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1
Content available Wpływ rodzaju, grubości pokrycia ceramicznego oraz gęstości zespołu modelowego na stopień zagazowania odlewu
Buczkowska K., Just P., Świniarska J., Pacyniak T.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 2 spec.
7--12
PL
W pracy poruszone zostały zagadnienia związane z technologią lost foam. Zbadano wpływ rodzaju oraz grubości pokrycia ceramicznego a także gęstości zespołu modelowego na stopień zagazowania odlewu. Badania przeprowadzono dla dwóch rodzajów pokryć ceramicznych Disopast 4805/3 oraz Disopast 7759, które nakładano na modele ze spienionego polistyrenu w jednej, dwóch i trzech warstwach. Tak przygotowane modele wykorzystano do wytworzenia odlewów ze stopu AlSi11 w technologii lost foam. Otrzymane odlewy zbadano pod kątem stopnia ich zagazowania. Zaprezentowane badania wykazały zależności pomiędzy gęstością modelu, rodzajem i grubością zastosowanych powłok ceramicznych, a stopieniem zagazowania odlewów. Wykazano, że badane właściwości mają istotny wpływ na stopień zagazowania odlewu, jego porowatość oraz liczbę gazową. Poprzez odpowiedni dobór pokrycia, jego grubości, gęstości modelu, możliwe jest zminimalizowanie stopnia zagazowania odlewu.
EN
The study addressed the issues associated with lost foam casting technology. The effect of the type and thickness of the ceramic coating and the density of the pattern set of the degree of gas porosity in casting. The study was conducted for two types of ceramic coatings Disopast 4805/3 and Disopast 7759, which was applied to patterns with expanded polystyrene in one, two and three layers. Thus prepared patterns were used to produce castings alloy AlSi11 lost foam technology. The resulting castings were tested for their level of gas porosity. Presented studies have shown the relationship between the density of the polystyrene pattern, type and thickness of the applied ceramic coatings gas porosity and casting melt. It has been shown that investigated the properties have a significant impact on the degree of gas porosity in cast, its porosity and the gaseous number. Through an appropriate choice of coating, its thickness, density model, it is possible to minimize the degree of gassing casting.
2
Content available The Aging Time Effects of the Pre-expanded Polystyrene on the Patterns Mechanical Properties
Buczkowska K., Pacyniak T.
Archives of Foundry Engineering
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2015
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Vol. 15, iss. 1
131--137
EN
The aging granulate is to activate the blowing agent during the manufacturing process to granulate models can re-expand and shape the model of well-sintered granules, smooth surface and a suitable mechanical strength. The article presents the results of studies which aim was to determine the optimum time for aging pre-foamed granules for pre-selected raw materials. The testing samples were shaped in an autoclave, with constant parameters sintering time and temperature. Samples were made at 30 minute intervals. Models have been subjected to flexural strength and hardness.
3
Content available Evaluation of Microwave Heating of Protective Coatings Used in the Lost Foam Technology
Opyd B., Granat K.
Archives of Foundry Engineering
|
2015
|
Vol. 15, iss. 2
65--70
EN
Presented are results of a preliminary research on determining a possibility to use microwave radiation for drying casting protective coatings applied on patterns used in the lost foam technology. Taken were measurements of permittivity εr and loss factor tgδ at 2.45 GHz, as well as attempts were made of microwave drying of a protective coating based on aluminium silicates, applied on shapes of foamed polystyrene and rigid polymeric foam. Time and results of microwave drying were compared with the results obtained by drying at 50 °C by the traditional method commonly used for removing water from protective coatings. Analysis of the obtained drying kinetics curves demonstrated that selection of proper operation parameters of microwave equipment permits the drying time to be significantly shortened. Depending on kind of the pattern material, drying process of a protective coating runs in a different way, resulting in obtaining different quality of the dried coating.
4
Content available Test bench for analyzing the lost foam process
Kaczorowski R., Just P., Pacyniak T.
Archives of Foundry Engineering
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2013
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Vol. 13, iss. 1
57--62
EN
The current work presents and describes the test bench for analyzing the lost foam process, especially measuring of the pressure of gases in the gas gap and continuous measuring of the rate of rise of the bath level when pouring the liquid metal into the mould. A series of preliminary research was carried out on the bench which was aimed at determining the influence of the basic parameters of the process, i.e. the density of the styrofoam pattern, thickness of the refractory coating applied on the pattern, kind of the alloy and the temperature of pouring on the mould cavity by the liquid metal and the pressure of gases in the gas gap.
5
Content available Optimization of master alloy amount and gating system design for ductile cast iron obtain in lost foam process
Just P., Kaczorowski R., Pacyniak T.
