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Testing the Veining Elimination using Pressure Changes and one Type of Additive in a Cold-box-amine Core Mixture

P. Delimanová I. Vasková O. Kožej
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 129-135 | DOI: 10.24425/afe.2024.151302
Keywords Cold-box Additive Shooting pressure Veinings Core mixture
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Abstract

This article presents a analysis of the impact of varying amounts of a specific additive in the core mixture and adjustments in shooting pressure on the elimination of surface defects in castings, particularly veinings. These defects, often located in inaccessible areas of the casting, cannot be effectively removed through conventional methods like punching, making the optimization of the core mixture composition crucial. Additives are frequently incorporated into the core mixture, as they have become an essential component in its production. For the core mixture to be effective, it is not only essential to identify the appropriate type of additive but also to precisely determine the optimal quantity of the additive and accurately set other critical production parameters, such as shooting pressure.This study investigates the influence of additive concentration and shooting pressure on the surface quality of cast iron castings, employing the cold box method for core production. The findings reveal that higher shooting pressure contributes positively to the reduction of veining defects. However, an increased additive content in the core mixture does not necessarily ensure vein-free castings. The additive also plays a role in reducing the gas content within the core, and increased core hardness is associated with a decrease in the occurrence of veining defects. The casting with the highest surface quality and the fewest veinings was produced using cores made from a mixture with 1% additive content, subjected to a shooting pressure of 4 bars.
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Bibliography


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[22] Hrubovčáková M. (2023). Analysis and action of additives in the nuclear mixture. Reasons for use and analysis of additives in molding compounds (41-56). Košice: Fakulta materiálov,metalurgie a recyklácie, Technická univerzita v Košiciach. (in Slovac).

[23] Abdulamer, D. (2023). Impact of the different moulding parameters on properties of the green sand mould. Archives of Foundry Engineering. 23(2), 5-9. DOI:10.24425/afe.2023.144288.

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Authors and Affiliations

P. Delimanová
1
ORCID: ORCID
I. Vasková
1
ORCID: ORCID
O. Kožej
1
ORCID: ORCID
  1. Technical University of Košice Faculty of Materials, Metallurgy and Recycling, Slovak Republik

Abrasive Wear Resistance of High-Entropy AlCoCuFeNi Alloy in SiC Mixture

K. Chrzan B. Kalandyk M. Grudzień-Rakoczy Ł. Rakoczy K. Cichocki
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 123-128 | DOI: 10.24425/afe.2024.151301
Keywords High-entropy alloys Microstructure Hardness Wear resistance Miller machine
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Abstract

The results of tribological tests carried out on two novel high-entropy alloys (HEAs) from the AlCoCuFeNi group are described in this study. Research was carried out using a Miller machine (ASTM G75 standard) in an abrasive slurry environment, which contained SiC and water in a 1:1 ratio. The results obtained showed a higher rate of abrasive wear in the material designated as D3 (total weight loss in D3-1.6g compared to 1.1g in the D5 alloy), characterised by a homogeneous microstructure and hardness of 186 HV5. The second dual phase alloy, designated D5, was characterised by a lower rate of abrasive wear. In this alloy, the appearance of the second phase precipitates, evenly distributed throughout the entire volume, with higher hardness (760 HV0,01) and in a content of approximately 65% has led to a decrease in wear. The different wear resistances of the tested materials are due to differences in the hardness of the phases that constitute the microstructure of the tested alloys and the interaction of hard abrasive particles with the tested material. This has a direct impact on the plastic nature of the deformation in the upper layers of the samples. A characteristic system of linear grooves and protrusions, visible on surface profiles, was observed on the surfaces tested. Small local defects were also observed as a result of hammering and subsequent removal of hard SiC abrasive particles from the alloys tested or, in the case of the D5 alloy, additional removal of precipitates of the harder phase from the matrix.
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Bibliography


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[18] Fan, Q., Chen, C., Fan, C., Liu, Z., Cai, X., Lin, S. & Yang, C. (2021). AlCoCrFeNi high-entropy alloy coatings prepared by gas tungsten arc cladding: Microstructure, mechanical and corrosion properties. Intermetallics. 138, 107337, 1-17. https://doi.org/10.1016/j.intermet.2021.107337.

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[20] Standard- ISO 6507-1:2023- Metallic materials-Vickers hardness test. [21] Standard- ASTM G75-15(2021)- Standard Test Method for Determination of Slurry Abrasivity (Miller Number) and Slurry Abrasion Response of Materials (SAR Number).

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[23] Cichocki, K., Bała, P., Kwiecień, M., Szymula, M., Chrzan, K., Hamilton, C. & Muszka, K. (2024). The influence of Mo addition on static recrystallization and grain growth behaviour in CoNiFeMn system subjected to prior deformation. Archives of Civil and Mechanical Engineering. 24. https://doi.org/10.1007/s43452-024-00888-8.

[24] Xiao, D.H., Zhou, P.F., Wu, W.Q., Diao, H.Y., Gao, M.C., Song, M. & Liwae, P.K. (2017). Microstructure, mechanical and corrosion behaviors of AlCoCuFeNi-(Cr,Ti) high entropy alloys. Materials & Design. 116, 438-447. https://doi.org/10.1016/j.matdes.2016.12.036.

