Archives of Metallurgy and Materials

This paper discusses issues related to optimising the technological parameters of the process of brazing gold in a vacuum

furnace. An investigation of the brazing process was carried out for materials used in constructing components for aircraft engine

fuel systems. The vacuum brazed material was AMS 5510 stainless steel (in the form of plates and pipes). AMS 4787 (BAu-4) was

used as the brazing filler. In particular, the influence of the method of preparing the surface on solder spreading and the thickness

of the diffusion zone were analysed. The best spreading of solder was obtained for nickel plated surfaces. When the sample surface

was more rough or scratched, the effect of the spreading of solder was limited and the diffusion process of the solder into the base

material became dominant. Moreover, the influence of the brazing temperature on microstructure changes and on interdiffusion

of the AMS 5510 stainless steel/BAu-4 solder system was determined. It was observed that an increase in the brazing temperature

modifies the morphology of the formed joint by forming a massive and rounded phase. Furthermore, an increase in the brazing

temperature enhances the exchange of components.

The aim of these studies was to obtain single phase cubic modification of Li7La3Zr2O12 by mechanical milling and annealing of La(OH)3, Li2CO3 and ZrO2 powder mixture. Fritsch P5 planetary ball mill, Rigaku MiniFlex II X-ray diffractometer, Setaram TG-DSC 1500 analyser and FEI Titan 80-300 transmission electron microscope were used for sample preparation and investigations. The applied milling and annealing parameters allowed to obtain the significant contribution of c-Li7La3Zr2O12 in the sample structure, reaching 90%. Thermal measurements revealed more complex reactions requiring further studies.

3D printing is a technology with possibilities related to the production of elements of any geometry, directly from a digital project. Elements made of plastic are metalized to give new properties such as conductivity or corrosion resistance. In this work, experimental work related to the electroless deposition of metallic coatings on plastics was carried out. For this purpose, the copper and nickel coatings were catalytically deposited on elements printed using hard-lightened resin. The effect of the metallization time on the properties of copper and nickel coatings was determined. In addition, the process of deposition metals in the magnetic field was analyzed with different direction of magnetic field to the surface of the samples. The coatings were analyzed by XRF, XRD method and morphology of surface was observed by scanning electron microscopy (SEM).

The influence of the electrode geometry on the microstructure and corrosion behaviour of Co-Mo nano-crystalline coatings elaborated by electrodeposition is studied. The corrosion behaviour was determined in the Ringer’s solution at 25°C. Electrodeposition mechanisms are also discussed as a function of the electrode geometry. The electrode geometry was found to affect the growth rate and, under certain conditions, the microstructure (existence of channels and pores). It does not have influence on the corrosion behaviour.

The aim of this work is to develop a numerical model capable of predicting the grain density in the Mg-based matrix phase of an AZ91/SiC composite, as a function of the total mass fraction of the embedded SiC particles. Based on earlier work in a range of alloy systems, we assume an exponential relationship between the grain density and the maximum supercooling during solidification. Analysis of data from cast samples with different thicknesses, and mass fractions of added SiCp, permits conclusions to be drawn on the role of SiCp in increasing grain density. By fitting the data, an empirical nucleation law is derived that can be used in a micro model. Numerical simulation based on the model can predict the grain density of magnesium alloys containing SiC particles, using the mass fraction of the particles as inputs. These predictions are compared with measured data.

Hot Isostatic Pressing elaboration of Norem02, an austenitic-ferritic hypereutectoid stainless steel, leads to the formation of an austenitic matrix with a mixture of acicular M7C3 and globular M23C6 carbides. The sintering tests, carried out by using an AISI 304L container, showed that the final microstructure and the carbides’ distribution of the HIPed Norem02 are strongly influenced by the process parameters (heating and cooling rate, sintering time, holding temperature and pressure) and by the particles’ size, microstructure and phase distribution of the initial powder. The morphological, crystallographic and chemical analysis of the sintered samples were completed by comprehension of the diffusion phenomena at the Norem02/304L interface, enabling the establishment of a correlation between elaboration process and final microstructure.

The influence on the corrosion behaviour of Co-Mo nano-crystalline coatings of dissolved oxygen is studied in the Ringer’s solution and artificial saliva at 25°C. This was done by means of potentiodynamic tests and surface observations. It was shown that dissolved oxygen has no influence on passivity, oxidation of the coating and selective dissolution of cobalt. By contrast, dissolved oxygen affects corrosion. General corrosion was observed in the Ringer’s solution whereas pitting corrosion was found in artificial saliva.

In this work, three ceramic composite coatings Al2O3-3TiO2 C, Al2O3-13TiO2 C, and Al2O3-13TiO2 N were plasma sprayed on steel substrates. They were deposited with two conventional powders differing the volume fraction of TiO2 and nanostructured powder. The mechanical and tribological properties of the coatings were investigated and compared. The increase in TiO2 content from 3 wt.% to 13 wt.% in the conventional feedstock improved the mechanical properties and abrasion resistance of coatings. However, the size of the used powder grains had a much stronger influence on the properties of deposited coatings than the content of the titania phase. The Al2O3-13TiO2 coating obtained from nanostructured powder revealed significantly better properties than that plasma sprayed using conventional powder, i.e. 22% higher microhardness, 19% lower friction coefficient, and over twice as good abrasive wear resistance. In turn, the Al2O3-13TiO2 conventional coating showed an increase in microhardness and abrasive wear resistance, 36% and 43%, respectively, and 6% higher coefficient of friction compared to the Al2O3-3TiO2 conventional coating.

