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Abstract

The paper presents Lusatian culture bronze artefacts recovered in the Orava region in northern Slovakia, which allows for tracing connections with the territory of present-day Poland in the Late Bronze Age and the Early Iron Age. The object is to discuss the provenance of the Lusatian bronze artefacts and analyse possible intercultural contacts with the north, across the Carpathians.

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Authors and Affiliations

Barbora Danielová
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Abstract

The paper presents the results of research aimed at developing assumptions for the preparation of a charge in the form of fine scrap copper alloys (chips/shells) guaranteeing effective removal of impurities and obtaining a metal bath of the required metallurgical quality. The tests were conducted for tin-zinc-lead bronze of the CC499K grade. As part of the work, the characteristics of this type of waste available on the market were made in terms of quality and the possibility of their use for the production of both alloys and finished products, taking into account the elimination of harmful impurities that may ultimately affect the production process adversely.
The subject of the work was the selection of appropriate waste cleaning methods in the form of an oily shell in the CC499K (CuZn5Sn5Pb2) grade and its drying in terms of increasing the use of impure waste from machining as scrap for direct melting. The waste was assessed in relation to individual parametres. The research was carried out on 3 groups of waste, with varying degrees of moisture.
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Authors and Affiliations

W. Malec
1
ORCID: ORCID
B. Cwolek
1
ORCID: ORCID
A. Brudny
1
ORCID: ORCID
J. Kulasa
1
ORCID: ORCID
W. Marek
2
K. Stolorz
2
D. Wróbel
2
A. Filipowicz
2

  1. Łukasiewicz Research Network - Institute of Non-Ferrous Metals, Poland
  2. COGNOR S.A. Oddział OM Szopienice w Katowicach, Poland
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Abstract

The mold temperature of the downward continuous unidirectional solidification (CUS) cannot be controlled higher than the liquidus of alloys to be cast. Therefore, the continuous casting speed becomes the main parameter for controlling the growth of columnar crystal structure of the alloy. In this paper, the tin bronze alloy was prepared by the downward CUS process. The microstructure evolution of the CUS tin bronze alloy at different continuous casting speeds was analysed. In order to further explain the columnar crystal evolution, a relation between the growth rate of columnar crystal and the continuous casting speed during the CUS process was built. The results show that the CUS tin bronze alloy mainly consists of columnar crystals and equiaxed crystals when the casting speed is low. As the continuous casting speed increases, the equiaxed crystals begin to disappear. The diameter of the columnar crystal increases with the continuous casting speed increasing and the number of columnar crystal decreases. The growth rate of columnar crystal increases with increasing of the continuous casting speed during CUS tin bronze alloy process.

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Authors and Affiliations

Jihui Luo
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Abstract

Casting is one method of making metal components that are widely used in industry and up to date. The sand casting method is used due to its simplicity, ease of operation, and low cost. In addition, the casting method can produce cast products in various sizes and is well-suited for mass production. However, the disadvantage of casting, especially gravity casting, is that it has poor physical and mechanical properties.
Tin bronze Cu20%wt.Sn is melted in a furnace, then poured at a temperature of 1100°C into a sand mold. The cast product is a rod with 400 mm in length, 10 mm in thickness, and 10 mm in width. The heat treatment mechanism is carried out by reheating the cast specimen at a temperature of 650°C, holding it for 4 hours, and then rapid cooling. The specimens were observed microstructure, density, and mechanical properties include tensile strength and bending strength. The results showed that there was a phase change from α + δ to α + β phase, an increase in density as a result of a decrease in porosity and a coarse grain to a fine grain. In addition, the tensile strength and bending strength of the Cu20wt.%Sn alloy were increased and resulted in a more ductile alloy through post-cast heat treatment.
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Bibliography

