JOURNAL OF CASTING & MATERIALS ENGINEERING

Permanent URI for this communityhttps://repo.agh.edu.pl/handle/AGH/102751

Adres wydawniczy: Kraków : Wydawnictwa AGH, 2017-
O czasopiśmie: http://journals.agh.edu.pl/jcme
ISSN: 2543-9901
DOI: https://doi.org/10.7494/jcme

Journal of Casting & Materials Engineering is a peer-reviewed, academic e-periodical devoted to issues in engineering processes and casting materials. The periodical is published as a quarterly in the open access system by the AGH University of Krakow. The JCME publishes original research articles, as well as reviews and theoretical articles. The mission of the periodical is to contribute to the development of knowledge and new scientific ideas in the field of engineering processes and casting materials.

New! Aktualny numer: 2026 - Vol. 10 - No. 2

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Access status: Open Access ,
Calculation of assimilation process of non-metallic inclusions by slag
(AGH University of Science and Technology Press, 2017) Kalisz, Dorota
This paper presents the results of calculating the phenomenon of the absorption of non-metallic precipitates in steel by slag. Calculations are made for the forces acting on the non-metallic particles in steel during the flow-out into the slag, depending on the particle radius and physicochemical properties of the liquid steel and slag. An analysis of the calculation results of capillary force acting on a particle in the vicinity of the steel-slag interface at changing surface energy values between the precipitates and slag shows that capillary force depends on the interfacial tension between the precipitates and slag only to a small degree.
Access status: Open Access ,
Etching method to create random speckle pattern on semi-solid cast A356 aluminium for DIC in-situ strain measurement
(2017) Sergolle, Maëlle; Santos, Jorge; Kasvayee, Keivan Amiri; Jarfors, Anders Eric Wollmar
Aluminum semi-solid casting is constantly evolving, as it offers a combination of reduced shrinkage porosity and gas entrapment defects together with high productivity and an extended die-life. The relationship between the microstructure and stress-strain behavior is not well-understood due to its non-conventional microstructure. In-situ tensile testing, combined with optical microscope and Digital Image Correlation (DIC), has been used for local strain distribution measuements in cast irons. The critical capability was an etching technique to generate a micro-scale random speckle pattern with a sufficiently high speckle density to enable the sufficient spatial resolution of displacement and strain. The current paper focuses on the development of a pit etching procedure for the semi-solid cast A356 aluminum alloy to study local strain accommodation on the microstructure during tensile loading. The critical challenge of this procedure was the generation of homogeneously distributed pits on both the primary aluminum and eutectic regions. Therefore, a heated solution used for wet-etch aluminum in microfabrication was modified as well as a process adapted to generate pits with suitable characteristics. In-situ tensile tests were performed attached to an optical microscope to record the microstructure and displacements during loading. DIC software was used for analysis. The procedure was validated through a comparison between the resulting Young´s moduls using standard tensile testing and the DIC process on the speckle pattern generated. A good fit between the two methods for Young´s modulus was found. The spatial resolution obtained was, however, not sufficient to fully resolve the strain gradients in the microstructure, but it did reveal large strain variations in the microstructure.
Access status: Open Access ,
Deoxidation impact on non-metallic inclusions and characterization methods
(AGH University of Science and Technology Press, 2017) Nicoli, Cécile; Carton, Jean-François; Vaucheret, Alexis; Jacquet, Philippe
Deoxidation is an unavoidable step in the elaboration of steel. The study of its influence could improve the quality of low-carbon steel (0.20-0.25 wt.% of carbon). There are many deoxidation methods, and the most-common one consists of adding aluminum. Although it is a classic method, determining the optimal process parameters (quantity, yield, etc.) could be very sensitive. Deoxidation plays a determining role on inclusion cleanliness, especially on sulfide morphology. In order to control the efficiency of deoxidation, different techniques can be used. In this paper, an automated counting procedure on a scanning electron microscope with a field emission gun (FEG-SEM) is presented. This method was applied on samples cast in our laboratory under different deoxidation conditions. According to this, the resulting inclusion population is correlated with the aluminum content to find the optimal process parameters.
