Journal of Casting & Materials Engineering
type: channel
description: 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.
publisher: AGH University Press, AGH-UST, 30 Mickiewicza Av., 30-059 Krakow
language: en
publication name: Journal of Casting & Materials Engineering
issn: 2543-9901
items: Harmonic Analysis in the Power Supply System of a Selected Single-Phase Industrial Robot
items: Influence of Cooling Rate on the Structure and Damping Properties of the AlSi6Cu4 Alloy
items: Design of a Solidification Rate Measurement Experiment for Cast Steel in Molds Made of Different Sands Using Computer Simulation
items: ANALYSIS OF TRANSIENT STATES IN THE POWER SUPPLY SYSTEM FOR SELECTED INDUSTRIAL ROBOT
items: Influence of Selected Corrosive Environment on the Scale Formation in Selected Materials Manufactured by Directed Energy Deposition 3D Printing Technology
items: 3-D Microstructure Reconstruction of Tetragonal Zirconia Polycrystalline
items: Occurrence of Chunky graphite in ductile cast iron solution strengthened by silicon
items: Theoretical Possibilities of Controlling the Cooling Rate in the Heat Treatment of Cast Iron with Water Mist
items: A Characterization of the Impact Toughness of Hot-rolled HSLA Steel
items: Bactericidal Properties of the Sol-gel Layer on Polymer Substrates in Medical Applications
items: Alloys for Hot Dip Galvanising on Thin-Walled Materials
items: An Experimental Derivation of Transient Nonuniform External Boundary Conditions for the Solidification Process Modeling of Equiaxed Investment Castings
items: New Pro-ecological Alkyd Binder for Moulding Sands with Limited Solvent Content
items: Evaluation of 3D-printed Pattern Material for Heat-hardened Inorganic Moulds
items: Solidification Process Modeling of Equiaxed Investment Castings with Transient Nonuniform Boundary Condition Definition
items: Effect of Titanium Alloying of Zn-Al-Cu Alloys for High Pressure Die Casting in Production Conditions
items: The Circular Economy in Terms of Zinc Recovery from Industrial Waste – Directions for the Development and Profitability of Recycling
items: Characterisation of Polacrylate-Polysacharide System. Part I. Infrared Structural Studies
items: Ecological Electroplating Baths and Their Application in the Tin-coating of Copper Wires Intended for Photovoltaic Cables
items: Effect of Cavitation Phenomenon on the Quality of High-Pressure Aluminium Alloy Castings
items: An Analysis of the Prospects of the Use of Magnetic Water Treatment in Foundry Engineering
items: Artificial Neural Networks as a Tool for Supporting a Moulding Sand Control System Based on the Dependency between Selected Moulding Sand Properties
items: Research on New Al-Ag-Mo Alloys Dedicated to Wire Applications in Overhead Power Lines
items: Polylactide Used as Filment in 3d Printing – Part 2: TG-DTG, DSC and DRIFT investigations
items: Effect of Particle Size of a Powder upon the Properties and Microstructure of Boron-modified Fe-Ni-Mo-Cu Sinters
items: The Formation, Properties and Use of Dispersed Iron-Graphite Metallurgical Waste
items: The Optimization of a Numerical Steel Foundry Simulation Through a Characterization of the Thermal Properties of the Materials
items: Editorial page
items: Front page
items: The Effect of High Silicon and Molybdenum Content on the Mechanical Properties and Microstructure of Gray Cast Iron

Harmonic Analysis in the Power Supply System of a Selected Single-Phase Industrial Robot
type: item
description: 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.
subject: Articles
  topic: section
subject: harmonic analysis
  topic: keywords
subject: FFT
  topic: keywords
subject: industrial robot
  topic: keywords
subject: robot power supply system
  topic: keywords
subject: electrical power quality
  topic: keywords
creator: Eugeniusz Ziółkowski
rights: Copyright (c) 2025 Eugeniusz Ziółkowski https://creativecommons.org/licenses/by/4.0/
date: 2025-09-18
publication date: 2025-09-18
starting page: 45
ending page: 49
doi: 10.7494/jcme.2025.9.3.45