Nanoparticles are very fascinating area of science not only due to their unique properties but also possibility of producing new more complex materials, which may find an application in modern chemistry, engineering and medicine. In process of nanoparticles formation very important aspect is a rate of individual stage i.e. reduction, nucleation and autocatalytic growth, because this knowledge allows for proper materials design, morphology manipulation, stability. The last one aspect can be realized using proper electrostatic, steric and electrosteric stabilization. However until now nobody reports and measures kinetic rates of all stages during process of particles formation in the presence of steric stabilizers. Thus, the main contribution of this paper is determination of individual rate constants for nanoparticles formation in the presence of steric stabilizers and their comparison to the system without stabilizer. For this purpose, an aqueous solution of Au(III) and Pt(IV) ions were mixed with steric stabilizers like PVA and PVP, and reduced using L-ascorbic acid as a mild and sodium borohydride as a strong reductant. As a results stable nanoparticles were formed and process of their formation was registered spectrophotometrically. From obtained kinetic curves the values of observed rate constants for reduction metal ions, slow nucleation and fast autocatalytic growth were determined using Watzky-Finke model. It was found that the addition of polymer affects the rate of the individual stages. The addition of steric stabilizers to gold ions reduced with L-ascorbic acid causes that the process of nucleation and autocatalytic growth slows down and the value of observed rate constants for nucleation changes from 3.79·10–3 (without polymer) to 7.15·10–5s–1 (with PVA) and for growth changes from 1.15·103 (without polymer) to 0.48·102s–1M–1 (with PVA). However, the rate of the reduction reaction of Au(III) ions is practically unchanged. In case of using strong reductant the addition of polymer effects on the shape of kinetic curve for reduction of Au(III) and it suggests that mechanism is changed. In case of Pt(IV) ions reduction with L-ascorbic acid, the process speeds up a little when PVA was added. Determined values of observed rate constants for nucleation and growth platinum nanoparticles decrease twice comparing to the system without polymer. The reduction of Pt(IV) ions with sodium borohydride accelerates when PVP was added and slows down when PVA was used. Moreover, the size of obtained colloidal gold and platinum was also analysed using DLS method. Obtained results (rate constants) may be useful in the process of nanomaterials synthesis, in particular in microflow.

The presented results of investigations are part of a larger study focused on the optimization of the flow and mixing of liquid steel in the industrial tundish of continuous casting machine. The numerical simulations were carried out concern the analysis of hydrodynamic conditions of liquid steel flow in a tundish operating in one of the national steelworks. Numerical simulations were performed using the commercial code ANSYS Fluent. The research concerns two different speeds of steel casting. In real conditions, these speeds are the most commonly used in the technological process when casting two different groups of steel. As a result of computational fluid dynamics (CFD) calculations, predicted spatial distributions of velocity and liquid steel turbulence fields and residence time distribution (RTD) curves were obtained. The volume fractions of different flows occurring in the tundish were also calculated. The results of the research allowed a detailed analysis of the influence of casting speed on the formation of hydrodynamic conditions prevailing in the reactor.

In this work, the authors proposed a modification of the working space one-strand tundish adapted for slab casting process. Numerical simulations of liquid steel flow in the considered flow reactor were performed. The tundish is equipped with a dam with a multi-hole filter. Two variants of the filter hole arrangement were tested and their effect on the liquid steel flow hydrodynamic structure in the tundish was examined. The computer calculations results were verified by performing experiments on the water model. The result of numerical and physical simulations an RTD (Residence Time Distribution) type F curve was generated, which define the transition zone between the cast steel grades during the sequential casting process. The results of the researches showed that the modification of a dam with a multi-hole filter affects on the formation of the liquid steel flow hydrodynamic structure and the transition zone. Furthermore, examinations of the liquid steel refining ability in the considered tundish were carried out. The influence of the filter holes arrangement on the non-metallic inclusions flotation process to the slag phase and liquid steel filtration processes was checked. Numerical simulations were performed in the Ansys-Fluent computer program.

Determining the boundary conditions of heat transfer in steel manufacturing is a very important issue. The heat transfer effect during contact of two solid bodies occurs in the continuous casting steel process. The temperature fields of solids taking part in heat transfer are described by the Fourier equation. The boundary conditions of heat transfer must be determined to get an accurate solution to the heat conduction equation. The heat flux between the tool and the object processed depends mainly on temperature, pressure and time. It is very difficult and complicated to accomplish direct identification and determination of the boundary conditions in this process. The solution to this problem may be the construction of a process model, performing measurements at a test stand, and using numerical methods. The proposed model must be verified on the basis of parameters which can easily be measured in industrial processes. One of them is temperature, which may be used in inverse methods to determine the heat transfer coefficient. This work presents the methodology for determining the heat flux between two solid bodies staying in contact. It consists of two stages – the experiment and the numerical computation. The problem was solved by using the finite element method (FEM) and a numerical program developed at AGH University of Science and Technology in Krakow. The findings of the conducted research are relationships describing the value of the heat flux versus the contact time and surface temperature.

The article reports the results of a comparative analysis made for three novel unconventional gear wheel forging processes based on the authors’ patented [5,6,21] plastic forming methods developed chiefly for the purposes of extruding hollow products as well as valves and pins. These processes are distinguished by the fact that part of the tooling elements which are normally fixed during conventional forging are purposefully set in motion. This is intended to change the conditions of friction at the metal-tool contact surface and to induce additional thermal effects due to the transformation of the plastic deformation energy into thermal energy and, as a consequence, to improve the plastic flow of metal and to reduce the force parameters of the process.

In this article the structural and mechanical properties of grain refinement of Cu-Sn alloys with tin content of 10%, 15% and 20% using the KOBO method have been presented. The direct extrusion by KOBO (name from the combination of the first two letters of the names of its inventors – A. Korbel and W. Bochniak) method employs, during the course of the whole process, a phenomenon of permanent change of strain travel, realized by a periodical, two-sided, plastic metal torsion. Moreover the aim of this work was to study corrosion resistance. The microstructure investigations were performed using an optical microscope Olimpus GX71, a scanning electron microscope (SEM) and a scanning transmission electron microscope (STEM). The mechanical properties were determined with INSTRON 4505/5500 machine. Corrosion tests were performed using «Autolab» set – potentiostat/galvanostat from EcoChemie B.V. with GPES software ver. 4.9. The obtained results showed possibility of KOBO deformation of Cu-Sn casting alloys. KOBO processing contributed to the refinement of grains and improved mechanical properties of the alloys. The addition of tin significantly improved the hardness. Meanwhile, with the increase of tin content the tensile strength and yield strength of alloys decrease gradually. Ductility is controlled by eutectoid composition and especially δ phase, because they initiate nucleation of void at the particle/matrix interface. No significant differences in the corrosion resistance between cast and KOBO processed materials were found.