Access status: Open Access ,
Manufacturing methods of alloy layers on casting surfaces
(2017) Szajnar, Jan; Wróbel, Tomasz; Dulska, Agnieszka
In this paper, we presented the technology of layered castings based on the founding method of layer coating directly in the cast process known as the method of mold cavity preparation by monolithic or granular material of insert. Prepared castings consist of two fundamental parts: the base part and working part (layer). The base part of a layered casting is usually typical foundry material (i.e., pearlitic grey cast iron with flake graphite or ferritic-pearlitic carbon cast steel), whereas the dependence of an insert type (i.e., monolithic or granular) working part (layer) is suitably plated with ferritic and austenitic alloy steels or a layer from a Cr-base alloy. The ratio of thickness between the base and working part is between 8:1 and 10:1. The quality of the layered castings was evaluated on the basis of ultrasonic non-destructive testing, structure, and selected usable property research. According to work out technology, the prepared layered castings can work in conditions that require high heat resistance and/or corrosion resistance from the working surface layer of an element in a medium of industrial water, for example. Moreover, in the case of applying an insert based on Cr-base alloy powder on the working surface layer, it is possible to obtain high hardness and abrasive wear resistance.
Access status: Open Access ,
Colloidal metal surfaces as biosensors of biological samples
(2017) Tąta, Agnieszka; Gralec, Barbara; Proniewicz, Edyta
Colloidal solutions of silver (AgNPs), gold (AuNPs), and platinum nanoparticles (PtNps) obtained under controlled conditions in an aqueous media by chemical methods were used as effective biosensors of biological compounds such as bombesins (BN). The BN adsorption at the metal/aqueous interface was investigated by surface-enhanced Raman scattering (SERS). Briefly, the spectral pattern of BN in the silver, gold, and platinum sols is strongly influenced by the indole ring vibrations of L-tryptophan at position 8 of the amino acid sequence (Trp$^{8}$). In addition, L-methionine (Met) at the C-terminus determines the BN adsorption, mainly onto the AuNPs and AgNPs surfaces.
Access status: Open Access ,
The effect of nickel on shaping the structure of Al-Cu-Mn alloys
(2017) Górny, Marcin; Sikora, Gabriela; Tyrała, Edward; Repeć, Paweł
This study investigated the effect of nickel on shaping the structure of aluminum alloys of the Al-Cu-Mn type in the »as-cast« condition and after heat treatment according to the T6 procedure. The aluminum alloys of type Al-5%Cu-1%Mn, containing nickel in a range of up to 1.9%, were taken into consideration in this work. Experiments were carried out for thin-walled thickness casting (g = 5 mm) and for reference casting with a wall thickness of g = 35 mm. Metallographic investigations of both the macro- and micro-structure were conducted to estimate the secondary dendrite arm spacing (SDAS), average diameter (dav) of the primary α (Al) grains, and surface fraction of the interdendritic phases (f). Moreover, the degree of dissolution of these interdendritic phases during the solution treatment process was determined. An SEM-EDS analysis was conducted, from which it follows that the addition of nickel at the level of 0.5% changes the un-dissolved particles from a needle-like β-Fe shape to blocky and coagulated. Higher additions of nickel starting from 0.88%) give rise to as many as four phases with higher copper content, the deficit of which results in the smaller strengthening effect of α (Al) dendrites.
Access status: Open Access ,
TG-DTG-DSC, FTIR, DRIFT, and Py-GC-MS studies of thermal decomposition for poly(sodium acrylate)/dextrin (PAANa/D) – new binder BioCo3
(2017) Grabowska, Beata; Kaczmarska, Karolina; Bobrowski, Artur; Żymankowska-Kumon, Sylwia; Kurleto-Kozioł, Żaneta
TG-DTG-DSC, FTIR, DRIFT, and Py-GC-MS studies have been conducted to determine the effect of the thermal decomposition conditions and structure of foundry binder BioCo3 in the form of a composition poly(sodium acrylate)/dextrin (PAANa/D) on the progress of degradation in terms of processes occurring in foundry sands in contact with liquid metal. TG-DTG-DSC curves of the composition allowed us to determine the temperature range in which they do not undergo degradation, by which they do not lose their binding properties. With temperature increasing, physical and chemical changes occur that are related to the evaporation of solvent water (20–110°C), followed by the release of constitution water, and finally intermolecular dehydration (110–230°C). In this temperature range, processes that are mainly reversible take place. Within a temperature range of 450–826°C, polymer chains are decomposed, including the decomposition of side chains. Within a temperature range of 399–663°C, polymer composition decomposition can be observed (FTIR, DRIFT), and gas products are generated from this destruction (Py-GC-MS).
