manufacturing technology march 201 3, vol. 13,...

MANUFACTURING TECHNOLOGYMarch 201

Content

Study of advanced Ni – base ŽS6K alloy by quantitative metallography methodsJuraj Belan

Influencing the crystallization of secondary alloy AlSi6Cu4 with strontiumDana Bolibruchová, Marek Brůna

Study of the gas content in aluminum alloys Dana Bolibruchová, Lukáš Richtárech

The Simulation of Influence of Quenching Temperature on Properties of Bearing RingsMartin Brezničan, Peter Fabian, Jozef Meško, Mário Drbúl

Complex evaluation of porosity in A356 aluminium alloy using advanced porosity moduleMarek Brůna, Lukáš Kucharčík, Augustín Sládek

Influence of repeated remelting of the alloy RR.350 on structure and thermoMarek Břuska, Petr Lichý, Michal Cagala, Jaroslav Beňo

Influence of returning material on porosity of die castingsĽubomír Eperješi, Jozef Malik, Štefan Eperješi, Daniel Fecko

Using of Thermal Analysis in the Industrial Practice –Optimization of Computer Simulation Results Marko Grzincic, Mile Djurdjevic, Florian Dirnberger

Elimination of the negative effect of Fe-rich intermetallic phases in secondary (recycled) aluminium cast alloyLenka Hurtalová, Eva Tillová

Impact Analysis of Mutual Rotation of Roller Bearing Rings on the Process of Contact Stresses in Rolling ElementsLenka Jakubovičová, Milan Sága, Milan Vaško

Experimental evaluation of the new lance for powder injectionJan Jezierski, Krzysztof Janerka

In-phase multiaxial fatigue experimental analysis of welded Peter Kopas, Milan Sága

Inoculant Addition Effect on Thermomechanical and Thermophysical Properties of MgPetr Lichý, Jaroslav Beňo, Michal Cagala

Modified hydrated sodium silicate as a modern binder for ecological moulding sandsKatarzyna Major-Gabryś, Stanisław M. Dobosz, Jarosław Jakubski

Squeeze casting results of aluminium alloys Iva Nová, Jiří Machuta

Finite Element Implementation of Multi-Pass Fillet Weld with Phase ChangesPavol Novák, Jozef Meško, Milan Žmindák

Metallurgical and Material Properties of Castings Manufactured from Stainless SteelJosef Odehnal, Stanislav Brotánek

Effect of opening material granularity on the mould properties andtechnology Richard Pastirčák, Emil Krivoš

Temperature gradient in cooling down Fe-C-Cr alloy castingAndrzej Studnicki, Jan Szajnar

The zone without carbon in alloy layer obtained on steel castJan Szajnar, Agnieszka Walasek, Czesław Baron

The role of antimony in modifying of Al-Si-Cu cast alloy Eva Tillová, Mária Farkašová, Mária Chalupová

Influence of heat treatment on the microstructure of synthetic nodular Alan Vaško

Hardness of Ductile Cast Iron Castings and its Control in PraxisIveta Vasková, Peter Šebek, Igor Muli

Assessment of the effect of temperature and annealing timeimage analysis methods and EDX

Viktorie Weiss, Ingrid Kvapilova

The Efficiency of Different Types of Inoculation of Pure Al and AlSi2 AlloyTomasz Wróbel

MANUFACTURING TECHNOLOGY

2013, Vol. 13, No. 1

J. E. Purkyne University in Usti nad

Pasteurova 3334/7, 400 01 Usti nad Labem

J. E. Purkyne University in Usti nad Labem

2 – 7 base ŽS6K alloy by quantitative metallography methods

7 – 14 AlSi6Cu4 with strontium

14 – 20

20 – 25 The Simulation of Influence of Quenching Temperature on Properties of Bearing Rings

26 – 30 in A356 aluminium alloy using advanced porosity module

31 – 35 Influence of repeated remelting of the alloy RR.350 on structure and thermo-mechanical properties

36 – 39 Influence of returning material on porosity of die castings Ľubomír Eperješi, Jozef Malik, Štefan Eperješi, Daniel Fecko

39 – 43 – Consumption Reduction of Grain-Refinement Master Alloy and

44 – 50 rich intermetallic phases in secondary (recycled) aluminium cast alloy

50 – 54 Impact Analysis of Mutual Rotation of Roller Bearing Rings on the Process of Contact Stresses in Rolling Elements

55 – 59 lance for powder injection

59 – 64 of welded cylindrical 6063-T66 aluminium alloy specimens

64 – 67 Thermomechanical and Thermophysical Properties of Mg-Sr Magnesium Alloy

68 – 73 Modified hydrated sodium silicate as a modern binder for ecological moulding sands

Jarosław Jakubski

73 – 79

79 – 85 Pass Fillet Weld with Phase Changes

85 – 91 Metallurgical and Material Properties of Castings Manufactured from Stainless Steel G-X4CrNi13-4 and G-X4CrNiCu13-4

92 – 97 on the mould properties and the quality of castings made by patternless process

98 – 103 Cr alloy casting

103 – 108 The zone without carbon in alloy layer obtained on steel cast

109 – 114

115 – 119 Influence of heat treatment on the microstructure of synthetic nodular cast irons

120 – 122 Hardness of Ductile Cast Iron Castings and its Control in Praxis

123 – 127 time homogenization AlCu4MgMn alloys in terms of microstructure

127 – 133 The Efficiency of Different Types of Inoculation of Pure Al and AlSi2 Alloy

Advisory BoardProf. hab. Dr. Stanislav Adamczak, MSc.

Politechnika Kielce, PolandProf. Dana Bolibruchová, MSc. PhD.

UZ in Zilina, SlovakiaProf. Milan Brožek, MSc., Ph.D.

CULS in Prague, CzechProf. Dr. František Holešovský, MSc.

president, JEPU in Usti n. Labem, CzechProf. Jiří Hrubý, MSc., Ph.D.

VSB TU in Ostrava, CzechProf. Karel Jandečka, MSc., Ph.D.

UWB in Pilsen, CzechProf. h. c. Stanislaw Legutko, MSc., Sc.D.

Politechnika Poznańska, PolandProf. Karel Kocman, MSc., Sc.D.

TBU in Zlin, CzechProf. Pavel Kovac, MSc., Ph.D.

University of Novi Sad, SerbiaProf. Dr. János Kundrák, MSc., Sc.D.

University of Miskolc, HungaryProf. Ivan Kuric, MSc., Ph.D.

UZ in Zilina, SlovakiaProf. Imrich Lukovics, MSc., Ph.D.

TBU in Zlin, CzechProf. Jan Mádl, MSc., Ph.D.

CTU in Prague, CzechProf. Ioan D. Marinescu, Ph.D.

University of Toledo, USAProf. Jozef Novak-Marcincin, MSc., PhD.

FPT in Presov, SlovakiaProf. Iva Nová, MSc., Ph.D.

TU in Liberec, CzechProf. Dr. Hitoshi Ohmori, MSc.

RIKEN, JapanProf. Ing. Ľubomír Šooš, PhD.

SUT in Bratislava, SlovakiaProf. Dr. Dalibor Vojtěch, MSc.

ICHT in Prague, CzechCol. Assoc. Prof. Milan Chalupa, Ph.D.

FMT, University of Defence, CzechAssoc. Prof. Jan Jersák, MSc., Ph.D.

TU in Liberec, CzechAssoc. Prof. Štefan Michna, MSc., PhD.

JEPU in Usti n. Labem, CzechAssoc. Prof. Dr. Ivan Mrkvica, MSc.

VSB TU in Ostrava, CzechAssoc. Prof. Pavel Novák, MSc., Ph.D.

ICHT in Prague, CzechAssoc. Prof. Iveta Vaskova, MSc., PhD.

FM, TU in Kosice, SlovakiaDr. Michael N. Morgan

John Moores University, Great BritainDr. Thomas Pearce

UWE Bristol, Great Britain

Editor-in-chief Martin Novak, Eng. MSc., Ph.D.

Editorial Office AddressJ. E. Purkyne University in Usti nad Labem

FVTM, Campus UJEP, Building HPasteurova 3334/7, 400 01 Usti nad Labem

Czech Republic , Tel.: +420 475 285 534e-mail: [email protected]

PrintPrintPoint Ltd., Prague, Czech Republic

PublisherJ. E. Purkyne University in Usti nad Labem

Pasteurova 1, 400 96 Usti nad Labem, Czech Republic, VAT: CZ44555601

Issue: 300 pcs.published in March 2013, 136 pages

Permission: MK CR E 20470ISSN 1213–2489

indexed on: http://www.scopus.com

March 2013, Vol. 13, No. 1 MANUFACTURING TECHNOLOGY – ABSTRACTS ISSN 1213–2489

2

Study of advanced Ni – base ŽS6K alloy by quantitative metallography methods

Juraj Belan University of Žilina, Faculty of Mechanical Engineering, Department of Materials Science, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic, [email protected] The aerospace industry is one of the biggest consumers of advanced materials because of its unique combination of mechanical and physical properties and chemical stability. Highly alloyed stainless steel, titanium alloys and nickel based superalloys are mostly used for aerospace applications. High alloyed stainless steel is used for the shafts of aero engine turbines, titanium alloys for compressor blades and finally nickel base superalloys are used for the most stressed parts of the jet engine – the turbine blades. Nickel base superalloys were used in various structural modifications: as cast polycrystalline, a directionally solidified, single crystal and in last year’s materials which were produced by powder metallurgy. In this chapter, a problem of polycrystalline (equiaxed) nickel base superalloy turbine blades - such as the most stressed parts of the aero jet engine - will be discussed. Also the application of quantitative metallography and colour contrast on the ŽS6K Ni–base superalloy are the main objectives discussed in this chapter.

Keywords: Ni - base superalloy, gamma prime phase, quantitative metallography, colour contrast

Acknowledgment The authors acknowledge the financial support of the projects VEGA No. 1/0841/11 and No. 1/0460/11, and

European Union - the Project “Systematization of advanced technologies and knowledge transfer between industry and universities (ITMS 26110230004)”.

References

[1] BELAN, J. (2008) Structural Analyses of Advanced Materials for Aerospace Industry. Materials science (Medžiagotyra), Lithuania, Vol. 14, No. 4, pp. 315 – 318, ISSN 1392-1320

[2] BELAN, J. (2011) Influence of cooling rate on γ′ morfology in cast Ni – base superalloy. Acta Metalurgica Slovaca, Vol. 17, 2011, No. 1, pp. 38-44, ISSN 1338-1156

[3] CETEL, A., D. & DUHL, D., N. (1988). Microstructure – Property Relationships In: Advanced Nickel Base Superalloy Airfoil Castings, 2nd International SAMPE Metals Conference, pp. 37 – 48, USA, August 2 – 4, 1988

[4] DONACHIE, M. J. & DONACHIE, S. J. (2002). Superalloys – A technical Guide (2nd edition), ASM International, ISBN 0–87170–749–7, USA.

[5] DURAND – CHARE, M. (1997). The Microstructure of Superalloys, Gordon & Breach Science Publishers, ISBN 90 – 5699 – 097 – 7, Amsterdam, Netherland

[6] ĎURINIKOVÁ, E., TILLOVÁ, E. (2011). Phase and structure characteristics of recycled AlZn10Si8Mg cast alloy. Manufacturing Technology, Vol. 11, No. 11, pp. 11 – 17.

[7] SIMS, CH., T., STOLOFF, N., S. & HAGEL, W., C. (1987). Superalloys II (2nd edition), Wiley-Interscience, ISBN 0 – 471 – 01147 – 9, USA

[8] SKOČOVSKÝ, P. & VAŠKO, A. (2007). The quantitative evaluation of cast iron structure (1st edition), EDIS, ISBN 978-80-8070-748-4, Žilina, Slovak Republic

[9] TILLOVÁ, E. & PANUŠKOVA, M. (2008). Effect of Solution Treatment on Intermetallic Phase’s Morphology in AlSi9Cu3 Cast Alloy. Mettalurgija/METABK, No. 47, pp. 133-137, 1-4, ISSN 0543-5846.

[10] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., BONEK,M., & DOBRZANSKI, L., A. (2011). Structural analysis of heat treated automotive cast alloy. Journal of Achievements in Materials and Manufacturing Engineering/JAMME, Vol. 47, No. 1, (July 2011), pp. 19-25, ISSN 1734-8412.

[11] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., ĎURINÍKOVÁ, E. (2011). Quality control of microstructure in recycled Al-Si cast alloys. Manufacturing Technology, Vol. 11, No. 11, pp. 70-76.

[12] VAŠKO, A. (2011) Influence of transformation temperature on structure and mechanical properties of austempered ductile iron, Acta metallurgica Slovaca, Vol. 17, 2011, No. 1, p. 45-50.

Copyright © 2013 Published by Manufacturing Technology. All rights reserved. Paper number: M201301

Manuscript of the paper received in 2012-12-21. The reviewers of this paper: Dalibor Vojtech, Iva Nova.


3

Influencing the crystallization of secondary alloy AlSi6Cu4 with strontium

Dana Bolibruchová, Marek Brůna University of Žilina,Faculty of Mechnical Engineering, Department of technological engineering, Univerzitná 1, Žilina, Slovakia. [email protected], [email protected]

This work deals with modification of aluminum alloy AlSi6Cu4 with strontium in graduated amounts. Submited article examines modification influence on the mechanical properties such as tensile strength (Rm), elongation (A5) and Brinell hardness (HBW). Article also includes analysis of alloy microstructure modified by strontium and analyzes the impact of strontium on the gas content of the melt. This work deals with finding the optimal amount of strontium to achieve changes in the shape of the coarse eutectic silicon plates to fine rounded AlSi6Cu4 alloy rods. Durin experiment was found, that optimum amount of the used modifier with respect to the mechanical properties of the surveyed sample is 2000 ppm AlSr5. But with the increasing amount of modifier in the alloy decreases fludity.

Keyword: AlSi6Cu4 Alloy, modification, strontium, mechanical properties, microstructure

Acknowledgements This work was created within the solution of the grant project VEGA no 1/0363/13. The authors thank to Grant Agency for support. References

[1] MAGÁTOVÁ M. (2012) Diploma thesis, pp. 57.

[2] BOLIBRUCHOVÁ, D., Pastirčák, R., SLÁDEK, A. (2005). Foundry metallurgy- non-ferrous metals with instructions for exercises. Žilina: 1 ed. EDIS, pp. 172, ISBN 80-8070-457-0.

[3] BOLIBRUCHOVÁ, D. - Tillová, E. (2005) Foundry Al-Si alloys. Žilina: 1 ed. EDIS, pp. 180, ISBN 80- 8070-485-5.

