How to search?
advanced search
Applied sciences

Archives of Foundry Engineering

Archives of Foundry Engineering

Description

Archives of Foundry Engineering continues the publishing activity started by Foundry Commission of the Polish Academy of Sciences (PAN) in Katowice in 1978. The initiator of it was the first Chairman Professor Dr Eng. Wacław Sakwa – Corresponding Member of PAN, Honorary Doctor of Czestochowa University of Technology and Silesian University of Technology. This periodical first name was „Solidification of Metals and Alloys” , and made possible to publish the results of works achieved in the field of the Basic Problems Research Cooperation. The subject of publications was related to the title of the periodical and concerned widely understand problems of metals and alloys crystallization in a casting mold. In 1978-2000 the 44 issues have been published. Since 2001 the Foundry Commission has had patronage of the annually published “Archives of Foundry” and since 2007 quarterly published “Archives of Foundry Engineering”. Thematic scope includes scientific issues of foundry industry:

  • Theoretical Aspects of Casting Processes,
  • Innovative Foundry Technologies and Materials,
  • Foundry Processes Computer Aiding,
  • Mechanization, Automation and Robotics in Foundry,
  • Transport Systems in Foundry,
  • Castings Quality Management,
  • Environmental Protection.

Scoring assigned by the Polish Ministry of Science and Higher Education: 100 points

IMPACT FACTOR 2022: 0.6

CiteScore metrics from Scopus 2022: 1.2
SCImago Journal Rank ( SJR) 2022: 0.197
Source Normalized Impact per Paper ( SNIP) 2022: 0.423


Submit your article

The journal content is available under the Creative Commons Attribution 4.0 International License https://creativecommons.org/licenses/by/4.0/


 
ISSN
eISSN 2299-2944
Publishers
The Katowice Branch of the Polish Academy of Sciences
Editor in Chief:
J. Jezierski ORCID logo0000-0003-2078-196X
Silesian University of Technology, Gliwice, Poland
jan.jezierski@polsl.pl

Deputy Editor:
D. Bartocha ORCID logo0000-0002-3011-4434
Silesian University of Technology, Gliwice, Poland
dariusz.bartocha@polsl.pl

Subject Editors:

Theoretical Aspects of Casting Processes
E. Guzik – ORCID logo0000-0002-4449-532X, AGH University of Technology, Kraków, Poland
S. Gnyloskurenko – ORCID logo0000-0003-0201-7191, PTIMA National Academy of Sciences of Ukraine, Kiev, Ukraine
J. Sobczak – ORCID logo0000-0002-8878-1037, AGH University of Technology, Kraków, Poland

Innovative Foundry Technologies and Materials
O. P. Pandey – ORCID logo0000-0002-6826-995X , Thapar University, Punjab, India
N. S. Tiedje – ORCID logo0000-0001-5198-3551, DTU in Lyngby, Denmark
P. Lichy – ORCID logo0000-0002-6170-4728, VSB - Technical University of Ostrava, Ostrava, Czech Republic

Foundry Processes Computer Aiding
B. Mochnacki – ORCID logo0000-0001-8504-3744, University of Occupational Safety Management, Katowice, Poland
E. Majchrzak – ORCID logo0000-0003-3555-2318, Silesian University of Technology, Gliwice, Poland
M. Szucki – ORCID logo0000-0002-2675-1836, TU Bergakademie Freiberg, Freiberg, Germany
M. Perzyk – ORCID logo0000-0003-4901-7746, Warsaw University of Technology, Warszawa, Poland

Mechanization, Automation and Robotics in Foundry
J. Bast – ORCID logo0000-0002-9795-2352, TU Bergakademie Freiberg, Freiberg, Germany
R. Dańko – ORCID logo0000-0003-2434-6025, AGH University of Technology, Kraków, Poland
M. Mróz – ORCID logo0000-0002-7433-4092, Rzeszow University of Technology, Rzeszów, Poland

Castings Quality Management
D. Bolibruchova – ORCID logo0000-0002-7374-9763, University of Zilina, Zilina, Slovak Republic
J. D. B. de Mello – ORCID logo0000-0001-8912-2132, Universidade Federal de Uberlandia, Uberlandia, Brazil
M. Górny – ORCID logo0000-0001-6682-2611, AGH University of Technology, Kraków, Poland

Environmental Protection
M. Holtzer – ORCID logo0000-0002-6988-3329, AGH University of Technology, Kraków, Poland
J. Roučka – ORCID logo0000-0003-0917-1810, Brno University of Technology, Brno, Czech Republic
S. Acharya – ORCID logo0000-0001-6428-8961, Sardar Vallabhbhai Patel Institute of Technology, Vasad, Gujarat, India

Editorial Advisory Board:
M. Cholewa – ORCID logo0000-0001-8598-6953, Silesian University of Technology, Gliwice, Poland
B. K. Dhindaw – ORCID logo0000-0001-6991-9793, Indian Institute of Technology, Kharagpur, India
W. A. Hufenbach – ORCID logo0000-0002-5131-3483, Technical University Dresden, Dresden, Germany
A. Zadera – ORCID logo0000-0002-0555-370X , Brno University of Technology, Brno, Czech Republic
A. Passerone – ORCID logo0000-0002-0005-5314, CNR, Genova, Italy
I. Riposan – ORCID logo0000-0002-4040-2798, Politehnica University of Bucharest Bucharest, Romania
A. Sládek – ORCID logo0000-0002-7628-3524, University of Zilina, Zilina, Slovak Republic
J. Szajnar – ORCID logo0000-0003-3622-843X, Silesian University of Technology, Gliwice, Poland
R. B. Tuttle – ORCID logo00000002-7689-259X, Western Michigan University, Kalamazoo, MI, USA
M. Okayasu – ORCID logo0000-0003-3897-070X, Okayama University, Okayama, Japan
I. Nova – ORCID logo0000-0003-2287-9346, Technical University of Liberec, Liberec, Czech Republic
C. Caceres – ORCID logo0000-0001-6521-2037, The University of Queensland, Brisbane, Australia
A. Dioszegi – ORCID logo0000-0002-3024-9005, Jönköping University, Jönköping, Sweden

Associate Editors:
A. Dulska – ORCID logo0000-0001-6903-328X, Silesian University of Technology, Gliwice, Poland
J. Suchoń – ORCID logo0000-0002-7019-3966, Silesian University of Technology, Gliwice, Poland
M. Kondracki – ORCID logo0000-0001-7840-5575, Silesian University of Technology, Gliwice, Poland
N. Przyszlak – ORCID logo0000-0003-1683-0001, Silesian University of Technology, Gliwice, Poland
J. Szymszal – ORCID logo0000-0002-3229-6470, Silesian University of Technology, Gliwice, Poland

ul. Towarowa 7,
44-100 Gliwice, Poland
e-mail: kikm@polsl.pl

https://www.journal-afe.pl

Copyright

Copyright on any open access article in the Archives of Foundry Engineering journal published by Polish Academy of Sciences is retained by the author(s). Authors grant Polish Academy of Sciences a license to publish the article and identify itself as the original publisher. Authors also grant any user the right to use the article freely if its integrity is maintained and its original authors, citation details and publisher are identified. The Creative Commons Attribution License 4.0 formalizes these and other terms and conditions of publishing articles.

 

The editorial team of Archives of Foundry Engineering implements an open access policy by publishing materials in the form of the so-called Gold Open Access and encourages authors to place articles published in the journal in open repositories (after the review or the final version of the publisher), provided that a link to the journal’s website is provided.

Exceptions to copyright policy

For the articles which were previously published, before year 2022, policies that are different from the above. In all such, access to these articles is free from fees or any other access restrictions. Permissions for the use of the texts published in that journal may be sought directly from the Commission of Foundry Engineering of the Polish Academy of Sciences, Gliwice, Poland, by e-mail: kikm@polsl.pl.
  • Volumes
  • Instructions for authors
  • Publication Ethics Policy
  • Peer-review Procedure
  • Reviewers

Select number

Content

Archives of Foundry Engineering | 2025 | vol. 25 | No 4

1 Analysis of Anomalies in the Thermal-Mechanical Fatigue Process Using Selected IT Tools
K. Jaśkowiec , D. Wilk-Kołodziejczyk , K. Nosarzewski
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 5-9 | DOI: 10.24425/afe.2025.155373
Keywords: Thermal-mechanical fatigue Vermicular cast iron Coffin method Isolation Forest One-Class SVM
Download PDF Download RIS Download Bibtex

Abstract

The article uses the results obtained during the tests of a wide group of metal alloys using a device operating by the Coffin method. The measure of resistance to thermal-mechanical fatigue is the number of cycles that the sample withstands before a macrocrack occurs, at a fixed current and temperature range. The device offers the possibility of working in two modes of sample mounting. The first mode allows the sample to freely elongate parallel to its axis, while the second mounting mode limits this elongation by using a transducer. The aim of the publication is to present possible solutions for anomaly detection. Anomaly detection concerns traps that may occur during the measurement process. Advanced machine learning methods were used to analyze and detect anomalies in data regarding thermal fatigue resistance. Isolation Forest and One-Class SVM algorithms were used for anomaly detection, which allow for effective identification of unusual patterns in the data. The conducted research confirmed the usefulness of one of the selected methods in the process of anomaly identification using the example of elongation.
Go to article

Bibliography

  • Domengès, B., Celis, M.M., Moisy, F., Lacaze, J. & Tonn, B. (2021). On the role of impurities on spheroidal graphite degeneracy in cast irons. Carbon. 172, 529-541 https://doi.org/10.1016/J.CARBON.2020.10.030.

