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Archives of Foundry Engineering

Archives of Foundry Engineering

Description

Archives of Foundry Engineering continues the publishing activity started by Foundry Commission of the Polish Academy of Sciences (PAN) in Katowice in 1978. The initiator of it was the first Chairman Professor Dr Eng. Wacław Sakwa – Corresponding Member of PAN, Honorary Doctor of Czestochowa University of Technology and Silesian University of Technology. This periodical first name was „Solidification of Metals and Alloys” , and made possible to publish the results of works achieved in the field of the Basic Problems Research Cooperation. The subject of publications was related to the title of the periodical and concerned widely understand problems of metals and alloys crystallization in a casting mold. In 1978-2000 the 44 issues have been published. Since 2001 the Foundry Commission has had patronage of the annually published “Archives of Foundry” and since 2007 quarterly published “Archives of Foundry Engineering”. Thematic scope includes scientific issues of foundry industry:

  • Theoretical Aspects of Casting Processes,
  • Innovative Foundry Technologies and Materials,
  • Foundry Processes Computer Aiding,
  • Mechanization, Automation and Robotics in Foundry,
  • Transport Systems in Foundry,
  • Castings Quality Management,
  • Environmental Protection.

Scoring assigned by the Polish Ministry of Science and Higher Education: 100 points

IMPACT FACTOR 2022: 0.6

CiteScore metrics from Scopus 2022: 1.2
SCImago Journal Rank ( SJR) 2022: 0.197
Source Normalized Impact per Paper ( SNIP) 2022: 0.423


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The journal content is available under the Creative Commons Attribution 4.0 International License https://creativecommons.org/licenses/by/4.0/


 
ISSN
eISSN 2299-2944
Publishers
The Katowice Branch of the Polish Academy of Sciences
Editor in Chief:
J. Jezierski ORCID logo0000-0003-2078-196X
Silesian University of Technology, Gliwice, Poland
jan.jezierski@polsl.pl

Deputy Editor:
D. Bartocha ORCID logo0000-0002-3011-4434
Silesian University of Technology, Gliwice, Poland
dariusz.bartocha@polsl.pl

Subject Editors:

Theoretical Aspects of Casting Processes
E. Guzik – ORCID logo0000-0002-4449-532X, AGH University of Technology, Kraków, Poland
S. Gnyloskurenko – ORCID logo0000-0003-0201-7191, PTIMA National Academy of Sciences of Ukraine, Kiev, Ukraine
J. Sobczak – ORCID logo0000-0002-8878-1037, AGH University of Technology, Kraków, Poland

Innovative Foundry Technologies and Materials
O. P. Pandey – ORCID logo0000-0002-6826-995X , Thapar University, Punjab, India
N. S. Tiedje – ORCID logo0000-0001-5198-3551, DTU in Lyngby, Denmark
P. Lichy – ORCID logo0000-0002-6170-4728, VSB - Technical University of Ostrava, Ostrava, Czech Republic

Foundry Processes Computer Aiding
B. Mochnacki – ORCID logo0000-0001-8504-3744, University of Occupational Safety Management, Katowice, Poland
E. Majchrzak – ORCID logo0000-0003-3555-2318, Silesian University of Technology, Gliwice, Poland
M. Szucki – ORCID logo0000-0002-2675-1836, TU Bergakademie Freiberg, Freiberg, Germany
M. Perzyk – ORCID logo0000-0003-4901-7746, Warsaw University of Technology, Warszawa, Poland

Mechanization, Automation and Robotics in Foundry
J. Bast – ORCID logo0000-0002-9795-2352, TU Bergakademie Freiberg, Freiberg, Germany
R. Dańko – ORCID logo0000-0003-2434-6025, AGH University of Technology, Kraków, Poland
M. Mróz – ORCID logo0000-0002-7433-4092, Rzeszow University of Technology, Rzeszów, Poland

Castings Quality Management
D. Bolibruchova – ORCID logo0000-0002-7374-9763, University of Zilina, Zilina, Slovak Republic
J. D. B. de Mello – ORCID logo0000-0001-8912-2132, Universidade Federal de Uberlandia, Uberlandia, Brazil
M. Górny – ORCID logo0000-0001-6682-2611, AGH University of Technology, Kraków, Poland

Environmental Protection
M. Holtzer – ORCID logo0000-0002-6988-3329, AGH University of Technology, Kraków, Poland
J. Roučka – ORCID logo0000-0003-0917-1810, Brno University of Technology, Brno, Czech Republic
S. Acharya – ORCID logo0000-0001-6428-8961, Sardar Vallabhbhai Patel Institute of Technology, Vasad, Gujarat, India

Editorial Advisory Board:
M. Cholewa – ORCID logo0000-0001-8598-6953, Silesian University of Technology, Gliwice, Poland
B. K. Dhindaw – ORCID logo0000-0001-6991-9793, Indian Institute of Technology, Kharagpur, India
W. A. Hufenbach – ORCID logo0000-0002-5131-3483, Technical University Dresden, Dresden, Germany
A. Zadera – ORCID logo0000-0002-0555-370X , Brno University of Technology, Brno, Czech Republic
A. Passerone – ORCID logo0000-0002-0005-5314, CNR, Genova, Italy
I. Riposan – ORCID logo0000-0002-4040-2798, Politehnica University of Bucharest Bucharest, Romania
A. Sládek – ORCID logo0000-0002-7628-3524, University of Zilina, Zilina, Slovak Republic
J. Szajnar – ORCID logo0000-0003-3622-843X, Silesian University of Technology, Gliwice, Poland
R. B. Tuttle – ORCID logo00000002-7689-259X, Western Michigan University, Kalamazoo, MI, USA
M. Okayasu – ORCID logo0000-0003-3897-070X, Okayama University, Okayama, Japan
I. Nova – ORCID logo0000-0003-2287-9346, Technical University of Liberec, Liberec, Czech Republic
C. Caceres – ORCID logo0000-0001-6521-2037, The University of Queensland, Brisbane, Australia
A. Dioszegi – ORCID logo0000-0002-3024-9005, Jönköping University, Jönköping, Sweden

