text:
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.
CHIEF EDITORS
J. Szajnar
J. Jezierski
SUBJECT EDITORS
Theoretical Aspects of Casting Processes
K. Eigenfeld – Freiberg, Germany
E. Guzik – Kraków, Poland
T. G. Mathia - Lyon, France
W. Wołczyński – Kraków, Poland
Innovative Foundry Technologies and Materials
T. Elbel – Ostrava, Czech Republic
Z. Ignaszak – Poznań, Poland
O. P. Pandey – Punjab, India
A. Pereira - Vigo, Spain
Foundry Processes Computer Aiding
B. Mochnacki – Częstochowa, Poland
J. Roučka – Brno, Czech Republic
J.S. Suchy – Kraków, Poland
Mechanization, Automation and Robotics in Foundry
J. Bast – Freiberg, Germany
R. Wrona – Kraków, Poland
Transport Systems in Foundry
J. Dańko – Kraków, Poland
Z. Li – Shijiazhuang, China
Castings Quality Management
D. Bolibruchova– Żilina, Slovak Republic
J. D. B. de Mello - Santa Monica, Brazil
M. Perzyk – Warszawa, Poland
Environment Protection
M. Holtzer – Kraków, Poland
H. Polzin – Freiberg, Germany
J. Sobczak – Kraków, Poland
I. Volchok – Zaporizhzhya, Ukraine
J. Braszczyński – Częstochowa, Poland
B. K. Dhindaw – Rupnagar, India
L. A. Dobrzański – Gliwice, Poland
W. A. Hufenbach – Dresden, Germany
P. Jelínek – Ostrava, Czech Republic
L. Jeziorski – Częstochowa, Poland
J. Lacaze – Toulouse, France
V. L. Naydek – Kiev, Ukraine
A. Passerone – Genova, Italy
I. Riposan – Bucharest, Romania
F. Romankiewicz – Zielona Góra, Poland
A. Sládek – Żilina, Slovak Republic
INTERNATIONAL SCIENTIFIC REVIEW COMMITTEE
S. A. Argyropoulos – Toronto, Canada
M. Azadi – Tehran, Iran
Y. Babaskin – Kiev, Ukraine
K. Bako – Miskolc, Hungary
E. Bayraktar – Paris, France
L. Bechný – Zilina, Slovak Republic
V. Bednarova - Ostrava, Czech Republic
F. Bińczyk – Katowice, Poland
A. Bokota – Częstochowa, Poland
G.P. Borisov – Kiev, Ukraine
A. Bydałek – Kraków, Poland
C. H. Cáceres – Brisbane, Australia
J. Čech – Brno, Czech Republic
L. Q. Chen – Shenyang, China
A. Chojecki – Kraków, Poland
M. Cholewa – Gliwice, Poland
I. A. Dibrov – Moscow, Russia
D. Dispinar – Istanbul, Turkey
S. M. Dobosz – Kraków, Poland
V. I. Dubodelov – Kiev, Ukraine
A. Fedoryszyn – Krakow, Poland
J. Głownia – Kraków, Poland
K. Granat – Wrocław, Poland
J. Hampl – Ostrava, Czech Republic
J. Helber – Düsseldorf, Germany
M. Hetmańczyk – Katowice, Poland
M. Horáček – Brno, Czech Republic
M. Kaczorowski – Warszawa, Poland
W. Kapturkiewicz – Kraków, Poland
R. Kawalla – Freiberg, Germany
Z. Konopka – Czestochowa, Poland
D. Kopyciński – Kraków, Poland
W. K. Krajewski – Kraków, Poland
Z. Libo – Beijing, China
P. Lichy – Ostrava, Czech Republic
Y. P. Lim – Setapak, Malaysia
T. Lipiński – Olsztyn, Poland
E. Majchrzak – Gliwice, Poland
A. Mityayev - Zaporizhzhya, Ukraine
M. Murgaš – Trnava, Slovak Republic
I. Nová – Liberec, Czech Republic
W. Orłowicz – Rzeszów, Poland
T. Pacyniak – Łódź, Poland
B. Piekarski – Szczecin, Poland
A. Rimmer – West Bromwich, United Kingdom
S. Samavedam – Hyderabad, India
P. Schumacher – Leoben, Austria
N. Sczygiol – Częstochowa, Poland
P. Skočovský – Żilina, Slovak Republic
M.S. Soiński – Częstochowa, Poland
J. Sokolowski – Ottawa, Kanada
K. V. Sudhakar – Butte, USA
B. G. Thomas - Champaign, USA
M. Trbižan – Ljubljana, Slovenia
J. Vuorinen – Tampere, Finland
E. Ziółkowski – Kraków, Poland
J. Zych – Kraków, Poland
D. Bartocha – Gliwice, Poland
ul. Towarowa 7,
e-mail: kikm@polsl.pl
vo. 21
Archives of Foundry Engineering | 2021 | vo. 21 | No 2 |
1 Automatic Measurement System of Hydrated Sodium Silicate Composition Analysis
Huafang Wang , Quanrun Wang , Wu Zhang , Xiang Gao , Jijun Lu
Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 5-8 | DOI: 10.24425/afe.2021.136091
Keywords: Hydrated sodium silicate Composition analysis Potentiometer titration
Sodium silicate is one of the most successful inorganic binder. Along with the broad application of sodium silicate for domestic and industrial purposes, the composition analysis, include modulus (m), ratio of SiO2:Na2O, Na2O%, SiO2%, and solid-containing content, is important for the products strength and service life. However, it is perplexing to operate, inefficient and low precision for traditional standard testing method of these parameters. In this study, an automatic measurement system of sodium silicate composition analysis, with the potential electrode for potentiometer titration, micro-controller, PCB, heater, stirrer, printer and micro peristaltic pump, was developed according to the determine method principle. The end-points of pH value in the two titrating steps, first was 4.3 and second was 6.0, were set in the micro-controller to control the reaction in the processing of the sodium silicate composition analysis. And all the potential signals of the pH electrode were transited in the special PCB for the micro-controller.
