Journal of Casting & Materials Engineering
The JOURNAL OF CASTING & MATERIALS ENGINEERING (JCME) is a peer-reviewed, academic e-periodical devoted to issues in engineering processes and casting materials. The periodical is published as a quarterly in the open access system by the AGH University of Science and Technology in Kraków. The JCME publishes original research articles, as well as reviews and theoretical articles. The mission of the periodical is to contribute to the development of knowledge and new scientific ideas in the field of engineering processes and casting materials.
AGH University Press, AGH-UST, 30 Mickiewicza Av., 30-059 Krakow
Reverse Engineering and Computer Modelling in Archaeometallurgy for the Reconstruction of Heritage Objects Using Precision Casting and 3D Printing
This article presents an interdisciplinary approach to the reconstruction of a copper-alloy artefact using reverse engineering techniques combined with modern digital and manufacturing technologies. The research was motivated by the need to better understand historical casting techniques while preserving the integrity of cultural heritage objects through non-destructive methods. The study integrates 3D scanning, CAD-based modelling, numerical simulations, investment casting, and metal additive manufacturing. The geometry of the artefact was captured using high-resolution 3D scanning, enabling the development of two CAD models: one representing the preserved state of the object and a second reconstructed model with the missing fragment digitally restored. Both models were used for numerical simulations of mould filling, solidification, cooling, and porosity formation performed in MAGMASOFT® 6.1, allowing the assessment of technological feasibility and defect formation. Based on the simulation results, physical replicas were produced using investment casting and selective laser melting. The obtained numerical and experimental results were compared in terms of geometry reproduction, surface characteristics, and predicted versus observed casting behaviour. The study demonstrates that the combination of digital reconstruction, simulation tools, and experimental manufacturing provides a reliable framework for analysing historical metallurgical processes. The proposed methodology supports both scientific interpretation and the practical reconstruction of heritage objects and can be applied to a wide range of archaeometallurgical studies.
Copyright (c) 2025 Karolina Marlicka, Andrzej Fijołek, Aldona Garbacz-Klempka, Marcin Piękoś https://creativecommons.org/licenses/by/4.0/
The Influence of the Knock-out Additive on the Mechanical Properties of Cores Made in the Core Blowing Process
The article presents the results of research on the effect of an additive improving shakeout (perlite ore with a specified grain size) on the mechanical properties of cores produced by the blowing process. The study was conducted on cores (standard specimens for tensile strength testing) made from core sands with varying amounts of loosening additive, depending on the core box temperature and shooting time, at a constant operating pressure of the shooting machine. The temperature of the core box at which the cores achieved the best mechanical properties was identified, and the necessity of optimizing both the amount of perlite ore additive and the binder content in the core sand to ensure the required mechanical properties of the cores was demonstrated.
Copyright (c) 2025 Artur Bobrowski, Jakub Kowalski https://creativecommons.org/licenses/by/4.0/
Harmonic Analysis in the Power Supply System of a Selected Single-Phase Industrial Robot
The selection of industrial robots in technological lines is primarily based on their technical characteristics, such as the type of construction, the number of axis, reach, maximum load, and power supply parameters (power consumption in single-phase or three-phase systems). In the overall energy balance, the transient states and the harmonics of voltages and currents in the power supply system of the selected industrial robot are also operationally significant. The article presents the results of harmonic analysis of voltage and current in the power supply system of a chosen industrial single-phase robot.
Copyright (c) 2025 Eugeniusz Ziółkowski https://creativecommons.org/licenses/by/4.0/
Influence of Cooling Rate on the Structure and Damping Properties of the AlSi6Cu4 Alloy
The investigated alloy was cast as a shaft into seven casting molds. Casting molds made of different materials were characterized by different abilities to conduct heat from the sample. This property significantly influenced the cooling rate of the sample casting from the AlSi6Cu4 alloy. The highest cooling rate was achieved in a steel mold at 25°C and the lowest in a mold made of insulating mass. Different cooling rates significantly influenced the structure of the alloy. Different grain sizes were obtained and the morphology of the microstructure components changed. At the highest cooling rate of 16.63 K·s−1, a grain with an average size of 0.58 mm was obtained. However, in the mold with the lowest cooling rate of 0.36 K·s−1, the average grain size was 3.76 mm. Changes in the structure of the alloy also influenced its damping properties. The tested values f the vibration damping coefficient α indicated that the AlSi6Cu4 alloy cooling with the highest cooling rate has the highest value of damping coefficient. This is influenced by the grain size and shape of the silicon precipitates. The refinement structure and fragmented components effectively disperse the vibration wave in the structure of the casting alloy.
