The foundry industry is an important component of the economy on which other progressive industries depend. The reliability of the products it manufactures is determined by the technologies used, but, most importantly, it ensures the expected level of quality. The purpose of the article is to develop a synergistic quality-cost model for the improvement of casting products. The model is based on an integral methodological configuration that makes it possible to determine the level of relevance of the causes of casting nonconformity in the quality-cost context. The model integrates techniques such as the Pareto-Lorenz diagram, ranking, brainwriting, Ishikawa diagram, Likert rating scale, and matrix diagram. Verification of the method by its implication in the manufacturing process of a gearbox casting is performed. The model makes it possible to identify quality-cost relationships between key categories of problem causes and major product nonconformities. The main causes of the loss of quality stability of the analyzed product are found to be low quality of molding sand, poor technical condition of foundry equipment (too infrequent repairs and overhauls), and ineffective quality control. Carrying out the analysis made it possible to develop appropriate improvement measures. It is proposed to implement changes in the casting process, implement the TPM method, conduct periodic training, develop job instructions, implement a control system, and provide supervision of employees. Further research directions will concern the implications of the method within the other positions in the casting company and its development towards automation of analysis.
The paper presents an attempt to produce aluminum matrix composites reinforced with short carbon fibers by precision casting in a chamber with a pressure lower than atmospheric pressure. The composite casting process was preceded by tests related to the preparation of the reinforcement. This is related to the specificity of the precision casting process, in which the mold for shaping the castings is fired at a temperature of 720°C before pouring. Before the mold burns, the reinforcement must be inside, while the carbon fiber decomposes in the atmosphere at 396°C. In the experiment, the reinforcement in the form was secured with flake graphite and quartz sand. The performed firing procedure turned out to be effective. The obtained composite castings were evaluated in terms of the degree of alloy saturation and the displacement of carbon fibers. As a result of the conducted tests, it was found that as a result of unfavorable arrangement of fibers in the CF preform, the flow of metal may be blocked and porosity may appear in the casting.
The article discusses the most important changes in the construction of permanent mould casting machines, as well as the method of casting engine pistons and their construction on the example of Federal-Mogul (FM) Gorzyce. The system of automatic cooling of the presently used permanent mould casting machines coupled with robots which pour the liquid alloy ensures uniform crystallization of the pistons and optimal efficiency of the casting process. As a result of the necessity to improve the engine efficiency and thus reduce the fuel consumption and harmful substance emission, the construction of the pistons has changed as well. The piston castings, which are produced by gravity casting for metal moulds, have undergone a diametric transformation. Typical piston designs for gasoline and Diesel engines are shown together with the most important parts of the piston, the crown (combustion chamber) and the guide part (skirt). Depending on the type of engine, the present pistons characterize in differently shaped crown, a slimmed internal construction as well as component participation (cooling channels and ring inserts), and the piston skirts undergo surface treatment procedures.
Good quality in composite castings can be confirmed primarily by their user. The producer is obliged to create a good product that meets the user’s needs that should undergo quality control. Omission of technological procedures and improper quality control may result in various defects like porosity. This paper presents the characteristics of the casting defect, namely porosity, with a particular focus on porosity in suspension and saturated metal composites. This defect is different, specific to composite castings, making its identification very difficult. The aim of the study is to detect and describe porosity in composites with the use of microscopic and submicroscopic examinations. The assessment of the porosity of the microstructure of composite castings allowed for the formulation of the following conclusions: in addition to the porosity that occurs in castings of classic materials (cast steel, cast iron, and non-ferrous metal alloys), metal composites also distinguish between primary and secondary agglomerates, leaving the reinforcement space not filled, occluded bubbles, and separated gas bubbles.
The paper presents an example of the application of vibratory machining for castings based on the results of visual testing. The purpose of the work is to popularize non-destructive testing and vibratory machining as finishing process, especially in the case of cast objects. Visual testing is one of the obligatory non-destructive tests used for castings and welded joints. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The tested castings, which had characteristic traces of the casting process, were subjected to vibratory machining. The machining with loose abrasive media in vibrating containers is aimed at smoothing the surface and reducing or completely removing flashes. To complement the visual testing were also conducted research on the contact profilometer Taylor Hobson PGI 1200. Particular attention was focused on measuring the height of flashes and changes in the surface of smoothed details based on BNIF No. 359 touch-visual patterns. Based on the work, it can be concluded that vibratory machining allows for removal flashes and smoothing of the surface of aluminum alloy cast objects.
