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The Role of Acid Hardener on the Hardening Characteristics, Collapsibility Performance, and Benchlife of the Warm-Box Sand Cores

I. Budavári H. Hudák G. Fegyverneki

Archives of Foundry Engineering | 2023 | vol. 23 | No 1 | 68-74 | DOI: 10.24425/afe.2023.144282

Keywords Warm-box Sand cores bending strength Collapsibility Benchlife

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Abstract

The heat-cured core-making process has been applied for over 60 years to produce molds and cores for different types of castings. The following technologies can be classified into the terminology of “heat-cured coremaking process”: croning-, hot-box -, and warm-box process. The latest technology provides good workability of core mixture, good strength properties, dimensional stability, and good knockout performance of the sand cores. Despite all its advantages, the warm-box technology is less widespread in foundries due to the cost of the high quality thermosetting resin and the maintenance cost of the core box. In this study, the influence of the acid hardener content on the hardening characteristics (bending strength), collapsibility, and the benchlife of the warm-box sand cores were investigated. From the results, it can be said, that within the investigated composition range, increasing the acid hardener content will improve the bending strength of the sand cores. The increased acid hardener content results in higher thermal stability at the beginning of the thermal exposure, and smaller residual bending strength after 15 minutes of thermal loading. The acid hardener level has little effect on the benchlife of the warm-box sand cores, although the sand core mixture is very sensitive to the combined effect of the sand temperature and dwelling time.

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Authors and Affiliations

I. Budavári

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ORCID:

H. Hudák

G. Fegyverneki

University of Miskolc, Faculty of Materials Science of Engineering, Institute of Foundry, Hungry

Parametric Optimization for Producing Semi-Solid A383 Alloy using Cooling Slope Casting Process

M.S. Rao H. Khandelwal M. Kumar A. Kumar

Archives of Foundry Engineering | 2023 | vol. 23 | No 1 | 43-52 | DOI: 10.24425/afe.2023.144279

Keywords Design of experiment ANOVA Response surface methodology Non-dendritic microstructure Hardness

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Abstract

Cooling slope casting is a simple technique to produce semi-solid feedstock with a non-dendritic structure. The cooling slope technique depends on various parameters like slope length, slope angle, pouring temperature etc, that has been investigated in the present study. This work presents an extensive study to comprehend the combined effect of slope angle, slope length, pouring temperature, on hardness and microstructure of A383 alloy. Response Surface Methodology was adopted for design of experiments with varying process parameters i.e. slope angle between 15° to 60°, slope length between 400 to 700 mm, and pouring temperature between 560 ºC to 600 ºC. The response factor hardness was analysed using ANOVA to understand the effect of input parameters and their interactions. The hardness was found to be increasing with increased slope length and pouring temperature; and decreased with slope angle. The empirical relation for response with parameters were established using the regression analysis and are incorporated in an optimization model. The optimum hardness with non-dendritic structure of A383 alloy was obtained at 27° slope angle, 596.5 mm slope length and 596 ºC pouring temperature. The results were successfully verified by confirmation experiment, which shows around 2% deviation from the predicted hardness (87.11 BHN).

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Bibliography

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Authors and Affiliations

M.S. Rao

e-mail:

ORCID:

H. Khandelwal

e-mail:

ORCID:

M. Kumar

A. Kumar

National Institute of Advanced Manufacturing Technology (Formerly National Institute of Foundry and Forge Technology) (A Centrally Funded Technical Institute under MHRD), Hatia, Ranchi, 834003, India

The Effect of Successive Stages of the Melting Process on the Nucleation of Ductile Cast Iron

J. Kołakowski M. Brzeżański D. Burdzy J. Sobieraj M. Urbanowicz T. Paruch K. Janerka

Archives of Foundry Engineering | 2023 | vol. 23 | No 1 | 61-67 | DOI: 10.24425/afe.2023.144281

Keywords Grey and ductile cast iron Inoculation DTA Minimum eutectic temperature (Temin) Nucleation

