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1

Analysis of qualitative and environmental attributes of success of foundry enterprises

Czerwińska Karolina, Pacana Andrzej

System Safety : Human - Technical Facility - Environment

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2023

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Vol. 5, iss. 1

10--18

EN

The purpose of the study was to identify and typify the main qualitative-environmental aspects of the success of foundry enterprises facing economic changes. The research method developed was based on methodological triangulation. This procedure influenced the credibility of the collected data by including a significant number of sources and reducing the measurement error. The study used: surveying, face-to-face interviews, multiple case studies and content analysis. The survey made it possible to categorize the attributes of success (quality, sustainability, resources, flexibility, environment, management strategy customer relations). Assuming that the frequency of occurrence of an attribute indicates the level of its effectiveness, the following were considered the main determinants: training/courses, supervision and control, reliability and durability of products and compliance with standards and requirements, waste management and waste disposal, core and reserve capital, and customer service.

2

Spojrzenie na polski przemysł odlewniczy. Stan aktualny i prognozy na przyszłość

Liszka Katarzyna, Dobosz Witold

Przegląd Odlewnictwa

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2023

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Vol. 73, nr 11-12

400--406

PL

Jak europejskie odlewnictwo radzi sobie z kryzysem? Jaki wpływ miały zmiany gospodarcze na produkcję odlewów w Europie? Gdzie w tym wszystkim jest Polska? Co Nas czeka i z czym przyjdzie się zmierzyć polskim odlewniom? Na te i inne pytania znajdą Państwo odpowiedź w tym artykule.

EN

How the European foundry manages with the crisis? What influence had economic changes on the casting production in Europe? Where – in all of these – is Poland now? What should be expected and what Polish foundries will be facing? Answers to these and other questions You will find in the hereby paper.

3

Podgrzewanie urządzeń wyłożonych materiałami ogniotrwałymi

Holleis Burkhardt, Lorenz Wolfgang, Prieler René Josef, Rauch Johannes, Spoljaric Davor, Demuth Martin, Schindler Philipp

Przegląd Odlewnictwa

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2023

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Vol. 73, nr 1-2

30--35

PL

Firma Messer Polska Sp. z o.o. jest częścią międzynarodowego koncernu produkującego i dystrybuującego gazy techniczne. Już ponad 120 lat jesteśmy obecni na międzynarodowych rynkach, oferując miedzy innymi rozwiązania technologiczne dla branży metalurgicznej w szczególności dla odlewni. W przedstawionej prezentacji będziecie mogli Państwo odnaleźć podstawowe informacje o firmie Messer Polska i firmie Messer Group. Firma Messer to nie tylko producent gazów technicznych. Zajmujemy się od wielu lat udostępnianiem naszej wiedzy w zakresie zastosowania produkowanych przez nas gazów w wielu branżach przemysłu takich jak przemysł cementowy, szklarski, chemiczny czy metalurgiczny. Głównym celem prezentacji jest przybliżenie możliwości zastosowania użycia gazów technicznych w przemyśle odlewniczym. W prezentacji obok wyzwań i problemów takich jak dekarbonizacja, zmniejszenie emisji CO2 pokazujemy nowoczesne produkty technologiczne naszej firmy mające zastawnie dla przemysłu odlewniczego.

EN

The company Messer Polska Sp. z .o. is part of an international concern producing and distributing technical gasesWe have been present on international markets for over 120 years, offering, among other things, technological solutions for the metallurgical industry, in particular for foundries. In the current presentation we can find basic information about Messer Polska and the Messer Group company. Messer is not only a producer of technical gases. For many years, we have been sharing our knowledge in the field of application of the gases we produce in many industries such as the cement, glass, chemical and metallurgical industries. The main purpose of the presentation is to present the possibilities of using technical gases in the foundry industry. In the presentation, in addition to challenges and problems such as decarbonisation, reduction of CO2 emissions, we show modern technological products of our company with collateral for the foundry industry.

