Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149256
D. Sundaram, T. Matsushita, I. Belov, A. Diószegi
Predicting the permeability of different regions of foundry cores and molds with complex geometries will help control the regional outgassing, enabling better defect prediction in castings. In this work, foundry cores prepared with different bulk properties were characterized using X-ray microtomography, and the obtained images were analyzed to study all relevant grain and pore parameters, including but not limited to the specific surface area, specific internal volume, and tortuosity. The obtained microstructural parameters were incorporated into prevalent models used to predict the fluid flow through porous media, and their accuracy is compared with respect to experimentally measured permeability. The original Kozeny model was identified as the most suitable model to predict the permeability of sand molds. Although the model predicts permeability well, the input parameters are laborious to measure. Hence, a methodology for replacing the pore diameter and tortuosity with simple process parameters is proposed. This modified version of the original Kozeny model helps predict permeability of foundry molds and cores at different regions resulting in better defect prediction and eventual scrap reduction.
预测具有复杂几何形状的铸造型芯和铸模不同区域的渗透性有助于控制区域放气，从而更好地预测铸件缺陷。在这项工作中，使用 X 射线显微层析技术对制备的具有不同体积特性的铸造型芯进行了表征，并对获得的图像进行了分析，以研究所有相关的晶粒和孔隙参数，包括但不限于比表面积、比内部体积和迂回度。获得的微观结构参数被纳入用于预测流体流经多孔介质的预估模型，并将其准确性与实验测量的渗透率进行比较。最初的 Kozeny 模型被认为是最适合预测砂模渗透性的模型。虽然该模型能很好地预测渗透率，但输入参数的测量却很费力。因此，提出了一种用简单工艺参数替代孔隙直径和迂回度的方法。这种原始 Kozeny 模型的改进版有助于预测铸造模具和型芯在不同区域的渗透性，从而更好地预测缺陷并最终减少废品。
{"title":"Evaluation of Permeability Models for Foundry Molds and Cores in Sand Casting Processes","authors":"D. Sundaram, T. Matsushita, I. Belov, A. Diószegi","doi":"10.24425/afe.2024.149256","DOIUrl":"https://doi.org/10.24425/afe.2024.149256","url":null,"abstract":"Predicting the permeability of different regions of foundry cores and molds with complex geometries will help control the regional outgassing, enabling better defect prediction in castings. In this work, foundry cores prepared with different bulk properties were characterized using X-ray microtomography, and the obtained images were analyzed to study all relevant grain and pore parameters, including but not limited to the specific surface area, specific internal volume, and tortuosity. The obtained microstructural parameters were incorporated into prevalent models used to predict the fluid flow through porous media, and their accuracy is compared with respect to experimentally measured permeability. The original Kozeny model was identified as the most suitable model to predict the permeability of sand molds. Although the model predicts permeability well, the input parameters are laborious to measure. Hence, a methodology for replacing the pore diameter and tortuosity with simple process parameters is proposed. This modified version of the original Kozeny model helps predict permeability of foundry molds and cores at different regions resulting in better defect prediction and eventual scrap reduction.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"16 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140229569","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149253
B. Białobrzeska
This article presents the results of research into the characteristics of cast steel alloyed with chromium and vanadium, subjected to heat treatment for increased strength parameters. In the first part, it discusses the state-of-the-art knowledge regarding technological developments in the field of cast-steel alloys and the influence of individual alloying additives on the microstructure and the properties of the steel alloy. Further sections present the results of microstructure observations performed with light microscopy, scanning electron microscopy, and transmission electron microscopy. This research focuses on the material in the state directly after casting and after heat treatment, which involved quenching and tempering at 200 °C. The microstructural analysis performed as part of this research has informed the discussion of the results obtained from tensile and impact strength tests. The article also includes the results of a fractography analysis performed as the final part of the tests and offers a general summary and conclusions.
