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1

Influence of initial casting temperature on the properties and microstructure of ultra-light cement-based foam composites for energy-saving buildings

Zhang Yangkai, Sang Guochen, Zhao Caiyun, Guo Teng, Cui Xiaoling, Guo Zhiqiang, Zou Saisai

Archives of Civil and Mechanical Engineering

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2023

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Vol. 23, no. 3

art. no. e190, 2023

EN

The application of ultra-light cement-based foam composites (ULCF) in buildings has been verified as an effective way to achieve energy conservation in the building sector. However, the production process of ULCF is difficult to complete at the ideal constant temperature during practical industrial production due to cost control and other factors. The sun exposure and residual heat from the machines will cause the initial casting temperature of ULCF to be raised in the preparation process, which will inevitably have an impact on the macroscopic properties of ULCF. In this study, a series of tests were conducted to explore the effect of initial casting temperature (30–55 °C) on the macroscopic properties and microstructure of ULCF for the first time. The results indicated that the 28-day compressive strength of ULCF exhibited a tendency to first increase and then decrease with the increase of initial casting temperature, which was attributed to the variation of its internal pore structure. The thermal conductivity test shows that the thermal conductivity of ULCF existed a minimum value of 0.0651 Wm−1 K−1 when the initial casting temperature reached 40 °C. Meanwhile, SEM and XRD were employed to examine the microstructure and hydration products of ULCF with different initial casting temperatures. Furthermore, the internal pore structure parameters of ULCF were quantitatively analyzed through Image-Pro Plus software, and the results demonstrated that there is a critical value for the initial casting temperature of ULCF, which allows the internal pore structure of ULCF to have characteristics of small size and approximate spherical shape.

2

Impact of pouring temperature on the mechanical properties of Al5.9Cu1.9Mg alloy

Akhyar Akhyar, Iswanto P.T., Malau V.

Archives of Materials Science and Engineering

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2022

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Vol. 113, nr 2

49--55

EN

Purpose: This experiment aims to determine the influence of pouring temperature on the hardness, impact energy, tensile strength, and changes in the microstructure of the Al-5.9Cu- 1.9Mg alloy. Design/methodology/approach: A total of three samples of aluminium alloy were heated to 688, 738, and 788°C, and poured into permanent moulds in form of plates at a constant temperature of 220°C. The cast products are machined according to testing standards for hardness, impact tests, and tensile strength. Findings: The results showed that the metal hardness and impact energy increased to 103 BHN and 7.48 J at 788°C, respectively, while the tensile strength rises as the temperatures decreases. Furthermore, the changes in the microstructure were affected, which indicated that all the properties of the aluminium alloy were influenced by the variations in temperature. Research limitations/implications: During the metal casting process, only three different pouring temperatures affected the properties of the metal alloy, therefore, there is a need for more variations. Practical implications: The proposed pouring temperature parameter is an important condition for industrial foundry applications to obtain the right product for use in a machining element. Originality/value: This research shows the influence of the difference in pouring temperatures on the properties of metal alloys due to casting, where they will be adapted for a particular use.

3

Consecutive Casting of Iron Bimetal with Low-Carbon Steel Interface Plate

Purwadi W., Bandanadjaja B., Idamayanti D., Lilansa N.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

95--104

EN

Consecutive casting of bimetallic applies consecutive sequences of pouring of two materials into a sand mold. The outer ring is made of NiHard1, whereas the inner ring is made of nodular cast iron. To enable a consecutive sequence of pouring, an interface plate made of low carbon steel was inserted into the mold and separated the two cavities. After pouring the inner material at the predetermined temperature and the interface had reached the desired temperature, the NiHard1 liquid was then poured immediately into the mold. This study determines the pouring temperature of nodular cast iron and the temperature of the interface plate at which the pouring of white cast iron into the mold should be done. Flushing the interface plate for 2 seconds by flowing nodular cast iron liquid as inner material generated a diffusion bonding between the inner ring and interface plate at pouring temperatures of 1350°C, 1380°C, and 1410°C. The interface was heated up to a maximum temperature of 1242°C, 1260°C, and 1280°C respectively. The subsequent pouring of white cast iron into the mold to form the outer ring at the interface temperature of 1000°C did not produce a sufficient diffusion bonding. Pouring the outer ring at the temperature of 1430°C and at the interface plate temperature of 1125°C produced a sufficient diffusion bonding. The presence of Fe3O2 oxide on the outer surface of the interface material immediately after the interface was heated above 900⁰C has been identified. Good metallurgical bonding was achieved by pouring the inner ring at the temperature of 1380°C, interface temperature of 1125°C and then followed by pouring of the outer ring at 1430⁰C and flushing time of 7 seconds.

