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Abstract

The results of studies on the use of modern two cored wires injection method for production of nodular graphite cast iron with use of unique implementation of drum ladle as a treatment/ transport and casting ladle instead vertical treatment ladle was described. The injection of length of Ø 9mm wires, cored: in FeSi + Mg nodulariser mixture and inoculant master alloy is a treatment method which can be used to produce iron melted in coreless induction furnace. This paper describes the results of using this method for possibility production of ductile iron under specific industrial conditions. In this case was taken ductile iron with material designation: EN-GJS-450- 10 Grade according PN-EN 1563:2000. Microstructure of 28 trials was controlled on internally used sample which has been correlated with standard sample before. The paper presents typical metallic matrix and graphite characteristic. Additionally, mechanical properties were checked in one experiment. Because of further possibility treatment temperature reduction only the rough magnesium recovery and cost of this new method are given.

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Authors and Affiliations

E. Guzik
D. Wierzchowski
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Abstract

The results of studies on the use of modern two cored wires injection method for production of ferritic nodular cast iron (ductile iron) with use of unique implementation of drum ladle as a treatment / transport and casting ladle instead vertical treatment ladle was described. The injection of length of Ø 9mm wires, cored: in FeSi + Mg nodulariser mixture and inoculant master alloy is a treatment method which can be used to produce iron melted in coreless induction furnace. This paper describes the results and analysis of using this method for optimal production of ductile iron under specific industrial conditions. It means, that length of nodulariser wire plus treatment and pouring temperatures were optimized. In this case, was taken ductile iron with material designation: EN-GJS-SiMo40-6 Grade according EN 16124:2010 E. Microstructure of great number of trials was controlled on internally used sample which has been correlated with standard sample before. The paper presents typical ferritic metallic matrix and nodular graphite. Additionally, mechanical properties were checked in some experiments. Mean values of magnesium recovery and cost of this new method from optimized process parameters were calculated as well.
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Authors and Affiliations

E. Guzik
D. Wierzchowski
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Abstract

Studies were conducted on a zinc coating produced on the surface of ductile iron grade EN-GJS-500-7 to determine the eutectic grain

effect. For this purpose, castings with a wall thickness of 5 to 30 mm were made and the resulting structure was examined. To obtain a

homogeneous metal matrix, samples were subjected to a ferritising annealing treatment. To enlarge the reaction surface, the top layer was

removed from casting by machining. Then hot dip galvanising treatment was performed at 450°C to capture the kinetics of growth of the

zinc coating (in the period from 60 to 600 seconds). Analysing the test results it was found that within the same time of hot dip

galvanising, the differences in the resulting zinc coating thickness on samples taken from castings with different wall cross-sections were

small but could, particularly for shorter times of treatment, reduce the continuity of the alloyed layer of the zinc coating.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
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Abstract

Studies were carried out to determine the effect of heat treatment parameters on the plastic properties of unalloyed ausferritic ductile iron,

such as the elongation and toughness at ambient temperature and at – 60 °C. The effect of austenitizing temperature (850, 900 and 950°C)

and ausferritizing time (5 - 180 min.) at a temperature of 360°C was also discussed. The next step covered investigations of

a relationship that is believed to exist between the temperature (270, 300, 330, 360 and 390 °C) and time (5, 10, 30, 60, 90, 120, 150, 180,

240 min.) of the austempering treatment and the mechanical properties of unalloyed ausferritic ductile iron, when the austenitizing

temperature is 950°C. The “process window” was calculated for the ADI characterized by high toughness corresponding to the EN-GJS800-10-RT

and EN-GJS-900-8 grades according to EN-PN 1564 and to other high-strength grades included in this standard. Low-alloyed

cast iron with the nodular graphite is an excellent starting material for the technological design of all the ausferritic ductile iron grades

included in the PN-EN-1624 standard. The examined cast iron is characterized by high mechanical properties stable within the entire range

of heat treatment parameters.

