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EN
This article is devoted to basalt reprocessing together with magnetite concentrate in order to obtain ferrous alloy and calcium carbide. The studies have been based on thermodynamic simulation and electric smelting in arc furnace. The thermodynamic simulation has been performed using HSC-5.1 software based on the principle of minimum Gibbs energy. The blend was smelted in arc furnaces. On the basis of the obtained results of combined processing of basalt, it has been established that under equilibrium conditions, the increase in carbon content from 36 to 42 wt % of basalt and concentrate mixture makes it possible to increase the aluminum extraction into the alloy up to 81.4%, calcium into calcium carbide – up to 51.4%, and silicon into the alloy – up to 78.5% [...]
2
Content available Copper in Ausferritic Compacted Graphite Iron
EN
This paper shows how it is possible to obtain an ausferrite in compacted graphite iron (CGI) without heat treatment of castings. Vermicular graphite in cast iron was obtained using Inmold technology. Molybdenum was used as alloying additive at a concentration from 1.6 to 1.7% and copper at a concentration from 1 to 3%. It was shown that ausferrite could be obtained in CGI through the addition of molybdenum and copper in castings with a wall thickness of 3, 6, 12 and 24 mm. Thereby the expensive heat treatment of castings was eliminated. The investigation focuses on the influence of copper on the crystallization temperature of the graphite eutectic mixture in cast iron with the compacted graphite. It has been shown that copper increases the eutectic crystallization temperature in CGI. It presents how this element influences ausferrite microhardness as well as the hardness of the tested iron alloy. It has been shown that above-mentioned properties increases with increasing the copper concentration.
EN
This work contains many investigations to estimate the corrosion behaviour of iron alloys such as (BC18, BC13, 25CrMo4) during exposure to inorganic acids ( HCl – HNO3 – H2SO4) and (NaOH). Chemical compositions of allays were analysed by spectrometer type (ARL), in weight percent. Many heat treatments were done to show their effects on corrosion resistance. Investigated specimens in disc form were immersed in aggressive mentioned solutions, for defined times. The lost in weight of specimens due to corrosion were removed manually and registered. The corrosion rates (g/m2. h) were calculated according the equation number (2) referred to in the text, during exposure time of (120) hrs and (240) hrs for some alloys. This enables the conclusion that alloys with Cr% more than 12% had more corrosion resistance than others. Also heat treatment improved corrosion resistance, and that solution of the acids was the most aggressive medium.
PL
W niniejszej pracy podano wiele badań dotyczących oceny korozyjnych zachowań stopów żelaza, takich jak: BC18, BC13 oraz 25CrMo4 gdy są poddawane działaniu kwasów nieorganicznych: HCl – HNO3 – H2SO4 oraz zasady NaOH. Skład chemiczny stopów był analizowany za pomocą spektrometru (typu ARL) i podawany w procentach wagowych. Przeprowadzono wiele rodzajów obróbki cieplnej żeby pokazać jej wpływ na odporność na korozję stopów żelaza. Badane próbki w kształcie krążków zanurzano w agresywnych roztworach (wspomnianych powyżej) i utrzymywano w nich przez określony czas. Ubytki na wadze spowodowane korozją były usuwane ręcznie z próbek I zapisywane. Szybkości korozji (g/m2. h) były obliczane przez czas wystawienia próbek na korozyjne działanie, według równania 2 podanego w tekście. Czas ten wynosił 120 godzin - dla wszystkich stopów oraz 240 godzin - dla niektórych stopów. Umożliwiło to stwierdzenie, że stopy zawierające więcej niż 12% Cr wykazują większą odporność na korozję niż inne stopy. Również obróbka cieplna poprawiała odporność na korozję. Roztwory kwasów stanowiły najbardziej agresywne środowisko.
EN
The paper summarizes research realized by the author in laboratory and industrial conditions (foundries of cast steel and cast iron, castings up to 50 tons) on the effects of the chemically hardened molding sands regeneration using hard/soft rubbing in the dry reclamation. A reference was simultaneously made to advisability of application of the thermal regeneration in conditions, where chromite amount in the circulating (reclaimed) molding sand goes as high as above ten percent. An advisability of connecting standard and specialized methods of examination of the reclaimed sands and molding sands made using it was pointed out. A way of application of studies with the Hot Distortion Plus® method modified by the author for validation of modeling of the thermo-dynamic phenomena in the mold was shown.
