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Abstract

This article discusses issues related to continuous casting of brass. The tested material was CuZn39Pb2 brass with the use of continuous casting and different parameters of the process. The position consists of a melting furnace with a graphite refining pot of about 4000 cm3 chuting capacity, a graphite crystallizer of 9,5 mm nominal diameter, a primary and secondary cooling system and an extracting system as well. The analysis was carried out in terms of technological parameters of the process and type of charge. Highlighted: feedrate ingot, number of stops, and technological temperatures. The surface quality of the obtained ingots and the structure were analyzed. The most favorable conditions were indicated and technological recommendations indicated. They have been distinguished for ingots for plasticity and other technologies. Favorable casting conditions are low feed and low temperature. Due to the presence of impurities coming from the charge it is disadvantageous to have Ni greater than 0.053% by mass, and Fe more than 0.075% by mass. It is recommended to maintain a high zinc content in the melt which is associated with non-overheating of the metal during casting and earlier melting.

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Authors and Affiliations

P. Kwaśniewski
K. Najman
W. Wołczyński
A.W. Bydałek
P. Schlafka
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Abstract

Modern metal forming processes of non-ferrous metals, particularly aluminum and its alloys, are increasingly based on integrated technologies combining numerous operations in one process line. The subject of this paper focuses on the possibility of using materials after mould casting (simulating a continuous casting process between cylindrical crystallizers – Twin Roll Casting method) for the direct cold rolling process. As a part of this research a pilotage study on metallurgical synthesis and mould casting process of Al-Mg alloys with the magnesium contents of 5%-10%, testing their mechanical, electrical and structural properties as well as susceptibility to cold plastic deformation. This process was carried out with the measurement of strength parameters and confirmed the possibility of cold rolling alloys with a casting structure without prior hot deformation.

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Authors and Affiliations

W. Ściężor
A. Mamala
R. Kowal
P. Kwaśniewski
ORCID: ORCID
K. Franczak
ORCID: ORCID
P. Strzępek
ORCID: ORCID
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Abstract

Mating electrodes made of copper alloys are commonly used for welding galvanized steel sheets used in the production of car bodies. These alloys are characterized by high mechanical properties, a high level of electrical and thermal conductivity as well as the stability of these properties under changing conditions of current, thermal and mechanical load. Much careful attention was paid to the essence of the ongoing structural changes as well as to the mechanical properties in the welding process (RSW – Resistant Spot Welding) of steel sheets, including high-strength ones. There is a lack of research on structural changes and the related mechanical properties occurring in welding electrodes made of copper alloys caused by the welding process.
This study is devoted to these issues and contains a critical review of the research results enabling a better understanding of the relationships between the structure and properties of welding electrodes caused by the cyclic welding process. In order to illustrate the phenomena occurring during the welding process, both in the material to be welded and in the tip electrodes, hardness and structural tests were carried out on electrode samples before and after their exploitation. The data collected in the article supplements a certain lack of information in the literature regarding the microstructural aspects of the welding process of galvanized steel sheets for the production of car bodies. The conducted research may be the starting point for the search for more effective materials for the tip electrodes.
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Authors and Affiliations

Z. Rdzawski
1
ORCID: ORCID
P. Kwaśniewski
2
ORCID: ORCID
W. Głuchowski
1
ORCID: ORCID
M. Łagoda
1
ORCID: ORCID
M. Maleta
1
ORCID: ORCID
S. Boczkal
3
ORCID: ORCID
K. Franczak
2
ORCID: ORCID

  1. Łukasiewicz Research Network – Institute of Non-Ferrous Metals, 5 Sowińskiego Street, 44-100 Gliwice, Poland
  2. AGH University of Science and Technology, Al. Mickiewicza 30, 30-059 Krakow, Poland
  3. Łukasiewicz Research Network – Institute of Non-Ferrous Metals, Light Metals Division, 19 Piłsudskiego Street, 32-050 Skawina, Poland
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Abstract

This paper presents the results of research concerning the evaluation of tribological properties of graphite materials used, among others, for crystallisers for continuous casting of non-ferrous metals and their alloys. Graphite materials differing not only in their physical properties but also in the technology of their production were selected from a wide range of commercially available products. Wear resistance investigations of the tested graphite materials were carried out on a pin-on-disc tribometer under technically dry friction conditions on a sliding distance of 1000 m. A constant load but variable speed was used in the tests. The mean value of the coefficient of friction and the wear of the material were determined based on the tribological tests carried out. It was observed that as the speed increases, the average value of the coefficient of friction decreases, while the wear increases. A microstructural analysis of the wear track showed that the friction mechanism depends mainly on the graphite formation technology, which is related to the microstructure of the tested materials, and to a lesser extent to their physical and mechanical properties. Varying the speed values made it possible to trace changes in the wear mechanism, on the basis of which it is possible to predict the durability and reliability of graphite crystalliser operation.
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Bibliography

