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1

Analysis of the technological position in relation to aluminium casting production

Pacana Andrzej, Czerwińska Karolina

Advances in Mechanical and Materials Engineering

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2023

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Vol. 40, nr 1

15--21

EN

The dynamically developing production market, and in particular the metallurgic industry, enforces constant improvement of the level of production efficiency and product quality, which influences company position on the market and the level of its competitiveness. Therefore, the aim of the study was to determine the current position of the foundry enterprise, taking into account the aluminium gearbox casting, in the context of technological capabilities and market position, as well as to identify critical factors and, finally, to indicate the conditions for its strengthening. The study used a 3x3 matrix. The company under study, in the context of manufacturing the analysed product, is classified in the area of "marketing improvement". This area demonstrates the need to take measures to establish a marketing and development department and the need to make better use of the company's identified technological potential. The method presented in the study can be useful for analysing the position of manufacturing and service companies in various industries, in order to select an appropriate development strategy.

PL

Dynamicznie rozwijający się rynek produkcyjny, a w szczególności przemysłu metalurgicznego, wymusza stałe doskonalenie poziomu efektywności produkcji, jakości wyrobów, co wpływa na pozycję przedsiębiorstwa na rynku oraz na poziom jego konkurencyjności. Z tego względu celem opracowania było określenie aktualnej pozycji przedsiębiorstwa odlewniczego biorąc pod uwagę aluminiowy odlew skrzyni biegów, w kontekście możliwości technologicznych i pozycji na rynku, a także identyfikacja newralgicznych czynników i finalnie wskazanie warunków jej umocnienia. W badaniu wykorzystano macierz 3x3. Badane przedsiębiorstwo w kontekście wytwarzania analizowanego wyrobu zlokalizowane jest w obszarze „poprawa marketingu”. Lokalizacja ta świadczy o konieczności podjęcia działań związanych z utworzeniem działu marketingu i rozwoju oraz konieczności lepszego wykorzystania zidentyfikowanego potencjału technologicznego przedsiębiorstwa. Przedstawiona w opracowaniu metoda może być przydatna do analizy pozycji przedsiębiorstw produkcyjnych oraz usługowych z różnych branż, celem obrania adekwatnej strategii rozwojowej.

2

Improving the quality of Al-Si castings by using ceramic filters

Švecová Ivana, Tillová Eva, Kuchariková Lenka

Production Engineering Archives

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2020

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Vol. 26, Iss. 1

19--24

EN

The use of cast aluminium has still increased, so have the mechanical property requirements. By casting and also in other metallurgical processes, the inclusions enter to the molten aluminium alloy and it exhibits poor ductility or toughness. It can cause a variety of problems in the manufacture of aluminium alloy castings. Therefore, the purification of the molten aluminium alloy is one of the most important processes for improving the quality of Al-products. Filters have been used for many years in order to improve the quality of castings. The inclusions in molten secondary AlSi7Mg0.3 cast were removed using depth filtration by ceramic foam filters of 20 ppi porosity. Were used 4 types of ceramic filters in 2 thicknesses (15 and 22 mm); Brinell hardness and porosity were measured. Quality of microstructure (occurrence of oxidic particles and larger non-metallic inclusions) was observed. Experimental results show that the insertion of ceramic filters into the inlet system has contributed primarily to a decrease in porosity. On the microstructure, the inclusion of filters was not significantly reflected.

3

Technological Properties of Moulding Sands with Geopolymer Binder for Aluminium Casting

Vaskova I., Conev M., Hrubovčáková M.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 4

45--49

EN

The use of environmentally friendly inorganic binders and new technologies for cores production is widely discussed topic in recent years. This paper contains information about new hot curing process for core making with alumina-silicate based inorganic binders – geopolymers. Main differences between hot cured geopolymers and hot cured alkali silicate based inorganic binders are discussed. The main objective of this research paper was to investigate basic technological properties of geopolymer binder system such as strength, compaction, storage ability and knock-out properties. For this purpose, three mixtures with different powder additives were prepared and tested in laboratory conditions using specific methods. Strength properties evaluation showed sufficient levels as well as knock-out properties measurement, even with additives B and C originally designed for the use with alkali silicate based two component binder systems. Additives B and C were considered compatible with geopolymer binders after casting production trial results. Storage ability of geopolymers seems to be more sensitive than of alkali silicate based binders in the same tested conditions. Mixtures with geopolymer binder showed 20% more decrease of strength compared to alkali silicate binders after 24 hours in conditions of 25 °C and 65 %RH.

