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EN
Nowadays, the best castings’ manufacturers have to meet very demanding requirements and specifications applicable to mechanical properties and other characteristics. To fulfill those requirements, more and more sophisticated methods are being used to analyze the internal quality of castings. In many cases, the commonly used Non-Destructive Methods, like X-ray or ultrasonic testing, are not enough to ensure precise and unequivocal evaluation. Especially, when the properties of the casting only slightly fail the specification and the reasons for such failures are very subtle, thus difficult to find without the modern techniques. The paper presents some aspects of such an approach with the use of Scanning Electron Microscopy (SEM) to analyze internal defects that can critically decrease the performance of castings. The paper presents the so-called bifilm defects in ductile and chromium cast iron, near-surface corrosion caused by sulfur, micro-shrinkage located under the risers, lustrous carbon precipitates, and other microstructure features. The method used to find them, the results of their analysis, and the possible causes of the defects are presented. The conclusions prove the SEM is now a powerful tool not only for scientists but it is more and more often present in the R&D departments of the foundries.
EN
The paper presents an analysis of a selected grade of high silicon cast iron intended for work in corrosive and abrasive conditions. The text describes its microstructure taking into account the process of crystallization, TDA analysis, EDS, XRD and the chemical composition analysis. In order to determine the phase composition, X-ray diffraction tests were carried out. The tests were executed on a Panalytical X'Pert PRO X-ray diffractometer with filtration of radiation from a lamp with copper anode and PIXcel 3D detector on the deflected beam axis. Completed tests allowed to describe the microstructure with detailed consideration of intermetallic phases present in the alloy. Results of the analysis of the examined alloy clearly show that we deal with intermetallic phases of Fe3Si, Fe5Si3 types, as well as silicon ferrite and crystals of silicon. In the examined alloy, we observed the phenomenon of segregation of carbon, which, as a result of this process, enriches the surface of silicon crystals, not creating a compound with it. Moreover, the paper demonstrates capability for crystallization of spheroidal graphite in the examined alloy despite lack of elements that contribute to balling in the charge materials.
PL
W artykule omówione zostały wyniki badań tribologicznych kompozytów epoksydowych i rezolowych. Zbadano stan powierzchni próbek kompozytów, pracujących w węzłach ślizgowych. Stwierdzono, że istnieje możliwość zastosowania tańszych żywic rezolowych do kompozytów ślizgowych (w miejsce stosowanego Epidianu 5). Wykonano testy, które wykazały, że zwiększenie zawartości PTFE w kompozycie powodowało obniżenie zarówno współczynnika tarcia, jak i zużycie. Wyniki analizy rentgenograficznej potwierdziły występowanie zjawiska selektywnego przenoszenia.
EN
The article discusses the results of tribological tests of epoxy and resol composites. There was examined the surface condition of samples of composites operating in sliding nodes. It has been found that it is possible to use cheaper resole resins for sliding composites (in-stead of Epidian 5). Tests that have been carried out showed that increasing the PTFE content in the composite resulted in lowering both the coefficient of friction and wear. X-ray analysis results confirmed the occurrence of the selective transfer phenomenon.
EN
Silicon – molybdenum cast iron commonly called SiMo due to its unique properties has becoming more and more interesting engineering material. The history and development of this alloy is relatively long but, due to the significant difficulties during the manufacturing process resulting in the lower final quality than expected, it has not been applied to often in practice. The biggest challenge is its brittleness as a result of the carbides precipitations. During last few years, thanks to the many important researches made and the general foundry technology development, the interest in SiMo iron has been rapidly growing, especially for the castings for heavy duty applications like corrosion, high temperature and wear abrasion resistant parts. In the article the heat treatment attempts to improve the microstructure of SiMo castings has been presented. The goal was to destroy or at least to refine and uniformly distribute the carbides precipitations to improve mechanical properties of the exhaust manifold castings for the cars. The experiments were carried out for the alloy contains approx. 4% Si, 1% Mo and 3.2%C. The range of the research included: hardness measuring, standard mechanical properties and microstructure for as-cast state and after that the subsequent heat treatment process with another properties check. The result of the heat treatment was the elimination of pearlite from the metal matrix. Moreover, the changes of the carbide molybdenum – rich phase morphology were observed. The dispersion of the carbides precipitations in the carbides area was observed. The experiments proved the possibility to control the microstructure and the mechanical properties of the SiMo castings by means of heat treatment but only to some extent.
