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1
Content available The Role of Recycled Ceramic Material Obtained from the Ceramic Layered Moulds Used in the Investment Casting
Soroczyński A., Haratym R., Biernacki R.
Archives of Foundry Engineering
|
2019
|
iss. 1
71--74
EN
The article presents the role of the ceramic layered moulds used in the investment casting method with new (certified) and recycled material from ceramic moulds (CM) after casting process. The materials that were obtained are mainly aluminosilicates and SiO2. The investigation of changes in the quality of ceramic moulds (including the recycled ceramic material) includes the chemical composition of the ceramics as recovered ceramic material, changes in the particle size of the layered covering material, the gas permeability during the pouring of liquid metal, and the creation of the porosity are presented. Than the thermophysical parameters and dimensional accuracy of the casting manufactured in the new ceramic layered shell moulds were analysed. Additionally the global cost savings and improved ecological conditions in the foundry and its surroundings was estimated.
2
Content available Evaluation of Physical Properties of Wax Mixtures Obtained From Recycling of Patterns Used in Precision Casting
Biernacki R., Haratym R., Bałkowiec A., Wawulska-Marek P., Matysiak H., Zdunek J., Kurzydłowski K. J.
Archives of Metallurgy and Materials
|
2015
|
Vol. 60, iss. 1
345--349
EN
The study investigated the properties of selected certified mixtures used to make wax patterns for the production of precision castings for the aerospace industry. In addition, an assessment of the recycled mixtures consisting of certified wax materials recovered during autoclaving was carried out. Hardness was tested via a proposed method based on penetration, creep related deformation, bending strength and linear contraction. The hardness was studied on laboratory specimens and patterns made with the use of injection molding equipment. For these patterns, linear contraction was estimated at variable pressure and for different temperature injection parameters. Deformations connected with creep and resistance were evaluated on cylindrical specimens. Differences in creep resistance in relation to the hardness were observed depending on the type of pattern mixtures. Recycled mixture has a greater resistance and smaller linear contraction than certified mixtures used for making sprue, raisers and other parts of filler system.
PL
W pracy zbadano właściwości wybranych mieszanek modelowych atestowanych stosowanych do wykonywania modeli wytapianych przy produkcji odlewów precyzyjnych dla przemysłu lotniczego. Dodatkowo badaniom poddano masę z recyklingu składająca się z odzyskanych w procesie autoklawizacji mieszanek woskowych atestowanych. Zaproponowano badania twardości metodą penetracji, odkształceń związanych z pełzaniem, wytrzymałości na zginanie oraz skurczu liniowego. Twardość badano na próbkach laboratoryjnych oraz na modelach wykonanych na wtryskarce przemysłowej. Dla tych modeli oszacowano skurcz liniowy przy zmiennych parametrach ciśnienia i temperatury wytrysku. Odkształcenia związane z pełzaniem i wytrzymałość badano na modelach walcowych. Obserwuje się różnice odporności na pełzanie w odniesieniu do twardości w zależności od rodzaju mieszanki modelowej. Masa z recyklingu ma większą odporność i mniejszy skurcz liniowy niż masa atestowana stosowana na układy wlewowe.
3
Content available Analysis of Impact of the Multilayer Ceramic Moulds Quality on the Steel Precision Castings Dimensional Accuracy
Haratym R., Biernacki R., Kwapisz J.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 2 spec.
27--30
EN
Results of analysis presented in this paper were based on analysis of casts made especially for this research purpose and related to actual cast – industrial. The evaluation of the dimensional accuracy of casts was made in relation to the pressure of the liquid metal with consideration of the ceramic mould temperature. Ceramic moulds used in these analyses were made from crystalline quartz with an aqueous colloidal silica binder containing polymers (KK), and ethyl silicate (KE).