Associate Editors:
A. Dulska – ORCID logo0000-0001-6903-328X, Silesian University of Technology, Gliwice, Poland
J. Suchoń – ORCID logo0000-0002-7019-3966, Silesian University of Technology, Gliwice, Poland
M. Kondracki – ORCID logo0000-0001-7840-5575, Silesian University of Technology, Gliwice, Poland
N. Przyszlak – ORCID logo0000-0003-1683-0001, Silesian University of Technology, Gliwice, Poland
J. Szymszal – ORCID logo0000-0002-3229-6470, Silesian University of Technology, Gliwice, Poland

ul. Towarowa 7,
44-100 Gliwice, Poland
e-mail: kikm@polsl.pl

https://www.journal-afe.pl

Copyright

Copyright on any open access article in the Archives of Foundry Engineering journal published by Polish Academy of Sciences is retained by the author(s). Authors grant Polish Academy of Sciences a license to publish the article and identify itself as the original publisher. Authors also grant any user the right to use the article freely if its integrity is maintained and its original authors, citation details and publisher are identified. The Creative Commons Attribution License 4.0 formalizes these and other terms and conditions of publishing articles.

 

The editorial team of Archives of Foundry Engineering implements an open access policy by publishing materials in the form of the so-called Gold Open Access and encourages authors to place articles published in the journal in open repositories (after the review or the final version of the publisher), provided that a link to the journal’s website is provided.

Exceptions to copyright policy

For the articles which were previously published, before year 2022, policies that are different from the above. In all such, access to these articles is free from fees or any other access restrictions. Permissions for the use of the texts published in that journal may be sought directly from the Commission of Foundry Engineering of the Polish Academy of Sciences, Gliwice, Poland, by e-mail: kikm@polsl.pl.
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Archives of Foundry Engineering | Accepted articles

1 Analysis of Anomalies in the Thermal-Mechanical Fatigue Process Using Selected IT Tools
K. Jaśkowiec , D. Wilk-Kołodziejczyk , K. Nosarzewski
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155373
Keywords: Thermal-mechanical fatigue Vermicular cast iron Coffin method Isolation Forest One-Class SVM
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Abstract

The article uses the results obtained during the tests of a wide group of metal alloys using a device operating by the Coffin method. The measure of resistance to thermal-mechanical fatigue is the number of cycles that the sample withstands before a macrocrack occurs, at a fixed current and temperature range. The device offers the possibility of working in two modes of sample mounting. The first mode allows the sample to freely elongate parallel to its axis, while the second mounting mode limits this elongation by using a transducer. The aim of the publication is to present possible solutions for anomaly detection. Anomaly detection concerns traps that may occur during the measurement process. Advanced machine learning methods were used to analyze and detect anomalies in data regarding thermal fatigue resistance. Isolation Forest and One-Class SVM algorithms were used for anomaly detection, which allow for effective identification of unusual patterns in the data. The conducted research confirmed the usefulness of one of the selected methods in the process of anomaly identification using the example of elongation.
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Bibliography

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  • Coffin, L.F. & Wesley, R.P. (1954). Apparatus for study of effects of cyclic thermal stresses on ductile metals. Journal of Fluids Engineering. 76, 923-930. https://doi.org/10.1115/1.4015019.

  • Seifert, T. & Riedel, H. (2010). Mechanism-based thermomechanical fatigue life prediction of cast iron. Part I: Models. International Journal of Fatigue. 32, 1358-1367. https://doi.org/10.1016/J.IJFATIGUE.2010.02.004.

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  • Li, W., Chen, H., Guo, J., Zhang, Z., Wang, Y. (2022). Brain-inspired multilayer perceptron with spiking neurons. In Proceedings of the IEEE/CVF Conference on Computer Vision and Pattern Recognition, 18-24 June 2022 (pp. 773-783). https://doi.org/10.1109/CVPR52688.2022.00086. New Orleans, LA, USA: IEEE.

  • Shu, X., Zhang, S., Li, Y. & Chen, M. (2022). An anomaly detection method based on random convolutional kernel and isolation forest for equipment state monitoring. Eksploatacja i Niezawodność – Maintenance and Reliability. 24(4), 758-770. https://doi.org/10.17531/EIN.2022.4.16.

  • Wu, X., Kang, H., Yuan, S., Jiang, W., Gao, Q. & Mi, J. (2023). Anomaly detection of liquid level in mold during continuous casting by using forecasting and error generation. Applied Sciences. 13(13), 7457, 1-16. https://doi.org/10.3390/app13137457.

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Authors and Affiliations

K. Jaśkowiec
1
ORCID: ORCID
D. Wilk-Kołodziejczyk
2
ORCID: ORCID
K. Nosarzewski
2
  1. Łukasiewicz Research Network – Krakow Institute of Technology, Kraków, Poland
  2. AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059 Kraków, Poland
2 The Effect of Addition of the Natural Zeolite on the Microstructure and Properties of Sintered Iron Matrix Composite
M. Kargul , J.M. Borowiecka-Jamrozek
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155374
Keywords: Metal matrix Iron Zeolite Powder metallurgy
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Abstract

The paper presents the results of research on the production and application of a sintered iron-based composite reinforced with natural zeolite particles. Mechanical properties were tested and the quality of the connection between the particles and the metal matrix was assessed. Before the composite production process, the chemical composition and morphology of natural zeolite particles were examined. Zeolite particles with a diameter of less than 0.2 mm were used to produce sinters. The zeolite particles were subjected to chemical composition (EDS) and phase (XRD) analyses. Zeolite particles were introduced into the iron matrix in amounts of 5, 10, and 15% by weight. Before the sintering process, the zeolite particles were compacted in a hydraulic press at a pressure of 400 MPa. Sintering of the green compacts was carried out in a tubular furnace at 950°C in an atmosphere of dissociated ammonia for 60 minutes. The obtained composites were subjected to porosity, hardness, and density measurements. Microstructure and chemical composition studies were conducted using a scanning electron microscope (SEM). Iron–zeolite composites are characterized by higher hardness and porosity compared to sintered iron. The introduction of zeolite particles also reduces the density of the composites.
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Bibliography

