Wyniki wyszukiwania - BazTech

1

The Effect of Adding Iron Powder From Plasma Cutting on the Microstructure, Mechanical Properties of the Composite Based on Aluminum Powder Matrix Made Using Powder Metallurgy

Wędrychowicz M., Bydałek A. W., Migas P., Skrzekut T., Noga P., Madej P., Kałasznikow A.

Archives of Metallurgy and Materials

|

2021

|

Vol. 66, iss. 1

273--279

EN

The paper presents the results of research on the effect of added iron powder from plasma cutting on the mechanical properties and structure of a composite rod based on aluminum powder. The iron powder came from plasma cutting of steel elements and was handed over by the enterprise “AK Anatol” from Żary. One of the ways to dispose of it is to use it as a filler in aluminum composite rods. Research shows that Fe can be distributed in aluminum evenly, and increase in mechanical properties is achieved at the expense of only a slight increase in density. The proposed system does not reduce the amount of waste produced by plasma cutting but finds a use for some of it. The sintering point of the powder required a strongly reducing atmosphere (Po2 < 10-50 atm) which seems virtually unachievable under laboratory conditions. The reinforcing mechanism is related to the fragmentation of the matrix aggregate particles and the uniform distribution of Fe particles in the aluminum matrix.

2

The Influence of the Proportion of Charge from Waste Materials on the Quality of High Pressure Castings

Schlafka P., Bydałek A. W.

Archives of Foundry Engineering

|

2019

|

iss. 2

21--24

EN

Nowadays, the most popular production method for manufacturing high quality casts of aluminium alloys is the hot and cold chamber die casting. Die casts made of hypereutectoid silumin Silafont 36 AlSi9Mg are used for construction elements in the automotive industry. The influence of the metal input and circulating scrap proportion on porosity and mechanical properties of the cast has been examined and the results have been shown in this article. A little porosity in samples has not influenced the details strength and the addition of the circulating scrap has contributed to the growth of the maximum tensile force. Introducing 80% of the circulating scrap has caused great porosity which led to reduce the strength of the detail. The proportion of 40% of the metal input and 60% of the circulating scrap is a configuration safe for the details quality in terms of porosity and mechanical strength.

3

Integrated Analytical and Measurement System for the Evaluation of the Properties of Cast Metals and Alloys

Biernat S., Bydałek A. W.

Archives of Foundry Engineering

|

2019

|

iss. 1

13--18

EN

The article presents an integrated analytical and measurement system for evaluation of the properties of cast metals and alloys. The presented platform is an extension of the SLAG - PROP application with new modules, which allow to use information on metallurgical processes in an even more effective way, as well as to evaluate the finished product. In addition, the construction of a measuring station for the analysis of thermal processes taking place in a metal bath allows for precise observation of phenomena together with their appropriate interpretation. The article presents not only the cooling curves of certain copper alloys. The analysis also covered mechanical properties related to hardness, finished products depending on the mold in which the products were cast. In the literature one can find information about the mechanical properties of products in the improved state, usually after plastic or thermal treatment, omitting their properties obtained as a result of a naturally made casting. The article also presents the method of placing information in the database using a convenient graphical tool.

4

Analysis of the Impact of Modifiers on the Formation of Non-metallic Inclusions During Continuous Casting of CuZn39Pb2 Brass

Bydałek A. W., Kula A., Błaż L., Najman K.

Archives of Foundry Engineering

|

2019

|

iss. 3

21--26

EN

In this paper results of microstructural observations for series of CuZn39Pb2 alloys produced from qualified scraps are presented. The individual alloy melts were differentiated in terms of thermal parameters of continuous casting as well as refining methods and modifications. Structural observations performed by SEM and TEM revealed formation of different types of intermetallic phases including “hard particles”. EDS results show that “hard particles” are enrich in silicon, phosphorus, iron, chromium and nickel elements. Additionally, formation of Al-Fe-Si and Al-Cr in alloy melts was observed as well. It was found that quantity and morphology of intermetallic phases strongly depends upon the chemical composition of raw materials, process parameters, modifiers and refining procedure applied during casting. It was observed that refining process results in very effective refinement of intermetallic phases, whereas modifiers, particularly carbon-based, results in formation of large particles in the microstructure.