Copyright (c) 2025 Grzegorz Piwowarski, Mateusz Ogrodnik https://creativecommons.org/licenses/by/4.0/
Design of a Solidification Rate Measurement Experiment for Cast Steel in Molds Made of Different Sands Using Computer Simulation
This article presents the design process of the casting technology for a step-shaped casting made of steel using simulation tools. A series of proposals for gating and feeding systems were simulated in the MAGMASoft® software. Results of numerical simulations allowed the Authors to select the casting technology which allows defect-free casting to be obtained. A numerical analysis of the cooling rate of a step-shaped casting made of GX70CrMnSiNiMo2 tool steel with a 5% Ti addition was carried out for the selected manufacturing technology. Due to the nature of the material used and the extended presence of martensite during cooling, in-mold hardening of the casting may occur. The simulations showed that the type of molding material affects the cooling rate, which is confirmed by the analysis of cooling curves and the morphology of shrinkage porosity. The analysis of solidification rates provides a valuable starting point and basis for subsequent research stages, taking into account the actual properties of the molding sands and the phase transformations occurring in the selected steel type. The casting technology design, which ensures the production of sound casting, was developed as part of this study. A series of simulations using different molding materials confirms the significant impact that the choice of mold material has on the casting solidification and cooling process.
Copyright (c) 2025 Paweł Żak, MSc. Eng. Natalia Mordyl, Prof. Jarosław Jakubski https://creativecommons.org/licenses/by/4.0/
Influence of the Addition of Tellurium and Heat Treatmenton the Microstructure of Hypoeutectic White Cast Iron
This study investigates how the addition of tellurium and heat treatment affects the microstructure of hypoeutectic white cast iron that has been modified with alloying elements such as titanium, chromium and vanadium. Samples with different chemical compositions were prepared and subjected to a two-step heat treatment process. Microstructural characterisation was performed using optical and scanning electron microscopy. The results show that introducing tellurium significantly affects the morphology of the cementite and carbide phases, causing them to fragment and become more evenly distributed. Furthermore, heat treatment enhanced matrix refinement and promoted phase stability. The combination of tellurium addition and heat treatment produced the most favourable microstructures, characterised by the high dispersion of hard phases within a fine-grained matrix.
Copyright (c) 2025 Alicja Trela-Przybyło, Prof. Magdalena Kawalec, Marcin Górny https://creativecommons.org/licenses/by/4.0/
The Implementation Potential of the Hybrid Hot Metal Desulfurization Model –The Transformation of Research Results into Technological Recommendations
This study presents the development of a hybrid model for the desulfurization of hot metal using dual reagent injection of CaO and Mg, integrating thermodynamic equilibrium calculations with kinetic analysis based on Tank Theory. The objective is to provide practical technological recommendations that enable effective industrial application of the process. The model allows real-time simulation of sulfur concentration changes under varying parameters such as reagent dosage and mixing intensity, while an optimization module supports the selection of operating conditions by balancing desulfurization efficiency with material consumption and operational costs. The system adapts to changing technological conditions including feedstock composition and process temperature, ensuring flexibility in industrial practice. In addition to process control, the model incorporates economic evaluation by correlating reagent consumption with achieved technological outcomes, which enhances its practical value. The proposed solution represents a step toward intelligent desulfurization systems that combine the precision of physicochemical modeling with the adaptability of modern process control. Implementation of the hybrid model may lead to higher efficiency, reduced consumption of consumables, and stable achievement of target sulfur levels, thereby strengthening the economic competitiveness of iron production.
Copyright (c) 2025 Angelika Podolska-Loska https://creativecommons.org/licenses/by/4.0/
ANALYSIS OF TRANSIENT STATES IN THE POWER SUPPLY SYSTEM FOR SELECTED INDUSTRIAL ROBOT
Industrial robots are controlled by dedicated controllers, which are powered by single-phase or three-phase power supply system. The main power parameters characterizing the power supply system of these robots are: nominal supply voltage (1-phase: 100-120 V, 200-240 V or 3-phase 200-575 V AC), frequency of the supply voltage (50 or 60 Hz), nominal power consumed by industrial robot. The dynamics of power consumption in the power supply system of controlled robot can be studied by recording instantaneous values of voltages and currents in each phase of the power grid. In this article are presented results for measurements of mentioned instantaneous values for chosen single-phase powered robot, taken by specialized recorder. Obtained measurements from recorder allows to calculate numerically various energetic values in the power supply system of robot: peak-peak values, RMS values, coefficients of deformation and values of harmonic amplitudes (FFT), values of active, reactive and apparent power and the power coefficient (tgϕ). The analysis of waveforms of instantaneous values of voltage and current allows to determine the occurrence of transient states during work of robot axes and characterizing its duration and the range of value changes). Carried out analyses can be using to properly design protection systems of the power supply system, at eventual selection of filters for higher harmonics and to determine effective power consumption of studied robot. The analyses of transient states which occurred during work of studied robot in this publication significantly expand the knowledge about the dynamics of power consumption and its possible impact on the quality of electricity in the power supply grid.
