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1

Developing the inoculation procedure for high-quality cast iron with flake graphite, intended for large-size casting (bottom or distance plates and counterweights) – produced in Krakodlew Foundry S.A.

Guzik Edward, Świątkowski Adrian, Szczęsny Andrzej, Kopyciński Dariusz, Mirek Piotr, Piotrowski Krzysztof

Technical Transactions

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2023

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Vol. 120, iss. 1

art. no. e2023009

EN

This article presents the first part of the research on the production of large-sizecastings, such as bottom plates and counterweights produced in the KrakodlewS.A. foundry. Castings of this type are not complicated in terms of construction butmust meet certain requirements, namely to be able to withstand the effects of hightemperature and associated stresses, or to have specific dimensions and weight inthe case of counterweights. In both cases, the most common method of formingcastings is horizontal moulding. However, this requires a lot of time for machiningthe finished castings. Forming heavy castings in a vertical orientation, although muchmore problematic, can mean that the amount of time required for machining may bereduced. The research presents the effect of overheating temperature on the effectsof inoculation with the Zircinoc inoculant, in which it was shown that increasing thetemperature by fifty degrees increased the amount of eutectic grains by around11–15%.

2

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

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2023

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Vol. 23, iss. 1

61--67

EN

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.

3

Influence of Charge Materials on the Metallurgical Quality of Gray Cast Iron

Dwulat Rafał, Janerka Krzysztof, Grzesiak K., Gałuszka M.

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 2

66--71

EN

The article presents the influence of the percentage share of pig iron and steel scrap on the chemical composition, physicochemical and mechanical properties. Using an induction furnace, 6 melts were carried out with a variable amount of pig iron in the charge from 0 to 50%. For carburizing, a RANCO 9905 carburizer with a carbon content of 99.2% was used. After melting and introducing FeSi75, temperature measurement was carried out and the metal was superheated to 1500°C. The next step was to pour the samples for chemical analysis, DTA (Derivation Thermal Analysis) and strength and hardness from the melting furnace without inoculation. The last step was to carry out the inoculation by introducing 0.3% barium inoculant into the vat and pouring samplers for DTA analysis. The inoculation was carried out solely to determine changes in DTA parameters, mainly Temin, compared to castings without inoculation.

4

Forecasting the Natural Frequency of the Brake Disccasting

Zyska Andrzej, Bieroński Mariusz

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 4

87--92

EN

The paper presents the results of calculations and measurements of the first natural frequency of castings of solid and ventilated brake discs made of gray cast iron of the EN-GJL-200 class. The tests were carried out for three types of chemical composition, taking into account the permissible minimum and maximum content of alloying elements. Numerical simulations of natural vibrations were carried out on the basis of our own production material databases. To determine the elastic properties of cast iron, the ultrasonic method with the measurement of the propagation velocity of longitudinal and transverse waves was used. Measurements were made directly on casts of raw discs of various thicknesses. The values of Young's modulus and Poisson's number calculated from ultrasonic measurements were used to define the stiffness matrix in the equilibrium equation, which is solved by the solver of the MSC Nastran program. A high compatibility between the results of numerical simulations and the results of experimental FRF frequency analysis was obtained. The differences between the calculated and actual values were at the level of several hertz, while the estimated average error of numerical simulations was 0.76%. It was also found out that cast iron melts for brake discs must be subject to strict control in terms of chemical composition. Slight deviations of the eutectic saturation coefficient from the optimal value cause a significant change in the first natural frequency of the brake discs, regardless of their geometry.

5

Designing of X46Cr13 Steel Heat Treatment in Condition of Casting Mould

Przyszlak Natalia, Piwowarski Grzegorz

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 2

119--126

EN

The paper presents issues related to the technology of layered castings manufactured in the system: working part made of high-chromium steel X46Cr13 - base part made of gray cast iron with flake graphite, using the mould cavity preparation technology. Considering the high hardenability of the above-mentioned steel grade, the aim of the research was to optimize the casting parameters of gray cast iron in such a way that it would be possible to perform heat treatment of X46Cr13 steel directly in the casting mould. As part of the research, the geometry of the working and base parts of layered castings was selected, and guidelines for mould technology from the point of view of the moulding sand were developed. In order to control the cooling rate, three matrix of the moulding sand were used - quartz sand, chromite sand and silicon carbide, with the same granularity. The thermal conductivity coefficient of sands made on selected matrix, bound with synthetic resin in the ratio of 30:1, was experimentally determined. Then, the bimetal casting process in a given mass was simulated in the MagmaSoft® (ver. 5.4.1). The purpose of the simulation was to determine the maximum virtual temperature Tm in the thermal center of the outer surface of the X46Cr13 steel insert. From the point of view of the research purpose, the insert was expected to heat up to the austenitization temperature, i.e. at least 950°C.