Influence of Cooling Rate on the Structure and Damping Properties of the AlSi6Cu4 Alloy
type: item
description: 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.
subject: Articles
  topic: section
subject: aluminum alloys
  topic: keywords
subject: damping coefficient
  topic: keywords
subject: cooling rate
  topic: keywords
subject: ultrasound testing
  topic: keywords
subject: Al-Si alloys, grain size
  topic: keywords
creator: Grzegorz Piwowarski
creator: Mateusz Ogrodnik
rights: Copyright (c) 2025 Grzegorz Piwowarski, Mateusz Ogrodnik https://creativecommons.org/licenses/by/4.0/
date: 2025-09-18
publication date: 2025-09-18
starting page: 32
ending page: 38
doi: 10.7494/jcme.2025.9.3.32

Design of a Solidification Rate Measurement Experiment for Cast Steel in Molds Made of Different Sands Using Computer Simulation
type: item
description: 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.
subject: Articles
  topic: section
subject: cooling rate
  topic: keywords
subject: molding materials
  topic: keywords
subject: GX70CrMnSiNiMo2 tool steel
  topic: keywords
subject: numerical simulation
  topic: keywords
creator: Paweł Żak
creator: Natalia Mordyl
creator: Jarosław Jakubski
rights: Copyright (c) 2025 Paweł Żak, MSc. Eng. Natalia Mordyl, Prof. Jarosław Jakubski https://creativecommons.org/licenses/by/4.0/
date: 2025-09-18
publication date: 2025-09-18
starting page: 39
ending page: 44
doi: 10.7494/jcme.2025.9.3.39

ANALYSIS OF TRANSIENT STATES IN THE POWER SUPPLY SYSTEM FOR SELECTED INDUSTRIAL ROBOT
type: item
description: 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.
subject: Articles
  topic: section
subject: industrial robot
  topic: keywords
subject: power supply system
  topic: keywords
subject: RMS values
  topic: keywords
subject: instantaneous values
  topic: keywords
subject: transient states
  topic: keywords
creator: Sebastian Nowocień
creator: Eugeniusz Ziółkowski
rights: Copyright (c) 2025 Sebastian Nowocień, Eugeniusz Ziółkowski https://creativecommons.org/licenses/by/4.0/
date: 2025-06-30
publication date: 2025-06-30
starting page: 16
ending page: 22
doi: 10.7494/jcme.2025.9.2.16

Influence of Selected Corrosive Environment on the Scale Formation in Selected Materials Manufactured by Directed Energy Deposition 3D Printing Technology
type: item
description: 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.
subject: Articles
  topic: section
subject: corrosion resistance
  topic: keywords
subject: oxide scale
  topic: keywords
subject: DED microstructure
  topic: keywords
subject: sulfur atmosphere
  topic: keywords
subject: high-temperature oxidation
  topic: keywords
creator: Marcin Małysza
rights: Copyright (c) 2025 Marcin Małysza https://creativecommons.org/licenses/by/4.0/
date: 2025-09-18
publication date: 2025-09-18
starting page: 23
ending page: 31
doi: 10.7494/jcme.2025.9.3.23

3-D Microstructure Reconstruction of Tetragonal Zirconia Polycrystalline
type: item
description: 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.
subject: Articles
  topic: section
subject: microstructure
  topic: keywords
subject: polycrystals
  topic: keywords
subject: tessellation
  topic: keywords
subject: 3-d reconstruction
  topic: keywords
subject: simulations
  topic: keywords
creator: Grzegorz Grabowski
rights: Copyright (c) 2025 Grzegorz Grabowski https://creativecommons.org/licenses/by/4.0/
date: 2025-03-28
publication date: 2025-03-28
starting page: 1
ending page: 7
doi: 10.7494/jcme.2025.9.1.1

Occurrence of Chunky graphite in ductile cast iron solution strengthened by silicon
type: item
description: 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.
subject: Articles
  topic: section
subject: Silicon reinforced ductile iron
  topic: keywords
subject: Chunky graphite
  topic: keywords
subject: Segregation of elements in cast iron
  topic: keywords
subject: hybrid modification
  topic: keywords
creator: Artur Zaczyński
creator: Maciej Królikowski
creator: Adam Nowak
creator: Marek Sokolnicki
creator: Edward Guzik
creator: Andriy Burbelko
rights: Copyright (c) 2025 Artur Zaczyński, Maciej Królikowski, Adam Nowak, Marek Sokolnicki, Edward Guzik, Andriy Burbelko https://creativecommons.org/licenses/by/4.0/
date: 2025-06-30
publication date: 2025-06-30
starting page: 9
ending page: 15
doi: 10.7494/jcme.2025.9.2.8

