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Developing the inoculation procedure for high-quality cast iron with flake graphite, intended for large-size casting (bottom or distance plates and counterweights) – produced in Krakodlew Foundry S.A.

Guzik Edward, Świątkowski Adrian, Szczęsny Andrzej, Kopyciński Dariusz, Mirek Piotr, Piotrowski Krzysztof

Technical Transactions

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2023

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Vol. 120, iss. 1

art. no. e2023009

EN

This article presents the first part of the research on the production of large-sizecastings, such as bottom plates and counterweights produced in the KrakodlewS.A. foundry. Castings of this type are not complicated in terms of construction butmust meet certain requirements, namely to be able to withstand the effects of hightemperature and associated stresses, or to have specific dimensions and weight inthe case of counterweights. In both cases, the most common method of formingcastings is horizontal moulding. However, this requires a lot of time for machiningthe finished castings. Forming heavy castings in a vertical orientation, although muchmore problematic, can mean that the amount of time required for machining may bereduced. The research presents the effect of overheating temperature on the effectsof inoculation with the Zircinoc inoculant, in which it was shown that increasing thetemperature by fifty degrees increased the amount of eutectic grains by around11–15%.

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The Method of Inoculation of High-Quality Grey Cast Iron Intended for Massive Castings for Bottom and Distance Plates as Well Counterweights Manufactured as Vertical Castings

Guzik Edward, Kopyciński Dariusz, Ziółko A., Szczęsny Andrzej

Archives of Metallurgy and Materials

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2023

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Vol. 68, iss. 1

359--368

EN

The technology of producing castings of high-quality inoculated cast iron with flake graphite particles in the structure is a combination of the melting and inoculation process. Maintaining the stability of the strength and microstructure parameters of this cast iron is the goal of a series of studies on the control of graphitization and austenitic inoculation (increasing the number of primary austenite dendrites), and which affects the type of metal matrix in the structure. The ability to graphitize the molten alloy decreases with its holding in the melting furnace more than an hour. The tendency to crystallize large dendritic austenite grains and segregation of elements such as Si, Ni and Cu reduce the ductility properties of this cast iron. The austenite inoculation process may introduce a larger number of primary austenite grains into the structure, affecting the even distribution of graphite and metal matrix precipitation in the structure. Known inoculation effects the interaction (in low mass) of additives: Sr, Ca, Ba, Ce, La, produces MC2 carbide). Addition of Fe in the inoculant influences the number and shape of austenite dendrites. Hybrid modification combines the effects of these two factors. The introduction of nucleation sites for the graphite eutectics and primary austenite grains result in the stabilization of the cast iron microstructure and an increase in mechanical properties. The obtained test results set the direction for further research in this area in relation to the production of heavy plate castings in vertical and horizontal pouring.

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The Melting Process and its Impact on the Properties of High-Chromium Cast Iron and the Economic Calculation

Mędoń Jan, Szczęsny Andrzej, Ziółkowski Eugeniusz, Guzik Edward, Czarny M., Kopyciński Dariusz

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 4

54--64

EN

The subject of this study is to show that the parameters of the melting process of high chromium cast iron affect the cost of casting and the properties of the cast iron. The analysis of the quality of the casting and its price was conducted in terms of the metal charge of high chromium cast iron. As is well known, in order to obtain the correct structure of the casting, and thus good strength properties, it is necessary to use clean batch components free of undesirable impurities. Unfortunately, the quality of the metal charge is proportional to its price. Thus, the use of expensive batch components offers the possibility of obtaining healthy and meeting the strength properties of castings. However, there is a flaw in this approach. And it is from the point of view of economics that production plants are forced to look for savings. Expensive feedstock materials are replaced by cheaper counterparts giving the possibility of obtaining castings with similar properties often, however, at the cost of increased inferior quality. It seems that a way out of this situation is to introduce a modification procedure into the alloyed iron manufacturing technology. The selected modifiers should affect the fragmentation of the structure of the primary austenite. At this point, it can be hypothesized that this will result in the elimination of hot cracking in high chromium cast iron. The industrial research carried out at the "Swidnica" Foundry Ltd. made it possible to show by means of the Althoff-Radtke method that by using the modification of the liquid metal of the so-called "inferior and cheaper" composition of the metal charge, a reduction in the occurrence of hot cracks and shrinkage cavities can be achieved. In addition, iron-niobium modification not only reduced the formation of casting defects in castings, but also slightly improved the impact strength of high-chromium cast iron. The work was written as part of an implementation PhD.

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Evaluation of the Phases Present in the Zinc Coating Obtained on the Ductile Cast Iron Substrate in the Bath with the Addition of Ti

Bracka-Kęsek Karolina, Szczęsny Andrzej, Kopyciński Dariusz, Guzik Edward

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 4

5--13

EN

This paper presents the effect of the addition of Ti to the zinc bath. Hot-Dip Galvanizing was carried out on a machined ductile cast iron substrate. The process was carried out at 550°C. Experimental baths A, B and C contained 0.01%, 0.05% and 0.1%Ti, respectively. Metallographic samples were prepared to reveal the microstructure of the coatings. Thickness measurements of the obtained coatings were carried out, and graphs of the approximate crystallization kinetics of the zinc coating were prepared. High-temperature galvanization carried out on the treated surface led to the release of graphite beads from the metal matrix and their diffusion into the coating. This phenomenon can have an adverse effect on the continuity of the coating and its adhesion to the substrate. Crystallization of the δ phase was observed in the coating, and at longer immersion times – a mixture of two-phase δ1 and η phases. With increasing Ti content in the bath, a deterioration in the casting properties of the bath was observed.

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Inoculation of Gray Cast Iron Intended for Large Scale and Heavy Weight Castings of Bottom Plates and Counterweights Manufactured in the KrakOdlew S.A.

Szczęsny Andrzej, Kopyciński Dariusz, Guzik Edward

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 3

19--24

EN

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions. The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).

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Directions of the Development of the Metallization of Iron Alloy Products

Szczęsny Andrzej, Kopyciński Dariusz, Guzik Edward

Journal of Casting & Materials Engineering

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2021

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Vol. 5, no. 3

40--44

EN

The article discusses the future of the production of protective coatings based on the hot-dip galvanizing of iron-carbon alloys, such as steel or cast iron. Currently exploited zinc deposits will be exhausted in the next two decades and it will be necessary to start the exploitation of new deposits in order to maintain the supply or quantity of Zn on the global market. In both cases, it will be related to the increasing cost of zinc on world markets. Zinc-based protective coatings (one of the best corrosion protection methods) constitute almost 50% of the world’s zinc consumption. Economic issues with the constant increase in the price of Zn will force the change or modification of hot-dip galvanizing technology. The article presents data on the production, consumption and development of zinc prices on the global market. Possible directions are presented which producers of zinc coatings will have to follow in order to maintain sales markets, such as the modification of chemical compositions of protective alloys which could be an alternative to pure zinc coatings and the possibility of limiting zinc consumption based on the influence of the surface of galvanized elements, i.e. its metal matrix, and surface roughness.