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APPLICATION OF MOULDING SANDS WITH GEOPOLYMER BINDER IN THE MANUFACTURE OF CASTINGS FROM ALUMINIUM ALLOYS


The article presents the results of laboratory tests on the binding characteristics of moulding sands with inorganic geopolymer binders and for comparison with furan resin and alkaline resin, designed for casting o...

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EFFECT OF TESTING CONDITIONS AND OXIDATION ON WETTING BEHAVIOUR IN Al/Ni SYSTEM


The wettability tests were carried out under a vacuum at 700°C in the drop/substrate couples, where drop is pure aluminium (99.999%), substrate - Ni (99.8%) and Niox (oxidized). Test were carried out...

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MECHANICAL PROPERTIES OF HIGH-ALLOYED, DISPERSION-HARDENED, MARTENSITIC CAST STEEL AFTER MULTI-STAGE HEAT TREATMENT


High-alloyed Cr-Ni-Cu cast steel with additions of Mo and Nb and high nitrogen content was melted. The cast test ingots were subjected to a heat treatment. Metallographic examinations were made under an optical mic...

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AN ASSESSMENT OF NITROGEN CONTENT EFFECT ON THE MECHANICAL PROPERTIES OF MARTENSITIC CAST STEEL


The GX5CrNiCu16-4 martensitic cast steel with graded nitrogen content comprised in a range of 0,064-0,12% was melted; the chemical composition, including oxygen and nitrogen content, was determined. Test bars were ...

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FROM FORGING TO CASTING – A CONVERSION IN BOTH MATERIAL AND DESIGN


The study presents an analysis of the possibilities to change the fabrication technology of a rocker for automotive applications, changing also the type of material used for this element. The application of high-st...

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INVESTIGATIONS OF A CORRELATION BETWEEN THE TYPE AND AMOUNT OF MODIFIER, HIGH-TEMPERATURE TRANSFORMATIONS AND RESIDUAL STRENGTH OF SANDS WITH MODIFIED SODIUM SILICATES


The article presents the results of high-temperature investigations of the modified samples of hydrated sodium silicate and of the sand mixtures with an addition of this compound. To improve the knocking out proper...

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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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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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RECYCLING OF WASTE FLY ASH FORMED DURING COMBUSTION OF HARD COAL FOR USE IN MOULDING MIXTURES MANUFACTURE


The article is a compilation of the most important results obtained during execution of own research project regarding the possibility of using fly ash formed during combustion of hard coal as a base granular material ...

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STUDY OF FILTRATION CHARACTERISTICS OF THE EXPERIMENTAL CERAMIC LAYERS


One of the main parameters determining proper course of the pattern evaporation process, which takes place in parallel with pouring of the foundry mould with metal, are properties of the ceramic coating applied on a po...

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A NOVEL METHOD FOR THE OXYGEN ACTIVITY MEASUREMENT APPLIED IN CONTROL OF THE DUCTILE IRON MANUFACTURING PROCESS


The objective of the present study was to evaluate a method for the measurement of oxygen activity in liquid cast iron to predict the cast iron properties after solidification. A series of experimental melts were made, testing the activity of oxyg...

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THE EFFECT OF Ca ADDITION ON THE MICROSTRUCTURE AND MECHANICAL PROPERTIES OF AZ91 ALLOY


This paper presents the results of research work related with the effect of calcium on the microstructure and mechanical properties of AZ91 alloy. Samples of appropriately prepared alloy grades containing the addition of calcium in different conce...

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AN OPTIMISING NUMERICAL ANALYSIS OF THE DISTRIBUTION OF STRESSES AND DISPLACEMENTS IN THE RUBBER CURING PROCESS OF CHECK VALVE BALLS


Decreasing the density of check valve dip balls by nearly 30% results in significant decrease in the wall thickness of the domes from which the balls are assembled. During the high pressure curing process a risk occurs of excessive deformation or ...

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CAST Al-Si MATRIX COMPOSITES REINFORCED WITH INTERMETALLIC PHASES


In the present paper research results of microstructure and selected mechanical properties of composite on EN AC-AlSi11 alloy matrix with reinforcement in the form of particle of Cr-Fe-C alloy (composite ex situ) and carbonitrides Ti, Zr, V (compo...

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THE COMPARISON OF THE MICROSTRUCTURE AND THE MECHANICAL CHARACTERISTIC OF AUSTEMPERED DUCTILE CAST IRON AND STEEL SUBJECT TO DYNAMIC DEFORMATION USING THE TAYLOR TEST


The article attempts to compare the resistance of austempered ductile cast iron and S215 steel to dynamic loads. The samples were subject to research using the Taylor test methodology at different speeds of deformation, in order to determine the c...

