.

ACS Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes 2020, 345 -355.

AMA Style

Emanuele Pagone, Prateek Saxena, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping. Blockchain Technology and Innovations in Business Processes. 2020; ():345-355.

Chicago/Turabian Style

Emanuele Pagone; Prateek Saxena; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Sustainability Assessment of Rapid Sand Mould Making Using Multi-criteria Decision-Making Mapping." Blockchain Technology and Innovations in Business Processes , no. : 345-355.

Conference paper
Published: 13 June 2020 in IOP Conference Series: Materials Science and Engineering
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ACS Style

M Papanikolaou; P Saxena; Emanuele Pagone; K Salonitis; Mark Jolly. Optimisation of the filling process in counter-gravity casting. IOP Conference Series: Materials Science and Engineering 2020, 861, 1 .

AMA Style

M Papanikolaou, P Saxena, Emanuele Pagone, K Salonitis, Mark Jolly. Optimisation of the filling process in counter-gravity casting. IOP Conference Series: Materials Science and Engineering. 2020; 861 ():1.

Chicago/Turabian Style

M Papanikolaou; P Saxena; Emanuele Pagone; K Salonitis; Mark Jolly. 2020. "Optimisation of the filling process in counter-gravity casting." IOP Conference Series: Materials Science and Engineering 861, no. : 1.

Journal article
Published: 30 April 2020 in Procedia Manufacturing
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The selection of the most appropriate casting gating system design is one of the most critical decision-making tasks in foundries as it is closely associated to the amount of air inclusions and surface defect concentration, which should be minimal in the final casting product to ensure superior quality and enhanced mechanical properties. Moreover, the design of the gating system influences the material and energy usage and consequently the cost of the sand casting manufacturing process. Therefore, its design should be thoughtfully considered and planned. In this investigation, Multi-Criteria Decision-Making (MCDM) is being coupled with Computational Fluid Dynamics (CFD) simulations in order to select the optimal gating system design with respect to the sustainability of the process. Besides process energy, three additional criteria were used for the evaluation of the gating system performance, namely: air entrainment, surface defect concentration and mould cost. CFD simulations were performed to evaluate each one of the 6 gating system designs considered against each one the aforementioned criteria. The selection of the most appropriate gating system was performed using the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS).

ACS Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. Sustainability-Based Evaluation of Casting Gating Systems: a Multi-Criteria Decision-Making Approach. Procedia Manufacturing 2020, 43, 704 -711.

AMA Style

Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis, Mark Jolly. Sustainability-Based Evaluation of Casting Gating Systems: a Multi-Criteria Decision-Making Approach. Procedia Manufacturing. 2020; 43 ():704-711.

Chicago/Turabian Style

Michail Papanikolaou; Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. 2020. "Sustainability-Based Evaluation of Casting Gating Systems: a Multi-Criteria Decision-Making Approach." Procedia Manufacturing 43, no. : 704-711.

Journal article
Published: 13 February 2020 in Metals
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Sand casting of lead sheet is a traditional manufacturing process used up to the present due to the special features of sand cast sheet such as their attractive sheen. Similarly to any casting process, sand casting of lead sheet suffers from the presence of surface defects. In this study, a surface defect type, hereby referred to as ‘grooves’, has been investigated. The focus has been laid on the identification of the main factors affecting defect formation in this process. Based on a set of screening experiments performed using Scanning Electron Microscopy (SEM) as well as the existing literature, a number of factors affecting the formation of such defects was identified and their corresponding significance was estimated using the Analysis of Variance (ANOVA) technique. The obtained results suggest that the most significant factor affecting defect formation in sand casting of lead sheet is the composition of the moulding mixture. Defect formation was also proven to be dependent on the sand grain fineness, the quality of the melt and some of the interactions between the aforementioned process parameters. Finally, an optimal set of process parameters leading to the minimisation of surface defects was identified.

