ProCEEdIngS - stahl-online.de · database of ProCast, prototypical numerical simulation was created. This simulation was then optimized and validated with real process of filling

Czech Foundrymen Society

and

Institute of Manufacturing TechnologyFaculty of Mechanical Engineering

Brno University of Technology

8th International PhD Foundry Conference

7th– 8th June 2011

ProCEEdIngS

Faculty of Mechanical Engineering

Technicka 2, Brno, Czech republic

� 8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o

ISBN 978-80-214-4295-5

© by BUT Faculty of Mechanical Engineering

8th International Phd Foundry Conference 7th–8th June 2011, Brno, Czech republic

8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o �

dear friends,

you are receiving the Proceedings of papers which were presented at the 8th International Phd Foundry Conference –held on 7th till 8th June 2011 in Brno, Czech republic.The majority of these papers were written by Phd students in different stages of their studies. The main objective of these Proceedings was to enable the Phd students from the World to present the results of their work in front of the international foundry forum.The organizers of the 8th International Phd Foundry Conference believe that the meeting of young foundry experts from the World on the occasion of this important event will become very important part of the whole event. Without young, starting generation of foundry experts, there would be no further development of this important industry.

Brno, 3rd June 2011

Prof. Milan HoracekCo-ordinator of the Phd conference


CONTENT

SESSION I – INVESTMENT CASTING

K. Altug guler (M. Cigdem)The effect of different bonded investment powders on surface quality and dimensional accuracy of investment castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

A. Kisasoz (K. Altug guler, A. Karaaslan)Production of AL2O3-AL composites using vacuum assited block mould investment casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

V. KosourOptimization of wax injection simulation – “Procast” software . . . . . . . . . . . . . . . . . . . . . 9

V. MikulkaOptimization of investment castings by numerical simulation . . . . . . . . . . . . . . . . . . . . . . . 10

L. Tomek (B. Láník, V. Vinter, J. Sedláček)Water leachable cores for aluminium investment casting foundries . . . . . . . . . . . . . . . . . 11

SESSION II – SAND MIXTURES

d. Urgela (r. Pastirčák, d. Medlen)Effect of grain size on the dilatation and mechanical properties of the CT moulding mixture with air set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

A. Kmita (B. Hutera, B. Stypuła, P. nowicki)Modification of water glass with colloidal solutions of metal oxides . . . . . . . . . . . . . . . . . 13

S. Żymankowska-KumonTemperature influence on properties of moulding sands with bentonite . . . . . . . . . . . 14

J. Tamás SvidróStudying binder decomposition characteristics in chemically bonded moulding materials through gas evolution measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

J. Toth Hot distortion of resin bonded sand cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

n. Špirutová (J. Beňo, J. Kříž, J. Komárek, M. Kandrál)Degradation montmorillonitic clay by interaction with organic binders . . . . . . . . . . . . 17


K. BurianováIntegrated measuring system for plasticity and calorimetry analysis of self hardening sand mixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

I. Stachovec (V. Pernica, A. Záděra)Active coats of moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

M. MackůDesign of new methodology for evaluating the plasticity of moulding sand . . . . . . . 20

SESSION III – METALLURGY OF FOUNDRY ALLOYS

H. Mollaoglu Altuner (A. Topuz)Diffusion bonding of SiCp/2124 aluminium composite with 380 casting aluminium alloy using copper interlayer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

d. Medlen (d. Bolibruchová)Effect of antimony on cast properties of AlSi6Cu4 alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

g. Huber (M. B. djurdjevic, B. rüdiger, B. Stauder)Determination of dendrite coherency point of cast automotive AlSiCu alloys using improved single thermocouple technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

M. BřuskaInfluence of repeated using of alloys RR.350 on tensile properties . . . . . . . . . . . . . . . . . . 24

M. Steinacher (M. Petrič, M. Vončina, J. Medved, P. Mrvar)Fluidity of AlSi9Cu3 alloy with additions of AlTi5B1 and AlSr10 master alloys . . . . . . 25

M. Vončina (S. Korec, F. Zupanič, P. Mrvar, J. Medved)Influence of Ce on the microstructure of A380 foundry alloy . . . . . . . . . . . . . . . . . . . . . . . . . 26

M. PetričGrain refining of pure aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

M. ŘíhováResearch influence used technology on mechanical and structural properties of die cast block of motor from Al-alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

n. Hong Hai (n. Huu dung)Processing window of ADI alloyed by copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

V. Kaňa (J. Laštovica)Influence of modification degree and the used modifier on cast iron properties. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30


SESSION IV – MISCELLANEOUS

S. Altuner (E. Keleşoğlu)Dry sliding behaviour of 6061-Al2O3 com-posites manufactured by squeeze casting in case Y2O3 interface coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

g. ozer (A. Kisasoz, K. Altug guler, A. Karaaslan)Aluminium matrix composite fabrications by infiltration of SiC preforms using squeeze casting technique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

M. Hajos (B. Stypuła)Synthesis of ZnO nanoparticles in the process of anodic dissolution of Zn in methanol solutions of salts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

M. Tokár (J. dúl, T. Mende)Study of the inhomogeneous parts of thick-wall high pressure die castings by computer image analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Z. Andršová (B. Skrbek)Non-destructive structuroscopy of ADI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

W. Sebzda (J. Szajnar)Grey cast iron continuous casting process computer simulation . . . . . . . . . . . . . . . . . . . . . 36

T. Szuter (M. Cholewa)Mechanical testing of skeleton casts with various filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

d. Fecko (L. Eperješi, I. vasková)Change of the gating system and its influence on shrinkage occurrence in the castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

A. dulęba (M. Cholewa)AlSi/CrFeC composite cast produced under electromagnetic field . . . . . . . . . . . . . . . . . . . 39

