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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%.
EN
Purpose: The current paper aims to present a new casting approach in dentistry by eliminating some conventional preliminary procedures and digitalising the process as much as possible. Design/methodology/approach: The experiment uses six digital crown patterns. They are aligned with each other and to the wall of a virtual casting ring. Then a digital sprue system is created. The object alignment and sizes are revised, and the optimal correlation is set. Finally, a single virtual object is created and is 3D printed of light curing acrylic resin suitable for casting, invested, and cast. Findings: The castings that are achieved have good quality and no defects. At the same time, the virtual designing and aligning of the patterns and all the components of the sprue system and casting ring save much time and allows better precision to be achieved. All these facts allow better control of the casting process results, making the process faster, more predictable, and more accurate. Research limitations/implications: The limitations of this study concerns pattern selection. It is well-known that the acrylic resin sublimates and expands massively during a temperature rise, which may cause mould fracture. This obstacle is very representative as solid objects with higher volumes are examined. This may enforce alignment revision or even temperature rate modification. Practical implications: Suggested approach will be very useful for daily dental laboratory practice by optimizing the working time of the dental technician, making the denture production process faster, more predictable, and more accurate. As a result, the process optimizes the working process in dental offices, by allowing shortening the time of each visit and treatment plan terms. Originality/value: Presented approach reveals some new opportunities for dental technicians to substitute the conventional raw stages of sprue system fabrication with digital planning and designing. This allows dental technicians to take advantage of the full potential of digital technologies.
EN
This paper presents the results of a study to determine the influence of casting parameters (cooling rate in the casting mould, casting temperature) on the primary structure of Mg-4%Li-1%Ca alloy ingots. The macro- and microstructure analysis of the Mg-4%Li-1%Ca alloy was performed using light and electron microscopy techniques. Microhardness measurements were made for the Mg-4%Li-1%Ca alloy and phase identification in the Mg-4%Li-1%Ca alloy was made using X-ray phase analysis.
EN
Air entrainment defect is a common type of defect in the casting process, which will seriously affect the quality of the casting. Numerical simulation technology can predict the occurrence of casting defects according to the evolution law of liquid metal in the process of filling and solidification. The simulation of air entrainment process is a hot and difficult issue in the field of numerical simulation. The evolution law of air entrainment and the tracking of induced bubbles in the process of metal filling are still lacking. So is the quantitative prediction of trained gas. In this paper, based on the numerical simulation software of Inte CAST, this paper proposes an algorithm for air entrainment search and tracking, which is used to develop a quantitative prediction system for air entrainment. The feasibility of the system is verified through the simulation calculation of the typical test pieces of the air entrainment and the prediction of air entrainment defects of the casting in the process of filling is obtained through the simulation calculation of the actual casting, which can provide a certain guiding role for the optimization of the process in the production practice.
EN
The purposes of this study were to investigate the impact of proportions of cast iron scrap, steel scrap, carbon and ferro silicon on hardness and the quality of cast iron and to obtain an appropriate proportion of the four components in iron casting process using a mixture experimental design, analysis of variance and response surface methodology coupled with desirability function. Monte Carlo simulation was used to demonstrate the impacts of different proportions of the four components by varying the proportions of components within ±5% of the four components. Microstructures of the cast iron sample obtained from a company and the cast iron samples casted with the appropriate proportions of the four components were examined to see the differences of size and spacing of pearlite particle. The results showed that linear mixture components were statistically significant implying a high proportion of total variability for hardness of the cast iron samples explained by the casting mixtures of raw materials. The graphite of the sample casted from the appropriate proportion has shorter length and more uniform distribution than that from the company. When varying percentages of the four components within ±5% of the appropriate proportion, simulated hardness values were in the range of 237 to 256 HB.