Theoretical Possibilities of Controlling the Cooling Rate in the Heat Treatment of Cast Iron with Water Mist
type: item
description: 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…
subject: Articles
  topic: section
subject: Austempered Ductile Iron
  topic: keywords
subject: quench
  topic: keywords
subject: PID controller
  topic: keywords
subject: system identification
  topic: keywords
subject: digital control system
  topic: keywords
creator: Piotr Stręk
rights: Copyright (c) 2024 Piotr Stręk https://creativecommons.org/licenses/by/4.0/
date: 2024-12-24
publication date: 2024-12-24
starting page: 68
ending page: 73
doi: 10.7494/jcme.2024.8.4.68

A Characterization of the Impact Toughness of Hot-rolled HSLA Steel
type: item
description: 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.
subject: Articles
  topic: section
subject: HSLA steel
  topic: keywords
subject: thermomechanical rolling
  topic: keywords
subject: impact toughness
  topic: keywords
subject: mechanical properties
  topic: keywords
subject: microstructure
  topic: keywords
creator: Tomasz Hamryszczak
creator: Tomasz Śleboda
creator: Oleksandr Lypchanskyi
creator: Krzysztof Pańcikiewicz
rights: Copyright (c) 2024 Tomasz Hamryszczak, Tomasz Śleboda, Oleksandr Lypchanskyi, Krzysztof Pańcikiewicz https://creativecommons.org/licenses/by/4.0/
date: 2024-12-02
publication date: 2024-12-02
starting page: 54
ending page: 58
doi: 10.7494/jcme.2024.8.4.54

Bactericidal Properties of the Sol-gel Layer on Polymer Substrates in Medical Applications
type: item
description: 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.
subject: Articles
  topic: section
subject: sol-gel method
  topic: keywords
subject: biocidal properties
  topic: keywords
subject: implants
  topic: keywords
subject: inert polymers
  topic: keywords
subject: silicone
  topic: keywords
creator: Paulina Armatys
creator: Elżbieta Długoń
creator: Wojciech Smółka
creator: Robert Sobota
creator: Aneta Frączek-Szczypta
creator: Jarosław Markowski
creator: Ewa Stodolak-Zych
rights: 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/
date: 2024-12-02
publication date: 2024-12-02
starting page: 59
ending page: 67
doi: 10.7494/jcme.2024.8.4.59

Alloys for Hot Dip Galvanising on Thin-Walled Materials
type: item
description: 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.
subject: Articles
  topic: section
subject: zinc
  topic: keywords
subject: hot deep galvanizing
  topic: keywords
subject: thin walled elements
  topic: keywords
creator: Piotr Żabiński
creator: Beata Leszczynska-Madej
creator: Grzegorz Włoch
creator: Piotr Lewartowski
rights: Copyright (c) 2024 Piotr Żabiński, Beata Leszczynska-Madej, Grzegorz Włoch, Piotr Lewartowski https://creativecommons.org/licenses/by/4.0/
date: 2024-10-23
publication date: 2024-10-23
starting page: 45
ending page: 53
doi: 10.7494/jcme.2024.8.3.45

An Experimental Derivation of Transient Nonuniform External Boundary Conditions for the Solidification Process Modeling of Equiaxed Investment Castings
type: item
description: 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 condit…
subject: Articles
  topic: section
subject: solidification process modeling
  topic: keywords
subject: casting simulation
  topic: keywords
subject: nickel-based superalloy
  topic: keywords
subject: equiaxed investment casting
  topic: keywords
subject: large gas turbine hardware
  topic: keywords
subject: transient nonuniform heat transfer
  topic: keywords
subject: initial condition natural convection
  topic: keywords
subject: surface condition natural convection
  topic: keywords
subject: mixed convection
  topic: keywords
subject: rotational convection
  topic: keywords
subject: ProCAST validation
  topic: keywords
creator: Weston Olson
creator: Michael Stemmler
creator: Erik Fernandez
creator: Jayanta Kapat
rights: Copyright (c) 2024 Weston Olson, Michael Stemmler, Erik Fernandez, Jayanta Kapat https://creativecommons.org/licenses/by/4.0/
date: 2024-09-30
publication date: 2024-09-30
starting page: 30
ending page: 44
doi: 10.7494/jcme.2024.8.3.30