4
Content available Shape Errors, Internal Porosity, Linear Dimensions Accuracy and Allowances for the Machining of Castings Made in the Replicast CS Process
Haratym R., Sieczka M., Biernacki R., Kwapisz J.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 3
25--28
EN
This research presents comprehensive assessment of the precision castings quality made in the Replicast CS process. The evaluation was made based on quality of the surface layer, shape errors and the accuracy of the linear dimensions. Studies were carried out on the modern equipment, among other things a Zeiss Calypso measuring machine and profilometer were used. Obtained results allowed comparing lost wax process models and Replicast CS process.
5
Content available Shape Accuracy of Iron Precision Castings in Terms of Ceramic Moulds Physical Properties Anisotropy
Biernacki R., Haratym R., Tomasik J., Kwapisz J.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 1
5--8
EN
While analyzing shape accuracy of ferroalloy precision castings in terms of ceramic moulds physical anisotropy, low-alloy steel castings ("cover") and cast iron ("plate") were included. The basic parameters in addition to the product linear shape accuracy are flatness deviations, especially due to the expanded flat surface which is cast plate. For mentioned castings surface micro-geometry analysis was also carried, favoring surface load capacity tp50 for Rmax = 50%. Surface load capacity tp50 obtained for the cast cover was compared with machined product, and casting plate surface was compared with wear part of the conveyor belt. The results were referred to anisotropy of ceramic moulds physical properties, which was evaluated by studying ceramic moulds samples in computer tomography equipment Metrotom 800.
6
Content available Optimization of Properties of Disposable Patterns in the Application for Ceramic Molds
Biernacki R., Haratym R., Bałkowiec A., Matysiak H., Kurzydłowski K.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 1 spec.
63--66
EN
Presentation of various disposable patterns variants in order to obtain accuracy in investment casting with particular focus on hard waxes. The analysis covered disposable patterns based on hard waxes, paraffin-stearic blends with addition of polyethylene wax and high density polystyrene.
7
Content available Investment Casting vs Replicast CS Considered in Terms of the Ceramic Mould Making and Dimensional Accuracy of Castings
Karwiński A., Haratym R., Biernacki R., Soroczyński A.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 1
45--48
EN
The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process, considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty.
8
Content available Investment Casting or Forging in the Aspect of Environmental Protection
Haratym R., Lewiński J., Biernacki R.
Archives of Foundry Engineering
|
2014
|
Vol. 14, iss. 2 spec.
29--32
EN
The article compares the energy intensity of ductile iron precision castings manufacturing process with the 0.5% C steel locking mechanism element made with forging die. During the analysis variations of manufacturing processes were taken into account and also additional comparison of energy intensity connected with the machining of the steel blank was made. The influence of the manufacturing processes on the environment was evaluated.
PL
W artykule porównano energochłonność wytwarzania odlewu precyzyjnego wykonanego z żeliwa sferoidalnego z odkuwką matrycową dla widełek mechanizmu blokującego ze staliwa 0,5 % C. Uwzględniono różne warianty procesów wytwarzania oraz porównano je z energochłonnością wyrobu otrzymanego z półfabrykatu hutniczego otrzymanego metodą obróbki skrawaniem. Oceniono wpływ procesów wytwarzania na środowisko.
9
Content available Ceramic Mould Internal Structure Anomalies in the Lost Wax Process
Biernacki R., Grześ J., Haratym R., Tomasik J.
Archives of Foundry Engineering
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2014
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Vol. 14, iss. 1 spec.
57--62
EN
The paper analyzes the structure of the ceramic mould, which include discussion about its structure creation. The results of research relate to the strength of the ceramic mould and its thermophysical properties. Structural anisotropy was found and its influence on the mould surface morphology depending on its position with respect to the sprue in the assembly set. The paper also presents evaluation of microgeometry of patterns, ceramic mould and casts produced in a joint production process. Last part includes the results of the fractal dimension measurements of ceramic mould cross-sections. The analysis was based on the mould porosity. For the analyzed structures the percentage of pores and linear fractal dimension was determined, using the line counting dimension method (LCD), which is a modification of box counting dimension method (BCD).