  • Valle, N., Theuwissen, K., Sertucha, J. & Lacaze, J. (2012). Effect of various dopant elements on primary graphite growth. IOP Conference Series: Materials Science and Engineering. 27(1), 012026, 1-6. https://doi.org/10.1088/1757-899X/27/1/012026.

  • Mrvar, P., Petrič, M. & Terčelj, M. (2023). Thermal fatigue of spheroidal graphite cast iron. TMS Annual Meeting & Exhibition. 406-415. https://doi.org/10.1007/978-3-031-22524-6_37.

  • Fourlakidis, V., Hernando, J.C., Holmgren, D. & Diószegi, A. (2023). Relationship between thermal conductivity and tensile strength in cast irons. International Journal of Metalcasting. 17, 2862-2867. https://doi.org/10.1007/s40962-023-00970-6.

  • Wang, L., Liu, H., Huang, C., Yuan, Y., Yao, P., Huang, J. & Han, Q. (2023). A methodology to predict thermal crack initiation region of tool for high-speed milling compacted graphite iron based on three-dimensional transient thermal stress field model. The International Journal of Advanced Manufacturing Technology. 125, 2065-2075. https://doi.org/10.1007/s00170-023-10832-4.

  • Coffin, L.F. & Wesley, R.P. (1954). Apparatus for study of effects of cyclic thermal stresses on ductile metals. Journal of Fluids Engineering. 76, 923-930. https://doi.org/10.1115/1.4015019.

  • Seifert, T. & Riedel, H. (2010). Mechanism-based thermomechanical fatigue life prediction of cast iron. Part I: Models. International Journal of Fatigue. 32, 1358-1367. https://doi.org/10.1016/J.IJFATIGUE.2010.02.004.

  • Amaro, R.L., Antolovich, S.D., Neu, R.W., Fernandez-Zelaia, P. & Hardin, W. (2012). Thermomechanical fatigue and bithermal–thermomechanical fatigue of a nickel-base single crystal superalloy. International Journal of Fatigue. 42, 165-171. https://doi.org/10.1016/J.IJFATIGUE.2011.08.017.

  • Boto, F., Murua, M., Gutierrez, T., Casado, S., Carrillo, A., & Arteaga, A. (2022). Data driven performance prediction in steel making. Metals. 12(2), 172, 1-19. https://doi.org/10.3390/met12020172.

  • Li, W., Chen, H., Guo, J., Zhang, Z., Wang, Y. (2022). Brain-inspired multilayer perceptron with spiking neurons. In Proceedings of the IEEE/CVF Conference on Computer Vision and Pattern Recognition, 18-24 June 2022 (pp. 773-783). https://doi.org/10.1109/CVPR52688.2022.00086. New Orleans, LA, USA: IEEE.

  • Shu, X., Zhang, S., Li, Y. & Chen, M. (2022). An anomaly detection method based on random convolutional kernel and isolation forest for equipment state monitoring. Eksploatacja i Niezawodność – Maintenance and Reliability. 24(4), 758-770. https://doi.org/10.17531/EIN.2022.4.16.

  • Wu, X., Kang, H., Yuan, S., Jiang, W., Gao, Q. & Mi, J. (2023). Anomaly detection of liquid level in mold during continuous casting by using forecasting and error generation. Applied Sciences. 13(13), 7457, 1-16. https://doi.org/10.3390/app13137457.

  • Liu, F.T., Ting, K.M., Zhou, Z.H. (2008). Isolation forest. In Proceedings - IEEE International Conference on Data Mining, ICDM, 15-19 December 2008 (pp. 413-422). https://doi.org/10.1109/ICDM.2008.17.

  • Seliya, N., Abdollah Zadeh, A., Khoshgoftaar, T.M. (2021). A literature review on one-class classification and its potential applications in big data. Journal of Big Data. 8, 1-31 https://doi.org/10.1186/s40537-021-00514-x.

Go to article

Authors and Affiliations

K. Jaśkowiec
1
ORCID: ORCID
D. Wilk-Kołodziejczyk
2
ORCID: ORCID
K. Nosarzewski
2
  1. Łukasiewicz Research Network – Krakow Institute of Technology, Kraków, Poland
  2. AGH University of Science and Technology, Al. A. Mickiewicza 30, 30-059 Kraków, Poland
2 The Effect of Addition of the Natural Zeolite on the Microstructure and Properties of Sintered Iron Matrix Composite
M. Kargul , J.M. Borowiecka-Jamrozek
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 10-15 | DOI: 10.24425/afe.2025.155374
Keywords: Metal matrix Iron Zeolite Powder metallurgy
Download PDF Download RIS Download Bibtex

Abstract

The paper presents the results of research on the production and application of a sintered iron-based composite reinforced with natural zeolite particles. Mechanical properties were tested and the quality of the connection between the particles and the metal matrix was assessed. Before the composite production process, the chemical composition and morphology of natural zeolite particles were examined. Zeolite particles with a diameter of less than 0.2 mm were used to produce sinters. The zeolite particles were subjected to chemical composition (EDS) and phase (XRD) analyses. Zeolite particles were introduced into the iron matrix in amounts of 5, 10, and 15% by weight. Before the sintering process, the zeolite particles were compacted in a hydraulic press at a pressure of 400 MPa. Sintering of the green compacts was carried out in a tubular furnace at 950°C in an atmosphere of dissociated ammonia for 60 minutes. The obtained composites were subjected to porosity, hardness, and density measurements. Microstructure and chemical composition studies were conducted using a scanning electron microscope (SEM). Iron–zeolite composites are characterized by higher hardness and porosity compared to sintered iron. The introduction of zeolite particles also reduces the density of the composites.
Go to article

Bibliography

  1. Abhik, R. & Xaviora, M. (2014). Evaluation of properties for Al.-SiC reinforced metal matrix composite for brake pads. Procedia Engineering. 97, 941-950. DOI: 10.1016/j.proeng.2014.12.370.

  2. Zakaria, H.M. (2014). Microstructural and corrosion behavior of Al/SiC metal matrix composites. Ain Shams Engineering Journal. 5(3), 831-838. https://doi.org/10.1016/j.asej.2014.03.003.

  3. Singla, M., Dwivedi, D., Singh, L. & Chavla, V. (2009). Development of aluminum based silicon carbide particulate metal matrix composite. Journal of Minerals and Materials Characterization and Engineering. 8(6), 455-467. DOI: 10.4236/jmmce.2009.86040.

  4. Nuruzzaman, D., Praveen, R. & Raghuraman, S. (2016). Processing and mechanical properties of aluminum- silicon carbide metal matrix composites. IOP Conference Series: Materials Science and Engineering. 114(1), 012123, 11-17. DOI: 10.1088/1757-899X/114/1/012123.

  5. Baisane, V. P., Sable, Y. S., Dhobe, M. M. & Sonawane, P. M. (2015). Recent development and challenges in processing of ceramics reinforced Al matrix composite through stir casting process: A Review. International Journal of Engineering and Applied Sciences. 2(10), 257814.

  6. Taha, M.A. & Zawrah M.F. (2017). Effect of nano ZrO2 on strengthening and electrical properties of Cu- matrix nanocomposites prepared by mechanical alloying, Ceramics International. 43(15), 12698-12704. DOI: 10.1016/j.ceramint.2017.06.153.

  7. Samal, C.P., Parihar, J.S. & Chaira, D, (2013). The effect of milling and sintering techniques on mechanical properties of Cu-graphite metal matrix composite prepared by powder metallurgy route. Journal of Alloys and Compounds. 569, 95-101, DOI: doi.org/10.1016/j.jallcom.2013.03.122.

  8. Wang, C., Lin, H., Zhang, Z. & Li W. (2018). Fabrication, interfacial characteristics and strengthening mechanism of ZrB2 microparticles reinforced Cu composites prepared by hot pressing sintering. Journal of Alloys and Compounds. 748, 546-552. https://doi.org/10.1016/j.jallcom.2018.03.169.

  9. Kumar, G., Rao, C. & Selvaraj, N. (2011). Mechanical and tribological behavior of particulate reinforced aluminum metal matrix composites- a review. Journal of Minerals and Materials Characterization and Engineering. 10(1), 59-91. DOI: 10.4236/jmmce.2011.101005.

