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1

The Leading Role of Aluminium in the Growing Production of Castings Made of the Non-Ferrous Alloys

Soiński M. S., Jakubus A.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 3

33--42

EN

The paper presents changes in the production volume of castings made of non-ferrous alloys on the background of changes in total production of casting over the 2000-2019 period, both on a global scale and in Poland. It was found that the dynamics of increase in the production volume of castings made of non-ferrous alloys was distinctly greater than the dynamics of increase in the total production volume of castings over the considered period of time. Insofar as the share of production of the non-ferrous castings in the total production of castings was less than 16% during the first two years of the considered period, it reached the level of 20% in the last four years analysed. This share, when it comes to Poland, increased even to the greater degree; it grew from about 10% of domestic production of castings to over 33% within the regarded 2000-2019 period. The greatest average annual growth rate of production, both on a global scale and in Poland, was recorded for aluminium alloys as compared with other basic non-ferrous alloys. This growth rate for all the world was 4.08%, and for Poland 10.6% over the 2000-2019 period. The value of the average annual growth rate of the production of aluminium castings in Poland was close to the results achieved by China (12%), India (10.3%) and the South Korea (15.4%) over the same period of time. In 2019, the total production of castings in the world was equal to about 109 million tonnes, including over 21 million tonnes of castings made of non-ferrous alloys. The corresponding data with respect to Poland are about 1 million tonnes and about 350 thousand tonnes, respectively. In the same year, the production of castings made of aluminium alloys was equal to about 17.2 million tonnes in the world, and about 340 thousand tonnes in Poland.

2

Trends in the Production of Castings in the World and in Poland in the XXI Century

Soiński M. S., Kordas P., Skurka K.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 2

5--10

EN

The paper presents data concerning the total production of castings over the 2000-2014 period, both on a global scale, and in Poland. The basic types of casting alloys were taken into account. Changes in the production volume and structure over the period of the analysed 15 years were pointed out with respect to countries leading in foundry production. The topmost position in the world foundry industry is held by China for several years (with almost 45% share in the foundry market), the second place is taken by India (with almost 9% share). A distinct reduction in the shares of the once significant producers of castings, such as USA, Japan, Germany, Russia, Italy, or France, was observed over the 2000-2014 period. Poland had a share of 1.16% in 2000, and of 1.02% in 2014. Comparing the detailed data concerning the years 2000 and 2014, one can see that the fractions of castings made of ductile iron, cast steel, aluminium alloys, or magnesium alloys increase on a global scale, while such alloys as grey cast iron or malleable are in decline.

3

Efektywność powłok nanowarstwowych przy wierceniu otworów przelotowych w blachach ze stopów nieżelaznych

Feldshtein E., Lisovskaya Y.

Mechanik

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2015

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R. 88, nr 8-9CD2

159--167

PL

Omówiono efekty wiercenia otworów przelotowych w blachach z siluminu AC-AlSi9Cu3(Fe) oraz mosiądzu Cu- Zn39Pb3. Zastosowano wiertła NWKa o średnicy 6 mm ze stali szybkotnącej i powlekane nanowarstwową powłoką PVD składającą się z 40 kolejno ułożonych bloków zawierających po cztery warstwy nanometryczne. Testy wykonano na 5-osiowym centrum frezarskim DMU 70 przy prędkości skrawania ok. 75 m/min i posuwie 0,06 mm/obr (warunki chłodzenia strefy obróbki: sprężone powietrze). Przeprowadzono ocenę zadziorów na wyjściu wierteł z otworów, obliczono wskaźniki strefy tworzenia wióra, określono postać i intensywność zużycia ostrzy oraz parametry chropowatości powierzchni. Wiertła powlekane wykazały zdecydowaną przewagę nad wiertłami bez powłok. Ich zastosowanie ograniczyło powstawanie zadziorów, które miały znacznie mniejsze wymiary i bardziej korzystną postać. Na podstawie obliczeń zarejestrowano wzrost kąta ścinania oraz zmniejszenie współczynników zgrubienia wióra i tarcia. Intensywność zużycia wierteł z powłokami zwiększyła się (w porównaniu z wiertłami niepowlekanymi) ok. 2,5-krotnie w przypadku obróbki siluminu AC-AlSi9Cu3(Fe) i 1,8-krotnie w przypadku obróbki mosiądzu CuZn39Pb3.