ACS Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach. Metals 2020, 10, 252 .

AMA Style

Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach. Metals. 2020; 10 (2):252.

Chicago/Turabian Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Minimising Defect Formation in Sand Casting of Sheet Lead: A DoE Approach." Metals 10, no. 2: 252.

Conference paper
Published: 12 February 2020 in Proceedings of the International Conference on Martensitic Transformations: Chicago
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This study presents the results of an investigation that characterises the thermophysical properties of an investment casting mould, comprising of a Zirconium dioxide/Cobalt aluminate prime slurry and a fused Silica/fibre reinforced backup slurry. Growing prevalence of successful computer simulations within the foundry industry enables defects that emerge during the casting process to become increasingly predictable, providing cost-effective alternatives to trial castings. The viability of these simulations as predictors is heavily dependent upon the facilitation of accurate material property data, as attained through this investigation. Differential scanning calorimetry (DSC) and laser flash analysis (LFA) were utilized to determine the specific heat capacity and thermal diffusivity, respectively. These values, in combination with the material density and linear coefficient of thermal expansion, have been used to determine the thermal conductivity of the mould. With the aim of verifying these parameters, initial studies in Flow-3D® simulation software have been performed to determine the constraints needed to reduce variability in simulation parameters. Due to the diversity of casting moulds used throughout the industry, ensuring the material database is kept as comprehensively populated as possible is a crucial undertaking.

ACS Style

C. A. Jones; Mark Jolly; A. E. W. Jarfors; M. Irwin. An Experimental Characterization of Thermophysical Properties of a Porous Ceramic Shell Used in the Investment Casting Process. Proceedings of the International Conference on Martensitic Transformations: Chicago 2020, 1095 -1105.

AMA Style

C. A. Jones, Mark Jolly, A. E. W. Jarfors, M. Irwin. An Experimental Characterization of Thermophysical Properties of a Porous Ceramic Shell Used in the Investment Casting Process. Proceedings of the International Conference on Martensitic Transformations: Chicago. 2020; ():1095-1105.

Chicago/Turabian Style

C. A. Jones; Mark Jolly; A. E. W. Jarfors; M. Irwin. 2020. "An Experimental Characterization of Thermophysical Properties of a Porous Ceramic Shell Used in the Investment Casting Process." Proceedings of the International Conference on Martensitic Transformations: Chicago , no. : 1095-1105.

Journal article
Published: 01 February 2020 in Journal of Cleaner Production
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A common feature of Multi-Criteria Decision Analysis (MCDA) to evaluate sustainable manufacturing is the participation (to various extents) of Decision Makers (DMs) or experts (e.g. to define the importance, or “weight”, of each criterion). This is an undesirable requirement that can be time consuming and complex, but it can also lead to disagreement between multiple DMs. Another drawback of typical MCDA methods is the limited scope of weight sensitivity analyses that are usually performed for one criterion at the time or on an arbitrary basis, struggling to show the “big picture” of the decision making space that can be complex in many real-world cases. This work removes all the mentioned shortcomings implementing automatic weighting through an ordinal combinatorial ranking of criteria objectively set by four pre-defined weight distributions. Such solution provides the DM not only with a fast, rational and systematic method, but also with a broader and more accurate insight into the decision making space considered. Additionally, the entropy of information in the criteria can be used to adjust the weights and emphasise the differences between potentially close alternatives. The proposed methodology is derived generalising a problem of material selection of automotive parts in metal casting manufacturing systems. In particular, three typical aluminium, magnesium and zinc alloys in a High-Pressure Die Casting (HPDC) process are compared using the deterministic Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) combining 18 criteria organised in 4 main categories (cost, quality, time and environmental sustainability). A detailed and systematic approach to calculate the considered criteria is also provided and it includes Life Cycle Assessment (LCA) considerations. Results show that, although in most of the cases the aluminium alloy is the best option, there are a few areas in the decision making space where magnesium and zinc alloys score better without a simple correlation to categories. This shows how valuable the proposed mapping process is to understand the complex MCDA analyses. The methodology does not make specific assumptions about metal casting and can be applied to sustainable manufacturing in general.

