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Ceramic-Carbon Filters for Molten Metal Alloys Filtration

Asłanowicz M., Ościłowski A., Lipowska B., Witek J., Robak Z., Muzyka R., Kowalski P., Wańczyk K.

Archives of Foundry Engineering

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2019

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iss. 1

98--102

EN

In 2014 we finished research works involved in the development of a technology for manufacturing innovative ceramic-carbon foam filters for molten metal alloys filtration, which were financed by the National Centre for Research and Development (NCBiR) from INNOTECH programme resources. A batch of the filters produced in this technology was tested in practice in domestic cast steel and cast iron foundries. The trials were successful and foundries declared their intention to purchase the newly-developed filters for the current production of casts. This provided an incentive for “Ferro-Term” Sp. z o.o. to start design works on the prototype line for a serial production of these filters. At the same time, in co-operation with a scientific consortium, including the co-authors of the technology, i.e. the Institute of Ceramics and Building Materials, Refractory Materials Division in Gliwice, Institute for the Chemical Processing of Coal in Zabrze and Foundry Research Institute in Cracow, the company made a successful attempt to raise some funds for the necessary adaptation of the developed technology from the semi-technical to industrial scale from Intelligent Development Operational Programme. In the article we have presented information on the effects of works performed within the framework of the project entitled “Modernization and adaptation of the existing technological line for purposes related to technology verification and start-up of the production of innovative ceramic-carbon filters for molten metal alloy filtration”.

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Proces wdrażania nowatorskiej technologii produkcji filtrów ceramiczno-węglowych

Lipowska B., Witek J., Asłanowicz M., Ościłowski A., Robak Z., Muzyka R.

Materiały Ceramiczne

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2017

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T. 69, nr 4

343--346

PL

W roku 2014 zakończono prace badawcze nad opracowaniem technologii produkcji innowacyjnych, piankowych filtrów ceramiczno-węglowych do filtracji ciekłych stopów metali, finansowane przez NCBiR ze środków programu InnoTech. Partia badawcza filtrów wykonanych wg tej technologii została sprawdzona w praktyce w krajowych odlewniach staliwa i żeliwa. Próby wypadły pomyślnie i odlewnie zadeklarowały chęć zakupu nowoopracowanych filtrów do bieżącej produkcji odlewów. Dla firmy „Ferro-Term” Sp. z o.o. było to bodźcem do rozpoczęcia prac projektowych nad prototypową linią do seryjnej produkcji tych filtrów. Równocześnie, wraz z konsorcjum naukowym, w którego skład weszli współtwórcy technologii, tj. Instytut Ceramiki i Materiałów Budowlanych, Oddział Materiałów Ogniotrwałych w Gliwicach, Instytut Chemicznej Przeróbki Węgla w Zabrzu i Instytut Odlewnictwa w Krakowie, podjęto udaną próbę pozyskania części środków na niezbędne dostosowanie opracowanej technologii ze skali półtechnicznej na przemysłową z Programu Operacyjnego Inteligentny Rozwój. W artykule przedstawiono informację o postępie badań objętych harmonogramem realizowanego projektu.

EN

In 2014 research works aimed at developing a technology of production of innovative foam ceramic-carbon filters for liquid metal alloy filtration were completed. They were financed by the National Centre for Research and Development from the funds of InnoTech programme. The testing batch of filters made according to this technology was tested in practice at domestic cast iron and steel foundries. The trials were successful and the foundries declared their intention to purchase the newly-developed filters for the current production of casts. This provided Ferro-Term with an incentive to start project works on a prototype line for the batch production of these filters. At the same time, together with the scientific consortium, composed of the technology co-authors, i.e. Institute of Ceramics and Building Materials, Refractory Materials Division in Gliwice, Institute for Chemical Processing of Coal in Zabrze and Foundry Research Institute in Cracow, the authors undertook a successful attempt to obtain a part of the funds for necessary adjustment of the developed technology from the half-technical to industrial scale from Smart Growth Operational Programme. In this article information about progress in project scheduled researches was presented.

