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The Influence of Ingate Size on the Lost Foam Casting Process

T. Pacyniak R. Kaczorowski
Archives of Foundry Engineering | 2012 | No 2 | DOI: 10.2478/v10266-012-0058-1
Keywords Foundry engineering Lost Foam EPS Models Protective Coating
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Abstract

The article presents analysis of the influence of ingate size on the Lost Foam casting process. In particular, analysis of simulation tests has been carried out to determine the ingate size influence on the rate of filling of the mould cavity, pressure in the gas gap and size of the gas gap. A specially prepared mathematical model of the process and an original calculation algorithm were used in simulation tests of full-mould casting. The tests have indicated that the increase of the ingate size results in the increase of filling rate and increase of pressure of gases in the gas gap. However, significant influence on mould cavity filling occurs only when the ingate size is less than ~1 cm2.

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Authors and Affiliations

T. Pacyniak
R. Kaczorowski

The Assessment of the Permeability of Selected Protective Coatings Used for Sand Moulds and Cores

Ł. Jamrozowicz A. Siatko
Archives of Foundry Engineering | 2020 | vol. 20 | No 1 | 17-22 | DOI: 10.24425/afe.2020.131276
Keywords Permeability Protective coatings Coating viscosity Core Mold
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Abstract

The article presents the results of permeability measurements of a zirconium alcohol coating applied on moulds and cores. The introduction extensively discusses the reasons for the application of protective coatings, as well as their advantages and disadvantages. Also, the problems related to the application of protective coatings are presented i.e. limited permeability and thus the possibility of the presence of gas-originated defects in the casts. Next, the paper discusses the methods of measuring the permeability of protective coating proposed by Falęcki and Pacyniak. The study also presents an indirect permeability measurement method. For the investigations, zirconium alcohol coatings with the three conventional viscosities 10, 20 and 30s were used. The viscosity was determined by means of the Ford cup with the clearance of 4mm. The coatings were applied onto profiles of Φ 50 x 50 mm, made of moulding sand consisting of a sand matrix with the mean grain size of dL = 0,11, 17, 24, 31 and 34 mm and phenol-formaldehyde resin. The effect of the matrix grain size on the permeability of the sand with and without a coating was determined.

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Authors and Affiliations

Ł. Jamrozowicz
ORCID: ORCID
A. Siatko

Gaseous Atmosphere During Gas Forming Tendency Measurements of the Selected Protective Coatings for Sand Moulds

J. Mocek
Archives of Foundry Engineering | 2021 | vo. 21 | No 3 | 11-18 | DOI: 10.24425/afe.2021.136107
Keywords Gas forming tendency oxygen hydrogen Carbon monoxide Protective coatings
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Abstract

Protective coatings have direct contacts with hot and liquid alloys. As the result of such contacts gases are emitted from coatings. Gas forming is a tendency of the tested material to emit gases under a temperature influence. In order to assess the gas forming tendency either direct or indirect methods are applied. In the hereby work, the measurements of the gas forming tendency were performed under laboratory conditions, by means of the developed indirect method. The research material constituted samples of six selected protective coatings dissolved either in alcohol or in water. These coatings are applied in sand moulds and cores for making cast iron castings. The assessment of their gas forming tendency was presented in relation to temperatures and heating times. The occurrence and changes of oxygen and hydrogen contents in gases outflowing from the measuring flask during tests, were measured by means of gas sensors. The process of the carbon monoxide (CO) emission during tests was also assessed. The following gas sensors were installed in flow-through micro chambers: for oxygen - lambda probe, for hydrogen – pellistor, for carbon monoxide - sensor (dedicated for CO) FIGARO TGS 822 TF. The results of direct CO measurements were recalculated according to the algorithm supplied by the producer of this sensor.
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Bibliography

