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Abstract

The paper presents a microscopic analysis of the surface and fracture of aluminium castings produced using the lost-wax method for patterns made of a composite material, i.e. polyethylene with the addition of bentonite. Castings are made of AlSi7 aluminium alloy (silumin) in a plaster mould. A new type of polymer waxes enriched with bentonite was used to obtain new composites, minimizing the defects caused by the casting production process. The castings were made in the centrifugal casting process. The prepared plaster moulds were removed from the furnace and poured with liquid aluminium alloy (AlSi7) at 750°C. The surface and fracture of the castings was analysed using an optical digital microscope type VHX-7000 manufactured by KEYENCE. It has been proven that the studied castings feature surface defects (raw surface defects) in the form of high roughness and the presence of bentonite inclusions classified as casting contamination. During the tests, shape defects related to mechanical damage were also detected.
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Bibliography

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Authors and Affiliations

D. Czarnecka-Komorowska
1
ORCID: ORCID
K. Gawdzińska
2
ORCID: ORCID
P. Popielarski
1
ORCID: ORCID

  1. Poznań University of Technology, Poland
  2. Maritime University of Szczecin, Poland
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Abstract

In this research, the quality of manufactured cast metal-ceramic foams (manufactured using blowing gas) was tested. The causes responsible for defect formation in the composite foams and their consequences were analyzed using the FMEA (Failure Mode and Effects Analysis) method, which is a useful tool for minimizing losses caused by low product quality. This method involves analytically determining correlations between the cause and consequences of potential product defects, and it takes into account the criticality factor (risk). The FMEA analysis showed that pore breaks were the most "critical defect" (with the highest number of effects on the product, the Risk Priority Number, affecting the quality of the composite foam). The second most critical defect was discontinuities in the foam frame structure. Destruction or damage to the foam structure (although very rare) deprived the composite foam of its primary function, which is to reinforce the product. The third most critical defect was non-uniform foam pore size.
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Authors and Affiliations

P. Popielarski
1
ORCID: ORCID
R. Sika
1
D. Czarnecka-Komorowska
1
ORCID: ORCID
P. Szymański
1
ORCID: ORCID
M. Rogalewicz
1
K. Gawdzińska
2
ORCID: ORCID

  1. Institute of Materials Technology, Poznan University of Technology Piotrowo 3, 61-138 Poznań, Poland
  2. Faculty of Marine Engineering, Maritime University of Szczecin, Willowa 2-4, 71-650 Szczecin, Poland

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