Study of Feeding Parameters for the Production of Sound High-Alloyed Ductile Iron Castings with Aluminum

2010 ◽  
Vol 457 ◽  
pp. 261-266
Author(s):  
Vladimir D. Belov ◽  
Edis B. Ten ◽  
Alexander S. Drokin
Keyword(s):  
Cast Iron ◽  
Combustion Engine ◽  
High Heat ◽  
Gray Iron ◽  
High Tendency ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Feeding Parameters ◽  
Casting Production ◽  
High Aluminum

This work deals with the problem of casting production from high-aluminum cast iron Al22D. This cast iron is characterized by unique combination of properties [1-3]: high heat-resistance in corrosive gases medium especially containing sulfurous gases; relatively low density in comparison with gray iron and satisfactory mechanical properties. In addition, castings made from high aluminum cast iron Al22D are required in many areas of mechanical engineering. However, obtaining high-quality products from this cast iron is a particular problem due to its low-casting properties, especially its high tendency to gas saturation, oxidization and forming scabs, shrinkage and gas-shrinkage defects. Therefore, the aim of this work is the study of the castings feeding parameters. In addition, the technology of "exhaust manifold" casting of internal combustion engine designed to work in forced mode was developed on the basis of the obtained results.

scholarly journals Shaping the Microstructure of High-Aluminum Cast Iron in Terms of the Phenomenon of Spontaneous Decomposition Generated by the Presence of Aluminum Carbide

Materials ◽  
2021 ◽  
Vol 14 (20) ◽  
pp. 5993
Author(s):  
Robert Gilewski ◽  
Dariusz Kopyciński ◽  
Edward Guzik ◽  
Andrzej Szczęsny
Keyword(s):  
Cast Iron ◽  
Aluminum Carbide ◽  
The Self ◽  
Molding Sand ◽  
Aluminum Scrap ◽  
Iron Aluminum ◽  
Iron Castings ◽  
Abrasive Properties ◽  
High Aluminum ◽  
Main Factor

A suitable aluminum additive in cast iron makes it resistant to heat in a variety of environments and increases the abrasion resistance of the cast iron. It should be noted that high-aluminum cast iron has the potential to become an important eco-material. The basic elements from which it is made—iron, aluminum and a small amount of carbon—are inexpensive components. This material can be made from contaminated aluminum scrap, which is increasingly found in metallurgical scrap. The idea is to produce iron castings with the highest possible proportion of aluminum. Such castings are heat-resistant and have good abrasive properties. The only problem to be solved is to prevent the activation of the phenomenon of spontaneous decomposition. This phenomenon is related to the Al4C3 hygroscopic aluminum carbide present in the structure of cast iron. Previous attempts to determine the causes of spontaneous disintegration by various researchers do not describe them comprehensively. In this article, the mechanism of the spontaneous disintegration of high-aluminum cast iron castings is defined. The main factor is the large relative geometric dimensions of Al4C3 carbide. In addition, methods for counteracting the phenomenon of spontaneous decay are developed, which is the main goal of the research. It is found that a reduction in the size of the Al4C3 carbide or its removal lead to the disappearance of the self-disintegration effect of high-aluminum cast iron. For this purpose, an increased cooling rate of the casting is used, as well as the addition of elements (Ti, B and Bi) to cast iron, supported in some cases by heat treatment. The tests are conducted on the cast iron with the addition of 34–36% mass aluminum. The molten metal is superheated to 1540 °C and then the cast iron samples are cast at 1420 °C. A molding sand with bentonite is used to produce casting molds.

scholarly journals Cellular Automaton Modeling of Ductile Iron Density Changes at the Solidification Time

2013 ◽  
Vol 13 (4) ◽  
pp. 9-14 ◽  
Author(s):  
A.A. Burbelko ◽  
D. Gurgul ◽  
M. Królikowski ◽  
M. Wróbel
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Liquidus Temperature ◽  
Temperature Phase ◽  
Casting Alloys ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Maximum Value ◽  
Three Stages

Abstract Formation of the shrinkage defects in ductile iron castings is far more complicated phenomenon than in other casting alloys. In the paper one of the aspects of formation of porosity in this alloy was considered - changes in cast iron's density during crystallization caused by varying temperature, phase fractions and phase's composition. Computer model, using cellular automata method, for determination of changes in density of ductile iron during crystallization was applied. Simulation of solidification was conducted for 5 Fe-C binarie alloys with ES from 0.9 to 1.1 for the estimation of the eutectic saturation influence on the ductile iron shrinkage and expansion. As a result of calculations it was stated that after undercooling ductile iron below liquidus temperature volumetric changes proceed in three stages: preeutectic shrinkage (minimal in eutectic cast iron), eutectic expansion (maximum value equals to about 1.5% for ES = 1.05) and last shrinkage (about 0.4% in all alloys regardless of ES).