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Huafang Wang
Quanrun Wang
Wu Zhang
Xiang Gao
Jijun Lu
School of Mechanical Engineering and Automation, Wuhan Textile University, Wuhan 430073, China
2 Use of Selective Laser Melting (SLM) as a Replacement for Pressure Die Casting Technology for the Production of Automotive Casting
J. Piekło , A. Garbacz-Klempka
Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 9-16 | DOI: 10.24425/afe.2021.136092
Keywords: Additive manufacturing (AM) Selective Laser Melting (SLM) Automotive casting AlSi10Mg Mechanical properties Microstructure
Selective laser melting is one of the additive manufacturing technologies that is used to produce complex-shaped components for applications in the automotive industry. The purpose of the changes in the design, technology, and material tests was to make a steering gear housing using the SLM method. The steering gear housing was produced by the pressure casting method using an AlSi9Cu3(Fe) alloy. The construction of this housing is adapted to the specifics of left-hand traffic. The change in technology was related to the change of the position of the steering system from right-hand to left-hand and the demand for a limited number of gear housings. It was necessary to make a virtual model of the housing on the basis of the part that was removed from the vehicle. In SLM technology, the AlSi10Mg aluminum alloy was used as a raw material in the form of CL 32Al gas-atomized powder. After the SLM process was completed, the housings were subjected to heat treatment. The AlSi10Mg alloy fabricated by the SLM method after heat treatment is characterized by good plasticity and an average value of tensile strength. The last stage was to check the geometry of the SLM housing with a 3D scanner. As a result, a map of the dimensional deviations from the nominal values was obtained. This data was used to modify the CAD model before the next fabrication process.
The use of 3D printing technology allowed for the quick production of elements. The time to develop the technology and the production of the first two gear housings based on a 3D model was seven days.
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J. Piekło
A. Garbacz-Klempka
AGH University of Science and Technology, Faculty of Foundry Engineering, Reymonta 23 Str., 30-059 Kraków, Poland
3 Spatial Thermo-Mechanical Model of Mushy Steel Deformation Based on the Finite Element Method
M. Hojny , T. Dębiński , M. Głowacki , Trang Thi Thu Nguyen
Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 17-28 | DOI: 10.24425/afe.2021.136093
Keywords: Mechanical properties Soft-reduction Semi-solid Numerical modelling Physical simulation
The paper reports the results of work leading to the construction of a spatial thermo-mechanical model based on the finite element method allowing the computer simulation of physical phenomena accompanying the steel sample testing at temperatures that are characteristic for the soft-reduction process. The proposed numerical model is based upon a rigid-plastic solution for the prediction of stress and strain fields, and the Fourier-Kirchhoff equation for the prediction of temperature fields. The mushy zone that forms within the sample volume is characterized by a variable density during solidification with simultaneous deformation. In this case, the incompressibilitycondition applied in the classic rigid-plastic solution becomes inadequate. Therefore, in the presented solution, a modified operator equation in the optimized power functional was applied, which takes into account local density changes at the mechanical model level (the incompressibility condition was replaced with the condition of mass conservation). The study was supplemented withexamples of numerical and experimental simulation results, indicating that the proposed model conditions, assumptions, and numerical models are correct.
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M. Hojny
T. Dębiński
M. Głowacki
Trang Thi Thu Nguyen
AGH University of Science and Technology, Cracow, Poland
4 Analysis of Fracture Mechanism of Cast Steel for Different States of Stress
J. Lachowski , J. Borowiecka-Jamrozek
Keywords: Metallography Mechanical properties Cast steel Damage evolution Computer modelling
In this paper a plastic deformation and a damage evolution in low-carbon cast steel containing non-metallic inclusions are analysed experimentally and numerically. Two microstructures of the cast steel have been obtained after appropriate heat treatment. Tensile tests of smooth specimens and axisymmetric notched specimens have been performed. The notched specimens have the notch radii: 1 mm, 3 mm and 7 mm. Fractography of the specimens was carried out to observe fracture mechanisms. The mechanism depended on the stress state in the notched specimens. The fractography showed the existence of two fracture mechanisms: ductile failure and by shear.
The process of the voids growth formed on the non-metallic inclusions was the process which included in the explanation of the damage mechanism. Modelling of deformation of the specimens has been used with the model suggested by Gurson, Tvergaard and Needleman. The model is implemented in the Abaqus finite element program. The computer simulation was performed using ABAQUS system. The computed output was compared with the experimental results obtained for specimens of the same shape.
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J. Lachowski
J. Borowiecka-Jamrozek
Kielce University of Technology, Al. Tysiąclecia PP. 7, 25-314 Kielce, Poland
5 Arc welding renovation of permanent steel molds
J. Šutka , R. Koňar , J. Moravec , L. Petričko
Keywords: Casting mold Renovation Welding Hardfacing Tribological test
The paper deals with the possibility of the renovation of permanent steel molds for casting using electric arc welding technology. When casting liquid metal into permanent steel molds, there is chemical-thermo-mechanical wear of the surface of the mold cavity and the inlet system, which causes a deterioration of the surface quality and dimensional accuracy of the casting. For this reason, it is necessary to renovate the steel mold after a certain casting interval - mold life. In this case, the technology of manual electric arc welding with a coated electrode was used for the renovation. The welding renovation aims to increase the service life of the mold using carbide hardfacing welds, which after welding achieve high mechanical properties of the renovated mold parts. Two types of hardfacing coated electrodes were used for welding, namely the OK Weartrode 55HD electrode and the OK Weartrode 50T electrode. Macroscopic analysis, tribological tests as well as the measurement of the hardness of the welded layers were performed to evaluate the quality and the friction coefficients of the additional materials used. The properties of hardfacing welds were compared with the properties of the basic material of the high-alloy steel mold. The main advantage is in addition to increasing the durability and longevity of the mold, also reducing the cost of mold renovation compared to other renovation technologies.
