Evaluation of the Effectiveness of Semolina in Improving the Bond Strength of Metal Alloys and Acrylic Resins for the Fabrication of Hybrid Prostheses for Implant Restoration: An In Vitro Study.

Introduction Fixed prosthodontic solutions for restorations of multiple implants are often done using acrylic-metal hybrid prosthesis. These restorations have a high failure rate due to poor bond strength between metal and acrylic, despite using digital attachments and primers. This study has been done to demonstrate an economical yet effective method of increasing shear bond strength between acrylic and metal. Materials and methods Disc specimens of 10 mm diameter and 2 mm thickness were designed using the Meshmixer version 3.5 software (Autodesk Inc., San Rafael, USA). The standard tessellation (STL) file was imported and sent for direct metal laser sintering (DMLS) in cobalt-chromium (CoCr), titanium (Ti), and wax milling. The groups were defined. Ten samples were included in each group. Group 1: Conventional Casting in CoCr; Group 2: Conventional Casting with Opaquer (CoCr); Group 3: DMLS CoCr; Group 4: DMLS CoCr with Opaquer; Group 5: DMLS Ti; Group 6: DMLS Ti with Opaquer; Group 7: Casting with Semolina (CoCr); and Group 8: Casting with Semolina and Opaquer (CoCr). Wax-up was performed using double wax sheet thickness of modeling wax. Flasking and acrylization were done using the injection moulding technique. A universal testing machine was used for shear bond strength. Results were tabulated and statistical analysis was done using IBM SPSS Statistics for Windows (IBM Corp., Armonk, USA). The Shapiro-Wilk test was done to confirm the normality of the data, followed by the one-way analysis of variance (ANOVA) test to compare the shear bond strength between metal alloys and heat cure acrylic resin.  Results The one-way ANOVA results reveal significant differences in bond strengths among the various groups. Conventional Casting with Opaquer showed no significant difference (p=0.335), but there were notable improvements in bond strength when compared to DMLS CoCr, DMLS CoCr with Opaquer, DMLS Ti, DMLS Ti with Opaquer, Semolina, and Semolina with Opaquer, with DMLS Ti having the largest mean difference (3.368). Conventional Casting with Opaquer significantly outperformed all groups, especially Semolina, which showed the highest mean difference (7.558). Similar trends were seen with DMLS CoCr and DMLS Ti, where Semolina consistently demonstrated superior bond strength. Overall, Semolina produced the highest bond strengths across all conditions. These results underscore the importance of material selection and treatment in enhancing bond strength. Conclusion Semolina can be used as an economical and reliable method to increase the shear bond strength between acrylic and metal bonding. Its ability to burn out during dewaxing without any remains or remnants in mould deems it a useful material for increasing mechanical bonding.

Sub-Micron Replication of Fused Silica Glass and Amorphous Metals for Tool-Based Manufacturing.

The growing importance of submicrometer-structured surfaces across a variety of different fields has driven progress in light manipulation, color diversity, water-repellency, and functional enhancements. To enable mass production, processes like hot-embossing (HE), roll-to-roll replication (R2R), and injection molding (IM) are essential due to their precision and material flexibility. However, these processes are tool-based manufacturing (TBM) techniques requiring metal molds, which are time-consuming and expensive to manufacture, as they mostly rely on galvanoforming using templates made via precision microlithography or two-photon-polymerization (2PP). In this work, a novel approach is demonstrated to replicate amorphous metals from fused silica glass, derived from additive manufacturing and structured using hot embossing and casting, enabling the fabrication of metal insets with features in the range of 300 nm and a surface roughness of below 10 nm. By partially crystallizing the amorphous metal, during the replication process, the insets gain a high hardness of up to 800 HV. The metal molds are successfully used in polymer injection molding using different polymers including polystyrene (PS) and polyethylene (PE) as well as glass nanocomposites. This work is of significant importance to the field as it provides a production method for the increasing demand for sub-micron-structured tooling in the area of polymer replication while substantially reducing their cost of production.

[Investigation of serum surface active protein D and clara cell protein levels in workers exposed to silica dust in ferrous metal foundry].

