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Decarbonization of Production Systems in Foundries

C. Kolmasiak

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 104-109 | DOI: 10.24425/afe.2024.149276

Keywords Decarbonization Renewable energy Foundry production

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Abstract

The article discusses the growing importance of decarbonization of production systems in the foundry industry as a response to climate challenges and increasing requirements for sustainable development. The process of reducing greenhouse gas emissions in foundry production is caused by a number of reasons. Decarbonization of the foundry industry refers to actions aimed at reducing greenhouse gas emissions, especially carbon dioxide (CO₂). Reducing carbon dioxide emissions is increasingly being considered as a key element of the strategy of both small and large foundries around the world. Foundry is one of the industries that generates significant amounts of carbon dioxide emissions due to the energy consumption in the process of melting and forming metals. There is virtually no manufacturing industry that does not use elements cast from iron, steel or non-ferrous metals, ranging from elements made of aluminum to zinc. The article presents various decarbonization strategies available to foundries, such as: the use of renewable energy, the use of more efficient melting technologies, or the implementation of low-energy technologies throughout the production process. Application examples from different parts of the world illustrate how these strategies are already being put into practice, as well as the potential obstacles and challenges to full decarbonization.

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Authors and Affiliations

C. Kolmasiak

1

Czestochowa University of Technology, Faculty of Production Engineering and Materials Technology, Department of Production Management, Poland

The Technique of Inorganic Core Sand Shooting with Reduced Pressure in Venting System

M. Skrzyński R. Dańko G. Dajczer

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 98-103 | DOI: 10.24425/afe.2024.149275

Keywords Foundry engineering Sand moulds and cores Inorganic binder materials Core shooting technique

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Abstract

The publication presents a new shooting technique with reduced pressure in venting system for manufacturing foundry cores using inorganic sand mixture with Cordis binder. Traditional technologies for producing casting cores using blowing methods, despite their undeniable advantages, including the ability to produce cores in series, also come with some disadvantages. The primary drawbacks of the process involve uneven compaction structure of the cores, with denser areas primarily located under the blow holes, and under-shooting defects, which often occur in regions away from the blow hole or in increased core cross-sectional areas. In an effort to improve core quality, a concept was developed that involves incorporating a reduced pressure in the core box venting system to support the basic overpressure process. The solutions proposed in the publication with a vacuum method of filling the cavities of multi-chamber core boxes solve a number of technical problems occurring in conventional blowing technologies. It eliminates difficulties associated with evacuating the sand from the chamber to the shooting head and into technological cavity and increases the uniform distribution and initial degree of compacting of grains in the cavity. The additive role of this “underpressure” support is to enhance corebox venting by eliminating 'air cushions' in crevices and structural elements that obstruct the flow of evacuated air. The publication presents the results of studies on core manufacturing using blowing methods conducted in three variants: classic overpressure, utilizing the core box filling phenomenon by reducing pressure, and an integrated approach combining both these methods.

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Authors and Affiliations

M. Skrzyński

1

R. Dańko

1

e-mail:

ORCID:

G. Dajczer

2

AGH University of Krakow, Poland
KPR PRODLEW-KRAKÓW Spółka z o.o., Alfreda Dauna 78, 30-629 Krakow, Poland

Bio-regeneration for Sodium Silicate Used Sands and its Unattended Monitoring System

Huafang Wang Zhaoxian Jing Ao Xue Yuhan Tang Lei Yang Jijun Lu

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 117-123 | DOI: 10.24425/afe.2024.149278

Keywords Sodium silicate used sands Diatom Water bloom Internet of Things platform

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Abstract

Sodium silicate, known for its low cost and non-toxicity, has been considered as a promising option for green foundry in terms of mould sands. However, the utilization of used sodium silicate sands has posed significant challenges. To address the issues of high energy consumption and secondary pollution associated with wet and dry regeneration of sodium silicate used sands, this paper proposes a novel unattended biological regeneration system. The system involves culturing diatoms in an incubator with a solution of sodium silicate used sands. The incubator is equipped with built-in sensors that continuously monitor temperature, illuminance, pH, and water level. The monitoring data is transmitted in real-time to the Yeelink Internet of Things platform via the controller using the TCP/IP protocol. By logging onto the corresponding web page, the experimenter can remotely observe the monitoring data. The results of the experiment indicate that diatoms bloomed five times, and the water pH decreased from 10.2 to 8.2 after 40 days of cultivation. Additionally, the film removal rate of the used sands reached 90.26%.

