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1

Effect of Cavitation Phenomenon on the Quality of High-Pressure Aluminium Alloy Castings

Brzeziński Marcin, Wiśniowski Jakub

Journal of Casting & Materials Engineering

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2023

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Vol. 7, no. 3

27--30

EN

This article presents an analysis of the effect of cavitation on the erosion of pressure moulds intended for the HPDC casting mould manufacturing process. Changes in the surface area of the eroded areas were investigated via photographs of castings at the beginning of the mould life as well as at 30%. The individual process variables were described and their influence verified via the cavitation potential module of the Flow3D simulation programme. The results are presented graphically with a description of the relationships and observations. The summary provides an explanation of the results and the dependencies that occurred.

2

Effectiveness of Absorbing Microwaves by the Multimaterial Sodium Silicate Base Sand - PLA (Polylactide) Mould Wall Systems

Stachowicz Mateusz

Archives of Foundry Engineering

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2023

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Vol. 23, iss. 3

30--37

EN

In the paper presented are results of a research on effectiveness of absorbing electromagnetic waves at frequency 2.45 GHz by unhardened sodium silicate base sands (SSBS) prepared of high-silica base sand and a PLA (Polylactide) 3D-prited (3DP) mould walls. Measurements of power loss of microwave radiation (Pin) expressed by a total of absorbed power (Pabs), output power (Pout) and reflected power (Pref) were carried-out on a stand of semiautomatic microwave slot line for determining balance of microwave power emitted into selected multimaterial systems. Values of microwave power loss in the rectangular waveguide filled with unhardened moulding sands and prepared by fused deposition modelling (FDM) 5 mm polylactide (PLA) walls with grid infill density from 25% to c.a. 100% served for determining effectiveness of microwave heating. Balance of microwave power loss is of technological importance for microwave manufacture of high quality casting sand moulds and cores in possibility of use 3D-printed mould tools and core boxes. It was found that apparent density of SSBS placed in a waveguide with PLA walls influences parameters of power output (Pout) and power reflected (Pref). The PLA wall position and grid infill density were identified to have a limited effect on effectiveness of absorbing microwaves (Pabs).

3

Zastosowanie skaningowej kalorymetrii różnicowej (DSC) w odlewnictwie

Gracz Beata

Laboratorium - Przegląd Ogólnopolski

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2022

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nr specjalny

28--35

PL

Skaningowa kalorymetria różnicowa (DSC) umożliwia stosunkowo szybkie i łatwe badanie materiałów charakteryzujących się różnym stanem skupienia i konsystencją, co zapewnia szerokie spektrum zastosowań badawczych dla przemysłu odlewniczego.

4

Evaluation of Collapsibility of Selected Core Systems

Obzina Tomas, Merta V., Rygel J., Lichý P., Drobíková K.

Archives of Foundry Engineering

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2022

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Vol. 22, iss. 1

48--52

EN

There are mainly two different ways of producing sand cores in the industry. The most used is the shooting moulding process. A mixture of sand and binder is injected by compressed air into a cavity (core), where it is then thermally or chemically cured. Another relatively new method of manufacturing cores is the use of 3D printing. The principle is based on the method of local curing of the sand bed. The ability to destroy sand cores after casting can be evaluated by means of tests that are carried out directly on the test core. In most cases, the core is thermally degraded and the mechanical properties before and after thermal exposure are measured. Another possible way to determine the collapsibility of core mixtures can be performed on test castings, where a specific casting is designed for different binder systems. The residual strength is measured by subsequent shake-out or knock-out tests. In this paper, attention will be paid to the collapsibility of core mixtures in aluminium castings.

