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Abstract

The paper, which is a summary and supplement of previous works and research, presents the results of numerical and physical modeling of the GX2CrNiMoCuN25-6-3 duplex cast steel thin-walled castings production. To obtain thin-walled castings with wall in the thinnest place even below 1 mm was used the centrifugal casting technology and gravity casting. The analyzed technology (centrifugal casting) enables making elements with high surface quality with reduced consumption of batch materials and, as a result, reducing the costs of making a unitary casting. The idea behind the production of cast steel with the use of centrifugal technology was to find a remedy for the problems associated with unsatisfactory castability of the tested alloy.

The technological evaluation of the cast construction was carried out using the Nova Flow & Solid CV 4.3r8 software. Numerical simulations of crystallization and cooling were carried out for a casting without a gating system and sinkhead located in a mold in accordance with the pouring position. It was assumed that the analyzed cast will be made in the sand form with dimensions 250×250×120 mm.

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Authors and Affiliations

G. Stradomski
M. Nadolski
ORCID: ORCID
A. Zyska
B. Kania
D. Rydz
ORCID: ORCID
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Abstract

Consecutive casting of bimetallic applies consecutive sequences of pouring of two materials into a sand mold. The outer ring is made of NiHard1, whereas the inner ring is made of nodular cast iron. To enable a consecutive sequence of pouring, an interface plate made of low carbon steel was inserted into the mold and separated the two cavities. After pouring the inner material at the predetermined temperature and the interface had reached the desired temperature, the NiHard1 liquid was then poured immediately into the mold. This study determines the pouring temperature of nodular cast iron and the temperature of the interface plate at which the pouring of white cast iron into the mold should be done. Flushing the interface plate for 2 seconds by flowing nodular cast iron liquid as inner material generated a diffusion bonding between the inner ring and interface plate at pouring temperatures of 1350 °C, 1380 °C, and 1410 °C. The interface was heated up to a maximum temperature of 1242 °C, 1260 °C, and 1280 °C respectively. The subsequent pouring of white cast iron into the mold to form the outer ring at the interface temperature of 1000 °C did not produce a sufficient diffusion bonding. Pouring the outer ring at the temperature of 1430°C and at the interface plate temperature of 1125 °C produced a sufficient diffusion bonding. The presence of Fe3O2 oxide on the outer surface of the interface material immediately after the interface was heated above 900 ⁰C has been identified. Good metallurgical bonding was achieved by pouring the inner ring at the temperature of 1380°C, interface temperature of 1125 °C and then followed by pouring of the outer ring at 1430⁰C and flushing time of 7 seconds.

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Authors and Affiliations

W. Purwadi
B. Bandanadjaja
D. Idamayanti
N. Lilansa
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Abstract

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions.
The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).
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Bibliography

