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EN
The exhaust valve seat face is a surface that degrades slowly as a result of mechanical and thermal stresses. There is extensive research on new materials for valves and for the improvement of valve production technology. This paper discusses the method of obtaining a filler metal made of Fe3Al intermetallic phase and the method of TIG hard-facing on a valve seating face made of H9S2 steel, evaluating the effects of essential hard-facing parameters. The resulting hard-facing build up was assessed in terms of quality using industrial radiography testing (RT).
EN
This study aimed to develop Fe/Al multilayered metallic/intermetallic composites produced by hot pressing under an air atmosphere. Analyses were carried out on the composite plates made up of alternatively situated sheets of AA1050 aluminum alloy and DN04 low carbon steel, which were annealed at 903 K for 2, 5, and 10 h. Annealing was performed to obtain reaction layers of distinct thickness. The samples were examined using X-Ray diffraction and scanning and transmission electron microscope equipped with an energy-dispersive X-Ray spectrometer. To correlate the structural changes with mechanical properties, microhardness measurements in near-the-interface layers were performed. All the reaction layers grew with parabolic kinetics with η-Al5Fe2 intermetallic phase as the dominant component. After annealing for 5 and 10 hours, a thin sublayer of θ-Al13Fe4 phase was also detected.
EN
Sodium orthovanadate was tested as a corrosion inhibitor of intermetallic Al2Cu in 1 M H3PO4. The Al2Cu–H3PO4–Na3VO4system was studied using the following methods: inductively coupled plasma optical emission spectrometry, scanning electron microscopy with energy dispersive x-ray spectroscopy, x-ray diffraction, electrochemical impedance spectroscopy, polarisation and open circuit potential. It was found that the corrosion rate decreased as the inhibitor concentration increased. The highest inhibition efficiency 99% was obtained when sodium orthovanadate initial concentration was equal to 100 mM, pH = 1.11, due to precipitation of a protective layer of insoluble salt, containing vanadium, phosphorus, sodium and oxygen, on the surface. At pH = 0.76 the protective layer was not formed and inhibition efficiency decreased to 76%. Selective corrosion of the intermetallic phase caused a significant increase of an electric double layer capacitance and decrease of a charge transfer resistance.
PL
W silnikach, w których stosuje się zasilanie sprężonym gazem ziemnym, LPG oraz innymi paliwami gazowymi, obserwuje się konieczność częstszej wymiany zaworów wydechowych. Zawory te w silnikach spalinowych mogą być eksploatowane przez krótszy czas niż ich odpowiedniki w silnikach zasilanych benzyną i olejem napędowym. Najbardziej narażona na degradację jest przylgnia zaworu wydechowego. Wynika to z temperatury spalania gazu ziemnego w komorze spalania oraz temperatury spalin mających kontakt z zaworem. W pracy przedstawiono porównawczy rozkład mikrotwardości w zaworach wydechowych napawanych fazą międzymetaliczną Fe3Al oraz stellitem.
EN
In engines, fuelled with concentrated natural gas, LPG, and other gaseous fuels, the necessity for more frequent replacement of exhaust valves is observed. These valves in combustion engines may be operated for a shorter period than their equivalents in engines fuelled with petrol and diesel oil. The exhaust valve face is most exposed to degradation. This results from the combustion temperature of natural gas in the combustion chamber and the temperature of exhaust gas in contact with the valve. The paper presents a comparative distribution of microhardness in exhaust valves pad welded with Fe3Al intermetallic phase and stellite.
EN
This study includes the results of tests related to selecting the data collection parameters for EBSD analysis, correction and modification of the EBS diffraction patterns, and use of selected functionalities of the commercial OIM system. The study also shows the local misorientation range and the local relationships of the crystal lattice orientation at interfaces and grain boundaries, estimated in the polyphase microregions of selected AlFeMnSi alloys.
