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The Influence of Inorganic Binder Type on Properties of Self-Hardening Moulding Sands Intended for the Ablation Casting Process

100%

Puzio S. , Kamińska J. , Angrecki M. , Major-Gabryś K.

tom Vol. 60, iss. 4

99--108

The aim of the present work is to compare the properties of self-hardening moulding sands based on inorganic binders based on sodium silicate of different modules, geopolymer binders and phosphate binders and to prove they can be used in the ablation casting process. Ablation casting is a process in which, directly after pouring the liquid alloy, the mould is sprayed with water until it is completely eroded and a finished, cooled casting is obtained. The use of proecological water-dilutable binder makes it possible to recover the sand matrix after drying the suspension that remains after the process. Moulding sands were prepared on the basis of four inorganic binders available on the market. For each of the moulding sands the bending strength was tested after 1, 2, 4 and 24 h of hardening. Then, the masses with optimum bending strength were selected and subjected to gas emissivity tests. A thermal analysis of moulding sands selected for testing was also carried out in order to determine the loss of mass during annealing. The susceptibility of moulds to erosion under the influence of ablative medium was also assessed by measuring the time of mould erosion. Tests showed the possibility of using self-hardening moulding sands based on inorganic binders for the ablation casting process of aluminium-silicon alloys.

Computer modelling of the ablation casting process and prediction of the strength properties of AC-42000 castings

75%

Małysza M. , Puzio S. , Major-Gabryś K. , Głowacki M. , Wilk-Kołodziejczyk D. , Kamińska J.

tom Vol. 22, No. 2

79--88

The demand for castings with superior properties has compelled the development and optimization of manufacturing technologies. By further developing already known techniques, we are able to contribute to the introduction of new research possibilities. The article presents the methodology of conducting simulation tests of the gravity casting process into sand moulds with the use of ablation. The ablation technique consists in spraying water through evenly spaced nozzles onto a mould into which the liquid casting alloy has been poured. The conducted research focuses on an alloy from the group of Al-Si alloys. In order to compare the effects of different techniques, additional tests were carried out for gravity casting into sand and metal die moulds. At the same time, virtual experiments were conducted to develop a simulation methodology for ablation casting technology, taking into account mould degradation. Additionally, the possibility of predicting the final mechanical properties of various manufacturing technologies was tested. Destructive tests were carried out to determine the mechanical properties in the cast samples, as well as microstructure tests and secondary dendrite spacing. The results of the mechanical tests are compared with the predicted simulation properties.