[1] Benedetti, M., Torresani, E., Fontanari, V. & Lusuardi, D. (2017). Fatigue and fracture resistance of heavy-section ferritic ductile cast iron. Metals. 7(3), 88.
[2] Dorula, J., Kopyciński, D., Guzik, E., Szczęsny, A. & Gurgul, D. (2021). The influence of undercooling ΔT on the structure and tensile strength of grey cast iron. Materials. 14(21), 6682.
[3] Wang, Q., Cheng, G. & Hou, Y. (2020). Effect of titanium addition on as-cast structure and high-temperature tensile property of 20Cr-8Ni stainless steel for heavy castings. Metals. 10(4), 529.
[4] Wang, Q., Chen, S. & Rong, L. (2020). -Ferrite formation and its effect on the mechanical properties of heavy-section AISI 316 stainless steel casting. Metallurgical and Materials Transactions A. 51, 2998-3008.
[5] Kalandyk, B., Zapała, R., Sobula, S., Górny, M. & Boroń, Ł. (2014) Characteristics of low nickel ferritic-austenitic corrosion resistant cast steel. Metalurgija-Metallurgy. 53(4), 613-616.
[6] Kalandyk, B. & Zapała, R. (2013). Effect of high-manganese cast steel strain hardening on the abrasion wear resistance in a mixture of SiC and water. Archives of Foundry Engineering. 13(4), 63-66.
[7] Tęcza, G. & Zapała, R. (2018). Changes in impact strength and abrasive wear resistance of cast high manganese steel due to the formation of primary titanium carbides. Archives of Foundry Engineering. 18(1), 119-122.
[8] Tęcza, G. & Garbacz-Klempka, A. (2016). Microstructure of cast high-manganese steel containing titanium. Archives of Foundry Engineering. 16(4), 163-168.
[9] Celis, M., Domengès, B., Hug, E. & Lacaze, J. (2018). Analysis of nuclei in a heavy-section nodular iron casting. Materials Science Forum. 925, 173-180.
[10] Kopyciński, D., Siekaniec, D., Szczęsny, A., Sokolnicki, M. & Nowak, A. (2016). The Althoff-Radtke test adapter for high chromium cast iron. Archives of Foundry Engineering. 16(4), 74-77.
[11] Szczęsny, A., Kopyciński, D., Guzik, E. Soból, G., Piotrowski, K., Bednarczyk, P. & Paul, W. (2020). Shaping of ductile cast iron dedicated for slag ladle. Acta Metallurgica Slovaca. 26, 74-77. https://doi.org/10.36547/ams.26.2.312
[12] Mourad, M.M. & El-Hadad, S. (2015). Effect of processing parameters on the mechanical properties of heavy section ductile iron. Journal of Metallurgy. 2015, 1-11.
[13] Foglio, E., Gelfi, M., Pola, A. & Lusuardi, D. (2017). Effect of shrinkage porosity and degenerated graphite on fatigue crack initiation in ductile cast iron. Key Engineering Materials. 754, 95-98.
[14] Kavicka, F., Sekanina, B., Stetina, J., Stransky, K., Gontarev, V. & Dobrovska, J. (2009). Numerical optimization of the method of cooling of a massive casting of ductile cast-iron. Materials and Technology. 43, 73-78.

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Authors and Affiliations

A. Szczęsny
1
ORCID: ORCID
D. Kopyciński
1
ORCID: ORCID
Edward Guzik
ORCID: ORCID

  1. AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Polska
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Abstract

The objective of this work is to gain a deeper understanding of the separation effects and particle movement during filtration of non-metallic inclusions in aluminum casting on a macroscopic level. To understand particle movement, complex simulations are performed using Flow 3D. One focus is the influence of the filter position in the casting system with regard to filtration efficiency. For this purpose, a real filter geometry is scanned with computed tomography (CT) and integrated into the simulation as an STL file. This allows the filtration processes of particles to be represented as realistically as possible. The models provide a look inside the casting system and the flow conditions before, in, and after the filter, which cannot be mapped in real casting tests. In the second part of this work, the casting models used in the simulation are replicated and cast in real casting trials. In order to gain further knowledge about filtration and particle movement, non-metallic particles are added to the melt and then separated by a filter. These particles are then detected in the filter by metallographic analysis. The numerical simulations of particle movement in an aluminum melt during filtration, give predictions in reasonable agreement with experimental measurements.
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Bibliography

[1] Ishikawa, K., Okuda, H. & Kobayashi, Y. (1997). Creep behaviors of highly pure aluminum at lower temperatures. Materials Science and Engineering A. 234-236, 154-156.
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[8] Wang, Q., Zhang, L., Xu, Y., Liu, C., Zhao, X., Xu, L., Yang, Y. & Cia, Y. (2020). Creep aging behavior of retrogression and re-aged 7150 aluminum alloy. Transactions of Nonferrous Metals Society of China. 30(10), 2599-2612.
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[13] Shuvho, M.B.A. Chowdhury, M.A., Kchaou, M., Rahman, A. & Islam, M.A. (2020). Surface characterization and mechanical behavior of aluminum-based metal matrix composite reinforced with nano Al2O3, SiC, TiO2 particles. Chemical Data Collections. 28, 100442.
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[18] Gonga, D., Jianga, L., Guanc, J., Liua, K., Yua, Z. & Wua, G. (2020). Stable second phase: the key to high-temperature creep performance of particle reinforced aluminum matrix composite. Materials Science and Engineering A. 770, 138551.
[19] Zhao, Q., Zhang, H., Zhang, X., Qiu, F. & Jiang, Q. (2018). Enhanced elevated-temperature mechanical properties of Al-Mn-Mg containing TiC nano-particles by pre-strain and concurrent precipitation. Materials Science and Engineering A. 718, 305-310.
[20] Bhoi, N., Singh, H. & Pratap, S. (2020). Developments in the aluminum metal matrix composites reinforced by micro/nano-particles - A review. Journal of Composite Materials. 54(6), 813-833.
[21] Azadi, M., Zomorodipour, M. & Fereidoon, A. (2021). Study of effect of loading rate on tensile properties of aluminum alloy and aluminum matrix nano-composite. Journal of Mechanical Engineering. 51(1), 9-18.
[22] Bhowmik, A., Dey, D. & Biswas, A. (2021). Characteristics study of physical, mechanical and tribological behavior of SiC/TiB2 dispersed aluminum matrix composite. Silicon. 06 January. DOI: https://doi.org/10.1007/s12633-020-00923-2.
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Authors and Affiliations