This article proposes to use abrasive waterjet cutting (AWJ) for deflashing, deburring and similar finishing operations in casting. The basic requirements concerning the dimensional accuracy and surface texture of cast components are not met if visible surface flaws are detected. The experiments focused on the removal of external flash from elements made of EN-GJL-150 cast iron. The method employed for finishing was abrasive waterjet cutting. The tests were carried out using an APW 2010BB waterjet cutting machine. The form profiles before and after flash removal were determined with a Taylor Hobson PGI 1200 contact profiler. A Nikon AZ100 optical microscope was applied to observe and measure the changes in the flash height and width. The casting surface after finishing was smooth, without characteristic sharp, rough edges that occur in the cutting of objects with a considerable thickness. It should be emphasized that this method does not replace precise cutting operations. Yet, it can be successfully used to finish castings for which lower surface quality is required. An undoubted advantage of waterjet cutting is no effect of high temperature as is the case with plasma, laser or conventional cutting. This process is also easy to automate; one tool is needed to perform different finishing operations in order to obtain the desired dimensions, both internal and external.
The paper presents the production problems related to casting using precision casting methods. The essential adverse effect of the casting process is the presence of burrs understood as oversize material necessary to remove the next finishing operations. In addition, the surfaces of the cast often characterized by a porous structure. One of the methods to improve the smoothness of the area proposed by the authors is the use of vibro-abrasive finishing. This type of treatment is widely used in the treatment of finishing small objects as well as complex shapes. Objects in the form of casting in the first step was treated with aggressive deburring polyester matrix abrasive media. The second stage was polishing, with using smoothing porcelain media. The study evaluated the effect of vibro-abrasive machining typical cast on the basic parameters of the geometric structure of the surface. Observations using optical microscope Nicon Eclipse MA 200 compared changes in surface microstructure and the effect of deburring. Clearly we can say that vibro-abrasive machining an effective way of reducing the size of burrs, smoothing and lightening the surface of objects made by casting.
The paper presents results of measuring heat diffusivity and thermal conductivity coefficients of used green foundry sand in temperature range ambient – 600°C. During the experiments a technical purity Cu plate was cast into the green-sand moulds. Basing on measurements relationships of the measured properties were evaluated. It was confirmed that the obtained relationships are complex and that water vaporization strongly influences thermal conductivity of the moulding sand in the first period of the mould heating by the poured and solidified casting.
The main aim of this study was to examine the compression-induced state of stress arising in castings of the guide grates during operation in pusher-type furnaces for heat treatment. The effect of grate compression is caused by its forced movement in the furnace. The introduction of flexible segments to the grate structure changes in a significant way the stress distribution, mainly by decreasing its value, and consequently considerably extends the lifetime of the grates. The stress distribution was examined in the grates with flexible segments arranged crosswise (normal to the direction of the grate compression) and lengthwise (following the direction of force). A regression equation was derived to describe the relationship between the stress level in a row of ribs in the grate and the number of flexible segments of a lengthwise orientation placed in this row. It was found that, regardless of the distribution of the flexible segments in a row, the stress values were similar in all the ribs included in this row, and in a given row of the ribs/flexible segments a similar state of stress prevailed, irrespective of the position of this row in the whole structure of the grate and of the number of the ribs/flexible segments introduced therein. Parts of the grate responsible for the stress transfer were indicated and also parts which play the role of an element bonding the structure.
In order to increase wear resistance cast steel casting the TiC-Fe-Cr type composite zones were fabricated. These zones were obtained by means of in situ synthesis of substrates of the reaction TiC with a moderator of a chemical composition of white cast iron with nickel of the Ni-Hard type 4. The synthesis was carried out directly in the mould cavity. The moderator was applied to control the reactive infiltration occurring during the TiC synthesis. The microstructure of composite zones was investigated by electron scanning microscopy, using the backscattered electron mode. The structure of composite zones was verified by the X-ray diffraction method. The hardness of composite zones, cast steel base alloy and the reference samples such as white chromium cast iron with 14 % Cr and 20 % Cr, manganese cast steel 18 % Mn was measured by Vickers test. The wear resistance of the composite zone and the reference samples examined by ball-on-disc wear test. Dimensionally stable composite zones were obtained containing submicron sizes TiC particles uniformly distributed in the matrix. The macro and microstructure of the composite zone ensured three times hardness increase in comparison to the cast steel base alloy and one and a half times increase in comparison to the white chromium cast iron 20 % Cr. Finally ball-on-disc wear rate of the composite zone was five times lower than chromium white cast iron containing 20 % Cr.