PL
Ciągły wzrost zapotrzebowania na powłoki aluminiowe dla przemysłu motoryzacyjnego wiąże się z koniecznością poprawy ich jakości w zakresie właściwości ochronnych i mechanicznych. W powłokach aluminiowych, wytworzonych ogniowo, na granicy ze stalowym podłożem powstają fazy pośrednie FeAl3 i Fe2Al5, które zmniejszają odporność na korozję i ograniczają możliwości kształtowania pokrytego wyrobu. W pracy dokonano określenia wpływu dodatku 7% Si do aluminiowej powłoki (690°C/60 s) na jej mikrostrukturę, grubość i rodzaj faz pośrednich oraz twardość i cechy powierzchni. Wykazano, że dodatek Si powoduje 40% zwiększenie twardości powłoki oraz zmniejszenie jej chropowatości. Dodatkowo, zostaje ograniczona dyfuzja wzajemna Al i Fe, w wyniku czego formuje się warstwa faz międzymetalicznych, wzbogacona w fazę Al7-9Fe2Si, 4-krotnie cieńsza niż w powłoce bez dodatku Si, przy zachowaniu grubości zewnętrznej warstwy powłoki.
EN
The continuous increase in demand for aluminum coatings for the automotive industry is associated with the need to improve their quality in terms of protective and mechanical properties. The aluminum coatings produced hot-dip, on the border with the steel substrate formed intermediate phases FeAl3, and Fe2Al5, which reduce the corrosion resistance and limit the possibility of forming a coated article. The paper determines the effect of the addition of 7% Si to an aluminum coating (690°C/60 s) on the microstructure thickness and type of intermediate phases as well as hardness and surface features. It has been shown that the addition of Si results in a 40 % increase in the hardness of the coating and reduce the surface roughness. In addition, is limited interdiffusion of Al and Fe, as a result of which an intermetallic phase layer is formed, Al7-9Fe2Si enriched phase, 4 times thinner than a coating without the addition of Si, while maintaining the thickness of the outer coating layer.
PL
Powłoki ochronne zapewniają ochronę konstrukcji przed korozją, ale także mają na celu spełnienie wymogów marketingowych – walory dekoracyjne. Jednym z przedstawicielem powłok ochronnych, są powłoki ogniowe na bazie Al i Al-Si, które znalazły zastosowanie m. in. w przemyśle motoryzacyjnym. Wytwarzanie powłok Al-Si metodą ogniową (alias: zanurzeniowa), polega na zanurzeniu, uprzednio odtłuszczonego detalu w kąpieli roztopionego metalu powłokowego. Powłoki Al-Si nanoszone są na stale, a połączenie pomiędzy powłoką a podłożem zapewnione jest poprzez wzajemną dyfuzję aluminium i żelaza, co prowadzi do wytworzenia faz międzymetalicznych. W pracy badaniom poddano powłoki Al-Si stosowane w przemyśle motoryzacyjnym. Badania objęły ocenę powłok pod względem ukształtowania struktury, twardości, rozkładu pierwiastków, czy stanu powierzchni (chropowatość). Skład chemiczny powłok określono wykorzystując mikroanalizę EDX, a skład fazowy analizą dyfraktometryczną. Finalną ocenę stanowiło wpływ gięcia na jakość połączenia pomiędzy podłożem a powłoką.
EN
Protective coatings provide protection of structures against corrosion, but they also aim to meet marketing requirements – decorative qualities. One of the representatives of protective coatings are fire coatings based on Al and Al-Si, which have been used, among others, in the automotive industry. The production of Al-Si coatings using the fire method (known as: immersion) consists in immersing a previously degreased detail in a bath of molten coating metal. Al-Si coatings are applied permanently, and the connection between the coating and the substrate is ensured by the mutual diffusion of aluminum and iron, which leads to the formation of intermetallic phases. The study examines Al-Si coatings used in the automotive industry. The research included assessment of coatings in terms of structure, hardness distribution of elements, and surface condition (roughness). The chemical composition of the coatings was determined using EDX microanalysis and phase composition by diffractometric analysis. The final assessment focused on the impact of bending on the quality of the connection between the substrate and the coating.
