The levitation melting has a potentially wide range of applications, especially in the processing of reactive metals whose contact with the crucible material causes their contamination and damage to the crucible itself. Despite its advantages, levitation melting, already proposed in the 1920s, has not yet found significant use in industrial conditions. This is due to the nature of the electromagnetic field used in previously developed devices. The disappearance of this field in the system axis causes overcoming, in the case of larger charges, surface tension forces and metal leakage from the device. The article contains a comparative analysis of a conventional solution and a newly developed levitation melting device, whose completely different design eliminates the previous weight limit of the charge.
The densification behavior of H13 tool steel powder by dual speed laser scanning strategy have been characterized for selective laser melting process, one of powder bed fusion based metal 3d printing. Under limited given laser power, the laser re-melting increases the relative density and hardness of H13 tool steel with closing pores. The single melt-pool analysis shows that the pores are located on top area of melt pool when the scanning speed is over 400 mm/s while the low scanning speed of 200 mm/s generates pores beneath the melt pool in the form of keyhole mode with the high energy input from the laser. With the second laser scanning, the pores on top area of melt pools are efficiently closed with proper dual combination of scan speed. However pores located beneath the melt pools could not be removed by second laser scanning. When each layer of 3d printing are re-melted, the relative density and hardness are improved for most dual combination of scanning. Among the scan speed combination, the 600 mm/s by 400 mm/s leads to the highest relative density, 99.94 % with hardness of 53.5 HRC. This densification characterization with H13 tool steel laser re-melting can be efficiently applied for tool steel component manufacturing via metal 3d printing.
Nickel alloys belong to the group of most resistant materials when used under the extreme operating conditions, including chemically aggressive environment, high temperature, and high loads applied over a long period of time. Although in the global technology market one can find several standard cast nickel alloys, the vast majority of components operating in machines and equipment are made from alloys processed by the costly metalworking operations. Analysis of the available literature and own studies have shown that the use of casting technology in the manufacture of components from nickel alloys poses a lot of difficulty. This is due to the adverse technological properties of these alloys, like poor fluidity, high casting shrinkage, and above all, high reactivity of liquid metal with the atmospheric air over the bath and with the ceramic material of both the crucible and foundry mold. The scale of these problems increases with the expected growth of performance properties which these alloys should offer to the user. This article presents the results of studies of physico-chemical interactions that occur between theH282alloy melt and selected refractory ceramic materials commonly used in foundry. Own methodology for conducting micro-melts on a laboratory scale was elaborated and discussed. The results obtained have revealed that the alumina-based ceramics exhibits greater reactivity in contact with the H282 alloy melt than the materials based on zirconium compounds. In the conducted experiments, the ceramic materials based on zirconium silicate have proved to be a much better choice than the zirconia-silica mixture. Regardless of the type of the ceramic materials used, the time and temperature of their contact with the nickel alloy melt should always be limited to an absolutely necessary minimum required by the technological regime.
The article describes the optimization of the melting brass. Brasses, as one of the most popular alloys of copper, deserve special attention in the context of the processes of melting, which in turn would provide not only products of better quality, but also reduce the cost of their production or refining. For this purpose, several studies carried out deriatographic (DTA) and thermogravimetric (TG) using derivatograph. The results were confronted with the program SLAG - PROP used to evaluate the physicochemical properties of the coatings extraction. Based on the survey and analysis of the program can identify the most favorable physico - chemical properties, which should be carried out treatments. This allows for slag mixtures referred configurations oxide matrix containing specific stimulators of the reaction. Conducted empirical studies indicate a convergence of the areas proposed by the application. It should also be noted that the program also indicates additional areas in which to carry out these processes would get even better, to optimize the melting process, the results.
A section of a gravel−dominated coast in Isbjørnhamna (Hornsund, Svalbard) was analysed to calculate the rate of shoreline changes and explain processes controlling coastal zone development over last 50 years. Between 1960 and 2011, coastal landscape of Isbjørnhamna experienced a significant shift from dominated by influence of tide−water glacier and protected by prolonged sea−ice conditions towards storm−affected and rapidly changing coast. Information derived from analyses of aerial images and geomorphological mapping shows that the Isbjørnhamna coastal zone is dominated by coastal erosion resulting in a shore area reduction of more than 31,600 m 2 . With ~3,500 m 2 of local aggradation, the general balance of changes in the study area of the shore is negative, and amounts to a loss of more than 28,000 m 2 . Mean shoreline change is −13.1 m (−0.26 m a −1 ). Erosional processes threaten the Polish Polar Station infrastructure and may damage of one of the storage buildings in nearby future.