Objective: To investigate the levels of serum surface active protein D (SP-D) and clara cell protein (CCl6) in workers exposed to black silica dust, and analyze its influencing factors. Methods: From July to September 2021, 174 workers in 37 positions exposed to silica dust in 5 ferrous metal foundry were investigated by cross-sectional research method. The exposure concentration of silica dust workers was obtained through occupational health field investigation and detection, and the general situation of the study subjects was obtained through questionnaire survey and peripheral blood was collected. Double antigen sandwich enzyme-linked immunosorbent assay (ELISA) was used to detect the concentrations of SP-D and CC16 in serum of workers. The mean values were compared by one-way ANOVA, and the influencing factors of SP-D and CC16 concentrations in serum were analyzed by ordered multiple logistic regression. Results: The time-weighted average concentration (C-TWA) of 174 workers exposed to silica dust (respirable dust) ranged from 0.09 mg/m(3)~3.58 mg/m(3), and the C-TWA overstandard rate of dust exposed workers was 32.18% (56/174) , with differences among workers in different positions (χ(2)=28.85, P<0.001) . The highest concentration of silica dust was (0.82±0.11) mg/m(3). Using C-TWA<50% OEL occupational exposure limit (OEL) as reference, serum SP-D concentration in workers with ≥50% OEL was increased (OR=4.95, 95%CI: 1.86~13.17, P=0.001) , while CC16 concentration was decreased (OR=0.15, 95%CI: 0.05~0.40, P<0.001) ; Serum CC16 concentration decreased in workers exposed to silica dust C-TWA≥OEL (OR=0.46, 95%CI: 0.28~0.98, P=0.043) . Compared with those with low occupational health literacy, the serum SP-D concentration of workers with high occupational health literacy decreased (OR=0.48, 95%CI: 0.25~0.92, P=0.027) and CC16 concentration increased (OR=2.09, 95%CI: 1.10-3.97, P=0.024) . Conclusion: When no abnormality was found in the physical examination of workers, the serum SP-D and CC16 concentration levels changed, and the change was related to the concentration of workers exposed to silica dust.

[Analysis of dust hazard characteristics in 59 ferrous metal foundry enterprises in Ningbo City].

Objective: To analyze the post distribution of dust concentration in ferrous metal foundry enterprises and evaluate the occupational health risks, and provide basis for policies of the formulation of pneumoconiosis prevention and control. Methods: From August to September in 2020, the basic information, dust hazard information and occupational health management information of 59 ferrous metal casting enterprises were investigated, the dust concentration distribution was analyzed, and the risk assessment was carried out by using the quantitative assignment model. The dust concentration is tested by LSD method after logarithmic treatment. The 3 times time weighted average allowable exposure concentration of dust is taken as the peak concentration limit of dust; The time weighted average allowable exposure concentration of dust converted by exposure time is taken as the time weighted average exposure concentration limit of dust, and whether the time weighted average exposure concentration and peak concentration of dust at the same post exceed the limit is taken as the basis for exceeding the limit of dust post concentration to calculate the post exceeding the limit rate. Results: The dust hazards were mainly distributed in the posts of sand treatment, molding, sand falling, sand cleaning and cutting and grinding. Dust exposure time weighted average concentration was 0.44 (0.03, 5.11) mg/m(3), peak exposure concentration was 1.30 (0.18, 10.94) mg/m(3), and the over standard rate of Posts was 38.92% (79/203) . Weighted average exposure concentration of other dust (total dust) in the cutting and grinding post is 1.50 (0.15, 7.40) mg/m(3), peak exposure concentration is 0.90 (0.07, 12.48) mg/m(3), and the post exceedance rate is 4.88% (2/41) . Weighted average exposure concentration of silica dust (exhaling dust) in dust operation posts of investment casting enterprises is 0.43 (0.05, 6.35) mg/m(3), peak exposure concentration is 0.90 (0.12, 8.28) mg/m(3), and the post over standard rate is 35.77% (49/137) ; Weighted average exposure concentration of other dust (total dust) at the cutting and grinding post is 2.00 (11.00, 21.00) mg/m(3), and the post exceedance rate is 2.50% (2/80) . There was no significant difference in the concentration of respirable dust between sand casting and investment casting (P>0.05) . The concentration of respirable dust in sand casting was higher than that in sand treatment, molding and sand cleaning posts (P<0.05) . The concentration of silica dust in investment casting was higher than that in sand treatment and molding posts, and that in sand cleaning posts was higher than that in sand treatment posts (P<0.05) . 98.48% (454/461) of the dust operation posts have an occupational health risk value greater than or equal to 400, and 1.52% (7/461) of the dust operation posts have an occupational health risk value of 200~399. Conclusion: there is a high rate of exceeding the standard in the dust work posts in the ferrous metal foundry enterprises in Ningbo, and the workers have a high occupational health risk of pneumoconiosis or metal and its compound pneumoconiosis. Targeted measures should be taken to reduce the occupational health risk.

