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1
Content available Introducing Advanced Data Analytics in Perspective of Industry 4.0 in a Die Casting Foundry
Perzyk M., Dybowski B., Kozłowski J.
Archives of Foundry Engineering
|
2019
|
iss. 1
53--57
EN
The paper presents some aspects of a development project related to Industry 4.0 that was executed at Nemak, a leading manufacturer of the aluminium castings for the automotive industry, in its high pressure die casting foundry in Poland. The developed data analytics system aims at predicting the casting quality basing on the production data. The objective is to use these data for optimizing process parameters to raise the products’ quality as well as to improve the productivity. Characterization of the production data including the recorded process parameters and the role of mechanical properties of the castings as the process outputs is presented. The system incorporates advanced data analytics and computation tools based on the analysis of variance (ANOVA) and applying an MS Excel platform. It enables the foundry engineers and operators finding the most efficient process variables to ensure high mechanical properties of the aluminium engine block castings. The main features of the system are explained and illustrated by appropriate graphs. Chances and threats connected with applications of the data-driven modelling in die casting are discussed.
2
Content available WC-Co coatings and sinters modified with nano-sized tic microstructure – quantitative evaluation
Myalska H., Dybowski B., Moskal G.
Advances in Science and Technology. Research Journal
|
2017
|
Vol. 11, no 1
220--231
EN
The different concepts of WC-Co thermally sprayed coatings improvement may be considered and the application of nanoparticles, as the mechanical strengthening addition, is one of them. Nanostructured WC-Co coatings are characterized by higher hardness than the coatings formed from micrometric WC grains; whereas coatings with bimodal distribution of particles reveal greater wear resistance than the coatings obtained exclusively from nano-sized powders. Mixed effect of the matrix reinforcement by nanoparticles and strong fix of the micron-sized WC grains was proposed as a possible reason for enhanced wear resistance of bimodal coatings. In order to obtain a bimodal distribution of particles in the material standard WC-Co (83-17) powder was mixed with nanometric TiC powder (40–100 nm). The amount of TiC in powder mixtures was in the range from 1 to 7 wt.%. The mixtures were deposited on steel substrate using HVAF method and also hot pressed in vacuum. The microstructure of obtained coatings and sinters was quantitatively evaluated. Sinters revealed more homogenous distribution of the nano-sized TiC particles than the coatings. The addition of nano-sized TiC in the case of coatings has led to the decrease of its porosity. The agglomeration of nano-sized TiC particles in the coatings results in the decrease of material’s hardness.
3
Content available The Microstructure of WE43 MMC Reinforced with SiC Particles
Dybowski B., Rzychoń T., Chmiela B., Gryc A.
Archives of Metallurgy and Materials
|
2016
|
Vol. 61, iss. 1
393--398
EN
It is well known that the properties of a metal matrix composites depend upon the properties of the reinforcement phase, of the matrix and of the interface. A strong interface bonding without any degradation of the reinforcing phase is one of the prime objectives in the development of the metal matrix composites. Therefore, the objective of this work is to characterize the interface structure of WE43/SiC particles composite. Magnesium alloys containing yttrium and neodymium are known to have high specific strength, good creep and corrosion resistance up to 250°C. The addition of SiC ceramic particles strengthens the metal matrix composite resulting in better wear and creep resistance while maintaining good machinability. In the present study, WE43 magnesium matrix composite reinforced with SiC particulates was fabricated by stir casting. The SiC particles with 15 μm, 45 μm and 250 μm diameter were added to the WE43 alloy. The microstructure of the composite was investigated by optical microscopy, scanning electron microscopy, scanning transmission electron microscopy and XRD analysis. YSi and Y2Si reaction products are observed at the interfaces between SiC particles and WE43 matrix in the composite stirred at 780°C. Microstructure characterization of WE43 MMC with the 45 μm, stirred at 720°C showed relative uniform reinforcement distribution. Moreover, the Zr-rich particles at particle/matrix interface were visible instead of Y-Si phases. In the case of composite with 15 μm particles the numerous agglomerates and reaction products between SiC particles and alloying elements were observed. The presence of SiC particles assisted in improving hardness and decreasing the tensile strength and plastic properties.
4
Content available The Influence of Aluminum on the Microstructure and Hardness of Mg-5Si-7Sn Alloy
Rzychoń T., Dybowski B.