A. Walasek (C. Baron, J. Szajnar)The influence of silicon on the process of surface alloy layer forming. . . . . . . . . . . . . . . . 40

M. Česal, B. Bryksí StunováInfluence of alloying magnesium alloy AM60 by rare earth metals and oxides of rare earth metals on microstructure of alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

d. Scelina (M. Cholewa, A. dulęba)Call adhesive in casting composites epoxy resin/AlSi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


THEEFFECTOFDIFFERENTBONDEDINVESTMENTPOWDERSONSURFACEQUALITYANDDIMENSIONALACCURACYOFINVESTMENTCASTINGS

KeremAltugGuler,MustafaCigdem

Yildiz Technical University Metallurgical and Material Engineering Dept. Davutpasa Campus, Esenler Istanbul Turkey

[email protected]

In the present work, the effect of different types of investment powders on the surface and dimensional characteristics of castings produced by block mold investment casting process were investigated. Commercial and laboratory made investment materials including gypsum bonded, phospahte bonded and high alumina cement bonded powders were used for mold making. The main aim of this study to establish the relationships between casting quality and the investment powder type. For this purpose, wax patterns for sur face roughness specimens and linear dimensional measurement specimens were designed and produced with special geometry. These patterns were molded by different investement powders. Conventional tin bronze were subsequently cast into these moulds by vacuum assisted casting process. After the mould removal, surface roughness of specimens were measured and linear dimensions of wax patterns and cast specimens were compared to determine dimensional difference.

Keywords: Investment casting, surface roughness, dimensional accuracy


PRODUCTIONOFAL�O�-ALCOMPOSITESUSINGVACUUMASSITEDBLOCKMOLDINVESTMENTCASTING

AlptekinKisasoz,KeremAltugGuler,AhmetKaraaslan

Yildiz Technical University Metallugical and Material Engineering Dept. Davutpasa Campus, Esenler Istanbul Turkey

[email protected]

In this study, a novel manufacturing technique to cast metal matrix com-posites is introduced. Production of A413 aluminum alloy matrix composite using vacuum assisted block mold investment casting has been investigated. In order to produce metal matrix composites by investment casting, Al2o3 preforms with 55 µm average grain size were fabricated. Afterwards, A413 molten alloy was infiltrated into preforms which were placed in the block investment casting molds. Porosity fraction of preforms was determined using Archimedes’ test. Fabricated cast specimens were characterized using hardness tests, image analysis and scanning electron microscope observations. The results show that, in the vacuum assisted block mold investment casting method, infiltration of the preforms by molten metal was successfully achieved. Moreover, hardness of the composite specimen increases up to ratio of 60 % by Al2o3 reinforcement.

Keywords: MMC’s; Investment Casting; Al2o3 Preform


OPTIMALIzATIONOFWAxINjECTIONSIMULATION–PROCASTSOFTWARE

VojtěchKosour

Brno University of Technology, Faculty of Mechanical Engineering, Institute of Manufacturing Technology, Brno, Czech Republic

[email protected]

The article deals with the preparation and optimization of numerical simulation of wax injection in programme ProCast. Based on the measured thermophysical data of the wax blend which were put into the material database of ProCast, prototypical numerical simulation was created. This simulation was then optimized and validated with real process of filling of testing mould. Finally, simulation of mass produced wax pattern was made. The result was again compared to the real process of mould filling.

Keywords: investment casting, ProCAST, simulation, wax pattern

10 8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o

OPTIMIzATIONOFINVESTMENTCASTINGSBYNUMERICALSIMULATION

VítMikulka

Brno University of Technology, Brno, Czech Republic

[email protected]

This article deals with possibilities of using numerical simulation to optimize production of highly demanding castings produced by investment casting process. It is possible to analyse current technology or better to analyze the technology in development process by numerical simulation. Based on this simulation the gating and the feeder systems might be changed. There is also a possibility to influence parameters of investment casting mould, especially heat transfer. All these steps can lead to better results.

Keywords: numerical simulation

8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o 11

WATERLEACHABLECORESFORALUMINIUMINVESTMENTCASTINGFOUNDRIES

LadislavTomek*,BorisLáník*,V.Vinter*,j.Sedláček*

*Igor Láník – Techservis Boskovice, Czech Republic, Czech Republic

[email protected]

Presented paper describes ongoing research of water leachable core materials based on alkali salts for application in aluminium investment casting foundries. It summarizes demands on core mixture for production (rheology of the mixture, mouldability, shape and dimension stability, shrinkage, coating treatment, etc.) and it also describes requirements on cores during application in foundry (steam and water proofness, refractoriness, leachability, resistance to interaction with poured alloy, etc.). during research works was proved that suitable type and content of the salt in the mixture has to be chosen with reference to mechanism of core leaching from the casting.

Keywords: cores, investment casting

1� 8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o

EFFECTOFGRAINSIzEONTHEDILATATIONANDMECHANICALPROPERTIESOFTHECTMOULDINGMIxTUREWITHAIRSET

DušanUrgela,RichardPastirčák,DušanMedlen

University of Žilina, Faculty of Mechanical Engineering, Žilina, Slovak Republic

[email protected]

This article dealing with mechanical properties measuring of selected CT moulding mixtures with moulding sand based on „air set“ method, measuring the shear strength, measuring the compressive strength and tensile strength measurements. Moulding mixtures contains of silicon sand as a opening material and novanol 165 as a binding material. These moulding mixtures were hardened by Co2. These mixtures were different by grain size of opening material. After hardened the test rollers these were used for the measurement of the mechanical properties.The article deals with the dilatation measuring of these compounds, where dimensions for measuring of these moulding mixtures under the temperature inf luence are changing. All experiments were carried out in foundry laboratories at department of Engineering Technology, Technical University of Liberec. The results were analyzed and graphically processed.

