Andrzej Fijołek, Jagoda Ryba, Paweł Żak, Janusz Lelito

The application of CAD and CAE software to design and selection of foundry technology for casting of grey cast iron – brake disc


Describes the process of casting technology design that produces an iron casting brake disc using CAD and CAE tools. For design calculations of the individual filling and ventilating systems uses the formulas commonly available in the literature for the foundry industry. Design calculations, design CAD software - SOLIDWORKS and numeric simulations MAGMASOFT software made for four different technology. Analysis has allowed the selection of the best casting technology for cast iron brake disc. The selected technology is the best design of the casting system in terms of both shape and its powering. In addition, the selected technology is characterized by high yield out of other technologies, which leads to a reduction of the costs associated with the process of casting part - brake disc.

Keywords: 3D design, casting technology, CAD software, CAE software, numerical simulation,

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Piotr Dudek, Robert Żuczek, Mirosław Kaźmierczak, Michał Trojanowski

Strength analysis of horseshoes made using casting techniques


The article presents a fragment of results of R&D works carried out at the Foundry Research Institute concerning the development of modern casting materials from ferrous and non-ferrous alloys to make horseshoes with increased durability. Problems related to the development of the horse’s movement model and hoof mechanics are presented. On the basis of generally available data, strength analyzes of horseshoes made using castings techniques were carried out.

Keywords: horseshoe, strength analysis, aluminum alloys, iron alloys,

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Sabina Puzio

The effect of nickel content on structure and hardness of ductile iron in thin-walled castings


In the technology of ductile iron manufacture, graphite precipitates take the form of spheroids, and this shape has the least harmful effect on cast iron mechanical properties. The strength of ductile iron depends mainly on its matrix, and hence on the chemical composition, solidification kinetics and heat treatment technology. This article presents the results of micro-hardness and hardness measurements, and the results of metallographic examinations and thermal analysis carried out on thin-walled ductile iron castings with varying nickel content. The main aim of the research was to determine the effect of nickel content on structure and properties of ductile iron in thin-walled castings. To achieve the goal, ductile iron containing 0.001; 1.0; 10 and 24% Ni was manufactured. It has been shown that nickel stabilizes austenite. With the nickel content of 24%, a completely austenitic matrix was obtained, the addition of 10% Ni to the matrix produced martensite, considerably increasing the cast iron hardness. Low content of this additive had a pearlite-forming effect.

Keywords: ductile iron, structure, chemical composition, hardness, nickel content, thin-wall castings,

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Bartosz Opitek, Ewa Olejnik, Janusz Lelito

Composite zones obtained in situ in steel casts of crushing mill beaters


The aim of the presented study was to obtain the element of a crushing mill beater reinforced with a composite zone, working under the conditions of high abrasive wear as well as high pressures. By means of the SHSB method, a local composite zone was created consisting of very hard titanium carbide - TiC. The moulded pieces prepared beforehand in the casting mould were filled with liquid metal, whose heat caused the initiation of an in situ reaction - the formation of titanium carbide. The cast obtained in this way was subjected to tests. An analysis of the physical composition was performed on an X-ray diffractometer - XRD. Additionally, investigations with the use of a scanning electron microscope SEM were carried out in order to determine the shape, size and distribution of TiC. As a result of the conducted research, a high quality material was obtained, which was in line with the authors’ expectations.

Keywords: MMCs, TiC, in situ, local reinforcement, microstructure, crushing mill,

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Marcin Latałło-Anulewicz

Technical and economic aspects of technological conversion of Ni-based superalloys working in extreme conditions


The essence of the conversion process is the introduction of innovative in terms of materials and technology of cast parts, as components of manufactured machines and equipment in place of the traditional elements forged, welded, mechanically assembled parts. It is well known that the technology of casting, in contrast to other metal forming, mentioned above techniques will make it possible to give to metal even the most complicated shape - which gives the possibility to make integrated castings - essential elements of modern machines and equipment. Commonly used metal elements made by forging techniques have to be integrated by the use of welding techniques, or other metal joining techniques. This means that in almost every case a significant increase in weight of the entire item, low resistance to work in high temperature conditions, lower abrasion resistance. With the help to solve that case there are foundry technologies that are at the disposal of durable, resistant to high temperatures and thermal fatigue different types of metal material. At the same time using modern molding techniques it is possible to create an integrated casting component, which, as an element of the device is able to replace complex combined different techniques other metal parts. This will ensure the optimization of the performance of the final device. It is natural and obvious that not every piece of metal construction machine or equipment will be possible to replace by an integrated casting part. Therefore, the performing of conversion process should be preceded by a detailed study, research and application-oriented process towards the technical and economic viability of such a conversion. The current level of technology allows the realization of the conversion of cast metal components essential for construction machinery used in agriculture, construction, power generation and exploitation of natural resources.

Keywords: technological conversion, nickel superalloys,

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