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INFLUENCE OF MODIFICATION ON THE STRUCTURE AND IMPACT STRENGTH OF ALUMINIUM BRASS CuZn30Al3


Studies on the modification of aluminum brass CuZn30Al3 have shown that the additives used in combination 0.01−0.02% boron and 0.025−0.05% titanium resulted in a favorable change in the structure of the tested alloy. As a result, there...

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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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SIMULATION TESTS TO FORECAST SELECTED PROPERTIES OF THIN-WALLED CASTS OF DUCTILE IRON DOMES


Thin-walled dome casts (hemispheres) with a wall thickness of 4.2 and 10.3 mm made of ductile iron underwent simulation tests within the frame of forecasting the tendency to create residual stresses, casting defects, the shaping of structures and ...

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The application of bentonite in classical moulding sands


The article presents results of laboratory tests to develop a new generation of foundry hybrid bentonite. Hybrid bentonite is intended for use as binder for synthetic moulding sands and sandmixes. In the previous practice foundry bentonite was a p...

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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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The effect of the addition of circulating scrap on the tensile properties of die cast magnesium alloy


Recycling of magnesium alloys is a complex issue not only because of their high reactivity and flammability even below melting temperature, but primarily because of a lack of equipment and experience in foundries. Nonetheless the environmental fac...

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The use of low-volume cup samplers for test solidification of cast iron


The aim of this paper was to assess the possibilities and benefits of using low-volume (thinned) samplers for thermal analysis of cast iron. As part of the research, a series of melts of plain cast iron and low-alloy cast iron with different struc...

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Evaluation of selected properties in austempered vermicular cast iron (AVCI)


The work herein presents the tests to produce austempered vermicular cast iron (AVCI - Austempered Vermicular Cast Iron) and the results of examination of the produced AVCI. The work includes the methodology of heats, the structure of the AVCI bef...

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Effect of phosphorus content on the wettability of Ni-P coated surfaces by SAC305 alloy


The aim of this study was to determine the effect of the chemical composition of Ni-P coating on the wettability kinetics of SAC305 liquid solder in contact with the Ni-P coating. The study was conducted in vacuum, at 230°C, for 5 minutes, usi...

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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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Influence of the structure index WB of the soluble sodium silicate on the residual strength of molding sand


Results of Rctk residual strength tests are presented for samples of moulding sands prepared with a stable content of soluble sodium silicate binding agents of different WB structure indicator values, hardened in the ester pr...

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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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The microstructure and properties of cast alloyed G200CrNiMo4-3-3 steel


The subject of the study is the analysis of the microstructure and mechanical properties of cast G200CrNiMo4-3-3 steel. The investigated alloyed cast steel, containing approximately 2% C, is nearly an ideal material for the hot mill work rolls, an...

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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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Effect of molybdenum on the crystallization, microstructure and properties of silumin 226


The article presents the results of studies of hypoeutectic silumin with a molybdenum addition used for pressure casting. The studies included a thermal-derivative analysis of the crystallization process, a metallographic analysis of the microstru...

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Improvement of plasticity of the AlSi11 alloy due to soft annealing treatment


The paper presents research on the possibility of improving the plasticity of near-eutectic AlSi11 alloy by the use of soft annealing treatment. For two assumed input quantities, i.e. temperature and duration of the soaking treatment, based on the...

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Impact of penetration depth of protective coating on thermal deformation of masses determined by the hot distortion parameter


Protective coatings are applied in order to obtain casts with an even surface, without faults. Protective coatings can contain a solvent based on water or alcohol; however, due to their harmfulness, it is recommended to limit the use of alcohol co...

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Optimization of Ni and Cu additions in ADI cast iron in respect of cast cooling rate


The study analyzes the effect of Ni and Cu additions on the mechanical properties of ADI cast iron in casts with different wall thickness values. The applied experiment plan included the use of combinations of the Ni addition in the amount of 0.5%...

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The role of the densification of moulding sands with inorganic binders in the modeling of their strength obtained after microwave hardening


The study attempts to complement the information on the effect of the density of moulding sands with inorganic binders on basic strength parameters, i.e. the tensile and bending strength of moulding sands with hydrated sodium silicate, after the p...

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Effect of the way of modification of hydrated sodium silicate on the effectiveness of the changes in the residual strength of a moulding sand


The article discusses the ways of modification of hydrated sodium silicate as a silicate binder of moulding sands which were applied in the studies. It determines the change in the residual strength of the moulding sand with used silicate binders ...