Keywords: grain dize, moulding mixture

8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o 1�

MODIFICATIONOFWATERGLASSWITHCOLLOIDALSOLUTIONSOFMETALOxIDES

1B.Hutera,2B.Stypuła,3AngelinaKmita,4P.Nowicki

1, 3, 4 – Department of Moulding Materials, Mould Technology and Foundry of Non-Ferrous Metals / Section of Moulding Materials, Faculty of Foundry Engineering AGH, Cracow, Poland 2 – Department of Chemistry and Metals Corrosion, Faculty of Foundry Engineering AGH, Cracow, Poland

[email protected]

There were taken attempts to modify the properties of water glass with suspensions of zinc oxide (Zno) nanoparticles dissolved in various solvents. It has been shown that the wetting properties of quartz (Sio2) can be effected by:• the amount of modifier, • the type of solvent,• nanoparticles size, The best wetting properties of water glass has been achived with modify catione of Zno nanoparticles suspensed in propanol and buthyl acetate ester.

Keywords: nanoparticles, water glass, modification


TEMPERATUREINFLUENCEONPROPERTIESOFMOULDINGSANDSWITHBENTONITE

SylwiaŻymankowska-Kumon

AGH University of Science and Technology, Faculty of Foundry Engineering, Department of Engineering of Foundry Processes, Cracow, Poland

[email protected]

The results of investigations of green sand with calcium bentonite, activated by sodium carbonate (green sand without carbon dust) applied in the) applied in theapplied in the foundry industry – are presented in the paper. Investigations were performed – are presented in the paper. Investigations were performedare presented in the paper. Investigations were performed by the technological method (compactability, permeability, compression strength) and the modern Cu(II)-TET complex method (used for the determination of the montmorillonite content in bentonite samples). Tests. Tests Tests were performed for moulding sand heated at temperatures: 100, 300, 550, 700 oC and a heating time was 1 hour.

Keywords: bentonite, foundry, determination of montmorillonite, green sand.


STUDYINGBINDERDECOMPOSITIONCHARACTERISTICSINCHEMICALLYBONDEDMOULDINGMATERIALSTHROUGHGASEVOLUTIONMEASUREMENT

jozsefTamasSvidro

University of Miskolc, Department of Foundry Engineering, Miskolc, Hungary

[email protected]

Application of chemically bonded sand mixtures is indispensable in most foundry production processes. These moulding materials contain fire resistand basic matrices, and varoius bonding materials and additives, in the proper production ratios. The effect of gas evolution from mould materials have a significant impact on chemical reactions in the metal/mould interface, and also on the surfacial quality of the casting. Though it is very important to know and control the amount and rate of evolved gas. In this recent work, earlier gas measurement methods and their results are discussed, and it concludes the initial results of moulding materail examiniations which were executed by using a self built gas measurement unit.

Keywords: moulding materials, gas evolution, surface quality, metal-mould interface


HOTDISTORTIONOFRESINBONDEDSANDCORES

juditToth

University of Miskolc, Department of Foundry Engineering, Miskolc, Hungary

[email protected]

Core making technologies are very important parts of the whole casting production. Application of thin walled cores is very prevalent today, these cores must match the most basic expectations: dimension accuracy, proper strenght, etc. Many casting defects can be related to core fractures due to buoyancy of molten metal, thermal deformation of cores, and initial decomposition of binder. Though it is very important to identify the grain size distribution of the basic sand, and even the thermal dilatation and hot distortion standards. In this work, grain size distribution and thermal dilatation of various basic sand types was identified. Hot distortion analysis of dif ferent core mixtures were executed along with tensile strenght measurements. different commonly used core mixtures was compared by the results. Keywords: core mixtures, deformation, grain size, thermal dilatation, tensile strenght


DEGRADATIONMONTMORILLONITICCLAYBYINTERACTIONWITHORGANICBINDERS

NikolŠpirutová,Beňojaroslav,janKříž,jakubKomárek,MichalKandrnál

Department of Foundry Engineering, FMMI, VŠB-Technical University of Ostrava, Ostrava, Czech Republic

[email protected]

Today, about two thirds of iron alloys casting (especially for graphitizing alloys of iron) are produced into green sand systems with usually organically bonded cores. Separation of core sands from the green sand mixture is very dif ficult, af ter pouring. The core sand concentration increase due to circulation of green sand mixture in a closed circulation system. Furthermore in some foundries, core sands have been adding to green sand systems as a replacement for new sands. The goal of this contribution is: “How the green sand systems are influenced by core sands?”This ef fect is considered by determination of selected technological properties and degree of green sand system re-bonding. From the studies, which have been published yet, there is not consistent opinion on influence of core sand on green sand system. In order to simulation of the effect of core sands on the technological properties of green sands, there were applied the most common used technologies of cores production, which are based on bonding with phenolic resin: method PUr CoLd – BoX (based on phenolic polyurethane resin) and method HoT – BoX (based on phenolic resin). Concentration of core sand, which was added to green sand system, was up to 50%. Inf luence of core sand dilution on basic properties of green sand systems was determined by evaluation of basic industrial properties: moisture, green compression strength and splitting strength (on equipment of the firm WAdAP the LrU-1 type), tensile strength in water condensation zone +gF+, the SPnF type, stability of the mixture against staling and physical-chemistry properties (pH, conductivity, loss of ignition). ratio of active betonite by Methylene blue test was also determined.