5
EN
The article presents results of studies of silicon – molybdenum cast iron (4.42% Si, 2.59% Mo and 2.48% C wt.-%) crystallization process. Metallographic analysis was carried out using SEM-scanning electron microscopy with the EDS system. In order to determine the phase composition, X-ray diffraction studies were performed. Thermo-Calc, a computer simulation program, was used to simulate the crystallization process. . The obtained data allowed to describe the effect of some elements on the crystallization process. The silicon phase of MnSi could not be identified during metallographic studies. Also, computer simulation of the crystallization process did not answer the question at which point the silicon phase of MnSi crystallizes in the tested alloy. Therefore, not all results obtained were linked to the registered crystallization process (TDA process). The EDS analysis revealed an unusual distribution of molybdenum in the microstructure of the sample, where it is clearly visible that the area enriched with this element is also the separation of spheroidal graphite. The possibility of occurrence of Mo-rich micro-areas found in graphite is considered. The case is debatable and difficult to resolve at this stage. Perhaps, at such a high concentration of molybdenum (2.59% Mo) in the alloy, conditions are created for simultaneously crystallization of graphite and molybdenum phases.
6
Content available SiMo Ductile Iron Crystallization Process
EN
The article presents crystallization process of silicon molybdenum ductile cast iron (SiMo). The alloy with 5% silicon content and with variable amounts of Mo in a range of 0-1% was chosen for the research. The carbon content in the analysed alloys did not exceed 3,1%. The studies of crystallization process were based on thermal – derivative analysis (TDA). Chemical composition of all examined samples was analysed with the use of LECO spectrometer. Additionally, the carbon and the sulphur content was determined basing on carbon and sulphur LECO analyser. For metallographic examination the scanning electron microscopy (SEM) with EDS analyser was used. Disclosed phases have been also tested with the use of X-ray diffraction. The results allowed the description of crystallization processes of silicon molybdenum ductile cast iron using thermal – derivative analysis (TDA). Conducted studies did not allow for the clear identification of all complex phases containing molybdenum, occurring at the grain boundaries. Therefore, the further stages of the research could include the use of a transmission electron microscope to specify the description of complex compounds present in the alloy.
EN
The paper presents the research results of horizontal continuous casting of ingots of aluminium alloy containing 2% wt. silicon (AlSi2). Together with the casting velocity (velocity of ingot movement) we considered the influence of electromagnetic stirring in the area of the continuous casting mould on refinement of the ingot’s primary structure and their selected mechanical properties, i.e. tensile strength, yield strength, hardness and elongation. The effect of primary structure refinement and mechanical properties obtained by electromagnetic stirring was compared with refinement obtained by using traditional inoculation, which consists in introducing additives, i.e. Ti, B and Sr, to the metal bath. On the basis of the obtained results we confirmed that inoculation done by electromagnetic stirring in the range of the continuous casting mould guarantees improved mechanical properties and also decreases the negative influence of casting velocity, thus increasing the structure of AlSi2 continuous ingots.
8
Content available Physicochemical Properties of Silicon Cast Iron
EN
The article presents results of pitting corrosion studies of selected silicon cast irons. The range of studies included low, medium and high silicon cast iron. The amount of alloying addition (Si) in examined cast irons was between 5 to 25 %. Experimental melts of silicon cast irons [1-3] were conducted in Department of Foundry of Silesian University of Technology in Gliwice and pitting corrosion resistance tests were performed in Faculty of Biomedical Engineering in Department of Biomaterials and Medical Devices Engineering of Silesian University of Technology in Zabrze. In tests of corrosion resistance the potentiostat VoltaLab PGP201 was used. Results obtained in those research complement the knowledge about the corrosion resistance of iron alloys with carbon containing Si alloying addition above 17 % [4-6]. Obtained results were supplemented with metallographic examinations using scanning electron microscopy. The analysis of chemical composition for cast irons using Leco spectrometer was done and the content of alloying element (silicon) was also determined using the gravimetric method in the laboratory of the Institute of Welding in Gliwice. The compounds of microstructure was identify by X-ray diffraction.