Effect of the Biodegradable Component Addition to the Molding Sand on the Microstructure and Properties of Ductile Iron Castings.

In this work, the results of the examinations of the effect of the mold material and mold technology on the microstructure and properties of the casts parts of ductile cast iron have been presented. Four different self-hardening molding sands based on fresh silica sand from Grudzen Las, with organic binders (no-bake process), were used to prepare molds for tested castings. A novelty is the use of molding sand with a two-component binder: furfuryl resin-polycaprolactone PCL biomaterial. The molds were poured with ductile iron according to standard PN-EN 1563:2018-10. The microstructure of the experimental castings was examined on metallographic cross-sections with PN-EN ISO 945-1:2019-09 standard. Observations were made in the area at the casting/mold boundary and in a zone approximately 10 mm from the surface of the casting with a light microscope. The tensile test at room temperature was conducted according to standard PN-EN ISO 6892-1:2016-09. Circular cross-section test pieces, machined from samples taken from castings, were used. In the present experiment, it was stated that interactions between the mold material of different compositions and liquid cast iron at the stage of casting solidification led to some evolution of casting's microstructure in the superficial layer, such as a pearlite rim observed for acidic mold sand, a ferritic rim for alkaline sand, and graphite spheroids degeneration, especially spectacular for the acidic mold with polycaprolactone (PCL) addition. These microstructural effects may point to the interference of the direct chemical interactions between liquid alloy and the components released from the mold sand, such as sulfur and oxygen. Particularly noteworthy is the observation that the use of molding sand with furfuryl resin with the addition of biodegradable PCL material does not lead to an unfavorable modification of the mechanical properties in the casting. The samples taken from Casting No. 2, made on the acidic molding sand with the participation of biodegradable material, had an average strength of 672 MPa, the highest average strength UTS-among all tested molding sands. However, the elongation after fracture was 48% lower compared to the reference samples from Casting No. 1 from the sand without the addition of PCL.

Environmental Impact of the Reclaimed Sand Addition to Molding Sand with Furan and Phenol-Formaldehyde Resin-A Comparison.

Increasingly strict regulations, as well as an increased public awareness, are forcing industry, including the foundry industry, to develop new binders for molding sands, which, while being more environmentally friendly, would simultaneously ensure a high quality of castings. Until recently, binders based on synthetic resins were considered to be such binders. However, more accurate investigations indicated that such molding sands subjected to high temperatures of liquid metal generated several harmful, even dangerous substances (carcinogenic and/or mutagenic) from the benzene, toluene, ethylbenzene and xylenes (BTEX) and polycyclic aromatic hydrocarbons groups (PAHs). An assessment of the most widely used molding sands technologies at present with organic binders (synthetic resins) from the no-bake group (furan no-bake and phenolic-ester no-bake) and their harmfulness to the environment and work conditions is presented in this paper. In the first stage of this research, gases (from the BTEX and PAHs groups) emitted when the tested molds were poured with liquid cast iron at 1350 °C were measured (according to the authors' own method). The second stage consisted of measuring the emission of gases released by binders subjected to pyrolysis (the so-called flash pyrolysis), which simulated the effects occurring on the boundary: liquid metal/molding sand. The gases emitted from the tested binders indicated that, in both cases, the emission of harmful and dangerous substances (e.g., benzene) occurs, but, of the given binder systems, this emission was lower for the phenolic-ester no-bake binder. The obtained emission factors of BTEX substances show higher values for furan resin compared to formaldehyde resin; for example, the concentration of benzene per 1 kg of binder for furan no-bake (FNB) was 40,158 mg, while, for phenol-formaldehyde no-bake (PFNB), it was much lower, 30,911 mg. Thus, this system was more environmentally friendly.

A Combined Thin Film/Thick Film Approach to Realize an Aluminum-Based Strain Gauge Sensor for Integration in Aluminum Castings.