EN
Al2Cu phase has been obtained by melting pure metals in the electric arc furnace. It has been found that the intermetallic phase undergoes selective corrosion in the H3PO4 aqueous solutions. Aluminium is dissolved, the surface becomes porous and enriched with copper. The corrosion rate equals to 371 ±17 g∙m-2∙day-1 (aerated solution) and 284 ± 9 g∙m-2∙day-1 (deaerated solution). The surface of Al2Cu phase after selective corrosion was characterised by using electrochemical impedance spectroscopy. It was found that the surface area of the specimens increases with temperature due to higher corrosion rate and is between 2137 and 3896 cm2.
9
Content available remote Ocena mikrostruktury napoiny ze srebra na tytanie
PL
W pracy podjęto próbę oceny mikrostruktury napoiny wykonanej z drutu srebrnego na blachach tytanowych. Ocenę przeprowadzono z wykorzystaniem mikroskopii świetlnej i skaningowej mikroskopii elektronowej. Ujawnione wyniki obserwacji wskazują na występowanie złożonej struktury płytkowej w obszarze materiału rodzimego (tytanu) i budowę dendrytyczną w napoinie.
EN
The microstructure of Ag on Ti plate padding weld was investigated in the paper. The evaluation was carried out using light microscopy and scanning electron microscopy. Observation results indicate the presence of a complex lamellar structure in the area of the native material (titanium) and dendritic structure in the clad.
10
Content available remote Natryskiwanie łukowe powłok Fe-Al
PL
W artykule przedstawiono wstępne wyniki badań wytwarzania kompozytowych powłok z układu Fe-Al z udziałem faz międzymetalicznych in-situ za pomocą natryskiwania łukowego. Proces natryskiwania prowadzono poprzez jednoczesne topienie dwóch różnych drutów elektrodowych, aluminiowego i stalowego. Celem prowadzonych badań jest wytworzenie powłok ochronnych o kompozytowej strukturze ze znaczącym udziałem faz międzymetalicznych FexAly, których synteza zachodzi podczas procesu natryskiwania (in-situ). Otrzymane wyniki wykazały lokalne występowanie faz międzymetalicznych z układu Fe-Al, a dominujące składniki struktury to roztwory aluminium w żelazie i żelaza w aluminium. Udział faz międzymetalicznych w powłoce jest stosunkowo niski, lecz jego wpływ na właściwości materiału powłoki jest istotny.
EN
The paper presents preliminary results of research on the production of composite coatings from the Fe-Al system with participation of intermetallic phases in-situ using arc spraying. The spraying process was carried out by simultaneously melting two different electrode wires, aluminium and steel. The aim of the research is to create protective coatings with a composite structure with a significant participation of FexAly as a intermetallic phases reinforcement. The synthesis of intermetallic takes place during the (in-situ) spraying process. Currently most of coatings involving intermetallic phases are being manufactured by different thermal spraying methods using coating materials in form of prefabricated powders containing intermetallic phases. The obtained results showed that the local occurrence of intermetallic phases from the Fe-Al system, and the dominant components of the structure are two phases, aluminium solid solutions in iron and iron in aluminium. The participation of intermetallic phases in the coating is relatively low, but it’s effect on the properties of the coating material is significant.
EN
The research described in this contribution is focused on fractographic analysis of the fracture area of newly developed eutectic silumin type AlSi9NiCuMg0.5 (AA 4032), which was developed and patented by a team of staff of the Faculty of Mechanical Engineering. The paper presents determination of the cause of casting cracks in operating conditions. Fractographic analysis of the fracture area, identification of the structure of the casting, identification of structural components on the surface of the fracture surface and chemical analysis of the material in the area of refraction were performed within the experiment. Al-Si alloys with high specific strength, low density, and good castability are widely used in pressure-molded components for the automotive and aerospace industries. The results shown that the inter-media phases Fe-Al and Fe-Si in aluminium alloys lead to breakage across the entire casting section and a crack that crossed the entire cross section, which was confirmed by EDS analysis.