4

Assessment of surface waviness of casting patterns made using 3D printing technologies

Zmarzły Paweł, Gogolewski Damian, Kozior Tomasz

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2023

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Vol. 71, nr 1

art. no. e144585

EN

The application of 3D printers significantly improves the process of producing foundry patterns in comparison to traditional methods of their production. It should be noted that the quality of the surface texture of the foundry pattern is crucial because it affects the quality of the casting mold and eventually the finished casting. In most studies, the surface texture is examined by analyzing the 2D or 3D roughness parameters. This is a certain limitation because, in the case of 3D printing, the influence of technological parameters is more visible for irregularities of a longer range, such as surface waviness. In the paper, the influence of the 3D printing layer thickness on the formation of waviness of the surface of casting patterns was analyzed. Three 3D printers, differing in terms of printing technology and printing material, were tested: PJM (PolyJet Matrix), FDM (fused deposition modeling) and SLS (selective laser sintering). In addition, the surface waviness of patterns manufactured with traditional methods was analyzed. Surface waviness has been measured using the Form Talysurf PGI 1200 measuring system. Preliminary results of the research showed that the layer thickness significantly influences the values of waviness parameters of the surface in the casting patterns made with FDM, PJM and SLS additive technologies. The research results indicated that the smallest surface waviness as defined by parameters Wa, Wq and Wt was obtained for patterns printed using the PJM technology, while the highest was noted when using the FDM technology.

5

Tomografia komputerowa w przemyśle odlewniczym

Bańkowski Damian

Przegląd Odlewnictwa

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2022

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Vol. 72, nr 11-12

596--597

PL

Tomografia komputerowa to badania radiograficzne 3D materiałów, wyrobów i urządzeń z wykorzystaniem promieniowania X. To jedna z metod badań nieniszczących, umożliwiająca pełną weryfikację objętościową. Nowoczesne detektory promieniowania o dużych rozdzielczościach pozwalają na bardzo szczegółową analizę skanowanych przedmiotów.

EN

The computer tomography constitutes radiographic 3D tests of materials, products and devices with using the X-ray radiation. This is one of the non-destructive tests, allowing the total volumetric verification. Modern radiation detectors of high resolutions allow for a very detailed analysis of the scanned objects.

6

Sytuacja polskiego przemysłu odlewniczego w 2021 roku

Liszka Katarzyna, Dobosz Witold

Przegląd Odlewnictwa

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2022

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Vol. 72, nr 7-8

432--437

PL

W 2022 roku, po raz kolejny Stowarzyszenie Techniczne Odlewników Polskich i Odlewnicza Izba Gospodarcza prowadziły proces zbierania podstawowych danych statystycznych od polskich odlewni. Narzędziem pozyskania danych są proste i czytelne ankiety statystyczne dostępne online. Artykuł prezentuje dane dotyczące sytuacji polskiego przemysłu odlewniczego w roku 2021 oraz aktualna sytuację w odlewniach wynikającą z konfliktu zbrojnego na Ukrainie.

EN

In 2022, the Polish Foundrymen’s Association (STOP) and the Foundry Chamber of Economy (OIG) conducted the process of collecting basic statistical data from Polish foundries. The tool of obtaining data constitute simple and legible online statistical surveys. The article presents data on the situation of the Polish foundry industry in 2021 and the current situation in foundries resulting from the armed conflict in Ukraine.

7

Zastosowanie skaningowej kalorymetrii różnicowej (DSC) w odlewnictwie

Gracz Beata

Laboratorium - Przegląd Ogólnopolski

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2022

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nr specjalny

28--35

PL

Skaningowa kalorymetria różnicowa (DSC) umożliwia stosunkowo szybkie i łatwe badanie materiałów charakteryzujących się różnym stanem skupienia i konsystencją, co zapewnia szerokie spektrum zastosowań badawczych dla przemysłu odlewniczego.

8

The Effect of Reclaim Primary Quality on Moulding Sand Parameters and Quality of Ductile Iron Casting Surface Layer

Kamińska Jadwiga, Angrecki M., Puzio S., Stachowicz M.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 2

83--88

EN

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.

9

Impact of Values of Diffusion Coefficient on Results of Diffusion Modelling Driven by Chemical Potential Gradien

Wróbel Marek, Burbelko Andriy

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 3

81--90

EN

In the paper critical role of including the right material parameters, as input values for computer modelling, is stressed. The presented model of diffusion, based on chemical potential gradient, in order to perform calculations, requires a parameter called mobility, which can be calculated using the diffusion coefficient. When analysing the diffusion problem, it is a common practice to assume the diffusion coefficient to be a constant within the range of temperature and chemical composition considered. By doing so the calculations are considerably simplified at the cost of the accuracy of the results. In order to make a reasoned decision, whether this simplification is desirable for particular systems and conditions, its impact on the accuracy of calculations needs to be assessed. The paper presents such evaluation by comparing results of modelling with a constant value of diffusion coefficient to results where the dependency of Di on temperature, chemical composition or both are added. The results show how a given deviation of diffusivity is correlated with the change in the final results. Simulations were performed in a single dimension for the FCC phase in Fe-C, Fe-Si and Fe-Mn systems. Different initial compositions and temperature profiles were used.

