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3 pages, 190 KiB

Open AccessEditorial

Modern Trends in Foundry

by Mariola Saternus and Ladislav Socha

Metals 2023, 13(7), 1236; https://doi.org/10.3390/met13071236 - 5 Jul 2023

Cited by 1 | Viewed by 750

Abstract

The production volume of metals and their alloys, taking into account the current demand for materials containing steel, cast iron, non-ferrous metals and their alloys, will continue to increase in the near future [...] Full article

(This article belongs to the Special Issue Modern Trends in Foundry)

Research

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14 pages, 4348 KiB

Open AccessArticle

The Effect of Bismuth on Technological and Material Characteristics of Low-Alloyed Automotive Steels with a Good Machinability

by Vladislav Kurka, Zdeněk Kuboň, Ladislav Kander, Petr Jonšta and Ondřej Kotásek

Metals 2022, 12(2), 301; https://doi.org/10.3390/met12020301 - 9 Feb 2022

Cited by 2 | Viewed by 2326

Abstract

The aim of this work is to compare the technological and material properties of CMnCr steels without bismuth, with 0.08 wt. % Bi and 0.12 wt. % Bi. Experimental heats showed that the most advantageous alloying of Bi into the heat was in [...] Read more.

The aim of this work is to compare the technological and material properties of CMnCr steels without bismuth, with 0.08 wt. % Bi and 0.12 wt. % Bi. Experimental heats showed that the most advantageous alloying of Bi into the heat was in the ladle, with an efficiency of about 20%. The optimal temperature range for forming steel was found to be 1160–1050 °C. With increasing Bi content, the formability of steels and plastic properties decreased, while the yield stress and tensile strength increased. Manganese sulfides, aluminum oxides, or oxysulfides, which were segregated both individually and in clusters, were found in the matrix of all tested steels. In steels with Bi, the Bi particles segregate the separately in the form of globules, either as envelopes of elongated MnS or Al₂O₃ particles segregated in rows. Sulfur dot-shaped segregations in the steel with 0.12 wt. % of Bi and the steel without Bi were essentially uniform over the whole area. For the steel with 0.08 wt. % of Bi, both dot-like and ray-ordered sulfur segregations were observed. The microstructure of all tested steels was ferritic–pearlitic with islands of bainite. Towards the center of the forged bars, variable shape and size of bainite blocks were observed. Machinability tests evaluated by the extend of tool wear showed that the most advantageous was CMnCr steel alloyed with 0.08 wt. % Bi. Full article

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13 pages, 1844 KiB

Open AccessArticle

Technological and Quality Aspects of the Use of Innovative Inorganic Binders in the Production of Castings

by Tomáš Obzina, Václav Merta, Martin Folta, Josef Bradáč, Jaroslav Beňo, Nikol Novohradská, Martina Gawronová, Ivana Kroupová, Petr Lichý, Filip Radkovský, Kamila Janovská, Iveta Vasková, Klára Drobíková and Isabel Nguyenová

Metals 2021, 11(11), 1779; https://doi.org/10.3390/met11111779 - 4 Nov 2021

Cited by 3 | Viewed by 1783

Abstract

The production of cores for the pre-casting of holes in castings places high demands on the quality of the molding mixtures used. For this reason, organic binders are still used to a large extent, which, although they meet the technological requirements, are a [...] Read more.

The production of cores for the pre-casting of holes in castings places high demands on the quality of the molding mixtures used. For this reason, organic binders are still used to a large extent, which, although they meet the technological requirements, are a source of pollutant emissions during the production of castings. The current trend towards greening production is therefore looking for a suitable alternative in ‘green’ inorganic binders. Although for many decades standard inorganic binders could not be compared with organic resins in terms of technological properties, new inorganic binder systems are currently being developed that can largely eliminate these disadvantages, which include, in particular, significantly lower collapsibility and reclaimability, and lower mechanical strength values. Last but not least, the use of these binder systems may be limited by the technological parameter of shelf-life, which is the main focus of this study. The aim of this paper is to evaluate the influence of technological parameters of core production using a new generation of inorganic binder systems on their shelf-life. Shelf-life, defined as the change in mechanical strength and wear resistance as a function of exposure time in a given environment, is evaluated under different climatic conditions. Full article