EN
Purpose: The goal of this work is to investigate structure and properties of Fe54Cr16Mo12C18 alloy rods with different diameters obtained by the pressure die casting method. Design/methodology/approach: Master alloy ingot with compositions of Fe54Cr16Mo12C18 was prepared by induction melting of pure Fe, Cr, Mo, C elements in argon atmosphere. The investigated material were cast in form of rods with different diameters. Glassy and crystalline structures were examined by X-ray diffraction. The microscopic observation of the fracture morphology was carried out by the SEM with different magnification. The thermal properties of the studied alloy were examined by DTA and DSC method. Findings: These materials exhibit high glass-forming ability, excellent mechanical properties and corrosion resistance. Research limitations/implications: It is difficult to obtain a metallic glass of Fe54Cr16Mo12C18 alloy. The investigations carried out on the different samples of Fe54Cr16Mo12C18 bulk metallic alloy allowed to state that the studied ribbon was amorphous whereas rods were amorphous – crystalline. Originality/value: The formation and investigation of the casted Fe-Cr-Mo-C bulk materials and the study of glass-forming ability of this alloy.
PL
Przedstawiono fragment badań strukturalnych, których celem było określenie struktury i zasięgu dyfuzji podstawowych składników w obszarze warstwy kompozytowej i strefy przejściowej. Badania prowadzone były przy użyciu mikroskopu świetlnego i elektronowego skaningowego z systemem EDS oraz dyfraktometru rentgenowskiego. Na podstawie uzyskanych wyników określono charakterystyczne struktury i ich składniki występujące w obszarze powierzchniowej warstwy kompozytowej, strefy przejściowej i osnowy. Strukturę warstwy kompozytowej można podzielić na osnowę, która stanowi ferryt stopowy oraz wydzielenia węglików, głównie M7C3. Wyróżniono węgliki iglaste oraz eutektykę węglikową. Ponadto można zaobserwować, że wraz ze wzrostem masywności odlewu rośnie zasięg dyfuzyjny niektórych pierwiastków. Ma to duże znaczenie dla powstałej strefy przejściowej, warunkującej dobre połączenie warstwy z materiałem bazowym odlewu.
EN
The paper presents a method of usable properties of surface layers improvement of cast carbon steel, by put directly in founding process a composite surface layer on the basis of Fe-Cr-C alloy. Technology of composite surface layer guarantees mainly increase in hardness and aberasive wear resistance of cast steel and cast iron castings on machine elements. This technology can be competition for generally applied welding technology (surfacing by welding and thermal spraying). In earlier studies authors showed, that exist possibility of control of thickness, hardness and aberasive wear resistance of type metal-mineral of composite surface layer by suitable selection of parameters i.e. thickness of composite insert, pouring temperature and solidification modulus of casting. Composite layers with large thickness are results from use of larger thickness of composite insert, higher pouring temperature and larger thickness of casting wall i.e. larger solidification modulus. Thicker layers have smaller hardness than thin layers. It result from larger diluting of alloying constituents after long time of diffusion. Moreover obtained thickness of composite layers are proper for assurance of suitable time of castings exploitation. The industrial application of composite surface layers technology among other things take in founding of cast steel slide bush for combined cutter loader, in which moves a arm of head to mining of hard coal, in founding of aberasive wear resistant skid and in founding of cast iron ingot moulds, which have high thermal shock resistance. Whereas in particular the paper presents a part of structure studies, which were made with use of light microscope Nikon EPIPHOT-TME, scanning electron microscope Inspect F with EDS system and X-ray diffractometer Panalytical RTG XPertPro. On the basis of results was affirmed that structure of composite surface layer contains matrix i.e. alloy ferrite and carbides mainly M7C3. Acicular carbides and carbide eutectic were distinguished. Moreover was observed, that increase of casting mass results in increase in range of selected elements diffusion for example carbon and chromium. This is very important for created transition zone, which strongly influences on quality of joint between layer and base casting.
