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EN
In paper the selection of the composition and determination of main properties of novel moulding sand was described. The mail goal was to create moulding sand characterized by high thermal insulating properties in relations with low specific weight. This type of moulding sand will find application in thin walled castings with complex geometry, in particular for cores of the skeleton castings. In this work the results of the compressive strength, permeability and friability was presented. It was noted that aluminosilicate microspheres are suitable as moulding sand matrix. Influence of the polyglicol addition on quality and properties of the moulding sand was described. The use of the aluminosilicate microspheres allowed to obtain the moulding sand characterized by high insulation rate, low specific weight and good mechanical properties.
PL
W artykule przedstawiono dobór składu oraz określenie podstawowych własności nowoczesnej jakościowo masy formierskiej. Głównym celem pracy było wytworzenie masy formierskiej charakteryzującej się wysoką termoizolacyjnością w połączeniu z niską masą właściwą. Masa taka znajdzie zastosowanie do wytwarzania cienkościennych odlewów o rozbudowanej geometrii ze szczególnym przeznaczeniem na rdzenie odlewów szkieletowych. W pracy przedstawiono wyniki badań wytrzymałości na ściskanie, przepuszczalności, oraz osypliwości. Stwierdzono przydatność mikrosfer glinokrzemianowych, jako osnowy masy formierskiej. Określono korzystny wpływ poliglikolu na jakość i własności wytworzonej masy. Zastosowanie mikrosfer glinokrzemianowych pozwoliło na uzyskanie masy o wysokiej izolacji cieplnej w połączeniu z niską masą właściwą i dobrymi własnościami mechanicznymi.
2
Content available remote Skeleton castings dynamic load resistance
EN
Purpose: The article is to show selected results of research in a field of new type of cast spatial composite reinforcements. This article shows skeleton casting case as a particular approach to continuous, spatial composite reinforcement. Design/methodology/approach: The research is concerning properties of cast spatial microlattice structures called skeleton castings. In this paper results of impact test of skeleton casting with octahedron elementary cell were shown. The selection of internal topology of skeleton casting was based on numerical simulations of stress distribution. Findings: The possibility of manufacturing of geometrically complex skeleton castings without use of advanced techniques was confirmed. Research limitations/implications: With use of computer tomography, analysis of deformation mechanisms was carried out. Different levels of impact energies were used. Practical implications: Spatial skeleton casting with octahedron elementary cell confirmed their usefulness as impact energy absorbers. Originality/value: The overall aim of presented research was to determine the mechanisms of skeleton castings deformation processes. Thanks to CT data next step will be to create accurate numerical model for further simulation and design optimization.
3
Content available Structure of AlSi skeleton castings
EN
Skeleton castings macrostructure can be shaped in many ways, by choosing an appropriate material of cores and manufacturing technologies. Important factor, which puts foundry techniques over the other technologies of periodic cellular materials, is ability to adjust mechanical properties by changing the microstructure of an alloy from which the casting is made. The influence on the microstructure of the skeleton casting can be implemented by choosing the thermal properties, mainly thermal conductivity factor, of mould and core materials. Macro- and microstructure of skeleton castings with octahedron elementary cells was presented in this paper. The analysis concerns the differences in morphology of eutectic silicone depending on the location of measurements cross sections areas. The use of thermo-insulating material with appropriate properties assures correct fill of mould cavity and homogeneous microstructure on whole volume of skeleton casting. The selection of technological parameters of the casting process if very important as well.
4
Content available remote Basic properties of 3D cast skeleton structures
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.
EN
In this article authors showed influence of technological parameters and modification treatment on structural properties for closed skeleton castings. Approach obtained maximal refinement of structure and minimal structure diversification. Skeleton castings were manufactured in accordance with elaborated production technology. Experimental castings were manufactured in variables technological conditions: range of pouring temperature 953÷1013 K , temperature of mould 293÷373 K and height of gating system above casting level 105÷175 mm. Analysis of metallographic specimens and quantitative analysis of silicon crystals and secondary dendrite-arm spacing analysis of solution α were performed. Average values of stereological parameters for all castings were determined. (B/L) and (P/A) factors were determined. On basis results of microstructural analysis authors compares research of samples. The aim of analysis was selected samples on least diversification of refinement degree of structure and least silicon crystals. On basis microstructural analysis authors state that samples 5 (AlSi11, Tpour 1013K, Tmould 333K, h – 265 mm) has the best structural properties (least diversification of refinement degree of structure and the least refinement of silicon crystals). Then statistical analysis results of structural analysis was obtained. On basis statistical analysis autors state that the best structural properties for technological parameters: Tpour = 1013 K, Tmould = 373 K and h = 230 mm [4]. The results of statistical analysis are the prerequisite for optimization studies.