Keywords: organic binders, montmorillonitic clay


INTEGRATEDMEASURINGSYSTEMFORPLASTICITYANDCALORIMETRYANALYSISOFSELFHARDENINGSANDMIxTURES

KláraBurianová

Brno University of Technology, Foundry Department, Brno, Czech Republic

[email protected]

Possibilities of use hydraulically solidifying binders based on aluminous and Portland cements with dif ferent hardening accelerators and organic additives, plasticizers in particular, are advantageous. The binder system is simple, handling is easy, mixtures are well compactable, rapidly hardening, without considerable interactions with liquid metal with low gas development, they are well collapsible and easy reclaimable. From the point of view of ecology they are excellent ones. As a substitution for organic phenol/furan mixtures for manufacture of moulds and cores for heavy castings the cement mixtures are evaluated positively. In spite of it one property necessary for this technology is lacking and namely plasticity in initial period of hardening. This physical property of cement composites has not been solved up to now and it is very important when comparing it with phenol/furan systems.The LrU-d integrated measuring system controlled with the LabVIEW 8.6 program has been compiled in collaboration with the Physical Institute and it consists of a master computer, the LrU-d strength tester, the Mitutoyo detector of sample straining and an isoperibolic calorimeter compiled in collaboration with the Material Chemistry Institute. The system enables automatic reading of compression strength values of standard samples of the mixture under constant load rate and graphical recording of sample deformation in real time. From the measured values the modulus of deformation of the given mixture is calculated which is a characteristic of its plasticity.By digitalization of the LrU-d strength tester with the Mitutoyo detector of deformations and the isoperibolic calorimeter and due to the connection with the master computer a device has been formed that favourably completes the moulding mixture laboratory with new possibilities of evaluating the properties of self-setting mixtures based on furan, cement and sodium silicates.

Keywords: cement mixtures, furan mixtures, mixtures with waterglass, plasticity, calorimetry


ACTIVECOATSOFMOULDS

IvoStachovec,VítězslavPernica,Antonínzáděra

Brno University of Technology/Foundry Department, Brno, Czech Republic

[email protected]

Purpose of this work was to improve properties of zirconium coat, which is used as a protection of moulds for steel castings. The zirconium coat was completed by deoxidating additives. It has to avoid deoxidizing efficiency and decreases of defects occurrence. The smooth surface of castings without defects is the main demand of quality production. There were made some laboratory and practical tests. For practical tests we were cooperated with dSB EUro s.r.o. foundry. We were testing influence of deoxidizing additives on a technological and physicals properties of coats and a defects occurrence. We made some laboratory and practical test of this modify coat.

Keywords: moulds, active coats

�0 8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o

DESIGNOFNEWMETHODOLOGYFOREVALUATINGTHEPLASTICITYOFMOULDINGSAND

MartinMacků

Brno University of Technology, Brno, Czech Republic

[email protected]

The subject of this thesis was propound and experience new way for evaluation of plasticity of molding sand. From research was used on four types of mixtures that are used in the foundry industry. For the evaluation of plasticity was important to provide an indicator of the deformation ability, calculation of deformation and logarithmic transformation for compression. Plasticity methodology was applied in this work only on the pressure effect. Studies of this issue can have a great influence on the production of correct forms due to the ability to withstand tension without breaking form.

Keywords: evaluation of plasticity, molding sandevaluation of plasticity, molding sand

8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o �1

DIFFUSIONBONDINGOFSiCP/�1��ALUMINIUMCOMPOSITEWITH��0CASTINGALUMINIUMALLOYUSINGCOPPERINTERLAYER

HaticeMollaogluAltuner,AhmetTopuz

Yildiz Technical University, Metallurgical and Materials EngineeringMetallurgical and Materials Engineering Department, İstanbul, Turkey

[email protected]

diffusion bonding of 17% SiC particulate reinforced aluminum matrix composite (2114/SiC/17p) with 380 casting aluminum alloy using copper interlayer at 560°C with 60 and 90 minute holding times was studied. The materials were successfully bonded without a significant macroscopic deformation. The microstructures of the bonded joints were examined by light microscopy, scanning electron microscopy (SEM) equipped with an energy dispersive X-ray spectrometer (EdS) and X-ray diffractometer (Xrd). The micro hardness investigations of the joints were also performed. The shear strength of bonded joints was evaluated by means of a specially designed fixture. different diffusion zones were observed at the interface. The shear strength of joints increased with holding time.

Keywords: aluminum alloy, copper interlayer

�� 8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o

EFFECTOFANTIMONYONCASTPROPERTIESOFAlSi�Cu�ALLOY

DušanMedlen,DanaBolibruchová

University of Žilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Žilina, Slovakia

[email protected]

AlSi6Cu4 alloy was selected for study in the present work due to its wide use in many applications. This alloy is used in automotive and aerospace industries for the complicated castings, with various wall thicknesses – engine blocks, heads and pistons or clutch housing. Therefore cast properties such as f luidity, gas content and shrinkage are important for creating these complicated castings. For improving mechanical and cast properties they can be modified and grain refined, casting temperature can be changed etc. Strontium is now widely used in practice for modification of AlSi6Cu4 alloy, which has negative effect on gas content, f luidity. The effect of Sb on AlSi6Cu4 cast properties has not been yet investigated. The aim of present The aim of present article is to investigate the effect of antimony on selected cast properties - gas content, fluidity and shrinkage of foundry alloy AlSi6Cu4.