Archives of Foundry Engineering
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2013
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Vol. 13, iss. 3
43--46
EN
The paper presents the optimization of master alloy amount for the high nodular graphite yield (80-90%) in cast iron obtain in lost foam process. The influence of the gating system configuration and the shape of the reaction chamber, the degree of spheroidisation cast iron was examined. Research has shown that the, optimal of master alloy amount of 1.5% by mass on casting iron. The degree of spheroidisation is also influenced by the gating system configuration. The best spheroidisation effect was obtained for liquid cast iron was fed into the reaction chamber from the bottom and discharged from the top.
6
Content available The influence of the shape of the reaction chamber on spheroidisation of cast iron produced in the lost foam casting process with use of the inmold method
Just P., Pacyniak T.
Archives of Foundry Engineering
|
2012
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Vol. 12, iss. 2
175-178
EN
The article presents the results of the research on the influence of the shape of reaction chamber on spheroidisation of cast iron produced with use of the inmold method. The amounts of nodular graphite precipitates in castings produced with the use of different reaction chambers have been compared.
7
Content available The influence of the basic styrofoam patterns final shaping parameters on the resistance properties
Pacyniak T., Buczkowska K.
Archives of Foundry Engineering
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2012
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Vol. 12, iss. 4
121-126
EN
This work presents the analysis of the final shaping process of the patterns aimed at determining the influence of the pressure and the time of sintering on the resistance to bending. The analysis of the research results proved that when the pressure of the sintering rises and reaches Ps=2.1 bar the resistance to bending increases, above this level of the pressure the resistance value starts decreasing. The time of styrofoam sintering at which the highest bending resistance values were obtained is ts=90 s. When the sintering pressure is less than 2 bar prolongation of the time of sintering over 90 s causes a slight increase in the resistance, however, at higher pressures prolongation of the time of sintering causes submelting of the styrofoam pattern.
8
Content available The influence of ingate size on the lost foam casting process
Pacyniak T., Kaczorowski R.
Archives of Foundry Engineering
|
2012
|
Vol. 12, iss. 2
171-174
EN
The article presents analysis of the influence of ingate size on the Lost Foam casting process. In particular, analysis of simulation tests has been carried out to determine the ingate size influence on the rate of filling of the mould cavity, pressure in the gas gap and size of the gas gap. A specially prepared mathematical model of the process and an original calculation algorithm were used in simulation tests of full-mould casting. The tests have indicated that the increase of the ingate size results in the increase of filling rate and increase of pressure of gases in the gas gap. However, significant influence on mould cavity filling occurs only when the ingate size is less than [...]1 cm2.
9
Content available The analysis of the influence of the polystyrene patterns shaping parameters on the resistance properties
Pacyniak T., Buczkowska K., Bogus W.
Archives of Foundry Engineering
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2012
|
Vol. 12, iss. 2
227-234
EN
This work presents the technology of making foam plastics patterns used in casting as well as the final shaping stand. The analysis of the sintering process was carried out aiming at determining the influence of the pressure and the time of sintering on the flexural strength properties. The analysis of the research results confirmed that when the sintering pressure grows to the value of Pa =1,7 bar the flexural strength also increases, when the pressure value is higher than that, the degradation of the material takes place and the strength properties decrease.
10
Content available Influence of time and pressure of forming a pattern on mechanical properties
Pacyniak T., Buczkowska K., Kaczorowski R.
Archives of Foundry Engineering
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2011
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Vol. 11, iss. 3 spec.
151--156
EN
In this paper, the technology of forming patterns on a research station equipped with an autoclave A-600 of Polish company GROM is presented. This study was conducted to determine the influence of pressure and time of forming a pattern on the bending strength. Analysis of the results confirmed that bending strength increases with increasing the pressure. The time of forming a pattern has a similar effect.
11
Content available remote Effect of pouring temperature on the Lost Foam Process
Pacyniak T., Kaczorowski R.
Archives of Foundry Engineering
|
2011
|
Vol. 11, iss. 3
149-154
EN
In this study, the analysis of the influence of the pouring temperature on manufacture process of castings by the Lost Foam method was introduced. In particular, numerical simulation results of effect of silumin and grey cast iron pouring temperature on pouring rate and gas gap pressure were analyzed. For simulating investigations of the Lost Foam process introduced mathematical model of the process was used. For calculations, the author's own algorithm was applied. The investigations have proved that with increasing pouring temperature the pouring rate increases, while pressure in the gas gap are decreasing. The author's own investigations showed a more significant effect of the silumin pouring temperature than grey cast iron pouring temperature on the lost foam process.
12
Content available remote Evaluation of the lost foam process in terms of casting dimensional accuracy and ecology
Karwiński A., Haratym R., Biernacki R.