New Pro-ecological Alkyd Binder for Moulding Sands with Limited Solvent Content
type: item
description: 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.
subject: Articles
  topic: section
subject: pro-ecological moulding sand
  topic: keywords
subject: innovative binder
  topic: keywords
subject: alkyd binder
  topic: keywords
subject: solvent content
  topic: keywords
subject: properties of moulding sand
  topic: keywords
creator: Stanisław M. Dobosz
creator: Jan Kozień
creator: Dariusz Drożyński
creator: Małgorzata Hosadyna-Kondracka
rights: Copyright (c) 2024 Stanisław M. Dobosz, Jan Kozień, Dariusz Drożyński, Małgorzata Hosadyna-Kondracka https://creativecommons.org/licenses/by/4.0/
date: 2024-05-27
publication date: 2024-05-27
starting page: 19
ending page: 24
doi: 10.7494/jcme.2024.8.2.19

Evaluation of 3D-printed Pattern Material for Heat-hardened Inorganic Moulds
type: item
description: 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.
subject: Articles
  topic: section
subject: solid silicate
  topic: keywords
subject: inorganic binder
  topic: keywords
subject: additive manufacturing
  topic: keywords
subject: patternmaking
  topic: keywords
subject: heat hardening
  topic: keywords
creator: Kalle Jalava
creator: Nurul Anwar
creator: Juhani Orkas
rights: Copyright (c) 2024 Kalle Jalava, Nurul Anwar, Juhani Orkas https://creativecommons.org/licenses/by/4.0/
date: 2024-06-05
publication date: 2024-06-05
starting page: 25
ending page: 29
doi: 10.7494/jcme.2024.8.2.25

Solidification Process Modeling of Equiaxed Investment Castings with Transient Nonuniform Boundary Condition Definition
type: item
description: 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.
subject: Articles
  topic: section
subject: Solidification process modeling
  topic: keywords
subject: casting simulation
  topic: keywords
subject: nickel-based superalloy
  topic: keywords
subject: equiaxed investment casting
  topic: keywords
subject: large gas turbine hardware
  topic: keywords
subject: ransient anisotropic heat transfer
  topic: keywords
subject: natural convection
  topic: keywords
subject: ProCAST
  topic: keywords
creator: Weston Olson
creator: Michael Stemmler
creator: Erik Fernandez
creator: Jayanta Kapat
rights: Copyright (c) 2024 Weston Olson, Michael Stemmler, Erik Fernandez, Jayanta Kapat https://creativecommons.org/licenses/by/4.0/
date: 2024-03-30
publication date: 2024-03-30
starting page: 1
ending page: 10
doi: 10.7494/jcme.2024.8.1.1

Effect of Titanium Alloying of Zn-Al-Cu Alloys for High Pressure Die Casting in Production Conditions
type: item
description: 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.
subject: Articles
  topic: section
creator: Łukasz Pasierb
creator: Jan Łakomski
creator: Krzysztof Figurski
rights: Copyright (c) 2023 Łukasz Pasierb, Jan Łakomski, Krzysztof Figurski https://creativecommons.org/licenses/by/4.0/
date: 2023-12-15
publication date: 2023-12-15
starting page: 56
ending page: 62
doi: 10.7494/jcme.2023.7.4.56

The Circular Economy in Terms of Zinc Recovery from Industrial Waste – Directions for the Development and Profitability of Recycling
type: item
description: 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.
subject: Articles
  topic: section
creator: Artur Bobrowski
creator: Aleksander Nejranowski
rights: Copyright (c) 2023 Artur Bobrowski, Aleksander Nejranowski https://creativecommons.org/licenses/by/4.0/
date: 2023-12-15
publication date: 2023-12-15
starting page: 49
ending page: 55
doi: 10.7494/jcme.2023.7.4.49