Access status: Open Access ,
Evaluation of interfacial tension in the liquid aluminum alloy-liquid slag system
(2017) Suchora-Kozakiewicz, Magdalena; Jackowski, Jacek
In the present paper, the results from investigations regarding interfacial tensions present at the borders of a liquid aluminum alloy and two selected melted fluxes (mixtures of salts) are presented. The fluxes feature solidification characteristic curves that are very close to each other as well as differentiated chemical compositions. For the comparative investigations, the so-called surface property index (WS) is calculated for both fluxes with the use of the ion theory of slags. The investigations of the interfacial tensions were conducted on a stand that enabled the measurement of the force values accompanying the tearing-off of the probe from the interfacial surface. A very clear relationship between the interfacial tension values and the WS index values that characterize both fluxes was found. An increase in the WS index value resulted in an increase in the investigated interfacial tension values. It was also found that, in both cases under investigation, an increase in the system temperature value resulted in an increase of the values of the interfacial tensions present within. In the conclusion, we state that the metallurgical treatments (for instance, the recycling of the cast metal composite materials by way of component separation) should be conducted with the use of salt mixtures (fluxes) characterized with WS index and melting temperature values as low as possible.
Access status: Open Access ,
Influence of internal scrap on mechanical properties of selected cobalt alloys
(AGH University of Science and Technology Press, 2017) Dęsoł, Bartosz; Zapała, Renata; Pałka, Paweł
This paper presents the results of mechanical tests carried out on two different commercially available cobalt alloys applied in dental prosthetics for the production of frame dentures. The test samples were obtained by the method of investment casting using as a charge pure primary materials and pure primary materials mixed with various additions of process scrap (25, 50, and 75%). The tests showed that the alloys could not reach the mechanical properties reported by the manufacturer in either case. In the case of the alloy without the addition of tantalum, the general conclusion was that both the plastic and strength properties decreased with increasing amounts of the introduced process scrap. The mechanical properties (mainly elongation) of the alloy containing Ta reached the highest values in the samples containing 75% of the process scrap. Examinations of fractures carried out by SEM have revealed their varied character - ductile or transcrystalline. All of the samples tested showed the presence of dendrites and solidification areas, with shrinkage porosity occurring in the internal sample zones.
Access status: Open Access ,
Power consumption comparison of model vibratory unit in power supply system with and without inverter for frequency setting of 50 Hz
(AGH University of Science and Technology Press, 2017) Ziółkowski, Eugeniusz; Skrzyński, Mateusz
The article presents the instantaneous voltage and current values recorded in the power-supply system of a vibratory unit directly from the power grid or through an inverter for a frequency setting of 50 Hz. The obtained measurement data was used to perform digital signal processing algorithms, calculations of effective voltages, currents, power (active, reactive, and apparent), and power factor tgφ. The results of the calculations were used to compare the two power systems examined.
Access status: Open Access ,
Microstructure and mechanical properties of rope drum casting
(AGH University of Science and Technology Press, 2017) Futáš, Peter; Pribulová, Alena; Mahút, Dávid; Bartošová, Marianna; Junáková, Andrea
Ductile iron is a high-carbon-containing iron-based alloy in which the carbon, as graphite, is present in a spheroidal shape. With its good mechanical properties, ductile iron approximates the properties of steel and the cost per unit of strength compared to other materials. With suitable metallurgical treatments, we can influence its microstructure and resulting properties. Incorrect manufacturing technology and metallurgical processes give rise to casting defects and decreased mechanical properties. The contribution is devoted to measures to prevent the occurrence of defects in the casting of rope drums and to achieve the required mechanical properties of these castings. The most-common defects in these castings are micro-shrinkages in casting heat centers and unsatisfactory mechanical properties such as tensile strength, yield strength, and elongation.
Access status: Open Access ,
The effect of rapid cooling on the corrosion resistance of as-cast aluminium alloy 5052
(AGH University of Science and Technology Press, 2017) Szklarz, Zbigniew; Krawiec, Halina; Rogal, Łukasz
The effect of rapid cooling by the vacuum suction casting method (VSC) on the microstructure and electrochemical response of the as-cast 5052 aluminium alloy is presented. The VSC method allowed us to obtain massive samples with a very high cooling rate (10$^{2}$ - 10$^{3}$)°C/s. The microstructure of the quick-cooled sample (QC) has been significantly changed. Finer grains and more-homogeneous intermetallic phase distribution has been observed. Corrosion potential (OCP) and polarization measurements (LSV) revealed a higher activity of the QC alloy than ingot (IN), which leads to a denser and thicker corrosion-product formation on the surface. Electrochemical Impedance Spectroscopy (EIS) indicates higher resistance values, which suggests a greater thickness of the corrosion products.
