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The paper presents the results of research on the kinetics of the binding process of self-hardening moulding sands with an organic binder under conditions of forced air flow at various pressure values. Three moulding sands made using urea-furfuryl resin Furanol FR75A technology were studied. The moulding sands were prepared on a base of quartz sand with an average grain size of dL = 0.25, 0.29 and and 0.37 mm , with permeability values of 306 , 391 and and 476 m ²/10 ⁸Pa ∙ s (for ρ0 = 1.60 , 1.60 and and 1.61 g/cm ³, respectively). The research was conducted for a resin content of 1% with a constant proportion of hardener to resin, which was equal to 50%. Samples of the tested moulding sands were blown with air at pressures of 0.1, 0.2, 0.4, 0.6, 0.8, and 1.0 bar. The kinetics of the hardening process was monitored using ultrasound technology, according to a previously developed methodology [1]. The research was carried out on an ultrasound testing station equipped with a temperature chamber and an airflow reducer. The tests were conducted at a temperature of 20°C, and of the air flow pressure on the changes in ultrasonic wave velocity in the hardening mouldins sand as a function of time, the kinetics of the hardening process, and the degree of moulding sand hardening were determined. Additionally, the influence of the moulding sand permeability on the course of the hardening process at a constant air flow pressure was determined.

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Bibliography

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Authors and Affiliations

Natalia Matonis

1

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AGH University of Science and Technology, Faculty of Foundry Engineering, Poland

Binding Capability of Ashes and Dusts from Municipal Solid Waste Incineration with Salt Brine and Geotechnical Parameters of the Cemented Samples

Krzysztof Skrzypkowski Waldemar Korzeniowski Katarzyna Poborska-Młynarska

Archives of Mining Sciences | 2018 | vol. 63 | No 4 | 903-918 | DOI: 10.24425/ams.2018.124983

Keywords municipal waste salt chambers ashes hardening backfill

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Abstract

Based on laboratory tests of selected properties of secondary waste (ashes and dusts) from municipal waste incineration plants, the possibility of recovering some properties of waste in the process of filling the post-mining voids in the salt mine was assessed. The furnace bottom ash and the waste from the flue gas treatment from one of the national incineration plants were examined. The grain curves of dry waste and the density of the prepared mixtures were characterized. Twelve variants of the compositions of ash-based mixtures with varying proportions of the individual components were considered, taking into account both fresh water and brine. For each variant of the composition, the amount of redundant liquid appeared as well as the time of solidifying of the mixture to a certain strength and the compressibility values obtained. Considering the possibility of transporting mixtures in mines by means of pipelines at relatively long distances, and allowing the filling of large salt chambers to be filled and evenly filled, flow parameters were determined. In addition, the permeability of solidified waste samples was investigated, showing the potential for reducing the strength of the waste mass due to the action of water or brine. The technical feasibility of eliminating redundant liquid in the binding process has been confirmed, which is particularly important in salt mines. Preliminary values for the amount of binder (5%÷10%) to be added to the mixtures to obtain the specified strength properties of the artificially formed mass at Rc = 0.5 MPa. Attention was paid to the important practical aspect resulting from the rapid increase of this type of waste in the comming years in Poland and at the same time vast potential for their use in salt mining, where we have a huge capacity of salt chambers available.

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Authors and Affiliations

Krzysztof Skrzypkowski

Waldemar Korzeniowski

Katarzyna Poborska-Młynarska

Use of the Precipitation Hardening to Improve the Properties of Combustion Engine Pistons Made of Eutectic Silumins

M. Trepczyńska-Łent K. Műller

Archives of Foundry Engineering | 2021 | vo. 21 | No 4 | 77-81 | DOI: 10.24425/afe.2021.138682

Keywords Precipitation hardening Silumins Heat treatment Hardness

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Abstract

The study presents methods to be used for improving the performance parameters of car engine pistons made of EN AC-AlSi12CuNiMg alloy according to the PN-EN 1706: 2011. Pistons of slow sucking and turbocharged engines were researched. A solution heat and ageing treatments were applied according to four variants. Temperatures of the solution heat treatment were: 550 ±5°C; 510°C ±5°C; and alternate: 276 ±5°C/510 ±5°C. The solution time ranged from 6 min to 4 h. Temperatures of the ageing heat treatment were 20°C and 250°C, while the ageing time ranged from 1,5 to 3h. Natural ageing was performed in 5 days. Measurements of hardness HRB and the piston diameters were performed. An improvement in the performance parameters of combustion engines was observed. Three solution heat treatment and ageing variants, allowed to obtain the pistons with hardness equal/higher than pistons of the turbocharged engines. The test results confirmed the possibility of providing a piston with properties exceeding the high load parameters specified by the manufacturer. Further studies will make it possible to improve the effects of the proposed solutions.

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Bibliography

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Authors and Affiliations

M. Trepczyńska-Łent

1

e-mail:

ORCID:

K. Műller

2

Mechanical Engineering Faculty, Bydgoszcz University of Science and Technology, Al. prof. S. Kaliskiego 7, 85-796 Bydgoszcz, Poland
Bergerat Monnoyeur Sp. z o.o. – Caterpillar, Poland

The use of extraction methods to assess the immobilization of metals in hardening slurries

Paweł Falaciński Małgorzata Wojtkowska

Archives of Environmental Protection | 2021 | 47 | 3 | 60-70 | DOI: 10.24425/aep.2021.138464

Keywords hardening slurry cut-off walls sewage sludge thermal treatment immobilization of metals