PL
W artykule zamieszczono dane odnośnie wielkości emisji procesowej CO2, pochodzącej z przemysłu odlewniczego w Polsce (procesy wytapiania żeliwa i stali na odlewy). Ocena została dokonana przy zastosowaniu metodyki opracowanej przez Autorów, opartej na bilansie węgla pierwiastkowego w procesach produkcji odlewów. W przypadku wytapiania żeliwa uwzględniono emisję CO2 pochodzącą z rozkładu węglanu wapnia, a w przypadku procesów wytwarzania stali na odlewy - emisję pochodzącą z wypalania elektrod węglowych w elektrycznych piecach łukowych oraz emisję pochodzącą z wypalania węgla (operacja świeżenia) ze stali. Wartość emisji procesowej CO2 z produkcji odlewów ze stopów żelaza w Polsce w roku 2006 wyniosła 12 700 t. Obliczony na tej podstawie wskaźnik emisji procesowej wyniósł 11,6 kg CO2/t ciekłego stopu żelaza. Emisja ta stanowi znikomy udział, wynoszący tylko 0,28% emisji tego gazu z całej podkategorii 2C "Produkcja metali".
EN
In the article data have been placed concerning quantities of the CO2 process emission originating from the activity of the foundry industry (melting processes of cast iron and steel for castings) in Poland. The evaluation has been carried out by using the method developed by authors and based on the balance of the elemetary carbon in the processes of casting production. In the case of melting cast iron the CO2-emission originating from decomposition of calcium carbonate and in the case of steel melting - the emission originating from burning electrodes in arc furnaces and from decarburation process (steel refining process) of liquid metal were taken into consideration. The total value of the CO2 process emission from the production of iron and steel castings in the year 2006 amounted to 12 700 t. The process emission index calculated on this base amounted to 11,6 kg CO2 /t of liquid iron alloy. This emision makes only a slight yield (0,28%) of total emission determined for the CO2 in the subcategory 2C "Metal production".
8
Content available remote Emisja pyłów i gazów w procesie topienia stopów żelaza w odlewniach
PL
W artykule dokonano oceny emisji szkodliwych zanieczyszczeń z agregatów metalurgicznych stosowanych do wytapiania stopów żelaza w odlewniach. Szczegółowej ocenie poddano takie parametry, jak emisja pyłów i gazów w czasie procesu. Na podstawie przedstawionych danych sformułowano ogólne wytyczne doboru takich agregatów metalurgicznych do topienia stopów żelaza w odlewniach, których zastosowanie pozwoli na ograniczenie emisji pyłów i gazów.
EN
This article presents data and information concerning current emission level of dust and waste gases in foundries during melting ferrous alloys. The detail information about dust emission rate, particles range and theirs chemical composition are discussed as well. Typical flowrates of waste gases and theirs chemical composition are presented too. On the base of these date the best kind of melting furnaces for steel and cast iron melting are selected. Melting iron alloys in these furnaces permit decrease dust and waste gases emission in foundries.
9
Content available remote Problems of phase identification in high-nitrogen chromium-manganese cast steel
EN
An attempt has been made to offer an interpretation of the microstructure of chromium-manganese cast Steel after adding to this steel a large amount of nitrogen as an alloying element. Nitrogen was added to the cast steel by two methods: the first method consisted in adding anitrided ferromanganese, the second method in remelting the nitrogen-free alloy under the atmosphere of nitrogen maintaining high N2 pressure above the metal melt (3,5 MPa). Some important differences in the microstructure of the examined cast Steel have been observed, depending on how the nitrogen was introduced to the alloy. When melting was carried out under the atmospheric pressure adding the nitrided ferroalloys, the matrix was composed of nitrided austenite, and numerous nitrides (carbonitrides) were forming a well-developed network along the grain boundaries. Melting of alloy under the high pressure of nitrogen enables obtaining much higher concentration of this element in metal. The network of precipitates along the grain boundaries is observed to exist no longer, and the lamellar structure occupies now practically the entire metal volume. When alloys are melted in the air, only small fragments of the lamellar structure, forming the, so called, “Chinese script” and local clusters are present. At this stage of the research, an attempt has been made to identify the phases in chromium-manganese cast Steel using a transmission electron microscope. The conducted studies partly confirmed the conclusions resulting from the examinations carried out previously under the optical microscope. So far, however, no consistent answer has been found to the question of what type are the precipitates present in the structure of the examined alloy. Attempts at further interpretation of the obtained results will be taken at the next stage of the work with attention focussed on the precipitates formed during the process of solidification of the examined chromium-manganese cast steel with an addition of nitrogen.
