Journal of Casting & Materials Engineering
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ISSN 2543-9901
Issue Date
2026
Volume
Vol. 10
Number
No. 2
Description
Journal Volume
Journal of Casting & Materials Engineering
Vol. 10 (2026)
Projects
Pages
Articles
Comparison of component properties between HPDC and rheocasting applying the RheoMetal$^{TM}$ process
(AGH University Press, 2026) Cziegler, Andreas
Since the 1970s, there has been increasing interest in semi-solid processes, allowing improved mould filling with lower gas porosity and lower melt temperatures with improved tool life compared to the standard HPDC process. Challenges lie in the process know-how and the precise temperature control to ensure process stability and reproducibility. In contrast to other semi-solid processes, the RheoMetal$^{TM}$ process achieves the semi-solid state by stirring in an enthalpy exchange material (EEM). This work compares component properties (engine mount) produced by standard HPDC and rheocasting, applying the RheoMetal$^{TM}$ process using an AlSi7MnMg alloy. The results of component testing and radioscopic examination reveal promising outcomes regarding process stability, pore formation, and component properties compared to the standard HPDC process.
Microstructure-erosion resistance correlation in high chromium cast iron: a digital image processing approach
(AGH University Press, 2026) Vezzania, Ottavia; Fortinia, Annalisa; Gragnaninia, Michele; Sumana, Alessio; Zanini, Nicola
High chromium cast irons (HCCIs) are widely employed as wear-resistant hardfacing materials in industrial applications where solid particle erosion (SPE) represents a primary degradation mechanism, such as in energy production, mining, and cement manufacturing. The erosive wear resistance of these alloys is strongly dependent on the microstructural features of the primary $M_{7}C_{3}$ carbides, particularly their size, morphology, and spatial distribution within the metallic matrix. The quantitative relationship between carbide distribution homogeneity and erosion resistance has received limited attention in the literature. This study investigates the erosive wear resistance of a Fe-Cr-C cast iron hardfacing alloy and proposes three digital image processing methods to quantitatively characterise the carbide microstructure and correlate it with experimental erosion test results. Optical microscopy combined with image binarisation was used to segment primary $M_{7}C_{3}$ carbides. Three methods were adopted: carbide volume fraction (CVF), minimum inter-carbide distances, and a moving scanning area approach. Erosion tests were conducted according to ASTM G76 guidelines using two Arizona road dust powder grades with two mean diameters under equal kinetic energy conditions. Results show that the erosion rate decreases significantly with the increasing erodent particle size and that carbide distribution homogeneity plays a critical role in determining the erosion resistance. The moving scanning area method proved particularly effective at correlating microstructural coverage with experimental erosion rates.
Numerical optimisation of investment-cast wheel components for drone applications using MAGMASOFT®
(AGH University Press, 2026) Jonthalaa, Joshua Samuel Isaac; Lelito, Janusz
Investment casting technology of thin-walled components for drone applications requires precise filling and solidification control to minimise porosity and ensure structural integrity. Porosity is one of the most common defects found in castings, and its prediction and analysis are essential for improving the quality of complex superalloy components. In this work, porosity-related defects were examined using the MAGMASOFT® 6.1 numerical simulation software for casting, focusing on the filling and solidification behaviour of an investment casting wheel body component in drone applications. A series of simulations were performed, and two design and simulation versions were developed, analysed and compared. The wheel body component selected for this work is made of IN713 superalloy. The numerical modelling included the assessment of porosity distribution, hot spot formation, filling behaviour, cooling, and solidification patterns. Fifteen combinations of alloy and shell initial temperatures were evaluated to determine the most favourable thermal conditions for reducing porosity, considering the specific geometry and casting characteristics of the wheel. Based on the initial results, the casting design was modified by adjusting the runner geometry and assembly configuration. This study introduces a two-stage simulation approach to optimise porosity reduction. The second version of the simulations demonstrated a noticeable reduction in pores, particularly in critical regions of the wheel body. The findings can support drone component manufacturers in improving casting reliability. The results confirm that simulation-driven optimisation of the casting design and thermal parameters can significantly improve the quality of the components produced by investment casting technology.
Antibacterial polyurethane adhesives for medical applications
(AGH University Press, 2026) Pitera, Dominika; Pilch-Pitera, Barbara; Woźny, Ireneusz; Krajewski, Dariusz; Ciszkowicz, Ewa; Bester, Karol
In this study, polyurethane prepolymers and two-component adhesive systems with antibacterial properties were synthesised and characterised for potential biomedical applications as tissue adhesives. The developed materials were designed to operate in moist biological environments and to provide simultaneous adhesive and antibacterial functions. The viscosity of the obtained prepolymers, measured using a Brookfield viscometer, ranged from 2.30 to 3.36 Pa·s, indicating favourable rheological properties for dosing, mixing, and application on tissue surfaces. The chemical structure of the crosslinked adhesives was confirmed by FTIR spectroscopy, which revealed characteristic urethane bands and the absence of isocyanate groups, indicating complete conversion during curing. Contact angle measurements demonstrated the hydrophilic nature of the materials, suggesting good potential for adhesion to wet biological tissues. Mechanical characterisation showed medium hardness (medium-soft materials) and high adhesive strength exceeding 5 MPa, confirming suitable mechanical performance for tissue bonding applications. Antibacterial testing indicated that the incorporation of a biopolymer-based antimicrobial agent resulted in strong biocidal activity, outperforming conventional silver-based additives. The results demonstrate that the developed polyurethane-based adhesive systems combine favourable mechanical, physicochemical, and antibacterial properties, making them promising candidates for surgical applications.