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Abstract

In Poland, in recent years, there has been a rapid accumulation of sewage sludge – a by-product in the treatment of urban wastewater. This has come about as a result of infrastructure renewal, specifically, the construction of modern sewage treatment plants. The more stringent regulations and strategic goals adopted for modern sewage management have necessitated the application of modern engineering methodology for the disposal of sewage sludge. One approach is incineration. As a consequence, the amount of fly ash resulting from the thermal treatment of municipal sewage sludge has grown significantly. Hence, intensive work is in progress for environmentally safe management of this type of waste. The aim of the experiment was to evaluate the possibility of using the fly ash that results from municipal sewage sludge thermal treatment (SSTT) as an additive to hardening slurries. The article presents the technological and functional parameters of hardening slurries with an addition of fly ash obtained by SSTT. Moreover, the usefulness of these slurries is analyzed on the basis of their basic properties, i.e., density, contractual viscosity, water separation, structural strength, volumetric density, hydraulic conductivity, compressive and tensile strength. The research on technological and functional properties was carried out, the aim of which was to determine the practical usefulness of the hardening slurries used in the experiment. Subsequently, leaching tests were performed for heavy metals in the components, the structure of the hardening slurries. An experiment showed leaching of hazardous compounds at a level allowing their practical application. The article presents the potential uses of fly ash from SSTT in hardening slurry technology.

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Authors and Affiliations

Paweł Falaciński

1

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Małgorzata Wojtkowska

1

Warsaw University of Technology, Faculty of Building Services, Hydro and Environmental Engineering, Warsaw

The Effect of the Parameters of Robotic TIG Welding on the Microstructure of 17-4PH Stainless Steel Welded Joint

A. Nalborczyk-Kazanecka G. Mrowka-Nowotnik

Archives of Metallurgy and Materials | 2023 | vol. 68 | No 1 | 339-344 | DOI: 10.24425/amm.2023.141510

Keywords welding 17-4PH stainless steel precipitation hardening heat treatment

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Abstract

17-4PH stainless steel finds application in the aerospace industry owing to its good mechanical properties and corrosion resistance. In the literature, this steel is described as good for welding, but research shows that it may be problematic due to the formation of defects. In this study, the welded joints were made by the robotic TIG welding method with various welding speeds (2 and 3 mm/s). The joints were subjected to non-destructive testing and were free from defects. The microstructure was observed by light microscopy and scanning electron microscopy. Changes in the microstructure of the heat affected zone were observed and discussed. Based on the observation of the microstructure and the change in the hardness profile, the heat affected zone was divided into 4 characteristic regions. δ-ferrite and NbC were observed in the martensite matrix. The welded joints were subjected to heat treatment consisting of solution and aging in 550°C for 4 h. The microstructure of the heat affected zone become homogenized as a result of the heat treatment. The content of stable austenite in the welded joint after the heat treatment was about 3%.

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Authors and Affiliations

A. Nalborczyk-Kazanecka

1

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G. Mrowka-Nowotnik

1

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Rzeszow University of Technology, Faculty of Mechanical Engineering and Aeronautics, 12 Powstańców Warszawy Av., 35-959 Rzeszów, Poland

The Effect of Zirconium as an Alloying Additive on the Microstructure and Properties of AlSi9Mg Alloy Cast in Sand Moulds

J. Kamińska M. Angrecki P. Dudek

Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 5-13 | DOI: 10.24425/afe.2022.140245

Keywords Silumins Precipitation hardening Alloying additives Microstructure examinations strength tests

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Abstract

The aim of the study was to select the optimal content of zirconium introduced as an alloying additive to obtain the best strength properties of Al-Si alloy. A technically important disadvantage is the tendency of silumins to form a coarse-grained structure that adversely affects the mechanical properties of castings. To improve the structure, modification processes and alloying additives are used, both of which can effectively refine the structure and thus increase the mechanical properties. According to the Hall-Petch relationship, the finer is the structure, the higher are the mechanical properties of the alloy. The proposed addition of zirconium as an alloying element has a beneficial effect on the structure and properties of silumins, inhibiting the grain growth. The starting material was an aluminium-silicon casting alloy designated as EN AC-AlSi9Mg (AK9). Zirconium (Zr) was added to the alloy in an amount of 0.1%, 0.2%, 0.3%, 0.4% and 0.5% by weight. From the modified alloy, after verification of the chemical composition, samples were cast into sand moulds based on a phenolic resin.
The first step in the research was testing the casting properties of alloys with the addition of Zr (castability, density, porosity). In the next step, the effect of zirconium addition on the structure and mechanical properties of castings was determined.

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Authors and Affiliations

J. Kamińska

1

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ORCID:

M. Angrecki

1

e-mail:

ORCID:

P. Dudek

1

e-mail:

ORCID:

Łukasiewicz Research Network – Krakow Institute of Technology, Krakow, Poland

Effect of Methyl Silicone Oil to Moisture Resistance of Sodium Silicate Sands by Microwave Hardening

Huafang Wang Xiang Gao Lei Yang Wei He Jijun Lu

Archives of Foundry Engineering | 2022 | vol. 22 | No 1 | 43-47 | DOI: 10.24425/afe.2022.140215

Keywords Sodium silicate sands Microwave hardening Methyl silicone oil Moisture absorption

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Abstract

The sodium silicate sands hardened by microwave have the advantages of high strength, fast hardening speed and low residual strength with the lower addition of sodium silicate. However, the sodium ion in the sands will absorb moisture from the atmosphere, which would lead to lower storing strength, so the protection of a bonding bridge of sodium silicate between the sands is crucial. Methyl silicone oil is a cheap hydrophobic industrial raw material. The influence of the addition amount of methyl silicone oil modifier on compressive strength and moisture absorption of sodium silicate sands was studied in this work. The microscopic analysis of modified before and after sodium silicate sands has been carried on employing scanning electron microscopy(SEM) and energy spectrum analysis(EDS). The results showed that the strength of modified sodium silicate sands was significantly higher than that of unmodified sodium silicate sands, and the best addition of methyl silicone oil in the quantity of sodium silicate was 15%. It was also found that the bonding bridge of modified sodium silicate sands was the density and the adhesive film was smooth, and the methyl silicone oil was completely covered on the surface of the sodium silicate bonding bridge to protect it.