Keywords: antimony, cast properties

8 t h I n t e r n a t i o n a l P h d F o u n d r y C o n f e r e n c e l 7 t h – 8 t h J u n e 2 011 l B r n o ��

DETERMINATIONOFDENDRITECOHERENCYPOINTOFCASTAUTOMOTIVEALSICUALLOYSUSINGIMPROVEDSINGLETHERMOCOUPLETECHNIQUE

GerhardHuber*,MileB.Djurdjevic*,BährRüdiger**,BernhardStauder*

* Nemak Linz GmbH, Linz, Austria., **University of Magdeburg

[email protected]

The dendrite Coherency Point (dCP) temperature refers to the state of a solidifying alloy at which a coherent dendrite network is established during the formation of grains. Several relatively complex methods for detection of the dCP temperature have been developed. There are four main dCP temperature testing approaches: (i) the rheological technique (ii) thermal analysis of the minimum temperature diffference between two cooling curves, (iii) thermal analysis of the second derivative of one cooling curve and (iv) the thermal diffusivity measurement technique. This paper proposes a new methodology for dCP detection based on the application of Thermal Analysis Technique using single thermocouple. Several casting process parameters (cooling rate and temperature gradient) and alloys compositions (major and minor alloying elements and liquid metal treatment) have impact on the dCP. Applying new established methodology, in this study have been only analyzed the impact of chemistry (major alloying elements Si and Cu) on the dCP of synthetically made AlSi(7-9)Cu(1-4) alloys.

Keywords: dendrite, AlSiCu alloys


INFLUENCEOFREPEATEDUSINGOFALLOYSRR.��0ONTENSILEPROPERTIES

MarekBřuska

VŠB – TECHNICAL UNIVERSITY OF OSTRAVA, FMMI, Ostrava , Czech Republic

[email protected]

Influence of repeated using of alloys on base Al – Cu is the goal of this study. Alloy rr350 was used for this study. Specimens for tension examination were casted to the metal forms, which were protected by preservative coating. Pouring temperature and temperature of iron mold were controlled in order to keep constant conditions of experiments for all testing samples. From poured samples the testing rods were prepared to determination of tensile strength under laboratory (20 °C) and under higher temperature (with maximum about 350 °C). Specimens were also taken for determination of hardness (HBS) and metallographic analysis from poured samples. Metaloographic analysis was evaluated by using microscope gX 51, which equips polarization light with magnification from 12.5 to 1000. Thermo-mechanical properties were carried out at the author´s working place – department of Foundry Engineering, Faculty of Metallurgy and Material Engineriing, Technical University of ostrava.description of this measurement methodology and metallographic analysis of microstructures are also part of this contribution. At the experimental part of this study hardness of experimental samples, which were prepared at different melts with further determination of chemical composition by spectral method analysis, are evaluated. The results of this study definite confirmed negative influence of repeated using studied alloy on thermo-mechanical and structure properties. At the conclusion of this study there are also described possibilities of further treatment and machining of studied material (inoculation and further precipitation hardening).

Keywords: tensile properties


FLUIDITYOFAlSi�Cu�ALLOYWITHADDITIONSOFAlTi�B1ANDAlSr10MASTERALLOYS

MatejSteinacher1,MitjaPetrič1,MajaVončina1,josefMedved1,PrimožMrvar1

1University of Ljubljana, Faculty of Natural Sciences and Engineering,Department for Materials and Metallurgy, Aškerčeva 12, 1000 Ljubljana, Slovenia

[email protected]

This paper describes the influence of pouring temperatures, grain refines and modifiers on the fluidity of AlSi9Cu3 alloys. The aluminium alloy was tested in different states, as basic alloy and with additions of AlTi5B1 and AlSr10 master alloys. Samples were casted at different pouring temperatures which were 640 °C, 670 °C, 700 °C and 710 °C. The solidification behavior of alloys was investigated using “in situ” thermal analyses and measuring cooling curves. The fluidity was measured with Sipp spiral probe. With increasing pouring temperature and modification the fluidity increases.

Key words: fluidity, pouring temperature, grain refining, modify and AlSi9Cu3 alloys


INFLUENCEOFCeONTHEMICROSTRUCTUREOFA��0FOUNDRYALLOY

MajaVončina1,S.Kores1,F.zupanič�,PrimožMrvar1,josefMedved1

1 University of Ljubljana, Faculty of Natural Science and Engineering, Department for Materials and Metallurgy, Ljubljana, Slovenia2 University of Ljubljana, Faculty of Mechanical Engineering, Chair for Materials and Forming, Maribor, Slovenia

[email protected]

The effect of Ce addition on the microstructure of A380 alloy was investigated using equilibrium thermodynamic calculation, thermal analysis, differential scanning calorymetry (dSC), light microscopy and scanning electron microscopy (SEM). The purpose was to study the variations that occur in the microstructure, as well as its effect on the mechanical properties. The results show that the Ce addition decreases the precipitation enthalpy, while precipitation takes place more rapidly and intensively, indicating increased reaction kinetics. Ce also changed the morphology of eutectic Al2Cu phase and caused small formation of primary crystals of αAl. Furthermore Ce phase was detected indicating quaternary phase AlCeCuSi (Al9Ce2Cu5Si3). The mechanical properties such as tensile strength increase with higher Ce additions.

Keywords: A380 alloy, Ce addition, microstructure, reaction kinetics, mechanical properties


GRAINREFININGOFPUREALUMINIUM

MitjaPetrič,PrimožMrvar,AntonSmolej,jožefMedved

Faculty of Natural Sciences and Engineering, University of Ljubljana, Ljubljana, Slovenia

[email protected]

This paper describes influences of grain refinement on microstructure development of pure aluminium at different cooling rates. 99,9 % pure aluminium was used and grain refined with different additions of AlTi5B1 and AlB3 master alloys. Simple thermal analysis was used in two different measuring cells. one was made by Croning process to achieve lower cooling rates and cone probe made of grey iron for higher cooling rates. Microstructures were analyzed by optic microscopy in polarized light and grain sizes were determined.

