The current work presents and describes the test bench for analyzing the lost foam process, especially measuring of the pressure of gases in the gas gap and continuous measuring of the rate of rise of the bath level when pouring the liquid metal into the mould. A series of preliminary research was carried out on the bench which was aimed at determining the influence of the basic parameters of the process, i.e. the density of the styrofoam pattern, thickness of the refractory coating applied on the pattern, kind of the alloy and the temperature of pouring on the mould cavity by the liquid metal and the pressure of gases in the gas gap.

Foam fractionation process for concentration of laccases from two Basidiomycete strains under different process conditions was investigated. Culture supernatants of Cerrena unicolor and Pleurotus sapidus containing active laccase were used with and without surfactant additives. Two surfactants: cationic cetrimonium bromide (CTAB) and non-ionic Polysorbate 80 were applied in the range from 0.2 mM to 1.5 mM. The pH levels ranging from 3 to 10 were examined with particular attention to pH=4, which is close to the pI of the enzymes. Results show that the source of the enzyme is significant in terms of partitioning efficiency in a foam fractionation process. Laccase from Cerrena unicolor showed the best activity partitioning coefficients between foamate and retentate of almost 200 with yields reaching 50% for pH 7.5 and concentration of CTAB cCTAB = 0.5 mM, whereas laccase from Pleurotus sapidus showed partitioning coefficients of up to 8 with 25% yield for pH 4 and cCTAB = 0.5 mM.

Trials of cast steel filtration using two types of newly-developed foam filters in which carbon was the phase binding ceramic particles have

been conducted. In one of the filters the source of carbon was flake graphite and coal-tar pitch, while in the other one graphite was

replaced by a cheaper carbon precursor. The newly-developed filters are fired at 1000o

C, i.e. at a much lower temperature than the

currently applied ZrO2-based filters. During filtration trials the filters were subjected to the attack of a flowing metal stream having

a temperature of 1650°C for 30 seconds.

Characteristic of the filters’ properties before and after the filtration trial were done. It was found, that the surface reaction of the filter

walls with molten metal, which resulted in local changes of the microstructure and phase composition, did not affect on expected filter

lifetime and filtration did not cause secondary contamination of cast steel.

Metallic foams are materials of which the research is still on-going, with the broad applicability in many different areas (e.g. automotive

industry, building industry, medicine, etc.). These metallic materials have specific properties, such as large rigidity at low density, high

thermal conductivity, capability to absorb energy, etc. The work is focused on the preparation of these materials using conventional casting

technology (infiltration method), which ensures rapid and economically feasible method for production of shaped components. In the

experimental part we studied conditions of casting of metallic foams with open pores and irregular cell structure made of ferrous and nonferrous

alloys by use of various types of filler material (precursors).

This work presents the technology of making foam plastics patterns used in casting as well as the final shaping stand. The analysis of the sintering process was carried out aiming at determining the influence of the pressure and the time of sintering on the flexural strength properties. The analysis of the research results confirmed that when the sintering pressure grows to the value of Pa =1,7 bar the flexural strength also increases, when the pressure value is higher than that, the degradation of the material takes place and the strength properties decrease.

This work presents the analysis of the final shaping process of the patterns aimed at determining the influence of the pressure and the time of sintering on the resistance to bending. The analysis of the research results proved that when the pressure of the sintering rises and reaches Ps=2.1 bar the resistance to bending increases, above this level of the pressure the resistance value starts decreasing. The time of styrofoam sintering at which the highest bending resistance values were obtained is ts=90 s. When the sintering pressure is less than 2 bar prolongation of the time of sintering over 90 s causes a slight increase in the resistance, however, at higher pressures prolongation of the time of sintering causes submelting of the styrofoam pattern.

The paper discusses the use of multiclustering statistical analysis in the assessment of domestic wastewater filtration effectiveness. Calculations included data collected over four months of experiments with using waste as filling material of vertical flow filters for domestic sewage treatment. The effectiveness of pollutants removal was analysed in case of me-chanically shredded waste in the form of PET flakes, PUR foam trims, shredded rubber tires and wadding. The organic compounds (CODcr, BOD5) removal, suspend solids, biogens (as NH4+, PO43– ions) and oxygen saturation changing com-pared with sand filling was analysed. Multiclustering statistical analysis allowed to divide pollutants removal efficiency of analysed materials into 3 clusters, depending on the hydraulic loading. The first group consisted in quality parameters of treated sewage: the highest reduction of BOD5 and NH4-N. It included the values of quality parameters and indicators for the filtrates obtained at the lowest hydraulic load from columns filled with 60 cm of rubber tires or sand. The second group comprised the results for fillings containing foam, PET and rubber tires (the other hydraulic loads).It featured the highest reduction of total suspended solids and PO43–. Removal of easily biodegradable organic compounds was at a similar level in both cluster groups. The filter filled with polyester waste (wadding), which was as effective as 30 cm layer of sand, and the filters filled with 60 cm of sand working at the highest hydraulic load. Third group showed the lowest values of parameters and indicators for analysed filtrates.

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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The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process,

considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of

ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured

with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty.

Presented are results of a preliminary research on determining a possibility to use microwave radiation for drying casting protective

coatings applied on patterns used in the lost foam technology. Taken were measurements of permittivity εr and loss factor tgδ at 2.45 GHz,

as well as attempts were made of microwave drying of a protective coating based on aluminium silicates, applied on shapes of foamed

polystyrene and rigid polymeric foam. Time and results of microwave drying were compared with the results obtained by drying at 50 °C

by the traditional method commonly used for removing water from protective coatings. Analysis of the obtained drying kinetics curves

demonstrated that selection of proper operation parameters of microwave equipment permits the drying time to be significantly shortened.

Depending on kind of the pattern material, drying process of a protective coating runs in a different way, resulting in obtaining different

quality of the dried coating.

The work deals with possibilities of using this specific material. It is focused on cast metal foams with a regular arrangement of internal cells and it refers to already used casting technologies – the production of metal foamswith the aid of sand cores. Metal foamsare used in many industries, such as: automotive, aerospace, construction, power engineering. They have unique propertiesand due to lower weight with sufficient strength and greater contact surface can be used, for example, for the conduction of heat. This article deals with the useof the metal foam as a heat exchanger. The efficiency of the heat exchanger depends on its shape and size and therefore the study is focused first on the optimization of the shape before the proper manufacture.

Geometry of plate heat exchangers (PHE) is characterized by a complex net of narrow channels. It enhances turbulence and results in better heat transfer performance. Theoretically, larger number of channels (plates) should proportionally increase the PHE heat power capacity. In practice a nonuniform massflow distribution in consecutive flow channels can significantly deteriorate the overall heat exchange performance. The flow maldistribution is one of the most commonly reported exploitation problems and is present in PHE with and without phase-change flows. The presented paper investigates numerically a flow pattern in PHE with evaporation of R410A refrigerant. Various sizes of PHE are considered. The paper introduces a robust methodology to transform the complicated geometry of a real 3D PHE to its 2D representation. It results in orders of magnitude faster calculations and allows for fast evaluation of different geometrical changes of PHE and their effect on flow maldistribution.