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1
Content available Difficulties in the Production of Ausferritic Nodular Cast Iron without Heat Treatment
Stawarz Marcin, Lenert Małgorzata, Piasecki Karol
Archives of Foundry Engineering
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2023
|
Vol. 23, iss. 3
5--11
EN
The paper presents results of tests carried out on ausferrite carbide matrix alloyed ductile cast iron. The ausferrite was obtained via addition of Cu and Mo alloying elements. This eliminated heat treatment from the alloy production cycle. The article presents results of tests of the quality of the obtained material. Emphasis was put on metallographic analysis using light and scanning microscopy. Works also included chemical composition tests and EDS analysis. Strength tests were executed in an accredited laboratory. It is possible to create a raw ausferrite carbide matrix without subjecting an alloy to heat treatment. However, it turned out that quality parameters of cast iron were insufficient. The obtained material hardness was 515 HB, while Rm strength and A5 ductility were very low. The low tensile strength of the analyzed alloy resulted from the presence of degenerate graphite secretion (of flake or vermicular shape) in the cast iron. The tests also demonstrated that the alloy was prone to shrinkage-related porosity, which further weakened the material. Alloys made of alloyed ductile iron of ausferrite matrix micro-structure are very attractive due to elimination of the heat treatment process. However, their production process and chemical composition must be optimized.
2
Content available Some Possibilities of Using Statistical Methods While Solving Poor Quality Production
Lakomá R., Čamek L., Lichý P., Kroupová I., Radkovský F., Obzina T.
Archives of Foundry Engineering
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2021
|
Vol. 21, iss. 1
18--22
EN
This paper presents an overview of a research on six practical cases that were solved in a precise casting company where parts are cast by the mean of the low-wax casting method (investment casting) in order to decrease poor quality production. The steel cast parts production technology by the lost-wax method requires the detailed work procedures observation. On the base of statistical processing data of given types of casting products, it was possible to assess the significance of each particular checking events by using the statistical hypothesis testing. The attention was focused on wax and ceramic departments. The data in technological flow were compared before and after the implementation of the change and statistical confirmative influences were assessed. The target consisted in setting such control manners in order to get the right conditions for decreasing poor quality parts. It was evidenced that the cast part defect cause correct identification and interpretation is important.
3
Content available Defects Appearing in the Surfacing Layers of Abrasion Resistant
Bęczkowski R., Gucwa M.
Archives of Foundry Engineering
|
2016
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Vol. 16, iss. 4
23--28
EN
The surfacing technologies are used for constitution of protection layer against wear and is destined for obtaining coating with high hardness. Among many weldings methods currently used to obtain the hard surface layer one of the most effective way of hardfacing is using flux cored arc welding. This additional material gives more possibilities to make expected hard surface layer. Chemical composition, property and economic factors obtained in flux cored wire are much richer in comparison to these obtained with other additional materials. This is the reason why flux cored wires give possibilities of application this kind of material for improving surface in different sectors of industry. In the present paper the imperfection in the layers was used for hardfacing process in different situations to show the possible application in the surface layer. The work presents studies of imperfection of the welds, contains the picture of microstructures, macrostructures and shows the results of checking by visual and penetrant testing methods.
4
Content available Symulacja spiętrzania stopu w komorze zimnokomorowej maszyny ciśnieniowej
Wiktor T., Burbelko A.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 4 spec.
151--154
PL
Technologia odlewania do form metalowych z wykorzystaniem wysokiego ciśnienia jest jednym ze sposobów wytwarzania odlewów precyzyjnych. Forma metalowa zapewnia precyzję odwzorowania wymiarów gotowego wyrobu, lecz z powodu szczelności materiału, z którego jest wykonana, utrudnia odprowadzanie powietrza z wnęki. Dodatkowo powstawaniu okluzji powietrza sprzyja wysoka prędkość strugi i związany z tym skomplikowany charakter ruchu ciekłego metalu wewnątrz formy. W największym stopniu problem okluzji powietrza występuje w maszynach zimnokomorowych z poziomą komorą wtrysku. W maszynach tego typu dodatkowym źródłem gazów w odlewie może być niewłaściwy przebieg pierwszej fazy pracy maszyny ciśnieniowej. W pracy za pomocą symulacji komputerowych z wykorzystaniem oprogramowania ProCAST (ESI Group®) przeanalizowano zmiany kształtu swobodnej powierzchni stopu EN-AC 44300 AlSi12(Fe) podczas jego spiętrzania w komorze prasowania. Przeanalizowano wpływ prędkości ruchu tłoku, długości komory i stopnia jej wypełnienia na poprawny przebieg tego procesu.