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Authors and Affiliations

K. Chrzan
1 2
ORCID: ORCID
B. Kalandyk
2
M. Grudzień-Rakoczy
1
ORCID: ORCID
Ł. Rakoczy
3
K. Cichocki
3
  1. Łukasiewicz Research Network – Krakow Institute of Technology, Centre of Materials and Manufacturing Research, Poland
  2. AGH University of Krakow, Faculty of Foundry Engineering, Poland
  3. AGH University of Krakow, Faculty of Metals Engineering and Industrial Computer Science, Poland

Application of SiC Based Moulding Sand in Technology of Layered Castings

N. Przyszlak T. Wrobel
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 115-122 | DOI: 10.24425/afe.2024.151300
Keywords Layered casting SiC High chromium steel Gray cast iron Heat treatment
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Abstract

The article concerns the technology of layered castings made with a system where the base part is made of gray cast iron with flake graphite and the working part is made of high-chromium steel X46Cr13. The castings were produced using mould cavity preparation method utilizing a molding sand based on SiC. The idea of the research was to perform heat treatment of X46Cr13 steel directly in the casting mould, with the success of this approach guaranteed by selecting molding sand with appropriate physicochemical parameters. During the pouring and cooling of the mould, the temperature on the outer surface of the steel insert was recorded to check if it reached the required austenitization temperature. The castings were then examined for the quality of the bond between the gray cast iron base part and the steel working part, microstructure studies were conducted using light and scanning microscopes, and hardness was measured on the surface of X46Cr13 steel. Based on the conducted research, it was found that the high thermal conductivity of the molding sand made with a silicon carbide base disqualifies it for use in the analyzed technology of integrating heat treatment of X46Cr13 steel with the process of producing a bimetal system with gray cast iron. In the microstructure of the steel, in addition to martensite, pearlite and ferrite were present. Therefore, a satisfactory increase in the hardness of the working surface compared to the annealed state of X46Cr13 steel was not achieved, which ultimately confirmed that the hardening of the steel insert was unsuccessful.
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Bibliography


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[9] Przyszlak, N. & Wróbel, T. (2019). Self-hardening of X46Cr13 steel integrated with base from grey cast iron in bimetallic system. Archives of Foundry Engineering, 19(2), 29-34. DOI:10.24425/afe.2019.127112.

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[11] PN-EN 10088-1,2

[12] Przyszlak, N. & Piwowarski, G. (2023). Designing of X46Cr13 steel heat treatment in condition of casting mould. Archives of Foundry Engineering. 23(2), 119-126. DOI:10.24425/afe.2023.144304.

[13] PN-H-11077:1983

[14] PN-H-11001:1985

[15] Staub, F., Adamczyk, J., Cieślakowa, Ł., Gubała J , Maciejny, A. (1994). Metallography. Katowice, Śląskie Wydawnictwo Techniczne. (in Polish).
 
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Authors and Affiliations

N. Przyszlak
1
T. Wrobel
1
  1. Department of Foundry Engineering, Silesian University of Technology, Towarowa 7 St., 44-100 Gliwice, Poland

The Influence of Cooling Rate on the Damping Characteristics of the ZnAl27Cu2 Alloy

G. Piwowarski J. Cepielik
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 109-114 | DOI: 10.24425/afe.2024.151299
Keywords Zinc alloys damping coefficient High-damping metals Cooling rate Ultrasound testing
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Abstract

The paper presents the results of damping coefficient tests on the ZnAl27Cu2 alloy (ZL27). The tested alloy was cast into five types of molds made of different materials (a steel mold with an ambient temperature of 20°C, a steel mold with a temperature of 100°C, a humid green sand mold, a dried green sand mold and a mold made of foundry gypsum mass). The thermophysical properties of these materials are different, and that's affecting the rate of heat absorption from the cast. Different mold materials affect obtaining different cooling rates. The cooling rate significantly affects the microstructure of the tested alloy. The specimens of investigate alloy were subjected to ultrasound and microscopic tests to assess the alloy structure. The damping coefficient has been calculated on the basis of specimen measurements obtained with the use of the signal echo method. Research shows that high structural fragmentation adversely affects the damping properties of alloys is confirmed. On the other hand, very low cooling rate, resulting in the formation of large, overgrown dendrites, does not guarantee the highest vibration damping capacity for this particular alloy. It turns out in this case a humid green sand mold, (cooling rate of 5.1 K/s) guarantees the best damping properties for the ZL27 alloy.
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[13] Nikolić, F. Štajduhar, I. & Čanađija, M. (2021) Casting microstructure inspection using computer vision: dendrite spacing in aluminum alloys. Metals. 11(5), 756, 1-13. https://doi.org/10.3390/met11050756.

[14] Vandersluis, E. & Ravindran, C. (2019) Influence of solidification rate on the microstructure, mechanical properties, and thermal conductivity of cast A319 Al alloy. Journal of Materials Science. 54, 4325-4339. https://doi.org/10.1007/s10853-018-3109-3.

