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Abstract

Refinement is one of the most energy consuming technological process, aimed at obtaining mineral raw materials of the proper grain size. Cast structural elements such as jaws or hammers in crushing machines operate under conditions of an intensive wear. The data indicate that 80 % of failures of machines and devices is caused by wearing of rubbing surfaces. This problem became the subject of several scientific and industrial investigations carried out in the whole world in order to produce materials ultra- wear resistant. Methods allowing to obtain wear resistant composite castings are discussed in the hereby paper. Within the performed research microstructures of the produced composite zones were presented and the comparative analysis with regard to mechanical and functional properties of local composite reinforcements in relation to the commercial alloys of increased wear resistance was performed. The results show almost twenty five times increase in wear resistance compared to manganese cast steel containing 18 % Mn.
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Abstract

In order to increase wear resistance cast steel casting the TiC-Fe-Cr type composite zones were fabricated. These zones were obtained by means of in situ synthesis of substrates of the reaction TiC with a moderator of a chemical composition of white cast iron with nickel of the Ni-Hard type 4. The synthesis was carried out directly in the mould cavity. The moderator was applied to control the reactive infiltration occurring during the TiC synthesis. The microstructure of composite zones was investigated by electron scanning microscopy, using the backscattered electron mode. The structure of composite zones was verified by the X-ray diffraction method. The hardness of composite zones, cast steel base alloy and the reference samples such as white chromium cast iron with 14 % Cr and 20 % Cr, manganese cast steel 18 % Mn was measured by Vickers test. The wear resistance of the composite zone and the reference samples examined by ballon-disc wear test. Dimensionally stable composite zones were obtained containing submicron sizes TiC particles uniformly distributed in the matrix. The macro and microstructure of the composite zone ensured three times hardness increase in comparison to the cast steel base alloy and one and a half times increase in comparison to the white chromium cast iron 20 % Cr. Finally ball-on-disc wear rate of the composite zone was five times lower than chromium white cast iron containing 20 % Cr.
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Abstract

The study presents the results of research on the development of composite zones in castings based on the intermetallic phase of Ni3Al. Composite zones were obtained by placing packets with substrates for the reaction of titanium carbide in a foundry mould. To provide a variable carbides content in the composite zone, two compositions of the packets were prepared. The first packet contained only substrates for the reaction of TiC synthesis; the second one also contained a filler. The resulting composite zones in castings were examined for the filler effect on changes in the volume fraction, size and morphology of carbides in the zone. In addition, the effect of filler on the mechanical properties of the zone was verified, observing changes of Vickers hardness in this area. It was found that the presence of filler in the composition of the packet for synthesis reduced the content of carbides, as well as their size and morphology. Lower surface content of carbides reduced hardness of the zone, which enabled smooth control of the mechanical properties. At the same time, the use of the selected filler did not disturb the course of the TiC carbide synthesis.
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