B. Baumann
1
A. Keßler
1
E. Hoppach
1
G. Wolf
1
M. Szucki
1
ORCID: ORCID
O. Hilger
2

  1. Foundry Institute, Technische Universität Bergakademie Freiberg, 4 Bernhard-von-Cotta-Str., 09599 Freiberg, Germany
  2. Simcast GmbH, Westring 401, 42329 Wuppertal, Germany
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Abstract

This paper presents a new stand for studying the linear shrinkage kinetics of foundry alloys. The stand is equipped with a laser displacement sensor. Thanks to this arrangement, the measurement is of a contactless nature. This solution allows for the elimination of errors which occur in measurements made using intermediary elements (steel rods). The supposition of the expansion (shrinkage) of the sample and the expansion of the heated rod lead to the distortion of the image of the actual dimensional changes of the studied sample. A series of studies of foundry alloys conducted using the new stand allowed a new image of shrinkage kinetics to be obtained, in particular regarding cast iron. The authors introduce in the study methodology a real-time measurement of two linked quantities; shrinkage (the displacement of the free end of the sample) and temperature in the surface layer of the sample casting. This generates not only a classic image of shrinkage (S) understood as S = f (t), but also the view S = f (T). The latter correlation, developed based on results obtained using the contactless method, provide a new, so far poorly known image of the course of shrinkage in foundry alloys, especially cast iron with graphite in the structure. The study made use of hypo- and hypereutectic cast iron in order to generate an image of the differences which occur in the kinetics of shrinkage (as well as in pre-shrinkage expansion - expansion occurs during solidification).

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Authors and Affiliations

J. Zych
ORCID: ORCID
T. Snopkiewicz
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Abstract

The temperature of liquid steel for continuous casting determines the casting speed and cooling conditions. The failure to meet the required casting process parameters may result in obtaining slabs of inconsistent quality. Numerical methods allow for real processes to be modelled. There are professional computer programs on the market, so the results of the simulations allow us to understand the processes that occur during casting and solidification of a slab. The study attempts to evaluate the impact of the superheat temperature on the slab structure based on the industrial operating parameters of the continuous casting machine.

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Authors and Affiliations

P. Drożdż
ORCID: ORCID
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Abstract

The paper presents results of tests carried out on ausferrite carbide matrix alloyed ductile cast iron. The ausferrite was obtained via addition of Cu and Mo alloying elements. This eliminated heat treatment from the alloy production cycle. The article presents results of tests of the quality of the obtained material. Emphasis was put on metallographic analysis using light and scanning microscopy. Works also included chemical composition tests and EDS analysis. Strength tests were executed in an accredited laboratory. It is possible to create a raw ausferrite carbide matrix without subjecting an alloy to heat treatment. However, it turned out that quality parameters of cast iron were insufficient. The obtained material hardness was 515 HB, while Rm strength and A5 ductility were very low. The low tensile strength of the analyzed alloy resulted from the presence of degenerate graphite secretion (of flake or vermicular shape) in the cast iron. The tests also demonstrated that the alloy was prone to shrinkage-related porosity, which further weakened the material. Alloys made of alloyed ductile iron of ausferrite matrix micro-structure are very attractive due to elimination of the heat treatment process. However, their production process and chemical composition must be optimized.
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Bibliography