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J. Šutka
R. Koňar
J. Moravec
L. Petričko
Department of Technological Engineering, University of Zilina, Univerzitna 1, 010 26 Zilina, Slovakia
6 Crystallization of the Structural Components of Multiple Remelted AlSi9Cu3 Alloy
M. Matejka , D. Bolibruchová , M. Kuriš
Keywords: Al-Si-Cu Remelting Returnable material Structural components scanning electron microscope
At present, Al-Si-Cu based alloys (with a typical representative AlSi9Cu3 alloy) represent more than half of the castings used in various industries (automotive, aerospace and electrical engineering). These are most often sub-eutectic (exceptionally eutectic) alloys with a content of 6 to 13 wt. % Si and 1 to 5 wt. % Cu. The aim of the paper is to point out the importance of the evaluation of input raw materials that determines the overall properties of the casting and the costs invested in its production. A negative impact on performance can be expected when using an alloy made up of a high proportion of recycled material, despite its economic benefits. Experimental alloys were evaluated based on the results of crystallization process and a combination of scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX), and deep etching. The effect of remelting and increasing the remelted returnable material in the batch was manifested especially in the crystallization of iron-rich phases. The negative effect of remelting on the structural components was manifested after the fourth remelting. Gradual increase of remelted returnable material in the batch causes harmful changes in the crystallization process.
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M. Matejka
D. Bolibruchová
M. Kuriš
University of Zilina, Faculty of Mechanical Engineering, Department of Technological Engineering, Univerzitna 1, 010 26 Zilina, Slovak Republic
7 Synthesis of Natural Phenolic Compound Contained Alkaline Phenolic Foundry Resin and Its Performance Evaluation on Casting
A.E. Güvendik , K. Ay
Keywords: Phenolic resins Lignin Sustainability Foundry No-Bake
In foundry, metal casting can be done with various methods. One of the most important methods preferred around the world is sand casting. Ester curable alkaline phenolic resins have produced to make sand molds by No-bake systems. They must have specific properties to make sand casting efficient and reliable. Production of these resins depends on some fossil raw-materials like phenol. To investigate more sustainable and green resin synthesis method, lots experiment have been done by substitution of phenol with renewable alternative phenolic materials like resorcinol, lignosulphonates and tannic acid and its derivatives. Different properties of resins were produced with competitive performance with the market product, ÇKE Alfanol A 72 No-Bake Resin. Without loss of performance, calcium lignosulfonate was used in polymer synthesis at the rate of 15% instead of phenol. On the other hand, the reaction in which lignin and resorcinol were combined instead of phenol by reducing it by 25% gave better results in terms of mechanical and thermal properties. Thermal properties were investigated for resorcinol and lignin modified resins by using TGA-DSC and mechanical performance of cured sand core sample were tested by Simpson Sand Strength Testing Machine as compression strength as N/cm2.. After laboratory testing casting performance of new resins are compared with two different companies' resins in steal casting demo. Experimental results were matched with casting trail and no defect was detected.
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A.E. Güvendik
K. Ay
Çukurova Kimya Endüstrisi A.Ş., Turkey
Manisa Celal Bayar University, Turkey
8 Determination of Phase Transformation Temperatures by Dilatometric Test of S960MC Steel
M. Málek , M. Mičian , J. Moravec
Keywords: Metallography Microstructure Dilatometry S960MC Transformation temperatures
The phenomenon of "soft zone" is occurring in the heat affected zone (HAZ) of high strength low alloy (HSLA) steels. Therefore, the process of weld metal solidification and phase transformation in HAZ is essential to understand the behaviour of the material, especially in the case where welded joints are debilitating part of the construction. The simulation program SYSWELD is powerful tool to predict solidification and phase transformation of welding joint, what correspond to the mechanical properties of the joints. To achieve relevant results of the simulation, it is necessary to use right mathematic-material model of the investigated material. Dilatometric test is the important methods to gather necessary input values for material database. In this paper is investigated physical and metallurgical properties of S960MC steel. The dilatometric curves were carried out on the laboratory machine dilatometer DIL 805L. In addition to determination of the phase transformation temperatures at eight levels of the cooling rate, the microstructure and hardness of the material are further analysed. The hardness of the samples reflects the achieved microstructure. Depending on the cooling rate, several austenitic transformation products were observed such as pearlite, bainite, martensite and many different ferritic microstructures. The differences between the transformation temperature results using the first derivation method and the three tangent method are up to 2%. The limit cooling rate was set at value 30°C/s. The microstructure consists only of bainite and martensite and the hardness reaches a value of 348HV and higher.