[1] C.D. Association, (1992). Copper Development Association Equilibrium Diagrams the major types of phase transformation.
[2] He, Z., Jian, C.A.O. & Ji-cai, F. (2009). Microstructure and mechanical properties of Ti6Al4V / Cu-10Sn bronze diffusion-bonded joint. Transaction Nonferrous Metals Society of China. 19, 414-417.
[3] Chen, X., Wang, Z., Ding, D., Tang, H., Qiu, L., Luo, X. & Shi, G. (2015). Strengthening and toughening strategies for tin bronze alloy through fabricating in-situ nanostructured grains. Material and Design. 1-31. ISSN: 0261-3069.
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[5] Taslicukur, Z., Altug, G.S., Polat, S., Atapek, Ş.H., Turedi E. (2012). A Microstructural study on CuSn10 bronze produced by sand and investment casting techniques. In 21st International Conference on Metallurgy and Materials METAL 2012, 23-25 May 2012 . Brno, Czech Republic, EU.
[6] Goodway M (1992). Metals of Music. Materials Characterization. 29, 177-184.
[7] Audy J, Audy K (2008). Analysis of bell materials: Tin bronzes. China Foundry. 5, 199-204.
[8] Debut, V., Carvalho, M., Figueiredo, E., Antunes, J. & Silva, R. (2016). The sound of bronze: Virtual resurrection of a broken medieval bell. Jurnal of Cultural Heritage. 19, 544-554.
[9] S.Slamet, Suyitno & Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu(20-24)wt.%Sn by sand casting on fluidity and mechanical properties, Journal of Mechanical Engineering and Science. 13(4), 6022-6035.
[10] S. Slamet, Suyitno and Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu-Sn alloys on the fluidity and microstructure by investment casting. IOP Conf. Series: Materials Science and Engineering. 547, 1-8.
[11] S. Slamet, Suyitno, Kusumaningtyas, I. & Miasa, I.M. (2021). Effect of high-tin bronze composition on physical, mechanical, and acoustic properties of gamelan materials. Archives of Foundry Engineering. 21(1), 137-145.
[12] Fletcher, N. (2012). Materials and musical instruments. Acoustics Australia. 40, 30-134.
[13] Sumarsam, (2002). Introduction to javanese gamelan (Javanese Gamelan-Beginners). Syllabus. 451, 1-28.
[14] Salonitis. K., Jolly. M. & Zeng, B. (2017). Simulation based energy and resource efficient casting process chain selection. A case study. Procedia Manufacturing. 8, 67-74.
[15] Sulaiman, S. & Hamouda, A.M.S. (2001). Modeling of the thermal history of the sand casting process. Journal of Materials Processing Technology. 113, 245-250.
[16] Kim, E., Cho, G., Oh, Y. & Junga, Y. (2016). Development of a high-temperature mold process for sand casting with a thin wall and complex shape. Thin Solid Films. 620, 70-75.
[17] S. Slamet, Suyitno, Kusumaningtyas, I. (2019). Forging process on gamelan bar tin bronze Cu-25 wt. % Sn post casting deformation to changes in microstructure, density, hardness, and acoustic properties. IOP Conf. Series: Materials Science and Engineering. 673, 1-9.
[18] S. Slamet, Suyitno, & Kusumaningtyas, I. (2020). Comparative study of bonang gamelan musical instrument between hot forging and Post Cast Heat Treatment / PCHT on microstructure and mechanical properties. IOP Conf. Series: Materials Science and Engineering. 1430, 1-9.
[19] Morando, C., Fornaro, O., Garbellini, O. & Palacio, H. (2015). Fluidity on metallic eutectic alloys. Procedia Materials Science. 8, 959-967.
[20] Pang, S., Wu, G., Liu, W., Sun, M., Zhang, Y., Liu, Z. & Ding, W. (2013). Effect of cooling rate on the microstructure and mechanical properties of sand-casting Mg-10Gd-3Y-0.5 Zr magnesium alloy. Materials Science Engineering A. 562, 152-160.
[21] Chuaiphan, W. & Srijaroenpramong, L. (2013). The Effect of Tin and heat treatment in brass on microstructure and mechanical properties for solving the cracking of nut and bolt. Applied Mechanics and Materials. 389, 237-244.
[22] Sláma, P., Dlouhý, J. & Kövér, M. (2014). Influence of heat treatment on the microstructure and mechanical properties of aluminium bronze. Materials and Technology. 48(4), 599-604.
[23] Hanson. D, Pell-Walpole, W.T. (1951). Chill-Cast Tin Bronzes. 1-368
[24] Sanchez, J.A.B.F., Bolarin, A.M. , Tello, A. & Hernandez, L.E. (2006). Diffusion at Cu / Sn interface during sintering process. Materials Science of Technology. 22, 590-596.
[25] Gupta, R., Srivastava, S., Kishor, N. & Panthi, S.K. (2016). High leaded tin bronze processing during multi-directional forging : Effect on microstructure and mechanical properties. Materials Science Engineering A. 654, 282-291.

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Authors and Affiliations

S. Slamet
1
S. Suyitno
2
I. K. Indraswari Kusumaningtyas
3

  1. Universitas Muria Kudus, Indonesia
  2. Universitas Tidar Magelang, Indonesia
  3. Universitas Gadjah Mada, Indonesia
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Abstract

Among different bearing materials, copper-based alloys are the most important source for bearing and bushing applications. In this work, the tribological behavior of a leaded tin bronze (Cu-22Pb-4Sn) against an EN31 Steel for various loads (20 N, 70 N, 120 N) and different sliding velocity (1 m/s, 3 m/s, 5 m/s) at 3000 m sliding distance is performed using a pin on disk tribometer. Irrespective of all loads and sliding velocity, a higher specific wear rate is observed at 1 m/s and 120 N that fails to facilitate the formation of lubricating film, whereas a lower specific wear rate is evident when the sliding velocity is increased to 5 m/s. This is attributed to the formation of a stable oxide layer that has been confirmed through the Energy dispersive X-ray spectroscopy analysis and Scanning electron microscopy. The coefficient of friction is observed in reducing trend from 0.69 to 0.48 for the increasing load (70 N, 120 N) and sliding velocity (3 m/s and 5 m/s) due to stable thin oxide film formation. Also, the increase in frictional force and loading the interacting surface temperature is increased to a maximum of 102°C. The Grey relational analysis indicates that the optimal parameters for the minimum specific wear rate and coefficient of friction is 120 N and 5 m/s that has been confirmed with experimental analysis.
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Bibliography