ACS Style

Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. Automatically weighted high-resolution mapping of multi-criteria decision analysis for sustainable manufacturing systems. Journal of Cleaner Production 2020, 257, 120272 .

AMA Style

Emanuele Pagone, Konstantinos Salonitis, Mark Jolly. Automatically weighted high-resolution mapping of multi-criteria decision analysis for sustainable manufacturing systems. Journal of Cleaner Production. 2020; 257 ():120272.

Chicago/Turabian Style

Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. 2020. "Automatically weighted high-resolution mapping of multi-criteria decision analysis for sustainable manufacturing systems." Journal of Cleaner Production 257, no. : 120272.

Conference paper
Published: 28 January 2020 in The Minerals, Metals & Materials Series
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Despite the continuous and remarkable development of experimental techniques for the investigation of microstructures and the growth of nuclei during the solidification of metals, there are still unknown territories around the topic of nucleation during solidification. Such nanoscale phenomena can be effectively observed by means of Molecular Dynamics (MD) simulations which can provide a deep insight into the formation of nuclei and the induced crystal structures. In this study, MD simulations have been performed to investigate the solidification of Aluminium melt and the effects of process parameters such as the cooling rate and hydrostatic pressure on the final properties of the solidified material. A large number of Aluminium atoms have been used in order to investigate the grain growth over time solidification. The population of the Face Centred Cubic (FCC) and amorphous (or non-crystalline) phases has been recorded during the evolution of the process to illustrate the nanoscale mechanisms during solidification. Finally, the exothermic nature of the solidification process has been effectively captured by measuring the temperature of the Al atoms during grain formation.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Molecular Dynamics Simulations of the Solidification of Pure Aluminium. The Minerals, Metals & Materials Series 2020, 158 -167.

AMA Style

Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Molecular Dynamics Simulations of the Solidification of Pure Aluminium. The Minerals, Metals & Materials Series. 2020; ():158-167.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2020. "Molecular Dynamics Simulations of the Solidification of Pure Aluminium." The Minerals, Metals & Materials Series , no. : 158-167.

Journal article
Published: 01 January 2020 in Metals
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The most common problems encountered in sand casting foundries are related to sand inclusions, air, and oxide films entrainment. These issues can be addressed to a good extent or eliminated by designing proper running systems. The design of a good running system should be based on John Campbell’s “10 casting rules”; it should hinder laminar and turbulent entrainment of the surface film on the liquid, as well as bubble entrainment. These rules have led to the establishment of a group of components such as high and low placed filters (HPF/LPF) and standard gate designs such as the trident gate (TG) and vortex gate (VG) which are incorporated in well-performing running system designs. In this study, the potential of the aforementioned running system designs to eliminate air entrainment and surface defects has been investigated via means of computational fluid dynamics (CFD) simulations. The obtained results suggest that the use of filters significantly enhances the quality of the final cast product; moreover, all of the gating system designs appear to perform better than the basic running system (BRS). Finally, the five in total running and gating system designs have been evaluated with respect to their ability to produce good quality cast products (reduced air entrainment and surface defects) and their sustainability component (runner scrap mass).

ACS Style

Michail Papanikolaou; Emanuele Pagone; Mark Jolly; Konstantinos Salonitis. Numerical Simulation and Evaluation of Campbell Running and Gating Systems. Metals 2020, 10, 68 .

AMA Style

Michail Papanikolaou, Emanuele Pagone, Mark Jolly, Konstantinos Salonitis. Numerical Simulation and Evaluation of Campbell Running and Gating Systems. Metals. 2020; 10 (1):68.