A series of nanocomposite graphene/CoFe2O4 and graphene/NiFe2O4 hybrid materials was synthesized via facile, one-pot solvothermal route. The materials were obtained using two pressure methods: synthesis in the autoclave and synthesis in the microwave solvothermal reactor. The use of a microwave reactor enabled to significantly shorten the synthesis time up to 15 min. All the syntheses were carried out in a solution of ethanol. The effect of processing conditions and composite composition on the physicochemical properties and electric conductivity was studied. The specific surface area, density, morphology, phase composition, thermal properties and electric conductivity of the obtained composites were investigated. The results of studies of composites obtained in an autoclave and in a microwave reactor were compared.

The article presents the results of research concerning AlCu4MgSi alloy ingots produced using horizontal continuous casting process under variable conditions of casting speed and cooling liquid flow through the crystallizer. The mechanical properties and structure of the obtained ingots were correlated with the process parameters. On the basis of the obtained results, it has been shown that depending on the cooling rate and the intensity of convection during solidification, significant differences in the mechanical properties and structure and of the ingots can occur. The research has shown that, as the casting speed and the flow rate of the cooling liquid increase, the hardness of the test samples decreases, while their elongation increases, which is related to the increase of the average grain size. Also, the morphology of the intermetallic phases precipitations lattice, as well as the centerline porosity and dendrite expansion, significantly affect the tensile strength and fracture mechanism of the tested ingots.

In this paper, the deviation from eutectic composition in boundary layer for eutectic growth is studied by phase-field method. According to a series of artificial phase diagram, the lamellar eutectic growth of these alloy is simulated during directional solidification. At steady state, average growth velocity of eutectic lamella is equal to the pulling velocity. With the increasing of the liquidus slope of β phase, the average composition in boundary layer would deviate from eutectic composition and the deviation increases. The constitutional undercooling difference between both solid phases caused by the deviation increases with the increasing of the deviation. The β phase would develop a depression under the influence of the deviation.

In contemporary high-pressure die casting foundries, the mastery of each sequence in the production cycle is more and more important. In the paper, an example of virtual analysis of gearbox casting from Al alloy will be presented. It includes a large variety of parameters, as follows: choosing of appropriate foundry technology, calculation of computer simulation of casting process which takes into account the filling process of cold chamber and filling of cavity, model description of three phases in high-pressure die casting, flow of molten metal, solidification, formation of stress and deformations. Additionally, the optimization of cooling and heating systems will be compared with calculated volume defects, dimensions of castings and their deformations with experimentally obtained values.

Many wire products (e.g. nets) are made from galvanized material. The hot dip galvanizing process gives the possibility of applying in a respectively thick coat of zinc (also depending on the time of staying wires in the bath) which provides the protection of the product against corrosion. In the available literature there were no research concerned with the influence of hot dip galvanizing process on the mechanical properties TRIP structure steel wires. Therefore, an experiment was carried out in laboratory conditions allowing the determination of the influence of hot dip galvanizing process parameters on the mechanical properties (tensile strength UST and yield strength YS) of TRIP steel wires as well as on the amount of retained austenite in their structure. It has been stated that the hot galvanizing process of TRIP steel wires influences, proportionally to the time of staying wires in zinc bath, on their plastic properties (the increase in yield strength YS) as well as the decrease in the amount of retained austenite in their structure. Such a phenomenon can be caused by stresses responsible for rapid heating of the wire put in the zinc bath in temperature of 450°C and by the strengthening of the materials resulting from the transformation of retained austenite.

The results are based on two experimental high-manganese X98MnAlSiNbTi24-11 and X105MnAlSi24-11 steels subjected to thermo-mechanical treatment by hot-rolling on a semi-industrial processing line. The paper presents the results of diffraction and structural studies using scanning and transmission electron microscopy showing the role of Nb and Ti micro-additives in shaping high strength properties of high-manganese austenitic-ferritic steels with complex carbides. The performed investigations of two experimental steels allow to explain how the change cooling conditions after thermo-mechanical treatment of the analysed steels affects the change of their microstructure and mechanical properties. The obtained results allow assessing the impact of both the chemical composition and the applied thermo-mechanical treatment technology on the structural effects of strengthening of the newly developed steels.

This paper presents results obtained from a laboratory investigation conducted on material from a pressure vessel after longterm operation in the oil refinery industry. The tested material contained structural defects which arose from improper heat treatment during steel plate manufacturing. Complex tensile tests with acoustic emission signal recording were conducted on both notched and unnotched specimens. The detailed analysis of different acoustic emission criteria allowed as to detect each stage of plastic deformation and microstructural damage processes after a long-term operation, and unused carbon steels during quasi-static axial tension testing. The acoustic emission activity, generated in the typical stages of material deformation, was correlated by microscopy observations during the tensile test. The results are to be used as the basis for new algorithms for the assessment of the structural condition of in-service pressure equipment.

The paper includes the TG-DTG thermogravimetric air-testing of a cellulose mixture modified with the additives of expanded vermiculite or expanded perlite. A thermal degradation test was carried out at 1000°C with a simultaneous qualitative analysis of the emitted gases. During the thermal degradation process, the thermal effects were also measured. The research results indicate that expanded vermiculite or expanded perlite do not emit toxic gases during thermal degradation. The cellulose mixture modification, with the additives of expanded vermiculite or perlite, does not result in the creation of new gaseous compounds in the process of thermal degradation. A s investigated below, the mixtures tested in this article find application in gating systems for supplying liquid metal in no-bake moulds. Such cellulose-based material solutions shall allow the foundry industry to introduce less gas vaporising technologies within the entire casting production process.

In this paper small punch test (SPT) which is one of miniaturized samples technique, was employed to characterize the mechanical properties of carbon steel P110. The tests were carried out in the range of –175°C to RT. Results obtained for SPT were compared to those calculated for tensile and Charpy impact test. Based on tensile and SPT parameters numerical model was prepared. 8 mm in diameter and 0.8 mm in height (t) discs with and without notch were employed in this research. The specimens had different depth notch (a) in the range of 0.1 to 0.4 mm. It was estimated that α factor for comparison of Tsp and DBTT for carbon steel P110 is 0.55 and the linear relation is DBTT = 0.55TSPT. The numerical model fit with force – deflection curve of SPT. If the factor of notch depth and samples thickness is higher than 0.3 the fracture mode is transformed from ductile to brittle at –150°C.