本文介绍了为提高强度参数而对铬和钒合金铸钢进行热处理的特性研究成果。文章第一部分讨论了铸钢合金领域技术发展的最新知识，以及各种合金添加剂对合金钢微观结构和性能的影响。其他部分介绍了用光学显微镜、扫描电子显微镜和透射电子显微镜观察微观结构的结果。本研究的重点是材料铸造后的直接状态和热处理后的状态，热处理包括 200 °C 淬火和回火。作为研究一部分的微观结构分析为拉伸和冲击强度测试结果的讨论提供了依据。文章还包括作为试验最后一部分进行的断口分析结果，并提供了总体总结和结论。
{"title":"Characteristics of High-Strength Cast Steel Micro-Alloyed with Vanadium","authors":"B. Białobrzeska","doi":"10.24425/afe.2024.149253","DOIUrl":"https://doi.org/10.24425/afe.2024.149253","url":null,"abstract":"This article presents the results of research into the characteristics of cast steel alloyed with chromium and vanadium, subjected to heat treatment for increased strength parameters. In the first part, it discusses the state-of-the-art knowledge regarding technological developments in the field of cast-steel alloys and the influence of individual alloying additives on the microstructure and the properties of the steel alloy. Further sections present the results of microstructure observations performed with light microscopy, scanning electron microscopy, and transmission electron microscopy. This research focuses on the material in the state directly after casting and after heat treatment, which involved quenching and tempering at 200 °C. The microstructural analysis performed as part of this research has informed the discussion of the results obtained from tensile and impact strength tests. The article also includes the results of a fractography analysis performed as the final part of the tests and offers a general summary and conclusions.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"2 4","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140228990","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149263
A. Bajwoluk, P. Gutowski
Austenitic Fe-Ni-Cr alloys are commonly used for the production of castings intended for high-temperature applications. One area where Fe-Ni-Cr castings are widely used is the equipment for heat treatment furnaces. Despite the good heat resistance properties of the materials used for the castings, they tend to develop cracks and deformations over time due to cyclic temperature changes experienced under high temperature operating conditions. In the case of carburizing furnace equipment, thermal stresses induced by the temperature gradient in each operating cycle on rapidly cooled elements have a significant influence on the progressive fatigue changes. In the carburized subsurface zone, also the different thermal expansion of the matrix and non-metallic precipitates plays a significant role in stress distribution. This article presents the results of analyses of thermal stresses in the surface and subsurface layer of carburized alloy during cooling, taking into account the simultaneous effect of both mentioned stress sources. The basis for the stress analyzes were the temperature distribution in the cross-section of the cooled element as a function cooling time, determined numerically using FEM. These distributions were taken as the thermal load of the element. The study presents the results of analyses on the influence of carbide concentration increase on stress distribution changes caused by the temperature gradient. The simultaneous consideration of both thermal stress sources, i.e. temperature gradient and different thermal expansions of phases, allowed for obtaining qualitatively closer results than analyzing the stress sources independently
{"title":"The Effect of Carbide Concentration at Grain Boundaries on Thermal Stresses in Castings for Heat Treatment Furnace Tooling","authors":"A. Bajwoluk, P. Gutowski","doi":"10.24425/afe.2024.149263","DOIUrl":"https://doi.org/10.24425/afe.2024.149263","url":null,"abstract":"Austenitic Fe-Ni-Cr alloys are commonly used for the production of castings intended for high-temperature applications. One area where Fe-Ni-Cr castings are widely used is the equipment for heat treatment furnaces. Despite the good heat resistance properties of the materials used for the castings, they tend to develop cracks and deformations over time due to cyclic temperature changes experienced under high temperature operating conditions. In the case of carburizing furnace equipment, thermal stresses induced by the temperature gradient in each operating cycle on rapidly cooled elements have a significant influence on the progressive fatigue changes. In the carburized subsurface zone, also the different thermal expansion of the matrix and non-metallic precipitates plays a significant role in stress distribution. This article presents the results of analyses of thermal stresses in the surface and subsurface layer of carburized alloy during cooling, taking into account the simultaneous effect of both mentioned stress sources. The basis for the stress analyzes were the temperature distribution in the cross-section of the cooled element as a function cooling time, determined numerically using FEM. These distributions were taken as the thermal load of the element. The study presents the results of analyses on the influence of carbide concentration increase on stress distribution changes caused by the temperature gradient. The simultaneous consideration of both thermal stress sources, i.e. temperature gradient and different thermal expansions of phases, allowed for obtaining qualitatively closer results than analyzing the stress sources independently","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"46 11","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140228705","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149261