EN
High Pressure Die Casting gives the possibility to produce the cast products with a high precision. Unfortunately, physical properties of the metal molds prevent the air evacuation from the mold cavity. High velocity of the stream and of the free surface movement as well as complicated character of the liquid metal movement prevent the air evacuation and promote the occlusions in the casting. Risk of the air occlusion is the highest in the case of the cold-chamber machines with a horizontal press-chambers. In the HP die casters of this type the addition source of the gas in the casting is the improper evolution of the alloy free surface during the first stage of the cycle (alloy up-rise). In this paper the evolution of the free surface of the EN-AC 44300 AlSi12(Fe) alloy was analyzed by ProCAST software (ESI Group®) in the HP chamber during the first stage of the working cycle. The influence of the piston velocity, shot chamber length and initial level of the alloy in the shot chamber on the behavior of the alloy free surface at this stage was analyzed.
5
Content available Mechanical Properties and Melt Quality Relationship of Sr-modified Al-12Si Alloy
Uludağ M., Uyaner M., Yilmaz F., Dişpinar D.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 4
134--140
EN
The formation of oxide film on the surface of aluminium melts, i.e. bifilms, are known to be detrimental when they are incorporated into the cast part. These defects causes premature fractures under stress, or aid porosity formation. In this work, Al-12 Si alloy was used to cast a step mould under two conditions: as-received and degassed. In addition, 10 ppi filters were used in the mould in order to prevent bifilm intrusion into the cast part. Reduced pressure test samples were collected for bifilm index measurements. Samples were machined into standard bars for tensile testing. It was found that there was a good agreement with the bifilm index and mechanical properties.
6
Content available Assessment of Reliability of Measurement Data and Adequacy of the Measurement Systems in Improving Quality of Casting Products
Fedoryszyn A., Brzeziński M.
Archives of Foundry Engineering
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2015
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Vol. 15, iss. 3 spec.
124--126
EN
The study summarises the analysis of reliability assessment of measurements of a selected critical property of a high-precision casting product. Measurement data must be sufficiently reliable to be used in decision-making relating to quality control and the selection of the casting manufacturing technology. The applied procedure is illustrated by study of the variability range of readouts depending on the measurement conditions, obtained by the computer methods. The applied R&R (Repeatability and Reproducibility) procedure is major component of the widely employed Measurement System Analysis (MSA).
7
Content available Comparison of Quality of Investment Castings Produced Based on the Rapid Prototyping Techniques with Products of Powder Sintering
Karwiński A., Haratym A., Soroczyński A., Kowalski P.
Archives of Foundry Engineering
|
2014
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Vol. 14, iss. 3 spec.
31--34
EN
The proposed research work will be related to the comparison of the dimensional accuracy and surface roughness of elements produced by two different methods. Castings are made using modern rapid prototyping techniques and investment casting. For selected parts there will be presented an assessment in terms of manufacturability, design manufacturing costs, operating parameters and energy consumption of production. The analysis of used methods allow for the evaluation of their suitability as alternative manufacturing techniques.
8
Content available Jakość wody jako jeden z czynników determinujących właściwości mas formierskich z bentonitem
Harabasz M., Holtzer M.
Archives of Foundry Engineering
|
2013
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Vol. 13, iss. 3 spec.
45--50
PL
W artykule omówiono problem jakości wody, która wykorzystywana jest w cyklu produkcyjnym odlewni stosującej masy z bentonitem. Praktycznie jakość wody stosowanej do odświeżenia masy z bentonitem, jak i jej chłodzenia nie jest przedmiotem rozważań w krajowych odlewniach. Zagadnienie to dotyczy wpływu stopnia zasolenia wody na właściwości wytrzymałościowe mas z bentonitem, a w konsekwencji na jakość gotowych odlewów. W kolejnych cyklach obiegu masy następuje kumulacja soli w masie i pogorszenie właściwości wytrzymałościowych, szczególnie wytrzymałości na rozciąganie w strefie przewilżonej. Parametrem charakteryzującym stopień zasolenia wody jest przewodnictwo elektrolityczne. W artykule przedstawiono sposób zmniejszenia zasolenia wody miejskiej metodą odwróconej osmozy oraz uzyskane efekty w zakresie zmniejszenia zużycia mieszanki bentonitowej. Prawdopodobnie głównymi jonami powodującymi wzrost przewodnictwa są jony Cl-.
EN
The article discusses the problem of water quality, which is used in the foundry used green sand in production cycle. The issue involves the problem of the salinity of water, which translates mainly to reduce the strength properties of the green sand. This article presents a method of reducing the salinity of city water and the results of its systematic research. It also indicated the results of green sand, done with the addition of city water with a high and a low conductivity. Analyses show that water is a determining factor in the properties of the sand mould, so the focus should be on maintaining its high quality.