The paper presents the results of studies of hybrid composite layers Ni/Al2O3/Cgraphite produced by the electrodeposition method. Three variants of hybrid composite layers were prepared in electrolyte solutions with the same amounts of each dispersion phases which were equal to 0.25; 0.50 and 0.75 g/dm3. The structure of Ni/Al2O3/Cgraphite layers as well as the Al2O3 and graphite powders, which were used as dispersion phases was investigated. The results of morphology and surface topography of produced layers are presented. The modulus of elasticity and microhardness of the material of produced layers were determined by DSI method. Tribological and corrosion resistance tests of produced layers were carried out. Realized studies have shown that the material of the produced layers is characterized by a nanocrystalline structure. Incorporation of dispersion phases into the nickiel matrix increases the degree of surface development of layers. Ni/Al2O3/Cgraphite layers are characterized by high hardness and abrasion resistance by friction, furthermore, they provide good corrosion protection for the substrate material.

Modified Bohm’s formalism was applied to solve the problem of abstruse layer depth profiles measured by the Auger electron spectroscopy technique in real physical systems. The desorbed carbon/passive layer on an NiTi substrate and the adsorbed oxygen/ surface of an NiTi alloy were studied. It was shown that the abstruse layer profiles can be converted to real layer structures using the modified Bohm’s theory, where the quantum potential is due to the Auger electron effect. It is also pointed out that the stationary probability density predicts the multilayer structures of the abstruse depth profiles that are caused by the carbon desorption and oxygen adsorption processes. The criterion for a kind of break or “cut” between the physical and unphysical multilayer systems was found. We conclude with the statement that the physics can also be characterised by the abstruse measurement and modified Bohm’s formalism.

The knowledge whether and how chemical species react with tissues is important because of protection against harmful factors, diagnose of dermatological diseases, validation of dermatological procedures as well as effectiveness of topical therapies. In presented work the effects of chemical agents on plates of human fingernails were studied using Atomic Force Microscopy and Scanning Electron Microscopy. Apart from that, mapping of the elastic properties of the nails was also carried out. To obtain reliable measures of spatial evolution of the surface variations, recorded images were analyzed in terms of scaling invariance brought by fractal geometry, instead of common though not unique statistical measures.

Effects of charge composition on microstructure, mechanical and fatigue properties of nodular cast irons have been studied. For experiments, five melts of nodular cast iron were used – three types of unalloyed nodular cast irons (with different ratio of steel and pig iron in a charge and different additives for regulation of the chemical composition) and two types of alloyed nodular cast irons (SiMo- and SiCu- nodular cast iron). The microstructure of the specimens was evaluated according to a norm and by automatic image analysis. The mechanical properties were investigated by the tensile test, impact bending test and Brinell hardness test. The fatigue tests were carried out at sinusoidal cyclic push-pull loading at ambient temperature. The best mechanical properties were reached in the nodular cast iron alloyed by Si and Cu, what is related to its microstructure.

The paper presents investigations of microstructure of varistors of damaged surge arrester counters. A similar ZnO varistor, not subjected before to operation, was a point of reference in this research. The results of investigations of the ZnO varistors show an untypical phase composition of their material, which was characterized by unsatisfying homogeneity and cohesion. The degradation processes of varistor material in the subsequent stages were recognized and described. A harmful impact of humidity inside the untight surge arrester counter on its operation and its ZnO varistors was proved. Some conclusions being the result of the operation checking of surge arrester counters were presented too.

A method of using the electric charge in a capacitor was applied for the manufacture of thermocouple micro-joints. The motivation for the study was the need to produce a stable welded connection without affecting the geometry of the substrate, which was a thin sheet of Inconel 625 alloy (UNS designation N06625). Within the framework of the research work, a suitable workstation for micro-joints elaboration was built and welding experiments were performed using different electric charges. Studies carried out within the framework of the present work have shown that joints based on Inconel 625 alloy and platinum have the best application properties in the range of small-scale temperature measurements. They can be used, e.g., for monitoring the temperature distribution on the inner surfaces of electric motor casings. An undeniable advantage is in this case the high thermal resistance of both materials used to produce the joint, i.e. the Inconel 625 alloy and platinum. This allows them to be used at high temperatures under atmospheric conditions.

This paper analyses the heat treatment of the hot-dip zinc coating deposited on both cast iron and steel. The aim of research is to increase coating hardness and wear resistance without decreasing its anticorrosion properties. Hot-dip zinc coating was deposited in industrial conditions (acc. PN-EN ISO 10684) on disc shape samples and bolts M12x60. The achieved results were assessed on the basis of microscopic observation (with the use of an optical and scanning microscope), EDS (point and linear) analysis and micro-hardness measurements. It was discovered that the heat treatment of zinc coating results in an increase in hardness which is caused by the corresponding changes in microstructure.

The effect of cationic, anionic and nonionic surface active additives, organic compounds and polymers on the electrodeposition of Zn-Mo coatings on steel substrate and detailed characterization in chosen optimal conditions was studied. The influence of polyethylene glycol (PEG) various concentration, sodium dodecyl sulphate (SDS), triton X-100, d-sorbitol, cetyl trimethyl ammonium bromide (CTAB), thiourea and disodium ethylenediaminetetraacetate (EDTA) on the electrodeposition process was examined. The composition of deposits was defined by wavelength dispersive X-ray fluorescence spectrometry (WDXRF). Results has shown that the current efficiency of the electrodeposition of Zn-Mo coatings is 71.4%, 70.7%, 66.7% for 1.5 g/dm3 PEG 20000, 0.1 g/dm3 Triton X-100 and 0.75 M D-sorbitol respectively. The surface topography and roughness of selected coatings on steel was investigated by atomic force microscopy (AFM). The attendance of D-sorbitol of 0.75 M in the solution cause clear reduction of grain size and the value of roughness parameter (Ra) in relation to SDS, PEG, Triton X-100 and the sample prepared without the additives. The morphology of electrodeposited layers was studied by scanning electron microscopy (SEM). The addition of selected additives to the electrolytic bath results in the formation of smoother, brighter and more compact Zn-Mo coatings in comparison to layers obtained from similar electrolytes but without the addition of surfactants. The optimal concentration of the most effective additives such as PEG 20000, Triton X-100 and D-sorbitol is 1.5 g/dm3, 0.1 g/dm3, 0.75 M respectively.