4

The assessment of castings quality using selected quantitative methods

Kucharikova L., Tillova E., Zavodska D.

Production Engineering Archives

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2016

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Vol. 13, No. 4

7--10

EN

Aluminium alloys represent an important category of materials due to their high technological value and wide range of applications. The alloys of the Al-Si-Cu system have become increasingly important in recent years, mainly in automotive industry that uses secondary aluminium (recycled) in the form of various motor mounts, pistons, cylinder heads, heat exchangers, air conditioners due to their high strength at room and high temperature. This work deals with possibilities of quick and correct assessment of aluminium castings microstructure, especially focused on volume, size and shape of structural parameters – eutectic Si and intermetallic phases different chemical compositions. These structural parameters affect the properties of castings and it is important to study their features. The features were studied by using image analyser software NIS Elements.

5

The effect of toughening combined with microjet cooling during quenching (solution heat treatment) of calcium carbide-modified CuAl10Fe4Ni4 alloy on its mechanical properties

Górny Z., Kluska-Nawarecka S., Saja K.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 1

29--32

EN

The work presents the results of the experimental research concerning the impact of a heat treatment (toughening) of aluminum bronze CuAl10Fe4Ni4 on its mechanical properties. The conditions of the experiments and selected results are described. A detailed description of the effects of individual heat treatment conditions namely low and high temperature aging is also presented in the work.

6

Comparative Studies of Continuously Cast Semi-finished Al Grade EN AW 1370

Knych T., Uliasz P., Piwowarska-Uliasz M.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 2 spec.

65--69

EN

The current development of processing technologies of aluminium and its alloys is oriented towards special technologies of continuous casting, dedicated to specific applications. The good point of such approach constitutes limiting of production costs and time needed for making these products. An example of utilising dedicated technologies is sheets production technology of aluminium and its alloys by continuous casting. Another example constitutes technologies of producing charges for the drawing process, where technologies of rods continuous castings of copper and its alloys are known an industrial scale. However, there is a lack of such solutions regarding continuous casting of aluminium and aluminium alloys. Comparative studies of aluminium materials obtained in continuous casting and in continuous casting and rolling technology are presented in the paper.

7

Badania nad nową technologią wytwarzania wsadu do produkcji drutów aluminiowych

Knych T., Uliasz P., Piwowarska M.

Hutnik, Wiadomości Hutnicze

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2011

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Vol. 78, nr 1

40-42

PL

W ostatnich latach w przemyśle kablowym obserwuje się wyraźny rozwój wyrobów z aluminium. Sytuacja ta wymusza badania nad nowymi technologiami produkcji aluminiowego wsadu do procesu ciągnienia, w tym technologii ciągłego odlewania (CO). Linie technologiczne tego typu są obecnie stosowane do produkcji wyrobów z miedzi oraz jej stopów. W pracy przedstawiono wyniki badań procesu ciągnienia odlewanych w sposób ciągły drutów z aluminium gatunku EN AW 1370 otrzymanych w warunkach laboratoryjnych (AGH) oraz na pół-przemysłowej instalacji fińskiej firmy Upcast. Badania obejmują laboratoryjne próby ciągnienia odlewanych prętów aluminiowych oraz ocenę własności użytkowych otrzymanych drutów.

EN

In recent years in the cable industry it is observed a tendency of development new aluminium products. This situation is a reason of research on new technologies of production aluminium rod for example continuous casting. Advantages of technology CC gave the need of development a modern installation for production of aluminium and aluminium alloys rod. This paper presents results of the research on the process of the aluminium wire drawing obtained in laboratory and industrial-scale in the R&D department of Upcast company. Laboratory tests includes a drawing process and final properties of obtained wires.

8

Basic properties of 3D cast skeleton structures

Cholewa M., Szuter T., Dziuba M.

