Applied sciences

Archives of Foundry Engineering

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Archives of Foundry Engineering | 2024 | vol. 24 | No 2

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Abstract

The aim of the article was to determine the impact of crushed condition (work hardening) on the effectiveness of the vibratory machining. The vibratory machining processing was carried out in two steps. The first step consisted of mechanical abrasion and remove oxides from the surface of the workpieces with abrasive media. While in the second step, smoothing - polishing with metal media was performed. Vibratory polishing also strengthened the treated surfaces. The test results were compared for samples in the crushed state (work hardening, plastic processing) and samples subjected to recrystallization annealing heat treatment. Mass losses, changes in the geometric structure of the surface and changes in the hardness of the machining surfaces were analyzed. Samples subjected to recrystallization, as compared to the samples in the state after work hardening-plastic working, are characterized by a slightly higher arithmetic mean surface roughness and lower surface hardness than for analogous processes for samples not subjected to heat treatment. Heat treatment of annealing allows to remove the effects of crushing and thus it is possible to obtain larger mass losses. Smaller burrs dimensions were obtained for samples after the heat treatment – annealing than after work hardening.
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Authors and Affiliations

D. Bańkowski
1
ORCID: ORCID
S. Spadło
1
ORCID: ORCID

  1. Kielce University of Technology, Poland
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Abstract

The aim of the following work was to determine the possibility of using barley malt as a binder in moulding sands technology. The moulding sands prepared on the basis of three kinds of sands, i.e. quartz, olivine and chromite sands were analyzed. In order to determine the properties of moulding sands, typical determinations were made, i.e. moisture content, flowability, permeability, strength properties and abrasion wear. The obtained results indicate that it is possible to use barley malt as an independent binder for masses made of quartz, olivine and chromite sands.
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Bibliography

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Authors and Affiliations

B. Samociuk
1
ORCID: ORCID
D. Nowak
1
ORCID: ORCID
D. Medyński
2
ORCID: ORCID

  1. Wroclaw University of Technology, Poland
  2. Collegium Witelona Uczelnia Państwowa, Poland
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Abstract

Binder jetting (BJ) sand printing is a 3D printing process in which a sand mould or sand core is produced from an STL file. A single layer of a sand matrix consisting of one or more grains in height of sand is applied to a worktable, and then a liquid resin or binder is applied to bond the grains together. This process is repeated until the final result matches the CAD model. The sand matrix is the main component of ceramic cores and moulds. The present study aims to demonstrate the influence of the matrix used on the properties of the resulting moulding sand. Three types of sand matrices were selected for the study. The first was a quartz matrix for 3D printing with binder jetting; this is characterised by a sharp geometry that allows for proper layering during printing. Ordinary quartz sand was also used for the study; this type of sand is usually used for the production of sand cores in the hotbox process, among other things. The shape of this sand is irregular. The last matrix to be tested was Cerabeads sand; this was selected because its spherical geometry clearly distinguishes it from the other two matrices. The matrices were analysed for their grain sizes. Scanning electron microscope images were also taken to compare the geometries and chemical compositions of the respective matrices. In presented research utilises a sand matrix for the production of self-curing compounds with furan resin dedicated for binder jetting 3D printing. The moulding masses were produced in a laboratory circulation mixer. The laboratory moulds were produced with wooden core boxes and pre-compacted by vibration. The samples from the matrix for the 3D printing were produced using the binder jetting method. The samples were produced to determine the flexural strength, tensile strength, gas permeability, hot distortion, and apparent density. It was not possible to carry out tests for the Cerabeads sand, as the obtained moulds were too brittle to perform adequate tests. Tests with the other matrices have shown that the shape and size of the matrix affect the apparent density and gas permeability.
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Bibliography

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Authors and Affiliations

D.R. Gruszka
1
ORCID: ORCID
R. Dańko
1
ORCID: ORCID
M. Dereń
1
A. Wodzisz
1

  1. AGH University of Krakow, Faculty of Foundry Engineering, Poland
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Abstract

Composite Multimetal Stahl 1018 has been used in the process of preserving worn surfaces of materials operating in extremely difficult conditions. This work presents the results of simulation of the mechanical properties of steel samples in contact with the MM "Stahl 1018" composite. Tests were carried out for various models with with one- and two-sided contact sample models with the composite. Theoretical tests were conducted in the "SolidWorks 2019" environment. It was found that the maximum strength of the specimen layer made of MM "Stahl 1018" material, which closely adheres to the surfaces of steel bases on both sides (444 MPa) is higher than that of the material layer in one-sided contact (358 MPa), for specimens with a height of 4.5 mm and at 80 °C. Simulations also revealed a significant increase in the maximum stress in the composite MM "Stahl 1018" for specimens in the so-called free state from 285 MPa to 358 MPa with the increasing temperature from 20 °C to 80 °C, for specimens 4.5 mm high.
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Authors and Affiliations

A. Arustamian
D. Kalisz
1
ORCID: ORCID

  1. AGH University of Krakow, Poland
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Bibliography

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Authors and Affiliations

Jljun Lu
1
ORCID: ORCID
Zhuofan Zhong
1
ORCID: ORCID
Hu Yongluan
ORCID: ORCID
Di Wu
1
ORCID: ORCID
Huafang Wang
1
ORCID: ORCID

