The aim of presented studies was to develop a new geometry of the overflow part of standard ATD–C tester for derivative thermal analysis
in a way that it would allow to obtain samples for abrasion and mechanical properties tests in the same mould without the need of cutting
them from a block of material. The pattern of new ATD–P tester has parts reflecting implemented samples. Computer simulations
regarding initial verification of new tester were performed in NovaFlow software. Chromium cast iron melts were made for testing the
sampler in real conditions and TDA analysis for casting material were conducted. The sandmix was prepared on silica sand matrix per the
ALPHASET technology. This new solution greatly simplifies the preparations of materials difficult to machine.
The article presents results of pitting corrosion studies of selected silicon cast irons. The range of studies included low, medium and high
silicon cast iron. The amount of alloying addition (Si) in examined cast irons was between 5 to 25 %. Experimental melts of silicon cast
irons [1-3] were conducted in Department of Foundry of Silesian University of Technology in Gliwice and pitting corrosion resistance
tests were performed in Faculty of Biomedical Engineering in Department of Biomaterials and Medical Devices Engineering of Silesian
University of Technology in Zabrze. In tests of corrosion resistance the potentiostat VoltaLab PGP201 was used. Results obtained in those
research complement the knowledge about the corrosion resistance of iron alloys with carbon containing Si alloying addition above 17 %
[4-6]. Obtained results were supplemented with metallographic examinations using scanning electron microscopy. The analysis of
chemical composition for cast irons using Leco spectrometer was done and the content of alloying element (silicon) was also determined
using the gravimetric method in the laboratory of the Institute of Welding in Gliwice. The compounds of microstructure were identify by
X-ray diffraction.
The article is a case study of the steel milling ring casting of about 6 tonnes net weight. The casting has been cast in the steel foundry the authors have been cooperating with. The aim was to analyse the influence of the shape of the chills and the material which was used to make them on the casting crystallization process. To optimally design the chills the set of the computer simulation has been carried out with 3 chills’ shape versions and 3 material’s versions and the results have been compared with the technology being in use (no chills). The proposed chills were of different thermal conductivity from low to high. Their shapes were obviously dependant on the adjacent casting surface geometry but were the result of the attempt to optimise their effect with the minimum weight, too. The chills working efficiency was analysed jointly with the previously designed top feeders system. The following parameters have been chosen to compare their effectiveness and the crystallization process: time to complete solidification and so-called fed volume describing the casting feeding efficiency. The computer simulations have been carried out with use of MagmaSoft v. 5.2 software. Finally, the optimisation has led to 15% better steel yield thanks to 60% top feeders weight reduction and 40% shorter solidification time. The steel ring cast with use of such technology fulfil all quality criteria.
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