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[3] S . Equey, A. Houriet, S. Mischler, Wear. 273 (1), 9-16 (2011). DOI: https://doi.org/10.1016/j.wear.2011.03.030
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[15] M. Aksoy, V. Kuzucu, H. Turhan, J. Mater. Process. Technol. 124 (1-2), 113-119 (2002). DOI: https://doi.org/10.1016/S0924-0136(02)00137-1
[16] A.W.J. De Gee, G.H.G. Vaessen, A. Begelinger, ASLE Transactions. 12 (1), 44-54 (2008). DOI: https://doi.org/10.1080/05698196908972245
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[19] B.K. Prasad, J. Mater. Eng. Perform, 21 (10), 2155-2164 (2012). DOI: https://doi.org/10.1007/s11665-012-0139-x
[20] B. Juszczyk, J. Kulasa, S. Malara, M. Czepelak, W. Malec, B. Cwolek, L. Wierzbicki, Arch. Metall. Mater. 59 (2), 615-620 (2014). DOI: https://doi.org/10.2478/amm-2014-0101
[21] F . Summer, F. Grun, M. Offenbecher, S. Taylor, Tribol. Int. 131, 238- 250 (2019). DOI: https://doi.org/10.1016/j.triboint.2018.10.042
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Authors and Affiliations

D. Dinesh
1
ORCID: ORCID
A. Megalingam
1
ORCID: ORCID

  1. Bannari Amman Institute of Technology, Department of Mechanical Engineering, Sathyamangalam, Erode-638401, Tamil Nadu, India
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Abstract

High tin bronze alloy (Cu>17wt.%Sn) is commonly as raw material to fabricate musical instruments. Gamelan musical instruments in Indonesia are produced using tin bronze alloy raw materials. The tin bronze alloy used by each gamelan craftsman has a different tin composition, generally in the range of Cu(20-24) wt.% Sn. This study aims to investigate the effect of microstructure, density, and mechanical properties of Cu(20-24)wt.%Sn against the acoustic properties processed by the sand casting method. The material is melted in a crucible furnace until it reaches a pouring temperature of 1100ºC by the sand casting method. The specimens were subjected to microstructure observations, density and porosity as well as mechanical properties testing including tensile strength, bending strength, hardness, and modulus of elasticity. Mechanical properties data then used to calculate several parameters of acoustic properties including speed of sound (c), impedance (z) and radiation coefficient (R). Processes simulation using Finite Element Analysis (FEA) and Experiment Method Analysis (EMA) were carried out to determine acoustic properties including sound intensity, natural frequency and damping capacity.
The experimental result shows that the increase in tin composition in Cu(20-24) wt.% Sn changed the microstructure of coarse grains into dendrite-columned fine grains. Physical properties of density decrease, while porosity increases. Mechanical properties including tensile strength, modulus of elasticity, and bending strength decreased, while the hardness of the alloy increases. The calculation of acoustic parameters such as the speed of sound (c), impedance (z) and radiation coefficient (R) has decreased. Moreover, sound intensity (dB), natural frequency (Hz) and damping capacity also decrease with increasing tin composition. Hence, tin bronze alloy Cu20wt.%Sn is the recommended raw material for the manufacture of gamelan instruments through the sand casting method.
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Bibliography