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M. Málek
M. Mičian
Faculty of Mechanical Engineering, Technical University of Liberec, Studentská 1402/2, 461 17 Liberec I, Czech Republic
9 Formation Mechanism for the TiN–MnS Complex Inclusions in Tire Cord Steel
Jialiu Lei , Xiumin Wang , Dongnan Zhao , Yongjun Fu
Keywords: Thermodynamic calculations Formation mechanism TiN–MnS complex inclusions Tire cord steel
High strength tire cord steel is extensively used in radial ply tyres as the framework material, but the presence of brittle single titanium inclusions or complex titanium inclusions can cause failure of the wires and jeopardize their performance in production. In order to provide a key guidance on the control of titanium inclusions, it is necessary to clarify their formation mechanism during solidification. In the present work, the thermodynamic calculations were employed for an elaboration on their formation mechanism, combined with the industrial test. The TiN–MnS complex inclusions observed by SEM–EDS shows that the internal corresponds to TiN and the external is MnS. Thermodynamic calculations based on the microsegregation model indicate that MnS forms first, which can act as a nucleation site for the co–deposit of TiN in the mushy zone. As the MnS inclusions have a better deformation than that of TiN inclusions, then the TiN inclusions are wrapped by the MnS inclusions, generating TiN–MnS complex inclusions after rolling.
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[21] Huang, X.H. (2001). Theory of Iron and Steel Metallurgy. (3rd ed.). Beijing: Metallurgical Industry Press.
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[27] Gao, S., Wang, M., Guo, J.L., Wang, H. & Bao, Y.P. (2019). Extraction, distribution, and precipitation mechanism of TiN–MnS complex inclusions in Al-killed titanium alloyed interstitial free steel. Metals and Materials International. 12, 1-9.
Jialiu Lei
Xiumin Wang
Dongnan Zhao
Yongjun Fu
Hubei Polytechnic University, China
10 Analysis of the Current State and Forecast of Cast Iron Production in Russia
S.S. Golubev , V.D. Sekerin , A.E. Gorokhova , G.V. Komlatskiy , Y.I. Arutyunyan
Keywords: Steel Innovations Capacity load Competitiveness factors Priority strategies
The purpose of the study is to analyze the current state of the cast iron production and to predict production volume and cost in the near future based on the analysis results. Cast iron is one of the most common materials used in various industrial sectors. Cast iron scrap processing is the least expensive and saves both money and time. It is produced both in Russia and abroad and is one of the export types. Cast iron production significantly influences other industrial sectors. All this confirms the relevance of the study. The novelty of the study consists in the identification of the leaders among the cast-iron producers in the world and Russian metallurgical companies, as well as the determination of trends in its production at the present stage of economic development. The increasing consolidation level of cast iron producers has been revealed: China, India, Japan, and Russia represented 85% of the cast iron global production in 2019. In Russia, nine metallurgical companies account for 80% of cast iron production. In general, cast iron production in the world is stable and the import share of cast iron is about 4%. Cast iron prices tend to decline. The work identifies the lower and upper limits of the possible range of the cast iron prices. The authors conclude that the declining prices of cast iron in Russia may make its production unprofitable.
[1] Arab, N. (2017). Competitive nucleation in grey cast irons. Archives of Foundry Engineering. 17(4), 185-189.
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[11] Shatokha, V. (2016). Post-Soviet issues and sustainability of ferrous metallurgy in Eastern Europe. Mineral Processing and Extractive Metallurgy, 3, 1-8.
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[15] ACG (2020). Rynok chuguna v Rossii. Tekushchaya situatsiya i prognoz 2020-2024 gg. [Cast iron market in Russia. The current situation and the outlook for the period from 2020 to 2024]. Retrieved from: https://alto-group.ru/otchot/rossija/380-rynok-chuguna-tekushhaya-situaciya-i-prognoz-2014-2018-gg.html/.
S.S. Golubev
V.D. Sekerin
A.E. Gorokhova
G.V. Komlatskiy
Y.I. Arutyunyan
Moscow Polytechnic University, Bolshaya Semenovskaya Street, 38, Moscow, 107023, Russia
Kuban State Agrarian University, Kalinina Street, 13, Krasnodar, 350044, Russia
11 Influence of Overflow Connecting Channel Cross-Section Design on Selected Parameters of High Pressure Die Casting
J. Majerník , M. Podařil , D. Gojdan
Keywords: HPDC Gas entrapment Product development Overflows dimensions Melt flow
High pressure die casting technology (HPDC) is a method enabling the production of shape-complex casts with good mechanical properties, with high repeatability of production within narrow tolerance limits. However, the casts show, to some extent, basic porosity, which may reduce their mechanical and qualitative properties. One of the main areas to focus on in order to reduce the porosity of casts is the correct design and structure of the gating and overflow system. Submitted article is devoted to the assessment of the connecting channel cross-section design for connecting the overflows to the cast on selected parameters of the casting process. Five different cross-section designs of connecting channels are considered, enabling the removal of gases and vapors from the volume during the molding. The connecting channels are designed with a constant width g = 10mm and variable height h1 = 1.50 mm, h2 = 1.25 mm, h3 = 1.00 mm, h4 = 0.75 mm and h5 = 0.6 mm. The primary monitored parameter is the gas entrapment in selected points of the cast. The following is an evaluation of the pressure conditions change in the mold cavity at the end of the filling mode and local overheating of the mold material just below the surface of the mold face. With regard to the monitored parameters, based on the performed analyzes, the most suitable design solution of the connecting channel is assessed and recommendations for the design and structure of the overflows and their connection to the cast are derived.
[1] Gaspar, S., Pasko, J., Majernik, J. (2017). Influence of structure adjustment of gating system of casting mould upon the quality of die cast. Lüdenscheid: RAM-Verlag.
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[4] Majernik, J. (2019) The issue of the gating system design for permanent dies (Problematika návrhu vtokových soustav permanentních forem pro lití kovů pod tlakem). Stalowa Wola: Wydawnictwo Sztafeta Sp. z.o.o.
