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Optimizing of Metal Foam Design for the Use as a Heat Exchanger

F. Radkovský M. Gebauer V. Merta
Archives of Metallurgy and Materials | 2018 | vol. 63 | No 4 | 1875-1881 | DOI: 10.24425/amm.2018.125118
Keywords metal foam 3D modeling heat exchanger heat conduction efficiency
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Abstract

The work deals with possibilities of using this specific material. It is focused on cast metal foams with a regular arrangement of internal cells and it refers to already used casting technologies – the production of metal foamswith the aid of sand cores. Metal foamsare used in many industries, such as: automotive, aerospace, construction, power engineering. They have unique propertiesand due to lower weight with sufficient strength and greater contact surface can be used, for example, for the conduction of heat. This article deals with the useof the metal foam as a heat exchanger. The efficiency of the heat exchanger depends on its shape and size and therefore the study is focused first on the optimization of the shape before the proper manufacture.

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Authors and Affiliations

F. Radkovský
M. Gebauer
V. Merta

Influence of Silica Sand on Surface Casting Quality

J. Beňo K. Adamusová V. Merta T. Bajer
Archives of Foundry Engineering | 2019 | vol. 19 | No 2 | 5-8 | DOI: 10.24425/afe.2019.127107
Keywords Innovative foundry technologies and materials Castings defects Silica sand Veining COLD-BOX amine
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Abstract

The current casting production of castings brings increased demands for surface and internal quality of the castings. Important factors, that influence the quality of casted components, are the materials used for the manufacture of moulds and cores. For the preparation and production of moulds and cores, in order to achieve a low level of casting defects, then it used a high quality input materials, including various types of sands, modified binders, additives, etc. However, even the most expensive raw materials are not a guarantee to achieve the quality of production.

It is always necessary to choose the appropriate combination of input material together with an appropriate proposal for the way of the production, the metallurgical treatment of cast alloy, etc. The aim of this paper is to establish the basic principles for the selection of the base core mixtures components – sands to eliminate defects from the tension, specifically veining. Various silica sand, which are commonly used in foundries of Middle Europe region, were selected and tested.

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Authors and Affiliations

J. Beňo
K. Adamusová
V. Merta
T. Bajer

Design of Proven Technology of Metal Foam and Porous Metal Casting Production

F. Radkovský V. Merta T. Obzina
Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 125-131 | DOI: 10.24425/afe.2021.136088
Keywords Casting Porous metal metallic foam Lost Foam Heat exchanger
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Abstract

The article describes the design of a proven technology for the production of metal foam and porous metal by the foundry. Porous metal formed by infiltrating liquid metal into a mould cavity appears to be the fastest and most economical method. However, even here we cannot do without the right production parameters. Based on the research, the production process was optimised and subsequently a functional sample of metal foam with an irregular internal structure - a filter - was produced. The copper alloy filter was cast into a gypsum mould using an evaporable model.
Furthermore, a functional sample of porous metal with a regular internal structure was produced - a heat exchanger. The aluminium alloy heat exchanger was cast into a green sand mould using preforms. Also, a porous metal casting with a regular internal structure was formed for use as an element in deformation zones. This aluminium alloy casting was made by the Lost Foam method. The aim is therefore to ensure the production of healthy castings, which would find use in the field of filtration of liquid metal or flue gases, in vehicles in the field of shock energy absorption and also in energy as a heat exchanger.
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Bibliography