10
Content available The Quality of Steel Castings in Terms of Precision Ceramic Mould Structure
Biernacki R., Haratym R., Kwapisz J.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 1 spec.
9--12
EN
In the opinion of metrologists, technologists and trybologists surface microgeometry is one of the most important factors affecting the performance characteristics of the machine parts (resistance to wear, sliding and lubricating properties, durability and tightness of joints, fatigue strength, corrosion resistance, etc.). The analysis was made of the ceramic mould elements structure influence on the microgeometry of steel castings surface and their dimensional accuracy. To assess the structure of the ceramic mould previous studies made with usage of computer tomography where used, those studies highlight the ceramic mould structure anisotropy and its properties.
11
Content available Non-ferrous Metals Precision Casting Shape Accuracy in Terms of Ceramic Moulds Anisotropic Material Properties
Biernacki R., Haratym R., Kwapisz J.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 1 spec.
5--8
EN
Shape accuracy analysis of aluminum alloy castings was made in function of ceramic mould properties. Taken it to account was anisotropy of those properties, including influence of ceramic mould properties on the porosity of castings. Ceramic moulds strains, which occur in sintering phase, were evaluated with taking into account the design and production process.
12
Content available Evaluation criteria of wax pattern strength tests and their role in forecasting the shape accuracy of wax patterns
Haratym R., Biernacki R., Lewiński J., Kwapisz J.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 4
49--52
EN
This research paper will present and analyze selected testing of wax patterns - bending strength test, test of resistance to creep and penetration hardness test. Evaluation of these tests will be carried out in terms of the shape accuracy of wax patterns. Additionally, statistical evaluation will be carried out of relationships between selected parameters of previously mentioned tests. Standard bending tests will be statistically evaluated and compared with two other test methods conducted on corresponding patterns. Particular attention will be given to creep resistance, which is a very useful test method for assessing changes in the shape of complex patterns in the function of time and temperature. At the same time an evaluation of hardness tests of wax patterns will be carried out with usage of appropriate samples or by direct examination of the production patterns.
13
Content available Accuracy of ceramic mould filling with liquid AlSi9 aluminium alloy in the process using back-pressure
Karwiński A., Haratym R., Biernacki R.
Archives of Foundry Engineering
|
2013
|
Vol. 13, iss. 1
73--76
EN
The paper presents the effect of suction pressure exerted on the liquid AlSi alloy when it is introduced into a ceramic mould made in the investment process and the results compared with data obtained on gravity poured castings. The study used special pattern sets and ceramic moulds made with the alternately applied soluble silicate binder and ethyl silicate. Additionally, self-supported moulds based entirely on the Ekosil binder were used. In the analysis of castings, the following parameters were examined: a linear dimensional accuracy, the state of surface microgeometry and the possibility of metal penetration into a complex ceramic mould, allowing also for the presence of capillary phenomena. In the process of casting with back-pressure, the pressure values of 500 hPa, 600 hPa and 700 hPa were applied in the chamber where the ceramic mould was located, with the temperature of the said mould kept at a level of 150±10ºC.
14
Content available Ocena możliwości wykorzystania w odlewnictwie gipsu syntetycznego uzyskanego podczas procesu mokrego odsiarczania spalin w energetyce
Biernacki R., Haratym R., Krzyńska A.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 1s
5--8
PL
Przedstawiono analizę możliwości wykorzystania w odlewnictwie gipsu odpadowego (syntetycznego) uzyskiwanego w procesie odsiarczania spalin w energetyce. Energetyka jest jednym z największych producentem SO2. W celu ochrony środowiska i obniżenia ilości zanieczyszczeń stosuje się odsiarczanie spalin metodą mokrą. W wyniku tego procesu powstaje gips odpadowy, który może być stosowany w praktyce. Przeprowadzono badania, w wyniku których określono sposoby przygotowania tego gipsu do wykonywania form odlewniczych. W artykule oceniono skład chemiczny, wytrzymałość i przepuszczalność form z uzyskanego gipsu syntetycznego, porównano je z właściwościami gipsu odlewniczego GoldStar XL oraz właściwościami form ceramicznych. Zbadano strukturę gipsów, wykonano badania na derywatografie oraz określono energochłonność procesu wytwarzania gipsu odpadowego w instalacji mokrego odsiarczania. Po analizie zebranych danych można stwierdzić, że gips syntetyczny może być używany jako materiał na formy odlewnicze. Nie obserwuje się znaczącego spadku najważniejszych właściwości, a z drugiej strony istnieje wiele dodatkowych korzyści, w tym niskie zużycie energii, obniżenie kosztów i zmniejszenie wpływu na środowisko.