PL
W pracy przedstawiono wyniki dotyczące modyfikacji metodą mieszania elektromagnetycznego wybranych podeutektycznych stopów aluminium z krzemem gatunku AlSi2 i AlSi7. Celem realizacji procesu modyfikacji zastosowano mieszadło zasilane prądem o podwyższonej częstotliwości, wytwarzające wirujące pole elektromagnetyczne. Skuteczność modyfikacji oceniono na podstawie wyników badań metalograficznych makro- i mikroskopowych. Ponadto przedstawiono możliwość aplikacji uzyskanych wyników badań w procesie poziomego odlewania ciągłego stopów Al-Si.
EN
In this research paper results concerning the inoculation method based on electromagnetic stirring of hypoeutectic aluminum with silicon alloys AlSi2 and AlSi7 grade are presented. The inoculation process used a stirrer supplied by current with a high frequency, generating a rotating electromagnetic field. The efficiency of inoculation was estimated in the results of the metallographic macro- and microscopic research. Moreover, the possibility of using the obtained results in horizontal continuous casting process of Al-Si alloys was presented.
EN
Silicon cast iron with high chemical resistance, which is the biggest advantage of this material, did not have any competition for a long time. It was popular on the market of metal materials because of its low price. However, the production of this material requires special attention and precautions, which is a barrier for foundry. The article presents the results of research of high silicon cast iron crystallization based on thermal derivative analysis (which has identified characteristic temperatures of the investigated alloy crystallization process basis on the part of Fe–Si phase diagram and process analysis using calculations made in Thermo–Calc software) and metallographic analysis of the structure.
EN
In paper is presented results of studies concerning ingot of Al with a purity of 99.5% cast with use of stand of horizontal continuous casting. Mainly together with casting velocity was considered influence of electromagnetic stirrer, which was placed in continuous casting mould on refinement of ingots structure and theirs usability to plastic deformation. Effect of structure refinement and usability to plastic deformation obtained by influence of electromagnetic stirring was compared with refinement obtained by use of traditional inoculation, which consists in introducing of additives i.e. Ti and B to metal bath. On the basis of obtained results was affirmed that inoculation realized by electromagnetic stirring in range of continuous casting mould guarantees improvement in structure refinement and usability to rolling of pure Al continuous ingots.
EN
Purpose: The aim of the study was to determine the relationships between time of running over a 15–25 m section of a 30-meter run along a straight line and changes in the angle and angular velocity observed in ankle, knee and hip joints. Therefore, the authors attempted to answer the question of whether a technique of lower limbs movement during the phase of sprint maximum velocity significantly correlates with the time of running over this section. Methods: A group of 14 young people from the Lower Silesia Voivodeship Team participated in the experiment. A Fusion Smart Speed System was employed for running time measurements. The kinematic data were recorded using Noraxon MyoMotion system. Results: There were observed statistically significant relationships between sprint time over a section from 15 to 25 m and left hip rotation (positive) and between this time and left and right ankle joint dorsi-plantar flexion (negative). Conclusions: During the maximum velocity phase of a 30 m sprint, the effect of dorsi-plantar flexion performed in the whole range of motion was found to be beneficial. This can be attributed to the use of elastic energy released in the stride cycle. Further, hip rotation should be minimized, which makes the stride aligned more along a line of running (a straight line) instead of from side to side.
EN
The method of powder injection into molten metal has been widely known since tens of years and successfully utilized in various metallurgical processes. The most common is a solution with injection lance submerged under the liquid alloy surface, because it is easier apart from some of disadvantages of this approach. In this paper the authors’ complex experiments on the pneumatic injection process with non-submerged lance have been presented. The new approach on jet cone angle importance and its influence on the efficiency of the injection process has been shown. The issue of the effective jet radius that was proposed by former scientists as well as computer modelling and injection experiments recorded with high speed camera have been presented. The final comparison of the typical injection lance and developed by authors new lance with flange was presented, too. The benefits of use of a new one for the treatment of small liquid alloy volume (e.g. inoculation or alloys addition introduction) have been pointed.