Characterisation of Polacrylate-Polysacharide System. Part I. Infrared Structural Studies
type: item
description: 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.
subject: Articles
  topic: section
subject: material engineering
  topic: keywords
subject: hydrogel
  topic: keywords
subject: native starch
  topic: keywords
subject: polyacrylic acid
  topic: keywords
subject: spectroscopy FT-IR
  topic: keywords
creator: Karolina Kaczmarska
creator: Mateusz Śmietana
creator: Dariusz Drożyński
creator: Faustyna Woźniak
creator: Artur Bobrowski
rights: Copyright (c) 2024 Karolina Kaczmarska, Mateusz Śmietana, Dariusz Drożyński, Faustyna Woźniak, Artur Bobrowski https://creativecommons.org/licenses/by/4.0/
date: 2024-03-30
publication date: 2024-03-30
starting page: 11
ending page: 18
doi: 10.7494/jcme.2024.8.1.11

Ecological Electroplating Baths and Their Application in the Tin-coating of Copper Wires Intended for Photovoltaic Cables
type: item
description: 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.
subject: Articles
  topic: section
creator: Aleksander Olędzki
creator: Tadeusz Knych
creator: Małgorzata Zasadzińska
rights: Copyright (c) 2023 Aleksander Olędzki, Tadeusz Knych, Małgorzata Zasadzińska https://creativecommons.org/licenses/by/4.0/
date: 2023-07-26
publication date: 2023-07-26
starting page: 31
ending page: 40
doi: 10.7494/jcme.2023.7.3.31

Effect of Cavitation Phenomenon on the Quality of High-Pressure Aluminium Alloy Castings
type: item
description: 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.
subject: Articles
  topic: section
creator: Marcin Brzeziński
creator: Jakub Wiśniowski
rights: Copyright (c) 2023 Marcin Brzeziński, Jakub Wiśniowski https://creativecommons.org/licenses/by/4.0/
date: 2023-07-20
publication date: 2023-07-20
starting page: 27
ending page: 30
doi: 10.7494/jcme.2023.7.3.27

An Analysis of the Prospects of the Use of Magnetic Water Treatment in Foundry Engineering
type: item
description: 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.
subject: Articles
  topic: section
creator: Leonid Dan
creator: Larysa Trofimova
rights: Copyright (c) 2023 Leonid Dan, Larysa Trofimova https://creativecommons.org/licenses/by/4.0/
date: 2023-06-30
publication date: 2023-06-30
starting page: 22
ending page: 26
doi: 10.7494/jcme.2023.7.2.22

Artificial Neural Networks as a Tool for Supporting a Moulding Sand Control System Based on the Dependency between Selected Moulding Sand Properties
type: item
description: 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.
subject: Articles
  topic: section
creator: Barbara Mrzygłód
creator: Jarosław Jakubski
creator: Andrzej Opaliński
creator: Krzysztof Regulski
rights: Copyright (c) 2023 Barbara Mrzygłód, Jarosław Jakubski, Andrzej Opaliński, Krzysztof Regulski https://creativecommons.org/licenses/by/4.0/
date: 2023-05-22
publication date: 2023-05-22
starting page: 15
ending page: 21
doi: 10.7494/jcme.2023.7.2.15

Research on New Al-Ag-Mo Alloys Dedicated to Wire Applications in Overhead Power Lines
type: item
description: 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.
subject: Articles
  topic: section
creator: Justyna Grzebinoga
creator: Andrzej Mamala
creator: Wojciech Ściężor
creator: Radosław Kowal
rights: Copyright (c) 2023 Justyna Grzebinoga, Andrzej Mamala, Wojciech Ściężor, Radosław Kowal https://creativecommons.org/licenses/by/4.0/
date: 2023-03-31
publication date: 2023-03-31
starting page: 9
ending page: 14
doi: 10.7494/jcme.2023.7.1.9

Polylactide Used as Filment in 3d Printing – Part 2: TG-DTG, DSC and DRIFT investigations
type: item
description: 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.
subject: Articles
  topic: section
creator: Beata Grabowska
creator: Mateusz Skowron
creator: Karolina Kaczmarska
rights: Copyright (c) 2023 Beata Grabowska, Mateusz Skowron, Karolina Kaczmarska https://creativecommons.org/licenses/by/4.0/
date: 2023-10-23
publication date: 2023-10-23
starting page: 41
ending page: 48
doi: 10.7494/jcme.2023.7.4.41

