Journal of Casting & Materials Engineering
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ISSN 2543-9901
Issue Date
2022
Volume
Vol. 6
Number
No. 2
Description
Journal Volume
Journal of Casting & Materials Engineering
Vol. 6 (2022)
Projects
Pages
Articles
A novel approach to quantifying the effect of the density of sand cores on their gas permeability
(AGH University Press, 2022) Sundaram, Dinesh; Svidró, József Tamás; Svidró, Judit; Diószegi, Attila
The density of moulding mixtures used in the foundry industry plays a significant role since it influences the strength, porosity, and permeability of moulds and cores. The latter is routinely tested in foundries using different solutions to control the properties of the moulding materials that are used to make moulds and cores. In this paper, the gas permeability of sand samples was measured using a custom-made setup to obtain the gas permeability in standard units instead of the usual permeability numbers (PN) with calibrated units. The aim of the work was to explore the effect of density variations in moulding materials on their gas permeabilities. Permeability in this work is quantified in SI units, square metres [m$^{2}$]. The setup works based on Darcy's law and the numbers obtained from the measurements can be used to deduce the gas permeability, $k$, of a sample. Two furan resin bonded mixtures with the same grain size distribution were hand-rammed with varying compaction forces to obtain a variation in density. Cylindrical samples (50 × 50 mm) were prepared using a silica sand aggregate sourced from a Swedish lake. The results of the measurement provided the difference in gas permeability between the samples that have varying densities. The results of permeability were then extrapolated by modifying the viscosity value of the air passed through the sample. In order to find the effect of apparent density variation on the pore characteristics of the samples, mercury intrusion porosimetry (MIP) was also performed. The results were in line with the gas permeability measurements.
A diffusion model of binary systems controlled by chemical potential gradient
(AGH University Press, 2022) Wróbel, Marek; Burbelko, Andriy A.
The paper presents a model of diffusion in a single phase with chemical potential gradient as the driving force of the process. Fick's laws are strictly empirical and the assumption that the concentration gradients are the driving forces of diffusion is far from precise. Instead, the gradient of chemical potential $\mu_{i}$ of component i is the real driving force. The matter of governing equations of models that incorporate this approach will be raised and discussed in this article. One of more important features is the ability to acquire results where diffusion against the concentration gradient may occur. The presented model uses the Finite Difference Method (FDM) and employs the CALPHAD method to obtain chemical potentials. The calculations of chemical potential are carried out for instant conditions - temperature and composition - in the entire task domain by Thermo-Calc via a TQ-Interface. Then the heterogeneity of chemical potentials is translated into mass transfer for each individual element. Calculations of two modelling tasks for one-dimension diffusion field were carried out. First: isothermal conditions with linear initial composition distribution and second: constant temperature gradient with uniform chemical composition in the specimen. Results for two binary solid solutions: Fe-C and Fe-Si, in the FCC phase for the given tasks will be presented. Modelling allows us to estimate the time needed to reach a desired state in a particular equilibrium or quasi-equilibrium state. It also shows the path of the composition change during the process. This can be used to determine whether the system at some point is getting close to the formation of another phase due to significant deviation from its initial conditions.
A simulation and experimental investigation of the thermal characteristics of refractory bricks produced using fireclay and agroforestry wastes
(AGH University Press, 2022) Obidiegwu, Eugenia Obiageli; Esezobor, David Ehigie; Mgbemere, Henry Ekene; Chiosa Odili, Cletus
Manufacturing and processing industries usually consume large quantities of materials and energy in the course of their operations. The energy supplied for high-temperature processes are used partially for the actual technical process and between 30 to 40% of the energy escapes through the walls of the reactor into the atmosphere, leading to a high degree of thermal inefficiency and fuel consumption. This paper studies the thermal behaviour of insulating refractory bricks produced from a blend of fireclay and agroforestry wastes. The fireclays used were obtained from Ukpor deposit in Anambra State (Latitude 5.95°N, Longitude 6.92°E), Osiele deposit in Abeokuta, Ogun State (Latitude 7.18°N, Longitude 3.45°E) and Kankara Katsina State (Latitude 11.93°N, Longitude 7.41°E), all of which are in Nigeria. Samples were prepared with various weight percentages (60-100 wt.%) clays and (0-40 wt.%) of agroforestry waste, with grain sizes between 212 and 600 µm. Raw materials and the developed refractory bricks were characterised using appropriate standard techniques. The chemical, mineralogical constituents and phases present in the microstructure were examined. Physical and thermo-mechanical properties were investigated. The insulating refractory bricks developed have porosity of 78.83% , cold crushing strength (CCS) 3.144 kN/m$^{2}$ and thermal conductivity 0.04-0.046 W/(m$\cdot$K) that compare favourably with imported bricks 75-85%, 2.756 kN/m$^{2}$ and 0.049 W/(m$\cdot$K) in both physical, mechanical and thermal properties respectively. The reason is that the agroforestry waste used (coconut shell), served to create the pores that improve insulation after burning. Also the ash that remains serves as reinforcement to improve the mechanical properties. The thermal behaviour of the bricks was studied using Finite Element Method and shows a strong correlation with the experimental findings. This indicates that the produced insulating bricks have the thermal properties required for insulation of furnaces.