program konferencji a - agh university of science and ......3 program konferencji czwartek, 24...

WYDZIAŁ ODLEWNICTWA AKADEMII GÓRNICZO-HUTNICZEJ IM. ST. STASZICA W

KRAKOWIE

FAKULTA METALURGIE A MATERIALOVEHO INŻENYRSTVI VŠB – TECHNICKÁ UNIVERZITA V OSTRAVIE

FAKULTA STROJNÍCKA

ŽILINSKA UNIVERZITA V ŽILINIE

KPR Podlew-Kraków, Sp.z o.o.

PROGRAM JUBILEUSZOWEJ

XX MIĘDZYNARODOWEJ KONFERENCJI NAUKOWEJ

ODLEWNIKÓW POLSKICH, CZESKICH I SŁOWACKICH

Pod honorowym patronatem Dziekana Wydziału Odlewnictwa AGH

prof. zw. dr hab. inż. Józefa Szczepana Suchego

24 - 26.04.2014 r. IZBICKO k/OPOLA

22001144

2

SZANOWNI PAŃSTWO!

Pragniemy Państwa zaprosić na tradycyjne, już XX spotkanie odlewników z naszych trzech zaprzyjaźnionych krajów. Problematyka konferencji obejmuje szerokie spektrum zainteresowań nauk odlewniczych, w tym także aktualne problemy funkcjonowania odlewni. Będzie zatem okazją do zaprezentowania najnowszych osiągnięć nauk odlewniczych i ich praktycznych zastosowań. Ale będzie także dyskusją nad zagrożeniami i problemami rozwojowymi tej branży. Stąd mamy nadzieję – szczególnie w jej jubileuszowej XX odsłonie - na udział przedstawicieli wszystkich ośrodków naukowych polskich, czeskich i słowackich zajmujących się tą problematyką.

Nazwa Konferencji WSPÓŁPRACA nawiązuje także do potrzeby dyskusji nie tylko w gronie pracowników nauki, ale także do wymiany poglądów z pracownikami odlewni oraz firm działających dla odlewnictwa. Zwracamy się zatem także do praktyków - odlewników o czynny udział i zaprezentowania swoich osiągnięć. Będzie do tego służyć nie tylko udział w dyskusjach plenarnych ale także prywatna wymiana myśli i doświadczeń w czasie towarzyskich spotkań.

Tradycyjnie organizujemy nasze spotkania w rożnych krajach i różnych miejscach dla lepszego poznania naszych stron, kuchni i zwyczajów. W latach poprzednich były to Zamek w Krasiczynie i Zamek w Książu. W 2014 roku pragniemy Państwa zaprosić w dniach 24 – 26 kwietnia do historycznego Pałacu w Izbicku k/Opola.

Z odlewniczym pozdrowieniem

Stanisław M. Dobosz Przewodniczący Komitetu Organizacyjnego

3

Program Konferencji

Czwartek, 24 kwietnia 2014

Godz. 1100 – 1400 Rejestracja uczestników Konferencji Godz. 1300 – 1400 Obiad Godz. 1500 Uroczyste Otwarcie Konferencji,

Sala Królewska Balowa Wystąpienie:

Prof. Stanisław M. Dobosz – AGH Kraków Prof. Tomaś Elbel – VŚB TU Ostrava Prof. Augustin Sladek - TU Żylina Prof. Józef S. Suchy – Dziekan Wydziału Odlewnictwa AGH

Godz. 1600 – 1730 Sesja naukowa I, Sala Konferencyjna

Przewodniczący sesji: Prof. Dana Bolibruchova Prof. Witold Krajewski

Referaty:

1. P. Jelínek, St. M. Dobosz, J. Beňo, K. Major-Gabryś - THE BEHAVIOR OF BENTONITE BINDERS FOR THE ELEVATED AND HIGH TEMPERATURES – str. 11

2. D. Bolibruchová, M. Žihalová - VANADIUM INFLUENCE ON IRON BASED INTERMETALLIC PHASES IN AlSi6Cu4 ALLOY – str. 12

3. I. Kroupová, V. Bednářová, T. Elbel, F. Radkovský - PROPOSAL OF METHOD OF REMOVAL OF MOULD MATERIAL FROM THE FINE STRUCTURE OF METALLIC FOAMS USED AS FILTERS – str. 13

4. E. Guzik, D. Kopyciński, D. Wierzchowski - MANUFACTURING OF FERRITIC LOW-SILICON AND MOLYBDENUM NODULAR CAST IRON WITH THE INNOVATIVE 2PE- 9 TECHNIQUE – str. 14

4

5. J. Malik, Š. Eperješi, P. Futáš, I. Vasková, D. Fecko - EVALUATION OF HOMOGENITY BREACH CAUSE ON DIE CASTED CASTINGS – str. 15

6. W. K. Krajewski, G. Piwowarski, P. K. Krajewski - PROTECTING MELTED ZINC-ALUMINIUM BASED FOUNDRY ALLOYS AGAINST HYDROGEN PICK-UP – str. 16

7. M. S. Soiński, A. Jakubas - INITIAL ASSESSMENT OF ABRASIVE WEAR RESISTANCE OF AUSTEMPERED CAST IRON WITH VERMICULAR GRAPHITE – str. 17

I. Robak - PREZENTACJA FIRMY PT.: „ROZWÓJ OFERTY

PRODUKTOWEJ SPÓŁKI POLWAX S.A.”

Dyskusja Godz. 1730 – 1745 Przerwa kawowa, Godz. 1745 – 1900 Sesja naukowa II, Sala Konferencyjna

Przewodniczący sesji: Prof. Petr Jelinek Prof. Edward Guzik

Referaty:

1. D. Nowak, K. Granat, B. Opyd - MEASUREMENT OF ELECTRICAL PROPERTIES AS EFFECTIVENESS APPRAISAL OF MICROWAVE ABSORPTION BY MOULDING AND CORE SANDS SUBJECT TO MICROWAVE UTILIZATION – str. 18

2. J. Odehnal, J. Hampl, J. Jakub - METALLURGICAL TREATMENT AND MATERIAL PROPERTIES OF EN-GJS-450-18 QUALITY SPHEROIDAL GRAPHITE CAST IRON – str. 19

3. J. Jezierski, K. Janerka, M. Stawarz - THEORETICAL AND PRACTICAL ASPECTS OF PNEUMATIC POWDER INJECTION INTO LIQUID ALLOYS WITH A NON-SUBMERGED LANCE – str. 20

5

4. I. Vasková, M. Hrubovčáková, J. Malik, Š. Eperješi - INFLUENCE OF TECHNOLOGICAL PARAMETERS OF FURANE MIXTURES ON SHRINKAGE CREATION IN DUCTILE CAST IRON CASTINGS – str. 21

5. C. Rapiejko, B. Pisarek, T. Pacyniak - EFFECT OF CR AND V ALLOY ADDITIONS ON THE MICROSTRUCTURE AND MECHANICAL PROPERTIES OF ALLOY AM60 – str. 22

6. A. Pasieka, Z. Konopka - DISTRIBUTION OF REINFORCING PARTICLES IN THE PRESSURE DIE CAST AlSi11/20% SiC COMPOSITE – str. 23

7. D. Bolibruchová, J. Macko, M. Brůna - ELIMINATION OF NEGATIVE EFFECT OF FE IN SECONDARY ALLOYS AlSi6Cu4 (EN AC 45 000, A 319) BY NICKEL – str. 24

Dyskusja Godz. 2000 Uroczyste Spotkanie Odlewników,

Sala Królewska Balowa

Piątek, 25 kwietnia 2014 Godz. 730 – 900 Śniadanie Godz. 930 – 1400 Wycieczka krajoznawcza Godz. 1400 -1500 Obiad Godz. 1500 – 1600 Sesja naukowa III, Sala Konferencyjna

Przewodniczący sesji: Doc. Iveta Vaśkova Prof. Jerzy Zych Prof. Tadeusz Pacyniak

Komunikaty:

1. J. Piekło, M. Maj - METHODS OF ADDITIVE MANUFACTURING USED IN THE TECHNOLOGY OF SKELETON CASTINGS – str. 25

2. J. Beňo, F. Mikšovský, P. Jelínek, K. Konečná, P. Smysl - ALTERNATIVE EVALUATION OF THE PROPERTIES OF THE SILICA SANDS – str. 26

6

3. R. Lakomá, L. Čamek - HYPOTHESIS TESTING TO CONFIRM THE INFLUENCE OF TECHNOLOGICAL PARAMETERS ON POOR QUALITY PRODUCTION – str. 27