  10. Leszczyńska-Madej, B. (2013). The effect of sintering temperature on microstructure and properties of Al-SiC composites. Archives of Metallurgy and Materials. 58(1), 43-48. DOI: 10.2478/v10172-012-0148-7.

  11. Kargul, M. & Konieczny, M. (2020). Fabrication and characteristics of copper-intermetallics composites. Archives of Foundry Engineering. 20(3), 25-30. 10.24425/afe.2020.133325.

  12. Krüger, C. & Mortensen, A. (2013). In situ copper- alumina composites. Materials Science and Engineering: A. 585, 396-407. https://doi.org/10.1016/j.msea.2013.07.074.

  13. Sulima, I., Kowalik, R., Stępień, M. & Hyjek, P. (2024). Effect of ZrB2 content on properties of copper matrix composite. Materials. 17(24), 6105. https://doi.org/10.3390/ma17246105.

  14. Chakthin, S., Morakotjinda, M., Yodkaew, T., Torsangtum, N., Krataithong, R., Siriphol, P., Coovattanachai, O., Vetayanugul, B., Thavarungkul, N., Poolthong, N. & Tongsri, R. (2008). Influence of carbides on properties of sintered Fe-base composites. Journal of Metals, Materials and Minerals. 18(2), 67-70.

  15. Bandura, L., Franus, M., Panek, R., Woszuk, A. & Franus W. (2015). Characterization of zeolites and their use as adsorbents of petroleum substances. Przemysł Chemiczny. 94(3). DOI: 10.15199/62.2015.3.11. (in Polish).

  16. Król, M., Mozgawa, W. & Pichór W. (2008). Application of clinoptilolite to heavy metal cations immobilization and to obtaining autoclaved building materials. Materiały Ceramiczne. 60(2), 71-80. (in Polish).

  17. Łach, M. (2010). Structure of metal matrix composites with an addition of tuff. Archives of Foundry Engineering. 10(3), 135-140.

  18. Łach, M., Mikuła, J. & Hebda M. (2016). Thermal analysis of the by-products of waste combustion. Journal of Thermal Analysis and Calorimetry. 125(3), 1035-1045. DOI: 10.1007/s10973-016-5512-9.

  19. Mikuła, J., Łach, M. & Kowalski J.S. (2015). Copper matrix composites reinforced with volcanic tuff. Metalurgija. 54(1), 143-146.

  20. Ciciszwili, G.W., Andronikaszwili, G.N., Kirow Ł.D. (1990). Zeolity naturalne. Warszawa: WNT.

  21. Gottardi, G., & Galli, E. (1985). Zeolites of the heulandite group. In Natural zeolites (pp. 256-305). Berlin, Heidelberg: Springer Berlin Heidelberg.

  22. Nanbin, H., Dianyue, G., Bekkum, H., Flanigen, E., Jacobs, P. & Jansen J. (2001). Introduction to Zeolite Science and Practice. New York: Elsevier.

  23. Kocich, R., Opela, P. & Marek, M. (2023). Influence of structure development on performance of copper composites processed via intensive plastic deformation. Materials. 16(13), 4780. https://doi.org/10.3390/ma16134780.

  24. Kargul, C., Konieczny, M. & Borowiecka-Jamrozek J. (2018). The effect of the addition of zeolite particles on the performance characteristics of sintered copper matrix composites. Tribologia. 282(6), 51-62. DOI: 10.5604/01.3001.0012.8421.

  25. Borowiecka-Jamrozek, J. & Depczyński W. (2017). The effect of the addition of zeolite on the properties of a sintered copper-matrix composite. In 26th International Conference on Metallurgy and Materials, 24th - 26th May 2017. Brno, Czech Republic.

Go to article

Authors and Affiliations

M. Kargul
1
ORCID: ORCID
J.M. Borowiecka-Jamrozek
1
ORCID: ORCID
  1. Kielce University of Technology, Poland
3 Cavitation Erosion Resistance Tests of WCCoCr and CrCNi Coatings Sprayed Using the APS Method
M. Radoń , B. Kupiec
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 16-23 | DOI: 10.24425/afe.2025.155375
Keywords: Air plasma spraying coating Scratch test Cavitation erosion
Download PDF Download RIS Download Bibtex

Abstract

This article presents structural analysis and mechanical property evaluation of two coatings applied using the APS (Air Plasma Spraying) method on a P250GH boiler steel substrate. Two different powders were used for coating deposition: WCCoCr, based on tungsten carbide, and CrCNi, based on chromium carbide. To assess the coating-substrate bond quality, a scratch test was conducted using a Rockwell diamond indenter under a constant load of 10 N, moving from the substrate toward the coating. No delamination at the coating-substrate interface was observed, indicating a high-quality bond. Microhardness measurements were performed using a 200 g load. The average microhardness values were 886 HV0.2 for the WCCoCr coating and 904 HV0.2 for the CrCNi coating. The coatings were also tested for cavitation resistance according to the ASTM G32-16 standard. Surface roughness profiles were measured before and after 120 minutes of cavitation exposure. Cavitation wear was evaluated based on the difference in roughness values, determined by the Sz parameter, which, according to ISO 25178, is defined as the difference between the highest peak and the lowest valley on the surface. The obtained results indicate that APS thermal spray coatings based on tungsten carbide powders can be used for machine components to enhance cavitation erosion resistance.
Go to article

Bibliography

  • Kumar, K., Kumar, L. & Gill, H. (2024). Role of carbide-based thermal-sprayed coatings to prevent failure for boiler steels: a review. Journal of Failure Analysis and Prevention. 24(4), 1628-1663. DOI:10.1007/s11668-024-01974-y.

  • Rodolpho, V., Silveira, L., Cruz, J. & Pukasiewicz, A. (2023). Cavitation resistance of FeMnCrSi coatings processed by different thermal spray processes. Hybrid Advances. 5, 100125, 1-18. DOI: 10.1016/j.hybadv.2023.100125.

  • Cheng, F.T., Shi, P. & Man, H.C. (2001). Correlation of cavitation erosion resistance with indentation-derived properties for a NiTi alloy. Scripta Materialia. 45(9), 1083-1089. https://doi.org/10.1016/S1359-6462(01)01143-5.

  • Stachowiak, G.B. & Stachowiak, G.W. (2010). Tribological characteristics of WC-based claddings using a ball-cratering method. International Journal of Refractory Metals and Hard Materials. 28(1), 95-105. https://doi.org/10.1016/j.ijrmhm.2009.07.015.

  • Murthy, J.K.N. & Venkataraman, B. (2006). Abrasive wear behaviour of WC–CoCr and Cr3C2–20(NiCr) deposited by HVOF and detonation spray processes. Surface and Coatings Technology. 200(8), 2642-2652, https://doi.org/10.1016/j.surfcoat.2004.10.136.

  • Yang, X., Zhang, J. & Li, G. (2016). Cavitation erosion behaviour and mechanism of HVOF-sprayed NiCrBSi–(Cr3C2–NiCr) composite coatings. Surface Engineering. 34(3), 211-219. https://doi.org/10.1080/02670844.2016.1258770.

  • Matikainen, V., Koivuluoto, H. & Vuoristo, P. (2020). A study of Cr3C2-based HVOF-and HVAF-sprayed coatings: Abrasion, dry particle erosion and cavitation erosion resistance. Wear. 446-447, 203188, 1-11. https://doi.org/10.1016/j.wear.2020.203188.

  • Silveira, L.L., Pukasiewicz, A.G.M., de Aguiar, D.J.M., Zara, A.J. & Björklund, S. (2019). Study of the corrosion and cavitation resistance of HVOF and HVAF FeCrMnSiNi and FeCrMnSiB coatings. Surface and Coatings Technology. 374, 910-922. https://doi.org/10.1016/j.surfcoat.2019.06.076.

  • Nowakowska, M., Łatka, L., Sokołowski, P., Szala, M., Toma, F. & Walczak, M. (2022). Investigation into microstructure and mechanical properties effects on sliding wear and cavitation erosion of Al2O3–TiO2 coatings sprayed by APS, SPS and S-HVOF. Wear. 508-509, 204462, 1-15. https://doi.org/10.1016/j.wear.2022.204462.

  • Odhiambo, J.G., Li, W., Zhao, Y. & Li, C. (2019). Porosity and its significance in plasma-sprayed coatings. Coatings. 9(7), 460, 1-19. https://doi.org/10.3390/coatings9070460.

  • Sun, P., Fang, Z.Z., Zhang, Y. & Xia Y. (2017). Review of the methods for production of spherical Ti and Ti alloy powder. JOM: the journal of the Minerals, Metals & Materials Society. 69, 1853-1860. DOI: https://doi.org/10.1007/s11837-017-2513-5.

  • Matikainen, V., Koivuluoto, H., Vuoristo, P., Schubert, J. & Houdková, Š. (2018). Effect of nozzle geometry on the microstructure and properties of HVAF-sprayed WC-10Co4Cr and Cr3C2-25NiCr coating. Journal od Thermal Spray Technology. 27(4), 680-694. DOI: 10.1007/s11666-018-0717-z.