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[10] Masuda, Y., Tsubota, K., Ishii, K., Imakoma, H. & Ohmura, N. (2009). Drying rate and surface temperature in solidification of glass particle layer with inorganic binder by microwave drying. KAGAKU KOGAKU RONBUNSHU. 35(2), 229-231.
[11] Kosuge, K., Sunaga, M., Goda, R., Onodera, H. & Okane, T. (2018). Cure and collapse mechanism of inorganic mold using spherical artificial sand and water glass binder. Materials transactions. 59(11), 1784-1790.
[12] Zhang, Y.H., Liu, Z.Y., Liu, Z.C. & Yao, L.P. (2020). Mechanical properties of high-ductility cementitious composites with methyl silicone oil. Magazine of Concrete Research. 72(14), 747-756.

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Authors and Affiliations

Huafang Wang

1

e-mail:

ORCID:

Xiang Gao

1

Lei Yang

1

e-mail:

ORCID:

Wei He

1

Jijun Lu

1

e-mail:

ORCID:

School of Mechanical Engineering and Automation, Wuhan Textile University, China

Plasticity Changes of Moulding Sands with Chemical Binders Caused by Increasing the Hardening Degree

Natalia Matonis J. Zych

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 71-76 | DOI: 10.24425/afe.2022.140227

Keywords Self-setting sands (SSS) Plastic properties Hardening degree Ultrasounds

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Abstract

The results of investigations of plasticity of moulding sands with binders obtained by measuring deflection angles in the single point bend test in dependence on their hardening degree are presented in the hereby paper. Shaped samples made of moulding sands obtained in the technology with urea-furfuryl resin Furanol FR75A and in the technology with water glass, were subjected to various tests. Shaped samples were made on the quartz matrix of a medium grains size ��=0,29 ��. Investigations were performed for the resin content being 1% and 2%, at a constant proportion of a hardener versus resin -- equal 60%. In the case of sands from the technology with water glass, investigations were performed for 3.5% of water glass versus sand matrix and 0.35% of Flodur. Plasticity tests were carried out with using the strength machine with a continuous recording of a sample deflection value. Measurements of deflection angles values in the bend test were performed on a series of simultaneously made samples at constant time intervals from the moment of their making. To determine the sand hardening degree the ultrasound technique was applied, according to the previously developed methodology [1]. Every time from the obtained results the characteristic of the growing stress as a function of deflection was prepared (��). In addition, for the tested group of moulding sands, empirical relationships between the maximum deflection angle (αmax) in the bend test and the hardening degree were determined (Sx): α = f(Sx).

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Bibliography

[1] Zych, J. (2002). New, nondestructive method of quality inspection of mould’s elements made of moulding sands with chemical binders. Archives of Foundry. 2(5), 132-139.
[2] Fredrickson, A.G. (1964). Principles and applications of rheology. New York: Prentice Hall, Englewood Cliffs.
[3] Reiner M. (1958). Theoretical rheology. Warszawa: PWN. (in Polish).
[4] Kembłowski, Z. (1973). Rheometry of non-Newtonian fluids. Warszawa: WNT. (in Polish).
[5] Malkin, A. JU. (1994). Rheology Fundamentals. ChemTec Publishing. Canada.
[6] Barnes, H.A. (1997). Thixotropy-a review. Journal of Non-Newtonian Fluid Mechanics. 70(1-2), 1-33.
[7] Gröning, P. (2014). Properties and use of the modern PUR cold-box system. 4th Conference: Molding and core materials - theory and practice. 28 -30 August. Iława – Poland: Hüttenes-Albertus Poland. (in Polish).
[8] Gröning, P., Schreckenberg, S. & Jenrich, K. (2015). Herstellung von hoch-komplexen Zylinderkurbel-gehäusen. Giesserei. 102(01), 42-47.
[9] Grabarczyk, A., Dobosz, M.St., Kusiński, J., & Major-Gabryś, K. (2018). The tendency of moulding sands to generate core cracs. Archives of Foundry Engineering. 18(1), 157-161.
[10] Dobosz, M.St., Grabarczyk, A. & Major-Gabryś, K. (2017). Elasticity of moulding sands – a method of reducing core cracking. Archives of Foundry Engineering. 17(1), 31-36.
[11] Grabarczyk, A. (2018). Analysis and evaluation of mechanical and thermal deformation of molding sands with selected binders. Unpublished doctoral dissertation, AGH University of Science and Technology, Kraków. (in Polish).
[12] Zych, J. (2007). Synthesis of ultrasonic technique applications in the analysis of the kinetics of selected processes in molding materials. Kraków: AGH Uczelniane Wydawnictwa Naukowo-Dydaktyczne. Seria: Rozprawy i Monografie nr 163. (in Polish).

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Authors and Affiliations

Natalia Matonis

e-mail:

ORCID:

J. Zych

1

e-mail:

ORCID:

AGH University of Science and Technology, Faculty of Foundry Engineering, ul. Reymonta 23, 30-059 Cracow, Poland

Investigation of Self-Hardening AlZn10Si8Mg Cast Alloy for the Automotive Industry

L. Kuchariková L. Pastierovičová E. Tillová M. Chalupová D. Závodská

Archives of Metallurgy and Materials | 2023 | vol. 68 | No 2 | 517-524 | DOI: 10.24425/amm.2023.142430

Keywords self-hardening alloy mechanical properties fatigue deep-etching aluminium alloy

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Abstract

Self-hardening aluminium alloys represent a new and interesting group of aluminium alloys. They have the advantage that they do not need to be heat treated, which is an important advantage that contributes to a significant reduction in production costs of some components and in the amount of energy used. The present paper deals with the possibility to replace the most used heat treatable AlSi7Mg0.3 cast alloys with a self-hardened AlZn10Si8Mg cast alloy. In this study, microstructural characterization of tensile and fatigue-tested samples has been performed to reveal if this replacement is possible. The results of fatigue tests show that AlSi7Mg0.3 alloy after T6 heat treatment and self-hardened AlZn10Si8Mg has comparable values of fatigue properties. The self-hardening alloy has slightly lower strength, ductility, and hardness.