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[3] Uyar, A., Sahin, O., Nalcaci, B., & Kilicli. V. (2022). Effect of austempering times on the microstructures and mechanical properties of dual-matrix structure austempered ductile iron (DMS-ADI). International Journal of Metalcasting. 16(1), 407-418. DOI: 10.1007/s40962-021-00617-4.
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[5] Tyrała, E., Górny, M., Kawalec, M., Muszyńska, A. & Lopez, H.F. (2019). Evaluation of volume fraction of austenite in austempering process of austempered ductile iron. Metals. 9(8), 1-10. DOI: 10.3390/met9080893.
[6] Fraś, E., Górny, M., Tyrała, E. & Lopez. H. (2012). Effect of nodule count on austenitising and austempering kinetics of ductile iron castings and mechanical properties of thin walled iron castings. Materials Science and Technology. 28(12), 1391-1396. DOI: 10.1179/1743284712Y.0000000088.
[7] Ibrahim, M.M., Negm, A.M., Mohamed, S.S. & Ibrahim. K.M. (2022). Fatigue properties and simulation of thin wall ADI and IADI castings. International Journal of Metalcasting. 16(4), 1693-1708. DOI: 10.1007/s40962-021-00711-7.
[8] Gumienny, G. & Kacprzyk. B. (2018). Copper in ausferritic compacted graphite iron. Archives of Foundry Engineering. 18(1), 162-166. DOI: 10.24425/118831.
[9] Abdullah, B., Alias, S. K., Jaffar, A., Rashid, A.A., Ramli, A. (2010). Mechanical properties and microstructure analysis of 0.5% niobium alloyed ductile iron under austempered process in salt bath treatment. International Conference on Mechanical and Electrical Technology, (pp. 610-614). DOI: 10.1109/ICMET.2010.5598431.
[10] Akinribide, O.J., Ogundare, O.D., Oluwafemi, O.M., Ebisike, K., Nageri, A.K., Akinwamide, S.O., Gamaoun, F. & Olubambi, P.A. (2022). A review on heat treatment of cast iron: phase evolution and mechanical characterization. Materials. 15(20), 1-38. DOI: 10.3390/ma15207109. [11] Samaddar, S., Das, T., Chowdhury, A.K., & Singh, M. (2018). Manufacturing of engineering components with Austempered ductile iron - A review. Materials Today: Proceedings. 5(11), 2561525624. DOI: 10.1016/j.matpr.2018.11.001.
[12] Stachowiak, A., Wieczorek, A.N., Nuckowski, P., Staszuk, M. & Kowalski, M. (2022). Effect of spheroidal ausferritic cast iron structure on tribocorrosion resistance. Tribology International. 173. DOI: 10.1016/j.triboint.2022.107688.
[13] Myszka, D. & Wieczorek, A. (2015). Effect of phenomena accompanying wear in dry corundum abrasive on the properties and microstructure of austempered ductile iron with different chemical composition. Archives of Metallurgy and Materials. 60(1), 483-490. DOI: 10.1515/amm-2015-0078.
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Authors and Affiliations

M. Stawarz
1
ORCID: ORCID
M. Lenert
1
K. Piasecki
1
ORCID: ORCID

  1. Department of Foundry Engineering, Silesian University of Technology, Towarowa 7 St., 44-100 Gliwice, Poland
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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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Abstract

The paper reports the results of a physical modelling study of the production of a hypereutectic aluminium alloy to be used for making an alloy vapour source for operation in the magnetron. Within the study, targets from a hypereutectic aluminium-silicon alloy were made in laboratory conditions. Thus obtained material was subjected to heat treatment, porosity analysis, and the assessment of the microstructure and fitness for being used in the magnetron. The process of melting the hypereutectic Al-Si alloy was carried out at the Department of Foundry of the Czestochowa University of Technology. The investigation into the production of the alloy vapour source for the synthesis of the dielectric material from the hypereutectic aluminium alloy has confirmed.