EN
This article investigates possible use of waste gypsum (synthetic), recovered via flue-gas desulfurization from coal-fired electric power plants, in foundries. Energy sector, which in Eastern Europe is mostly composed from coal-fired electric power plants, is one of the largest producers of sulfur dioxide (SO2). In order to protect the environment and reduce the amount of pollution flue-gas desulfurization (FGD) is used to remove SO2 from exhaust flue gases of fossil-fuel power plants. As a result of this process gypsum waste is produced that can be used in practical applications. Strength and permeability tests have been made and also in-depth analysis of energy consumption of production process to investigate ways of preparing the synthetic gypsum for casting moulds application. This paper also assesses the chemical composition, strength and permeability of moulds made with synthetic gypsum, in comparison with moulds made with traditional GoldStar XL gypsum and with ceramic molds. Moreover examination of structure of synthetic gypsum, the investigations on derivatograph and calculations of energy consumption during production process of synthetic gypsum in wet flue-gas desulfurization were made.
15
Content available Evaluation of synthetic gypsum recovered via wet flue-gas desulfurization from electric power plants for use in foundries
Biernacki R., Haratym R., Kwapisz J.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 3
5-8
EN
This article investigates possible use of waste gypsum (synthetic), recovered via flue-gas desulfurization from coal-fired electric power plants, in foundries. Energy sector, which in Eastern Europe is mostly composed from coal-fired electric power plants, is one of the largest producers of sulfur dioxide (SO2). In order to protect the environment and reduce the amount of pollution flue-gas desulfurization (FGD) is used to remove SO2 from exhaust flue gases of fossil-fuel power plants. As a result of this process gypsum waste is produced that can be used in practical applications. Strength and permeability tests have been made and also in-depth analysis of energy consumption of production process to investigate ways of preparing the synthetic gypsum for casting moulds application. This paper also assesses the chemical composition, strength and permeability of moulds made with synthetic gypsum, in comparison with moulds made with traditional GoldStar XL gypsum and with ceramic moulds. Moreover examination of structure of synthetic gypsum, the investigations on derivatograph and calculations of energy consumption during production process of synthetic gypsum in wet flue-gas desulfurization were made. After analysis of gathered data it's possible to conclude that synthetic gypsum can be used as a material for casting mould. There is no significant decrease in key properties, and on the other hand there is many additional benefits including low energy consumption, decreased cost, and decreased environmental impact.
16
Content available Błędy kształtu, porowatość wewnętrzna, dokładność wymiarów liniowych staliwnych odlewów precyzyjnych w aspekcie ekologii ich wytwarzania
Tomasik J., Sieczka M., Haratym R.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 1s
191--194
PL
Dokonano kompleksowej oceny jakości odlewów precyzyjnych przez badanie warstwy wierzchniej, ocenę błędu kształtu, dokładności wymiarów liniowych. Badania wykonano w oparciu o nowoczesną aparaturę, miedzy innymi zastosowano maszynę pomiarową Zeiss Calypso. Otrzymane wyniki badań pozwolą na zastosowanie optymalnej technologii wytwarzania odlewów w procesie wytapianych modeli w aspekcie ekologii.