5

Energy-I-system – inteligentne narzędzie planowania produkcji i zarządzania energią w zakładach odlewniczych

Sawczuk Mariola, Kurek Damian

Przegląd Odlewnictwa

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2021

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Vol. 71, nr 11-12

586--588

PL

MODUS Sp. z o.o. przedstawi, z punktu widzenia audytora i doradcy ograniczającego koszty zużycia energii, analizę trudnej sytuacji w jakiej obecnie znajdują się polskie zakłady energochłonne. Związane jest to z szalejącymi cenami energii elektrycznej, gazu oraz surowców. Przedstawione zostaną przykładowe rozwiązania zaradcze w postaci dostępnych mechanizmów wsparcia oraz opłacalnych technologii ograniczających koszty. Szczególny nacisk zostanie położony na przedstawienie inteligentnego narzędzia Energy-I-System rozwijanego przez firmę. Celem systemu jest maksymalna redukcja kosztów w zakładach energochłonnych, poprzez lepsze zarządzanie źródłami energii, skorelowane z wykorzystywaniem zmienności obciążenia i cen energii w czasie. Energy-I-System optymalizuje plan produkcji nie tylko uwzględniając priorytety zamówień i optymalne obciążenie środków produkcji, ale również bierze pod uwagę koszty energii. Zarysowany zostanie także plan UE w ramach ‘fit for 55’ i wskazówki jak się do niego przygotować.

EN

MODUS Sp. z o.o. as an auditor and an advisor reducing energy costs, will present an analysis of the difficult situation in which Polish energy-intensive plants currently experience. This is due to the soaring prices of electricity, gas and raw materials. Company will present examples of remedial solutions in the form of available support mechanisms and cost-effective technologies that reduce costs. Particular emphasis will be placed on the presentation of the intelligent Energy-I-System tool developed by the company. The purpose of the system is the maximum reduction of costs in energy-intensive plants through better management of energy sources, correlated with the use of load volatility and energy prices over time. Energy-I-System optimizes the production plan by taking into account order priorities, the optimal load on the production resources and corresponding energy costs. The EU plan of ‘fit for 55’ will also be outlined with conclusions and tips on how to prepare for it.

6

Investigation of flowability of the green sand mould by remote control of portable flowability sensor

Abdulamer D.

Archives of Materials Science and Engineering

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2021

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Vol. 112, nr 2

70--76

EN

Purpose: The useful data and information during the sand compaction process steps should be collected. Direct measurement methods of the sand mould properties during the actual moulding process are not adopted yet. Design/methodology/approach: In this work, a remote control system [1] have been integrated into a new flowability sensor [2]. Findings: To overcome the complexity of the tools and equipment that existed in laboratory, and in foundry. Research limitations/implications: In order to investigate, and control behavior of the moulding process of bentonite-bonded green sand process, the sensors have been equipped with the Bluetooth technology for a wireless transmission of the measured data to computers. Originality/value: This technique contributes to improve of the compaction process based on the non-destructive tests, enhances prediction of the optimum parameter conditions, and reduced the energy, and the compaction time consumed for the green sand moulding process.

7

Synthesis of Natural Phenolic Compound Contained Alkaline Phenolic Foundry Resin and Its Performance Evaluation on Casting

Güvendik A. E., Ay Kadir

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 2

46--56

EN

In foundry, metal casting can be done with various methods. One of the most important methods preferred around the world is sand casting. Ester curable alkaline phenolic resins have produced to make sand molds by No-bake systems. They must have specific properties to make sand casting efficient and reliable. Production of these resins depends on some fossil raw-materials like phenol. To investigate more sustainable and green resin synthesis method, lots experiment have been done by substitution of phenol with renewable alternative phenolic materials like resorcinol, lignosulphonates and tannic acid and its derivatives. Different properties of resins were produced with competitive performance with the market product, ÇKE Alfanol A 72 No-Bake Resin. Without loss of performance, calcium lignosulfonate was used in polymer synthesis at the rate of 15% instead of phenol. On the other hand, the reaction in which lignin and resorcinol were combined instead of phenol by reducing it by 25% gave better results in terms of mechanical and thermal properties. Thermal properties were investigated for resorcinol and lignin modified resins by using TGA-DSC and mechanical performance of cured sand core sample were tested by Simpson Sand Strength Testing Machine as compression strength as N/cm2. After laboratory testing casting performance of new resins are compared with two different companies’ resins in steal casting demo. Experimental results were matched with casting trail and no defect was detected.