[4] CASTRO-ROMAN, M. et al. (2006) Strontium Effect on the Solidification Path of a 319 - Type Aluminium. USA: Publisher. American Foundrymen's Society Illinois

[5] DAHLE A. K., NOGITA, K., McDONALD, S. D. (2005) Eutektic modification and microstructure development in Al-Si Alloys. Brisbane: The University of Queensland, pp. 243-248. 0921-5093.

[6] GRUZLESKI J. E., ClOSSET, B. M. (1990) The Treatment of Liquid Aluminium - Silicon Alloys. USA: Publisher. American Foundrymen's Society of Illinois, pp. 256.

[7] MICHNA, Š. et al. (2005) Encyclopedia of aluminum. Prešov: 1. ed. Edin, 720 p. ISBN80-89041-88-4.

[8] MULAZIMOGLU, N., TENEKEDJEV, N., GLOSSET. B. (1995). Commercial and Microstructures of Al Alloy With 319 Mg and Sr Additions. Canada: The University of Quebec - Chicoutimi, 15 p. 951-962.

[9] SAMUEL F. H., OUELLET, P. (1997) Microstructural Interpretation of Thermal Analysis of Commercial 319 Al Alloy With Mg and Sr Additions. Canada: The University of Quebec - Chicoutimi, 15 p. 951-962.

[10] TENEKEDJIEV et al. (1995) Microstructures Thermal Analysis of Strontium - Treated Aluminium-Silicon Alloys. USA: Publisher. American Foundrymen's Society Illinois, pp. 79.

[11] TILLOVÁ, E., CHALUPOVÁ, M. (2009) Structural analysis of Al-Si alloys. Zilina: EDIS, pp. 191, ISBN 978- 80-554-0088-4.

[12] PASTIRČÁK, R., URGELA, D., KRIVOŠ, E.: Production of casting by patternless process. In: Archives of foundry engineering. ISSN 1897-3310. Vol. 12, issue 1, (2012), s. 87-92.

[13] MICHNA, Š. – NÁPRSTKOVÁ, N.: Research into the causes cracking of aluminium alloys of Al – Cu during mechanical machining. In: Manufacturing Technology, volume 12, 2012, ISSN 1213-2489.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Stefan Michna.


4

Study of the gas content in aluminum alloys

Dana Bolibruchová, Lukáš Richtárech Department of Technological Engineering, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26, Slovak Republic, Email: [email protected]

This article deals with the gas content of aluminum alloys and prediction of gas content using the foundry simulation software. In the theoretical section summarizes the main causes of gas content of aluminum alloys, the effects of modifications and inoculation, as the survey gas content and the possibility of using simulation software for predicting the gas content. The experimental part is tested for gas content f the test castings and verificated by simulation program ProCAST. As an experimental alloy was used AlSi7Mg0,3. The specimens were evaluated using four methods: microscopically, macroscopically, using a stereomicroscope and by evaluating the density. This type of experiment was performed at the Department of Technological Engineering for the first time, simulation of the gas content and its verification by this method can be considered as a unique.

Keywords: gas content, porosity, simulation, aluminum alloys

Acknowledgements This project is solved under the financial support of VEGA number 1/0363/13 Authors would like to thank for their support.

References

[1] ROUČKA, J. (2004). Metallurgy of Non-ferrous alloys. Brno. 1. Edition. VUT Brno, 2004, 148 p. ISBN 80-214-2790-6.

[2] PEQUET, CH. - GREMAUD, M. - RAPPAZ, M. (2002). Modeling of Microporosity, Macroporosity, and Pipe-Shrinkage Formation during the Solidification of Alloys Using a Mushy-Zone Refinement Method: Applications to Aluminum Alloys. In Metallurgical and Materials Transactions. 2002, vol. 33A. p. 2095-2106.

[3] ROUČKA, J. et al. (2007). Influence of gas content and cooling rate on the structure, porosity and mechanical properties of castings made from AlSi9Cu3 alloy. In Technological Engineering. ISSN 1336-567. 2007, vol. 4. p. 25-28.

[4] CAMPBELL, J. (2003). Castings. 2. Edition. Oxford : Butterwort – Heinemann, 2003, 329 p. ISBN 0-7506-4790-6.

[5] SAMUEL, A.M, SAMUEL, F.H. (1992). Porosity Factor in Quality Aluminum Castings. In AFS Transactions. 1992, vol. 100, p.657-666

[6] http://www.esi-group.com/

[7] BRŮNA, M., SLÁDEK, A., KUCHARČÍK, L. (2012). Formation of porosity in Al-Si alloys. In Archives of foundry engineering. ISSN 1897 – 3310, 2012, volume 12, Issue 1/2012, p. 5-8.

[8] PASTIRČÁK, R., URGELA, D., BRŮNA, M. (2011). Infuence of various opening materials on the mechanical properties and dilatation of moulding mixtures. In International foundry research: official journal of the World Foundry Organization. ISSN 0046-5933. Vol. 63, no. 4 (2011), pp. 2-6.

[9] MICHALCOVÁ, A., VOJTĚCH, D. (2012). Structure of rapidly solidified aluminium alloys. In Manufacturing Technology. ISSN 1213-2489. vol. 12, p.166-169.

[10] LIPIŃSKI, T. (2011). Use Properties of the AlSi9Mg Alloy With Exothermical Modifier. In Manufacturing Technology. ISSN 1213-2489. vol. 11, p. 44-49.

[11] JAVOŘÍK, J. 2003. Využití metody konecných prvku pro materiýlovou analýzu nekovových materiálu. In Strojírenská technologie. ISSN 1211-4162. vol. 8, p. 12-16.

[12] HAUPTVOGEL, J., JANDEČKA, K. (2006). Využiti metod FEM při modelovani procesů v technologii. In Strojírenská technologie. ISSN 1211-4162. vol. 11. p. 17-19.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Stefan Michna.


5

The Simulation of Influence of Quenching Temperature on Properties of Bearing Rings

Martin Brezničan1, Peter Fabian1, Jozef Meško1, Mário Drbúl2

1 Department of Technological Engineering, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic. [email protected] 2 Department of Machining and Manufacturing Technology, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic.

Roller bearings are a very important part of modern machineries and equipments. They have a significant impact on the smooth running, reliable performance and durability. Replacing worn or damaged roller bearings often require extensive disassembly of the machine and the costs often exceed the price of the replaced bearings. There is an influence of the correct bearing construction and dimensional accuracy on the durability, but the grade and quality of used steel and its heat treatment are very important, too. Tempering is an important chapter. Tempering has the effect to modifying the properties of martensite after quenching and transformation of residual austenite, which is related to the change of bearing rings dimensions, growth, roundness and hardness. Decrease in hardness of bearing steel is associated with a reduction in the basic dynamic load rating of rolling bearings and thus durability. In this article there is analysed the influence of quenching and tempering on their mechanical properties after heat treatment. There was also used simulation software to verify the possibility of modeling of bearing rings quenching.

Keywords: bearing rings, 100Cr6 steel, quenching, tempering, simulations

Acknowledgement

The experimental works and measurements were made with the help of Ministry of Education of the Slovak republic, grants VEGA no. 1/0186/09 and KEGA no. 054ŽU-4/2012 – responsible researcher: Prof. Jozef Meško, MSc., PhD.

References

[1] BESWICK, J. (2002): Bearing Steel Technology, ASTM, West Conshohocken.

[2] DURAND-CHARRE, M. (2004). Microstructure of Steels and Cast Irons. Berlín: Springer-Verlag Berlin Heidelberg New York. 399 p. ISBN 978-3-540-20963-8

[3] HAKAN GŰR, C., PAN, J. (2008). Handbook of Thermal Process Modeling of Steels. pp. 342 – 380, Taylor & Francis Group LLC, Boca Raton.

[4] KANG, S. H. – IM, Y. T. (2007). Thermo-elasto-plastic finite elements analysis of quenching process of carbon steel. Journal of Materials Processing Technology, No. 192 – 193, pp. 381 – 390.

[5] JERSÁK, J., et al. (2009). The Integrity of the Surface after Milling of Quenched Bearing Steel. Manufacturing Technology, No. 4. pp. 13 - 20. ISSN 1211-4162.

[6] LLEWELLYN D. T., HUDD, R. C (1998). Steels: Metallurgy and Applications. 3rd edition. Oxford: Butterworth-Heinemann, 1998. 389 p. ISBN 0-7506-3757-9

[7] MARTIENSSEN, W., WARLIMONT, H. (2005). Springer Handbook of Condensed Matter and Materials Data. Berlin: Springer-Verlag Berlin Heidelberg, New York. 1120 p. ISBN 978-3-540-44376-6.

[8] PANDA, A. et al. (2011). Optimization of heat treatment bearing rings with goal to eliminate deformation of material. The Chemical Sheets, No. 16/2011, pp. 459 – 467.

[9] PEREZ, M et al. (2009). Microstructural evolution of martensitic 100Cr6 bearing steel during tempering. Acta Materialia, Vol. 57, No. 11, pp. 3171-3180.

[10] SKOČOVSKÝ, P. et al. (2000). Construction Materials. Žilina: EDIS, 2000. 338 p. ISBN 20-7100-608-4.

[11] TOTTEN, G. E., BATES, C. E., CLINTON, N. A. (1992). Handbook of Quenchants and Quenching Technology. ASM International.

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[13] VANDER VOORT, G. F. (1991). Atlas of time-temperature diagrams for irons and steels. ASM International.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Pavel Novak.


6

Complex evaluation of porosity in A356 aluminium alloy using advanced porosity module

Marek Brůna, Lukáš Kucharčík, Augustín Sládek Department of technological engineering, University Of Žilina, Univerzitná 1, 010 01 Žilina, Slovak Republic, [email protected]

In this work, the formation of porosity (micro, macro porosity and pipe shrinkage) has been examined under different casting conditions aimed at manipulating cooling rate and pouring temperature of aluminium alloy A356. The results of the experiment will attempt to verify that the solidification rate and pouring temperature have an effect on the formation and character of gas pores in castings from A356 alloy. For this purposes was used advanced porosity module integrated into simulation software ProCAST. Specific casting and mold was designed to be able observe porosity formation. Main aim was to choose the right shape, so all types of porosity occur during solidification. Top part of casting is optimized for creation of pipe shrinkage. Bottom part connected with top part through narrowed area (which will solidifies first and additional feeding will not be possible) is ideal for formation of internal micro and macroporosity.

Keywords: simulation, porosity, aluminum alloys

Acknowledgements

This work was created within the solution of the grant project VEGA no. 1/0610/12, VEGA no. 1/0785/13 focusing on technology and simulation for applications in manufacturing and KEGA no. 006ŽU-4/201. The authors thank the Grant Agency for support.

References

[1] CAMPBELL, J. (2003). Castings. Vol. 2, Butterworth – Heinemann, Oxford, pp. 242 – 255. ISBN 978-0750647908.

[2] HUANG, L.W., SHU, W.J., SHIH, T.S. (2000). Diagnosis and analysis of oxide films on alloys Al-Mg-Si. AFS Transactions, 108. Pp. 547 – 561.

[3] PASTIRČÁK, R., URGELA, D. (2010). Production of casting molds for computer-controlled basis. In: Quo vadis foundry III. Ecological aspects of metallurgy and foundry. Košice, HF TU Košice. Pp. 148-152. ISBN 978-80-553-0506-6.

[4] BRŮNA, M., SLÁDEK, A. (2011): New trends in numerical simulations for casting. In: Technológ: Journal for the theory and practice of mechanical technology. EDIS, Žilina. Pp. 27-30. ISSN 1337-8996.

[5] BRŮNA, M., BOLIBRUCHOVÁ, D. (2010). Analysis of the impact of the thickness of the filter medium on reoxidation processes using computer simulation. In: Quo vadis foundry III. Ecological aspects of metallurgy and foundry. Košice, HF TU Košice. Pp. 28 – 34. ISBN 978-80-553-0506-6.

[6] PASTIRČÁK, R., URGELA, D. (2011). Device for production of prototype moulds by milling. In: Archives of foundry engineering, 2011, Vol. 11, Spec. Issue 1. pp. 45-50. ISSN 1897-3310

[7] BOLIBRUCHOVÁ, D. (2012). Properties, production, and industrial application of aluminium foam. In: Technológ: časopis pre teóriu a prax mechanických technológií, issue. 2. Pp. 111-116. ISSN 1337-8996.

[8] MEDLEN, D., BOLIBRUCHOVÁ, D. (2012). The influence of remelting on the properties of AlSi6Cu4 alloy modified by antimony. In: Archives of foundry Engineering, January-march. Pp. 81-86, vol. 12. ISSN 1897-3310.

[9] KANTORÍK, R., BOLIBRUCHOVÁ, D. (2011). Free melt surface monitoring with the help of metal flow simulation in moulds. In: International Foundry Research. Vol. 63, issue 2. Pp. 18 – 23. ISSN 0046-5933.

[10] SLÁDEK, A., BOLIBRUCHOVÁ, D., PASTIRČÁK, R., VAŠKO, I. (2010). The influence of antimony on the properties of AlSi7Mg0.3 alloy. In: Proceedings of 69th world foundry congress: Hangzhou China. Pp 261 – 266.

[11] WEISS, V., STRIHAVKOVA, E. (2012). Influence of the homogenization annealing on microstructure and mechanical properties of AlZn5.5Mg2.5Cu1.5 alloy. In: Manufacturing Technology, Volume 12, pp. 297 – 302. ISSN 1213-2489.

[12] MICHALCOVÁ, A., VOJTECH, D. (2012). Structure of rapidly solidified aluminium alloys. In: Manufacturing Technology, Volume 12, pp. 166 – 169. ISSN 1213-2489.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Iveta Vaskova, Pavel Novak.


7

Influence of repeated remelting of the alloy RR.350 on structure and thermo-mechanical properties

Marek Břuska, Petr Lichý, Michal Cagala, Jaroslav Beňo VŠB-TU Ostrava, FMMI, Department of metallurgy and foundry, 17. listopadu 15/2172, CZ 708 33, Ostrava-Poruba, Czech Republic, [email protected]

This research investigates the influence of repeated use of the Al-Cu-based alloy. In our case we used the alloy RR.350. Specimens for the tensile test were cast into a metallic mould, to which a protective coating was applied. Altogether 15 specimens were prepared from each melt in order to obtain more accurate results. During casting the temperature of metal and mould was controlled from the viewpoint of ensuring constant conditions of the experiment. Test bars were prepared from the cast specimens for measurement of tensile strength at normal (20°C) and elevated temperatures (up to 350°C). Furthermore parts were taken from the cast specimens for measurement of hardness (HB) and for metallographic analysis. Thermo-mechanical properties of the investigated alloy were determined at the working site of the authors – Department of Metallurgy and Foundry at the Faculty of Metallurgy and Materials Engineering, VŠB - Technical University of Ostrava. This experiment has unequivocally confirmed the negative effect of repeated use of the investigated alloy on its thermo-mechanical and structural properties.

