The identification of pouring conditions of cast iron to sand moulds

Abstract The structure and properties of the castings in cast iron put on spheroidization depend especially on the pouring conditions. Decisive factor of local castings properties can be the flow ability of liquid metal in sand mould, which depends not only on chemical constitutions but also on temperature and velocity of pouring. The parameter, which take into consideration various factors is a substitute rheological parameter θ proposed in early author's paper

Effect of Antimony and Cerium on the Formation of Chunky Graphite during Solidification of Heavy-Section Castings of Near-Eutectic Spheroidal Graphite Irons

Thermal analysis is applied to the study of the formation of chunky graphite (CHG) in heavysection castings of spheroidal graphite cast irons. To that aim, near-eutectic melts prepared in one single cast house were poured into molds containing up to four large cubic blocks 30 cm in size. Four melts have been prepared and cast that had a cerium content varying in relation with the spheroidizing alloy used. Postinoculation or addition of antimony was achieved by fixing appropriate amounts of materials in the gating system of each block. Cooling curves recorded in the center of the blocks show that solidification proceeds in three steps: a short primary deposition of graphite followed by an initial and then a bulk eutectic reaction. Formation of CHG could be unambiguously associated with increased recalescence during the bulk eutectic reaction. While antimony strongly decreases the amount of CHG, it appears that the ratio of the contents in antimony and cerium should be higher than 0.8 in order to avoid this graphite degeneracy

Vanadyl sulfates:molecular structure, magnetism and electrochemical activity

Reaction of differing amounts of vanadyl sulfate with p-tert-butylthiacalix[4]areneH4 and base allows access to the vanadyl-sulfate species [NEt4]4[(VO)4(3-OH)4(SO4)4]∙1/2H2O (1), [HNEt3]5[(VO)5(3-O)4(SO4)4]∙4MeCN (2∙4MeCN) and [NEt4]2[(VO)6(O)2(SO4)4(OMe)(OH2)]∙MeCN (3∙MeCN). Similar use of p-tert-butylsulfonylcalix[4]areneH4, p-tert-butylcalix[8]areneH8 or p-tert-butylhexahomotrioxacalix[3]areneH3 led to the isolation of [HNEt3]2[H2NEt2]2[VO(OMe)]2p-tert-butylcalix[8-SO2]areneH2] (4), [HNEt3]2[V(O)2p-tert-butylcalix[8]areneH5] (5) and [HNEt3]2[VIV2VV4O11(OMe)8] (6), respectively. Dc magnetic susceptibility measurements were performed on powdered microcrystalline samples of 1-3 in the T = 300 - 2 K temperature range. Preliminary screening for electrochemical water oxidation revealed some activity for 2 with turnover frequency (TOF) and number (TON) of 2.2 × 10-4 s-1 and 6.44 × 10-6 (mmol O2 / mmol cat.), respectively. The compound 3 showed an improved electrochemical activity in the presence of water. This is related to the increased number and the rate of electrons exchanged during oxidation of V4+ species, facilitated by protons generated in the water discharge process

Discussion on the Methodology and Apparatus for Hot Distortion Studies

The paper refers to earlier publications of the author, on identification of properties of thermomechanical, chemically hardened core/mold sands. In that earlier period, first version of the original DMA apparatus, produced by a Polish company Multiserw-Morek, was used. The Hot Distortion (HD) study results, published by the author in 2008, referred to phenomena accompanying a thermal shock in real conditions of thermal interaction of a liquid alloy on a mold, in reference to a shock possible to obtain in laboratory conditions, without use of liquid alloy as a heat source, with analysis of solutions applied in the DMA apparatus. This paper presents author’s observations on testing a new, innovative version of the LRu-DMA apparatus, containing a module allowing the Hot Distortion (HD) study. Temperature of specimens achieved in the case of the gas burner heating reaches values definitely above 800°C on the heated side and 610°C on the other side. Using an electric radiator, with maximal temperature of 900°C allows obtaining temperatures in between 225-300°C

Discussion on Usability of the Niyama Criterion for Porosity Predicting in Cast Iron Castings

The paper refers to previous publications of the author, focused on criteria of casting feeding, including the thermal criterion proposed by Niyama. On the basis of this criterion, present in the post-processing of practically all the simulation codes, danger of casting compactness (in the sense of soundness) in form of a microporosity, caused by the shrinkage phenomena, is predicted. The vast majority of publications in this field concerns shrinkage and feeding phenomena in the cast steel castings – these are the alloys, in which parallel expansion phenomenon does not occur as in the cast irons (graphite crystallization). The paper, basing on the simulation-experimental studies, presents problems of usability of a classic, definition-based approach to the Niyama criterion for the cast iron castings, especially of greater massiveness, for prediction of presence of zones of dispersed porosity, with relation to predictions of the shrinkage type defects. The graphite expansion and its influence on shrinkage compensation during solidification of eutectic is also discussed

Specificity of SPC procedures application in foundry in aspect of data acquisition and data exploration

The paper presents an analysis of SPC (Statistical Process Control) procedures usability in foundry engineering. The authors pay particular attention to the processes complexity and necessity of correct preparation of data acquisition procedures. Integration of SPC systems with existing IT solutions in area of aiding and assistance during the manufacturing process is important. For each particular foundry, methodology of selective SPC application needs to prepare for supervision and control of stability of manufacturing conditions, regarding specificity of data in particular 'branches' of foundry production (Sands, Pouring, Metallurgy, Quality)

Contribution to the Identification of Porosity Type in AlSiCu High-Pressure-Die-Castings by Experimental and Virtual Way

The paper concerns the problem of discontinuity in high pressure die castings (HPDC). The compactness of their structure is not perfect, as it is sometimes believed. The discontinuities present in these castings are the porosity as follow: shrinkage and gas (hydrogen and gas-air occlusions) origin. The mixed gas and shrinkage nature of porosity makes it difficult to identify and indicate the dominant source. The selected parameters of metallurgical quality of AlSi9Cu3 alloy before and after refining and the gravity castings samples (as DI - density index method), were tested and evaluated. This alloy was served to cast the test casting by HPDC method. The penetrating testing (PT) and metallographic study of both kinds of castings were realized. The application of the NF&S simulation system allowed virtually to indicate the porosity zones at risk of a particular type in gravity and high-pressure-die-castings. The comparing of these results with the experiment allowed to conclude about NF&S models validation. The validity of hypotheses concerning the mechanisms of formation and development of porosity in HPDC casting were also analyzed

Experimental and Simulation Tests on the Impact of the Conditions of Casting Solidification from AlSi9Cu3 Alloy on their Structure and Mechanical Properties

The impact of casting conditions on microstructure a and mechanical properties was described, especially for cast products from AlSi9Cu3 alloy. Particular attention was paid to the parameters of dendritic structure: DAS 1 and DAS 2. Selected mechanical properties (by static tension test) of test castings made using basic technologies of casting: GSC - gravity sand casting, GDC - gravity die-casting and HPDC - high-pressure die-casting, are presented for cast-on test bars and cast separately. Casts were made of the same alloy AlSi9Cu3. Fractures and the zone near the fracture (after static tension test) was subjected to VT - visual tests, PT - penetration tests and metallographic tests. The condition of porosity (fracture zone) was also assessed. The analysis of virtual results was performed using the NovaFlow & Solid system together with the database and they were compared to experimental tests. This way of validation was applied in order to assess the correlation between the local rate of cooling and the size of DAS for GSC, GDC and HPDC technologies. Finally, the correlation between the parameters of structure and mechanical properties with regard to the impact of porosity was signalized