Chicago/Turabian Style

Michail Papanikolaou; Emanuele Pagone; Mark Jolly; Konstantinos Salonitis. 2020. "Numerical Simulation and Evaluation of Campbell Running and Gating Systems." Metals 10, no. 1: 68.

Original article
Published: 20 November 2019 in The International Journal of Advanced Manufacturing Technology
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Sandcast lead sheets are characterised by their superior aesthetic performance and mottled surface. Lead sheet casting is widely used in the construction industry for roofing and flashing applications, while the roots of this process can be tracked back to the Roman times. In this study, two-dimensional computational fluid dynamics (CFD) simulations have been performed to simulate the melt flow and solidification stages of the lead sandcasting process. The effects of process parameters such as pouring temperature, screed velocity and clearance between the screed and the sandbed on the final quality of the lead sheet are investigated. Lead sheet quality has been quantified by measuring the variance and the average value of the final sheet thickness over the sandbed length. The developed CFD model has been validated against experimental results by comparing the time evolution of the lead-sandbed interface temperature against data collected by thermocouples during the real-time process. The numerical results show that all of the aforementioned parameters affect the final quality of the cast product and suggest that superior quality lead sheets can be produced for a range of relatively low values of the pouring temperature and slow strickle motion.

ACS Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Sand casting of sheet lead: numerical simulation of metal flow and solidification. The International Journal of Advanced Manufacturing Technology 2019, 106, 177 -189.

AMA Style

Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Sand casting of sheet lead: numerical simulation of metal flow and solidification. The International Journal of Advanced Manufacturing Technology. 2019; 106 (1-2):177-189.

Chicago/Turabian Style

Arun Prabhakar; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2019. "Sand casting of sheet lead: numerical simulation of metal flow and solidification." The International Journal of Advanced Manufacturing Technology 106, no. 1-2: 177-189.

Journal article
Published: 12 November 2019 in Metals
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Despite the continuous and remarkable development of experimental techniques for the investigation of microstructures and the growth of nuclei during the solidification of metals, there are still unknown territories around this topic. The solidification in nanoscale can be effectively investigated by means of molecular dynamics (MD) simulations which can provide a deep insight into the mechanisms of the formation of nuclei and the induced crystal structures. In this study, MD simulations were performed to investigate the solidification of pure Aluminium and the effects of the cooling rate on the final properties of the solidified material. A large number of Aluminium atoms were used in order to investigate the grain growth over time and the formation of stacking faults during solidification. The number of face-centred cubic (FCC), hexagonal close-packed (HCP) and body-centred cubic (BCC) was recorded during the evolution of the process to illustrate the nanoscale mechanisms initiating solidification. The current investigation also focuses on the exothermic nature of the solidification process which has been effectively captured by means of MD simulations using 3 dimensional representations of the kinetic energy across the simulation domain.

ACS Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly; Michael Frank. Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium. Metals 2019, 9, 1217 .

AMA Style

Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly, Michael Frank. Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium. Metals. 2019; 9 (11):1217.

Chicago/Turabian Style

Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly; Michael Frank. 2019. "Large-Scale Molecular Dynamics Simulations of Homogeneous Nucleation of Pure Aluminium." Metals 9, no. 11: 1217.

Journal article
Published: 03 July 2019 in Energies
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Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional cast iron (CI) with lighter metals. Currently, aluminum alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review was performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminum alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, were collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” was implemented to take into account the energy input of each stage of the component life cycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that, although aluminum components contribute toward reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

ACS Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron. Energies 2019, 12, 2557 .

AMA Style

Konstantinos Salonitis, Mark Jolly, Emanuele Pagone, Michail Papanikolaou. Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron. Energies. 2019; 12 (13):2557.

Chicago/Turabian Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. 2019. "Life-Cycle and Energy Assessment of Automotive Component Manufacturing: The Dilemma Between Aluminum and Cast Iron." Energies 12, no. 13: 2557.