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Zmiany fazowe i mikrostrukturalne filtrów ceramiczno-węglowych podczas filtracji staliwa

Lipowska B., Witek J., Wala T., Karwiński A., Wieliczko P., Asłanowicz M., Ościłowski A.

Materiały Ceramiczne

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2014

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T. 66, nr 3

281--285

PL

Przeprowadzono próby filtracji stopionego staliwa z zastosowaniem dwóch rodzajów nowoopracowanych filtrów o budowie piankowej, w których fazą wiążącą cząstki ceramiczne był węgiel. W jednym z nich źródłem węgla był grafit płatkowy i pak węglowy, natomiast w drugim grafit zastąpiono tańszym prekursorem węgla. Nowoopracowacowane filtry wypalono w temperaturze 1000 °C, zdecydowanie niższej niż stosowane obecnie filtry z ZrO2. Podczas prób filtry poddano działaniu płynącej strugi metalu o temperaturze 1650 °C przez czas 30 sek. Dokonano charakterystyki właściwości filtrów przed i po wykonaniu próby filtracji. Stwierdzono, że powierzchniowa reakcja stopionego metalu z materiałem ścianek filtra, której efektem są lokalne zmiany mikrostruktury i składu fazowego, nie powoduje degradacji mechanicznej tworzywa w stopniu wpływającym na wymagany czas pracy filtra. Zmiany te nie powodują również uwalniania się elementów filtra do staliwa, a tym samym jego wtórnego zanieczyszczenia.

EN

Trials of cast steel filtration using two types of newly-developed foam filters, in which carbon bonded ceramic particles, have been conducted. In one of the filters, the source of carbon was composed of flake graphite and coal-tar pitch, while in the other one the graphite was replaced by a cheaper carbon precursor. The newly-developed filters were fired at 1000 °C which is much lower than in the case of the currently applied ZrO2-based filters. During filtration trials, the filters were subjected for 30 seconds to the attack of a flowing stream of metal, having a temperature of 1650 °C. Properties of the filters were characterised before and after the filtration trial. It has been found that molten metal reacted with material of the filter wall surface, which resulted in local changes in its microstructure and phase composition with no degradation of the filters’ mechanical properties and no secondary contamination of cast steel.

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Cast Steel Filtration Trials Using Ceramic-Carbon Filters

Lipowska B., Witek J., Wala T., Karwiński A., Wieliczko P., Asłanowicz M., Ościłowski A.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 4

61--66

EN

Trials of cast steel filtration using two types of newly-developed foam filters in which carbon was the phase binding ceramic particles have been conducted. In one of the filters the source of carbon was flake graphite and coal-tar pitch, while in the other one graphite was replaced by a cheaper carbon precursor. The newly-developed filters are fired at 1000C, i.e. at a much lower temperature than the currently applied ZrO2-based filters. During filtration trials the filters were subjected to the attack of a flowing metal stream having a temperature of 1650C for 30 seconds. Characteristic of the filters’ properties before and after the filtration trial were done. It was found, that the surface reaction of the filter walls with molten metal, which resulted in local changes of the microstructure and phase composition, did not affect on expected filter lifetime and filtration did not cause secondary contamination of cast steel.

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Integration of computer tomography and simulation analysis in evaluation of quality of ceramic-carbon bonded foam filter

Karwiński A., Małysza M., Tchórz A., Gil A., Lipowska B.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 4

67--72

EN

Filtration of liquid casting alloys is used in casting technologies for long time. The large quantity of available casting filters allows using them depending on casting technology, dimensions of casting and used alloys. Technological progress of material science allows of using new materials in production of ceramic filters. In this article the Computed Tomography (CT) technique was use in order to evaluate the thickness of branch in cross section of 20ppi ceramic-carbon bonded foam filter. Than the 3D image of foam filter was used in computer simulation of flow of liquid metal thru the running system.