  • Houdková, Š., Zahálka, F., Kašparová, M. & Berger, L.M. (2011). Comparative study of thermally sprayed coatings under different types of wear conditions for hard chromium replacement. Tribology Letters. 43(2), 139-154. DOI: 10.1007/s11249-011-9791-9.

  • Lugscheider, E., Barimani, C., Eckert, P. & Eritt, U. (1996). Modeling of the APS plasma spray process. Computational Materials Science. 7(1-2), 109-114. https://doi.org/10.1016/S0927-0256(96)00068-7.

  • Wang, J., Wang, L., Lu, H., Du, J., Qi, X., Lu, L., Zhao, Y., Liu, Z. & Meng, W. (2025). Enhanced erosion resistance of Cr3C2-TiC-NiCrCoMo coatings: experimental and numerical investigation of erosion mechanisms. Coatings. 15(3), 294, 1-25. DOI: 10.3390/coatings15030294.

  • Houdková, Š., Česánek, Z., Smazalová, E. & Lukáč, F. (2018). The high-temperature wear and oxidation behavior of CrC-based HVOF coatings. Journal of Thermal Spray Technology. 27(1), 179-195. DOI: 10.1007/s11666-017-0637-3.

  • Padture, N.P., Gell, M., Jordan, E.H. (2002). Thermal barrier coatings for gas-turbine engine applications. Science. 296(5566), 280-284. DOI: 10.1126/science.1068609.

  • Weeks, M.D., Subramanian, R., Vaidya, A. & Mumm, D.R. (2015). Defining optimal morphology of the bond coat–thermal barrier coating interface of air-plasma sprayed thermal barrier coating systems. Surface and coating technology. 273, 50-59. DOI: 10.1016/j.surfcoat.2015.02.012.

  • Sampath, S., Schulz, U., Jarligo, M.O. & Kuroda, S. (2012). Processing science of advanced thermal-barrier systems. MRS Bulletin. 37(10), 903-910. DOI: 10.1557/mrs.2012.233.

  • Mutter, M., Mauer, G., Mücke, R., Guillon, O. & Vaßen, R. (2017). Correlation of splat morphologies with porosity and residual stress in plasma-sprayed YSZ coating. Surface and coating technology. 318, 157-169. https://doi.org/10.1016/j.surfcoat.2016.12.061.

  • McPherson, R. (1989). A review of microstructure and properties of plasma sprayed ceramic coatings. Surface and coating technology. 39-40(1), 173-181. https://doi.org/10.1016/0257-8972(89)90052-2.

Go to article

Authors and Affiliations

M. Radoń
1
ORCID: ORCID
B. Kupiec
1
ORCID: ORCID
  1. Rzeszow University of Technology, Poland
4 Application of Elasto-Optical Methods in Research on Casting Structures
M.L. Maj , W. Stachurski
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 24-29 | DOI: 10.24425/afe.2025.155376
Keywords: Photoelastic method Isochromatics and isoclines Polarized light Photoelastic coating
Download PDF Download RIS Download Bibtex

Abstract

Verification of design conclusions using experimental methods is often employed and usually more justified than other techniques for producing machine or device components. Castings are characterized by complex shapes, varying sizes and, as a result, diverse physical and mechanical properties. Additionally, relatively small batches of alloys prepared for casting introduce unintended variation that affects final characteristics and acceptance criteria. It is therefore important to consider the slightly different mechanical properties of finished castings, which may vary even within the same part due to different solidification and cooling conditions. Despite these limitations, the foundry industry occupies an important position in national economies, with indicators showing steady development driven by low manufacturing costs, improved technologies, and new designs with stricter acceptance criteria. The aim of this work is to briefly present one experimental method of stress and strain analysis — the photoelastic method.
Go to article

Bibliography

  • Metzger, D., Jarrett New, K. & Dantzig, J. (2001). A sand surface element for efficient modeling of residual stress in casting. Applied Mathematical Modelling. 25(10), 825-842. https://doi.org/10.1016/S0307-904X(01)00017-8.

  • James, M.N., Hughes, D.J., Chen, Z., Lombard, H., Hattingh, D.G., Asquith, D., Yates, J.R. & Webster, P.J. (2007). Residual stresses and fatigue performance. Engineering Failure Analysis. 14(2), 384-395. https://doi.org/10.1016/j.engfailanal.2006.02.011.

  • Rossini, N.S., Dassisti, M., Benyounis, K.Y. & Olabi, A.G. (2012). Methods of measuring residual stresses in components. Materials & Design. 35, 572-588. https://doi.org/10.1016/j.matdes.2011.08.022.

  • Shet, C. & Deng, X. (2003). Residual stresses and strains in orthogonal metal cutting. International Journal of Machine Tools and Manufacture. 43(6), 573-587. https://doi.org/10.1016/S0890-6955(03)00018-X.

  • Tabatabaeian, A., Ghasemi, A.R., Shokrieh, M.M., Marzbanrad, B., Baraheni M. & Fotouhi M. (2022). Residual stress in engineering materials: a review. Advanced engineering materials. 24(3), 2100786, 1-28. https://doi.org/10.1002/adem.202100786.

  • Jun, T.-S. & Korsunsky, A.M. (2010). Evaluation of residual stresses and strains using the eigenstrain reconstruction method. International Journal of Solids and Structures. 47(13), 1678-1686. https://doi.org/10.1016/j.ijsolstr.2010.03.002.

  • Wyatt, J.E., Berry, J.T. & Williams, A.R. (2007). Residual stresses in aluminum castings. Journal of materials processing technology. 191(1-3), 170-173. https://doi.org/10.1016/j.jmatprotec.2007.03.018.

  • Carrera, E., Rodríguez, A., Talamantes, J., Valtierra, S. & Colás, R. (2007). Measurement of residual stresses in cast aluminium engine blocks. Journal of materials processing technology. 189(1-3), 206-210. https://doi.org/10.1016/j.jmatprotec.2007.01.023.

  • Guan, J., Dieckhues, G.W. & Sahm, P.R. (1994) Analysis of residual stresses and cracking of γ-TiAl castings. Intermetallics. 2(2), 89-94. https://doi.org/10.1016/0966-9795(94)90002-7.

  • Skarbiński, M. (1957). Construction of Castings. Warszawa: PWT.

  • Training materials from Vishay.

  • Maj, M. (2024). The formation of the strength of castings including stress and strain analysis. Materials. 17(11), 2484, 1-19. https://doi.org/10.3390/ma17112484.

  • Maj, M. (2012). Fatigue endurance of selected casting alloys. Katowice-Gliwice: Archives of Foundry Engineering.

  • Wolna, M. (1993). Elastooptic Materials. Warsaw: Wydawnictwo Naukowe PWN.

  • Jakubowicz, A., Orłoś, Z. (1972), Strength of Materials. Warszawa: Wydawnictwa Naukowo-Techniczne.

  • Orłoś, Z. (1977). Experimental Analysis of Deformations and Stresses [Doświadczalna analiza odkształceń i naprężeń.]; Warszawa: PWN. (in Polish)

  • Stachurski, W., Siemieniec, A. (2005). Structural Studies of Castings Using Elastooptics Methods. Kraków: WN AKAPIT.

  • Siemieniec, A. (1977). Elastooptics. Kraków: Wydawnictwo AGH. (in Polish).

  • Zandman, F., Redner, S., & Dally, J. W. (1977). Photoelastic coatings (SESA Monograph No. 3). Iowa State University Press.

  • Ulutan, D., Ulutan, B., Erdem, A. & Lazoglu, I. (2007). Analytical modelling of residual stresses in machining. Journal of Materials Processing Technology. 183(1), 77-87. https://doi.org/10.1016/j.jmatprotec.2006.09.032.

  • Raptis, K.G., Costopoulos, Th.Ν., Papadopoulos, G.,Α. & Tsolakis, Α.D. (2010). Rating of spur gear strength using photoelasticity and the finite element method. American Journal of Engineering and Applied Sciences. 3(1), 222-231. ISSN 1941-7020.

  • Umezaki, E. & Terauchi, Sh. (2002). Extraction of isotropic points using simulated isoclinics obtained by photoelasticity-assisted finite element analysis. Optics and lasers in engineering. 38(1-2), 71-85. https://doi.org/10.1016/S0143-8166(01)00158-0.

  • Marle Ramachandra, P., Sungar, S., Mohan Kumara, G.C. (2022). Stress analysis of a gear using photoelastic method and Finite element method. Materials Today: Proceedings. 65(8), 3820-3828. https://doi.org/10.1016/j.matpr.2022.06.579.

  • Corby Jr, T.W., Nickola Wayne, E. (1997). Residual strain measurement using photoelastic coatings. Optics and Lasers in Engineering. 27(1), 111-123. https://doi.org/10.1016/S0143-8166(95)00012-7.