5

Dynamic Mode of Copper Recovery from the Post-Processing Slags

Wołczyński W., Bydałek A. W., Migas P., Tarasek A., Najman K.

Archives of Metallurgy and Materials

|

2018

|

Vol. 63, iss. 4

1923--1930

EN

The post-processing slags containing about 0.8 wt.% of copper were subjected to the treatment of a complex reagent. The chemical composition of the complex reagent has been elaborated and patented in frame of the Grant No. PBS3/A5/45/2015. The slags had an industrial origin and were delivered by the Smelter and Refinery Plant, Głogów, as a product of the direct-to-blister technology performed in the flash furnace assisted by the arc furnace. An agglomeration of copper droplets suspended in the liquid slag, their coagulation, and deposition on the bottom of furnace were observed after the treatment this post-processing slag by the mentioned reagent. The treatment of the post-processing slags by the complex reagent was performed in the arc furnace equipped with some additional electrodes situated at the furnace bottom (additional, in comparison with the arc furnace usually applied in the Smelter and Refinery Plant, Głogów). The behaviour of the copper droplets in the liquid slag within the competition between buoyancy force and gravity was studied from the viewpoint of the required deposition of coagulated copper droplets. The applied complex reagent improves sufficiently the surface free energy of the copper droplets. In the result, the mechanical equilibrium between coagulated copper droplets and surrounding liquid slag is properly modified. Eventually, sufficiently large copper droplets are subjected to a settlement on the furnace bottom according to the requirements. The agglomeration and coagulation of the copper droplets were significantly improved by an optimized tilting of the upper electrodes and even by their rotation. Moreover, the settlement was substantially facilitated and improved by the employment of both upper and lower system of electrodes with the simultaneous substitution of the variable current by the direct current.

6

Optimisation of a Production System in the Process of Remelting of Post-Reduction Slag by Applying New Physical and Chemical Conditions

Bydałek A. W., Wołczyński W., Wędrychowicz M., Holtzer M., Basiura B., Palimąka P.

Archives of Foundry Engineering

|

2018

|

Vol. 18, iss. 4

5--8

EN

Production processes at KGHM are complex and require from customers products of constantly higher quality at relatively lowest prices. Such situation results in an increase of the importance of optimisation of processes. As products and technologies change rapidly, technologists at the plant in Głogów have less time to achieve optimisation basing on own experiences. Analysing a particular process, we can e.g. detect occurring disturbances, find factors having an influence on quality problems, select optimal settings or compare various production procedures. Analysis of the course of production process is the basis of process optimisation. One optimisation in case of the process of decopperisation of flash slag can be a change of a technological additive to a less energy-consuming one, and its final result can be an improvement of the productivity index, a change of the relation between final effects and born expenditures, as well as optimisation of production costs.

7

Determination of the Technological Parameters Process for Continuously Cast Brass Ingot

Bydałek A. W., Kwaśniewski P., Schlafka P., Wołczyński W., Najman K.

Archives of Foundry Engineering

|

2018

|

Vol. 18, iss. 1

9--14

EN

This article discusses issues related to continuous casting of brass. The tested material was CuZn39Pb2 brass with the use of continuous casting and different parameters of the process. The position consists of a melting furnace with a graphite refining pot of about 4000 cm3 chuting capacity, a graphite crystallizer of 9,5 mm nominal diameter, a primary and secondary cooling system and an extracting system as well. The analysis was carried out in terms of technological parameters of the process and type of charge. Highlighted: feedrate ingot, number of stops, and technological temperatures. The surface quality of the obtained ingots and the structure were analyzed. The most favorable conditions were indicated and technological recommendations indicated. They have been distinguished for ingots for plasticity and other technologies. Favorable casting conditions are low feed and low temperature. Due to the presence of impurities coming from the charge it is disadvantageous to have Ni greater than 0.053% by mass, and Fe more than 0.075% by mass. It is recommended to maintain a high zinc content in the melt which is associated with non-overheating of the metal during casting and earlier melting.