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Authors and Affiliations

L. Kuchariková

1

e-mail:

ORCID:

L. Pastierovičová

1

e-mail:

ORCID:

E. Tillová

1

e-mail:

ORCID:

M. Chalupová

1

e-mail:

ORCID:

D. Závodská

1 2

University of Žilina, Faculty of Mechanical Engineering, Department of Materials Engineering, Univerzitná 8215/1, 010 26 Žilina, Slovak Republic
Schaeffler Slovakia, Kysucké Nové Mesto, Slovak Republic

Strain-Hardening Prediction of DP600 Steel Considering the Heterogeneous Deformation Between Ferrite and Martensite

Gou Rui-Bin Dan Wen-Jiao Xu Yong-Sheng Yu Min Li Tong-Jie

Archives of Metallurgy and Materials | 2023 | vol. 68 | No 4 | 1555-1562 | DOI: 10.24425/amm.2023.146222

Keywords Strain-hardening model DP600 GNDs heterogeneous deformation mechanical behaviors

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Abstract

Dual-phase steels have received extensive attention in autobody frame manufacturing due to the resulting characteristics of an interesting combination of ductile ferrite and hard martensite. Moreover, the ductile ferrite and hard martensite lead to heterogeneous deformation in the boundary between the two phases. Then, geometrically necessary dislocations (GNDs) are created to accommodate a lattice mismatch due to the deformation incompatibility of the boundary in straining. In this study, a new empirical GND model is developed, in which the GND density is a function of local plastic deformation; the GND density is distributed in the phase boundary in accordance with an “S” model of material plastic strain. The boundary conditions are applied to define the parameters. The proposed model is verified with DP600 steel. The effects of the GNDs and the width between ferrite and martensite on the strain hardening of DP600 steel are evaluated.

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Authors and Affiliations

Gou Rui-Bin

1

Dan Wen-Jiao

1

Xu Yong-Sheng

2

Yu Min

3

Li Tong-Jie

1

Anhui Science and Technology University, College of Mechanical Engineering, Fengyang 233100, Anhui, China
Shanghai Jiao Tong University, Department of Engineering Mechanics, School of Naval Architecture, Ocean and Civil Engineering, Shanghai 200240, China
Anhui Science and Technology University, College of Architecture, Bengbu 233000, Anhui, China

Microstructural Evolution and Oxidation Behavior of Fe-4Cr-6Ti Ferritic Alloy with Fe2Ti Laves Phase Precipitates

Ahmet Demirel Emre Can Çetin Ali Karakuş Mehmet Şahin Ataş Mehmet Yildirim

Archives of Metallurgy and Materials | 2022 | vol. 67 | No 3 | 827-836 | DOI: 10.24425/amm.2022.139672

Keywords Ferritic alloy Microstructure Precipitation hardening Laves phase Oxidation

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Abstract

The microstructural properties and hardness of a model ternary Fe-4Cr-6Ti ferritic alloy aged at 800°C for 8, 16 and 24 h are investigated in detail. Fine Fe2Ti Laves phase particles precipitate in the α-Fe (ferrite) matrix phase after solutionizing and subsequent aging treatments. The size and amount of Fe2Ti precipitates gradually increase with increasing aging time. The magnetic measurements of the aged samples confirm the variations in the microstructural properties including the volume fraction of the constituent phases, and Ti content of the α-Fe matrix phase. The mean Vickers microhardness value also increases from 203.5 to 238.4 with increasing aging time from 8 to 24 h. In addition, the cyclic oxidation behavior of 24 h aged sample, which contains maximum amount of Fe2Ti precipitates, is also investigated in detail. X-ray diffraction analysis reveals that scale product is α-Fe2O3 (hematite). Significant scale spallation and void formation is observed on the surfaces of 24 h aged Fe-4Cr-6Ti sample oxidized at 500°C.

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Authors and Affiliations

Ahmet Demirel

1

e-mail:

ORCID:

Emre Can Çetin

1

e-mail:

ORCID:

Ali Karakuş

1

e-mail:

ORCID:

Mehmet Şahin Ataş

1

e-mail:

ORCID:

Mehmet Yildirim

1

e-mail:

ORCID:

Konya Technical University, Faculty of Engineering and Natural Sciences, Department of Metallurgical and Materials Engineering, Konya , Turkey

Acceleration of Early Strength Development in Mortars Containing Soluble Silica Extracted from Palm Oil Clinker

A.H. Ismail A. Kusbiantoro L.T. Yian K. Muthusamy N.A.M. Mortar

Archives of Metallurgy and Materials | 2024 | vol. 69 | No 1 | 269-273 | DOI: 10.24425/amm.2024.147818

Keywords Palm oil clinker powder soluble silica extraction rapid hardening mortar

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Abstract

Soluble silica from palm oil clinker was extracted using Laine’s method. It involved two major steps, namely water reflux and distillation. The use of 480 g of POCP and 12 hours of distillation in the extraction experiment resulted in 53.50% of dissolved silica, which was the highest gain among the trial experiments and was chosen as an optimum parameter for the subsequent characterisation analysis. In addition, its effect on cement hydration was studied by including it as a filler in mortar mixtures. Mortar with 7.50% of extracted silica gained high strength in the early days of curing and performed well throughout the maturing age. The rapid hardening properties of soluble silica-based mortar would promote the potential of soluble silica as an additive for rapid hardening.