[1] Sumarsam. (2002). Introduction to Javanese gamelan (Javanese gamelan-beginners). Wesleyan University. Middletown.
[2] Sutton, R.A. (2007). Gamelan: The Traditional Sounds of Indonesia (review). Asian Music. 38(1), 142-144.
[3] Suyanto, Tjokronegoro H.A, Merthayasa I.G.N. & Supanggah R. (2015). Acoustic parameter for javanese gamelan performance in pendopo mangkunegaran Surakarta. Procedia – Social and Behavioral Sciences. 184. 322-327.
[4] Goodway, M. (1992). Metals of music. Materials Characterization. 29. 177-184.
[5] Audy, J. & Audy, K. (2008). Analysis of bell materials: Tin bronzes. China Foundry. 5(3). 199-204.
[6] Debut, V. Carvalho, M. Figueiredo, E. Antunes, J. & Silva, R. (2016). The sound of bronze: Virtual resurrection of a broken medieval bell. Journal of Cultural Heritage. 19. 544-554.
[7] Sugita, I.K.G. Soekrisno, R. Miasa, I.M. & Suyitno. (2011). Mechanical and damping properties of silicon bronze alloys for music applications. International Journal of Engineering &. Technology. 11(6). 81-85.
[8] Sugita, I.K.G. Soekrisno, R. & Miasa, I.M. (2011). The effect of annealing temperature on damping capacity of the bronze 20 % Sn alloy. International Journal of Mechanical & Mechatronics Engineering. IJMME-IJENS. 11(4).1-5.
[9] Slamet, S. Suyitno, & Kusumaningtyas, I. (2019). Effect of composition and pouring temperature of Cu (20-24) wt.% Sn by sand casting on fluidity and Mechanical Properties, Journal of Mechanical Engineering and Science. 13(4). 6022-6035.
[10] Sugita, I.K.G. & Miasa, I.M. (2013). Feasibility Study On The Use Of Silicon-Bronze Alloys As An Alternative Material For Balinese Musical Instruments. 20th International Congress on Sound & Vibration; 7-11 July 2013.1-5. Bangkok, Thailand
[11] Prayoga, B.T. Suyitno, Dharmastiti, R. & Akbar, F. (2018). Microstructural characterization, defect, and hardness of titanium femoral knee joint produced using vertical centrifugal investment casting. Journal of Mechanical Science and Technology.32(1).149-156.
[12] Salonitis, K. Jolly, M. & Zeng, B. (2017). Simulation-based energy and resource-efficient casting process chain selection : A case study. Procedia Manufacturing. 8. 67-74.
[13] Wegst, U.G. (2006). Wood For Sound. American Journal of Botany. 93.1439-1448.
[14] Adams, R. D. & Fox, M.A.O. (1973). Correlation of the damping capacity of cast iron with its mechanical properties and microstructure. Journal of Mechanical Engineering Science. 15(2). 81-94.
[15] Grafov, B.M. (1994). The archimedes law and electrocapillarity. Electrochimica Acta. 39. 467-469.
[16] ASTM. (2015). Standard test methods for bend testing of material for ductility.1.1-10.
[17] Sutiyoko & Suyitno. (2012). Effect of pouring temperature and casting thickness on fluidity, porosity and surface roughness in lost foam casting of gray cast iron. Procedia Engineering. 50. 88-94.
[18] Halvaee, A. & Talebi, A. (2001). Effect of process variables on microstructure and segregation in the centrifugal casting of C92200 alloy. Journal of Materials Processing Technology. 118, 123-127.
[19] Sutiyoko. Suyitno. & Mahardika. M. (2016). Effect of gating system on porosity and surface roughness of femoral stem in centrifugal casting. Adv. Sci. Technol. Soc. AIP Conference Proceedings. 1755, 1-6.
[20] Sulaiman, S. & Hamouda, A.M.S. (2004). Modeling and experimental investigation of the solidification process in sand casting. Journal of Materials Processing Technology. 156, 1723-1726.
[21] Nadolski, M. (2017). The Evaluation of Mechanical Properties of High-tin Bronzes. Archives of Foundry Engineering. 17(1), 127-130.
[22] Nimbulkar, S.L. & Dalu. R.S. (2016). Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspectives in Science. 8.39-42.
[23] Singh, R. & Singh, S. (2013). Effect of process parameters on surface hardness, dimensional accuracy, and surface roughness of investment cast components; Journal of Mechanical Science and Technology. 27(1), 191-197.
[24] Bartocha, D. & Baron, C. (2016). Influence of tin-bronze melting and pouring parameters on its properties and bells ’ tone. Archives of Foundry Engineering. 16(4), 17-22.

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Authors and Affiliations

S. Slamet
1 2
S. Suyitnoa
1
I. Kusumaningtyasa
1
I.M. Miasaa
1

  1. Universitas Gadjah Mada, Yogyakarta, Indonesia
  2. Universitas Muria Kudus, Kudus, Indonesia
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Abstract

One of the most interesting categories of artifacts for archaeometallurgical research includes deposits of bronze items, so-called “metallurgists hoards”. They contain, aside of final products, many fragments of raw material and, moreover, metallurgical tools. An important source for the studies on the history of metallurgical technology is hoard from Przybysław, Greater Poland district.
Thus, the aim of the work is the identification and interpretation of bronze-working practices and strategies adopted by prehistoric communities of the Late Bronze Age and the Early Iron Age (ca. 600 BC). The examined objects are characterized in terms of their design, structure, and chemical composition. The methods chosen for the studies of artifacts include: metallographic macro- and microscopic observations using optical microscopy (OM) and scanning electron microscopy (SEM), the analysis of chemical composition with the methods of energy dispersive X-ray spectroscopy (EDS), and X-ray fluorescence (ED-XRF).
The thermodynamic analysis of the alloys was performed on the basis of the CALPHAD method. The experimental melts allowed to verify the theoretical considerations and to determine the characteristic temperatures of changes.
The old casting technology can be analyzed basing on computer modeling and computer simulation methods. Simulations in the MAGMASOFT® software are a good example to illustrate how to fill a mould cavity with a molten bronze for a hoop ornament. It is also an appropriate tool to determine temperature distribution in a mould. The simulations also show the possible disadvantages with this old technology.
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Authors and Affiliations

A. Garbacz-Klempka
1
ORCID: ORCID
M. Piękoś
1
ORCID: ORCID
M. Perek-Nowak
2
ORCID: ORCID
J. Kozana
1
ORCID: ORCID
P. Żak
1
ORCID: ORCID
A. Fijołek
1
ORCID: ORCID
P. Silska
3
ORCID: ORCID
M. Stróżyk
3
ORCID: ORCID

  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Historical Layers Research Centre, Kraków, Poland
  2. AGH University of Science and Technology, Faculty of Non Ferrous Metals, Historical Layers Research Centre, Kraków, Poland
  3. Archaeological Museum in Poznań, Poznań, Poland
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Abstract