[1] Lefebvre, L.P., Banhart, J. & Dunand, D. (2008). Porous metals and metallic foams: current status and recent developments. Advanced Engineering Materials. 10(9), 775-787.
[2] Banhart, J. (2001). Manufacture, characterisation and application of cellular metals and metal foams. Progress in Materials Science. 46(6), 559-632.
[3] Banhart, J. (2007). Metal Foams - from Fundamental Research to Applications [online], URL: < https://www.helmholtz-berlin.de/media/media/spezial/people/banhart/html/B-Conferences/b097_banhart2007.pdf>.
[4] Gaillard, Y., Dairon, J., & Fleuriot, M. (2011). Porous materials: innovations with many uses. Slévárenství. 11-12, roč. LIX, 374-378. (in Czech).
[5] Banhart, J. (2005). Aluminium foams for lighter vehicles. International Journal of Vehicle Design. 37, Nos. 2/3, 114-125. [online]. URL: < http://www.helmholtz-berlin.de/media/media/spezial/people/banhart/html/A-Journals/open/article/a082_banhart2005.pdf>.
[6] García-Moreno, F. Commercial Applications of Metal Foams: Their Properties and Production. [online]. URL: < http://www.mdpi.com/1996-1944/9/2/85/html>.
[7] Banhart, J. Metallic Foams II: properties and application [online]. URL: < http://materialsknowledge.org/docs/ Banhart-talk2.pdf>.
[8] Landolsi, M.W. (2016). Metal foam - an innovative material. [online]. URL: < https://conceptec.net/actualites/innovations/ 111-mousse-metallique-un-materiau-innovant>. (in Czech).
[9] Lulusoso. Composite cladding panel manufacturers [online]. URL: < http://www.lulusoso.com/products/ Composite-Cladding-Panel-Manufacturers.html>.
[10] Erg Materials and Aerospace; Duocel® Foam Cells. [online]. URL: < http://www.ergaerospace.com/products/ fuel-cells.html>.
[11] Kroupová, I., Lichý, P., Ličev, L., Hendrych, J. & Souček, K. (2018). Evaluation of properties of cast metal foams with irregular inner structure. Archives of Metallurgy and Materials. 63(4), 1845-1849. ISSN 1733-3490.
[12] Kroupova, I., Bednarova, V., Elbel, T. & Radkovsky, F. (2014). Proposal of method of removal of mould material from the fine structure of metallic foams used as filters. Archives of Metallurgy and Materials. 59(2), 727-730. ISSN 1733-3490.
[13] Yamada. Y., Shimojima, K., Sakaguchi, Y., Mabuchi, M., Nakamura, M., Asahina, T., Mukai, T., Kanahashi, H. & Higashi, K. (2000). Effects of heat treatment on compressive properties of AZ91 Mg and SG91A Al foams with open-cell structure. Materials Science and Engineering: A. 280(1), 225-228. DOI: https://doi.org/ 10.1016/S0921-5093(99)00671-1.
[14] Gawdzinska, K., Chybowski, L. & Przetakiewicz, W. (2017). Study of thermal properties of cast metal-ceramic composite foams. Archives of Metallurgy and Materials. 17(4), 47-50. ISSN 1897-3310.
[15] Haack, P.D., Butcher, R.P., Kim, T. & Lu, J.T. (2001). Novel lightweight metal foam heat exchangers. porvair fuel cell technology, Inc., Department of Engineering, University of Cambridge. January, [online]. URL: < https://www.researchgate.net/publication/267721239_Novel_Lightweight_Metal_Foam_Heat_Exchangers>.
[16] Radkovský, F., Merta, V. (2020). Use of numerical simulation in production of porous metal casting. Archives of Metallurgy and Materials. 54(2), 259-261. ISSN 1580-2949. DOI: 10.17222/mit.2019.145.
[17] Radkovský, F., Gebauer, M., Kroupová, I., Lichý, P. (2017). Metal foam as a heat exchanger. In METAL 2017, Conference proceedings, 26th Anniversary International Conference on Metallurgy and Materials, Tanger Ltd., Ostrava, 24. - 26. 5. 2017, Hotel Voroněž I, Brno.
[18] Lu, T.J., Stone, H.A. & Ashby, M.F. (1998). Heat transfer in open-cell metal foams. Acta Materialia. 46(10, 12) June, 3619-3635. DOI: https://doi.org/10.1016/S1359-6454(98) 00031-7
[19] Boomsma, K., Poulikakos, D. & Zwick, F. (2003). Metal foams as compact high performance heat exchangers. Mechanics of Materials, 35(12), 1161-1176. DOI: https://doi.org/10.1016/j.mechmat.2003.02.001.
[20] Hutter, C., Büchi, D., Zuber, V. & Rohr, R. (2011). Heat transfer in metal foams and designed porous media. Chemical Engineering Science. 66(17), 1 September 2011, 3806-3814. DOI: https://doi.org/10.1016/j.ces.2011.05.005
[21] Lichý, P., Elbel, T., Kroupová, I. & Radkovský, F. (2017). Preparation and evaluation of properties of cast metallic foams with regular inner structure. Archives of Metallurgy and Materials. 62(3), 1643-1646. ISSN 1733-3490. DOI: 10.1515/amm-2017-0251.
[22] Romanek, T. (2017). Manufacturing and Properties of Cast Metallic Foams with Regular Structure, Ostrava, Diploma thesis, VSB - Technical University of Ostrava, [online]. URL: http://www.ergaerospace.com/products/fuel-cells.htm>.
[23] Radkovský, F., Gebauer, M. & Merta, V. (2018). Optimizing of metal foam design for the use as a heat exchanger. Archives of Metallurgy and Materials. 63(4), 1875-1881. ISSN 1733-3490.

