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Improvement of Mechanical Properties of Cast Ceramic Cores Based on Ethyl Silicate

P. Bořil V. Kaňa M. Myška V. Krutiš

Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 47-52 | DOI: 10.24425/afe.2022.143949

Keywords Ethyl silicate Shaw proces Cast cores Ceramics Fibre reinforcement Mechanical properties

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Abstract

The aim of the paper is experimental verification of the influence of the composition of the ceramic mixture on the mechanical properties of cast ethyl silicate cores. Cast ceramic cores have a great potential in the production of complex castings, especially in the field of hydropower. However, the disadvantage of the cast ceramic cores is their low strength during cores removing from the core box and handling with them. The research is focused mainly on the possibilities of increasing the handling strength of the cores during removal from the core box and after their ignition. The paper investigates different ways of increasing the strength of cast ceramic cores by adjusting the composition of the ceramic mixture. Further, the research verifies the possibility of increasing the strength of ceramic cores by adding synthetic fibers to the ceramic mixture. The paper also contains the results of measuring the strength of the cores after impregnation with a solution of phosphorous binder and subsequent annealing.

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Bibliography

[1] Cihlář, J. (1993). Hydrolysis and polycondensation of ethyl silicates. 2, Hydrolysis and polycondensation of ETS40 (ethyl silicate 40). Colloids and Surfaces A: Physicochemical and Engineering Aspects. 7093), 253-268. https://doi.org/10.1016/0927-7757(93)80299-T.
[2] Doškář, J. (1976). Production of precision castings. (1st ed.). Prague: SNTL. (in Czech)
[3] Lewis, J.A. (2000). Colloidal processing of ceramics. Journal of the American Ceramic Society. 83(10), 2341-2359. https://doi.org/10.1111/j.1151-2916.2000.tb01560.x.
[4] Raza, N., Raza, W., Madeddu, S., Agbe, H., Kumar, R.V. & Kim, K.H. (2018). Synthesis and characterization of amorphous precipitated silica from alkaline dissolution of olivine. RSC advances. 8(57), 32651-32658. https://doi.org/10.1039/c8ra06257a.
[5] Doškář, J., Kaštánek, O., Gabriel, J., Valihrach, O. (1961). Precision casting in ceramic molds: designed high techn. foundry staff, work. development and research in mechanical engineering. Prague: SNTL. (in Czech).
[6] Wagh, A.S. (2004). Chemically BondedPhosphate Ceramics. 21st Century Materials with Diverse Applications. Oxford: Elsevier. Retrieved March 15, 2022, from https://doi.org/10.1016/B978-008044505-2/50006-5
[7] Wagh, A.S. & Jeong, S.Y. (2003). Chemically bonded phosphate ceramics: i, A dissolution model of formation. Journal of the American Ceramic Society. 83(11). 1838-1844. DOI: https://doi.org/10.1111/j.1151-2916.2003.tb03569.x
[8] Hlaváč, J. (1988). Fundamentals of silicate technology. Prague: SNTL. (in Czech)
[9] Lü, K., Liu, X., Du, Z., & Li, Y. (2016). Bending strength and fracture surface topography of natural fiber-reinforced shell for investment casting process. China Foundry, 13, 211-216. DOI: 10.1007/s41230-016-5100-4.
[10] Lü, K., Liu, X., & Duan, Z. (2018). Effect of firing temperature and time on hybrid fiber-reinforced shell for investment casting. International Journal of Metalcasting. 13(3), 666-673. DOI: 10.1007/s40962-018-0280-x.

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Authors and Affiliations

P. Bořil

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ORCID:

V. Kaňa

e-mail:

ORCID:

M. Myška

e-mail:

ORCID:

V. Krutiš

e-mail:

ORCID:

Brno University of Technology, Czech Republic

Corrosion Resistance of Cast Duplex Steels

P. Müller V. Pernica V. Kaňa

Archives of Foundry Engineering | 2022 | vol. 22 | No 3 | 5-10 | DOI: 10.24425/afe.2022.140230

Keywords Cast duplex steel Pitting resistance equivalent number Ferric chloride Critical pitting temperature Mechanical properties

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Abstract

The aim of this work is to investigate the resistance of cast duplex (austenitic-ferritic) steels to pitting corrosion with respect to the value of PREN (Pitting Resistance Equivalent Number). Pitting corrosion is one of the most common types of corrosion of stainless steels. In most cases, it is caused by the penetration of aggressive anions through the protective passive layer of the steel, and after its disruption, it leads to subsurface propagation of corrosion. The motivation for the research was a severe pitting corrosion attack on the blades of the gypsum-calcium water mixer in a thermal power plant operation.
In order to examine the corrosion resistance, 4 samples of 1.4517 steel with different concentrations of alloying elements (within the interval indicated by the steel grade) and thus with a different PREN value were cast. The corrosion resistance of the samples was evaluated by the ASTM G48 – 11 corrosion test in a 6% aqueous FeCl3 solution at room and elevated solution temperatures. To verify the possible effect of different alloying element concentrations on the mechanical properties, the research was supplemented by tensile and Charpy impact tests. Based on the results, it was found that a significant factor in the resistance of duplex steels to pitting corrosion is the temperature of the solution. For the components in operation, it is therefore necessary to take this effect into account and thoroughly control and manage the temperature of the environment in which the components operate.

