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FLY ASH AS A COMPONENT OF THE REINFORCEMENT OF LIGHT ALLOY METAL MATRIX COMPOSITES. PART 1. COAL COMBUSTION BY-PRODUCTS MANAGEMENT


The first part of the publication presents the structure of global power industry market. Fundamental technologies of heat and electricity production in conventional coal combustion processes are considered,with sp...

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MANUFACTURING PROCESS AND MECHANICAL PROPERTIES OF ORDERED, CELLULAR CONSTRUCTIONS CAST FROM Al-Si ALLOY


Ordered cellular constructions are an important structural element used in armaments, aerospace and automotive industry. The use of Rapid Prototyping technique and control of solidification process allow making cas...

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EFFECT OF ULTRASOUNDS ON LOW-ENERGY PROCESSES AND ELECTROLYTIC CONDUCTIVITY OF MOULDING DUST WASTE SUBJECTED TO ADVANCED OXIDATION


The article presents the basic characteristics of the pollutants emitted in the process of foundry mould manufacture. A method to reduce harmful emissions through the application of advanced oxidation was described...

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DEVELOPMENT OF TECHNOLOGY TO MANUFACTURE „MODIFIED BENTONITE” USED IN PRODUCTION OF STEEL CASTINGS WITH SPECIAL REGARD TO CASTING SURFACE QUALITY


The article presents the most important results of the research, development and implementation studies carried out under one of the Target Projects as a result of cooperation between the CERTECH Technical and Comm...

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ANALYSIS OF THE POURING AND SOLIDIFICATION PROCESS OF ALLOYED STEEL CASTINGS FOR LOW - TEMPERATURE PERFORMANCE


The study forms a part of the program of applied industrial research executed under Target Project No. ROW-II-403/2008 at MAGNUS-NORD Sp z o.o in Toruń. Pouring and solidification of two large steel castings weigh...

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IDENTIFICATION BY DSH POWDER METHOD OF CRYSTAL PHASES OF SILICA IN DUST EMITTED FROM SAND FOUNDRY


In view of the documented pathogenic effect on human health of dust containing crystalline silica, an attempt has been made to identify different variations of polymorphic silica in samples of dust emitted from fou...

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EFFECT OF HEAT TREATMENT ON THE MECHANICAL PROPERTIES OF GS-20Mn5 CAST STEEL ASSIGNED FOR OPERATION AT LOW TEMPERATURES


The study formed a part of industrial (applied) research executed under Target Project ROW-II-403/2008 at MAGNUS-NORD in Toruń. The aim of the study was to select the heat treatment parameters ensuring the require...

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CONTROL OF GRADED STRUCTURE IN GASARS


Development of instruments for micro- and macrostructure design in functionally graded materials is a challenge for the modern industry. In this path, mathematical modeling and numerical simulation are extremely he...

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APPLICATION OF GEOPOLYMER BINDER IN MANUFACTURING OF CASTING FROM FERROUS ALLOYS


The article presents the results of laboratory and industrial tests on the application of a new geopolymer Rudal A binder used in production of moulding and core sands for castings from carbon and alloyed cast stee...

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STRUCTURE FORMATION AND PROPERTIES OF Cr3C2 – NiCr CARBIDE COATINGS APPLIED BY PLASMA SPRAYING ONTO THE SURFACE OF DUCTILE IRON CASTINGS


The study presents the results of structure examinations and mechanical tests carried out on coatings based on Cr3Cr2-NiCr chromium carbide, applied onto the surface of ductile iron castings. The chromiu...

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STUDIES ON THE PROPERTIES IMPROVEMENT AND APPLICATION OF NEW INORGANIC BINDERS USED IN THE MANUFACTURE OF ENVIRONMENT-FRIENDLY MOULDING AND CORE SANDS


The article gives the results obtained in a fragment of the studies, carried out under a statutory activity, on optimising of the foundry sand technology with new modified inorganic binders, chemically bonded and C...

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EVALUATING THE FEASIBILITY OF MAKING ALUMINIUM ALLOY NANOMODIFIERS BY THE METHOD OF MECHANICAL ALLOYING


Nanomaterials extend the range of their application in human activities. The past few years have faced a considerable increase of interest in various aspects of the application of nanotechnology in liquid phase met...

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NEW COAL DUST SUBSTITUTES FOR BENTONITE MOULDING SANDS USED IN MANUFACTURE OF CASTINGS FROM MALLEABLE IRON AND ALUMINIUM ALLOYS


The article discusses the most important results of research, development and implementation works conducted under Target Projects in years 2006-2007 at the two Polish foundries, i.e. „Radom" Fittings Factory...