Archives of Metallurgy and Materials
|
2016
|
Vol. 61, iss. 1
425--432
EN
Magnesium alloys due the low density and good mechanical properties are mainly used in the automotive and aerospace industry. In recent years, magnesium alloys are extensively developed for use in high temperatures (above 120°C). Among these alloys, magnesium alloys containing tin and silicon have large possibilities of application due to the formation of thermally stable intermetallic Mg2Sn and Mg2Si. In this paper the influence of aluminum and heat treatment on the on the microstructure and hardness of Mg-7Sn-5Si alloy is reported. It was found that the microstructure of Mg-7Sn-5Si alloy consist of α-Mg solid solution, Mg2Sn and Mg2Si compounds. Addition of 2 wt% of Al to Mg-7Sn-5Si alloy causes the formation of Al2Sn phase. Moreover, Al dissolves in the α-Mg solid solution. The solution heat-treatment of tested alloys at 500°C for 24 h causes the dissolve the Mg2Sn phase in the α-Mg matrix and spheroidization of Mg2Si compound. The Mg2Si primary crystals are stable at solution temperature. After ageing treatment the precipitation process of equilibrium Mg2Sn phase was found in both alloys. The addition of aluminum has a positive effect on the hardness of Mg-7Sn-5Si alloy. In case of Mg-5Si-7Sn-2Al alloy the highest hardness was obtained for sample aged for 148 h at 250°C (88 HV2), while in case of Al-free alloy the highest hardness is 70 HV for material aged for 148 h at 250°C.
5
Content available Influence of the Chemical Composition on Electrical Conductivity and Mechanical Properties of the Hypoeutectic Al-Si-Mg Alloys
Dybowski B., Szymszal J., Poloczek Ł., Kiełbus A.
Archives of Metallurgy and Materials
|
2016
|
Vol. 61, iss. 1
353--360
EN
Due to low density and good mechanical properties, aluminium alloys are widely applied in transportation industry. Moreover, they are characterized by the specific physical properties, such as high electrical conductivity. This led to application of the hypoeutectic Al-Si-Mg alloys in the power generation industry. Proper selection of the alloys chemical composition is an important stage in achievement of the demanded properties. The following paper presents results of the research on the influence of alloys chemical composition on their properties. It has been revealed that Si and Ti addition decreases electrical conductivity of the Al-Si-Mg alloys, while Na addition increases it. The mechanical properties of the investigated alloys are decreased by both silicon and iron presence. Sodium addition increases ductility of the Al-Si-Mg alloys.
6
Content available The Influence of Strontium on the Microstructure of Cast Magnesium Alloys Containing Aluminum and Calcium
Rzychoń T., Dybowski B., Kiełbus A.
Archives of Metallurgy and Materials
|
2015
|
Vol. 60, iss. 1
167--170
EN
The structure of Mg-9Al-2Ca-xSr alloys is composed of a-Mg grains and the Al2Ca and Al4 Sr phases in the interdendritic areas. These phases are formed as a result of eutectic reactions. Globular particles of the Al8Mn5 phase are observed within the interior of the grains. The addition of strontium to Mg-9Al-2Ca-0.4Mn alloys causes the formation of the Al4Sr phase and increase of its volume fraction with increasing strontium levels. Moreover, increase of the strontium amount causes a decrease of aluminum content in the a-Mg solid solution.
PL
W artykule przedstawiono wyniki badań wpływu strontu na mikrostrukturę odlewniczych stopów magnezu zawierających aluminium i wapń. Jakościową analizę fazową przeprowadzono za pomocą rentgenowskiej analizy fazowej i metody EBSD. Do ilościowej analizy fazowej zastosowano metody analizy obrazu. Po odlewaniu mikrostruktura stopów zawierających 9% mas. aluminium, 2% mas. wapnia, 0,3% mas. strontu i 0,4% mas. manganu składa się z roztworu stałego α-Mg oraz wydzieleń faz międzymetalicznych Al2Ca, Al4Sr i Al8Mn5. Zwiększenie zawartości strontu do 2% mas. powoduje zwiększenie udziału objętościowego fazy Al4Sr i zmniejszenie stężenia aluminium w roztworze stałym α-Mg.
7
Content available Influence of Age Hardening Parameters on the Microstructure and Properties of the AlSi7Mg Sand Cast Alloy
Poloczek Ł., Dybowski B., Rodak K., Jarosz R., Kiełbus A.
Archives of Metallurgy and Materials
|
2015
|
Vol. 60, iss. 4
3035--3042
EN
Aluminium alloys are characterized by a low density, acceptable mechanical properties and good technological properties. This unique connection of features made aluminium alloys perfect structural material for the transportation industry. Also, due to their good electrical conductivity they also found application in energy production industry. High mechanical properties and electrical conductivity of the Al-Si alloys with Mg addition may be achieved by heat treatment. However, the highest mechanical properties are achieved in the early stages of age hardening - due to precipitation of coherent phases, while high electrical conductivity may be achieved only by prolonged aging, during precipitation of semi-coherent or fully noncoherent, coarse phases. Carefully heat treated AlSi7Mg alloy may exhibit both fairly high electrical conductivity and slightly increased mechanical properties. The following article present results of the research of influence of heat treatment on the properties and microstructure of sand cast AlSi7Mg alloy. Microstructure observations were performed using light microscopy, scanning electron and scanning-transmission electron microscopy. Hardness and electrical conductivity of the AlSi7Mg alloy were investigated both in as-cast condition and after heat treatment. Maximum hardness of the alloy is achieved after solutioning at 540°C for 8h, followed by 72h of aging at 150°C, while maximal electrical conductivity after solutioning at 540°C for 48h, followed by 96h of aging at 180°C. Increase of the electrical conductivity is attributed to increasing distance between Si crystals and precipitation of semi coherent phases.