R. Władysiak
This paper presents the results of a study on the use of infrared thermography to assess the quality of liquid metal, a basic semi-finished product used in foundry production. EN AC-46000 alloy with the designation AlSi9Cu3(Fe) was used for the study. The crystallization process of the alloy was investigated using the TDA method with a Crystaldigraph device and Optris PI thermal imaging camera. The research describes how to use a thermal imaging camera to assess the quality of aluminium alloys. These alloys, due to their propensity in the liquid state to oxidise and absorb hydrogen, a refining procedure in the melting process. The effects of alloy refining are evaluated during technological tests of hydrogen solubility, density and casting shrinkage. The results presented in this paper showed that there is a statistical correlation between the density of the metal and the temperature values from the thermogram of the sample, obtained during its solidification. The existing correlation makes it possible to develop a thermographic inspection algorithm that allows a fast and non-contact assessment of aluminium alloy quality.
本文介绍了使用红外热成像技术评估液态金属质量的研究结果，液态金属是铸造生产中使用的一种基本半成品。研究使用了名称为 AlSi9Cu3(Fe)的 EN AC-46000 合金。使用 TDA 方法、Crystaldigraph 设备和 Optris PI 热像仪对合金的结晶过程进行了研究。该研究介绍了如何使用热像仪评估铝合金的质量。这些合金由于在液态下容易氧化和吸收氢气，因此在熔化过程中需要进行精炼。在氢溶解度、密度和铸造收缩率的技术测试中，对合金精炼的影响进行了评估。本文的研究结果表明，金属密度与样品凝固过程中的热图温度值之间存在统计相关性。现有的相关性使得开发一种热成像检测算法成为可能，这种算法可以快速、非接触式地评估铝合金的质量。
{"title":"Quality Control of Liquid Aluminium Alloy Using Thermal Imaging Camera","authors":"R. Władysiak","doi":"10.24425/afe.2024.149261","DOIUrl":"https://doi.org/10.24425/afe.2024.149261","url":null,"abstract":"This paper presents the results of a study on the use of infrared thermography to assess the quality of liquid metal, a basic semi-finished product used in foundry production. EN AC-46000 alloy with the designation AlSi9Cu3(Fe) was used for the study. The crystallization process of the alloy was investigated using the TDA method with a Crystaldigraph device and Optris PI thermal imaging camera. The research describes how to use a thermal imaging camera to assess the quality of aluminium alloys. These alloys, due to their propensity in the liquid state to oxidise and absorb hydrogen, a refining procedure in the melting process. The effects of alloy refining are evaluated during technological tests of hydrogen solubility, density and casting shrinkage. The results presented in this paper showed that there is a statistical correlation between the density of the metal and the temperature values from the thermogram of the sample, obtained during its solidification. The existing correlation makes it possible to develop a thermographic inspection algorithm that allows a fast and non-contact assessment of aluminium alloy quality.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"36 7","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140230283","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149262
A. Dmitruk, K. Naplocha, A. Żak, A. Strojny-Nędza
Microwave Assisted Self-propagating High-temperature Synthesis (MASHS) was used to prepare open-porous MAX phase preforms in Ti-Al-C and Ti-Si-C systems, which were further used as reinforcements for Al-Si matrix composite materials. The pretreatment of substrates was investigated to obtain open-porous cellular structures. Squeeze casting infiltration was chosen to be implemented as a method of composites manufacturing. Process parameters were adjusted in order to avoid oxidation during infiltration and to ensure the proper filling. Obtained materials were reproducible, well saturated and dense, without significant residual porosity or undesired interactions between the constituents. Based on this and the previous work of the authors, the reinforcement effect was characterized and compared for both systems. For the Al-Si+Ti-Al-C composite, an approx. 4-fold increase in hardness and instrumental Young's modulus was observed in relation to the matrix material. Compared to the matrix, Al-Si+Ti-Si-C composite improved more than 5-fold in hardness and almost 6-fold in Young's modulus. Wear resistance (established for different loads: 0.1, 0.2 and 0.5 MPa) for Al-Si+Ti-Al-C was two times higher than for the sole matrix, while for Al-Si+Ti-Si-C the improvement was up to 32%. Both composite materials exhibited approximately two times lower thermal expansion coefficients than the matrix, resulting in enhanced dimensional stability.