6

Analysis of the selected machining factors influence on the milling process of grey cast iron

Ziarkowski Piotr, Klamczyński Kamil, Sójka Radosław, Kowalska Natalia, Błasiak Sławomir, Nowakowski Łukasz, Skrzyniarz Michał

Mechanik

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2022

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R. 95, nr 11

22--29

EN

The quality of the geometric structure of a surface is influenced by factors such as the geometry of the cutting tool, the cutting conditions and the displacements in the tool-workpiece system. This paper describes the results of a study to analyse the influence of selected machining factors accompanying the face milling process on the geometric structure of the surface. During the machining tests, relative displacements in the T-W system were recorded, as well as the components of forces and moments of the face milling process for specimens made of grey cast iron. The tests were carried out on an AVIA VMC 800 milling centre, and the accuracy of the machined surface was checked. A Talysurf CCI - Lite Non-contact 3D Profiler, which was equipped with TalyMap Platinum software, was used to measure the geometric structure of the surface.

PL

Na jakość struktury geometrycznej powierzchni wpływają takie czynniki, jak: geometria narzędzia skrawającego, warunki skrawania oraz przemieszczenia w układzie narzędzie-przedmiot obrabiany. W artykule opisano wyniki badań, których celem była analiza wpływu wybranych czynników obróbki towarzyszących procesowi frezowania czołowego na strukturę geometryczną powierzchni. W trakcie prób skrawania rejestrowano przemieszczenia względne w układzie N-P oraz składowe sił i momentów procesu frezowania walcowo-czołowego próbek wykonanych z żeliwa szarego. Próby przeprowadzono na centrum frezarskim AVIA VMC 800. Sprawdzono dokładność wykonania powierzchni poddanej obróbce frezarskiej. Strukturę geometryczną powierzchni zmierzono profilometrem Talysurf CCI - Lite Non-contact 3D Profiler, wyposażonym w oprogramowanie TalyMap Platinum.

7

Case study of accelerated wear of brake discs made of grey cast iron characterized by increased thermal stability

Zemlik Martyna, Dziubek Mateusz, Pyka Dariusz, Konat Łukasz, Grygier Dominika

Combustion Engines

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2022

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R. 61, nr 3

45--49

EN

In this paper, the subject of the analysis is Rotinger High Performance brake disc, characterized by increased thermal resistance, which is a result of adequate design and material solutions. However, despite declared performance, the analyzed discs suffered accelerated wear over a period of about 20 months. The aim of this study was to assess the causes of the disc failure. As a result, it was showed that the applied material solution still does not differ from standard ones. According to the authors of this paper, an appropriate procedure to improve resistance to thermal fatigue is, among others, changing the shape of graphite precipitates from flake to spheroidal.

8

Inoculation of Gray Cast Iron Intended for Large Scale and Heavy Weight Castings of Bottom Plates and Counterweights Manufactured in the KrakOdlew S.A.

Szczęsny Andrzej, Kopyciński Dariusz, Guzik Edward

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 3

19--24

EN

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions. The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).

9

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

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2021

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Vol. 5, no. 4

89--93

EN

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.

10

A Process of As-Cast Ferritic Gray Cast Iron Production

Hossain Md Sojib

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 3

5--10

EN

Though normal air cooling and green sand mold-casted gray iron convey an essentially pearlitic matrix, ferritic gray iron is used in some electro-mechanical applications to have better magnetic properties, ductility, and low hardness. Conventionally, to produce ferritic gray iron, foundryman initially produces pearlitic gray iron, then it is carried through a long annealing cycle process for ferritic transformation. This experiment is conducted to eliminate the long annealing cycle from the conventional process. A process is developed to produce as-cast ferritic gray cast iron by air cooling in the green sand mold. In this experiment, Si content is kept high, but Mn content is kept low based on sulfur content; a unique thermodynamic process is established for decreasing the Mn content from the melt. After a successful preconditioning and optimum foundry return charging, the melt is specially inoculated, and metal is poured into the green sand mold. An extra feeder is added for slowing down the cooling rate where casting thickness is around 15mm. Finally, hardness and metallographic images are observed for final confirmation of the ferritic matrix.