8

Complex Reagent Efficiency in Reduction of Copper from the Slags in Conditions of the Smelter & Refinery Plant - Głogów

Wołczyński W., Migas P., Bydałek A. W., Najman K., Senderowski C., Kwapisiński P.

Archives of Foundry Engineering

|

2018

|

Vol. 18, iss. 3

86--90

EN

The copper droplets contained in the post-processing liquid slag are subjected to the treatment by the complex reagent. The complex reagent has been recently elaborated and patented in frame of the Grant No. PBS3/A5/45/2015. In particular, the complex reagent is dedicated to the post-processing slags coming from the Smelter and Refinery Plant, Głogów, as a product of the direct-to-blister technology performed in the flash furnace. The recently patented complex reagent effectively assists not only in agglomeration, and coagulation but also in the deposition of the copper droplets at the bottom of crucible / furnace as well. The treatment of the post-processing slags by the complex reagent was performed in the BOLMET S.A. Company as in the industrial conditions which were similar to those usually applied in the KGHM – Polish Copper (Smelter and Refinery Plant, Głogów). The competition between buoyancy force and gravity is studied from the viewpoint of the required deposition of coagulated copper droplets. The applied complex reagent improves sufficiently the surface free energy of the copper droplets. In the result, the mechanical equilibrium between coagulated copper droplets and surrounding liquid slag is properly modified. Finally, sufficiently large copper droplets are subjected to a settlement on the crucible / furnace bottom according to the requirements.

9

Analysis of Slag Activity on Corrosion of Ceramic Materials in a Slurry Furnace

Wędrychowicz M., Bydałek A. W., Basiura B.

Archives of Foundry Engineering

|

2018

|

Vol. 18, iss. 3

95--100

EN

The article discusses the process of copper production in a slurry furnace and in a converter, with the indication of corrosion effects of the extractor. The furnace shaft and settling furnace of the flash furnace were analyzed. The basic factors determining the choice of single-stage technology of copper smelting in relation to the exploitation of refractory materials were indicated. The effects of dissolving the furnace lining material through slag have been presented. Structural analysis results using a scanning microscope are also included. The kinetics of destruction of ceramic materials under the influence of copper slag were evaluated. It has been shown that detailed analyzes are necessary in order to extend the time of furnace extensibility of furnaces in copper processes. The surface layer of the crucible softens due to saturation with slag reagents and is then washed out and moves in the solid form to the slag. The research in the article indicate not only the possibility of dissolution of the ceramic material in the molten slag, but also possibility of erosive activity of the slag on that material.

10

Copper droplets agglomeration/coagulation in the conditions similar to industrial ones

Wołczyński W., Sypien A., Tarasek A., Bydałek A. W.

Archives of Metallurgy and Materials

|

2017

|

Vol. 62, iss. 1

289--296

EN

The studied copper droplets suspension in the liquid slag came from the direct-to-blister technology developed in the KGHM - Polska Miedź S.A. plants. A treatment by the stimulators and reagents was performed in the conditions delivered / ensured by the BOLMET S.A., Wiechlice. These conditions were similar to those usually applied to the industrial process. Particularly, this treatment was similar, to some extent, to that known for the electric arc-furnace technology employed in the Smelter and Refinery Plant, Głogów. An effectiveness of the newly developed and patented complex chemical/reagent for the copper removal from slag was tested during the treatment. The effect of the liquid slag stirring on the copper droplets self-cleaning was also analysed. The performed test confirmed the effectiveness of the studied complex reagent in agglomeration, coagulation and sedimentation of the copper droplets.

11

Analysis of the Possibility of Calculating the Charges on the Example of Brasses

Biernat S., Bydałek A. W., Wołczyński W., Najman K.