The five-layer Aurivillius type structures with the general chemical formula Bi5Fe2-xMnxTi3O18, where x = 0, 0.6, 1.2 have been synthesized and tested. The SEM studies showed a significant increase in grain size in the manganese-modified Aurivillius type ceramic material (for x = 1.2). The increase in the amount of manganese ions (Mn3+) affects the decrease in the temperature at which the relaxation processes take place. Namely from 525 K (1 kHz) and 725 K (1 MHz) for BFT sample (x = 0) to 355 K (1 kHz) and 565 K (1 MHz) for BFM12T sample (x = 1.2). Using the Arrhenius’s law and the Vogel-Fulcher’s relationship the activation energy (Ea) and the relaxation time have been calculated. The value of Ea increases with the increase of the Mn amount from 0.737 eV (for x = 0) to 0.915 eV (for x = 1.2).

The paper presents the results of research on the influence of sintering temperature on microstructure, DC electrical conductivity, dielectric, ferroelectric and magnetic properties of PbFe1/2Nb1/2O3 ceramics doped by Li in the amount of 5.0% wt., in the abbreviation PLiFN. The ceramic samples of the PLiFN material were obtained by the two-stage synthesis – columbite method and sintered by free sintering methods. Introduction to the basic PbFe1/2Nb1/2O3 composition of the lithium admixture to decrease the electrical conductivity and reduction of dielectric loss. The tests have shown that the increase in sintering temperature orders the PLiFN ceramic microstructure, which has a positive effect on its electrophysical properties. At room temperature, the PLiFN ceramic samples show both ferroelectric and ferromagnetic properties. Considering the functional parameters of the obtained ceramic samples, the optimal technological conditions are 1100°C/2 h.

The objective of the research in this work was the modification of structure of carbide-type chromized layers, by the combination of diffusion chromizing with subsequent PVD treatment, consisting of chromium nitride deposition, carried out to improve their tribological properties. As a result, hybrid layers on the surface of tool steel were obtained. For comparison, the properties of single chromized carbide layers obtained in a diffusion chromizing process were tested. Investigations of layer microstructure, their mechanical properties, surface topography, adhesion of layers to the steel substrate, as well as tribological properties were conducted. The layer microstructure was characterized by X-ray diffraction and scanning electron microscopy. Topography of the layer surface was studied by an optical profilometer. The scratch test for investigations of layers adhesion to the steel substrate was used. Testing of tribological properties (linear wear) of the layers was performed by the three-cylinder-cone method. It was shown, that hybrid layers are characterized by a significantly smaller surface roughness than that of chromized carbide layers and their wear resistance improved almost twice with respect to carbide layers.

A series of copper oxide thin films were synthesized through direct current magnetron sputtering on glass and silicon substrates with various process parameters. Initially, optical microscopy images and their histograms were analyzed to determine the optical quality of the obtained layers and then histograms were created using Image Histogram Generator software. Next, the morphology, and cross-section and layer composition of the samples were evaluated. Finally, the transmission spectra of the thin films were recorded. Transmittance and reflection spectra of the UV–vis analysis were utilized to calculate the optical band gap, the extinction coefficient, and the absorption coefficient of the oxidized layers. Samples showed low transmittance (up to 40%) in the region of 400 to 1000 nm. The mean absorption coefficient varied from ~3 · 105 to ~6 · 105 1/cm and from ~2 · 105 to ~4 · 105 1/cm in the region of 2 eV to 3.5 eV. The extinction coefficient ranged from 0 to 0.11 in the region from 300 to 3000 nm. Reflectance of the samples was ~20% in the region of 1000 to 2500 nm and ranged from 20%-50% in the region of 1000 to 3000 nm. We verified the process parameters of the Cu2O structure to improve the quality as a buffer layer. On the basis of this preliminary analysis, we propose the most promising and future-oriented solutions in photovoltaic applications.

Analytical transmission electron microscopy has been applied to characterize the microstructure, phase and chemical composition of the Ag–Al wear track throughout its thickness down to the atomic level. Microscopy findings have been correlated with Ag–Al film tribological properties to understand the effect of the hexagonal solid solution phase on the tribological properties of this film. Ag–25Al (at.%) films have been produced by simultaneous magnetron sputtering of components in Ar atmosphere under 1 mTorr pressure and subjected to pin-on-disc tribological tests. It has been shown that hcp phase with (001) planes aligned parallel to the film surface dominates both in as-deposited and in tribofilm areas of the Ag–Al alloy film. Possible mechanisms of reduced friction in easily oxidized Ag–Al system are discussed and the mechanism based on readily shearing basal planes of the hcp phase is considered as the most probable one.

To figure out the reason causing ladle nozzle clogging during CC (continuous casting) of a non-oriented electrical steel with high silicon (or HNO for short) and get a method to address it, this paper studied the theoretical calculation of flow rates during CC, the inclusions around the slide gate where ladle nozzle clogging happened, and Ca-treatment at the end of RH for decreasing ladle clogging of the electrical steel both theoretically and practically. The results showed that: The bigger diameter of a nozzle or less nozzle clogging can guarantee an enough flow rate for reaching the target casting speed. Ladle nozzle clogging can be predicted by comparing the percentage of slide gate opening. Al2O3 and its composite inclusions were the main reason that caused the ladle nozzle clogging of the electrical steel. Higher [Al] or TO will increase the amount of Pure Ca wires for Ca-treatment. The results of the verification tests fit the thermodynamic calculation, and Ca-treatment using pure Ca wires could prevent ladle nozzles from clogging without affecting the magnetic properties of the electrical steel.