[1] Di Muoio G.L., Skat Tiedje N., Budolph Johansen B. (2014). Automatic vapour sorption analysis as new methodology for assessing moisture content of water based foundry coating and furan sands. Mar del Plata, BS. As., Argentina
[2] Nwaogu, U. & Tiedje, N. (2011). Foundry coating technology: A Review. Materials Sciences and Applications. 2(8), 1143-1160. DOI: 10.4236/msa.2011.28155.
[3] Scarber Jr, P., Bates, C. & Griffin, J. (2006). Avoiding gas defects through mold and core package design. Modern Casting. 96(12), 38-40.
[4] Zych, J, Mocek, J. (2019). Thermal Volumetric Analysis (TVA): a new test method of the kinetics of gas emissions from moulding sands and protective coatings heated by liquid alloy. London: IntechOpen, 13-33. ISBN: 978-1- 78985-161-8; e-ISBN: 978-1-78985-162-5. https://www.intechopen.com/chapter/pdf-download/62133.
[5] Z.B.P. SENSOR GAZ Andrzej Rejowicz. Explosimetric sensing head. Retrieved January 15, 2021 from http://sensorgaz.com.pl/wp-content/uploads/2017/06/EKP1WH.pdf
[6] Figaro Engineering Inc. Tentative product information TGS822TF. Retrieved January 15, 2021 from https://cdn.sos.sk/productdata/ad/97/a7c71525/tgs-822tf.pdf
[7] HA International. Refractory Coating Products. Retrieved January 15, 2021 from https://www.ha.international.com/content/products/refractory _coatings/refractory_coatings.aspx
[8] Marć, A.W. (2018). Multi-parameter assessment of gas formation of selected protective coatings for sand forms. Master thesis. Kraków: AGH WO. (in Polish).
[9] Mocek, J. (2019). Multiparameter assessment of the gas forming tendency of foundry sands with alkyd resins. Archives of Foundry Engineering. 19(2), 41-48.
[10] Zych, J., Mocek, J. & Snopkiewicz, T. (2014). Gas generation properties of materials used in the sand mould technology – modified research method. Archives of Foundry Engineering. 14(3), 105-109.
[11] Lewandowski, J.L., Solarski, W. & Pawłowski, Z. (1993). Classification of molding and core sands in terms of gas formation. Przegląd Odlewnictwa. 5, 143-149. (in Polish).
[12] Lewandowski, J.L. (1997). Foundry mold materials. Kraków. (in Polish).
[13] Mocek, J. & Chojecki, A. (2009). Evolution of the gas atmosphere during filing the sand moulds with iron alloys. Archives of Foundry Engineering. 9(4), 135-140.
[14] Pietkun-Greber I. Janka R. (2010). Effect of hydrogen on metals and alloys. Proceedings of EC Opole. 4(2), 471-476. (in Polish).
[15] Bobrowski, A., Holtzer, M., Dańko, R. & Żymankowska-Kumon S. (2013). Analysis of gases emitted during a thermal decomposition of the selected phenolic binders. Metalurgia International. 18(si.7), 259-261.
[16] Holtzer, M., Kwaśniewska-Królikowska, D., Bobrowski, A., Dańko, R., Grabowska, B., Żymankowska-Kumon, S., & Solarski, W. (2012). Investigations of a harmful components emission from moulding sands with bentonite and lustrous carbon carriers when in contact with liquid metals. Przegląd Odlewnictwa. 62(3-4), 124-132.
[17] Holtzer, M., Dańko, R., Kmita, A., Drożyński, D., Kubecki, M., Skrzyński, M., Roczniak, A. (2020). Environmental Impact of the Reclaimed Sand Addition to Molding Sand with Furan and Phenol-Formaldehyde Resin-A Comparison. Materials. 13, 4395, 1-12. DOI: 10.3390/ma13194395 www.mdpi.com/journal/materials.
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Authors and Affiliations

J. Mocek
1
  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Cast Non-Ferrous Metals, Al. Mickiewicza 30, 30-059 Kraków, Poland

Protection properties of conversion coatings based on nitrates for resorbable Mg alloy

Katarzyna Cesarz-Andraczke
Bulletin of the Polish Academy of Sciences Technical Sciences | 2021 | 69 | No. 1 | e136045 | DOI: 10.24425/bpasts.2021.136045
Keywords magnesium alloys protection coatings hydrogen evolution corrosion behavior
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Abstract