8

Research on Selected Types of Lustrous Carbon Carriers After the High - Temperature Pyrolysis

Kamińska Jadwiga, Stachowicz M., Kubecki M.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 1

56--62

EN

For research purposes and to demonstrate the differences between materials obtained from the carbonaceous additives to classic green moulding sands, five lustrous carbon carriers available on the market were selected. The following carbonaceous additives were tested: two coal dusts (CD1 and CD2), two hydrocarbon resins (HR1 and HR2) and amorphous graphite (AG1). The studies of products and material effects resulting from the high-temperature pyrolysis of lustrous carbon carriers were focused on determining the tendency to gas evolution, including harmful compounds from the BTEX group (benzene, toluene, ethylbenzene and xylene). Moreover, the content of lustrous carbon (LC), the content of volatile matter and loss on ignition (LOI) of the carbonaceous additives were tested. The solid products formed during high-temperature pyrolysis were used for the quantitative and qualitative evaluation of elemental composition after the exposure to temperatures of 875oC in a protective atmosphere and 950oC in an oxidizing atmosphere. The conducted studies have indicated the necessity to examine the additives to classic green moulding sands, which is of particular importance for the processing, rebonding and storage of waste sand. The studies have also revealed some differences in the quantitative and qualitative composition of elements introduced to classic moulding sands together with the carbonaceous additives that are lustrous carbon carriers. It was also considered necessary to conduct a research on lustrous carbon carriers for their proper and environmentally friendly use in the widely propagated technology of classic green sand system.

9

Influence of Microwave Heating on the Molding Mass with Gypsum Binder Structure and Strength

Paduchowicz Patrycja J., Granat K., Biały P.

Archives of Foundry Engineering

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2021

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Vol. 21, iss. 1

113--118

EN

The paper presents results of influence microwave drying on strength and technological properties of molding sand with gypsum binder researches, which, immediately after making and after the natural initial setting in air for 1, 2 or 5 hours, was heated with 250 W microwave power for 3, 6, 9 and 12 min time periods. The test was carried out on a mass containing (% -wt.): 88% Grudzeń-Las quartz sand, 12% "Dolina Nidy" plaster gypsum and 6% water. The loss of moisture content during natural drying and then microwave drying was determined, significant from the point of view of using the mass with gypsum binder in the production of products, using an environmentally friendly technology without casting incompatibilities. Additionally, the compressive strength of the mass was measured. The influence of both drying methods on the binder crystallization process and the associated mass strength was demonstrated, especially in terms of the possibility of selecting parameters and / or intensifying a specific drying method for use in the technology of manufacturing molds and foundry cores.

10

Zastosowanie biodegradowalnego polilaktydu PLA jako spoiwa do mas formierskich stosowanych w odlewnictwie

Tryznowski Mariusz, Soroczyński Artur

Przemysł Chemiczny

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2020

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T. 99, nr 10

1552--1555

PL

Zbadano przydatność polilaktydu (PLA) jako spoiwa do wielokrotnego stosowania do mas formierskich wykorzystywanych w procesach odlewniczych. PLA otrzymano z dużą wydajnością (71%) przez polikondensację laktydu. Masy formierskie z 2-proc. zawartością spoiwa uzyskano w wyniku odparowania chloroformowego roztworu PLA. Zbadano wytrzymałość na rozciąganie mas formierskich po ich wielokrotnym zawracaniu. Masy formierskie z 2-proc. zawartością PLA jako spoiwem, stapiane w wysokiej temp. 325°C można było zawracać nawet 13-krotnie, otrzymując masy charakteryzujące się dobrą jakością.

EN

Polylactide (PLA) was used as a binder for recycled molding sands in foundry processes. PLA was produced by lactide polycondensation with a high efficiency (71%). The molding sands with 2% binder content were prepd. by evaporating the solvent from CHCl3 soln. of PLA. The PLA-contg. molding sands cured at 325°C were successfully recycled up to 13 times.