Archives of Materials Science and Engineering

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2011

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Vol. 52, nr 2

101-111

EN

Purpose: of this paper is to present recent achievements in field of skeleton structures. The aim of this work is to show results of searching for mechanically and technologically advantageous micro- and macrostructures. Methods of microstructure controlling were described. Most important parameters of the manufacturing process were identified. Design/methodology/approach: The influence of internal topology to stress distribution was described with the use of computer simulations. Simulations of the mold filling processes were also carried out. Real experiments were performed to prove the simulation results. The Qualitative and quantitative metallographic analysis were also carried out. Findings: It was found that the octahedron shape of internal cell causes best stress distribution and that the skeleton castings are a good alternative for cellular materials such as metal foams, lattice structures and sandwich panels. Their structured arranged topology allows precise design of properties. Research limitations/implications: Casting methods used to manufacture materials such as described skeleton castings confirmed their usefulness. Not well known and used yet rheological properties of liquid metals allow obtaining shape complicated structures near to metallic foams but structured arranged. Practical implications: Technological parameters of the skeleton castings manufacturing process were developed. Without use of advanced techniques there is a possibility to manufacture cheap skeleton structures in a typical foundry. With use of advanced technology like 3D printing there are almost unlimited possibilities of the skeleton castings internal topologies. Originality/value: Three dimensional cast skeleton structures with internal topology of octahedron confirmed their usefulness as elements used for energy dissipation. Obtaining the homogenous microstructure in the whole volume of complicated shape castings can be achieved.

9

Badania nad procesem ciągnienia prętów z aluminium wytworzonych metodą ciągłego odlewania

Knych T., Kwaśniewski P., Kiesiewicz G., Piwowarska M., Uliasz P.

Rudy i Metale Nieżelazne

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2010

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R. 55, nr 7

464-468

PL

Jedna z koncepcji prac nad nowymi technologiami przetwórstwa aluminium, polega na eliminacji segmentu odkształcenia na gorąco. Przykładem rozwiązania praktycznego w tym względzie może być proces produkcji blach z aluminium i jego stopów z pominięciem tradycyjnej technologii DC odlewania wlewków i procesu ich gorącego walcowania. W przypadku produkcji materiałów wsadowych przeznaczonych na druty do celów elektrycznych wykorzystuje się linie ciągłego odlewania i walcowania (COiW). Produkcja walcówki aluminiowej w stanie miękkim obejmuje jej wytworzenie w linii COiW, a następnie obróbkę cieplną. Materiał uzyskany w ten sposób charakteryzuje się niejednorodnością struktury, która może powodować pewne ograniczenia w procesie ciągnienia drutów, zwłaszcza drutów o niskich średnicach. Ze względu, że najnowsze aplikacje przewodów z aluminium, takie jak żyły giętkie klasy 5 i 6 oraz przewody emaliowane wymagają drutów o średnicach dochodzących do 0,2 mm prowadzone się intensywne badania nad nowymi technologiami uzyskiwania aluminiowego wsadu do procesu ciągnienia. W artykule przedstawiono badania nad laboratoryjną technologią ciągłego odlewania prętów z aluminium oraz ich dalszego przetwórstwa na druty o niskich średnicach.

EN

One of the subjects of industrial process research is the elimination of hot rolling from the manufacturing of various products. An example of a practical solution in this field is the manufacturing of metal sheets from aluminium and its alloys, in which hot rolling step has been eliminated. In case of production aluminium wire rod intended for electrical application the rod is manufactured in continuous casting and rolling lines. Production of aluminium rods in temper O includes its production casting and rolling line and after that its heat treatment. Material obtained in this way has a non-homogeneous structure that may cause a reduction in the process of drawing wires, especially for low wire diameters. The newest applications of wires from aluminium and its alloys include flexible strands of class 5 and 6 conductors, and enamelled wire, requiring wires with diameters as small as 0.2 mm. This is the reason of intensive research into new technologies for obtaining aluminium batch to drawing process. In this work presents research on development technologies continuous casting rods with aluminium and their further processing into wires of low diameters.

10

Qualification of welding procedures for aluminium, steel and iron castings

Pfeifer T., Mazur Ł., Rykała J.

Archives of Foundry Engineering

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2010

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Vol. 10, iss. 1 spec.

325--330

EN

The article presents the qualification process concerned with the following procedures: finishing welding of aluminium castings pursuant to PN-EN ISO 15614-4, production welding of steel castings pursuant to PN-EN ISO 11970 and production- and finishing welding of cast irons pursuant to PN-EN ISO 15614-3. The work enumerates the cases of qualification of welding procedures for aluminium, steel and iron castings and presents details related to test joint designs as well as the manner of their preparation taking into account welding conditions and other technological aspects. The text also contains precise characteristics of test joint examinations and their range of application while qualifying a given welding procedure. In addition, the article informs about test results which justify the qualification of a finishing welding procedure for aluminium castings and test plate butt joints in case of cast irons and cast steels. In all cases particular attention was paid to the range of qualification of procedures for characteristic conditions of the welding process and its basic variables.