Go to article

Authors and Affiliations

M.L. Maj
1
ORCID: ORCID
W. Stachurski
1
  1. AGH University of Krakow, Faculty of Foundry Engineering, Poland
5 Stable Production of High-volume and High-quality ADI and Further Improvement of Consistency
Wenbang Gong , Zhongding Zhou , Mintang Zhang , Wenqing Yang , Li Sun
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 30-37 | DOI: 10.24425/afe.2025.155377
Keywords: Stable production of high-volume and high-quality ADI Casting process control Austempering process control Statistical data and analysis of ADI production
Download PDF Download RIS Download Bibtex

Abstract

This paper presents 419 test data from 6 months continuous production. The results show that, through strict control of raw materials, melting, and spheroidization processes, high-quality, as-cast ductile iron casting with stable composition and stable as-cast structure are obtained, and with using advanced professional heat treatment equipment for austempering treatment, the ADI properties are excellent, all higher than the minimum requirements of ASTM and Chinese national standards. The results also show that the dispersion of high strength grade ADI properties is relatively small, while that of high ductility grade ADI is relatively high. By analyzing the statistical data, in order to further reduce the dispersion of mechanical properties in high-volume production and improve the stability and consistency of ADI products, it is necessary to strictly control the production process, ensuring that ADI products for one grade have as similar chemical compositions and as-cast microstructures as possible. Additionally, precise control of the austempering treatment process should be implemented in a categorized manner based on factors such as casting section thickness, chemical and alloying composition, and as-cast microstructure.
Go to article

Bibliography

  • Elliott, R. (1997). The role of research in promoting austempered ductile iron. Heat treatment of Metals. 3, 55-59.
  • Keough, J. R. (2002). ADI developments in North America – revisited 2002. In Proceedings of the 2002 World Conference on ADI, September 26–27 (pp. 111–122). Louisville, KY, United States.
  • Keough J.R., Hayrynen, K.L. (2006). Developments in the technology and engineering application of austempered ductile iron (ADI). In Proceedings of the 8th International Symposium on the Science and Processing of Cast Irion (SPCI8), 16-19 October 2006 (pp. 474-479). Beijing, China.
  • Nofal, A.A. (2014). The current status of the metallurgy and processing of austempered ductile iron (ADI). In the 10th International Symposium on the Science and Processing of Cast Irion (SPCI10), 10-13 November 2014 (pp. 69-82).
  • Li Kerui, Li Zengli, Cui Yu, Wei Donghai, & Chen Zhao. (2022). Status and development trend of cast iron production technology in China. Foundry (Chinese Journal). 71(2), 123-135.
  • Liu J. & Gong W. (2020). Some recent progresses of ADI research and development abroad. Modern Casting (Chinese Journal). 40(3), 1-4.
  • Gong W., Liu J., Xiang G. (2020). Austempered Ductile Iron (ADI) - Theory, Production Technology and Application. China Machine Press, ISBN 978-7-111-66450-5, September.
  • Yan Q., Gong W., Liu J. (2024). The current status, problems and prospects of ADI in China: A Review. In the 75th World Foundry Congress, 25-30 October 2024. Deyang, Sichuan, China.
  • Yan Q., Gong X., Gong W. & Liu J. (2024). Lightweight innovation ADIs help development of renewable energy and new technology industries in China. China Foundry. 21(5), 507-515. https://doi.org/10.1007/s41230-024-4141-3.
  • Gong W., Liu J., Yuan Z., Sun L., Zhang M., & Li C. (2020). Design and control of suitable carbon-silicon content of austempered ductile iron. Foundry (Chinese Journal). 69(8), 816-821.
  • Nazarboland, A. & Elliott, R. (1997). The relationship between austempering parameters, microstructure and mechanical properties in a Mn-Mo-Cu alloyed ductile iron. International Journal of Cast Metals Research. 9, 295-308. https://doi.org/10.1080/13640461.1997.11819671.
  • Darwish, N. & Elliott, R. (1993). Austempering of low manganese ductile irons. Materials Science and Technology. 9(7), 572-585. https://doi.org/10.1179/mst.1993.9.7.57.
  • Bayati, H. & Elliott, R. (1995). Relationship between structure and mechanical properties in high manganese alloyed ductile iron. Materials Science and Technology. 11(3), 284-293. https://doi.org/10.1179/mst.1995.11.3.284.

 

Go to article

Authors and Affiliations

Wenbang Gong
1
Zhongding Zhou
1
Mintang Zhang
2
Wenqing Yang
2
Li Sun
1
  1. School of Mechanical Engineering and Automation, Wuhan Textile University, China
  2. Henan ADI Casting Co., Ltd, China
6 Evaluation of Foundry Properties of Locally Available Molding Sand with Bentonite Clay Additions for Cost-Effective Aluminum Alloy Casting
F. Hussain , M. Kamran , A. Inam , M. Ishtiaq , M.H. Hassan , F. Riaz , T. Khan , M. Ammar , M. Salman
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 38-45 | DOI: 10.24425/afe.2025.155378
Keywords: Molding sand Bentonite clay Grain size Surface roughness Strength
Download PDF Download RIS Download Bibtex

Abstract

This study addresses an existing gap by examining the foundry properties of Ravi River sands, a subject that has not been explored in earlier studies. Several mechanical and physical tests were used to assess the foundry qualities of sands from different areas. These local sands were used to make molds for Al alloy castings, and the parts' surface roughness (Ra) was assessed. The findings showed that the grain size of the sand varied by location, with the highest grain fineness number (GFN) being 106 and the lowest being 71. All samples exhibited a pH > 7, confirming their suitability for strong binder adhesion. The sand from Syed Wala Bridge had the highest grain fineness number (~106), whereas the sand from Sheraza Pattan Bridge had the lowest (~71). All sand samples showed a constant increase in mold strength when the binder (bentonite clay) percentage was raised from 5% to 25%. The study demonstrates the potential of Ravi River sands to eliminate reliance on imported materials and reduce costs.
Go to article