PL
W pracy przedstawiono wyniki badań warstwy alfinowanej na stopach żelaza. Podano jej budowę oraz mikrostrukturę. Omówiono wybrane czynniki technologiczne wpływające na grubość warstwy. Wykazano, że decyduje o niej: rodzaj stopu żelaza, chropowatość jego powierzchni, czas wytrzymania w kąpieli siluminowej, temperatura kąpieli oraz stężenie w niej krzemu. Wyniki badań zweryfikowano w warunkach produkcyjnych wytwarzania odlewu warstwowego.
EN
In this paper the results of alphinizing coat on iron alloys have been presented. The structure and microstructure of the coat have been presented. Selected technological elements which have the influence on the coat thickness have been discussed. It was demonstrated, that kind of iron alloy, the roughness of its surface, time of silumin bath, bath temperature and Si concentration decided on it. The results were verified in production conditions of layered cast.
11
PL
Przedstawiono problematykę związaną z zastosowaniem modeli polistyrenowych cieplnie zgazowywanych, formowanych w medium o różnej szybkości odprowadzenia ciepła krzepnącego i stygnącego staliwnego odlewu. Porównywano własności mechaniczne odlewu wykonywanego w masie składającej się z 100% piasku kwarcowego oraz mieszaninie piasku kwarcowego oraz śrutu żeliwnego. Formę wykonano z mieszaniny dwóch mediów o różnym wzajemnym procentowym stosunku wagowym. Tak wykonana masa formy charakteryzuje się różną prędkością przewodzenia ciepła oraz pojemnością cieplną. Starano się określić wpływ szybkości odprowadzenia ciepła z krzepnącego i stygnącego odlewu na jego własności mechaniczne oraz strukturę.
EN
Problems related with the application of evaporative polystyrene patterns placed in moulding media characterised by diffrent rate of heat transfer from the solidifying and cooling steel casting were discussed. Mechanical properties of casting made in mixture composed in 100% of the silica sand and in mixture composed of silica sand and cast iron shot were compared. The mould was made of two different media mixed in different percent ratios. Thus prepared moulding mixture was characterised by different heat conduction rate and thermal capacity. An attempt was made to determine the effect of heat transfer rate from the solidifying and cooling casting on its mechanical properties and structure.
12
Content available remote Odlewanie tiksotropowe żeliwa
PL
W oparciu o literaturę przedstawiono w dużym skrócie zagadnienie krystalizacji stopów metali podeutektycznych w warunkach sprzyjających fragmentaryzacji i sferoidyzacji fazy pierwotnej, a zatem w warunkach sprzyjających powstawaniu struktury tiksotropowej. Wykonano także przegląd literatury na temat technik semi-solid w zastosowaniu do stopów metali, w tym również przedstawiono dane dotyczące możliwości uzyskiwania struktury tiksotropowej w żeliwie.
EN
Basing on data given in literature, the problems related with solidification of hypoeutectic metal alloys under the conditions promoting fragmentation and spheroidisation of the primary phase, and hence under the conditions favouring the formation of thixotropic structure, were outlined. A review of technical literature on the semi-solid techniques applied to metal alloys was presented, including information on the possibilities of obtaining thixotropic structure in cast iron.
PL
W strukturze niektórych badanych stopów na bazie żelaza stwierdzono zmniejszenie się ilości austenitu pod wpływem zewnętrznych naprężeń rozciągających. Naprężenia te nie wpłynęły istotnie na umocnienie tych stopów, natomiast naprężenia ściskające znacznie te stopy umocniło. Zaobserwowano wzrost twardości nawet o około 40% w przypadku staliwa duplex z dodatkiem 0,4% azotu i żeliwa ADI.
EN
The structure of some investigated ferrous alloys shows the reduction in austenite content as a result of the applied external tensile stresses. The external stresses not significantly affecting on the strain hardening, whereas the compressive stresses hardened these alloys considerably. The increase in hardness even by about 40% was observed in duplex cast steel with the additions of 0.4% of nitrogen and in the case of ADI.