[15] Djurdjevič, M. & Grzinčič, M. (2012) The effect of major alloying elements on the size of the secondary dendrite arm spacing in the as-cast Al-Si-Cu alloys. Archives of Foundry Engineering. 12(1), 19-24. DOI: 10.2478/v10266-012-0004-2

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Authors and Affiliations

G. Piwowarski
1
J. Cepielik
1
  1. AGH University of Krakow, Poland

Effect of Core Temperature at HPDC on the Internal Quality of the Casting

M. Matejka D. Bolibruchová R. Podprocká P. Oslanec
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 81-87 | DOI: 10.24425/afe.2024.151295
Keywords HPDC Al-Si-Cu alloy Porosity Microstructure
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Abstract

High pressure die casting (HPDC) is one of the most productive casting methods to produce a wide range of aluminum components with high dimensional accuracy and complex geometries. The process parameters of high-pressure casting generally directly affect the resulting quality of the castings, such as the presence of pores in the casting or the microstructure. In addition to air entrapment, porosity can also be caused by the dissolution of hydrogen. Hydrogen is released by the reaction of water vapor and melt at high temperatures and is released during solidification. These defects can lead to a significant reduction in mechanical properties such as strength and ductility and especially fatigue properties. The aim of the presented article is to describe the effect of the temperature of the core of the high-pressure mold on the presence and distribution of porosity and the microstructure of the aluminum casting in two geometric variants. The temperature of the core was changed due to the use of two flowing media in the thermoregulation circuit of the core, i.e. demineralized water and heat transfer oil and worked with a core temperature of 130 ± 5 and 165 ± 5 °C. With both geometric variants, a higher porosity was achieved when using water (core temperature 130 ± 5 °C) than when using oil (core temperature 165 ± 5 °C). The opposite results were observed for microporosity, where higher microporosity was observed for tempering oil. The microstructure of the casting with water-cooled cores was more characterized by finer grains of phase α (Al) and eutectic Si. In tempering oil, the microstructure was characterized by coarse grains of the α phase (Al) and the Si lamellae were in the form of sharp-edged formations.
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Authors and Affiliations

M. Matejka
1
ORCID: ORCID
D. Bolibruchová
1
ORCID: ORCID
R. Podprocká
2
P. Oslanec
3
ORCID: ORCID
  1. University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Slovakia
  2. Rosenberg-Slovakia s.r.o., Slovakia
  3. Slovak Academy of Sciences, Institute of Materials and Machine Mechanics, Slovakia

Effect of Span-80 to Moisture Resistance of Near-infrared Curing 3D Printing Sodium Silicate Foundry Sands

Ao Xue Yuhan Tang Yao Li Weihong Dai Jijun Lu Huafang Wang
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 94-100 | DOI: 10.24425/afe.2024.151297
Keywords Sodium silicate sands Span-80 Near-infrared curing 3D printing Moisture resistance
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Abstract

In this work, a new method of near-infrared curing 3D printing sodium silicate sands (NIRC3DPSSS) driven by photovoltaic cells was proposed, and the Span-80 moisture resistance modifier was studied. NIRC3DPSSS had the advantages of high strength, rapid curing and low residual strength. However, the 24h storage strength would reduce because Na+ in the bonding bridges could absorb moisture. The experimental results showed that the strength of Span-80 modified sands molds reached 0.95MPa after 4 hours in a humidistat with 99%RH (relative humidity) containing 2.2% sodium silicate, an increase of 97.9% comparing to common sands molds. In air(80%RH), the strength reached 1.25MPa, an increase of 40.4%. The optimal effect of modification was achieved when Span-80 was 0.066% of the raw sands. Additionally, the bonding film and bridges in sodium silicate sands modified with Span-80 were more stable, smoother and free of cracks when observed using scanning electron microscopy (SEM) and energy dispersive spectroscopy(EDS).
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Authors and Affiliations

Ao Xue
1
Yuhan Tang
1
Yao Li
2
Weihong Dai
1
Jijun Lu
1
ORCID: ORCID
Huafang Wang
1
ORCID: ORCID
  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
  2. Dongfeng Motor Corporation Research & Development Institute, China

Studies of Accelerated Drying of Ceramic Moulds with the use of Microwaves

P. Just R. Kaczorowski M. Topola T. Pacyniak C. Rapiejko
Archives of Foundry Engineering | 2024 | vol. 24 | No 3 | 101-108 | DOI: 10.24425/afe.2024.151298
Keywords Casting Ceramic mould microwave drying Foamed patterns Replicast CS
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Abstract

The article presents the results of studies of the process of accelerated drying performed by means of microwave radiation of ceramic moulds deposited on patterns made of foamed plastics used in the Ceramic Shell technology. The studies aimed at determining the microwave radiation parameters (power, downtime, and uninterrupted operation time) in order to obtain the maximally short drying times which do not cause pattern destruction. The analysis of results confirmed that an increase of the microwave radiation power shortens the drying time of the particular layers of the ceramic mould, however, at the same time, it excessively raises the temperature of the mould. With the microwave power over 1200 W, we can obtain the drying time of one layer at the level of about 30 min, and the temperature of the mould reaches the value of 70oC, which does not cause deformation or partial melting of the polystyrene pattern. From the point of view of production effectiveness, as a result of the application of microwave drying, the time of production of ceramic moulds was shortened from 7 days to 1 working day.
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Authors and Affiliations

P. Just
1
R. Kaczorowski
1
M. Topola
1
T. Pacyniak
1
ORCID: ORCID
C. Rapiejko
1
ORCID: ORCID
  1. Department of Materials Engineering and Production Systems, Lodz University of Technology, ul. Stefanowskiego 1/15, 90-537 Łódź, Poland

Synthesis and Characterization of Novel Aluminum Composites: A Compo-Casting Approach with ZrO2 , Al2O3 , and SiC