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Authors and Affiliations

M. Kargul
1
ORCID: ORCID
J.M. Borowiecka-Jamrozek
1
ORCID: ORCID
  1. Kielce University of Technology, Poland
3 Cavitation Erosion Resistance Tests of WCCoCr and CrCNi Coatings Sprayed Using the APS Method
M. Radoń , B. Kupiec
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155375
Keywords: Air plasma spraying coating Scratch test Cavitation erosion
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Abstract

This article presents structural analysis and mechanical property evaluation of two coatings applied using the APS (Air Plasma Spraying) method on a P250GH boiler steel substrate. Two different powders were used for coating deposition: WCCoCr, based on tungsten carbide, and CrCNi, based on chromium carbide. To assess the coating-substrate bond quality, a scratch test was conducted using a Rockwell diamond indenter under a constant load of 10 N, moving from the substrate toward the coating. No delamination at the coating-substrate interface was observed, indicating a high-quality bond. Microhardness measurements were performed using a 200 g load. The average microhardness values were 886 HV0.2 for the WCCoCr coating and 904 HV0.2 for the CrCNi coating. The coatings were also tested for cavitation resistance according to the ASTM G32-16 standard. Surface roughness profiles were measured before and after 120 minutes of cavitation exposure. Cavitation wear was evaluated based on the difference in roughness values, determined by the Sz parameter, which, according to ISO 25178, is defined as the difference between the highest peak and the lowest valley on the surface. The obtained results indicate that APS thermal spray coatings based on tungsten carbide powders can be used for machine components to enhance cavitation erosion resistance.
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Authors and Affiliations

M. Radoń
1
ORCID: ORCID
B. Kupiec
1
ORCID: ORCID
  1. Rzeszow University of Technology, Poland
4 Application of Elasto-Optical Methods in Research on Casting Structures
M.L. Maj , W. Stachurski
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155376
Keywords: Photoelastic method Isochromatics and isoclines Polarized light Photoelastic coating
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Abstract

Verification of design conclusions using experimental methods is often employed and usually more justified than other techniques for producing machine or device components. Castings are characterized by complex shapes, varying sizes and, as a result, diverse physical and mechanical properties. Additionally, relatively small batches of alloys prepared for casting introduce unintended variation that affects final characteristics and acceptance criteria. It is therefore important to consider the slightly different mechanical properties of finished castings, which may vary even within the same part due to different solidification and cooling conditions. Despite these limitations, the foundry industry occupies an important position in national economies, with indicators showing steady development driven by low manufacturing costs, improved technologies, and new designs with stricter acceptance criteria. The aim of this work is to briefly present one experimental method of stress and strain analysis — the photoelastic method.
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Authors and Affiliations

M.L. Maj
1
ORCID: ORCID
W. Stachurski
1
  1. AGH University of Krakow, Faculty of Foundry Engineering, Poland
5 Stable Production of High-volume and High-quality ADI and Further Improvement of Consistency
Wenbang Gong , Zhongding Zhou , Mintang Zhang , Wenqing Yang , Li Sun
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155377
Keywords: Stable production of high-volume and high-quality ADI Casting process control Austempering process control Statistical data and analysis of ADI production
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Abstract

This paper presents 419 test data from 6 months continuous production. The results show that, through strict control of raw materials, melting, and spheroidization processes, high-quality, as-cast ductile iron casting with stable composition and stable as-cast structure are obtained, and with using advanced professional heat treatment equipment for austempering treatment, the ADI properties are excellent, all higher than the minimum requirements of ASTM and Chinese national standards. The results also show that the dispersion of high strength grade ADI properties is relatively small, while that of high ductility grade ADI is relatively high. By analyzing the statistical data, in order to further reduce the dispersion of mechanical properties in high-volume production and improve the stability and consistency of ADI products, it is necessary to strictly control the production process, ensuring that ADI products for one grade have as similar chemical compositions and as-cast microstructures as possible. Additionally, precise control of the austempering treatment process should be implemented in a categorized manner based on factors such as casting section thickness, chemical and alloying composition, and as-cast microstructure.
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Authors and Affiliations

Wenbang Gong
1
Zhongding Zhou
1
Mintang Zhang
2
Wenqing Yang
2
Li Sun
1
  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
  2. Henan ADI Casting Co., Ltd, China
6 Evaluation of Foundry Properties of Locally Available Molding Sand with Bentonite Clay Additions for Cost-Effective Aluminum Alloy Casting
F. Hussain , M. Kamran , A. Inam , M. Ishtiaq , M.H. Hassan , F. Riaz , T. Khan , M. Ammar , M. Salman
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155378
Keywords: Molding sand Bentonite clay Grain size Surface roughness Strength
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Abstract

This study addresses an existing gap by examining the foundry properties of Ravi River sands, a subject that has not been explored in earlier studies. Several mechanical and physical tests were used to assess the foundry qualities of sands from different areas. These local sands were used to make molds for Al alloy castings, and the parts' surface roughness (Ra) was assessed. The findings showed that the grain size of the sand varied by location, with the highest grain fineness number (GFN) being 106 and the lowest being 71. All samples exhibited a pH > 7, confirming their suitability for strong binder adhesion. The sand from Syed Wala Bridge had the highest grain fineness number (~106), whereas the sand from Sheraza Pattan Bridge had the lowest (~71). All sand samples showed a constant increase in mold strength when the binder (bentonite clay) percentage was raised from 5% to 25%. The study demonstrates the potential of Ravi River sands to eliminate reliance on imported materials and reduce costs.
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Authors and Affiliations

F. Hussain
1
ORCID: ORCID
M. Kamran
1
A. Inam
1
M. Ishtiaq
1
M.H. Hassan
1
ORCID: ORCID
F. Riaz
1
T. Khan
1
M. Ammar
1
M. Salman
1
  1. Institute of Metallurgy and Materials Engineering, University of the Punjab, Lahore, Pakistan.
7 The Influence of Vanadium and Niobium Micro-additions on the Microstructure and Mechanical Properties of ADI
A. Zaczyński , M. Królikowski , A. Nowak , M. Sokolnicki , J. Jaroszek , A. Burbelko
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155379
Keywords: ADI Austempering Graphitization inoculation Metal matrix inoculation Hybrid inoculation
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Abstract

