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The Effect of Successive Stages of the Melting Process on the Nucleation of Ductile Cast Iron

Kołakowski Jakub, Brzeżański Mateusz, Burdzy Daniel, Sobieraj J., Urbanowicz M., Paruch T., Janerka Krzysztof

Archives of Foundry Engineering

2023

Vol. 23, iss. 1

61--67

The article discusses issues related to the melting of grey and ductile cast iron in terms of metallurgical quality. The derivative and thermal analysis (DTA) was used to assess this quality. The article presents the results of research carried out in industrial conditions and analysed by the Itaca system. In the paper, the effect of the furnace type, the charge materials and the inoculation process on the parameters characterising the cast iron being melted was analysed. The most important of these are the minimum eutectic temperature (Temin), the liquidus temperature (Tliquidus) and the nucleation rate. The results of the research and calculations are shown in graphs and as dependencies. Some of DTA results were compared to the microstructure analysis results. The article shows that the derivative and thermal analysis is a very effective tool in the assessment of the metallurgical quality of cast iron. It is a very good addition to chemical analysis. Based on the results of the research, it was concluded that a very high correlation exists between the rate of nucleation (DTA) and the number of graphite nuclei (microstructure analysis). Furthermore, it was also found that an improvement in nucleation could be achieved by ensuring a high value of carbon equivalent (CE) and, above all, by conducting the primary and secondary inoculation processes, respectively.

The Importance of TDA Thermal Analysis in an Automated Metallurgical Process

Petrus Łukasz, Bulanowski Andrzej, Kołakowski Jakub, Sobieraj Jakub, Paruch Tomasz, Urbanowicz Mariusz, Brzeżański Mateusz, Burdzy Daniel, Zych Jerzy, Janerka Krzysztof

Journal of Casting & Materials Engineering

2021

Vol. 5, no. 4

89--93

The article presents the results of research and work related to the implementation of the research and development project POIR.01.01.01-00-0120/17 co-financed by the EU, through the NCBR, entitled: Innovative technology using thermal analysis, TDA, of self-feeding manufacturing of high-quality cast iron to produce new generation, enhanced performance casts. In many foundries, thermal derivative analysis (TDA) is used in addition to chemical analysis to evaluate the physical and chemical properties of an alloy while it is still in the melting furnace or ladle and before it is poured into the mold. This fact makes it possible to improve the metallurgical quality of the alloy by introducing alloying additives, carburizers or modifiers into the furnace as part of the pre-modification or primary or secondary modification in the ladle or when pouring into molds. Foundry machinery (modifier dosing systems and spheroidizing station) is very important in these operations. Only the full synergy of modern equipment with modern technology ensures high quality and repeatability of the casting process. The article mainly discusses the obtained parameters of TDA analysis (with the use of the ITACA system) at different stages of melting and how to improve them by using modern and fully automated dosing systems (Itaca OptiDose, ItacaWire and ItacaStream). Special attention was paid to the minimum temperature of the eutectoid. The change of its value after the modification process, its influence on the quality of the melted metal, a very strong correlation with the number of nuclei and the number of graphite precipitations in the casts were shown.