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Analysis of the Current State and Forecast of Cast Iron Production in Russia

S.S. Golubev V.D. Sekerin A.E. Gorokhova G.V. Komlatskiy Y.I. Arutyunyan

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 70-74 | DOI: 10.24425/afe.2021.136100

Keywords Steel Innovations Capacity load Competitiveness factors Priority strategies

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Abstract

The purpose of the study is to analyze the current state of the cast iron production and to predict production volume and cost in the near future based on the analysis results. Cast iron is one of the most common materials used in various industrial sectors. Cast iron scrap processing is the least expensive and saves both money and time. It is produced both in Russia and abroad and is one of the export types. Cast iron production significantly influences other industrial sectors. All this confirms the relevance of the study. The novelty of the study consists in the identification of the leaders among the cast-iron producers in the world and Russian metallurgical companies, as well as the determination of trends in its production at the present stage of economic development. The increasing consolidation level of cast iron producers has been revealed: China, India, Japan, and Russia represented 85% of the cast iron global production in 2019. In Russia, nine metallurgical companies account for 80% of cast iron production. In general, cast iron production in the world is stable and the import share of cast iron is about 4%. Cast iron prices tend to decline. The work identifies the lower and upper limits of the possible range of the cast iron prices. The authors conclude that the declining prices of cast iron in Russia may make its production unprofitable.

Bibliography

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Authors and Affiliations

S.S. Golubev

1

V.D. Sekerin

1

A.E. Gorokhova

1

G.V. Komlatskiy

2

Y.I. Arutyunyan

2

Moscow Polytechnic University, Bolshaya Semenovskaya Street, 38, Moscow, 107023, Russia
Kuban State Agrarian University, Kalinina Street, 13, Krasnodar, 350044, Russia

Synthesis of Natural Phenolic Compound Contained Alkaline Phenolic Foundry Resin and Its Performance Evaluation on Casting

A.E. Güvendik K. Ay

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 46-56 | DOI: 10.24425/afe.2021.136097

Keywords Phenolic resins Lignin Sustainability Foundry No-Bake

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Abstract

In foundry, metal casting can be done with various methods. One of the most important methods preferred around the world is sand casting. Ester curable alkaline phenolic resins have produced to make sand molds by No-bake systems. They must have specific properties to make sand casting efficient and reliable. Production of these resins depends on some fossil raw-materials like phenol. To investigate more sustainable and green resin synthesis method, lots experiment have been done by substitution of phenol with renewable alternative phenolic materials like resorcinol, lignosulphonates and tannic acid and its derivatives. Different properties of resins were produced with competitive performance with the market product, ÇKE Alfanol A 72 No-Bake Resin. Without loss of performance, calcium lignosulfonate was used in polymer synthesis at the rate of 15% instead of phenol. On the other hand, the reaction in which lignin and resorcinol were combined instead of phenol by reducing it by 25% gave better results in terms of mechanical and thermal properties. Thermal properties were investigated for resorcinol and lignin modified resins by using TGA-DSC and mechanical performance of cured sand core sample were tested by Simpson Sand Strength Testing Machine as compression strength as N/cm2.. After laboratory testing casting performance of new resins are compared with two different companies’ resins in steal casting demo. Experimental results were matched with casting trail and no defect was detected.

Bibliography

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[25] Mocek, J. (2019). Multiparameter Assessment of the Gas Forming Tendency of Foundry Sands with Alkyd Resins. Archives of Foundry Engineering. 19(2), 41-48. DOI: 10.24425/afe.2019.127114.
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Authors and Affiliations

A.E. Güvendik

1

K. Ay

2

Çukurova Kimya Endüstrisi A.Ş., Turkey
Manisa Celal Bayar University, Turkey

Crystallization of the Structural Components of Multiple Remelted AlSi9Cu3 Alloy

M. Matejka D. Bolibruchová M. Kuriš

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 41-45 | DOI: 10.24425/afe.2021.136096

Keywords Al-Si-Cu Remelting Returnable material Structural components scanning electron microscope