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Authors and Affiliations

Huafang Wang

1

e-mail:

ORCID:

Zhaoxian Jing

1

Ao Xue

1

Yuhan Tang

1

Lei Yang

1

e-mail:

ORCID:

Jijun Lu

1

e-mail:

ORCID:

School of Mechanical Engineering and Automation, Wuhan Textile University, China

Study on Mn Volatilization Behavior During Vacuum Melting of High-manganese Steel

Jialiu Lei Yongjun Fu Li Xiong

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 110-116 | DOI: 10.24425/afe.2024.149277

Keywords Mn volatilization behavior Vacuum melting Thermodynamics High-manganese steel

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Abstract

As an alloying element in steel, manganese can considerably enhance the mechanical properties of structural steel. However, the Mn volatilisation loss in vacuum melting is severe because of the high saturated vapour pressure, resulting in an unstable Mn yield and Mn content fluctuation. Therefore, a systematic study of the volatilisation behaviour of Mn in vacuum melting is required to obtain a suitable Mn control process to achieve precise control of Mn composition, thereby providing a theoretical basis for industrial melting of high-Mn steel. In order to explore the Mn volatilization behavior, the volatilization thermodynamics and volatilisation rate of Mn, as well as the influence factors are discussed in this study. The results shows that Mn is extremely volatilised into the vapour phase under vacuum, the equilibrium partial pressure is closely related to Mn content and temperature. With an increase in the Mn content, a higher C content has a more obvious inhibitory effect on the equilibrium partial pressure of Mn. The maximum theoretical volatilisation rate of Mn shows a linear upward trend with an increase in Mn content. However, a higher C content has a more obvious effect on the reduction of the maximum theoretical volatilisation rate with the increase of Mn content. This study provides an improved understanding of Mn volatilisation behaviour as well as a theoretical foundation for consistent Mn yield control during the vacuum melting process of high-Mn steel.

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Authors and Affiliations

Jialiu Lei

1

Yongjun Fu

1

Li Xiong

2

Hubei Polytechnic University, China
Hubei Guoan Special Steel Inspection and Testing Co., Ltd.

Analysis of Fragmentation Phenomenon of Composite Layers of Fe-TiC Type Obtained “in situ” in Steel Casting

J. Marosz S. Sobula

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 131-136 | DOI: 10.24425/afe.2024.149280

Keywords Surface layer Cast steel “In situ” composite MMCs composites SHSM reaction

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Abstract

A method for fabrication of a composite layer on the surface of a steel casting using coating containing TiC substrates was presented. The reaction of the synthesis of the ceramic phase was based on the SHS method (Self-propagating High-temperature Synthesis) and was triggered by the heat of molten steel. High hardness titanium carbide ceramic phases were obtained, which strengthened the base material improving its performance properties presented in this article. Microstructural examinations carried out by light microscopy (LM) on the in-situ produced composite layers showed that the layers were the products of reaction of the TiC synthesis – the phenomenon called “fragmentation” by the authors of study. The examinations carried out by scanning electron microscopy (SEM) have revealed the presence of spheroidal precipitated and free of impurities. The presence of titanium carbide was twofold increase in hardness in the area of the composite layer as compared to the base alloy which was carbon cast steel.