S. Farahany M.K. Hamdani M.R. Salehloo M. Krol E. Cheraghali
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 88-97 | DOI: 10.24425/afe.2024.149274
Keywords Hybrid composite Aluminum Compo-casting Wear Bismuth
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Abstract

The present study evaluates the microstructural features, mechanical properties, and wear characteristics of the newly developed hybrid composite of A356/ZrO2/Al2O3/SiC produced by compo-casting at 605±5 °C, 600 rpm for 15 minutes with less than 30% solid fraction in which Bi and Sn were added separately to the matrix before introducing reinforcements. FESEM micrographs and corresponding EDS illustrated the successful incorporation of particles in the matrix. Fine particles of ZrO2 were observed close to the coarse Al2O3, and SiC particles, along with Bi and Sn elements, were detected at the eutectic evolution region. The A356+Bi/Al2O3+ZrO2+SiC hybrid composite exhibited the lowest specific wear rate (1.642 ×10-7cm3/Nm) and friction coefficient (0.31) under applied loads of 5, 10, and 20 N, in line with the highest hardness (73.4 HBN). Analysis of the worn surfaces revealed that the wear mechanism is mostly adhesive in all synthesized composites, which changed to the combination of adhesive and abrasive mode in the case containing Bi and SiC. Inserting Bi not only leads to the refinement of eutectic Si but also enhances the adhesion between the matrix/particles and improves lubricity. This, in turn, reduces the wear rate and coefficient of friction, ultimately improving the performance of the hybrid composite.
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Authors and Affiliations

S. Farahany
1
M.K. Hamdani
2
M.R. Salehloo
2
M. Krol
2
E. Cheraghali
3
  1. Buein Zahra Technical University, Iran
  2. Iran University of Science and Technology, Iran
  3. Silesian University of Technology

Impact of Aging Time on the Metallurgical Properties and Hardness Characteristics of an Al-Si-Mg-Cr Hypoeutectic Alloy Intended for Automotive Applications

V.V. Ramalingam K.V. Shankar B. Shankar R. Abhinandan A. Dineshkumar P.A. Adhithyan K. Velusamy A. Kapilan N. Sudheer
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 137-142 | DOI: 10.24425/afe.2024.149281
Keywords Al-Si-Mg Microstructure Hardness Eutectic
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Abstract

This research investigates the microstructural evolution and mechanical properties of LM25 (Al-Si-Mg) alloy and Cr-modified LM25-Cr (Al-Si-Mg-Cr) alloy. Microstructural analysis reveals distinctive ε-Si phase morphologies, with Cr addition refining dendritic structures and reducing secondary dendrite arm spacing in the as-cast condition. Cr modification results in smaller-sized grains and a modified ε-Si phase, enhancing nucleation sites and reducing ε-Si size. Microhardness studies demonstrate significant increases in hardness for both alloys after solutionising and aging treatments. Cr-enriched alloy exhibits superior hardness due to solid solution strengthening, and prolonged aging further influences ε-Si particle size and distribution. The concurrent rise in microhardness, attributed to refined dendritic structures and unique ε-Si morphology, underscores the crucial role of Cr modification in tailoring the mechanical properties of aluminium alloys for specific applications.
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Authors and Affiliations

V.V. Ramalingam
1
K.V. Shankar
2
B. Shankar
2
R. Abhinandan
3
A. Dineshkumar
3
P.A. Adhithyan
3
K. Velusamy
3
A. Kapilan
3
N. Sudheer
3
  1. Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 64112, India
  2. Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amritapuri, India; Centre for Flexible Electronics and Advanced Marerials, Amrita Vishwa Vidyapeetham, Amritapuri, India
  3. Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amritapuri, India

Analysis of Fragmentation Phenomenon of Composite Layers of Fe-TiC Type Obtained “in situ” in Steel Casting

J. Marosz S. Sobula
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 131-136 | DOI: 10.24425/afe.2024.149280
Keywords Surface layer Cast steel “In situ” composite MMCs composites SHSM reaction
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Abstract

A method for fabrication of a composite layer on the surface of a steel casting using coating containing TiC substrates was presented. The reaction of the synthesis of the ceramic phase was based on the SHS method (Self-propagating High-temperature Synthesis) and was triggered by the heat of molten steel. High hardness titanium carbide ceramic phases were obtained, which strengthened the base material improving its performance properties presented in this article. Microstructural examinations carried out by light microscopy (LM) on the in-situ produced composite layers showed that the layers were the products of reaction of the TiC synthesis – the phenomenon called “fragmentation” by the authors of study. The examinations carried out by scanning electron microscopy (SEM) have revealed the presence of spheroidal precipitated and free of impurities. The presence of titanium carbide was twofold increase in hardness in the area of the composite layer as compared to the base alloy which was carbon cast steel.
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Authors and Affiliations

J. Marosz
ORCID: ORCID
S. Sobula
1
ORCID: ORCID
  1. AGH University of Krakow, Poland

Influence of the Rate of Cooling/Solidification on the Location of Characteristic Points on the AT and ADT Curves of Cast Iron

J.S. Zych
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 124-130 | DOI: 10.24425/afe.2024.149279
Keywords thermal analysis cast iron cooling/solidification rate cups AT
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Abstract