Short communication
Published: 15 June 2019 in Materials Letters
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Porous foams from cellulose nanofibres (CNF) and poly-vinyl alcohol CNF/PVA were prepared by uni-directional freezing to create a homogeneous pore structure. The CNF was derived from paper mills sludge (PMS), a by-product of paper manufacturing waste-water treatment. Sodium tetraborate decahydrate (borax) was used as a crosslinking agent. The density of the CNF/PVA foams were 0.03gcm-3 with a compressive strength of 116 kPa at 20% strain. The foams were competitive to commercial expanded polystyrene (EPS) foam.

ACS Style

Cynthia Adu; Sameer Rahatekar; Jyoti Filby; David Ayre; Mark Jolly. Structural packaging foams prepared by uni-directional freezing of paper sludge cellulose nanofibres and poly (vinyl alcohol). Materials Letters 2019, 253, 242 -245.

AMA Style

Cynthia Adu, Sameer Rahatekar, Jyoti Filby, David Ayre, Mark Jolly. Structural packaging foams prepared by uni-directional freezing of paper sludge cellulose nanofibres and poly (vinyl alcohol). Materials Letters. 2019; 253 ():242-245.

Chicago/Turabian Style

Cynthia Adu; Sameer Rahatekar; Jyoti Filby; David Ayre; Mark Jolly. 2019. "Structural packaging foams prepared by uni-directional freezing of paper sludge cellulose nanofibres and poly (vinyl alcohol)." Materials Letters 253, no. : 242-245.

Preprint
Published: 11 June 2019
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Considering the manufacturing of automotive components, there exists a dilemma around the substitution of traditional Cast Iron (CI) with lighter metals. Nowadays, aluminium alloys, being lighter compared to traditional materials, are considered as a more environmentally friendly solution. However, the energy required for the extraction of the primary materials and manufacturing of components is usually not taken into account in this debate. In this study, an extensive literature review has been performed to estimate the overall energy required for the manufacturing of an engine cylinder block using (a) cast iron and (b) aluminium alloys. Moreover, data from over 100 automotive companies, ranging from mining companies to consultancy firms, have been collected in order to support the soundness of this investigation. The environmental impact of the manufacturing of engine blocks made of these materials is presented with respect to the energy burden; the “cradle-to-grave approach” has been implemented to take into account the energy input of each stage of the component lifecycle starting from the resource extraction and reaching to the end-of-life processing stage. Our results indicate that although aluminium components contribute towards reduced fuel consumption during their use phase, the vehicle distance needed to be covered in order to compensate for the up-front energy consumption related to the primary material production and manufacturing phases is very high. Thus, the substitution of traditional materials with lightweight ones in the automotive industry should be very thoughtfully evaluated.

ACS Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron. 2019, 1 .

AMA Style

Konstantinos Salonitis, Mark Jolly, Emanuele Pagone, Michail Papanikolaou. Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron. . 2019; ():1.

Chicago/Turabian Style

Konstantinos Salonitis; Mark Jolly; Emanuele Pagone; Michail Papanikolaou. 2019. "Life Cycle and Energy Assessment of Automotive Components Manufacturing: The Dilemma Between Aluminium and Cast Iron." , no. : 1.

Journal article
Published: 01 April 2019 in Journal of Alloys and Compounds
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ACS Style

Martin E. Stiehler; Mark R. Jolly; Konstantinos Georgarakis. On the impact of global interactions on the structure of metallic glasses. Journal of Alloys and Compounds 2019, 782, 496 -505.

AMA Style

Martin E. Stiehler, Mark R. Jolly, Konstantinos Georgarakis. On the impact of global interactions on the structure of metallic glasses. Journal of Alloys and Compounds. 2019; 782 ():496-505.

Chicago/Turabian Style

Martin E. Stiehler; Mark R. Jolly; Konstantinos Georgarakis. 2019. "On the impact of global interactions on the structure of metallic glasses." Journal of Alloys and Compounds 782, no. : 496-505.