4. E. Krivoš, R. Pastirčák, R. Madaj - EFFECT OF TECHNOLOGICAL PARAMETERS ON THE QUALITY AND DIMENSIONAL ACCURACY OF CASTINGS MANUFACTURED BY PATTERNLESS PROCESS TECHNOLOGY – str. 28

5. A. Karwiński, Z. Żółkiewicz - THE RESEARCH OF PROPERTIES OF EXPERIMENTAL CERAMIC LAYERS – str. 29

6. Š. Eperješi, M. Matvija, Ľ. Eperješi, M. Vojtko - EVALUATION OF CRACKING CAUSES OF AlSi5Cu3 ALLOY CASTINGS – str. 30

7.F. Radkovský, I. Kroupová, V. Bednářová, I. Lána - METAL FOAM IN THE CASTING WITH COMPLEX DESIGN – str. 31

8. D. Kopyciński, E. Guzik, A. Szczęsny - ANALYSIS OF EQUIAXED AND ORIENTED MICROSTRUCTURE IN HIGH CHROMIUM CAST IRON – str. 32

9. J. Zych, J. Wróbel - INFLUENCE OF THE SELECTED FACTORS ON THERMAL FATIGUE OF THE ADI IN AN ASPECT OF ITS SUITABILITY AS THE MATERIAL FOR METAL MOULDS – str. 33

10. I. Izdebska-Szanda, A. Baliński, M. Angrecki, A. Palma - THE EFFECT OF NANOSTRUCTURE MODIFICATION OF THE SILICATE BINDER ON ITS BINDING CHARACTERISTICS AND FUNCTIONAL PROPERTIES – str. 34

11. J. Mocek, A. Chojecki - GAS ATMOSPHERE FORMED IN CASTING BY FULL MOLD PROCESS – str. 35

Dyskusja

Godz. 1600 – 1615 Przerwa kawowa,

7

Godz. 1615 – 1715 Sesja naukowa IV, Sala Konferencyjna

Przewodniczący sesji: Dr hab. Maria Maj Doc. Jerzy Malik Prof. Jan Szajnar

Komunikaty: 1. M. Kawalec - MORPHOLOGY OF CARBIDES

CRYSTALLIZING IN Fe-C-V AND FE-C-V-SI ALLOYS – str. 36

2. J. Beňo, P. Jelínek, F. Mikšovský, E. Adámková - OPTIMIZATION OF TECHNOLOGICAL PROPERTIES OF SALT WATER SOLUBLE CORES – str. 37

3. P. K. Krajewski, G. Piwowarski, J. Buraś, W. K. Krajewski, P. Rutkowski, M. Szeliga - THERMO-PHYSICAL PROPERTIES OF SELECTED INCONEL ALLOYS – str. 38

4. M. Stachowicz, K. Granat - POSSIBILITIES OF RECLAMATION MICROWAVE-HARDENED MOLDING SANDS WITH WATER GLASS – str. 39

5. M. Małek, P. Wiśniewski, H. Matysiak, M. Zagórska, K. J. Kurzydłowski - TECHNOLOGICAL PROPERTIES OF SiC-BASED CERAMIC SLURRIES FOR MANUFACTURING INVESTMENT CASTING SHELL MOULDS – str. 40

6. S. Kluska-Nawarecka, D. Wilk-Kołodziejczyk, J. Dajda, M. Macura, K. Regulski - COMPUTER-ASSISTED INTEGRATION OF KNOWLEDGE IN THE CONTEXT OF IDENTIFICATION OF THE CAUSES OF DEFECTS IN CASTINGS – str. 41

7. St. Rzadkosz, A. Garbacz-Klempka, J. Kozana, M. Piękoś, M. Kranc - STRUCTURE AND PROPERTIES RESEARCH OF CASTS MADE WITH COPPER ALLOYS MATRIX – str. 42

8. M. Cholewa, T. Szuter - THERMO-INSULATING MOULDING SAND FOR THIN WALLED CASTINGS – str. 43

8

9. J. Szajnar, M. Stawarz, T. Wróbel, W. Sebzda - INFLUENCE OF SELECTED PARAMETERS OF CONTINUOUS CASTING IN THE ELECTROMAGNETIC FIELD ON THE DISTRIBUTION OF GRAPHITE AND PROPERTIES OF GREY CAST IRON – str. 44

10. M. Rozmus-Górnikowska, Ł. Cieniek, M. Blicharski, J. Kusiński - MICROSTRUCTURE AND MICROSEGREGATION OF AN INCONEL 625 WELD OVERLAY PRODUCED ON STEEL PIPES BY THE COLD METAL TRANSFER TECHNIQUE – str. 45

Dyskusja Godz. 1715 – 1730 Przerwa kawowa, Godz. 1730 – 1830 Sesja naukowa V, Sala Konferencyjna

Przewodniczący sesji: Dr hab. Katarzyna Gawdzińska Prof. Marek Soiński Prof. Dariusz Kopyciński

Komunikaty: 1. A. Kadauw - CHARACTERIZATION OF THE PARAMETERS

OF SAND MOULDS IN COMPACTION PROCESS BY USE OF THE INDUSTRIAL COMPUTER TOMOGRAPHY (ICT) – str. 46

2. J. Szajnar, A. Dulska, T. Wróbel, J. Suchoń - DIFFUSION OF C AND Cr DURING CREATION OF SURFACE LAYER ON CAST STEEL CASTING – str. 47

3. B. Kalandyk, R. Zapała, Ł. Boroń, M. Solecka - IMPACT STRENGTH OF AUSTENITIC AND FERRITIC-AUSTENITIC Cr-Ni STAINLESS CAST STEEL IN -40 AND +20°C TEMPERATURE – str. 48

4. K. Gawdzińska, J. Grabian, M. Szweycer, W. Przetakiewicz - FORMING THE STRUCTURE OF COMPOSITE METALLIC FOAMS – str. 49

9

5. M. Łucarz, B. Grabowska, G. Grabowski - DETERMINATION OF PARAMETERS OF THE MOULDING SAND RECLAMATION PROCESS, ON THE THERMAL ANALYSIS BASES – str. 50

6. M. Łągiewka - MECHANICAL AND TRIBOLOGICAL PROPERTIES OF METAL MATRIX COMPOSITES REINFORCED WITH SHORT CARBON FIBRE – str. 51

7. K. Major-Gabryś, St. M. Dobosz, P. Jelínek, J. Jakubski, J. Beňo - THE MEASUREMENT OF HIGH-TEMPERATURE EXPANSION AS THE STANDARD OF ESTIMATION THE KNOCK-OUT PROPERTIES OF MOULDING SANDS WITH HYDRATED SODIUM SILICATE – str. 52

8. M. Brzeziński, K. Smyksy - ENERGY CONSUMPTION ASPECTS IN THE VACUUM ASSISTED MOULDING PROCESS – str. 53

9. M. Brzeziński - VIRTUAL MODEL OF THE SUBSYSTEM OF MOULDING SYSTEM – str. 54

10. St. M. Dobosz, D. Drożyński, J. Jakubski, K. Major-Gabryś - THE INFLUENCE OF THE CONTENT OF FURFURYL ALCOHOL MONOMER ON THE PROCESS OF MOULDING SAND’S THERMAL DESTRUCTION – str. 55

11. J. Jakubski, K.Major-Gabryś, St.M.Dobosz - USING THE ARTIFICIAL NEURAL NETWORKS TO DETECT DEPENDENCIES BETWEEN SELECTED GREEN MOULDING SANDS PROPERTIES – str. 56

Dyskusja

Godz. 1900 Grill Odlewniczy

Sobota, 26 kwietnia 2014 Godz. 7.30 – 9.00 Śniadanie Godz. 9.00 Zakończenie Konferencji, pożegnanie Gości

10

ZASADY ORGANIZACJI OBRAD

- Wszystkie wygłaszane prace w postaci referatów i komunikatów zostały pozytywnie zrecenzowane i zakwalifikowane do druku w numerach 2-3/2014 i 1/2015, czasopisma Polskiej Akademii Nauk Archives of Metallurgy and Materials (LF).

- Autorzy artykułów którzy wnieśli opłatę konferencyjną otrzymają czasopisma drogą pocztową.

- Całe artykuły zostały także wydane w wersji elektronicznej na płycie CD.

- Języki obrad: polski, czeski, słowacki, angielski. - Do dyspozycji prezentujących jest komputer oraz rzutnik

multimedialny. - Czas referowania jest ograniczony do 10 minut, czas na

zaprezentowanie komunikatu 5 minut.