Austempered Ductile Iron (ADI) casting technology is a combination of the smelting process, its post-furnace treatment and the heat treatment of castings. Maintaining the process parameter stability of this innovative high quality cast iron with high Tensile Strength UTS and ductility properties is the aim of a number of studies on the control of graphitization inoculation and inoculation of the metal matrix. The ability to graphitise the liquid alloy decreases with its holding in the furnace, time of pouring into moulds from pouring machines. The tendency to dendritic grains crystallization and the segregation of elements such as Si, Ni and Cu decrease the ductile properties. The austenitizing process can introduce austenite grains growth negatively affecting of the ausferrite morphology. The modifying effect of small amounts of additives on the metal matrix in steel and low alloy cast steel, well known in materials engineering, has been applied to ADI. The addition of cast iron chips, Fe-V and Fe-Nb to the liquid alloy in the first inoculation is an example of a hybrid interaction. The introduction of graphitization nucleus particles and austenite crystallisation nucleus particles resulted in a stabilisation of the ductility of ADI and an increase in mechanical properties. Grains refinement of the primary austenite and precipitation hardening of ausferrite stabilise the mechanical properties of ADI. As a result of graphitization and additive structure inoculation, graphite and ausferrite morphology is improved. The obtained results point the way to further research in the field of hybrid inoculation of Ductile Cast Iron.
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Authors and Affiliations

A. Zaczyński
1
ORCID: ORCID
M. Królikowski
1
ORCID: ORCID
A. Nowak
1
ORCID: ORCID
M. Sokolnicki
1
ORCID: ORCID
J. Jaroszek
1
A. Burbelko
2
ORCID: ORCID
  1. Odlewnie Polskie S.A., 27-200 Starachowice, inż. Władysława Rogowskiego Street 22, Poland
  2. AGH University of Krakow, Faculty of Foundry Engineering, 23 Reymonta Str., 30-059 Krakow, Poland
8 A Study of the Mechanical Properties of Conventional and Additive Mould Parts for Die Casting of Aluminum Alloys
M. Pinta , L. Socha , J. Sviželová , L. Kucerova , M. Dvořák , J. Häusler
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155380
Keywords: Mechanical properties Tool steel H13 3D printing HPDC
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Abstract

The article focuses on the mechanical properties of mould parts created using 3D printing technology, for use in the production of castings by High-Pressure Die Casting (HPDC). The mould shapes produced by 3D printing technology bring innovative approaches to optimising production processes. H13 tool steel is widely used for its excellent mechanical properties and resistance to thermal stress. The study focuses on the comparison of the mechanical properties of mould parts produced by traditional methods and 3D printing, with emphasis on their strength, hardness and wear resistance under repeated working cycles. The experimental part includes roughness measurements and tests of mechanical properties, which provide important data on the ability of these components to withstand high mechanical loads and temperature fluctuations during the HPDC process. The results of the study show the advantages and limitations of 3D printing compared to traditional manufacturing processes and give insight into the use of additive technologies in industrial manufacturing. Specifically, the study identified clear quantitative differences in mechanical properties: the 3D printed mould parts had comparable ultimate tensile strength and yield strength to conventionally manufactured parts, but significantly lower ductility (below 1% compared to about 20% in traditional parts) due to higher porosity (0.25–0.30% compared to 0.03–0.04%). Additive mould parts exhibited higher hardness (approximately 510 HV) compared to conventional parts (approximately 450 HV). Surface roughness of the 3D printed parts was more variable, highlighting the need for optimising printing parameters. Thus, additive technology offers benefits in stable hardness and comparable strength, albeit at the expense of reduced ductility and increased variability in surface quality. The research also includes an analysis of the effect of repetitive loading on the mechanical properties of the mould parts made of H13, which provides valuable information for improving their durability and reliability in practice. This research contributes to the development of 3D printing technologies in the field of HPDC and offers new opportunities for improving the efficiency and quality of manufacturing processes in industrial applications.
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Bibliography

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Authors and Affiliations

M. Pinta
1
ORCID: ORCID
L. Socha
1
ORCID: ORCID
J. Sviželová
1
ORCID: ORCID
L. Kucerova
2
ORCID: ORCID
M. Dvořák
3
J. Häusler
4
  1. Department of Applied Technologies and Materials Research, Institute of Technology and Business in České Budějovice, Okružní 517/10, 370 01 České Budějovice, Czech Republic
  2. Department of Materials and Engineering Metallurgy, Faculty of Mechanical Engineering, University of West Bohemia, Univerzitní 2732/8, 301 00 Plzeň, Czech Republic
  3. Tool Shop Division, MOTOR JIKOV Fostron a.s., Kněžskodvorská 2277, 370 04 České Budějovice, Czech Republic
  4. MOTOR JIKOV Strojírenská a.s., Zátkova 495, 392 01 Soběslav II, Czech Republic
9 Effect of Ni Addition on the Hardness and Impact Resistance of Manganese Cast Steel for Railway Infrastructure Castings
T. Wróbel , S. Sobula , G. Tęcza , D. Bartocha , J. Jezierski , K. Kostrzewa
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155381
Keywords: Manganese cast steel Nickel Railway crossovers Hardness Impact resistance
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Abstract

This paper presents the results of research concerning manganese cast steel, also called Hadfield cast steel. The aim of the research was to determine the effect of Ni addition on the usable properties, i.e., hardness and impact resistance of manganese cast steel for cast components of railway crossovers. The scope of the research included making test castings with a unit weight of 1.5 kg in molds from molding sand prepared using Alphaset technology on a chromite sand matrix. The technological process of the test castings included heat treatment, i.e., oversaturation in water from a temperature of 1050°C. The effect of Ni addition from approx. 0,1 to approx. 1,5 wt.% on the usable properties of manganese cast steel were assessed through impact resistance tests performed in a railway impact bending test, Brinell hardness measurements, and microstructure analysis using light optical and scanning electron microscopy. Analysis of the obtained experimental results allowed for the optimization of the chemical composition of manganese cast steel for cast elements of railway infrastructure.
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Authors and Affiliations