Copper-based alloys with the addition of Al present excellent properties and can be considered a proper choice for applications as contact materials based on their good strength and fret resistance. Cu-Al alloys are used in different systems parts as bearings, gears and worm gears. The intention is to replace steel materials with new copper-based materials for parts that work in a possible explosive environment to reduce the possibility of spark appearance. Copper-berilyum alloys are known as non-sparking alloys and are used in different tools obtaining for environments with possible explosive gaseous. Results from the obtaining and analysis of a new alloy based on CuAlBe are given. The material was melted in a vacuum induction furnace from CuBe master alloy and high purity aluminium and cast into a metallic die. The alloys obtained were analyzed using EDS – energy dispersive spectroscopy for chemical composition, OM-optical and SEM-electronic microscopy for the microstructure, and the electro-corrosion resistance was tested using linear Tafel diagram and cyclic potentiometry.
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Authors and Affiliations

R.G Chelariu
1
ORCID: ORCID
N. Cimpoeșu
1
ORCID: ORCID
T.I. Birnoveanu
1
ORCID: ORCID
B. Istrate
2
ORCID: ORCID
C. Baciu
1
ORCID: ORCID
C. Bejinariu
1
ORCID: ORCID

  1. “Gheorghe Asachi” University of Iasi, Faculty of Materials Science Engineering, Prof.dr.doc. D. Mangeron Street, no. 41, Iași 700050, Romania
  2. “Gheorghe Asachi” University of Iasi, Faculty of Mechanical Engineering, Prof.dr.doc. D. Mangeron Street, No. 61-63, Iași 700050, Romania
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Abstract

The focus of the article is the Vatin culture settlement at the site of Vinča-Belo Brdo in Northern Serbia. The general idea is that this settlement, whose existence was relatively short in time, benefited from being established by the Danube — a great connective factor in the world of the Middle Bronze Age. It shares many characteristics with the contemporary settlements in the southernmost part of the Carpathian basin, starting from the position in the vicinity of the Danube, at the places which had already been settled in prehistory, prior to the Middle Bronze Age. Not only do they have pottery style in common, but the wider repertoire of finds illustrating the material culture. What’s more, comparison of the material remains from Vinča with the neighbouring sites from the left Danube bank enlightens how the Vatin culture was integrated into a wider space of the Bronze Age cultures of the Carpathian basin, influencing the Balkans hinterland, too.

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Authors and Affiliations

Marija Ljuština
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Abstract

Among the copper based alloys, Cu-Al-X bronzes are commonly used as mold materials due to their superior physical and chemical properties. Mold materials suffer from both wear and corrosion, thus, it is necessary to know which one of the competitive phenomenon is dominant during the service conditions. In this study, tribo-corrosion behavior of CuAl10Ni5Fe4 and CuAl14Fe4Mn2Co alloys were studied and electrochemical measurements were carried out using three electrode system in 3.5 % NaCl solution in order to evaluate their corrosion resistance. In tribo-corrosion tests, alloys were tested against zirconia ball in 3.5 % NaCl solution, under 10N load with 0.04 m/s sliding speed during 300 and 600 m. The results indicate that (i) CuAl10Ni5Fe4 alloy is more resistant to NaCl solution compared to CuAl14Fe4Mn2Co alloy that has major galvanic cells within its matrix, (ii) although CuAl10Ni5Fe4 alloy has lower coefficient of friction value, it suffers from wear under dry sliding conditions, (iii) as the sliding distance increases, corrosion products on CuAl14Fe4Mn2Co surface increase at a higher rate compared to CuAl10Ni5Fe4 leading to a decrease in volume loss due to the lubricant effect of copper oxides.

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Authors and Affiliations

Ş.H. Atapek
G. Aktaş Çelik
Ş. Polat
B. Pisarek
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Abstract

Metallographic investigations and a computer simulation of stresses in a gravity die-casting bushing were performed. Simulation of the casting process, solidification of the thick-walled bushing and calculations of the stress was performed using MAGMA5.3 software. The size variability of phases κIIaffecting the formation of phase stresses σf, depending on the location of the metallographic test area, was identified. The distribution of thermal σtand shrinkage stresses σs, depending on the location of the control point SC in the bushing's volume, was estimated. Probably the nature of these stresses will change slightly even after machining. This can cause variations in operating characteristics (friction coefficient, wear). Due to the strong inhomogeneity of the stress distribution in the bushing's casting, it is necessary to perform further tests of the possibility to conduct thermal treatment guaranteeing homogenization of the internal stresses in the casting, as well as to introduce changes in the bushing's construction and the casting technology. The paper presents the continuation of the results of research aimed at identifying the causes of defects in the thick-walled bushing, die-casting made of CuAl10Fe5Ni5Cr aluminium bronze.

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Authors and Affiliations

T. Pacyniak
B.P. Pisarek
D. Kołakowski
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Abstract

The article presents research results performed on aluminum bronze CuAl10Fe5Ni5 (BA1055) castings used for marine propellers.