6
Content available remote Processing of Boron Nitride Nanotubes Reinforced Aluminum Matrix Composite
EN
Aluminum and its alloys are one of the most favored metal-based materials for engineering applications that require lightweight materials. On the other hand, composites are getting more preferable for different kinds of applications recently. Boron nitride nanotubes (BNNTs) are one of the excellent reinforcement materials for aluminum and its alloys. To enhance mechanical properties of aluminum, BNNTs can be added with different processes. BNNT reinforced aluminum matrix composites also demonstrate extraordinary radiation shielding properties. This study consists of BNNT reinforced aluminum matrix composite production performed by casting method. Since wetting of BNNT in liquid aluminum is an obstacle for casting, various casting techniques were performed to distribute homogeneously in liquid aluminum. Different methods were investigated in an aim to incorporate BNNT into liquid method as reinforcement. It was found that UTS was increased by 20% and elongation at fracture was increased by 170% when BNNT was preheated at 800°C for 30 minutes.
EN
The paper presents the application of the casting method for the production of porous composites, called syntactic foams, of the casting alloy - solid particles type. This method was used to produce composites based on Al alloys reinforced with particles of clinoptilolite, a natural mineral from the zeolite group. Before the casting process, tests were carried out on the morphology, physicochemical properties and chemical composition of the zeolite, which was obtained from a rock called zeolite tuff, mined in a quarry in Kucin, (VSK PRO-ZEO s.r.o., Slovakia). Observations of the microstructure of the produced composites were also carried out using a scanning electron microscope. Diffractometric tests of zeolite rock as delivered for research and of the produced samples reinforced with zeolite particles were also carried out. Initial studies of the density and porosity of the produced composites were performed. The usefulness of the presented method of composite production was assessed on the basis of the conducted structural tests, with particular emphasis on the particle distribution in the alloy matrix.
EN
This paper contains selected results of primary microsctructure analysis of a novel superalloy, Co-20Ni-10Al-5Mo-2Nb-2Ti. Research on this class of superalloys was started by J. Sato in 2006, and further expanded by S.K. Makineni in 2015. It is implied that Co-based, W-free superalloys will resolve the issues that the aircraft industry currently faces with Ni-based γ/γ’ superalloys. It is believed that the addition of the Ti alloying element will help with γ’ stabilisation due to high Co3(Mo, Al, Nb) fragmentation. Ti content has to be carefully selected to avoid precipitation of harmful phases, such as Co(Ti, Al).
PL
Artykuł zawiera wyniki badań mikrostrukturalnych nowego nadstopu Co-20Ni-10Al-5Mo-2Nb-2Ti. Badania nad tą klasą superstopów zostały zapoczątkowane w 2006 r. przez J. Sato, a następnie rozwinięte w 2015 r. przez S.K. Makineni. Powszechna jest wiara, że nadstopy oparte na Co i wolne od W rozwiążą problemy z jakimi boryka się obecnie branża lotnicza, w której powszechne jest stosowanie nadstopów Ni γ/γ’. Uważa się, że dodatek Ti do nadstopu spowoduje stabilizację fazy γ’ poprzez silną fragmentację fazy Co3(Mo, Al., Nb). Ilość Ti w badanym stopie została dobrana ze szczególną starannością w celu uniknięcia wydzielania szkodliwych faz takich jak Co(Ti, Al).
9
Content available remote „Milczenie Form” - uwolniona materia betonowa w rzeźbie
PL
Zastosowanie betonu w sztukach wizualnych, chociaż nie tak szerokie jak w budownictwie, odzwierciedla różnorodne postawy twórcze i oczekiwania wobec tego materiału. Przykłady jego wykorzystania napotkamy przede wszystkim w przestrzeni publicznej, będącej niejako naturalnym środowiskiem tego architektonicznego tworzywa. W dziełach rzeźbiarskich o mniejszej skali, prezentowanych w galeriach sztuki beton jest z kolei tworzywem stosunkowo mało popularnym. Rzeźba jest szerokim obszarem, zaanektowanym z jednej strony przez tradycyjne tworzywa, takie jak brąz, kamień, ceramika, z drugiej strony otwartym na eksperymenty przestrzenne i materiałowe. W artykule opisano autorskie próby twórczego wykorzystania betonu w rzeźbie: zastosowaną metodę, osiągnięte wyniki i nasuwające się wnioski. Celem tego artystycznego projektu było umowne odejście od typowo architektonicznej funkcji betonu na rzecz ukazania formy niestabilnej i zarazem próbą wydobycia ekspresyjnych właściwości tego tworzywa. W wyniku podjętych działań powstał cykl prac zatytułowany “Milczenie Form”, który został zaprezentowany w całości oraz fragmentarycznie na kilku wystawach artystycznych w latach 2019-2021.