Keywords: Tensile test, thermo-mechanical properties, metallic mould

Acknowledgments The paper was prepared under financial support of TAČR (TA02011333 - Physical and metallurgical aspects of

preparation of cast metallic foams from iron alloys and alloys of non-ferrous metals) and the project of specific research of VŠB-TU Ostrava SP2013/62 and RMSTC (Regional Materials Science and Technology Centre at the VŠB-TU Ostrava – CZ.1.05/2.1.00/01.0040).

References

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[3] WEISS, V., STRIHAVKOVA, E. (2012). Influence of the homogenization annealing on microstructure and mechanical properties of AlZn5,5Mg2,5Cu1,5 alloy, Manufacturing Technology, Vol. 12, No. 13, pp. 297 – 302, ISSN 1213-2489.

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[6] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., ĎURINÍKOVÁ, E. (2011). Quality control of microstructure in recycled Al-Si cast alloys, Manufacturing Technology, Vol. 11, No. 11, pp. 70 - 76, ISSN 1213 - 2489.

[7] PÍŠEK, F., JENÍČEK, L., RYŠ, P. (1973). Material science I, Metal science, Textbook, Vol. 3, Non-ferrous metals, 595 pp. Academia, Praha.

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[10] KOŘENÝ, R. (1991). Possibilities of enhancement of quality of high-strength and refractory foundry aluminium alloys, Textbook, VŠB, Ostrava.

[11] BIROL, Y. (2012). Performance of AlTi5B1, AlTi3B3 and AlB3 master alloys in refining grain structure of aluminium foundry alloys. Materials Science and Technology, Vol. 28, No. 4, pp. 481-486.

[12] NAGLIĆ, I., SMOLEJ, A., DOBERŠEK, M. (2009). The influence of alloying elements in aluminium on the grain refinement with AlTi5B1. Metalurgija, Vol. 48, No. 3, pp. 147-150.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Dana Bolibruchova, Milan Brozek.


8

Influence of returning material on porosity of die castings

Ľubomír Eperješi, Jozef Malik, Štefan Eperješi, Daniel Fecko Technicla University of Kosice. E-mail: [email protected]

With increasing tendency of die castings production, also the possibility to produce castings with maximum usage of molten metal grows. Residual of non-used molten metal, e.g. sprues, feeders, splashes and saw-dusts are used in next production as returning material. With returning material a lot of non-suitable elements is brought into the melting process, but with decreasing of input costs it creates inseparable part of production process. Usage of returning material in melt production has negative influence on final quality of produced castings, because of bringing of inheritable properties into produced melt. Important factor in melt production with the amount of returning material is to know to set its optimal amount and the way of melt treatment to achieve the same results in casting quality in comparison to the casting production from clean materials.

Keywords: returning material, porosity, die casting, casting

References:

[1] MALIK, J. (2008). Technology of pressure die casting of aluminium alloys, Inaugural dissertation, Košice.

[2] ĽONC, D. (2008). Suggest a process for using recycled material from aluminum alloys for die casting technology, diploma thesis, Košice.

[3] MALIK, J., FUTÁŠ, P., VASKOVÁ, I. (2009). Recycled material in die casting technology, Slévarenství, březen – april.

[4] RAGAN, E., PAVEL, J., FEDÁK, M. (2008). Trvanlivosť foriem a ďalších častí strojov pre liatie pod tlakom vzhľadom na styk s kvapalným kovom, Nové smery vo výrobných technológiach, Prešov, jún 2008.

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[6] GAŠPÁR, Š.; PAŠKO, J.; MALIK, J.; PANDA, A.; JURKO, J.; MAŠČENIK, J. (2012). Dependence of Pressure Die Casting Quality on Die Casting Plunger Velocity Inside a Filling Chamber of a Pressure Die Casting Machine , Advanced Science Letters. Vol. 14, no. 1.

[7] GAŠPÁR, Š.; MAŠČENIK, J. (2011). Kvalitatívne vlastnosti tlakových odliatkov určených pre automobilový priemysel v závislosti na zmene dotlaku; Automobil Industry. Vol. 7, no. 2., p. 18-21.

[8] TUREKOVÁ,I.;KURACINA,R.;BALOG,K.;MARTINKA,J.: (2012). Technologické a prírodné havárie. - 1. vyd. - Trnava : AlumniPress, 2012, 232 s. - e-skriptá. - ISBN 978-80-8096-154-1.

[9] GAŠPÁR, Š.; PAŠKO, J.; KULIK, V. (2012). Analysis of increased pressure effect on internal homogeneity of pressure die castings , Kvalita a spoľahlivosť technických systémov: zborník vedeckých prác : 22. - 23.5.2012, Nitra. - Nitra: SPU, 2012 S. 129-133. - ISBN 978-80-552-0798-8.

[10] GONOS, J. (2009). Analýza dlhodobej likvidity podniku; 2009. In: Acta Montanistica Slovaca. Roč. 14, č. 1 (2009), s.82-85. – ISSN 1335-1788.

[11] TILLOVÁ E., CHALUPOVÁ M., HURTALOVÁ L., ĎURINÍKOVÁ E. (2011). Quality control of microstructure in recycled Al-Si cast alloys; In: Manufacturing Technology, December 11, 70-76, ISSN: 1213-2489.

[12] PAŠKO J. (2010). Die Casting Plunger Pressing Velocity and Analysis of Its Influence on a Permanent Deformation Value of a Casting Made from an EN AC 47100 Alloy; In: Manufacturing Technology, December 10, 23-26, ISSN: 1213-2489.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Augustin Sladek, Miroslav Muller.


9

Using of Thermal Analysis in the Industrial Practice – Consumption Reduction of Grain-Refinement Master Alloy and Optimization of Computer Simulation Results

Marko Grzincic1), Mile Djurdjevic2), Florian Dirnberger3)

1) Process Engineering, Nemak Slovakia Ltd., Ladomerská Vieska 394, 965 01 Žiar nad Hronom, Slovakia, [email protected] 2) Product Development Center, Nemak Linz Ltd., Zeppelinstrasse 24, 4030 Linz, Austria, [email protected] 3) Process Engineering, Nemak Linz Ltd., Zeppelinstrasse 24, 4030 Linz, Austria, [email protected]

The solidification process of a metal or alloy is accompanied by the evolution of heat the magnitude of which depends on the various phases that form during the solidification. Recorded temperature-time data can yield quantitative information about the alloy solidification process. Such a plot is called a cooling curve and the general name given to the technique is thermal analysis. The cooling curve serves as a “finger print” of the solidification process and can be used to predict the structure of the test sample and consequently the actual casting. The aim of this paper is to show the ability of the thermal analysis technique in order to predict some of the key solidification parameters, which can be used to monitor and improve the quality of the casting. In addition, some of the results collected from the cooling curve can be used as an input data in existing software packages in order to improve their accuracy.

Keywords: thermal analysis, cooling curve analysis, grain-refinement, master alloy AlTi5B1, dendrite coherency point

References

[1] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., ĎURINIKOVÁ, E: Quality control of microstructure in recycled Al-Si cast alloys. Manufacturing Technology, 11, No. 12 - 2011, p. 70 – 76.

[2] BÄCKERUD, L., CHAI, G., TAMMINEN, J.: Solidification Characteristics of Aluminum alloys. Volume 2. AFS-SKANALUMINIUM, 1986, p. 95-105.

[3] Cibula, A.: The Mechanism of Grain Refinement of Sand Castings in Aluminum Alloys. J. Ins. Metals vol. 76, p. 312.

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[5] MURTY, B. S., KORI, S. A. AND CHAKRABORTY M.: Grain Refinement of Aluminum and its Alloys by Heterogeneous Nucleation and Alloying. International Materials Reviews, Vol. 47, No. 1, p. 3-29, 2002.

[6] KASHYAP, K. T. AND CHANDRASHEKAR, T.: Effects and Mechanisms of Grain Refinement in Aluminum Alloys. Bull. Mater. Sci. Vol. 24, No. 4, August 2001, p. 345-353.

[7] JOHNSSON, M.: Grain Refinement of Aluminum Studied by Use of a Thermal Analytical Technique. Thermochimica Acta 256, 1995, p. 107-121.

[8] EASTON, M. A. AND STJOHNS, D. H.: A Model of Grain Refinement Incorporating Alloy Constitution and Potency of Heterogeneous Nucleant Particles. Acta Materialia, 49, 2001, p. 1867-1878.

[9] PASCIAK, K. J. AND SIGWORTH, G. K.: Role of Alloy Composition in Grain Refining Aluminum 319 Alloy. AFS Transactions, p. 329-338.

[10] SIGWORTH, G. K. AND GUZOWSKI, M. M.: Grain Refining of Hypo-Eutectic Al-Si Alloys. AFS Transactions, Vol. 93, 1985, p. 907-912.

[11] DIRNBERGER, F.: Einfluss der Begleitelemente auf die Wirkung von Kornfeinung und Veredelung in der Legierung G-AlSi8Cu3. Diploma work, Fachhochschule Oberösterreich, Wels, Austria, November 2009.

[12] CAMPBELL, J.: Feeding Mechanisms in Castings. AFS Cast Metal Research Journal, 1969, p. 1-8.

[13] CHAI, G.: Dendrite Coherency During Equiaxed Solidification in Aluminum Alloys. Chemical Communications. No. 1, Stockholm University, Stockholm, Sweden 1994.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Augustin Sladek.


10

Elimination of the negative effect of Fe-rich intermetallic phases in secondary (recycled) aluminium cast alloy

Lenka Hurtalová, Eva Tillová University of Žilina, Faculty of Mechanical Engineering, Department of Materials Engineering, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic. [email protected]; [email protected]

Improved mechanical properties of secondary alloys are strongly dependent upon the morphologies, type and distribution of the second phases, which are in turn a function of alloy composition and cooling rate. In Al-Si-Cu type alloys, however, Fe showed to have the most detrimental effect on ductility of all of the common impurities. Iron impurities can either come from the original bauxite ore or be acquired during subsequent melting, remelting and casting, e.g. by contamination from the melting pot etc. The shape of iron compounds is more influential than the quantity of those iron compounds. Therefore was used heat treatment of experimental material that consisted of solution treatment for 2, 4, 8, 16 or 32 hours at temperatures 515 and 525 °C; water quenching at 40 °C and natural aging for 24 hours at room temperature. In that smaller cooling rate setting causes granular structure and lower values of mechanical properties by casting into the sand moulds (sand casting) and higher cooling rate setting causes fine-grained structure and higher values of mechanical properties by casting into the metallic moulds (chill casting), were used AlSi9Cu3 cast alloy cast in to the sand and the metallic moulds.

Keywords: sand casting, chill casting, secondary aluminium alloys, heat treatment, Fe-rich phases

Acknowledgement This work has been supported by Scientific Grant Agency of Ministry of Education of Slovak republic and Slovak Academy of Sciences, No 1/0841/11, No 1/0460/11 and the Project EÚ: The competence Centrum for industrial research and development in the field of light metals and composites - ITMS: 26220220154.

References

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[2] SEIFEDDINE, S. (2007). The influence of Iron on the microstructure and mechanical properties of cast Al-Si alloys, Literature review, Vilmer project - 5.2 casting, Sweden.

[3] BLAŠČÍK F. et al. (1988). Technológia tvárnenia, zlievarenstva a zvárania. Bratislava (in Slovak)

[4] MAE, H. et al. (2008). Comparison of ductile fracture properties of aluminium casting: Sand mold vs. metal mold. International Journal of Solids and Structures, Vol. 45, pp. 1430-1444.

[5] NADELLA, R., ESKIN, G. D., DU, Q., KATGERMAN, L. (2008). Macrosegregation in direct-chill casting of aluminium alloys. Progress in Materials Science, Vol. 53, pp. 421-480.

[6] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L. (2011). Evolution of phases in a recycled Al-Si cast alloy during solution treatment. The Scaning Electron Microscope. INTECH, pp. 411-438.

[7] TAYLOR, J. A. (2004). The effect of iron in Al-Si casting alloys, 35th Australian Foundry Institute National Conference, Adelaide, South Australia, pp. 148-157.

[8] TILLOVÁ, E. et al. (2011). Quality control of microstructure in recycled Al-Si alloy. Journal for science, research and production, Manufacturing Technology, Vol. 11, No. 11, pp. 70-76.

[9] ĎURINÍKOVÁ, E., TILLOVÁ, E. (2011). Phase and structure characteristics of recycled AlZn10Si8Mg cast alloy. Journal for science, research and production, Manufacturing Technology, Vol. 11, No. 11, pp. 70-76.

[10] HURTALOVÁ, L. et al. (2012). Changes in structural characteristics of hypoeutectic al-Si cast alloy after age hardening. Materials science (Medžiagotyra), Vol. 18, No. 3, pp. 228- 233.

[11] HURTALOVÁ, L. et al. (2012). Effect of chemical composition of secondary Al-Si cast alloy on intermetallic phases. MTM - Machines technologies materials, International virtual journal, Issue 9, Y. 6, pp. 11-14.

[12] WEISS, V. (2011). Influence of the casting mould on surface and structure duality of the AlZn5.5Mg2.5Cu1.5 alloy. Slévarenství, Foundry Industry Journal, Vol. 7-8, pp. 216-218.

[13] SAMUEL, A. M., SAMUEL, F. H., DOTY, H. W. (1996). Observations on the formation of β-Al5FeSi phase in


11

319 type Al-Si alloys. Journal of Materials Science, Vol. 31, pp. 5529-5539

[14] MA Z. et al. (2008). A study of tensile properties in Al-Si-Cu and Al-Si-Mg alloys: Effect of β-iron intermetallics and porosity. Materials Science and Engineering, A 490, pp. 36-51

[15] SEIFEDDINE, S., JOHANSSON, S., SVENSSON, I. (2008). The influence of cooling rate and manganese content on the β-Al5FeSi phase formation and mechanical properties of Al-Si based alloys. Materials Science and Engineering, A 490, pp. 385-390.

[16] KIM, H. Y. et al. (2006). Effects of Mn on the crystal structure of α-Al(Mn,Fe)Si particles in A356 alloys. Journal of Crystal Growth, Vol. 291, pp. 207-211.