Archives of Metallurgy and Materials

|

2017

|

Vol. 62, iss. 4

2165--2170

EN

This paper describes the subject of brasses and the method of their production from the secondary raw materials. It focuses on two very important aspects extremely important for today’s world. The first of them is the theme of rational management of materials, particularly metallic scrap. The second issue is the growing importance of products made of brass, which in recent times get also special recognition in medicine. This article presents a proposal for a methodology for calculating the metal charge for brasses of two or more components. It turns out that by using suitable mathematical calculations one can accurately determine the amount of metal charge to obtain a product having the desired chemical composition and desired mechanical properties. Mathematical calculations are also presented in the graphical form for the visualization of dependency and a better explanation of the accepted approach.

12

The Concept of Optimizing the Decopperisation of Slag Slurry in Electrical Furnace

Wędrychowicz M., Bydałek A. W., Wołczyński W.

Archives of Foundry Engineering

|

2017

|

Vol. 17, iss. 4

169--174

EN

This paper presents the idea of increasing the effectiveness of slag decopperisation in an electric furnace in the "Głogów II" Copper Smelter by replacing the currently added CaCO3 with a less energy-intensive technological additive. As a result of this conversion, one may expect improved parameters of the process, including process time or power consumption per cycle. The incentives to optimize the process are the benefits of increasing copper production in the company and the growing global demand for this metal. The paper also describes other factors that may have a significant impact on the optimization of the copper production process. Based on the literature analysis, a solution has been developed that improves the copper production process. The benefits of using a new technology additive primarily include increased share of copper in the alloy, reduced production costs, reduced amount of power consumed per cycle and reduced time it takes to melt. At the conclusion of the paper, the issues raised are highlighted, stressing that mastering the slag slurry process in electric furnaces requires continuous improvement.

13

Structural Analysis of the Selected Products From the Suspension Furnace Produced in the Internal Recycling

Bydałek A. W., Schlafka P., Grządko K., Wołczyński W., Kwapisiński P., Bromber S., Wędrychowicz M.

Archives of Foundry Engineering

|

2017

|

Vol. 17, iss. 2

9--14

EN

There are presents the internal recycling in anode furnace, in addition to mainly blister copper and converter copper. During the process there arise the two types of semi-finished products intended for further pyro metallurgical processing: anode copper and anode slag. The stream of liquid blister copper enters into the anode furnace treatment, in which the losses are recovered, e.g. copper, resulting from oxidation and reduction of sulfides, oxides and the oxidation of metallic compounds of lead, zinc and iron. In the liquid phase there are still gaseous states, which gives the inverse relationship relating to the solid phase, wherein the gases found an outlet in waste gas or steam. The results of chemical analysis apparently differ from each other, because crystallite placement, the matrix structure and the presence of other phases and earth elements are not compared, which can be regained in the process of electrorefining. One should not interpret negatively smaller proportion of copper in the alloy, since during the later part of the production more elements can be obtained, for example from sludge, such as platinum group metals and lanthanides. According to the research the quality of blister copper, to a large extent, present in the alloy phase to many other elements, which can be recovered.

14

Method and Apparatus for Assessing the Properties of Slags

Biernat S., Bydałek A. W., Wołczyński W., Holtzer M.

Archives of Foundry Engineering

|

2017

|

Vol. 17, iss. 3

13--18

EN

A special Slag-Prop Cu database has been developed to archive data from laboratory and industrial tests related to post-reduction slags. In order to enrich the data areas, it was decided to design a system for measuring the temperature of the liquid slag and its viscosity. Objectives of research work are to gather information on the properties of post-slags such as the temperature of liquid slag and its viscosity. The discussed issues are especially important in the foundry practice. Designed research stand and using of database applications can greatly facilitate the work of metallurgists, foundrymen, technologists and scientists. The viscosity measurement was developed and presented earlier. The author's analytical methodology was supplemented by a thyristor measuring system (described in the article). The system temperature measurement can be performed simultaneously in 3 ways to reduce the measurement error. Measurement of the voltage mV - using the Seebeck effect can be measured throughout the entire range of thermocouple resistance, up to 1300 °C. Direct temperature measurement ⁰C - measurement only below 1000 ⁰C. Additional measurement - the measurement can also be read from the pyrometer set above the bath. The temperature and the reading frequency depend on the device itself. The principle of measurement is that in a molten metal / slag crucible, we put a N-type thermocouple. The thermocouples are hung by means of a tripod above the crucible and placed in a crucible. The thermocouple is connected to a compensating line dedicated to this type of thermocouple. The cable is in turn connected to a special multimeter that has the ability to connect to a computer and upload results. Temperature measurement can be performed simultaneously in 3 ways to reduce the measurement error. The Sn-Pb alloy has been subjected to testing for proper operation of the device. In this foot should be observed the supercooling of the liquid, which initiates the crystallization process and in which latent heat begins to exude raising the temperature until the coagulation temperature is reached.

