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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
1
ORCID: ORCID
V. Kaňa
1
ORCID: ORCID
M. Myška
1
ORCID: ORCID
V. Krutiš
1
ORCID: ORCID
  1. Brno University of Technology, Czech Republic

Effect of Friction Machining on Low Carbon Steel with Titanium Traces in terms of Surface Hardening

Ali R. Sheikh
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 41-46 | DOI: 10.24425/afe.2022.143948
Keywords Knee type vertical milling machine High speed steel tool Mild steel work piece Thermo-mechanical face milling
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Abstract

This work is an experimental study of thermo-mechanical surface hardening of mild steel with trace elements like titanium in negligible concentrations. This is somewhat an advanced technique used to harden steel surface which can be hardened in many typical ways. The concept is combining the thermal as well as mechanical technique to attain better results. It is quite obvious that mechanical refers to the compressive loading during machining and thermal refers to producing heat on the surface of work piece. The ideal conditions are when the heat produced is enough to achieve austenite and then subsequent quick cooling helps in the formation of martensite, which is metallurgically the most highly strong phase of steel, in terms of hardness. The coolant used preferably is the emulsified oil which flows on the surface during machining with variable rate of flow as the optimum effect is. This process hardens the surface of steel and increases its resistance against wear and abrasion. Preference is to achieve surface hardening using the conventional equipment so that operational cost is kept low and better results are attained. This technique has been quite successful in the laboratory. It can be termed as friction hardening. Some improvements in the process scheme and working environment can be made to get better results.
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Bibliography

[1] Muñoz, J.A., Avalos, M., Schell, N., Brokmeier, H.G. & Bolmaro, R.E. (2021). Comparison of a low carbon steel processed by Cold Rolling ( CR ) and Asymmetrical Rolling (ASR): Heterogeneity in strain path, texture, microstructure and mechanical properties. Journal of Manufacturing Processes. 64(February), 557-575. DOI: 10.1016/J.JMAPRO.2021.02.017.
[2] Hotz, H. & Kirsch, B. (2020). Influence of tool properties on thermomechanical load and surface morphology when cryogenically turning metastable austenitic steel AISI 347. Journal of Manufacturing Processes. 52(August 2020), 120-31. https://doi.org/10.1016/j.jmapro.2020.01.043.
[3] Burke, J.J., Weiss, V. (1974). Advances in deformation processing. New York: Plenum Press.
[4] Bernardo, L., Tressia, G., Masoumi, M., Mundim, E., Regattieri, C. & Sinatora, A. (2021). Roller crushers in iron mining, how does the degradation of Hadfield steel components occur ? Engineering Failure Analysis. 122(February), 105295, 1-18. DOI: 10.1016/j.engfailanal. 2021.105295.
[5] Fedorova, L.V., Fedorov, S.K., Serzhant, A.A., Golovin, V.V. & Systerov, S.V. (2017). Electromechanical surface hardening of tubing steels. Metal Science and Heat Treatment. 59(3-4), 173-175. DOI: 10.1007/s11041-017-0123-z.
[6] Vafaeian, S., Fattah-Alhosseini, A., Mazaheri, Y. & Keshavarz, M.K. (2016). On the study of tensile and strain hardening behavior of a thermomechanically treated ferritic stainless steel. Materials Science and Engineering A. 669, 480-489. http://dx.doi.org/10.1016/j.msea.2016.04.050.
[7] Shi, F., Yin, S., Pham, T.M., Tuladhar, R. & Hao, H. (2021). Pullout and flexural performance of silane groups and hydrophilic groups grafted polypropylene fibre reinforced UHPC. Construction and Building Materials. 277, 122335, 1-10. https://doi.org/10.1016/j.conbuildmat.2021.122335.
[8] Gao, J., Yu, M., Liao, D., Zhu, S., Zhu, Z. & Han, J. (2021). Foreign object damage tolerance and fatigue analysis of induction hardened S38C axles. Materials & Design. 202, 109488, 1-10. https://doi.org/10.1016/j.matdes.2021.109488.
[9] Bedford, G.M., Vitanov, V.I. & Voutchkov, I.I. (2001). On the thermo-mechanical events during friction surfacing of high speed steels. Surface and Coatings Technology. 141, 34-39. https://doi.org/10.1016/S0257-8972(01)01129-X.
[10] Ahmed, W., Hegab, H., Mohany, A. & Kishawy, H. (2021). On machining hardened steel AISI 4140 with self-propelled rotary tools : experimental investigation and analysis. The International Journal of Advanced Manufacturing Technology. 11-12, 113, 3163–3176.
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Authors and Affiliations