{"title":"Refinement of the Manufacturing Route and Evaluation of the Reinforcement Effect of MAX Phases in Al Alloy Matrix Composite Materials","authors":"A. Dmitruk, K. Naplocha, A. Żak, A. Strojny-Nędza","doi":"10.24425/afe.2024.149262","DOIUrl":"https://doi.org/10.24425/afe.2024.149262","url":null,"abstract":"Microwave Assisted Self-propagating High-temperature Synthesis (MASHS) was used to prepare open-porous MAX phase preforms in Ti-Al-C and Ti-Si-C systems, which were further used as reinforcements for Al-Si matrix composite materials. The pretreatment of substrates was investigated to obtain open-porous cellular structures. Squeeze casting infiltration was chosen to be implemented as a method of composites manufacturing. Process parameters were adjusted in order to avoid oxidation during infiltration and to ensure the proper filling. Obtained materials were reproducible, well saturated and dense, without significant residual porosity or undesired interactions between the constituents. Based on this and the previous work of the authors, the reinforcement effect was characterized and compared for both systems. For the Al-Si+Ti-Al-C composite, an approx. 4-fold increase in hardness and instrumental Young's modulus was observed in relation to the matrix material. Compared to the matrix, Al-Si+Ti-Si-C composite improved more than 5-fold in hardness and almost 6-fold in Young's modulus. Wear resistance (established for different loads: 0.1, 0.2 and 0.5 MPa) for Al-Si+Ti-Al-C was two times higher than for the sole matrix, while for Al-Si+Ti-Si-C the improvement was up to 32%. Both composite materials exhibited approximately two times lower thermal expansion coefficients than the matrix, resulting in enhanced dimensional stability.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"35 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140229212","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-19DOI: 10.24425/afe.2024.149254
M. Bruna, I. Vasková, M. Medňanský, P. Delimanová
The paper deals with the possibilities of using alkali silicate based inorganic binders for automotive industry aluminium castings production. In recent years, inorganic binders are coming back to the foreground and their manufacturers are developing new processes, which are starting to progressively supersede organic binder systems. Paper describes known knowledge about classic alkali silicate binders with focus on hardening processes and on improving their technological properties. Trends from the area of development and the use new alkali silicate based inorganic binders are also shortly described. As part of the experimental work, specific methods of producing samples were developed, with the help of which properties such as disintegration were subsequently evaluated by measuring abrasion and residual strengths. Characteristics such as residual compressive strength or shear strength at different thermal loads were also evaluated. When comparing the laboratory results with the results of de-coring in real conditions, a high degree of correlation was achieved, which makes it possible to determine the optimal recipe/procedure for the production of geometrically complex cores.