EN
Although the application of concrete in the visual arts is not as wide as in the construction industry, it reflects diverse artistic attitudes and expectations regarding this material. We come across its use mostly in public space, being a natural space for concrete. When it comes to small-scale sculptures exhibited in art galleries, concrete is not found that often. Sculpture is a vast field dominated from one hand by traditional materials such as bronze, stone, ceramics, but also open to spatial and material experiments. The articles presents a number of concrete use cases in the creative way: its method, the output, and the conclusions. The aim of the project was to depart from the typical architectural function of concrete and to present it as the flexible one that enables one to take advantage of its expressive features. As a result, a set of works called “The Silence of Forms” was created, which was fully or partially presented in some art exhibitions in the years 2019-2021.
EN
In the present research, the wear behaviour of magnesium alloy (MA) AZ91D is studied and optimized. MA AZ91D is casted using a die-casting method. The tribology experiments are tested using pin-on-disc tribometer. The input parameters are sliding velocity (1‒3 m/s), load (1‒5 kg), and distance (0.5‒1.5 km). The worn surfaces are characterized by a scanning electron microscope (SEM) with energy dispersive spectroscopy (EDS). The response surface method (RSM) is used for modelling and optimising wear parameters. This quadratic equation and RSM-optimized parameters are used in genetic algorithm (GA). The GA is used to search for the optimum values which give the minimum wear rate and lower coefficient of friction. The developed equations are compared with the experimental values to determine the accuracy of the prediction.
EN
The influence of the cooling rate on the extent of precipitation hardening of cast aluminum alloy (ADC12) was investigated experimentally. This study explored the cooling rate of the solidification of Cu in the α-Al phase to improve the mechanical properties of ADC12 after an aging process (Cu based precipitation hardening). The solid solution of Cu occurred in the α-Al phases during the casting process at cooling rates exceeding 0.03°C/s. This process was replaced with a solid solution process of T6 treatments. The extent of the solid solution varied depending on the cooling rate; with a higher cooling rate, a more extensive solid solution was formed. For the cast ADC12 alloy made at a high cooling rate, high precipitation hardening occurred after low-temperature heating (at 175°C for 20 h), which improved the mechanical properties of the cast Al alloys. However, the low-temperature heating at the higher temperature for a longer time decreased the hardness due to over aging.
EN
The article describes the design of a proven technology for the production of metal foam and porous metal by the foundry. Porous metal formed by infiltrating liquid metal into a mould cavity appears to be the fastest and most economical method. However, even here we cannot do without the right production parameters. Based on the research, the production process was optimised and subsequently a functional sample of metal foam with an irregular internal structure - a filter - was produced. The copper alloy filter was cast into a gypsum mould using an evaporable model. Furthermore, a functional sample of porous metal with a regular internal structure was produced - a heat exchanger. The aluminium alloy heat exchanger was cast into a green sand mould using preforms. Also, a porous metal casting with a regular internal structure was formed for use as an element in deformation zones. This aluminium alloy casting was made by the Lost Foam method. The aim is therefore to ensure the production of healthy castings, which would find use in the field of filtration of liquid metal or flue gases, in vehicles in the field of shock energy absorption and also in energy as a heat exchanger.
EN
This study investigated the impact of the equal channel angular pressing (ECAP) combined with heat treatments on the microstructure and mechanical properties of AlSi10Mg alloys fabricated via selective laser melting (SLM) and gravity casting. Special attention was directed towards determining the effect of post-fabrication heat treatments on the microstructural evolution of AlSi10Mg alloy fabricated using two different routes. Three initial alloy conditions were considered prior to ECAP deformation: (1) as-cast in solution treated (T4) condition, (2) SLM in T4 condition, (3) SLM subjected to low-temperature annealing. Light microscopy, transmission electron microscopy, X-ray diffraction line broadening analysis, and electron backscattered diffraction analysis were used to characterize the microstructures before and after ECAP. The results indicated that SLM followed by low-temperature annealing led to superior mechanical properties, relative to the two other conditions. Microscopic analyses revealed that the partial-cellular structure contributed to strong work hardening. This behavior enhanced the material’s strength because of the enhanced accumulation of geometrically necessary dislocations during ECAP deformation.