  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
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Abstract

The article presents the most significant material defects found in pistons for internal combustion engines, along with a graphical method of categorization using a Pareto-Lorenz chart. For the top three defects (constituting approximately 80% of all issues), a slightly different Ishikawa chart was employed to identify the causes behind their occurrence. Remedial actions were proposed, to be implemented primarily within the interoperative quality control of piston casting. It was concluded that it is crucial to prevent the excessive iron content in the alloy used for alfin inserts (AS9 alloy), particularly for cast iron ring carriers. The research was conducted in collaboration with Federal-Mogul company in Gorzyce (F-MG), one of the largest piston foundries in Poland.
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Authors and Affiliations

J. Piątkowski
1
ORCID: ORCID
M Łent-Trepczyńska
A. Krępa
2
M. Ferdyn
3

  1. Faculty of Materials Engineering, Silesian University of Technology, Poland
  2. Federal-Mogul Gorzyce, Poland
  3. Magna Casting Kędzierzyn-Koźle, Poland
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Abstract

There is growing interest in developing more advanced materials, as conventional materials are unable to meet the demands of the automotive, aerospace, and military industries. To meet the needs of these sectors, the use of advanced materials with superior properties, such as metal matrix composites, is essential. This paper discusses the evaluation of microstructural and mechanical properties of conventional eutectic EN AC-AlSi12CuNiMg aluminum alloy (AlSi12) and advanced composite based on EN AC-AlSi12CuNiMg alloy matrix with 10 wt% SiC particle reinforcement (AlSi12/10SiCp). The microstructure of these materials was investigated with the help of metallographic techniques, specifically using a light microscope (LM) and a scanning electron microscope (SEM). The results of the microstructural analysis show that the SiC particles are uniformly distributed in the matrix. The results of the mechanical tests indicate that the tensile properties and hardness of the AlSi12/10SiCp composite are significantly higher than those of the unreinforced eutectic alloy. For AlSi12/10SiCp composite, the tensile strength is 21% higher, the yield strength is 16% higher, the modulus of elasticity is 20% higher, and the hardness is 11% higher than unreinforced matrix alloy. However, the unreinforced AlSi12 alloy has a percentage elongation that is 16% higher than the composite material. This shows that the AlSi12/10SiCp composite has a lower ductility than the unreinforced AlSi12 alloy. The tensile specimens of the tested composite broke apart in a brittle manner with no discernible neck development, in contrast to the matrix specimens, which broke apart in a ductile manner with very little discernible neck formation.
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Authors and Affiliations

G.G. Sirata
1
ORCID: ORCID
K. Wacławiak
1
ORCID: ORCID
A.J. Dolata
1

  1. Department of Materials Technologies, Faculty of Materials Engineering, Silesian University of Technology, Krasińskiego 8, 40-019 Katowice, Poland
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Abstract

In the paper, the results of a numerical analysis of KCl and KF particles present in liquid aluminium assimilation to the slag are presented. The authors analysed particle movement in the slag model, which is based on buoyant, capillary, viscosity, Newton and repulsion forces, interfacial tensions at the interface of phases and surface energy during the particle movement through phases boundary. On the basis of the mathematical model, a computer programme was written to make simulations under different conditions. The results of particle position in the slag are presented for different particle radiuses: 1, 5, 10, 20 μm, and constant viscosity of the slag including velocity evolution of the velocity. Another approach was used to indicate the influence of slag viscosity on particle and slag penetration depth. During computations, selected viscosities of slag of 0.0012, 0.0015, 0.0018 [kg/m·s] were taken into account. Different comparisons were made for the chosen particle sizes. Each examination takes into account the impact of the particle type. The results clearly show that for larger particles the penetration depth is greater and viscosity of the slag has an impact on the velocity evolution during assimilation process.
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Authors and Affiliations

P.L. Żak
1
K. Kuglin
2
M. Szucki
3
ORCID: ORCID
D. Kalisz
1
ORCID: ORCID
N. Mrówka
E. Dand

  1. AGH University of Krakow, Krakow, Poland
  2. NPA Skawina Sp. z o. o., Poland
  3. Technische Universität Bergakademie Freiberg, Germany
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Abstract

To improve the mechanical properties of casting aluminum-copper alloy, the mixed rare earth (RE) was added to ZL206 and its properties and the enhanced mechanism of alloy were researched. The results showed that the strength and hardness of the composite were improved by 10.2% and 6.2%, respectively. After adding mixed RE, which was led by the heterogeneous enrichment area blocking the growth of the α-Al phase and making grain refinement during the solidification process. The simulation results of RE surface adsorption models by first principles also showed that the elastic constant calculation improved the bulk modulus, shear modulus, and Young's modulus of the material. The addition of mixed RE enhances the strength and hardness, although it adversely affects toughness and reduces the machining index. Also, the work function decreased, and the Fermi level increased, reflecting that the electron locality on each band was strong and the bonding state of the alloy system was covalent, which showed that the corrosion resistance was enhanced after adding mixed RE. It provides a new method for the mechanism of RE-modified aluminum-copper alloys and expands the direction of cast aluminum-copper alloy modification.
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