EN
The monograph concerns the chosen aspects of the construction of the gating systems designed for ferrous metals in sand moulds. On the ground of the results of fluidity investigations: rod test and spiral test, there has been presented the method of determination the rheological parameters of liquid metals alloys. On the ground of the fluidity rod test it has been defined the curves of fluxion of metals alloys about different overheating degrees. The simulating investigations of pouring process of the perpendicular channels in the rod test has confirmed the thesis about the growth of boundary layer about the same parameters in channels about different diameters. It has been proved, that the parameters of metal boundary layer (supplementary rheological parameter and shape factor of boundary layer), appointed in definite conditions, can be applied to calculation of the thickness of metal boundary layer in the channels of gating system. There are two boundary layers: rheological and solidified. The thickness of the rheological boundary layer in channel of gating systems depends on: the value of supplementary rheological parameter appointed on the ground of the fluidity tests, the metallostatic pressure and length of the channel. The thickness of solidified boundary layer depends on the time and the thermophysical properties of the sand mould material. It has been affirmed, that in the first several seconds of pouring the sand moulds with the liquid ferrous metals, there is a violent fall of the flow ratio value in the channels of the gating systems. In this work there has been an attempt to prove that this phenomenon had been caused by the violent growth of the gas pressure and the large over-cooling of the metal boundary layer in the channels of gating system. On the basis of the hydraulic model of the heat flow, the method of determination heat dissipation coefficient in the sand moulds channels has been proposed. This coefficient allows to determinate the required overheating value for any element of gating system about definite dimensions. The simulation-experimental investigations of the ferrous metals flow through the furcated gating system permitted on ascertainment of occurrence the phenomenon of reflection the planes of metal stream in horizontal distributor channel and on explanation its influence on the process of filling niches of sand mould. On the ground of the analyses of the investigations results there have been presented the new proposals of calculation methods of metal flow efficiency coefficient through elements of gating systems.
PL
W pracy przedstawiono charakterystyczne dla stopów żelaza postacie przełomów uzyskiwane w próbach udarności. Badaniom poddano wybrane stale nisko- i wysokostopowe, staliwo konstrukcyjne oraz 3 odmiany żeliwa. Analizowano wpływ czynników strukturalnych na występowanie mikroszczelin w strukturze oraz rozwój pękania i morfologię przełomu. Zwrócono szczególną uwagę na morfologiczne cechy przełomów wskazujące na wzrost energochłonności mechanizmu pękania, a tym samym zwiększenie udarności. Stwierdzono, że w stopach ferrytycznych transkrystaliczne łupliwe przełomy mają zróżnicowaną postać w zależności od wielkości i substruktury ziarna ferrytu oraz temperatury wykonywania przełomu. W stalach austenitycznych generowanie pęknięć następuje głównie na granicach międzyfazowych osnowy oraz wtrąceń niemetalicznych i wydzieleń faz węglikowych. W staliwach o strukturze ferrytyczno-perlitycznej wyżarzanie normalizujące zapewnia korzystny dla właściwości przełom transkrystaliczny ciągliwy. Ferryt i perlit w żeliwach wykazują znaczną podatność do pękania transkrystalicznego łupliwego. Na granicy osnowy i wydzieleń grafitu następuje generowanie pęknięć. Zdefektowany o rozwiniętej substrukturze ferryt w żeliwie ciągliwym pęka w próbach udarności mechanizmem quasi-łupliwym.
EN
The paper presents characteristic forms of iron alloy's fractures obtained during impact tests. Chosen Iow- and high-alloy steels, constructional cast steel and three types of cast irons have been investigated. Influence of the structural factors on cracking development and fracture morphology was analysed. Special attention was devoted to the fractures' morphological features indicating increase of the cracking mechanism's energy consumption, hence of the impact strength. It was found that in the ferritic alloys the transcrystalline cleavage fractures are of various forms depending on size and substructure of the ferrite grains as well as of temperature of the tests (Fig. 1-6). In austenitic steels cracks formation occur mainly on phase boundaries of matrix, nonmetallic inclusions and carbide precipitations (Fig. 7, 8). In the cast steels of ferritic-pearlitic structure, normalizing treatment yields, advantageous as far as the properties are considered, transcrystalline ductile fracture (Fig. 9-12). Ferrite and pearlite in the cast irons reveal marked susceptibility to transcrystalline cleavage cracking (Fig. 17, 18). Formation of cracks takes place on matrix-graphite precipitation boundaries (Fig. 19). The ductile cast irons ferrite of developed substructure and high damage degree cracks during the impact tests through quasi-cleavage mechanism (Fig. 20).