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Abstract

At present, Al-Si-Cu based alloys (with a typical representative AlSi9Cu3 alloy) represent more than half of the castings used in various industries (automotive, aerospace and electrical engineering). These are most often sub-eutectic (exceptionally eutectic) alloys with a content of 6 to 13 wt. % Si and 1 to 5 wt. % Cu. The aim of the paper is to point out the importance of the evaluation of input raw materials that determines the overall properties of the casting and the costs invested in its production. A negative impact on performance can be expected when using an alloy made up of a high proportion of recycled material, despite its economic benefits. Experimental alloys were evaluated based on the results of crystallization process and a combination of scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX), and deep etching. The effect of remelting and increasing the remelted returnable material in the batch was manifested especially in the crystallization of iron-rich phases. The negative effect of remelting on the structural components was manifested after the fourth remelting. Gradual increase of remelted returnable material in the batch causes harmful changes in the crystallization process.

Bibliography

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[8] Campbell, J. (2011). Complete Casting Handbook: Metal Casting Processes, Metallurgy, Techniques and Design. Butterworth-Heinemann, Oxford, UK.
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[10] Lukač, I. (1981). Properties and structure of non-ferrous metals. ALFA Bratislava. (in Slovak).

Authors and Affiliations

M. Matejka

1

e-mail:

ORCID:

D. Bolibruchová

1

e-mail:

ORCID:

M. Kuriš

1

University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Univerzitna 1, 010 26 Zilina, Slovak Republic

Formation Mechanism for the TiN–MnS Complex Inclusions in Tire Cord Steel

Jialiu Lei Xiumin Wang Dongnan Zhao Yongjun Fu

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 57-64 | DOI: 10.24425/afe.2021.136099

Keywords Thermodynamic calculations Formation mechanism TiN–MnS complex inclusions Tire cord steel

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Abstract

High strength tire cord steel is extensively used in radial ply tyres as the framework material, but the presence of brittle single titanium inclusions or complex titanium inclusions can cause failure of the wires and jeopardize their performance in production. In order to provide a key guidance on the control of titanium inclusions, it is necessary to clarify their formation mechanism during solidification. In the present work, the thermodynamic calculations were employed for an elaboration on their formation mechanism, combined with the industrial test. The TiN–MnS complex inclusions observed by SEM–EDS shows that the internal corresponds to TiN and the external is MnS. Thermodynamic calculations based on the microsegregation model indicate that MnS forms first, which can act as a nucleation site for the co–deposit of TiN in the mushy zone. As the MnS inclusions have a better deformation than that of TiN inclusions, then the TiN inclusions are wrapped by the MnS inclusions, generating TiN–MnS complex inclusions after rolling.

Bibliography

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Authors and Affiliations

Jialiu Lei

1

Xiumin Wang

1

Dongnan Zhao

1

Yongjun Fu

1

Hubei Polytechnic University, China

Determination of Phase Transformation Temperatures by Dilatometric Test of S960MC Steel

M. Málek M. Mičian J. Moravec

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 57-64 | DOI: 10.24425/afe.2021.136098

Keywords Metallography Microstructure Dilatometry S960MC Transformation temperatures

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Abstract

The phenomenon of “soft zone” is occurring in the heat affected zone (HAZ) of high strength low alloy (HSLA) steels. Therefore, the process of weld metal solidification and phase transformation in HAZ is essential to understand the behaviour of the material, especially in the case where welded joints are debilitating part of the construction. The simulation program SYSWELD is powerful tool to predict solidification and phase transformation of welding joint, what correspond to the mechanical properties of the joints. To achieve relevant results of the simulation, it is necessary to use right mathematic-material model of the investigated material. Dilatometric test is the important methods to gather necessary input values for material database. In this paper is investigated physical and metallurgical properties of S960MC steel. The dilatometric curves were carried out on the laboratory machine dilatometer DIL 805L. In addition to determination of the phase transformation temperatures at eight levels of the cooling rate, the microstructure and hardness of the material are further analysed. The hardness of the samples reflects the achieved microstructure. Depending on the cooling rate, several austenitic transformation products were observed such as pearlite, bainite, martensite and many different ferritic microstructures. The differences between the transformation temperature results using the first derivation method and the three tangent method are up to 2%. The limit cooling rate was set at value 30°C/s. The microstructure consists only of bainite and martensite and the hardness reaches a value of 348HV and higher.

