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 Integrated influence of melting parameters of rail steel on rail products quality and technical and economic indicators of the production

2018 ◽  
Vol 61 (11) ◽  
pp. 876-883
Author(s):  
A. A. Umanskii ◽  
L. V. Dumova
Keyword(s):  
Cast Iron ◽  
Sulfur Content ◽  
Surface Defects ◽  
Rail Steel ◽  
Economic Indicators ◽  
Metal Charge ◽  
Linear Decrease ◽  
Solid Iron ◽  
Technical And Economic Indicators

Analysis of literature and production data has shown that despite the significant improvement in quality of domestic rail products, achieved in the last decade due to fundamental technical re-equipment of rail production, there is a problem of increased rejection of rails for surface defects. Based on studies of influence of rail steel chemical composition on quality of rails produced by «EVRAZ ZSMK», there was established a significant effect of increasing copper content in the range of 0.07 - 0.15 % and of sulfur - in the range of 0.006 - 0.011 % in E76KhF steel to increase rejection caused by rail surface defects. Mechanism of the influence of these elements concentration in rail steel on finished rails quality was revealed. Decisive influence of ratio of pig iron and scrap in metal charge on copper and sulfur content in rail steel was evidenced - higher rate of cast iron in metal charge within 20 - 50 % contributes to decrease of copper concentration and increase of sulfur content. To justify optimal composition of the charge for rail steel melting in regard to rail products quality and technical and economic indicators of production, study of the effect of cast iron (liquid and solid) to scrap ratio in metal charge on basic parameters of furnaces’ operation was conducted. As a result, it was found that with an increase in share of both liquid and solid iron in metal charge, there are linear decrease in specific electricity consumption, increase in specific oxygen consumption according to parabolic law and a linear decrease in manganese content in furnace output. The obtained dependences of melting duration on ratio of charge components in metal charge indicates presence of prominent minimum, when using liquid iron in the range of 35 - 40 %, and when using solid iron - in the range of 30 - 35 %. Based on the regression equations, statistical model was constructed for the influence of metal charge composition on technical and economic performance of the melt charge in rail steel smelting, in which optimization parameters are: total cost, depending on the metal stock composition and performance of the shop for suitable billets produced by continuous casting. Application of the obtained model allows to develop reasonable recommendations on the optimal proportion of iron in the metal for current level of prices for materials and energy used in electric smelting, taking into account changes in the shop productivity.

Effects of Particle Size on Microstructures and Properties of Si/Al Composites

2013 ◽  
Vol 873 ◽  
pp. 361-365 ◽  
Author(s):  
Wei Chen Zhai ◽  
Zhao Hui Zhang ◽  
Fu Chi Wang ◽  
Shu Kui Li
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Flexural Strength ◽  
Spark Plasma Sintering ◽  
Thermal Conductivity Coefficient ◽  
Coefficient Of Thermal Expansion ◽  
High Strength ◽  
Plasma Sintering ◽  
Spark Plasma

Si/Al composites with different Si particle sizes were fabricated using spark plasma sintering process for electronic packaging. The density, thermal conductivity, coefficient of thermal expansion and flexural strength of the composites were investigated. Effect of Si particle size on structure and properties of the Si/Al composites were studied. The results showed that the Si/Al composites synthesized by spark plasma sintering were composed of Si and Al. Al was uniformly distributed among the Si phase, leading to a high thermal conductivity (>120 W/m·k). The relative density of the Si/Al composites decreased with increasing Si particle size. Small Si particle size produced small grains, leading to a low coefficient of thermal expansion and a high strength. There is an optimal matching among the thermal conductivity, coefficient of thermal expansion and flexural strength when the Si particle size was 44 um.

Computational Design and Development of Alumina-Nickel Droplet Composites

2016 ◽  
Author(s):  
S. Sohail Akhtar ◽  
A. F. M. Arif ◽  
M. U. Siddiqui ◽  
Kabeer Raza ◽  
L. Taiwo Kareem ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Thermal Expansion Coefficient ◽  
Expansion Coefficient ◽  
Volume Fraction ◽  
Matrix Material ◽  
Microstructural Analysis ◽  
Computational Design ◽  
Minimum Size

