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Number of results: 5
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Abstract

This article is devoted to basalt reprocessing together with magnetite concentrate in order to obtain ferrous alloy and calcium carbide. The studies have been based on thermodynamic simulation and electric smelting in arc furnace. The thermodynamic simulation has been performed using HSC-5.1 software based on the principle of minimum Gibbs energy. The blend was smelted in arc furnaces. On the basis of the obtained results of combined processing of basalt, it has been established that under equilibrium conditions, the increase in carbon content from 36 to 42 wt % of basalt and concentrate mixture makes it possible to increase the aluminum extraction into the alloy up to 81.4%, calcium into calcium carbide – up to 51.4%, and silicon into the alloy – up to 78.5%. Increase in the amount of lime to 32% allows to increase the content of calcium carbide to 278 dm3/kg. Electric smelting of the blend under laboratory conditions in the presence of 17-32% of lime makes it possible to extract ferrous alloy containing 69.5-72.8% of silicon, 69.1-70.2% of aluminum, and to obtain ferrous alloy containing 49-53% of ΣSi and Al and calcium carbide in the amount of 233-278 dm3/kg. During large-scale laboratory smelting of blend comprised of basalt (38.5%), magnetite concentrate (13.4%), lime (15.4%), and coke fines (32.7%), the ferrous alloy has been produced containing 48-53% of ΣSi and Al, calcium carbide in amount of 240-260 dm3/kg. Extraction of Si and Al into the alloy was 70.4 and 68.6%, respectively; Ca into carbide – 60.3%; Zn and Pb into sublimates – 99.6 and 92.8%, respectively.

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Authors and Affiliations

V.M. Shevko
G.E. Karataeva
A.D. Badikova
M.A. Tuleev
R.A. Uteeva
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Abstract

Recyclability is one of the great features of aluminium and its alloys. However, it has been typically considered that the secondary aluminium quality is low and bad. This is only because aluminium is so sensitive to turbulence. Uncontrolled transfer and handling of the liquid aluminium results in formation of double oxide defects known as bifilms. Bifilms are detrimental defects. They form porosity and deteriorate the properties. The detection and quantification of bifilms in liquid aluminium can be carried out by bifilm index measured in millimetres as an indication of melt cleanliness using Reduced Pressure Test (RPT). In this work, recycling efficiency and quality change of A356 alloy with various Ti additions have been investigated. The charge was recycled three times and change in bifilm index and bifilm number was evaluated. It was found that when high amount of Ti grain refiner was added, the melt quality was increased due to sedimentation of bifilms with Ti. When low amount of Ti is added, the melt quality was degraded.

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Authors and Affiliations

O. Gursoy
E. Erzi
K. Tur
D. Dispinar
ORCID: ORCID
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Abstract

The paper presents the properties of plastics under the trade names of PMMA and Midas, and of Formowax, Romocast 305 and Romocast 930 casting waxes. Their effect on the quality of foundry patterns used in the manufacture of ceramic moulds for precision casting is also discussed. From the selected materials for foundry patterns, samples were made for testing using the following methods: (i) 3D printing in the case of plastics, and (ii) conventional method based on tooling in the form of metal moulds (dies) in the case of casting waxes.

The most important physico-mechanical properties of materials for foundry patterns were determined, i.e. linear shrinkage, softening temperature, relative elongation and coefficient of thermal linear expansion. Bending tests were carried out on samples of patterns printed and made in metal moulds, including determination of the surface roughness of patterns.

After the process of melting out patterns from the cavities of ceramic moulds in an autoclave, the degree of their melting out was visually assessed (i.e. the residues from pattern removal were evaluated). The ash content after burning out of foundry patterns was also determined. The conducted tests allowed comparing the important parameters of materials used for foundry patterns and assessing the suitability of selected plastics as a material for foundry patterns used in the manufacture of high-quality precision castings.

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Authors and Affiliations

A. Dydak
M. Książek
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Abstract

The paper presents an example of the application of vibratory machining for castings based on the results of visual testing. The purpose of the work is to popularize non-destructive testing and vibratory machining as finishing process, especially in the case of cast objects. Visual testing is one of the obligatory non-destructive tests used for castings and welded joints. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The tested castings, which had characteristic traces of the casting process, were subjected to vibratory machining. The machining with loose abrasive media in vibrating containers is aimed at smoothing the surface and reducing or completely removing flashes. To complement the visual testing were also conducted research on the contact profilometer Taylor Hobson PGI 1200. Particular attention was focused on measuring the height of flashes and changes in the surface of smoothed details based on BNIF No. 359 touch-visual patterns. Based on the work, it can be concluded that vibratory machining allows for removal flashes and smoothing of the surface of aluminum alloy cast objects.

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Authors and Affiliations

D. Bańkowski
ORCID: ORCID
P. Młynarczyk
ORCID: ORCID
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Abstract

This article is a description of the progress of research and development in the area of massive large-scale castings - slag ladles implemented in cooperation with the Faculty of Foundry Engineering of UST in Krakow. Slag ladles are the one of the major castings that has been developed by the Krakodlew (massive castings foundry) for many years. Quality requirements are constantly increasing in relation to the slag ladles. Slag ladles are an integral tool in the logistics of enterprises in the metallurgical industry in the process of well-organized slag management and other by-products and input materials. The need to increase the volume of slag ladles is still growing. Metallurgical production is expected to be achieved in Poland by 2022 at the level of 9.4 million Mg/year for the baseline scenario - 2016 - 9 million Mg/year. This article describes the research work carried out to date in the field of technology for the production of massive slag ladles of ductile cast iron and cast steel.

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Authors and Affiliations

M. Paszkiewicz
Edward Guzik
ORCID: ORCID
D. Kopyciński
ORCID: ORCID
Barbara Kalandyk
ORCID: ORCID
A. Burbelko
ORCID: ORCID
D. Gurgul
S. Sobula
ORCID: ORCID
A. Ziółko
K. Piotrowski
ORCID: ORCID
P. Bednarczyk

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