6
Content available remote Heat-insulating moulding sand with the glycol addition
EN
The article presents a selection of the composition and basic properties of highly insulating moulding sand. Sandmix is designed especially for thin-walled castings with high tendency to oxidation - particularly in spatial cores skeleton castings. An example of matrix of sandmix are aluminosilicate microspheres and the binder is bentonite plasticized with water and polyglycol. By using the microspheres high insulation, high mechanical strength and low specific weight core sand was obtained. Addition of polyglycol improved the mechanical properties, deformation characteristics, surface smoothness and reduced friability of sandmix.
7
Content available remote Kompozyty na bazie polimeru siarkowego ze szkieletowym wzmocnieniem AlSi
PL
Przedstawiono metodę wykonania kompozytowych elementów zbudowanych z zamkniętych odlewów szkieletowych ze stopów AlSi z wypełnieniem polimerowo-ceramicznym. Wypełnienie polimerowe stanowiła polimerowa osnowa SULCEM® z ziarnistym wypełnieniem mineralnym, dając polimerowy, siarkowy beton SULBET®. Wzmacniające próbne odlewy szkieletowe wykonano w zmiennych warunkach technologicznych: temperatura zalewania 983 oraz 1013 K, temperatura formy 293 oraz 333 K przy stałej wysokości układu wlewowego na poziomie 265 mm. W celu określenia wytrzymałości na ściskanie przeprowadzono badania na próbkach z odlewu kompozytowego, z betonu polimerowego oraz na próbkach z samego szkieletu aluminiowego. Zaobserwowano liniową zależność naprężenia ściskającego od odkształcenia względnego dla próbek z kompozytu oraz z osnowy polimerowej. Próbki z polimerowego betonu siarkowego pod działaniem maksymalnej siły ulegają pękaniu kruchemu. Natomiast w przypadku próbek z kompozytu szkielet aluminiowy ogranicza kruche pękanie betonu. W próbkach kompozytowych uzyskano znaczne zwiększenie wytrzymałości na ściskanie w porównaniu do próbek osnowy i wzmocnienia. Określono warunki wytwarzania odlewów próbnych szkieletowych, zapewniających korzystne własności wytrzymałościowe kształtek kompozytowych.
EN
In article method of manufacturing composite elements was shown. The composite elements was constructed with closed skeleton casting and polymer - ceramic filler. AlSi alloys with antimony were used for manufacturing the closed skeleton castings. Polymer warp SULCEM® and seediness mineral filler were created polymer, sulfuric concrete SULBET®. Sulfuric concrete, which was filled aluminium skeletons very good mechanical properties was characterized (for specialist solutions compression strenght is Rc = 73-86 MPa, whereas bending strenght is Rg = 10-15 MPa), excellent corrosion resistance, fast-ness to acid, fastness oil, minicipal wastes resistance and very low absorbability. Al-Si alloys with antimony were used for manufacturing the reinforcement skeletons. Antimony belong to the group of chemical elements which modify structure of Al-Si alloys. Application of antimony as modifier is often unsatisfactory. In presented research antymony was applied in order to decrease surface tension of liquid alloy to minimize production of Al2O3 oxides on stream front and to maximize the castability of the alloy. Application antimony as a modifier of structure was assumed in the background. Reinforcement experimental castings were manufactured in variables technological conditions: range of pouring temperature 983-1013 K, temperature of mould 293-333 K and height of gating system 265 mm. The aim of researches of mechanical properties was investigated influence filler on compression strenght of composite shaped. Researches of compression strenght on composite samples, polymer concreate and aluminium skeleton samples were conducted. For samples of aluminium skeleton was obtained nonlinear dependence compresive stress on strain. This connected with buckling insignificant, which connectors of aluminium skeleton reinforcement were undergo during compression. Linear dependence compresive stress on strain for composite samples and polymer warp samples was observed. Polymer, sulfuric concrete samples under effect maximal stress undergo brittle cracking. However in case of samples from composite, aluminium skeleton limits brittle cracking of concrete. In composite samples obtained considerable increase of compression strenght in comparision with warp and reinforcement samples. The manufacturation conditions of experimental skeleton castings which ensure profitable mechanical properties of composite shaped. Based on tests, which were performed authors deduced, that manufacturing of composite castings is possible with use of traditional casting technology, without use of expensive laboratory - devices, with applied classical gating system. The following research will aimed to increase complexity of external and internal structure casting skeleton reinforcement.