The paper presents results of measuring thermal conductivity of green sand mould material and time of castings solidification evaluated from cooling curves. During the experiments pure Cu (99,8 %) plate was cast into the examined sand moulds. Basing on the measurements it was stated that thermal conductivity of the moulding sand has complex temperature variability, especially during the water vaporization. It was confirmed that water vaporization strongly influences thermal conductivity of the moulding sand in the first period of the mould heating by the poured casting. The obtained dependence should be used in the numerical calculations to improve their accuracy.
PL
Artykuł prezentuje wyniki pomiarów współczynnika przewodzenia ciepła materiału wilgotnej formy piaskowej z bentonitem oraz czas krzepnięcia odlewu płyty z miedzi o czystości 99.8%. Na podstawie eksperymentów stwierdzono, że temperaturowa zależność przewodności cieplnej badanej masy formierskiej nie ma prostego przebiegu, szczególnie w okresie odparowywania wilgoci, a uzyskana w części eksperymentalnej temperaturowa zależność powinna być stosowana w obliczeniach numerycznych w celu polepszenia jakości obliczeń.
This study shown possibilities of Rapid Prototyping techniques (RP) and metal casting simulation software (MCSS), including non inertial reference systems. RP and MCSS have been used in order to design and produce essential elements for artificial heart. Additionally it has been shown possibilities of Fused Deposition Modeling (FDM) technique and DodJet technology using prototyped elements of rotodynamic pump. MAGMASOFT® software allowed to verify the cast kit heart valves model. Optical scanner Atos III enabled size verification of experimental elements supplied by rapid prototyping together with metal casting elements. Due to the selection of ceramic materials and assessment of molten metal – ceramic reactivity at high temperatures together with pattern materials selection model it was possible to design, manufacture a ceramic mould for titanium based alloys. The casting structure modification has been carried out by means of high isostatic pressure technique (HIP). The quality assessment of the casting materials has been performed using X-ray fluorescence (XRF), ARL 4460 Optical Emission Spectrometer, metallographic techniques and X-ray computed tomography.
PL
W artykule przedstawiono wykorzystanie technik szybkiego prototypowania oraz programów do symulacji przepływów stopów odlewniczych, w tym w nieinercyjnych układach odniesienia, do projektowania, a następnie wykonania elementów sztucznego serca. Zaprezentowano kolejno technikę Fused Deposition Modeling (FDM) oraz technologię DodJet na przykładzie wykonania prototypowych elementów pomp wirowych. Program MAGMASOFT® pozwolił zweryfikować projekt zestawu odlewniczego zastawki serca. Zastosowanie skanera optycznego Atos III umożliwiło weryfikację wymiarów doświadczalnych elementów otrzymanych przy wykorzystaniu technik RP oraz elementów odlewanych. Dzięki doborowi materiałów ceramicznych pod kątem oceny ich reakcji z ciekłym metalem oraz doborowi mas modelowych możliwe było opracowanie doświadczalnych form ceramicznych przeznaczonych do odlewania stopów tytanu. Modyfikację struktury odlewów wykonano przy zastosowaniu obróbką techniką HIP. Ocenę jakości wykonanych odlewów przeprowadzono kolejno metodą mikrofluorescencji rentgenowskiej, emisyjnym spektrometrem optycznym, technikami metalograficznymi oraz rentgenowską tomografią komputerową.
The paper presents results of measuring thermal conductivity of sand mould material and time of castings solidification evaluated from cooling curves and from Nova Flow & Solid numerical calculations. During the experiments pure Al (99,95%) plate was cast into the sand moulds. The analysed variable parameter in numerical calculations was mould thermal conductivity of fixed value taken from the range 0.5-0.9 W/(mK). Other mould parameters (initial temperature, mass density, heat capacity) and thermo-physical properties of liquid and solid casting were taken invariable. Basing on the measurements it was stated that thermal conductivity of the moulding sand has complex temperature variability, especially during the water vaporization and the obtained dependence should be used in the numerical calculations to improve their accuracy.
