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Abstract

The technology of producing castings of high-quality inoculated cast iron with flake graphite particles in the structure is a combination of the melting and inoculation process. Maintaining the stability of the strength and microstructure parameters of this cast iron is the goal of a series of studies on the control of graphitization and austenitic inoculation (increasing the number of primary austenite dendrites), and which affects the type of metal matrix in the structure. The ability to graphitize the molten alloy decreases with its holding in the melting furnace more than an hour. The tendency to crystallize large dendritic austenite grains and segregation of elements such as Si, Ni and Cu reduce the ductility properties of this cast iron. The austenite inoculation process may introduce a larger number of primary austenite grains into the structure, affecting the even distribution of graphite and metal matrix precipitation in the structure. Known inoculation effects the interaction (in low mass) of additives: Sr, Ca, Ba, Ce, La, produces MC2 carbide). Addition of Fe in the inoculant influences the number and shape of austenite dendrites. Hybrid modification combines the effects of these two factors. The introduction of nucleation sites for the graphite eutectics and primary austenite grains result in the stabilization of the cast iron microstructure and an increase in mechanical properties. The obtained test results set the direction for further research in this area in relation to the production of heavy plate castings in vertical and horizontal pouring.
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Authors and Affiliations

Edward Guzik
ORCID: ORCID
D. Kopyciński
1
ORCID: ORCID
A. Ziółko
2
A. Szczęsny
1
ORCID: ORCID

  1. AGH University of Science and Technology, Department of Engineering of Cast Alloys and Composites, Faculty of Foundry Engineering, Al. Mickiewicza 30, 30-059 Krakow, Poland
  2. Krakodlew S.A., 1 Ujastek St., 30-969 Krakow, Poland
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Abstract

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions.
The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).
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Bibliography

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[7] Tęcza, G. & Zapała, R. (2018). Changes in impact strength and abrasive wear resistance of cast high manganese steel due to the formation of primary titanium carbides. Archives of Foundry Engineering. 18(1), 119-122.
[8] Tęcza, G. & Garbacz-Klempka, A. (2016). Microstructure of cast high-manganese steel containing titanium. Archives of Foundry Engineering. 16(4), 163-168.
[9] Celis, M., Domengès, B., Hug, E. & Lacaze, J. (2018). Analysis of nuclei in a heavy-section nodular iron casting. Materials Science Forum. 925, 173-180.
[10] Kopyciński, D., Siekaniec, D., Szczęsny, A., Sokolnicki, M. & Nowak, A. (2016). The Althoff-Radtke test adapter for high chromium cast iron. Archives of Foundry Engineering. 16(4), 74-77.
[11] Szczęsny, A., Kopyciński, D., Guzik, E. Soból, G., Piotrowski, K., Bednarczyk, P. & Paul, W. (2020). Shaping of ductile cast iron dedicated for slag ladle. Acta Metallurgica Slovaca. 26, 74-77. https://doi.org/10.36547/ams.26.2.312
[12] Mourad, M.M. & El-Hadad, S. (2015). Effect of processing parameters on the mechanical properties of heavy section ductile iron. Journal of Metallurgy. 2015, 1-11.
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Authors and Affiliations

A. Szczęsny
1
ORCID: ORCID
D. Kopyciński
1
ORCID: ORCID
Edward Guzik
ORCID: ORCID

  1. AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Polska
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Abstract

This paper presents the effect of the addition of Ti to the zinc bath. Hot-Dip Galvanizing was carried out on a machined ductile cast iron substrate. The process was carried out at 550°C. Experimental baths A, B and C contained 0.01%, 0.05% and 0.1%Ti, respectively. Metallographic samples were prepared to reveal the microstructure of the coatings. Thickness measurements of the obtained coatings were carried out, and graphs of the approximate crystallization kinetics of the zinc coating were prepared. High-temperature galvanization carried out on the treated surface led to the release of graphite beads from the metal matrix and their diffusion into the coating. This phenomenon can have an adverse effect on the continuity of the coating and its adhesion to the substrate. Crystallization of the δ phase was observed in the coating, and at longer immersion times – a mixture of two-phase δ1 and η phases. With increasing Ti content in the bath, a deterioration in the casting properties of the bath was observed.
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Bibliography