11

Comparison of tribological properties and structure of coatings produced in powder flame spraying process on grey cast iron

Czupryński Artur, Adamiak Marcin, Bayraktar Emin, Wyględacz Bernard

Welding Technology Review

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2020

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R. 92, nr 3

7--21

EN

In this article results of tribological and structural properties comparison of flame sprayed, by SupJet-S-Eutalloy® multipurpose system, two self-fluxing alloys of Ni-B-Si type in the form of powder for spraying with remelting are presented. Layers were produced on EN-GJL-250 grade grey cast iron with flake graphite in an austenitic matrix. Abrasive wear resistance examination acc. to ASTM G65-00 and erosive wear resistance examination acc. to ASTM G76-2 were performed. Obtained results were compared with abrasion-resistant steel Hardox® 400. Macro- and microscopic examination were carried enabling layer quality evaluation and structure of examined layer and base material determination. X-ray microanalysis was performed to obtain qualitative and quantitative data about microareas chemical composition. The Eutalloy® BronzoChrom 10185 powder flame sprayed layer with higher Boron and Silicon content was characterized by 13% lower wear intensity under mineral abrasive conditions and about 30% higher erosion wear resistance than Eutalloy® NiTec 10224 powder flame sprayed layer.

PL

W artykule przedstawiono wyniki badań dotyczące porównania właściwości tribologicznych i strukturalnych powłok, natryskiwanych płomieniowo za pomocą wielofunkcyjnego systemu SupJet-S-Eutalloy® dwoma różniącymi się składem chemicznym samotopnikującymi stopami typu Ni-B-Si w postaci proszku metalicznego przeznaczonego do natrysku z jednoczesnym przetopieniem. Powłoki wykonano na podłożu z żeliwa szarego gatunku EN-GJL-250 z grafitem płatkowym w osnowie austenitycznej. Przeprowadzono badania odporności na zużycie ścierne wg normy ASTM G65-00 oraz odporności na zużycie erozyjne zgodnie z normą ASTM G 76-2. Uzyskane wyniki porównano z parametrami zużycia abrazyjnego stali trudnościeralnej Hardox® 400. Wykonano obserwacje metalograficzne makro i mikroskopowe pozwalające na określenie jakości powłok oraz struktur badanych warstw i materiału podłoża. W celu określenia jakościowego i ilościowego składu chemicznego mikroobszarów powłok przeprowadzono badania metodą mikroanalizy rentgenowskiej. Stwierdzono, że powłoka natryskiwana płomieniowo proszkiem Eutalloy® BronzoChrom 10185 zawierającym większe stężenie boru i krzemu wykazywała o ok. 13% mniejszą intensywność zużycia pod wpływem oddziaływania ścierniwa mineralnego oraz o ok. 30% większą odporność na zużycie erozyjne niż powłoka natryskiwana płomieniowo proszkiem Eutalloy® NiTec 10224.

12

The Influence of Selected Melting Parameters on the Physical and Chemical Properties of Cast Iron

Petrus Ł., Bulanowski A., Kołakowski J., Brzeżański M., Urbanowicz M., Sobieraj J., Matuszkiewicz G., Szwalbe L., Janerka K.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

105--110

EN

This paper presents the problems related to smelting gray and ductile cast iron. Special attention is paid to the metallurgical quality of cast iron. It depends on the type of furnace, charge materials and the special combination of charge, overheating and holding temperature, melting time, modification and spheroidization method. The evaluation of metallurgical quality has been performed by using derivative-thermal analysis (DTA). During the smelting process and secondary metallurgy, the ITACA system was used allowing to obtain information on alloy characteristic temperatures (Tliquidus, TeMin, TeMax, Tsolidus), VPS value, recalescence value, IGQ coefficient, nucleation gauge, porosity etc. The results of investigations and calculations are displayed in the form of graphs and dependencies. It has been shown that the derivative-thermal analysis (DTA) is an effective complement of chemical analysis and it has been found that both the increase in temperature and metal holding time have a negative impact on the metallurgical quality of liquid metal. The metallurgical quality can be improved by using proper composition of charge materials and modifiers.

