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Number of results: 12
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Abstract

The article presents a case study on the effectiveness of photovoltaic farm and battery energy storage in one of the Polish foundries. In the study, we consider two investment options: stand-alone PV farm of 1MWp and the farm together with battery energy storage with a maximum capacity of 4MWh. The Payback Period and Net Present Value were used as measures of investment profitability. The paper provides a detailed presentation of the assumptions made, as well as the PV electricity production model of the farm and the optimization model that determines the operation cycle of the energy storage. The case study presented in the article shows that the PV farm is economically sensible and profitable, but the battery energy storage is too costly to give a positive economic effect. Energy storage is an important element that provides flexibility in the energy supply system, so it is necessary to find a technical solution that gives this flexibility. Such a solution could be a virtual power plant, which could include a foundry energy system with a RES installation inside.
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Authors and Affiliations

A. Stawowy
1
ORCID: ORCID
R. Wrona
2
M. Sawczuk
2
D. Lasek
2

  1. AGH University of Science and Technology, Faculty of Management, Poland
  2. Modus Sp. z o.o., Poland
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Abstract

The article presents an example of analysis of the influence of selected parameters deriving from data acquisition in foundries on the occurrence of Gas porosity defects (detected by Visual testing) in castings of ductile cast iron. The possibilities as well as related effectiveness of prediction of this kind of defects were assessed. The need to rationally limit the number of possible parameters affecting this kind of porosity was indicated. Authors also benefited from expert group's expertise in evaluating possible causes associated with the creation of the aforementioned defect. A ranking of these parameters was created and their impact on the occurrence of the defect was determined. The classic statistical tools were used. The possibility of unexpected links between parameters in case of uncritical use of these typical statistical tools was indicated. It was emphasized also that the acquisition realized in production conditions must be subject to a specific procedure ordering chronology and frequency of data measurements as well improving the casting quality control. Failure to meet these conditions will significantly affect the difficulties in implementing and correcting analysis results, from which INput/OUTput data is expected to be the basis for modelling for quality control.

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Authors and Affiliations

Z. Ignaszak
R. Sika
M. Rogalewicz
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Abstract

Today’s industry aims at such situation, where number of defective products, so called defects shall approach to zero. Therefore, one introduces a various changes in technology of production, introduces improvements which would help in accomplishment of this objective. Another important factor is introduction of different type of testing, which shall help in assessment which factor has significant effect on quantity of rejects, and which one could be neglected. Existence of casting rejects is unavoidable; therefore a new ideas, technologies and innovations are necessary in the entire widely understood foundry branch, in order to minimize such adverse effect. Performance of tests aimed at unequivocal determination of an effect of vibrations during crystallization on mechanical properties and porosity of the EN ACAlSi17 alloy was the objective of the present work. To do this, there were produced 36 castings from EN AC-AlSi17 alloy. All the castings underwent machining operations. Half of the casting was destined to strength tests, the other half served to determination of an effect of vibrations on porosity of the alloy. The specimens were divided into 12 groups, depending on amplitude of vibrations and tilt angle of metal mould during pouring operation.

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Authors and Affiliations

T. Ciućka
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Abstract

An innovative method for determining the structural zones in the large static steel ingots has been described. It is based on the

mathematical interpretation of some functions obtained due to simulation of temperature field and thermal gradient field for solidifying

massive ingot. The method is associated with the extrema of an analyzed function and with its points of inflection. Particularly, the CET

transformation is predicted as a time-consuming transition from the columnar- into equiaxed structure. The equations dealing with heat

transfer balance for the continuous casting are presented and used for the simulation of temperature field in the solidifying virtual static

brass ingot. The developed method for the prediction of structural zones formation is applied to determine these zones in the solidifying

brass static ingot. Some differences / similarities between structure formation during solidification of the steel static ingot and virtual brass

static ingot are studied. The developed method allows to predict the following structural zones: fine columnar grains zone, (FC), columnar

grains zone, (C), equiaxed grains zone, (E). The FCCT-transformation and CET-transformation are forecast as sharp transitions of the

analyzed structures. Similarities between steel static ingot morphology and that predicted for the virtual brass static ingot are described.

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Authors and Affiliations

A.A. Ivanova
B. Kania
P. Kwapisiński
W. Wołczyński
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Abstract

Mechanization of the process of core making with the use of inorganic and organic binders is based, almost solely, on core blowing machines. Presently the core blowing machines are equipped with tools and devices that allow for application of different technologies of core making. Cold-box, hot-box and warm-air technologies require that core blowing machines shall be additionally equipped with either core-box pre-heating system or gas purging and neutralization system, or hot air purging systems. Considering the possibility of using varied, the most advantageous technologies of core making, the production of universal core blowing machines equipped with replaceable devices has been undertaken in Poland. The universal core blowing systems allow for mechanization of core making process also with the use of sand, bonded by modern, eco-friendly binder systems. The paper presents selected results-based evaluation of core blowing process showing the scope of conducted design and implementation works.
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Authors and Affiliations

A. Fedoryszyn
R. Dańko
J. Dańko
M. Asłanowicz
T. Fulko
A. Ościłowski
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Abstract

Vacuum conditions in foundry installations are generated using electric-driven vacuum pumps. The purpose of the experiment is to evaluate the performance of a vacuum-assisted system for compaction of moulding sand basing on registered plots of selected electric power parameters of the power-supplying system of the pumps. Model testing done on an experimental vacuum system installation, power-supplied from a system incorporating the recorders of instantaneous current and voltage values. Following the numerical procedure, the experimental data are analysed to yield mathematical relationships between the variations of the generated vacuum pressure levels and variations of selected electric power parameters. Registered and computed values of selected parameters: instantaneous and RMS voltage and current values, active, reactive and apparent power levels and power coefficient allow for diagnosing the adequacy and reliability of the system operation. According to the authors, the applied monitoring of the power parameters of a vacuum-assisted installation may become an effective and easy practical method of evaluating the performance of such installations, used also in foundry plants.