T. Wróbel
1 2
ORCID: ORCID
S. Sobula
3
ORCID: ORCID
G. Tęcza
3
ORCID: ORCID
D. Bartocha
1 2
ORCID: ORCID
J. Jezierski
1 2
ORCID: ORCID
K. Kostrzewa
2
  1. Silesian University of Technology, Department of Foundry Engineering, Towarowa 7, 44-100 Gliwice, Poland
  2. Huta Małapanew Sp. z o.o., Kolejowa 1, 46-040 Ozimek, Poland
  3. AGH University of Science and Technology, Department of Alloys and Cast Composites Engineering, Reymonta 23, 30-059 Kraków, Poland
10 Formation of the Fe₂Al₅ Intermetallic Phase and Its Effect on Microstructure and Properties in Al–Fe PM Sinters
M. Majchrowska , M. Nowak
Archives of Foundry Engineering | Accepted articles | DOI: 10.24425/afe.2025.155382
Keywords: Al–Fe system Intermetallic phases Fe₂Al₅ Powder metallurgy
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Abstract

This study investigates the formation and influence of the Fe₂Al₅ intermetallic phase in Al–Fe sintered composites produced via solid-state powder metallurgy. Aluminium–iron powder mixtures containing 25, 29, and 34 at.% Fe were compacted under a pressure of 400 MPa and vacuum-sintered at 580 °C. Microstructural characterisation was performed using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). Image analysis confirmed the presence of three distinct regions: an aluminium matrix, Fe-rich zones, and a newly formed η-phase (Fe₂Al₅). The formation of the Fe₂Al₅ phase was observed locally at the interfaces between the aluminium matrix and iron particles, as a result of solid-state diffusion during sintering. The growth direction of this phase suggests that aluminium diffused into iron, resulting in the formation of reaction layers characteristic of aluminium-rich compositions. XRD analysis revealed no detectable peaks corresponding to FeAl₃ or FeAl₂ phases, confirming that intermetallic phase evolution proceeded entirely in the solid state. Microhardness measurements showed significantly elevated values in Fe₂Al₅-rich regions, highlighting its strengthening potential. The results confirm that Fe₂Al₅ can be effectively synthesised via solid-state diffusion, without liquid phase formation. This approach enables the controlled development of intermetallic phases in Al–Fe systems and offers promising prospects for low-temperature manufacturing of materials with improved mechanical properties.
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Authors and Affiliations