Bibliography

  • Perry, N., Bosch-Mauchand, M., Bernard, A. (2010). Costs models in design and manufacturing of sand casting products. In A. Bramley, D.Brissaud, D. Coutellier, C. McMahon (Eds.), Advances in Integrated Design and Manufacturing in Mechanical Engineering (pp. 69-80). Dordrecht: Springer Netherlands.
  • Saikaew, C. & Wiengwiset, S. (2012). Optimization of molding sand composition for quality improvement of iron castings. Applied Clay Science. 67-68, 26-31, https://doi.org/10.1016/j.clay.2012.07.005.
  • Shilpa, M., Prakash, G.S. & Shivakumar, M.R. (2021). A combinatorial approach to optimize the properties of green sand used in casting mould. Materials Today: Proceedings. 39(4), 1509-1514, https://doi.org/10.1016/j.matpr.2020.05.465.
  • Paluszkiewicz, C., Holtzer, M. & Bobrowski, A. (2008). FTIR analysis of bentonite in moulding sands. Journal of Molecular Structure. 880(1-3), 109-114, https://doi.org/10.1016/j.molstruc.2008.01.028.
  • Kundu, R.R. & Lahiri, B.N. (2008). Study and statistical modelling of green sand mould properties using RSM. International Journal of Materials and Product Technology. 31, 143-158. https://doi.org/10.1504/IJMPT.2008.018016.
  • Sadarang, J., Nayak, R.K. & Panigrahi, I. (2021). Effect of binder and moisture content on compactibility and shear strength of river bed green sand mould. Materials Today: Proceedings. 46(11), 5286-5290, https://doi.org/10.1016/j.matpr.2020.08.640.
  • Khandelwal, H. & Ravi, B. (2016). Effect of molding parameters on chemically bonded sand mold properties. Journal of manufacturing processes. 22, 127-133. https://doi.org/10.1016/j.jmapro.2016.03.007.
  • Atanda, P., Olorunniwo, O., Alonge, K. & Oluwole, O. (2012). Comparison of bentonite and cassava starch on the moulding properties of silica sand. International Journal of materials and chemistry. 2(4), 132-136.
  • Samociuk, B., Nowak, D. & Medyński, D. (2024). Effect of matrix type on properties of moulding sand with barley malt. Archives of Foundry Engineering. 24(2), 11-16. DOI:10.24425/afe.2024.149266.
  • Samociuk, B., Medyński, D., Nowak, D., Kawa-Rygielska, J., Świechowski, K., Gasiński, A. & Janus, A. (2022). The use of barley malt as a binder in molding sand technology. 15(9), 3375, 1-20. https://doi.org/10.3390/ma15093375.
  • Ocheri, C., Agboola, J.B., Mbah, C.N., Onyia, C.W., Ezeanyanwu, J.N., Njoku, R.E. & Urama, N.A. (2021). The study on acacia gum for the production of cores for foundry processes. Transactions of the Indian Institute of Metals. 74, 851-870. DOI:10.1007/s12666-021-02190-0.
  • Kausarian, H., Choanji, T., Karya, D., Gevisioner & Willyati, R. (2017). Distribution of silica sand on the muda island and ketam island in the estuary of kampar river. International Journal of Advances in Science Engineering and Technology. 5(2), 37-40.
  • Guharaja, S., Noorul Haq, A. & Karuppannan, K.M. (2006). Optimization of green sand casting process parameters by using Taguchi’s method. The International Journal of Advanced Manufacturing Technology. 30, 1040-1048, DOI:10.1007/s00170-005-0146-2.
  • Ganesan, T., Vasant, P. & Elamvazuthi, I. (2013). Normal-boundary intersection based parametric multi-objective optimization of green sand mould system. Journal of Manufacturing Systems. 32(1), 197-205. https://doi.org/10.1016/j.jmsy.2012.10.004.
  • Bala, K. C., & Khan, R. H. (2013). Characterization of beach/river sand for foundry application. Leonardo Journal of Sciences. 12(23), 77-83. ISSN: 1583-233.
  • Shuaib-Babata, Y., Kabiru Suleiman, A., Ambali, I. & Bello, M. (2019). Evaluation of the foundry properties of oyun river (ilorin) moulding sand. Adeleke University Journal of Engineering and Technology. 2(1), 12-24.
  • Aweda, J. & Jimoh, Y. (2009). Assessment of properties of natural moulding sands in Ilorin and Ilesha, Nigeria. Journal of Research Information in Civil Engineering. 6(2), 68-77.
  • Ugwuoke, J. (2018). Investigation on the suitability of Adada river sand and Nkpologwu clay deposit as foundry moulding sand and binder. International Journal of Scientific Research and Engineering. 3, 19-27.
  • Beeley, P. (2001). The moulding material: Properties, preparation and testing. Foundry Technology. 178-238.
  • Brown, J. (2000). Foseco ferrous foundryman's handbook. Butterworth-Heinemann: 2000.
  • Kumar, S., Kumar, P. & Shan, H.S. (2006). Parametric optimization of surface roughness castings produced by Evaporative Pattern Casting process. Materials Letters. 60(25-26), 3048-3053, https://doi.org/10.1016/j.matlet.2006.02.069.
  • Loto, C. & Adebayo, H. (1990). Effects of variation in water content, clay fraction and sodium carbonate additions on the synthetic moulding properties of Igbokoda clay and silica sand. Applied clay science. 5(2), 165-181. https://doi.org/10.1016/0169-1317(90)90021-G.
  • Jasim, H.H., Selman, M.H. & Mohammed, S.I. (2022). Quality assessment of river sand from different sources used in construction purposes in duhok governorate at kurdistan – iraq. Eurasian Journal of Science And Engineering. 7(2), 139-148. DOI: 10.23918/eajse.v7i2p139.
  • Zhang, L., Chen, S., Li, Q. & Chang, G. (2020). Formation mechanism and conditions of fine primary silicon being uniformly distributed on single αAl matrix in Al-Si alloys. Materials & Design. 193, 108853, 1-12, https://doi.org/10.1016/j.matdes.2020.108853.
Go to article

Authors and Affiliations

F. Hussain
1
ORCID: ORCID
M. Kamran
1
A. Inam
1
M. Ishtiaq
1
M.H. Hassan
1
ORCID: ORCID
F. Riaz
1
T. Khan
1
M. Ammar
1
M. Salman
1
  1. Institute of Metallurgy and Materials Engineering, University of the Punjab, Lahore, Pakistan.
7 The Influence of Vanadium and Niobium Micro-additions on the Microstructure and Mechanical Properties of ADI
A. Zaczyński , M. Królikowski , A. Nowak , M. Sokolnicki , J. Jaroszek , A. Burbelko
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 46-53 | DOI: 10.24425/afe.2025.155379
Keywords: ADI Austempering Graphitization inoculation Metal matrix inoculation Hybrid inoculation
Download PDF Download RIS Download Bibtex

Abstract

Austempered Ductile Iron (ADI) casting technology is a combination of the smelting process, its post-furnace treatment and the heat treatment of castings. Maintaining the process parameter stability of this innovative high quality cast iron with high Tensile Strength UTS and ductility properties is the aim of a number of studies on the control of graphitization inoculation and inoculation of the metal matrix. The ability to graphitise the liquid alloy decreases with its holding in the furnace, time of pouring into moulds from pouring machines. The tendency to dendritic grains crystallization and the segregation of elements such as Si, Ni and Cu decrease the ductile properties. The austenitizing process can introduce austenite grains growth negatively affecting of the ausferrite morphology. The modifying effect of small amounts of additives on the metal matrix in steel and low alloy cast steel, well known in materials engineering, has been applied to ADI. The addition of cast iron chips, Fe-V and Fe-Nb to the liquid alloy in the first inoculation is an example of a hybrid interaction. The introduction of graphitization nucleus particles and austenite crystallisation nucleus particles resulted in a stabilisation of the ductility of ADI and an increase in mechanical properties. Grains refinement of the primary austenite and precipitation hardening of ausferrite stabilise the mechanical properties of ADI. As a result of graphitization and additive structure inoculation, graphite and ausferrite morphology is improved. The obtained results point the way to further research in the field of hybrid inoculation of Ductile Cast Iron.
Go to article

Bibliography

  • Guzik, E., Sokolnicki, M. & Nowak, A. (2016). Effect of heat treatment parameters on the toughness of unalloyed ausferritic ductile iron. Archives of Foundry Engineering. 16(2), 79-84. DOI: 10.1515/afe-2016-0030.
  • Sokolnicki, M., Nowak, A., Królikowski, M., Ronduda, M., Guzik, E., Kopyciński, D. (2018). Effect of austenitizing temperature on microstructures and mechanical properties of low alloyed ausferritic cast iron. In The 73rd World Foundry Congress "Creative Foundry", 23-27 September 2018 (pp. 1-2). Kraków, Poland.
  • Benam, S. (2015). Effect of alloying elements on austempered ductile iron (ADI) properties and its process: Review. China Foundry. 12(1), 54-70.
  • Li, Y., Wilson, J.A., Crowther, D., Mitchell, P.S., Craven, A.J & Baker, T.N. (2004). The effects of vanadium, niobium, titanium and zirconium on the microstructure and mechanical properties of thin slab cast steels. ISIJ International. 44(6), 1093-1102.
  • Li, Y., Wilson, J.A., Craven, A.J., Mitchell, P.S., Crowther, D.N. & Baker, T.N. (2007) Dispersion strengthening particles in vanadium micro-alloyed steels processed by simulated thin slab casting and direct charging. Part 1- processing parameters, mechanical properties and microstructure. Materials Science and Technology. 23(5), 509-518.  
  • Pluphrach, G. (2016). Effect of vanadium and niobium alloying elements on the microstructure and mechanical properties of a drop forging micro-alloyed HSLA steel. Songklanakarin Journal of Science & Technology. 38(4), 357-363.
  • Wachelko, T., Nowak, A. & Soiński, M.S. (1986). Effect of micro-alloying by vanadium and niobium on microstructure of cast steel with elevated manganese content. Giessereiforschung. 38(4), 137-145. ISSN: 0046-5933.
  • Fraś, E., Górny, M. & Kawalec, M. (2007). Effect of small additions of vanadium and niobium on structure and mechanical properties of ductile iron. Archives of Foundry Engineering. 7(1), 89-92. ISSN (1897-3310).
  • Das, A. K., Dhal, J. P., Panda, R. K., Mishra, S. C. & Sen, S. (2013). Effect of alloying elements and processing parameters on mechanical properties of austempered ductile iron. Journal of Materials and Metallurgical Engineering. 3(1), 8-16. ISSN (2231-3818).
  • Sckudlarek, W., Krmasha, M., Al-Rubaie, K.S., Preti, O., Milana, J.C.G. & da Costa C.E. (2021). Effect of austempering temperature on microstructure and mechanical properties of ductile cast iron modified by niobium. Journal of Materials Research and Technology. 12, 2414-2425. https://doi.org/10.1016/j.jmrt.2021.04.041.
  • Abdullah, B., Alias, S., Jaffar, A. & Amiral, A.R. (2012). Tensile strength properties of niobium alloyed austempered ductile iron on different austempering time. Advanced Materials Research. 457-458, 1155-1158. https://doi.org/10.4028/www.scientific.net/AMR.457-458.1155.
  • García, E.C., Ramirea, A.C., Castellanos, G. R., Alcala, J.F.Ch., Ramirez, J.T. & Hernandez, A.M. (2021). Heat Treatment Evaluation for the Camshafts Production of ADI Low Alloyed with Vanadium. Metals. 11, 1036. https://doi.org/10.3390/met1171036.
  • Gol'dshtein, M. I. (1979). Carbonitride strengthening of low-alloy steels. Metallovedenie i Termicheskaya Obrabotka Metallov. (7), 2–5.
  • Guzik, E. (2001). Cast iron refining processes, selected issues. Monography, Foundry Archives, Polish Academy of Sciences – Katowice Branch.
  • Nofal, A.A., El-din H. & Ibrahim, M.M. (2006). Thermomechanical treatment of austempered ductile iron. International Journal of Cast Metals Research. 20(2), 47-52. https://doi.org/10.1179/136404607X216613.
  • Myszka, D., Olejnik, L. & Kłębczyk, M. (2009). Microstructure transformation during plastic deformation of the austempered ductile iron. Archives of Foundry Engineering. 9(1), 169-174. ISSN (1897-3310).