Organizatorzy

11

THE BEHAVIOR OF BENTONITE BINDERS FOR THE ELEVATED AND HIGH TEMPERATURES

P. Jelínek*, St. M. Dobosz**, J. Beňo*, K. Major-Gabry ś**

* VSB – Technical University of Ostrava,

Department of Metallurgy and Foundry Engineering, 17. Listopadu, 708 33, Ostrava Czech Republic. ** AGH University of Science and Technology,

Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-Ferrous Metals,

Al. Mickiewicza 30, 30-059 Krakow, Poland. Corresponding author. E-mail address: [email protected]

Abstract

Bentonite binders rank among the most widespread applied systems for the production of molds. Their resistance to high temperatures (thermal stability) is mainly defined by genesis of binders, chemical composition and the content of Montmorillonite. The aim of this contribution is to compare selected bentonite binders commonly used in the foundries of the Central European region, in different ways of the thermostability determination as a result of changes of the mechanical strengths of the bentonite bonded sand mixture.

Notatki

12

VANADIUM INFLUENCE ON IRON BASED INTERMETALLIC PHASES IN AlSi6Cu4 ALLOY

D. Bolibruchová*, M. Žihalová*

University of Žilina, Faculty of Mechanical Engineering,

Department of Technological Engineering, Slovak Republic Corresponding author. E-mail address: [email protected]

Abstract

Negative effect of iron in Al-Si alloys mostly refers with iron based intermetallic phases, especially Al5FeSi phases. These phases are present in platelet-like forms, which sharp edges are considered as main cracks initiators and also as contributors of porosity formation. In recent times, addition of some elements, for example Mn, Co, Cr, Ni, V, is used to reduce influence of iron. Influence of vanadium in aluminium AlSi6Cu4 alloy with intentionally increased iron content is presented in this article. Vanadium amount has been graduated and chemical composition of alloy has been analysed by spectral analysis. Vanadium influence on microstructural changes was evaluated by microstructural analysis and some of intermetallic particles were reviewed by EDX analysis.

Notatki

13

PROPOSAL OF METHOD OF REMOVAL OF MOULD MATERIAL FROM THE FINE STRUCTURE OF METALLIC FOAMS USED AS

FILTERS

I. Kroupová, V. Bednářová, T. Elbel, F. Radkovský

∗ VŠB-Technical University of Ostrava, Faculty of Metallurgy and Materials Engineering,

Department of Metallurgy and Foundry, 17. Listopadu 15/2172, Ostrava-Poruba, Czech Republic

Corresponding author. E-mail address: [email protected] Abstract

Metallic foams are materials that are subject of an ongoing research with the broad applicability in many different areas (e.g. automotive industry, building industry, medicine, etc.). These metal materials contain in their structure artificially created pores. These pores give them specific properties, such as: large rigidity at low density, high thermal conductivity, capability to absorb energy, etc. Since the discovery of porous metallic materials numerous methods of production have been developed. The aim of the paper is to introduce effective casting methods of manufacturing of metallic foams, namely cast metal filters from the aluminum alloy. Research deals with investment casting with use of pattern made of polymeric foam, which is used for production of metallic foam with open pores. The main disadvantage of this procedure consists in removing the mould material without damaging the fine structure of the cast filter. Plaster is used as the mould material and the most important result of this paper is the presentation of the effective procedure of plaster removal from the porous structure of cast filters. Notatki

14

MANUFACTURING OF FERRITIC LOW-SILICON AND MOLYBDENUM NODULAR CAST IRON WITH THE INNOVATIVE

2PE- 9 TECHNIQUE

E. Guzik*, D. Kopyciński*, D. Wierzchowski**

*AGH, University of Science and Technology, Faculty of Foundry Engineering,

30-059 Kraków, Al. Mickiewicza 30, Poland ** Krakodlew S.A. 30-969 Krakow, Ujastek 1 St. Poland Corresponding author. E-mail address: [email protected]

Abstract

It has Below are described results of the analysis concerning the use of two cored wire injection method (2PE- 9) and the unique application of a drum ladle as a treatment, transport and casting one, instead of a vertical treatment ladle. Parameter optimization, like: length of nodulariser wire, treatment and pouring temperature have been shown. Influence of various treatment temperatures on magnesium recovery are demonstrated. Typical microstructure, mechanical properties and treatment costs, production of ferritic SiMo ductile iron (EN-GJS-SiMo40-6 Grade, according with EN 16124:2011 (E) are presented. Injection of two Ø 9 mm as well wires; cored in FeSi + Mg nodulariser mixture and inoculant master alloy into a drum ladle is a treatment method that can be used for the production of ferritic ductile iron (SiMo) melted in a coreless induction furnace. Notatki

15

EVALUATION OF HOMOGENITY BREACH CAUSE ON DIE CASTED CASTINGS

J. Malik, Š. Eperješi, P. Futáš, I. Vasková, D. Fecko

Department of Ferrous Metallurgy and Foundry, Faculty of Metallurgy,

Technical University in Košice, Slovakia, Corresponding author. E-mail address: [email protected]

Abstract

Homogenity of die casted casting is influenced by a lot of factors. One of them is correct construction of die casting, into which belongs gating system and vents and cooling system of die. Also other factors have influence on casting´s homogenity, as die casting machine, type of casted alloy, quality itself of produced die, technological parameters of pouring and last but not least, the operation of die casting machine. Optimal construction solution of die and setting of all technological metalurgical parameters gives forecast for production of homogenous castings. Homogenity of die casted casting shows itself mainly by different range of cavities in its individual parts, what corresponds with filling regime of die cavity.

To assure production of homogenous castings with sufficient reliability it is not enough just to notice errors, but it is needed to determine their type and based on this identification determine reasons of their creation and eliminate them.

To achieve the final quality of die casted castings, in all phases of production great attention must be paid to quality control of production with aim to notice and remove the reasons for rejecting castings as soon as possible. Notatki

16

PROTECTING MELTED ZINC-ALUMINIUM BASED FOUNDRY ALLOYS AGAINST HYDROGEN PICK-UP

W. K. Krajewski, G. Piwowarski, P. K. Krajewski

AGH University of Science and Technology - Faculty of Foundry Engineering

23 Reymonta Street, 30-059 Krakow, Poland Corresponding author. E-mail address: [email protected]

Abstract

The paper is devoted to examinations of the refining efficiency of fluxes and refiners applied during melting of zinc and zinc-aluminium alloys. The content of gases, mainly hydrogen, in the alloys not protected during the charge melting and in the ones protected with the fluxes and/or refined is discussed. The performed examinations show that using the protecting fluxes and melt-refining before pouring leads to significant improvement of ductility in Zn and binary Zn-Al alloys as well as significant increase of the material clearness confirmed by increased density. Furthermore, the metallurgical yields are also increased. Notatki

17

INITIAL ASSESSMENT OF ABRASIVE WEAR RESISTANCE OF AUSTEMPERED CAST IRON WITH VERMICULAR GRAPHITE

M. S. Soiński, A. Jakubus

Politechnika Częstochowska;

Wydział Inżynierii Produkcji i Technologii Materiałów; al. Armii Krajowej 19, 42-200 Częstochowa, Polska.


The work compares the abrasive wear resistance of cast iron with vermicular graphite in the as-cast state and after austempering carried out at 290°C, 340°C, or 390°C. The examinations were performed by means of the T-01M tribological tester using the pin-on-disc configuration. Specimens used for examinations were taken from the end tabs of the tensile specimens, these being cut out of the test walls of the double-leg keel block test castings. Examinations proved that the austempering process increases the abrasive wear resistance of vermicular cast iron by several times as compared with the as-cast material. A tendency for a slight decrease in abrasive wear with an increase in austempering temperature can be stated. The coefficient of friction took a little higher values for cast iron after thermal treatment than for the as-cast material. The work was completed with roughness examination by means of electron scanning microscopy. Notatki

18

MEASUREMENT OF ELECTRICAL PROPERTIES AS EFFECTIVENESS APPRAISAL OF MICROWAVE ABSORPTION BY

MOULDING AND CORE SANDS SUBJECT TO MICROWAVE UTILIZATION

D. Nowak, K. Granat, B. Opyd

Wrocław University of Technology,

Institute of Production Engineering and Automation, 50-371 Wrocław, 5 Ignacego Łukasiewicza Str., Poland

Corresponding author. E-mail address: [email protected]