EN
Comprehensive assessment of precision castings quality was done by investigation of surface layer, shape errors, and accuracy of linear dimensions. The study was performed on modern apparatus, among other uses measuring machine Zeiss Calypso. The obtained results will allow usage of optimal lost wax casting process in environmentally friendly cast production.
17
Content available Anizotropia właściwości fizycznych form ceramicznych wpływających na ekologiczne wytwarzanie aluminiowych odlewów precyzyjnych
Haratym R., Lewiński J., Biernacki R., Kowaluk T.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 1s
53--56
PL
W referacie przedstawiono analizę parametrów powodujących anizotropię właściwości fizycznych form ceramicznych wpływającą na jakość odlewów z aluminium. Przeprowadzono ocenę oryginalnych badań takich, jak przepływ gazów przez ścianki formy, trzypunktowa ocena wytrzymałości formy na zginanie, stan warstwy wierzchniej formy w aspekcie jej zwilżalności przez ciekły metal oraz sprawdzono porowatość formy ceramicznej w badaniach z użyciem tomografu komputerowego. Przeprowadzono ocenę wpływu właściwości form ceramicznych na jakość odlewów w aspekcie ich wytwarzania.
EN
The paper presents analysis of parameters affecting the anisotropy of ceramic moulds physical properties which affect quality of aluminum castings. An evaluation of original research, such as the permeability of mould surface, three-point bending strength, the state of mould surface layer in terms of wettability by the liquid metal, and ceramic molud porosity tested in studies using a CT (computerized tomography) scanner. Investigation of impact made by ceramic mold properties on casting quality in terms of their production was also made.
18
Content available The quality of precision steel castings produced in the Replicast CS process
Tomasik J., Haratym R., Kwapisz J.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 2 spec.
209--212
EN
The quality in ceramic mould precision casting process include mostly surface quality of casts and their dimensional accuracy represented by six sigma deviation from the nominal dimensions (ΔL6δ). This article present achieved results of examination of cast’s surface finish. The dimensional analysis accuracy of expended polystyrene patterns and castings made from these patterns was executed.
PL
Jakość w procesie odlewnictwa precyzyjnego w formy ceramiczne obejmuje przede wszystkim stan powierzchni odlewów i ich dokładność wymiarową rozumianą jako odchyłkę sześciosigmową wymiarów nominalnych (ΔL6δ). W artykule zaprezentowano uzyskane wyniki badań stanu powierzchni odlewów. Wykonano analizę dokładności modeli z polistyrenu i odlewów wykonanych na tych modelach.
19
Content available Impact of analysis method on evaluation of ceramic mould surface microgeometry in the lost wax process
Matysiak H., Haratym R., Kwapisz J., Kłębczyk M.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 3 spec.
131--134
EN
In this article two methods of ceramic mould surface microgeometry analysis were presented. First was a contact method, in which Profilometer S3P produced by Perthen Mahr was used. In second optical method optical profiler Veeco NT 9300 was used for surface microgeometry analysis. Evaluation of the results gathered with those methods was made. It was found that optical analysis method of surface microgeometry give better research possibilities (it’s more optimal).
20
Content available remote Evaluation of wax pattern properties in the lost-wax process
Matysiak H., Haratym R., Biernacki R.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 2
85-88
EN
This article present achieved results of examination of wax pattern properties (wax compounds) which are used in lost wax process. Evaluation of those results was made with approach as it is taken in foundry. Evaluation included: evaluation of wax compound shrinkage, bending strength test, hardness test using penetration method, and resistance to creep of wax patterns in precision foundry environment.
PL
W artykule przedstawiono dane dotyczące badań własności modeli (mieszanek modelowych) stosowanych w procesie wytapianych modeli. Dokonano oceny badań w aspekcie prowadzenia ich bezpośrednio w odlewni precyzyjnej. Badania obejmowały: ocenę skurczu mieszanek modelowych, badania wytrzymałości na zginanie, ocenę twardości mieszanek metodą penetracyjną oraz ocenę odporności na pełzanie modeli wytapianych w warunkach każdej odlewni precyzyjnej.
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