Metallographic studies were made on light microscope and a scanning electron microscope to assess quantitatively and qualitatively the

alloy microstructure. It has been shown that the shape, size and distribution of the iron-rich κ−phase precipitates in bronze microstructure

significantly affect its mechanical properties. With an increase in the number of small κ−phase precipitates increases the tensile strength of

castings, while the presence of large globular precipitates improves ductility. Fragmentation and shape of κ−phase precipitates depends on

many factors, particularly on the chemical composition of the alloy, Fe/Ni ratio, cooling rate and casting technology.

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Authors and Affiliations

J. Łabanowski
T. Olkowski
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Abstract

The exudation layer seriously affects the properties and the surface finish of the tin bronze alloy. The effective control of the exudation thickness is important measure for improving the properties of the alloy. In order to study the influence of process parameters on the thickness of exudate layer, the tin bronze alloy was prepared by continuous unidirectional solidification technology at different process parameters. The microstructure of the continuous unidirectional solidification tin bronze alloy was analyzed. The effect of process parameters on microstructure and chemical compositions was studied by orthogonal experiment. The results show that there exists an exudation layer on the surface of the continuous unidirectional solidification tin bronze alloy, and the exudation is mainly composed of a tin-rich precipitated phase. It indicates that the continuous casting speed is the main factor affecting the thickness of exudation layer, followed by mold temperature, melt temperature, cooling water temperature and cooling distance.

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Authors and Affiliations

Jihui Luo
Fang He
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Abstract

A significant part of the knowledge used in the production processes is represented with natural language. Yet, the use of that knowledge

in computer-assisted decision-making requires the application of appropriate formal and development tools. An interesting possibility is

created by the use of an ontology that is understandable both for humans and for the computer. This paper presents a proposal for

structuring the information about the foundry processes, based on the definition of ontology adapted to the physical structure of the

ongoing technological operations that make up the process of producing castings.

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Authors and Affiliations

Z. Górny
D. Wilk-Kołodziejczyk
A. Smolarek-Grzyb
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Abstract

The publication presents a novel concept of the process of plastic forming of variable longitudinal-section cylindrical products, being the subject of Patent Application P.427426 [1]. Additionally, these products are provided with a connection stub pipe. The plastic forming method proposed in the article combines many advantages and utilitarian benefits associated with the manufacturing technology itself, as well as with its further implementation. Using stock in the form of normalized bar commonly available in the metal product market as a finished product obviously reduces the process costs involved with stock preparation, i.e. casting, rolling, machining, etc. It also results in obtaining a much smaller surface area of stock contact with the tool and, as a consequence, a smaller surface of stock friction against the tool, which contributes to a reduction of force needed for the plastic forming of the product. The smaller contact surface area and the shorter time of stock contact with the cooler tool cause, above all, less intensive heat exchange and stock chilling. This has a significant effect on the plasticity of the cast material and, as a consequence, the plastic forming force. The proposed method enables also manufacturing cylinders with either a closed or open stub pipe with a regulated length and a varying section. In addition, unlike the method known from Polish Patent Specification PL 212062 [2], the proposed method does not require using a multi-tool press. The upper punch is furnished with a flange, whose job is to start the stock extruding sleeve at the next process stage.

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Authors and Affiliations

J. Michalczyk
S. Wiewiórowska
Z. Muskalski
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Abstract

The article presents tests on a new lead-free bronze CuSn4Zn2PS, intended for fittings for contact with drinking water, in which the addition of lead was replaced with sulphur. The subject of the experimental work was the production of semi-finished products from this alloy based on the charge coming entirely from waste generated after machining. A specialized pilot line was used for the tests, and after cleaning, the waste was melted and then were continuously cast in the form of rods and hollow rods. The cleaning efficiency was assessed, and the manufactured semi-finished products were subjected to tests, including the assessment of the chemical and mechanical homogeneity and the structure of the test batch of the semi-finished casting products in terms of the possibility of manufacturing products meeting the requirements of technical specifications. The obtained results, both in terms of a stable chemical composition, homogeneous and reproducible mechanical properties, fully compliant with the specifications for fittings bronzes (CC499K), as well as the lack of faults of the obtained semi-finished products, despite a very large share of waste material, indicate the possibility of using the tested recycling method for the production of semi-products of sulphur bronze, which is an alloy that is relatively difficult to manufacture.
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Bibliography

[1] Directive (EU) 2020/2184 of the European Parliament and of the Council of 16 December 2020 on the quality of water intended for human consumption, Dz.U.L 435/1 of 23.12.2020.
[2] Acceptance of metallic materials used for products in contact with drinking water, 4MS Common Approach Part B “4MS Common Composition List” Retrieved July, 12, 2022 from http://www.umweltbundesamt.de/en/topics/water/drinking-water/distributing-drinking-water/guidelines-evaluation-criteria.
[3] DIN SPEC 2701:2018.
[4] Haake, M., Hansen, A., Leistritz, F. (2019). EP Patent No. EP 3436615. Germany. The German Patent and Trade Mark Office.
[5] PN-EN 1982:2017 Copper and copper alloys - Ingots and castings
[6] Wieland G05, GD1, GS1, SW3 material specification. Retrieved 12, July, 2022 from https://www.wieland.com/en/content/download/.
[7] Marek, W., Kopańska, D., Bieniek, J., Wróbel, D., Stolorz, K., Filipowicz, A., Malec, W., Cwolek, B., Brudny, A., Juszczyk B., Kulasa, J. (2022). PL Patent application No. PL 436188. Poland. The Patent Office of the Republic of Poland.
[8] Cwolek, B., Malec, W., Brudny, A., Kulasa, J., Marek, W., Stolorz, K., Wróbel, D. & Filipowicz, A. (2022). Development of process conditions for the preparation of copper alloys post-production chips for the continuous casting process. Archives of Foundry Engineering. (in publication).
[9] PN-EN 12861:2018-07 Copper and copper alloys – Scrap.
[10] Hansen, A. (2019). Bleifreier rotguss als armaturen-und installationswerkstoff in der trinkwasserinstallation. METALL – Forschung. 73(11), 452-455.