4

The Influence of the Pouring Temperature on the Structure and Mechanical Properties of High-Chromium Cast Iron

Kopyciński D., Siekaniec D.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 4 spec.

63--66

EN

The article presents the results of the influence of pouring temperature on the structure and selected properties of high-chromium cast iron. The study was performed on two different pouring temperatures 1490°C and 1460°C for cast iron of the same chemical composition. Melts were performed in the induction furnace crucible capacity of 15 kg located in the Department of Engineering Alloys and Composites in Foundry Engineering Faculty of AGH. For each temperature cast 2 sets of rollers with dimensions ø30mm, ø20mm, ø15mm x 250mm. During the heats poured cup with installed S type thermocouple to record the cooling curves. Rollers put to the static bending strength test. Samples were cut from the rollers for the test microstructure. The study shown that the pouring temperature has a significant impact on the way of crystallization of high-chromium cast iron and consequently, on the microstructure and mechanical properties. It follows that, by appropriate selection of the pouring temperature can control certain properties of the casting.

PL

W pracy przedstawiono wyniki badań wpływu temperatury odlewania na strukturę i wybrane właściwości wytrzymałościowe żeliwa wysokochromowego. W ramach badań wykonano dwa wytopy z różną wartością temperatury odlewania 1490 °C i 1460 °C, dla żeliwa o tym samym składzie chemicznym. Wytopy wykonano w piecu indukcyjnym o pojemności tygla 15 kg znajdującym się w Katedrze Inżynierii Stopów i Kompozytów Odlewanych na Wydziale Odlewnictwa AGH. Dla każdej temperatury odlano 2 zestawy wałków o wymiarach ø30 mm, ø20 mm, ø15 mm x 250 mm. Podczas wytopów zalano kubki pomiarowe z termoelementem typu S do rejestracji krzywej krystalizacji i stygnięcia. Wałki poddano statycznej próbie wytrzymałości na zginanie. Następnie z wałków wycięto próbki do badania mikrostruktury. Z przeprowadzonych badań wynika, że temperatura odlewania ma istotny wpływ na sposób krystalizacji odlewu z żeliwa wysokochromowego, a w konsekwencji na mikrostrukturę i właściwości wytrzymałościowe. Wynika z tego, że przez odpowiedni dobór temperatury odlewania można sterować niektórymi właściwościami mechanicznymi odlewu.

5

Evaluation of Casting Shrinkage and Liquid Metal Fluidity of IN-713C Alloy

Binczyk F., Cieśla M., Gradoń P., Findziński A.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1

9--12

EN

This paper presents the results of measurements of liquid metal fluidity and linear shrinkage of nickel alloy IN-713C in vacuum induction melting furnace Balzers VSG-2. Because of limited volume of the furnace chamber special models for technological trials were fluidity of hypoeutectic silumin, however in case of nickel superalloy the mould cavity was completely filled in each test because of high required pouring temperature. Positive results were obtained from the modified spiral test for all alloys used in the research. Relationship between the linear shrinkage for the test rod and a specific indicator of contraction defined on a spiral was observed.

6

Influence of the casting temperature on dental Co-base alloys properties

Reimann Ł., Dobrzański L.A.

