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The Use of Phosphate Binder for Ablation Casting of AlSi7Mg Modified TiB Alloy

Puzio Sabina, Kamińska J., Major-Gabryś K., Angrecki M.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 1

62--68

EN

The possibilities of using an inorganic phosphate binder for the ablation casting technology are discussed in this paper. This kind of binder was selected for the process due to its inorganic character and water-solubility. Test castings were made in the sand mixture containing this binder. Each time during the pouring liquid alloy into the molds and solidification process of castings, the temperature in the mold was examined. Then the properties of the obtained castings were compared to the properties of the castings solidifying at ambient temperature in similar sand and metal molds. Post-process materials were also examined - quartz matrix and water. It has been demonstrated that ablation casting technology promotes refining of the microstructure, and thus upgrades the mechanical properties of castings (Rm was raised about approx. 20%). Properties of these castings are comparable to the castings poured in metal moulds. However, the post-process water does not meet the requirements of ecology, which significantly reduces the possibility of its cheap disposal.

2

The Influence of Various Matrixes on the Strength Properties of Moulding Sands with Thermally Hardened Hydrated Sodium Silicate for the Ablation Casting Process

Major-Gabryś Katarzyna, Puzio Sabina, Bryłka Agata, Kamińska Jadwiga

Journal of Casting & Materials Engineering

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2021

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Vol. 5, no. 2

31--35

EN

The essence of ablation casting technology consists in pouring castings into single-use moulds made from the mixture of sand and a water-soluble binder. After pouring the mould with liquid metal yet while the casting is still solidifying, the mould destruction (washing out, erosion) takes place using a stream of cooling medium, which in this case is water. This paper focuses on the selection of moulding sands with hydrated sodium silicate for moulds used in ablation casting. The research is based on the use of water glass 145 and 150 as binders. As part of the research, loose moulding mixtures based on two silica sands from different sand mines with different content of binders were prepared. The review of literature data and the results of own studies have shown that moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties to be used in the ablation casting process. Our own research also confirmed the possibility of using these sand mixtures in terms of both casting surface quality and sand reclamation. The results presented in this paper prove that both sand grains and types of binder tested may be used as components in moulding sands devoted to ablation casting.

3

Utwardzane mikrofalowo masy formierskie ze spoiwami nieorganicznymi przeznaczone do odlewania ablacyjnego

Puzio Sabina, Kamińska Jadwiga, Angrecki Michał, Hosadyna-Kondracka Małgorzata, Major-Gabryś Katarzyna

Przegląd Odlewnictwa

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2019

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Vol. 69, nr 5-6

114--120

PL

Celem niniejszej pracy jest wykazanie możliwości zastosowania proekologicznych mas z uwodnionym krzemianem sodu na formy do odlewania ablacyjnego. Technologia odlewania ablacyjnego przeznaczona jest przede wszystkim do wykonywania odlewów w formach piaskowych o zróżnicowanej grubości ścianki i skomplikowanych kształtach. W ramach niniejszej pracy przedstawiono wpływ zawartości spoiwa oraz czasu utwardzania na wytrzymałość na zginanie Rg mas formierskich ze spoiwami na bazie uwodnionego krzemianu sodu utwardzanych w technologii utwardzania mikrofalowego. Celem badań jest opracowanie optymalnego składu mas, który zapewni wytrzymałość niezbędną do wytworzenie formy do przeprowadzenia procesu odlewania ablacyjnego. Zastosowana mas musi jednocześnie zagwarantować podatność formy na destrukcyjne działanie medium ablacyjnego, którym jest woda. Przeprowadzone badania wykazały, że utwardzanie mikrofalowe zapewnia uzyskanie zadowalających wytrzymałości przy niskiej zawartości spoiwa w masie.

