Archives of Foundry Engineering continues the publishing activity started by Foundry Commission of the Polish Academy of Sciences (PAN) in Katowice in 1978. The initiator of it was the first Chairman Professor Dr Eng. Wacław Sakwa – Corresponding Member of PAN, Honorary Doctor of Czestochowa University of Technology and Silesian University of Technology. This periodical first name was „Solidification of Metals and Alloys” , and made possible to publish the results of works achieved in the field of the Basic Problems Research Cooperation. The subject of publications was related to the title of the periodical and concerned widely understand problems of metals and alloys crystallization in a casting mold. In 1978-2000 the 44 issues have been published. Since 2001 the Foundry Commission has had patronage of the annually published “Archives of Foundry” and since 2007 quarterly published “Archives of Foundry Engineering”. Thematic scope includes scientific issues of foundry industry:
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0000-0003-2078-196X 0000-0002-3011-4434 0000-0002-4449-532X, AGH University of Technology, Kraków, Poland 0000-0003-0201-7191, PTIMA National Academy of Sciences of Ukraine, Kiev, Ukraine 0000-0002-8878-1037, AGH University of Technology, Kraków, Poland 0000-0002-6826-995X , Thapar University, Punjab, India 0000-0001-5198-3551, DTU in Lyngby, Denmark 0000-0002-6170-4728, VSB - Technical University of Ostrava, Ostrava, Czech Republic 0000-0001-8504-3744, University of Occupational Safety Management, Katowice, Poland 0000-0003-3555-2318, Silesian University of Technology, Gliwice, Poland 0000-0002-2675-1836, TU Bergakademie Freiberg, Freiberg, Germany 0000-0003-4901-7746, Warsaw University of Technology, Warszawa, Poland 0000-0002-9795-2352, TU Bergakademie Freiberg, Freiberg, Germany 0000-0003-2434-6025, AGH University of Technology, Kraków, Poland 0000-0002-7433-4092, Rzeszow University of Technology, Rzeszów, Poland 0000-0002-7374-9763, University of Zilina, Zilina, Slovak Republic 0000-0001-8912-2132, Universidade Federal de Uberlandia, Uberlandia, Brazil 0000-0001-6682-2611, AGH University of Technology, Kraków, Poland 0000-0002-6988-3329, AGH University of Technology, Kraków, Poland 0000-0003-0917-1810, Brno University of Technology, Brno, Czech Republic 0000-0001-6428-8961, Sardar Vallabhbhai Patel Institute of Technology, Vasad, Gujarat, India 0000-0001-8598-6953, Silesian University of Technology, Gliwice, Poland 0000-0001-6991-9793, Indian Institute of Technology, Kharagpur, India 0000-0002-5131-3483, Technical University Dresden, Dresden, Germany 0000-0002-0555-370X , Brno University of Technology, Brno, Czech Republic 0000-0002-0005-5314, CNR, Genova, Italy 0000-0002-4040-2798, Politehnica University of Bucharest Bucharest, Romania 0000-0002-7628-3524, University of Zilina, Zilina, Slovak Republic 0000-0003-3622-843X, Silesian University of Technology, Gliwice, Poland 00000002-7689-259X, Western Michigan University, Kalamazoo, MI, USA 0000-0003-3897-070X, Okayama University, Okayama, Japan 0000-0003-2287-9346, Technical University of Liberec, Liberec, Czech Republic 0000-0001-6521-2037, The University of Queensland, Brisbane, Australia 0000-0002-3024-9005, Jönköping University, Jönköping, Sweden 0000-0001-6903-328X, Silesian University of Technology, Gliwice, Poland 0000-0002-7019-3966, Silesian University of Technology, Gliwice, Poland 0000-0001-7840-5575, Silesian University of Technology, Gliwice, Poland 0000-0003-1683-0001, Silesian University of Technology, Gliwice, Poland 0000-0002-3229-6470, Silesian University of Technology, Gliwice, Poland
The paper presents the results of tests on the spheroidising treatment of vanadium carbides VC done with magnesium master alloy and mischmetal. It has been proved that the introduction of magnesium master alloy to an Fe-C-V system of eutectic composition made 34% of carbides crystallise in the form of spheroids. Adding mischmetal to the base alloy melt caused 28% of the vanadium carbides crystallise as dendrites. In base alloy without the microstructure-modifying additives, vanadium carbides crystallised in the form of a branched fibrous eutectic skeleton. Testing of mechanical properties has proved that the spheroidising treatment of VC carbides in high-vanadium cast iron increases the tensile strength by about 60% and elongation 14 - 21 times, depending on the type of the spheroidising agent used. Tribological studies have shown that high-vanadium cast iron with eutectic, dendritic and spheroidal carbides has the abrasive wear resistance more than twice as high as the abrasion-resistant cast steel.
