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1

Study of the Influence of Additions on the Formation of Microstructure of Al-Zn-Mg-Cu Alloys

Pisarek B. P., Czekaj E., Pacyniak T.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 4

39--44

EN

The article presents the investigations of 7xxx aluminium alloys performed by the method of thermal and derivational analysis. The studies made it possible to identify the effect of the changes in the Cu concentration, the total Zn and Mg weight concentrations and the Zn/Mg weight concentration ratio on their crystallization process: the cooling as well as the kinetics and dynamics of the thermal process of cooling and crystallization. Metallographic studies were performed on the microstructure of the examined alloys and their HB hardness was measured. The evaluation of the changes was presented in reference to the model alloys EN AW-7003 and EN AW-7010, whose microstructure under the conditions of thermodynamic equilibrium are described by the phase diagrams: Al-Zn-Mg and Al-Zn-Mg-Cu. The performed investigations confirmed that the hardness HB of the examined alloys is mainly determined by the reinforcement of the matrix αAl by the introduced alloy additions and the presence of phases Θ(Al2Cu) and S(Al2CuMg) rich in copper, as well as η(MgZn2), in the examined alloys' microstructure. The increase of the amount of intermetallic phases precipitated in the microstructure of the examined alloys is caused, beside Cu, by the characteristic change of Zn wt. concentration and Mg. It was proposed that the process of one-stage thermal treatment of the examined alloys be introduced at a temperature of up to tJ-20 °C, which will prevent the exceedance of the solidus temperature.

2

Microstructural and Tribological Characterization of Aluminium Bronzes with Additions of Si and Cr

Pisarek B. P., Kowalski B., Atapek H., Polat Ş., Tüfekçi T.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 1

93--98

EN

The article presents the investigation results of the crystallization (performed by means of the TDA method) and the microstructure of complex aluminium bronzes with the content of 6% Al, 4% Fe and 4% Ni, as well as Si additions in the scope of 1–2% and Cr additions in the scope of 0.1–0.3%, which have not been simultaneously applied before. For the examined bronze, the following tests were performed: hardness HB, impact strength (KU2). For bronze CuAl6Fe4Ni4Si2Cr0.3, characterizing in the highest hardness, wear tests were conducted with dry friction and the dry friction coefficient. The investigations carried out by means of the X-ray phase analysis demonstrated the following phases in the microstructure of this bronze: αCu, γ2 and complex intermetallic phases based on iron silicide type Fe3Si (M3Si M={Fe,Cr,…}). Compared to the normalized aluminium bronzes (μ=0.18–0.23), the examined bronze characterizes in relatively low wear and lower friction coefficient during dry friction (μ=0.147±0.016).

3

Simulation of Stress Distribution in a Thick- Walled Bushing Produced by Die-Casting

Pisarek B. P., Kołakowski D., Pacyniak T.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 4

127--132

EN

Metallographic investigations and a computer simulation of stresses in a gravity die-casting bushing were performed. Simulation of the casting process, solidification of the thick-walled bushing and calculations of the stress was performed using MAGMA5.3 software. The size variability of phases κII affecting the formation of phase stresses σf, depending on the location of the metallographic test area, was identified. The distribution of thermal σt and shrinkage stresses σs, depending on the location of the control point SC in the bushing's volume, was estimated. Probably the nature of these stresses will change slightly even after machining. This can cause variations in operating characteristics (friction coefficient, wear). Due to the strong inhomogeneity of the stress distribution in the bushing's casting, it is necessary to perform further tests of the possibility to conduct thermal treatment guaranteeing homogenization of the internal stresses in the casting, as well as to introduce changes in the bushing's construction and the casting technology. The paper presents the continuation of the results of research aimed at identifying the causes of defects in the thick-walled bushing, die-casting made of CuAl10Fe5Ni5Cr aluminium bronze.