13

The Effect of Structure on Thermal Power of Cast-iron Heat Exchangers

Mróz M., Orłowicz A. W., Tupaj M., Jacek-Burek M., Radoń M., Kawiński M.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

27--30

EN

The objective of the study reported in this paper was to determine the effect of structure on thermal power of cast-iron heat exchangers which in this case were furnace chambers constituting the main component of household fireplace-based heating systems and known commonly as fireplace inserts. For the purpose of relevant tests, plate-shaped castings were prepared of gray iron with flake graphite in pearlitic matrix (the material used to date typically for fireplace inserts) as well as similar castings of gray cast iron with vermicular graphite in pearlitic, ferritic-pearlitic, and ferritic matrix. For all the cast iron variants of different structures (graphite precipitate shapes and matrix type), calorimetric measurements were carried out consisting in determining the heat power which is quantity representing the rate of heat transfer to the ambient environment. It has been found that the value of the observed heat power was affected by both the shape of graphite precipitates and the type of alloy matrix. Higher thermal power values characterize plate castings of gray iron with vermicular graphite compared to plates cast of the flake graphite gray iron. In case of plates made of gray cast iron with vermicular graphite, the highest values of thermal power were observed for castings made of iron with ferritic matrix.

14

Preconditiong and Inoculation of Low Sulphur Grey Iron

Hossain Md Sojib S., Bazlur B. Rashid A. K. M.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

61--66

EN

For quality grey cast iron production, the challenging issues are to avoid cementite structure and obtain the desired graphite morphology with proper matrix as well as hardness. The objective of the present research is to find out the right combination of preconditioner and inoculant that may help to overcome the challenges. In this work, sulphur content is kept low (0.01%). Two preconditioners namely metallurgical SiC and zirconium bearing FeSi with two types of inoculant are individually used to make four combinations of sample and for each case metal is poured into the green sand mould. Finally Brinell hardness and graphite morphology is observed in the thickest and thinnest portions of the castings. Metallurgical SiC with barium bearing inoculant gives better graphite morphology and hardness than strontium bearing inoculant, on the other hand zirconium bearing FeSi gives more satisfying result than SiC with every type of inoculant. Among all of the combinations Zr bearing preconditioner with Ba bearing inoculant gives good graphite morphology with best mechanical properties in both thickest and thinnest portions of the casting.

15

Influence of Cast Iron Modification on Free Vibration Frequency of Casting

Konopka Z., Łągiewka M., Zyska A.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

23--26

EN

The paper presents the results of investigations concerning the influence of gray cast iron modification on free vibration frequency of the disc casting. Three different chemical composition melts of gray cast iron were prepared in induction furnace. During gravity casting 0.05% and 0.3% mass of the Inolate modifier was added on stream of metal for changing graphite flakes in castings. Sound signal vibration of cast iron sample was registered by means on microphone for free vibration frequency measurements. Decreasing of free vibration frequency of modified cast iron in comparison with non modified castings was observed. Higher contents of modifier causes more decreasing of free vibration frequency. Cast iron with smaller contents of carbon and silicon have higher free vibration frequency in comparison with eutectic composition cast iron. Hardness of examined cast iron is lower when the more modifier is added during modification process. Free frequency is smaller with smaller Brinell hardness of disc casting. It was concluded that control of free vibration frequency of disc castings by means of chemical composition and modification process can improved comfort and safety of working parts.

16

The Influence of the Shape of Graphite Precipitates on the Cast Iron Abrasion Resistance

Jakubus A., Soiński M. S.

Archives of Foundry Engineering

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2019

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iss. 4

87--90

EN

The paper presents the initial results of investigation concerning the abrasion resistance of cast iron with nodular, vermicular, or flake graphite. The nodular and vermicular cast iron specimens were cut out of test coupons of the IIb type with the wall thickness equal to 25 mm, while the specimens made of grey cast iron containing flake graphite were cut out either of special casts with 20 mm thick walls or of the original brake disk. The abrasion tests were carried out by means of the T-01M tribological unit working in the pin-on-disk configuration. The counterface specimens (i.e. the disks) were made of the JT6500 brand name friction material. Each specimen was abraded over a distance of 4000 m. The mass losses, both of the specimens and of the counterface disks, were determined by weighting. It was found that the least wear among the examined materials was exhibited by the nodular cast iron. In turn, the smallest abrasion resistance was found in vermicular cast iron and in cast iron containing flake graphite coming from the brake disk. However, while the three types of specimens (those taken from the nodular cast iron and from grey cast iron coming either from the special casts or from the brake disk) have almost purely pearlitic matrix (P95/Fe05), the vermicular cast iron matrix was composed of pearlite and ferrite occurring in the amounts of about 50% each (P50/Fe50). Additionally, it was found that the highest temperature at the cast iron/counterface disk contact point was reached during the tests held for the nodular cast iron, while the lowest one occurred for the case of specially cast grey iron.