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[6] El-Fotouh, M.R.A., Shash, A.Y. & Gadallah, M.H. (2018). Semi-automated gating system design with optimum gate and overflow positions for aluminum HPDC. In A. Öchsner & H. Altenbach (Eds.) Improved Performance of Materials (37-51). Cham, Switzerland:Springer Verlag. DOI: 10.1007/978-3-319-59590-0_4.
[7] Pinto, H.A., et al. (2019). Improvement and validation of Zamak die casting moulds. In 29th International Conference on Flexible Automation and Intelligent Manufacturing, 24-38 June 2019 (pp. 1547-1557). Limerick; Ireland: Elsevier B.V.. DOI: 10.1016/j.promfg.2020.01.131.
[8] Chavan, R. & Kulkarni, P.S. (2020). Die design and optimization of cooling channel position for cold chamber high pressure die casting machine. In 2nd International Conference on Emerging trends in Manufacturing, Engines and Modelling, 23-24 December 2019 (Article number 012017). Mumbai, India: Institute of Physics Publishing. DOI: 10.1088/1757-899X/810/1/012017.
[9] Dabhole, S.S., Kurundwad, C.A. & Prajapati, S.R. (2017). Design and development of die casting die for rejection reduction. International Journal of Mechanical Engineering and Technology. 8(5), 1061-1070.
[10] Altuncu, E., Doğan, A. & Ekmen, N. (2019). Performance evaluation of different air venting methods on high pressure aluminum die casting process. Acta Physica Polonica A. 135(4), 664-667. DOI: 10.12693/APhysPolA.135.664.
[11] Zhao, X. et al. (2018). Gating system optimization of high pressure die casting thin-wall AlSi10MnMg longitudinal loadbearing beam based on numerical simulation. China Foundry. 15(6), 436-442. DOI: 10.1007/s41230-018-8052-z.
[12] Qin, X.-Y., Su, Y., Chen, J. & Liu, L.-J. (2019). Finite element analysis for die casting parameters in high-pressure die casting process. China Foundry. 16(4), 272-276. DOI: 10.1007/s41230-019-8088-8.
[13] Cleary, P.W., Savage, G., Ha, J. & Prakash, M. (2014). Flow analysis and validation of numerical modelling for a thin walled high pressure die casting using SPH. C omputational Particle Mechanics. 1(3), 229-243. DOI: 10.1007/s40571-014-0025-4.
[14] Majernik, J. & Podaril, M. (2019). Influence of runner geometry on the gas entrapment in volume of pressure die cast. A rchives of Foundry Engineering. 19(4), 33-38. DOI: 10.24425/afe.2019.129626.
[15] Dańko, R., Dańko, J. & Stojek, J. (2015). Experiments on the Model Testing of the 2nd Phase of Die Casting Process Compared with the Results of Numerical Simulation. Archives of Foundry Engineering. 15(4), 21-24. DOI: 10.1515/afe-2015-0072.
[16] Gaspar, S. & Pasko, J. (2016). Pressing Speed, Specific Pressure and Mechanical Properties of Aluminium Cast. A rchives of Foundry Engineering. 16(2), 45-50. DOI: 10.1515/afe-2016-0024
J. Majerník
M. Podařil
D. Gojdan
Institute of Technology and Business in České Budějovice, Czech Republic
Technical University of Košice, Faculty of Manufacturing Technologies with the Seat in Prešov, Slovak Republic
12 Comparison of Microstructure and Mechanical Properties of Cast Steel Carried out on Cast-on Samples and Samples Cast Separately
B.E. Kalandyk , R.E. Zapała
Keywords: Mechanical properties Metallography Heat treatment Cast steel
The results of microstructure examinations and UTS, YS, El, RA carried out on low-carbon cast steel containing 0.15% C. The tests were carried out on specimens cut out from samples cast on a large-size casting and from samples cast in separate foundry moulds. It has been shown that significant differences in grain size observed in the material of the separately cast samples and cast-on samples occur only in the as-cast. In the as-cast state, in materials from different tests, both pearlite percent content in the structure and mean true interlamellar spacing remain unchanged. On the other hand, these parameters undergo significant changes in the materials after heat treatment. The mechanical properties (after normalization) of the cast-on sample of the tested cast steel were slightly inferior to the values obtained for the sample cast in a separate foundry mould. The microscopic examinations of the fracture micro-relief carried out by SEM showed the presence of numerous, small non-metallic inclusions, composed mainly of oxide-sulphides containing Mn, S, Al, Ca and O, occurring individually and in clusters.
[1] Kniaginin, G. (1977). Metallurgy and casting of steel. Katowice: Śląsk. (in Polish).
[2] Standard PN-ISO 3755-1994. Cast carbon steels for general engineering purposes.
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[4] Kasińska, J. (2017). Effects of rare earth metal addition on wear resistance of chromium-molybdenum cast steel. Archives of Foundry Engineering. 17(3), 63-68. ISSN: 1897-3310.
[5] Lis, T. (2009). High purity steel metallurgy. Gliwice: Wyd. Politechniki Śląskiej. (in Polish).
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[7] Bartocha, D., Suchoń, J., Baron, Cz. & Szajnar, J. (2015). Influence of low alloy cast steel modification on primary structure refinement type and shape of nonmetallic inclusions. Archives of Metallurgy and Materials. 60(1). 77-83. DOI: 10.1515/2015-0013.
[8] Żak, A., Zdonek, B., Adamczyk, M., Szypuła, I., Kutera, W. & Kostrzewa, K. (2015) Technology for manufacturing large – size steel castings for applications under extreme operating conditions. Prace IMŻ. 2: 21-28.