4

Effect of Alloy Additions on the Structure and Mechanical Properties of the AlSi7Mg0.3 Alloy

Pisarek B. P., Rapiejko C., Szymczak T., Pacyniak T.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 1

137--142

EN

The study presents the results of the investigations of the effect of Cu, Ni, Cr, V, Mo and W alloy additions on the microstructure and mechanical properties of the AlSi7Mg0.3 alloy. The examinations were performed within a project the aim of which is to elaborate an experimental and industrial technology of producing elements of machines and devices complex in their construction, made of aluminium alloys by the method of precision investment casting. It was demonstrated that a proper combination of alloy additions causes the crystallization of complex intermetallic phases in the silumin, shortens the SDAS and improves the strength properties: Rm, Rp0.2,HB hardness. Elevating these properties reduces At, which, in consequence, lowers the quality index Q of the alloy of the obtained casts. Experimental casts were made in ceramic moulds preliminarily heated to 160 °C, into which the AlSi7Mg0.3 alloy with the additions was cast, followed by its cooling at ambient temperature. With the purpose of increasing the value of the quality index Q, it is recommended that the process of alloy cooling in the ceramic mould be intensified and/or a thermal treatment of the casts be performed (ageing) (T6).

5

Analysis of the Causes of Cracks in a Thick-Walled Bush Made of Die-Cast Aluminum Bronze

Pisarek B. P., Kołakowski D., Pacyniak T.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 4

119--124

EN

For the die casting conditions of aluminium bronzes assumed based on the literature data, a thick-walled bush was cast, made of complex aluminium bronze (Cu-Al-Fe-Ni-Cr). After the cast was removed from the mould, cracks were observed inside it. In order to identify the stage in the technological production process at which, potentially, the formation of stresses damaging the continuity of the microstructure created in the cast was possible (hot cracking and/or cold cracking), a computer simulation was performed. The article presents the results of the computer simulation of the process of casting the material into the gravity die as well as solidifying and cooling of the cast in the shape of a thick-walled bush. The simulation was performed with the use of the MAGMA5 program and by application of the CuAl10Ni5,5Fe4,5 alloy from the MAGMA5 program database. The results were compared with the location of the defects identified in the actual cast. As a result of the simulation of the die-casting process of this bush, potential regions were identified where significant principal stresses accumulate, which can cause local hot and cold cracking. Until now, no research has been made of die-cast aluminium bronzes with a Cr addition. Correlating the results of the computer simulation validated by the analysis of the actual cast made it possible to clearly determine the critical regions in the cast exposed to cracking and point to the causes of its occurrence. Proposals of changes in the bush die casting process were elaborated, in order to avoid hot tearing and cold cracking. The article discusses the results of preliminary tests being a prologue to the optimization of the die-casting process parameters of complex aluminium bronze thick-walled bushs.

6

Effect of Inhibitor Coating of a Ceramic Mould on the Surface Quality of an AM60 Alloy Cast with Cr and V

Pisarek B. P., Rapiejko C., Święcik R., Pacyniak T.

Archives of Foundry Engineering

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2015

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Vol. 15, iss. 3

51--56

EN

The work presents the results of the investigations of the effect of inhibitors coated on the internal walls of a ceramic mould on the quality of the obtained casts made of the AM60 alloy containing additions of chromium and vanadium. In order to reduce the reactivity of magnesium alloy cast by the technology of investment casting with the material of the mould and the ambient atmosphere, solid inhibitors were applied in the form of a mixture of KBF4 and H3BO3 after the stage of mould baking and before the mould’s being filled with the liquid alloy. For the purpose of examining the effect of the inhibitors on the surface quality of the obtained casts, profilometric tests were performed and the basic parameters describing the surface roughness, Ra, Rz and Rm, were determined.