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Bibliography

[1] Reardon, A. (2011). 12.5 Duplex Stainless Steels. In metallurgy for the non-metallurgist (2nd Edition). Ohio: ASM International, ISBN 978-1-61503-821-3, Retrieved from https://app.knovel.com/hotlink/pdf/id:kt009JBTT4/metallurgy-non-metallurgist/duplex-stainless-steels
[2] McGuire, M.F. (2008). Duplex stainless steels. in stainless steels for design engineers (91–108) [online]. Materials Park, Ohio 44073-000: ASM International, [cit. 2020-05-19]. ISBN 978-1-61503-059-0., Retrieved from: https://app.knovel.com/hotlink/pdf/id:kt008GRPY2/stainless-steels-design/duplex-stainless-introduction
[3] O'Brien, A. ed. (2011) Stainless and Heat-Resistant Steels. In Welding Handbook, Volume 4 - Materials and Applications, Part 1 [online]. 9th Edition. Miami: American Welding Society (AWS), p. 351 [cit. 2020-05-27]. ISBN 978-1-61344-537-2. Retrieved from https://app.knovel.com/hotlink/pdf/id:kt0095SGE2/welding-handbook-volume/duplex-sta-composition
[4] Revie, R.W. ed. (2011). In Uhlig’s Corrosion Handbook [online]. Third edition. Duplex stainless steels. (695–705). Hoboken, New Jersey: John Wiley & Sons, 2011 [cit. 2020-06-14]. ISBN 978-1-61344-161-9. Retrieved from https://app.knovel.com/hotlink/pdf/id:kt008TZY32/uhlig-s-corrosion-handbook/duplex-sta-history
[5] Prošek, T. & Šefl, V. (2018). Corrosion resistance of stainless steel in drinking water treatment plants and water storage units. Koroze a ochrana materialu. 62(4), 141-147. DOI: 10.2478/kom-2018-0020.
[6] Cicek, V. (2014). Corrosion engineering. Hoboken, New Jersey: Scrivener Publishing/Wiley. ISBN 978-1-118-72089-9. Retrieved from https://app.knovel.com/hotlink/toc/id:kpCE00004B/corrosion-engineering/corrosion-engineering.
[7] Marcus, P. ed. (2012). Corrosion mechanisms in theory and practice. Third edition. Boca Raton: CRC Press, Corrosion technology (Boca Raton, Fla.). ISBN 978-1-4200-9463-3.
[8] G48 - 11(2015). Standard test methods for pitting and crevice corrosion resistance of stainless steels and related alloys by use of ferric chloride solution. West Conshohocken: ASTM International, 2015.
[9] Jargelius-Pettersson, R.F.A. (1998). Application of the pitting resistance equivalent concept to some highly alloyed austenitic stainless steels. Corrosion. 54(2), 162-168. DOI: 10.5006/1.3284840.
[10] (2015). Austenitic-ferritic (duplex) casting materials [online]. Otto Junker, 2015 [cit. 2020-06-25]. Retrieved from: https://www.otto-junker.com/cache/dl-Austenitic-Ferritic-DUPLEX-Casting-Materials-aa4d1dd1db00d37343728c6ba0598a75.pdf

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Authors and Affiliations

P. Müller

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ORCID:

V. Pernica

e-mail:

ORCID:

V. Kaňa

e-mail:

ORCID:

Brno University of Technology, Czech Republic

Integration of Virtual Engineering and Additive Manufacturing for Rapid Prototyping of Precision Castings

V. Krutiš P. Šprta V. Kaňa A. Zadera J. Cileček

Archives of Foundry Engineering | 2021 | vo. 21 | No 1 | 51-55 | DOI: 10.24425/afe.2021.136077

Keywords Product development Innovative foundry technologies Virtual engineering Rapid prototyping

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Abstract

The present paper is concerned with the practical interconnection between virtual engineering tools and additive model manufacturing technologies and the subsequent production of a ceramic shell by rapid prototyping with the use of Cyclone technology to produce the aluminium casting prototype. Prototypes were developed as part of the student formula project, where several parts originally produced by machining were replaced by castings. The techniques of topological optimization and the combination with the tools of the numerical simulation were used to optimise the virtual prototype before a real production of the first prototype. 3D printing of wax pattern ensured direct and fast assembly of the cluster without any additional operations and troubles during dewaxing. The shell was manufactured in 6 hours thanks to a system of quick-drying of individual layers of ceramic shell. It has been verified that the right combination of individual virtual tools with the rapid prototyping can shorten the development time and delivery of the first prototypes from a few months to a few weeks.