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Thermal shock resistance of solution-hardened spheroidal cast iron with selected alloy elements


The study involved the preparation of seven melts of spheroidal cast iron solution reinforced by means of an elevated content of silicon, including Cu, Mo and Ni additions. Thermal analyses of the melted cast iron were made and the ...

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Effect of vanadium on the crystallization process, microstructure and properties of Al-Si alloy EN AC-46000


The paper presents the results of the study of Al-Si alloys with a vanadium addition used in pressure casting. The hypoeutectic Al-Si alloy grade EN AC-46000 was applied as the initial alloy. The master alloy AlV10 was introduced into the initial ...

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Application of squeeze casting technology to obtain aluminum alloy castings


The article presents the results of investigations into castings made of four aluminum alloys produced with the use of squeeze casting technology.The investigations used the following alloys: EN AW 7022 (AlZn5Mg3Cu) and its modification with...

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Investigation of mechanical properties and coefficients of sound insulation of innovative silicone composite material


A new non-combustible, non-flammable, waterproof, long-lasting, heat-insulating composite material was made of glass foam granules (derived from glass waste) and a hydraulic inorganic binder in the form of a white Portland cement solution (CE...

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Development of a technology for the production of ceramic moulds with reduced thermal conductivity to control the solidification of thin-walled castings


During the project a technology of making ceramic moulds using aluminosilicate microspheres was developed. According to the developed technology, ceramic samples were used to determine thermal conductivity in the temperature range of 500°C to ...

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XRD phase investigations of steam oxidized Fe and Ni rich Cr alloys


The aim of this work was to summarise XRD investigations performed after the tests carried out in steam oxidation conditions in the temperature range 700‒800°C for 3000 hours. In this work, two solid-solution strengthened alloys; Haynes®...

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High temperature corrosion of metallic materials in coal fired power plant boilers


The aim of this work was to perform high temperature tests in steam conditions at 700‒800°C for 3000 hours. In this work seven alloys were studied: Cr rich austenitic steels 309S, 310S, HR3C, and two solid-solution strengthened Ni based allo...

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The evaluation of microporosity and mechanical properties in high strength aluminum alloys with the use of numerical analysis and computed tomography


One of the aspects of sustainable development is the reduction of the concentration of CO2 in the atmosphere. This could be achieved for example by the reduction of fuel consumption. That is why the research for the new construction and...

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Viscous flow features of amorphous Zr65(Ni,Pd)35 alloy


Viscous flow behavior of amorphous Zr65(Ni,Pd)35 alloy has been studied at a heating rate of 20 K/min. The viscosity experimental results are interpreted on the basis of the free volume model. The values of the model paramete...

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Effect of chromium on the crystallization process, microstructure and properties of hypoeutectic Al-Si alloy


The paper presents the results of studies of hypoeutectic silumin with a chromium addition used for pressure casting. A silumin with the composition similar to that of EN AC-46000 was used as the initial one. In order to introduce chromi...

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Influence of two-step austempering process on mechanical properties and wear resistance of carbidic austempered ductile iron (CADI)


CADI (Carbidic ADI) - ausferritic ductile iron containing carbides - is a relatively new engineering material which exhibits excellent wear resistance and adequate impact strength. In this work the influence of two-step austempering process on sel...

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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. Prob...

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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 o...

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Microstructure formation and grain refinement of Al-Mg-Si-Mn casting alloys


Together with development of casting technology for Al-Si-Mg alloys, new groups of casting materials are undergoes its implementation into foundry practice. Al-Mg-Si casting alloys possessed several advantages such as good strength ...

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Preliminary testing of microwave-cured joints made of adhesives based on hydrated sodium silicate and quartz sand


In this paper an attempt was made to explain the phenomena accompanying the formation and destruction of bonded elements of moulds and cores in which a mixture of unmodified hydrated sodium silicate with a molar module of 2.9 (...

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Assessment criteria for binding characteristics of foundry bentonites


The paper presents laboratory test results for an assessment of the binding characteristics of two grades of calcium bentonite compounds for casting moulds. The bentonite compounds were chemically modified with sodium carbonate at several differen...

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Testing of mechanical properties and computer simulations of the manufacturing process of castings obtained in gypsum moulds from high-strength AlZnMgCu aluminum alloys


The paper presents an attempt to assess the mechanical properties of high-strength AlZnMgCu aluminium alloy samples cast in gypsum moulds. The first stage of the study involved the use of computer simulations to select the opti...

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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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