7

Granulation of Cu-Al-Fe-Ni Bronze

Pisarek B. P.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 3

61--66

EN

With the increase in wall thickness of the casting of iron-nickel-aluminium-bronze, by the reduction of the cooling rate the size of &κII phase precipitates increases. This process, in the case of complex aluminium bronzes with additions of Cr, Mo and W is increased. Crystallization of big κII phase, during slow cooling of the casting, reduces the concentration of additives introduced to the bronze matrix and hardness. Undertaken research to develop technology of thick-walled products (g> 6 mm) of complex aluminium bronzes. Particular attention was paid to the metallurgy of granules. As a result, a large cooling speed of the alloy, and also high-speed solidification casting a light weight of the granules allows: to avoid micro-and macrosegregation, decreasing the particle size, increase the dispersion of phases in multiphase alloys. Depending on the size granules as possible is to provide finished products with a wall thickness greater than 6 mm by infiltration of liquid alloy of granules (composites). Preliminary studies was conducted using drip method granulate of CuAl10Fe5Ni5 bronze melted in a INDUTHERM-VC 500 D Vacuum Pressure Casting Machine. This bronze is a starting alloy for the preparation of the complex aluminium bronzes with additions of Cr, Mo, W and C or Si. Optimizations of granulation process was carried out. As the process control parameters taken a casting temperature t (°C) and the path h (mm) of free-fall of the metal droplets in the surrounding atmosphere before it is intensively cooled in a container of water. The granulate was subjected to a sieve analysis. For the objective function was assume maximize of the product of Um*n, the percentage weight "Um" and the quantity of granules 'n' in the mesh fraction...

8

Feeding and Cooling and Time of Thermal Treatment of a Massive Bush Made of the Complex Aluminum Bronze Cast by the Lost Foam

Just P., Pisarek B. P.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 4

39--44

EN

Small additions of Cr, Mo and W to aluminium-iron-nickel bronze are mostly located in phases &kappa i (i=II; III; IV),and next in phase &alpha (in the matrix) and phase γ2. They raise the temperature of the phase transformations in aluminium bronzes as well as the casts’ abrasive and adhesive wear resistance. The paper presents a selection of feeding elements and thermal treatment times which guarantees structure stability, for a cast of a massive bush working at an elevated temperature (650–750°C) made by means of the lost foam technology out of composite aluminium bronze. So far, there have been no analyses of the phenomena characteristic to the examined bronze which accompany the process of its solidification during gasification of the EPS pattern. There are also no guidelines for designing risers and steel internal chill for casts made of this bronze. The work identifies the type and location of the existing defects in the mould’s cast. It also proposes a solution to the manner of its feeding and cooling which compensates the significant volume contraction of bronze and effectively removes the formed gases from the area of mould solidification. Another important aspect of the performed research was establishing the duration time of bronze annealing at the temperature of 750°C which guarantees stabilization of the changes in the bronze microstructure – stabilization of the changes in the bronze HB hardness.

9

Model of Cu-Al-Fe-Ni bronze crystallization

Pisarek B. P.

Archives of Foundry Engineering

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2013

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Vol. 13, iss. 3

72--79

EN

According to the analysis of the current state of the knowledge shows that there is little information on the process of phase transformations that occur during the cooling Cu-Al-Fe-Ni hypo-eutectoid bronzes with additions of Cr, Mo and/or W, made additions individually or together, for the determination of: the type of crystallizing phases, crystallizing phases, order and place of their nucleation. On the basis of recorded using thermal and derivative analysis of thermal effects phases crystallization or their systems, analysis of the microstructure formed during crystallization - observed on the metallographic specimen casting ATD10-PŁ probe, analysis of the existing phase equilibrium diagrams forming elements tested Cu-Al-Fe-Ni bronze, with additions of Cr, Mo, W and/or Si developed an original model of crystallization and phase transformation in the solid state, the casting of high quality Cu-Al-Fe-Ni bronze comprising: crystallizing type phase, crystallizing phase sequence, place of nucleation.

10

Effect of annealing time for quenching CuAl7Fe5Ni5W2Si2 bronze on the microstructure and mechanical properties

Pisarek B. P.