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[13] Standard PN-EN ISO 3755-1994. 6892-1:2009. Metallic materials. Tensile testing. Part 1: Method of test at room temperature.
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B.E. Kalandyk
R.E. Zapała
AGH University of Science and Technology, Department of Cast Alloys and Composites Engineering, Faculty of Foundry Engineering, ul. Reymonta 23, 30-059 Krakow, Poland
13 Heat Treatment of AlSi7Mg0.3 Aluminium Alloys with Increased Zirconium and Titanium Content
E. Kantoríková , M. Kuriš , R. Pastirčák
Keywords: Heat treatment Aluminum Alloys Zirconium Titan Mechanical properties
The paper compares changes in the structure and mechanical properties due to the synergistic effect of alloying elements Zr and Ti. It is assumed that by increasing the content of Zr and Ti in the aluminium alloy, better mechanical properties will be achieved. Paper focuses on description of the differences between the samples casted into the shell mold and the metal mold. Main difference between mentioned molds is a different heat transfer coefficient during pouring, solidification and cooling of the metal in the mold. The main goal was to analyse the influence of Zr and Ti elements and compare the mechanical properties after the heat treatment. Curing and precipitation aging were used during the experiment. The effect of the elements on AlSi7Mg0.3 alloy created differences between the excluded Zr phases after heat treatment. Evaluation of the microstructure pointed to the decomposition of large predominantly needle Zr phases into smaller, more stable formations.
[1] Bolibruchová, D., Tillová, E. (2005). Al-Si foundry alloys. Žilina.
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[4] Bolibruchová, D., Kuriš, M. & Matejka, M. (2019). Effect of Zr on selected properties and porosity of AlSi9Cu1Mg alloy for the purpose of production of high-precision castings. Manufacturing Technology. 19(4), 1213-2489.
[5] Bolibruchova, D., Macko, J. & Bruna, M. (2014). Elimination of negative effect of Fe in secondary alloys AlSi6Cu4 (EN AC 45 000, A 319) by nickel. Archives of Metallurgy and Materials, 59, 717-721
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[12] Pourkia, N., Emamy, M., Farhangi, H. & Seyed, E. (2010). The effect of Ti and Zr elements and cooling rate on the microstructure and tensile properties of a new developed super high-strength aluminium alloy. Materials Science and Engineering A. 527, 5318-5325.
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E. Kantoríková
R. Pastirčák
Department of Technological Engineering, University of Žilina in Žilina, Univerzitná 8215/1, 010 26 Žilina, Slovakia
14 A New Technology of TRIAD Cement-Free Castables – Practical Aspects
B. Cygan , J. Dorula , J. Jezierski
Keywords: Cement-free concrete Refractory lining Pouring ladle Pouring device Cast iron
The article presents the new technology of the refractory materials used for the ladles and pouring devices. The aim for solving the majority of the problems that originated from the refractory lining was to develop the group of cement-free TRIAD products by Vesuvius company. The cement-free setting system in the TRIAD products eliminates calcium oxide (CaO) that occurs in low and extra low cement concretes resulting in its higher strength at higher temperatures. The features of the new cement-free castables were described. One of the most unique features of this technology is the porous material structure. Small venting microchannels are formed during the concrete setting process. These micro-channels allow for removing water vapor from the lining without affecting its refractory properties. On the other hand, the diameter of pores is so low that it disallows the penetration of slag and metal into the lining, extends its operating life at the same time facilitates cleaning and removing build-ups. The procedure of the preparation of these materials, as well as the method of building of the lining, were presented. An example of the practical use of these materials in the ductile cast iron foundry was presented, showing the advantages of the new refractory materials over the traditional ones.
[1] Drevin, J. (2014). Triad – a new range of user-friendly, high-strength refractory concretes. Przegląd Odlewnictwa. 9-10, 390-393. (in Polish).
[2] Rybak, M. (2011). Influence of alumina cement hydration conditions on concrete properties. Piece Przemysłowe & Kotły. 1, 21-25. (in Polish).
[3] Drevin J. (2011). Triad – Triad high-performance castable linings. Foundry Practice. 253(6) 16-20.
[4] Cygan B., Dorula J., Jezierski J. (2018). TRIAD - modern technology of non-cement concrete in cast iron foundry. In Congress Proceedings of the 73rd World Foundry Congress "Creative Foundry", 23rd–27th September 2018 (pp. 561-562). Krakow, Poland: Polish Foundrymen's Association.
B. Cygan
J. Dorula
Silesian University of Technology, Department of Foundry Engineering, 7 Towarowa, 44-100 Gliwice, Poland
Teksid Iron Poland Sp. z o.o., 49 Ciężarowa, 43-430 Skoczów, Poland
Vesuvius Poland Sp. z o.o. , Foundry Division - Biuro Handlowe, Portowa Business Center, 8 Portowa, 44-100 Gliwice, Poland
15 Investigation on the Effect of Granulometric Features on the Permeability of No-Bake Resin Bonded Sand Cores
H. Hudák , G. Gyarmati , L. Varga
Archives of Foundry Engineering | 2021 | vo. 21 | No 2 | 99-105 | DOI: 10.24425/afe.2021.136105
Keywords: Foundry sand granulometry grain size Grain morphology Grain shape Permeability
Foundry sand is the main element of sand mixtures from which molds or sand cores are made. Due to the continuous development of coremaking technologies, the selection of the right type of base sand becomes more and more important. The major features of foundry sand are determined by the following factors: chemical and mineralogical composition, sand grain size, grain size distribution, sand grain shape, and surface quality. The main goal of our research was to develop a qualification method that can be used to predict the characteristics of sand cores made from different sand types. Samples made from different types of foundry sand were used during the research whose properties were examined with a new qualification system, and then its connection with the gas permeability of sand cores was analyzed. Based on the research results, a strong correlation could be established between the suggested quality indicators: CQi (Core Quality Index), CG (Coefficient of Granulometry), and permeability.
