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Thermomechanical Analysis of the Charge Heating in a Rotary Furnace

A. Gołdasz Z. Malinowski A. Cebo-Rudnicka
Archives of Metallurgy and Materials | 2019 | vol. 64 | No 4 | 1377-1384 | DOI: 10.24425/amm.2019.130104
Keywords charge heating heating curves thermal stresses
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Abstract

This paper presents the methodology for determining thermal strains and stresses during heating the charge in a rotary furnace. The calculations were made with the original software, which uses the finite element method. The heat transfer boundary conditions used for computing were verified on the basis of industrial tests. Good compatibility between the experimental data and numerical calculations was obtained. The possibility of the material cracking occurrence was checked for a set exhaust gas temperature distribution on the furnace length. As a result, it was possible to develop steel heating curves characterized by short process times.

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Authors and Affiliations

A. Gołdasz
ORCID: ORCID
Z. Malinowski
ORCID: ORCID
A. Cebo-Rudnicka
ORCID: ORCID

The Effect of Carbide Concentration at Grain Boundaries on Thermal Stresses in Castings for Heat Treatment Furnace Tooling

A. Bajwoluk P. Gutowski
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 149-157 | DOI: 10.24425/afe.2024.149263
Keywords Cast grates thermal stresses Heat treatment equipment Thermal shock
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Abstract

Austenitic Fe-Ni-Cr alloys are commonly used for the production of castings intended for high-temperature applications. One area where Fe-Ni-Cr castings are widely used is the equipment for heat treatment furnaces. Despite the good heat resistance properties of the materials used for the castings, they tend to develop cracks and deformations over time due to cyclic temperature changes experienced under high temperature operating conditions. In the case of carburizing furnace equipment, thermal stresses induced by the temperature gradient in each operating cycle on rapidly cooled elements have a significant influence on the progressive fatigue changes. In the carburized subsurface zone, also the different thermal expansion of the matrix and non-metallic precipitates plays a significant role in stress distribution. This article presents the results of analyses of thermal stresses in the surface and subsurface layer of carburized alloy during cooling, taking into account the simultaneous effect of both mentioned stress sources. The basis for the stress analyzes were the temperature distribution in the cross-section of the cooled element as a function cooling time, determined numerically using FEM. These distributions were taken as the thermal load of the element. The study presents the results of analyses on the influence of carbide concentration increase on stress distribution changes caused by the temperature gradient. The simultaneous consideration of both thermal stress sources, i.e. temperature gradient and different thermal expansions of phases, allowed for obtaining qualitatively closer results than analyzing the stress sources independently
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Bibliography

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[21] Bajwoluk, A. & Gutowski, P. (2018). Design options to decrease the thermal stresses in cast accessories for heat and chemical treatment furnaces. Archives of Foundry Engineering. 18(4), 125-130. DOI:10.24425/afe.2018. 125181.
[22] Bajwoluk, A. & Gutowski, P. (2019). Thermal stresses in the accessories of heat treatment furnaces vs cooling kinetics. Archives of Foundry Engineering. 19(3), 88-93. DOI: 10.24425/afe.2019.127146.
[23] Bajwoluk, A. & Gutowski, P. (2021). Effect of thermal nodes reduction in wall connections of the charge-handling furnace grates on thermal stresses. Archives of Foundry Engineering. 21(3), 53-58. DOI: 10.24425/afe.2021.138665.
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Authors and Affiliations

A. Bajwoluk
1
ORCID: ORCID
P. Gutowski
1
ORCID: ORCID
  1. Mechanical Engineering Faculty, West Pomeranian University of Technology, Szczecin Al. Piastów 19, 70-310 Szczecin, Poland

Optimum heating of cylindrical pressure components weakened by holes

Piotr Dzierwa Jan Taler
Archives of Thermodynamics | 2012 | No 3 October | 106-116 | DOI: 10.2478/v10173-012-0022-z
Keywords inverse heat conduction problem Thermal stress Heating optimization Pressure vessels Boiler standards
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Abstract