10

Experimental Verification of the Cast Iron Solidification Model

Mendakiewicz Jerzy

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 3

91--94

EN

The article concerns the experimental verification of the numerical model simulating the solidification and cooling processes proceeding in the domain of cast iron casting. The approximate course of the function describing the evolution of latent heat and the value of substitute specific heat resulting from its course were obtained using the thermal and derivative analysis (TDA) method The TDA was also used to measure the cooling curves at the distinguished points of the casting. The results obtained in this way were compared with the calculated cooling curves at the same points. At the stage of numerical computations, the explicit scheme of the finite difference method was applied. The agreement between the measured and calculated cooling curves is fully satisfactory.

11

Comparison of the Classical Algorithm with the Training Algorithm in Scheduling Problem ADI Production

Wilk-Kołodziejczyk D., Chrzan K., Jaśkowiec K., Pirowski Z., Żuczek R., Bitka A., Machulec D.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 1

5--12

EN

A classical algorithm Tabu Search was compared with Q Learning (named learning) with regards to the scheduling problems in the Austempered Ductile Iron (ADI) manufacturing process. The first part comprised of a review of the literature concerning scheduling problems, machine learning and the ADI manufacturing process. Based on this, a simplified scheme of ADI production line was created, which a scheduling problem was described for. Moreover, a classic and training algorithm that is best suited to solve this scheduling problem was selected. In the second part, was made an implementation of chosen algorithms in Python programming language and the results were discussed. The most optimal algorithm to solve this problem was identified. In the end, all tests and their results for this project were presented.

12

Methodology for Diagnosing the Causes of Die-Casting Defects, Based on Advanced Big Data Modelling

Okuniewska A., Perzyk M. A., Kozłowski J.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 4

103--109

EN

The purpose of this paper was to develop a methodology for diagnosing the causes of die-casting defects based on advanced modelling, to correctly diagnose and identify process parameters that have a significant impact on product defect generation, optimize the process parameters and rise the products’ quality, thereby improving the manufacturing process efficiency. The industrial data used for modelling came from foundry being a leading manufacturer of the high-pressure die-casting production process of aluminum cylinder blocks for the world's leading automotive brands. The paper presents some aspects related to data analytics in the era of Industry 4.0. and Smart Factory concepts. The methodology includes computation tools for advanced data analysis and modelling, such as ANOVA (analysis of variance), ANN (artificial neural networks) both applied on the Statistica platform, then gradient and evolutionary optimization methods applied in MS Excel program’s Solver add-in. The main features of the presented methodology are explained and presented in tables and illustrated with appropriate graphs. All opportunities and risks of implementing data-driven modelling systems in high-pressure die-casting processes have been considered.

13

Aluminum Alloy Development for Wheel Production by Low Pressure Die Casting with New Generation Computational Materials Engineering Approaches

Yağcı T., Cöcen Ü., Çulha O.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 4

35--46

EN

Computational Materials Engineering (CME) is a high technological approach used to design and develop new materials including the physical, thermal and mechanical properties by combining materials models at multiple techniques. With the recent advances in technology, the importance of microstructural design in CME environments and the contribution that such an approach can make in the estimation of material properties in simulations are frequently discussed in scientific, academic, and industrial platforms. Determination of the raw material characteristics that can be modeled in a virtual environment at an atomic scale by means of simulation programs plays a big role in combining experimental and virtual worlds and creating digital twins of the production chain and the products. In this study, a new generation, alternative and effective approach that could be used to the development of Al-Si based wheel casting alloys is proposed. This approach is based on the procedure of optimizing the physical and thermodynamic alloy properties developed in a computer environment with the CME technique before the casting phase. This article demonstrates the applicability of this approach in alloy development studies to produce Al-Si alloy wheels using the low pressure die casting (LPDC) method. With this study, an alternative and economical way is presented to the alloy development studies by trial and error in the aluminum casting industry. In other respects, since the study is directly related to the automotive industry, the reduction in fuel consumption in vehicles is an expected effect, as the new alloy aims to reduce the weight of the wheels. In addition to conserving energy, reducing carbon emissions also highlights the environmental aspects of this study.

