Internal casting defects that are detected by radiography may also be detected by ultrasonic method. Ultrasonic testing allows investigation of the cross-sectional area of a casting, it is considered to be a volumetric inspection method. The high frequency acoustic energy travels through the casting until it hits the opposite surface or an interface or defect. The interface or defect reflects portions of the energy, which are collected in a receiving unit and displayed for the analyst to view. The pattern of the energy deflection can indicate internal defect. Ultrasonic casting testing is very complicated in practice. The complications are mainly due to the coarse-grain structure of the casting that causes a high ultrasound attenuation. High attenuation then makes it impossible to test the entire volume of material. This article is focused on measurement of attenuation, the effect of probe frequency on attenuation and testing results.
The main goal of the article is to identify artificially created defects like lack of fusion and incomplete penetration in butt weld joint using non-destructive volumetric methods. These defects are the most serious defects in welds of steel constructions from the safety point of view. For identification, an ultrasonic phased array technique and a conventional X-ray using digital imaging were used. The theoretical part of the article describes the current state of the given issue and provides basic theoretical knowledge about ultrasonic and X-ray welding tests. In the experimental part, the procedure and results of testing butt weld joint are described by both non-destructive methods. The butt weld joint was made from steel S420MC. Each indication obtained by the ultrasonic and x-ray technique is supplemented by the macrostructure of the weld taken from the indication position. The results of the experimental work mentioned in the article point to the possibility and reliability of the identification of melting defects by selected nondestructive methods in terms of their character and orientation.
Use of welding technology for the repair of steel castings is particularly common in two areas. These include weld surfacing of protrusions that remained incomplete after casting, or filling the surface defects (cavities). These defects are more common for steel casting than for graphite cast iron, due to the lower fluidity of steel. This article describes a suitable technological process of repairing the defects on the casting using the welding technology. A specimen produced for this purpose was prepared by carving a groove into a cast steel plate 20 GL, which was then filled with a weld metal using MAG (135) technology. The following evaluation of the basic characteristics of the repaired site point to the suitability of the selected technological parameters of the repair procedure. Metallographic evaluation was carried out, further evaluation of mechanical properties by tensile test, bend test and Vickers hardness test. The proposed methodology for the evaluation repair of foundry defects in steel castings also meets the requirements for the approval of welding procedures in accordance with the relevant valid legislation.
Materials based on cast irons are often used for protection against wear. One of the methods of creating protective surface with cast iron structures is hardfacing. The application of hardfacing with self shielded flux cored wire with high carbon content is one of the economical ways often used to protect machinery parts exposed to both abrasion and erosion. The wear resistance of hardfacings depends on their chemical composition, structure obtained after hardfacing, parameters of depositing process and specific conditions of wear. As the base material in the investigation the steel grade S235JR was used. The wear behavior mechanism of hardfacings made with one type of self shielded flux cored wire and different process parameters were evaluated in this paper. Structures obtained in deposition process were different in hardness, amount of carbides and resistance to wear with two investigated impingement angles. The erosion tests showed that impingement angle 30° gives lower erosion rate than angle 60°.
The article summarizes the theoretical knowledge from the field of brazing of graphitic cast iron, especially by means of conventional flame brazing using a filler metal based on CuZn (CuZn40SnSi – brass alloy). The experimental part of the thesis presents the results of performance assessment of brazed joints on other than CuZn basis using silicone (CuSi3Mn1) or aluminium bronze (CuAl10Fe). TIG electrical arc was used as a source of heat to melt these filler materials. The results show satisfactory brazed joints with a CuAl10Fe filler metal, while pre-heating is not necessary, which favours this method greatly while repairing sizeable castings. The technological procedure recommends the use of AC current with an increased frequency and a modified balance between positive and negative electric arc polarity to focus the heat on a filler metal without melting the base material. The suitability of the joint is evaluated on the basis of visual inspection, mechanic and metallographic testing.
The article deals with ultrasonic testing possibilities of the copper alloy centrifugal casts. It focused on the problems that arise when testing of castings is made of non-ferrous materials. Most common types of casting defects is dedicated in theoretical introduction of article. Ultrasonic testing technique by conventional ultrasound system is described in the theoretical part too. Practical ultrasonic testing of centrifugal copper alloy cast - brass is in experimental part. The experimental sample was part of centrifugally cast brass ring with dimensions of Ø1200x34 mm. The influence of microstructure on ultrasonic attenuation and limitations in testing due to attenuation is describes in experimental part. Conventional direct single element contact ultrasound probe with frequencies of 5 MHz, 3.5 MHz and 2 MHz were used for all experimental measurements. The results of experimental part of article are recommendations for selecting equipment and accessories for casting testing made of non-ferrous metals.