M. Majchrowska
1
ORCID: ORCID
M. Nowak
1
ORCID: ORCID
  1. AGH University of Science and Technology, Poland

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Reviewers

List of Reviewers 2022

Shailee Acharya - S. V. I. T Vasad, India
Vivek Ayar - Birla Vishvakarma Mahavidyalaya Vallabh Vidyanagar, India
Mohammad Azadi - Semnan University, Iran
Azwinur Azwinur - Politeknik Negeri Lhokseumawe, Indonesia
Czesław Baron - Silesian University of Technology, Gliwice, Poland
Dariusz Bartocha - Silesian University of Technology, Gliwice, Poland
Iwona Bednarczyk - Silesian University of Technology, Gliwice, Poland
Artur Bobrowski - AGH University of Science and Technology, Kraków
Poland Łukasz Bohdal - Koszalin University of Technology, Koszalin Poland
Danka Bolibruchova - University of Zilina, Slovak Republic
Joanna Borowiecka-Jamrozek- The Kielce University of Technology, Poland
Debashish Bose - Metso Outotec India Private Limited, Vadodara, India
Andriy Burbelko - AGH University of Science and Technology, Kraków
Poland Ganesh Chate - KLS Gogte Institute of Technology, India
Murat Çolak - Bayburt University, Turkey
Adam Cwudziński - Politechnika Częstochowska, Częstochowa, Poland
Derya Dispinar- Istanbul Technical University, Turkey
Rafał Dojka - ODLEWNIA RAFAMET Sp. z o. o., Kuźnia Raciborska, Poland
Anna Dolata - Silesian University of Technology, Gliwice, Poland
Tomasz Dyl - Gdynia Maritime University, Gdynia, Poland
Maciej Dyzia - Silesian University of Technology, Gliwice, Poland
Eray Erzi - Istanbul University, Turkey
Flora Faleschini - University of Padova, Italy
Imre Felde - Obuda University, Hungary
Róbert Findorák - Technical University of Košice, Slovak Republic
Aldona Garbacz-Klempka - AGH University of Science and Technology, Kraków, Poland
Katarzyna Gawdzińska - Maritime University of Szczecin, Poland
Marek Góral - Rzeszow University of Technology, Poland
Barbara Grzegorczyk - Silesian University of Technology, Gliwice, Poland
Grzegorz Gumienny - Technical University of Lodz, Poland
Ozen Gursoy - University of Padova, Italy
Gábor Gyarmati - University of Miskolc, Hungary
Jakub Hajkowski - Poznan University of Technology, Poland
Marek Hawryluk - Wroclaw University of Science and Technology, Poland
Aleš Herman - Czech Technical University in Prague, Czech Republic
Mariusz Holtzer - AGH University of Science and Technology, Kraków, Poland
Małgorzata Hosadyna-Kondracka - Łukasiewicz Research Network - Krakow Institute of Technology, Poland
Dario Iljkić - University of Rijeka, Croatia
Magdalena Jabłońska - Silesian University of Technology, Gliwice, Poland
Nalepa Jakub - Silesian University of Technology, Gliwice, Poland
Jarosław Jakubski - AGH University of Science and Technology, Kraków, Poland
Aneta Jakubus - Akademia im. Jakuba z Paradyża w Gorzowie Wielkopolskim, Poland
Łukasz Jamrozowicz - AGH University of Science and Technology, Kraków, Poland
Krzysztof Janerka - Silesian University of Technology, Gliwice, Poland
Karolina Kaczmarska - AGH University of Science and Technology, Kraków, Poland
Jadwiga Kamińska - Łukasiewicz Research Network – Krakow Institute of Technology, Poland
Justyna Kasinska - Kielce University Technology, Poland
Magdalena Kawalec - AGH University of Science and Technology, Kraków, Poland
Gholamreza Khalaj - Islamic Azad University, Saveh Branch, Iran
Angelika Kmita - AGH University of Science and Technology, Kraków, Poland
Marcin Kondracki - Silesian University of Technology, Gliwice Poland
Vitaliy Korendiy - Lviv Polytechnic National University, Lviv, Ukraine
Aleksandra Kozłowska - Silesian University of Technology, Gliwice, Poland
Ivana Kroupová - VSB - Technical University of Ostrava, Czech Republic
Malgorzata Lagiewka - Politechnika Czestochowska, Częstochowa, Poland
Janusz Lelito - AGH University of Science and Technology, Kraków, Poland
Jingkun Li - University of Science and Technology Beijing, China
Petr Lichy - Technical University Ostrava, Czech Republic
Y.C. Lin - Central South University, China
Mariusz Łucarz - AGH University of Science and Technology, Kraków, Poland
Ewa Majchrzak - Silesian University of Technology, Gliwice, Poland
Barnali Maji - NIT-Durgapur: National Institute of Technology, Durgapur, India
Pawel Malinowski - AGH University of Science and Technology, Kraków, Poland
Marek Matejka - University of Zilina, Slovak Republic
Bohdan Mochnacki - Technical University of Occupational Safety Management, Katowice, Poland
Grzegorz Moskal - Silesian University of Technology, Poland
Kostiantyn Mykhalenkov - National Academy of Science of Ukraine, Ukraine
Dawid Myszka - Silesian University of Technology, Gliwice, Poland
Maciej Nadolski - Czestochowa University of Technology, Poland
Krzysztof Naplocha - Wrocław University of Science and Technology, Poland
Daniel Nowak - Wrocław University of Science and Technology, Poland
Tomáš Obzina - VSB - Technical University of Ostrava, Czech Republic
Peiman Omranian Mohammadi - Shahid Bahonar University of Kerman, Iran
Zenon Opiekun - Politechnika Rzeszowska, Rzeszów, Poland
Onur Özbek - Duzce University, Turkey
Richard Pastirčák - University of Žilina, Slovak Republic
Miroslawa Pawlyta - Silesian University of Technology, Gliwice, Poland
Jacek Pezda - ATH Bielsko-Biała, Poland
Bogdan Piekarski - Zachodniopomorski Uniwersytet Technologiczny, Szczecin, Poland
Jacek Pieprzyca - Silesian University of Technology, Gliwice, Poland
Bogusław Pisarek - Politechnika Łódzka, Poland
Marcela Pokusová - Slovak Technical University in Bratislava, Slovak Republic
Hartmut Polzin - TU Bergakademie Freiberg, Germany
Cezary Rapiejko - Lodz University of Technology, Poland
Arron Rimmer - ADI Treatments, Doranda Way, West Bromwich, West Midlands, United Kingdom
Jaromír Roučka - Brno University of Technology, Czech Republic
Charnnarong Saikaew - Khon Kaen University Thailand Amit Sata - MEFGI, Faculty of Engineering, India
Mariola Saternus - Silesian University of Technology, Gliwice, Poland
Vasudev Shinde - DKTE' s Textile and Engineering India Robert Sika - Politechnika Poznańska, Poznań, Poland
Bozo Smoljan - University North Croatia, Croatia
Leszek Sowa - Politechnika Częstochowska, Częstochowa, Poland
Sławomir Spadło - Kielce University of Technology, Poland
Mateusz Stachowicz - Wroclaw University of Technology, Poland
Marcin Stawarz - Silesian University of Technology, Gliwice, Poland
Grzegorz Stradomski - Czestochowa University of Technology, Poland
Roland Suba - Schaeffler Skalica, spol. s r.o., Slovak Republic
Maciej Sułowski - AGH University of Science and Technology, Kraków, Poland
Jan Szajnar - Silesian University of Technology, Gliwice, Poland
Michal Szucki - TU Bergakademie Freiberg, Germany
Tomasz Szymczak - Lodz University of Technology, Poland
Damian Słota - Silesian University of Technology, Gliwice, Poland
Grzegorz Tęcza - AGH University of Science and Technology, Kraków, Poland
Marek Tkocz - Silesian University of Technology, Gliwice, Poland
Andrzej Trytek - Rzeszow University of Technology, Poland
Mirosław Tupaj - Rzeszow University of Technology, Poland
Robert B Tuttle - Western Michigan University United States Seyed Ebrahim Vahdat - Ayatollah Amoli Branch, Islamic Azad University, Amol, Iran
Iveta Vaskova - Technical University of Kosice, Slovak Republic
Dorota Wilk-Kołodziejczyk - AGH University of Science and Technology, Kraków, Poland
Ryszard Władysiak - Lodz University of Technology, Poland
Çağlar Yüksel - Atatürk University, Turkey
Renata Zapała - AGH University of Science and Technology, Kraków, Poland
Jerzy Zych - AGH University of Science and Technology, Kraków, Poland
Andrzej Zyska - Czestochowa University of Technology, Poland