EN
New materials used in various industries require sufficiently high mechanical properties, fine-grained structure and ease of metal forming while minimizing production costs. For this reason, work is being carried out to develop new groups of alloys that make it possible to increase the strength of the obtained components while reducing their weight, and thus reducing production costs. This article focuses on two aluminium-based alloys with different content of alloying additives: copper and magnesium i.e., AlCu3Mg3 and AlCu4.5Mg6, which were produced by metallurgical synthesis. The as-cast alloys were characterized for their basic physical, mechanical and electrical properties and were subjected to structural analysis. In the next stage, the alloys were modified with 100, 500, 1000 and 2000 ppm of titanium and then their hardness, electrical conductivity and density were tested. Samples were also subjected to microstructural analysis. The obtained results allowed to examine the evolution of the AlCuMg alloy properties depending on the content of alloy additives and the amount of used modifier.
15
Content available Defects analysis of seat belt tensioner cast body
EN
The article presents an analysis of the implementation of a selected element of the traveler safety system used in road transport. The results of metallographic tests were presented, and the state of stress introduced to the casting by means of forming the element by means of plastic forming was analyzed. An analysis of the manufacturing process was carried out indicating the risks that may lead to cracks in the material structure. Possible causes of founding defects were pointed out and possible technological solutions were pointed out in order to avoid them.
PL
W artykule przedstawiono analizę wykonania wybranego elementu wyposażenia systemu bezpieczeństwa podróżnych, stosowanego w transporcie samochodowym. Przedstawiono wyniki badań metalograficznych oraz dokonano analizy stanu naprężeń wprowadzanych do odlewu poprzez kształtowanie elementu metodą obróbki plastycznej. Dokonano analizy procesu wytwarzania wskazując na zagrożenia, które mogą prowadzić do powstawania pęknięć w strukturze materiału. Wskazano na możliwe przyczyny powstawania wad odlewniczych oraz wskazano możliwe rozwiązania technologiczne w celu ich uniknięcia.
16
Content available remote Guidelines for the manufacture of heavy ductile iron castings
EN
This study is devoted to the analysis of the impact that the basic constituents of ductile iron (carbon and silicon) and spheroidising treatment combined with inoculation exert on the final properties of heavy ductile iron castings. To evaluate the possibility of the application of ductile iron technology in the manufacture of castings for wind power plants, simulations were conducted on cast hubs of the rotor blades for wind turbines. For this type of product, it is necessary to produce castings characterised by a ferritic matrix (over 90% ferrite) and to reduce the amount of pearlite and graphite to a minimum, both of which are considered as the main structural constituents that affect the casting properties. The key guidelines for the manufacture of heavy castings from ductile iron, wind turbines included, were discussed, with particular emphasis placed on the process of spheroidising treatment and inoculation, both of which are aimed at producing in the structure of castings a spheroidal graphite of a size from 5 to 12 mm (class V to VI) and a ferritic structure in an amount exceeding 90%. This article is the result of the work done by Krakodlew S.A to implement research project No. POIG 01.04.00-12-116/12, supported by the National Centre for Research and Development and financed by the European Regional Development Fund, measure 1.4 POIG (Execution of industrial research and development in the company Krakodlew S.A., 2014).