11

Influence of Automatic Core Shooting Parameters in Hot-Box Technology on the Strength of Sodium Silicate Olivine Moulding Sands

Stachowicz M.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 1

67--72

EN

The paper presents the results of preliminary research on the application of olivine moulding sands with hydrated sodium silicate containing 1.5 % wt. of binder to perform ecological casting cores in hot-box technology using a semi-automatic core shooter. The following parameters were used in the process of core shooting: initial shot pressure of 6 bar, shot time 3 s, the temperature of the core-box: 200, 250 and 300°C and the core curing time: 30, 60, 90, 120 and 150 s. The matrix of the moulding mixture was olivine sand, and the binder of the sandmix was commercial, unmodified hydrated sodium silicate with molar module SiO2/Na2O of 2.5. In one shot of the automatic core-shooter were formed three longitudinal specimens (cores) with a dimensions 22.2×22.2×180 mm. The samples obtained in this way were subjected to the assessment of the influence of the shooting parameters, i.e. shooting time, temperature and curing time in core-box, using the following criteria: core box fill rate, mechanical strength to bending RgU, apparent density, compaction degree and susceptibility to friability of sand grains after hardening. The results of trials on the use of olivine moulding sands with hydrated sodium silicate (olivine SSBS) in the process of core shooting made it possible to determine the conditions for further research on the improvement of inorganic hot-box process technology aimed at: reduction of the heating temperature and the curing time. It was found that correlation between the parameters of the shooting process and the bending strength of olivine moulding sands with sodium silicate is observed.

12

Impact of Hardening Methods on the Moulding Sand’s Properties with Gypsum Binder

Granat K., Paduchowicz P., Dziedzic A., Jamka M., Biały P.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 4

13--17

EN

The research paper presents the results of testing the strength and technological properties of molding sand with gypsum binder, the bonding process proceeded: naturally or conventionally. The tests included mass containing (parts by weight): 78 pbw. Grudzeń-Las quartz sand, 22 pbw. plaster gypsum "Dolina Nidy” and 9 pbw. water. Measurements of compressive strength, shear, tensile and bending as well as permeability and looseness were carried out on standard cylindrical samples kept in the air for 1-96 hours or dried at 110oC for 1-8 hours. The results of the analysis were analyzed in connection with the mass structure and construction binding bridges warp grains observed with a scanning microscope (SEM). The influence of drying intensity on the bonding process and related mass properties has been demonstrated, especially from the point of view of the possibility of selection and / or intensification of a specific curing method for use in the production of gypsum binger molds and cores.

13

Evaluation of the Chemical Composition, TG – DTA and Tensile Strength Tests of Commercial Gypsum Kinds for Foundry Sandmixes Application

Paduchowicz P., Stachowicz M., Baszczuk A., Hasiak M., Granat K.

Archives of Foundry Engineering

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2020

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Vol. 20, iss. 2

59--64

EN

The paper presents the preliminary results of research on determining the possibilities of using available on the market commercial gypsum kinds as a binder for foundry moulding and core sandmixes. Construction gypsum and plaster gypsum, finishing coat and jewelry casting gypsum were tested. Elemental composition of gypsum kinds were carried out using a scanning electron microscope (SEM) with EDS/EDX probe, their crystal structure and phase composition was determined by analyzing the results of X-ray diffraction measurements (XRD) and thermogravimetric studies (TG-DTA). Evaluation of the mechanical properties of selected materials was carried out at the tensile strength test of the dog-bone samples after initial hardening of gypsum mortar at 25°C for 5 h and drying at 110°C for 24 hours. The impact of the properties of the used commercial gypsum kinds on the possibility of their use as a valuable binders in the manufacture of the foundry sandmixes for moulds and cores was evaluated. Construction gypsum and finishing coat have the highest tensile strength. Plaster gypsum and finishing coat have the longest setting time. In all tested types of gypsum, the initial water loss during heating occurs at a temperature of about 200°C. The lowest valuable properties as a binder for sand moulding mixtures has jewelry casting gypsum mass.

14

Maszyny CNC do szlifowania odlewów, niezbędne wyposażenie inteligentnych odlewni (Biznes 4.0)

Zatoń Janusz

Przegląd Odlewnictwa

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2019

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Vol. 69, nr 7-8

222--223

15

Historia żelazek do prasowania na ziemiach polskich w XIX i na pocz. XX w. Cz. 1. Odlewnie i ich udział w produkcji żelazek

Skowron Marek

Przegląd Odlewnictwa

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2019

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Vol. 69, nr 9-10

286--289

16

Studies of Poly(Acrylic Acid-co-Maleic Acid) Sodium Salt Intercalated Montmorillonite

Grabowska B., Cukrowicz S., Kurleto-Kozioł Ż., Kaczmarska K., Drożyński D., Sitarz M., Bobrowski A.