PL
Technologia wdmuchiwania proszków do ciekłego metalu jest znana od kilkudziesięciu lat i z powodzeniem stosowana w różnorodnych procesach metalurgicznych i odlewniczych. Zdecydowanie najczęściej stosowane jest rozwiązanie z użyciem lancy zanurzonej pod lustro obrabianego stopu, jako łatwiejsze choć nie pozbawione wielu istotnych wad. W pracy zaprezentowano zakończone kompleksowe badania autorów nad procesem wdmuchiwania proszków bez zanurzania lancy w kąpieli. Przedstawiono nowe spojrzenie na tzw. „kąt stożka rozejścia strumienia” i jego wpływ na skuteczność procesu, przeanalizowano zagadnienie tzw. „skutecznego promienia strumienia” proponowanego przez wcześniejszych badaczy oraz opisano wyniki badań symulacyjnych oraz eksperymentów wdmuchiwania, zarejestrowanych z użyciem kamery do szybkich zdjęć. Podjęto się także ostatecznego porównania rozwiązań lancy zwykłej i opracowanej przez autorów tzw. „lancy kołnierzowej” wskazując na zalety tej drugiej, jako narzędzia do obróbki niewielkich objętości ciekłych stopów np. w procesach wprowadzania żelazostopów czy też modyfikacji.
EN
In paper problem concerning modification of grey cast iron EN-GJL-200 Grade, which is realized mainly by intensification of liquid metal movement in horizontal continuous casting mould containing electromagnetic stirrer is presented. The range of studies contains influence of electromagnetic field on morphology of graphite and usable properties i.e. tensile strength, hardness and machinability. Moreover the influence of velocity of ingot pulling on microstructure was analyzed. The results of studies and their analysis show possibility of improvement in quality of grey cast iron continuous ingot firstly in result of elimination of hard spots in structure by properly selection of velocity of ingot pulling and second in result of unification of size, shape and distribution of flake graphite by application of electromagnetic field.
PL
W pracy przedstawiono problematykę modyfikacji żeliwa szarego gatunku EN-GJL-200 realizowanej głównie poprzez intensyfikację ruchu ciekłego metalu w krystalizatorze zawierającym mieszadło elektromagnetyczne w procesie poziomego odlewania ciągłego. Zakres badań obejmował badania wpływu pola elektromagnetycznego na morfologię grafitu oraz właściwości użytkowe tj. wytrzymałości na rozciąganie, twardości oraz skrawalność. Ponadto analizowano wpływ prędkości wyciągania wlewka na jego mikrostrukturę. Wyniki badań oraz ich analiza pokazały, że istnieje możliwość poprawy jakości wlewka ciągłego z żeliwa szarego po pierwsze w wyniku wyeliminowania ze mikrostruktury zabieleń poprzez właściwie dobraną prędkości wyciągania oraz po drugie w wyniku ujednorodnienia wielkości, kształtu oraz rozmieszczenia grafitu płatkowego poprzez zastosowanie oddziaływania pola elektromagnetycznego.
PL
Żeliwo krzemowe z uwagi na wysoką odporność chemiczną, która stanowi kluczową zaletę tego materiału, przez długi czas nie posiadało większej konkurencji i cieszyło się dużą popularnością na rynku materiałów metalowych ze względu na niewielką cenę. Niestety produkcja odlewów z tego materiału wymaga szczególnej uwagi i ostrożności, co stanowi barierę dla odlewni [1]. W artykule zaprezentowano wyniki badań związanych z procesem krystalizacji żeliwa wysokokrzemowego przeprowadzonych w oparciu o analizę termiczno derywacyjną (wyznaczono temperatury charakterystyczne procesu krystalizacji analizowanego stopu, posiłkując się odpowiednim fragmentem wykresu układu równowagi fazowej Fe – Si oraz analizą procesu w oparciu o obliczenia z wykorzystaniem programu Thermo – Calc) oraz analizę metalograficzną mikrostruktury.
EN
Silicon cast iron with high chemical resistance, which is the biggest advantage of this material, did not have any competition for a long time. It was popular on the market of metal materials because of its low price. However, the production of this material requires special attention and precautions, which is a barrier for foundry [1]. The article presents the results of research of high silicon cast iron crystallization based on thermal derivative analysis (have been identified characteristic temperatures of the investigated alloy crystallization process basis on the part of Fe – Si phase diagram and process analysis using calculations made in Thermo – Calc software) and metallographic analysis of the structure.
PL
Autorzy prezentują wyniki badań nad analizą nieprawidłowości w sposobie poruszania się na podstawie danych chodu uzyskanych za pomocą techniki motion capture. Badaniu poddano 3 grupy pacjentów: ze zwyrodnieniami stawu biodrowego, kręgosłupa i po udarze mózgu oraz grupę osób zdrowych. Sekwencje chodu nagrywano w dwóch sesjach – przed i po trzytygodniowym okresie rehabilitacji. Jako wskaźników nieprawidłowości użyto indeksów chodu.