Modelling of the Density Changes of Nodular Cast Iron During Solidification by CA-FD Method

2014 ◽  
Vol 790-791 ◽  
pp. 140-145
Author(s):  
Andriy A. Burbelko ◽  
Daniel Gurgul ◽  
Wojciech Kapturkiewicz ◽  
Edward Guzik
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Liquidus Temperature ◽  
Nodular Cast Iron ◽  
Solidification Path ◽  
Temperature Phase ◽  
Casting Alloys ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Three Stages

Formation of the shrinkage defects in ductile iron castings is far more complicated phenomenon than in other casting alloys. In the presented paper changes the ductile iron density during solidification is analyzed. During the solidification path the influence of the temperature, phase fractions and phase composition is taking into account. Computer model, using cellular automata method, for estimation of changes in density of ductile iron during its solidification is applied. Results of the solidification modeling for Fe-C binary alloys with different composition in the castings with a different wall thickness are presented. As a result of calculations it was stated that after undercooling ductile iron below liquidus temperature volumetric changes proceed in three stages: pre-eutectic shrinkage (minimal in eutectic cast iron), eutectic expansion and the last shrinkage.

scholarly journals Increasing of Utility Properties of Grey Cast Iron Castings with Heat Treatment

2015 ◽  
Vol 15 (2) ◽  
pp. 13-16 ◽  
Author(s):  
Š. Eperješi ◽  
J. Malik ◽  
I. Vasková ◽  
D. Fecko
Keyword(s):  
Heat Treatment ◽  
Cast Iron ◽  
Metal Matrix ◽  
Wide Spectrum ◽  
Grey Cast Iron ◽  
Treatment Processes ◽  
Iron Castings ◽  
Grey Cast ◽  
The Subject ◽  
Casting Production

Abstract Grey cast iron belongs to materials for casting production, which have wide application for different industry branches. Wide spectrum of properties of these materials is given by the structure of base metal matrix, which can be influenced with heat treatment. Processes of annealing can be applied for grey cast iron without problems. During heat treatment processes, where higher cooling rates are used, the thermal and structural strains become important. Usage and conditions of such heat treatment for grey cast iron castings of common production are the subject of evaluation of this article.

scholarly journals Validation Tests of Prediction Modules of Shrinkage Defects in Cast Iron Sample

2017 ◽  
Vol 17 (1) ◽  
pp. 57-66 ◽  
Author(s):  
J. Hajkowski ◽  
P. Roquet ◽  
M. Khamashta ◽  
E. Codina ◽  
Z. Ignaszak
Keyword(s):  
Cast Iron ◽  
Cast Alloy ◽  
Processing Parameters ◽  
Standard Test ◽  
Experimental Simulation ◽  
Simulation Code ◽  
Iron Castings ◽  
Shrinkage Defects ◽  
Iron Sample ◽  
Validation Tests

Abstract The paper presents the results of experimental-simulation tests of expansion-shrinkage phenomena occurring in cast iron castings. The tests were based on the standard test for inspecting the tendency of steel-carbon alloys to create compacted discontinuities of the pipe shrinkage type. The cast alloy was a high-silicone ductile iron of GJS - 600 - 10 grade. The validation regarding correctness of prognoses of the shrinkage defects was applied mostly to the simulation code (system) NovaFlow & Solid CV (NFS CV). The obtained results were referred to the results obtained using the Procast system (macro- and micromodel). The analysis of sensitivity of the modules responsible for predicting the shrinkage discontinuities on selected pre-processing parameters was performed, focusing mostly on critical fractions concerning the feeding flows (mass and capillary) and variation of initial temperature of the alloy in the mould and heat transfer coefficient (HTC) on the casting - chill interface.