Ali R. Sheikh
1
ORCID: ORCID
  1. AGH University of Science and Technology, Poland

Influence of Sawdust Ash Addition on Molding Sand Properties and Quality of Iron Castings

R. Khuengpukheiw S. Veerapadungphol V. Kunla C. Saikaew
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 53-64 | DOI: 10.24425/afe.2022.143950
Keywords Sawdust ash Rubber wood molding sand Iron castings design of experiments
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Abstract

Sand molding casting has been widely used for a long time. But, one of its main drawbacks is that surface quality of the castings is not good enough for some applications. The purposes of this research were to investigate the effect of addition of sawdust ash of rubber wood (SARW) on molding sand properties and the surface quality of iron castings and to find an appropriate level of SARW with the appropriate properties of the iron castings. The molding sand compositions for making a sand mold consisted of the recycled molding sand, bentonite, water and SARW. The percentage levels of SARW were 0%, 0.1%, 0.2%, 0.3% and 0.4%. The different proportions of molding sand samples were investigated for the molding sand properties including permeability, compression strength and hardness. The results showed that addition of SARW had an effect on the molding sand properties. The appropriate percentage proportion of molding sand was obtained at 95.8% recycled molding sand, 0.8% bentonite, 3% water and 0.4% SARW. There were statistically significant differences of mean surface roughness and hardness values of the iron castings made from molding sand samples without SARW addition and the appropriate percentage proportion of molding sand. In addition, the average surface roughness value of the iron castings made from the sand mold with the appropriate percentage proportion of molding sand was ~40% lower than those of the iron castings made from molding sand samples without SARW addition.
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Authors and Affiliations

R. Khuengpukheiw
1
S. Veerapadungphol
1
V. Kunla
1
C. Saikaew
1
ORCID: ORCID
  1. Department of Industrial Engineering, Khon Kaen University, Khon Kaen 40002 Thailand

Effect of Maximum Piston Velocity on Internal Homogeneity of AlSi9Cu3(Fe) Alloy Processed by High-Pressure Die Casting

M. Matejka D. Bolibruchová R. Podprocká
Archives of Foundry Engineering | 2022 | vol. 22 | No 4 | 34-40 | DOI: 10.24425/afe.2022.140249
Keywords Al-Si-Cu alloy High-pressure die casting Porosity Brinell hardness Microstructure
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Abstract

High-pressure die casting results in a high quality surface and good mechanical properties of castings. Under the effect of pressure, integral and solid castings are achieved without a large number of foundry defects. The correct and proper setting of technological parameters plays a very important role in minimizing casting defects. The aim of the presented article is to determine the optimum maximum piston velocity for a casting in the high-pressure casting process with two height variants, depending on their internal quality. It is because the internal quality of particular castings is important in terms of proper functionality in operations where the biggest problem is the porosity of the casting. The main cause of porosity formation is the decreasing solubility of gases (most often hydrogen) during the melt solidification. Solubility represents the maximum amount of gas that can dissolve in a metal under equilibrium conditions of temperature and pressure. Macroporosity and microporosity were determined from the sections of the surfaces in the determined zones of the castings. Here, the results was that the macroporosity decreased with increasing piston velocity. Ideal microstructure was evaluated at a piston velocity of 3 m/s for both types of castings. On the other hand, the increase in tube size has shown that velocities of 3 m/s and higher, the tube is more prone to macroporosity formation. The highest hardness was achieved at the piston velocity of 2 m/s at both tube lengths.
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Authors and Affiliations

M. Matejka
1
ORCID: ORCID
D. Bolibruchová
1
ORCID: ORCID
R. Podprocká
2
  1. University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Slovak Republic
  2. Rosenberg-Slovakia s.r.o., Slovak Republic

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