EN
The authors present results of the research aiming at analysis of gait abnormalities based on the gait motion capture data. Three groups of patients suffering from the following affections: osteoarthritis of the hip, osteoarthritis of the spine and stroke underwent the recording process twice – before and after three-week rehabilitation. Healthy volunteers were also recorded. Gait indices were used as indicators of abnormality.
PL
W artykule przedstawiono wpływ zmiennych warunków pracy skojarzenia ciernego tarcza hamulcowa – okładziny cierne na parametry pracy układu. Do badań laboratoryjnych zastosowano unikatowe autorskie stanowisko badawcze do badań skojarzeń ciernych typu tarcza hamulcowa – okładziny cierne. Badania prowadzono z środowisku suchym, wilgotnym oraz środowisku wilgotnym – chemicznie korozyjnym.
EN
The paper presents the impact of changing service conditions of brake disc friction–the friction linings association on their working conditions. For laboratory tests an unique self-constructed test stand for testing the brake disc – friction linings association was used. The experiments were conducted in dry, wet and humid – chemically corrosive environments.
EN
In paper is presented idea of construction and influence of selected parts of stand of horizontal continuous casting on quality of pure Al and AlSi2 alloy ingots. The main parts of the made stand belong to induction furnace, which is also tundish, water cooled continuous casting mould, system of recooling, system of continuous ingot drawing and cutting. Mainly was considered influence of electromagnetic stirrer, which was placed in continuous casting mould on refinement of ingots structure. Effect of structure refinement obtained by influence of electromagnetic stirring was compared with refinement obtained by use of traditional inoculation, which consists in introducing of additives i.e. Ti and B to metal bath. The results of studies show possibility of effective refinement of Al and AlSi2 alloy primary structure, only with use of horizontal electromagnetic field and without necessity of application of inoculants. This method of inoculation is important, because inoculants decrease the degree of purity and electrical conductivity of pure aluminum and moreover are reason of point cracks formation during rolling of ingots.
19
Content available Odlewanie Al99,5 sposobem ciągłym
PL
W pracy przedstawiono technologię poziomego odlewania ciągłego aluminium o czystości 99,5%. Proces odlewania ciągłego prowadzono przy użyciu stanowiska znajdującego się w Katedrze Odlewnictwa Politechniki Śląskiej i składającego się przede wszystkim z pieca elektrycznego indukcyjnego, pełniącego również rolę kadzi pośredniej, chłodzonego wodą krystalizatora, układu chłodzenia wtórnego oraz systemu wciągania i cięcia wlewka. W ramach badań określono wpływ wybranych parametrów poziomego odlewania ciągłego na strukturę pierwotną wlewka z czystego Al o średnicy 30mm oraz przedstawiono możliwość jej rozdrobnienia w wyniku zastosowania modyfikacji przy użyciu pola elektromagnetycznego.
EN
In paper is presented the technology of horizontal continuous casting of aluminum with a purity 99,5%. Process of continuous casting was made with use of stand placed in Foundry Department of Silesian University of Technology containing induction furnace, which is also tundish, water cooled continuous casting mould, system of recooling, system of continuous ingot drawing and cutting. In the range of studies was determined influence of selected parameters of horizontal continuous casting on primary structure of pure Al ingot with diameter 30mm. Moreover is presented inoculation of primary structure in result of using of electromagnetic field.
PL
W pracy zaprezentowano wpływ warunków prowadzenia badań tribologicznych na topografię powierzchni okładzin ciernych. Analizy tej dokonano na podstawie zdjęć wykonanych na mikroskopie konfokalnym. Oceniono stan powierzchni wybranych okładzin ciernych z trzech różnych mieszanek oznaczonych symbolami A, B, C współpracujących w różnych warunkach chłodzenia układu par tarcza hamulcowa - okładzina cierna.
EN
The paper presents the influence of the conditions the tribological research is conducted on the topography of the friction linings surfaces. This analysis was undertaken on the basis of photographs taken with a confocal microscope. We monitored the status of the selected surface friction linings of the three different mixtures marked with symbols A, B, C, co-operating in various conditions of cooling the pairs: disc brake - friction lining.
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