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[8] Beňo, J. & Adamusová K. & Merta V. & Bajer T. (2019) Influence of Silica Sand on Surface Casting Quality. Archives of Foundry Engineering. 19(2), 5-8. DOI: 10.24425/afe.2019.127107.
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[13] Iden, F., Pohlmann, U., Tilch, W. & Wojtas, H.J. (2011). Strukturen von Cold-Box-Bindersystemen und die Möglichkeitihrer Veränderung. Giesserei Rundschau. 58, 1/2, 3-8.
[14] Iden, F., Tilch, W. & Wojtas, H.J. (2011). Die Haftungsmechanismen von Cold-Box-Bindemitteln auf der Formstoffoberfläche. Giesserei. 5/2011, 24-36.
[15] Dargai, V., Polzin, H., Varga, L., Dúl, J. (2015). Determination of granulometric properties of foundry sands with image analysis. (Öntödei homokok granulometriai tulajdonságainak meghatározása képelemzéssel). MultiScience - XXIX. microCAD International Multidisciplinary Scientific Conference, 9-10 April 2015. University of Miskolc – Miskolc, Hungary.
[16] Dargai, V., Polzin, H. & Varga, L. (2018). Die Bestimmung der granulometrischen Eigenschaften von Gießereisanden mittels dynamischer Bildanalyse. Giesserei Praxis. 4/2018, 19-22.
[17] Bodycomb, J. (2018). Size and shape of Particles from Dynamic Image Analysis. Retrieved January 29, 2021, from: https://www.slideshare.net/HORIBA/size-and-shape-of-particles-from-dynamic-image-analysis.
[18] Microtrac MRB (2017). Comparison Between Dynamic Image Analysis, Laser Diffraction and Sieve Analysis. Retrieved January 29, 2021, from: https://www.azom.com/article.aspx?ArticleID=14331.
[19] Raatz, G. (2014). Trends in der Partikelgrößenanalyse. Powtech / Technopharm – Messtechnik. 9/2014, 25-28. [20] Ridsdale and Ridsdale DieterT. Foundry sand testing equipment operating instructions (AFS). Catalogue No. 800, Retrieved January 29, 2021, from: https://www.basrid.co.uk/ridsdale/images/pdf/AFS_OIM.pdf
H. Hudák
G. Gyarmati
L. Varga
Institute of Foundry, Faculty of Materials Science and Engineering, University of Miskolc, Hungary
Instructions for the preparation of an Archives of Foundry Engineering Paper


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Education departments are weird
By Eric Crampton • 11/08/2020 This post was syndicated from Offsetting Behaviour - View original source
So our Joel Hernandez has completed some more work on what's all going on in New Zealand's school system and an Auckland Uni education prof is mad about it.
Joel's long term project has been to look at differences in outcomes across students and schools, using the administrative data held in the StatsNZ data lab to adjust for a rather broad assortment of things that students bring with them into the classroom.
Naive league tables will credit, or damn, schools for outcomes that are largely due to differences in the communities that those schools serve. Getting better measures on outcomes, adjusting for the differences across families that we can see in the data lab, helps.
Our measures don't tell you what's going on in any particular school, but they do let you know whether a school is doing about as well as expected in the current system given the kids it teaches, or whether it's a place that the Education Review Office might want to go visit to see what's going on. It could be that better-than-expected performance in one school has nothing to do with that school's practices but instead has everything to do with an after-school tutoring club the parents set up – for example.
Earlier, Joel looked at differences across schools to show that most of the difference in public school performance, by decile, disappears when you account for the differences in the families those schools serve. Piles of low-decile schools showed up as top performers, if you run the stats properly.
The broader project, which will take some time because lab work is onerous and we only have Joel doing this work for us, will extend to a much broader set of outcomes going beyond NCEA. The Ministry of Ed has like 3000 staff; we have a bit over a dozen staff and we only have Joel in the lab.
I'm keen to know how different schools vary in stuff like Not In Education, Employment or Training (NEET) status in years following high school completion; tertiary completion; salaries a few years after completing high school; crime rates; benefit uptake – there's a lot that can be looked at. But it'll take a while. We start with one set of data matches and build outward from there, adding things on as we go.
Anyway, Joel's most recent project looks at whether there are differences in outcomes across state, state-integrated, and private schools. Not many kids go to private school in New Zealand, but private and integrated schools dominate the league tables for achieving University Entrance.
Because of the cost of private schools, they're mostly going to be attended by kids from richer families. We're still looking at outcomes observable in school data available in the data lab. School data includes every student's performance on every NCEA standard they've sat, and whether they've achieved University Entrance. But it doesn't include data on whether they took up options available in some private schools to attend International Baccalaureate classes instead, or to take the Cambridge exams instead of NCEA. So Joel looked at UE as basis for comparison.
And remember that the broader project will eventually get to a lot more outcomes. Those take time, and we have one econometrician on the job.
Joel found that state-integrated schools outperformed state and private schools on University Entrance, adjusting for all the family background characteristics observable in the lab. You can't adjust for everything in the lab, but the stuff you can adjust for, like parents' education, will also be correlated with some of the things you can't observe.
So, for example, the weight and value parents put on education can matter a lot, but you can't observe that in the data lab. If parents who put the highest value on education will both push their kids harder at home, helping them through, and be more likely to select out of public schools and choose an integrated or private school, then you could be unfairly crediting private schools for effects that come from family background. But, at the same time, if, on average, the parents who put the highest value on education also have high levels of education themselves, then you'll have mopped up some of the effects of "parents value education" by controlling for parents' own education. It isn't perfect, but so long as the unobservables correlate positively with the observables, then you've handled some of that selection issue.