Conference paper
Published: 09 February 2019 in Proceedings of the International Conference on Martensitic Transformations: Chicago
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Lead sheet is widely used for roofing and flashing applications. Continuous casting and rolling are the most common processes used for manufacture of such sheet. Sand casting of lead sheet is a traditional process used since the Romans. Sand cast lead sheet is presently used for restoration of heritage buildings, churches and cathedrals. It possesses a distinct texture due to the uniqueness of the manufacturing process and is considered a premium product. In the present study, sand cast lead sheet samples were collected and characterised. The observations are then compared with characteristics of continuously cast lead sheet obtained from the literature and are reported in this paper.

ACS Style

Arun Prabhakar; Konstantinos Salonitis; Mark Jolly. Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique. Proceedings of the International Conference on Martensitic Transformations: Chicago 2019, 283 -292.

AMA Style

Arun Prabhakar, Konstantinos Salonitis, Mark Jolly. Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique. Proceedings of the International Conference on Martensitic Transformations: Chicago. 2019; ():283-292.

Chicago/Turabian Style

Arun Prabhakar; Konstantinos Salonitis; Mark Jolly. 2019. "Characterisation of Lead Sheet Manufactured Using Traditional Sand-Casting Technique." Proceedings of the International Conference on Martensitic Transformations: Chicago , no. : 283-292.

Conference paper
Published: 09 February 2019 in Proceedings of the International Conference on Martensitic Transformations: Chicago
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In the 1980s, John Campbell developed a new casting process from his research in the industry over a number of years. The Cosworth process was for delivering very high-quality aluminium components for the automotive industry. The process was very capital-intensive and not very flexible for smaller companies delivering lower volumes of product. However, the principles behind the process have been taken and used to develop a range of different so-called running systems to help improve the quality of castings. Some of these designs have been published in ‘Castings Handbook’ [1] authored by Campbell. This paper presents the results of an MSc project during which a number of the proposed designs from Campbell’s Mini Casting Handbook [2] for certain features in running systems have been modelled using a validated CFD software.

ACS Style

Chengcheng Lyu; Michail Papanikolaou; Mark Jolly. Numerical Process Modelling and Simulation of Campbell Running Systems Designs. Proceedings of the International Conference on Martensitic Transformations: Chicago 2019, 53 -64.

AMA Style

Chengcheng Lyu, Michail Papanikolaou, Mark Jolly. Numerical Process Modelling and Simulation of Campbell Running Systems Designs. Proceedings of the International Conference on Martensitic Transformations: Chicago. 2019; ():53-64.

Chicago/Turabian Style

Chengcheng Lyu; Michail Papanikolaou; Mark Jolly. 2019. "Numerical Process Modelling and Simulation of Campbell Running Systems Designs." Proceedings of the International Conference on Martensitic Transformations: Chicago , no. : 53-64.

Book chapter
Published: 01 January 2019 in Gießtechnik im Motorenbau 2019
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Der Bericht ist ausschließlich als PDF-Datei erschienen! Parallel fand auch die 1. VDI-Fachtagung Gießen von Groß- und Nutzfahrzeugmotoren 2019″ statt, die als „– neuer Treffpunkt für Motorenexperten der Off-Highway- und Transportindustrie – etabliert werden soll. Inhalt Gießtechnik im Motorenbau 2019 Keynotes Powertrain 2030 – Driven by Diversification 1 A. Pfeifer, MAHLE GmbH, Stuttgart The future of large and commercial engines – The next milestones in engine development for cpt 5 P. Heuser, FEV Group GmbH, Aachen Zukunft des Verbrennungsmotors Methodische Integration der virtuellen Versuchsplanung in die schwingfeste und robuste Auslegung von hochbelasteten Aluminiumgussteilen 23 M. Weidt, C. Thomser, MAGMA Gießereitechnologie GmbH, Aachen Traceability als Erfolgsfaktor – Industrie 4.0 in der Großserienproduktion von Aluminium-Druckguss Zylinderkurbelgehäusen 39 F. Loerwald, Martinrea Honsel Germany GmbH, Meschede Innovative Produktion: Verfahren – W...