Archives of Foundry Engineering

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2012

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Vol. 12, iss. 2

187-204

EN

This paper presents the influence of annealing time 30, 60 and 120 min at 1000 C for quenching CuAl7Fe5Ni5W2Si2 bronze in 10% water solution of NaCl, on the microstructure and mechanical properties. The presented results concern the species newly developed aluminum-iron-nickel bronze, with additions W and Si. In order to determine changes in the microstructure of the hardened bronze metallographic studies were performed on cylindrical samples of diameter 10 mm, on the metallographic microscope with digital image analysis, X-ray phase analysis, EDX point with the digital recording on the computer. Specified percentage of the microstructure of martensite and bainite, participation of proeutectoid \alfa phase in the microstructure, grain size of former \beta phase, the amount of dissolved \kappa phase. It was found that in the microstructure of bronze in the cast state, there are a number of intermetallic phases of \kappa type. At interphase boundaries of primary intermetallic faceted precipitates, especially rich in tungsten (IM_W), nucleate and grow dendritic primary intermetallic [...] phases, with chemical composition similar to the type of Fe3Si iron silicide. Dissolved, during the heating, in the \beta phase are all the intermediate phase included in the microstructure, with the exception of primary intermetallic phases of tungsten and [...]. Prolongation of the isothermal annealing causes coagulation and coalescence of primary phases. In microstructure of the bronze after quenching obtained the \alfa phase precipitation on the grain boundary of secondary \beta phase, coarse bainite and martensite, for all annealing times. With the change of annealing time are changed the relative proportions of individual phases or their systems, in the microstructure. In the microstructure of bronze, hold at temperature of 1000 C for 60 min, after quenching martensitic microstructure was obtained with the primary phases, and the least amount of bainite.

11

Effect of two-stage isothermal annealing on microstructure CuAl10Fe5Ni5 bronze with additions of Si, Cr, Mo, W and C

Pisarek B. P.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 3 spec.

187--194

EN

The aim of this study was to investigate the effect of a two-step isothermal annealing respectively at 1000 ˚C for 30 min, then at the range of 900÷450 ˚C increments 50 ˚C on the microstructure CuAl10 Ni5Fe5 bronze with additions of Si, Cr, Mo, W and C, cast into sand moulds. The study concerned the newly developed species, bronze, aluminium-iron-nickel with additions of Si, Cr, Mo, W and C. In order to determine the time and temperature for the characteristic of phase transitions that occur during heat treatment of the test method was used thermal and derivation analysis (TDA). The study was conducted on cylindrical test castings cast in the mould of moulding sand. It was affirmed that one the method TDA can appoint characteristic for phase transformations points about co-ordinates: τ (s), t (˚C), and to plot out curves TTT for the studied bronze with their use. It was also found that there is a five isothermal annealing temperature ranges significantly altering the microstructure of examined bronze.

12

Effect of additions of Cr, Mo, W and/or Si on the technological properties of aluminum-iron-nickel bronze

Pisarek B. P.

Archives of Foundry Engineering

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2011

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Vol. 11, iss. 3

199-208

EN

The aim of this study was to investigate the effect of additives of Cr, Mo, W and / or Si CuAll0Fe5Ni5 bronze, cast into sand moulds, the bronze technological properties such as: porosity, volumetric shrinkage Sv, linear shrinkage s and prone hot to cracking. The study relate to the newly developed grades aluminum-iron-nickel bronze, with additions of Cr, Mo, W and/or Si. In order to determine the technological properties of the test castings were made in the form of moulding sand, which made the mould cavities designed patterns. To evaluate the porosity and volumetric shrinkage was used for digital image analysis method. Volumetric shrinkage was determined using developed, the new method, the surface shrinkage Svp designation, and then converting it to the volumetric shrinkage, using prepared relation Sv=f(Djs)*Svp. It was found that made the bronze alloy additions to reduce the size of pores surface area of gas and shrinkage in the test bronze. The probability of microporosity with an area of 0.002560-0.120647 mm2 can be described by gamma distribution. Changing the chemical composition of the grades tested bronze strongly alter the first volumetric shrinkage Sv, and less to change the linear shrinkage s. The increase in gas porosity and shrink in bronze reduces the volumetric shrinkage and linear. The addition of Cr, Mo, W and/or Si to the bronze CuAll0Fe5Ni5 does not change its prone to hot cracking.

13

The influence of wall thickness on the microstructure of bronze BA1055 with the additions of Si, Cr, Mo and/or W

Pisarek B. P.

Archives of Foundry Engineering

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2008

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Vol. 8, iss. 4

185-192

EN

Aluminium bronzes belong to the high-grade constructional materials applied on the put under strongly load pieces of machines, about good sliding, resistant properties on corrosion both in the cast state how and after the thermal processing. It moves to them Cr and Si in the aim of the improvement of their usable proprieties. Additions Mo and/or W were not applied so far in the larger concentration, these elements were introduced to the melts of the copper as the components of modifiers. It was worked out therefore the new kind of bronzes casting including these elements. Make additions to the Cu-Al-Fe-Ni bronze of Si, Cr, Mo and/or W in the rise of these properties makes possible. The investigations of the influence of the wall thickness of the cast on size of crystallites were conducted: the primary phase [beta] and intermetallic phase ę and the width separates of the secondary phase [kappa] precipitate at phase boundary. It results from conducted investigations, that in the aluminium bronze BA1055 after simultaneous makes additions Si, Cr, Mo and in the primary phase [beta] it undergoes considerable reducing size [...]