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[37] Jędrzejczyk, D. & Hajduga, M. (2011). Effect of the surface oxidation on the hot-dip zinc galvanizing of cast iron. Archives of Metallurgy and Materials. 56(3), 839-849. https://doi.org/10.2478/v10172-011-0093-x.
[38] Jędrzejczyk. D. (2010). The influence of high-temperature treatment of cast iron on the structure of the surface layer formed as a result of hot-dip galvanizing. Ochrona przed Korozją. 2, 46-48.
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Authors and Affiliations

Karolina Bracka-Kęsek
1
ORCID: ORCID
Andrzej Szczęsny
1
ORCID: ORCID
Dariusz Kopyciński
1
ORCID: ORCID
Edward Guzik
1
ORCID: ORCID

  1. AGH University of Science and Technology, Department of Foundry Engineering, Al. Mickiewicza 30, 30-059 Kraków, Poland
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Abstract

The subject of this study is to show that the parameters of the melting process of high chromium cast iron affect the cost of casting and the properties of the cast iron. The analysis of the quality of the casting and its price was conducted in terms of the metal charge of high chromium cast iron. As is well known, in order to obtain the correct structure of the casting, and thus good strength properties, it is necessary to use clean batch components free of undesirable impurities. Unfortunately, the quality of the metal charge is proportional to its price. Thus, the use of expensive batch components offers the possibility of obtaining healthy and meeting the strength properties of castings. However, there is a flaw in this approach. And it is from the point of view of economics that production plants are forced to look for savings. Expensive feedstock materials are replaced by cheaper counterparts giving the possibility of obtaining castings with similar properties often, however, at the cost of increased inferior quality. It seems that a way out of this situation is to introduce a modification procedure into the alloyed iron manufacturing technology. The selected modifiers should affect the fragmentation of the structure of the primary austenite. At this point, it can be hypothesized that this will result in the elimination of hot cracking in high chromium cast iron. The industrial research carried out at the "Swidnica" Foundry Ltd. made it possible to show by means of the Althoff-Radtke method that by using the modification of the liquid metal of the so-called "inferior and cheaper" composition of the metal charge, a reduction in the occurrence of hot cracks and shrinkage cavities can be achieved. In addition, iron-niobium modification not only reduced the formation of casting defects in castings, but also slightly improved the impact strength of high-chromium cast iron. The work was written as part of an implementation PhD.
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Bibliography