Effect of Particle Size of a Powder upon the Properties and Microstructure of Boron-modified Fe-Ni-Mo-Cu Sinters
type: item
description: 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.
subject: Articles
  topic: section
creator: Małgorzata Perek-Nowak
creator: Magdalena Majchrowska
creator: Joanna Karwan-Baczewska
creator: Mario Rosso
rights: Copyright (c) 2023 Małgorzata Perek-Nowak, Magdalena Majchrowska, Joanna Karwan-Baczewska, Mario Rosso https://creativecommons.org/licenses/by/4.0/
date: 2023-03-30
publication date: 2023-03-30
starting page: 1
ending page: 8
doi: 10.7494/jcme.2023.7.1.1

The Formation, Properties and Use of Dispersed Iron-Graphite Metallurgical Waste
type: item
description: 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.
subject: Articles
  topic: section
creator: Leonid Dan
creator: Vladimir Maslov
creator: Larysa Trofimova
creator: Grzegorz Cios
rights: Copyright (c) 2022 Leonid Dan, Vladimir Maslov, Larysa Trofimova, Grzegorz Cios https://creativecommons.org/licenses/by/4.0/
date: 2022-12-30
publication date: 2022-12-30
starting page: 81
ending page: 92
doi: 10.7494/jcme.2022.6.4.81

The Optimization of a Numerical Steel Foundry Simulation Through a Characterization of the Thermal Properties of the Materials
type: item
description: In many foundries, numerical simulation is used to determine the origins of different defects as this tool allows the acceleration of the design process. However, the databases provided by different software do not seem to tally with the actual properties of the material. In fact, every foundry uses a different grade of steel and varying mixtures of sand. An evaluation of the impact of different material properties showed the importance of measuring every physical property to improve the database of the software. Following this, an experiment was conducted to evaluate the gap between numerical simulations and the results obtained through experimentation. This experiment, called thermal analysis, consists in measuring the solidification and cooling of a cylinder filled with liquid steel. After the calculation of the steel properties and a simulation with real experimental parameters, a comparison between each cooling curve was realized. This comparison shows that the calculated properties provide a simulated cooling curve which is closer to the experimental curve than the properties in the original database. We did not explore all of the metal properties in this study, but the modification of the sand properties was explored, together with the thermal conductivity of the steel and sand. These other measurements will be obtained in a future study.
subject: Articles
  topic: section
creator: Morgan Souêtre
creator: Alexis Vaucheret
creator: Philippe Jacquet
creator: Jean-François Carton
rights: Copyright (c) 2022 Morgan Souêtre, Alexis Vaucheret, Philippe Jacquet, Jean-François Carton https://creativecommons.org/licenses/by/4.0/
date: 2022-12-22
publication date: 2022-12-22
starting page: 76
ending page: 80
doi: 10.7494/jcme.2022.6.4.76

Editorial page
type: item
subject: Others
  topic: section
rights: Copyright (c) 2022 Karolina Kaczmarska https://creativecommons.org/licenses/by/4.0/
date: 2022-07-11
publication date: 2022-07-11

Front page
type: item
subject: Others
  topic: section
rights: Copyright (c) 2022 Karolina Kaczmarska https://creativecommons.org/licenses/by/4.0/
date: 2022-07-11
publication date: 2022-07-11

The Effect of High Silicon and Molybdenum Content on the Mechanical Properties and Microstructure of Gray Cast Iron
type: item
description: This paper presents an overview of the current knowledge concerning SiMo ductile cast iron begins by describing the standard type of ductile cast iron before proceding to description of its microstructures. The paper then presents its chemical composition and the significant influence of individual elements on technological and mechanical properties. The research section focuses the influence of the addition of Si and Mo to the matrix of gray iron. After casting, stepped samples were carried out on the microstructure along with UTS tensile strength tests. The research presented in the article is a preliminary step towards the goal of obtaining a stable production process for silico-molybdenum cast iron.
subject: Articles
  topic: section
creator: Łukasz Dyrlaga
creator: Dariusz Kopyciński
creator: Edward Guzik
creator: Grzegorz Soból
creator: Dariusz Borak
rights: Copyright (c) 2022 Łukasz Dyrlaga, Dariusz Kopyciński, Edward Guzik, Grzegorz Soból, Dariusz Borak https://creativecommons.org/licenses/by/4.0/
date: 2022-10-01
publication date: 2022-10-01
starting page: 64
ending page: 68
doi: 10.7494/jcme.2022.6.3.64