The paper presents results of a study concerning an AlSi7Mg alloy and the effect of subjecting the liquid metal to four different processes: conventional refining with hexachloroethane; the same refining followed by modification with titanium, boron, and sodium; refining by purging with argon carried out in parallel with modification with titanium and boron salts and strontium; and parallel refining with argon and modification with titanium, boron, and sodium salts. The effect of these four processes on compactness of the material, parameters of microstructure, and fatigue strength of AlSi7Mg alloy after heat treatment. It has been found that the highest compactness (the lowest porosity ratio value) and the most favorable values of the examined parameters of microstructure were demonstrated by the alloy obtained with the use of the process including parallel purging with argon and modification with salts of titanium, boron, and sodium. It has been found that in the fatigue cracking process observed in all the four variants of the liquid metal treatment, the crucial role in initiation of fatigue cracks was played by porosity. Application of the process consisting in refining by purging with argon parallel to modification with Ti, B, and Na salts allowed to refine the microstructure and reduce significantly porosity of the alloy extending thus the time of initiation and propagation of fatigue cracks. The ultimate effect consisted in a distinct increase of the fatigue limit value.
The objective of the study reported in this paper was to determine the effect of structure on thermal power of cast-iron heat exchangers which in this case were furnace chambers constituting the main component of household fireplace-based heating systems and known commonly as fireplace inserts. For the purpose of relevant tests, plate-shaped castings were prepared of gray iron with flake graphite in pearlitic matrix (the material used to date typically for fireplace inserts) as well as similar castings of gray cast iron with vermicular graphite in pearlitic, ferritic-pearlitic, and ferritic matrix. For all the cast iron variants of different structures (graphite precipitate shapes and matrix type), calorimetric measurements were carried out consisting in determining the heat power which is quantity representing the rate of heat transfer to the ambient environment. It has been found that the value of the observed heat power was affected by both the shape of graphite precipitates and the type of alloy matrix. Higher thermal power values characterize plate castings of gray iron with vermicular graphite compared to plates cast of the flake graphite gray iron. In case of plates made of gray cast iron with vermicular graphite, the highest values of thermal power were observed for castings made of iron with ferritic matrix.
The paper summarises results of measurements of remelting area geometry, thermal efficiency and melting efficiency characterising the surface remelting process applied to castings of MAR-M-509 cobalt alloy. The remelting process was carried out with the use of GTAW (Gas Tungsten Arc Welding) method in protective atmosphere of helium, at the electric current intensity in the range from 100 A to 300 A, and the electric arc scanning velocity vs in the range from 200 mm/min to 800 mm/min. The effect of current intensity and electric arc scanning velocity on geometrical parameters of remeltings, thermal efficiency, and melting efficiency characterising the remelting process has been determined.
Elaborated shapes of many car components are the reason for which the use of casting techniques to fabricate them is a solution wellfounded from the economical point of view. Currently applicable regulatory requirements concerning emissions of exhaust fumes force the carmakers to reduce the overall weight of their products, as this is a basic precondition for reducing fuel consumption. As a result, newly launched car models contain a continuously increasing share of thin-walled castings made of materials which ensure a satisfactory level of service properties. At the same time, developing new technological processes allowing to extend the service life of individual components by means of surface improving becomes more and more important.
The paper presents an analysis of factors affecting the wear of cylinder liners. The effect of the graphite precipitation morphology on the cylinder liner wear mechanism is presented. Materials used to cast cylinder liners mounted in a number of engines have been examined for their conformity with requirements set out in applicable Polish industrial standard. A casting for a prototype cylinder liner has been made with a microstructure guaranteeing good service properties of the part.
The paper proposes a methodology useful in verification of results of dilatometric tests aimed at determination of temperatures defining the start and the end of eutectoid transformation in the course of ductile cast iron cooling, based on quenching techniques and metallographic examination. For an industrial melt of ductile cast iron, the effect of the rate of cooling after austenitization at temperature 900°C carried out for 30 minutes on temperatures TAr1 start and TAr1 end was determined. The heating rates applied in the study were the same as the cooling rates and equaled 30, 60, 90, 150, and 300°C/h. It has been found that with increasing cooling rate, values of temperatures TAr1 start and TAr1 end decrease by several dozen degrees.
This study presents results of stress rupture test of MAR-M-509 cobalt alloy samples, as-cast and after surface refining with a concentrated stream of heat. Tests were conducted on samples of MAR-M-509 alloy castings, obtained using the lost-wax method. Casting structure refining was performed with the GTAW method in argon atmosphere, using the current I = 200 A and electrical arc scanning velocity vs = 100, 150, 200 and 250 mm/min. The effect of rapid resolidification of the MAR-M-509 alloy on the microstructure was examined and significant improvement in stress rupture test was observed.