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Authors and Affiliations

M. Nadolski
ORCID: ORCID
G. Stradomski
K. Zdunek
S. Okrasa
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Abstract

The purposes of this study were to investigate the impact of proportions of cast iron scrap, steel scrap, carbon and ferro silicon on hardness and the quality of cast iron and to obtain an appropriate proportion of the four components in iron casting process using a mixture experimental design, analysis of variance and response surface methodology coupled with desirability function. Monte Carlo simulation was used to demonstrate the impacts of different proportions of the four components by varying the proportions of components within ±5% of the four components. Microstructures of the cast iron sample obtained from a company and the cast iron samples casted with the appropriate proportions of the four components were examined to see the differences of size and spacing of pearlite particle. The results showed that linear mixture components were statistically significant implying a high proportion of total variability for hardness of the cast iron samples explained by the casting mixtures of raw materials. The graphite of the sample casted from the appropriate proportion has shorter length and more uniform distribution than that from the company. When varying percentages of the four components within ±5% of the appropriate proportion, simulated hardness values were in the range of 237 to 256 HB.
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Authors and Affiliations

C. Saikaew
1
ORCID: ORCID
S. Harnsopa
1

  1. Department of Industrial Engineering, Khon Kaen University, Khon Kaen 40002 Thailand
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Abstract

The article discusses the most important changes in the construction of permanent mould casting machines, as well as the method of casting engine pistons and their construction on the example of Federal-Mogul (FM) Gorzyce. The system of automatic cooling of the presently used permanent mould casting machines coupled with robots which pour the liquid alloy ensures uniform crystallization of the pistons and optimal efficiency of the casting process. As a result of the necessity to improve the engine efficiency and thus reduce the fuel consumption and harmful substance emission, the construction of the pistons has changed as well. The piston castings, which are produced by gravity casting for metal moulds, have undergone a diametric transformation. Typical piston designs for gasoline and Diesel engines are shown together with the most important parts of the piston, the crown (combustion chamber) and the guide part (skirt). Depending on the type of engine, the present pistons characterize in differently shaped crown, a slimmed internal construction as well as component participation (cooling channels and ring inserts), and the piston skirts undergo surface treatment procedures.
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Authors and Affiliations

M. Czerepak
1
J. Piątkowski
2
ORCID: ORCID

  1. Federal-Mogul Gorzyce sp. z o.o., Odlewników 52, 39-432 Gorzyce, Poland
  2. Silesian University of Technology, Krasińskiego 8, 44-100 Gliwice, Poland
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Abstract

The paper presents results of research on steel castings GX120Mn13 (L120G13 by PN-89/H-83160), zone-reinforced by elektrocorundum particles (Al2O3), with a grain size from 2 to 3.5 mm. Studies revealed continuity at interface between composite components and formation of a diffusion zone in the surface layer of electrocorundum grains. In the area of this zone, simple manganese segregation and reverse iron and chromium segregation were found. The transfer of these elements from cast steel to electrocorundum grains resulted superficial depletion in aluminum and oxygen in this area. No porosity was observed at the interface between two components of the composite. We found it very beneficial from an exploitation point of view, as confirmed by the study of resistance to abrasive wear.
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Bibliography

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Authors and Affiliations

Daniel Medyński
ORCID: ORCID
A.J. Janus
1

  1. Witelon State University of Applied Science in Legnica ul. Sejmowa 5A, 59 – 220 Legnica, Poland
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Abstract

An analysis has been carried out of the influence of annealing time at the preheating temperature of 650 °C on the change in hardness and alloy structure of lamellar graphite cast iron in the working as well as in the laboratory conditions. This preheat temperature is common during reclaiming welding of castings with complex shapes. The changes in unalloyed cast iron EN-GJL 200 to EN-GJL 300 according to ISO 1690 standard and cast iron with low amount of elements such as Sn, Cu, Cr, and Mo and their combinations were assessed. It was found that the cast iron of higher strength grades has better hardness and structural stability. Cast iron alloyed with chromium or its combinations has the highest stability. In unalloyed cast iron, a partial degradation of pearlite occurs; in alloyed cast iron the structural changes are not conclusive.