Copyright (c) 2025 Sebastian Nowocień, Eugeniusz Ziółkowski https://creativecommons.org/licenses/by/4.0/
Influence of Selected Corrosive Environment on the Scale Formation in Selected Materials Manufactured by Directed Energy Deposition 3D Printing Technology
Additive technologies, and in particular Directed Energy Deposition (DED), are becoming an increasingly important tool for the rapid production of components operating in, among others, the energy, aviation, petrochemical industries, where components are exposed to extreme thermochemical conditions. In the article, the influence of various corrosive atmospheres atmospheric air, water vapor and SO₂-argon- mixture – on the process of scale formation on the surface of materials manufactured using Directed Energy Deposition (DED) technology is presented. The tests were carried out at a temperature of 600°C (for air and water vapor) and 300°C (for SO₂-argon atmosphere). The mass increase and surface damage was monitored. It has been shown that the chemical composition of materials, especially the content of alloying elements such as Cr and Ni, is crucial for corrosion resistance. The obtained results provide the basis for further optimization of the composition of powders used in additive manufacturing techniques, in terms of operating conditions in aggressive environments.
Copyright (c) 2025 Marcin Małysza https://creativecommons.org/licenses/by/4.0/
3-D Microstructure Reconstruction of Tetragonal Zirconia Polycrystalline
The microstructure of a material is fundamental to its properties and behavior under mechanical and thermal loads. Understanding the internal structure of a material and controlling the microstructure at the stage of ceramic materials synthesis are essential for designing materials with desired properties. This study focuses on the three-dimensional reconstruction of the microstructure of yttria-stabilized tetragonal zirconia polycrystalline (TZP). The goal was to create accurate digital models of the microstructure, which could be used for further material analysis. The study utilized images obtained through scanning electron microscopy (SEM), based on which the basic stereological parameters were determined. The microstructure reconstruction was performed using the Laguerre tessellation method, allowing for the generation of three-dimensional digital models of the microstructure that represent the material's internal structure. The results confirm that based on the basic stereological parameters obtained from two-dimensional cross-sections, three-dimensional reconstruction of the microstructure of polycrystalline zirconia is possible. This work, therefore, represents a step towards the effective design of ceramic materials with high performance parameters, through the control and optimization of their microstructure.
Copyright (c) 2025 Grzegorz Grabowski https://creativecommons.org/licenses/by/4.0/
Occurrence of Chunky graphite in ductile cast iron solution strengthened by silicon
Solution strengthened ferritic cast iron is characterised in EN 1563:2018 (and also in ISO 1083:2018) as grades EN-GJS-450-18, EN-GJS-500-14 and EN-GJS-600-10. Machine and plant builders have been using this material in new designs since 2011. The strength and ductile properties, competitive in comparison with the previous classical ductile cast iron grades, make it possible to reduce the weight of castings. Particularly preferred is grade EN-GJS-600-10 with UTS min. 600 MPa and A min. 10%. Strengthening of the ferritic matrix is possible due to the content of approximately 4.2% of silicon in the cast iron. In casting practice, this material is difficult to produce in a stable manner due to the frequent occurrence of degenerate Chunky graphite in the casting structure, resulting in a loss of ductile properties of the cast iron. In this article, an analysis has been made, based on literature, of the occurrence of strong negative segregation of silicon in classical ductile cast iron. Own research has confirmed the occurrence of chunky graphite in the cast. Dendritic crystallisation of austenite and strong segregation of silicon favours the formation of Chunky graphite. A much stronger proportion of silicon was found in the Chunky graphite zone, compared to the adjacent ball graphite zone. The introduction of micro-additives into the liquid melt eliminated the presence of Chunky graphite in the casting. The applied modifiers of graphite and metal matrix (hybrid modification) seem to be an effective method to stabilise the technological process of this innovative casting material.