9
Content available The dependence of castings quality produced in clay moulding mixtures from the properties of binder based on a montmorillonite
Vasková I., Fecko D., Malik J.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 3
123-128
EN
Casting quality depends on many factors including the quality of the input materials, technology, material securing and last but not least, the mould into which the casting is casted. By pouring into a single-shot mould, based mainly on 1st generation binders, is is a very important factor. Basically, a bentonite mixture represents either a three- or four-component system, but each component of the system is a heterogeneous substance. This heterogeneity punctuates mainly a non-stationary heat field, presented throughout the whole process of the casting production. The most important component is a binder and in the case of first generation binders mostly bentonites are used - clays that contain minimum of 80% of montmorillonite.
10
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.
11
Content available remote The influence of the tablet height and final pressure on the final quality of the casting
Malik J., Eperješi Ľ., Fecko D., Gašpar Š.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 1s
37-40
EN
The technology of die casting is in the connection of final quality of produced castings influenced by a lot of technological factors. These factors influence each other. This represents the complex reciprocal connections between the character of alloy, mould cavity filling time, construction of a mould and the efficiency of die cast machine. Between technological factors influencing the quality of casting belong the final pressure and the height of the tablet in the filling chamber. The final pressure should replace the gravity feeding of the molten metal into empty spaces of the casting and inhibit the clustering of bubbles, the tablet height eliminates the air amount enclosed in casting after pressing.
12
Content available remote Geometrical modulus of a casting and its influence on solidification process
Havlicek F., Elbel T.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 4
170-176
EN
Object: The work analyses the importance of the known criterion for evaluating the controlled solidification of castings, so called geometrical modulus defined by N. Chvorinov as the first one. Geometrical modulus influences the solidification process. The modulus has such specificity that during the process of casting formation it is not a constant but its initial value decreases with the solidification progress because the remaining melt volume can decrease faster than its cooling surface. Methodology: The modulus is determined by a simple calculation from the ratio of the casting volume after pouring the metal in the mould to the cooled mould surface. The solidified metal volume and the cooled surface too are changed during solidification. That calculation is much more complicated. Results were checked up experimentally by measuring the temperatures in the cross-section of heavy steel castings during cooling them. Results: The given experimental results have completed the original theoretical calculations by Chvorinov and recent researches done with use of numerical calculations. The contribution explains how the geometrical modulus together with the thermal process in the casting causes the higher solidification rate in the axial part of the casting cross-section and shortening of solidification time. Practical implications: Change of the geometrical modulus negatively affects the casting internal quality. Melt feeding by capillary filtration in the dendritic network in the casting central part decreases and in such a way the shrinkage porosity volume increases. State of stress character in the casting is changed too and it increases.
13
Content available remote Evaluation of the lost foam process in terms of casting dimensional accuracy and ecology
Karwiński A., Haratym R., Biernacki R.
Archives of Foundry Engineering
|
2009
|
Vol. 9, iss. 4
249-253
EN
The paper discusses some of the major issues that are related with the use of polystyrene foam (of the density above 1,04 /cm3) in the manufacture of investment castings characterised by intricate shapes. Test patterns were made from the high impact polystyrene and from styrene polymers (styrene acrylonitrile SAN). The process of polystyrene patterns removal from ceramic moulds considerably reduces the quality of these moulds in terms of surface microgeometry and dimensional accuracy of castings. The results of the studies can find practical application in the manufacture of near-net-shape castings for industrial applications as well as prototype castings. They may also serve as a tool in evaluation of the rapid prototyping process using polystyrene foam and polymers in the manufacture of investment castings characterised by high dimensional accuracy. The said technology has also been estimated in terms of its impact on the natural environment, taking into consideration the energy consumption during castings manufacture and their later use. It is possible to further improve the casting accuracy, raising it from class CT7 to CT6 according to Polish Standard PN [5].
14
Content available remote The quality of cast parts of printing machines
Tabor A., Zarębski K., Dziadur W.
Archives of Foundry Engineering
|
2008
|
Vol. 8, iss. 1 spec.
321--326
EN
The study presents the results of metallographic examinations and mechanical tests carried out to evaluate the cast iron toothed wheel damaged during standard operation as an element of the printing machine. The research procedures were described as well as the results of investigations which enabled specification of the supplied material and evaluation in terms of its applicability in the manufacture of toothed wheel castings.
15
Content available remote Zastosowanie badań dźwiękowych (sonic testing) do oceny jakości odlewów
Białobrzeski A., Orliński M., Grochal T.