[17] MOUSTAFA, M. A. et al. (2003). Effect of solution heat treatment and additives on the microstructure of Al-Si (A413.1) automotive alloys. Journal of Materials Science, Vol. 38, pp. 4507-4522.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Iveta Vaskova, Iva Nova.


12

Impact Analysis of Mutual Rotation of Roller Bearing Rings on the Process of Contact Stresses in Rolling Elements

Lenka Jakubovičová, Milan Sága, Milan Vaško Department of Applied Mechanics, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovak Republic. {lenka.jakubovicova, milan.saga, milan.vasko}@fstroj.uniza.sk

Purpose of this paper is to present the magnitude of the impact of roller bearing rings mutual slewing to the process of contact stresses in rolling elements. The roller bearing satisfies prescribed basic static load rating if it is loaded by the maximum specified load only in the radial direction according to the ISO/TS 16281. However, the real roller bearings are not loaded only in the radial direction in practice. During operation there is mutual slewing of the bearing roller rings. This leads to a change in the conditions of contact and to a change in contact stresses. Stress state will be evaluated in the most loaded element of the roller bearing. Equivalent stress will evaluated according to the theory of HMH, stresses P1 to P3 at gradual slewing of the roller bearing rings, angle ϕϕϕϕ from 0′′′′ to 8′′′′. For the analysis of this problem was used the finite-element program ADINA.

Keywords: computational analysis, stress analysis, roller bearing, Hertz contact stresses, ADINA

Acknowledgements

This work has been supported by VEGA grant No. 1/1089/11 and KEGA grant No. 004ŽU-4/2012.

We support research activities in Slovakia / The project is co-financed by the European Union.

This contribution is the result of the project implementation: Development of optimum technology for the analysis of limit states of structural elements in contact, ITMS code 26220220118, supported by the Research & Development Operational Programme funded by the ERDF.

References

[1] BATHE, K. J. (1982). Finite Element Procedures. New Jersey, Prentice Hall, 1982. ISBN 0–13–301456–4.

[2] HILLS, D. A., NOWELL, D. AND SACKFIELD, A. (1993). Mechanics of Elastic Contacts. Butterworth & Heinemann, Oxford. ISBN 0–7506–0540–5.

[3] JAEGER, J. (2005). New Solutions in Contact Mechanics. WIT Press, Southampton, Boston. ISBN 1–85312–994–1.

[4] JAKUBOVIČOVÁ, L., VAŠKO, M., KOMPIŠ, V. (2003). Trefftz Functions Using the Fundamental Solution with the Singularity Outside the Domain. In Computer Assisted Mechanics and Engineering Sciences. 2003, Vol. 10, No. 4, p. 515–521. ISSN 1232–308X.

[5] JOHNSON, K. L. (1985). Contacts Mechanics. Cambridge University Press, Cambridge. ISBN 0–521–25576–7.

[6] KRYNKE, M., SELEJDAK, J., BORKOWSKI, S. (2012). Diagnosis and Damage of Bearings. In Manufacturing Technology. 2012, Vol. 12, No. 13, p. 140–144. ISSN 1213–2489.

[7] NOVÝ, F., ČINČALA, M., KOPAS, P., BOKŮVKA, O. (2007). Mechanisms of High-strength Structural Materials Fatigue Failure in Ultra-wide Life Region. In Materials Science and Engineering A. 2007, Vol. 462, No. 1-2, pp. 189–192. ISSN 0921–5093.

[8] SÁGA, M., VAŠKO, M. (2009). Stress Sensitivity Analysis of the Beam and Shell Finite Elements. In Communications. 2009, Vol. 11, No. 2, pp. 5–12. ISSN 1335–4205.

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[10] SLÁDEK, A., FABIAN, P., PASTIRČÁK, R., BREZNIČAN, M. (2012). The Roundness and Microstructure of Thin-wall Bearing Rings. In Manufacturing Technology. 2012, Vol. 12, No. 13, p. 237–241. ISSN 1213–2489.

[11] VAŠKO, A. (2007). Image Analysis in Materials Engineering. In: Konferencje, Poland. 2007, No. 61, pp. 667-


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670. ISSN 1234-9895.

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[13] British/International Standard BS ISO/281 (2007). Rolling bearings – Dynamic load ratings and rating life.

[14] Technical specification ISO/TS 16281 (2008). Rolling bearings – Methods for calculating the modified reference rating life for universally loaded bearings.

[15] http://www.tribology-abc.com/calculators/e2_3.htm


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Jiri Hruby, Karol Vasilko.


14

Experimental evaluation of the new lance for powder injection

Jan Jezierski, Krzysztof Janerka Department of Foundry, Silesian University of Technology, 7 Towarowa, 44-100 Gliwice, Poland, [email protected], [email protected]

The paper presents the results of the evaluation experiments of the new lance for powder injection process. The pneumatic powder injection process itself has been well known since many years and it can be operated both with submerged and non-submerged lance. The new invented by authors injection lance is dedicated for processes without its submersion especially when the powders are injected into liquid metal bath inside the ladles or induction crucible furnaces. In these cases it is important to not introduce the carrier gas into metal volume to make the temperature decrease as low as possible. However, when the lance is not submerged the problem with particles jet introduction into liquid metal with proper distribution appears. The new lance of special design with slots and flange at the outlet was checked both in model water experiments and real conditions for ferroalloys injection into liquid cast grey iron. The results proved the efficiency of the powder introduction and low liquid alloy temperature decrease, too.

Keywords: powder injection, injection lance, cast iron production, alloying, induction furnace

Acknowledgements This research project was financed from support funds for science during 2010-2013.

References

[1] SZAJNAR, J., WRÓBEL, T. (2008). Inoculation of pure aluminum with an electromagnetic field. Journal of Manufacturing Processes, Vol. 10, No. 2, pp. 74 – 81.

[2] SZAJNAR, J., WRÓBEL, T. (2008). Influence of magnetic field and inoculation on size reduction in pure aluminium structure. International Journal of Materials and Product Technology, Vol. 33, No. 3, pp. 322 – 334.

[3] WRÓBEL, T. (2011). Review of inoculation methods of pure aluminium primary structure. Archives of Materials Science and Engineering, Vol. 50, No. 2, pp. 110 – 119.

[4] LIM, Y.-P. (2005). Grain refinement of LM6 Al-Si alloy sand castings to enhance mechanical properties. Journal of Materials Processing Technology, Vol 162-163, pp. 435-441.

[5] GREGER, M., WIDOMSKÁ, M. (2011). Analysis of influence of structure on mechanical properties of AlSiMg aluminium alloy processed by ECAP. Manufacturing Technology, Vol. 11, No. 11, pp. 17-22.

[6] KOVÁC, I., ŽARNOVSKÝ, J., DRLICKA, R., RUŽBARSKÝ, J. (2010). An improvement of tribological properties of boron alloyed layers. Manufacturing Technology, Vol. X, pp. 78-80.

[7] JANERKA, K., BARTOCHA, D., SZAJNAR, J., JEZIERSKI, J. (2010). The carburizer influence on the crystallization process and the microstructure of synthetic cast iron. Archives of Metallurgy and Materials, Vol. 55, No. 3, pp. 851 – 859.

[8] JANERKA, K., BARTOCHA, D., JEZIERSKI, J., SZAJNAR, J. (2010). The effect of the carburiser quality on the cast iron recarburisation process. Foundry Trade Journal International, Vol. 184, No. 3679, pp. 282 – 286.

[9] SCHEEPERS, E., EKSTEEN, J.J., ALDRICH, C. (2006). Optimisation of the lance injection desulphurisation of molten iron using dynamic modeling. Minerals Engineering, Vol. 19, pp. 1163 – 1173.

[10] LIMMANEEVICHITR, C., EIDHED, W. (2003). Novel technique for grain refinement in aluminum casting by Al-Ti-B powder injection. Materials Science and Engineering, Vol. A355, pp. 174 – 179.

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metali. Patent RP 206 465 Int. Cl. F27D 3/18.

[15] JEZIERSKI, J., SZAJNAR, J. (2007). Relationship between stream forces and parameters of the powder injection into liquid metal bath. Archives of Materials Science and Engineering, Vol. 28, No. 4, pp. 238 – 245.

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[17] JEZIERSKI, J., SZAJNAR, J. (2006). Method and new lance for powder injection into liquid alloys. Journal of Achievements in Materials and Manufacturing Engineering, Vol. 17, No.1/2, pp. 349 – 352.

[18] JEZIERSKI, J., JANERKA, K. (2013). Two-phase jet in process of pneumatic powder injection into liquid alloy. Advanced Materials Research, Vols. 622-623, pp. 447-451. DOI: 10.4028/www.scientific.net/AMR.622-623.447.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Libuse Sykorova.


16

In-phase multiaxial fatigue experimental analysis of welded cylindrical 6063-T66 aluminium alloy specimens

Peter Kopas, Milan Sága Department of Applied Mechanics, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 010 26 Žilina, Slovak Republic. [email protected], [email protected]

This paper is concerned with an experimental and numerical study of the fatigue behaviour of cylindrical 6063-T66 welded specimens subjected to biaxial loading. In-phase torsion-bending fatigue tests under constant amplitude loading were performed in a standard electromechanical machine with a suitable gripping system. The experimental part was focused on the modeling of combined biaxial loading and determining the number of cycles to fracture in the region of low-cycle fatigue. In-phase loading can be treated fairly well using the conventional hypotheses (von Mises or Tresca) on basis of the nominal, structural or local strains or stresses. Based on the experimental results the fatigue design curves are compared to the fatigue data from base metal and weldments.

Keywords: multiaxial fatigue, computational analysis, experimental analysis, aluminium alloy, welding

Acknowledgements This work has been supported by VEGA grant No. 1/1089/11 and KEGA grant No. 004ŽU-4/2012. The authors gratefully acknowledge this support.

References

[1] BANNANTINE, J. A., SOCIE, D. F., (1992). A multiaxial fatigue life estimation technique. In: Advances in Fatigue Lifetime Predictive Techniques, ASTM STP 1122. Eds: M. R. Mitchell a R. W. Landgraf. Philadelphia, American Society for Testing and Materials, pp. 249-275.

[2] ROSENBERG, G., JUHAR, Ľ. (2012). Fatigue resistance of dual phase steels in presence of microstructural inhomogeneities. Manufacturing Technology 2012, Vol. 12, No. 13, pp. 217-221, ISSN 1213-2489

[3] BATHE, K. J. (1982). Finite Element Procedures. New Jersey, Prentice Hall, 1982.

[4] CHEN, H., SHANG, D. G., TIAN, Y. J., LIU, J.-Z. (2011). Comparison of multiaxial fatigue damage models under variable amplitude loading. Journal of Mechanical Science and Technology 26 (11), pp. 3439-3446.

[5] JAKUBOVIČOVÁ, L., VAŠKO, M., KOMPIŠ, V. (2003). Trefftz Functions Using the Fundamental Solution with the Singularity Outside the Domain. In Computer Assisted Mechanics and Engineering Sciences. 2003, Vol. 10, No. 4, p. 515-521. ISSN 1232-308X.

[6] LI, J., ZHANG, Z., SUN, Q., LI, C. Low-cycle fatigue life prediction of various metallic materials under multiaxial loading. Fatigue and Fracture of Engineering Materials and Structures 34 (4), pp. 280-290.

[7] MADDOX, S. J., 1991. Fatigue strength of welded structures, Second Edition, Woodhead Publishing, UK, ISBN 978-1855730137.

[8] MATHERS, G., 2002. The welding of aluminium and its alloys. Published by Woodhead Publishing Limited, Abington Hall, Abington Cambridge CB1 6AH, England, ISBN 0-8493-1551-4.

[9] KALINCOVA, D. (2012). Analysis of welded joint of band-saw blade – influence of annealing process mechanical properties. Manufacturing Technology 2012, Vol. 12, No. 13, pp. 125-131, ISSN 1213-2489.

[10] PODREZ-RADZISZEWSKA M.: Weldability problems of the technical AW7020 alloy. Manufacturing Technology 2011, Vol. 9, No. 11, pp. 59-66, ISSN 1213-2489.

[11] SÁGA, M., KOPAS, P., VAŠKO, M.: Some computational aspects of vehicle shell frames optimization subjected to fatigue life. Communications. Vol. 12, No. 4, 2010, pp. 73-79, ISSN 1335-4205.

[12] SAPIETOVÁ, A., DEKÝŠ, V., VAŠKO, M. (2010). A numerical model of rotating machine having unbalance and the measurements of its dynamical properties. Metalurgija (Metalurgy) 2010, No. 2, Vol. 49, pp. 503-507, ISSN 0543-5846.

[13] SUSMEL, L., ASKES, H. Modified Wöhler Curve Method and multiaxial fatigue assessment of thin welded joints. International Journal of Fatigue 43, pp. 30-42.

[14] TREBUŇA, F., BURŠAK, M. (2002). Medzné stavy, lomy. Grafotlač, Prešov 2002. ISBN 807165-362-4.


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[15] ZHANG, D., WANG, Y. Experimental investigation on fatigue damage rule of LY12CZ aluminum alloy under tension-torsion loading. Journal of Mechanical Strength 34 (5), pp. 772-776.

[16] ŽMINDÁK, M., RIECKY, D. (2012). Meshless Modelling of Laminate Mindlin Plates under Dynamic Loads. In Communications. 2012, Vol. 14, No. 3, pp. 24-31. ISSN 1335-4205.

[17] KOVANDA, K., HOLUB, L., KOLAŘIK, L., KOLAŘIKOVA, M., VONDROUŠ, P. (2012). Experimental Verification of FEM Simulation of GMAW Bead on Plate Welding. Manufacturing Technology 2012, Vol. 12, No. 12, pp. 30-33, ISSN 1213-2489.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Dalibor Vojtech.


18

Inoculant Addition Effect on Thermomechanical and Thermophysical Properties of Mg-Sr Magnesium Alloy

Petr Lichý, Jaroslav Beňo, Michal Cagala Department of Metallurgy and Foundry, VSB – Technical University of Ostrava, 17. listopadu 15/2172, 708 33 Ostrava - Poruba, Czech Republic. [email protected]

Satisfactory tensile properties, even at elevated temperatures, are very important for thermally stressed parts in car structures (e.g. cylinder heads and engine blocks). This condition is satisfied also by magnesium-based alloys containing strontium and rare earth metals, which are very expensive, though. The presented paper deals with study of Mg-Sr-type magnesium alloy. To be specific, this is AJ62 alloy which belongs among developmentally new magnesium-based alloys. This alloy combines very good castability and heat resistance, moreover, this is cost-effectively available material. This paper is focused on this alloy structure refinement. Analysis of the acquired structure after an inoculant addition and its effect upon thermomechanical properties was performed. In term of safety of the use of this alloy for thermally stressed automotive parts, thermal dilatation tests of prepared specimens were carried out as well.

