Residual stresses in surface layers and coatings

Methods of measurement and mechanisms of formation of residual stresses in the surface layers of metal alloys after ion nitriding, as well as in heat-shielding and refractory coatings are considered. Examples of the application of a technique based on the peculiarities of elastic anisotropy for measuring residual stresses in heterogeneous surface layers, for which the standard technique of diffraction tensometry “sin2Ψ” is not applicable, are given.

Synthesis of the new lost foam refractory coatings based on talc

This paper is focused on the preparation procedures, using talc-based filler to improve the rheologic properties of the lost foam refractory coatings. Talc, with grain size of 40 mm, was mechanically activated in a vibration mill over the following times: 10, 20 and 30 min. Depending on the time required for the mechanical activation, the change in the filler grain size and shape was analysed along their effects on the talc-filled lost foam coating dispersion ability and stability. In order to characterize the filler, the following methods were used: X-ray diffraction, scanning electron microscopy and optic microscopy. The coating compo-sition was tuned by choosing the suitable grain size and shape factor of the activated filler. In addition, different coating components (additives, solvent) were applied to alter the coating generation procedure. It was shown that the application of this type of the lost foam refractory coatings - water-based coatings - have a positive influence on quality of the aluminium alloy castings, which contributes to reducing the cost of cleaning and processing of the castings. Also, alcohol-based refractory coatings with talc-based activated fillers were tested and used to have the castings produced in the sand moulds.

Synthesis of the new lost foam refractory coatings based on talc

This paper is focused on the preparation procedures, using talc-based filler to improve the rheologic properties of the lost foam refractory coatings. Talc, with grain size of 40 mm, was mechanically activated in a vibration mill over the following times: 10, 20 and 30 min. Depending on the time required for the mechanical activation, the change in the filler grain size and shape was analysed along their effects on the talc-filled lost foam coating dispersion ability and stability. In order to characterize the filler, the following methods were used: X-ray diffraction, scanning electron microscopy and optic microscopy. The coating compo-sition was tuned by choosing the suitable grain size and shape factor of the activated filler. In addition, different coating components (additives, solvent) were applied to alter the coating generation procedure. It was shown that the application of this type of the lost foam refractory coatings - water-based coatings - have a positive influence on quality of the aluminium alloy castings, which contributes to reducing the cost of cleaning and processing of the castings. Also, alcohol-based refractory coatings with talc-based activated fillers were tested and used to have the castings produced in the sand moulds.

Influence of mechanical activation of a cordierite -based filler on sedimentation stability of lost foam refractory coatings

For the development of the Lost Foam refractory coatings with controlled rheologic properties, the influence of the mechanical activation process on the cordierite-based filler?s properties change was examined. First of all, the test referred to the change of filler particles? size and shape, as well as to dispersion ability and stability of the coating suspension. Cordierite was obtained by synthesis in a solid state, out of the mass consisting of kaoline, alumina, quartz, sepiolite. For characterization purposes, the following methods were used: X-ray diffraction, differential thermal analysis, SEM and optical microscopy. Mechanical activation of filler was performed in a vibrating mill. The upper boundary of the grain size was 100% -30 x 10-6 m, the times were (min): 15; 30; 60. The new composition of Lost foam refractory coatings has been developed with a change of the coating production process, as well. These newly synthesized coatings proved to be effective in terms of a positive influence on a surface quality, structural and mechanical properties of aluminium castings. Test results may be useful to have the Lost Foam refractory coatings specified together with other process parameters used for the production of castings according to this casting method.