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Authors and Affiliations

A.H. Ismail

1

e-mail:

ORCID:

A. Kusbiantoro

1

e-mail:

ORCID:

L.T. Yian

2

e-mail:

ORCID:

K. Muthusamy

3

e-mail:

ORCID:

N.A.M. Mortar

4

e-mail:

ORCID:

Universiti Tun Hussein Onn Malaysia, Faculty of Engineering Technology, Johor, Malaysia
Universiti Teknologi Malaysia, Faculty of Engineering, Johor, Malaysia
Universiti Malaysia Pahang, Faculty of Civil Engineering Technology Pahang, Malaysia
Universiti Malaysia Perlis (UniMAP), Centre of Excellence Geopolymer & Green Technology (CEGeoGTech), 01000 Perlis, Malaysia

Possibilities of using ash from thermal treatment of municipal solid waste in hardening slurries

Łukasz Szarek Paweł Falaciński Piotr Drużyński

Archives of Environmental Protection | 2023 | vol. 49 | No 2 | 76-84 | DOI: 10.24425/aep.2023.145899

Keywords municipal solid waste fly ash hardening slurry cement-bentonite slurry cementitious materials circular economy

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Abstract

In recent years, there has been a marked increase in the amount of municipal waste generated in Poland. In 2020, 21.6% of all municipal waste was subjected to a thermal treatment process. Consequently, the amount of ashes generated is significant. Due to their properties, it is difficult to utilize this type of waste within concrete production technology. One of the waste utilization methods is to add it to hardening slurries used in, among others, cut-off walls. The article assesses the possibility of using ashes from municipal waste incineration as an additive to hardening slurries. It also discusses the technological properties of hardening slurries with the addition of the ashes in question. The experiment showed that it is possible to compose a hardening slurry based on tested ashes with technological properties suitable for use as a cut-off wall. Further research directions were proposed.

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Falacinski, P. & Szarek, Ł. (2016). Possible applications of hardening slurries with fly ash from thermal treatment of municipal sewage sludge in environmental protection structures. Archives of Hydro-Engineering and Environmental Mechanics, 63, pp. 47-61.DOI: 10.1515/heem-2016-0004
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Authors and Affiliations

Łukasz Szarek

1

e-mail: lukasz.szarek@is.pw.edu.pl

ORCID:

Paweł Falaciński

1

e-mail:

ORCID:

Piotr Drużyński

1

Faculty of Building Services, Hydro and Environmental Engineering,Warsaw University of Technology, Poland

The Influence of the Modified Ablation Casting on Casts Properties Produced in Microwave Hardened Moulds with Hydrated Sodium Silicate Binder

K. Major-Gabryś M. Hosadyna-Kondracka S. Puzio J. Kamińska M. Angrecki

Archives of Metallurgy and Materials | 2020 | vol. 65 | No 1 | 497-502 | DOI: 10.24425/amm.2020.131753

Keywords Moulding sand Ablation casting Hydrated sodium silicate Microwave hardening Mechanical properties of casting

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Abstract

The ablation casting technology consists in pouring castings in single-use moulds made from the mixture of sand and water-soluble binder. After pouring the mould with liquid metal the mould is destructed (washed out) using a stream of cooling medium, which in this case is water. The process takes place while the casting is still solidifying.

The following paper focuses on testing the influence of the modified ablation casting of aluminum alloy on casts properties produced in moulds with hydrated sodium silicate binder. The authors showed that the best kind of moulding sands for Al alloy casting will be those hardened with physical factors – through dehydration. The analysis of literature data and own research have shown that the moulding sand with hydrated sodium silicate hardened by dehydration is characterized by sufficient strength properties for the modified ablation casting of Al alloys. In the paper the use of microwave hardened moulding sands has been proposed.

The moulds were prepared in the matrix specially designed for this technology. Two castings from the AlSi7Mg alloy were made; one by traditional gravity casting and the other by gravity casting using ablation.

The conducted casts tests showed that the casting made in modified ablation casting technology characterizes by higher mechanical properties than the casting made in traditional casting technology. In both experimental castings the directional solidification was observed, however in casting made by ablation casting, dimensions of dendrites in the structure at appropriate levels were smaller.

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Authors and Affiliations

K. Major-Gabryś

e-mail:

ORCID:

M. Hosadyna-Kondracka

e-mail:

ORCID:

S. Puzio

e-mail:

ORCID:

J. Kamińska

e-mail:

ORCID:

M. Angrecki

e-mail:

ORCID:

Modelling and Analysis of the Synergistic Alloying Elements Effect on Hardenability of Steel

W. Sitek J. Trzaska W.F. Gemechu

Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 102-108 | DOI: 10.24425/afe.2022.143957

Keywords Hardenability artificial neural network multiple regression Steel alloy composition modelling and simulation

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Abstract

The paper presents a methodology of modeling relationships between chemical composition and hardenability of structural alloy steels using computational intelligence methods, that are artificial neural network and multiple regression models. Particularly, the researchers used unidirectional multilayer teaching method based on the error backpropagation algorithm and a quasi-newton methods. Based on previously known methodologies, it was found that there is no universal method of modeling hardenability, and it was also noted that there are errors related to the calculation of the curve. The study was performed on large set of experimental data containing required information on about the chemical compositions and corresponding Jominy hardenability curves for over 400 data steel heats with variety of chemical compositions. It is demonstrated that the full practical usefulness of the developed models in the selection of materials for particular applications with intended performance in the area of application.