Keywords: Magnesium alloys, thermomechanical properties, microstructure, inoculation

Acknowledgement This work was elaborated within the frame of the research project TA02011333 (Technology Agency of the CR) and the internal project of VŠB-Technical university of Ostrava SP2013/62.

References

[1] MORDIKE, B. L.; EBERT, T. (2001). Magnesium properties - applications - potential. Materials Science and Engineering A, Vol. 30, No.1, pp. 37-45.

[2] DRAPALA, J.; KUCHAR, L.;TOMASEK, K.; TROJANOVA, Z. (2004). Magnesium, its alloys and Mg – admixture binary system. VŠB –TU Ostrava, 2004, 172 p. ISBN 80-248-0579-0.

[3] ROSKOSZ, S.; ADAMIEC, J.; BLOTNICKI, M. (2007) Influence of delivery state quality on microstructure and mechanical properties of as cast AZ91 Mg alloy. Archives of Foundry Engineering, Vol. 7, No. 1, pp. 143-146..

[4] VOJTECH, D., KUBASEK, J., VODEROVA, M. (2012). Structural, mechanical and in vitro corrosion characterization of as temporary biodegradable medical implants. Manufacturing Technology, Vol. 12, No. 13, pp. 292-296.

[5] ZHANG, W., SHEN, Y., PAN, H., LIN, K., LIU, X., DARVELL, B. W., HUANG, W. (2011). Effects of strontium in modified biomaterials. Acta Biomaterialia, Vol. 7, No. 2, pp. 800-808.

[6] STAIGER, M. P., PIETAK, A. M., HUADMAI, J., DIAS, G. (2006). Magnesium and its alloys as orthopedic biomaterials: A review. Biomaterials, Vol. 27, No. 9, pp. 1728-1734.

[7] KUBOTA, K., MABUCHI, M., HIGASHI, K. (1999). Processing and mechanical properties of fine-grained magnesium alloys. Journal of Materials Science, Vol. 34, No. 10, pp. 2255-2262.

[8] LEE, Y. C., DAHLE, A. K., STJOHN, D. H. (2000). The role of solute in grain refinement of magnesium. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, Vol. 31, No. 11, pp. 2895-2906.

[9] RALSTON, K. D., BIRBILIS, N. (2010). Effect of grain size on corrosion: A review. Corrosion, Vol. 66, No. 7, pp. 0750051-07500513.

[10] Zeng, X., Wang, Y., Ding, W., Luo, A. A., & Sachdev, A. K. (2006). Effect of strontium on the microstructure, mechanical properties, and fracture behavior of AZ31 magnesium alloy. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, Vol. 37, No. 4, pp. 1333-1341.

[11] YANG, M., PAN, F., CHENG, R., TANG, A. (2008). Effect of Mg-10Sr master alloy on grain refinement of AZ31 magnesium alloy. Materials Science and Engineering A, Vol. 491, No. 1-2, pp. 440-445.

[12] GREER, A. L., BUNN, A. M., TRONCHE, A., EVANS, P. V., BRISTOW, D. J. (2000). Modelling of inoculation of metallic melts: Application to grain refinement of aluminium by al-ti-B. Acta Materialia, Vol. 48, No. 11, pp. 2823-2835.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Dana Bolibruchova, Iveta Vaskova.


19

Modified hydrated sodium silicate as a modern binder for ecological moulding sands

Katarzyna Major-Gabryś, Stanisław M. Dobosz, Jarosław Jakubski AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-ferrous Metals, Al. A. Mickiewicza 30, 30-059 Krakow, Poland, [email protected]

This article is devoted to ecological moulding sands with hydrated sodium silicate as binder. The inorganic nature of the binder results in poor knock-out properties and low ability to mechanical reclamation of tested moulding sands. In the present study authors focused on developing a new addition to the composition of these environmental friendly foundry moulding sands, providing them better knock-out properties. The analysis of the literature data let authors focus on the use of additives containing Al2O3 as components of moulding sands with hydrated sodium silicate. These additives provide better knock-out properties of moulding sands measured according to retained strength Rc

tk and also lead to lower thermal expansion of moulding sands. The authors have developed a new supplement containing Al2O3 and demonstrated its positive impact on moulding sand with hydrated sodium silicate knock-out properties.

Keywords: moulding sand, hydrated sodium silicate, phase gamma Al2O3 (γ-Al2O3 phase), thermal expansion, knock-out properties

Acknowledgements Scientific research financed from AGH, No 11.11.170.318 – 3.

References

[1] DOBOSZ, ST.M., JELINEK, P., MAJOR-GABRYŚ, K. (2011). Development tendencies of moulding and core sands, China Foundry, Vol. 8, No. 4, pp. 438-446.

[2] MAJOR-GABRYŚ, K., DOBOSZ ST.M. (2007). High-temperature expansion and knock-out properties of moulding sands with water glass. Archives of Foundry Engineering. Vol. 7, No. 1, pp.127-130.

[3] DOBOSZ, ST.M., MAJOR-GABRYŚ, K. (2008). The mechanism of improving the knock-out properties of moulding sands with water glass. Archives of Foundry Engineering. Vol. 8, No. 1, pp.37-42.

[4] SYČEV, I.S.(1965). Polučenije lehkovybijernych smešej. Litejnoje Proizvodstvo, No. 6 pp. 31-37. (in Russian)

[5] JELINEK, P. (1968) Vliv Al2O3 na rozpadavost CT – smesi. Sbornik vedeckych praci Vysoke skoly banske v Ostrave, Vol. 14, No. 6, pp. 75-102. (in Czech)

[6] JELINEK, P. (2004). Pojivove soustavy slevarenskych formovacich smesi. (in Czech)

[7] LEVIN, E.M., ROBBINS, C.R., MCMURDIE, H.F. (1964). Phase Diagram for Ceramists, Columbus, Ohio, USA

[8] BIELAŃSKI A. (2002): Podstawy chemii nieorganicznej. Part 2. . Polish Scientific Publishers PWN. Warsaw. (in Polish)

[9] KOLDITZA, L. (1994). Inorganic Chemistry (Chemia nieorganiczna). Part 1. Polish Scientific Publishers PWN. Warsaw. (in Polish)

[10] PAGLIA, G. (2004). Determination of the Structure of γ-Alumina using Empirical and First Principles Calculations combined with Supporting Experiments. Faculty of Science. Department of Applied Physics and Department of Applied Chemistry. Curtin University of Technology.

[11] KRYUKOVA, G.N., KLENOV, D.O., IVANOVA, A.S., TSYBULYA, S.V. (2000). Vacancy ordering in the structure of γ-Al2O3. Journal of European Ceramic Society, No. 20, pp. 1187-1189.

[12] JAYARAM, V., LEVI, C.G. (1989). The structure of δ-alumina evolved from the melt and the γ - δ transformation. Acta Metallurgica, Vol. 37, No. 2, pp. 569-578.

[13] WANG, X., XU, X., CHOI, S.U.S. (1999). Thermal conductivity of nanoparticle–fluid mixture, Journal of Thermophysics and Heat Transfer, Vol.13, No. 4, pp. 474–480.

[14] LIPPENS, B.C., DE BOER, J.H. (1964). Study of phase transformations during calcination of aluminum hydroxides by selected area electron diffraction, Acta Crystallographica., Vol. 17, No. 10, pp. 1312-1321.

[15] STACHOWICZ, M., GRANAT, K., NOWAK, D. (2011). Influence of α-Al2O3 on residual strength of


20

microwave-hardened moulding sands with water-glass, Archives of Foundry Engineering, Vol. 11, No 2, pp. 203-208. (in Polish)

[16] CORBETT, J., RIEMER, O. (2004). Nanotechnology and Its Place in Modern Production, Manufacturing Technology, Vol. 4, October 2004, pp. 23-27.

[17] VOJTĚCH, D., MICHALCOVA, A., KNOTEK, V., MAREK, I. (2012). Study of nano-crystalline metals prepared by selective chemical leaching, Manufacturing Technology, Vol. 12, No 13, pp. 292-296.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Eva Tillova, Miroslav Muller.


21

Squeeze casting results of aluminium alloys

Iva Nová, Jiří Machuta Faculty of Mechanical Engineering, Department of Engineering Technology, Technical University of Liberec, Czech Republic, e-mail: [email protected], [email protected]

The paper deals with a squeeze casting process. This process added a new knowledge in to research in the branch by crystallization of aluminium alloys. Due to this purpose there was designed a special tool, which was placed on hydraulic press. The squeeze casting was carried out on an aluminium alloy (AlSi12, with 12 % silicon). The main aim was study of the aluminium alloy structure, which was established at a pressure of crystallizing melt. In this way of the material crystallization was produced a truncated cone part with the larger the base (∅∅∅∅ 100 mm x 105 mm). The structure of specimens was monitored on a light microscope and was evaluated by means of software NIS Elements. The main results of the pressure melt to fine crystalline structure, which is represented fine dendrites both on surface and in an interior parts of the processed material. The influence of this pressure on the mechanical properties was monitored too.

Keywords: alloy AlSi12, pressure, crystallization, structure

Acknowledgement This paper was supported by the project TUL SGS 2822.

References

[1] GHOMASHCHI, M. R. VIKHROV, A. (2000). Squeeze casting: an overview, J. Mater.Process. Technol. 101, pp. 1–9.

[2] MORTON, J. R., BARLOW, J. (1994). Squeeze casting: from a theory to profit and future, J. Inst. Brit. Foundryman, Part 1, 87, pp. 23–28.

[3] LEE, J. H., KIM, H.S. et al. (1999). Effect of die geometry on the microstructure of indirect squeeze cast and gravity die cast 5083 wrought Al alloy and numerical analysis of the cooling behavior, J. Mater. Process. Technol. 96 (1999), pp. 188–197.

[4] ROLALAND, T. et. al. (1993). Strain induced macrosegregation in Squeeze cast Al-Mg and Al-Si alloys. Materials Science and Engineering, A 173, 1993, pp. 267-270.

[5] YANG, L. J. (2003). The Effect of Casting temperature on the Properties of Squeeze Casting Aluminium and Zinc Alloys. Journal of Materials Processing Technology. Vol. 140, Iss.1-3, pp. 391- 396.

[6] YOUN, S. W., KANG, C, G. (2004). Thermal /Fluid Solidification Analysis of Automobile part by Horizontal Squeeze Casting Process and Experimental Evaluation. Journal of Materials Processing Technology. Vol. 146, Issue 3, 2004, pp. 294 - 302.

[7] MICHNA, Š. (2010). Legování hliníkových slitin pomocí chromových legovacích tablet. Strojírenská technologie, roč. XV, č. 1, pp. 22 -26, ISSN 1211-4162 (in Czech).

[8] Michna, Š, Vojtěch, D. (2008). Problematika kvality Al taveniny při lití automobilových disk. Strojírenská Technologie, roč. XIII, č. 3, pp. 17 – 23. ISSN 1211-4162 (in Czech).

[9] HAZLINGER, M. et. al. (2010). Degradačné procesy a predikcia životnosti materiálov. [Degradation processes and materials life prediction]. 1. vyd. Slovenská technická univerzita Bratislava, 2010 (in Slovak).

[10] LIPINSKI, T. (2011). Microstructure and Mechanical Properties of the AlSi13Mg1CuNi Alloy with Ecological modifier. In: Manufacturing Technology December 2011, Vol. 11, No. 11 pp. 40-44. ISSN 1213-2489.

[11] GREGER, M.,WIDOMSKÁ, M. (2011). Analysis of influence of structure on mechanical properties of AlSiMg aluminium alloy processed by ECAP. Manufacturing Technology XI, December 2011, Vol. 11, No. 11 pp. 17-22. ISSN 1213-2489.

[12] BORKOWSKI, S., STASIAK-BETLEJEVSKA, R., NÁPRSTKOVÁ, N. (2011). The Kaizen philosophy in the aluminium products improvement. In: Manufacturing Technology, December 2011, Vol. 11, No. 11 pp. 2-5. ISSN 1213-2489.


Manuscript of the paper received in 2012-09-08. The reviewer of this paper: Pavel Novak.


22

Finite Element Implementation of Multi-Pass Fillet Weld with Phase Changes

Pavol Novák, Jozef Meško, Milan Žmindák University of Žilina, Faculty of Mechanical Engineering, Department of Applied Mechanics, Univerzitná 1, 01026 Žilina. [email protected]

First, in this paper, a brief review of theoretical aspects of weld simulation and residual stress modelling using the finite element method (FEM) is presented. Thermo-elastic-plastic formulations using a von Mises yield criterion with nonlinear isotropic hardening has been employed. Residual stresses obtained from the analysis have been shown. The commercial FEM code ANSYS and a user created code were used for uncoupled thermal-mechanical analysis. Second, the aim of this paper is to compare ANSYS capabilities extended by authors to model weld phenomena versus well known SYSWELD code. Element birth and death FEM technique was used to simulate the weld metal added to base metal due the welding process and to reset plastic history for molten portion of material. Goldak’s double ellipsoid heat source was used to model welding heat source. The Leblond’s model was used to simulate ferritic and bainitic phase transformations and Koistinen - Marburger model was used to simulate martensitic transformation.

Keywords: phase changes, metallurgical transformations, residual stresses, finite element method.

Acknowledgement The work has been supported by the grant project KEGA No. 054 ŽU-4-2012 and VEGA 1/1259/12.

References

[1] GÜR, C. H., PAN, J., (2009).Hanbook of thermal process modelling of steel, Taylor & Francis Group, 2009.

[2] SÁGA, M., KOPAS, P., VAŠKO, M. (2010). Some Computational Aspects of Vehicle Shell Frames Optimization Subjected to Fatigue Life. Communications, Vol. 12, No. 4, pp. 73–79.

[3] MEŠKO, J., FABIAN, P., HOPKO, A., KOŇÁR, R. (2011). Shape of heat source in simulation program SYSWELD using different types of gases and welding methods. Strojírenská technologie, Vol. XVI, No. 5, pp. 6-11.

[4] CHOTEBORSKÝ, R., HRABĚ, P., NAVRÁTILOVÁ, M. (2009). Influence of Welding parameters on geometry of weld deposite bead. In: Proceedings of the International Scientific Conference, (M. Brožek, (Ed)), pp. 91-95, Czech University of Life Science, Prague.

[5] ŽMINDÁK, M., NOVÁK, P., MEŠKO, J. (2010), Numerical simulation of arc welding processes with metallurgical transformations, Metallurgy, Vol. 49, No.2, pp. 595-599.