14

Abrasive wear of BA1055 bronze with additives of Si, Cr, Mo and/or W

Pisarek B. P.

Archives of Foundry Engineering

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2008

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Vol. 8, iss. 3

209-216

EN

Aluminium bronzes belong to the high-grade constructional materials applied on the put under strongly load pieces of machines, about good sliding, resistant properties on corrosion both in the cast state how and after the thermal processing. It moves to them Cr and Si in the aim of the improvement of their usable proprieties. The additions Mo and/or W were not applied so far. It was worked out therefore the new kind of bronzes casting including these elements. Make additions to the Cu-Al-Fe-Ni bronze of Si, Cr, Mo and/or W in the rise of these properties makes possible. The investigations of the surface distribution of the concentration of elements in the microstructure of the studied bronze on X-ray microanalyzer were conducted. It results from conducted investigations, that in the aluminium bronze BA1055 after makes additions Si, Cr, Mo and/or W the phases of the type [kappa]_Fe, [kappa]_Ni crystallize, probably as complex silicides. Elements such as: Fe and Si dissolve first of all in phases [kappa], in smaller stage in the matrix of the bronze; Mn, Ni and W they dissolve in matrix and phases [kappa]. It dissolves Cr and Mo in the larger stage in phases [kappa] than in the matrix. The sizes of the abrasive wear were compared in the state cast multicomponent new casting Cu-Al-Fe-Ni bronzes with the additives Cr, Mo or W with the wear of the bronze CuAl10Fe5Ni5Si. The investigations of the wear were conducted on the standard device. It results from conducted investigations, that make additions to bronze BA1055 of the additives of Si, Cr, Mo, and/or W it influences the rise of the hardness (HB) of the bronze in the cast state, in the result of the enlarged quantity separates of hard phases [kappa], and in the consequence the decrease of the abrasive wear. The addition of molybdenum made possible obtainment of the microhardness of the phase [alpha] and [gamma]_2 on the comparable level. From the microstructure of the bronze CuAl10Fe5Ni5MoSi is characterizes the smallest abrasive wear among studied bronzes. More far works over new multicomponent aluminium bronzes will be guided in the direction of the identification of the changes of mechanical properties of studied bronzes under the influence of the thermal processing.

15

The crystallisation of the aluminium bronze with additions of Si, Cr, Mo and/or W

Pisarek B. P.

Archives of Materials Science and Engineering

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2007

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Vol. 28, nr 8

461-466

EN

Purpose: The aim of this paper is description of the process of the crystallization of new aluminium bronzes with the complex silicides of the iron. Design/methodology/approach: Additions Cr, W, Mo and Si were introduced to create in the microstructure of the aluminium bronze of the complex silicides of the iron about high mechanical and physical proprieties to the bronze BA1044. The process of formation the microstructure of the bronze with use of the method of the thermal and derivative analysis (TDA) was analysed. The examinations under the microscope and X-ray microanalysis of the surface distribution of elements were conducted. Findings: From carried research results, that in the aluminium bronze BA1044 after addition Si, Cr, Mo and/or W the phase κ Fe, κ Ni crystallize as the complex silicides of the iron. Elements such as: Fe and Si dissolve first of all in silicides in the smaller stage in the matrix of the bronze, Mn and Ni they dissolve in matrix and silicides, Cr dissolves in the larger stage in silicides than in the matrix, W and Mo dissolve in silicides however they crystallize as nanocrystals in the metal matrix and create with her composite. Research limitations/implications: Results of investigations of aluminium bronze BA1044 and alloys after adding to him about 1% Si were introduced in the article and suitably: 1.22 % C; 0.82 % Mo; 0.020 % W; 0.60 % Cr, 0.17 % Mo and 0.017 % W. Originality/value: The original results of the investigations of the crystallization of the new bronzes (innovative materials and casting technologies) for which the process of arising microstructure the method TDA was not analysed so far were introduced in the article. The article possesses cognitive values not only essential for researcher but and practician-melters.