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Fly ash as the reinforcement of light alloy metal matrix composites. Part 2: High temperature investigations


The second part of the publication presents the results of high temperature investigations of selected sorts of fly ash serving as a reinforcement in ALFA composites. Using graphs illustrating changes of sample dimensions in function of temperatur...

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HIGH-QUALITY FOUNDRY BENTONITE MADE FROM THE RAW DRIED MATERIAL AND SELECTED FRACTIONS FORMED IN THE PRODUCTION OF HYGIENE SORBENTS


The paper presents the results of laboratory and industrial tests undertaken in order to develop and implement in foundry production the high-quality bentonite made from the raw dried material and selected fractions formed in the production of hyg...

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STUDIES OF ODOUR NUISANCE IN INVESTMENT FOUNDRY


The emission of odours associated with the activities of various industrial plants and facilities is treated as a nuisance, and not as a factor harmful to humans and the environment. The smell, even when subjectively perceived as pleasant, with a ...

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ON THE DAMPING CAPACITY OF COMPOSITE MATERIALS


The study adresses the problem of the damping capacity of metal matrix composites based on A359 alloy reinforced with 10%, 20% and 30% SiCp, subjected to multiple remelting. The aim of the research was to prove that the recycling proces...

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EFFECT OF SUBSTRATE OXIDATION OF NICKEL ON WETTING BEHAVIOUR IN INDUSTRIAL ALLOY 226D/Ni SYSTEM


The aim of this study was to determine the impact of technological factors (surface treatment and contact time) on the kinetics of wetting of nickel substrates by a liquid aluminum alloy. Wetting kinetics studies were carried out in vacuum at 700&...

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Reclamability of moulding sands with new inorganic binders for non-ferrous castings


The article presents results of an investigation which constitutes a section of research under the project POIG.01.01.02-00-015/09 "Advanced materials and technologies", one of the aims which is the introduction of new ecological inorganic binders...

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The application of Integrated Computational Materials Engineering (ICME) in foundry practice


This article presents the latest tendencies within the scope of the application of computer simulation in the process of developing new solutions, including solutions in foundry practice. The functioning of Integrated Computational Materials Engin...

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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...

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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 carri...

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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 co...

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Research problematics of casting technology machines and equipment


The article discusses the research problematics of machines and equipment for casting technologies, with the consideration of the scope of research performed in Poland in the second half of the twentieth century at main domestic university facilit...

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The ecological and material-saving technology for producing brake blocks with stable parameters of quality Part 2. Verification of modernized technology under real conditions


The presented article is the second 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 Ins...

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Development of innovative method to procedure chemically active nano-coatings for moulds and cores


Tests were conducted to develop a new generation of functional nano-coatings used in the foundry industry. The research focused on the introduction of modern and innovative coatings based on nanoparticles of cast elements and active chemical compo...

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Comparison of layer thickness on materials produced by sol-gel transition on substrates removed from aqueous solutions of colloidal binders


This paper presents the method of investigating the sol-gel transition by constant speed removal of plates, made of suitable substrate, from an aqueous colloidal binder. The thickness of the deposited colloidal binder layer depends on the particle...

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Application of topological optimisation in forming of cast cellular structures


Cellular structures are critical components which perform as energy absorbers in the defense, aerospace and automotive industries. Simultaneous application of topological optimisation algorithms for strength forming, solidification simulation soft...

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Application of X-ray computed tomography to compare gravity casting to counter-gravity low-pressure air-melted process


The purpose of this paper is to evaluate the internal structure of alloys similar to AlSi9Mg (EN AC-43300), made with the counter-gravity low-pressure air-melted process (CLA) and with the gravity casting process. The X-ray computed tomography (CT...

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Possibilities of waste binder reclamation using the example of moulding sands with water glass hardened by the conventional drying process


The article presents the results of preliminary studies on the possible application of innovative activation treatments of inorganic binders during the reclamation of waste water glass moulding sands hardened by conventional drying. The test mould...

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Choice of mould-making technology for the modified ablation casting process


The article presents the results of tests and studies carried out within the framework of statutory activities on various additives to moulding sands based on water-soluble inorganic binders for ablative knocking out of castings. As a result of te...