Effects of solution treatment on room temperature mechanical properties were studied in cast AZ91 (Mg-9%Al-1%Zn-0.2%Mn) and AZ91-0.5%Ca alloys. In as-cast state, the Ca addition contributed to the suppression of discontinuous β phase precipitation and the formation of Al2Ca phase. After solution treatment, the AZ91 alloy had only a small amount of Al8Mn5 particles, while β and Al2Ca phases were still present in the Ca-containing alloy. In as-cast state, the AZ91-0.5%Ca alloy showed better yield strength and hardness than the AZ91 alloy. The solution treatment increased the elongation in both alloys, which eventually led to the increase in ultimate tensile strength. The solution treatment resulted in a marked decrease in yield strength and hardness in the AZ91 alloy, whereas the decrements in those values were relatively negligible in the Ca-containing alloy due to the residual phases and solution hardening effect of Ca.

Temperature gradient zone melting (TGZM) method was used to obtain bulk Si continuously for the efficient separation and purification of primary Si from the Si-Al alloy in this work. The effects of alloy thickness, temperature gradient and holding time in TGZM purification technology were investigated. Finally, the continuous growth of bulk Si without eutectic inclusions was obtained. The results showed that the growth rate of bulk Si was independent of the liquid zone thickness. When the temperature gradient was changed from 2.48 K/mm to 3.97 K/mm, the growth rate of bulk Si was enhanced from 7.9×10–5 mm/s to 2.47×10–4 mm/s, which was increased by about 3 times. The bulk Si could grow continuously and the growth rate was decreased with the increase of holding time from 1 h to 5 h. Meanwhile, low refining temperature was beneficial to the removal of impurities. With a precipitation temperature of 1460 K and a temperature gradient of 2.48 K/mm, the removal rates of Fe, P and B were 99.8%, 94.0% and 63.6%, respectively.

The present study addresses the utilization of induction furnace steel slag which is an anthropogenic waste, for enhancing the mechanical properties of a commercial aluminium alloy A356. Different weight percentage (3wt%, 6wt%, 9wt%, and 12wt%) of steel slag particles in 1 to 10 μm size range were used as reinforcing particles in aluminium alloy A356 matrix. The composites were prepared through stir casting technique. The results revealed an improvement in mechanical properties (i.e. microhardness and tensile strength) and wear resistance with an increase in weight percentage of the steel slag particles. This research work shows promising results for the utilization of the steel slag for enhancing the properties of aluminium alloy A356 at no additional cost while assisting at same time in alleviating land pollution.

Sound joint of hollow-extruded 6005A-T6 aluminum alloy was achieved by friction stir welding and its high cycle fatigue performance was mainly investigated. As a result, the joint fatigue limit reaches 128.1 MPa which is 55% of the joint tensile strength. The fatigue fracture mainly occurs at the boundary between the stir zone and thermo-mechanically affected zone due to the large difference in the grain size. This difference is caused by the layered microstructure of the base material. The shell pattern with parallel arcs is the typical morphology in the fracture surface and the distance between arcs is increased with the increase of stress level. The specimen with the fracture located in the stir zone possesses a relatively low fatigue life.

The paper discusses the results of investigations of material, tribological and anti-corrosion properties of hybrid coatings of the Cr/CrN type, consisting of chromium and chromium nitride, formed on the surface of alloy tool steel by the Arc-PVD method. Investigations of the morphology and microstructure of hybrid coatings, as well as of their phase composition were carried out. The studies on mechanical properties included tests on hardness and Young’s modulus using the nanoindentation method. Tests on adhesion were conducted using the scratch-test method. Tribological properties of the obtained coatings were evaluated by the pin-on-disc method. Resistance to corrosion was determined by electrochemical methods. It was shown that hybrid coatings of the Cr/CrN type are characterized by good adhesion to the substrate and very good tribological properties, as well as by very good resistance to corrosion in a solution containing chlorine ions.

Deep cryogenic treatment (DCT) is gaining popularity as a treatment used to modify structures obtained during heat or thermo-chemical treatment. The article presents the influence of DCT, carried out during heat treatment before and after gas nitriding processes, on the formation of gas nitrided layers on X153CrMoV12 steel. It was found that the use of DCT between quenching and tempering performed prior to gas nitriding processes, increases the hardness, thickness and wear resistance of the nitrided layers. At the same time, if we apply cryogenic treatment during post-heat treatment of nitrided layers, we also get very high wear resistance and increased thickness of nitrided layers, in comparison with conventional gas nitriding of X153CrMoV12 steel. In this case, DCT significantly increases also the hardness of the core by the transformation of retained austenite and the precipitation of fine carbides of alloying elements.

The article presents a novel method that allows measurement of thermal conductivity that is based on Stefan-Boltzmann law. The developed method can be used to determine thermal conductivity of ceramic investment casting molds. The methodology for conducting thermal conductivity tests of ceramic material samples is presented. Knowledge of the value of thermal capacity and thermal conductivity as a function of temperature enables computer simulations of the process of cooling and solidification of liquid metal in a mold.

The paper presents a description of the phenomena occurring on the surface of the forging dies. A detailed analysis was made of 24 pre-forging dies due to the most intensive wear in this operation. To compare the results, new tools were also analysed. The research described in the study showed that the most dangerous factor for the hot forging process analysed is thermal-mechanical fatigue, which causes small cracks, which in turn quickly leads to the formation of a crack network on the entire contact surface of the tool with forged material. The second phenomenon is the tempering of the surface of the material for a long-term temperature effect. The presence of hard iron oxides in the form of scale from forging material is the accompanying phenomenon that intensifies the processes of tool wear. The paper presents the results of the analysis of the presence of residual magnetic field for forging tools and the results of laboratory tests of wear processes of tool steels for hot work in the presence of a magnetic field and in the presence of scale.