There is currently a large demand for aluminum components to measure the mechanical and thermal loads to which they are subjected. With structural health monitoring, components in planes, vehicles, or bridges can monitor critical loads and potentially prevent an impending fatigue failure. Externally attached sensors need a structural model to obtain knowledge of the mechanical load at the point of interest, whereas embedded sensors can be used for direct measurement at the point of interest. To produce an embedded sensor, which is automatically encapsulated against environmental influence, the sensor must be able to withstand the boundary conditions of the host component's manufacturing process. This embedding process is particularly demanding in the case of casting. Previous work showed that silicon-based sensors have a high failure rate when embedded in cast aluminum parts and that using aluminum as a substrate is preferable under these circumstances. In the present paper, we present the fabrication process for the combination of a thick-film insulation and a thin-film strain gauge sensor, on such an aluminum substrate. The sensor is capable of withstanding high temperatures of at least 600 °C for over 20 min and a subsequent embedding in a gravity die casting process.

A Spatially Distributed Fiber-Optic Temperature Sensor for Applications in the Steel Industry.

This paper presents a spatially distributed fiber-optic sensor system designed for demanding applications, like temperature measurements in the steel industry. The sensor system employed optical frequency domain reflectometry (OFDR) to interrogate Rayleigh backscattering signals in single-mode optical fibers. Temperature measurements employing the OFDR system were compared with conventional thermocouple measurements, accentuating the spatially distributed sensing capability of the fiber-optic system. Experiments were designed and conducted to test the spatial thermal mapping capability of the fiber-optic temperature measurement system. Experimental simulations provided evidence that the optical fiber system could resolve closely spaced temperature features, due to the high spatial resolution and fast measurement rates of the OFDR system. The ability of the fiber-optic system to perform temperature measurements in a metal casting was tested by monitoring aluminum solidification in a sand mold. The optical fiber, encased in a stainless steel tube, survived both mechanically and optically at temperatures exceeding 700 °C. The ability to distinguish between closely spaced temperature features that generate information-rich thermal maps opens up many applications in the steel industry.

Assessment of inhaled dust by workers and suspended dust for pollution control change and ergonomic intervention in metal casting industry: A cross-sectional study.

Metal casting industry including is an industry which produce high dust pollution (fly ash). Improvements in the form of ergonomic interventions have been carried out by many companies, but do not guarantee all parameters run well. The total indoor suspended dust (TSP) measurement results are not enough to guarantee healthy working conditions. Additional assessment of workers' inhaled dust is needed to change pollution control and work improvement to ergonomics. The design of this study is Cross Sectional Study. Research subjects numbered 84 people. All samples met the inclusion criteria. Measurement results of Characteristic of research subject, Working Environment Conditions, Exposition of dust inhaled by workers, Total Indoor Suspended Dust of the Company (p > 0.05). Found critical hours of workers exposed to dust (fly ash), starting from 4 h after working (Department of Process Cement, Department of Black Sand) and 2 h after working for the Department of Loam. Critical hours exposed to dust (fly ash) used as the basis for company management and regulators to take new policies in controlling fly ash pollution and ergonomic interventions. Ergonomic interventions can be carried out by activating the dust collector at critical hours, applying active resting hours at critical hours and conditioning workers to breathe fresh air. The impact of this ergonomic intervention is a decrease in musculoskeletal complaints by 25.27%, reduction in boredom 25.01%, and an increase in job satisfaction 38.46%.

Implementation of Cyber-Physical Production Systems for Quality Prediction and Operation Control in Metal Casting.

The prediction of internal defects of metal casting immediately after the casting process saves unnecessary time and money by reducing the amount of inputs into the next stage, such as the machining process, and enables flexible scheduling. Cyber-physical production systems (CPPS) perfectly fulfill the aforementioned requirements. This study deals with the implementation of CPPS in a real factory to predict the quality of metal casting and operation control. First, a CPPS architecture framework for quality prediction and operation control in metal-casting production was designed. The framework describes collaboration among internet of things (IoT), artificial intelligence, simulations, manufacturing execution systems, and advanced planning and scheduling systems. Subsequently, the implementation of the CPPS in actual plants is described. Temperature is a major factor that affects casting quality, and thus, temperature sensors and IoT communication devices were attached to casting machines. The well-known NoSQL database, HBase and the high-speed processing/analysis tool, Spark, are used for IoT repository and data pre-processing, respectively. Many machine learning algorithms such as decision tree, random forest, artificial neural network, and support vector machine were used for quality prediction and compared with R software. Finally, the operation of the entire system is demonstrated through a CPPS dashboard. In an era in which most CPPS-related studies are conducted on high-level abstract models, this study describes more specific architectural frameworks, use cases, usable software, and analytical methodologies. In addition, this study verifies the usefulness of CPPS by estimating quantitative effects. This is expected to contribute to the proliferation of CPPS in the industry.