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Authors and Affiliations

J. Marosz

S. Sobula

1

e-mail:

ORCID:

AGH University of Krakow, Poland

Influence of the Rate of Cooling/Solidification on the Location of Characteristic Points on the AT and ADT Curves of Cast Iron

J.S. Zych

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 124-130 | DOI: 10.24425/afe.2024.149279

Keywords thermal analysis cast iron cooling/solidification rate cups AT

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Abstract

The paper presents the results of the analysis of cooling curves of cast iron with approximately eutectic composition rasterized at different rates of cooling and ingot crystallization. The test samples were in the form of rods with a diameter of 30,0.mm and a coagulation modulus M = 0.75 cm. They were cast in a sand mould made of furan mass placed on a chill in the form of a cast-iron plate, with which one of the front surfaces of the rod casting was in contact. In this way, a differentiated cooling rate along the rod was achieved. At selected distances from the chiller (5, 15, 25, 25 and 45 mm) thermocouple moulds were placed in the cavity to record the cooling curves used in thermal (AT) and derivation (ATD) analysis. The solidification time of the ingot in the part farthest from the chiller was about 200s, which corresponds to the solidification time in the test cup AT. An analysis of the recorded cooling curves was performed in order to determine the values of characteristic points on the AT curve (Tsol. Tliq, ΔTrecal., τclot, etc.). Relationships between cooling time and rate and characteristic points on AT and ATD curves were developed. For example, Tsol min changes in the range of 1115 - 1145 for the range of cast iron solidification times in the selected ingot zone from ~ 70 to ~ 200 s, which corresponds to the process speed from 0.0047 to 0.014 [1/s]. The work also includes an analysis of other characteristic points on the AT and ATD curves as functions of the solidification rate of cast iron of the same composition.

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Authors and Affiliations

J.S. Zych

1

AGH University of Krakow, Faculty of Foundry Engineering, Reymonta 23. 30-059 Kracow, Poland,

Impact of Aging Time on the Metallurgical Properties and Hardness Characteristics of an Al-Si-Mg-Cr Hypoeutectic Alloy Intended for Automotive Applications

V.V. Ramalingam K.V. Shankar B. Shankar R. Abhinandan A. Dineshkumar P.A. Adhithyan K. Velusamy A. Kapilan N. Sudheer

Archives of Foundry Engineering | 2024 | vol. 24 | No 2 | 137-142 | DOI: 10.24425/afe.2024.149281

Keywords Al-Si-Mg Microstructure Hardness Eutectic

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Abstract

This research investigates the microstructural evolution and mechanical properties of LM25 (Al-Si-Mg) alloy and Cr-modified LM25-Cr (Al-Si-Mg-Cr) alloy. Microstructural analysis reveals distinctive ε-Si phase morphologies, with Cr addition refining dendritic structures and reducing secondary dendrite arm spacing in the as-cast condition. Cr modification results in smaller-sized grains and a modified ε-Si phase, enhancing nucleation sites and reducing ε-Si size. Microhardness studies demonstrate significant increases in hardness for both alloys after solutionising and aging treatments. Cr-enriched alloy exhibits superior hardness due to solid solution strengthening, and prolonged aging further influences ε-Si particle size and distribution. The concurrent rise in microhardness, attributed to refined dendritic structures and unique ε-Si morphology, underscores the crucial role of Cr modification in tailoring the mechanical properties of aluminium alloys for specific applications.

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Authors and Affiliations

V.V. Ramalingam

1

K.V. Shankar

2

B. Shankar

2

R. Abhinandan

3

A. Dineshkumar

3

P.A. Adhithyan

3

K. Velusamy

3

A. Kapilan

3

N. Sudheer

3

Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham, Coimbatore, 64112, India
Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amritapuri, India; Centre for Flexible Electronics and Advanced Marerials, Amrita Vishwa Vidyapeetham, Amritapuri, India
Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amritapuri, India

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Impact of Aging Time on the Metallurgical Properties and Hardness Characteristics of an Al-Si-Mg-Cr Hypoeutectic Alloy Intended for Automotive Applications

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