Abstract Within the research, carried-out were examinations of foundry rejects in

form of waste moulding and core sands in order to determine effectiveness of the microwave utilization process. Presented are measurements of permittivity and loss tangent that determine behaviour of materials in electromagnetic field. Measurements were performed on a stand of waveguide resonance cavity that permits precise determination of the above-mentioned parameters with the perturbation method. Examination results of five waste moulding sands confirm that effectiveness of microwave utilization depends on electrical properties of the sandmixes (permittivity and loss tangent). Notatki

19

METALLURGICAL TREATMENT AND MATERIAL PROPERTIES OF EN-GJS-450-18 QUALITY SPHEROIDAL GRAPHITE CAST I RON

J. Odehnal*, J. Hampl**, J. Jakub*

* Pilsen Steel S.R.O., Tylova 1/57, Plzeň, Czech Republic

** VŠB-Technical University of Ostrava, Faculty of Metallurgy and Materials Engineering,

Department of Metallurgy and Foundry / Regional Materials Science and Technology Centre, 17. Listopadu 15/2172, Ostrava-Poruba, Czech Republic


Abstract The article presents the metallurgical and material properties of spheroidal

graphite cast iron with increased silicon content to achieve increased elongation. It describes the melting process to produce EN-GJS-450-18 quality spheroidal graphite cast iron using an electrical induction furnace and the subsequent ladle processing of the melt to achieve the required quality. The achieved properties of the melt are shown in a representative melt analysis and in microstructures taken from samples with wall thickness 20, 50 and 75 mm. The mechanical properties of the spheroidal graphite cast iron are shown in graph form, giving the achieved values for proof stress, tensile strength, elongation, impact energy and fracture toughness.

Notatki

20

THEORETICAL AND PRACTICAL ASPECTS OF PNEUMATIC POWDER INJECTION INTO LIQUID ALLOYS WITH A NON-

SUBMERGED LANCE

J. Jezierski, K. Janerka, M. Stawarz

Silesian University of Technology, Department of Foundry Engineering, Towarowa 7, 44-100 Gliwice, Poland


The method of powder injection into molten metal has been widely known since tens of years and successfully utilized in various metallurgical processes. The most common is a solution with injection lance submerged under the liquid alloy surface, because it is easier apart from some of disadvantages of this approach. In this paper the complex authors’ experiments on the pneumatic injection process with non-submerged lance have been presented. The new approach on jet cone angle importance and its influence on the efficiency of the injection process has been shown. The issue of the effective jet radius what was proposed by former scientists as well as computer modelling and real injection experiments recorded with high speed camera have been presented. The final comparison of the typical injection lance and developed by authors new lance with flange was presented, too. The benefits of use of a new one for the treatment of small liquid alloy volume (e.g. inoculation or alloys addition introduction) have been pointed. Notatki

21

INFLUENCE OF TECHNOLOGICAL PARAMETERS OF FURANE MIXTURES ON SHRINKAGE CREATION IN DUCTILE CAST IRON

CASTINGS

I. Vasková, M. Hrubovčáková, J. Malik, Š. Eperješi

Department of Ferrous Metallurgy and Foundry, Faculty of Metallurgy, Technical University in Košice, Slovakia

Corresponding author. E-mail address: [email protected] Abstract Ductile cast iron (GS) has noticed great development in last decades and its boom has no analogue in history humankind. Ductile iron has broaden the use of castings from cast iron into areas, which where exclusively domains for steel castings. Mainly by castings, which weight is very high, is the propensity to shrinkage creation even higher. Shrinkage creation influences mainly material, construction of casting, gating system and mould. Therefore, the main realized experiment was to ascertain the influence of technological parameters of furane mixture on shrinkage creation in castings from ductile iron. Together was poured 12 testing items in 3 moulds. Notatki

22

EFFECT OF CR AND V ALLOY ADDITIONS ON THE MICROSTRUCTURE AND MECHANICAL PROPERTIES OF ALLOY

AM60

C. Rapiejko, B. Pisarek, T. Pacyniak

Lodz University of Technology, Department of Materials Engineering and Production Systems,

ul. Stefanowskiego 1, 90-924 Łódź, Poland Corresponding author. E-mail address: [email protected]

Abstract

The paper presents the results of the investigation of the effect of Cr and/or V alloy additions on the microstructure and mechanical properties of the magnesium alloy AM60. The examinations are performed within the frames of a project aiming at the elaboration of an experimental and industrial technology of producing constructively complex elements of machines and devices made of magnesium alloys with the method of lost mould casting. It has been proven that small numbers of Cr and V alloy additions improve the strength properties: Rm, A%, and the hardness HB of the obtained casts. The experimental casts were made in ceramic moulds. Notatki

23

DISTRIBUTION OF REINFORCING PARTICLES IN THE PRESSU RE DIE CAST AlSi11/20% SiC COMPOSITE

A. Pasieka, Z. Konopka

Częstochowa University of Technology


Abstract A method of pressure die casting of composites with AlSi11 alloy matrix

reinforced with 20 vol. % of SiC particles and the analysis of the distribution of particles within the matrix are presented. The composite castings were produced at various values of the piston velocity in the second stage of injection, at diverse intensification pressure values, and various injection gate width values. The distribution of particles over the entire cross-section of the tensile specimen is shown. The index of distribution was determined on the basis of particle count in elementary measuring fields. The regression equation describing the change of the considered index was found as a function of the pressure die casting parameters. The conclusion presents an analysis of the obtained results and their interpretation. Notatki

24

ELIMINATION OF NEGATIVE EFFECT OF FE IN SECONDARY ALLOYS AlSi6Cu4 (EN AC 45 000, A 319) BY NICKEL

D. Bolibruchová, J. Macko, M. Brůna

University of Žilina, Faculty of Mechanical Engineering,

Department of Technological Engineering, Slovak Republic Corresponding author. E-mail address: [email protected]

Abstract

Submitted article deals with influence of iron based phases segregation by nickel, which is in literature known as iron based phases corrector. Iron is one of the most common impurities that can be found in Al-Si alloys. It is impossible to remove iron from melt by standard operations, but it is possible to eliminate iron negative effects by addition of other elements, that enables segregation of iron in form of intermetallics with less harmful effect. For melt treatment was selected an exact alloy with requested iron content - master alloy AlNi20. Influence of nickel was evaluated quantitatively by chemical analysis (solubility), thermal analysis and microstructure evaluation. Experimental results analysis shows a new view on solubility of iron based phases during melt preparation and treatment with higher iron content and also nickel effect as iron corrector of iron based phases. It can be concluded that nickel did not influenced iron based phases (β-phases), it does not change their type into more favorable form. As an initial impulse for starting this work was insufficient theoretical knowledge of usage secondary alloys Al-Si-Cu with higher iron content and its appropriate elimination in process of castings production for automotive industry. Increased iron content in alloys causes segregation of iron phases in various shapes and types during solidification, which subsequently affects quality, soundness and lifetime of castings. Because of increased demands for casting quality, final mechanical properties and effort to reduce costs, it is necessary to look for compromises in casting production from secondary alloys with occurrence of various impurities. Notatki

25

METHODS OF ADDITIVE MANUFACTURING USED IN THE TECHNOLOGY OF SKELETON CASTINGS

J. Piekło, M. Maj

University of Science and Technology, Faculty of Foundry Engineering,

Department of Foundry Process Engineering, Section of Foundry Machines and Casting Design


Rapid development of the methods of additive manufacturing (AM) introduces a number of changes to the design of foundry equipment. AM methods are of particular importance in the development of technology to make small lots of castings or single cast items of complex shapes, such as skeleton castings manufactured also by means of other technologies. AM methods create the possibility of making single-use moulds, cores and wax patterns, as well as patterns made from plastics for repeated use. The development of AM techniques gives theoretically unlimited possibilities in the choice of the designed casting configurations. This fact can be used during the analysis of casting mechanical properties based on the methods of topology optimisation, when the said optimisation carried out at the initial stage of design "matches" the shape of parts to the field of stresses or displacements caused by external load and fixing mode. The article discusses the possibilities and advantages that result from combining the new methods of shaping the casting endurance with AM technologies. Notatki

26

ALTERNATIVE EVALUATION OF THE PROPERTIES OF THE SILICA SANDS

J. Beňo, F. Mikšovský, P. Jelínek, K. Konečná, P. Smysl

* VSB – Technical University of Ostrava, Faculty of Metallurgy and Material

Engineering, Department of Metallurgy and Foundry Engineering, 17. Listopadu 15/2173, 702 00 Ostrava, Czech Republic


Abstract For the evaluation of silica sands, which belongs to the most employed

sands of foundry molding mixtures, there are a number of methods and techniques to characterize their quality. This implies good knowledge of their strengths and weaknesses. However, a small proportion of published results are dedicated to the impact of transport on transport routes in the foundry and the processes of dry reclamation on the properties of the silica sands, in particular on changes to the granulometry and the formation of undesirable dust sands shares, which significantly affect the properties of the sand mixture.