Copyright (c) 2025 Artur Zaczyński, Maciej Królikowski, Adam Nowak, Marek Sokolnicki, Edward Guzik, Andriy Burbelko https://creativecommons.org/licenses/by/4.0/
Theoretical Possibilities of Controlling the Cooling Rate in the Heat Treatment of Cast Iron with Water Mist
The goal of the cooling procedure after austenitizing in the austempering heat treatment process applied to ausferritic ductile iron (ADI) castings is to rapidly reduce the temperature throughout the casting volume to the temperature range of the process window in which the proper metal matrix structure is formed. The lower limit of this range must be higher than the temperature at which the martensitic transformation starts. The upper limit is selected to eliminate the possibility of diffusion decomposition of austenite while holding castings at austempering temperature. Most often in heat treatment practice, salt baths are used for this purpose. Such a solution makes it possible to realize in one device both the procedure of cooling down to a given temperature and the procedure of isothermal heat treatment at this temperature. Unfortunately, the presence of molten salt in the process equipment has a very unfavorable impact on working conditions and ecology. The purpose of this research is to analyze the possibility of replacing the salt bath cooling procedure in the manufacturing process of ADI castings with a water mist spray cooling procedure on the surfaces of the heat-treated casting. If such cooling is effective, subsequent procedures of heat treatment operations can be carried out with traditional furnace equipment without the use of molten salt, which will clearly improve the environmental performance of the enterprise. The article, using analytical and numerical methods, analyzes the possibility of cooling objects made of cast iron with the help of a high-efficiency heat receiver such as water mist spraying. The limiting conditions for carrying out the process for the assumed cooling curve were considered. It was proposed to use a PID controller realizing the function of controlling the intensity of water mist spray, which corresponds to the intensity of the heat flux received from the heat-treated casting. The theoretical analysis carried out allows us to conclude that water mist cooling according to the assumed cooling curve is practically feasible.
Copyright (c) 2024 Piotr Stręk https://creativecommons.org/licenses/by/4.0/
A Characterization of the Impact Toughness of Hot-rolled HSLA Steel
Due to the wide use of HSLA steels in difficult conditions, e.g. at low temperatures, it is extremely important to test the impact strength of these steels. This is equally important because most of those structures are made by welding these steels, and the welding process itself has a significant impact on the properties of joints and welding zones. In this work, the authors analyzed two selected representative HSLA steels rolled in the Krakow branch of ArcelorMittal Poland S.A. – the only place in Poland where HSLA steels in the form of hot-rolled strips can be produced on an industrial scale. Impact tests were performed in accordance with technical acceptance standards, and then the fracture surfaces after impact tests were characterized using light and scanning microscopy. In the next part of the work, a set of previously gathered data were analyzed to determine the influence of thermomechanical rolling process parameters on the level of impact strength and the influence of chemical composition on it.
Copyright (c) 2024 Tomasz Hamryszczak, Tomasz Śleboda, Oleksandr Lypchanskyi, Krzysztof Pańcikiewicz https://creativecommons.org/licenses/by/4.0/
Bactericidal Properties of the Sol-gel Layer on Polymer Substrates in Medical Applications
Polymeric biomaterials are a group of plastics used in medical devices, implants, and artificial organ components. In order to maintain the higher asepticity of the products, solutions based on the modification of the volume or surface of a plastic with biocidal agents, e.g. antibiotics, nanoparticles, are used. One of the methods used to impart biocidal properties to the material can be the use of layers applied by the sol-gel method. The aim of this study was to produce homogeneous and durable coatings on inert and hydrophobic silicone surfaces based on polysiloxane sols with biocidal activity against model bacteria: Gram negative (Escherichia coli, Klebsiella pneumoniae) and Gram positive (Staphylococcus aureus, Enterococcus faecalis). This paper presents results of investigations on a commercial biomedical silicone material (DEMED Sp. zoo) modified with eight sols; siloxane (TD), phenol-siloxane (FD), siloxane-aluminum (TD-Al), siloxane-titanium (TD-Ti), titanium (Ti), zinc (Zn), and TD and TD-Al sols modified with green tea extract (TD-GT, TD-Al-GT). The reference for the tested materials was unmodified silicone. In order to be prepared for coating, the siloxane samples were etched with hydrofluoric acid. Residual acid was removed from the silicone by washing and the substrates were then coated with sols by means of dip coating. The modified materials were then polymerized at 100°C for one week. The produced layered composites were subjected to microstructural, physicochemical, structural and microbiological analysis by contacting them with Gramm negative and Gramm positive bacteria. It was shown that the strongest biocidal properties were exhibited by samples modified with the sols based on - Zn, TD-Ti, Ti, TD-Al-GT and TD-GT.