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Authors and Affiliations

F. Radkovský
1
ORCID: ORCID
V. Merta
1
ORCID: ORCID
T. Obzina
1
  1. VSB - Technical University of Ostrava, Czech Republic

Evaluation of Collapsibility of Selected Core Systems

T. Obzina V. Merta J. Rygel P. Lichý K. Drobíková
Archives of Foundry Engineering | 2022 | vol. 22 | No 1 | 48-52 | DOI: 10.24425/afe.2022.140216
Keywords Foundry Foundry cores De-coring Knocking-out Collapsibility
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Abstract

There are mainly two different ways of producing sand cores in the industry. The most used is the shooting moulding process. A mixture of sand and binder is injected by compressed air into a cavity (core), where it is then thermally or chemically cured. Another relatively new method of manufacturing cores is the use of 3D printing. The principle is based on the method of local curing of the sand bed. The ability to destroy sand cores after casting can be evaluated by means of tests that are carried out directly on the test core. In most cases, the core is thermally degraded and the mechanical properties before and after thermal exposure are measured. Another possible way to determine the collapsibility of core mixtures can be performed on test castings, where a specific casting is designed for different binder systems. The residual strength is measured by subsequent shake-out or knock-out tests. In this paper, attention will be paid to the collapsibility of core mixtures in aluminium castings.
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Bibliography

[1] Dietert, H.W. (1950). Core knock-out, in Foundry Core Practice, 2nd ed. Chicago: American Foundrymen’s Society.
[2] Jorstad, J.L. (2008). Expendable-mold casting processes with permanent patterns, in ASM Handbook Vol. 15 Casting, 10th ed. ASM International
[3] Almaghariz, E.S., Conner, B.P., Lenner, L., Gullapalli, R., Manogharan, G.P. (2016). Quantifying the role of part design complexity in using 3D sand printing for molds and cores. International Journal of Metalcasting. 10, 240-252. DOI: 10.1007/s40962-016-0027-5.
[4] Vykoukal, M., Burian, A., Přerovská, M., Bajer, T., Beňo, J. (2019). Gas evolution of GEOPOL® W sand mixture and comparison with organic binders. Archives of Foundry Engineering. 19(2), 49-54.
[5] Steinhäuser, T. (2017). Inorganic binders-Benefits, State of the art, Actual use. In World Cast in Africa, Innovative for Sustainability, Proceedings of the South African Metal Casting Conference, Johannesburg, South Africa, 13–17 March 2017; WFO: Johannesburg, South Africa, p. 26
[6] Ramrattan, S. (2019). Evaluating a ceramic resin-coated sand for aluminum and iron castings. International Journal of Metalcasting. 13(3), 519-527. DOI: https://doi.org/10.1007/s40962-018-0269-5
[7] Ettemeyer, F., Schweinefuß, M., Lechner, P., Stahl, J., Greß, T., Kaindl, J., Durach, L., Volk, W. & Günther, D. (2021). Characterisation of the decoring behaviour of inorganically bound cast-in sand cores for light metal casting. Journal of Materials Processing Technology. 296, 117201, ISSN 0924-0136. DOI: https://doi.org/10.1016/j.jmatprotec.2021. 117201.
[8] Dobosz, P., Jelínek, K., Major-Gabryś, K. (2011). Development tendencies of moulding and core sands. China Foundry. 8, 438-446.

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Authors and Affiliations

T. Obzina
1
V. Merta
1
ORCID: ORCID
J. Rygel
1
P. Lichý
1
ORCID: ORCID
K. Drobíková
1
  1. VSB - Technical University of Ostrava, Czech Republic

Technology of Production of Mold Filling Material for Specific Purposes in the Field of Metallic Foam Casting

I. Kroupová M. Bašistová P. Lichý V. Merta F. Radkovský J. Jezierski
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 2 | 757-763 | DOI: 10.24425/amm.2023.142458
Keywords molding mixture metallic foams precursor abrasion loss 3-point bending strength
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Abstract

This paper describes the technology for the production of precursors (space holder material) used to form the complex internal structure of cast metal foam. The precursor material must exhibit sufficient refractoriness, resist contact with liquid metal and at the same time should exhibit good collapsibility after casting. With regard to the greening of foundry production, the focus of this paper was on materials that could exhibit the above properties and at the same time do not have a negative impact on the environment. In this paper, the technology for the production of spherical precursors from a self-hardening mixture with a geopolymer-based binder system is described and verified. The motivation for the choice of material and all the sub-steps of the process – molding into the core box, tumbling, including the necessary accompanying tests of the mechanical properties of the core mixture being verified – are described.
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Authors and Affiliations

I. Kroupová
1
ORCID: ORCID
M. Bašistová
1
ORCID: ORCID
P. Lichý
1
ORCID: ORCID
V. Merta
1
ORCID: ORCID
F. Radkovský
1
ORCID: ORCID
J. Jezierski
2
ORCID: ORCID
  1. VŠB-Technical University of Ostrava, Faculty of Materials Science and Technology, Department of Metallurgical Technologies, 17. Listopadu 2172/15, Ostrava-Poruba, Czech Republic
  2. Silesian University of Technology, Faculty of Mechanical Engineering, Department of Foundry Engineering, 2 Towarowa Str., 744-100 Gliwice, Poland

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