PL
W pracy przedstawiono analizę zarówno wpływu podstawowych pierwiastków żeliwa sferoidalnego, takich jak węgiel i krzem, jak i procesów sferoidyzacji oraz modyfikacji na końcowe właściwości ciężkich odlewów z żeliwa sferoidalnego. Do oceny możliwości wykorzystania technologii do wykonywania odlewów w energetyce wiatrowej przeprowadzono badania symulacyjne odlewu piasty śmigła wirnika w elektrowni wiatrowej. Dla tego typu wyrobów zachodzi konieczność otrzymania odlewów o strukturze ferrytycznej (powyżej 90% ferrytu) i ograniczenia do minimum ilości perlitu oraz grafitu jako kluczowych składników strukturalnych mających wpływ na właściwości odlewów. Omówiono założenia wykonywania ciężkich odlewów z żeliwa sferoidalnego, w tym dla elektrowni wiatrowych, ze szczególnym uwzględnieniem procesów sferoidyzacji i modyfikacji, które mają zmierzać do osiągnięcia w strukturze odlewu grafitu kulkowego o wymiarach 5 do 12 mm (klasa V do VI) oraz struktury ferrytycznej powyżej 90%. Artykuł powstał w wyniku realizacji przez Krakodlew S.A. projektu badawczego nr POIG 01.04.00-12-116/12, objętego wsparciem Narodowego Centrum Badań i Rozwoju, finansowanego ze środków Europejskiego Funduszu Rozwoju Regionalnego, działanie 1.4 POIG.
EN
This paper presents practical capabilities of a system for ceramic mould quality forecasting implemented in an industrial plant (foundry). The main assumption of the developed solution is the possibility of eliminating a faulty mould from a production line just before the casting operation. It allows relative savings to be achieved, and faulty moulds, and thus faulty castings occurrence in the production cycle to be minimized. The numerical computing module (the DEFFEM 3D package), based on the smoothed particle hydrodynamics (SPH) is one of key solutions of the system implemented. Due to very long computing times, the developed numerical module cannot be effectively used to carry out multi-variant simulations of mould filling and solidification of castings. To utilize the benefits from application of the CUDA architecture to improve the computing effectiveness, the most time consuming procedure of looking for neighbours was parallelized (cell-linked list method). The study is complemented by examples of results of performance tests and their analysis.
EN
The paper presents the preliminary results of research on determining the possibilities of using available on the market commercial gypsum kinds as a binder for foundry moulding and core sandmixes. Construction gypsum and plaster gypsum, finishing coat and jewelry casting gypsum were tested. Elemental composition of gypsum kinds were carried out using a scanning electron microscope (SEM) with EDS/EDX probe, their crystal structure and phase composition was determined by analyzing the results of X-ray diffraction measurements (XRD) and thermogravimetric studies (TG-DTA). Evaluation of the mechanical properties of selected materials was carried out at the tensile strength test of the dog-bone samples after initial hardening of gypsum mortar at 25°C for 5 h and drying at 110°C for 24 hours. The impact of the properties of the used commercial gypsum kinds on the possibility of their use as a valuable binders in the manufacture of the foundry sandmixes for moulds and cores was evaluated. Construction gypsum and finishing coat have the highest tensile strength. Plaster gypsum and finishing coat have the longest setting time. In all tested types of gypsum, the initial water loss during heating occurs at a temperature of about 200°C. The lowest valuable properties as a binder for sand moulding mixtures has jewelry casting gypsum mass.
EN
The main purpose of the present study is to verify the possibility of decarbonizing the surface of heat-resistant ductile iron GJS-XSiMo5-1 to provide a significant difference in carbon content between this material and gray cast iron EN-GJL-250. In the future, this will allow to increase the diffusion of elements during the creation of the two-layered material using the casting process with materials in a liquid state and solid state. The above method was assumed to solve the problem of defects on turbocharger’s housing in an economically justified manner which occurred in some high-performance premium applications. Evaluation of decarbonized surface quality was investigated by microstructure observation (light microscopy) and alloy elements diffusion (scanning electron microscopy), and hardness measurement and the element content were checked by spark optical emission spectrometry and glow discharge optical emission spectrometry, respectively.
20
Content available remote Szkło z formy
PL
Część artystyczna dyplomu magisterskiego Gabrieli Osiniak zajęła w tym roku II miejsce w międzynarodowym konkursie Stanislav Libenský Award. A jak zaczęła się jej przygoda ze szkłem?
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