Bibliography

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[23] Pawłowski, B., Bała, P. & Dziurka, R. (2014). Improper interpretation of dilatometric data for cooling transformation in steels. Archives of Metallurgy and Materials. 59(3). DOI: 10.2478/amm-2014-0202.
[24] Motyčka, P., Kovér, M. (2012). Evaluation methods of dilatometer curves of phase transformations. In COMAT 2012, 2nd International Conference on Recent Trends in Structural Materials, 21-22 November 2012, Plzeň, Czech Republic, Recent trends in structural materials. Available on the Internet: http://comat2012.tanger.cz/files/proceedings/11/reports/1237.pdf.
[25] Ghafouri, M., Ahn, J., Mourujärvi, J., Björk, T., Larkiola, J. (2020) Finite element simulation of welding distortions in ultra-high strength steel S960 MC including comprehensive thermal and solid-state phase transformation models, Engineering Structures. 219, DOI: 10.1016/j.engstruct.2020.110804.
[26] Bayock, F.N., Kah, P., Mvola, B., Layus, P. (2019). Effect of heat input and undermatched filler wire on the microstructure and mechanical properties of dissimilar S700MC/S960QC high-strength steels. Metals. (9). DOI: 10.3390/met9080883

Authors and Affiliations

M. Málek

1

M. Mičian

1

e-mail:

ORCID:

J. Moravec

1

Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 1402/2, 461 17 Liberec I, Czech Republic

Spatial Thermo-Mechanical Model of Mushy Steel Deformation Based on the Finite Element Method

Marcin Hojny Tomasz Dębiński M. Głowacki Trang Thi Thu Nguyen

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 17-28 | DOI: 10.24425/afe.2021.136093

Keywords Mechanical properties Soft-reduction Semi-solid Numerical modelling Physical simulation

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Abstract

The paper reports the results of work leading to the construction of a spatial thermo-mechanical model based on the finite element method allowing the computer simulation of physical phenomena accompanying the steel sample testing at temperatures that are characteristic for the soft-reduction process. The proposed numerical model is based upon a rigid-plastic solution for the prediction of stress and strain fields, and the Fourier-Kirchhoff equation for the prediction of temperature fields. The mushy zone that forms within the sample volume is characterized by a variable density during solidification with simultaneous deformation. In this case, the incompressibilitycondition applied in the classic rigid-plastic solution becomes inadequate. Therefore, in the presented solution, a modified operator equation in the optimized power functional was applied, which takes into account local density changes at the mechanical model level (the incompressibility condition was replaced with the condition of mass conservation). The study was supplemented withexamples of numerical and experimental simulation results, indicating that the proposed model conditions, assumptions, and numerical models are correct.

Bibliography

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Authors and Affiliations

Marcin Hojny

Tomasz Dębiński

e-mail:

ORCID:

M. Głowacki

1

Trang Thi Thu Nguyen

1

AGH University of Science and Technology, Cracow, Poland

Arc welding renovation of permanent steel molds

J. Šutka R. Koňar J. Moravec L. Petričko

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 35-40 | DOI: 10.24425/afe.2021.136095

Keywords Casting mold Renovation Welding Hardfacing Tribological test

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Abstract

The paper deals with the possibility of the renovation of permanent steel molds for casting using electric arc welding technology. When casting liquid metal into permanent steel molds, there is chemical-thermo-mechanical wear of the surface of the mold cavity and the inlet system, which causes a deterioration of the surface quality and dimensional accuracy of the casting. For this reason, it is necessary to renovate the steel mold after a certain casting interval - mold life. In this case, the technology of manual electric arc welding with a coated electrode was used for the renovation. The welding renovation aims to increase the service life of the mold using carbide hardfacing welds, which after welding achieve high mechanical properties of the renovated mold parts. Two types of hardfacing coated electrodes were used for welding, namely the OK Weartrode 55HD electrode and the OK Weartrode 50T electrode. Macroscopic analysis, tribological tests as well as the measurement of the hardness of the welded layers were performed to evaluate the quality and the friction coefficients of the additional materials used. The properties of hardfacing welds were compared with the properties of the basic material of the high-alloy steel mold. The main advantage is in addition to increasing the durability and longevity of the mold, also reducing the cost of mold renovation compared to other renovation technologies.