PL
Stopy aluminium charakteryzują się małą gęstością, dobrymi właściwościami mechanicznymi, a przy tym bardzo dobrymi właściwościami odlewniczymi. Połączenie tych cech powoduje że stopy te znajdują szerokie zastosowanie w przemyśle motoryzacyjnym. Ich dużą zaletą jest również wysoka przewodność elektryczna oraz cieplna, dzięki której znajdują również zastosowanie w przemyśle energetycznym. Uzyskanie tak wysokich właściwości mechanicznych i przewodności elektrycznej w przypadku stopów Al-Si z dodatkiem Mg może być osiągnięte tylko poprzez przeprowadzenie obróbki cieplenj. Najwyższe właściwości mechaniczne są osiągane w początkowej fazie utwardzania wydzieleniowego (wydzielanie się koherentnych faz), podczas gdy uzyskanie wysokich wartości przewodności może być osiągnięte tylko przez długotrwałe starzenie, podczas wydzielania się pół koherentnych lub niekoherentnych, dużych faz. W przypadku stopu AlSi7Mg, starannie dobrana obróbka cieplna może powodować znaczne podwyższenie przewodności oraz polepszenie właściwości mechanicznych. Ninjiejszy artykuł przedstawia wyniki badań wpływu parametrów obróbki cieplnej na strukturę i właściwości stopu AlSi7Mg, odlanego grawitacyjnie do form piaskowych. Obserwacje mikrostruktury prowadzone były prz użyciu metod mikroskopii świetlnej, elektronowej mikroskopii skaningowej oraz elektronowej mikroskopii transmisyjnej. Twardość i przewodności stopu AlSi7Mg badano zarówno w stanie lanym, jak i po obróbce cieplnej. Maksymalną twardość stopu uzyskano po przesycaniu w 540°C przez 8h oraz starzeniu w temperaturze 150°C przez 72h. Maksymalną przewodność elektryczną uzyskano po przesycaniu w 540° C przez 48h, oraz starzeniem w temperaturze 180°C przez 96h. Wzrost przewodności elektrycznej spowodowany jest zwiększeniem się odległości pomiędzy kryształami Si oraz wydzielaniem się półkoherentnych faz.
8
Content available The Microstructure of AlSi9Cu3 Alloy after Different Stages of Liquid Metal Preparation
Poloczek Ł., Dybowski B., Łuszczak M., Kiełbus A.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 1 spec.
89--92
EN
Aluminium alloys are one of the most important casting alloys. Among them, the Al-Si alloys comprise perhaps the most important group – about 80% of the aluminium casts are made of them. These materials are characterized by a very good technological properties, good corrosion resistance and tribological properties. Their main disadvantage is, however, presence of the massive, brittle silicon crystals. They significantly affect alloys mechanical properties. Liquid metal treatment is essential for modification of Al-Si eutectic structure. The following work presents results of the research on the microstructure of the AlSi9Cu3 alloy after different stages of liquid metal preparation. Three casting processes have been conducted, chemical composition of the material in each case was in agreement with EN 1706 specification. During each casting process, three specimens were gravity cast: first, made from pure ingots; second, after the scrap addition and third one after the liquid metal treatment. Qualitative and quantitative evaluation of the microstructure was done on each specimen. Specimens cast from pure ingots are characterized by a refined Al-Si eutectic microstructure. After scrap addition, the silicon crystals became morphology of the massive platelets. What is more, intermetallic phases observed within the structure posses different morphologies after different stages of liquid metal preparation. After scrap addition, increased gas porosity was observed. Liquid metal treatment reduced slightly the formation of gas pores.
9
Content available Mechanical Properties and Microstructure of WE43 Magnesium Matrix Composite Reinforced SiC Particles
Rzychoń T., Dybowski B., Gryc A., Dudek M.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 1 spec.