The paper deals with possibility to improve operating performance of cast-iron heat exchangers by providing them with a copper alloy (CuTi2Cr) with the use of the flame spraying method. A test exchanger was cast of a gray cast iron with vermicular graphite in ferriticpearlitic matrix obtained in production conditions at KAW-MET Iron Foundry with the wire method used to vermicularize the material. The test samples were two plates cast in sand molds, of which one was given a flame-sprayed CuTi2Cr coat on one side. The operating performance of such model cast-iron heat exchangers, with and without CuTi2Cr coating, was tested on a set-up for determining the heat flow rate (thermal power) transferred by the heat exchanger to environment. The obtained results indicate that the value of the heat flow rate characterizing the CuTi2Cr-coated cast-iron heat exchanger was by 10% higher compared to the flow rate of heat conveyed to environment by the heat exchanger without coating.
The paper presents results of a study on the effect of the flux density of heat carried away for the remelting area to substrate in the course of surface remelting with concentrated heat stream on values of structural parameters λ1D and λ2D of α(Al) phase dendrites in C355 alloy. The remeltings were made with the use of GTAW method, at arc current intensity I = 200 A and concentrated heat stream scanning speed vs = 200, 400, 600, and 800 mm/min. The used protective gas was argon supplied at rate of 20 l/min. It has been found that the increase of the rate of scanning with concentrated heat stream results in a change of the remelting-substrate separation surface shape consisting in reduction of the remelting width and depth. This increases the value of the flux density of heat transmitted from the remelting area to substrate which in turn acts in favor of reduction of structural parameters λ1D and λ2D characterizing α(Al) phase dendrites in C355 alloy.
The paper deals with susceptibility of nodular cast iron with ferritic -pearlitic matrix on cavitation erosion . Cavitation tests were carried out with the use of a cavitation erosion vibratory apparatus employing a vibration exciter operated at frequency of 20 kHz. The study allowed to determine the sequence of subsequent stages in which microstr ucture of cast iron in superficial regions is subject to degradation. The first features to be damaged are graphite precipitates. The ferritic matrix of the alloy turned out to be definitely less resistant to cavitation erosion compared to the pearlitic matrix component.
The paper discusses the possibility of improving resistance of heat exchangers made of gray cast iron with flake graphite to hightemperature corrosion by providing them with metallic coatings. A metallic coating containing 76.9% Ni, 19.8% Cr, 1.7% Si, 0.9% Fe, and 0.9% Mn was applied by means of the plasma spraying method and subjected to cyclically variable thermal loads in the atmosphere of solid fuels combustion products (oxygen, sulfur, chlorine, and sodium). In a 30-day thermal load test held at temperature 500°C it has been found that thickness of the metallic coating decreased from the initial (240 ± 6) μm to (231 ± 6) μm. The depth to which sulfur, chlorine, and sodium penetrated the coating was about 30 μm. Increased oxygen content occurred along the whole coating depth. In the coating area adjacent to the substrate surface, the content was twice as high compared to this observed in the initial coating material. Although presence of oxygen was found within the whole depth of the coating, i.e. (231 ± 6) μm, no signs of susceptibility of the sprayed metallic layer to separation from substrate of gray cast iron with flake graphite were found.
A common problem encountered in hydraulic valves is a progressing deterioration of tightness of their water flow cutting-off seats. The seats are provided usually with a copper-alloy insert joined mechanically with cast-iron valve housing. The problem of unreliability of such joints can be solved by providing surface of the seat with a coating, deposited with the use of HVOF method and resistant to abrasive and cavitation wear. The tests were carried out for a sealing-draining seat insert made of CuZn39Pb2Al brass used to date and a specimen taken from the cast-iron valve housing which was the substrate for a plasma-sprayed coating of powder containing 86.1% Cr, 7.2% Ni, and 6.7% C. The coating, 345 ± 15 μm thick, was characterized with good quality of bonding with cast-iron substrate and high compactness of the material. The cavitation wear test on materials used in the study were carried out with the use of Vibra-Cell ultrasonic liquid processor (Sonics) equipped with a piezoelectric probe operating at the frequency of 20 kHz. Based on profilograms taken along a line crossing centers of cavitation craters, measurements of the height parameter Rt, and microscopic observations of surfaces it has been found that the coating plasma-sprayed onto substrate of nodular cast iron demonstrated higher resistance to cavitation compared to copper-alloy inserts used so far in cast-iron hydraulic valves. Cavitation craters on the material used typically for valve seats to date were more distinctly outlined and deeper compared to craters observed on the coating. Larger were also sizes of local tear-outs which resulted in larger difference between the peaks line and the valleys line.
The present paper is a presentation of results of a study on morphology, chemical composition, material properties (HVIT, HIT, EIT), and nanoindentation elastic and plastic work for carbide precipitates in chromium cast iron containing 24% Cr. It has been found that the carbides differ in chemical composition, as well as in morphology and values characterizing their material properties. The carbides containing the most chromium which had the shape of thick and long needles were characterized with highest values of the analyzed material properties.