Archives of Foundry Engineering
|
2009
|
Vol. 9, iss. 4
249-253
EN
The paper discusses some of the major issues that are related with the use of polystyrene foam (of the density above 1,04 /cm3) in the manufacture of investment castings characterised by intricate shapes. Test patterns were made from the high impact polystyrene and from styrene polymers (styrene acrylonitrile SAN). The process of polystyrene patterns removal from ceramic moulds considerably reduces the quality of these moulds in terms of surface microgeometry and dimensional accuracy of castings. The results of the studies can find practical application in the manufacture of near-net-shape castings for industrial applications as well as prototype castings. They may also serve as a tool in evaluation of the rapid prototyping process using polystyrene foam and polymers in the manufacture of investment castings characterised by high dimensional accuracy. The said technology has also been estimated in terms of its impact on the natural environment, taking into consideration the energy consumption during castings manufacture and their later use. It is possible to further improve the casting accuracy, raising it from class CT7 to CT6 according to Polish Standard PN [5].
13
Content available remote Effect of thickness of refractory coating on the Lost Foam Process
Pacyniak T.
Archives of Foundry Engineering
|
2009
|
Vol. 9, iss. 3
255-260
EN
The analysis of the influence of the thickness of refractory coating on the production process of casts in the Lost Foam process was introduced in the work. It was conducted in the peculiarity the analysis simulating investigations the influence the coating thickness on the pouring rate, pressure in the gas gap and gas gap size. For simulation tests of the Lost Foam process, a mathematical model presented in this study was used. For calculations, the author's own algorithm was applied. Investigations have proved that with increasing thickness of coating the pouring rate decreases, while pressure in the gas gap and the size of the gap are increasing. The author's own investigations have proved a very significant effect of the coating thickness on the Lost Foam process, and specially on the mould pouring rate.
14
Content available remote Effect of foamed pattern density on the lost foam process
Pacyniak T.
Archives of Foundry Engineering
|
2007
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Vol. 7, iss. 3
231-236
EN
The study examines the effect of the foamed polystyrene pattern density on the process of making castings by the lost foam technique with emphasis put on the analysis of simulation tests. The simulation regarded the effect that pattern density is said to have on the mould cavity filling rate, pressure in the gas gap, and size of this gap. For simulation tests of the full mould process, a mathematical model presented in this study was used. For calculations, the author's own algorithm was applied. The investigations have proved that with decreasing pattern density the pouring rate increases, while pressure in the gas gap and the size of the gap are decreasing. The increasing pouring rate ensures correct making of castings, even if their shapes are very intricate and the wall cross-sections are very small. Smaller size of the gas gap and lower pressure of gases in this gap reduce the risk of mould damage. The author�fs own investigations have proved a very significant effect of the density of foamed polystyrene pattern on the casting process, and specially on the mould pouring rate. The best pouring rate is ensured by patterns of the density comprised in a range of p2 =18-25 kg/m3.
15
Międzynarodowa konferencja - LOST FOAM
Nowak A.
Przegląd Odlewnictwa
|
1999
|
Vol. 49, z. 2
70-74
PL
Sprawozdanie z konferencji zorganizowanej przez Amerykańskie Stowarzyszenie Odlewników (AFS) w dniach 27-29 października 1998 r. w Birmingham (Alabama). Konferencja dotyczyła jednej odmiany technologii formy pełnej - lost foam (tracona piana). W artykule przedstawiano również inne odmiany tej technologii. Dodano polskie nazewnictwo stosowane w teh technologii oraz w jej odmianach. Omówiono wybrane referaty, które wskazały, że w USA w 2000 roku liczba odlewni stosujcych tę technologię wzrośnie do 55. W 1997 r. w 59 odlewniach w USA i w Kanadzie wyprodukowano blisko 128 tys. t (metrycznych) odlewów metodą formy pełnej. Pod względem masy produkowanych odlewów zaznaczy się wzrost ogółem o 83% w okresie 1997-2000, a w szczególności w produkcji armatury (+200%) i w samochodach ciężarowych (+232%). Przedstawiono krótkie charakterystyki czterech zwiedzanych odlewni amerykańskich. W obszernych wnioskach wskazano na konkurencyjność ekonomiczną tej metody w stosunku do innych metod, a mianowicie zmniejszenie zużycia energii, zmniejszenie wydzielania się pyłów i gazów, a także odpadów.
EN
A report from the conference organized by the American Foundrymen's Society in Birmingham (Alabama) on 27th - 29th October 1998 is given. The conference concerned one variety of the technology of full mould - the lost foam. In the article other variations of this technology are also presented. The Polish nomenclature used in this technology as well as in its variations is added. Some chosen papers have been discussed. They have indicated that the number of foundries using this technology in the USA in the year 2000 will increase to 55. In the year 1997 in 59 foundries in the USA and Canada nearly 128 thousands of metric tons of castings were produced by the full mould method. Considering the mass of the produced castings in the priod of 1997-2000 a general increase by about 83% will be marked, especially in the production of fitting (+200%) and lorries (+232%). Short characteristics of the four visited American foundries are presented. In broad conclusions the economic competitiveness of this method when compared with other methods has been pointed aut, and namely reduction of the energy consumption, lower emission of dust and gases as well as of waste material.
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