PL
Artykuł prezentuje wyniki pomiarów współczynnika przewodzenia ciepła materiału formy piaskowej oraz czas krzepnięcia odlewu oszacowany z krzywej stygnięcia i obliczony numerycznie za pomocą Nova Flow & Solid. W czasie eksperymentów odlew w kształcie płyty wykonywano z czystego aluminium (99,95%). Zmienna w obliczeniach była przewodność cieplna materiału formy z zakresu 0,5-0,9 W/(mK). Pozostałe parametry formy (temperatura początkowa, gęstość masy i pojemność cieplna) oraz właściwości termofizyczne ciekłego i zakrzepłego metalu były stałe. Na podstawie eksperymentów stwierdzono, że temperaturowa zależność przewodności cieplnej formy nie ma prostego przebiegu, szczególnie w okresie odparowywania wilgoci, a uzyskana w części eksperymentalnej temperaturowa zależność powinna być stosowana w obliczeniach numerycznych w celu polepszenia jakości obliczeń.
The paper presents results of measuring thermal conductivity of green-sand mould material and time of pure-copper plate castings solidification evaluated from cooling curves. During the experiments pure Cu (99,8 %) plate was cast into the green-sand moulds. Basing on the measurements it was stated that thermal conductivity of the moulding sand has complex temperature variability, especially during the water vaporization and the obtained dependence should be used in the numerical calculations to improve their accuracy.
Szybko rozwijająca się gospodarka oraz ciągłe wzrastające wymagania klientów wymuszają na odlewniach nieustanną rywalizację o egzystencję i dalszy rozwój. Osiągnięcie tych dwóch podstawowych rzeczy, jest sprawą niezmiernie trudną. Zarząd odlewni staje przed skomplikowanymi decyzjami związanymi z maksymalizacją efektywności produkcji. Do takich decyzji należy m.in. wdrażanie nowych systemów czy też instrumentów zarządzania jakością. W artykule poddano analizie i ocenie system kontroli jakości odlewów oparty na kartach kontrolnych do pomiarów liczbowych [...].
EN
Rapidly growing economy and the continuous increasing demands of customers force on foundry companies the ceaseless rivalry for existence and further development. Achieving these two basic aims is extremely difficult matter. Management of foundry is faced with complicated decisions connected with maximization of the production effectiveness. Such decisions include, among others, implementation of new systems or instruments of the quality management. The article analyzes and evaluates the quality control system of casting based on control charts of measurements [...]
A comparative laboratory research on a special testing stand of casting materials erosive wear have been conducted in terms of assessing their tribological properties. Different types of carbon iron alloys have been used, as well as modified alloys (metallurgically) in order to increase their resistance to this type of wear. Results have been presented in the form of tables and graphs.
PL
Przeprowadzono laboratoryjne porównawcze badania materiałów odlewniczych w warunkach zużycia erozyjnego w aspekcie oceny ich właściwości tribologicznych z użyciem specjalistycznego stanowiska badawczego. Wykorzystano różne stopy żelaza z węglem; do badań tych użyto także stopy modyfikowane metalurgicznie i cieplnie w celu zwiększenia ich odporności na ten rodzaj zużycia. Wyniki badań zaprezentowano w postaci wykresów i tabel.
The subject of the paper is heat exchange in the system casting - riser - ambient. The examinations were focused on evaluating temperature dependence of the coefficient of heat exchange from open (not shielded) top surface of riser to ambient. The examinations were carried out on the open surface of cast steel riser, of temperatures 1000-1500°C. On the basis of the performed examinations it was stated that heat emission coefficient changes its mean values by about 50% during feeding process of the mild steel casting, i.e. from about 0.28 in liquid state to about 0.42 at temperatures close to solidus. This wide range of surface heat emissivity changes should be taken into account when boundary conditions are formulated in elaborated models of solidification and in designing risering systems.
