This paper presents matters related to production of ceramic and cast iron composite. The composite was made with the use of a foam structured ceramic insert. The tests included measuring of hardness, impact strength and resistance to abrasive wear of the composite produced. On the basis of obtaining results was stated that the use of foamed ceramic filters provides good conditions of filling a ceramic framework with molten grey or chromium cast iron. The growth of hardness of the ceramic- grey cast iron composite is ca. 60% as compared to the grey cast iron hardness. The growth of hardness of the ceramic- chromium cast iron composite is slight and does not exceed 5 % in comparison to the chromium cast iron. Introduction of the ceramic inserts deteriorates the cast iron impact strength by ca. 20 - 30 %. The use of ceramic inserts increases the resistance to abrasive wear in case of grey cast iron by ca. 13% and in case of the chromium cast iron by ca. 10 %.
The paper presents selected granular ceramic materials available on the Polish market. Their characteristics have been determined in the aspect on application in the production of iron alloy-ceramic composite. The possibility of obtaining a composite layer by means of bulk grains in molds of plates were considered, which was the foundation for experimental molds to be used in service tests. On the basis of obtaining results was stated that the knowledge of the characteristics of bulk grains enables the calculation of their quantity necessary for the composite production. When using the bulk grains the thickness of the composite layer is restricted by the thermal relations (cooler) and the physical phenomena (buoyancy, metal static pressure). Increasing amount of grains above definite condition causes surface defects in the castings. Each casting, due to its weight, shape and place of composite layer production requires an individual approach, both at the stage of formation and that of calculation of the required quantity of ceramic grains.
The paper presents an innovative method of creating the layered castings. The innovation relies on application the 3D printing insert obtaining in SLM (selective laser melting) method. This type of scaffold insert made from pure Ti powder, was placed into mould cavity directly before pouring by grey cast iron. In result of used method was obtained grey cast iron casting with surface layer reinforced by titanium carbides. In range of studies were carried out metallographic researches using light microscope and scanning electron microscope, microhardness measurements and abrasive wear resistance. On the basis of obtaining results was stated that there is a possibility of reinforcing surface layer of the grey cast iron casting by using 3D printing scaffold insert in the method of mould cavity preparation. Moreover there was a local increase in hardness and abrasive wear resistance in spite of the precipitation of titanium carbides in surface layer of grey cast iron. While the usable properties of composite surface layer obtained in result of use of the method presented in the paper, strongly depend of dimensions of scaffold insert, mainly parameters Re and Ri.