The work deals with technology Patternless process that combines 3 manufacturing process mold by using rapid prototyping technology,

conventional sand formation and 3D milling. It's unconventional technology that has been developed to produce large-sized and heavyduty

castings weighing up to several tons. It is used mainly in prototype and small batch production, because eliminating production of

models. The work deals with the production of blocks for making molds of gypsum and gypsum drying process technology Thermomold.

Into blocks, where were made cavities by milling were casted test castings from AlSi10MgMn alloy by gravity casting. At machining of

the mold cavity was varied feed rate of tool of cemented carbide. Evaluated was the surface roughness of test castings, that was to 5

micrometers with feed from 900 to 1300 mm/min. The dimensional accuracy of castings was high at feed rate of 1000 and 1500 mm/min

did not exceed 0.025 mm.

The present article deals with the possibility of using the reverse engineering method for the production of prototype molds by Patternless

process technology. Article describes method how to obtain virtual model by using a 3D scanner. Article also explains principle of the

Patternless process technology, which is based on the milling mold cavity using CNC machining equipment. The aim of the research is the

use of advanced technologies that speed up and facilitate the process of production prototype mold. The practical result of the presented

experiment is bronze casting, which serves as a foot rest bracket on historic bike.

The paper deals with squeeze casting technology. For this research a direct squeeze casting method has been chosen. As an experimental material, the AlSi12 and AlSi7Mg0.3 alloys were used. The influence of process parameters variation (pouring temperature, mold temperature) on mechanical properties and structure will be observed. For the AlSi7Mg0.3 alloy, a pressure of 30 MPa was used and for the AlSi12 alloy 50 MPa. The thicknesses of the individual walls were selected based on the use of preferred numbers and series of preferred numbers (STN ISO 17) with the sequence of 3.15 mm, 4 mm, 5 mm, 6.3 mm and 8 mm. The width of each wall was 22 mm and length 100 mm. The mechanical properties (Rm, A5) for individual casting parameters and their individual areas of different thicknesses were evaluated. For the AlSi7Mg0.3 alloy, the percentage increase of the tensile strength was up to 37% and the elongation by 400% (at the 8 mm thickness of the casting). For the AlSi12 alloy, the strength increased from 8 to 20% and the tensile strength increased from 5 to 85%. The minimum thickness of the wall to influence the casting properties by pressure was set to 5 mm (based on the used casting parameters). Due to the effect of the pressure during crystallization, a considerable refinement and uniformity of the casting structure occured, also a reduction in the size of the eutectic silicate-eliminated needles was observed.

The paper deals with the impact of technological parameters on the mechanical properties and microstructure in AlSi12 alloy

using squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze

casting method. The goal was to affect crystallization by pressure with a value 100 and 150 MPa. From the experiments we

can conclude that operating pressure of 100 MPa is sufficient to influence the structural characteristics of the alloy AlSi12.

The change in cooling rate influences the morphology of the silicon particles and intermetallic phases. A change of excluded

needles to a rod-shaped geometries with significantly shorter length occurs when used gravity casting method. At a pressure

of 100 MPa was increased of tensile strength on average of 20%. At a pressure of 150 MPa was increased of tensile strength

on average of 30%. During the experiment it was also observed, that increasing difference between the casting temperature

and the mold temperature leads to increase of mechanical properties.

This paper deals with production of safety inlay for steam locomotive valve by the Patternless Process method. For the moulds creation was used moulding mixtures of II. generation, whereas binder was used a water glass. CNC miller was used for creation of mould cavity. Core was created also by milling into block made of moulding compound. In this article will be presented also making of 3D model, setting of milling tool paths and parameters for milling.

Pouring of liquid aluminium is typically accompanied by disturbance of the free surface. During these disturbances, the free surface oxide

films can be entrained in the bulk of liquid, also pockets of air can be accidentally trapped in this oxide films. The resultant scattering of

porosity in castings seems nearly always to originate from the pockets of entrained air in oxide films. Latest version of ProCast software

allows to identify the amount of oxides formed at the free surface and where they are most likely to end-up in casts. During a filling

calculation, ProCast can calculate different indicators which allow to better quantify the filling pattern. The fluid front tracking indicator “

Free surface time exposure” has the units [cm2*s]. At each point of the free surface, the free surface area is multiplied by the time. This

value is cumulated with the value of the previous timestep. In addition, this value is transported with the free surface and with the fluid

flow.Experiments to validate this new functions were executed.

The paper deals with the impact of technological parameters on the heat transfer coefficient and microstructure in AlSi12 alloy using

squeeze casting technology. The casting with crystallization under pressure was used, specifically direct squeeze casting method. The goal

was to affect crystallization by pressure with a value 100 and 150 MPa. The pressure applied to the melt causes a significant increase of

the coefficient of heat transfer between the melt and the mold. There is an increase in heat flow by approximately 50% and the heat

transfer coefficient of up to 100-fold, depending on the casting conditions. The change in cooling rate influences the morphology of the

silicon particles and intermetallic phases. A change of excluded needles to a rod-shaped geometry with significantly shorter length occurs

when used gravity casting method. By using the pressure of 150 MPa during the crystallization process, in the structure can be observed an

irregular silica particles, but the size does not exceed 25 microns.