17

The Impact of Selected Geometry Parameter of Titanium Spatial Insert on the Surface Layer Formation on Grey Cast Iron

Dziwoki G., Dulska A., Szajnar J., Król M.

Archives of Foundry Engineering

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2019

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iss. 1

58--62

EN

The paper presents a method of producing a grey cast iron casting locally reinforced with a titanium insert printed using SLM method (Selective Laser Melting). This article attempts to examine the impact of the selected geometry of titanium spatial insert on the surface layer formation on grey cast iron. The scope of the research focuses on metallographic examination - observation and analysis of the structure of the reinforced surface layer on a light and scanning microscope and a hardness measurement of the titanium layer area. Based on the obtained results, it was concluded that the reaction between titanium insert and metal (grey cast iron) locally develops numerous carbides precipitation (mainly TiC particles), which increases the hardness of the reinforced surface layer and local strengthening of the material. The ratio between the thickness of the support part (grey cast iron) and the working part (titanium insert) affects the resulting layers connection structure. The properties of the obtained reinforced surface layer depend mainly on the geometry of the insert (primarily on the internal dimensions of the connector) and the volume of the casting affecting the re-melting of the insert. A more concentrated structure of carbides precipitation occurs in castings with a full connector insert.

18

Self-hardening of X46Cr13 Steel Integrated with Base from Grey Cast Iron in Bimetallic System

Przyszlak N., Wróbel T.

Archives of Foundry Engineering

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2019

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iss. 2

29--34

EN

The paper presents the technology of manufacturing layered castings, consisting of grey cast iron (base part) and high-chromium stainless steel (working part/layer). The aim of researches was an attempt of integration of heat treatment of steel X46Cr13 grade with founding of grey cast iron in bimetallic system and determination of the influence of cooling rate of bimetallic system in classical sand mould with bentonite on microstructure and hardness of the working layer. The castings were manufactured using mould cavity preparation method, where steel plate was poured by grey cast iron using different pouring temperature and thickness of base part. Then, the quality of joint between cast iron and steel plate was estimated by using ultrasonic non-destructive testing. The efficiency of heat treatment process was analysed by measurement of hardness and in metallographic examination. Conducted studies showed, that self-hardening’s ability of steel X46Cr13 let obtain technologically usable layered casting characterized by hardness of working surface up to 35 HRC.

19

Wpływ wybranych warunków skrawania na siłę i moment podczas wiercenia żeliwa szarego

Miko E., Nowakowski Ł., Skrzyniarz M.

Mechanik

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2018

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R. 91, nr 8-9

760--762

PL

Przeanalizowano wpływ wybranych parametrów skrawania (prędkości i posuwu) na moment i siłę skrawania podczas wiercenia żeliwa EN-GJL-250. Operacja wiercenia została wykonana wiertłem składanym firmy Allied Machine z serii DEM22000S-20FM, na pionowym centrum frezarskim Hermle B300. Pomiar momentu i siły skrawania podczas wiercenia przeprowadzono siłomierzem firmy Kistler.

EN

The impact of selected cutting parameters (cutting speed and cutting feed) on the torque and cutting force during drilling gray cast iron EN-GJL-250 was analyzed. The drilling operation was carried out by Allied Machnie drill series: DEM22000S-20FM, on the Hermle B300 vertical milling center. The measurement of the torque and the cutting forces during drilling was carried out by Kistler device.

20

Grey Cast Iron Locally Reinforced Using 3D Printing Scaffold Insert

Przyszlak N., Dulska A., Wróbel T., Szajnar J.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 1

99--102

EN

The paper presents an innovative method of creating the layered castings. The innovation relies on application the 3D printing insert obtaining in SLM (selective laser melting) method. This type of scaffold insert made from pure Ti powder, was placed into mould cavity directly before pouring by grey cast iron. In result of used method was obtained grey cast iron casting with surface layer reinforced by titanium carbides. In range of studies were carried out metallographic researches using light microscope and scanning electron microscope, microhardness measurements and abrasive wear resistance. On the basis of obtaining results was stated that there is a possibility of reinforcing surface layer of the grey cast iron casting by using 3D printing scaffold insert in the method of mould cavity preparation. Moreover there was a local increase in hardness and abrasive wear resistance in spite of the precipitation of titanium carbides in surface layer of grey cast iron. While the usable properties of composite surface layer obtained in result of use of the method presented in the paper, strongly depend of dimensions of scaffold insert, mainly parameters Re and Ri.