The paper deals with the issue of potential for improvement of resistance of wood chip fine grinders to abrasive wear by providing them with WCCoCr coating applied with the use of atmospheric plasma spraying (APS). The study focused on establishing parameters of the technological process of spraying a 250–270 μm thick coating onto surface of ductile cast iron castings used to date as grinder linings. The presented data include results of microstructure examination, chemical composition analysis, HV hardness measurements, and scratch tests for both previous and new variant of linings. The obtained scratch test results indicate that the material of the coating is characterized with definitely lower susceptibility to scratching. The scratch made on coating was 75–84 μm wide and 7.2–8.2 μm deep, while the scratch on cast iron was distinctly wider (200–220 μm) and deeper (8.5–12.8 μm). In case of cast iron, the range of variability in scratch width and depth was definitely larger. This can be explained with large difference in hardness of individual components of microstructure of cast iron and significantly larger plastic deformation of cast iron compared to the coating revealed in the course of indenter motion over surfaces of the two materials. It has been found that application of WCCoCr coating offered better resistance of lining surfaces to scratching which can be considered a rationale for undertaking in-service tests.
The paper presents results of metallographic examination of faults occurring in the course of founding thin-walled cast-iron castings in furan resin sand molds. A non-conformance of the scab type was Observed on surface of the casting as well as sand buckles and cold shots. Studied the chemical composition by means of a scanning electron microscope in a region of casting defects: microanalysis point and microanalysis surface. Around the observed defects discloses high concentration of oxides of iron, manganese and silicon. A computer simulation of the casting process has been carried out with the objective to establish the cause of occurrence of cold shots on casting surface. The simulation was carried out with the use of NovaFlow & Solid program. We analyzed the flowing metal in the mold cavity. The main reason for the occurrence of casting defects on the surface of the casting was gating system, which caused turbulent flow of metal with a distinctive splash stream of liquid alloy.
The paper is a presentation of a study on issues concerning degradation of protective paint coat having an adverse impact on aesthetic qualities of thin-walled cast-iron castings fabricated in furan resin sand. Microscopic examination and microanalyses of chemistry indicated that under the coat of paint covering the surface of a thin-walled casting, layers of oxides could be found presence of which can be most probably attributed to careless cleaning of the casting surface before the paint application process, as well as corrosion pits evidencing existence of damp residues under the paint layers contributing to creation of corrosion micro-cells
The paper deals with the effect of microstructure diversified by means of variable cooling rate on service properties of AlSi7Mg cast alloy refined traditionally with Dursalit EG 281, grain refining with titanium-boron and modified with sodium and a variant of the same alloy barbotage-refined with argon and simultaneously grain refining with titanium-boron and modified with strontium. For both alloy variants, the castings were subject to T6 thermal treatment (solution heat treatment and artificial aging). It turned out that AlSi7Mg alloy after simultaneous barbotage refining with argon and grain refining with titanium-boron and modified with strontium was characterised with lower values of representative microstructure parameters (SDAS – secondary dendrite arm spacing, λE, lmax) and lower value of the porosity ratio compared to the alloy refined traditionally with Dursalit EG 281 and grain refining with titanium-boron and modified with sodium. The higher values of mechanical properties and fatigue strength parameters were obtained for the alloy simultaneously barbotagerefined with argon and grain refining with titanium-boron and modified with strontium.
The cooling rate is one of the main tools available to the process engineer by means of which it is possible to influence the crystallisation process. Imposing a desired microstructure on a casting as early as in the casting solidification phase widens significantly the scope of technological options at disposal in the process of aluminium-silicon alloy parts design and application. By changing the cooling rate it is possible to influence the course of the crystallisation process and thus also the material properties of individual microstructure components. In the study reported in this paper it has been found that the increase of cooling rate within the range of solidification temperatures of a complex aluminium-silicon alloy resulted in a decrease of values of the instrumented indentation hardness (HIT) and the instrumented indentation elastic modulus (EIT) characterising the intermetallic phase occurring in the form of polygons, rich in aluminium, iron, silicon, manganese, and chromium, containing also copper, nickel, and vanadium. Increased cooling rate resulted in supersaturation of the matrix with alloying elements.
The paper presents results of assessment of the unit pressure force within the refractory material volume in the course press-moulding of stampings for refractory precast shapes. The force was evaluated with the use of physical simulation of deformation undergone by lead balls placed in the raw refractory mass subjected to pressing in a metal die. To determine the value of unit pressure force applied to the aggregate grains in the course of stamping press-moulding, physical model of deformation of a sphere induced by the uniaxial stress state was used.
The paper presents results of an analysis of material density distribution in stampings press-moulded in metal dies from raw refractory materials based on alumina-magnesia-carbon aggregate. The stampings, fabricated on LAEIS HPF 1250 pressing machine, are blanks from which refractory precast shapes are manufactured by means of drying and firing. Samples for material density evaluation were cut out from test stampings with the use of diamond-reinforced disc. Density of the material was determined in thirteen layers of stampings denoted with letters A through M.
NC11 steel, in view of the specificity of its manufacturing process, is characterised with band-like orientation of carbides. Depending on the direction of cutting the material for the inserts out of commercially available steel products, carbide bands can be oriented in parallel or perpendicularly to the direction in which aggregate grains move in the process of pressing stampings. It has been found that in case of scratches made in direction perpendicular to carbide bands, depth of the scratches is less than this observed when scratches are made in direction coinciding with prevailing orientation of carbide precipitates.