A method for determining time-optimum medium temperature changes is presented. The heating of the pressure elements will be conducted so that the circumferential stress caused by pressure and fluid temperature variations at the edge of the opening at the point of stress concentration, do not exceed the allowable value. In contrast to present standards, two points at the edge of the opening are taken into consideration. The first point, P1, is located at the cross section and the second, P2, at the longitudinal section of the vessel. It will be shown that the optimum temperature courses should be determined with respect to the total circumferential stress at the point P2, and not, as in the existing standards due to the stress at the point P1. Optimum fluid temperature changes are assumed in the form of simple time functions. For practical reasons the optimum temperature in the ramp form is preferred. It is possible to increase the fluid temperature stepwise at the beginning of the heating process and then increase the fluid temperature with the constant rate. Allowing stepwise fluid temperature increase at the beginning of heating ensures that the heating time of a thick-walled component is shorter than heating time resulting from the calculations according to EN 12952-3 European Standard.
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Authors and Affiliations

Piotr Dzierwa
Jan Taler

Evaluation of High Pressure Die Casting Mold Temperature Relations Depending on the Location of the Tempering Channels

J. Majerník M. Podaril M. Majernikova
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 115-120 | DOI: 10.24425/afe.2024.149258
Keywords Product development Application of information technology to the foundry industry Thermal stress Mold material Tempering
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Abstract

During the casting cycle, the relatively cold material of the mold comes into contact with the significantly higher temperature melt, which causes high temperature fluctuations on the face of the mold and in its volume, which cause cyclic temperature stress. The submitted article is based on conclusions of the article “Evaluation of the temperature distribution of a die casting mold of X38CrMoV5_1 steel”, in which the modification of temperature relations of the mold in the direction from the mold face to its volume was investigated. In current article, the influence of the tempering channel distance on the temperature modification in the volume of high pressure die casting mold is investigated. Three variants of the tempering channels placements with different location respecting the mold cavity were investigated. The temperature was monitored in two selected locations, with distribution of 1mm, 2mm, 5mm, 10mm and 20mm in the direction from the mold cavity surface to the volume of fixed and movable part of the mold. As a comparative parameter, the temperature of the melt in the center of the runner above the measuring point and the temperature of the melt close to the face of the mold were monitored. The measurement was performed using Magmasoft simulation software. It was discovered that up to a distance of 5mm from the face of the mold, a zone with complete heat transit without its accumulation occurs. Above this limit, the mold begins to accumulate heat, and from distance of 20mm from the face of the mold, the heat gradually passes into the entire mass of the mold without significant temperature fluctuations. The propositions derived from the results of the experiments presented at the end of the article will subsequently be experimentally verified in further research works.
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Bibliography

[1] Ebrahimi, A., Fritsching, U., Heuser, M., Lehmhus, D., Struß, A., Toenjes, A., von Hehl, A. (2020). A digital twin approach to predict and compensate distortion in a High Pressure Die Casting (HPDC) process chain. In Proceedings of the 5th International Conference on System-Integrated Intelligence, 11-13 November 2020 (pp. 144-149). Bremen: Elsevier B.V. DOI: 10.1016/j.promfg.2020.11.026.
[2] Bi, C., Gou, Z. & Xiong, S. (2015). Modeling and simulation for die casting mould filling process using cartesian cut cell approach. International Journal of Cast Metals Research. 28(4), 234-241. DOI: 10.1179/1743133615Y.0000000006.
[3] Choi, J., et al. (2022). Fatigue life prediction methodology of hot work tool steel dies for high-pressure die casting based on thermal stress analysis. Metals. 12(10), 1744, 1-18. DOI: 10.3390/met12101744.
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[8] Majernik, J. & Podaril. M. (2019). Evaluation of the temperature distribution of a die casting mold of X38CrMoV5_1 steel. Archives of Foundry Engineering. 19(2), 107-112. DOI: 10.24425/afe.2019.127125.
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[12] Noga, P., Tuz, L., Żaba, K. & Zwoliński, A. (2021). Analysis of microstructure and mechanical properties of alsi11 after chip recycling, co-extrusion, and arc welding. Materials. 14(11), 3124, 1-22. DOI: 10.3390/ma14113124.
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Authors and Affiliations