PL
W artykule przedstawiono geometrię przykładowego szkieletu i rdzenia opartą na osiemnasto-ścianie „hydraulicznym" oraz technologie wykonania rdzenia. Opracowano warunki technologiczne wytwarzania zamkniętych odlewów szkieletowych ze stopów AISi. Celem badań była analiza stopnia rozdrobnienia i jednorodności struktury odlewów szkieletowych oraz właściwości użytkowych tych odlewów. W związku z tym zmierzono odległości gałęzi drugorzędowych dendrytów (DAS) w charakterystycznych obszarach wykonanych odlewów. W badanych odlewach odległości wtórnych osi dendrytów DAS roztworu a osiągają najmniejsze wartości w obszarze stanowiącym geometryczne naroże ścian zewnętrznych zamykających odlew próbny, aczkolwiek są to wartości zbliżone do wartości we wszystkich charakterystycznych obszarach. Zbadano wytrzymałość na ściskanie próbek z odlewów szkieletowych. Największą wartość tej wytrzymałości uzyskano dla odlewu wykonanego przy parametrach technologicznych ujmujących temperaturę zalewania, temperaturę formy oraz wysokość układu wlewowego, a mianowicie: T/iń = 1013 K, T(ormy = 333 K, h = 265 mm. Opracowane warunki technologiczne umożliwiają wytworzenie odlewów o wymaganej zewnętrznej i wewnętrznej postaci geometrycznej i korzystnych właściwościach strukturalnych i wytrzymałościowych.
EN
In this paper geometry of skeleton casting and the core was shown together with its technology. Manufacturing parameters were determined for production of closed skeleton castings made of AISi alloys. The main aim was to analyze the refinement degree of the microstructure and its homogeneity together with operational properties of the castings. Dendrite arm spacing (DAS) was observed in characteristic regions of the casting. For studied castings the lowest values of DAS were observed in the corner of external walls of the casting. Nevertheless, values observed are close to those observed in other characteristic regions. To evaluate the mechanical properties compression test were performed. The highest compression strength was observed for skeleton casting manufactured under following technological conditions: pouring temperature 1013 K, mould temperature 333 K, height of the gating system 265 mm. Determined technological conditions enabled manufacturing of skeleton castings with desired external and internal geometry and favorable mechanical and structural properties.
EN
Purpose: The aim of this research was the definition of technological parameters influence and modification treatment on structural properties of closed skeleton castings. Approach obtained maximal refinement of structure and minimal structure diversification. Design/methodology/approach: Skeleton castings were manufactured in acccordance to elaborated production technology. The subject of the research was the microstructural analysis of non - monolithic castings. Analisys of metallographic specimens and quantitative analysis of silicon crystals and secondary dentrite-arm spacing analysis of solution á were performed. Studies were executed for typical regions of skeleton castings. The regions were diversified regarding the cooling rate. Findings: Technological condictions and modification treatment were determined on advantageous structural properties (the great homogeneity and the greatest degree of fineness of microstructure). On basis of the reserach autors confirmed that in applied condictions of solidifiaction advantageous structur of AlSi11 alloy was obtained. Research limitations/implications: In the future autors will pursue to define influence of different modifiers (than antimony) on structural properties of skeleton castings. The modifiers are generally applied to refinement the structure of eutectic aluminium alloys. The aim of future resarch will be also to define optimum technological parameters which generate the best structural properties. Practical implications: This article shows method of structure design of AlSi11 alloys skeleton castings. This is essential with regard on usable properties of skeleton castings in future technical applications. Originality/value: Value of article is the elaborated manufacturing technology of skeleton castings and two methods of structure design of non – monolithic constructions with complicated geometry. The first method depended on elaborated parameters technological guidelines and advantageous technological condictions which enables to obtain the best structural properties. The second method depended on use of modifier which improve castability of AlSi11 alloys and enables to obtaine good filling of core channels of skeleton castings with more homogeneous structure.