Keywords: aluminium, grain refining


RESEARCHINFLUENCEUSEDTECHNOLOGYONMECHANICALANDSTRUCTURALPROPERTIESOFDIECASTBLOCKOFMOTORFROMAL-ALLOY

MarkétaŘíhová

Brno University of Technology, Institute of Manufacturing Technology, Department of Foundry Engineering, Brno, Czech Republic

[email protected]

In this article we present partly results of research into porosity of Al-alloys. Tested castings were blocks of motor from AlSi9Cu3. Used casting technologies for this research were die casting and local squeeze casting. Compared mechanical properties were – Tensile strength rm and Yield strength rp0,2

and the structural characteristics were selected porosity P and sphericity factor s. The resulting values were statistically evaluated and transformed into graphs.

Keywords: Al alloys, die casting, local squeeze casting, block of motor, mechanical properties, porosity, sphericity factor.


PROCESSINGWINDOWOFADIALLOYEDBYCOPPER

NguyenHongHai1,NguyenHuuDung2

1Department of Foundry Technology, FMMI, VSB-TUO, Ostrava-Poruba2 Department of Foundry Technology, Hanoi University of Technology, Hanoi, Viet Nam.

[email protected]

Austempered ductile iron (AdI) is an excellent material as it possesses attractive properties: high strength, ductility, toughness which are combined with good wear resistance and machinablity. These properties can be achieved upon adequate heat treatment which creates the optimum microstructure for a given chemical composition. As an alloying element, copper widens the austenite zone of the phase diagram, increasing both the transformation rate during an austenitising process and the carbon content in the matrix. on the other hand, during the subsequent austempering process, copper may restrain carbide formation. This paper presents some investigation results of austempering AdI alloying with 0,35 % Cu for a range of time and temperature. The as-cast microstructure was a (over 80 %) pearlitic matrix with 90 % modularity of graphite nodules. The results also show that the strength, elongation and hardness of AdI depend on the amount of bainite ferrite and retained austenite amount. Based on these results, the optimal processing window for austempering was established to be 380 °C, 2 h. In this AdI the microstructure consists of bainitic ferrite and retained austenite. This AdI gets good combination of mechanical properties: strength of 960 MPa, elongation of 7 %.

Keywords: AdI, copper


INFLUENCEOFMODIFICATIONDEGREEANDTHEUSEDMODIFIERONCASTIRONPROPERTIES

VáclavKaňa,jaroslavLaštovica

Brno University of Technology, Institute of Manufacturing Technology, Department of Foundry Engineering, Brno, Czech Republic

[email protected]

The work is aimed at the field of researching the properties of cast irons with pearlitic structure under different modification degree, and namely within the range from unmodified cast iron up to that one with spheroidal graphite. In dependence on the modification degree and the used modification preparation the cast iron mechanical properties were evaluated and compared, the structure was observed, and chemical composition was analyzed. niMg6 and FeSiMg6 master alloys were used as modification additives. There was a requirement to produce cast iron from pure raw materials and therefore pig iron forms a main component.

Key words: cast iron, graphite morphology, modification, graphitization


DRYSLIDINGBEHAVIOUROF�0�1-Al�O�COMPOSITESMANUFACTUREDBYSQUEEzECASTINGINCASEOFY�O�INTERFACECOATING

SerdarAltunera,ErgünKeleşoğlua

a) Yildiz Technical University , Metallurgical and Materials Department, Istanbul Turkey

[email protected]

Alumina particle reinforced aluminum matrix composites are promising candidates for automotive applications with respect to their high specific modulus, specific strength and wear resistance. However wettability of alumina particulates by liquid aluminum in most liquid phase manufacturing process is relatively poor. In order to modify the interfacial properties between particulate and matrix, Y2o3 coating on Al2o3 powder has been recently introduced. In the present work, wear behavior of 6061- Al2o3 composite modified by Y2o3 interface coating was studied. Composite samples reinforced with 5, 10, 15 and 20 % volume fraction of coated Al2o3 powder were produced by stirring process and squeeze casting with a pouring temperature of 750-800 C and a pressure of 100 MPa. optical microscopy, scanning electron microscopy, X-ray diffraction and energy dispersive spectrum analysis were conducted for microstructural characterization.A dry wear test of the samples was performed using a ball-on-disc tribometer. Friction coefficient, and wear rate of the samples were determined against a steel counterpart.As a result of increasing particle-matrix bonding strength, the samples reveal better wear resistance against steel counterpart.

Keywords: squeeze casting


ALUMINUMMATRIxCOMPOSITEFABRICATIONSBYINFLITRATIONOFSiCPREFORMSUSINGSQUEEzECASTINGTECHNIQUE

GokhanOzer,AlptekinKisasoz,KeremAltugGuler,AhmetKaraaslan

Yildiz Technical University Metallugical and Material Engineering Dept. Davutpasa Campus, Esenler Istanbul Turkey

[email protected]

In this study, fabrication of Al matrix SiC reinforced composite production with squeeze casting is proposed. Squeeze casting has advantages to enhance wetting ability between the matrix and reinforcement materials. Infiltration of porous preforms with molten metal offers different aspects for metal matrix composites. Moreover, squeeze casting has a great potential in industrial applications. In experimentals, SiC preforms were fabricated with various porosity contents and characterized using Archimedes’ test, image analysis and scanning electron microscope. The most convenient preform for squeeze casting was used to produce Al matrix SiC reinforced composite. A413 aluminum alloy was used as matrix material. fabricated specimens were characterized using image analysis, hardness tests and scanning electron microscope.