15

The Influence of the Chemical Composition of Selected Waste Materials from the Production of Copper on the Final Environmental Assessment

Bydałek A. W., Biernat S., Schlafka P., Holtzer M., Wołczyński W., Bydałek F.

Archives of Metallurgy and Materials

|

2016

|

Vol. 61, iss. 4

2135--2140

EN

This article presents qualitative and quantitative analysis of the waste produced by KGHM Polska Miedź. The waste has been analyzed according to its chemical composition and balanced in order to be reused and recycled. Special attention has been paid to mining industries producing the biggest amount of waste and ore enrichment businesses generating waste, which isn’t reused nowadays. Laboratory reseach has been conducted on floatation waste, different kinds of slags, waste gases and water slag extracts. Attention has been drawn to the possibility of using a computer program SLAG - PROP for analyzing physicochemical features, technological features and the refining of the acquired waste. Consequently, the further way of utilization of waste has been shown. From this point of view, analyses of DTA and TG slags in an oxide coating seem especially interesting. Having a particular composition they can be successfully utillised in the refining processes of copper pyrometallyrgy.

16

Structural Zones in Large Static Ingot. Forecasts for Continuously Cast Brass Ingot

Wołczyński W., Lipnicki Z., Bydałek A. W., Ivanova A. A.

Archives of Foundry Engineering

|

2016

|

Vol. 16, iss. 3

141--146

EN

Some metallographic studies performed on the basis of the massive forging steel static ingot, on its cross-section, allowed to reveal the following morphological zones: a/ columnar grains (treated as the austenite single crystals), b/ columnar into equiaxed grains transformation, c/ equiaxed grains at the ingot axis. These zones are reproduced theoretically by the numerical simulation. The simulation was based on the calculation of both temperature field in the solidifying large steel ingot and thermal gradient field obtained for the same boundary conditions. The detailed analysis of the velocity of the liquidus isotherm movement shows that the zone of columnar grains begins to disappear at the first point of inflection and the equiaxed grains are formed exclusively at the second point of inflection of the analyzed curve. In the case of the continuously cast brass ingots three different morphologies are revealed: a/ columnar structure, b/ columnar and equiaxed structure with the CET, and c/ columnar structure with the single crystal formation at the ingot axis. Some forecasts of the temperature field are proposed for these three revealed morphologies. An analysis / forecast of the behavior of the operating point in the mold is delivered for the continuously cast ingot. A characteristic delay between some points of breakage of the temperature profile recorded at the operating point and analogous phenomena in the solidifying alloy is postulated.

17

Sedimentation of Copper Droplets after their Coagulation and Growth. Laboratory Scale

Wołczyński W., Bydałek A. W.

Archives of Foundry Engineering

|

2016

|

Vol. 16, iss. 1

95--98

EN

The suspension of copper droplets in the slag is considered. The copper/slug suspension is delivered as the product from the direct-to-blister process which is applied in the KGHM – Polska Miedź (Polish Copper) S.A. factory. The droplets / slag suspension was treated by a special set of reagents (patented by the authors) to improve the coagulation process. On the other hand, the observations are made to estimate if the melting / reduction process in the furnace is sufficiently effective to avoid a remaining of carbon in the copper droplets. The coagulation process was carried out in the crucible (laboratory scale). However, conditions imposed to the coagulation / solidification process in the laboratory scale were to some extent similar to those applied usually in the industry when the suspension is subjected to the analogous treatment in the electric arc-furnace. Some suggestions are formulated how to improve the industrial direct-to-blister process.