 

 

Go to article

Authors and Affiliations

A. Zaczyński
1
ORCID: ORCID
M. Królikowski
1
ORCID: ORCID
A. Nowak
1
ORCID: ORCID
M. Sokolnicki
1
ORCID: ORCID
J. Jaroszek
1
A. Burbelko
2
ORCID: ORCID
  1. Odlewnie Polskie S.A., 27-200 Starachowice, inż. Władysława Rogowskiego Street 22, Poland
  2. AGH University of Krakow, Faculty of Foundry Engineering, 23 Reymonta Str., 30-059 Krakow, Poland
8 A Study of the Mechanical Properties of Conventional and Additive Mould Parts for Die Casting of Aluminum Alloys
M. Pinta , L. Socha , J. Sviželová , L. Kucerova , M. Dvořák , J. Häusler
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 54-62 | DOI: 10.24425/afe.2025.155380
Keywords: Mechanical properties Tool steel H13 3D printing HPDC
Download PDF Download RIS Download Bibtex

Abstract

The article focuses on the mechanical properties of mould parts created using 3D printing technology, for use in the production of castings by High-Pressure Die Casting (HPDC). The mould shapes produced by 3D printing technology bring innovative approaches to optimising production processes. H13 tool steel is widely used for its excellent mechanical properties and resistance to thermal stress. The study focuses on the comparison of the mechanical properties of mould parts produced by traditional methods and 3D printing, with emphasis on their strength, hardness and wear resistance under repeated working cycles. The experimental part includes roughness measurements and tests of mechanical properties, which provide important data on the ability of these components to withstand high mechanical loads and temperature fluctuations during the HPDC process. The results of the study show the advantages and limitations of 3D printing compared to traditional manufacturing processes and give insight into the use of additive technologies in industrial manufacturing. Specifically, the study identified clear quantitative differences in mechanical properties: the 3D printed mould parts had comparable ultimate tensile strength and yield strength to conventionally manufactured parts, but significantly lower ductility (below 1% compared to about 20% in traditional parts) due to higher porosity (0.25–0.30% compared to 0.03–0.04%). Additive mould parts exhibited higher hardness (approximately 510 HV) compared to conventional parts (approximately 450 HV). Surface roughness of the 3D printed parts was more variable, highlighting the need for optimising printing parameters. Thus, additive technology offers benefits in stable hardness and comparable strength, albeit at the expense of reduced ductility and increased variability in surface quality. The research also includes an analysis of the effect of repetitive loading on the mechanical properties of the mould parts made of H13, which provides valuable information for improving their durability and reliability in practice. This research contributes to the development of 3D printing technologies in the field of HPDC and offers new opportunities for improving the efficiency and quality of manufacturing processes in industrial applications.
Go to article

Bibliography

  • Véle, F., Ackermann, M., Bittner, V. & Šafka, J. (2021). Influence of selective laser melting technology process parameters on porosity and hardness of AISI H13 tool steel: statistical approach. 14(20), 6052, 1-19. https://doi.org/10.3390/ma14206052.
  • Nguyen, V.L., Kim, E., Lee, S.-R., Yun, J., Choe, J., Yang, D., Lee, H.-S., Lee, C.-W. & Yu, J.-H. (2018). Evaluation of strain-rate sensitivity of selective laser melted H13 tool steel using nanoindentation tests. 8(8), 589, 1-10. https://doi.org/10.3390/met8080589.
  • Wang, S., Ning, J., Zhu, L., Yang, Z., Yan, W., Dun, Y., Xue, P., Xu, P., Bose, S. & Bandyopadhyay, A. (2022). Role of porosity defects in metal 3D printing: Formation mechanisms, impacts on properties and mitigation strategies. Additive Manufacturing. 60(A), 103256, 1-12. https://doi.org/10.1016/j.addma.2022.103256.
  • Garcias, J.F., Martins, R. F., Branco, R., Marciniak, Z., Macek, W., Pereira, C. & Santos, C. (2021). Quasistatic and fatigue behavior of an AISI H13 steel obtained by additive manufacturing and conventional method. Fatigue & Fracture of Engineering Materials & Structures. 44(1), 3384-3398. https://doi.org/10.1111/ffe.13565.
  • Lei, F., Wen, T., Yang, F., Wang, J., Fu, J., Yang, H., Wang, J., Ruan, J. & Ji, S. (2022). Microstructures and mechanical properties of H13 tool steel fabricated by selective laser melting. Materials. 15(7), 2686, 1-15. https://doi.org/10.3390/ma15072686.
  • Kim, Y.W., Park, H. & Park, J.M. (2023). High-speed manufacturing-driven strength-ductility improvement of H13 tool steel fabricated by selective laser melting. Institute of Materials, Minerals and Mining. 66(5), 582-592. https://doi.org/10.1080/00325899.2023.2241245.
  • Ahn, W., Park, J., Lee, J., Choe, J., Jung, I., Yu, J. H., Kim, S. & Sung, H. (2018). Correlation between microstructure and mechanical properties of the additive manufactured H13 tool steel. Korean Journal of Materials Research. 28(11), 663-670. https://doi.org/10.3740/MRSK.2018.28.11.663.
  • Bose, A., Reidy, J.P. & Pötschke, J. (2024). Sinter-based additive manufacturing of hardmetals: Review. International Journal of Refractory Metals and Hard Materials. 119, 106493, 1-29. https://doi.org/10.1016/j.ijrmhm.2023.106493.
  • Giarmas, E., Tsakalos, V., Tzimtzimis, E., Kladovasilakis, N., Kostavelis, I., Tzovaras, D. & Tzetzis, D. (2024). Selective laser melting additive manufactured H13 tool steel for aluminum extrusion die component construction. The International Journal of Advanced Manufacturing Technology. 133, 4385-4400. https://doi.org/10.1007/s00170-024-14007-7.
  • Pirinu, A., Primo, T., Del Prete, A., Panella, F.W. & De Pascalis, F. (2022). Mechanical behaviour of AlSi10Mg lattice structures manufactured by the Selective Laser Melting (SLM). The International Journal of Advanced Manufacturing Technology. 1651-1680. https://doi.org/10.1007/s00170-022-10390-1.
  • Hu, Z., Xu, P., Pang, C., Liu, Q., Li, S. & Li, J. (2022). Microstructure and mechanical properties of a high-ductility Al-Zn-Mg-Cu aluminum alloy fabricated by wire and arc additive manufacturing. Journal of Materials Engineering and Performance. 31, 6459-6472. https://doi.org/10.1007/s11665-022-06715-6.
  • Leon, A. & Aghion, E. (2017). Effect of surface roughness on corrosion fatigue performance of AlSi10Mg alloy produced by Selective Laser Melting (SLM). Materials Characterization. 131, 188-194. https://doi.org/10.1016/j.matchar.2017.06.029.
  • Balachandramurthi, A.R., Moverare, J., Dixit, N. & Pederson, R. (2018). Influence of defects and as-built surface roughness on fatigue properties of additively manufactured Alloy 718. Materials Science and Engineering: A. 735, 463-474. https://doi.org/10.1016/j.msea.2018.08.072.
  • Pechlivani, E.M., Melidis, L., Pemas, S., Katakalos, K., Tzovaras, D. & Konstantinidis, A.A. (2023). On the effect of volumetric energy density on the characteristics of 3D-printed metals and alloys. Metals. 13(10), 1776, 1-18. https://doi.org/10.3390/met13101776.
  • SLM SOLUTIONS. (2023). H13 – Material data sheet. Retrieved March 18, 2025, from https://www.slm-solutions.com/fileadmin/Content/Powder/MDS/MDS_H13_2023-06_EN.pdf
  • Professional Exported Steel Supplier. (2023). H13 tool steel. Retrieved March 25, 2025, from https://cz.coldrolledsteels.com/info/h13-tool-steels-88814121.html
Go to article