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Authors and Affiliations

E. Guzik
M. Sokolnicki
A. Nowak
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Abstract

The paper presents the results of investigations of the growth of protective coating on the surface of ductile iron casting during the hot-dip

galvanizing treatment. Ductile iron of the EN-GJS-600-3 grade was melted and two moulds made by different technologies were poured to

obtain castings with different surface roughness parameters. After the determination of surface roughness, the hot-dip galvanizing

treatment was carried out. Based on the results of investigations, the effect of casting surface roughness on the kinetics of the zinc coating

growth was evaluated. It was found that surface roughness exerts an important effect on the thickness of produced zinc coating

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
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Abstract

The article presents results of heat treatment on the high chromium cast iron. The study was carrying out on samples cut from the casting

made from chromium cast iron. Those were hardened at different temperatures, then tempered and soft annealed. The heat treatment was

performed in a laboratory chamber furnace in the Department of Engineering Alloys and Composites at Faculty of Foundry Engineering

AGH. At each stage of the heat treatment the hardness was measured by Vickers and Rockwell methods, and the microscope images were

done. Additionally based on images from the optical microscope the microstructure was assessed. Based on these results, the effect of

hardening, tempering and soft annealing on the microstructure and hardness of high chromium cast iron was studied. Next the effects of

different hardening temperatures on the properties of high chromium cast iron were compared. The study led to systemize the literature

data of the parameters of heat treatment of high chromium cast iron, and optimal conditions for heat treatment was proposed for casts of

similar properties and parameters.

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Authors and Affiliations

D. Kopyciński
E. Guzik
D. Siekaniec
A. Szczęsny
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Abstract

This paper presents the study about defects found in industrial high silicon ductile iron. The microstructures were analysed using an optical microscope. Afterwards, a scanning electron microscope was used to analyse the chemical composition.The study also examined the origin of oxygen and what is the amount of oxygen in the cast iron.The amount of active oxygen was measured at two production processes. Firstly, at the end of melting process, and secondly, after the nodularization treatment. The research was carried out with different proportions of the raw materials. The focus was on determining the mechanism of the formation of slag defects to eliminate them in order to obtain ductile iron with increased silicon content of the highest possible quality. The research presented in this publication is a part of an implementation doctorate carried out in the METALPOL Foundry in Węgierska Górka (Poland). The presented research concerns the elaboration of initial parameters of liquid metal intended for processing into high-silicon ductile cast iron SiMo1000 type with aluminum and chromium additives.
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Bibliography

[1] Kopyciński, D. (2015). Shaping the structure and mechanical properties of cast iron intended for operation in difficult conditions of use (selected issues). Katowice-Gliwice: Monography. Archives of Foundry Engineering. (in Polish).
[2] Kleiner, S. & Track K. (2010). SiMo 1000 - Ein aluminium - legiertes gusseisen für Hochtemperatur-anwendungen. Giesserei. 97, 28-34.
[3] Papis, K., Tunziniand, S., Menk, W. (2014). Cast iron alloys for exhaust applications. In 10th International Symposium on the Science and Processing of Cast Iron - SPCI10, November 2014. Mar del Plata, Argentina.
[4] Öberg, Ch., Zhu, B. & Jonsson, S. (2017). Plastic deformation and creep of two ductile cast irons, SiMo51 and SiMo1000, during thermal cycling with large strain. Materials Science Forum. 925, 361-368. DOI: https://doi.org/10.4028/www.scientific.net/MSF.925.361.
[5] Guzik, E. (2001). Cast iron refining processes, selected issues. Katowice: Archiwum Odlewnictwa PAN. (in Polish).
[6] Collective work (2013). Foundry's guide. Kraków: STOP. 138-139. (in Polish).
[7] Keivan A. Kasvayee, & Ghasemali E. (2017). Characterization and modeling of the mechanical behavior of high silicon ductile iron. Material Science & Engineering A. 708, 159-170. DOI: https://doi.org/10.1016/j.msea.2017.09.115.
[8] Li, D., Perrin,. R., Burger, G., McFarlan, D., Black, B., Logan, R. & Williams, R. (2004). Solidification behavior, microstructure, mechanical properties, hot oxidation and thermal fatigue resistance of high silicon SiMo nodular cast irons. SAE International, Warrendale, 1-12. DOI: https://doi.org/10.4271/2004-01-0792.
[9] Muller, J., Wolf, G. (2001). Optimierte magnesiumdrahtinjektionstechnik zur herstellung von hochwertigem gusseisen mit kugelgraphit aus kupolofenbasiseisn. Giessereiforschung. 53(3), 85-103.
[10] Hampl, J. & Elbert, T. (2010). On modelling of the effect of oxygen on graphite morphology and properties of modified cast irons. Archives of Foundry Engineering. 10(4), 55-60.
[11] Mocek, J., Chojecki, A. (2009). Changes in the gas atmosphere of the casting mould during pouring iron alloys. In XXXIII Scientific Founder's Day Conference. Kraków. (in Polish).
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Authors and Affiliations