The aim of this contribution is the evaluation of inclination of the silica sand to crush (the formation of dust, change the granulometry) according to the newly developed methodology with regard to its nature of sand (genesis, the shape of the grains, the character of the surface). Notatki

27

HYPOTHESIS TESTING TO CONFIRM THE INFLUENCE OF TECHNOLOGICAL PARAMETERS ON POOR QUALITY

PRODUCTION

R. Lakomá *, L. Čamek **

* VŠB–Technical University of Ostrava, Faculty of Metallurgy and Materials Engineering, Department of Metallurgy and Foundry Industry,

17. listopadu 15/2172, 708 33 Ostrava, CZ ** VŠB–Technical University of Ostrava, Faculty of Metallurgy and Materials

Engineering, Department of Metallurgy and Foundry Industry, 17. listopadu 15/2172,, 708 33 Ostrava, CZ


Abstract This report addresses some chosen statistical methods that could be used to

confirm and set up the required functions of technology in foundry companies where parts are cast by the low-wax casting method, whereas these chosen statistical methods are intended to reduce poor quality of produced parts. This research was made on a practical example. Utilization of hypothesis testing methods was examined in order to confirm technological parameters having some influence on the products quality. The data were compared before and after the implementation of changes aimed at reduction of poor quality produced parts in the wax department. The results confirmed that the implemented change had a statistically conclusive influence. Notatki

28

EFFECT OF TECHNOLOGICAL PARAMETERS ON THE QUALITY AND DIMENSIONAL ACCURACY OF CASTINGS MANUFACTURED

BY PATTERNLESS PROCESS TECHNOLOGY

E. Krivoš*, R. Pastirčák** , R. Madaj***

* KTI, SjF, ŽU Žilina, Univerzitná 1, 010 26 Žilina. E-mail: [email protected] ,Tel.: 0907746897

** KTI, SjF, ŽU Žilina, Univerzitná 1, 010 26 Žilina. E-mail: [email protected] ,Tel.: 041/5132797

*** KKČS, SjF, ŽU Žilina, Univerzitná 1, 010 26 Žilina. E-mail: [email protected] ,Tel.: 041/5132925

Abstract

Submitted article deals with the effect of selected technological parameters on the quality and dimensional accuracy of prototype castings made by Patternless process technology. During experiments were used two types of molding compounds (foamed gypsum and compound based on silica sand and resin). Experiments were focused on optimization of cutting parameters in terms of efficiency, accuracy and possibilities to minimize tool wear. Article deals also with the dimensional and shape accuracy of the castings made by Z-Cast technology. The main aim of the research is to optimize Patternless process technology to such an extent, that achieved dimensional and shape accuracy will be comparable to castings made by the Z-Cast technology. Notatki

29

THE RESEARCH OF PROPERTIES OF EXPERIMENTAL CERAMIC LAYERS

A. Karwi ński, Z. Żółkiewicz

Foundry Research Institute, 30-418 Kraków, ul. Zakopiańska 73


Abstract In the evaporative pattern casting process, the surface of a polystyrene

pattern (Styrofoam) is coated with a ceramic layer. This ceramic layer, which coats the evaporative pattern, should have specific physiochemical properties including: resistance to thermal, chemical, and erosive activity of molten metal and proper permeability for gases which are produced by the evaporative polystyrene pattern. The article presents the research results of properties of experimentally selected ceramic layers applied on a polystyrene pattern in the evaporative pattern casting process. Notatki

30

EVALUATION OF CRACKING CAUSES OF AlSi5Cu3 ALLOY CASTINGS

Š. Eperješia*, M. Matvija a, Ľ. Eperješib, M. Vojtko a

a Faculty of Metallurgy, Technical University of Košice,

Letná 9, 040 01 Košice, Slovakia b ČZ, a. s., Tovární 202, 386 15 Strakonice, Czech Republic


Recently, the castings made from aluminum-silicon alloys by pressure casting into metal moulds are increasingly used in the automotive industry. In practice, on these castings are high demands, mainly demands on quality of their structure, operating life and safety ensuring of their utilization. The AlSi5Cu3 alloy castings are widely used for production of car components. After the prescribed tests, the cracks and low mechanical properties have been identified for several castings of this alloy, which were produced by low pressure casting into a metal mould and subsequent they were heat treated. Therefore, analyses of the castings were realized to determine the causes of these facts. Evaluation of the AlSi5Cu3 alloy structure and failure causes were the subject of investigation in this article. Notatki

31

METAL FOAM IN THE CASTING WITH COMPLEX DESIGN

F. Radkovský*, I. Kroupová*, V. Bednářová*, I. Lána**

* VŠB-Technical University of Ostrava, Faculty of Metallurgy and Materials

Engineering, Department of Metallurgy and Foundry, 17. Listopadu 15/2172, Ostrava-Poruba, Czech Republic

** Slévárna a Modelárna Nové Ransko, s.r.o. Corresponding author. E-mail address: [email protected]

Abstract

The article describes the manufacture, properties and applications of metal foams. Numerous methods of production put the emphasis on foundry production of metal foams with regular cellular structure. Manufacture of the casting mold is made using a preform or pattern for investment casting. Penetration of metal into the narrow cavities of the mould will have to be resolved, as well as the total metal fluidity at different designs of gating system. The aim of the work is to evaluate the foundry and mechanical properties of shaped castings with different shapes of individual inner cells. Notatki

32

ANALYSIS OF EQUIAXED AND ORIENTED MICROSTRUCTURE IN HIGH CHROMIUM CAST IRON

D. Kopyciński, E. Guzik, A. Szczęsny

AGH, University of Science and Technology, Faculty of Foundry Engineering,

30-059 Kraków, Al. Mickiewicza 30, Poland Corresponding author. E-mail address: [email protected]

Abstract

It has been proved that an addition of boron carbide and disintegrated steel scrap introduced as an inoculants to the chromium white cast iron changes the structure of castings. The said operation increases the number of crystallization nuclei for dendrites of the primary austenite. In this case, the iron particles act as substrates for the nucleation of primary austenite due to a similar crystallographic lattice. The more numerous are the dendrites of primary austenite and the structure more refined and the mechanical properties higher. Castings after B4C inoculation revealed a different structure of fine grained fracture. Primary precipitates of chromium carbide also appeared, reducing the mechanical properties of as-cast parts. Additionally, in order to increase the mechanical properties of chromium cast iron, unidirectional solidification was used. In this case, 0,3 wt. % cerium was used as inoculants.

Notatki

33

INFLUENCE OF THE SELECTED FACTORS ON THERMAL FATIGUE OF THE ADI IN AN ASPECT OF ITS SUITABILITY AS

THE MATERIAL FOR METAL MOULDS

J. Zycha, J. Wróbelb

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

b PIOMA - Odlewnia Sp. z o.o., ul. Dmowskiego 38, 97-300 Piotrków Trybunalski, Polska

Corresponding author. E-mail address: [email protected] Abstract:

The investigation results of the thermal fatigue resistance of two ADI grades (EN-GJS-1200-2 and EN-GJS-800-8) are presented in the paper. Tests were performed on the author’s research stand, by means of the resistance heating of samples acc. L.F. Coffin method. The thermal fatigue resistance is the basic criterion in assessing the material suitability for metal moulds. The maximal temperature (Tmax) of thermal cycles influence on their number, which the sample can withstand before cracking, were estimated. Structure transformations, hardness and strength changes of the austempered ductile iron (ADI) were analysed. It was found, that at cyclic heating to Tmax < 500oC, the ADI retains its primary ausferritic structure, even after more than 10.000 thermal cycles. Such ADI behaviour predisposes it to be applied as a material for metal moulds used in the pressure die casting, it means mainly at casting Mg and Zn alloys as well as for small castings of Al alloys.