Archives of Foundry Engineering

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2019

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iss. 4

67--75

EN

The intercalation into interlayer spaces of montmorillonite (MMT), obtained from natural calcium bentonite, was investigated. Modification of MMT was performed by the poly(acrylic acid-co-maleic acid) sodium salt (co-MA/AA). Efficiency of modification of MMT by sodium salt co-MA/AA was assessed by the infrared spectroscopic methods (FTIR), X-ray diffraction method (XRD) and spectrophotometry UV-Vis. It was found, that MMT can be relatively simply modified with omitting the preliminary organofilisation – by introducing hydrogel chains of maleic acid-acrylic acid copolymer in a form of sodium salt into interlayer galleries. A successful intercalation by sodium salt of the above mentioned copolymer was confirmed by the powder X-ray diffraction (shifting the reflex (001) originated from the montmorillonite phase indicating an increase of interlayer distances) as well as by the infrared spectroscopy (occurring of vibrations characteristic for the introduced organic macromolecules). The performed modification causes an increase of the ion exchange ability which allows to assume that the developed hybrid composite: MMT-/maleic acid-acrylic acid copolymer (MMT-co- MA/AA) can find the application as a binding material in the moulding sands technology. In addition, modified montmorillonites indicate an increased ability for ion exchanges at higher temperatures (TG-DTG, UV-Vis). MMT modified by sodium salt of maleic acid-acrylic acid copolymer indicates a significant shifting of the loss of the ion exchange ability in the direction of the higher temperature range (500–700°C).

17

Material balance of the technological process in the new foundry of new ferronikel in DRENAS 2017

Bajraktari-Gashi Zarife, Halilaj Behram

Journal of Technology and Exploitation in Mechanical Engineering

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2018

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Vol. 4, nr 1

29--35

EN

Experimental and industrial research of the technological process during the year 2017, including planning, is presented in this paper. That research was conducted in the new Foundry of new Ferronickel in Drenas, which is in the village of Cikatove, Drenas, the Republic of Kosovo. According to initial calculations, an amount of ore which would enter the process was determined, however the anticipated amount was different from the one used during the process. The same applies to fuel. Difference between the planned and the actual amount of ore used during the year 2017 resulted from the percentage of Ni in the amount of ore used in the foundry, demand for an Fe-Ni ferroalloy etc. The technological process in the foundry serves the purpose of processing ore of ironnickel with a high percentage of Ni in its composition. The material balance of the technological process in the new Foundry of new Ferronickel in Drenas, presented in this paper, is based on experimental and industrial data of the technological process acquired in the foundry. The material balance includes the technological process starting from calculation of the amount of ore and fuel, both making up the load for the rotary kiln. Additional contributors to the material balance are calculation of the amount of: fuel, which impacts the increase of temperature in rotary kilns, charge for the electric furnaces, metal and slags from the electric furnaces, metal and slags from the refining process (convertors) and mathematical calculation of the final product which is the ferroalloy of Fe-Ni. While preparing the material balance we have noticed greater acquisition of Ni than planned. The greater amount of Ni was produced by a smaller amount of ore than originally planned.

18

Impact of Higher Temperature on Quartz Moulding Sand with Gypsum Binders

Paduchowicz P., Stachowicz M., Granat K.