ACS Style

Mark Jolly; Konstantinos Salonitis; Emanuele Pagone; M. Papanikolaou. Substitution of cast iron engine components with aluminium alloys: A life cycle perspective. Gießtechnik im Motorenbau 2019 2019, 153 -168.

AMA Style

Mark Jolly, Konstantinos Salonitis, Emanuele Pagone, M. Papanikolaou. Substitution of cast iron engine components with aluminium alloys: A life cycle perspective. Gießtechnik im Motorenbau 2019. 2019; ():153-168.

Chicago/Turabian Style

Mark Jolly; Konstantinos Salonitis; Emanuele Pagone; M. Papanikolaou. 2019. "Substitution of cast iron engine components with aluminium alloys: A life cycle perspective." Gießtechnik im Motorenbau 2019 , no. : 153-168.

Chapter
Published: 13 December 2018 in Introduction to Mechanical Engineering
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Metal casting is one of the most energy-intensive manufacturing processes that have developed along the evolution of mankind. Although nowadays its scientific and technological aspects are well established, in the context of future resource scarcity and environmental pollution pressures, new studies appear necessary to describe the “foundry of the future” where energy and material efficiency are of great importance to guarantee competitiveness alongside environmental protection. In this chapter, both managerial and technical good practices aimed at implementing energy-efficient casting processes are presented alongside a few examples. The “Small is Beautiful” philosophy is presented as a systematic approach towards energy resilient manufacturing and, potentially, sustainability in the long term. Thus, this chapter aims at providing an overview of the different aspects comprising the state of the art in the industry and examples of research themes in academia about energy-efficient casting processes.

ACS Style

Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. Energy-Efficient Casting Processes. Introduction to Mechanical Engineering 2018, 77 -98.

AMA Style

Emanuele Pagone, Konstantinos Salonitis, Mark Jolly. Energy-Efficient Casting Processes. Introduction to Mechanical Engineering. 2018; ():77-98.

Chicago/Turabian Style

Emanuele Pagone; Konstantinos Salonitis; Mark Jolly. 2018. "Energy-Efficient Casting Processes." Introduction to Mechanical Engineering , no. : 77-98.

Conference paper
Published: 01 December 2018 in Blockchain Technology and Innovations in Business Processes
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The automotive sector is one of the main end-use markets for metal casting worldwide. The strong competitive pressure typical of this industry have been influenced in the recent years by sustainability as a new factor promoted by legislation, increased societal awareness of relevant instances and resource scarcity. Energy efficiency, although only a part of sustainability, is important for the metal casting practice because of its nature of large consumer of energy per unit product. Therefore, the effective use of appropriate energy efficient metrics in foundries is of great interest. In this work, a set of indicators developed by the authors (and derived by traditional metrics) to analyse the energy performance of foundries will be used to compare high pressure die casting processes producing car transfer cases with different suitable materials. On the basis of this analysis, it will be shown that the most energy efficient material can be identified whereas the traditional metrics cannot detect such opportunity.

ACS Style

Emanuele Pagone; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts. Blockchain Technology and Innovations in Business Processes 2018, 290 -303.

AMA Style

Emanuele Pagone, Michail Papanikolaou, Konstantinos Salonitis, Mark Jolly. Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts. Blockchain Technology and Innovations in Business Processes. 2018; ():290-303.

Chicago/Turabian Style

Emanuele Pagone; Michail Papanikolaou; Konstantinos Salonitis; Mark Jolly. 2018. "Metal Casting Energy Efficient Metrics for Material Selection of Automotive Parts." Blockchain Technology and Innovations in Business Processes , no. : 290-303.