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Authors and Affiliations

J. Roučka
ORCID: ORCID
J. Prochazka
V. Kana
V. Krutis
K. Nedelova
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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
1
ORCID: ORCID
N.S. Tiedje
1
ORCID: ORCID
J. Spangenberg
1
ORCID: ORCID

  1. Technical University of Denmark, Denmark
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Abstract

Nowadays, the best castings’ manufacturers have to meet very demanding requirements and specifications applicable to mechanical properties and other characteristics. To fulfill those requirements, more and more sophisticated methods are being used to analyze the internal quality of castings. In many cases, the commonly used Non-Destructive Methods, like X-ray or ultrasonic testing, are not enough to ensure precise and unequivocal evaluation. Especially, when the properties of the casting only slightly fail the specification and the reasons for such failures are very subtle, thus difficult to find without the modern techniques. The paper presents some aspects of such an approach with the use of Scanning Electron Microscopy (SEM) to analyze internal defects that can critically decrease the performance of castings. The paper presents the so-called bifilm defects in ductile and chromium cast iron, near-surface corrosion caused by sulfur, micro-shrinkage located under the risers, lustrous carbon precipitates, and other microstructure features. The method used to find them, the results of their analysis, and the possible causes of the defects are presented. The conclusions prove the SEM is now a powerful tool not only for scientists but it is more and more often present in the R&D departments of the foundries.
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Bibliography

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Authors and Affiliations

J. Jezierski
1
ORCID: ORCID
M. Dojka
1
M. Stawarz
1
ORCID: ORCID
R. Dojka
2

  1. Department of Foundry Engineering, Silesian University of Technology, 7 Towarowa, 44-100 Gliwice, Poland
  2. ODLEWNIA RAFAMET Sp. z o.o., 1 Staszica, 47-420 Kuźnia Raciborska, Poland
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Abstract

The article presents the results of research on the abrasion resistance of cast iron with vermicular graphite in the as-cast state and after austempering (the latter material is referred to as AVGI – Austempered Vermicular Graphite Iron). Austenitization was carried out at the temperature values of either 900°C or 960°C, and austempering at the temperature values of either 290°C and or 390°C. Both the austenitization and the austempering time was equal to 90 minutes. The change of the pearlitic-ferritic matrix to the ausferritic one resulted in an increase in mechanical properties. Abrasion tests were conducted by means of the T-01M pin-on-disc tribometer. The counter-sample (i.e. the disc) was made of the JT6500 friction material. Each sample was subject to abrasion over a sliding distance of 4000 m. The weight losses of both samples and counter-samples were determined by the gravimetric method. It was found that the vermicular cast iron austenitized at 900°C and austempered at 290°C was characterized by the lowest wear among the evaluated cast iron types. The geometric structure of the surface layer after the dry friction test exhibited irregular noticeable grooves, distinct oriented abrasion traces, plastic flow of the material, microcracks, and pits generated by tearing out the abraded material. The largest surface roughness was found for the AVGI cast iron heat-treated according to the variant 3 (Tγ =900 ºC; Tpi = 390°C), while the smallest one occurred in AVGI cast iron subject to either the variant 2 (Tγ =960 ºC; Tpi = 290°C) or the variant 4 (Tγ =900 ºC; Tpi = 290°C) of heat treatment and was equal to either 2.5 μm or 2.66 μm, respectively. It can be seen that the surface roughness decreases with the decrease in the austempering temperature.
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Authors and Affiliations

A. Jakubus
1
ORCID: ORCID

  1. The Jacob of Paradies University in Gorzów Wielkopolski, ul. Teatralna 25, 66-400 Gorzów Wielkopolski, Poland
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Abstract

The paper indicates the significance of the problem of foundry processes parameters stability supervision and assessment. The parameters, which can be effectively tracked and analysed using dedicated computer systems for data acquisition and exploration (Acquisition and Data Mining systems, A&D systems) were pointed out. The state of research and methods of solving production problems with the help of computational intelligence systems (Computational Intelligence, CI) were characterised. The research part shows capabilities of an original A&DM system in the aspect of selected analyses of recorded data for cast defects (effect) forecast on the example of a chosen iron foundry. Implementation tests and analyses were performed based on selected assortments for grey and nodular cast iron grades (castings with 50 kg maximum weight, casting on automatic moulding lines for disposable green sand moulds). Validation tests results, applied methods and algorithms (the original system’s operation in real production conditions) confirmed the effectiveness of the assumptions and application of the methods described. Usability, as well as benefits of using A&DM systems in foundries are measurable and lead to stabilisation of production conditions in particular sections included in the area of use of these systems, and as a result to improvement of casting quality and reduction of defect number.