Authors and Affiliations

M. Pinta
1
ORCID: ORCID
L. Socha
1
ORCID: ORCID
J. Sviželová
1
ORCID: ORCID
L. Kucerova
2
ORCID: ORCID
M. Dvořák
3
J. Häusler
4
  1. Department of Applied Technologies and Materials Research, Institute of Technology and Business in České Budějovice, Okružní 517/10, 370 01 České Budějovice, Czech Republic
  2. Department of Materials and Engineering Metallurgy, Faculty of Mechanical Engineering, University of West Bohemia, Univerzitní 2732/8, 301 00 Plzeň, Czech Republic
  3. Tool Shop Division, MOTOR JIKOV Fostron a.s., Kněžskodvorská 2277, 370 04 České Budějovice, Czech Republic
  4. MOTOR JIKOV Strojírenská a.s., Zátkova 495, 392 01 Soběslav II, Czech Republic
9 Effect of Ni Addition on the Hardness and Impact Resistance of Manganese Cast Steel for Railway Infrastructure Castings
T. Wróbel , S. Sobula , G. Tęcza , D. Bartocha , J. Jezierski , K. Kostrzewa
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 63-71 | DOI: 10.24425/afe.2025.155381
Keywords: Manganese cast steel Nickel Railway crossovers Hardness Impact resistance
Download PDF Download RIS Download Bibtex

Abstract

This paper presents the results of research concerning manganese cast steel, also called Hadfield cast steel. The aim of the research was to determine the effect of Ni addition on the usable properties, i.e., hardness and impact resistance of manganese cast steel for cast components of railway crossovers. The scope of the research included making test castings with a unit weight of 1.5 kg in molds from molding sand prepared using Alphaset technology on a chromite sand matrix. The technological process of the test castings included heat treatment, i.e., oversaturation in water from a temperature of 1050°C. The effect of Ni addition from approx. 0,1 to approx. 1,5 wt.% on the usable properties of manganese cast steel were assessed through impact resistance tests performed in a railway impact bending test, Brinell hardness measurements, and microstructure analysis using light optical and scanning electron microscopy. Analysis of the obtained experimental results allowed for the optimization of the chemical composition of manganese cast steel for cast elements of railway infrastructure.
Go to article

Bibliography

  • Hadfield R.A. (1888). Hadfield’s manganese steel. Science. 12, 284-286.
  • Petrov Y., Gavriljuk V., Berns H. & Schmalt F. (2006). Surface structure of stainless and Hadfield steel after impact wear. Wear. 260(6), 687-691. https://doi.org/10.1016/j.wear.2005.04.009.
  • Zhang G., Xing J. & Gao Y. (2006). Impact wear resistance of WC/Hadfield steel composite and its interfacial characteristic. Wear. 260(7-8), 728-734. https://doi.org/10.1016/j.wear.2005.04.010.
  • Atabaki M., Jafari S. & Abdollah-Pour H. (2012). Abrasive wear behavior of high chromium cast iron and Hadfield steel - a comparison. Journal of Iron and Steel Research, International. 19(4), 43-50. https://doi.org/10.1016/S1006-706X(12)60086-7.
  • Kalandyk B., Tęcza G., Zapała R. & Sobula S. (2015). Cast high-manganese steel – the effect of microstructure on abrasive wear behaviour in Miller test. Archives of Foundry Engineering. 15(2), 35-38. DOI: 10.1515/afe-2015-0033.
  • Efstathiou C. & Sehitoglu H. (2010). Strain hardening and heterogeneous deformation during twinning in Hadfield steel. Acta Materialia. 58(5), 1479-1488. https://doi.org/10.1016/j.actamat.2009.10.054.
  • Jabłońska M. (2016). Structure and properties of a high-manganese austenitic steel strengthened in the result of mechanical twinning in processes of dynamic deformation. Doctoral dissertation, Silesian University of Technology, Gliwice, Poland. (in Polish).
  • Głownia J. (2002). Alloy steel castings – application. Kraków: Fotobit. (in Polish).
  • Sobczak J. (2013). Foundrymens handbook – Modern foundry engineering. Kraków: STOP. (in Polish).  
  • Aniołek K. & Herian J. (2013). Burdening and wearing railway switches in exploitation conditions and materials applied for their construction. 2-3, 85-89. (in Polish).
  • Havlíček P., Bušová K. (2012). Experience with explosive hardening of railway frogs from Hadfield steel. In Conference Proceedings of 21st International Conference on Metallurgy and Materials METAL, 23 – 25 May 2012 (pp. 705-711). Brno, Czech Republic.
  • Dhar S., Danielsen H., Fæster S., Rasmussen C., Zhang Y. & Jensen D. (2019). Crack formation within a Hadfield manganese steel crossing nose. Wear. 438-439, 203049, 1-9. https://doi.org/10.1016/j.wear.2019.203049.
  • Ma Y., Mashal A. & Markine V. (2018). Modelling and experimental validation of dynamic impact in 1:9 railway crossing panel. Tribology International. 118, 208-226. https://doi.org/10.1016/j.triboint.2017.09.036.
  • Wu T., Ieong H., Hsu W., Chang C. & Lai Y. (2024). Assessment of fatigue crack growth in metro cast manganese steel frogs and inspection strategy. Engineering Failure Analysis. 163(A), 108512, 1-15. https://doi.org/10.1016/j.engfailanal.2024.108512.
  • Zambrano O., Tressia G. & Souza R. (2020). Failure analysis of a crossing rail made of Hadfield steel after severe plastic deformation induced by wheel-rail interaction. Engineering Failure Analysis. 115, 104621, 1-24. https://doi.org/10.1016/j.engfailanal.2020.104621.
  • Machado P., Pereira J., Penagos J., Yonamine T. & Sinatora A. (2017). The effect of in-service work hardening and crystallographic orientation on the micro-scratch wear of Hadfield steel. Wear. 376-377(B), 1064-1073. https://doi.org/10.1016/j.wear.2016.12.057.
  • Harzallah R., Mouftiez A., Felder E., Hariri S. & Maujean J. (2010). Rolling contact fatigue of Hadfield steel X120Mn12. Wear. 269(9-10), 647-654. https://doi.org/10.1016/j.wear.2010.07.001.
  • Wróbel T., Jezierski J., Bartocha D., Feliks E. & Paleń A. (2024). Quality assessment method for chromite sand to reduce the number of cast steel surface defects. Archives of Foundry Engineering. 24(4), 31-38. https://doi.org/10.24425/afe.2024.151307.

 

Go to article

Authors and Affiliations

T. Wróbel
1 2
ORCID: ORCID
S. Sobula
3
ORCID: ORCID
G. Tęcza
3
ORCID: ORCID
D. Bartocha
1 2
ORCID: ORCID
J. Jezierski
1 2
ORCID: ORCID
K. Kostrzewa
2
  1. Silesian University of Technology, Department of Foundry Engineering, Towarowa 7, 44-100 Gliwice, Poland
  2. Huta Małapanew Sp. z o.o., Kolejowa 1, 46-040 Ozimek, Poland
  3. AGH University of Science and Technology, Department of Alloys and Cast Composites Engineering, Reymonta 23, 30-059 Kraków, Poland
10 Formation of the Fe₂Al₅ Intermetallic Phase and Its Effect on Microstructure and Properties in Al–Fe PM Sinters
M. Majchrowska , M. Nowak
Archives of Foundry Engineering | 2025 | vol. 25 | No 4 | 72-80 | DOI: 10.24425/afe.2025.155382
Keywords: Al–Fe system Intermetallic phases Fe₂Al₅ Powder metallurgy
Download PDF Download RIS Download Bibtex

Abstract

This study investigates the formation and influence of the Fe₂Al₅ intermetallic phase in Al–Fe sintered composites produced via solid-state powder metallurgy. Aluminium–iron powder mixtures containing 25, 29, and 34 at.% Fe were compacted under a pressure of 400 MPa and vacuum-sintered at 580 °C. Microstructural characterisation was performed using scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD). Image analysis confirmed the presence of three distinct regions: an aluminium matrix, Fe-rich zones, and a newly formed η-phase (Fe₂Al₅). The formation of the Fe₂Al₅ phase was observed locally at the interfaces between the aluminium matrix and iron particles, as a result of solid-state diffusion during sintering. The growth direction of this phase suggests that aluminium diffused into iron, resulting in the formation of reaction layers characteristic of aluminium-rich compositions. XRD analysis revealed no detectable peaks corresponding to FeAl₃ or FeAl₂ phases, confirming that intermetallic phase evolution proceeded entirely in the solid state. Microhardness measurements showed significantly elevated values in Fe₂Al₅-rich regions, highlighting its strengthening potential. The results confirm that Fe₂Al₅ can be effectively synthesised via solid-state diffusion, without liquid phase formation. This approach enables the controlled development of intermetallic phases in Al–Fe systems and offers promising prospects for low-temperature manufacturing of materials with improved mechanical properties.
Go to article

Bibliography

  • Matysik, P., Jóźwiak, S., & Czujko, T. (2015). Characterization of low-symmetry structures from phase equilibrium of Fe–Al system—Microstructures and mechanical properties. 8(3), 914-931. https://doi.org/10.3390/ma8030914.
  • Šesták, P., Friák, M., Holec, D., Všianská, M. & Šob, M. (2018). Strength and brittleness of interfaces in Fe–Al superalloy nanocomposites under multiaxial lo