List of Reviewers 2021

Czesław Baron - Silesian University of Technology, Gliwice, Poland
Imam Basori - State University of Jakarta, Indonesia
Leszek Blacha - Silesian University of Technology, Gliwice
Poland Artur Bobrowski - AGH University of Science and Technology, Kraków, Poland
Danka Bolibruchova - University of Zilina, Slovak Republic
Pedro Brito - Pontifical Catholic University of Minas Gerais, Brazil
Marek Bruna - University of Zilina, Slovak Republic
Marcin Brzeziński - AGH University of Science and Technology, Kraków, Poland
Andriy Burbelko - AGH University of Science and Technology, Kraków, Poland
Alexandros Charitos - TU Bergakademie Freiberg, Germany
Ganesh Chate - KLS Gogte Institute of Technology, India
L.Q. Chen - Northeastern University, China
Zhipei Chen - University of Technology, Netherlands
Józef Dańko - AGH University of Science and Technology, Kraków, Poland
Brij Dhindaw - Indian Institute of Technology Bhubaneswar, India
Derya Dispinar - Istanbul Technical University, Turkey
Rafał Dojka - ODLEWNIA RAFAMET Sp. z o. o., Kuźnia Raciborska, Poland
Anna Dolata - Silesian University of Technology, Gliwice, Poland
Agnieszka Dulska - Silesian University of Technology, Gliwice, Poland
Maciej Dyzia - Silesian University of Technology, Poland
Eray Erzi - Istanbul University, Turkey
Przemysław Fima - Institute of Metallurgy and Materials Science PAN, Kraków, Poland
Aldona Garbacz-Klempka - AGH University of Science and Technology, Kraków, Poland
Dipak Ghosh - Forace Polymers P Ltd., India
Beata Grabowska - AGH University of Science and Technology, Kraków, Poland
Adam Grajcar - Silesian University of Technology, Gliwice, Poland
Grzegorz Gumienny - Technical University of Lodz, Poland
Gábor Gyarmati - Foundry Institute, University of Miskolc, Hungary
Krzysztof Herbuś - Silesian University of Technology, Gliwice, Poland
Aleš Herman - Czech Technical University in Prague, Czech Republic
Mariusz Holtzer - AGH University of Science and Technology, Kraków, Poland
Małgorzata Hosadyna-Kondracka - Łukasiewicz Research Network - Krakow Institute of Technology, Kraków, Poland
Jarosław Jakubski - AGH University of Science and Technology, Kraków, Poland
Krzysztof Janerka - Silesian University of Technology, Gliwice, Poland
Robert Jasionowski - Maritime University of Szczecin, Poland
Agata Jażdżewska - Gdansk University of Technology, Poland
Jan Jezierski - Silesian University of Technology, Gliwice, Poland
Karolina Kaczmarska - AGH University of Science and Technology, Kraków, Poland
Jadwiga Kamińska - Centre of Casting Technology, Łukasiewicz Research Network – Krakow Institute of Technology, Poland
Adrian Kampa - Silesian University of Technology, Gliwice, Poland
Wojciech Kapturkiewicz- AGH University of Science and Technology, Kraków, Poland
Tatiana Karkoszka - Silesian University of Technology, Gliwice, Poland
Gholamreza Khalaj - Islamic Azad University, Saveh Branch, Iran
Himanshu Khandelwal - National Institute of Foundry & Forging Technology, Hatia, Ranchi, India
Angelika Kmita - AGH University of Science and Technology, Kraków, Poland
Grzegorz Kokot - Silesian University of Technology, Gliwice, Poland
Ladislav Kolařík - CTU in Prague, Czech Republic
Marcin Kondracki - Silesian University of Technology, Gliwice, Poland
Dariusz Kopyciński - AGH University of Science and Technology, Kraków, Poland
Janusz Kozana - AGH University of Science and Technology, Kraków, Poland
Tomasz Kozieł - AGH University of Science and Technology, Kraków, Poland
Aleksandra Kozłowska - Silesian University of Technology, Gliwice Poland
Halina Krawiec - AGH University of Science and Technology, Kraków, Poland
Ivana Kroupová - VSB - Technical University of Ostrava, Czech Republic
Wacław Kuś - Silesian University of Technology, Gliwice, Poland
Jacques Lacaze - University of Toulouse, France
Avinash Lakshmikanthan - Nitte Meenakshi Institute of Technology, India
Jaime Lazaro-Nebreda - Brunel Centre for Advanced Solidification Technology, Brunel University London, United Kingdom
Janusz Lelito - AGH University of Science and Technology, Kraków, Poland
Tomasz Lipiński - University of Warmia and Mazury in Olsztyn, Poland
Mariusz Łucarz - AGH University of Science and Technology, Kraków, Poland
Maria Maj - AGH University of Science and Technology, Kraków, Poland
Jerzy Mendakiewicz - Silesian University of Technology, Gliwice, Poland
Hanna Myalska-Głowacka - Silesian University of Technology, Gliwice, Poland
Kostiantyn Mykhalenkov - Physics-Technological Institute of Metals and Alloys, National Academy of Science of Ukraine, Ukraine
Dawid Myszka - Politechnika Warszawska, Warszawa, Poland
Maciej Nadolski - Czestochowa University of Technology, Poland
Daniel Nowak - Wrocław University of Science and Technology, Poland
Mitsuhiro Okayasu - Okayama University, Japan
Agung Pambudi - Sebelas Maret University in Indonesia, Indonesia
Richard Pastirčák - University of Žilina, Slovak Republic
Bogdan Piekarski - Zachodniopomorski Uniwersytet Technologiczny, Szczecin, Poland
Bogusław Pisarek - Politechnika Łódzka, Poland
Seyda Polat - Kocaeli University, Turkey
Hartmut Polzin - TU Bergakademie Freiberg, Germany
Alena Pribulova - Technical University of Košice, Slovak Republic
Cezary Rapiejko - Lodz University of Technology, Poland
Arron Rimmer - ADI Treatments, Doranda Way, West Bromwich West Midlands, United Kingdom
Iulian Riposan - Politehnica University of Bucharest, Romania
Ferdynand Romankiewicz - Uniwersytet Zielonogórski, Zielona Góra, Poland
Mario Rosso - Politecnico di Torino, Italy
Jaromír Roučka - Brno University of Technology, Czech Republic
Charnnarong Saikaew - Khon Kaen University, Thailand
Mariola Saternus - Silesian University of Technology, Gliwice, Poland
Karthik Shankar - Amrita Vishwa Vidyapeetham , Amritapuri, India
Vasudev Shinde - Shivaji University, Kolhapur, Rajwada, Ichalkaranji, India
Robert Sika - Politechnika Poznańska, Poznań, Poland
Jerzy Sobczak - AGH University of Science and Technology, Kraków, Poland
Sebastian Sobula - AGH University of Science and Technology, Kraków, Poland
Marek Soiński - Akademia im. Jakuba z Paradyża w Gorzowie Wielkopolskim, Poland
Mateusz Stachowicz - Wroclaw University of Technology, Poland
Marcin Stawarz - Silesian University of Technology, Gliwice, Poland
Andrzej Studnicki - Silesian University of Technology, Gliwice, Poland
Mayur Sutaria - Charotar University of Science and Technology, CHARUSAT, Gujarat, India
Maciej Sułowski - AGH University of Science and Technology, Kraków, Poland
Sutiyoko Sutiyoko - Manufacturing Polytechnic of Ceper, Klaten, Indonesia
Tomasz Szymczak - Lodz University of Technology, Poland
Marek Tkocz - Silesian University of Technology, Gliwice, Poland
Andrzej Trytek - Rzeszow University of Technology, Poland
Jacek Trzaska - Silesian University of Technology, Gliwice, Poland
Robert B Tuttle - Western Michigan University, United States
Muhammet Uludag - Selcuk University, Turkey
Seyed Ebrahim Vahdat - Ayatollah Amoli Branch, Islamic Azad University, Amol, Iran
Tomasz Wrobel - Silesian University of Technology, Gliwice, Poland
Ryszard Władysiak - Lodz University of Technology, Poland
Antonin Zadera - Brno University of Technology, Czech Republic
Renata Zapała - AGH University of Science and Technology, Kraków, Poland
Bo Zhang - Hunan University of Technology, China
Xiang Zhang - Wuhan University of Science and Technology, China
Eugeniusz Ziółkowski - AGH University of Science and Technology, Kraków, Poland
Sylwia Żymankowska-Kumon - AGH University of Science and Technology, Kraków, Poland
Andrzej Zyska - Czestochowa University of Technology, Poland