Or, at least, you've somewhat bounded it. Take a very different area: the persistent arguments about whether unobserved confounds drive the J-curve in alcohol and health. If adjusting for all of the observable health behaviours you can find doesn't do much to reduce the J-curve, and those observable health behaviours are real likely to be correlated with unobservable health behaviours, then it isn't plausible that unobserved confounds are driving the rest. Here, adjusting for the kitchen sink of family background reduced the coefficient on state-integrated schools but hardly got rid of it. You'd need the effects of the unobservables that aren't already mopped up by the observables to be as big as the effects of the observables, and to have driven the selection of private over state schools, to knock out the effect of private schools – and you'd need huge effects of unobservables to take out the effect of state-integrated schools.
Anyway, here's Auckland Uni Prof of Ed Peter O'Connor on it all:
However University of Auckland Professor Peter O'Connor argues that the focus on UE results alone "reduces the complexity of learning to such a narrow construct that it becomes meaningless".
"As a professor of education, I'd fail my master's students on that. It's a false science," he said.
"There is nothing to suggest that going to a private school means you will be happier, lead a more purposeful life, contribute more to the world, have better relationships with your partner or your children. That in fact your life matters for having been lived.
"You might have better connections, even more money, but that isn't much in the grand scheme of life."
It's kinda funny. We never said anything about happiness, leading a more purposeful life, or any of that. We were just looking at the average effects of integrated and private schools as compared to state schools on university entrance – a metric a lot of people still do care about, and the one that it's possible to check in the lab. We will be broadening to more outcomes in future.
But I guess if you're a student contemplating doing grad work in education that has any kind of econometrics in it, you probably shouldn't pick O'Connor as supervisor. If he doesn't like whatever numbers you get, he might fail you because he didn't understand the study or the methods. Michael Johnston over at Vic's education department would be a way better choice if you wanted to do it in an Ed department.
Or, perhaps even better, do it in economics.
Either way, you can even start with all the code Joel's used to run the data matches – we've got it all up in there freely available for anyone else to build on. There are years and years worth of studies to be done in there, and we've only got Joel. It's basically the best administrative dataset in the world for linking high school students' grades, their family backgrounds, and their later life outcomes. Drop us a line if you're considering picking up on any of this in your thesis work – we're always happy to provide a bit of advice.
Photo by Taylor Wilcox on Unsplash
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The Dismal Science brings together commentary from some of New Zealand's leading and most outspoken economists. Click on the authors' bylines to find out more about each individual contributor.

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The development of societies brings with it constant change. An ever-expanding population means less space for each individual The subdivisions between the rooms of the house begin to dissolve. This is the aspect that Simone Bonanni proposes to consider with Kandinsky, a faucet designed for a kitchen that is simultaneously a dining room. A sculpture with clear geometric shapes and colors determined by the possible combination of different materials. Simone Bonanni's work is based on the union of three key elements: design, functionality and technology. The device hides in its apparent simplicity an extendable shower head, a flexible silicone hose and sensors for touchless operation.
"Flowing into the future" – Alessi by Hansa, member of Oras Group: Water, with its advanced use, is the component that revolves around the bold research project developed by Alessi and Hansa, a German company, specialised in the production of bathroom and kitchen accessories. For the ISH 2019 fair in Frankfurt, the results of this study were presented, the second collaboration between the two companies: five concepts of avant-garde faucets for the kitchen of the next decade. Conducted under the artistic direction of Giulio Iacchetti, with a team of young designers – Simone Bonanni, Chiara Moreschi, Alessandro Stabile – "Flowing into the Future" intends to explore the possible scenarios of future living spaces, considering their social aspects, sustainability, technology and functionality.
Alberto Alessi: The "Flowing into the future" project bears witness to our constant attention to the new generations of Italian designers: certainly not due to any parochial issues, rather as recognition that they are young talents who are open to the world and bring something ineffable to their work, a refined quality that has always been a characteristic force of Italian design.
The analysis was inspired by a crucial question: how will our way of life change and, consequently, what will we ask of the new devices? A common factor of the five studies is the idea of placing the object at the centre of the scene, specifically placing the faucet in the centre of the kitchen, as a sculptural element charged with active and visionary tension.
The works of Chiara Moreschi – "Acquedotto" – and Alessandro Stabile – "Water Machine" – place emphasis on the theme of sustainability; Simone Bonanni with "Kandinsky", adopts a universal language experimenting with the use of noble materials; another project by Chiara Moreschi – "Paesaggio" – imagines a modular faucet with various functions. "Lingotto" is the proposal by Giulio Iacchetti, a faucet that is surprising for its unusual ring shape. The flow of water is turned on and off by rotating its various parts.
Giulio Iacchetti: Usually, we designers are called upon to create products that are rapidly launched on the market and designed for the very near future. The request to assemble and manage a team of designers to generate five concepts for the next 5, 10 or even 15 years was, to say the least, unusual and challenging. The designers involved have brought a courageous, elegant, ethical and sustainable point of view to a very familiar everyday object: the kitchen tap. In my opinion, their work has opened extraordinary perspectives that deserve to be investigated and narrated today, for the near future.
A neoplastic painting gains three-dimensionality: the metal delimits the space and frames the air creating multiple layers. Characterized by lightness and depth, enriched with light and reflections thanks to the use of fused glass. Three simple and pure materials make up Theo, the new series of dining tables designed by Simone Bonanni for FIAM.


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