In this work, conversion coatings based on nitrates Ca(NO 3) 2 and Zn(NO 3) 2 were produced on the surface of MgZn49Ca4 to protect against corrosion. The main aim of this study was to prepare dense and uniform coatings using a conversion method (based on nitrates Ca(NO 3) 2 and Zn(NO 3) 2) for resorbable Mg alloys. The scientific goal of the work was to determine the pathway and main degradation mechanisms of samples with nitrate-based coatings as compared with an uncoated substrate. Determining the effect of the coatings produced on the Mg alloy was required to assess the protective properties of Mg alloy-coating systems. For this purpose, the morphology and chemical composition of coated samples, post corrosion tests and structural tests of the substrate were performed (optical microscopy, SEM/EDS). Immersion and electrochemical tests of samples were also carried out in Ringer’s solution at 37°C. The results of immersion and electrochemical tests indicated lower corrosion resistance of the substrate as compared with coated samples. The hydrogen evolution rate of the substrate increased with the immersion time. For coated samples, the hydrogen evolution rate was more stable. The ZnN coating (based on Zn(NO 3) 2) provides better corrosion protection because the corrosion product layer was uniform, while the sample with a CaN coating (based on Ca(NO 3) 2) displayed clusters of corrosion products. It was found that pitting corrosion on the substrate led to the complete disintegration and non-uniform corrosion of the coated samples, especially the CaN sample, due to the unevenly-distributed products on its surface.
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Bibliography

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Authors and Affiliations

Katarzyna Cesarz-Andraczke
1
  1. Department of Engineering Materials and Biomaterials, Faculty of Mechanical Engineering, Silesian University of Technology, ul. Konarskiego 18A, 44-100 Gliwice, Poland

The Effect of BN or SiC Addition on PEO Properties of Coatings Formed on AZ91 Magnesium Alloy

D. Pelczar P. Długosz P. Darłak A. Szewczyk-Nykiel M. Nykiel M. Hebda
Archives of Metallurgy and Materials | 2022 | vol. 67 | No 1 | 147-154 | DOI: 10.24425/amm.2022.137483
Keywords composite oxide film abrasive wear resistance corrosion behavior scratch resistance protective coatings
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Abstract

Currently, due to the economic and ecological aspects, light alloys are increasingly important construction material, in particular in the transport industry. One of the popular foundry magnesium alloys is the alloy AZ91, which among others due to mechanical properties and technological features, is used, for example, for light structural parts.
The paper presents the results of research on modification of the AZ91 alloy surface layer in the plasma electrolytic oxidation process. The change of usable properties of the produced coatings was obtained by introducing additions of silicon carbide or boron nitride. The thickness and hardness of the protective layers produced, resistance to scratches and corrosion resistance were determined. Moreover, the friction coefficient of the coating-steel pair was investigated. The quality of the connections made between the coating and the substrate, i.e. the magnesium alloy, was also evaluated. The results obtained for coatings with silicon carbide or boron nitride additives were always compared to the results obtained for unmodified samples.
On the basis of the obtained results, it was shown that the introduction of boron nitride additive to the AZ91 alloy coating produced in the plasma electrolytic oxidation process significantly improves the resistance to: (i) corrosion and (ii) abrasive wear of the coating.
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Authors and Affiliations

D. Pelczar
1
P. Długosz
2
ORCID: ORCID
P. Darłak
2
ORCID: ORCID
A. Szewczyk-Nykiel
1
ORCID: ORCID
M. Nykiel
1
ORCID: ORCID
M. Hebda
1
ORCID: ORCID
  1. Cracow University of Technology, Faculty of Materials Engineering and Physics, Department of Materials Engineering, 24 Warszawska St r., 31-155 Krakow, Poland
  2. Centre of Casting Technology, Research Network Lukasiewicz-Krakow Institute of Technology, Zakopiańska 73, 30-418 Krakow, Poland

Humidity Migration in Surface Layers of Sand Moulds During Processes of Penetration and Drying of Protective Coatings

Ł. Jamrozowicz J. Zych
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 72-78 | DOI: 10.24425/afe.2022.143952
Keywords Core Sand mould Porous medium Humidity migration Protective coatings Resistance measurement
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Abstract