The paper presents the results of the analysis of cooling curves of cast iron with approximately eutectic composition rasterized at different rates of cooling and ingot crystallization. The test samples were in the form of rods with a diameter of 30,0.mm and a coagulation modulus M = 0.75 cm. They were cast in a sand mould made of furan mass placed on a chill in the form of a cast-iron plate, with which one of the front surfaces of the rod casting was in contact. In this way, a differentiated cooling rate along the rod was achieved. At selected distances from the chiller (5, 15, 25, 25 and 45 mm) thermocouple moulds were placed in the cavity to record the cooling curves used in thermal (AT) and derivation (ATD) analysis. The solidification time of the ingot in the part farthest from the chiller was about 200s, which corresponds to the solidification time in the test cup AT. An analysis of the recorded cooling curves was performed in order to determine the values of characteristic points on the AT curve (Tsol. Tliq, ΔTrecal., τclot, etc.). Relationships between cooling time and rate and characteristic points on AT and ATD curves were developed. For example, Tsol min changes in the range of 1115 - 1145 for the range of cast iron solidification times in the selected ingot zone from ~ 70 to ~ 200 s, which corresponds to the process speed from 0.0047 to 0.014 [1/s]. The work also includes an analysis of other characteristic points on the AT and ATD curves as functions of the solidification rate of cast iron of the same composition.
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Authors and Affiliations

J.S. Zych
1
  1. AGH University of Krakow, Faculty of Foundry Engineering, Reymonta 23. 30-059 Kracow, Poland,

Bio-regeneration for Sodium Silicate Used Sands and its Unattended Monitoring System

Huafang Wang Zhaoxian Jing Ao Xue Yuhan Tang Lei Yang Jijun Lu
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 117-123 | DOI: 10.24425/afe.2024.149278
Keywords Sodium silicate used sands Diatom Water bloom Internet of Things platform
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Abstract

Sodium silicate, known for its low cost and non-toxicity, has been considered as a promising option for green foundry in terms of mould sands. However, the utilization of used sodium silicate sands has posed significant challenges. To address the issues of high energy consumption and secondary pollution associated with wet and dry regeneration of sodium silicate used sands, this paper proposes a novel unattended biological regeneration system. The system involves culturing diatoms in an incubator with a solution of sodium silicate used sands. The incubator is equipped with built-in sensors that continuously monitor temperature, illuminance, pH, and water level. The monitoring data is transmitted in real-time to the Yeelink Internet of Things platform via the controller using the TCP/IP protocol. By logging onto the corresponding web page, the experimenter can remotely observe the monitoring data. The results of the experiment indicate that diatoms bloomed five times, and the water pH decreased from 10.2 to 8.2 after 40 days of cultivation. Additionally, the film removal rate of the used sands reached 90.26%.
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Authors and Affiliations

Huafang Wang
1
ORCID: ORCID
Zhaoxian Jing
1
Ao Xue
1
Yuhan Tang
1
Lei Yang
1
ORCID: ORCID
Jijun Lu
1
ORCID: ORCID
  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China

Study on Mn Volatilization Behavior During Vacuum Melting of High-manganese Steel

Jialiu Lei Yongjun Fu Li Xiong
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 110-116 | DOI: 10.24425/afe.2024.149277
Keywords Mn volatilization behavior Vacuum melting Thermodynamics High-manganese steel
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Abstract

As an alloying element in steel, manganese can considerably enhance the mechanical properties of structural steel. However, the Mn volatilisation loss in vacuum melting is severe because of the high saturated vapour pressure, resulting in an unstable Mn yield and Mn content fluctuation. Therefore, a systematic study of the volatilisation behaviour of Mn in vacuum melting is required to obtain a suitable Mn control process to achieve precise control of Mn composition, thereby providing a theoretical basis for industrial melting of high-Mn steel. In order to explore the Mn volatilization behavior, the volatilization thermodynamics and volatilisation rate of Mn, as well as the influence factors are discussed in this study. The results shows that Mn is extremely volatilised into the vapour phase under vacuum, the equilibrium partial pressure is closely related to Mn content and temperature. With an increase in the Mn content, a higher C content has a more obvious inhibitory effect on the equilibrium partial pressure of Mn. The maximum theoretical volatilisation rate of Mn shows a linear upward trend with an increase in Mn content. However, a higher C content has a more obvious effect on the reduction of the maximum theoretical volatilisation rate with the increase of Mn content. This study provides an improved understanding of Mn volatilisation behaviour as well as a theoretical foundation for consistent Mn yield control during the vacuum melting process of high-Mn steel.
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Authors and Affiliations

Jialiu Lei
1
Yongjun Fu
1
Li Xiong
2
  1. Hubei Polytechnic University, China
  2. Hubei Guoan Special Steel Inspection and Testing Co., Ltd.