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Authors and Affiliations

W. Malec
1
ORCID: ORCID
B. Cwolek
1
ORCID: ORCID
A. Brudny
1
ORCID: ORCID
B. Juszczyk
1
ORCID: ORCID
J. Kulasa
1
ORCID: ORCID
A. Hury
1
ORCID: ORCID
W. Marek
2
K. Stolorz
2
D. Wróbel
2
A. Filipowicz
2

  1. Łukasiewicz Research Network — Institute of Non-Ferrous Metals, Poland
  2. COGNOR S.A. Oddział OM Szopienice w Katowicach, Poland
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Abstract

The subject of the study was to determine the impact of changes in mechanical properties of high-tin bronzes on the basic components of the sound of a bell. Change in the tin concentration in the range of about 7.5 to 20 parts wt. in a casting alloy significantly affects the mechanical properties of the alloy such as Young’s modulus or hardness. The free vibrations of bells were obtained with the help of the finite element method. In the numerical analyses the mechanical properties of standard alloys were adopted. The obtained natural frequencies of the bell made of a bronze with different tin concentration in copper were compared with the acoustic properties of a real bell casted on the basis of the same ribs. A significant effect of the increase in the alloying share of tin on the obtained results was stated. In addition, the acoustic analysis of aluminum bronze C95500 have been performed. Based on the obtained results, authors stated that this material can replace the commonly used high tin bronze C91300 for the unit production of bells.
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Authors and Affiliations

D. Cekus
1
ORCID: ORCID
M. Nadolski
2
ORCID: ORCID

  1. Czestochowa University of Technology, Department of Mechanics and Machine Design Fundamentals, 73 Dąbrowskiego S tr., 42-201 Czestochowa, Poland
  2. Czestochowa University of Technology, Faculty of Production Engineering and Materials Technology, 19 Armii Krajowej Av., 42-200 Czestochowa, Poland
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Abstract

The work done in this study is a preliminary investigation into the possibility of modelling the filling and solidification process of castings in molds made with the additive method. The work originated from an experiment to produce a bronze casting with a high tin content in an additive mold. The mold filling and solidification simulation was carried out in the MAGMASO FT program, and the lambda thermal conductivity coefficient used in the program’s material database was corrected based on the actual temperature values of the printed form. The results were compared with the modeling results for the physical properties of furan molds based on the program database. The microstructure of the castings obtained in the compared forms was assessed.
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Authors and Affiliations

M. Nadolski
1
ORCID: ORCID
Ł. Bernat
2
D. Cekus
3
ORCID: ORCID
P. Kwiatoń
ORCID: ORCID
A. Pietrzak
4

  1. Czestochowa University of Technology, Faculty of Production Engineering and Materials, Department of Metallurgy and Metal Technology, 42-200 Czestochowa, Poland
  2. Poznan University of Technology, Faculty of Mechanical Engineering, Institute of Materials Technology, Division of Foundry and Plastic Working,60-965 Poznan, Poland
  3. Czestochowa University of Technology, Faculty of Mechanical Engineering and Computer Science, Department of Mechanics and Machine Design Fundamentals, 42-200 Czestoch owa, Poland
  4. AGH University of Kraków, Faculty of Foundry Engineering, Department of Foundry, Al . Mickiewicza 30, 30-059 Krakow, Poland
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Abstract

Cast axes are one of the most numerous categories of bronze products from earlier phases of the Bronze Age found in Poland. They had multiple applications since they were not only used objects such as tools or weapons but also played the prestigious and cult roles.

Investigations of the selected axes from the bronze products treasure of the Bronze Age, found in the territory of Poland, are presented

in the hereby paper. The holder of these findings is the State Archaeological Museum in Warsaw. Metallurgical investigations of axes with bushing were performed in respect of the casting technology and quality of obtained castings. Macroscopic observations allowed to document the remains of the gating system and to assess the range and kind of casting defects. Light microscopy revealed the microstructure character of these relicts. The chemical composition was determined by means of the X-ray fluorescence method with energy dispersion (ED-XRF) and by the scanning electron microscopy with X-ray energy dispersion analysis in micro-areas (SEM-EDS). The shape and dimensions of cores, reproducing inner parts of axes were identified on the basis of the X-ray tomography images. Studies reconstructed production technology of the mould with gating system, determined chemical composition of the applied alloys and casting structures as well as revealed the casting defects being the result of construction and usage of moulds and cores.