The results of investigations of humidity migration in near surface layers of sand mould during processes of penetration and drying of protective coatings are presented in the hereby paper. The process of the humidity exchanging between surroundings and moulding sands as porous materials, is widely described in the introduction. In addition, the humidity flow through porous materials, with dividing this process into stages in dependence of the humidity movement mechanism, is presented. Next the desorption process, it means the humidity removal from porous materials, was described. Elements of the drying process intensity as well as the water transport mechanisms at natural and artificial drying were explained. The innovative research stands for measuring resistance changes of porous media due to humidity migrations was applied in investigations. Aqueous zirconium coatings of two apparent viscosities 10s and 30s were used. Viscosity was determined by means of the Ford cup of a mesh clearance of 4mm. Coatings were deposited on cores made of the moulding sand containing sand matrix, of a mean grain size dL = 0.25 mm, and phenol-formaldehyde resin. Pairs of electrodes were placed in the core at depths: 2, 3, 4, 5, 8, 12 and 16 mm. Resistance measurements were performed in a continuous way. The course of the humidity migration process in the core surface layer after covering it by protective coating was determined during investigations. Investigations were performed in the room where the air temperature was: T = 22˚C but the air humidity was not controlled, as well as in the climatic chamber where the air temperature was: T = 35˚C and humidity: H = 45%. During the research, it was shown that the process of penetration (sorption) of moisture into the moulding sand is a gradual process and that the moisture penetrates at least 16 mm into the sand. In the case of the drying (desorption) process, moisture from the near-surface layers of the moulding sand dries out much faster than moisture that has penetrated deeper into the sand. Keywords: Core, Sand mould, Porous medium, Humidity migration, Protective coatings, Resistance measurement
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Bibliography

[1] Pigoń, K., Ruziewicz, Z. (2005). Physical chemistry. Phenomenological foundations. Warszawa: PWN, (in Polish) [2] Zarzycki, R. (2005). Heat transfer and mass movement in environmental engineering. Warszawa: Wydawnictwo Naukowo-Techniczne. (in Polish) [3] Płoński, W., Pogorzelski, J. (1979). Building physics. Warszawa: Arkady. (in Polish) [4] Świrska-Perkowska, J. (2012). Adsorption and movement of moisture in porous building materials under isothermal conditions. Warszawa: Komitet Inżynierii Lądowej i Wodnej PAN. (in Polish) [5] Kubik, J. (2000). Moisture flows in building materials. Opole: Oficyna Wydawnicza Politechniki Opolskiej. (in Polish) [6] Gawin, D. (2000). Modeling of coupled hygrothermal phenomena in building materials and elements. Łódź: Politechnika Łódzka. (in Polish) [7] Rose, D. (1963). Water movement in porous materials. Part 1: isothermal vapour transfer. British Journal of Applied Physics. (14), 256-262. DOI:10.1088/0508-3443/14/5/308. [8] Rose, D. (1963): Water movement in porous materials. part 2: the separation of the components of water movement. British Journal of Applied Physics. (14), 491-496. DOI: 10.1088/0508-3443/14/8/310. [9] Marynowicz, A., Wyrwał, J. (2005). Testing the moisture properties of selected building materials under isothermal conditions. Warszawa: INB ZTUREK. (in Polish) [10] Kiessl, K. (1983) Kapillarer und dampffoermiger Fauchtetransport in mahrschichtigen Bauteilen. Essen: Dissertation. University Essen. [11] Politechnika Gdańska. The process of drying food substances - laboratory exercises. Retrieved January, 2022, from https://mech.pg.edu.pl/documents/4555684/4565480/suszenie.pdf (in Polish). [12] Baranowski, J., Melech, S., Adamski, P. (2002). Temperature and humidity control systems in the processes of drying food products. Zielona Góra: VI Sympozjum Pomiary i Sterowanie w Procesach Przemysłowych. (in Polish) [13] Ważny, J., Karyś, J. (2001). Protection of buildings against biological corrosion. Warszawa: Arkady. (in Polish) [14] Brooker, D., Bakker-Arkema, F., Hall, C. (1992). Drying and Storage of Grains and Oilseeds. New York: Van Nostrand Reinhold. [15] Reeds, J. (1991). Drying. ASM International Handbook Committee. 131-134. [16] Pel, L., Sawdy, A. & Voronina, V. (2010). Physical principles and efficiency of salt extraction by poulticing. Journal of Cultural Heritage. 11(1), 59-67. DOI:10.1016/j.culher. 2009.03.007. [17] Hii, C., Law, C. & Cloke, M. (2008). Modelling of thin layer drying kinetics of cocoa beans during artificial and natural drying. Journal of Engineering Science and Technology. 3(1), 1-10. [18] Zych, J. & Kolczyk, J. (2013). Kinetics of hardening and drying of ceramic moulds with the new generation binder – colloidal silica. Archives of Foundry Engineering. 13(4), 112-116. DOI: 10.2478/afe-2013-0093. [19] Kolczyk J. & Zych J. (2014). The kinetics of hardening and drying of ceramic molds with a new generation binder - colloidal silica. Przegląd Odlewnictwa. 64(3-4), 84-92. (in Polish) [20] Zych, J., Kolczyk, J. & Jamrozowicz, Ł. (2015). The influence of the shape of wax pattern on the kinetics of drying of ceramic moulds. Metalurgija. 54(1), 15-18. ISSN 0543-5846. [21] Jamrozowicz, Ł., Zych, J. & Kolczyk, J. (2015). The drying kinetics of protective coatings used on sand molds. Metalurgija. 54(1), 23-26. ISSN 0543-5846. [22] Jamrozowicz, Ł. & Siatko, A. (2020). The assessment of the permeability of selected protective coatings used for sand moulds and cores. Archives of Foundry Engineering. 20(1), 17-22. DOI: 10.24425/afe.2020.131276. [23] Jamrozowicz, Ł., Kolczyk-Tylka, J. & Siatko, A. (2018) Investigations of the thickness of protective coatings deposited on moulds and cores. Archives of Foundry Engineering. 18(4), 131-136. DOI: 10.24425/afe.2018. 125182. [24] Zych, J. & Snopkiewicz, T. (2010). Drying and hardening of ceramic moulds used in a modern investemnt casting technique – investigations of the process kinetics. Foundry Journal of the Polish Foundrymen's Association. 9-10, 506-512. [25] Zych, J., Snopkiewicz, T. (2018). Method for study the drying process self-hardening molding sand or core compound. Patent PL 228373 B1.
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Authors and Affiliations