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Authors and Affiliations

R. Sika
Z. Ignaszak
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Abstract

Dokra casting is famous for its Artistic value to the world but it is also sophisticated engineering. The technique is almost 4500 years old. It is practiced by the tribal artisans of India. It is a clay moulded wax-based thin-walled investment casting technique where liquid metal was poured into the red hot mould. Dimensional accuracy is always preferable for consumers of any product. Distortion is one of the barriers to achieving the accurate dimension for this type of casting especially for the bending parts. The cause and nature of the distortion for this type of casting must be analyzed to design a product with nominal tolerance and dimensional accuracy.
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Authors and Affiliations

R. Mandal
1
S. Roy
2
ORCID: ORCID
S. Sarkar
1
T. Mandal
3
A.K. Pramanick
2
G. Majumdar
1

  1. Mechanical Engineering Department, Jadavpur University, India
  2. Metallurgical and Material Engineering Department, Jadavpur University, India
  3. Metallurgy and Materials Engineering, IIEST Shibpur, India
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Abstract

The paper presents issues related to the technology of layered castings manufactured in the system: working part made of high-chromium steel X46Cr13 - base part made of gray cast iron with flake graphite, using the mould cavity preparation technology. Considering the high hardenability of the above-mentioned steel grade, the aim of the research was to optimize the casting parameters of gray cast iron in such a way that it would be possible to perform heat treatment of X46Cr13 steel directly in the casting mould. As part of the research, the geometry of the working and base parts of layered castings was selected, and guidelines for mould technology from the point of view of the moulding sand were developed. In order to control the cooling rate, three matrix of the moulding sand were used - quartz sand, chromite sand and silicon carbide, with the same granularity. The thermal conductivity coefficient of sands made on selected matrix, bound with synthetic resin in the ratio of 30:1, was experimentally determined. Then, the bimetal casting process in a given mass was simulated in the MagmaSoft® (ver. 5.4.1). The purpose of the simulation was to determine the maximum virtual temperature Tm in the thermal center of the outer surface of the X46Cr13 steel insert. From the point of view of the research purpose, the insert was expected to heat up to the austenitization temperature, i.e. at least 950°C.
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Authors and Affiliations

N. Przyszlak
1
G. Piwowarski
2

  1. Department of Engineering Processes Automation and Integrated Manufacturing Systems, Faculty of Mechanical Engineering, Silesian University of Technology, Konarskiego 18A St., 44-100 Gliwice, Poland
  2. AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Engineering of Foundry Processes, 23 Reymonta St., 30-059 Krakow, Poland
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Abstract

The presented article concerns the issue of supporting the ADI cast iron product manufacturing process and presents an IT system dedicated mainly to designers and technologists. Designers can be supported at the stage of selecting types of materials and technologies (including ADI cast iron) to produce products with required properties. Technologists can obtain support in determining the parameters (temperature and chemical) of the ADI cast iron manufacturing process in order to obtain products with specific properties. The system also contains an information resources (standards, documentation, examples) concerning ADI cast iron and products made of it. Examples of use by individual system users are presented as a case study.
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Authors and Affiliations

A. Opaliński
1
ORCID: ORCID
D. Wilk-Kołodziejczyk
1 2
ORCID: ORCID

  1. AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059 Krakow, Poland
  2. Łukasiewicz Research Network – Krakow Institute of Technology, 73 Zakopiańska Str., 30-418 Kraków, Poland
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Abstract