10
Content available remote Studies of structural and mechanical properties of aluminum skeleton castings
EN
Skeleton castings were manufactured in accordance to elaborated production technology. The subject of the research was the microstructural analysis of non - monolithic castings. Analysis of metallographic specimens and quantitative analysis of silicon crystals and secondary dendrite-arm spacing analysis of solution \alfa were performed. Studies were executed for typical regions of skeleton castings. The regions were diversified regarding the cooling rate. The greatest value of compression strength were observed for casting manufactured according to technological conditions: pouring temperature Tpour 1013 K, temperature of the mould Tmould 333 K and height of the gating system h - 265 mm. Technological conditions and modification treatment were determined on base of advantageous structural properties (high homogeneity and refinement). On basis of the research authors confirmed that in applied conditions of solidification advantageous structure of AlSi11 alloy was obtained. The article showed the method of structure design of AlSi11 alloys skeleton castings, which was essential to obtain favorable operating properties of skeleton castings in future technical applications.
11
Content available remote Structural analysis of aluminum skeleton castings
EN
In this article authors showed method for manufacturing of skeleton castings with continuous external surface. Wall thickness of the external surface was 6 mm. The experimental casting was manufactured in order to verify the results of filling mould cavity which were obtained by numerical simulation. The aluminosilicate core was used to produce experimental aluminum skeleton castings with dimensions of (115x65x136) mm. Lower ingate with vertical getting system was used. On based on numerical simulations and preliminary experimental tests technological conditions were determined, which enables obtained castings on repeatable satisfactory geometry and requirement quality. Degree of refinement of structure in typical region of skeleton casting was compared. Qualitative and quantitative different degree of fineness of eutectic was confirmed. Selection of modification conditions AlSi alloy of skeleton casting is necessary. Based on tests, which were performed authors deduced, that manufacturing of skeleton castings is possible with use of traditional casting technology, without use of expensive laboratory – devices, with applied classical gating system and typical pouring temperature of Al alloys (ex. 740°C).
12
Content available remote Quality of the joint between cast steel and cast iron in bimetallic castings
EN
The paper presents conception and production method of skeleton composite castings with use of cast steel G35CrSiMnMoNi skeleton casting and chromium cast iron EN-GJN-XCr15 filling. Working elements in winning machines and devices, which work in intensive aberasive wear i.e. liner of exhausters, percussive and ram hammers, are destination of bimetallic castings. Skeleton geometry was based on three-dimensional symmetrical cubic net consisting of circular connectors and nodes joining 6 connectors according to Cartesian coordinate system. Dimension of an elementary cell was equal to 10 mm and diameter of single connector was equal to 5 mm. In range of studies were casted cast steel skeletons with chromium cast iron filling and based on metallographic research on light and scanning electron microscope was made quality assessment of joint in bimetallic castings. Moreover in range of studies was used microanalysis of chemical composition in transition zone of cast steel-cast iron joint.
13
Content available remote Numerical simulation of pouring and solidification of closed skeleton casting
EN
In this work authors showed results of simulation manufacturing closed skeleton casting. The aim of conducted simulations was the choice of thermal and geometrical parameters for the needs of designed calculations of the skeleton castings and the estimation of the guidelines for the technology of manufacturing. During simulation effect at mould filling process for the skeleton casting was analyzed. Analysis of temperature distribution and analysis of solidification closed aluminium skeleton casting were conduced. It was confirmed that the metal is flows at the external surfaces and fills internal channels of skeleton, until the moment of overall filling of the mould. Whole casting is solidification in finish of pouring mould. It is advantageous by reasons of satisfactory mould filling. Part of casting which was connected with feeder, on upper surface of casting solidified the slowest. in consequence to the lowest heat give up.
14
Content available remote Microstructure quantitative analysis of aluminum skeleton castings
EN
In this article authors showed method for manufacturing of closed skeleton castings with hypo - eutectic and eutectic aluminium alloys. Experimental castings were manufactured in variables technological conditions: range of pouring temperature 680÷740 °C, temperature of mould 20÷100 °C and height of gating system above casting level 105÷175 mm. Structural analysis of studied skeleton castings was conducted. Degree of refinement of structure in typical region of skeleton casting was compared. Qualitative and quantitative different degree of fineness of eutectic silicon was confirmed. Casting in established technological conditions enables manufactured skeletons which repeatable geometry, suitable external geometrical form of casting and required quality.