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Abstract

The article discusses issues related to the melting of grey and ductile cast iron in terms of metallurgical quality. The derivative and thermal analysis (DTA) was used to assess this quality. The article presents the results of research carried out in industrial conditions and analysed by the Itaca system. In the paper, the effect of the furnace type, the charge materials and the inoculation process on the parameters characterising the cast iron being melted was analysed. The most important of these are the minimum eutectic temperature (Te _min), the liquidus temperature (T _liquidus) and the nucleation rate. The results of the research and calculations are shown in graphs and as dependencies. Some of DTA results were compared to the microstructure analysis results. The article shows that the derivative and thermal analysis is a very effective tool in the assessment of the metallurgical quality of cast iron. It is a very good addition to chemical analysis. Based on the results of the research, it was concluded that a very high correlation exists between the rate of nucleation (DTA) and the number of graphite nuclei (microstructure analysis). Furthermore, it was also found that an improvement in nucleation could be achieved by ensuring a high value of carbon equivalent (CE) and, above all, by conducting the primary and secondary inoculation processes, respectively.

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Bibliography

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[15] Petrus, Ł., Bulanowski, A., Kołakowski, J., Brzeżański, M., Urbanowicz, M., Sobieraj, J., Matuszkiewicz, G., Szwalbe, L., Janerka, K. (2020). The influence of selected melting parameters on the physical and chemical properties of cast iron. Archives of Foundry Engineering. 20(1), 105-110. DOI: 10.24425/afe.2020.131290.
[16] Petrus, Ł., Bulanowski, A., Kołakowski, J., Sobieraj, J., Paruch, T., Urbanowicz, M., Brzeżański, M., Burdzy, D. & Janerka. K. (2021). Importance of TDA thermal analysis in an automated metallurgical process. Journal of Casting & Materials Engineering. 5(4), 89-93. https://doi.org/10.7494/ jcme.2021.5.4.89.
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Authors and Affiliations

J. Kołakowski

e-mail:

ORCID:

M. Brzeżański

e-mail:

ORCID:

D. Burdzy

e-mail:

ORCID:

J. Sobieraj

M. Urbanowicz

T. Paruch

K. Janerka

e-mail:

ORCID:

“Śrem” Iron Foundry Sp. z o.o., ul. Staszica 1, 63-100 Śrem, Poland
Department of Foundry Engineering, Silesian University of Technology, ul. Towarowa 7, 44-100 Gliwice, Poland

Numerical Modelling for the Effect of Metal-mould Air Gaps on Shell Thickness in Horizontal Continuous Casting of Cast Iron

A. Chawla N.S. Tiedje J. Spangenberg

Archives of Foundry Engineering | 2023 | vol. 23 | No 1 | 53-60 | DOI: 10.24425/afe.2023.144280

Keywords Horizontal continuous casting Cast iron Process modelling Air gaps

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Abstract

This paper presents a numerical model for the horizontal continuous casting of cast iron (HCCCI). A computational three-dimensional (3D) steady-state, coupled with fluid flow and heat transfer simulation model was developed and validated against experimental results to study the shell thickness and solidification of ductile cast iron. The study introduces the influence of an air gap at the melt-mould interface, which has long been known to have a detrimental effect on the efficiency of the process. The effect of the length and thickness of the melt-mould air gaps (also referred to as top air gaps) on solidification and remelting of the solid strand is studied. Parametric studies on top air gaps suggested a substantial effect on the solid and eutectic area at the top-outlet end of the die when the length of air gas was varied. This study serves to create a foundational and working model with the overall objective of process optimisation and analyzing the effect of operating process input parameters on the shell thickness of the strand.

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Authors and Affiliations

A. Chawla

e-mail:

ORCID:

N.S. Tiedje

e-mail:

ORCID:

J. Spangenberg

e-mail:

ORCID:

Technical University of Denmark, Denmark

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The Role of Acid Hardener on the Hardening Characteristics, Collapsibility Performance, and Benchlife of the Warm-Box Sand Cores

Abstract

Authors and Affiliations

Parametric Optimization for Producing Semi-Solid A383 Alloy using Cooling Slope Casting Process

Abstract

Bibliography

Authors and Affiliations

The Effect of Successive Stages of the Melting Process on the Nucleation of Ductile Cast Iron

Abstract

Bibliography

Authors and Affiliations

Numerical Modelling for the Effect of Metal-mould Air Gaps on Shell Thickness in Horizontal Continuous Casting of Cast Iron

Abstract

Authors and Affiliations