11

Methodological conditionings of a modified low cycle fatigue method of tempered 41Cr4 steel in comparison to some other materials

Maj M., Moćko W., Pietrzak K., Klasik A.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 4

129-134

EN

In the research work results of the application of modified LCF method in the assessment of fatigue parameters of various materials were discussed. The new software algorithm was proposed in the determination of fatigue parameters. A comparative verification of the new procedure with bibliographical data confirmed the possibility of the replacement of classical LCF by proposed original MLCF method as especially suitable test in the case of heterogeneous materials microstructure, particularly when it is hard to design Wöhler's diagrams as well as to carry on research according to the classical LCF method.

12

Kwalifikowanie technologii łukowego spawania aluminium i spawania wykańczającego odlewów aluminiowych - procedura, wymagania i zakresy kwalifikacji wg norm międzynarodowych.

Pfeifer T.

Biuletyn Instytutu Spawalnictwa w Gliwicach

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2007

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R. 51, nr 1

38-38

PL

Przedstawiono przebieg procedury kwalifikowania technologii spawania aluminium i jego stopów, a także technologii spawania wykańczającego odlewów aluminiowych. Omówiono szczegółowo, jakie badania złączy próbnych należy przeprowadzić i jakie wyniki tych badań pozwalają na zakwalifikowanie technologii spawania blach i rur oraz spawania wykańczającego odlewów aluminiowych. W obydwu przypadkach zwrócono szczególną uwagę na zakresy kwalifikowania dla warunków procesu spawania oraz dla podstawowych jego zmiennych.

EN

It has been presented the course of qualification of welding technology for aluminium and its alloys as well as technology of finishing welding of aluminium casts. It is described in detail which examination of test joint should be carried out and which examination results allow to approve welding technology for plates and pipes and finishing welding technology for aluminium casts. In both cases the special attention was given to the scope of qualification for the welding process conditions and for its main variants.

13

Stanowisko do badania skurczu liniowego i naprężeń skurczowych w odlewach

Mutwil J.

Archiwum Odlewnictwa

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2003

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R. 3, nr 8

287--292

PL

Opisano stanowisko do badania ewolucji skurczu liniowego i naprężeń skurczowych w odlewie. Zastosowano mikroprocesorową rejestrację sygnałów pomiarowych. Przedstawiono przykładowe ilustracje zmian skurczowych w aluminium.

EN

A stand for examination of the development of linear contraction and shrinkage stresses in casting has been described. The microprocessor recorder has been used for registering of measure signals. Exemplary results of linear contraction development in aluminum have been presented.

14

Modelling of solidification using the control volume method

Szopa R., Siedlecki J.

Krzepnięcie Metali i Stopów

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2000

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R. 2, nr 44

349--354

EN

In the paper the control volume method is applied for numerical modelling of thermal processes proceeding in the system casting-mould. In particular, the oblique hot spot of L type (α=60º) is considered. The control volumes in the shape of equilateral triangles (2D problem is considered) are introduced. The balance equations concern the solidification of pure metal (e.g. aluminium). In the final part the example of computations is shown.

PL

W pracy przedstawiono algorytm metody bilansów (metody objętości kontrolnych) przystosowany do modelowania krzepnięcia odlewów, a w szczególności węzła cieplnego typu L o kącie rozwarcia 60º. Obszar podzielono na objętości kontrolne w kształcie trójkątów równobocznych (zadanie 2D), podano równania bilansów dla etapów stygnięcia i krzepnięcia. Pokazano przykład realizacji numerycznej (odlew aluminiowy).

15

Numerical model of aluminium casting solidification

Szopa R., Binczyk F.

Zeszyty Naukowe Katedry Mechaniki Stosowanej / Politechnika Śląska

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1999

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z. 10

285-290

EN

In the paper the boundary element method using discretization in time is applied for numerical simulation of aluminium casting solidification. The energy equation describing the process contains a term called the source function. The capacity of this function results from the considerations known in literature as the macro/micro approach. The results of computations presented in the final part of the paper have been experimentally verified.

PL

W pracy wykorzystano metodę elementów brzegowych z dyskretyzacją czasu do numerycznej symulacji krzepnięcia odlewu aluminiowego. W równaniu energii opisującym proces krzepnięcia występuje składnik nazywany funkcją źródła. Wydajność tej funkcji wynika z rozważań znanych w literaturze pod nazwą modelu makro/mikro. W końcowej części pracy przedstawiono wyniki obliczeń numerycznych, które zostały zweryfikowane doświadczalnie na odlewie próbnym.