PL
Przedmiotem artykułu jest wymiana ciepła w systemie odlew - nadlew - otoczenie. Celem badań było wyznaczenie temperaturowej zależności współczynnika wymiany ciepła z odkrytej, nieizolowanej powierzchni nadlewu do otoczenia. Badania wykonano dla odlewu staliwnego z odkrytym nadlewem, dla zakresu temperatury powierzchni nadlewu 1000-1500°C. Na podstawie wykonanych badań stwierdzono, iż współczynnik emisji ciepła z nieizolowanej powierzchni nadlewu do otoczenia zmienia swą wartość w badanym zakresie temperatury o około 50%, tj. od około 0.26 - 0.30 dla metalu w stanie ciekłym do około 0.42 - 0.46 dla metalu w stanie stałym, w pobliżu temperatury solidus. Powyższy szeroki zakres zmian emisyjności powinien być uwzględniany w budowanym modelach symulacji procesu krzepnięcia i projektowania systemów zasilania krzepnących odlewów.
The study discusses a method of producing composite zones at the edge of castings made of ferritic-pearlitic ductile iron. Composite zones were produced in castings made of ferritic-pearlitic ductile iron at the casting edge. The reinforcing phase for the composite zone was TiC carbide, obtained by in-situ synthesis of substrates introduced into the mould in the form of compacts. The composition of the substrates of the reaction of the TiC synthesis was next enriched with an Fe filler added in an amount of 10 and 50 wt. % to investigate the possibility of changing the hardness of the composite zone. The addition of filler changed the surface fraction and the average size of TiC precipitates. In the case of the 50 wt. % addition, a tenfold reduction in the dimensions of the carbides was obtained. This increased their surface fraction relative to the compact composition containing only 10 wt. % of the filler. Changes in mechanical properties were analysed within the zone area by the measurement of hardness HV. The study showed a gradual decrease of the zone hardness in function of the amount of the filler added. This trend was also true as regards the composite zone in castings, where a significant refinement and increased surface content of the TiC precipitates was observed.
PL
W pracy omówiono metodę wytwarzania stref kompozytowych w odlewach z ferrytyczno-perlitycznego żeliwa sferoidalnego. Faza wzmacniająca strefy kompozytowej był węglik tytanu (TiC), uzyskany w wyniku syntezy in situ substratów wprowadzonych do formy w postaci wyprasek. Do kompozycji substratów reakcji syntezy TiC wprowadzono wypełniacz, proszek Fe w ilości 10 i 50 %mas. w celu zbadania możliwości zmiany twardości strefy kompozytowej. Dodatek wypełniacza spowodował zmiane udziału powierzchniowego oraz średniej wielkości TiC. W przypadku 50 %mas. dodatku wypełniacza otrzymano dziesięciokrotne zmniejszenie wymiarów węglików. Analizowano zmiany mechaniczne w obrębie strefy, badając jej twardość HV. Badana wykazały stopniowy spadek twardości strefy wraz z ilością dodawanego wypełniacza. Tendencja ta dotyczyła również strefy kompozytowej odlewu, w którym stwierdzono znaczne rozdrobnienie wydzieleń TiC i wzrost ich udziału powierzchniowego.
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In cast iron foundry operations like melting, casting, feetling, casts cleaning and grinding of a high amount of dusts are produced. Three kinds of dusts from different parts of cast iron foundry were analysed; chemical analyses, granulometric analyses and microscopic analyses were carried out. The bentonite sand mixtures with different portion of dusts were prepared. Technological properties of prepared sand mixtures (compression strength, shearing strength and permeability) were measured.
PL
W poszczególnych operacjach procesu wykonywania odlewów powstają znaczne ilości pyłów. W większości pyły te są składowane, mimo że zawierają szereg cennych składników. Celem pracy było określenie możliwości dodatku pyłów do mas z bentonitem i wpływ na właściwości tych mas. Zbadano 3 rodzaje pyłów: niemagnetyczną część pyłów z oczyszczania odlewów, pyły z suchego odpylania żeliwiaków, pyły z odpylania stanowiska sporządzania mas z bentonitem i wykonywania form. Wykonano analizę chemiczną tych pyłów, analizę granulometryczną i badania mikroskopowe. Masy z bentonitem i dodatkiem tych pyłów badano w zakresie: wytrzymałości na ściskanie, wytrzymałości na ścinanie oraz przepuszczalności. Najlepsze wyniki uzyskano przy dodatku pyłów z odpylania stanowisk sporządzani masy oraz wykonywania form, aczkolwiek w tym przypadku miało miejsce zmniejszenie przepuszczalności masy.
The paper described of magnetic field near castings forming in flat carbon steel. Presents is self solution of forming tool employed of experiments about. The results certify aptitudes of employed behalf of introductions the work.
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