PL
Wdrożenie nowych materiałów do praktyki przemysłowej pozwala na konstrukcję trwalszych i bardziej wytrzymałych części maszyn przeznaczonych do pracy w wysokiej temperaturze oraz ekstremalnych warunkach. W artykule analizowano zastosowanie metody napawania do wykonania napoiny ze stopu na osnowie fazy międzymetalicznej Fe40Al5CrTiB na powierzchni stali S235JR. Proces prowadzono metodą TIG w atmosferze gazu obojętnego przy zastosowaniu prądu stałego (DC-). Próbki napawano w trzech wariantach: jednościegowym, wielościegowym oraz wielowarstwowym. Po procesie napawania przeprowadzono badania za pomocą mikroskopu świetlnego (LM), elektronowego mikroskopu skaningowego oraz dokonano pomiarów twardości metodą Vickersa (HV). Technologia ta może być zastosowana w przyszłości, na przykład w przemyśle energetycznym do wytworzenia powierzchni żaroodpornych.
EN
Implementation of new materials into industrial practice allows to build more durable and reliable machine parts suitable to operate at high temperature and other special conditions. The paper analyzes implementation of welding method to make intermetallic surface Fe40Al5CrTiB on material grade S235JR. The process was made with tungsten inert gas (TIG) and with the use of reserved polarity direct current (DC-). Welded sample was made as: single bead, multi bead and as multilayer. After the welding process, samples were tested with light microscopy (LM), scanning electron microscopy (SEM) and Vickers hardness (HV). This technology can by used to develop resistance surfaced in the power industry in the future.
EN
The article examines the impact of changes in homogenization temperature in the hardening process on the microstructure of aluminum alloys. The research samples were cast from AlSi10CuNiMn alloy produced by gravity casting technology in metal mold. Subsequently, the castings were subjected to a heat treatment. In an experiment with changing temperature and staying time in the process of homogenization. The microstructure of the alloy was investigated by methods of light and electron microscopy. Examination of the microstructure has focused on changing the morphology of separated particles of eutectic silicon and intermetallic phases. The analysis of intermetallic phases was supplemented by an analysis of the chemical composition – EDS analysis. Effect of heat treatment on the properties investigated alloy was further complemented by Vickers microhardness. Investigated alloy is the result of longtime research conducted at the Faculty of Production Technology and Management.
PL
W artykule przedstawiono wyniki badań dotyczących przyczyn pękania lutospoin w różnoimiennych złączach zakładkowych wykonanych laserem diodowym dużej mocy ROFIN DL 020 z użyciem materiału dodatkowego w postaci proszku aluminium, na przykładzie łączenia cienkiej blachy aluminiowej z blachą stalową pokrytą elektrolitycznie powłoką cynkową. Przedstawiono wyniki badań metalograficznych makroskopowych i mikroskopowych. Wskazano na problemy oraz przedstawiono sugestie dotyczące technologii lutospawania laserowego materiałów znacznie różniących się własnościami fizycznymi i składem chemicznym.
EN
A study on cracking phenomena during laser braze welding of dissimilar lap joints between aluminum thin plate and galvanized low carbon sheet steel is described. The experiments were carried out using a high power diode laser Rofin DL020 and aluminum powder as filler metal. Macro and microstructure analysis of the joints were analysed. Issues and problems in laser braze welding of materials having different chemical composition and physical properties are presented.