[6] SATTARI-FAR. I., FARAHI, M.R. (2009). Effect of the weld groove shape and pass number on residual stress in butt-welded pipes, International journal of Pressure vessels and Piping Vol. 86, pp. 723-731.

[7] NOVÁK, P. (2010). Analysis of Residual stresses in welding joints, Ph.D. thesis, University of Žilina, Žilina, (in Slovak).

[8] KOVANDA, K., HOLUB, L., KOLAŘÍK, L., KOLAŘÍKOVÁ, M., VONDROUŠ, P., (2012). Experimental verification of FEM Simulation of GMAW bead on plate welding, Manufacturing Technology Vol.12, No. 12, pp. 30-33.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Dana Bolibruchova.


23

Metallurgical and Material Properties of Castings Manufactured from Stainless Steel G-X4CrNi13-4 and G-X4CrNiCu13-4

Josef Odehnal, Stanislav Brotánek Technical Department, PILSEN STEEL s.r.o., [email protected]

This article presents the metallurgical and material properties of castings from stainless steel G-X4CrNi13-4 and G-X4CrNiCu13-4, which can be obtained under the conditions of the Foundry shop of PILSEN STEEL s.r.o. The article mentions furnace units of primary and secondary metallurgy in which the stated quality steel is produced. By way of illustration of achieved properties of melt, the heat analyses and micro-purity of steel are shown. Mechanical properties of steel are represented in well arranged graphs showing achieved values of the yield point, tensile strength, and impact energy at various temperatures, such as for example: 20, -10, -20, -30, -40, -50 a -60°C. By way of illustration, there are figures of the castings most frequently produced from stainless steel in the Foundry shop of PILSEN STEEL s.r.o. In the end, the article points out what effect has micro-purity of steel on the value of impact energy.

Keywords: metallurgy, stainless steel G-X4CrNi13-4, micro-purity of steel, mechanical properties, PILSEN STEEL s.r.o.

References

[1] STEFANESCU, D. M. (1970). Metals handbook: VOLUME 15 - Casting. 9th ed. Metals Park, Ohio: American Society for Metals, c1978-c1989, 948 - 957. ISBN 0-87170-007-7.

[2] ODEHNAL, J. (2012). Effect of metallurgy and casting technology on heavy steel castings quality. Ostrava, 2012, Diploma thesis. VŠB-TU Ostrava, FMMI, Department of Foundry.

[3] FRUEHAN, R. (2003). Casting volume: Historical aspects and key technologies. [Electronics Resource], 11. ed. Pittsburgh, Pa: AISE Steel Foundation, 2003. ISBN 0-930767-04-7.

[4] GHOSH, A. (2001). Secondary steelmaking: principles and applications. Boca Raton, Fla.: CRC Press, (c) 2001, 322 s. ISBN 08-493-0264-1.

[5] FRUEHAN, R. The making, shaping, and treating of steel: Reffining of Stainless Steels. 11th ed. Pittsburgh, PA: AISE Steel Foundation, c1998-c1999. ISBN 0-930767-02-0.

[6] STAVEHAUG, L. (1970). Operational Experiences with the ASEA-SKF Ladle Furnace in Stainless Steelmaking. Modern Refining Techniques: Electric Furnace Proceedings. 1970.

[7] GREVILLIUS, N., GEETE, P., KREY, T. (1970). Operational Experience of the ASEA-SKF Ladle Furnace process at Bofors Steelworks. Modern Refining Techniques: Electric Furnace Proceedings. 1970.

[8] CHUNG, S., SHIN, Y., YOON, Y. (2012). Flow Characteristics by Induction and Gas Stirring in ASEA-SKF Ladle. ISIJ International. 1992 (no. 12), 1287-1296.

[9] JONES, P. (2001). Degradation mechanisms of basic refractory materials during the secondary refining of stainless steel in VOD ladles. Heverlee (België), 2001. ISBN 90-5682-297-7. Doctoral theses. Katholieke Universiteit Leuven – Faculteit Toegepaste Wetenschappen Arenbergkasteel.

[10] Production of Stainless Steels: Part Three. Key to Metals: The World’s Most Comprehensive Metals Database. 1999 – 2012.

[11] LO, K.H., SHEK, C.H., LAI, J.K.L. (2009). Recent developments in stainless steel. Materials Science and Engineering: R: Reports, Volume 65, Issues 4-6, 29 May 2009, Pages 39-104.

[12] ČUBAN, J., CALONIUS, O., PIETOLA, M., JERSÁK, J. (2011). Fatigue life and surface integrity measurements of EN S355J2 steel used in hydraulic components. Manufacturing technology. December 2011, Volume 11, Issue 11, Pages 5-11. ISSN 1213-2489.

[13] ROSENBERG, G., JUHÁR, Ľ. (2012). Fatigue resistance of dual phase steels in presence of microstructural inhomogeneities. Manufacturing technology. December 2012, Volume 12, Issue 13, Pages 217-221. ISSN 1213-2489.

[14] ROSENBERG, G., SINAIOVÁ, I., JUHÁR, Ľ. (2012). Influence of microstructural heterogeneities on capacity to absorb energy of dual-phase steels. Manufacturing technology. December 2012, Volume 12, Issue 13, Pages 222-227. ISSN 1213-2489.

[15] FERREÑO, D., ÁLVAREZ, J.A., RUIZ, E., MÉNDEZ, D., RODRÍGUEZ, L., HERNÁNDEZ, D. (2011). Failure analysis of a Pelton turbine manufactured in soft martensitic stainless steel casting. Engeneering Failure Analysis, Volume 18, Issue 1, January 2011, Pages 256-270.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Eva Tillova.


24

Effect of opening material granularity on the mould properties and the quality of castings made by patternless process technology

Richard Pastirčák, Emil Krivoš Department of technological engineering. Faculty of Mechanical Engineering, University of Žilina, Univerzitná 1, 01026 Žilina, Slovak Republic. [email protected]

Submitted article deals with the methods to improve mould breathability when using the Patternless process method and also examines the influence of opening material grain size on the dimensional and shape precision of made castings. Mentioned methods are based on the principle of direct milling cavity into block from moulding mixture with CNC machining. As the moulding material was used CT moulding compound composed of opening materials SH 35, SH 31 and water glass as binder. The curing process took place by purging CO2 gas through moulding compound. To achieve the highest quality surface cavity was used protective coating PROTECT WC1. The final shape and dimensional accuracy of the castings was evaluated using a 3D measuring device and a contourgraph.

Keywords: Patternless process, mould cavity, opening material

Acknowledgements

This work was created within the solution of the grant project VEGA no. 1/0610/12, VEGA no. 1/0785/13 focusing on technology and simulation for applications in manufacturing and KEGA no. 006ŽU-4/201. The authors thank the Grant Agency for support.

References

[1] PASTIRČÁK, R., BOLIBRUCHOVÁ, D., SLÁDEK, A. (2009). Casting theory. Žilina: ŽU v Žiline, Georg, 2009, 155 pp. ISBN 978-80-89401-04-08

[2] PASTIRČÁK, R., URGELA, D., KRIVOŠ, E.: Production of castings by patternless process. In.: Archives of foundry engineering. ISSN 1897-3310, 2012, Vol. 12, Iss. 1(2012), pp. 87-92.

[3] PASTIRČÁK, R., URGELA, D.: Device for production of prototype moulds by milling. In: Archives of foundry engineering. ISSN 1897-3310, 2011, Vol. 11, Spec. Iss. 1 (2011), pp. 45-50.

[4] BABU, T. S., THUMBANGA, R. D. (2011). Reverse engineering, cad/cam & patternless process applications in casting. In International Journal of Mechanics. ISSN 1999-4448, 2011, vol. 5, no. 1, pp. 40-47.

[5] RODRÍGUEZ, A. et al. (2012). Maximal reduction of steps for iron casting one-of-a-kind parts. In Journal of Cleaner Production. ISSN 0959-6526, 2012, vol. 20, no. 24, pp. 48-55.

[6] PASTIRČÁK, R., URGELA, D.: Construction of milling machine for production moulds made by patternless process. In: TRANSCOM 2011: 9-th European conference of young research and scientific workers : Žilina, June 27-29, 2011, Slovak Republic. - Žilina: University of Žilina, 2011, ISBN 978-80-554-0374-8, pp. 151-154.

[7] KANTORÍK, R., BOLIBRUCHOVÁ, D.: Free melt surface monitoring with the help of metal flow simulation in moulds. In: International Foundry Research 2011, volume 63, issue 2, pp. 18 – 23, ISSN 0046 – 5933.

[8] BOLIBRUCHOVÁ, D., SLÁDEK, A., BRŮNA, M. (2010). Effect of filtration on reoxidation proceses in aluminium alloys. Archives of foundry engineering. ISSN 1897-3310. - Vol. 10, Spec. Issue 1, pp. 121-126.

[9] BOLIBRUCHOVA, D. (2010). Casting technology: GEORG Žilina, ISBN 978-80-89401-14-7, 248 pp.

[10] BRŮNA, M., BOLIBRUCHOVÁ, D., KANTORÍK, R.: Filtration of aluminium alloys and its influence on mechanical properties and shape of eutectical silicium. In: Archives of foundry engineering. ISSN 1897 – 3310, Vol. 8, issue 2 (2008), pp. 13-16.

[11] LIPIŃSKI, T. 2011. Use Properties of the AlSi9Mg Alloy With Exothermical Modifier. In Manufacturing Technology, Vol. 11, No. 11. pp. 44-49. ISSN 1213-2489.

[12] WEISS, V., STRIHAVKOVA, E.: Influence of the homogenization annealing on microstructure and mechanical properties of AlZn5.5Mg2.5Cu1.5 alloy. In: Manufacturing Technology, Volume 12, 2012, No. 13. ISSN 1213-2489, pp. 297 – 302.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Iva Nova.


25

Temperature gradient in cooling down Fe-C-Cr alloy casting

Andrzej Studnicki, Jan Szajnar Department of Foundry, Faculty of Mechanical Engineering, Silesian University of Technology, Towarowa 7, 44-100 Gliwice, Poland. [email protected] The fragment of investigations of primary crystallization process of casting made from chromium cast steel and chromium cast iron contain about 17% chromium was described in the article. The analysis of change in temperature gradient on cross-section of cooling model casting was introduced. To the investigations was applied TGDA (thermal gradient and derivative analysis) method worked out in the Department of Foundry in Silesian University of Technology in Gliwice which consists in multi-drop measurement of cooling temperature in casting using thermocouple locate on the direction of transferring warm from the casting to mould. On the basis of registered cooling curves were worked out graphs of temperature gradient and its first derivative (curves TGDA). The changes of course of TGDA curves describe the kinetics of primary crystallization process on cross-section of the studied casting and provides of created primary structure. At the analysis of temperature gradient curves also was used TDA (thermal and derivative analysis) method.

Keywords: chromium cast steel, chromium cast iron, crystallization, TDA, TGDA

Acknowledgements The work was made thanks to funding by Polish Ministry Science and Higher Education as developing project own No. NR507 0054 10

References

[1] SARE, I. R., CONSTANTINE, A. G. (1997). Development of methodologies for the evaluation of wear-resistant materials for the mineral industry. Wear, 203-204, pp. 671-678.

[2] ADLER, T. A., DOGAN, O., N. (1999). Erosive wear and impact damage of high-chromium white cast irons. Wear, 225-229 (I), pp. 174-180.

[3] XU, L., VOSE, C., JOHN, D. (1993). Abrasive wear study of selected white cast iron as a liner material for mining. Wear, 162-164, pp. 820-832.

[4] KILARSKI, J., STUDNICKI, A., SUCHOŃ, J. (2011) The study of chromium cast steel on the liners of mining combines, Archives of Foundry Engineering, vol. 10, Spec. Issue 4, pp. 31-36.

[5] LU, B., LUO, J., CHIOVELLI, S. (2006). Corrosion and wear resistance of chrome white irons – a correlation to their composition and microstructure. Metallurgical and Materials Transactions A, 37a, pp. 3029-3038.

[6] WIENGMOON, A., PEARCE, J.T.H., CHAIRUANGSRI, T. (2011). Relationship between microstructure, hardness and corrosion resistance in 20 wt.%Cr, 27 wt.%Cr and 36 wt.%Cr high chromium cast irons. Materials Chemistry and Physics, 125, pp. 739-748.

[7] LU, Z., RAO, Q., JIN, Z. (1999). An investigation of the corrosion-abrasion wear behavior of 6% chromium martensitic cast steel. Journal of Materials Processing Technology, 95, pp. 180-184.

[8] DOGAN, O. N., HAWK, J. A., LAIRD II, G. (1997). Solidification structure and abrasion resistance of high chromium white irons. Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science, 28 (6), pp. 1315-1328.

[9] WRÓBEL, T. (2011). Bimetallic layered castings alloy steel - grey cast iron. Archives of Materials Science and Engineering. 48 (2), pp. 118-125.

[10] BROZEK M. (2005). Abrasive wear resistance of selected hardfacing materials. Manufacturing Technology, vol. V, pp. 5-9.

[11] TOMIK P., MACHACKOVA A., TROJAN R., HRUBY J. (2006). Temperature measurement during the tensile test of 12013 steel with alternating magnetic field application. Manufacturing Technology, vol. VI, pp. 65-68.

[12] SYGUT P., LABER K., BORKOWSKI S. (2012). Investigation of the non-uniform temperature distribution on the metallic charge length during round bars rolling process, Manufacturing Technology, vol. 12, No 13, pp. 260-263.

[13] SCHON, C.G., SINATORA A. (1998). Simulation of solidification paths in high chromium white cast irons for


26

wear applications. Calphad-Computer Coupling of Phase Diagrams and Thermochemistry. Vol. 22, Issue 4, pp. 437-448.

[14] LAIRD, G., POWELL, G. L. F. (1993). Solidification and solid-state transformation mechanisms in Si alloyed high-chromium white cast irons. Metallurgical Transactions A, 24 (4), pp. 981-988.

[15] CORONADO, J.J., SINATORA, A. (2009). Abrasive wear study of white cast iron with different solidification rates. Wear, 267, Issue 11, pp. 2116-2121.

[16] ARNOLD, B. K., SARE, I. R. (1989). Thermal analysis study of alloy white cast irons. Fondryman, 82 (2), pp.71-76.

[17] CAMPOS, M., BLANCO, L., TORRALBA, J. M. (2006). Thermal analysis of prealloyed Fe-3Cr-0,5Mo sintered steel. Journal of thermal analysis and calorimetry. Vol. 84, pp. 483-487.