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Authors and Affiliations

P. Długosz
A. Garbacz-Klempka
Z. Kwak
Ł. Karczmarek
J. Kozana
M. Piękoś
M. Perek-Nowak
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Abstract

With the increase in wall thickness of the casting of iron-nickel-aluminium-bronze, by the reduction of the cooling rate the size of κII phase

precipitates increases. This process, in the case of complex aluminium bronzes with additions of Cr, Mo and W is increased. Crystallization

of big κII phase, during slow cooling of the casting, reduces the concentration of additives introduced to the bronze matrix and hardness.

Undertaken research to develop technology of thick-walled products (g> 6 mm) of complex aluminium bronzes. Particular attention

was paid to the metallurgy of granules. As a result, a large cooling speed of the alloy, and also high-speed solidification casting a light

weight of the granules allows: to avoid micro-and macrosegregation, decreasing the particle size, increase the dispersion of phases in

multiphase alloys. Depending on the size granules as possible is to provide finished products with a wall thickness greater than 6 mm by

infiltration of liquid alloy of granules (composites). Preliminary studies was conducted using drip method granulate of CuAl10Fe5Ni5

bronze melted in a INDUTHERM-VC 500 D Vacuum Pressure Casting Machine. This bronze is a starting alloy for the preparation of the

complex aluminium bronzes with additions of Cr, Mo, W and C or Si. Optimizations of granulation process was carried out. As the process

control parameters taken a casting temperature t (°C) and the path h (mm) of free-fall of the metal droplets in the surrounding atmosphere

before it is intensively cooled in a container of water. The granulate was subjected to a sieve analysis. For the objective function was

assume maximize of the product of Um*n, the percentage weight "Um" and the quantity of granules 'n' in the mesh fraction. The maximum

value of the ratio obtained for mesh fraction a sieve with a mesh aperture of 6.3 mm. In the intensively cooled granule of bronze was

identified microstructure composed of phases: β and fine bainite (α+β'+β'1) and a small quantity of small precipitates κII phase. Get high

microhardness bronze at the level of 323±27,9 HV0,1.

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Authors and Affiliations

B.P. Pisarek
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Abstract

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.

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Authors and Affiliations

E. Krivoš
R. Pastirčák
P. Lehocký
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Abstract

The main scope of the article is the development of a computer system, which should give advices at problem of cooper alloys

manufacturing. This problem relates with choosing of an appropriate type of bronze (e.g. the BA 1044 bronze) with possible modification

(e.g. calcium carbide modifications: Ca + C or CaC2) and possible heat treatment operations (quenching, tempering) in order to obtain

desired mechanical properties of manufactured material described by tensile strength - Rm, yield strength - Rp0.2 and elongation - A5. By

construction of the computer system being the goal of presented here work Case-based Reasoning is proposed to be used. Case-based

Reasoning is the methodology within Artificial Intelligence techniques, which enables solving new problems basing on experiences that

are solutions obtained in the past. Case-based Reasoning also enables incremental learning, because every new experience is retained each

time in order to be available for future processes of problem solving. Proposed by the developed system solution can be used by

a technologist as a rough solution for cooper alloys manufacturing problem, which requires further tests in order to confirm it correctness.

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Authors and Affiliations

S. Kluska-Nawarecka
K. Regulski
G. Rojek
D. Wilk-Kołodziejczyk
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Abstract

This paper presents the influence of annealing time 30, 60 and 120 min at 1000°C for quenching CuAl7Fe5Ni5W2Si2 bronze in 10% water solution of NaCl, on the microstructure and mechanical properties. The presented results concern the species newly developed aluminum-iron-nickel bronze, with additions W and Si. In order to determine changes in the microstructure of the hardened bronze metallographic studies were performed on cylindrical samples of diameter 10 mm, on the metallographic microscope with digital image analysis, X-ray phase analysis, EDX point with the digital recording on the computer. Specified percentage of the microstructure of martensite and bainite, participation of proeutectoid α phase in the microstructure, grain size of former β phase, the amount of dissolved κ phase. It was found that in the microstructure of bronze in the cast state, there are a number of intermetallic phases of κ type. At interphase boundaries of primary intermetallic faceted precipitates, especially rich in tungsten (IM_W), nucleate and grow dendritic primary intermetallic κI phases, with chemical composition similar to the type of Fe3Si iron silicide. Dissolved, during the heating, in the β phase are all the intermediate phase included in the microstructure, with the exception of primary intermetallic phases of tungsten and κI. Prolongation of the isothermal annealing causes coagulation and coalescence of primary phases. In microstructure of the bronze after quenching obtained the α phase precipitation on the grain boundary of secondary β phase, coarse bainite and martensite, for all annealing times. With the change of annealing time are changed the relative proportions of individual phases or their systems, in the microstructure. In the microstructure of bronze, hold at temperature of 1000°C for 60 min, after quenching martensitic microstructure was obtained with the primary phases, and the least amount of bainite

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Authors and Affiliations

B. Pisarek

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