PL
W artykule przedstawiono wyniki badań dotyczących skłonności do tworzenia się pęknięć w lutospoinach złączy zakładkowych cienkich blach aluminiowych i karoseryjnych blach stalowych obustronnie galwanizowanych cynkiem, które wykonywano laserem diodowym dużej mocy (HPDL) ROFIN DL 020 oraz łukowo metodą CMT z użyciem materiału dodatkowego odpowiednio w postaci proszku i drutu litego. Przedstawiono wyniki badań metalograficznych makroskopowych i mikroskopowych, rentgenografii strukturalnej, mikroanalizy rentgenowskiej EDS oraz pomiarów twardości. Wskazano na przyczyny powstawania w lutospoinach na osnowie aluminium, złączy różnoimiennych typu aluminium - ocynkowana stal niestopowa, kruchych faz międzymetalicznych typu Fe-Al.
EN
In this article results of studies on cracks formation susceptibility in braze-welded joints of thin aluminum sheets and double-sided zinc galvanized steel sheets for car body parts made by laser brazing with high power diode laser ROFIN DL 020 and CMT MIG-brazing, with filler material in form of powder and wire accordingly, were presented. Results of macro- and microscopic metallographic examinations, structural roentgenography, EDS microanalysis and hardness tests were presented. Causes of brittle intermetallic Fe-Al phases formation in Al-matrix filler metal in dissimilar aluminum - zinc plated carbon steel joints were pointed.
EN
The cooling rate is one of the main tools available to the process engineer by means of which it is possible to influence the crystallisation process. Imposing a desired microstructure on a casting as early as in the casting solidification phase widens significantly the scope of technological options at disposal in the process of aluminium-silicon alloy parts design and application. By changing the cooling rate it is possible to influence the course of the crystallisation process and thus also the material properties of individual microstructure components. In the study reported in this paper it has been found that the increase of cooling rate within the range of solidification temperatures of a complex aluminium-silicon alloy resulted in a decrease of values of the instrumented indentation hardness (HIT) and the instrumented indentation elastic modulus (EIT) characterising the intermetallic phase occurring in the form of polygons, rich in aluminium, iron, silicon, manganese, and chromium, containing also copper, nickel, and vanadium. Increased cooling rate resulted in supersaturation of the matrix with alloying elements.
EN
Al-enriched layer was formed on a magnesium substrate with use of casting. The magnesium melt was cast into a steel mould with an aluminium insert placed inside. Different conditions of the casting process were applied. The reaction between the molten magnesium and the aluminium piece during casting led to the formation of an Al-enriched surface layer on the magnesium substrate. The thickness of the layer was dependent on the casting conditions. In all fabricated layers the following phases were detected: a solid solution of Mg in Al, Al3Mg2, Mg17Al120 and a solid solution of Mg in Al. When the temperature of the melt and the mould was lower (variant 1 – 670oC and 310oC; variant 2 – 680oC and 310oC, respectively) the unreacted thin layer of aluminium was observed in the outer zone. Applying higher temperatures of the melt (685oC) and the mould (325oC) resulted in deep penetration of aluminium into the magnesium substrate. Areas enriched in aluminium were locally observed. The Al-enriched layers composed mainly of Mg-Al intermetallic phases have hardness from 187-256 HV0.1.
18
Content available remote Obróbka elektroerozyjna kompozytów Ni₃Al-TiC
PL
Obróbce elektroerozyjnej WEDM poddano materiały kompozytowe z intermetaliczną osnową Ni₃Al i fazą zbrojącą TiC w ilości 0, 10, 20, 30% obj. wytworzone w procesie metalurgii proszków. Jako parametry obróbki przyjęto czas impulsu ti i napięcie w impulsie U. W funkcji tych parametrów oceniano wydajność obróbki Vw, topografię i chropowatość powierzchni oraz stan tzw. warstwy białej.