The growth kinetics of the zinc coating formed on the surface of casting made from ductile iron grade EN-GJS-500-3 was investigated. To produce homogenous metal matrix in test samples, the normalising and ferritising annealing was carried out. Studies showed a heterogeneous structure of cast iron with varying content of the phases formed. This was followed by hot dip galvanising treatment at 450°C to capture the growth kinetics of the zinc coating (the time of the treatment ranged from 60 to 600 seconds). Nonlinear estimation of the determined growth kinetics of the alloyed layer of a zinc coating was made and an equation of the zinc coating growth was derived. Based on the results of the investigations it was concluded that thickness of the zinc coating formed on the surface of casting with a 100% pearlitic matrix makes 55% of the thickness of coating formed on the surface in 100% ferritic.
Thin metal film subjected to a short-pulse laser heating is considered. The parabolic two-temperature model describing the temporal and spatial evolution of the lattice and electrons temperatures is discussed and the melting process of thin layer is taken into account. At the stage of numerical computations the finite difference method is used. In the final part of the paper the examples of computations are shown.
AM50/Mg2Si composites containing 5.7 wt. % and 9.9 wt. %. of Mg2Si reinforcing phase were prepared successfully by casting method. The microstructure of the cast AM50/Mg2Si magnesium matrix composites was investigated by light microscopy and X-ray diffractometry (XRD). The microstructure of these composites was characterized by the presence of α-phase (a solid solution of aluminium in magnesium), Mg17Al12 (γ-phase), Al8Mn5 and Mg2Si. It was demonstrated that the Mg2Si phase was formed mainly as primary dendrites and eutectic.
Mathematical description of alloys solidification in a macro scale can be formulated using the one domain method (fixed domain approach). The energy equation corresponding to this model contains the parameter called a substitute thermal capacity (STC). The analytical form of STC results from the assumption concerning the course of the function fS = fS (T) describing the changes of solid state volumetric fraction and the temperature at the point considered. Between border temperatures TS , TL the function fS changes from 1 to 0. In this paper the volumetric fraction fS (more precisely fL = 1- fS ) is found using the simple models of macrosegregation (the lever arm rule, the Scheil model). In this way one obtains the formulas determining the course of STC resulting from the certain physical considerations and this approach seems to be closer to the real course of thermal processes proceeding in domain of solidifying alloy.
This study presents results of stress rupture test of MAR-M-509 cobalt alloy samples, as-cast and after surface refining with a concentrated stream of heat. Tests were conducted on samples of MAR-M-509 alloy castings, obtained using the lost-wax method. Casting structure refining was performed with the GTAW method in argon atmosphere, using the current I = 200 A and electrical arc scanning velocity vs = 100, 150, 200 and 250 mm/min. The effect of rapid resolidification of the MAR-M-509 alloy on the microstructure was examined and significant improvement in stress rupture test was observed.
This work presents the analysis of the final shaping process of the patterns aimed at determining the influence of the pressure and the time of sintering on the resistance to bending. The analysis of the research results proved that when the pressure of the sintering rises and reaches Ps=2.1 bar the resistance to bending increases, above this level of the pressure the resistance value starts decreasing. The time of styrofoam sintering at which the highest bending resistance values were obtained is ts=90 s. When the sintering pressure is less than 2 bar prolongation of the time of sintering over 90 s causes a slight increase in the resistance, however, at higher pressures prolongation of the time of sintering causes submelting of the styrofoam pattern.
In this paper results of microsegregation in the newly developed nodular cast iron with carbides are presented. To investigate the pearlitic and bainitic cast iron with carbides obtained by Inmold method were chosen. The distribution of linear elements on the eutectic cell radius was examined. To investigate the microsegregation pearlitic and bainitic cast iron with carbides obtained by Inmold method were chosen. The linear distribution of elements on the eutectic cell radius was examined. Testing of the chemical composition of cast iron metal matrix components, including carbides were carried out. The change of graphitizing and anti-graphitizing element concentrations within eutectic cell was determined. It was found, that in cast iron containing Mo carbides crystallizing after austenite + graphite eutectic are Si enriched.
In this article the main problems related with the proper choice of the design and operation parameters of vacuum installation in vacuum moulding system have been discussed. In such system a vacuum are generated using electric-driven vacuum pumps. The aim of the experiment is to evaluate the performance of a vacuum system basing on registered plots of selected electric power parameters of the power-supplying system of the pumps with parallel measurements instantaneous values of pressure in selected points of model stand. The measurements system for power-supply unit has incorporated the recorders of instantaneous current and voltage values. Following the suitable numerical procedure, the experimental data are analysed to yield mathematical relationships between the variations of the generated vacuum pressure levels and variations of selected electric power parameters. According to the authors, the applied measurements system of the parameters of a vacuum-assisted installation may become an effective and easy practical method of evaluating the performance of such installations, used also in industry.