14

Zastosowanie procesu Fentona w oczyszczaniu ścieków z przemysłu odlewniczego

Dawczak Paulina, Dudziak Mariusz

Proceedings of ECOpole

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2020

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Vol. 14, No. 1

79--87

PL

Celem pracy była ocena skuteczności procesu Fentona w oczyszczaniu wybranych ścieków z przemysłu odlewniczego, które wstępnie poddano koagulacji. W procesie koagulacji wydzielono ze ścieków zanieczyszczenia występujące zarówno w fazie zawieszonej, jak i koloidalnej. Dobór korzystnego przebiegu procesu Fentona prowadzono pod względem następujących parametrów: pH ścieków, dawki nadtlenku wodoru, stosunku masowego Fe2+/H2O2 oraz czasu procesu. Dobrane parametry procesu Fentona wynosiły odpowiednio: pH ścieków 2,5, dawka nadtlenku wodoru 5,00 g/dm3, stosunek masowy Fe2+/H2O2 = 0,3 oraz czas procesu 120 min. Dla podanych parametrów wykazano wysoką skuteczność procesu Fentona w obniżeniu chemicznego zapotrzebowania tlenu (ChZT) badanych ścieków z przemysłu odlewniczego. W ściekach obniżyło się również stężenie niejonowych substancji powierzchniowo czynnych (NSPC).

EN

The aim of the study was to evaluate the effectiveness of the Fenton process in the treatment of selected wastewater from the foundry industry, which was initially coagulated. In the coagulation process, contaminants found in the suspended and colloidal phase were separated from the wastewater. The selection of the favorable course of the Fenton process was carried out with the following parameters in mind: wastewater pH, hydrogen peroxide dose, Fe2+/H2O2 mass ratio and process time. The selected parameters of the Fenton process were: wastewater pH = 2.5, hydrogen peroxide dose 5.00 g/dm3, Fe2+/H2O2 mass ratio = 0.3 and process time 120 min. For the given parameters, high efficiency of the Fenton process in lowering the chemical oxygen demand (COD) of the treated wastewater from the foundry industry was demonstrated. In wastewater, the concentration of non-ionic surfactants (NSPC) also decreased.

15

Production Scheduling for the Two Furnaces – One Casting Line System

Stawowy A., Duda J.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

43--48

EN

The paper presents a production scheduling problem in a foundry equipped with two furnaces and one casting line, where the line is a bottleneck and furnaces, of the same capacity, work in parallel. The amount of produced castings may not exceed the capacity of the line and the furnaces, and their loads determine metal type from which the products are manufactured on the casting line. The purpose of planning is to create the processing order of metal production to prevent delays in the delivery of the ordered products to the customers. The problem is a mix of a lot-sizing and scheduling problems on two machines (the furnaces) run in parallel. The article gives a mathematical model that defines the optimization problem, and its relaxed version based on the concept of a rolling-horizon planning. The proposed approaches, i.e. commercial solver and Iterated Local Search (ILS) heuristic, were tested on a sample data and different problem sizes. The tests have shown that rolling horizon approach gives the best results for most problems, however, developed ILS algorithm gives better results for the largest problem instances with tight furnace capacity.

16

Treatment of wastewater from the foundry industry using Fenton process

Dawczak Paulina, Dudziak Mariusz

Architecture Civil Engineering Environment

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2020

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Vol. 13, no. 1

115--120

EN

The aim of the study was to evaluate the effectiveness of the Fenton process in the treatment of selected wastewater from the foundry industry, which was initially coagulated. In the coagulation process, contaminants found in the suspended and colloidal phase were separated from the wastewater. The selection of the favorable course of the Fenton process was carried out with the following parameters in mind: wastewater pH, hydrogen peroxide dose, Fe2+/H2O2mass ratio and process time. The selected parameters of the Fenton process were: wastewater pH 2.5, hydrogen peroxide dose 5.00 g/L, Fe2+/H2O2 mass ratio 0.3 and process time 120 min. For the given parameters, high efficiency of the Fenton process in lowering the chemical oxygen demand (COD) of the treated wastewater from the foundry industry was demonstrated. In wastewater, the concentration of non-ionic surfactants (NS) also decreased.