[18] CHOLEWA, M., JURA, Z., STUDNICKI, A. (2009). The development of thermal analysis and derivative method in Department of Foundry Silesian University of Technology, Progresses Theory and The Casting practice, Publisher PAN Katowice, pp. 49-70.

[19] STUDNICKI, A. (2008). The temperature gradient on cross-section of casting in process of primary crystallization of chromium cast iron, Archives of Foundry Engineering, vol.8, Spec. Issue 3, pp. 149-153.

[20] STUDNICKI, A. (2005). The temperature of crystallization of chromium cast iron in function of rate cooling the casting. Foundry Archive, vol. 5, no. 15, pp. 371-378.

[21] STUDNICKI, A., JEZIERSKI, J. (2012). Stereological parameters of carbides in modified wear resistant Fe-C-Cr alloys, Metal 2012; International Conference on Metallurgy and Materials, Brno, Czech Republic, 23-25.05.2012.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Pavel Novak.


27

The zone without carbon in alloy layer obtained on steel cast

Jan Szajnar, Agnieszka Walasek, Czesław Baron Faculty of Mechanical Engineering, Department of Foundry, Silesian University of Technology ul. Towarowa 7, 44-100 Gliwice, Poland. [email protected]

In the submitted article are presented the results of researches on the steel cast with surface alloy layer in this article. The simulation of the disintegration of the elements in the place where two materials were in contact was done in order to observe the effects between them. The temperature, the thickness of the layer, micro hardness and the structure were thoroughly examined. The researches were conducted to examine the zone without carbon forming in the joint of two materials. The influence of pouring temperature, the thickness of the cast wall and the size of pad grain on the zone without carbon forming process were also examined. It was also proposed to base the process of the zone out of carbon forming on the work of chromium carbides forming process.

Keywords: composite layer, ferrochromium, cast, mechanism of creation, the zone without carbon

References

[1] BARTOCHA, D., JANERKA, K., SUCHOŃ., J. (2005). Charge materials and technology of melt and structure of gray cast iron, Archives of Metallurgy and Materials., Vol. 162, Special Issue, pp. 465 – 470.

[1] STUDNICKI, A., JEZIERSKI, J. (2012). Stereolgical parametrs of carbides in modified wear resistant Fe-C-Cr alloy, Metal 2012, Internatinal Conderence on Metallurgy and Materials, Brno.

[2] WRÓBEL, T. (2011). Bimetallic layered castings alloy steel – grey cast iron, Archives of Materials Science and Engineering, Vol. 48, No. 2, pp. 118 – 125.

[3] CHOLEWA, M., WRÓBEL, T., TENEROWICZ, S., SZUTER, T. (2010). Diffusion phenomena between alloy steel and gray cast iron in layered bimetallic casting. Archives of Metallurgy and Materials, Vol. 55, No. 3, pp. 9 – 15.

[4] SZAJNAR, J., BARTOCHA, D., BARON, C., WALASEK, A. (2008). The attempt of determination of parameters for the alloy layer forming process based on the empirical examination, Archives of Foundry Engineering, Vol. 8, Special Issue 3, pp. 139 – 143.

[5] WRÓBEL, P. (2004).. Improvement of the cast steel castings surface by creating the alloy composite layer in casting process, Doctor’s thesis, pp. 4 – 20. Silesian University of Technology, Gliwice.

[6] BARON, C. (2007). The surface composite layer on the steel cast, Doctor’s thesis, pp. 4 – 22. Silesian University of Technology, Gliwice.

[7] WALASEK, A. (2012). Designing of the structure and properties of the alloyed surface layer on the cast steel castings, Doctor’s thesis, pp. 4 – 30. Silesian University of Technology, Gliwice.

[8] WRÓBEL, T. (2011). Ni and Cr base layers in bimetallic castings, Metal 2011: International Conference on Metallurgy and Materials. Brno, pp. 758-764.

[9] BROŽEK, M. (2005). Abrasive wear resistance of selected hardfacing materials, Manufacturing Technology Vol. V. pp. 5 – 9.

[10] KOVAČ, I., ŽARNOVSKY, J., DRLIČKA, R., RUŽBARSKY, J. (2010). An improvement of tribological properties of boron alloyed layers, Manufacturing Technology Vol. X. pp. 78 – 80.

[11] FRAŚ, E., KAWALEC, M., LOPEZ, H.F. (2009). Solidification microstructures and mechanical properties of high-vanadium Fe-C-V and Fe-C-V-Si alloys, Materials Science and Engineering, Vol. 524 (1-2) , pp. 193-203.

[12] WOŁCZYŃSKI, W., OKANE, T., SENDEROWSKI, C., KANIA, B., ZASADA, D., JANCZAK-RUSCH, J. (2011)., Meta-stable conditions of diffusion brazing, Archives of Metallurgy and Materials, Vol. 56 (2), pp. 311-324.

[13] WOŁCZYŃSKI, W. (2006)., Transition phenomena in the diffusion soldering / brazing, Archives of Metallurgy and Materials, Vol. 51 (4) , pp. 609-615.

[14] JANERKA, K., BARTOCHA, D., SZAJNAR, J., JEZIERSKI, J. (2010). The carburizer influence on the crystallization process and the microstructure of synthetic cast iron, Archives of Metallurgy and Materials , Vol. 55, issue 3, pp. 851-859.

[15] JANERKA, K., JEZIERSKI, J., BARTOCHA, D., SZAJNAR, J. (2013). Heredity of the structure and properties of gray cast iron melted on a basis of steel scrap, Advanced Materials Research, Vol. 622-623, pp. 685-689.

[16] JANERKA, K., BARTOCHA, D., JEZIERSKI, J., SZAJNAR, J. (2012) Heat Up and Dissolution of Carburizers in Liquid Ferrous Alloys, Metal 2012; International Conference on Metallurgy and Materials, Brno.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Dana Bolibruchova.


28

The role of antimony in modifying of Al-Si-Cu cast alloy

Eva Tillová, Mária Farkašová, Mária Chalupová University of Žilina, Faculty of Mechanical Engineering, Department of Material Engineering, Univerzitná 8215/1, 010 26 Žilina, Slovakia Corresponding author: [email protected]

The microstructure evolution and the tensile strength changes of hypoeutectic AlSi6Cu4 cast alloy modified by AlSb10 (0 - 10 000 ppm) was systematically investigated. The samples were study without and after T6 heat treatment. Several types of etching were used, which includes standard black and white etching (0.5 % HF), colour etching by Weck-Al (for documentation the eutectic cells) and deep etching by HCl (for eutectic Si morphology study). The results show that the addition of Sb into AlSi6Cu4 cast alloy should act as a modifier, so it supposes to change the eutectic Si morphology. However, its effect as a modifier is not as significant as we have expected. Its effect was more inoculation and caused refinement of microstructure what has led to mechanical properties increasing. Refinement of microstructure could obviously improve the size and distribution of eutectic cells. The eutectic cells are refined significantly in a fully modified eutectic microstructure (more than 1 000 ppm Sb). It can be speculated that the stick-fibrous transition of eutectic Si morphology involving in impurity modification may be independent of the frequency and mode of eutectic nucleation.

Keywords: microstructure, modifying, heat treatment, aluminium alloys, antimony

Acknowledgement This work has been supported by Scientific Grant Agency of Ministry of Education of Slovak republic and Slovak

Academy of Sciences, No 1/0841/11, No 1/0196/12 and the Project EÚ: The competence Centrum for industrial research and development in the field of light metals and composites - ITMS: 26220220154.

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[1] HANSEN, S. C., LOPER JR., C. R. (2000). Effect of antimony on the phase equilibrium of binary Al-Si alloys. Calphad, Vol. 24, No. 3, pp. 339-352.

[2] TILLOVÁ, E., CHALUPOVÁ, M. (2009). Structural analysis of Al-Si alloys. EDIS Žilina (in Slovak).

[3] SUN, YU., PANG, S., LIU, X., YANG, Z., SUN, G. (2011). Nucleation and growth of eutectic cell in hypoeutectic Al-Si alloy. Transactions of Nonferrous Metals Society of China, 1, pp. 2186-2191.

[4] ASM Handbook (2002). Vol. 15 - Casting, ASM International.

[5] KNUUTINEN, A., NOGITA, K., MCDONALD, S. D., DAHLE, A. K. (2001). Modification of Al-Si alloys with Ba, Ca, Y and Yb. Journal of Light Metals, 1, pp. 229-240.

[6] COMALCO (1997). Modification of foundry Al-Si alloys. Technical report No. 4., Comalco Aluminum Limited. Brisbane, Australia.

[7] TILLOVÁ E. et al. (2010). Evolution of the Fe-rich phases in recycled AlSi9Cu3 cast alloy during solution treatment. Communications - Scientific letters of the University of Žilina, Vol. 12, No. 4, pp. 95-101.

[8] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., ĎURINÍKOVÁ, E. (2011). Quality control of microstructure in recycled Al-Si cast alloys. Manufacturing Technology, Vol. 11, pp. 70-76.

[9] MICHNA, Š., NÁPRSTKOVÁ, N. (2012). Research into the causes cracking of aluminum alloys of Al-Cu during mechanical machining. Manufacturing Technology. Volume 12, June 2012, pp. 47-51.

[10] LEJČEK, P., KONEČNÁ, R., JANOVEC, J. (2008). Solute segregation to ferrite grain boundaries in nodular cast iron, experiment and prediction. Surface and Interface Analysis, Vol. 40, No. 3-4, pp. 503-506.

[11] VAŠKO, A. (2009). Analysis of the factors influencing microstructure and mechanical properties of austempered ductile iron. Communications, Vol. 11, No. 4, pp. 43-47.

[12] BELAN, J. (2008). Structural analyses of advanced materials for aerospace industry. Materials Science (Medžiagotyra), Vol. 14, No. 3, pp. 315-318.

[13] MAKHLOUF, M. M., GUTHY H. V. (2001). The aluminium-silicon eutectic reaction: mechanisms and crystallography. Journal of Light Metals, 1, pp. 199-218.

[14] PRASADA RAO, A. K., DAS, K., MURTY, B. S., CHAKRABORTY, M. (2008). On the modification and segregation behavior of Sb in Al-7Si alloy during solidification. Materials Letters, 62, pp. 2013-2016.

[15] BASAVAKUMAR, K.G., MUKUNDA P. G., CHAKRABORTY, M. (2008). Influence of grain refinement and modification on microstructure and mechanical properties of Al-7Si and Al-7Si-2.5Cu cast alloys. Materials Characterization, 59, pp. 283-289.


Manuscript of the paper received in 2012-12-17. The reviewer of this paper: Milan Brozek.


29

Influence of heat treatment on the microstructure of synthetic nodular cast irons

Alan Vaško Department of Materials Engineering, Faculty of Mechanical Engineering, University of Žilina, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic, [email protected]

The article deals with the influence of charge composition on the microstructure and mechanical properties of synthetic nodular cast irons after casting and after heat treatment (ferritizing annealing and isothermal heat treatment). The paper shows a comparison of the microstructure of nodular cast irons with the graded amount of steel scrap in a charge. The chemical composition of individual meltages was regulated alternatively by ferrosilicon (FeSi) and carburizer or metallurgical silicon carbide (SiC). The results of the experiments show that the SiC additive positively influences the microstructure as well as the mechanical properties of nodular cast iron, especially in specimens from the meltages with a higher ratio of steel scrap in the charge. Moreover, the production of synthetic nodular cast irons with a SiC additive is economically advantageous.

Keywords: nodular cast iron, ferritizing annealing, isothermal heat treatment, silicon carbide

Acknowledgements Author is grateful for the support of experimental works by grant projects VEGA No. 1/0460/11 and No.

1/0841/11.

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[4] ONSOIEN, M. I., SKALAND, T. (2001). Preconditioning of gray iron melts using ferrosilicon or silicon carbide, Transactions of the American Foundry Society, p. 1-12.

[5] VENKATESWARAN, S., WILFING, J., SCHUBERT, W. D., LUX, B., BENECKE, T. (1989). Influence of SiC and FeSi additions on the microstructure, cooling curve and shrinkage porosity of ductile iron. In: Physical metallurgy of cast iron, pp. 171-178. Tokyo, Japan.

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[12] BELAN, J. (2008). Structural analyses of advanced material for aerospace industry. Materials science (Medžiagotyra), Vol. 14, No. 4, pp. 315-318.

[13] TILLOVÁ, E., CHALUPOVÁ, M., HURTALOVÁ, L., ĎURINÍKOVÁ, E. (2011). Quality control of microstructure in recycled Al-Si cast alloys. Manufacturing Technology, Vol. 11, No. 11, pp. 70-76.

[14] ĎURINÍKOVÁ, E., TILLOVÁ, E. (2011). Phase and structure characteristics of recycled AlZn10Si8Mg cast alloy. Manufacturing Technology, Vol. 11, No. 11, pp. 11-17.

[15] VAŠKO, A., SKOČOVSKÝ, P. (2009). Properties and means of use of materials, 96 p. EDIS, Žilina.

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Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Dalibor Vojtech, Ivan Lukac.


30

Hardness of Ductile Cast Iron Castings and its Control in Praxis

Iveta Vasková, Peter Šebek, Igor Mulik Technical University of Košice, Faculty of Metallurgy, Letná 9, 04001 Košice, Slovakia. [email protected], [email protected],

Foundry is one of the oldest industry branch. In the evolution of humankind it played great role wih always improving mechanical properties of metals and in using of newest knowledges, it still plays one of the key function in all spheres of our lives. We meet everyday with the castings. It is the same if we sit in the car or we are eating the waffle. The production of every single casting needs individual approach for repeatidly achievement of desired material properties. Hardness is one of the basic property of metal materials in common. From hardness depends how easy, or how hard would be given material machined and what kind of materials, tools and machines would we need. In todays world of planning it is a matter of course to demand the same hardness for given material, so that the same machinability could be ensured and costs and machining time were minimalized. It is not always easy to assure this condition in praxis.

Keywords: ductile cast iron, hardness of castings, machinability, statistics

Acknowledgements „This work was supported by the Slovak Research and Development agency under the contract no. VEGA 1/0498/11“.

References

[1] TRYTEK A., ORLOWICZ A.W., MRÓZ M., TUPAJ M.: Examination of cast iron properties by means of then scratch method. Archives of Foundry Engineering, z.2 special, t.12, s.75-80,

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[4] BERANEK L., BAČANOVA L., VAŠTA F, ZELENKA A:: Praktické využití statistických metod při navrhování experimentu, Strojírenská technologie, XII. roč., prosinec 2007, str. 22-26, ISSN 1211-4162.