Copyright (c) 2024 Paulina Armatys, Elżbieta Długoń, Wojciech Smółka, Robert Sobota, Aneta Frączek-Szczypta, Ewa Stodolak-Zych, Jarosław Markowski https://creativecommons.org/licenses/by/4.0/
Alloys for Hot Dip Galvanising on Thin-Walled Materials
The article reviews alloy additives to zinc and their impact on the quality of coatings achieved on structural steel. It also analyses the impact of the concentration of acid used for the chemical stripping of raw material on the zinc coating thickness of the steel. The zinc layer thickness changed depending on the concentration of alloy elements in the bath. It was stated that aluminium and bismuth have a low impact on the decrease in zinc coating thickness, while in the case of tin, a small change to the content (from 0.6% to 0.8%) significantly decreased the zinc layer thickness. Furthermore, it was found that, during the hot dip galvanising of steel, particular alloy elements are extracted from the bath. This results in the need to supplement alloy elements through periodical melting in for the purpose of maintaining the assumed bath composition. It was observed that, together with the increase in alloy elements concentration, zinc uptake (galvanised component weight ratio to black component weight) decreases, improving the process economics.
Copyright (c) 2024 Piotr Żabiński, Beata Leszczynska-Madej, Grzegorz Włoch, Piotr Lewartowski https://creativecommons.org/licenses/by/4.0/
An Experimental Derivation of Transient Nonuniform External Boundary Conditions for the Solidification Process Modeling of Equiaxed Investment Castings
The external heat transfer mechanisms acting on the external mold surfaces for equiaxed casting processes are very complex. The mechanisms are multi-mode, transient, and nonuniform, consisting of very complex radiative and convective definitions. In this work, a real-life mold, SGT6-5000 FD 3/4 Blade 4 cast in Alloy-247, was instrumented with thermocouples and temperature readings were recorded throughout the entire casting sequence of events. Analytical models based on the first law of thermodynamics, Fourier’s law, Newton’s Law of Cooling, and diffuse gray radiation for an N-sided enclosure were developed to use the thermocouple data as input to back calculate the emissivity of the mold, as well as the spatially varying heat transfer coefficients for a number of local regions. The derived external heat transfer mechanisms are presented as transient Biot numbers. The derived emissivity and nonuniform heat transfer coefficients for these surfaces were then validated in ProCAST numerical simulation by comparing the external mold temperature profiles. An extensive iterative, curve fitting, extrapolating, and averaging procedure was exercised to derive an expression for emissivity across the entire temperature range associated with the casting process. The predicted temperatures on the nodes corresponding to the thermocouple locations agree within reasonable error with the experimental data. The model also qualitatively predicted the shrinkage porosity detected via x-ray imaging for this casting. The current study confirms the hypothesis of previous work by the current authors with respect to the transient nonuniform boundary condition concept. Unique values of heat transfer coefficients were observed at different vertical positions along the airfoil. The analytical models were also able to capture phenomena associated with specific sequences of the casting process. This work provides the analytical models, and procedure, needed to derive these spatially varying conditions. The current authors contribute to the intellectual know-how of the large gas turbine casting industry which by other foundries is considered highly proprietary and strictly confidential. This paper should be used to set the precedence for how foundries derive and validate the external boundary conditions used in solidification process modeling.
Copyright (c) 2024 Weston Olson, Michael Stemmler, Erik Fernandez, Jayanta Kapat https://creativecommons.org/licenses/by/4.0/
New Pro-ecological Alkyd Binder for Moulding Sands with Limited Solvent Content
Moulding sands with an alkyd binder are used primarily in the production of massive castings, mainly of cast steel, but they can also be used for castings made of other alloys. Moulding sands with an alkyd binder compete with self-hardening sands with phenolic and furfuryl resins. They have several advantages in common with furan moulding sands, such as excellent knock-out properties and very good quality of the casting surface. Additionally, alkyd moulding sands do not contain nitrogen, sulphur, formaldehyde and water, various sands can be used as a matrix: quartz, chromite, zircon or olivine and a high proportion of reclaimed material (up to 90%), moreover the moulding sand has high plasticity. The disadvantages of this technology include limited ability to adjust the hardening time, high binder viscosity and high sensitivity of the moulding sand to the matrix and the ambient humidity. The Prec-Odlew company is a Polish manufacturer of, among others, alkyd resins for the foundry industry. As part of the project: “Development and implementation of technologies for obtaining ecological binders (systems) for bonding highly refractory ceramic materials” (RPMP.01.02.01-12-0636/18) two new alkyd resins were developed with a reduced amount of solvents: SL2017 and SL2019. So far, resins of this type contained approximately 40–50% of solvents, including aromatic ones. The newly developed resins have a reduced amount of solvents in their composition – they contain from 20% to 30% and mainly non-aromatic solvents. The SL 2019 resin contains solvents that do not include any aromatic compounds in the form of hydrocarbons. This article presents the results of testing the properties of moulding sands using the standard alkyd resin and the newly developed resins. The obtained results confirmed the possibility of making moulding sands with innovative binders, and even higher strength values were observed than in the case of the reference moulding sand with the SL 2002 binder.