Keywords: squeeze casting, SiC Preform, MMC


SYNTHESISOFznONANOPARTICLESINTHEPROCESSOFANODICDISSOLUTIONOFznINMETHANOLSOLUTIONSOFSALTS

MichałHajos1,BarbaraStypuła�

1, 2 AGH – UST Cracow, Faculty of Foundry Engineering, Department of Chemistry and Corrosion of Metals, Poland

[email protected]

In this paper the studies of anodic dissolution of zinc were carried out. We investigated the influence of water content on the process of anodic dissolution of zinc and the formation of anodic dissolution product. Analysis with use of spectroscopic methods such as FTIr-ATr, UV-Vis and SEM confirmed the possibility of application of the process of anodic dissolution of zinc in methanol solutions with different water content for synthesis of nanoparticles of zinc oxide and zinc salts.

Keywords: Zno nanoparticles


STUDYOFTHEINHOMOGENEOUSPARTSOFTHICK-WALLHIGHPRESSUREDIECASTINGSBYCOMPUTERIMAGEANALYSIS

1aMonikaTokár,1jenőDúl,�TamásMende

1 University of Miskolc, Metallurgical and Foundry Engineering InstituteUniversity of Miskolc, Metallurgical and Foundry Engineering Institute2 University of Miskolc, Material Science InstituteMiskolc-Egyetemváros, Hungary

[email protected]

nowadays, one of the most up to date and dinamically developing measuring/evaluation possibility is the computer image analysis. We determined the pore distribution on microscope photos by using imageby using image using image analysing to study the failures of the thick-wall high pressure die castings. In case of not suitable casting geometry and technical parameters the thick-wall parts includes an inhomogeneous inside zone and a fail-safe outside skin. In the interest of availability we can refine just the outside skin, because just this layer has good mechanical properties. In our work we produced and analysed different thickness experimental casting and analysed a real industrial casting. After sample polishing we made a series of microscopy pictures from the one side to the other side in the function of the wall thickness. We measured the pore size in every picture and measured the pore distribution in the function of the wall thickness by using a computer image analysing method. We compared the inside and the other side parts.

Keywords: pressure die castings


NON-DESTRUCTIVESTRUCTUROSCOPYOFADI

zuzanaAndršová1*,BřetislavSkrbek1

1 Technical University of Liberec, Liberec, Czech Republic

[email protected]

AdI (Austempered ductile Iron) is an isothermal-hardened iron with a nodular graphite. As default material are used the nodular iron casts with ferritic-pearlitic matrix. Isothermal hardening (or austempering) is realized using salt bath with 240–400 °C. The matrix of AdI is simmilar to bainite and it consists of ferrite lamellae and carbon-oversaturated austenite (ausferrite). By a properly selected plastic deformation (gear wheel engagement, steel-grit blasting...) is induced an austenite to martensite phase transformation in the surface. This material is outstanding for its andvantageous combination of strenght, ductility, resistance to dynamic stress and abrasion resistance and is determined to be used as material for demanding engineering and automotive components. graphite causes noise reduction (absorbs surges) and excellent sliding properties compared with steel. It´s ecologically friendly, modern material, mass used for automotive components in the USA and the great Britain instead of cemented steel. Heat-treated cast steel and a wrought steel were effectively replaced by AdI. Controlled phase transformation initiated by the plastic deformation allows even applications in the sphere of cementation steel.The production of AdI in Czech republic is insufficient. An optimal rate of mechanical properties depends on exact adherence to parametres of default structure, chemical composition, austenitization and austempering. different content and morfology of martensite, ausferrite and ferrite are connected with unusual behaviour of physical properties. Until now nobody has taken the plunge to use these properties for diagnostics of AdI heat treatment.non-destructive structuroscopy research will be also necessary. Controlling methods for AdI products as tools of permanent quality will support the production of AdI, even the AgI (with laminated graphite) in the Czech republic.The purpose of Phd. thesis with the name of non-destructive structuroscopy of AdI is to acquire some knowledge about the promising AdI technology


and use it for engineering applications with propitious economical and ecological impacts, including designing and producing the samples, isothermal heat treatment and mapping of basic material and physical properties. All along with parametres used by non-destructive testing metods, such as ultrasound, spot magnetic pole and X-ray diffraction – this will be the key for simple and cheap 100% check of products during their difficult manufacturing.

Keywords: Austempered ductile iron, isothermal heat treatment, phase transformation, non-destructive structuroscopy.

GREYCASTIRONCONTINUOUSCASTINGPROCESSCOMPUTERSIMULATION

janSzajnara,WojciechSebzda*a

a Foundry Department, Silesian University of Technology, Gliwice, Poland

e-mail: [email protected]

Cast ingot pulling speed does significantly affect the nature of the resulting structure and the quality of the outer surface. By introducing a variable algorithm for extraction of the ingot we may to some extent control the shape and location of solid / liquid interface and temperature field in the cross-section of the ingot. The shape of the solid / liquid interface, as well as its position relative to mold plays an important role in the process of continuous casting of iron, and affects the structure of the casting. In order to verify the impact of the pulling algorithms on the shape of the and the location of solid / liquid interface, a number of simulations in AnSYS FLUEnT 12 were made. This article shows the results of this research.

Keywords: grey cast iron, computer simulation


MECHANICALTESTINGOFSKELETONCASTSWITHVARIOUSFILLING

MiroslawCholewaa,TomaszSzuter*a

a Foundry Department, Silesian University of Technology, Gliwice, Polska

[email protected]

In article authors present selection of the geometry of engineering casted skeleton structure using the analysis of the stress state of structural variants. The main criterion for selection was using the simplest geometry and casting techniques for the manufacturing of the skeleton castings. After defining the best geometry samples of skeleton casting was made. Castings were subjected to quasi-static compressive load to determine maximum compressive strength. one cast was filled with dry ceramic core. other casting core was saturated with high viscosity fluid to eliminate air content, and increase mechanical properties.