Computational design for property management of composite materials offers a cost sensitive alternate approach in order to understand the mechanisms involved in the thermal and structural behavior of material under various combinations of inclusions and matrix material. The present study is concerned with analyzing the elasto-plastic and thermal behavior of Al2O3-Ni droplet composites using a mean field homogenization and effective medium approximation (EMA) using an in-house code. Our material design approach relies on a method for predicting potential optimum thermal and structural properties for Al2O3-Ni composites by considering the effect of inclusion orientation, volume, size, thermal interface resistance, percolation and porosity. The primary goal for designing such alumina-based composites is to have enhanced thermal conductivity for effective heat dissipation and spreading capabilities. At the same time, other functional properties like thermal expansion coefficient, elastic modulus, and electrical resistivity have to be maintained or enhanced. The optimum volume fraction was found to occur between 15 and 20 vol. %Ni while the average nickel particle size of 5 μm was found a minimum size that will enhance the thermal conductivity. The Young’s modulus was found decreasing as the volume fraction of nickel increases, which would result in enhanced fracture toughness. Electrical conductivity was found to be greatly affected by the percolation phenomenon in the designed range of volume fraction minimum particle size. As a validation, Al2O3 composites with 10% and 15% volume fraction Ni and droplet size of 18 μm are developed using spark Plasma Sintering process. Thermal conductivity and thermal expansion coefficient of the samples are measured to complement the computational design. Microstructural analysis of the sintered samples was also studied using optical microscope to study the morphology of the developed samples. It was found that the present computational design tool was accurate enough in predicting the desired properties of Al2O3-Ni composites.

Effects of Particle Size on the Thermal Physical Properties of SiCp/Al Composites

2007 ◽  
Vol 351 ◽  
pp. 131-134 ◽  
Author(s):  
Lin Geng ◽  
Yi Wu Yan
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Room Temperature ◽  
Thermal Loading ◽  
Thermal Residual Stresses ◽  
Powder Metallurgy Process ◽  
The Difference ◽  
Metallurgy Process ◽  
Thermal Physical Properties

The coefficients of thermal expansion (CTEs) of the 20 vol% SiCp/Al composites fabricated by powder metallurgy process were measured and examined from room temperature to 450°C The SiC particles are in three nominal sizes 5μm, 20μm and 56μm. The CTEs of the SiCp/Al composites were shown to be apparently dependent on the particle size. That the larger particle size, the higher CTEs of the composites, is thought to be due to the difference in original thermal residual stresses and matrix plasticity during thermal loading. The thermal conductivity of the composites also increases with particle size increasing.

scholarly journals The Impact of Process Factors on Creating Defects, Mainly Lustrous Carbon, during the Production of Ductile Iron Using the Lost-Foam Casting (LFC) Method

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1022
Author(s):  
Jan Jezierski ◽  
Michał Jureczko ◽  
Rafał Dojka
Keyword(s):  
Cast Iron ◽  
Ductile Iron ◽  
Surface Defects ◽  
Ductile Cast Iron ◽  
High Tech ◽  
Lost Foam Casting ◽  
Iron Castings ◽  
Process Factors ◽  
The Impact ◽  
Lost Foam

The purpose of this paper was to analyze the process factors affecting the occurrence of lustrous carbon defects in ductile cast iron castings when using the lost-foam casting (LFC) method. This phenomenon results in creating raw surface defects, which sometimes may even lead to cast iron scrapping. A series of trial melting batches were carried out for variable process assumptions. The analysis was performed to reflect, to the greatest extent possible, real foundry production conditions. Industrial tests were performed in Odlewnia Rafamet Sp. z o.o., Kuźnia Raciborska, Poland. The polystyrene patterns created by gluing components together, used in the tests, met the requirements of the high-tech lost-foam casting (LFC) process. The performed analysis allowed the obtaining of lustrous carbon defects in test castings as well as the determination of the process parameters with the highest impact on lustrous carbon inclusions in ductile iron castings. The test results were used to eliminate the possibility of creating a defect and thus directly improve the efficiency of the lost-foam casting (LFC) process used in the foundry.

scholarly journals Recent Advances in Cast Iron Structure and Properties Ultrasonic Testing and Flaw Detection

2018 ◽  
Vol 925 ◽  
pp. 499-503
Author(s):  
Liubov V. Voronkova
Keyword(s):  
Cast Iron ◽  
Ultrasonic Testing ◽  
Ultrasonic Method ◽  
Flaw Detection ◽  
Structure And Properties ◽  
Metallic Base ◽  
Acoustic Characteristics ◽  
Iron Castings ◽  
Electronic Signal Processing

The advantage of ultrasonic testing of iron castings prior to destructive control consists of an impressive reduction in time and costs, as well as the ability to assess the quality of the metal anywhere on the castings. According to the acoustic characteristics of cast iron it is possible to determine the form of graphite in it and its strength. The presence of chill in the metallic base and the thickness of the chilled layer is also determined by ultrasonic method. The use of electronic signal processing allows to distinguish it from high structural noise, which makes possible the testing of cast iron for a thickness of several meters. The use of transducers with phased array is the basis of the flaw detection of containers for nuclear waste from cast iron with globular graphite with a thickness of 500 mm.

scholarly journals Effects of polymorphic form and particle size of SiO2 fillers on the properties of SiO2–PEEK composites

2021 ◽  
Vol 11 (04) ◽  
pp. 2150021
Author(s):  
Peng Jie Xue ◽  
Shi Lin Liu ◽  
Jian Jiang Bian
Keyword(s):  
Thermal Conductivity ◽  
Particle Size ◽  
Thermal Expansion ◽  
Dielectric Loss ◽  
Mechanical Strength ◽  
Polymorphic Form ◽  
Fused Silica ◽  
High Frequencies ◽  
Silica Fillers ◽  
Filled Composite

