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1

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.

2

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.

3

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.

4

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.

5

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.

6

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

7

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

8

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).

9

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.

10

Zastosowanie spektrometrów HH-XRF w odlewniach i hutach

Linke P.

Przegląd Odlewnictwa

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2017

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Vol. 67, nr 5-6

178--179

11

Long-term Effects of Relative Humidity on Properties of Microwave Hardened Moulding Sand with Sodium Silicate

Stachowicz M., Granat K.

Archives of Foundry Engineering

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2017

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Vol. 17, iss. 3

127--132

EN

Moulding sands containing sodium silicate (water-glass) belong to the group of porous mixture with low resistance to increased humidity. Thanks to hydrophilic properties of hardened or even overheated binder, possible is application of effective methods of hydrous reclamation consisting in its secondary hydration. For the same reason (hydrophilia of the binder), moulds and foundry cores made of high-silica moulding sands with sodium silicate are susceptible to the action of components of atmospheric air, including the contained steam. This paper presents results of a research on the effect of (relative) humidity on mechanical and technological properties of microwave-hardened moulding mixtures. Specimens of the moulding sand containing 1.5 wt% of sodium water-glass with module 2.5 were subjected, in a laboratory climatic chamber, to long-term action of steam contained in the chamber atmosphere. Concentration of water in atmospheric air was stabilized for 28 days (672 h) according to the relative humidity parameter that was ca. 40%, 60% and 80% at constant temperature 20 °C. In three cycles of the examinations, the specimens were taken out from the chamber every 7 days (168 h) and their mechanical and technological parameters were determined. It was found on the grounds of laboratory measurements that moulds and cores hardened with microwaves are susceptible to action of atmospheric air and presence of water (as steam) intensifies action of the air components on glassy film of sodium silicate. Microwave-hardened moulding sands containing sodium silicate may be stored on a long-term basis in strictly determined atmospheric conditions only, at reduced humidity. In spite of a negative effect of steam contained in the air, the examined moulding mixtures maintain a part of their mechanical and technological properties, so the moulds and foundry cores stored in specified, controlled conditions could be still used in manufacture.

12

Quality and Safety Assurance of Iron Casts and Manufacturing Processes

Kukla S.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 2

17--20

EN

The scope of this work focuses on the aspects of quality and safety assurance of the iron cast manufacturing processes. Special attention was given to the processes of quality control and after-machining of iron casts manufactured on automatic foundry lines. Due to low level of automation and huge work intensity at this stage of the process, a model area was established which underwent reorganization in accordance with the assumptions of the World Class Manufacturing (WCM). An analysis of work intensity was carried out and the costs were divided in order to identify operations with no value added, particularly at individual manufacturing departments. Also an analysis of ergonomics at work stations was carried out to eliminate activities that are uncomfortable and dangerous to the workers' health. Several solutions were proposed in terms of rationalization of work organization at iron cast after-machining work stations. The proposed solutions were assessed with the use of multi-criteria assessment tools and then the best variant was selected based on the assumed optimization criteria. The summary of the obtained results reflects benefits from implementation of the proposed solutions.

13

Effect of Sand Base Grade and Density of Moulding Sands with Sodium Silicate on Effectiveness of Absorbing Microwaves

Stachowicz M.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 3

103--108

EN

In the paper, presented is a research on effectiveness of absorbing electromagnetic waves at frequency 2.45 GHz by unhardened moulding sands prepared of three kinds of high-silica base and a selected grade of sodium silicate. 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. Values of microwave power loss in the rectangular waveguide filled with unhardened moulding sands served for determining effectiveness of microwave heating. Balance of microwave power loss is of technological and economical importance for manufacture of high-quality casting moulds and cores of various shapes and sizes. It was found that relative density influences parameters of power output and power reflected from samples of moulding sand placed in a waveguide. Absorption expressed by the parameter Pabs is not related to granularity of high-silica base: fine, medium and coarse. It was found that the semiautomatic microwave slot line supports evaluation of effectiveness of microwave absorption on the grounds of power loss measurements and enables statistic description of influence of relative density of the sandmix on penetration of electromagnetic waves in unhardened moulding sands.

