There were three primary tasks involved in this research project, they included research in clean steel castings, electromagnetic separation of inclusions, and metal penetration in sand molds.
A model was developed, which described whether inclusions would be pushed or engulfed by the growing solid grains. Calculations were correlated with experimental observations. In analyzing pouring methods, a number of methods were identified which could significantly improve the cleanliness of steel castings. In identifying waste streams, a list of compounds which might be formed was compiled as well as a list of vendors capable of treating the emissions. The feasibility of shell removal was demonstrated. The feasibility of removal of ceramic cores was found to be limited by core composition, core geometry, and the possibility of recrystallization cast metal. In modifying the composition of superalloy 718, a variation of the alloy composition was developed which was approved for use in the upgraded Space Shuttle Main Engine. Characteristics were identified which influenced the action of iron oxide additions to no-bake sands. Also a function was identified which more accurately predicted microporosity than other functions which were previously employed.