The results presented in this paper are a continuation of the previously published studies. The results of hest treatment of ductile iron with content 3,66%Si and 3,80% Si were produced. The experimental castings were subjected to austempering process for time 30, 60 and 90 minutes at temperature 300o C. The mechanical properties of heat treated specimens were studied using tensile testing and hardness measurement, while microstructures were evaluated with conventional metallographic observations. It was again stated that austempering of high silicone ferritic matrix ductile iron allowed producing ADI-type cast iron with mechanical properties comparable with standard ADI.
Austenitization is the first step of heat treatment preceding the isothermal quenching of ductile iron in austempered ductile iron (ADI) manufacturing. Usually, the starting material for the ADI production is ductile iron with more convenient pearlitic matrix. In this paper we present the results of research concerning the austenitizing of ductile iron with ferritic matrix, where all carbon dissolved in austenite must come from graphite nodules. The scope of research includedcarrying out the process of austenitization at 900o Cusing a variable times ranging from 5 to 240minutes,and then observations of the microstructure of the samples after different austenitizing times. These were supplemented with micro-hardness testing. The research showed that the process of saturating austenite with carbon is limited by the rate of dissolution of carbon from nodular graphite precipitates.
Ductile iron casts with a higher silicone content were produced. The austempering process of high silicone ductile iron involving different austempering times was studied and the results presented. The results of metallographical observations and tensile strength tests were offered. The obtained results point to the fact that the silicone content which is considered as acceptable in the literature may in fact be exceeded. The issue is viewed as requiring further research.
Simulation software dedicated for design of casting processes is usually tested and calibrated by comparisons of shrinkage defects distribution predicted by the modelling with that observed in real castings produced in a given foundry. However, a large amount of expertise obtained from different foundries, including especially made experiments, is available from literature, in the form of recommendations for design of the rigging systems. This kind of information can be also used for assessment of the simulation predictions. In the present work two parameters used in the design of feeding systems are considered: feeding ranges in horizontal and vertical plates as well as efficiency (yield) of feeders of various shapes. The simulation tests were conducted using especially designed steel and aluminium castings with risers and a commercial FDM based software. It was found that the simulations cannot predict appearance of shrinkage porosity in horizontal and vertical plates of even cross-sections which would mean, that the feeding ranges are practically unlimited. The yield of all types of feeders obtained from the simulations appeared to be much higher than that reported in the literature. It can be concluded that the feeding flow modelling included in the tested software does not reflect phenomena responsible for the feeding processes in real castings properly. Further tests, with different types of software and more fundamental studies on the feeding process modelling would be desirable.
The paper undertakes an important topic of evaluation of effectiveness of SCADA (Supervisory Control and Data Acquisition) systems, used for monitoring and control of selected processing parameters of classic green sands used in foundry. Main focus was put on process studies of properties of so-called 1st generation molding sands in the respect of their preparation process. Possible methods of control of this processing are presented, with consideration of application of fresh raw materials, return sand (regenerate) and water. The studies conducted in one of European foundries were aimed at pointing out how much application of new, automated plant of sand processing incorporating the SCADA systems allows stabilizing results of measurement of selected sand parameters after its mixing. The studies concerned two comparative periods of time, before an implementation of the automated devices for green sands processing (ASMS - Automatic Sand Measurement System and MCM – Main Control Module) and after the implementation. Results of measurement of selected sand properties after implementation of the ASMS were also evaluated and compared with testing studies conducted periodically in laboratory.