List of Reviewers 2020

Shailee Acharya - S. V. I. T Vasad, India
Mohammad Azadi - Semnan University, Iran
Rafał Babilas - Silesian University of Technology, Gliwice, Poland
Czesław Baron - Silesian University of Technology, Gliwice, Poland
Dariusz Bartocha - Silesian University of Technology, Gliwice, Poland
Emin Bayraktar - Supmeca/LISMMA-Paris, France
Jaroslav Beňo - VSB-Technical University of Ostrava, Czech Republic
Artur Bobrowski - AGH University of Science and Technology, Kraków, Poland
Grzegorz Boczkal - AGH University of Science and Technology, Kraków, Poland
Wojciech Borek - Silesian University of Technology, Gliwice, Poland
Pedro Brito - Pontifical Catholic University of Minas Gerais, Brazil
Marek Bruna - University of Žilina, Slovak Republic
John Campbell - University of Birmingham, United Kingdom
Ganesh Chate - Gogte Institute of Technology, India
L.Q. Chen - Northeastern University, China
Mirosław Cholewa - Silesian University of Technology, Gliwice, Poland
Khanh Dang - Hanoi University of Science and Technology, Viet Nam
Vladislav Deev - Wuhan Textile University, China
Brij Dhindaw - Indian Institute of Technology Bhubaneswar, India
Derya Dispinar - Istanbul Technical University, Turkey
Malwina Dojka - Silesian University of Technology, Gliwice, Poland
Rafał Dojka - ODLEWNIA RAFAMET Sp. z o. o., Kuźnia Raciborska, Poland
Anna Dolata - Silesian University of Technology, Gliwice, Poland
Agnieszka Dulska - Silesian University of Technology, Gliwice, Poland
Tomasz Dyl - Gdynia Maritime University, Poland
Maciej Dyzia - Silesian University of Technology, Gliwice, Poland
Eray Erzi - Istanbul University, Turkey
Katarzyna Gawdzińska - Maritime University of Szczecin, Poland
Sergii Gerasin - Pryazovskyi State Technical University, Ukraine
Dipak Ghosh - Forace Polymers Ltd, India
Marcin Górny - AGH University of Science and Technology, Kraków, Poland
Marcin Gołąbczak - Lodz University of Technology, Poland
Beata Grabowska - AGH University of Science and Technology, Kraków, Poland
Adam Grajcar - Silesian University of Technology, Gliwice, Poland
Grzegorz Gumienny - Technical University of Lodz, Poland
Libor Hlavac - VSB Ostrava, Czech Republic
Mariusz Holtzer - AGH University of Science and Technology, Kraków, Poland
Philippe Jacquet - ECAM, Lyon, France
Jarosław Jakubski - AGH University of Science and Technology, Kraków, Poland
Damian Janicki - Silesian University of Technology, Gliwice, Poland
Witold Janik - Silesian University of Technology, Gliwice, Poland
Robert Jasionowski - Maritime University of Szczecin, Poland
Jan Jezierski - Silesian University of Technology, Gliwice, Poland
Jadwiga Kamińska - Łukasiewicz Research Network – Krakow Institute of Technology, Poland
Justyna Kasinska - Kielce University Technology, Poland
Magdalena Kawalec - Akademia Górniczo-Hutnicza, Kraków, Poland
Angelika Kmita - AGH University of Science and Technology, Kraków, Poland
Ladislav Kolařík -Institute of Engineering Technology CTU in Prague, Czech Republic
Marcin Kondracki - Silesian University of Technology, Gliwice, Poland
Sergey Konovalov - Samara National Research University, Russia
Aleksandra Kozłowska - Silesian University of Technology, Gliwice, Poland
Janusz Krawczyk - AGH University of Science and Technology, Kraków, Poland
Halina Krawiec - AGH University of Science and Technology, Kraków, Poland
Ivana Kroupová - VSB - Technical University of Ostrava, Czech Republic
Agnieszka Kupiec-Sobczak - Cracow University of Technology, Poland
Tomasz Lipiński - University of Warmia and Mazury in Olsztyn, Poland
Aleksander Lisiecki - Silesian University of Technology, Gliwice, Poland
Krzysztof Lukaszkowicz - Silesian University of Technology, Gliwice, Poland
Mariusz Łucarz - AGH University of Science and Technology, Kraków, Poland
Katarzyna Major-Gabryś - AGH University of Science and Technology, Kraków, Poland
Pavlo Maruschak - Ternopil Ivan Pului National Technical University, Ukraine
Sanjay Mohan - Shri Mata Vaishno Devi University, India
Marek Mróz - Politechnika Rzeszowska, Rzeszów, Poland
Sebastian Mróz - Czestochowa University of Technology, Poland
Kostiantyn Mykhalenkov - National Academy of Science of Ukraine, Ukraine
Dawid Myszka - Politechnika Warszawska, Warszawa, Poland
Maciej Nadolski - Czestochowa University of Technology, Częstochowa, Poland
Konstantin Nikitin - Samara State Technical University, Russia
Daniel Pakuła - Silesian University of Technology, Gliwice, Poland


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