The present work discusses results of increased temperature on shape-dimensional changes of a 110 type hose coupling, produced from EN AC-AlSi11 alloy with the use of pressure die casting technology. The castings were soaked for 3.5 h at temperatures 460°C, 475°C and 490°C. The verification of shape-dimensional accuracy of the elements after soaking treatment, in relation to raw casting, was carried out by comparing the 3D models received from 3D scanning. Soaking temperature of about 460°C-475°C results in no significant changes in the shapes and dimensions of the castings, or surface defects in the form of blisters, which can be seen at a temperature of 490°C.

The numerical algorithm of thermal phenomena is based on the solution of the heat conduction equations in Petrov-Galerkin’s formula using the finite element method. In the modeling of phase transformation in the solid state, the models based on the diagrams of continuous heating and continuous cooling (CHT and CCT). In the modeling of mechanical phenomena, equations of equilibrium and constitutive relationships were adopted in the rate form. It was assumed that the hardened material is elastic-plastic, and the plasticizing can be characterized by isotropic, kinematic or mixed strengthening. In the model of mechanical phenomena besides thermal, plastic and structural strains, the transformations plasticity was taken into account. Thermo-physical size occurring in the constitutive relationship, such as Young’s modulus and tangential modulus, while yield point depend on temperature and phase composition of the material. The modified Leblond model was used to determine transformation plasticity. This model was supplemented by an algorithm of modified plane strain state, advantageous in application to the modeling of mechanical phenomena in slender objects. The problem of thermoelasticity and plasticity was solved by the FEM. In order to evaluate the quality and usefulness of the presented numerical models, numerical analysis of temperature fields, phase fractions, stresses and strains was performed, i.e. the basic phenomena accompanying surface layer of progressive-hardening with a movable heat source of slender elements made of tool steel for cold work.

Aluminum profiles play an important role in civil engineering (facades, walls with windows) as well as in mechanical engineering (production lines, constructions of 3D printers and plotters). To ensure quick assembly, disassembly or changed the dimensions of constructions it is not possible to use such methods as welding, adhesive or riveting joints. The solution may be to use the so-called “popular lock”. It is a mechanism, the closure of which is caused by tightening of the conical screw, joining the “T” profile in the node. In order to properly design using the presented type of connection, it is necessary to know its strength and stiffness both in simple and complex loads states, also including imperfections. In the literature there is no information about the operation of the construction node with the so-called “popular lock”. The paper presents the results of experimental tests for connections subjected to uniaxial tensile test, paying special attention to the defects that may appear during the assembly. In the next step, a 3D solid connection model was created. Numerical simulations were performed in the Abaqus / Explicite program for both uniaxial tensile test and bending tests in two planes. Limit values of loads above which there is a plastic deformation of the material were determined. Determination of stiffness and strength of a single node allowed to make a simplified connector model. Using the numerical model, the analysis was performed taking into account the influence of imperfections on the work of the entire connection.

Casting industry has been enriched with the processes of mechanization and automation in production. They offer both better working standards, faster and more accurate production, but also have begun to generate new opportunities for new foundry defects. This work discusses the disadvantages of processes that can occur, to a limited extend, in the technologies associated with mould assembly and during the initial stages of pouring. These defects will be described in detail in the further part of the paper and are mainly related to the quality of foundry cores, therefore the discussion of these issues will mainly concern core moulding sands. Four different types of moulding mixtures were used in the research, representing the most popular chemically bonded moulding sands used in foundry practise. The main focus of this article is the analysis of the influence of the binder type on mechanical and thermal deformation in moulding sands.

Internal casting defects that are detected by radiography may also be detected by ultrasonic method. Ultrasonic testing allows investigation of the cross-sectional area of a casting, it is considered to be a volumetric inspection method. The high frequency acoustic energy travels through the casting until it hits the opposite surface or an interface or defect. The interface or defect reflects portions of the energy, which are collected in a receiving unit and displayed for the analyst to view. The pattern of the energy deflection can indicate internal defect. Ultrasonic casting testing is very complicated in practice. The complications are mainly due to the coarse-grain structure of the casting that causes a high ultrasound attenuation. High attenuation then makes it impossible to test the entire volume of material. This article is focused on measurement of attenuation, the effect of probe frequency on attenuation and testing results.

The ablation casting technology consists in pouring castings in single-use moulds made from the mixture of sand and watersoluble binder. After pouring the mould with liquid metal, while the casting is still solidifying, the mould destruction (washing out, erosion) takes place using a stream of cooling medium, which in this case is water. The following paper focuses on the selection of moulding sands with hydrated sodium silicate technologies for moulds devoted to the ablation casting of aluminum alloys. It has been proposed to use different types of moulding sands with a water-soluble binder, which is hydrated sodium silicate. The authors showed that the best kind of moulding sands for moulds for Al alloy casting will be moulding sands hardened with physical factors – through dehydration. The use of microwave hardened moulding sands and moulding sands made in hot-box technology has been proposed. The tests were carried out on moulding sands with different types of modified binder and various inorganic additives. The paper compares viscosity of different binders used in the research and thermal degradation of moulding sands with tested binders. The paper analyzes the influence of hardening time periods on bending strength of moulding sands with hydrated sodium silicate prepared in hot-box technology. The analysis of literature data and own research have shown that molding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties for the ablation foundry of Al alloys.

The paper describes the influence of graphite shape, size and amount to electrical properties of different cast irons. Experiments of electrical resistivity measurements were conducted during solidification of four different melts in different time intervals from melt treatment by inoculation and nodularization. Metallographic analyses were made in order to determine the shape, size, distribution and amount of graphite and correlate results with electrical resistivity measurements. It was found out that nodular graphite is giving the lowest electrical resistivity and is decreased during solidification. Electrical resistivity of lamellar cast iron is increased during solidification since lamellas interrupt metal matrix severely There is no significant difference in resistivity of vermicular cast iron from nodular cast iron. Smaller size of graphite and lower amount of graphite and higher amount of metal matrix also decrease resistivity.

The combination of the austempered ductile iron mechanical properties strongly depend on the parameters used on the austempering cycle. On this study, the influence of austempering time and austenitizing temperature on the properties of a ductile iron were evaluated. A metallic bath of Zamak at 380°C was used as an austempering mean. A set of ductile iron blocks were austenitized at 900°C for 90 minutes and submitted to different austempering times in order to determine the best combination of microstructural and mechanical properties. After the definition of the time of austempering, the reduction of the austenitizing temperature was evaluated. The best combination of properties was obtained with austenitizing at 860°C and austempering during 60 minutes.