{"title":"Research of the New Laboratory Methodology for Measuring the Disintegration of Mixtures with Inorganic Binders Hardened by Dehydration","authors":"M. Bruna, I. Vasková, M. Medňanský, P. Delimanová","doi":"10.24425/afe.2024.149254","DOIUrl":"https://doi.org/10.24425/afe.2024.149254","url":null,"abstract":"The paper deals with the possibilities of using alkali silicate based inorganic binders for automotive industry aluminium castings production. In recent years, inorganic binders are coming back to the foreground and their manufacturers are developing new processes, which are starting to progressively supersede organic binder systems. Paper describes known knowledge about classic alkali silicate binders with focus on hardening processes and on improving their technological properties. Trends from the area of development and the use new alkali silicate based inorganic binders are also shortly described. As part of the experimental work, specific methods of producing samples were developed, with the help of which properties such as disintegration were subsequently evaluated by measuring abrasion and residual strengths. Characteristics such as residual compressive strength or shear strength at different thermal loads were also evaluated. When comparing the laboratory results with the results of de-coring in real conditions, a high degree of correlation was achieved, which makes it possible to determine the optimal recipe/procedure for the production of geometrically complex cores.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"55 12","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140228665","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-18DOI: 10.24425/afe.2024.149252
Marcin M. Marciniak
This study investigates image processing techniques for detecting surface cracks in spring steel components, with a focus on applications like Magnetic Particle Inspection (MPI) in industries such as railways and automotive. The research details a comprehensive methodology that covers data collection, software tools, and image processing methods. Various techniques, including Canny edge detection, Hough Transform, Gabor Filters, and Convolutional Neural Networks (CNNs), are evaluated for their effectiveness in crack detection. The study identifies the most successful methods, providing valuable insights into their performance. The paper also introduces a novel batch processing approach for efficient and automated crack detection across multiple images. The trade-offs between detection accuracy and processing speed are analyzed for the Morphological Top-hat filter and Canny edge filter methods. The Top-hat method, with thresholding after filtering, excelled in crack detection, with no false positives in tested images. The Canny edge filter, while efficient with adjusted parameters, needs further optimization for reducing false positives. In conclusion, the Top-hat method offers an efficient approach for crack detection during MPI. This research offers a foundation for developing advanced automated crack detection system, not only to spring sector but also extends to various industrial processes such as casting and forging tools and products, thereby widening the scope of applicability.
{"title":"Image Processing Techniques for Crack Detection in MPI of Springs","authors":"Marcin M. Marciniak","doi":"10.24425/afe.2024.149252","DOIUrl":"https://doi.org/10.24425/afe.2024.149252","url":null,"abstract":"This study investigates image processing techniques for detecting surface cracks in spring steel components, with a focus on applications like Magnetic Particle Inspection (MPI) in industries such as railways and automotive. The research details a comprehensive methodology that covers data collection, software tools, and image processing methods. Various techniques, including Canny edge detection, Hough Transform, Gabor Filters, and Convolutional Neural Networks (CNNs), are evaluated for their effectiveness in crack detection. The study identifies the most successful methods, providing valuable insights into their performance. The paper also introduces a novel batch processing approach for efficient and automated crack detection across multiple images. The trade-offs between detection accuracy and processing speed are analyzed for the Morphological Top-hat filter and Canny edge filter methods. The Top-hat method, with thresholding after filtering, excelled in crack detection, with no false positives in tested images. The Canny edge filter, while efficient with adjusted parameters, needs further optimization for reducing false positives. In conclusion, the Top-hat method offers an efficient approach for crack detection during MPI. This research offers a foundation for developing advanced automated crack detection system, not only to spring sector but also extends to various industrial processes such as casting and forging tools and products, thereby widening the scope of applicability.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"265 29‐32","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140233540","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-18DOI: 10.24425/afe.2024.149255
P. Smolarczyk, M. Krupiński, M. Węglowski, W. Pakieła, P. Śliwiński
The paper presents the effect of electron beam alloying on the surface of a copper flat bar (M1Ez4) with titanium powder. Due to the quality of the surface after alloying and the obtained properties, the parameters used were given which met the assumed conditions to the greatest extent. The microstructure and mechanical properties as well as the chemical composition of surface-modified electron-beam copper show improved mechanical properties, i.e. hardness and abrasion resistance. This article uses research techniques using scanning electron microscopy and analysis of chemical composition in micro-areas (EDS). In order to examine the properties of the material after electron beam modification, hardness measurements were performed at low loads (HV0.1), abrasion resistance was tested, and conductivity was also measured. As a result of modifying the chemical and phase composition of M1E copper using an electron beam, the hardness increased by 46%, while the conductivity decreased by 16% due to the formation of intermetallic phases during solidification.