16
Content available remote Resistances of machine cutting in drilling of cast iron dedicated for valve guide
EN
Foundations and conditionses of investigations of two sorts of cast iron for diesel engines valve dedicated: till now used W1p and new - alloy, are presented. Example courses of resistances of machine cutting are showed. Results of investigations of machine cutting resistances for three different conditions of cooling are presented.
17
Content available remote Charging of the cast iron lapping tools
EN
The manual charging can be applied to a single - disk lapper, for which the tool is rotated. The changing time is relatively long. The efficiency and the quality of the charging is not very high, due to the difficulties of the uniformly distribution of the abradent micrograins. An additional problem is that the compression of the charging elements is not constant, which causes differences in the micrograin penetration of the lapping tool face. From some time, research has been done about machine surface charging. lntroducing a mechanical drive should eliminate the fundamental faults of the manual charging.
EN
The paper presents a review of selected experiments which have been carried out using partially devitrified Fe- and Co-based metallic glasses as the research objects. It is shown that by a suitable choice of the composition of the metallic glass and also by the conditions of annealing, a variety of magnetic phases can be created in these systems. It is also shown that by controlled processes of annealing, the coercivity of metallic glass can be altered by several orders of magnitude, giving a possibility to produce materials with the extremely soft magnetic properties, up to the magnetically semi-hard ones. The magnetostriction of nanocrystalline materials of the FINEMET-type is discussed as well, showing that the size-dependent phenomena and the symmetry restriction at the particle boundaries create the surface contribution to the effective magnetostriction. Finally, the magnetic interactions between particles in partially devitrified samples are considered and the observed effects of temperature and hydrostatic pressure discussed.
PL
Wyroby z żeliw wykazują w środowiskach agresywnych niedostateczną odporność korozyjną. Skuteczną metodą zabezpieczania przed korozją powierzchni żeliw jest metalizacja zanurzeniowa. Proces cynkowania stopów żelaza z węglem w postaci grafitu jest trudny. W artykule przedstawiono wyniki badań nad otrzymywaniem powłok cynkowych na wybranych gatunkach żeliw. Określono kinetykę wzrostu powłok na badanych materiałach w zależności od temperatury i czasu zanurzania. Przedstawiono strukturę powłok na tych materiałach. Otrzymane powłoki są ciągłe i równomierne a ich morfologia i grubość są porównywalne z powłokami cynkowymi otrzymanymi na stali.
EN
Cast iron products show insufficient corrosion resistance in the aggressive media. An effective method of corrosion protection of the cast iron surface is hot-dip metallization process. Galvanizing process of the iron alloys with carbon in the form of graphite is difficult. Results of investigations on forming zinc coatings on selected cast iron grades are presented in the article. Kinetics of coating growth on the materials tested was determined depending on the temperature and dip time. The coating structure on those materials is presented. The coatings formed are continuous and uniform and their morphology and thickness are comparable with galvanized coatings formed on steel.
PL
Jednoczesna modyfikacja żeliwa szarego niewielkimi dodatkami żelazostpów z bizmutem i metalami ziem rzadkich powoduje zmianę warunków krystalizacji grafitu. W rezultacie wydziela się grafit wermikularny i kulkowy. Następuje również ferrytyzacja osnowy. Wytrzymałość na rozciąganie przekracza 400 MPa, umowna granica plastyczności 320 MPa, a wydłużenie względne 10%. Twardość Brinella nie przekracza 170 jednostek. Te istotne zmiany wymagają obecności w żeliwie zaledwie do 0,03% Ce oraz poniżej 0,005% Bi.
EN
Simultaneous inoculation of grey cast iron with small additions of ferroalloys containing bismyth and rare-earth elements causes a change in the conditions of graphite crystallization. As a result vermicular and nodular graphite precipitate. The amount of graphite precipitations with the shape factor equal or higher 0,03 comes up to 100%. Ferritization of matrix also occurs. Tensile strength exeeds 400 MPa, yield strength 320 MPa and the unit elongation 10%. These essential changes require the presence in cast iron only up to 0,03% Ce and below 0,005% Bi.
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