The purpose of the present paper was to investigate the effect of shot peening on the condition of the surface layer and abrasion resistance of specimens made of Ti-6Al-4V titanium alloy produced by Direct Metal Laser Sintering (DMLS) process. The specimens have been produced by means of EOSINT M280 system dedicated for laser sintering of metal powders and their surfaces have been subjected to the shot peening process under three different working pressures (0.2, 0.3 and 0.4 MPa) and by means of three different media i.e. CrNi steel shot, crushed nut shells and ceramic balls. The specimens have been subjected to profilometric analysis, to SEM examinations, microhardness tests and to tribological tests on ball-on-disc stand in Ringer fluid environment. The general results of all tests indicate to favourable effect of shot peening process on the hardness and tribological performance of titanium alloy.

This work presents a numerical simulation of aviation structure joined by friction stir welding, FSW, process. The numerical simulation of aviation structure joined by FSW was created. The simulation uses thermomechanical coupled formulation. Th model required creation of finite elements representing sheets, stiffeners and welds, definition of material models and boundary conditions. The thermal model took into account heat conduction and convection assigned to appropriate elements of the structure. Time functions were applied to the description of a heat source movement. The numerical model included the stage of welding and the stage of releasing clamps. The output of the simulation are residual stresses and deformations occurring in the panel. Parameters of the global model (the panel model) were selected based on the local model (the single joint model), the experimental verification of the local model using the single joint and the geometry of the panel joints.

The aim of the study was to analyse mechanical properties and microstructure of joints obtained using friction stir welding (FSW) technology. The focus of the study was on overlap linear FSW joints made of 1.4541 DIN 17441 steel sheets with thickness of 1.2 mm. Tools used during friction stir welding of steel joints were made of W-Re alloy. The joints were subjected to visual inspection and their load bearing capacity was evaluated by means of the tensile strength test with analysis of joint breaking mechanism. Furthermore, the joints were also tested during metallographic examinations. The analysis performed in the study revealed that all the samples of the FSW joints were broken outside the joint area in the base material of the upper sheet metal, which confirms its high tensile strength. Mean load capacity of the joints was 15.8 kN. Macroscopic and microscopic examinations of the joints did not reveal significant defects on the joint surface and in the cross-sections.

The paper presents a multi-scale mathematical model dedicated to a comprehensive simulation of resistance heating combined with the melting and controlled cooling of steel samples. Experiments in order to verify the formulated numerical model were performed using a Gleeble 3800 thermo-mechanical simulator. The model for the macro scale was based upon the solution of Fourier-Kirchhoff equation as regards predicting the distribution of temperature fields within the volume of the sample. The macro scale solution is complemented by a functional model generating voluminal heat sources, resulting from the electric current flowing through the sample. The model for the micro-scale, concerning the grain growth simulation, is based upon the probabilistic Monte Carlo algorithm, and on the minimization of the system energy. The model takes into account the forming mushy zone, where grains degrade at the melting stage – it is a unique feature of the micro-solution. The solution domains are coupled by the interpolation of node temperatures of the finite element mesh (the macro model) onto the Monte Carlo cells (micro model). The paper is complemented with examples of resistance heating results and macro- and micro-structural tests, along with test computations concerning the estimation of the range of zones with diverse dynamics of grain growth.

An analysis of the effect of drawing speed on the formation of a zinc coating in the multi-stage fine steel wire drawing process has been carried out in the article. Pre-hardened 2.2 mm-diameter material was drawn into 1.00 mm-diameter wire in 6 draws on a multi-stage drawing machine. The drawing process was carried out at a drawing speed of 5, 10, 15, 20 and 20 m/s, respectively. Mechanical tests were tests were performed for the final wires to determine their yield strength, ultimate tensile strength, uniform and total elongation and reduction in area. The thickness of the zinc coating on the wire surface was determined by the gravimetric method and based on metallographic examination. The use of electron scanning microscopy, on the other hand, enabled the identification of individual phases in the zinc coating. The above investigations were supplemented with corrosion testing of 1.00 mm-diameter wires. It has been demonstrated that drawing speed significantly influences not only the thickness of the zinc coating on the drawn wire surface, buts also its morphology and corrosion resistance.

The subject of the work is the analysis of thermomechanical bending process of a thin-walled tube made of X5CrNi18-10 stainless steel. The deformation is produced at elevated temperature generated with a laser beam in a specially designed experimental setup. The tube bending process consists of local heating of the tube by a moving laser beam and simultaneous kinematic enforcement of deformation with an actuator and a rotating bending arm. During experimental investigations, the resultant force of the actuator and temperature at the laser spot are recorded. In addition to experimental tests, the bending process of the tube was modelled using the finite element method in the ABAQUS program. For this purpose, the tube deformation process was divided into two sequentially coupled numerical simulations. The first one was the heat transfer analysis for a laser beam moving longitudinally over the tube surface. The second simulation described the process of mechanical bending with the time-varying temperature field obtained in the first simulation. The force and temperature recorded during experiments were used to verify the proposed numerical model. The final stress state and the deformation of the tube after the bending process were analyzed using the numerical solution. The results indicate that the proposed bending method can be successfully used in forming of the thin-walled profiles, in particular, when large bending angles and a small spring-back effect are of interest.

The article presents the results of the investigations performed on high manganese austenitic steel which underwent the test of uniaxial tension, with the application of electric current impulses. The application of low voltage impulse alternating current of high intensity during the plastic deformation of the examined steel caused the occurrence of the electroplastic effect, which changed the shape of the stress-strain curve. A drop of flow stress and elongation of the tested material was observed in the case of the application of electric current impulses, in respect of the material stretched without such impulses and stretched at an elevated temperature. The analysis of the morphology of the fractures showed differences between the samples tested under the particular conditions. An analysis of the alloy’s microstructure was also performed under different conditions. The application of electric current impulses can have a significant influence on the reduction of the forces in the plastic forming processes for this type of steel.