Copyright (c) 2024 Stanisław M. Dobosz, Jan Kozień, Dariusz Drożyński, Małgorzata Hosadyna-Kondracka https://creativecommons.org/licenses/by/4.0/
Evaluation of 3D-printed Pattern Material for Heat-hardened Inorganic Moulds
Inorganic binders for sand moulding are currently of high interest due to the need to lessen our environmental impact and emissions. In this study, a heat hardened solid inorganic sodium silicate binder was tested with a 3D printed resin material to see how the use of such a material affected a silica mould’s quality, e.g. surface roughness. Results were compared to moulds made with metallic patterns. The unmodified binder had sticking issues when used with a metallic pattern, resulting in a rough as-moulded surface. Such issues were not seen with the printed resin patterns, also hinting at good performance with binders that contain performance increasing additives. The resin pattern material has a Heat Deflection Temperature (HDT) of 230°C, enabling the use of inorganic binders that require temperatures between 160–200°C to harden and dry. Additive manufacturing of such materials also allows designs for other hardening techniques than furnace heating, such as microwave heating. The moulds hardened with microwaves did not exhibit sticking issues. Additive manufacturing of tooling is a potential source of geometrical variation in final castings and are also studied in this work. In general, switching from traditional sand moulding patterns used with organic binder systems to inorganic systems, the patterns and core boxes need to be replaced by new ones made of a metallic or other heat resistant material. The studied material is a promising option for such a switch, especially when a complex shape enabled by additive manufacturing is also required.
Copyright (c) 2024 Kalle Jalava, Nurul Anwar, Juhani Orkas https://creativecommons.org/licenses/by/4.0/
Solidification Process Modeling of Equiaxed Investment Castings with Transient Nonuniform Boundary Condition Definition
The equiaxed investment casting process is a multi-physics problem which requires knowledge from engineers who have expertise in materials, metallurgy, fluid dynamics, thermodynamics, and heat transfer. Process modeling is a tool used by foundries to help predict casting defects such as shrinkage porosity, hot tears, and poor grain structure. The reliability of these predictions is strongly dependent on the accuracy of the thermal boundary conditions set in the model. In this work, a SGT5-2000E Vane 4 cast in Rene 80 nickel-based superalloy was modeled, using the FEA simulation package ProCAST, with two different methodologies. One methodology had very little effort invested into defining the thermal domain. The other methodology involved a thorough consideration of all heat transfer mechanisms acting on the mold. An extensive literature search was performed to define a unique natural convection heat transfer coefficient for each set of surfaces on the mold. The transient boundary layer development was also captured in the definition of the heat conditions. The shrinkage porosity predictions of the models were compared to real-world x-ray data and the transient nonuniform methodology predictions were much more representative than the low fidelity heat transfer methodology predictions. The low fidelity heat transfer model did predict some shrinkage, but not where it appeared in reality. The process modeler will be misdirected by the model results when deriving a solution to the casting process if the real-world physics are not appropriately accounted for in the model. This will be very counterproductive when the foundry is using the model to reduce developmental trials by running trials in model space. References and derived parameters are provided for material properties, emissivity of shell and insulation wraps, and external mold spatially varying heat transfer coefficients.
Effect of Titanium Alloying of Zn-Al-Cu Alloys for High Pressure Die Casting in Production Conditions
The paper presents the possibility of the industrial production of Zn4Al3Cu alloy with the addition of 0.41% Ti. Tests are described on the manner of introducing the ZnTi2 master alloy to the alloy, so that the chemical composition of the desirable elements proportion is obtained. The chemical persistence of the Zn4Al3CuTi was determined as low in the conditions of the long heating of the alloy before casting. Tests on the microstructure and mechanical properties of the obtained alloys were also conducted. The strength of the die-cast Zn4Al3Cu alloy was 265 MPa and, when measured on samples taken from the high pressure die-cast, it reached 369 MPa. It was determined that the addition of titanium to the Zn4Al3Cu alloy causes significant refinement of the structure and contributes to the formation of intermetallic phases.
Copyright (c) 2023 Łukasz Pasierb, Jan Łakomski, Krzysztof Figurski https://creativecommons.org/licenses/by/4.0/
The Circular Economy in Terms of Zinc Recovery from Industrial Waste – Directions for the Development and Profitability of Recycling
The article reviews the current state of the art in the field of zinc recycling. The results of model studies of the profitability (profitability) of the process of zinc recovery in precipitation in the form of dusts and sludges are presented. The cost of purchasing waste and the necessary energy and material expenditures were taken into account. It has been shown that access to a cheap source of waste is essential for the profitability of the zinc recovery process.
