Władysław Madej, Stanisław Pysz, Irena Izdebska-Szanda, Janusz Miklaszewski, Tadeusz Zdończyk

The ecological and material-saving technology for producing brake blocks with stable parameters of quality. Part 1. Technology modernization using computer simulation


The presented article is the first in the series, which presents research related to the improvement of technology for producing brake blocks for the railway industry in the Spomel foundry in Lębork.
The cooperation with the Foundry Research Institute started with the implementation of a project which modernised the process for producing casts of a new generation of non-sparking brake blocks for the needs of the railway industry in the years 2000-2001. Within the framework of this project an ecological and material-saving technology was developed for producing non-sparking brake blocks with high quality parameters. The research results obtained from the development of the technology are presented in the present article.
The research included, among other things, the development of a method for feeding the cast, the selection of moulding and core sands which ensure improved dimensional accuracy and quality of surfaces of casts, stabilisation of technological parameters of produced casting moulds, the research of the structure, mechanical properties and abrasion of examined cast material, as well as determination of technological parameters for the casting process.

Keywords: brake block casts, improving the quality of the cast, moulding sand, reducing costs, saving energy and material, environmental protection, decreasing work arduousness,

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Piotr Dudek, Aleksander Fajkiel, Tomasz Reguła, Jacek Bochenek

Research on ablation casting technology for aluminium alloys


The article presents preliminary results of research on ablation casting technology. The guidelines for the design of equipment to carry out the process are described. Based on the above mentioned instructions a test stand was developed and built. Many tests were performed concerning the influence of the water jet directed at a sand mould on its removal tendency. The effect of the cooling rate of tested cast parts on its microstructure were studied based on metallographic and radiographic tests.

Keywords: ablation casting, aluminum alloys, microstructure,

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Robert Żuczek, Andrzej Gwiżdż, Damian Wróblewski

Computer simulation of stresses occurring as a result of applied heat treatment


On the basis of assumed curves of treatment the distribution of temperature fields was determined in selected model castings achieved during heat analysis, then assuming these values as boundary conditions an integrated strength analysis was carried out with the aim of determining maximum values which describe the effort of the construction under the impact of operating heat stresses. The conducted static analysis of stresses and displacements in a casting placed in a furnace assumed placing a single element without the possibility of heat interaction with other elements, with the assumption of two schemes of conducted heat treatment.

Keywords: computer simulation of stresses in castings, ferritic spheroidal graphite cast iron, heat treatment, castings for the rail industry ablation casting, aluminum alloys, microstructure,

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Piotr Długosz, Paweł Darłak, Piotr Drzymała, Jerzy J. Sobczak

Fly ash as a reinforcement of light metal matrix composites. Part 3. The influence of a chemical composition on characteristic fusibility temperatures of coal fly ashes


Temperature properties of fly ash are closely correlated to the chemical composition and proportions of the main compounds, comprising the waste material. Statistical analysis of data obtained during the measurement of fusibility, showed a high correlation of characteristic temperatures and chemical composition, especially in the case of melt and flow temperature of the ash with a high content of silica and alumina oxides. A large amount of experimental data collected allowed for reliable and confirmed formulation of mathematical models describing the temperature characteristics as a function of the fraction of a given element in the chemical composition.

Keywords: power industry, coal, fly ash, waste management, high temperature investigations, AL FA composites,

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