Archiwum Odlewnictwa
|
2006
|
R. 6, nr 18/2
337--342
PL
Metoda badań dźwiękowych (akustycznych) polega na pomiarze częstotliwości drgań własnych elementów (odlewów) lub na pomiarze czasu zaniku drgań po ich wzbudzeniu, czyli pomiarem zdolności tłumienia drgań. Uzyskana wartość pierwszej częstotliwości rezonansowej = częstotliwości drgań własnych, lub czasu tłumienia drgań badanego odlewu (elementu), jest porównywana z częstotliwością drgań własnych lub czasem tłumienia drgań odlewu (elementu) wzorcowego, spełniającego wszystkie wymagania wynikające z warunków technicznych odbioru (WTO).
EN
The method of sonic (acoustic) testing consists in measuring the frequency of free vibrations in elements (castings), or in measuring the time elapsing since the moment of exciting the vibrations till the moment of their fading, i.e. in measurement of the damping capacity. The obtained value of the first resonance frequency equal to the frequency of free vibrations or to the time required for damping of vibrations in the examined element (casting) is compared with the frequency of free vibrations or with the time of damping the vibrations in a reference element (casting), satisfying all the requirements dictated by the technical conditions of acceptance.
16
Content available remote Rola badań elementarnych zjawisk i procesów odlewniczych w podnoszeniu jakości odlewów
Mutwil J.
Archiwum Odlewnictwa
|
2006
|
R. 6, nr 18/1
59--66
PL
Wskazano na istotną rolę badań podstawowych zjawisk i procesów odlewniczych w podnoszeniu jakości odlewów. Przedstawiono koncepcję badań procesu zalewania form. Opisano sposób badania ewolucji skurczu odlewniczego i naprężeń skurczowych.
EN
The important weight of examinations of fundamental castings phenomena and processes in improving of casings quality has been pointed. Investigation conception of mould pouring processes has been presented. The method of examination of casting contraction and contraction stresses evolution has been described.
17
Content available remote Możliwości oceny nieciągłości powierzchniowych odlewów
Sozański L.
Archiwum Odlewnictwa
|
2006
|
R. 6, nr 18/2
331--336
PL
Jednym z podstawowych elementów oceny jakości odlewu jest stan jego powierzchni. W normach europejskich szereg dokumentów technicznych określa metody, sposób i interpretację wyników badania powierzchni odlewu. W pracy rozpatrzono niektóre aspekty związane z określaniem nieciągłości powierzchniowych w trakcie badań wizualnych, penetracyjnych i magnetyczno proszkowych odlewów. Zwrócono uwagę na wymagania ogólne dotyczące uprawnień personelu oraz warunków w jakich należy te badania przeprowadzać.
EN
One of fundamental components of the assessment of the casting’s quality are properties of its surface. There are documents in the European Standards in which methods, ways and interpretations of results of casting’s surface investigation are defined. In the paper some aspects connected with casting’s surface discontinuities description during visual examination, penetrant testing and magnetic-particle testing were presented. The formal requirements concerning personnel qualification and conditions of testing were highlighted.
18
Content available remote Sterowanie jakością odlewów żeliwnych w zarządzaniu procesowym odlewnią żeliwa
Siekański K., Borkowski S.
Archiwum Odlewnictwa
|
2003
|
R. 3, nr 8
177--182
PL
W artykule dokonano podziału procesu odlewania na procesy składowe, przedstawiono również strukturę procesów w systemie zarządzania jakością odlewni żeliwa, powiązania międzyprocesowe oraz dla wybranego procesu sporządzono mapę. Na podstawie wyróżnionych w trakcie mapowania wejść, wyjść procesu oraz czynników determinujących jakość przebiegu poszczególnych czynności produkcyjnych zaproponowano metodę sterowania produkcją odlewów żeliwnych dla uzyskania ich wyższej jakości.
EN
A casting process was divided into part process in the paper. A structure of processes in the quality management system of the examined foundry was introduced. Some interprocess relations were shown, as well as a process map for chosen processes was prepared. On the basis of presented factors: process input, output and the others measurable values, which decide of a quality of the process course, the method of production process control and steering was proposed.
19
Content available remote Jakość kompozytowych odlewów odśrodkowych po wtórnym przetopie
Tomczyński S.
Krzepnięcie Metali i Stopów
|
2000
|
R. 2, nr 43
509--514
PL
Recykling, czyli powtórne, a nawet wielokrotne przetapianie odpadów z produkcji odlewów kompozytowych (układów wlewowych, wybrakowanych lub zużytych odlewów) staje się od pewnego czasu problemem w krajach stosujących szeroko odlewane materiały kompozytowe. Brak jest dotychczas w świecie jednoznacznych metod recyklingu. Firmy produkujące kompozyty na skalę przemysłową (np. firma DURALCAN) przedstawiają przeważnie swoim odbiorcom jedynie wskazówki technologiczne dotyczące jednostopniowego procesu recyklingu, nie wyjaśniając szczegółowo zjawisk fizykochemicznych zachodzących w procesie przetapiania. [...]
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