Copyright (c) 2023 Artur Bobrowski, Aleksander Nejranowski https://creativecommons.org/licenses/by/4.0/
Characterisation of Polacrylate-Polysacharide System. Part I. Infrared Structural Studies
For the prepared polymer systems based on an poly(acrylic acid) and a colloidal solution of native starch, a series of IR (FTIR) structural studies and tests under heating conditions (ATR-FTIR) were carried out. Two components from the group of native starch of different biological origin (potato, cassava) were selected. The analysis of the collected results was aimed at assessing the effect of the biological origin of the starch on the structure, thermal sensitivity of the acrylic polymer-based system. On the basis of interaction effects occurring in the obtained synthetic polymer-natural polymer systems, the validity of mixing selected components to obtain composition was verified.
Copyright (c) 2024 Karolina Kaczmarska, Mateusz Śmietana, Dariusz Drożyński, Faustyna Woźniak, Artur Bobrowski https://creativecommons.org/licenses/by/4.0/
Ecological Electroplating Baths and Their Application in the Tin-coating of Copper Wires Intended for Photovoltaic Cables
Copper wires are covered with various coatings for many different applications. The most popular are tin based coatings and both their thickness and quality have been standardized by means of appropriate standard specifications. Copper wires intended for photovoltaic cables are subjected to especially high requirements due to their exceptionally long operating time and extremely unfavourable working conditions. Tin coatings are applied using the electroplating method and generally a fluoroborate bath is used during the process, however, it has been proved to be a health hazard in general and harmful to the environment as a whole. The paper presents the research results of a new ecological methane-sulfonate bath which does not form hazardous waste in the process. The examples of tin coatings of various thickness and the way of obtaining them at varying electrodeposition speeds at constant current or constant speed with varying current intensity were analysed. It has been determined that the use of the new electroplating bath is not only beneficial from an ecological point of view, but also in terms of the coating quality and efficiency of the process.
Copyright (c) 2023 Aleksander Olędzki, Tadeusz Knych, Małgorzata Zasadzińska https://creativecommons.org/licenses/by/4.0/
Effect of Cavitation Phenomenon on the Quality of High-Pressure Aluminium Alloy Castings
This article presents an analysis of the effect of cavitation on the erosion of pressure moulds intended for the HPDC casting mould manufacturing process. Changes in the surface area of the eroded areas were investigated via photographs of castings at the beginning of the mould life as well as at 30%. The individual process variables were described and their influence verified via the cavitation potential module of the Flow3D simulation programme. The results are presented graphically with a description of the relationships and observations. The summary provides an explanation of the results and the dependencies that occurred.
Copyright (c) 2023 Marcin Brzeziński, Jakub Wiśniowski https://creativecommons.org/licenses/by/4.0/
An Analysis of the Prospects of the Use of Magnetic Water Treatment in Foundry Engineering
Scientists are currently focused on creating technologies that produce positive results without affecting the environment. One such technology is magnetic water treatment. In this paper, an analytical review of publications devoted to the application of magnetic treatment of water in various branches of engineering, agriculture, and medicine is carried out. Current views on the structure of water molecules, as well as the theories explaining the influence of the magnetic treatment of water on its properties, are reviewed. The results of studies of the influence of water treated by a magnetic field on the properties of molding sand are analyzed, including those in which the authors of the article took part. It is shown that the magnetic treatment of still water can increase the green strength of the molding sand containing this water from 0.035 to 0.052 MPa, and that of water in motion to 0.075 MPa. Thanks to this, the amount of binder in the molding sand can be reduced. It is concluded that the use of magnetically treated water in foundries is promising.
Copyright (c) 2023 Leonid Dan, Larysa Trofimova https://creativecommons.org/licenses/by/4.0/
Artificial Neural Networks as a Tool for Supporting a Moulding Sand Control System Based on the Dependency between Selected Moulding Sand Properties
The article presents the potential for using artificial neural networks to support decisions related to the rebonding of green moulding sand. The basic properties of the moulding sand tested in foundries are discussed, especially compactibility as it gives the most information about the quality of green moulding sand. First, the data that can predict the compactibility value without the need for testing are defined. Next, a method for constructing an artificial neural network is presented and the network model which produced the best results is analysed. Additionally, two applications were designed to allow the investigation results to be searchable by determining the range of values of the moulding sand parameters.