Decarbonization of Production Systems in Foundries

C. Kolmasiak
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 104-109 | DOI: 10.24425/afe.2024.149276
Keywords Decarbonization Renewable energy Foundry production
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Abstract

The article discusses the growing importance of decarbonization of production systems in the foundry industry as a response to climate challenges and increasing requirements for sustainable development. The process of reducing greenhouse gas emissions in foundry production is caused by a number of reasons. Decarbonization of the foundry industry refers to actions aimed at reducing greenhouse gas emissions, especially carbon dioxide (CO2). Reducing carbon dioxide emissions is increasingly being considered as a key element of the strategy of both small and large foundries around the world. Foundry is one of the industries that generates significant amounts of carbon dioxide emissions due to the energy consumption in the process of melting and forming metals. There is virtually no manufacturing industry that does not use elements cast from iron, steel or non-ferrous metals, ranging from elements made of aluminum to zinc. The article presents various decarbonization strategies available to foundries, such as: the use of renewable energy, the use of more efficient melting technologies, or the implementation of low-energy technologies throughout the production process. Application examples from different parts of the world illustrate how these strategies are already being put into practice, as well as the potential obstacles and challenges to full decarbonization.
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Bibliography

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Authors and Affiliations

C. Kolmasiak
1
  1. Czestochowa University of Technology, Faculty of Production Engineering and Materials Technology, Department of Production Management, Poland

The Technique of Inorganic Core Sand Shooting with Reduced Pressure in Venting System

M. Skrzyński R. Dańko G. Dajczer
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 98-103 | DOI: 10.24425/afe.2024.149275
Keywords Foundry engineering Sand moulds and cores Inorganic binder materials Core shooting technique
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Abstract

The publication presents a new shooting technique with reduced pressure in venting system for manufacturing foundry cores using inorganic sand mixture with Cordis binder. Traditional technologies for producing casting cores using blowing methods, despite their undeniable advantages, including the ability to produce cores in series, also come with some disadvantages. The primary drawbacks of the process involve uneven compaction structure of the cores, with denser areas primarily located under the blow holes, and under-shooting defects, which often occur in regions away from the blow hole or in increased core cross-sectional areas. In an effort to improve core quality, a concept was developed that involves incorporating a reduced pressure in the core box venting system to support the basic overpressure process. The solutions proposed in the publication with a vacuum method of filling the cavities of multi-chamber core boxes solve a number of technical problems occurring in conventional blowing technologies. It eliminates difficulties associated with evacuating the sand from the chamber to the shooting head and into technological cavity and increases the uniform distribution and initial degree of compacting of grains in the cavity. The additive role of this “underpressure” support is to enhance corebox venting by eliminating 'air cushions' in crevices and structural elements that obstruct the flow of evacuated air. The publication presents the results of studies on core manufacturing using blowing methods conducted in three variants: classic overpressure, utilizing the core box filling phenomenon by reducing pressure, and an integrated approach combining both these methods.
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Bibliography

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[15] Dajczer, G. (2024). Integrated process of making casting cores by blowing method using reduced pressure of venting the core box. PhD dissertation. AGH Krakow.

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Authors and Affiliations

M. Skrzyński
1
R. Dańko
1
ORCID: ORCID
G. Dajczer
2
  1. AGH University of Krakow, Poland
  2. KPR PRODLEW-KRAKÓW Spółka z o.o., Alfreda Dauna 78, 30-629 Krakow, Poland

Calculations of Non-Metallic Particles Removal from Liquid Aluminium to Top Slag

P.L. Żak K. Kuglin M. Szucki D. Kalisz N. Mrówka E. Dand
Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 60-68 | DOI: 10.24425/afe.2024.149272
Keywords Numerical simulation Liquid aluminium Particle motion Inclusions
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Abstract

In the paper, the results of a numerical analysis of KCl and KF particles present in liquid aluminium assimilation to the slag are presented. The authors analysed particle movement in the slag model, which is based on buoyant, capillary, viscosity, Newton and repulsion forces, interfacial tensions at the interface of phases and surface energy during the particle movement through phases boundary. On the basis of the mathematical model, a computer programme was written to make simulations under different conditions. The results of particle position in the slag are presented for different particle radiuses: 1, 5, 10, 20 μm, and constant viscosity of the slag including velocity evolution of the velocity. Another approach was used to indicate the influence of slag viscosity on particle and slag penetration depth. During computations, selected viscosities of slag of 0.0012, 0.0015, 0.0018 [kg/m·s] were taken into account. Different comparisons were made for the chosen particle sizes. Each examination takes into account the impact of the particle type. The results clearly show that for larger particles the penetration depth is greater and viscosity of the slag has an impact on the velocity evolution during assimilation process.
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Authors and Affiliations

P.L. Żak
1
K. Kuglin
2
M. Szucki
3
ORCID: ORCID
D. Kalisz
1
ORCID: ORCID
N. Mrówka
E. Dand
  1. AGH University of Krakow, Krakow, Poland
  2. NPA Skawina Sp. z o. o., Poland
  3. Technische Universität Bergakademie Freiberg, Germany

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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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

Refinement of the Manufacturing Route and Evaluation of the Reinforcement Effect of MAX Phases in Al Alloy Matrix Composite Materials

A. Dmitruk K. Naplocha A. Żak A. Strojny-Nędza
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 141-148 | DOI: 10.24425/afe.2024.149262
Keywords MAX phases Composite Squeeze casting SHS synthesis Pressure infiltration
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Abstract

Microwave Assisted Self-propagating High-temperature Synthesis (MASHS) was used to prepare open-porous MAX phase preforms in Ti-Al-C and Ti-Si-C systems, which were further used as reinforcements for Al-Si matrix composite materials. The pretreatment of substrates was investigated to obtain open-porous cellular structures. Squeeze casting infiltration was chosen to be implemented as a method of composites manufacturing. Process parameters were adjusted in order to avoid oxidation during infiltration and to ensure the proper filling. Obtained materials were reproducible, well saturated and dense, without significant residual porosity or undesired interactions between the constituents. Based on this and the previous work of the authors, the reinforcement effect was characterized and compared for both systems. For the Al-Si+Ti-Al-C composite, an approx. 4-fold increase in hardness and instrumental Young's modulus was observed in relation to the matrix material. Compared to the matrix, Al-Si+Ti-Si-C composite improved more than 5-fold in hardness and almost 6-fold in Young's modulus. Wear resistance (established for different loads: 0.1, 0.2 and 0.5 MPa) for Al-Si+Ti-Al-C was two times higher than for the sole matrix, while for Al-Si+Ti-Si-C the improvement was up to 32%. Both composite materials exhibited approximately two times lower thermal expansion coefficients than the matrix, resulting in enhanced dimensional stability.
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Authors and Affiliations