The paper presents results of examination of material parameters of cast iron with structure obtained under rapid resolidification conditions carried out by means of the nanoindentation method.
The work is a continuation of research on the use of water mist cooling in order to increase efficiency of the die-casting process for aluminum alloys. The paper describes the multipoint sequential cooling system of the casting die and its computer control and monitoring. It also includes results of the tests and analysis of cooling methods during making of the casting. These methods differ from each other in the sequence of casting die cooling and cause effective changes in microstructure and mechanical properties of castings made of AlSi11 alloy. The study demonstrated that the use of multipoint sequential cooling with water mist affects the microstructure refinement and reduces the segregation in the cast as well as more than by 20% increases the mechanical properties of castings in the rough state. The study also demonstrates that the sequential cooling of casting die accelerates the cooling of the casting and shortens die-casting cycle.
The paper presents a new numerical model of solidification processes in hypoeutectic alloys. The model combines stochastic elements, such as e.g. random nucleation sites and orientation of dendritic grains, as well as deterministic methods e.g. to compute velocity of dendritic tips and eutectic grains. The model can be used to determine the temperature and the size of structure constituents (of both, the primary solid phase and eutectics) and the arrangement of individual dendritic and eutectic grains in the consecutive stages of solidification. Two eutectic transformation modes, typical to modified and unmodified hypoeutectic alloys, have been included in the model. To achieve this, cellular automata and Voronoi diagrams have been utilized.
The contribution summarises the results of oxygen activity determinations, which were measured and registered continuously in castings from cast irons with various types of graphite. The results were used to find the relationship between two variables: natural logarithm of oxygen activities and reverse value of thermodynamic temperature 1 /T. Obtained regression lines were used to calculate oxygen activity at different temperatures, to calculate Gibbs free energy ΔG at the different temperatures and to calculate the single ΔG value for significant temperature of the graphite solidification. The results were processed by a statistical analysis of data files for the different types of graphite with flake, vermicular and spheroidal graphite. Each material has its proper typical oxygen activities range and individual temperature function of Gibbs free energy for analysing and governing casting quality.
In sand moulds, at a distance of 3 mm from the metal- mould interface, the sensors of temperature, and of oxygen and hydrogen content were installed. Temperature and the evolution of partial gas pressure have been analysed in moulds bonded with bentonite with or without the addition of seacoal, water glass or furan resin. Moulds were poured with ductile iron. For comparison, also tests with the grey iron have been executed. It was found that the gas atmosphere near the interface depends mainly on the content of a carbonaceous substance in the mould. In the green sand moulds with 5% of seacoal or bonded with furan resin, after the mould filling, a sudden increase in the hydrogen content and the drop of oxygen is observed. This gas evolution results from the oxidation of carbon and reduction of water vapour in the mould material, and also from the reduction of water vapour and alloy reoxidation. In carbon-free sand, the evolution in the gas composition is slower because water vapour is reduced only at the interface. Changes of oxygen and hydrogen content in the controlled zone are determined by the transport phenomena.
The aim of the paper was an attempt at applying the time-series analysis to the control of the melting process of grey cast iron in production conditions. The production data were collected in one of Polish foundries in the form of spectrometer printouts. The quality of the alloy was controlled by its chemical composition in about 0.5 hour time intervals. The procedure of preparation of the industrial data is presented, including OCR-based method of transformation to the electronic numerical format as well as generation of records related to particular weekdays. The computations for time-series analysis were made using the author’s own software having a wide range of capabilities, including detection of important periodicity in data as well as regression modeling of the residual data, i.e. the values obtained after subtraction of general trend, trend of variability amplitude and the periodical component. The most interesting results of the analysis include: significant 2-measurements periodicity of percentages of all components, significance 7-day periodicity of silicon content measured at the end of a day and the relatively good prediction accuracy obtained without modeling of residual data for various types of expected values. Some practical conclusions have been formulated, related to possible improvements in the melting process control procedures as well as more general tips concerning applications of time-series analysis in foundry production.
A determination of the heating degree of the moulding sand with bentonite on the grounds of simulating investigations with the application of the MAGMA program, constitutes the contents of the paper. To this end the numerical simulation of the temperature distribution in the virtual casting mould was performed. It was assumed that the mould cavity was filled with a moulding sand with bentonite of a moisture content 3,2 % and bentonite content 8 %. A computer simulation can be used for predicting the heating degree of moulding sands with bentonite. Thus, prediction of the active bentonite (montmorillonite) content in individual layers of the overheated moulding sand can be done by means of the simulation. An overheating degree of a moulding sand with bentonite, and thus the bentonite deactivation depends on a temperature of a casting alloy, casting mass, ratio of: masssand : masscasting, moulding sand amount in the mould and contact area: metal – mould (geometry of the casting shape). Generally it can be stated, that the bentonite deactivation degree depends on two main factors: temperature of moulding sand heating and time of its operation.
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