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Inoculation of Gray Cast Iron Intended for Large Scale and Heavy Weight Castings of Bottom Plates and Counterweights Manufactured in the Krakodlew S.A.

A. Szczęsny D. Kopyciński Edward Guzik
Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 19-24 | DOI: 10.24425/afe.2022.140232
Keywords Heavy castings Large scale casting Grey cast iron Inoculation
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Abstract

The paper presents research carried out during the development of new technology for the production of heavy-weight castings of counterweights. The research concerns the procedure of inoculation gray cast iron with flake graphite and indicates guidelines for the development of new technology for obtaining inoculated cast iron for industrial conditions.
The research was conducted in order to verify the possibility of producing large size or heavy-weight castings of plates in a vertical arrangement. The aim is to evenly distribute graphite in the structure of cast iron and thus reduce the volumetric fraction of type D graphite. The tests were carried out using the ProCast program, which was used to determine the reference chemical composition, and the inoculation procedure was carried out with the use of three different inoculants. The work was carried out in project no. RPMP.01.02.01-12-0055 / 18 under the Regional Operational Program of the Lesser Poland Voivodeship in Krakow (Poland).
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Bibliography

[1] Benedetti, M., Torresani, E., Fontanari, V. & Lusuardi, D. (2017). Fatigue and fracture resistance of heavy-section ferritic ductile cast iron. Metals. 7(3), 88.
[2] Dorula, J., Kopyciński, D., Guzik, E., Szczęsny, A. & Gurgul, D. (2021). The influence of undercooling ΔT on the structure and tensile strength of grey cast iron. Materials. 14(21), 6682.
[3] Wang, Q., Cheng, G. & Hou, Y. (2020). Effect of titanium addition on as-cast structure and high-temperature tensile property of 20Cr-8Ni stainless steel for heavy castings. Metals. 10(4), 529.
[4] Wang, Q., Chen, S. & Rong, L. (2020). -Ferrite formation and its effect on the mechanical properties of heavy-section AISI 316 stainless steel casting. Metallurgical and Materials Transactions A. 51, 2998-3008.
[5] Kalandyk, B., Zapała, R., Sobula, S., Górny, M. & Boroń, Ł. (2014) Characteristics of low nickel ferritic-austenitic corrosion resistant cast steel. Metalurgija-Metallurgy. 53(4), 613-616.
[6] Kalandyk, B. & Zapała, R. (2013). Effect of high-manganese cast steel strain hardening on the abrasion wear resistance in a mixture of SiC and water. Archives of Foundry Engineering. 13(4), 63-66.
[7] Tęcza, G. & Zapała, R. (2018). Changes in impact strength and abrasive wear resistance of cast high manganese steel due to the formation of primary titanium carbides. Archives of Foundry Engineering. 18(1), 119-122.
[8] Tęcza, G. & Garbacz-Klempka, A. (2016). Microstructure of cast high-manganese steel containing titanium. Archives of Foundry Engineering. 16(4), 163-168.
[9] Celis, M., Domengès, B., Hug, E. & Lacaze, J. (2018). Analysis of nuclei in a heavy-section nodular iron casting. Materials Science Forum. 925, 173-180.
[10] Kopyciński, D., Siekaniec, D., Szczęsny, A., Sokolnicki, M. & Nowak, A. (2016). The Althoff-Radtke test adapter for high chromium cast iron. Archives of Foundry Engineering. 16(4), 74-77.
[11] Szczęsny, A., Kopyciński, D., Guzik, E. Soból, G., Piotrowski, K., Bednarczyk, P. & Paul, W. (2020). Shaping of ductile cast iron dedicated for slag ladle. Acta Metallurgica Slovaca. 26, 74-77. https://doi.org/10.36547/ams.26.2.312
[12] Mourad, M.M. & El-Hadad, S. (2015). Effect of processing parameters on the mechanical properties of heavy section ductile iron. Journal of Metallurgy. 2015, 1-11.
[13] Foglio, E., Gelfi, M., Pola, A. & Lusuardi, D. (2017). Effect of shrinkage porosity and degenerated graphite on fatigue crack initiation in ductile cast iron. Key Engineering Materials. 754, 95-98.
[14] Kavicka, F., Sekanina, B., Stetina, J., Stransky, K., Gontarev, V. & Dobrovska, J. (2009). Numerical optimization of the method of cooling of a massive casting of ductile cast-iron. Materials and Technology. 43, 73-78.