A. Dmitruk
1
ORCID: ORCID
K. Naplocha
1
ORCID: ORCID
A. Żak
2
A. Strojny-Nędza
3
  1. Wrocław University of Science and Technology, Faculty of Mechanical Engineering, Department of Lightweight Elements Engineering, Foundry and Automation, Poland
  2. Wrocław University of Science and Technology, Faculty of Chemistry, Institute of Advanced Materials, Poland
  3. Łukasiewicz Institute of Microelectronics and Photonics, Poland

Quality Control of Liquid Aluminium Alloy Using Thermal Imaging Camera

Ryszard Władysiak
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 135-140 | DOI: 10.24425/afe.2024.149261
Keywords thermal imaging camera Aluminium alloy Quality control
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Abstract

This paper presents the results of a study on the use of infrared thermography to assess the quality of liquid metal, a basic semi-finished product used in foundry production. EN AC-46000 alloy with the designation AlSi9Cu3(Fe) was used for the study. The crystallization process of the alloy was investigated using the TDA method with a Crystaldigraph device and Optris PI thermal imaging camera. The research describes how to use a thermal imaging camera to assess the quality of aluminium alloys. These alloys, due to their propensity in the liquid state to oxidise and absorb hydrogen, a refining procedure in the melting process. The effects of alloy refining are evaluated during technological tests of hydrogen solubility, density and casting shrinkage. The results presented in this paper showed that there is a statistical correlation between the density of the metal and the temperature values from the thermogram of the sample, obtained during its solidification. The existing correlation makes it possible to develop a thermographic inspection algorithm that allows a fast and non-contact assessment of aluminium alloy quality.
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Bibliography

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Authors and Affiliations

Ryszard Władysiak
1
ORCID: ORCID
  1. Lodz University of Technology, Department of Materials Engineering and Production Systems, Łódź, Poland

Remelting of Aluminum Scrap Into Billets Using Direct Chill Casting

Kardo Rajagukguk Suyitno Suyitno Harwin Saptoadi I. K. Indraswari Kusumaningtyas Budi Arifvianto Muslim Mahardika
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 40-49 | DOI: 10.24425/afe.2024.149250
Keywords Direct chill casting Recycling aluminum scrap Microstructure Mechanical properties Macrosegregation
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Abstract

An as-cast aluminum billet with a diameter of 100 mm has been successfully prepared from aluminum scrap by using direct chill (DC) casting method. This study aims to investigate the microstructure and mechanical properties of such as-cast billets. Four locations along a cross-section of the as-cast billet radius were evaluated. The results show that the structures of the as-cast billet are a thin layer of coarse columnar grains at the solidified shell, feathery grains at the half radius of the billet, and coarse equiaxed grains at the billet center. The grain size tends to decrease from the center to the surface of the as-cast billet. The ultimate tensile strength (UTS) and the hardness values obtained from this research slightly increase from the center to the surface of the as-cast billet. The distribution of Mg, Fe, and Si elements over the cross-section of the as-cast billet is inhomogeneous. The segregation analysis shows that Si has negative segregation towards the surface, positive segregation at the middle, and negative segregation at the center of the as-cast billet. On the other hand, the Mg element is distributed uniformly in small quantities in the cross-section of the as-cast billet.
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Authors and Affiliations

Kardo Rajagukguk
1 2 4
ORCID: ORCID
Suyitno Suyitno
3 4
Harwin Saptoadi
1
I. K. Indraswari Kusumaningtyas
1
Budi Arifvianto
1 4
Muslim Mahardika
1 4
  1. Department of Mechanical and Industrial Engineering, Faculty of Engineering, Universitas Gadjah Mada, Jl. Grafika 2, Yogyakarta 55281, Indonesia
  2. Department of Mechanical Engineering, Institut Teknologi Sumatera (ITERA), Jl. Terusan Ryacudu, South Lampung, Lampung 35365, Indonesia
  3. Department of Mechanical Engineering, Faculty of Engineering, Universitas Tidar, Jl. Kapten Suparman 39, North Magelang, 56116, Indonesia
  4. Center for Innovation of Medical Equipment and Devices (CIMEDs), Universitas Gadjah Mada, Jl. Teknika Utara Yogyakarta 55281, Indonesia

The Use of 3D Printed Sand Molds and Cores in the Castings Production

Dawid Halejcio Katarzyna Major-Gabryś
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 32-39 | DOI: 10.24425/afe.2024.149249
Keywords Additive technologies Molding and core sands 3D printing Mold technology Castings quality
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Abstract