{"title":"Copper Beam Electron Alloying with Ti Powder","authors":"P. Smolarczyk, M. Krupiński, M. Węglowski, W. Pakieła, P. Śliwiński","doi":"10.24425/afe.2024.149255","DOIUrl":"https://doi.org/10.24425/afe.2024.149255","url":null,"abstract":"The paper presents the effect of electron beam alloying on the surface of a copper flat bar (M1Ez4) with titanium powder. Due to the quality of the surface after alloying and the obtained properties, the parameters used were given which met the assumed conditions to the greatest extent. The microstructure and mechanical properties as well as the chemical composition of surface-modified electron-beam copper show improved mechanical properties, i.e. hardness and abrasion resistance. This article uses research techniques using scanning electron microscopy and analysis of chemical composition in micro-areas (EDS). In order to examine the properties of the material after electron beam modification, hardness measurements were performed at low loads (HV0.1), abrasion resistance was tested, and conductivity was also measured. As a result of modifying the chemical and phase composition of M1E copper using an electron beam, the hardness increased by 46%, while the conductivity decreased by 16% due to the formation of intermetallic phases during solidification.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"10 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140234584","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-18DOI: 10.24425/afe.2024.149260
Junjie Zhu, Jian Feng, Ling Liu, Huafang Wang, Jijun Lu
Iron black commonly employs in thermal insulation riser sleeves due to its ability to react with aluminum powder, generating heat. However, the complex production process and unstable composition of iron black lead to high production costs. The potential of using arc furnace flue ash (AFFA) as a complete substitute for iron black and MnO2 and KNO3 oxidizing agents in conventional riser sleeves was investigated in this study. Waste material can be transformed into a valuable resource, while production costs can be reduced by utilizing arc furnace flue ash. The research examined the impact of varying types and amounts of arc furnace flue ash on riser sleeve temperature and holding time by conducting single-factor and orthogonal optimization experiments. The orthogonal optimization experiment determined that the optimum ratio of each oxidant was 6 % arc flue ash, 3 % MnO2 and 6 % KNO3. At this time, the highest temperature was 1512 ℃ and the holding time was 244 s. Results indicated that different types of arc furnace flue ash used as an oxidizing agent demonstrated superior holding capacity and heat generation performance compared to iron black. Additionally, a comparative analysis of factory casting experiments using ductile iron 600-3 (IS) revealed that both arc furnace flue ash and iron black risers effectively countered shrinkage. However, arc furnace flue ash risers exhibited improved mechanical properties, as evidenced by the hardness of the castings.