Archives of Foundry Engineering

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2018

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Vol. 18, iss. 1

81--86

EN

This paper presents initial findings from research into the possibility of using gypsum binders in quartz moulding sand that could be used in the production of casting moulds and cores. For the purposes of the research two commercial types of gypsum were used as binders: building gypsum and gypsum putty. Dry components of moulding sand i.e. medium quartz sand and gypsum were mixed in proportion of 89/11 parts by weight. In order to achieve bonding properties for the binders, 5 parts by weight of water was added to the mixture of dry components. After 24 hours of adding water and mixing all the components, the moulding sand, naturally hardened, was subjected to high temperature. The moulding sand thus produced, i.e. with cheap and environmentally-friendly gypsum binders, was eventually analysed after heating (at temperatures of 300oC, 650oC and 950oC) and cooling in order to determine changes in the following parameters: LOI – loss on ignition, chemical composition and pH. Moreover, investigated were bonding bridges, before and after the moulding sand was roasted. The research results revealed differences in the structure of bonding bridges and the occurrence of automatic adhesive destruction for both types of gypsum binders. For two types of moulding sands under the investigation of the LOI exceeded 2.59wt.% (with building gypsum) or 2.84wt.% (with putty gypsum) and pH increased to ca. 12 as a result of increasing roasting temperature from 300oC to 650oC. Next, roasting at 950oC decrease value of LOI in both types of moulding sands. Moulding sand with builoding gypsum roasted at 950oC revealed a return to the value of pH parameter measured prior to annealing.

19

ITM Polska w hołdzie dla innowacyjności 6-9 czerwca 2017 roku

Świat Obrabiarek i Narzędzi

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2017

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R. 12, nr 3-4

16

PL

Innowacyjność, dynamika, promocja nowości i nieszablonowych rozwiązań to wartości, które targom poznańskim przyświecają od blisko 100 lat. Były istotne w 1921 roku, gdy Międzynarodowe Targi Poznańskie rozpoczynały swoją drogę i są ważne dziś, w przededniu największych targów dedykowanych branży przemysłowej - ITM Polska.

20

Proces wdrażania nowatorskiej technologii produkcji filtrów ceramiczno-węglowych

Lipowska B., Witek J., Asłanowicz M., Ościłowski A., Robak Z., Muzyka R.

Materiały Ceramiczne

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2017

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T. 69, nr 4

343--346

PL

W roku 2014 zakończono prace badawcze nad opracowaniem technologii produkcji innowacyjnych, piankowych filtrów ceramiczno-węglowych do filtracji ciekłych stopów metali, finansowane przez NCBiR ze środków programu InnoTech. Partia badawcza filtrów wykonanych wg tej technologii została sprawdzona w praktyce w krajowych odlewniach staliwa i żeliwa. Próby wypadły pomyślnie i odlewnie zadeklarowały chęć zakupu nowoopracowanych filtrów do bieżącej produkcji odlewów. Dla firmy „Ferro-Term” Sp. z o.o. było to bodźcem do rozpoczęcia prac projektowych nad prototypową linią do seryjnej produkcji tych filtrów. Równocześnie, wraz z konsorcjum naukowym, w którego skład weszli współtwórcy technologii, tj. Instytut Ceramiki i Materiałów Budowlanych, Oddział Materiałów Ogniotrwałych w Gliwicach, Instytut Chemicznej Przeróbki Węgla w Zabrzu i Instytut Odlewnictwa w Krakowie, podjęto udaną próbę pozyskania części środków na niezbędne dostosowanie opracowanej technologii ze skali półtechnicznej na przemysłową z Programu Operacyjnego Inteligentny Rozwój. W artykule przedstawiono informację o postępie badań objętych harmonogramem realizowanego projektu.

EN

In 2014 research works aimed at developing a technology of production of innovative foam ceramic-carbon filters for liquid metal alloy filtration were completed. They were financed by the National Centre for Research and Development from the funds of InnoTech programme. The testing batch of filters made according to this technology was tested in practice at domestic cast iron and steel foundries. The trials were successful and the foundries declared their intention to purchase the newly-developed filters for the current production of casts. This provided Ferro-Term with an incentive to start project works on a prototype line for the batch production of these filters. At the same time, together with the scientific consortium, composed of the technology co-authors, i.e. Institute of Ceramics and Building Materials, Refractory Materials Division in Gliwice, Institute for Chemical Processing of Coal in Zabrze and Foundry Research Institute in Cracow, the authors undertook a successful attempt to obtain a part of the funds for necessary adjustment of the developed technology from the half-technical to industrial scale from Smart Growth Operational Programme. In this article information about progress in project scheduled researches was presented.