(This article belongs to the Special Issue Modern Trends in Foundry)

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14 pages, 25213 KiB

Open AccessArticle

Innovative Inorganic Binder Systems for the Production of Cores for Non-Ferrous Metal Alloys Reflecting the Product Quality Requirements

by Václav Merta, Jaroslav Beňo, Tomáš Obzina, Filip Radkovský, Ivana Kroupová, Petr Lichý, Martin Folta, Kamila Janovská, Isabel Nguyenová and Miroslav Dostál

Metals 2021, 11(5), 733; https://doi.org/10.3390/met11050733 - 29 Apr 2021

Cited by 4 | Viewed by 2845

Abstract

The aim of this study is the evaluation of the parameters of core mixtures using different binder systems with regard to the collapsibility of cores after casting and the resulting product quality of castings reflecting surface requirements based on non-ferrous alloys. The research [...] Read more.

The aim of this study is the evaluation of the parameters of core mixtures using different binder systems with regard to the collapsibility of cores after casting and the resulting product quality of castings reflecting surface requirements based on non-ferrous alloys. The research compares organically bonded core mixtures based on phenol-formaldehyde resins for the production of cores with the shell molding (resin coated sand), currently used in the production of aluminum alloy castings in the Brembo Czech s.r.o., and mixtures using innovative inorganic binder systems based on geopolymers; GEOPOL^® W. The aim of the research is to compare the advantages and disadvantages of these binder systems in order to evaluate the potential of inorganically bonded mixtures to replace organically bonded mixtures, which would lead to a significant reduction in the environmental impacts of industrial production of castings. Full article

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18 pages, 5973 KiB

Open AccessArticle

On Numerical Simulation of Casting in New Foundries: Dynamic Process Simulations

by Amir M. Horr and Johannes Kronsteiner

Metals 2020, 10(7), 886; https://doi.org/10.3390/met10070886 - 3 Jul 2020

Cited by 10 | Viewed by 3661

Abstract

New and more complex casting technologies are growing, and foundries are using innovative methods to reduce cost and energy consumption and improve their product qualities. Numerical techniques, as tools to design and examine the process improvements, are also evolving continuously to embrace modelling [...] Read more.

New and more complex casting technologies are growing, and foundries are using innovative methods to reduce cost and energy consumption and improve their product qualities. Numerical techniques, as tools to design and examine the process improvements, are also evolving continuously to embrace modelling of more dynamic systems for industrial applications. This paper will present a fresh approach towards the numerical simulation of dynamic processes using an evolving and dynamic mesh technique. While the conventional numerical techniques have been employed for these dynamic processes using a fixed domain approach, the more realistic evolving approach is used herein to match the complex material processes in new foundries. The underpinning of this new dynamic approach is highlighted by an evolving simulation environment where multiple mesh entities are appended to the existing numerical domain at timesteps. Furthermore, the change of the boundary and energy sources within casting process simulations have rationally been presented and its profound effects on the computational time and resources have been examined. The discretization and solver computational features of the technique are presented and the evolution of the casting domain (including its material and energy contents) during the process is described for semi-continuous casting process applications. Full article

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11 pages, 4330 KiB

Open AccessArticle

Mg-Based Materials with Quasiamorphous Phase Produced by Vertical Twin-Roll Casting Process

by Hai Liu, Wenxin Li, Zhipu Pei and Mengyuan Yan

Metals 2020, 10(4), 452; https://doi.org/10.3390/met10040452 - 29 Mar 2020

Cited by 4 | Viewed by 2897

Abstract

Metallic materials with micron grains, submicron grains, or amorphous structures have attracted great interest in recent decades owing to their excellent mechanical properties and corrosion resistance. Compared with traditional forming processes, rapid solidification technology has shown great superiority and potential in the preparation [...] Read more.