18

Reagents Activity in a Copper Droplets / Post-Processing Slag Suspension

Wołczyński W., Karwan-Baczewska J., Najman K., Bydałek A. W.

Archives of Foundry Engineering

|

2016

|

Vol. 16, iss. 3

147--150

EN

The suspension of the copper droplets in the post-processing slag taken directly from the KGHM-Polska Miedź S.A. Factory (from the direct-to-blister technology as performed in the flash furnace) was subjected to the special treatment with the use of the one of the typical industrial reagent and with the complex reagent newly patented by the authors. This treatment was performed in the BOLMET S.A. Company in the semi-industrial conditions. The result of the CaCO3, and Na2CO3 chemicals influence on the coagulation and subsequent sedimentation of copper droplets on the crucible bottom were subjected to comparison with the sedimentation forced by the mentioned complex reagent. The industrial chemicals promoted the agglomeration of copper droplets but the coagulation was arrested / blocked by the formation of the lead envelope. Therefore, buoyancy force forced the motion of the partially coagulated copper droplets towards the liquid slag surface rather than sedimentation on the crucible bottom. On the other hand, the complex reagent was able to influence the mechanical equilibrium between copper droplets and some particles of the liquid slag as well as improve the slag viscosity. Finally, the copper droplets coagulated successfully and generally, were subjected to a settlement on the crucible bottom as desired / requested.

19

Evaluation of Precipitates Type in Brasses as a Function of Charge Material

Bydałek A. W., Najman K., Kula A., Biernat S., Błaż L., Wołczyński W.

Archives of Foundry Engineering

|

2016

|

Vol. 16, iss. 3

19--24

EN

Trial series of cast alloy MO59 obtained from qualified scrap was investigated. SEM and TEM of resulting precipitates were conducted. The SEM analysis demonstrated the dependence of silicon, phosphorus, iron, chromium and nickel in the composition of the so-called hard precipitates. TEM analysis showed the formation of phase AlFeSi and AlCr. Made studies have shown the important role of the composition of the batch melts brass CuZn39Pb2 type. The analysis of SEM and TEM resulting precipitates pointed to the formation of various forms of divisions, only one of which was described in the literature character of the so-called hard inclusions. The SEM studies demonstrated the dependence of the occurrence of inclusions rich in silicon, phosphorus, iron, chromium and nickel. In contrast, additional TEM analysis indicated the formation of AlFeSi phase type and AlCr. The results of the analyses referred to the structure of the batch. Due to the difficulty of obtaining recycled materials that do not contain these elements necessary to carry out further analyzes in the direction of defining the role of phosphorus in the formation of the so-called hard inclusions.

20

Determining the Degree of Removal of Copper From Slag

Bydałek A. W., Migas P., Wołczyński W., Biernat S., Bydałek A., Jasińska K., Kwapisiński P.

Archives of Foundry Engineering

|

2016

|

Vol. 16, iss. 4

41--46

EN

The scope of work included the launch of the process of refining slag suspension in a gas oven using a variety of technological additives. After the refining process (in the context of copper recovery), an assessment of the effect of selected reagents at the level of the slag refining suspension (in terms of copper recovery). Method sieve separated from the slag waste fraction of metallic, iron - silicate and powdery waste. Comparison of these photographs macroscopic allowed us to evaluate the most advantageous method of separating metallic fraction from the slag. After applying the sample A (with KF2 + NaCl) we note that in some parts of the slag are still large amounts of metallic fraction. The fraction of slag in a large majority of the elements has the same size of 1 mm, and a larger portion of the slag, the size of which is from 2 to 6 mm. Definitely the best way is to remove the copper by means of the component B (with NaCl ) and D (with KF2). However, as a result of removing the copper by means of component C (with CaO) were also obtained a relatively large number of tiny droplets of copper, which was problematic during segregation. In both cases we were able to separate the two fractions in a fast and simple manner.