Access status: Open Access ,
Phase analysis and crystallographic orientation of high chromium cast iron grain using EBSD technique
(2017) Siekaniec, Dorota; Kopyciński, Dariusz
Grain orientation, properties, microstructure borders, and types and sizes of phases have had a major impact on the traits of modern engineering materials. Therefore, it is important to study, analyze, and (further) control the method of crystallizing alloys. One of the methods used to assess the orientation of grain growth is the EBSD technique. EBSD (Electron Backscatter Diffraction Analysis) enables us to perform quantitative analyses on the microstructure of materials (on a scale of millimetres to nanometres) in a scanning electron microscope. Using the EBSD technique can help us gain valuable information about the following properties of crystalline materials: crystal orientation, disorientation, grain boundaries, global and local texture, fractions recrystallization/deformation, stress analysis, characterization of intergranular boundaries, identification of phases, phase distribution, and so on. In this paper, we present the results of phase analysis and crystallographic orientation of the grains of high chromium cast iron via EBSD. These were preliminary studies to determine the possibility of using the EBSD technique for analyzing high chromium cast iron. Castings were produced under industrial conditions, then samples were cut out and testing using the EBSD technique. This method proved to be effective for this type of material.
Access status: Open Access ,
Influence of process parameters on ceroxide formation in low-carbon steels
(AGH University of Science and Technology Press, 2017) Vaucheret, Alexis; Nicoli, Cécile; Carton, Jean-François; Jacquet, Philippe
Ceroxides are surface defects caused by a mold-metal reaction during the casting process of steels. This type of defect may affect a large area, but it is located only on the skin of the parts. It does not affect the core of the parts nor its mechanical properties. Nevertheless, ceroxides induce a lack of material on the surface, forming a kind of crater and needing complementary surfacing. The defect is also composed by several non-metallic inclusions containing Al, Mg, Si and O. An EDX analysis by mapping show these elements involved in the mold-metal reaction. The presence of these oxides could confirm the hypothesis of the deoxidizer reoxidation found in the bibliography. To better understand the specific conditions of ceroxide formation, the first step was to find of way to generate systematically this defect at each casting. Two patterns with different filling rate were designed, simulated on Quikcast and tested. The pattern with turbulent filling rate allowed the formation of ceroxide at each casting and so was used during this study. This result shows that the filling rate of the mold could be considered as a first order parameter in ceroxide formation. Then, a specific experimental set up was designed to characterize this defect. The analysis of the defect was done for sizing it: surface and depth. Finally, some key parameters on defect formation were determined like the nature of deoxidizer or the amount of oxygen in the mould. Some laboratory tests were lead to show the influence of these parameters by characterization of the casted parts in comparison with a reference sample. This study allowed us to find process parameters responsive of ceroxide formation and to propose some way of improvement to reduce the size and the occurrence of ceroxides.
Access status: Open Access ,
Impact of density degree and grade of inorganic binder on behavior of molding sand at high temperature
(AGH University of Science and Technology Press, 2017) Stachowicz, Mateusz; Paduchowicz, Patrycja; Granat, Kazimierz
This paper discusses the impact of high temperatures (up to 900°C) on molding and core sand with inorganic binders selected from among the group of unmodified grades of hydrated sodium silicate (water-glass). Molding sands with medium quartz sand were made under laboratory conditions and compacted at the different energy inputs necessary for obtaining various apparent densities (?0). Due to the different composition and apparent density of molding mixtures hardened via microwaves at a frequency of 2.45 GHz, it was possible to assess their deformation (L) at a high temperature above the binder's eutectic temperature. For this purpose, an apparatus for hot distortion tests was used whose construction and equipment allows us to measure the thermoplastic deformations in molding sand in many aspects; i.e., in its time of annealing. The article proposes new possibilities of interpreting the hot distortion phenomena in comparative studies of molding materials and mixtures. The application of this new measurement method revealed the differences between molding mixtures made with five inorganic binders with a molar module ranging from 2.0 to 3.4 and apparent density ranging from 1.34 to 1.57 g/cm$^{3}$. It was established that distortions under the influence of high temperatures last the longest in molding sand with a binder with the highest molar module (3.4). Research also revealed that the density of molding sand is significant for increasing/decreasing the rate of thermoplastic deformations following the heating of samples only if the molding sand includes binders with a molar module of between 3.0 to 3.4. For molding sand with binders with molar modules from 2.0 to 2.5, it was established that this is excessively susceptible to thermoplastic deformation.