Glacierized fjords are dynamic regions, with variable oceanographic conditions and complex ice−ocean interactions, which are still poorly understood. Recent studies have shown that passive underwater acoustics offers new promising tools in this branch of polar research. Here, we present results from two field campaigns, conducted in summer 2013 and spring 2014. Several recordings with a bespoke two−hydrophone acoustic buoy were made in different parts of Hornsund Fjord, Spitsbergen in the vicinity of tidewater glaciers to study the directionality of underwater ambient noise. Representative segments of the data are used to illustrate the analyses, and determine the directions of sound sources by using the time differences of arrivals between two horizontally aligned, broadband hydrophones. The results reveal that low frequency noise (< 3 kHz) is radiated mostly from the ice cliffs, while high−frequency (> 3 kHz) noise directionality strongly depends on the distribution of floating glacial ice throughout the fjord. Changing rates of iceberg production as seen for example in field photographs and logs are, in turn, most likely linked to signal amplitudes for relevant directions. These findings demonstrate the potential offered by passive acoustics to study the dynamics of individual tidewater glaciers.
The most important feature of bells is their sound. Its clarity and beauty depend, first of all, on the bell’s geometry - particularly the shape of its profile, but also on the quality of alloy used to its cast. Hence, if the melting and pouring parameters could influence the alloy’s properties, what influence they would have on the frequencies of bell’s tone. In the article authors present their own approaches to find answers on that and more questions.
Energy conservation is an important step to overcome the energy crisis and prevent environmental pollution. Casting industry is a major consumer of energy among all the industries. The distribution of electrical energy consumed in all the departments of the foundry is presented. Nearly 70% of the energy is consumed especially in the melting department alone. Production of casting involves number of process variables. Even though lot of efforts has been taken to prevent defects, it occurs in the casting due to variables present in the process. This paper focuses the energy saving by improving the casting yield and by reducing the rejections. Furthermore an analysis is made on power consumption for melting in the induction furnace to produce defective castings and improvement in the casting yield. The energy consumed to produce defective castings in all other departments is also presented. This analysis reveals that without any further investment in the foundry, it is possible to save 3248.15 kWh of energy by reducing the rejections as well as by improving the casting yield. The redesign of the feeding system and the reduced major rejection shrinkage in the body casting improved the casting yield from 56% to 72% and also the effective yield from 12.89% to 66.80%.
The paper summarises results of measurements of remelting area geometry, thermal efficiency and melting efficiency characterising the surface remelting process applied to castings of MAR-M-509 cobalt alloy. The remelting process was carried out with the use of GTAW (Gas Tungsten Arc Welding) method in protective atmosphere of helium, at the electric current intensity in the range from 100 A to 300 A, and the electric arc scanning velocity vs in the range from 200 mm/min to 800 mm/min. The effect of current intensity and electric arc scanning velocity on geometrical parameters of remeltings, thermal efficiency, and melting efficiency characterising the remelting process has been determined.
Aconitum lasiocarpum (Carpathian endemic) and A. variegatum (European endemic) occur sympatrically in the Polish Western Carpathians. Here their taxonomic hybrid A. ×pawlowskii occurs. The aim of this study was to determine the relationship between the taxonomic (Linnaean approach) and genetic structure (PCR-ISSR analysis) of the populations and individuals in two allopatric and four sympatric populations. We determined 309 individuals (OTUs) to species, subspecies and nothospecies using the Linnaean system of classification, and then genetically fingerprinted 39 randomly chosen OTUs. Comparison of the Nei and Li distances obtained from ISSR and morphological matrices using the Mantel test indicated a significant correlation (n = 39, r = 0.53, P = 0.001). Genetic analysis (NEWHYBRIDS) pointed to 7 OTUs as being later-generation hybrids (B1 introgessants) in the sympatric area. Five of them belong to A. variegatum, indicating cryptic introgression, and two belong to A. ×pawlowskii. Nonmetric multidimensional scaling (NDMS) showed gene flow between A. lasiocarpum and A. ×pawlowskii. Allopatric, morphologically pure A. lasiocarpum and A. variegatum populations differed significantly in their ISSR profiles (Fischer's R×C test, P < 0.0001). Expected heterozygosity (Hj) was significantly (p=0.05) lower in allopatric (0.1261-0.1268) than in sympatric populations (0.1348-0.1509), indicating a genetic melting pot in sympatry. The results support the existence of a natural interspecific hybrid swarm zone in the sympatric area of occurrence of Aconitum, and the taxonomic circumscription of the nothospecies within the Linnaean taxonomic system
Blast furnace and cupola furnace are furnace aggregates used for pig iron and cast iron production. Both furnace aggregates work on very similar principles: they use coke as the fuel, charge goes from the top to down, the gases flow against it, etc. Their construction is very similar (cupola furnace is usually much smaller) and the structures of pig iron and cast iron are very similar too. Small differences between cast iron and pig iron are only in carbon and silicon content. The slags from blast furnace and cupola furnace are very similar in chemical composition, but blast furnace slag has a very widespread use in civil engineering, primarily in road construction, concrete and cement production, and in other industries, but the cupola furnace slag utilization is minimal. The contribution analyzes identical and different properties of both kinds of slags, and attempts to explain the differences in their uses. They are compared by the contribution of the blast furnace slag cooled in water and on air, and cupola furnace slag cooled on air and granulated in water. Their chemical composition, basicity, hydraulicity, melting temperature and surface were compared to explain the differences in their utilization.
