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Plasticity Changes of Moulding Sands with Chemical Binders Caused by Increasing the Hardening Degree

Natalia Matonis J. Zych

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 71-76 | DOI: 10.24425/afe.2022.140227

Keywords Self-setting sands (SSS) Plastic properties Hardening degree Ultrasounds

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Abstract

The results of investigations of plasticity of moulding sands with binders obtained by measuring deflection angles in the single point bend test in dependence on their hardening degree are presented in the hereby paper. Shaped samples made of moulding sands obtained in the technology with urea-furfuryl resin Furanol FR75A and in the technology with water glass, were subjected to various tests. Shaped samples were made on the quartz matrix of a medium grains size ��=0,29 ��. Investigations were performed for the resin content being 1% and 2%, at a constant proportion of a hardener versus resin -- equal 60%. In the case of sands from the technology with water glass, investigations were performed for 3.5% of water glass versus sand matrix and 0.35% of Flodur. Plasticity tests were carried out with using the strength machine with a continuous recording of a sample deflection value. Measurements of deflection angles values in the bend test were performed on a series of simultaneously made samples at constant time intervals from the moment of their making. To determine the sand hardening degree the ultrasound technique was applied, according to the previously developed methodology [1]. Every time from the obtained results the characteristic of the growing stress as a function of deflection was prepared (��). In addition, for the tested group of moulding sands, empirical relationships between the maximum deflection angle (αmax) in the bend test and the hardening degree were determined (Sx): α = f(Sx).

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Bibliography

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Authors and Affiliations

Natalia Matonis

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ORCID:

J. Zych

1

e-mail:

ORCID:

AGH University of Science and Technology, Faculty of Foundry Engineering, ul. Reymonta 23, 30-059 Cracow, Poland

The Effect of Reclaim Primary Quality on Moulding Sand Parameters and Quality of Ductile Iron Casting Surface Layer

J. Kamińska M. Angrecki S. Puzio M. Stachowicz

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 83-88 | DOI: 10.24425/afe.2022.140229

Keywords Foundry industry Furfuryl resin Reclaim Self-hardening moulding sand Surface quality

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Abstract

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.

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Authors and Affiliations

J. Kamińska

1

e-mail:

ORCID:

M. Angrecki

1

e-mail:

ORCID:

S. Puzio

1

e-mail:

ORCID:

M. Stachowicz

2

e-mail:

ORCID:

Łukasiewicz Research Network – Krakow Institute of Technology, Poland
Wroclaw University of Technology, Faculty of Mechanical Engineering, Poland

Corrosion Behavior of FeAl and Fe3Al Based Fe-Al-C Alloys in Sulfuric Acid

A.P. Silva P.P. Brito N. Martins

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 77-82 | DOI: 10.24425/afe.2022.140228

Keywords Iron Aluminides Microstructure Mechanical properties corrosion resistance

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Abstract

Iron aluminides are iron-aluminum alloys that have excellent resistance to oxidation at high temperatures with low density, high resistance/weight ratio and a low manufacturing cost. Due to its characteristics, these alloys are presented as an option to replace stainless steels in certain applications. This works intends report the casting process and subsequent analyses involving microstructure, mechanical properties, and corrosion resistance of two Fe-Al-C alloys (Fe-11wt%Al and Fe-25wt%Al, containing 0.31-0.37%C), which were prepared in an induction furnace and poured in a permanent mold. Samples of these alloys were characterized and presented elevated hardness values of 37 HRC (alloy Fe-11wt%Al) and 49.6HRC (alloy Fe-25wt%Al) and microstructure with aluminides type Fe3Al and FeAl and also carbides type K. The Fe-11wt%Al alloy exhibited superior resistance to uniform corrosion, although both Fe-Al-C alloys exhibited significantly higher corrosion rates compared to a binary iron aluminide in 0.5M H2SO4 containing naturally dissolved oxygen.

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Bibliography

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Authors and Affiliations

A.P. Silva

1

e-mail:

ORCID:

P.P. Brito

1

N. Martins

1

PUC Minas, Brazil

Mold Temperature and Its Effect on Selected Properties of Cast AlSi5Cu2Mg Alloy

L. Širanec D. Bolibruchová M. Chalupová

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 57-62 | DOI: 10.24425/afe.2022.140225