Notatki

34

THE EFFECT OF NANOSTRUCTURE MODIFICATION OF THE SILICATE BINDER ON ITS BINDING CHARACTERISTICS AND

FUNCTIONAL PROPERTIES

I. Izdebska-Szanda, A. Baliński, M. Angrecki, A. Palma

Foundry Research Institute, Cracow, Poland Corresponding author. E-mail address: [email protected]

Abstract

A method for the chemical modification of silicate binder (hydrated sodium silicate) affecting the distribution of its nanostructure elements was disclosed. The effect of silicate binder modification on the resulting technological properties of moulding sands, determined under standard conditions and at elevated temperatures in the range from 1000C to 9000C, was discussed. Modification of this type is done on inorganic binders in order to reduce their unfavourable functional properties. It is particularly important when moulding sands with the silicate binder are used for casting of low-melting alloys. Therefore special attention was paid to the impact that modification of inorganic binders may have on the knocking out properties of sands prepared with these binders, when they are used in the process of casting non-ferrous alloys.

Notatki

35

GAS ATMOSPHERE FORMED IN CASTING BY FULL MOLD PROCESS

J. Mocek, A. Chojecki

AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-

ferrous Metals, Al. Mickiewicza 30, 30-059 Krakow, Poland


Abstract A test mold was designed to investigate the full mold process. Pressure

changes in a gap developing between the pattern made of foamed polystyrene and the raising column of liquid alloy were determined. Studies were conducted pouring molds with cast iron and with AK11 silumin. It was found that pressure is significantly higher in the case of cast iron, due to a higher rate of pattern decomposition and more advanced dissociation of hydrocarbons. The increase in pressure was observed to have no significant effect on changes in the pouring rate as it was compensated by higher metallostatic pressure. The increase of pressure occurs immediately after the start of pouring, it reaches a maximum and then stabilizes or decreases smoothly as a result of the drop in metallostatic pressure. The temperature of pouring has a significant effect on the decomposition rate of hydrocarbons evolving from the metal. During pouring of cast iron, the presence of hydrogen was revealed. It was particularly evident across the gas-permeable coating, where the concentration has exceeded 40%. Hydrogen precipitation was accompanied by an evolution on the casting surface of considerable amounts of pyrolytic carbon. It was found that gases forming in the gap were totally free from oxygen.

Notatki

36

MORPHOLOGY OF CARBIDES CRYSTALLIZING IN Fe-C-V AND Fe-C-V-Si ALLOYS

M. Kawalec*

*AGH, University of Science and Technology,

Faculty of Foundry Engineering, 30-059 Kraków, Al. Mickiewicza 30, Poland


Fe-C-V alloys with high vanadium content are included in the family of white cast irons, because all carbon present in this material is bound into vanadium carbides. The study presents the results of microstructural examinations of the volume solidifying Fe-C-V and Fe-C-V-Si alloys containing carbon in the range of 1.38÷4.14%, vanadium in the range of 6.77÷16.34% and silicon in the range of 0÷3.10%. Attention was focussed on near-eutectic alloys.

In Fe-C-V and Fe-C-V-Si alloys, depending on the chemical composition, can crystallize eutectic composed of ferrite and VC-type carbides highly differentiated morphology. In these alloys were observed following types of eutectic: fibrous eutectic, spiral, quasi-regular and globular.

Moreover, both these alloys are crystallized in the form of non-faceted dendrites primary carbides and faceted dendrites primary carbides. The paper presents examples of the different microstructures. Also in order to examine the shape of the primary carbides and eutectics in a closer detail the specimens were deep-etched with aqua regia and then examined in the SEM.

Notatki

37

OPTIMIZATION OF TECHNOLOGICAL PROPERTIES OF SALT WATER SOLUBLE CORES

J. Beňo, P. Jelínek, F. Mikšovský, E. Adámková

VSB – Technical University of Ostrava, Faculty of Metallurgy and Material

Engineering, Department of Metallurgy and Foundry Engineering Corresponding author. E-mail address: [email protected]

Abstract Applications of cores based on inorganic salts are known at present in particular in the field of gravity and low-pressure casting. Their use for high-pressure casting is considerably more complicated and for successful using them it is necessary to define and meet a number of complex conditions. This contribution is aimed at optimization of strength characteristics of cores based on inorganic salts by thermal treatment of cores and the influence of treatments on required property of cores – solubility. Notatki

38

THERMO-PHYSICAL PROPERTIES OF SELECTED INCONEL ALLOYS

1a P. K. Krajewski, 1a G. Piwowarski, 1a J. Buraś, 1a* W. K. Krajewski,

1b P. Rutkowski, 2 M. Szeliga

1AGH University of Science and Technology aFaculty of Foundry Engineering, 23 Reymonta Street, 30-059 Krakow, Poland

bFaculty of Materials Science and Ceramics, 30 Mickiewicza Alee, 30-059 Krakow, Poland

2Rzeszow Technical University, Faculty of Mechanical Engineering, 35-959 Rzeszów, Al. Powstańców Warszawy 12


The paper brings results of examinations of main thermo-physical properties of selected Inconel alloys, i.e. their heat diffusivity, thermal conductivity and heat capacity, measured in wide temperature range of 20 – 900 oC. The mathematical relationships of the above properties vs. temperature were obtained for the IN 100 and IN 713C alloys. These data can be used when modelling the IN alloys solidification processes aimed at obtaining required structure and properties as well as when designing optimal work temperature parameters. Notatki

39

POSSIBILITIES OF RECLAMATION MICROWAVE-HARDENED MOLDING SANDS WITH WATER GLASS

M. Stachowicz, K. Granat

Wrocław University of Technology,

Wybrzeże Wyspiańskiego 25, 50-370 Wrocław, Poland Corresponding author. E-mail address: [email protected]

Abstract

The paper presents results of a research on identifying opportunities for effective reclamation of waste molding sand with water-glass, hardened by microwave heating. The molding sand applied in the tests was prepared with use of selected type 145 of sodium water-glass. The sand was sequentially processed by microwave hardening, cooling, thermal loading to 800 °C, cooling to ambient temperature, crushing and mechanical reclamation. These stages create a closed processing loop. After each cycle, changes of tensile strength and bending strength were determined. Results of the study show that it is possible to activate surface of high-silica grains of waste foundry sand hardened with microwaves, provided that applied are appropriate processing parameters in successive operation cycles. Notatki

40

TECHNOLOGICAL PROPERTIES OF SiC-BASED CERAMIC SLURRIES FOR MANUFACTURING INVESTMENT CASTING

SHELL MOULDS

M. Małek1*, P. Wiśniewski1, H. Matysiak2, M. Zagórska1, K. J. Kurzydłowski 1

1Faculty of Materials Science and Engineering, Warsaw University of Technology,

141 Wołoska Street, 02- 507 Warsaw 2Functional Materials Research Centre, Warsaw University of Technology,

25 Janka Bytnara Rudego Street, 02-645 Warsaw Corresponding author. E-mail address: [email protected]

Abstract

In this work technological properties of ceramic slurries based on silicon carbide were characterized. Silicon carbide and poly(vinyl alcohol) in an amount 6%, 10% and 15 wt. % as a solution were added to prepare the ceramic slurries. Solid phase content in ceramic slurries was 62,5 wt.%. Plate weight test, pH, density, viscosity (measured by the Zhan 4# cup) and dynamic viscosity were investigated. Dipping test on wax model was done to measure adhesive properties. Characterization of SiC fillers powder was made by determination of grain size, density, chemical composition, Zeta potential and by use of scanning electron microscopy. Obtained results of ceramic slurries based on SiC meet standard specification in industrial investment casting and its properties are very promising for future application in investment casting of superalloys. Notatki

41

COMPUTER-ASSISTED INTEGRATION OF KNOWLEDGE IN THE CONTEXT OF IDENTIFICATION OF THE CAUSES OF DEFECTS IN

CASTINGS

S. Kluska-Nawarecka*, D. Wilk-Kołodziejczyk *, J. Dajda** , M. Macura ** , K. Regulski**

*Foundry Research Institute, Cracow, Poland;

** AGH University of Science and Technology, Cracow, Poland; Corresponding author. E-mail address: [email protected]

Abstract

The paper outlines the rules of creating diagnostic tasks scenarios in determining the causes of defects in castings. The paper presents as well the rules of operation of the computer system for data integration based on Extract-Trasform-Load technology, and a description of prototype implementation of this system, also examples of the tests that was carried out. Notatki

42

STRUCTURE AND PROPERTIES RESEARCH OF CASTS MADE WITH COPPER ALLOYS MATRIX

St. Rzadkosza, A. Garbacz-Klempkaa, J. Kozanaa,

M. Piękośa, M. Kranc b a Faculty of Foundry Engineering, AGH-University of Science and Technology,

Reymonta 23, 30-059 Kraków, Poland b Foundry Research Institute, Zakopiańska 73, Kraków, Poland Corresponding author. E-mail address: [email protected]