As a part of this work, an analysis of the current state of knowledge regarding the use of additive technology - binder jetting in the production of castings was made. The binder jetting (so-called 3D printing) has become the leading method of sand mold and core production. Within this paper types of molding and core sands with organic and inorganic binders that are and can be used in technology were analyzed. The need to carry out works aimed at developing pro-ecological molding / core sands with inorganic binders and organic binders with reduced harmfulness to the environment dedicated to binder jetting technology was noticed. The influence of technology parameters on the properties of molding / core sands and the properties of cast components was analyzed. It was shown that thanks to the unlimited shapes of the systems obtained with the use of additive technologies, it is possible to influence the rate of heat dissipation through the mold, which positively effects the process of solidification and crystallization of the castings.
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Authors and Affiliations

Dawid Halejcio
1
ORCID: ORCID
Katarzyna Major-Gabryś
1
ORCID: ORCID
  1. AGH University of Krakow, Faculty of Foundry Engineering Department of Moulding Materials, Mould Technology and Non-ferrous Metals al. A. Mickiewicza 30, 30-059 Krakow

Investigation of The Effect of Mechanical Vibration Applied During Solidification on The Microstructure and Properties of Aluminum 356 Alloy

Taha Süreyya Özgü Recep Çalın Naci Arda Tanış
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 26-31 | DOI: 10.24425/afe.2024.149248
Keywords Casting A356 Aluminum vibration
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Abstract

Manufacturing by casting method in aluminum and its alloys is preferred by different industries today. It may be necessary to improve the mechanical properties of the materials according to different industries and different strength requirements. The mechanical properties of metal alloys are directly related to the microstructure grain sizes. Therefore, many grain reduction methods are used during production or heat treatment. In this study, A356 alloys were molded into molds at 750 °C and exposed to vibration frequency at 0, 8.33, 16.66, 25, and 33.33 Hz during solidification. Optical microscopes images were analyzed in image analysis programs to measure the grain sizes of the samples that solidified after solidification. In addition, microhardness tests of samples were carried out to examine the effect of vibration and grain reduction on mechanical behavior. In the analyzes made, it was determined that the grain sizes decreased from 54.984 to 26.958 μm and the hardness values increased from 60.48 to 126.94 HV with increasing vibration frequency.
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Authors and Affiliations

Taha Süreyya Özgü
1
ORCID: ORCID
Recep Çalın
1
ORCID: ORCID
Naci Arda Tanış
1
ORCID: ORCID
  1. Kırıkkale University, Turkey

Use of Used Graphite Electrodes as Metal Matrix Composites Reinforcement

Małgorzata Łągiewka
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 21-25 | DOI: 10.24425/afe.2024.149247
Keywords Recycling Graphite electrode Natural graphite Metal composite materials Mechanical properties
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Abstract

The work presents the effect of the addition of graphite from recycled graphite electrodes on the mechanical properties of metal matrix composites (MMC) based on the AlMg10 alloy. A composite based on the AlMg10 alloy reinforced with natural graphite particles was also tested. Further, tests of the mechanical properties of the AlMg10 alloy were performed for comparative purposes. Composites with a particle content of 5, 10 and 15 percent by volume were produced by adding introduction of particles into the liquid matrix while mechanically mixing molten alloy. The composite suspensions were gravitationally cast into metal molds. Samples for the Rm, R0.2, A and E tests were made from the prepared castings. Photos of the microstructures of the materials were also taken. The research shows that the addition of graphite to the matrix alloy causes minor changes in tensile strength (Rm) and yield strength (R02), regardless of the type of graphite used. The results of the relative elongation tests showed that the introduction of graphite particles into the matrix alloy had an adverse effect on the elongation values in the case of each of the tested composites. The introduction of graphite particles into the AlMg10 alloy significantly increased the Young’s modulus value, both in the case of composites with flake graphite (natural) and graphite from ground graphite electrodes.
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Authors and Affiliations

Małgorzata Łągiewka
1
ORCID: ORCID
  1. Czestochowa University of Technology, Poland

The Effect of Work Hardening on the Structure and Hardness of Hadfield Steel

Damian Bańkowski Piotr S. Młynarczyk Wojciech P. Depczyński Kazimierz Bolanowski
Archives of Foundry Engineering | 2024 | vol. 24 | No 1 | 14-20 | DOI: 10.24425/afe.2024.149246
Keywords Manganese steel Hardness Modified Hadfield steel Solution heat treatment Computed tomography
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Abstract

The article aims to characterize Hadfield steel by analyzing its chemical composition, mechanical properties, and microstructure. The study focused on the twinning-induced work hardening of the alloy, which led to an increase in its hardness. The experimental data show that the material hardness at the surface improved considerably after solution heat treatment and work hardening, reaching more than 750 HV. By contrast, the hardness of the material core in the supersaturated condition was about 225 HV. The chemical and phase compositions of the material at the surface were compared with those of the core. The microstructural analysis of the steel revealed characteristic decarburization of the surface layer after solution heat treatment. The article also describes the effects of heat treatment on the properties and microstructure of Hadfield steel. The volumetric (qualitative) analysis of the computed tomography (CT) data of Hadfield steel subjected to heavy dynamic loading helped detect internal flaws, assess the material quality, and potentially prevent the structural failure or damage of the element tested.
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Authors and Affiliations

Damian Bańkowski
1
ORCID: ORCID
Piotr S. Młynarczyk
1
ORCID: ORCID
Wojciech P. Depczyński
1
ORCID: ORCID
Kazimierz Bolanowski
1
ORCID: ORCID
  1. Kielce University of Technology, Poland

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