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Authors and Affiliations

A. Szczęsny
1
ORCID: ORCID
D. Kopyciński
1
ORCID: ORCID
Edward Guzik
ORCID: ORCID
  1. AGH University of Science and Technology, Department of Foundry, ul. Reymonta 23, 30-059 Kraków, Polska

Effective Laboratory Method of Chromite Content Estimation in Reclaimed Sands

Z. Ignaszak J-B. Prunier
Archives of Foundry Engineering | 2016 | No 3 | DOI: 10.1515/afe-2016-0071
Keywords Chromite sand Magnetic recuperation Neodymium magnets Furan sand dry reclamation Ferrous alloys Heavy castings
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Abstract

The paper presents an original method of measuring the actual chromite content in the circulating moulding sand of foundry. This type of

material is applied for production of moulds. This is the case of foundry which most frequently perform heavy casting in which for the

construction of chemical hardening mould is used, both the quartz sand and chromite sand. After the dry reclamation of used moulding

sand, both types of sands are mixed in various ratios resulting that in reclaimed sand silos, the layers of varying content of chromite in

mixture are observed. For chromite recuperation from the circulating moulding sand there are applied the appropriate installations

equipped with separate elements generating locally strong magnetic field. The knowledge of the current ratio of chromite and quartz sand

allows to optimize the settings of installation and control of the separation efficiency. The arduous and time-consuming method of

determining the content of chromite using bromoform liquid requires operational powers and precautions during using this toxic liquid.

It was developed and tested the new, uncomplicated gravimetric laboratory method using powerful permanent magnets (neodymium).

The method is used in the production conditions of casting for current inspection of chromite quantity in used sand in reclamation plant.

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Authors and Affiliations

Z. Ignaszak
J-B. Prunier

Synergy of Practical Knowledge of Molding Sands Reclamation in Heavy Casting Foundry of Iron Alloys

Z. Ignaszak J-B. Prunier
Archives of Foundry Engineering | 2013 | No 3 | DOI: 10.2478/afe-2013-0054
Keywords Furan molding sands Dry mechanical reclamation Iron alloy foundry Heavy castings Life time of furan sands Thermomechanicaldatabases
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Abstract

The paper summarizes research realized by the author in laboratory and industrial conditions (foundries of cast steel and cast iron, castings up to 50 tons) on the effects of the chemically hardened molding sands regeneration using hard/soft rubbing in the dry reclamation. A reference was simultaneously made to advisability of application of the thermal regeneration in conditions, where chromite amount in the circulating (reclaimed) molding sand goes as high as above ten percent. An advisability of connecting standard and specialized methods of examination of the reclaimed sands and molding sands made using it was pointed out. A way of application of studies with the Hot Distortion Plus® method modified by the author for validation of modeling of the thermo-dynamic phenomena in the mold was shown.
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Authors and Affiliations

Z. Ignaszak
J-B. Prunier

The Method of Inoculation of High-Quality Grey Cast Iron Intended for Massive Castings for Bottom and Distance Plates as Well Counterweights Manufactured as Vertical Castings

Edward Guzik D. Kopyciński A. Ziółko A. Szczęsny
Archives of Metallurgy and Materials | 2023 | vol. 68 | No 1 | 359-368 | DOI: 10.24425/amm.2023.141512
Keywords high-quality cast iron heavy castings massive casting graphitizing inoculation hybrid inoculation
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Abstract

The technology of producing castings of high-quality inoculated cast iron with flake graphite particles in the structure is a combination of the melting and inoculation process. Maintaining the stability of the strength and microstructure parameters of this cast iron is the goal of a series of studies on the control of graphitization and austenitic inoculation (increasing the number of primary austenite dendrites), and which affects the type of metal matrix in the structure. The ability to graphitize the molten alloy decreases with its holding in the melting furnace more than an hour. The tendency to crystallize large dendritic austenite grains and segregation of elements such as Si, Ni and Cu reduce the ductility properties of this cast iron. The austenite inoculation process may introduce a larger number of primary austenite grains into the structure, affecting the even distribution of graphite and metal matrix precipitation in the structure. Known inoculation effects the interaction (in low mass) of additives: Sr, Ca, Ba, Ce, La, produces MC2 carbide). Addition of Fe in the inoculant influences the number and shape of austenite dendrites. Hybrid modification combines the effects of these two factors. The introduction of nucleation sites for the graphite eutectics and primary austenite grains result in the stabilization of the cast iron microstructure and an increase in mechanical properties. The obtained test results set the direction for further research in this area in relation to the production of heavy plate castings in vertical and horizontal pouring.
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Authors and Affiliations

Edward Guzik
ORCID: ORCID
D. Kopyciński
1
ORCID: ORCID
A. Ziółko
2
A. Szczęsny
1
ORCID: ORCID
  1. AGH University of Science and Technology, Department of Engineering of Cast Alloys and Composites, Faculty of Foundry Engineering, Al. Mickiewicza 30, 30-059 Krakow, Poland
  2. Krakodlew S.A., 1 Ujastek St., 30-969 Krakow, Poland

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