Abstract The article presents the research results obtained at the Department of

Foundry of Non-Ferrous Metals at the Foundry Faculty of AGH, the University of Science and Technology, in Krakow. The research comprises the processes connected with the technology of melting, refining and making casts based on copper matrix, both contemporary and historical, especially bronzes containing tin, zinc and lead. These issues are well-known but they still pose problems for contemporary foundries. The article presents the results of modifying formulas on the improvement of mechanical properties and limiting casting defects. Notatki

43

THERMO-INSULATING MOULDING SAND FOR THIN WALLED CASTINGS

M. Cholewa, T. Szuter

Institute of Ceramic and Building Materials, Refractory Materials Division


In paper the selection of the composition and determination of main properties of novel moulding sand was described. The mail goal was to create moulding sand characterized by high thermal insulating properties in relations with low specific weight. This type of moulding sand will find application in thin walled castings with complex geometry, in particular for cores of the skeleton castings. In this work the results of the compressive strength, permeability and friability was presented. It was noted that aluminosilicate microspheres are suitable as moulding sand matrix. Influence of the polyglicol addition on quality and properties of the moulding sand was described. The use of the aluminosilicate microspheres allowed to obtain the moulding sand characterized by high insulation rate, low specific weight and good mechanical properties. Notatki

44

INFLUENCE OF SELECTED PARAMETERS OF CONTINUOUS CASTING IN THE ELECTROMAGNETIC FIELD ON THE

DISTRIBUTION OF GRAPHITE AND PROPERTIES OF GREY CAS T IRON

J. Szajnar, M. Stawarz, T. Wróbel, W. Sebzda

Politechnika Śląska, Katedra Odlewnictwa, Towarowa Str. 7, 44-100 Gliwice, Poland


In paper problem concerning modification of grey cast iron EN-GJL-200, which is realized mainly by intensification of liquid metal movement in horizontal continuous casting mould containing electromagnetic stirrer is presented. The range of studies contains influence of electromagnetic field on morphology of graphite and usable properties i.e. tensile strength, hardness and machinability. Moreover the influence of velocity of ingot pulling on structure was analyzed. The results of studies and their analysis show possibility of improvement in quality of grey cast iron continuous ingot firstly in result of elimination of hard spots in structure by properly selection of velocity of ingot pulling and second in result of unification of size, shape and distribution of flake graphite by application of electromagnetic field. Notatki

45

MICROSTRUCTURE AND MICROSEGREGATION OF AN INCONEL 625 WELD OVERLAY PRODUCED ON STEEL PIPES BY THE COL D

METAL TRANSFER TECHNIQUE

M. Rozmus-Górnikowska, Ł. Cieniek, M. Blicharski, J. Kusiński

AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science,

al. Mickiewicza 30, 30-059 Krakow, Poland Corresponding author. E-mail address: [email protected]

Abstract The aim of this work was to investigate the development of microstructure and variations in chemical composition in commercial Inconel 625 coatings on a ferritic-pearlitic steel overlaid by the CMT. The investigation showed that microsegregation occurring during the weld overlay solidification makes the dendrite cores to be richer in Ni, Fe and Cr and interdendritic areas in Mo and Nb. Niobium shows the strongest tendency to segregation during solidification; molybdenum tends to segregate less and chromium has the lowest tendency to segregation. Although Inconel 625 is a solid solution strengthened alloy, Nb and Mo-rich phases are formed in the interdendritic areas of weld overlays. Notatki

46

CHARACTERIZATION OF THE PARAMETERS OF SAND MOULDS IN COMPACTION PROCESS BY USE OF THE INDUSTRIAL

COMPUTER TOMOGRAPHY (ICT)

A. Kadauw

Technical University Bergakademie Freiberg Agricola 1; 09596 Freiberg, Germany


Abstract One main problem in moulding is the proper characterization of the local

density of the mould, the best without its destroying, for assessment the quality of the mould and to compare results of compaction modeling with experimental results. Industrial computer tomography (ICT) is a technique that allows the non-destructive and contact-free visualization and characterization of the internal and external parts of physical objects including also sand moulds. It is possible to apply ICT technique for the specific research presented here. Moulding sand compaction plays an important role for the quality of the mould and as the consequence for the quality of manufactured casting. The required quality of the castings can be achieved by selecting optimum manufacturing process parameters. The determination of these parameters is often carried out by trial-and-error-method, which is expensive and time consuming. To improve the understanding of the influence of various parameters, mathematical modeling of the compaction processes using numerical solutions was performed. Theoretical results of the compaction simulations have then been compared with practical results of mould compaction obtained by ICT. It was found that simulation results agree well with data from computer tomography and provide insight into the spatial distribution of the density of sand moulds under industrial condition. Notatki

47

DIFFUSION OF C AND Cr DURING CREATION OF SURFACE LAYER ON CAST STEEL CASTING

J. Szajnar, A. Dulska, T. Wróbel, J. Suchoń

Silesian University of Technology, Department of Foundry,

ul. Towarowa 7, 44-100 Gliwice, Poland. Corresponding author. E-mail address: [email protected]

Abstract

In paper a method of improvement in usable properties of unalloyed cast steel casting in result of diffusion of C and Cr in process of creation of surface layer is presented. The aim of paper was determination of diffusion range of basic elements of alloy surface layer. Moreover a quantitative analysis of carbides phase strengthens surface layer of casting was carried out. The results of studies shown that important factors of surface layer creation are maximal temperature Tmax on granular insert – cast steel boundary dependent of pouring temperature, granularity Zw of Fe-Cr-C alloy insert and thickness of casting wall gśo. On the basis of obtained results was affirmed that with increase of thickness of casting wall increases range of diffusion in solid state in Fe-Cr-C grains and in liquid state. Moreover the range of Tmax = 1300÷1500oC favours to creation of proper alloy surface layers on cast steel. Notatki

48

IMPACT STRENGTH OF AUSTENITIC AND FERRITIC-AUSTENITIC Cr-Ni STAINLESS CAST STEEL IN -40 AND +2 0°C

TEMPERATURE

B. Kalandyk*, R. Zapała*, Ł. Boroń** , M. Solecka***

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

** Foundry Research Institute, Krakow, Poland *** AGH University of Science and Technology, Faculty of Metals Engineering and Industrial Computer Science, 30-059 Kraków, 30 Mickiewicza Av., Poland


Abstract Studies described in this paper relate to common grades of cast

corrosion resistant Cr-Ni steel with different matrix. The test materials were subjected to heat treatment, which consisted in the solution annealing at 1060°C followed by cooling in water. The conducted investigations, besides the microstructural characteristics of selected cast steel grades, included the evaluation of hardness, toughness (at a temperature of -40 and +20oC) and type of fracture obtained after breaking the specimens on a Charpy impact testing machine. Based on the results of the measured volume fraction of ferrite, it has been found that the content of this phase in cast austenitic steel is 1.9%, while in the two-phase ferritic-austenitic grades it ranges from 50 to 58%. It has been demonstrated that within the scope of conducted studies, the cast steel of an austenitic structure is characterised by higher impact strength than the two-phase ferritic-austenitic (F-A) grade. The changing appearance of the fractures of the specimens reflected the impact strength values obtained in the tested materials. Fractures of the cast austenitic Cr-Ni steel obtained in these studies were of a ductile character, while fractures of the cast ferritic-austenitic grade were mostly of a mixed character with the predominance of brittle phase and well visible cleavage planes. Notatki

49

FORMING THE STRUCTURE OF COMPOSITE METALLIC FOAMS

K. Gawdzińska, J. Grabian, M. Szweycer, W. Przetakiewicz

Maritime University of Szczecin, Poland Corresponding author. E-mail address: [email protected]

Abstract

The Department of Marine Materials Engineering, Maritime University of Szczecin, has conducted research on the technology of metallic composites, focusing on composite aluminium foams stabilized with ceramic particles. The research was aimed at seeking large-scale applications of these foams in maritime transport. One technology which enables efficient, inexpensive and diversified – in terms of foam structure – control of foam properties is the foundry technology consisting in gas injection into liquid metal. This method requires precise control of the process parameters, especially regarding temperature stabilization, as well as precise injection of the gas into the metal. The process of foaming of liquid aluminium or its silicon alloys can also be conducted using ceramic particles. This is a metallic-ceramic composite foaming process (patent PL 211439 B1). The paper presents the process of structure forming of metallic-ceramic foams. Notatki