99--102
EN
Magnesium alloys containing yttrium and neodymium are known to have high specific strength, good creep and corrosion resistance up to 250°C. The addition of ceramic particles strengthens the metal matrix composite resulting in better wear and creep resistance while maintaining good machinability. In the present study, WE43 magnesium matrix composite reinforced with SiC particles were fabricated by stir casting. The microstructure of the composite was investigated by optical microscopy, quantitative metallography, scanning electron microscope and XRD analysis. Microstructure characterization of WE43 MMC showed homogeneous reinforcement distribution and presence of the small amount of porosity at the interface. A thin layer consists of zirconium-rich particles was observed at the interface. In the microstructure, inclusions of the yttrium oxide were found. The presence of SiC particles assisted in improving hardness and in decreasing the ultimate tensile strength, yield tensile strength and elongation.
10
Content available Influence of the Mould Material Coatings on the Microstructure of AlSi7Mg Alloy
Dybowski B., Poloczek Ł., Jarosz R., Kiełbus A.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 1 spec.
13--16
EN
Family of the aluminium alloys with silicon addition is an important group of non-ferrous casting alloys. They exhibit very good technological properties, especially castability. Aluminium alloys are known for their low density, which in connection with high mechanical properties and relatively low price create very good structural material. Magnesium addition to the Al-Si alloys enables their age-hardening, resulting in even better mechanical properties. However, formation of the microstructure of the alloy has to be precisely controlled to avoid formation of massive, brittle silicon crystal. Presence of large, platelet-like particles of silicon, dramatically decreases material mechanical properties. Second factor, which must be taken into consideration is casting porosity, which may significantly decrease fatigue life of the element. Many researches consider effect of modification or refining on the microstructure of the castings made from the Al-Si alloys. However there is lack of detailed investigation on the mould components influence on the microstructure. Such components may be protective coatings applied for the mould sand during the gravity casting of Al-Si alloys. Following paper presents results of the research on the influence of applied mould protective coatings on the microstructure of AlSi7Mg sand cast alloy. Five different protective coatings were applied. Macro observations, qualitative and quantitative microstructure evaluation of the AlSi7Mg alloy was conducted during the researches. Results revealed, that application of the coatings does not influence the size and distribution of the α- Al dendrites, however it influences size of Si particles in a significant way. It was revealed that application of water-based coatings affects the heat flow in the mould material-liquid alloy system, thus causing growth of silicon particles.
11
Content available Effect of Mould Components on the Cooling Rate, Microstructure, and Quality of WE43 Magnesium Casting Alloy
Dybowski B., Kiełbus A., Jarosz R.
Archives of Metallurgy and Materials
|
2014
|
Vol. 59, iss. 4
1527--1532
EN
We investigated the impact of the applied cooling and feeding method on the microstructure and metallurgical quality of castings made from WE43 magnesium alloy. Six identical plates with dimensions of 100x50x20 mm were sand cast for use as samples. Each casting was fed and cooled in a different way. The solid solution grain size was evaluated quantitatively using the Met-Ilo software program, and casting defects were observed using a scanning electron microscope Hitachi S3400N. The finest solid solution grain was observed in the castings with only the coolers applied. Non-metallic inclusions were observed in each plate. The smallest shrinkage porosity was observed in the castings with feeders applied.
PL
Celem badań było zbadanie wpływu zastosowanej metody chłodzenia i zasilana na mikrostrukturę i jakość metalurgiczną odlewów wykonanych ze stopu magnezu WE43. Sześć identycznych płyt o wymiarach 100x50x20 mm, chłodzonych i zasilanych na różne sposoby, odlano do formy piaskowej. Wielkość ziarna roztworu stałego zostały wyznaczone ilościowo w programie Met-Ilo. Obserwacje wad odlewniczych prowadzono na skaningowym mikroskopie elektronowym Hitachi S3400N. Najmniejszym ziarnem roztworu stałego charakteryzowały się odlewy z zastosowanymi tylko ochładzalnikami. W strukturze każdego z odlewów stwierdzono wtrącenia niemetaliczne. Najmniejszą porowatością skurczową charakteryzowały się odlewy z zastosowanymi nadlewami.
12
Content available Mould components impact on structure and quality of elektron 21 alloy
Dybowski B., Kiełbus A., Jarosz R.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 2
17--23
EN
Magnesium alloys due to their low density and high strength-to-weight ratio are promising material for the automotive and aerospace industries. Many elements made from magnesium alloys are produced by means of sand casting. It is essential to investigate impact of the applied mould components on the microstructure and the quality of the castings. For the research, six identical, 100x50x20mm plates has been sand cast from the Elektron 21 magnesium casting alloy. Each casting was fed and cooled in a different way: one, surrounded by mould sand, two with cast iron chills 20mm and 40mm thick applied, another two with the same chills as well as feeders applied and one with only the feeder applied. Solid solution grain size and eutectics volume fraction were evaluated quantitatively in Met-Ilo program, casting defects were observed on the scanning electron microscope Hitachi S3400N. The finest solid solution grain was observed in the castings with only the chills applied. Non metallic inclusions were observed in each plate. The smallest shrinkage porosity was observed in the castings with the feeders applied.
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