Bibliography

[1] Jankura, D., (2013). Wear evaluation of renovation layers based on hardfacing (Hodnotenie opotrebenia renovačných vrstiev na báze tvrdonávarov). Transfer Inovácií. 26, 126-129.
[2] Moravec, J. et.al. (2018). Experimental casting of forging ingots from model maeriál. In 22nd Slovak_Polish Scientific Conference on Machine Modelling and Simulations, 5-8 September 2017 (article No. 05017). Sklene Teplice, Slovakia: Univerzity of Zilina.
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[4] Ptáček, Luďek et. al. (2002). Materials science (Nauka o material II). Brno: Akademické nakaldatelství CERM, s.r.o, ISBN: 80-7204-248-3.
[5] Jhvar, S.; Paul, C.P.; Jain, N.K. (2013). Causes of failure and repairing optinos for diels and molds. A review. Engineering Failure Analysis 34, 519-535.
[6] Mician, M. et al. (2018). The Repair of Foundry Defects in Steel Castings Using Welding Technology. Archives of Foundry Engineering. 18(2), 177-180. DOI: 10.24425/122524.
[7] Chander, S., Chawla, V. (2017). Failure of forging dies an update prespective. Materials Today: Proceedings 4, 1147-1157
[8] Chan, C.; Wang, Y.; Ou, H.; He, Y.; Tang, X. (2014). A review on remanufacture of dies and moulds. Journal of Cleaner Production. 64, 13-23.
[9] Pliszka, I. et al. (2018). Surface improvement by wc-cu electro-spark coatings with laser modification. In: 10th conference on terotechnology, 18-19 October 2017 (pp. 237-242). Kielce, Poland: Kielce University of Technology.
[10] Pastircak, R., Scury, J. (2017). Effect of Pressure on Crystalization of AlSiMg Alloy. Archives of Metallurgy and Materials. 62 (4), 2193-2198. DOI: 10.1515/amm-2017-0323.
[11] Gucwa, M., Beczkowski, R. & Winczek, J. (2017). The effect of type of welding sequence during hardfacing chromium cast iron for erosion resistance. Archives of Foundry Engineering. 17(3), 51-54. DOI: 10.1515/afe-2017-0089.
[12] Bronček, J., Vicen, M., Fabian, P., Radek, N., 2020, Investigation of the tribological properties of the nitride layer on heat-treated steel 100Cr6, Lecture notes in mechanical engineering, 59th International Conference of Machine Design, 11-14 September 2018, (pp. 463-471). Žilina, Slovakia: University of Žilina.
[13] Mician, M. et al. (2020) Effect of the t(8/5) cooling time on the properties of S960MC steel in the HAZ of welded joints evaluated by thermal physical simulation. Metals. 10(2), 229. DOI: 10.3390/met10020229
[14] Winczek, J. et al. (2019). The Evaluation of the Wear mechanism of High-Carbon Hardfacing Layers. Archives of Metallurgy and Materials. 64 (3), 1111-1115. DOI: 10.24425/amm.2019.129502.

Authors and Affiliations

J. Šutka

1

R. Koňar

1

J. Moravec

1

L. Petričko

1

Department of Technological Engineering, University of Zilina, Univerzitna 1, 010 26 Zilina, Slovakia

Analysis of Fracture Mechanism of Cast Steel for Different States of Stress

J. Lachowski J. Borowiecka-Jamrozek

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 29-34 | DOI: 10.24425/afe.2021.136094

Keywords Metallography Mechanical properties Cast steel Damage evolution Computer modelling

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Abstract

In this paper a plastic deformation and a damage evolution in low-carbon cast steel containing non-metallic inclusions are analysed experimentally and numerically. Two microstructures of the cast steel have been obtained after appropriate heat treatment. Tensile tests of smooth specimens and axisymmetric notched specimens have been performed. The notched specimens have the notch radii: 1 mm, 3 mm and 7 mm. Fractography of the specimens was carried out to observe fracture mechanisms. The mechanism depended on the stress state in the notched specimens. The fractography showed the existence of two fracture mechanisms: ductile failure and by shear.
The process of the voids growth formed on the non-metallic inclusions was the process which included in the explanation of the damage mechanism. Modelling of deformation of the specimens has been used with the model suggested by Gurson, Tvergaard and Needleman. The model is implemented in the Abaqus finite element program. The computer simulation was performed using ABAQUS system. The computed output was compared with the experimental results obtained for specimens of the same shape.