J. Majerník
1
ORCID: ORCID
M. Podaril
1
ORCID: ORCID
M. Majernikova
1
  1. Institute of Technology and Business in České Budějovice, Czech Republic

Effect of Thermal Nodes Reduction in Wall Connections of the Charge-Handling Furnace Grates on Thermal Stresses

A. Bajwoluk P. Gutowski
Archives of Foundry Engineering | 2021 | vo. 21 | No 3 | 53-58 | DOI: 10.24425/afe.2021.138665
Keywords Cast grates Heat-resistant castings Heat treatment equipment Thermal stress analyses
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Abstract

The paper presents FEM approach for comparative analyses of wall connections applied in cast grates used for charge transport in furnaces for heat and thermal-chemical treatment. Nine variants of wall connection were compared in term of temperature differences arising during cooling process and stresses caused by the differences. The presented comparative methodology consists of two steps. In first, the calculations of heat flow during cooling in oil for analysed constructions were carried out. As a result the temperature distributions vs cooling time in cross-sections of analysed wall connections were determined. In the second step, based on heat flow analyses, calculations of stresses caused by the temperature gradient in the wall connections were performed. The conducted calculations were used to evaluate an impact of thermal nodes reduction on maximum temperature differences and to quantitative comparison of various base design of the cast grate wall connection in term of level of thermal stresses and their distribution during cooling process. The obtained results clearly show which solution of wall connection should be applied in cast grate used for charge transport in real constructions and which of them should be avoided because the risk of high thermal stresses forming during cooling process.
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Bibliography

[1] Lai, G.Y. (2007). High-Temperature Corrosion and Materials Applications. ASM International.
[2] Davis, J.R. (Ed.). (1997). Industrial Applications of HeatResistant Materials. In Davis, J.R. (Eds.), ASM Specialty Handbook - Heat-Resistant Materials (pp. 67-85). ASM International.
[3] Piekarski, B. (2012). Creep-resistant castings used in heat treatment furnaces. Szczecin: West Pomeranian University of Technology Publishing House. (in Polish).
[4] Ul-Hamid et al. (2006). Failure analysis of furnace tubes exposed to excessive temperature. Engineering Failure Analysis. 13(6), 1005-1021. DOI: 10.1016/j.engfailanal.2005.04.003.
[5] Reihani, A., Razavi, S.A., Abbasi, E. et al. (2013). Failure Analysis of welded radiant tubes made of cast heat-resisting steel. Journal of failure Analysis and Prevention. 13, 658–665. DOI: https://doi.org/10.1007/s11668-013-9741-y.
[6] Piekarski, B. (2010). Damage of heat-resistant castings in a carburizing furnace. Engineering Failure Analysis. 17(1), 143-149. DOI: 10.1016/j.engfailanal.2009.04.011.
[7] Nandwana, D., et al. (2010). Design, Finite Element analysis and optimization of HRC trays used in heat treatment process. In World Congress on Engineering 2010, June 30 - July 2, 2010 (pp. 1149-1154). London, U.K.: Newswood Limited.
[8] Sandeep, K., Ajit, K. & Mahesh, N.S. (2012). Improving productivity in a heat treatment shop for piston Pins. SASTECH Journal. 11(2), 38-46.
[9] Standard PN-EN 10295: 2004. Heat resistant steel castings.
[10] Bajwoluk, A. & Gutowski, P. (2019). Thermal stresses in the accessories of heat treatment furnaces vs cooling kinetics. Archives of Foundry Engineering. 19(3), 88-93, DOI: 10.24425/afe.2019.127146.
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Authors and Affiliations

A. Bajwoluk
1
ORCID: ORCID
P. Gutowski
1
ORCID: ORCID
  1. Mechanical Engineering Faculty, West Pomeranian University of Technology, Szczecin, Al. Piastów 19, 70-310 Szczecin, Polska

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