Keywords: casted skeleton structure, filling


CHANGEOFTHEGATINGSYSTEMANDITSINFLUENCEONSHRINKAGEOCCURENCEINTHECASTINGS

DanielFecko,ĽubomírEperješi,IvetaVasková

[email protected]

gating system belongs to one of the basic parts of the foundry mould. It is located on the model pattern with the models of castings and feeders. The basic role of the gating system in foundry production is to ensure that the molten metal will fill the mould cavity completely, without any problems. The basic parts of the gating system are the basis, downrunner, runners and ingates. The molten metal is poured through the basis into the mould cavity, continues through the downrunner and runners to the ingate, and through the ingates into the mould cavity, where it will produce the castings. The main purpose of the gating system is to direct the rate and direction of metal flow to ensure complete filling of the mould before freezing. The flow of molten metal should be smooth and uniform, with minimum turbulence. According to this, entrapment of air, metal oxidation and mould erosion are thus avoided. The technique should promote the ideal temperature distribution within the completely filled mould cavity, so that the pattern of subsequent cooling is favourable to feeding. The gating system can incorporate traps and filters for the separation of non-metallic inclusions, whether dislodged in the gating system or introduced with the metal.When talking about ingates, we can use the simple ingates to ensure that the molten metal will enter the casting cavity in a calm way, without any splashes or turbulence. on the other hand, the Connor inlets can be also used as an ingate. Connor inlets overlap the casting in the thickness of approximately 3 milimeters and also ensure the feeding of the molten metal into the casting. It can be said that Connor inlets have two functions: they act as an ingate and also act as a feeder for the casting.The presented work describes the possibilities of changing the gating system in accordance to the shrinkage occurrence in the castings. In the first version, the basic type of gating system is used and in the other version is used the gating system with the Connor inlets. From this review it should be clear how the gating system influences the probability of shrinkage occurrence in the castings. For the evaluation of the results was used the foundry simulation


software novaFlow&Solid, where simulations of filling of solidification were executed for both versions. The simulated casting is produced on the automatic forming line dISAMATIC.

Keywords: gating system, shrinkage

AlSi/CrFeCCOMPOSITECASTPRODUCEDUNDERELECTROMAGNETICFIELD

AnnaDulęba,MirosławCholewa

Department of Foundry, Faculty of Mechanical Engineering, Silesian University of Technology, Gliwice, Poland

[email protected]

In this paper technology of AlSi/CrxCy composite with used CrFeC ex situ particles included of CrxCy carbide phase in CrFe matrix was shown. Possibility application of electromagnetic field on the solidify composite to distribution of reinforcement phase was shown. Purpose of investigation was the analysis of current frequency influence supplying of the inductor of electromagnetic field on segregation, quantity and morphology of reinforcement phase in aluminum matrix composite. Technological conception of investigations was based on assumption that chromic-iron matrix of participles dissolved in aluminium composite matrix, and carbide phases became actual reinforcement of composite with variable portion of Al-CrFe intermetallic phases appeared on the border contact of components. on the basis of microstructure observation quantity analysis of segregation, morphology and surface portion reinforcement phase in composite matrix was achieved.

Keywords: composite, segregation, electromagnetic field


THEINFLUENCEOFSILICONONTHEPROCESSOFSURFACEALLOYLAYERFORMING

AgnieszkaWalasek,CzesławBaron,janSzajnar

Department of Foundry, Faculty of Mechanical Engineering, Silesian University of Technology , Gliwice, Poland

[email protected]

In this work the results of researches connected with the influence of the silikon on the fundamental parameters of surface alloy layer forming process were presented. The solidus and liquidus temperatures were also determined for high – karbon ferrochromium with the use of ling drop method.

Keywords: alloy layer, ferrochromium, cast steel


INFLUENCEOFALLOYINGMAGNESIUMALLOYAM�0BYRAREEARTHMETALSANDOxIDESOFRAREEARTHMETALSONMICROSTRUCTUREOFALLOY

MarekČesal,BarboraBryksíStunová

CTU in Prague, Faculty of Mechanical Engineering, Department of Manufacturing Technology, Prague, Czech Republic

[email protected]

This paper deals on the topic of alloying magnesium alloy AM60 by rare earth metals and rare earth metal oxides. Main goal is to show influence of these alloying elements on the microstructure of resulting alloy and thus prove possibility of using rare earth metals as an alloying element in magnesium alloys. It is focused on using dysprosium as alloying element.

Keywords: AM60 microstructure, magnesium, dysprosium, rare earth metals, rare earth metals oxides


CALLADHESIVEINCASTINGCOMPOSITESEPOxYRESIN/AlSi

DawidScelina,MirosławCholewa,AnnaDulęba

Department of Foundry, Faculty of Mechanical Engineering, Silesian University of Technology , Gliwice, Poland

[email protected]

The paper presents the results of preparation of sample composite castings AlSi11 / epoxy Epidian 53 / Z-1 resin. The aim of the research was to determine the effect of surface treatment by electrolysis on the adhesion of the components contact interface. The technological concept of the research has been based on the assumption that by electrolysis preferred surface morphology will be achieved and the creation of oxide layer as a transient phase which provides a sufficiently high adhesion between materials. on the base of strength tests of composite samples correctness of the connection of components depending on the surface preparation was determined.

Keywords: composite, epoxy resin, electrolisys


ABSTRACTSAREINORIGINALVERSION

Author: Composite authorsEdited by: Iveta MusilovaPublished by the: Brno University of Technology,Faculty of Mechanical Engineering,department of Foundry Engineering8th International Phd Foundry ConferenceBrno May 2011 The book had a first printing of 100Printed by: rEProCEnTrUM Blansko

ISBN 978-80-214-4295-5

Documents

ProCEEdIngS - stahl-online.de · database of ProCast, prototypical numerical simulation was created. This simulation was then optimized and validated with real process of filling