Archives of Materials Science and Engineering

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2013

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Vol. 60, nr 1

5--12

EN

Purpose: The goal of the study is to find the relationship between the value of casting temperature on corrosion resistance, hardness and mechanical properties of two Co-Cr-Mo alloys Remanium 2000+ and Wirobond LFC used in dentistry. Design/methodology/approach: Realized investigations starts from preparing the mould and cast two CoCrMo alloys in 1430, 1440, 1450 and 1460°C. Electrochemical corrosion research were made in water centre which simulated artificial saliva environment, by recording of anodic polarization curves with use the potentiodynamic methods. The compression strength, yield strength and unit shortening was evaluated during the static compression tests on multi-role testing machine MTS. Hardness test were obtained by use the microhardness FM ARS 9000 FUTURE TECH Vickers methods with load 1 kg. Findings: The manufacturing conditions for the Co-Cr-Mo alloys are one of the possible method which effects in increase or decrease of the safety factor in construction. Realized research of the increasing casting temperature about 10-20°C in regard to conditions offered by producer was found that hardness and corrosion resistance change only in small value, while corrosion current of samples casted from 1460°C increase by one order of magnitude to casting from 1430°C. Increase or decrease casting temperature results in decrease the mechanical properties yield strength and compression strength for both alloys. Practical implications: Scientific research of the cobalt alloys used on the dentures confirmed that casting temperature as one of the condition during the manufacturing influence on the most important useful properties like corrosion resistance, strength of the prosthetic constructions and machinability of the CoCrMo alloys. Originality/value: The paper presents an effect of correct selection the casting temperature, on the most important properties of CoCrMo alloys use in dental engineering.

7

Effect of technological parameters on structure of castings made from IN-713C nickel alloy

Binczyk F., Śleziona J., Szymszal J., Gradoń P.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 4

9-12

EN

The work includes studies to determine the significance of the effect of selected technological parameters of moulding and casting conditions on the macrostructure of IN-713C cast nickel alloy. Two-level, fractional 24-1 experiment was carried out, requiring eight experiments. The evaluation covered the number of grains per 1mm2 of the sample surface, the average grain surface area, and the shape index. Macrostructure of test castings indicates a positive effect of combined surface and bulk inoculation treatment, with the effect of surface inoculation prevailing as regards its importance. Statistically significant effect on the number and surface of grains have in descending order: surface modification, bulk modification and temperature of alloy pouring.

8

Akwizycja i wstępne opracowanie danych niejednorodnych na potrzeby systemów data mining na przykładzie przemysłu odlewniczego

Sika R., Ignaszak Z.

Archiwum Technologii Maszyn i Automatyzacji

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2009

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Vol. 29, nr 1

57-71

PL

W artykule przedstawiono założenia, jakie powinny obowiązywać w systemie zapewnienia jakości na etapie akwizycji danych w przemyśle odlewniczym. Zwrócono uwagę na aspekt akwizycji danych pochodzących z różnych systemów pomiarowych - automatycznych, półautomatycznych oraz manualnych - istotny w wykorzystaniu danych pochodzących z systemów informatycznych. Uwzględniono pochodzenie i rodzaj danych gromadzonych przez wielu użytkowników. Położono nacisk na stabilność procedur pomiarowych oraz systemów gromadzenia i przetwarzania danych. Wskazano na dużą rolę właściwego rejestrowania niejednorodnych danych pochodzących ze zróżnicowanych źródeł informacji o procesach technologicznych odlewania. Zaprezentowane przykłady akwizycji i wstępnej obróbki danych oparto na badaniach autorów pochodzących z praktyki odlewniczej.

EN

In the paper the main assumptions of Assurance Quality system for data acquisition in foundry manufacturing were presented. The authors concentrated to aspect of data acquisition from various measurement systems - automatic, semi-automatic and manual which are significant to use data from information systems. It was taken into account the source and type of data collected through many users. Authors emphasized the stability of measurement procedures and systems for collected and process data. Authors shown large significance non-homogenous data registration process from diverse measurement points which are potential source of new technological knowledge. In the paper some examples for acquisition and preliminary data processing were presented which based on author's casting practice experiences.

9

Selection of the temperature of casting the bronzes to plaster moulds

Pisarek B., Pawlak M.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 4

203-208

EN

The results of the investigations of the process of solidification of the bronze CuSn5Zn5Pb5-C (B555) and CuSn10-C (B10) in the hot plaster mould show in the work. For four temperatures of casting: 1200 o C, 1180 o C, 1160 o C and 1140 o C was conducted the investi-gation: the size of contraction cavity, the fulfillment of the mould cavity formative the casts of test slats about the thickness: 4 mm, 0,8 mm and 0,5 mm. It was conducted the investigation the processes sets in the arrangement the cast-mould and X-ray analysis phase XRD of compound coming into being in indirect layer created among mould and cast in the result of the thermal decomposition of the anhydrite. It results that the temperature 1140 o C is the optimum temperature of casting the bronze to hot plaster mould from carried out investigations. The minimum thickness of the wall of the cast from the bronze B555 is 0.5 mm, and from the bronze B10 0.8 mm. The realization of casts about thinner walls is made difficult because of giving off formed gases in the result of the thermal decomposition of the anhydrite. The products of the decomposition of the anhydrite react with elements steps in the chemical composition of studied bronzes, create in the arrangement the cast-mould the indirect layer folded from: sulphites, sulphides, oxides and clean metals (Pb) or their compounds, especially Sn and Sb.