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Authors and Affiliations

W. Sitek

1

e-mail:

ORCID:

J. Trzaska

1

e-mail:

ORCID:

W.F. Gemechu

1

e-mail:

ORCID:

Department of Engineering Materials and Biomaterials, Silesian University of Technology, Poland

The Effect of Reclaim Primary Quality on Moulding Sand Parameters and Quality of Ductile Iron Casting Surface Layer

J. Kamińska M. Angrecki S. Puzio M. Stachowicz

Archives of Foundry Engineering | 2022 | vol. 22 | No 2 | 83-88 | DOI: 10.24425/afe.2022.140229

Keywords Foundry industry Furfuryl resin Reclaim Self-hardening moulding sand Surface quality

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Abstract

The aim of the research was to determine the effect of the primary quality of reclaim from dry mechanical reclamation on the strength properties and service life of moulding sands based on this reclaim. Another aim was to establish the effect of the quality of reclaim, sulphur content - in particular, on the surface quality and thickness of the deformed surface layer in ductile iron castings. The research has revealed differences in the strength parameters and service life (mouldability) of sands based on the tested reclaims, depending on the type of the furfuryl resin used, including resins whose synthesis was done as part of the Żywfur project. Examinations of the structure of the surface layer of test castings poured in moulds made of loose self-hardening sands containing the addition of reclaim have confirmed the occurrence of degenerated spheroidal graphite in this part of the casting. It should be noted here that when massive castings with a long solidification time are made, the graphite degeneration effect can be more visible and the layer with the changed structure can increase in thickness. The research has clearly shown that it is necessary to control the parameters of the reclaim, including sulphur content which is transferred from the hardener and accumulates on the grains. This phenomenon has a negative impact not only on the sand strength and technological properties but also on the surface layer of castings.

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Bibliography

[1] Lewandowski, J.L. (1997). Materials for foundry moulds. Kraków: WN Akapit. ISBN: 83-7108-21-2 (in Polish).
[2] Kamińska, J., Puzio, S., Angrecki, M., Stachowicz, M. & Łoś, A. (2019). Preliminary tests of innovative eco-friendly furfuryl resins and foundry sand mixtures based on these resins. Journal of Ecological Engineering. 20(9), 285-292, DOI: 10.12911/22998993/112510.
[3] Acharya, S.G., Vadher, J.A. & Kanjariya, P.V. (2016). Identification and quantification of gases releasing from furan no bake binder. Archives of Foundry Engineering. 16(3), 5-10. DOI: 10.1515/afe-2016-0039.
[4] Chate, G.R., Patel, GC M., Deshpande, A.S. & Parappagoudar, M.B. (2018). Modeling and optimization of furan moulding sand system using design of experiments and particle swarm optimization. Journal of Process Mechanical Engineering. 232(5), 1-20. DOI: 10.1177/0954408917728636.
[5] Sappinen, T., Orkas, J. & Konqvist, T. (2018). Thermal Reclamation of Foundry Sands Using Repurposed Sand Dryer Equipment. Archives of Foundry Engineering. 18(4), 99-102. DOI: 10.24425/afe.2018.125176.
[6] Kamińska, J., Puzio, S., Angrecki, M. & Łoś, A. (2020). Effect of reclaim addition on the mechanical and technological properties of moulding sands based on pro-ecological furfuryl resin. Archives of Metallurgy and Materials. 65(4), 1425-1429. DOI: 10.24425/amm.2020.133709.
[7] Yan-lei, L., Guo-hua, W., Wen-cai, L., An-tao, C., Liang, Z. & Ying-xin Wang, W. (2017). Effect of reclaimed sand additions on mechanical properties and fracture behavior of furan no-bake resin sand. China Foundry. 14(2), 128-137. DOI: 10.1007/s41230-017-6024-3.
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[15] Sheladiya, M.V., Acharya, S.G., Mehta, K., Acharya, G.D. (2019). Evaluate sulphur diffusion at mould-metal interface in no-bake mould system. Archives of Foundry Engineering. 19(1), 63-70. DOI: 10.24425/afe.2018.125193.
[16] Anca, D., Stan, I., Chisamera, M., Riposan, I. & Stan, S. (2021). Experimental study regarding the possibility of blocking the diffusion of sulfur at casting-mold interface in ductile iron castings. Coatings. 11(673), 1-10. DOI: https://doi.org/10.3390/coatings11060673.
[17] Dańko, J., Dańko, R. & Łucarz, M. (2007). Processes and devices for the matrix regeneration of spent molding sands. Kraków: WN Akapit. ISBN: 978-83-89541-88-8 (in Polish).
[18] Holtzer, M., Bobrowski, A., Drożyński, D., Isendorf, B., Mazur, (2012). Influence of the reclaim on the properties of moulding sands with furfuryl resin applied for moulds for manganese steel castings. Archives of Foundry Engineering. 12(1), 57-62.
[19] Dańko, R., Górny, M., Holtzer, M., Żymankowska-Kumon, S. (2014). Effect of the quality of furan moulding sand on the skin layer of ductile iron castings. ISIJ International. 54(6), 1288-1293. DOI: https://doi.org/10.2355/isijinternational.54.1288.
[20] Pałyga, Ł., Stachowicz, M., Granat, K. (2015). Evaluation of 2D and 3D surface roughness of die castings from alloy AlSi9Cu3. Archives of Foundry Engineering. 15(1), 75-80.

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Authors and Affiliations

J. Kamińska

1

e-mail:

ORCID:

M. Angrecki

1

e-mail:

ORCID:

S. Puzio

1

e-mail:

ORCID:

M. Stachowicz

2

e-mail:

ORCID:

Łukasiewicz Research Network – Krakow Institute of Technology, Poland
Wroclaw University of Technology, Faculty of Mechanical Engineering, Poland

The Use of Phosphate Binder for Ablation Casting of AlSi7Mg Modified TiB Alloy

S. Puzio J. Kamińska K. Major-Gabryś M. Angrecki

Archives of Foundry Engineering | 2022 | vol. 22 | No 1 | 62-68 | DOI: 10.24425/afe.2022.140218

Keywords Ablation casting technology alumina Phosphate binder Self-hardening sands Inorganic binder

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Abstract

The possibilities of using an inorganic phosphate binder for the ablation casting technology are discussed in this paper. This kind of binder was selected for the process due to its inorganic character and water-solubility. Test castings were made in the sand mixture containing this binder. Each time during the pouring liquid alloy into the molds and solidification process of castings, the temperature in the mold was examined. Then the properties of the obtained castings were compared to the properties of the castings solidifying at ambient temperature in similar sand and metal molds. Post-process materials were also examined - quartz matrix and water. It has been demonstrated that ablation casting technology promotes refining of the microstructure, and thus upgrades the mechanical properties of castings (Rm was raised about approx. 20%). Properties of these castings are comparable to the castings poured in metal moulds. However, the post-process water does not meet the requirements of ecology, which significantly reduces the possibility of its cheap disposal.