The effects of polymorphic form and particle size of SiO2 fillers on the dielectric, mechanical and thermal properties of SiO2–Polyetheretherketone (SiO2–PEEK) composites were investigated in this paper. Strong low frequency (<10Hz) Debye-like dielectric dispersions could be observed for all samples. The dielectric permittivity at high frequencies of the composite exhibits little morphology or particle size-sensitive characteristics of the SiO2 fillers. All the composites obtained in this case demonstrate the dielectric permittivities of [Formula: see text] at high frequencies. The crystalline [Formula: see text]-cristobalite filled composite exhibits lower dielectric loss and mechanical strength, but larger thermal expansion coefficient and thermal conductivity, compared with the similar particle sized amorphous SiO2 filled one. The crystalline [Formula: see text]-quartz filled composite demonstrates the lowest mechanical strength and highest dielectric loss. An increase in particle size of the spherical fused silica fillers decreases the dielectric loss, while increases the thermal conductivity of the composite. The flexural strength of the composite reaches the maximum value of 113 MPa when the particle size of spherical SiO2 filler is [Formula: see text]m. Particle packing by combining optimal amounts of differently sized spherical fused silica fillers leads to a substantial improvement of mechanical strength (153MPa) coupled with reasonable dielectric and thermal properties due to the synergic effect (dielectric permittivity ([Formula: see text] = 3.35, dielectric loss (tan[Formula: see text] @10 GHz, thermal conductivity ([Formula: see text] = 0.74 W/m*k ([Formula: see text]C), coefficient of thermal expansion ([Formula: see text]C and relative density ([Formula: see text]) = 99.72%).

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%

Researches about the Determination of the Thermal Conductivity Coefficient for Silica Sand Moulds Used in Romanian Foundries

2010 ◽  
Vol 457 ◽  
pp. 312-317 ◽  
Author(s):  
Ioan Ciobanu ◽  
Mihai Chisamera ◽  
Sorin Ion Munteanu ◽  
Aurel Crişan ◽  
Iulian Riposan ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Cast Iron ◽  
Thermal Conductivity Coefficient ◽  
Thermal Analyses ◽  
Transport Processes ◽  
Solidification Time ◽  
Silica Sand ◽  
Water Evaporation ◽  
Mould Wall

The paper presents the results of the researches regarding the determination of the thermal conductivity coefficient of the moulds used for cast iron parts in Romanian foundries. The instantaneous values of the thermal conductivity coefficient of the moulds are influenced by the type of materials that compose the moulding batch (sand, binder, additional materials) their content (percentage) their characteristics (grains form and dimensions), but also by the temperature. Many software used for casting solidification uses a mean substitutive value. This one include the effect of heat transmission by conduction in the mould wall and the secondary processes that influence the heat transfer throw the mould wall ( burning processes of organic substances, water evaporation and re-condensation processes, mass transport processes). The determination of this mean value in the case of casting grey cast iron parts with thickness of 20 mm is presented in the paper. A regressive method was applied. The solidification time experimentally determined throw thermal analyses is compared with the solidification time obtained by simulation, in three points of the casting. The value of the substitutive coefficient of thermal conductivity that assure the best closeness between the simulated solidification time and the solidification time experimentally determined throw thermal analysis in the three points was established.

Characterization of homoepitaxial diamond films by Electron microscopy

1991 ◽  
Vol 49 ◽  
pp. 880-881
Author(s):  
D.P. Malta ◽  
S.A. Willard ◽  
R.A. Rudder ◽  
G.C. Hudson ◽  
J.B. Posthill ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
Surface Defects ◽  
Substrate Surface ◽  
Diamond Films ◽  
Chemical Vapor ◽  
Polycrystalline Diamond ◽  
Large Degree ◽  
Rf Plasma ◽  
Semiconducting Diamond

Semiconducting diamond films have the potential for use as a material in which to build active electronic devices capable of operating at high temperatures or in high radiation environments. A major goal of current device-related diamond research is to achieve a high quality epitaxial film on an inexpensive, readily available, non-native substrate. One step in the process of achieving this goal is understanding the nucleation and growth processes of diamond films on diamond substrates. Electron microscopy has already proven invaluable for assessing polycrystalline diamond films grown on nonnative surfaces.The quality of the grown diamond film depends on several factors, one of which is the quality of the diamond substrate. Substrates commercially available today have often been found to have scratched surfaces resulting from the polishing process (Fig. 1a). Electron beam-induced current (EBIC) imaging shows that electrically active sub-surface defects can be present to a large degree (Fig. 1c). Growth of homoepitaxial diamond films by rf plasma-enhanced chemical vapor deposition (PECVD) has been found to planarize the scratched substrate surface (Fig. 1b).

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