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Manuscript of the paper received in 2012-12-17. The reviewer of this paper: David Manas.


31

Assessment of the effect of temperature and annealing time homogenization AlCu4MgMn alloys in terms of microstructure image analysis methods and EDX

Viktorie Weiss, Ingrid Kvapilova Faculty of Production Technology and Management, University J. E. Purkyně, Ústí nad Labem. [email protected], [email protected]

Homogenization is defined as a method of heat treatment, which consists of holding time at high temperature near the liquidus (approx. 0.7 to 0.8 the melting temperature) to eliminate chemical inhomogeneity diffusion processes. Cause of segregation is selective crystal solidification in the gradual change in composition of the solid phase. Melt began to appear after certain of the hypothermia during cooling, and the growth of germs in accordance with the general laws of crystallization. Each rigid layer has a different chemical composition. The first part of the solid phase ingredient low concentration of the element last, on the contrary, very high. Susceptibility to crystal alloy segregation is greater, the greater the temperature interval solidification of alloys and the horizontal distance between the liquidus and solidus lines. Crystal segregation will also increase with increasing content of alloying elements, which in these experimental alloys occurs as containing 6-9% alloying elements. Crystal segregation can be removed by diffusion, for which it is necessary to create conditions by homogenization annealing.

Keywords: homogenization annealing, AlCu4MgMn alloy, crystal segregation, EDX analysis, image analysis

References

[1] GRÍGEROVÁ,T., LUKAČ, I., KOŘENÝ, R. (1988). Non-ferrous metal foundry, Prague, 1988, 063-566-88.

[2] MICHNA, Š.- LUKÁČ, I., LOUDA, P., Očenášek a kol. (2005). Aluminium materials and technologies from A to Z, Adin s.r.o, ISBN 978-80-89244-18-8.

[3] LUKAČ, I., MICHNA, Š. (2001). Colour kontrast, strukcture and defects in aluminium and aluminium alloys, Cambridge International Science Publishing, ISBN 18-983-26-70-3.

[4] MICHNA, Š., NOVÁ, I. (2008). Technology and Processing of Metals, Adin, s.r.o., Prešov, ISBN 978-80-89244-38-6.

[5] VAJSOVÁ, V. (2011). Optimization of homogenizing annealing for Al-Zn5,5-Mg2,5-Cu1,5 alloy, Metallurgist, Volume 54, Issue 9, 2011, ISSN 0026 – 0894.

[6] VAJSOVÁ, V., MICHNA, Š. (2010). Optimization of AlZn5.5Mg2.5Cu1.5, Alloy Homogenizing Annealing, Metallofizika i noveishie tekhnologii, Volume 32, No.7, ISSN 1024 – 1809.

[7] VAJSOVÁ, V. (2009). Structural inhomogeneity by Al - Cu alloys casting into metal and bentonic form. Transactions of the Universities of Košice, ISSN 1335 – 2334.

[8] VAJSOVÁ, V. (2010). Homogenization annealing of alloy AlCu4MgMn, Strojirenska technologie, Volume XIV, ISSN 1211 – 4162.

[9] VAJSOVA, V. (2010). The influence of molds on the structure of alloy AlCu4MgMn, Slévarenství, 7 - 8/2010, ISNN 0037 – 6825.

[10] WEISS, V., MICHNA, Š., STŘIHAVKOVA, E. (2010). The use of color metallography in identifying crystal and band segregation of aluminum alloys, Metallography, methods and procedures, 2010, ISBN 978 – 80 – 89244 – 74 – 4.

[11] STŘIHAVKOVA, E., MICHNA, Š., WEISS, V. . (2010). The role of color metallography in identifying structures of aluminum alloys, Metallography, methods and procedures, ISBN 978 – 80 – 89244 – 74 – 4.

[12] VAJSOVÁ, V, MICHNA, Š, STŘIHAVKOVA, E. (2010). Analysis of the parameters which influence diffusion processes in the course of homogeneous annealing of aluminium alkou doped zinc, Toyotarity. Structure of kontrol elements importace,Yurii V. Makovetsky, Dnipropetrovsk, ISBN 978 – 966 – 1507 –40-0.

[13] VAJSOVÁ, V. (2009). The influence of molds on the structure of alloy AlCu4MgMn, Transactions of the Universities of Košice, 4/2009, ISSN 1335 – 2334.

[14] WEISS, V. (2011). Effect of molds on the surface quality and structure of alloys AlZn5,5Mg2,5Cu1,5, Slévárenství, LXI, 7 - 8/2011, červenec – srpen 2011, ISSN 0037 – 6825.

[15] WEISS, V., STŘIHAVKOVÁ, E. (2011). Optimization of homogenizing annealing of alloys AlCu4MgMn, Strojirenska technologie, Volume XVI, 10/2011, ISSN 1211 – 4162.


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Dana Stancekova, Iva Nova.


32

The Efficiency of Different Types of Inoculation of Pure Al and AlSi2 Alloy

Tomasz Wróbel Silesian University of Technology, Foundry Department, Towarowa 7, 44-100 Gliwice, Poland. Email: [email protected]

In paper problem concerning inoculation of primary structure of aluminum with purity of 99,5% and 99,8% and AlSi2 alloy, which is realized mainly by intensification of liquid metal movement in mould is presented. In aim of realization of forced movement during the crystallization of liquid metal was used rotating electromagnetic field produced by the induction coil supplied by current with elevated frequency. The degree of structure refinement was represented by equiaxed crystals zone content on transverse section of ingot and average area of macro-grain in this zone. Effect of structure refinement obtained by influence of electromagnetic field was compared with refinement obtained by use of traditional inoculation, which consists in introducing of additives i.e. titanium, boron, carbon and strontium to metal bath. The results of studies and their analysis show possibility of effective refinement of pure Al and Al-Si alloy primary structure, only with use of rotating electromagnetic field and without necessity of application of inoculants such a Ti, B and C. This method of inoculation is important, because inoculants decrease the degree of purity and electrical conductivity of pure Al. Moreover inoculants are reason of point cracks formation during rolling of ingots.

Keywords: Aluminum, Al-Si alloy, Primary structure, Inoculation, Electromagnetic field

Acknowledgements Project financed from means of National Science Centre

References

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33

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[18] http://www.struers.com/knowledge


Manuscript of the paper received in 2012-12-17. The reviewers of this paper: Ivan Lukac, Eva Tillova.

March 2013, Vol. 13, No. 1

34

Trade Fair FOR INDUSTRY 2013

12th International Trade Fair of Engineering Technologies PRAGUE on April 23 – 25, 2013.

7th year of International Trade Fair of Surface Treatments and Finishing Technologies held simultaneously with 1st year of Welding, Soldering and Gluing Technologies Trade Fair with a two-year periodicity in odd years.

Fairs FOR INDUSTRY, FOR SURFACE and FOR WELD 2013 are prepared in cooperation with ainstitutions, professional sponsors and media partners. With their support the Trade Fairs can offer the most effective conditions for presentation of companies and new technological solutions. The International Trade Fairs provide a unique opportunity to present advanced and progressive technology and innovative trends that have broad application. The aim is to create a comprehensive platform for sotechnological cooperation and job opportunities in technical fields.

A number of major companies will take place at Trade Fair FOR INDUSTRY. Among them you can find: and filtration elements, materials for the aerospace and automotive industries, printers and scanners for 3D modeling; grinders, OBRÁBĚCÍ STROJE, Ltdwas confirmed by: surface treatment for automotive and metalworking induspecializes in the production of galvanic lines for metal surface treatment; Ltd., that will present powder coating and technology for varnishing and blasting.

At the Trade Fair ARCcomprehensive temetal processing and professional welding machines, safety and work equipment for

welding. Tools and drilling machines will be presented by Ltd.

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There will not be missing a Trade Fair competition for visitors, and competition for the most innovative product exhibitors.

ABF prepared many interesting offers for the participrices, the possibility of stand location consultation or any number of complimentary tickets for customers and business partners (both in print and in electronic form) free of charge.

PVA EXPO PRAGUE is located in Prague with total area of 8,200 square meters. At present it is the most modern exhibition facilities in Prague. Industrial fairs FOR INDUSTRY, FOR SURFACE and

Current information can be found on webpage: www.forindustry.cz, www.forsurface.cz and

MANUFACTURING TECHNOLOGY


Trade Fair FOR INDUSTRY 2013 – place for presentation of technological innovations

12th International Trade Fair of Engineering Technologies FOR INDUSTRY 2013 will be held in

year of International Trade Fair of Surface Treatments and Finishing Technologies FORyear of Welding, Soldering and Gluing Technologies Trade Fair

years.

Fairs FOR INDUSTRY, FOR SURFACE and FOR WELD 2013 are prepared in cooperation with ainstitutions, professional sponsors and media partners. With their support the Trade Fairs can offer the most effective

of companies and new technological solutions. The International Trade Fairs provide a unique opportunity to present advanced and progressive technology and innovative trends that have broad application. The aim is to create a comprehensive platform for solving problems in various engineering fields with an emphasis on technological cooperation and job opportunities in technical fields.

A number of major companies will take place at Trade Fair FOR INDUSTRY. Among them you can find: BIBUS, Ltd. that specializes in the supply of mechanical, electrical and filtration elements, materials for the aerospace and automotive industries, printers and scanners for 3D modeling; Misan, Ltd. that represents companies grinders, Sumitomo - tools and Parlec - adjusting apparatus; OBRÁBĚCÍ STROJE, Ltd. The participation in the Trade Fair FOR SURFACE 2013 was confirmed by: Chemetall, Ltd. that produces and supplies industrial chemicals for surface treatment for automotive and metalworking industry, KFspecializes in the production of galvanic lines for metal surface treatment;

, that will present powder coating and technology for varnishing and blasting.

At the Trade Fair ARC-H company will offer comprehensive technological equipment for metal processing and professional welding machines, safety and work equipment for

welding. Tools and drilling machines will be presented by hall-welding.cz,

has been thoroughly planned in cooperation with professional partners. The topics: "Lean production - modern methods and tools to increase productivity and process efficiency", "Business and

Soviet republics" or "Digital prototypes – from design are being prepared.

There will not be missing a Trade Fair competition for visitors, and competition for the most innovative product GRAND PRIX and the most well done exhibition

ABF prepared many interesting offers for the participants, including turnkey exposure, discounted exhibition space prices, the possibility of stand location consultation or any number of complimentary tickets for customers and business partners (both in print and in electronic form) free of charge.

PRAGUE is located in Prague - Letňany. On October 12, 2012 there were opened two new exhibition halls with total area of 8,200 square meters. At present it is the most modern exhibition facilities in Prague. Industrial fairs FOR INDUSTRY, FOR SURFACE and FOR WELD will take place in these new halls.

Current information can be found on webpage: www.forindustry.cz, www.forsurface.cz and

ISSN 1213–2489


place for presentation of technological innovations

2013 will be held in PVA EXPO

FOR SURFACE 2013 will be year of Welding, Soldering and Gluing Technologies Trade Fair FOR WELD that is held

Fairs FOR INDUSTRY, FOR SURFACE and FOR WELD 2013 are prepared in cooperation with a number of major institutions, professional sponsors and media partners. With their support the Trade Fairs can offer the most effective

of companies and new technological solutions. The International Trade Fairs provide a unique opportunity to present advanced and progressive technology and innovative trends that have broad application.

lving problems in various engineering fields with an emphasis on

A number of major companies will take place at Trade Fair FOR INDUSTRY. Among that specializes in the supply of mechanical, electrical

and filtration elements, materials for the aerospace and automotive industries, printers that represents companies Okamoto - adjusting apparatus; TECNOTRADE

. The participation in the Trade Fair FOR SURFACE 2013 that produces and supplies industrial chemicals for

KF-NOVODUR,Ltd., that specializes in the production of galvanic lines for metal surface treatment; SURFIN,

, that will present powder coating and technology for varnishing and blasting.

and the most well done exhibition TOP EXPO for

pants, including turnkey exposure, discounted exhibition space prices, the possibility of stand location consultation or any number of complimentary tickets for customers and business

Letňany. On October 12, 2012 there were opened two new exhibition halls with total area of 8,200 square meters. At present it is the most modern exhibition facilities in Prague. Industrial fairs

Current information can be found on webpage: www.forindustry.cz, www.forsurface.cz and www.forweld.cz

March 2013, Vol. 13, No. 1 MANUFACTURING TECHNOLOGY ISSN 1213–2489

indexed on: http://www.scopus.com 35

Prof. Ing. Iva Nova, Ph.D. was celebrated her second thirtieth birthday on

15th of March this year. She has been university lecturer at the Technical University of Liberec for a long time. She was born in Beroun, she graduated

in Technical High School in Horovice and after that she worked in np. PAL Beroun. In 1975, she was sent by this factory to study at the university VSST

FS (TU) in Liberec. In 1980, she successfully completed the study and she started to work as an assistant professor at the Department of Materials and

Manufacturing Metallurgy of this university. In 1986 she defended her candidate work and in 1995 she became a docent and then Associate

Professor of Engineering Technology. The president of the Czech Republic appointed her to be a professor in 2003. Prof. Nova's life is devoted to

technology, foundry casting and educating future experts which including 15 doctors (Ph.D.). During her teaching and scientific career she has written numerous publications issued not

only at home but also abroad, where she is known and recognized (odlewnictva committee member of the Polish Academy of Sciences, Department of Katowice). She has written or participated in the 6 professional books, 3 patents and utility models. Prof. Nova is a member of the scientific councils on two technical focus

Czech universities. She was a member of the SUB ADVISORY Committee of Technical Sciences GA. Now she is also the chairwoman for habilitation and appointment (Appointment) process managing the Technical

University and member of the committee for doctoral exams in engineering technology.

On behalf of everybody else we would like to wish you good health and a lot of energy and success in all

future activities.

Your colleagues and also friends Stanislava Kryslova and Jiri Machuta

To the wish are joined Editors of Manufacturing Technology and Advisory Board Members

March 2013, Vol. 13, No. 1 MANUFACTURING TECHNOLOGY ISSN 1213–2489

36 indexed on: http://www.scopus.com

http://journal.strojirenskatechnologie.cz

Cover sheet photos: * Microstructure of alloy layer with the zone out of carbon, authors: J. Szajnar, A. Walasek, C. Baron, p. 106 * ICPM 2013 Invitation – Miskolc, Hungary.

The journal is indexed in SciVerse Scopus by Elsevier.

Copyright ©2013, Faculty of Production Technology and Management, J. E. Purkyne University in Usti nad Labem, VAT: CZ44555601. All articles are subject to copyright law. The authors agree with the publication of articles under the Agreement of copyright transfer.

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