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Bibliography

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Authors and Affiliations

S. Puzio

1

e-mail:

ORCID:

J. Kamińska

1

e-mail:

ORCID:

K. Major-Gabryś

2

e-mail:

ORCID:

M. Angrecki

1

e-mail:

ORCID:

ŁUKASIEWICZ Research Network - Foundry Research Institute, Zakopianska 73, 30-418 Cracow, Poland
AGH University of Science and Technology, Faculty of Foundry Engineering, Mickiewicza 30, 30-059 Cracow, Poland

Study on Reclamation of CO ₂-hardened Sodium Silicate Used Sands by CaO Powder

J. Lu L. Yang J. Qian W. He H. Wang

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 99-106 | DOI: 10.24425/afe.2022.140242

Keywords CO2 hardened sodium silicate used sands CaO reclamation Orthogonal experiment

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Abstract

Aiming at the problems of wet reclamation consuming a lot of water, dry(mechanical) reclamation having wear and power consumption, this paper to find suitable reclamation reagents to reduce the influence of harmful substances in used sodium silicate sands. By comparing the reclamation effect of CaO, Ca(OH) ₂ and Ba(OH) ₂ reclamation powder reagents, it was concluded that CaO had the best reclamation effect. Through the single factor experiment, the influence of CaO on the reclamation effect was explored: 1. addition amount of CaO;2. the additional amount of water ;3. reclamation time. The orthogonal results showed that the CaO reclamation effect was the best when the amount of CaO was 1.5%, the amount of sodium silicate was 4.0%, the amount of water added was 6.0%, and the reclamation time was 12.0h. In this experiment, 82.2% carbonate and 75.0 % silicate in used sands can be removed. The microscopic analysis of the reclamation sands was carried out by scanning electron microscope (SEM); The surface was relatively smooth, without large area cracks and powder accumulation. Compared with the used sands, the instant, 24h ultimate, and residual strengths of the reclaimed sands were increased by 536.5%, 458.1%, and 89.8%, respectively, which was beneficial to the reclamation of the CO2 sodium silicate used sands.

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Bibliography

[1] Gong, X.L. & Fan, Z.T. (2020). Research and application of green casting materials. MW Metal Forming. (10), 15-18.
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[3] Nowak, D. (2017). The impact of microwave penetration depth on the process of hardening the moulding sand with sodium silicate. Archives of Foundry Engineering. 17(4),115-118. DOI: 10.1515/afe-2017-0140
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[18] Chen, J.Q., Han, D.D., Qiu, A. & Zhu, H, et al. (2018). Orthogonal experimental design of liquid-cooling structure on the cooling effect of a liquid-cooled battery thermal management system. Applied Thermal Engineering.132, 508-520. https://doi.org/10.1016/j.applthermaleng.2017.12.115

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Authors and Affiliations

J. Lu

1

e-mail:

ORCID:

L. Yang

1

e-mail:

ORCID:

J. Qian

1

e-mail:

ORCID:

W. He

1

e-mail:

ORCID:

H. Wang

1

e-mail:

ORCID:

School of Mechanical Engineering and Automation, Wuhan Textile University, Wuhan 430200, China

Influence of modelling phase transformations with the use of LSTM network on the accuracy of computations of residual stresses for the hardening process

Joanna Wróbel Adam Kulawik

Bulletin of the Polish Academy of Sciences Technical Sciences | 2023 | 71 | 4 | e145681 | DOI: 10.24425/bpasts.2023.145681

Keywords RNN network hardening process temperature phase transformations in the solid state effective stresses numerical modelling

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Abstract

Replacing mathematical models with artificial intelligence tools can play an important role in numerical models. This paper analyses the modeling of the hardening process in terms of temperature, phase transformations in the solid state and stresses in the elastic-plastic range. Currently, the use of artificial intelligence tools is increasing, both to make greater generalizations and to reduce possible errors in the numerical simulation process. It is possible to replace the mathematical model of phase transformations in the solid state with an artificial neural network (ANN). Such a substitution requires an ANN network that converts time series (temperature curves) into shares of phase transformations with a small training error. With an insufficient training level of the network, significant differences in stress values will occur due to the existing couplings. Long-Short-Term Memory (LSTM) networks were chosen for the analysis. The paper compares the differences in stress levels with two coupled models using a macroscopic model based on CCT diagram analysis and using the Johnson-Mehl-Avrami-Kolmogorov (JMAK) and Koistinen-Marburger (KM) equations, against the model memorized by the LSTM network. In addition, two levels of network training accuracy were also compared. Considering the results obtained from the model based on LSTM networks, it can be concluded that it is possible to effectively replace the classical model in modeling the phenomena of the heat treatment process.