Keywords Mold temperature AlSi5Cu2Mg Cylinder head

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Abstract

The European Commission's ambitious plan to reduce CO2 emissions has a significant impact on the global automotive industry. Recent development of new diesel and petrol engines with direct injection is aimed at improving fuel efficiency while maintaining (or enhancing) engine performance. This naturally also increases the demands on the properties of the most stressed engine components (e.g., cylinder heads, engine blocks, pistons), which leads to the development of new materials. Presented work analysed the effect of different mold temperatures (60; 120; 180 °C) on mechanical, physical properties and microstructure of AlSi5Cu2Mg aluminium alloy. This alloy is currently being used for the production of cylinder head castings. The results showed that the changing mold temperature had an effect on mechanical properties (ultimate tensile strength and Young modulus values). SEM with EDX analysis of intermetallic phases revealed there were no size and morphology changes of Cu, Mg and Fe intermetallic phases when the mold temperature changed. No significant effect of different mold temperature on physical properties (thermal and electrical conductivity) and fracture mechanism occurred during experiment. Optimal combination of mechanical and physical properties of AlSi5Cu2Mg alloy was achieved using a permanent mold with temperature ranging from 120 to 180 °C.

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Authors and Affiliations

L. Širanec

1

e-mail:

ORCID:

D. Bolibruchová

1

e-mail:

ORCID:

M. Chalupová

1

e-mail:

ORCID:

Department of Technological Engineering, Faculty of Mechanical Engineering, University of Žilina, Slovakia

Initial Analysis of the Surface Layer of AVGI Cast Iron Subject to Abrasion

A. Jakubus

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 50-56 | DOI: 10.24425/afe.2022.140224

Keywords Vermicular cast iron Abrasion resistance Austempering Abrasion of cast iron AVGI

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Abstract

The article presents the results of research on the abrasion resistance of cast iron with vermicular graphite in the as-cast state and after austempering (the latter material is referred to as AVGI – Austempered Vermicular Graphite Iron). Austenitization was carried out at the temperature values of either 900°C or 960°C, and austempering at the temperature values of either 290°C and or 390°C. Both the austenitization and the austempering time was equal to 90 minutes. The change of the pearlitic-ferritic matrix to the ausferritic one resulted in an increase in mechanical properties. Abrasion tests were conducted by means of the T-01M pin-on-disc tribometer. The counter-sample (i.e. the disc) was made of the JT6500 friction material. Each sample was subject to abrasion over a sliding distance of 4000 m. The weight losses of both samples and counter-samples were determined by the gravimetric method. It was found that the vermicular cast iron austenitized at 900°C and austempered at 290°C was characterized by the lowest wear among the evaluated cast iron types. The geometric structure of the surface layer after the dry friction test exhibited irregular noticeable grooves, distinct oriented abrasion traces, plastic flow of the material, microcracks, and pits generated by tearing out the abraded material. The largest surface roughness was found for the AVGI cast iron heat-treated according to the variant 3 (Tγ =900 ºC; Tpi = 390°C), while the smallest one occurred in AVGI cast iron subject to either the variant 2 (Tγ =960 ºC; Tpi = 290°C) or the variant 4 (Tγ =900 ºC; Tpi = 290°C) of heat treatment and was equal to either 2.5 μm or 2.66 μm, respectively. It can be seen that the surface roughness decreases with the decrease in the austempering temperature.

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A. Jakubus

1

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The Jacob of Paradies University in Gorzów Wielkopolski, ul. Teatralna 25, 66-400 Gorzów Wielkopolski, Poland

Application of the Triboelectric Method for the Ongoing Assessment of the Quality of Reclaim in Mechanical Reclaimers

R. Dańko A. Pietrzak D. Gruszka

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 63-70 | DOI: 10.24425/afe.2022.140226

Keywords Reclaim Reclamation process Regeneration Foundry engineering Phenol resin Moulding sand

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Abstract

The method of the ongoing assessment of the reclaim quality originating from the mechanical reclamation is described in this paper. In the process, the triboelectric system of measuring amounts of dust in the dedusting part of a reclamation device was applied. Based on the online measurements of the amounts of dust generated in the spent sand-reclamation process and the post-process determinations of the ignition losses and granular structures of the removed dust, the proper work parameters of the experimental reclaimer were selected. The allowable value of the ignition losses as well as the main fraction of the reclaimed matrix being similar to fresh sand was assumed as the main criteria of the positive assessment of the process. Within the presented investigations, a periodically operating device for rotor-mechanical reclamation was developed. The possibility of changing the intensity and time of the reclamation treatment as well as the triboelectric system of the dust-amount measuring were applied in this device. Tests were performed for the spent moulding sand with phenol-resol resin Carbophen 5692 hardened by CO2. This sand represents the moulding sand group with a less harmful influence on the surroundings for which the recovery of the quartz matrix utilising the reclamation requires stricter control of the parameters of the reclamation process and reclaim quality.

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Authors and Affiliations

R. Dańko

1

e-mail:

ORCID:

A. Pietrzak

1

D. Gruszka

1

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

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