For the manufacture of near net shape complex titanium products, it is necessary to use investment casting process. Melting of titanium is promising to carry out by electron beam casting technology, which allows for specific processing of the melt, and accordingly control the structure and properties of castings of titanium alloys. However, the casting of titanium in ceramic molds is usually accompanied by a reaction of the melt with the mold. In this regard, the aim of the work was to study the interaction of titanium melt with ceramics of shell molds in the conditions of electron beam casting technology. Ceramic molds were made by using the following refractory materials – fused corundum Al2O3, zircon ZrSiO4 and yttria-stabilized zirconium oxide ZrO2, and ethyl silicate as a binder. Melting and casting of CP titanium was performed in an electron beam foundry. Samples were made from the obtained castings and electron microscopic metallography was performed. The presence and morphology of the altered structure, on the sample surface, were evaluated and the degree and nature of their interaction were determined. It was found that the molds with face layers of zirconium oxide (Z1) and zircon (ZS1) and backup layers of corundum showed the smallest interaction with the titanium melt. Corundum interacts with titanium to form a non-continuous reaction layer with thickness of 400-500 μm. For shell molds with face and backup layers of zircon on the surface of the castings, a reaction layer with thickness of 500-600 μm is formed. In addition, zirconium-silicon eutectic was detected in these layers.
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Bibliography

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Authors and Affiliations

Pavlo Kaliuzhnyi
M. Voron
1
O. Mykhnian
1
A. Tymoshenko
1
O. Neima
1
O. Iangol
1

  1. Physico-Technological Institute of Metals and Alloys of the National Academy of Sciences of Ukraine, Ukraine
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Abstract

The paper presents the results of investigations concerning the influence of gray cast iron modification on free vibration frequency of the disc casting. Three different chemical composition melts of gray cast iron were prepared in induction furnace. During gravity casting 0.05% and 0.3% mass of the Inolate modifier was added on stream of metal for changing graphite flakes in castings. Sound signal vibration of cast iron sample was registered by means on microphone for free vibration frequency measurements. Decreasing of free vibration frequency of modified cast iron in comparison with non modified castings was observed. Higher contents of modifier causes more decreasing of free vibration frequency. Cast iron with smaller contents of carbon and silicon have higher free vibration frequency in comparison with eutectic composition cast iron. Hardness of examined cast iron is lower when the more modifier is added during modification process. Free frequency is smaller with smaller Brinell hardness of disc casting. It was concluded that control of free vibration frequency of disc castings by means of chemical composition and modification process can improved comfort and safety of working parts.

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Authors and Affiliations

Z. Konopka
Małgorzata Łągiewka
ORCID: ORCID
A. Zyska
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Abstract

The paper presents the problem which concerning the technology of bimetallic castings in materials configuration: high-chromium steel as the working layer and grey cast iron as the base part. The aim of the studies was integrate the process of manufacturing of bimetallic casting with the heat treatment of hardening type of X46Cr13 steel insert by applying the mould with sandmix on a matrix of chromite sand. Range of studies included the chemical composition analysis, non-destructive ultrasonic tests to examine the quality of the permanent bond between the working layer (steel insert) and the base part (grey cast iron) of the bimetallic castings, hardness measurements as well as metallographic examinations performed on the optical and scanning electron microscopes. On the basis of obtained results was concluded that the self-hardening process occurred in the X46Cr 13 steel working layer and in result of this the hardness on its surface equalled approx. 45HRC in case of the bimetallic castings with full permanent bond between both parts.

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Authors and Affiliations

N. Przyszlak
T. Wróbel
ORCID: ORCID
A. Dulska
ORCID: ORCID
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Abstract

The article considers the method of obtaining reinforced castings from gray cast iron by lost foam casting. The aim of this study was to determine the microstructure formation of gray cast iron reinforced with inserts of carbon and stainless steel in this casting method. The results of the research have shown that the products of destruction of expanded polystyrene have a positive effect on the bonding formation of cast iron with reinforcing inserts. When steel wire is used as reinforcement, a decarbonized layer of cast iron is being formed around it, in which the inclusions of graphite are smaller and their quantity is less than in the main metal. Due to carburization, the surface structure of the reinforcement changes from ferrite to pearlite with cementite. Steel wire reinforcement can be effective in increasing strength and toughness of gray cast iron. The usage of stainless steel reinforcement leads to the formation of a transition layer on the part of the matrix metal. It contains ledeburite with dissolved chromium, which increase the wear resistance of cast iron.
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Authors and Affiliations

Pavlo Kaliuzhnyi
1
Inna Shalevska
1
ORCID: ORCID
Vadym Sliusarev
1
ORCID: ORCID

  1. Department of Physical Chemistry of Foundry Processes, Physico-Technological Institute of Metals and Alloys of the National Academy of Sciencesof Ukraine, Ukraine

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