15
Content available remote Closed aluminium skeleton casting
EN
In this article authors showed method for manufacturing of skeleton castings with continuous external surface. Wall thickness of the external surface was 6 mm. The experimental casting was manufactured in order to verify the results of filling mould cavity which were obtained by numerical simulation. The aluminosilicate core was used to produce experimental aluminum skeleton castings with dimensions of (115x65x136) mm. Experimental casting was manufactured with elevated temperature of mould (370 K). Lower and stotted ingate with high geting system (300mm) was used. Analysis of ability of metal to fill the mould cavity in establish technological conditions was perfomed. Degree of refinement of structure in typicall region of skeleton casting was compared. Qualitative different degree of fineness of eutectic was confirmed. Selection of modification conditions AlSi alloy of skeleton casting is necessary. The manufacturing of skeleton casting in establish technological conditions enables obtained very good filling of mould cavity and suitable external geometrical form of casting.
EN
In this work authors showed selected results of simulation and experimental studies on temperature distribution during solidification of composite skeleton casting and mould filling process (Fig. 4, 5, 6). The basic subject of the computer simulation was the analysis of ability of metal to fill the channels creating the skeleton shape and prepared in form of a core. Analysis of filling for each consecutive levels of the skeleton casting was conducted for simulation results and real casting. The skeleton casting was manufactured according to proposed technology (Fig. 5). Number of fully filled nodes in simulation was higher than obtained in experimental studies. It was observed in the experiment, that metal during pouring did not flow through the whole channel section, what enabled possibilities of reducing the channel section and pointed out the necessity of local pressure increase.
17
Content available remote Warunki wytwarzania i postać geometryczna odlewów szkieletowych
PL
Przedstawiono dobór geometrii odlewu szkieletowego przeznaczonego do badań modelowych, symulacji zalewania i krzepnięcia oraz własności mechanicznych. Porównano wpływ ciśnienia metalostatycznego stopu aluminium i żeliwa na zapełnianie wnęki formy odlewniczej. Przedstawiono różnice w technologicznych własnościach badanych stopów na wypełnienie wnęki formy. Wykazano wpływ innych czynników poza ciśnieniem na uzyskanie odlewu szkieletowego.
EN
In this work geometry selection for model skeleton casting was shown. This model was used for properties investigation and numerical simulation. Comparison of metalostatic pressure was conducted for Al alloy and cast iron. Influence of technological properties of studied alloys on cavity filling and skeleton casting creation was indicated.
18
Content available remote Rdzenie ceramicznie odlewu szkieletowego o komórkach otwartych
PL
Celem pracy jest dobór składników masy rdzeniowej i opracowanie optymalnych proporcji między jej składnikami, umożliwiających zastosowanie powstałej w ten sposób masy do wykonania rdzenia ceramicznego odlewu szkieletowego o regularnych komórkach otwartych. Zaproponowano skład masy rdzeniowej do wytwarzania odlewu szkieletowego po optymalizacji proporcji jej składników. Przedstawiono geometrię i sposób wykonania rdzenia krystobalitowo - gipsowego.
EN
The main aim of this work is components of mass on core selection and optimal proportion between its components elaborations, this way bringing application of this mass execution skeleton casting with open cells regular. Composition of mass skeleton casting was presented. Geometry and method of core cristobalite - gypsum were presented.
19
Content available remote Dobór geometrii i materiału rdzenia odlewu szkieletowego o komórkach otwartych
PL
Celem pracy był dobór geometrii szkieletu i materiału rdzenia do wytwarzania metalowych materiałów szkieletowych o regularnych komórkach otwartych. Plan zaprojektowania rdzenia odlewu szkieletowego obejmował: podział rdzenia na najmniejsze powtarzalne elementy, wyznaczenie geometrycznych cech komórek szkieletu metalowego, wytypowanie modelu kształtowego odlewu próbnego. Zaproponowano trzy koncepcje kształtu pojedynczych komórek. Na podstawie analizy geometrii pojedynczej komórki wyznaczono kształt rdzenia. Przedstawiono krystabalitowo - gipsową masę formierską.
EN
The main aim of this work was cell geometry and material selection for skeleton castings. The core design plan enclosed core division into smallest repeateble elements, metal cell geometry determination and idetification of shape model for example casting. Three concepts for elementary cells were presented. On base of elementary cell geometrical analysis the core shape was determined.
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