Production of High-Quality Castings from Gray Iron by Differentiated Cooling in Iron Mould

2019 ◽  
Vol 973 ◽  
pp. 15-20 ◽  
Author(s):  
Natalia I. Gabelchenko ◽  
Artem A. Belov ◽  
Oksana N. Meshcheryakova
Keyword(s):  
Tensile Strength ◽  
Cast Iron ◽  
Cooling Rate ◽  
Gray Cast Iron ◽  
Gray Iron ◽  
Gray Cast ◽  
High Quality ◽  
Iron Castings

The paper considers the possibility of improving the quality of gray cast iron castings by controlling the cooling rate of castings in a mold. It is shown that the use of differentiated cooling can increase tensile strength of cast iron by 12-16%

scholarly journals Management of the activity of quality assurance of cast iron castings in foundries

2021 ◽  
Vol 1781 (1) ◽  
pp. 012050
Author(s):  
A Josan ◽  
E Ardelean ◽  
M Ardelean ◽  
V Puţan
Keyword(s):  
Quality Assurance ◽  
Cast Iron ◽  
Iron Castings

scholarly journals Influence of Technological Parameters of Furane Mixtures on Shrinkage Creation in Ductile Cast Iron Castings

2014 ◽  
Vol 59 (3) ◽  
pp. 1037-1040 ◽  
Author(s):  
I. Vasková ◽  
M. Hrubovčáková ◽  
J. Malik ◽  
Š. Eperješi
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Ductile Cast Iron ◽  
Gating System ◽  
Technological Parameters ◽  
Iron Castings ◽  
Steel Castings ◽  
The Impact ◽  
Very High ◽  
Great Development

Abstract Ductile cast iron (GS) has noticed great development in last decades and its boom has no analogue in history humankind. Ductile iron has broaden the use of castings from cast iron into areas, which where exclusively domains for steel castings. Mainly by castings, which weight is very high, is the propensity to shrinkage creation even higher. Shrinkage creation influences mainly material, construction of casting, gating system and mould. Therefore, the main realized experiment was to ascertain the influence of technological parameters of furane mixture on shrinkage creation in castings from ductile iron. Together was poured 12 testing items in 3 moulds forto determine and compare the impact of various technological parameters forms the propensity for shrinkage in the casting of LGG.

scholarly journals Opening Material as the Possibility of Elimination Veining in Foundries

2016 ◽  
Vol 16 (3) ◽  
pp. 157-161 ◽  
Author(s):  
M. Hrubovčáková ◽  
I. Vasková ◽  
M. Benková ◽  
M. Conev
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Cast Iron ◽  
Granular Material ◽  
Surface Defects ◽  
Silica Sand ◽  
Iron Castings ◽  
Thermal Dilatation

Abstract The main bulk density representation in the molding material is opening material, refractory granular material with a particle size of 0.02 mm. It forms a shell molds and cores, and therefore in addition to activating the surface of the grain is one of the most important features angularity and particle size of grains. These last two features specify the porosity and therefore the permeability of the mixture, and thermal dilatation of tension from braking dilation, the thermal conductivity of the mixture and even largely affect the strength of molds and cores, and thus the surface quality of castings. [1] Today foundries, which use the cast iron for produce of casts, are struggling with surface defects on the casts. One of these defects are veining. They can be eliminated in several ways. Veining are foundry defects, which arise as a result of tensions generated at the interface of the mold and metal. This tension also arises due to abrupt thermal expansion of silica sand and is therefore in the development of veining on the surface of casts deal primarily influences and characteristics of the filler material – opening material in the production of iron castings.

scholarly journals RESEARCH OF THE INFLUENCE OF SLOW-DOWN COOLING SPEED IN THE INTERVAL OF EUTEKTIC TRANSFORMATION ON THE STRUCTURE AND MECHANICAL PROPERTIES OF CAST IRON CASTINGS

2020 ◽  
pp. 51-55
Author(s):  
N. I. Gabelchenko ◽  
N. A. Kidalov ◽  
A. A. Belov ◽  
M. D. Bezmogorychnyy ◽  
A. I. Gabelchenko
Keyword(s):  
Mechanical Properties ◽  
Cast Iron ◽  
Cooling Rate ◽  
Quality Index ◽  
Fuel Oil ◽  
Controlled Cooling ◽  
Slowing Down ◽  
Eutectic Transformation ◽  
Iron Castings ◽  
Cooling Speed

The work is devoted to the study of the effect of slowing down the cooling rate in the interval of eutectic transformation on the structure and mechanical properties of castings from gray doeutectic iron. To slow down the cooling rate in the interval of eutectic transformation, an exothermic carbon-containing additive, fuel oil M-100, was used. It is shown that the use of controlled cooling can significantly increase the quality index of cast iron without introducing additional alloying elements into the composition of cast iron.

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