Ł. Dyrlaga
1 2
D. Kopyciński
1
E. Guzik
1

  1. AGH University of Science and Technology, Department of Foundry Engineering, Al. Mickiewicza 30, 30-059 Kraków, Poland
  2. METALPOL Węgierska Górka ul. Kolejowa 6, 34-350 Węgierska Górka, Poland
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Abstract

The paper presents results of Ti-addition to High Chromium Cast Iron (HCCI) on the structure and selected mechanical properties. For this

study casted two sets of cylinders with dimensions ø20 mm, ø15 mm x 250 mm, for the High Chromium Cast Iron (HCCI) and with the

4% by mass Ti-addition. Melts were performed in the induction furnace crucible capacity of 15 kg. During the heats the cup with installed

S type thermocouple was poured to record the cooling curves. The cylinders were subjected to the static bending strength test. Samples for

the test microstructure and Rockwell hardness were cut from the cylinders. The study shows that the addition of titanium had an impact on

the structure and thus the properties of High Chromium Cast Iron (HCCI). In subsequent studies, through an appropriate choice of

chemical composition and proper process control, it is planned to obtain in the structure the titanium carbides TiC and chromium carbides

with type (Cr, Fe)7C3.

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Authors and Affiliations

D. Kopyciński
E. Guzik
D. Siekaniec
A. Szczęsny
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Abstract

This study presents an analysis of aluminium cast iron structure (as-cast condition) which are used in high temperatures. While producing casts of aluminium iron, the major influence has been to preserve the structure of the technological process parameters. The addition of V, Ti, Cr to an Fe-C-Al alloy leads to the improvement of functional and mechanical cast qualities. In this study, a method was investigated to eliminate the presence of undesirable Al4C3 phases in an aluminium cast iron structure and thereby improve the production process. V and Ti additions to aluminium cast iron allow the development of FeAl - VC or TiC alloys. In particular, V or Ti contents above 5 wt.% were found to totally eliminate the presence of Al4C3. In addition, preliminary work indicates that the alloy with the FeAl - VC or TiC structure reveals high oxidation resistance. The introduction of 5 wt.% chromium to aluminium cast iron strengthened the Al4C3 precipitate. Thus, the resultant alloy can be considered an intermetallic FeAl matrix strengthened by VC and TiC or modified Al4C3 reinforcements.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
R. Gilewski
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Abstract

The article presents the method to assess the diffusion coefficient D in the sub-layer of intermetallic phases formed during hot-dip

galvanizing “Armco” iron and ductile cast iron EN-GJS-500-7. Hot-dip galvanizing is one of the most popular forms of long-term

protection of Fe-C alloys against corrosion. The process for producing a protective layer of sufficient quality is closely related to diffusion

of atoms of zinc and iron. The simulation consist in performed a hot-dip galvanizing in laboratory condition above Fe-C alloys, in the

Department of Engineering of Cast Alloys and Composites. Galvanizing time ranged from 15 to 300 seconds. Then metallographic

specimens were prepared, intermetallic layers were measured and diffusion coefficient (D) were calculated. It was found that the diffusion

coefficient obtained during hot-dip galvanizing “Armco” iron and zinc is about two orders of magnitude less than the coefficient obtained

on ductile cast iron EN-GJS-500-7.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Szczęsny
D. Siekaniec
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Abstract

The results of studies on the use of magnesium alloy in modern Tundish + Cored Wire injection method for production of vermicular graphite cast irons were described. The injection of Mg Cored Wire length is a treatment method which can be used to process iron melted in an electric induction furnace. This paper describes the results of using a high-magnesium ferrosilicon alloy in cored wire for the production of vermicular graphite cast irons at the; Tundish + Cored Wire to be injected methods (PE) for pearlitic-ferritic matrix GJV with about 25 %ferrite content. The results of calculations and experiments have indicated the length of the Cored Wire to be injected basing on the initial sulfur content and weight of the treated melt. The paper presents a microstructure matrix and vermicular graphite in standard sample and different walled castings. The results of numerous trials have shown that the magnesium Tundish + PE Method process can produce high quality vermicular graphite irons under the specific industrial conditions of the above mentioned foundries.