14

Application of ALSV(FD) logic and XTT knowledge representation in the range of ADI properties

Regulski K., Wilk-Kołodziejczyk D., Rojek B., Kluska-Nawarecka S., Adrian W. T.

Archives of Foundry Engineering

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2016

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Vol. 16, iss. 2

75--78

EN

The objective of studies presented in this publication was structuring of research knowledge about the ADI functional properties and changes in these properties due to material treatment. The results obtained were an outcome of research on the selection of a format of knowledge representation that would be useful in further work aiming at the design, application and implementation of an effective system supporting the decisions of a technologist concerning the choice of a suitable material (ADI in this case) and appropriate treatment process (if necessary). ALSV(FD) logic allows easy modelling of knowledge, which should let addressees of the target system carry out knowledge modelling by themselves. The expressiveness of ALSV (FD) logic allows recording the values of attributes from the scope of the modelled domain regarding ADI, which is undoubtedly an advantage in the context of further use of the logic. Yet, although the logic by itself does not allow creating the rules of knowledge, it may form a basis for the XTT format that is rule-based notation. The difficulty in the use of XTT format for knowledge modelling is acceptable, but formalism is not suitable for the discovery of rules, and therefore the knowledge of technologist is required to determine the impact of process parameters on values that are functional properties of ADI. The characteristics of ALSV(FD) logic and XTT formalism, described in this article, cover the most important aspects of a broadly discussed, full evaluation of the applicability of these solutions in the construction of a system supporting the decisions of a technologist.

15

The Influence of Reclaim Addition on the Emission of PAHs and BTEX from Moulding Sands with Furfuryl Resin with the Average Amount of Furfuryl Alcohol

Holtzer M., Żymankowska-Kumon S., Bobrowski A., Dańko R., Kmita A.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1 spec.

37--42

EN

In this paper, the results of decomposition of the moulding sand with furan-formaldehyde resin (with middle content of furfuryl alcohol about 50 %) also on a quartz matrix and with additions of a reclaimed material, under industrial conditions, are presented. Investigations of the gases emission in the test foundry plant were performed according to the original method developed in the Faculty of Foundry Engineering, AGH UST. The dependence of the emitted PAHs and BTEX group substances and ignition losses on the reclaim fraction in a moulding sand are of a linear character of a very high correlation coefficient R2. On the bases of the derived equations, it is possible to determine the amount of the emitted hazardous substances from the moulding sand containing the known fraction of the reclaim.

16

Nowe podejście do zarządzania zasobami ludzkimi w odlewni

Liszka K., Malinowski P.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 3 spec.

95--99

PL

Istotnym elementem zarządzania współczesnym przedsiębiorstwem jest zarządzanie zasobami ludzkimi, a zwłaszcza kompetencjami posiadanymi przez personel. Właściwe zarządzanie kompetencjami pracowników przekłada się na efektywność działania całego przedsiębiorstwa i wykorzystywane jest na etapie rekrutacji, oceny pracowniczej, wyznaczania ścieżek karier oraz opracowywania planu szkoleń. Luki w systemie kształcenia zawodowego na potrzeby branży odlewniczej sprzyjają rozwojowi tej koncepcji. Artykuł prezentuje sposób tworzenia i analizę profilu kompetencyjnego na przykładzie stanowiska „wytapiacza stali” oraz możliwość jego wykorzystania do stworzenia narzędzia informatycznego ułatwiającego prowadzenie polityki personalnej ukierunkowanej na kompetencje pracownicze zwłaszcza w kontekście zatrudniania nowych, często niewykwalifikowanych pracowników.

EN

An essential element of managing a modern enterprise is human resources management in which managing the competences of the personnel plays a significant role. Not only does it correspond with the efficiency of the whole company but is also used in recruitment process, employees' appraisal and proves extremely useful in the process of preparing the training plans or determining career paths. As the educational system in the field of foundry sector, is not fully developed and full of gaps the aforementioned concept is at an advantage. The article presents the way of creating and analyzing the competence profile based on an example of a position of a steel melter as well as the possibility of using such profile to create an information tool which will facilitate the human resources policy aimed at the employees' competences especially while hiring new and very often unqualified ones.

17

Natężenie hałasu na stanowisku do poziomego odlewania ciągłego aluminium

Wróbel T., Gonscz D., Kozakiewicz Ł.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 4 spec.