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Comparison of parameters of the granulation process of dust waste from sand reclamation


The results of studies of the process of pressure-free granulation of foundry dust were described, including dust generated in the mechanical reclamation of waste bentonite sand (Dust 1), dust generated in the dry mechanical reclamation of waste s...

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New ledeburite cast steel with precipitation hardened matrix


A new ledeburite cast steel was designed based on a matrix precipitation hardened with intermetallic compounds of a chemical composition enriched by adding about 4.25% V totally balanced with carbon. A martensitic-austenitic matrix with a ledeburi...

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The effect of wetting agent on the parameters of dry moulding silica sands bonded with sodium water glass


An attempt has been made to determine the effect of the addition of an agent wetting the surface of silica sand grains, introduced in order to increase the hardening efficiency of selected physical methods applied to the ecological foundry sands b...

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Perspectives and directions of the development of new generation lead-free soldering alloys and their application possibilities in the consumer electronics lead-free soldering technology


The new technological challenges and the high economical and commercial potential connected with the development of new generation soldering alloys used in the consumer electronics lead-free soldering technology is a subject which is gaining incre...

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Cast iron with vermicular graphite as a prospective material


The study presents the general data on modern cast iron with vermicular graphite, developed in Poland, which can be successfully used for casts of machine and device elements, especially those working under the conditions of thermal fatigue....

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Effect of a biodegradable addition as a binary binder component for cast moulding and core sands on the properties of the binder and the sands


The increasing requirements concerning the emission of hazardous substances force the casting industry to search for new, more environment-friendly solutions. Such solutions may include technologies of developing moulding and core sands with the u...

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Surface analysis and chemical composition of dust from dry dedusting system of moulding sand with bentonite using scanning electron microscopy (SEM)


The article presents the results of surface morphology of dust from dry dedusting of moulding sand with bentonite and mixtures of bentonite with lustrous carbon carrier using scanning electron microscopy. The study identifies the approxi...

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Technological solutions to extend the operating cycle of tools and industrial machinery


One of the most significant problems that engineers and researchers face is the development of technological solutions to extend the exploitation cycle of tools and industrial machinery. The research shows there are a few possibilities to solve th...

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Selected casting processes in the aspect of their effect on the environment protection


The article discusses the impact of selected operations of the casting production technological process on the workplace environment, as well as on the external environment. The casting production is associated with technological operati...

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Selected methods of testing protective coatings applied on casting moulds and cores


This article presents selected research methods related to protective coatings used for sand moulds and cores in the foundry industry. The research methodology has been divided into studies of the technological properties of sand moulds and cores ...

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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 f...

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Quality check of H282 castings by Computed Tomography (CT) technique


As a part of the international project carried out at the Foundry Research Institute in Krakow in cooperation with Energy Industries of Ohio, anopen induction furnace melting technology and gravity casting of nickel superalloys have been developed...

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Hot cracking tendency of foundry alloys – an innovative testing method


The results of testing the tendency of light metals to forming defects from the group of discontinuities - hot cracks (W-301) [1], are presented in the hereby study. These are alloys of a small or moderate tendency for hot cracking. However this t...

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Material-technological conversion of nickel alloys. Part 1. The classification and application of nickel alloys


The present study was created as a result of the execution of the project entitled "Technological conversion of nickel alloys working under extreme conditions". This project, contract No.: TANGO2/340100/NCBR/2017 of 28.04.2017 ...

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Simulation analysis of liquid metal flow through an innovative reaction chamber (and its shape optimization) used in ductile iron production technology


Ductile iron castings are widely used in many industrial branches because of their mechanical properties. The production process of such a grade of cast iron requires the maintenance of the technological regime and the purity of initial charge mat...

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Measurement of gas contents in a metal bath as a method for the optimisation of deoxidation and modification procedures for cast steel


The paper presents the results of works concerning the optimisation of the process of steel melting for castings of industrial fittings in an induction furnace with an acid lining. Materials containing high activity elements such as Al, Ca, Ti, Zr...

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Integration of numerical analyses and experimental research in the process of forming light cast structures


The evolution of the integrated design of engineering processes and structures, including in particular advanced numerical modelling and computer simulations, has enabled a significant shortening of the implementation cycle of innovative material,...

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Industrial mineralogy of the Polish fly ashes and their unique utilization


This study was undertaken to recognize sintering-, softening-, melting-, flow temperature, mineralogy, chemistry and prospects for utilization of the Polish fly ashes (FA, FAs). The study is metallurgy-foundry oriented, i.e. it regards the ashes a...

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