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Authors and Affiliations

M. Brzeziński
E. Ziółkowski
R. Wrona
K. Smyksy
P. Zyzak
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Abstract

In this article the main problems related with the proper choice of the design and operation parameters of vacuum installation in vacuum moulding system have been discussed. In such system a vacuum are generated using electric-driven vacuum pumps. The aim of the experiment is to evaluate the performance of a vacuum system basing on registered plots of selected electric power parameters of the power-supplying system of the pumps with parallel measurements instantaneous values of pressure in selected points of model stand. The measurements system for power-supply unit has incorporated the recorders of instantaneous current and voltage values. Following the suitable numerical procedure, the experimental data are analysed to yield mathematical relationships between the variations of the generated vacuum pressure levels and variations of selected electric power parameters. According to the authors, the applied measurements system of the parameters of a vacuum-assisted installation may become an effective and easy practical method of evaluating the performance of such installations, used also in industry.

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Authors and Affiliations

K. Smyksy
E. Ziółkowski
M. Brzeziński
R. Wrona
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Abstract

Foundry resistance furnaces are thermal devices with a relatively large time delay in their response to a change in power parameters. Commonly used in automation classical PID controllers do not meet the requirements of high-quality control. Developed in recent years, fuzzy control theory is increasingly being used in various branches of economy and industry. Fuzzy controllers allow to introduce new developments in control systems of foundry furnaces as well. Correctly selected fuzzy controller can significantly reduce energy consumption in a controlled thermal process of heating equipment. The article presents a comparison of energy consumption by control system of foundry resistance furnace, equipped with either a PID controller or fuzzy controller optimally chosen.
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Authors and Affiliations

E. Ziółkowski
P. Śmierciak
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Abstract

The Structural Peclet Number has been estimated experimentally by analyzing the morphology of the continuously cast brass ingots. It

allowed to adapt a proper development of the Ivantsov’s series in order to formulate the Growth Law for the columnar structure formation

in the brass ingots solidified in stationary condition. Simultaneously, the Thermal Peclet Number together with the Biot, Stefan, and

Fourier Numbers is used in the model describing the heat transfer connected with the so-called contact layer (air gap between an ingot and

crystallizer). It lead to define the shape and position of the s/l interface in the brass ingot subjected to the vertical continuous displacement

within the crystallizer (in gravity). Particularly, a comparison of the shape of the simulated s/l interface at the axis of the continuously cast

brass ingot with the real shape revealed at the ingot axis is delivered. Structural zones in the continuously cast brass ingot are revealed: FC

– fine columnar grains, C – columnar grains, E – equiaxed grains, SC – single crystal situated axially.

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Authors and Affiliations

A.A. Ivanova
Z. Lipnicki
P. Kwapisiński
W. Wołczyński
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Abstract

Heating process in the domain of thin metal film subjected to a strong laser pulse are discussed. The mathematical model of the process

considered is based on the dual-phase-lag equation (DPLE) which results from the generalized form of the Fourier law. This approach is,

first of all, used in the case of micro-scale heat transfer problems (the extremely short duration, extreme temperature gradients and very

small geometrical dimensions of the domain considered). The external heating (a laser action) is substituted by the introduction of internal

heat source to the DPLE. To model the melting process in domain of pure metal (chromium) the approach basing on the artificial mushy

zone introduction is used and the main goal of investigation is the verification of influence of the artificial mushy zone ‘width’ on the

results of melting modeling. At the stage of numerical modeling the author’s version of the Control Volume Method is used. In the final

part of the paper the examples of computations and conclusions are presented.

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Authors and Affiliations

B. Mochnacki
M. Ciesielski
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Abstract

Thermal processes in domain of thin metal film subjected to a strong laser pulse are discussed. The heating of domain considered causes

the melting and next (after the end of beam impact) the resolidification of metal superficial layer. The laser action (a time dependent belltype

function) is taken into account by the introduction of internal heat source in the energy equation describing the heat transfer in domain

of metal film. Taking into account the extremely short duration, extreme temperature gradients and very small geometrical dimensions of

the domain considered, the mathematical model of the process is based on the dual phase lag equation supplemented by the suitable

boundary-initial conditions. To model the phase transitions the artificial mushy zone is introduced. At the stage of numerical modeling the

Control Volume Method is used. The examples of computations are also presented.

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Authors and Affiliations

E. Majchrzak
B. Mochnacki
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Abstract

According to the analysis of the current state of the knowledge shows that there is little information on the process of phase transformations

that occur during the cooling Cu-Al-Fe-Ni hypo-eutectoid bronzes with additions of Cr, Mo and/or W, made additions individually

or together, for the determination of: the type of crystallizing phases, crystallizing phases, order and place of their nucleation.

On the basis of recorded using thermal and derivative analysis of thermal effects phases crystallization or their systems, analysis of the

microstructure formed during crystallization - observed on the metallographic specimen casting ATD10-PŁ probe, analysis of the existing

phase equilibrium diagrams forming elements tested Cu-Al-Fe-Ni bronze, with additions of Cr, Mo, W and/or Si developed an original

model of crystallization and phase transformation in the solid state, the casting of high quality Cu-Al-Fe-Ni bronze comprising: crystallizing

type phase, crystallizing phase sequence, place of nucleation.

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Authors and Affiliations

B.P. Pisarek

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