Ł. Jamrozowicz
1
ORCID: ORCID
J. Zych
1
ORCID: ORCID
  1. AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Cast Non-Ferrous Metals, Al. Mickiewicza 30, 30-059 Kraków, Poland

Combined 3-Components Phosphate and Organic Coatings on Zinc Surfaces

D. Fachikova T. Liubenova G. Ilieva
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 3 | 973-980 | DOI: 10.24425/amm.2023.145462
Keywords Zinc surfaces Phosphatizing zinc Nickel and Calcium Phosphates organic coatings protective coatings
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Abstract

In recent years, the production of galvanized sheet steels with organic coatings applied to its surfaces has considerably expanded. Phosphating of the zinc surfaces raises its roughness and surface tension, providing high adhesion of subsequent organic coatings and respectively, significant increasing of their protective properties. The paper presents the results obtained in the investigation of combined anti-corrosion coatings, including formation of phosphate films on galvanized steel surfaces followed by the application of three types of paint and varnish coatings. The indicators characterizing the phosphating preparation (density, pH, conductivity, acid capacity) as well as the thickness of the coatings were measured. The chemical composition of the phosphate films, their morphology and topography were determined by means of EDX and SEM, respectively. The adhesion, elasticity and impact toughness of the organic coatings, with and without phosphating treatment of the zinc surfaces were measured. The corrosion resistance of the combined coatings in a model sodium chloride solution was also determined.
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Authors and Affiliations

D. Fachikova
1
ORCID: ORCID
T. Liubenova
1
G. Ilieva
1
  1. University of Chemical Technology and Metallurgy, Faculty of Chemical Technology, 8 Kliment Ohridski Blvd., 1756 Sofia, Bulgaria

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