EN
Composites with intermetallic matrix Ni₃Al reinforced with 0, 10, 20, 30% vol. TiC were wire electro discharge machined (WEDM). Materials were manufactured by powder metallurgy (P/M) using hot isostatic pressing (HIP).Material remove rate Vw, surface topography and roughness, white layer were investigated as a function of machining parameters (pulse time ti and load voltage U).
19
EN
Purpose: of this paper is to compare some properties of Ti-Al and Ti-Nb alloys to investigate on the possibility to jointly employed them industrially. Ti-Al alloys have been proposed because they present challenging characteristics for high temperature purposes and β type Ti-Nb alloy has specific mechanical properties at room temperature. Ti-Al alloys are very attractive materials and represent one of the most important materials employed for aero jet engines. The most promising alloy belonging to the above mentioned classes are predominantly based on simultaneously presence of two phases, namely γ-TiAl (gamma titanium aluminides) and α2-Ti3Al both with a fully lamellar microstructure and could replace Ni-based superalloys in some high temperature applications in aerospace and automotive industries. The most important advantages of such alloys compared to some superalloys consist in their low density correlated to their superior efficiency in service and reduced gas emission. Design/methodology/approach: The Ti-Al alloy have been produced by gravity casting, using a vibrating furnace, while the Ti-Nb alloy samples have been realized by the cold crucible levitation melting (CCLM) casting technology. Microstructural and mechanical characterization have been performed. Findings: The microstructural analysis for the Ti-Al alloy reveals a fully-lamellar microstructure with alternate plates of α2-(Ti3Al) and γ-(TiAl) plates. The grains have an average size of about 200 μm. For the Ti-Nb based alloy only a β mono-phase has been detected. This alloy has a equiaxed microstructure with an average grain dimension of about 170 μm. The Ti-Nb alloy presents a high mechanical strength while on the contrary that of the Ti-Al has been deleteriously affected by the presence of large gas porosities. Superior hardness values have been reached with Ti-Al alloy, due to the presence of hard γ-TiAl. Practical implications: The most important implication is related to the transfer toward the proper choice of the correct parameters during manufacturing. Originality/value: Investigation on the influence of the elemental composition enriched by other elements and casting processes on the defect development, the microstructural characteristics and on the mechanical behaviour of the alloys.
EN
he work is a continuation of the research carried out on a high-temperature calorimeter solution type on alloys from Ni-Al-Cr system. Thanks to the construction innovation introduced by authors the device allows the determination of the formation enthalpy of alloys at ambient and elevated temperatures. Experiments described in this article were carried out at three temperatures: 873K, 996K and 1150K on the alloys of the chemical compositions from the Ni75Al25 ÷ Ni87Cr13 section of the Ni-Al-Cr system. On the basis of changes in the enthalpy of formation with increasing chromium content of the alloys, points corresponding to places of phase boundaries γ′ / γ′+γ / γ in Ni-Al-Cr system were determined. A similar relationship was observed in previous studies of alloys from Ni75Al25÷Ni75Cr25 section. For precise determination of these characteristic points a statistical model was applied.
PL
Praca jest kontynuacją badań prowadzonych na skonstruowanym przez autorów wysokotemperaturowym kalorymetrze typu rozpuszczania. Urządzenie pozwala na określanie entalpii tworzenia stopów w podwyższonej temperaturze. Opisywane badania przeprowadzono w trzech temperaturach: 873K, 996K i 1150K na stopach o składach chemicznych znajdujących się na linii Ni75Al25÷Ni87Cr13 układu Ni-Al-Cr. Na podstawie zmian wartości entalpii tworzenia wraz ze wzrostem zawartości chromu w stopach stwierdzono istnienie punktów odpowiadających miejscom występowania granic międzyfazowych γ′ / γ′+γ / γ w układzie Ni-Al-Cr. Podobną zależność zaobserwowano w poprzednich badaniach dotyczących obszaru Ni75Al25÷Ni75Cr25. Aby precyzyjnie wyznaczyć te charakterystyczne punkty opracowano i zastosowano model statystyczny.
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