The article presents the results of a comparative analysis of the metal substructure for dental prosthesis made from a Co-Cr-Mo-W alloy by two techniques, i.e. precision investment casting and selective laser melting (SLM). It was found that the roughness of the raw surface of the SLM sinter is higher than the roughness of the cast surface, which is compensated by the process of blast cleaning during metal preparation for the application of a layer of porcelain. Castings have a dendritic structure, while SLM sinters are characterized by a compact, fine-grain microstructure of the hardness higher by about 100 HV units. High performance and high costs of implementation the SLM technology are the cause to use it for the purpose of many dental manufacturers under outsourcing rules. The result is a reduction in manufacturing costs of the product associated with dental work time necessary to scan, designing and treatment of sinter compared with the time needed to develop a substructure in wax, absorption in the refractory mass, casting, sand blasting and finishing. As a result of market competition and low cost of materials, sinter costs decrease which brings the total costs related to the construction unit making using the traditional method of casting, at far less commitment of time and greater predictability and consistent sinter quality.
The paper presents an application of advanced data-driven (soft) models in finding the most probable particular causes of missed ductile iron melts. The proposed methodology was tested using real foundry data set containing 1020 records with contents of 9 chemical elements in the iron as the process input variables and the ductile iron grade as the output. This dependent variable was of discrete (nominal) type with four possible values: ‘400/18’, ‘500/07’, ‘500/07 special’ and ‘non-classified’, i.e. the missed melt. Several types of classification models were built and tested: MLP-type Artificial Neural Network, Support Vector Machine and two versions of Classification Trees. The best accuracy of predictions was achieved by one of the Classification Tree model, which was then used in the simulations leading to conversion of the missed melts to the expected grades. Two strategies of changing the input values (chemical composition) were tried: content of a single element at a time and simultaneous changes of a selected pair of elements. It was found that in the vast majority of the missed melts the changes of single elements concentrations have led to the change from the non-classified iron to its expected grade. In the case of the three remaining melts the simultaneous changes of pairs of the elements’ concentrations appeared to be successful and that those cases were in agreement with foundry staff expertise. It is concluded that utilizing an advanced data-driven process model can significantly facilitate diagnosis of defective products and out-of-control foundry processes.
Thermal processes in domain of thin metal film subjected to a strong laser pulse are discussed. The heating of domain considered causes the melting and next (after the end of beam impact) the resolidification of metal superficial layer. The laser action (a time dependent belltype function) is taken into account by the introduction of internal heat source in the energy equation describing the heat transfer in domain of metal film. Taking into account the extremely short duration, extreme temperature gradients and very small geometrical dimensions of the domain considered, the mathematical model of the process is based on the dual phase lag equation supplemented by the suitable boundary-initial conditions. To model the phase transitions the artificial mushy zone is introduced. At the stage of numerical modeling the Control Volume Method is used. The examples of computations are also presented.
The aim of the paper was an attempt at applying the time-series analysis to the control of the melting process of grey cast iron in production conditions. The production data were collected in one of Polish foundries in the form of spectrometer printouts. The quality of the alloy was controlled by its chemical composition in about 0.5 hour time intervals. The procedure of preparation of the industrial data is presented, including OCR-based method of transformation to the electronic numerical format as well as generation of records related to particular weekdays. The computations for time-series analysis were made using the author’s own software having a wide range of capabilities, including detection of important periodicity in data as well as regression modeling of the residual data, i.e. the values obtained after subtraction of general trend, trend of variability amplitude and the periodical component. The most interesting results of the analysis include: significant 2-measurements periodicity of percentages of all components, significance 7-day periodicity of silicon content measured at the end of a day and the relatively good prediction accuracy obtained without modeling of residual data for various types of expected values. Some practical conclusions have been formulated, related to possible improvements in the melting process control procedures as well as more general tips concerning applications of time-series analysis in foundry production.