EN

The aim of this work is to demonstrate the possibility of using Environmentally friendIy molding sands with hydrostated sodium silicate for ablation casting molds. The ablation casting technology is intended primarily for making casts in sand molds with diversified wall thickness and complex shapes. This paper presents the effect of binder content and curing time on the bending strength Rg of molding sands with binders based on hydrated sodium silicate hardened in microwave curing technology. The aim of the research is to develop an optimal molding sand composition that will provide the strength necessary to form a mold for carrying out the ablative casting process. the applied sands must simultaneously guarantee the susceptibility of the mold to the destructive action of the ablative medium, which is water. The tests have shown that microwave curing provides satisfactory strengths with low binder content.

4

The Use of Floster S Technology in Modified Ablation Casting of Aluminum Alloys

Kamińska J., Angrecki M., Puzio S., Hosadyna-Kondracka M., Major-Gabryś K.

Archives of Foundry Engineering

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2019

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iss. 4

81--86

EN

Ablation casting is a technological process in which the increased cooling rate causes microstructure refinement, resulting in improved mechanical properties of the final product. This technology is particularly suitable for the manufacture of castings with intricate shapes and thin walls. Currently, the ablation casting process is not used in the Polish industry. This article presents the results of strength tests carried out on moulding sands based on hydrated sodium silicate hardened in the Floster S technology, intended for ablation casting of the AlSi7Mg (AK7) aluminium alloy. When testing the bending and tensile strengths of sands, parameters such as binder and hardener content were taken into account. The sand mixtures were tested after 24h hardening at room temperature. The next stage of the study describes the course of the ablation casting process, starting with the manufacture of foundry mould from the selected moulding mixture and ending in tests carried out on the ready casting to check the surface quality, structure and mechanical properties. The results were compared with the parallel results obtained on a casting gravity poured into the sand mould and solidifying in a traditional way at ambient temperature.

5

Moulding Sand with Inorganic Cordis Binder for Ablation Casting

Hosadyna-Kondracka M., Major-Gabryś K., Kamińska J., Grabarczyk A., Angrecki M.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 4

110--115

EN

The essence of ablation casting technology consists in pouring castings in single-use moulds made from the mixture of sand and a water-soluble binder. After pouring the mould with liquid metal, while the casting is still solidifying, the mould destruction (washing out, erosion) takes place using a stream of cooling medium, which in this case is water. This paper focuses on the selection of moulding sands with hydrated sodium silicate for moulds used in the ablation casting. The research is based on the use of Cordis binder produced by the Hüttenes-Albertus Company. It is a new-generation inorganic binder based on hydrated sodium silicate. Its hardening takes place under the effect of high temperature. As part of the research, loose moulding mixtures based on the silica sand with different content of Cordis binder and special Anorgit additive were prepared. The reference material was sand mixture without the additive. The review of literature data and the results of own studies have shown that moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties to be used in the ablation casting process. Additionally, at the Foundry Research Institute in Krakow, preliminary semi-industrial tests were carried out on the use of Cordis sand technology in the manufacture of moulds for ablation casting. The possibility to use these sand mixtures has been confirmed in terms of both casting surface quality and sand reclamation.

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Badania nad technologią odlewania ablacyjnego stopów aluminium

Dudek P., Fajkiel A., Reguła T., Bochenek J.

Prace Instytutu Odlewnictwa

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2014

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T. 54, nr 2

23--35

PL

W artykule przedstawiono wstępne wyniki badań nad technologią odlewania ablacyjnego. W ramach pracy opracowano założenia do budowy doświadczalnego stanowiska do zmodyfikowanej technologii odlewania ablacyjnego. Wykonano stanowisko, na którym przeprowadzono badania destrukcji formy piaskowej strumieniem wody pod wysokim ciśnieniem. Wpływ szybkiego chłodzenia odlewu podczas krzepnięcia na jego strukturę określono na podstawie badań rentgenograficznych i metalograficznych.

EN

The article presents preliminary results of research on ablation casting technology. The guidelines for the design of equipment to carry out the process are described. Based on the above mentioned instructions a test stand was developed and built. Many tests were performed concerning the influence of the water jet directed at a sand mould on its removal tendency. The effect of the cooling rate of tested cast parts on its microstructure were studied based on metallographic and radiographic tests.