Metallic materials with micron grains, submicron grains, or amorphous structures have attracted great interest in recent decades owing to their excellent mechanical properties and corrosion resistance. Compared with traditional forming processes, rapid solidification technology has shown great superiority and potential in the preparation of materials in such structures. In this study, fine-grained quasiamorphous Mg-based alloy strips fabricated by a twin-roll strip casting process were explored using simulation and experimental methods. The concept of critical casting speed was proposed to reflect the optimum casting conditions. The product of critical casting speed and strip thickness was used to evaluate the cooling capacity of the casting system. Based on simulation results, a twin-roll strip-casting experiment was performed on a Mg-rare earth alloy. A novel puddle-like microstructure of the as-cast alloy strip was obtained. Tensile testing results showed that the novel strip exhibited improved ductility. Full article

(This article belongs to the Special Issue Modern Trends in Foundry)

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14 pages, 8826 KiB

Open AccessArticle

Examination of Behavior from Selected Foundry Sands with Alkali Silicate-Based Inorganic Binders

by Iveta Vasková, László Varga, Ingo Prass, Viktoria Dargai, Martin Conev, Martina Hrubovčáková, Marianna Bartošová, Branislav Buľko and Peter Demeter

Metals 2020, 10(2), 235; https://doi.org/10.3390/met10020235 - 10 Feb 2020

Cited by 16 | Viewed by 4193

Abstract

The automotive industry is one of the most important customers for the foundry industry. In particular, casting of engine parts for combustion engines is one of the most demanding areas of casting technology. New generation of engine blocks and cylinder heads are getting [...] Read more.

The automotive industry is one of the most important customers for the foundry industry. In particular, casting of engine parts for combustion engines is one of the most demanding areas of casting technology. New generation of engine blocks and cylinder heads are getting geometrically more complicated in order to maintain or even increase performance. With the increased complexity, the strain for the casting molds is growing and the widely used technology of core making with standard silica sands is, for several applications, no longer reaching the demanded results. Furthermore, in last decade, there has been an effort in using inorganic binders in core making process, which brings along some additional technological challenges. In order to cope with these challenges, in this paper, silica and non-silica sands with round and angular grains as well as with fine and coarse grains are examined using an inorganic binder for strength, permeability, and thermal stability. The results shall provide useful information about the possibilities of application and combining different types of foundry sands, both silica and non-silica. With their impact on the selected sand core properties, they can help in solving problems in the core making process as well as reaching a high quality of the final product-casting. Full article

(This article belongs to the Special Issue Modern Trends in Foundry)

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8 pages, 2591 KiB

Open AccessArticle

Crystallization and Structure of AlSi10Mg0.5Mn0.5 Alloy with Dispersion Strengthening with Al–Fe_xAl_y–SiC Phases

by Jarosław Piątkowski and Robert Wieszała

Metals 2019, 9(8), 865; https://doi.org/10.3390/met9080865 - 8 Aug 2019

Cited by 4 | Viewed by 2659

Abstract

The paper characterizes a composite with dispersion phases cast via the use of stir casting method on an aluminum matrix. A mixture of aluminum with Fe_xAl_y and SiC powders was achieved in the process of mechanical alloying and self-propagating high [...] Read more.

The paper characterizes a composite with dispersion phases cast via the use of stir casting method on an aluminum matrix. A mixture of aluminum with Fe_xAl_y and SiC powders was achieved in the process of mechanical alloying and self-propagating high temperature synthesis (ASHS). Chemical composition of agglomerates was chosen in such a way that the strengthening components made up 25% of the mass of the AlSi10Mg0.5Mn0.6 (EN AC-43400) alloy matrix. The characteristic temperatures of crystallization of the tested alloy were measured by thermal analysis ATD (analysis thermal derivative). A change of chemical and phase composition was confirmed in the elements of the intermetallic phase FeAl in the aluminum matrix. A silumin casting structure was achieved, with the matrix including micro-areas of ceramic phases and intermetallic phases, which are characteristic for hybrid strengthening. A refinement of dendrites in solid solution α was found, together with a transition from a binary plate eutectic composition α(Al) + β(Si) into modified eutectic composition. Full article

(This article belongs to the Special Issue Modern Trends in Foundry)

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