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Authors and Affiliations

E. Guzik
D. Kopyciński
T. Kleingartner
M. Sokolnicki
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Abstract

The present investigation focuses on the study of the influence of titanium inoculation on tribological properties of High Chromium Cast Iron. Studies of tribological properties of High Chromium Cast Iron, in particularly the wear resistance are important because of the special application of this material. High Chromium Cast Iron is widely used for parts that require high wear resistance for example the slurry pumps, brick dies, several pieces of mine drilling equipment, rock machining equipment, and similar ones. Presented research described the effects of various amounts of Fe-Ti as an inoculant for wear resistance. The results of wear resistance were collated with microstructural analysis. The melts were conducted in industrial conditions. The inoculation was carried out on the stream of liquid metal. The following amount of inoculants have been used; 0.17% Fe-Ti, 0.33% Fe-Ti and 0.66% Fe-Ti. The tests were performed on the machine type MAN. The assessment of wear resistance was made on the basis of the weight loss. The experimental results indicate that inoculation improve the wear resistance. In every sample after inoculation the wear resistance was at least 20% higher than the reference sample. The best result, thus the smallest wear loss was achieved for inoculation by 0.66% Fe-Ti. There is the correlation between the changing in microstructure and wear resistance. With greater amount of titanium the microstructure is finer. More fine carbides do not crumbling so quickly from the matrix, improving the wear resistance.

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Authors and Affiliations

D. Siekaniec
D. Kopyciński
A. Szczęsny
E. Guzik
E. Tyrała
A. Nowak
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Abstract

The results of studies on the use of magnesium alloy in modern Tundish for production of vermicular graphite cast irons were described. This paper describes the results of using a low-magnesium ferrosilicon alloy for the production of vermicular graphite cast irons. The paper presents a vermicular (and nodular) graphite in different walled castings. The results of trials have shown that the magnesium Tundish process can produce high quality vermicular graphite irons under the specific industrial conditions of Foundries - Odlewnie Polskie S.A. in Starachowice. In this work describes too preliminary studies on the oxygen state in cast iron and their effect on graphite crystallization.

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Authors and Affiliations

D. Kopyciński
E. Guzik
A. Nowak
M. Ronduda
M. Sokolnicki
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Abstract

The present work, presented the study of effect of different inoculants on impact toughness in High Chromium Cast Iron. The molds were

pouring in industrial conditions and samples were tested in laboratory in Faculty of Foundry Engineering at AGH. Seven samples were tested

- one reference sample, three with different addition of Fe-Ti, and three with different addition of Al. The samples were subjected to impact

toughness on Charpy hammer and the hardness test. The presented investigations indicate that for the each inoculant there is an optimal

addition at which the sample obtained the highest value of impact toughness. For the Fe-Ti it is 0.66% and for Al is 0.17%. Of all the

examined inoculants best results were obtained at a dose of 0.66% Fe-Ti. Titanium is a well-known as a good modifier but very interesting

results gives the aluminum. Comparing the results obtained for the Fe-Ti and Al can be seen that in the case of aluminum hardness is more

stable. The hardness of all samples is around 40-45 HRC, which is not high for this type of cast iron. Therefore, in future studies it is

planned to carry out the heat treatment procedure that may improves hardness.

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Authors and Affiliations

D. Siekaniec
D. Kopyciński
E. Guzik
E. Tyrała
A. Nowak
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Abstract

Metal alloys with matrix based on an Fe-Al system are generally considered materials for high-temperature applications. Their main advantages are compact crystallographic structure, long-range ordering and structural stability at high temperatures. These materials are based on an intermetallic phase of FeAl or Fe3Al, which is stable in the range from room temperature up to the melting point of 1240°C. Their application at high temperatures is also beneficial because of the low cost of production, very good resistance to oxidation and corrosion, and high mechanical strength. The casting alloy the structure of which includes the FeAl phase is, among others, highaluminium cast iron. This study has been devoted to the determination of the effect of vanadium and titanium on the transformation of the high-aluminium cast iron structure into an in-situ FeAl-VC composite.
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Authors and Affiliations

D. Kopyciński
E. Guzik
R. Gilewski
A. Szczęsny
J. Dorula

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