[1] Kwaśniewski, P., Strzępek, P., Kiesiewicz, G., Kordaszewski, Sz., Franczak, K., Sadzikowski, M., Ściężor, W., Brudny, A., Kulasa, J., Juszczyk, B., Wycisk, R. & Śliwka, M. (2021). External surface quality of the graphite crystallizer as a factor influencing the temperature of the continuous casting process of ETP grade copper. Materials. 14(21), 6309, 1-14. DOI: 10.3390/ma14216309.
[2] Brudny, A., Kulasa, J., Cwolek, B., Malec, W. & Juszczyk, B. (2022). Influence of the continuous casting process of tin-zinc-lead bronze on the wear of the graphitecrystallizer. Metalurgija. 61(3-4), 785-788. ISSN 0543-5846.
[3] Lee, S.-M., Kang, D.-S. & Roh, J.-S. (2015). Bulk graphite: materials and manufacturing process. Carbon Letters. 16(3), 135-146. DOI: 10.5714/CL.2015.16.3.135.
[4] Özmen, Y. (2015). Tribological behavior of carbon-based materials. In ASME 2015 International Mechanical Engineering Congress and Exposition, 12-19 November (pp. 13-19). Houston, Texas, USA. DOI: 10.1115/IMECE2015-50233.
[5] Erdemir, A. & Donnet, C. (2006). Tribology of diamond-like carbon films: recent progress and future prospects. Journal of Physics D Applied Physics. 39(18), 311-327. DOI: 10.1088/0022-3727/39/18/R01.
[6] Alisin, V. & Roshchin, M.N. (2019). Tribology of carbon-containing materials at high temperatures. Journal of Physics Conference Series. 1399(4), 044034, 1-6. DOI: 10.1088/1742-6596/1399/4/044034.
[7] Zhai, W., Srikanth, N., Kong, L.B. & Zhou, K. (2017). Carbon nanomaterials in tribology. Carbon. 119, 150-171. DOI: 10.1016/j.carbon.2017.04.027.
[8] Grill, A. (1993). Review of the tribology of diamond-like carbon. Wear. 168(1-2), 143-153. DOI: 10.1016/0043-1648(93)90210-D.
[9] Szeluga, U., Pusz, S., Kumanek, B., Myalski, J. Hekner, B., Tsyntsarski, B., Oliwa, R. & Trzebicka, B. (2018). Carbon foam based on epoxy/novolac precursor as porous micro-filler of epoxy composites. 105, 28-39. DOI: 10.1016/j.compositesa.2017.11.004.
[10] Szeluga, U., Olszowska, K., Pusz, S., Myalski, J., Godzierz, M., Kobyliukh, A. & Tsyntsarski, B. (2021) Effect of grain fractions of crushed carbon foam on morphology and thermomechanical and tribological properties of random epoxy-carbon composites. Wear. 466-467, 1-14. DOI: 10.1016/j.wear.2020.203558.
[11] SGL Carbon. (2022). SGL Carbon. Retrieved March 2022 from https://www.sglcarbon.com/
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[13] Pérez-Mayoral, E., Matos, I., Bernardo, M. & Fonesca, I.M. (2019). New and advanced porous carbon materials in fine chemical synthesis. Emerging precursors of porous carbons. Catalysts. 9 (2), 133, 1-35. DOI: 10.3390/catal9020133.
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Authors and Affiliations

A. Brudny
1
ORCID: ORCID
J. Kulasa
1
ORCID: ORCID
B. Juszczyk
1
ORCID: ORCID
J. Myalski
2
ORCID: ORCID
S. Roskosz
2
ORCID: ORCID
R. Wycisk
3
P. Kwaśniewski
4
ORCID: ORCID
P. Strzępek
4
ORCID: ORCID
M. Poręba
5
ORCID: ORCID

  1. Łukasiewicz Research Network - Institute of Non-Ferrous Metals, Poland
  2. Silesian University of Technology, Faculty of Materials Engineering, Poland
  3. Carbo-Graf Sp. z o.o., Poland
  4. AGH University of Science and Technology, Department of Non-Ferrous Metals, Poland
  5. Rzeszów University of Technology, The Faculty of Mechanical Engineering and Aeronautics, Poland

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