50

DETERMINATION OF PARAMETERS OF THE MOULDING SAND RECLAMATION PROCESS, ON THE THERMAL ANALYSIS BASES

M. Łucarz 1, B. Grabowska1, G. Grabowski2

1 AGH University of Science and Technology, Faculty of Foundry Engineering,

30-059 Kraków, 23 Reymonta Str., Poland 2 AGH University of Science and Technology, Faculty of Material Engineering

and Ceramics, 30-059 Kraków, 30 Mickiewicza Ave., Poland Corresponding author. E-mail address: [email protected]

Abstract For the practical and functional reasons the investigation of the thermal

decomposition process is of an essential meaning in relation to the thermal stabilisation of materials and obtaining for them the desired thermal properties. On the other side, thermal tests are carried out in order to identify degradation mechanisms, which is important in the environment protection context, including materials reuse. The cycle of investigations in which thermal TG-DTA methods were applied as supplementary ones for the works on the optimisation of the thermal reclamation process is presented in the hereby paper. The thermal reclamation process as a utilisation method of spent moulding and core sands is more costly than other reclamation methods, but in the majority of cases it simultaneously provides the best cleaning of mineral matrices from organic binders. Thus, the application of the thermal analysis methods (TG-DTA), by determining the temperature range within which a degradation followed by a destruction of bounded organic binders in moulding sands, can contribute to the optimisation of the thermal reclamation process and to the limiting its realisation costs. Notatki

51

MECHANICAL AND TRIBOLOGICAL PROPERTIES OF METAL MATRIX COMPOSITES REINFORCED WITH SHORT CARBON

FIBRE

M. Ł ągiewka

Czestochowa University of Technology Corresponding author. E-mail address: [email protected]

Abstract

The paper constitutes the culmination of the foregoing investigations concerning the influence of short carbon fibre on the enhancement of AlMg10 alloy properties. The presented work brings forward the results of examinations of mechanical and tribological properties of metal matrix composites (MMCs) based on this alloy. Composites were produced by two methods: either by gravity casting or by squeeze casting in semi-solid state of a composite suspension previously obtained through mixing of its components. The volume fraction of the reinforcing phase was varied and took the value of either 5, or 10, or finally 15 vol. %. Specimens cut out of the experimental castings were examined with respect both to their mechanical properties, i.e. the tensile strength and unit elongation, and to their tribological behaviour. A series of examinations of the mechanical properties proved a slight increase in tensile strength and a minor decrease in unit elongation of the examined composite materials both for gravity cast and squeeze cast specimens, as compared with the properties of pure matrix alloy. The introduction of short carbon fibre into the matrix alloy resulted also in the increased abrasive wear resistance of the examined composites in comparison to the non-reinforced matrix. Notatki

52

THE MEASUREMENT OF HIGH-TEMPERATURE EXPANSION AS THE STANDARD OF ESTIMATION THE KNOCK-OUT PROPERTIES

OF MOULDING SANDS WITH HYDRATED SODIUM SILICATE

K. Major-Gabry śa, St. M. Dobosza, P. Jelínekb, J. Jakubskia, J. Beňob

a)AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-


b)VSB – Technical University of Ostrava, Faculty of Metallurgy and Material Engineering, Department of Metallurgy and Foundry Engineering, Czech

Republic Corresponding author. E-mail address: [email protected]

Abstract

The necessity of receiving high quality castings forces undertaking research to elaborate moulding and core sands ensuring obtaining the materials with relevant technological parameters and also with high environmental standards. The most important group here are moulding sands with hydrated sodium silicate. Unfortunately, their fundamental disadvantages are weak knock-out properties. The article presents the most commonly used methods of measuring the knock-out properties of moulding and core sands. The authors propose a new method for estimation this parameter. The method is based on the measurement of high-temperature expansion. Notatki

53

ENERGY CONSUMPTION ASPECTS IN THE VACUUM ASSISTED MOULDING PROCESS

M. Brzeziński, K. Smyksy

AGH University of Science and Technology,

Faculty of Foundry Engineering, Krakow, Poland Corresponding author. E-mail address: [email protected]

Abstract In the manufacturing of foundry sand moulds currently are used

various methods of moulding sand compaction. Investigators are still looking for the optimal methods of mould manufacturing not only in terms of achieved technological effects, but also in important terms of energy consumption. The article presents selected results of research of own variant of the synthetic moulding sand compaction process with vacuum using. The measurements were also designed for evaluation the energy consumption in this method. The results were compared with other air flow moulding methods which currently are wide used. The study was performed on the original own design test stand. The stand allows the visualization of the compaction process. Notatki

54

VIRTUAL MODEL OF THE SUBSYSTEM OF MOULDING SYSTEM

M. Brzeziński

AGH University of Science and Technology, Faculty of Foundry Engineering, Krakow, Poland


Abstract The occurring changes in the foundry industry are due to an increasing in

global competition and customer requirements. In order to meet these challenges, foundries use a new approach to the manufacture of theirs products. It is inter alia the use of new species of alloys, innovative methods of casting and the reconstruction of the machinery, e.g. through investment in new highly efficient automated moulding machines . All of these changes are forced by striving of increasing of the casting production efficiency. One of the method of increasing the efficiency is the use of computer modeling of manufacturing processes. For analysis of the changes occurring in the complex processes are used different methods of modeling for decisions support. One method is a systematic approach to the design and reconstruction. System methodology forces the parallel consideration of technological, technical organizational and economic issues. The paper presents a methodology of creating simulation model called Virtual Foundry Plant as a tool for foundry plant design illustrated with the example of moulds manufacturing subsystem. The proposed iterative approach to the creating of the model is resulting in a possibility of design of more efficient manufacturing systems .The principles of the construction of such a model is presented with the description of the basic steps of the methodology and determination of the possibility of its application.

Notatki

55

THE INFLUENCE OF THE CONTENT OF FURFURYL ALCOHOL MONOMER ON THE PROCESS OF MOULDING SAND’S THERMAL

DESTRUCTION

St. M. Dobosz, D. Drożyński, J. Jakubski, K. Major-Gabry ś AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-



The article discusses the issue of the influence of furfuryl alcohol content in resin binders on properties of moulding sand at elevated temperature. Reducing the share of this component - due to the requirements of the European Union regarding its toxicity - may cause a decrease in temperature of moulding sands’ destruction and, consequently, the thermal deformation of moulds and the creation of many casting defects. The study examined the impact of the furfuryl alcohol content of the thermal destruction processes and on the strength of the moulding sand at an ambient temperature and the tendency to thermal deformation. Notatki

56

USING THE ARTIFICIAL NEURAL NETWORKS TO DETECT DEPENDENCIES BETWEEN SELECTED GREEN MOULDING SANDS

PROPERTIES

J. Jakubski, K. Major-Gabry ś, St. M. Dobosz

AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Moulding Materials, Mould Technology and Foundry of Non-


Corresponding author. E-mail address: [email protected] Abstract In the time of the development of techniques for making molding and core sands, which are designed to reduce the time of their execution, it is important to ensure fast and effective methods for determining the moulding sand properties. Because not all laboratories have the appropriate apparatus to this, the use of databases and data mining tools are the solution to solve this problem. Artificial neural networks allow finding patterns and predict chosen moulding sand properties based on measurements of other properties. The article presents a comparison of several data analysis tools such as artificial neural networks naive Bayes classifier to analyze the properties of synthetic molds. Analyses were performed using gathered experimental data. The moulding sand friability prediction based on the of other properties measurements was determined. Notatki

KOMITET ORGANIZACYJNY KONFERENCJI

Prof. dr hab. inż. St. M. Dobosz – przewodniczący Dr inż. D. Drożyński Dr inż. J. Jakubski

Dr inż. K. Major-Gabryś Dr inż. M. Brzeziński

Wydział Odlewnictwa AGH 30-059 Kraków, ul. Reymonta 23

Pałac Izbicko 47-180 Izbicko

Tel. +48 77 456 19 00

e-mail: [email protected]

http://www.palacizbicko.pl/

Mapka dojazdu

Szczegółowe informacje na stronie: www.tf.agh.edu.pl

KOMITET NAUKOWY KONFERENCJI

Prof. dr hab. inż. St. M. Dobosz AGH Kraków, Polska

Prof. Ing. T. Elbel, CSc VŠB Ostrava, Czeska Republika

Prof. Ing. A. Sládek , PhD TU Żylina, Słowacka Republika Prof. dr hab. inż. P. Zięba

Instytut Metalurgii i Inżynierii Materiałowej PAN, Polska

SPONSORZY KONFERENCJI

program konferencji a - agh university of science and ......3 program konferencji czwartek, 24...

Documents