17

Thermal Stresses in the Accessories of Heat Treatment Furnaces vs Cooling Kinetics

Bajwoluk A., Gutowski P.

Archives of Foundry Engineering

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2019

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iss. 3

88--93

EN

Depending on the course of the processes of heat treatment and thermo-chemical treatment, the technological equipment of heat treatment furnaces is exposed to different operating conditions, as the said processes differ among themselves in the temperature of annealing and atmosphere prevailing in the furnace chamber, in the duration of a single work cycle and in the type and temperature of the coolant. These differences affect the magnitude of stresses occurring in each cycle of the operation of furnace accessories, and thus play an important role in fatigue processes leading to the destruction of these accessories. The kinetics of temperature changes during each cooling process plays an important role in the formation of thermal stresses on the cross-section of the cooled parts. It depends on many factors, including the initial cooling temperature, the type and temperature of the cooling medium, or the dimensions and shape of the object. This article presents a numerical analysis of the effect of the initial temperature on the distribution of stresses on the cross-section of the grate ribs, generated in the first few seconds of the cooling process carried out in two cooling media, i.e. hardening oil and water. The analysis was carried out by the finite element method, based on the results of experimental testes of temperature changes in the rib during its cooling.

18

New Use of Instruments for More Accurate Wax Pattern Blade Segment Production

Herman A., Kubelková I., Vrátný O.

Archives of Foundry Engineering

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2019

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iss. 2

101--106

EN

Precision casting is currently motivated by high demand especially for castings for the aerospace, automotive and gas turbine industries. High demands on precision of this parts pressure foundries to search for the new tools which can help them to improve the production. One of these tools is the numerical simulation of injection process, whereas such software especially for investment casting wax injection, process does not exist yet and for this case must be the existing software, for alloys or plastic, modified. This paper focuses on the use of numerical simulations to predict the behavior of injected models of gas turbine blades segments. The properties of wax mixtures, which were imported into the Cadmould simulation software as a material model, were found. The results of the simulations were verified using the results of 3D scanning measurements of wax models. As a supporting technology for verifying the results was used the Infrared Thermography.

19

Introducing Advanced Data Analytics in Perspective of Industry 4.0 in a Die Casting Foundry

Perzyk M., Dybowski B., Kozłowski J.

Archives of Foundry Engineering

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2019

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iss. 1

53--57

EN

The paper presents some aspects of a development project related to Industry 4.0 that was executed at Nemak, a leading manufacturer of the aluminium castings for the automotive industry, in its high pressure die casting foundry in Poland. The developed data analytics system aims at predicting the casting quality basing on the production data. The objective is to use these data for optimizing process parameters to raise the products’ quality as well as to improve the productivity. Characterization of the production data including the recorded process parameters and the role of mechanical properties of the castings as the process outputs is presented. The system incorporates advanced data analytics and computation tools based on the analysis of variance (ANOVA) and applying an MS Excel platform. It enables the foundry engineers and operators finding the most efficient process variables to ensure high mechanical properties of the aluminium engine block castings. The main features of the system are explained and illustrated by appropriate graphs. Chances and threats connected with applications of the data-driven modelling in die casting are discussed.

20

Integrated Analytical and Measurement System for the Evaluation of the Properties of Cast Metals and Alloys

Biernat S., Bydałek A. W.

Archives of Foundry Engineering

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2019

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iss. 1

13--18

EN

The article presents an integrated analytical and measurement system for evaluation of the properties of cast metals and alloys. The presented platform is an extension of the SLAG - PROP application with new modules, which allow to use information on metallurgical processes in an even more effective way, as well as to evaluate the finished product. In addition, the construction of a measuring station for the analysis of thermal processes taking place in a metal bath allows for precise observation of phenomena together with their appropriate interpretation. The article presents not only the cooling curves of certain copper alloys. The analysis also covered mechanical properties related to hardness, finished products depending on the mold in which the products were cast. In the literature one can find information about the mechanical properties of products in the improved state, usually after plastic or thermal treatment, omitting their properties obtained as a result of a naturally made casting. The article also presents the method of placing information in the database using a convenient graphical tool.