10

Macrostructure of IN-713C superalloy after volume modification

Binczyk F., Śleziona J.

Archives of Foundry Engineering

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2009

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Vol. 9, iss. 2

105-108

EN

The study discusses the results of the preliminary investigations of the process of volume modification of nickel and cobalt superalloys. The investigations were carried out on an IN-713C alloy. As an inoculant, cobalt aluminate CoAl2O4 in composition with aluminium powder and zircon flour was used. Experiments included the use of inoculant-coated filters and inoculant placed on and between the filters. As a criterion for evaluation of the modification effect, the macrostructure produced in a stepped test casting was used. It has been concluded that the modification effect depends, first of all, on the pouring temperature and on the time of contact between the liquid alloy and inoculant. Compared with the non-modified alloy, which has columnar grains in its structure, the refining treatment gave very fine and equiaxial grains. The higher was the cooling rate (or the smaller was the thickness of the step), the finer were the equiaxial grains.

11

System do eksploracji wybranych danych produkcyjnych oraz jego testowania w odlewni

Ignaszak Z., Sika R.

Archiwum Technologii Maszyn i Automatyzacji

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2008

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Vol. 28, nr 1

61-72

PL

W artykule przedstawiono założenia, procedury i opis działania autorskiego systemu KonMas--final służącego do eksploracji wybranych danych o procesie odlewania. Dane te są wprowadzane częściowo z układu automatycznego pomiaru temperatury, a częściowo przez obsługę laboratorium zamiast zapisów w postaci raportów - rękopisów. Omówiono sposób akwizycji danych i ich wykorzystanie do weryfikacji warunków produkcji. Wskazano, jak ważny jest ten sposób udostępniania wiarygodnych informacji, do tej poiy niedostępnych w superkrótkim czasie, podczas analizy przyczyn powstawania wad odlewów i sterowania jakością. System KonMas-final może być łatwo sprzężony z systemem SAP R/3 i służyć do sterowania jakością w szerszym wymiarze.

EN

In the article, the assumptions, procedures and a description of KonMas-fmal are presented as the author's system to explore chosen data about foundry processes. These data are bring partly from the automated measurement temperatures system, and partly by the personnel of laboratory, instead of results recorded in report-manuscripts. A way of data acquisition and using them for the verification of production conditions are discussed. They pointed how this way of making the credible and available informations is important, so far unavailable in the super short time during analysis of causes of casting defects and control of their quality. System Kompas-final perhaps easily to be linked to the superior SAP R/3 system and to serve for quality controlling in the foundry in the wider dimension.

12

Wpływ temperatury odlewania na intensywność przepływu stopów Al-Si w kanale próby spiralnej

Binczyk F., Piątkowski J., Smoliński A.

Krzepnięcie Metali i Stopów

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1999

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R. 1, nr 40

269--273

PL

Lejność jest jedną z podstawowych własności technologicznych istotnie wpływających na uzyskanie odlewów bez wad. Dla siluminów duże znaczenie ma temperatura przegrzania ciekłego metalu. Badania wstępne wskazują iż istnieje związek pomiędzy temperaturą odlewania a przebiegiem procesu przepływu stopu w kanale próby spiralnej. W pracy przedstawiono wyniki badań nad wpływem temperatury odlewania siluminów: AK11 i AK 20 na szybkość przepływu czołówki strugi metalu w kanale próby spiralnej. W określonych odcinkach spirali dokonano pomiaru temperatury metodą jednoczesnej analizy termicznej krzywych ATD i DTA, z których obliczono czasy przepływu czoła strugi stopu oraz charakterystyczne temperatury krzepnięcia i przechłodzenia.