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Bibliography

[1] Xiao, A., Bryden, K.M. (2004). Virtual engineering: A vision of the next-generation product realization using virtual reality technologies. Proceedings of the ASME 2004 Design Engineering Technical Conferences – DETC’04, 28 September – 2 October, pp 1-9.Salt Lake City, Utah, #57698.
[2] Pekkola, S. & Jäkälä, M. (2007) From technology engineering to social engineering: 15 years of research on virtual worlds. The DATA BASE for Advances in Information Systems. 38(4), 11-16.
[3] Bao, Jin, J.S., Gu, Y., Yan, M.Q. & Ma, J.Q. (2002). Immersive virtual product development. Journal of Materials Processing Technology. 129(1-3), 592-596. DOI: 10.1016/S0924-0136(02)00655-6.
[4] Van der Auweraer, H. (2010). Virtual engineering at work: The challenges for designing intelligent products. In: Proceedings of the TMCE 2010 Symposium, April 12-16, (pp. 3-18), Ancona, Italy.
[5] Stawowy, A., Wrona, R., Brzeziński, M. & Ziółkowski, E. (2013). Virtual factory as a method of foundry design and production management. Archives of Foundry Engineering. 13(1), 113-118. DOI: 10.2478/afe-2013-0022
[6] Dépincé, P., Chablat, D., Woelk, P.O. (2004) Virtual manufacturing: tools for improving design and production, Dans International Design Seminar - CIRP International Design Seminar, Egypt.
[7] Kumar, P., Ahuja, I.P.S. & Singh, R. (2013). Framework for developing a hybrid investment casting process. Asian Review of Mechanical Engineering, 2(2), 49-55.
[8] Kügelgen, M. (2008). From 7 days to 7 hours – Investment casting parts within the shortest time, 68th WFC - World Foundry Congress, 7th - 10th February, 2008, (pp. 147-151).

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Authors and Affiliations

V. Krutiš

e-mail:

ORCID:

P. Šprta

V. Kaňa

e-mail:

ORCID:

A. Zadera

J. Cileček

Brno University of Technology, Czech Republic
Alucast s.r.o., Czech Republic

Precipitation of Sigma and Chi Phases in Cast Standard Duplex Stainless Steel

M. Myška P. Bořil V. Krutiš V. Kaňa A. Zádĕra

Archives of Foundry Engineering | 2023 | vol. 23 | No 2 | 29-34 | DOI: 10.24425/afe.2023.144292

Keywords precipitation Cast duplex steel Intermetallics sigma phase Chi phase

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Abstract

This work deals with the problem of intermetallic phases in cast standard duplex steel ASTM A890 Gr 4A (generally known as 2205). The investigated steel was subjected to isothermal heat treatment in the range from 595 °C to 900 °C and in the duration from 15 minutes to 245 hours, and was also investigated in terms of anisothermal (natural) cooling after casting into the mould. The precipitation starts at grain boundaries with a consistent ferrite transformation. The work is focused on the precipitation of the sigma phase (σ) and the chi phase (χ). Examination of the microstructure was conducted using light and scanning electron microscopy. Their statistical analysis was carried out using the results of the investigations of precipitation processes in the microstructure, both within the grains and at the grain boundaries. To illustrate this impact, the surface area of precipitates was evaluated. The percentage of these intermetallic phases was calculated by measuring their area using a computer image analysis system. Based on their observations, a combined time-temperature transformation (TTT) diagram with continuous cooling transformation (CCT) curves was created.

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Authors and Affiliations

M. Myška

e-mail:

ORCID:

P. Bořil

e-mail:

ORCID:

V. Krutiš

e-mail:

ORCID:

V. Kaňa

e-mail:

ORCID:

A. Zádĕra

e-mail:

ORCID:

Brno University of Technology, Czech Republic

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Improvement of Mechanical Properties of Cast Ceramic Cores Based on Ethyl Silicate

Abstract

Bibliography

Authors and Affiliations

Corrosion Resistance of Cast Duplex Steels

Abstract

Bibliography

Authors and Affiliations

Integration of Virtual Engineering and Additive Manufacturing for Rapid Prototyping of Precision Castings

Abstract

Bibliography

Authors and Affiliations

Precipitation of Sigma and Chi Phases in Cast Standard Duplex Stainless Steel

Abstract

Authors and Affiliations