The paper deals with the influence of manganese in AlSi7Mg0.3 alloy with higher iron content. Main aim is to eliminate harmful effect of intermetallic – iron based phases. Manganese in an alloy having an iron content of about 0.7 wt. % was graded at levels from 0.3 to 1.4 wt. %. In the paper, the effect of manganese is evaluated with respect to the resulting mechanical properties, also after the heat treatment (T6). Morphology of the excluded intermetallic phases and the character of the crystallisation of the alloy was also evaluated. From the obtained results it can be concluded that the increasing level of manganese in the alloy leads to an increase in the temperature of the β-Al5FeSi phase formation and therefore its elimination. Reducing the amount of β-Al5FeSi phase in the structure results in an improvement of the mechanical properties (observed at levels of 0.3 to 0.8 wt. % Mn). The highest addition of Mn (1.4 wt.%) leads to a decrease in the temperature corresponding to the formation of eutectic silicon, which has a positive influence on the structure, but at the same time the negative sludge particles were also present

Main aim of submitted work is evaluation and experimental verification of inoculation effect on Al alloys hot-tear sensitivity. Submitted work consists of two parts. The first part introduces the reader to the hot tearing in general and provides theoretical analysis of hot tearing phenomenon. The second part describes strontium effect on hot tearing susceptibility, and gives the results on hot tearing for various aluminium alloys. During the test, the effect of alloy chemical composition on hot tearing susceptibility was also analyzed. Two different Al-based alloys were examined. Conclusions deals with effect of strontium on hot tearing susceptibility and confirms that main objective was achieved.

The paper deals with squeeze casting technology. For this research a direct squeeze casting method has been chosen. The influence of process parameters variation (casting temperature, mold temperature, pressure) on mechanical properties and structure will be observed. The thicknesses of the individual walls were selected based on the use of preferred numbers and series of preferred numbers (STN ISO 17) with the sequence of 3.15, 4.00, 5.00, 6.00 and 8.00 mm. The width of each wall was 22 mm with a length of 100 mm. As an experimental material was chosen the AlSi12 and AlSi7Mg0.3 alloys. The mechanical properties (UTS, E) for individual casting parameters and their individual areas of different thicknesses were evaluated. In the structure the influence of pressure on the change of the eutectic morphology, the change of the volume of eutectic and the primary alpha phase, the effect of the pressure on the more fine-grain and the regularization of the structure were evaluated.

The fluidity is the term to determine the materials ability to fill the mold cavity properly. Fluidity is complex property with many variables. Up to this date, there is no methodology for defining the fluidity in a semisolid material state. Submitted paper deals with the proposal of a new method designed for aluminium alloy fluidity evaluation in semi-solid state trough the design of the layered construction die. Die will be primary used for fluidity tests of semi-solid squeeze casted aluminium alloy and to observe the pressing force flow by mentioned casting technology. The modularity consists of possibility to change each die segment. In the experiment the die design was evaluated by simulation in ProCAST 11.5 and by production of experimental castings. The die was made by laser cutting technology from construction steel S355JR. Experimental material was aluminium alloy AlSi7Mg0.3. The temperature of the semisolid state was chosen to achieve 35% of solid phase. The result of next study should be a selected parameters observation and their effect on the fluidity of aluminium alloy in semi-solid state. This will be very important step to determine the optimal conditions to achieve a castings with certain wall thickness produced by the method of semi-solid squeeze casting.

Casting industry has been enriched with the processes of mechanization and automation in production. They offer both better working standards, faster and more accurate production, but also have begun to generate new opportunities for new foundry defects. This work discusses the disadvantages of processes that can occur, to a limited extend, in the technologies associated with mould assembly and during the initial stages of pouring. These defects will be described in detail in the further part of the paper and are mainly related to the quality of foundry cores, therefore the discussion of these issues will mainly concern core moulding sands. Four different types of moulding mixtures were used in the research, representing the most popular chemically bonded moulding sands used in foundry practise. The main focus of this article is the analysis of the influence of the binder type on mechanical and thermal deformation in moulding sands.

The article focuses on the analysis of the effect of Zr on the properties of the aluminium alloy AlSi9Cu1Mg. The effect of Zr was evaluated depending on the change in mechanical properties and heat resistance during a gradual addition of Zr with an increase of 0.05 wt. % Zr. Half of the cast experimental samples from each variant were heat treated by precipitation hardening T6 (hereinafter HT). The measured values in both states indicate an improvement of the mechanical properties, especially in the experimental variants with a content of Zr ≥ 0.20 wt. %. In the evaluation of Rm, the most significant improvement occurred in the experimental variant with an addition of Zr 0.25 wt. % after HT and E in the experimental variant with addition of Zr 0.20 wt. % after HT. Thus, a difference was found from the results of the authors defining the positive effect of Zr, in particular at 0.15 wt. %. When evaluating the microstructure of the AlSi9Cu1Mg alloy after Zr alloying, Zr phases are already eliminated with the addition of Zr 0.10 wt. %. Especially at higher levels of Zr ≥ 0.20 wt. %, long needle phases with slightly cleaved morphology are visible in the metal matrix. It can be stated that a negative manifestation of Zr alloying is expressed by an increase in gassing of experimental alloys, especially in variants with a content of Zr ≥ 0.15 wt. %. Experimental samples were cast into ceramic moulds. The development of an experimental alloy AlSi9Cu1Mg alloyed with Zr would allow the production of a more sophisticated material applicable to thin-walled Al castings capable of operating at higher temperature loads.

The paper deals with the effect of heating of various prepared batch materials into semisolid state with subsequent solidification of the cast under pressure. The investigated material was a subeutectic aluminium alloy AlSi7Mg0.3. The heating temperature to the semisolid was chosen at 50% liquid phase. The used material was prepared in a variety of ways: heat treatment, inoculation and by squeeze casting. Also the influence of the initial state of material on inheritance of mechanical properties and microstructure was observed. The pressure was 100 MPa. Effect on the resulting casting structure, alpha phase distribution and eutectic silicon was observed. By using semisolid squeeze casting process the mechanical properties and microstructures of the casts has changed. The final microstructure of the casts is very similar to the microstructure that can be reached by technology of thixocasting. The mechanical properties by using semisolid squeeze casting has been increased except the heat treated material.