131--136

PL

Hałas jest zjawiskiem niepożądanym, występującym zarówno w życiu prywatnym jak i zawodowym człowieka , który w niesprzyjających warunkach może prowadzić do nieszczęścia. Celem niniejszej publikacji jest określenie poziomu natężenia hałasu emitowanego przez pracujący piec indukcyjny do poziomego ciągłego odlewania aluminiowego wlewka o średnicy 30 mm, chłodnicy oraz współpracującej piły tarczowej wykorzystywanej do cięcia wytworzonego wyrobu. Analiza wyników pozwoli na wskazanie, które spośród stanowisk roboczych operatora linii technologicznej mieści się w granicach normatywów higienicznych dotyczących dopuszczalnego natężenia hałasu, a które przekracza dozwolone wartości. Pozwoli to na dobór odpowiednich i skutecznych metod zabezpieczenia operatora przed niekorzystnym wpływem warunków pracy na jego zdrowie oraz przyczyni się do poprawy warunków pracy w ramach przyjętych standardów BHP.

EN

The noise is undesirable effect, occurring in private and professional life of a man which in unfavourable conditions can lead to disaster. The aim of the paper is to determine the level of noise emitted by induction furnace working for horizontal continuous casting of aluminium ingot with a diameter of 30 mm, a cooler and mating circular saw used to cut the manufactured product. Analysis of the results will indicate which of the operator workstations technological line is in the range of hygienic standards relating to the permissible noise level, which exceeds the allowed values. This will allow the selection of appropriate and effective methods to protect the operator from the adverse effects of working conditions on the health and contribute to the improvement of working conditions within accepted safety standards.

18

Investment Casting vs Replicast CS Considered in Terms of the Ceramic Mould Making and Dimensional Accuracy of Castings

Karwiński A., Haratym R., Biernacki R., Soroczyński A.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 1

45--48

EN

The article presents an analysis of the applicability of the Replicast CS process as an alternative to the investment casting process, considered in terms of the dimensional accuracy of castings. Ceramic shell moulds were based on the Ekosil binder and a wide range of ceramic materials, such as crystalline quartz, fused silica, aluminosilicates and zirconium silicate. The linear dimensions were measured with a Zeiss UMC 550 machine that allowed reducing to minimum the measurement uncertainty.

19

Comparison of Quality of Investment Castings Produced Based on the Rapid Prototyping Techniques with Products of Powder Sintering

Karwiński A., Haratym A., Soroczyński A., Kowalski P.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 3 spec.

31--34

EN

The proposed research work will be related to the comparison of the dimensional accuracy and surface roughness of elements produced by two different methods. Castings are made using modern rapid prototyping techniques and investment casting. For selected parts there will be presented an assessment in terms of manufacturability, design manufacturing costs, operating parameters and energy consumption of production. The analysis of used methods allow for the evaluation of their suitability as alternative manufacturing techniques.

20

Analysis of the Possibility of Using Dynamic Methods for Assessment of Investment Projects in the Domestic Foundry Industry

Szymszal J., Lis T., Gajdzik B., Kliś J.

Archives of Foundry Engineering

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2014

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Vol. 14, iss. 3

103--106

EN

A comparative analysis involving the evaluation of the effectiveness of investment projects can be based on various rules indicating selection of the most favorable decisions. The dynamic methods for assessment of investment projects discussed in this article, which consider the possibility of modifying the predetermined investment options, are quite complex and difficult to implement. They are used both in the construction phase of the new company, as well as in its subsequent modernization. The assessments should be characterized by a high coefficient of the economic efficiency. The, observed in practice, high dynamic variability of both the external and internal conditions under which the company operates is the reason why in the process of calculating the economic efficiency of investment projects, there is a significant number of random parameters affected by high uncertainty and risk. Investments in the metallurgical industry are characterized by a relatively long cycle of implementation and operation. These are capital-intensive projects and often mistakenly taken investment decisions end in failure of the investment project and, consequently, in the collapse of the company. In addition, the applied methods of risk assessment of investment projects, especially the dynamic ones, should be fully understood by managerial staff and constitute an easy to use, yet accurate tool for improving the efficiency of the company.