16

Influence Cr on crystallization and the phase transformations of the bronze BA1044

Pisarek B. P.

Archives of Foundry Engineering

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2007

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Vol. 7, iss. 3

129-136

EN

The investigations were introduced in the paper, method of thermal and derivative analysis (TDA), the process of crystallization and phase transformation in the solid state of the aluminium bronze CuA110Fe4Ni4 (BA1044) and with the addition 0.3 % Cr. Two intermetallic phase were identified in the microstructure of the bronze BA1044: [kappa]Fe1-- rich in Fe and Cu and [kappa]Fe2 - rich in Fe, and in the microstructure of the bronze BA1044+0.3 % Cr only one phase [kappa]Fel - rich in Fe, Cu and Cr. The presence of chrome in the bronze BA1044 reduce size the primary crystals of the phase [beta], reduces the dynamics of the processes of thermal phase transformation in the solid state and lengthens the time their of duration.

17

Monitorowanie produkcji i kontrola jakości stopów odlewniczych za pomocą programów komputerowych

Pietrowski S. K., Gumienny G., Pisarek B. P., Władysiak R.

Odlewnictwo - Nauka i Praktyka

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2005

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R. 7, nr 3

3-18

PL

Przedstawiono możliwości monitorowania produkcji i kontroli jakości stopów odlewniczych za pomocą autorskich programów komputerowych. Zostały one opracowane dla stopów żelaza, miedzi i aluminium. W systemie komputerowym wykorzystano metodą analizy termicznej i derywacyjnej (ATD). Przedstawiono reprezentatywne krzywe ATD i mikrostrukturę różnych gatunków staliwa, żeliwa, brązu aluminiowo-niklowo-żelazowego i siluminu wieloskładnikowego. Pomiędzy ich charakterystycznymi wielkościami a składem chemicznym i właściwościami mechanicznymi stopu występują określone zależności statystyczne. Przykładowo podano j e dla żeliwa sferoidalnego gatunku EN-GJS-400-15. Stanowią one podstawę budowy algorytmu autorskich programów komputerowych monitorowania i kontroli jakości stopów. Zaprezentowano schemat procesu kontroli stopów oraz przykładowe ekrany programu komputerowego kontroli żeliwa sferoidalnego. Programy komputerowe wdrożono w odlewniach staliwa, żeliwa i siłuminów w ramach realizacji projektów celowych.

EN

In this paper fhe possibility of production monitoring and quality control of casting alloys with self-written computer programmes have been presented. They have been elaborated for ferrous, copper and aluminum alloys. In the computer system thermal derivative analysis (TDA) method have been used. In this paper representative TDA curves and microstructure of: cast steel, cast iron, aluminum-nickel-iron bronze and mulficomponent silumin have been shown. Among their characteristic volumes, chemical composition and mechanical properties of alloy there are statistic relationships. Exemplary relationships for EN-GJS-400-15 ductile cast iron have been given in this work. They are the basis of computer programmes algorithm of monitoring and quality control of alloys. In this paper the scheme of alloys control process and exemplary screen displays of computer programme of ductile cast iron control have been presented. Computer programmes have been implemented in cast iron, cast steel and silumin foundries during the realization of grants.

18

Wpływ chromu, niklu i molibdenu na stukturę i odporność na ścieranie żeliwa białego

Pisarek B. P.

Przegląd Odlewnictwa

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1998

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Vol. 48, z. 9

287-291

PL

Celem pracy było zbadanie metodą analizy termiczno-derywacyjnej (ATD) procesu krystalizacji pierwotnej i wtórnej żeliwa chromowego zawierającego 4-19% Cr z dodatkami Mo do 5% oraz Ni do 9,5%.

EN

The aim of the work was to investigate, by the use of thermal-derivative analysis, the process of primary and secondary cristallization of chromium cast iron containig 4-19% Cr and some additions of Mo (up to 5%) an Ni (up to 9,5%).