Bibliography

[1] Lachowski, J. & Biel-Gołaska M. (2000). Modelling of Damage Evolution in Cast Steel, Conference Advances in Mechanical Behaviour, Plasticity and Damage EUROMAT 2000, 7-9 November, pp. 1457-1462, Tours, France.
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[11] SIMULIA Dassault System, Abaqus analysis user’s manual, Version 6.12 , 2017.

Authors and Affiliations

J. Lachowski

1

J. Borowiecka-Jamrozek

1

Kielce University of Technology, Al. Tysiąclecia PP. 7, 25-314 Kielce, Poland

Automatic Measurement System of Hydrated Sodium Silicate Composition Analysis

Huafang Wang Quanrun Wang Wu Zhang Xiang Gao Jijun Lu

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 5-8 | DOI: 10.24425/afe.2021.136091

Keywords Hydrated sodium silicate Composition analysis Potentiometer titration

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Abstract

Sodium silicate is one of the most successful inorganic binder. Along with the broad application of sodium silicate for domestic and industrial purposes, the composition analysis, include modulus (m), ratio of SiO2:Na2O, Na2O%, SiO2%, and solid-containing content, is important for the products strength and service life. However, it is perplexing to operate, inefficient and low precision for traditional standard testing method of these parameters. In this study, an automatic measurement system of sodium silicate composition analysis, with the potential electrode for potentiometer titration, micro-controller, PCB, heater, stirrer, printer and micro peristaltic pump, was developed according to the determine method principle. The end-points of pH value in the two titrating steps, first was 4.3 and second was 6.0, were set in the micro-controller to control the reaction in the processing of the sodium silicate composition analysis. And all the potential signals of the pH electrode were transited in the special PCB for the micro-controller.

Bibliography

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[10] Fan ZT, Liu M, Wang HF, Long W, Hu XT. (2010). Chinese Patent No. 201010558029.3. Beijing, China National Intellectual Property Administration.

Authors and Affiliations

Huafang Wang

1

e-mail:

ORCID:

Quanrun Wang

1

Wu Zhang

1

Xiang Gao

1

Jijun Lu

1

e-mail:

ORCID:

School of Mechanical Engineering and Automation, Wuhan Textile University, Wuhan 430073, China

Use of Selective Laser Melting (SLM) as a Replacement for Pressure Die Casting Technology for the Production of Automotive Casting

J. Piekło A. Garbacz-Klempka

Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 9-16 | DOI: 10.24425/afe.2021.136092

Keywords Additive manufacturing (AM) Selective Laser Melting (SLM) Automotive casting AlSi10Mg Mechanical properties Microstructure

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Abstract

Selective laser melting is one of the additive manufacturing technologies that is used to produce complex-shaped components for applications in the automotive industry. The purpose of the changes in the design, technology, and material tests was to make a steering gear housing using the SLM method. The steering gear housing was produced by the pressure casting method using an AlSi9Cu3(Fe) alloy. The construction of this housing is adapted to the specifics of left-hand traffic. The change in technology was related to the change of the position of the steering system from right-hand to left-hand and the demand for a limited number of gear housings. It was necessary to make a virtual model of the housing on the basis of the part that was removed from the vehicle. In SLM technology, the AlSi10Mg aluminum alloy was used as a raw material in the form of CL 32Al gas-atomized powder. After the SLM process was completed, the housings were subjected to heat treatment. The AlSi10Mg alloy fabricated by the SLM method after heat treatment is characterized by good plasticity and an average value of tensile strength. The last stage was to check the geometry of the SLM housing with a 3D scanner. As a result, a map of the dimensional deviations from the nominal values was obtained. This data was used to modify the CAD model before the next fabrication process.
The use of 3D printing technology allowed for the quick production of elements. The time to develop the technology and the production of the first two gear housings based on a 3D model was seven days.

Bibliography

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Authors and Affiliations

J. Piekło

1

e-mail:

ORCID:

A. Garbacz-Klempka

1

e-mail:

ORCID:

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

1

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