{"title":"Application of Arc Furnace Flue Ash in Casting Heat Insulation Riser","authors":"Junjie Zhu, Jian Feng, Ling Liu, Huafang Wang, Jijun Lu","doi":"10.24425/afe.2024.149260","DOIUrl":"https://doi.org/10.24425/afe.2024.149260","url":null,"abstract":"Iron black commonly employs in thermal insulation riser sleeves due to its ability to react with aluminum powder, generating heat. However, the complex production process and unstable composition of iron black lead to high production costs. The potential of using arc furnace flue ash (AFFA) as a complete substitute for iron black and MnO2 and KNO3 oxidizing agents in conventional riser sleeves was investigated in this study. Waste material can be transformed into a valuable resource, while production costs can be reduced by utilizing arc furnace flue ash. The research examined the impact of varying types and amounts of arc furnace flue ash on riser sleeve temperature and holding time by conducting single-factor and orthogonal optimization experiments. The orthogonal optimization experiment determined that the optimum ratio of each oxidant was 6 % arc flue ash, 3 % MnO2 and 6 % KNO3. At this time, the highest temperature was 1512 ℃ and the holding time was 244 s. Results indicated that different types of arc furnace flue ash used as an oxidizing agent demonstrated superior holding capacity and heat generation performance compared to iron black. Additionally, a comparative analysis of factory casting experiments using ductile iron 600-3 (IS) revealed that both arc furnace flue ash and iron black risers effectively countered shrinkage. However, arc furnace flue ash risers exhibited improved mechanical properties, as evidenced by the hardness of the castings.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"46 2","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140232479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-03-18DOI: 10.24425/afe.2024.149258
J. Majerník, M. Podaril, M. Majernikova
During the casting cycle, the relatively cold material of the mold comes into contact with the significantly higher temperature melt, which causes high temperature fluctuations on the face of the mold and in its volume, which cause cyclic temperature stress. The submitted article is based on conclusions of the article “Evaluation of the temperature distribution of a die casting mold of X38CrMoV5_1 steel”, in which the modification of temperature relations of the mold in the direction from the mold face to its volume was investigated. In current article, the influence of the tempering channel distance on the temperature modification in the volume of high pressure die casting mold is investigated. Three variants of the tempering channels placements with different location respecting the mold cavity were investigated. The temperature was monitored in two selected locations, with distribution of 1mm, 2mm, 5mm, 10mm and 20mm in the direction from the mold cavity surface to the volume of fixed and movable part of the mold. As a comparative parameter, the temperature of the melt in the center of the runner above the measuring point and the temperature of the melt close to the face of the mold were monitored. The measurement was performed using Magmasoft simulation software. It was discovered that up to a distance of 5mm from the face of the mold, a zone with complete heat transit without its accumulation occurs. Above this limit, the mold begins to accumulate heat, and from distance of 20mm from the face of the mold, the heat gradually passes into the entire mass of the mold without significant temperature fluctuations. The propositions derived from the results of the experiments presented at the end of the article will subsequently be experimentally verified in further research works.
{"title":"Evaluation of High Pressure Die Casting Mold Temperature Relations Depending on the Location of the Tempering Channels","authors":"J. Majerník, M. Podaril, M. Majernikova","doi":"10.24425/afe.2024.149258","DOIUrl":"https://doi.org/10.24425/afe.2024.149258","url":null,"abstract":"During the casting cycle, the relatively cold material of the mold comes into contact with the significantly higher temperature melt, which causes high temperature fluctuations on the face of the mold and in its volume, which cause cyclic temperature stress. The submitted article is based on conclusions of the article “Evaluation of the temperature distribution of a die casting mold of X38CrMoV5_1 steel”, in which the modification of temperature relations of the mold in the direction from the mold face to its volume was investigated. In current article, the influence of the tempering channel distance on the temperature modification in the volume of high pressure die casting mold is investigated. Three variants of the tempering channels placements with different location respecting the mold cavity were investigated. The temperature was monitored in two selected locations, with distribution of 1mm, 2mm, 5mm, 10mm and 20mm in the direction from the mold cavity surface to the volume of fixed and movable part of the mold. As a comparative parameter, the temperature of the melt in the center of the runner above the measuring point and the temperature of the melt close to the face of the mold were monitored. The measurement was performed using Magmasoft simulation software. It was discovered that up to a distance of 5mm from the face of the mold, a zone with complete heat transit without its accumulation occurs. Above this limit, the mold begins to accumulate heat, and from distance of 20mm from the face of the mold, the heat gradually passes into the entire mass of the mold without significant temperature fluctuations. The propositions derived from the results of the experiments presented at the end of the article will subsequently be experimentally verified in further research works.","PeriodicalId":505283,"journal":{"name":"Archives of Foundry Engineering","volume":"20 5","pages":""},"PeriodicalIF":0.0,"publicationDate":"2024-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"140232834","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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