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Authors and Affiliations

Joanna Wróbel

1

Adam Kulawik

1

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Department of Computer Science, Czestochowa University of Technology, Dabrowskiego 73, 42-201 Czestochowa, Poland

Effects of ageing heat treatment temperature on the properties of DMLS additive manufactured 17-4PH steel

Aleksander Świetlicki Mariusz Wlaczak Mirosław Szala Marcin Turek Dariusz Chocyk

Bulletin of the Polish Academy of Sciences Technical Sciences | 2023 | 71 | 4 | e146237 | DOI: 10.24425/bpasts.2023.146237

Keywords 17-4PH steel precipitation hardening additive manufacturing heat treatment nanohardness

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Abstract

Additive manufacturing (AM) is a modern, innovative manufacturing method that enables the production of fully dense products with high mechanical properties and complex shapes that are often impossible to obtain by traditional methods. The 17-4PH grade steel is often applied where high mechanical performance is required. 17-4PH, or AISI 630, is intended for precipitation hardening, an operation that combines solution and ageing treatments and is used to significantly change the microstructure of the steel and enhance its mechanical properties. This study investigates the effect of precipitation hardening on the properties of 17-4PH steel. To examine microstructure and morphology, metallographic tests were performed together with phase composition and chemical composition analyses. Mechanical parameters were determined via Vickers hardness testing and the Oliver-Pharr method. Samples were fabricated using direct metal laser sintering (DMLS), which is one of the powder bed fusion methods. The use of a constant solution treatment temperature of 1040_C and different ageing temperatures made it possible to evaluate the effects of ageing temperature on the mechanical properties and microstructure of 17-4PH. The presence of face-centered cubic FCC g-austenite and body-centerd cubic BCC a-martensite structures were detected. The tests revealed that – similarly to the wrought material – the highest hardness of 382_10:3 HV0:2 was obtained after ageing at 450_C. The nanoindentation test showed the same H/E ratio for the sample after fabrication and after solution treatment at 0.016769, but this value increased after ageing to 127–157.5%. The sample aged at 450_C was characterized by the highest H/E ratio of 0.026367, which indicates the highest wear resistance of this material under employed treatment conditions. In general, the sample treated at 450_C showed the best performance out of all tested samples, proving to have the smallest grain size as well as high Vickers and nanoindentation hardness. On the other hand, the use of solution treatment led to reduced hardness and improved workability of the AM material.

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Authors and Affiliations

Aleksander Świetlicki

1

Mariusz Wlaczak

1

e-mail:

ORCID:

Mirosław Szala

1

e-mail:

ORCID:

Marcin Turek

2

Dariusz Chocyk

3

e-mail:

ORCID:

Department of Materials Engineering, Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36, 20-618 Lublin, Poland
Institute of Physics, Maria Curie-Sklodowska University in Lublin, pl. M. Curie-Sklodowskiej 1, 20-031 Lublin, Poland
Department of Applied Physics, Faculty of Mechanical Engineering, Lublin University of Technology, Nadbystrzycka 36D, 20-618 Lublin, Poland

The Critical Conditions and Kinetics Required for Dynamic Recrystallization in a High-Carbon Tool Steel

Yong-Ji Zhang Guang-Liang Wu Shang-Wen Wu

Archives of Metallurgy and Materials | 2021 | vol. 66 | No 1 | 119-125 | DOI: 10.24425/amm.2021.134767

Keywords high-carbon steel critical conditions dynamic recrystallization work-hardening kinetics model

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Abstract

A hot compression test was conducted on a Gleeble-3500 thermo-simulation machine to study the critical conditions and kinetics of dynamic recrystallization in a high-carbon tool steel. The critical conditions for the initiation of dynamic recrystallization were determined using the working-hardening theory. The quantitative relationship between the critical characteristics of dynamic recrystallization and the hot deformation parameters were elucidated based on two different methods:the apparent method and physically based method. It was found that the two methods both have high applicability for the investigated steel, but the physically-based method needs less parameters and makes it possible to study the effect of different factors. A dynamic recrystallization kinetics model was used to calculate the recrystallization volume fraction under different conditions. The calculation results matched well with the data obtained from the flow curves.

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Authors and Affiliations

Yong-Ji Zhang

Guang-Liang Wu

Shang-Wen Wu

Effect of Reclaim Addition on the Mechanical and Technological Properties of Moulding Sands Based on Pro-Ecological Furfuryl Resin

J. Kamińska S. Puzio M. Angrecki A. Łoś

Archives of Metallurgy and Materials | 2020 | vol. 65 | No 4 | 1425-1429 | DOI: 10.24425/amm.2020.133709

Keywords loose self-hardening sands pro-ecological furfuryl resin environmental protection strength tests gas-forming tendency

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Abstract

Increasing demands are imposed on foundries to enforce the manufacture of castings characterized by tight dimensional tolerances, high surface finish and total absence of casting defects. To face these challenges, castings are increasingly made in loose self-hardening sands with furfuryl resin, commonly known as furan sands. In the group of self-hardening sands with synthetic resins, loose self-hardening sands with furfuryl resin enjoy the greatest popularity. The sand mixtures based on furan resins are usually subjected to mechanical reclamation. The consumption of binder and hardener and thus the cost of the sand depend on the quality of reclaim, and mainly on the dust removal degree.

The planned tightening of the environmental protection regulations in the EU countries, including limiting the content of free furfuryl alcohol in resins and reducing the emission of furfuryl alcohol, formaldehyde and BTEX compounds at workplaces, necessitated the development of a new generation of eco-friendly furfuryl resins that have recently appeared on the market.

The main aim of this article was to determine the effect of reclaim content on the sand parameters, such as bending strength, tensile strength, bench life, gas-forming tendency and loss on ignition. Tests were carried out with reclaim content in the sand mixture varying from 50 to 90%. The reclaim obtained by dry mechanical reclamation was supplied by one of the domestic foundries.

The results showed that the highest mechanical properties were obtained in sands containing 60% of the reclaim.

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Authors and Affiliations

J. Kamińska

e-mail:

ORCID:

S. Puzio

e-mail:

ORCID:

M. Angrecki

e-mail:

ORCID:

A. Łoś

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