Access status: Open Access ,
Utilization of slags from foundry process
(AGH University of Science and Technology Press, 2017) Pribulová, Alena; Futáš, Peter; Bartošová, Marianna; Petrík, Jozef
The melting of steel or cast iron is one step of the foundry process. The foundry industry uses different types of furnaces, and metallurgical slags are products of the pyrometallurgical processes defecting in these furnaces. Furnace slag is a non-metallic by-product that consists primarily of silicates, alumina silicates, and calcium-alumina-silicates. As a by-product of the melting process, furnace slags vary considerably in form depending on the melted metal furnace types, and slag cooling method used. Most quantity of slags from the foundry processes are created in a cupola furnace that is used for cast iron production. An electric arc furnace is usually used for steel production, but it can be used for cast iron production as well. Universal use features an electric induction furnace. Slags from the melting processes in a foundry can be in the form of gravel, or the slag from a cupola furnace can be granulated. The utilization of slags from foundry processes is very delimited in Slovakia because of their quantity. This article deals with the possibility of using foundry slag as a binder in civil engineering. A basic property of a binder in civil engineering is its hydraulicity, which can be given by compression strength. Four metallurgical slags were tested. The values of the compressive strength of the slags were low, but addition cement to the slags resulted in a strong increase in the value of the compressive strength.
Access status: Open Access ,
Density distribution and resin migration investigations in samples of sand core made by blowing method
(AGH University of Science and Technology Press, 2017) Dańko, Rafał; Jamrozowicz, Łukasz
Resin migration in a core can occur during the core production process performed by blowing methods in which the core sand is transported into the core box as a two-phase sand-air flux characterized by various working parameters (working pressure, shooting time, volumetric concentration). This migration is the result of the resin being blown off from the matrix grain surfaces by compressed air. The methodology of the investigation of this effect developed at AGH University of Science and Technology is presented in this paper. The results of the resin migration tests obtained for cores made with cold-box technology at various working parameters of the shooting process are also shown.
Access status: Open Access ,
Application of computer support for design of shaft furnaces - cupolas
(AGH University of Science and Technology Press, 2017) Dajczer, Grzegorz; Dańko, Rafał
Designing a machine's constructions and an object's structures is one of the areas of technology design. The complexity of the structure is defined by the technology for which it is used. Following the theory of construction and mechanisms, the full characteristics of a machine or device is defined by its shape and operating parameters. The shape reflects geometry. As a result of using the correct parameters, the construction should functional correctly (which means according to its general principles of operation). The project of any structure is a creative process performed by a team of designers and constructors. The contemporary design is not solely based on the personal preferences of engineers. More and more scientific and computerized design methods are being introduced to this process. They are characterized as computer-aided systems and are based on algorithms, programs, and IT equipment. This article presents the methodological application of computer-aided design on an example of the design of shaft furnaces that are used in foundries as cast iron smelters. These furnaces, called cupolas, have again become objects of interest for research. In the design of the cupola construction, Autodesk Inventor techniques were used.
Access status: Open Access ,
Welcome to the Journal of Casting and Materials Engineering
(AGH University Press, 2017) Grabowska, Beata
Access status: Open Access ,
Bending and compression properties of ABS and PET structural materials printed using FDM technology
(AGH University of Science and Technology Press, 2017) Szczepanik, Stefan; Bednarczyk, Piotr
The bend and compression mechanical properties of 3D-printed polyethylene terephthalate (PET) and acrylonitrile butadiene styrene (ABS) rectangular and cylindrical specimens (fully-dense and with circular, hexagonal, and rectangular perforations) are presented. In three-point bending, fully-dense PET flexural strength was 69 MPa, yield stress was 48.9 MPa, and yield stress from compression was 31.4 MPa. For ABS, these values were 59, 41.7, and 51.2 MPa, respectively - not significantly different from those of polymers manufactured by common techniques. Whereas perforation reduced density, the strength values were significantly lower, decreased for the circular perforation to a value of 20% strength for the fully-dense specimen. Specific strengths dropped quite significantly for the specimens tested in bending, whereas they did not differ significantly when tested by compression.