[1] Podrzucki, C. (1991). Cast iron. Structure Features Application Volumes 1 and 2. Wydawnictwo ZG STOP. (in Polish).
[2] Zhou, J. (2009). Colour metallography of cast iron. China Foundry. 6(2), 152-163.
[3] Guoxiong, S., Xiaoming, Z. & Zhidong, L. (1989). Microstructure and properties of grey cast iron. Spherical Graphite Cast Iron. 50-62.
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[6] Guzik, E., Kopyciński, D., Burbelko, A. & Szczęsny, A (2023). Evaluation of the number of primary grains in hypoeutectic chromium cast iron with different wall thickness using the ProCAST program. Materials. 16(8), 3217, 1-15. https://doi.org/10.3390/ma16083217.
[7] Döpp, R. (1975). Solidification and graphite formation in white cast iron. In proceedings of the Second International Symposium on the Metallurgy of Cast Iron, Geneva, Switzerland, May 29-31, 1974. Switzerland: Georgi Publishing Company.
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[9] Filipovic, M., Kamberovic, Z., Korac, M., Gavrilovski, M. (2013). Microstructure and mechanical properties of Fe–Cr–C–Nb white cast irons. Materials & Design. 47, 41-48. https://doi.org/10.1016/j.matdes.2012.12.034.
[10] Stefanescu, D.M. (1998). Solidification of eutectic alloys: Cast iron. In: ASM Handbook, Vol. 15 Casting, ASM International, Metals Park, OH.
[11] da Silva, A.E. Rabelo de Melo I.N., Pinheiro I.P., da Silva L. R. (2020). Characterisation and machinability of high chromium hardened white cast iron with and without the addition of niobium. Wear. 460-461, 15, 203-463. https://doi.org/10.1016/j.wear.2020.203463.
[12] Kopyciński, D., Kawalec, M., Szczȩsny, A., Gilewski, R. & Piasny, S. (2013). Analysis of the structure and abrasive wear resistance of white cast iron with precipitates of carbides Archives of Metallurgy and Materials. 58(3), 973-976. DOI: 10.2478/emm-2013-0113.
[13] Penagos, J.J., Pereira, J.I., Machado, P.C., Albertin, E. & Sinatora, A. (April 2017). Synergetic effect of niobium and molybdenum on abrasion resistance of high chromium cast irons. Wear. 376-377, B, 983-992. https://doi.org/10.1016/ j.wear.2017.01.103.
[14] Dojka, M., Dojka, R., Studnicki, A., Stawarz, M. (2018). Influence of Ti and Re on primary crystallization and wear resistance of chromium cast iron. In 73rd World Foundry Congress “Creative Foundry”: WFC 2018 – Proceedings, pp. 61-62.
[15] Dojka, M., Dojka, R., Stawarz, M., Studnicki, A. (2019). Influence of Ti and REE on primary crystallization and wear resistance of chromium cast iron. Journal of Materials Engineering and Performance. 28(7), 4002-4011. https://doi.org/10.1007/s11665-019-04088-x. [16] Studnicki, A., Dojka, R., Gromczyk, M., Kondracki, M. (2016). Influence of titanium on crystallization and wear resistance of high chromium cast iron. Archives of Foundry Engineering. 16(1), 117-123. DOI: 10.1515/afe-2016-0014.
[17] Tęcza, G. (2023). Changes in abrasion resistance of cast Cr-Ni steel as a result of the formation of niobium carbides in alloy matrix. Materials. 16(4), 1726, 1-14. https://doi.org/10.3390/ma16041726.
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[19] Dorula, J. (2013). Macro- and microstructure formation of modified cast iron with low sulfur content. PhD thesis. Kraków. Akademia Górniczo-Hutnicza. (in Polish). [20] Podrzucki, C., Kalata, C. (1976). Metallurgy and cast iron foundry. Katowice: Wyd. Śląsk. (in Polish).
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[23] Data provided by Sylwia Rosińska Head of Purchasing Department of "Świdnica" Foundry Ltd.
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Authors and Affiliations

Jan Mędoń
1
ORCID: ORCID
Andrzej Szczęsny
1
ORCID: ORCID
Eugeniusz Ziółkowski
1
ORCID: ORCID
Edward Guzik
1
ORCID: ORCID
M. Czarny
2
Dariusz Kopyciński
1
ORCID: ORCID

  1. AGH University of Krakow, al. Adama Mickiewicza 30, 30-059 Kraków, Poland
  2. Odlewnia „Świdnica” Sp. z o.o., Świdnica ul. Kliczkowska 53, Poland
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Abstract

This article is a description of the progress of research and development in the area of massive large-scale castings - slag ladles implemented in cooperation with the Faculty of Foundry Engineering of UST in Krakow. Slag ladles are the one of the major castings that has been developed by the Krakodlew (massive castings foundry) for many years. Quality requirements are constantly increasing in relation to the slag ladles. Slag ladles are an integral tool in the logistics of enterprises in the metallurgical industry in the process of well-organized slag management and other by-products and input materials. The need to increase the volume of slag ladles is still growing. Metallurgical production is expected to be achieved in Poland by 2022 at the level of 9.4 million Mg/year for the baseline scenario - 2016 - 9 million Mg/year. This article describes the research work carried out to date in the field of technology for the production of massive slag ladles of ductile cast iron and cast steel.

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Authors and Affiliations

M. Paszkiewicz
Edward Guzik
ORCID: ORCID
D. Kopyciński
ORCID: ORCID
Barbara Kalandyk
ORCID: ORCID
A. Burbelko
ORCID: ORCID
D. Gurgul
S. Sobula
ORCID: ORCID
A. Ziółko
K. Piotrowski
ORCID: ORCID
P. Bednarczyk

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