EN

The paper presents the results of drilling of holes in plates of AC-AlSi9Cu3 (Fe) silumin and CuZn39Pb3 brass. NWKa drills of high speed steel of 6 mm diameter were used as well as coated with the nanolayer coating PVD. The total PVD coating consists of 40 sequentially stacked blocks, each of which has four nanolayers. Tests were realized using 5-axis machining center DMU 70 with cutting speed of ~75 m/min and feed rate of 0.06 mm/rev. The pressured air was used for cooling. Some drilling process factors were investigated, such as burrs, parameters of cutting zone, shape and wear rate od drilla and surface roughness. Coated drills showed the clear advantage compared with uncoated drills. There are no burrs when using coated drills, or burrs have much smaller dimensions and a more useful shape. On the basis of calculations the increase the shear angle and a decrease in the chip compression ratio and the coefficient of friction were registered. The wear rate of the coated drills for AC-AlSi9Cu3 (Fe) silumin increased approximately 2.5 times and for CuZn39Pb3 brass - 1.8 times in comparison with uncoated drills.

4

Production of Castings in the World and in Selected Countries from 1999 to 2013

Soiński M. S., Jakubus A., Kordas P., Skurka K.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 1 spec.

103--110

EN

The paper compares the foundry production in years 1999-2013 on a world scale, in countries counted among the leading producers of castings, and in Poland. Various types of foundry alloys were taken into account. It was found that the position of China – the leader in the world production of castings – was not changed over many years, however China's share in the total production of casting has stabilised at the level of 42-44% during the recent five years. In the analysed period of time Poland increased the share in the world production of castings from 1.07% to about 1.23%, so that Polish production of castings was almost doubled. There is a tendency on the world scale that the grey cast iron fraction in the total production of castings decreases, while an increase occurs as far as spheroidal graphite cast iron, cast steel, and aluminium alloy castings are concerned.

5

Materials for Conveyor Pouring Ingot Moulds of Non-Ferrous Alloys

Volchok I. P., Jakovlev A. J.

Archives of Metallurgy and Materials

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2007

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Vol. 52, iss. 3

525-528

EN

Researches on increase of graphite steel mechanical properties and thermal stability were executed with the purpose of its application for conveyor pouring ingot moulds of non-ferrous alloys. Influence of copper on structure, shape of graphite inclusions and parameters of thermostability of steel are investigated. It is shown, that alloying by copper in quantity of 1.2-1.8% results in essential increase in strength and thermal stability, and also in decrease of graphite steel scale formation at temperatures 750-900C .

PL

Zbadano zmiany właściwości mechanicznych i stabilności termicznej stali grafitowej, w celu ich zastosowania przy odlewaniu stopów metali nieżelaznych do wlewnic. Przeanalizowano wpływ miedzi na strukturę i kształt wtrąceń grafitowych, a także parametry stabilności termicznej stali. Wykazano, że dodanie miedzi do stopów w ilości 1.2-1.8% powoduje znaczny wzrost wytrzymałości i stabilności termicznej a także ogranicza powstawanie zgorzeliny w temperaturach 750-900C.

6

Procesy topienia stopów metali nieżelaznych a wyłożenia ogniotrwałe jednostek piecowych. Cz. 2. Materiały ogniotrwałe w metalurgii i przetwórstwie cynku

Lachowski M., Wesołowski J., Stuczyński T., Geryń W.

Ceramika. Materiały Ogniotrwałe

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2001

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R. 53, nr 2

53-56

PL

Zaprezentowano ogólne dane dotyczące trwałości materiałów ogniotrwałych stosowanych w krajowym przetwórstwie miedzi, cynku i aluminium oraz ich stopów. Omówiono oddziaływanie składników stopowych ciekłego metalu na materiały ogniotrwałe. Podano przykłady wad powstających podczas eksploatacji materiałów ogniotrwałych. Przedstawiono kierunki zmian konstrukcyjnych, które powinny zapobiec przyśpieszonemu zużyciu wyłożenia ogniotrwałego w piecach przemysłu metali nieżelaznych.

EN

Data on the resistance of refractory materials used in copper, zinc, aluminum and their alloys processing in Poland were presented. The impact of liquid metal alloy components on refractory materials was discussed. Examples of defects oceurred in the use of refractory materials were presented. Constructional changes that should prevent accelerated wear of refractory Iining of furnaces in non-ferrous metallurgy were focused on.