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Abstract

The paper presents the results of the analysis of cooling curves of cast iron with approximately eutectic composition rasterized at different rates of cooling and ingot crystallization. The test samples were in the form of rods with a diameter of 30,0.mm and a coagulation modulus M = 0.75 cm. They were cast in a sand mould made of furan mass placed on a chill in the form of a cast-iron plate, with which one of the front surfaces of the rod casting was in contact. In this way, a differentiated cooling rate along the rod was achieved. At selected distances from the chiller (5, 15, 25, 25 and 45 mm) thermocouple moulds were placed in the cavity to record the cooling curves used in thermal (AT) and derivation (ATD) analysis. The solidification time of the ingot in the part farthest from the chiller was about 200s, which corresponds to the solidification time in the test cup AT. An analysis of the recorded cooling curves was performed in order to determine the values of characteristic points on the AT curve (Tsol. Tliq, ΔTrecal., τclot, etc.). Relationships between cooling time and rate and characteristic points on AT and ATD curves were developed. For example, Tsol min changes in the range of 1115 - 1145 for the range of cast iron solidification times in the selected ingot zone from ~ 70 to ~ 200 s, which corresponds to the process speed from 0.0047 to 0.014 [1/s]. The work also includes an analysis of other characteristic points on the AT and ATD curves as functions of the solidification rate of cast iron of the same composition.
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Bibliography

[1] Humphreys, J.G. (1961). Effect of composition on the liquidus and eutectic temperatures on the eutectic point of cast iron. BCIRA Journal. 9(5), 609-621.

[2] Władysiak, R. (2001). Quality control of austenitic cast iron using the ATD method. Archives of Foundry. 1(2), 400-407. (in Polish)

[3] Falęcki, Z., Zych, J., Pyka, M. (1982). Research and development of comprehensive quality control of liquid cast iron using thermal analysis. AGH, Project No. 5.371.50, Kraków. (in Polish).

[4] Falęcki, Z., Zych, J. (1989). Equipment for quality control of liquid metal. Patent PRL, No. 247772. Warszawa. (in Polish).

[5] Gawroński, J., Szajnar, J., Jura, Z., & Studnicki, A. (2004). Prof. S. Jura, creator of the theory and industrial applications of diagnostics and consumption of metals and alloys. Archives of Foundry. 4(16), 1-74. (in Polish).

[6] Heraeus (2024). Thermal Analysis of Cast Iron. Retrieved January 21, 2024 from www.electro-nite.be.

[7] Novacast (2024). ATAS - Thermal Analysis System, NovaCast Foundry Saltions. Retrieved January 15, 2024 from www.novacastfoundry.se

[8] Stefanescu, D.M. (2015). Thermal analysis - theory and applications in metalcasting. International Journal of Metalcasting. 9(1), 7-22. https://doi.org/10.1007/BF03355598.

[9] Zych, J. (2016). Impact of speed of cooling of initial phase (α) and of eutectics (α + β) on physical and mechanical properties of Al-Si-Mg alloys. In 72nd World Foundry Congress, 21-25th May 2016 (pp. 1-2). Nagoya, Japan.

[10] Stawarz, M. & Szajnar, J. (2003). Quality assessment of ductile iron using the ATD method. Archives of Foundry. 3(10), 199-206. ISSN 1642-5308. (in Polish).

[11] Jura, S., Sakwa, J. & Borek, K. (1980). Differential analysis of solidification and crystallization processes of gray cast iron. Krzepnięcie Metali i Stopów. 3, 25-35. (in Polish)

[12] Jura, S. (1985). The essence of the ATD method. Modern methods of assessing the quality of alloys. PAN- Katowice, Foundry Institute of the Silesian University. (in Polish).

[13] Jura, S., Sakwa, J. & Borek, K. (1980). Thermal and differential analysis of solidification and crystallization of cast iron. Przegląd Odlewnictwa. 1, 7-10. (in Polish).

[14] Zych, J. (2015). Analisys of castings defects - selected problems – laboratory. AGH. Kraków, SU 1737. (in Polish).

[15] Zych, J. (2013). Assessment of the cooling curve using the thermal and derivation-gradient analysis method (ATDG), Foundry’s guide. vol. I, Materials (pp. 964-981). Poland: Wydawnictwo Stowarzyszenia Technicznego Odlewników Polskich (in Polish).

[16] Döpp, R., Blankenagel, D. (1979). Zur thermischen analyse von temperguss und grauguss. Giesserei. 66(7), 182-186.
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Authors and Affiliations

J.S. Zych
1

  1. AGH University of Krakow, Faculty of Foundry Engineering, Reymonta 23. 30-059 Kracow, Poland,
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Abstract

The paper presents the test results of molding compounds, sand casting molds and their analysis. The subject of testing was compound containing furan resins prepared according to the following recipe: matrix – regenerate 90% + fresh sand – 10%, furan resin – 1.10% by weight, hardener – 0.40% by weight. The impact of adhesive type and its quantity (Quan = 0.90, 1.1 and 1.5%) on the strength indexes of molding compound subject to densification was analyzed. The publication presents the test results: tensile strength Rm, compressive strength Rc and flexural strength Rg, as well as compound permeability as function of its density. The analysis also covers the impact of density level on mold strength and the distribution of density level along the mold height.

Based on the test results, it was found that the best method to obtain high strength molds made from compounds with chemical adhesives was to densify it by vibrating the system: match plate – molding flask – compound filling the mold. The effectiveness of this densification method depends on the amplitude and frequency of vibrations.

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Authors and Affiliations

Ł. Petrus
A. Bulanowski
J. Kołakowski
ORCID: ORCID
M. Urbanowicz
J. Sobieraj
M. Jelonek
M. Brzeżański
ORCID: ORCID
J.S. Zych
K. Janerka
ORCID: ORCID

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