Copyright (c) 2023 Barbara Mrzygłód, Jarosław Jakubski, Andrzej Opaliński, Krzysztof Regulski https://creativecommons.org/licenses/by/4.0/
Research on New Al-Ag-Mo Alloys Dedicated to Wire Applications in Overhead Power Lines
The latest research work in the field of electric power systems focuses on the development of new wire materials which will allow the increase of the transmission capacity of power lines currently in use. The reason for this research was the often limited possibilities of continuous and failure-free transmission of electricity. In this paper, the authors present research on a new aluminium-based alloy dedicated for use as a conductive braid in the HTLS cable group. There are many technical solutions for this group of cables on the market, although they are solutions with a number of disadvantages, ranging from their high price, various operational shortcomings, complicated installation techniques, and ending with the risk of monopolistic practices, which is related to the inability to attract several competitive suppliers. The main aim of the research was to develop a new alloy based on aluminium with the addition of silver and molybdenum dedicated for use in special overhead power cables. Experimental research on new materials focused on obtaining the necessary knowledge to produce an overhead wire from these alloys with higher current carrying capacity in relation to the currently used conventional wire materials based on aluminium.
Copyright (c) 2023 Justyna Grzebinoga, Andrzej Mamala, Wojciech Ściężor, Radosław Kowal https://creativecommons.org/licenses/by/4.0/
Polylactide Used as Filment in 3d Printing – Part 2: TG-DTG, DSC and DRIFT investigations
A series of structural and thermal analysis research (TG-DTG, DSC, DRIFT) were performed for the samples of polylactide (PLA), which is commonly used in additive technologies as a structural material. In total four materials were considered, including two containing dyes with different colors, a material made of PLA recyclate and a graphene-modified PLA material. It was noted that PLA material reinforced with graphene phase (GRAFYLON®) retains the best thermal properties (TG-DTG), which results in wider possibilities of its processing, including further modification and usability in manufacturing vehicle structural elements. Recycled PLA material (ALFA+W) was characterized by a higher melting point (Tp) by more than 20oC than other samples (DSC analysis), so it can be more useful in the production of structural elements operating, as well as used at elevated temperatures.
Copyright (c) 2023 Beata Grabowska, Mateusz Skowron, Karolina Kaczmarska https://creativecommons.org/licenses/by/4.0/
Effect of Particle Size of a Powder upon the Properties and Microstructure of Boron-modified Fe-Ni-Mo-Cu Sinters
The article discusses the effect of different particle fractions of prealloyed iron powder on the microstructure, density and hardness of sintered material. Each particle fraction (apart from 160–200 µm, which is a trace fraction) was modified with boron, its contents being, respectively, 0.2 wt.%, 0.4 wt.% and 0.6 wt.%. Next, the powder mixtures were pressed under a pressure of 600 MPa, and the final compacts were subject to sintering at 1200°C for 60 min in a hydrogen atmosphere. It was observed that the higher values of density and hardness were found in samples made from finer fractions of powder. A higher homogeneity of the microstructure and the highest degree of compactness was obtained in sinters from powder of 40–56 µm particle size, with 0.4 wt.% boron. Due to the use of small particle fractions of prealloyed powder, a higher degree of compactness in sinters was obtained with lower boron content. Also indicated was which particle fraction of Fe-Ni-Mo-Cu powder should be applied to obtain density in sinters with boron addition equal to almost 100% of the relative density of the analyzed alloy. The presented studies have both scientific and technological aspects.
Copyright (c) 2023 Małgorzata Perek-Nowak, Magdalena Majchrowska, Joanna Karwan-Baczewska, Mario Rosso https://creativecommons.org/licenses/by/4.0/
The Formation, Properties and Use of Dispersed Iron-Graphite Metallurgical Waste
Dispersed wastes containing graphite, iron, and its oxides, getting into the air and accumulating in landfills, cause serious harm to human health and the environment. Moreover, even if the issue of the localization of these wastes has been solved successfully, their disposal has not yet been fully organized. In the present study, a systematic analysis of the dispersed iron-graphite waste (IGW) conditions for the formation at metallurgical enterprises, their structure, and their properties were carried out. In this case, special attention is focused on the electrophysical properties: specific saturation magnetization and volume resistivity. The presence of magnetic properties in IGW, combined with low electrical resistivity, makes IGW a promising and inexpensive raw material for obtaining cheap composite materials with radio shielding and radio absorbing properties in the microwave range. As a result of the research, effective ways of improving the magnetic properties of IGW by high-temperature treatment were obtained. The practical result of the research was the development and implementation of a technological scheme of dispersed IGW complex processing, which makes it possible to solve a twofold task – to exclude the ingress of iron-graphite wastes into the environment and to obtain a cheap material for protection against microwave radiation.
Copyright (c) 2022 Leonid Dan, Vladimir Maslov, Larysa Trofimova, Grzegorz Cios https://creativecommons.org/licenses/by/4.0/