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K. Zaba, S. Nowak, M. Kwiatkowski, M. Nowosielski, P. Kita and A. Sioma

Abstract

The aim of this paper is manufacturing of turbocharger engine jet blades made of nickel superalloys. Processes for producing molds and casting realized in a production line are special processes. It means that the results are known only after inspection of the finished product. There is lack of the methods and techniques of effective and efficient quality control of the work in stock, above all molds. Therefore, the unknown is the state ceramic mold for the precision casting, which resulting in risk of referral to a defective mold of the casting process and thus give the product does not comply, is eliminated in the final inspection.

One method of reducing this risk is particularly thorough monitoring of all parameters of each process and keeping them in the desired operating point. Operating point is a set of parameters of processes. Such monitoring is possible with the commitment to the methods and techniques to automatically, without human intervention, data collection and processing methods appropriate for use in operational control.

The paper presents results of research on the attitude to the problem of a special process. This change is the introduction to the process efficient and effective form of quality control tools in the course of its preparation. In this case, the method of photogrammetry, thermal imaging and computed tomography were used.

With the infrared camera will be possible to determine the temperature field, the disorder in relation to the pattern indicates the type of defect. Computed tomography and will be used to develop patterns of correlated defects associated with thermal imagers. Photogrammetry is the use of a model set of quality control (comparison of the actual state of the model *.CAD). It also allows the designation of a wall thickness of the mold.

Open access

K. Żaba, P. Kita, M. Nowosielski, M. Kwiatkowski and M. Madej

Abstract

The article presents a properly planned and designed tests of the abrasive wear resistance 2024 aluminum alloy strips under friction conditions involving various lubricants. Test were focused on the selection of the best lubricant for use in industrial environment, especially for sheet metal forming. Three lubricants of the Orlen Oil Company and one used in the sheet metal forming industry, were selected for tests. Tests without the use of lubricant were performed for a comparison. The tester T-05 was used for testing resistance to wear. As the counter samples were used tool steel - NC6 and steel for hot working - WCL, which are typical materials used for tools for pressing. The results are presented in the form of the force friction, abrasion depth, weight loss and coefficient of friction depending on the lubricant used and the type of counter samples. The results allowed for predicting set lubricant-material for tools which can be applied to sheet metal made of aluminum alloy 2024.

Open access

K. Żaba, M. Nowosielski, P. Kita, M. Kwiatkowski, T. Tokarski and S. Puchlerska

Abstract

The paper presents the results of corrosion resistance of heat treated aluminized steel strips. Products coated by Al-10Si alloy are used among others in a manufacturing process of welded pipes as the elements of the car exhaust systems, working in high temperatures and different environments (eg. wet, salty). The strips and tubes high performance requirements are applied to stability, thickness and roughness of Al-Si coating, adhesion and corrosion resistance. Tubes working in elements of exhaust systems in a wide range of temperatures are exposed to the effects of many aggressive factors, such as salty snow mud. It was therefore decided to carry out research on the impact of corrosion on the environmental influence on heat treated aluminized steel strips. The heat treatment was carried out temperatures in the range 250-700°C for 30, 180, 1440 minutes. Then the coatings was subjected to cyclic impact of snow mud. Total duration of treatment was 12 months and it was divided into three stages of four months and at the end of each stage was made the assessment of factor of corrosion. The results are presented in the form of macroscopic, microscopic (using a scanning electron microscope) observations and the degree and type of rusty coating.

Open access

K. Żaba, M. Nowosielski, S. Puchlerska, M. Kwiatkowski, P. Kita, M. Głodzik, K. Korfanty, D. Pociecha and T. Pieja

The paper presents the research results of the mechanical properties and microstructure of the material in initial state and parts made from nickel superalloy Inconel®718 in the rotary forming process with laser heating. In the first step was carried out basic research of chemical composition, mechanical properties, hardness and microstructure of sheet in initial state. Then from the metal sheet, in industrial conditions, was made axisymmetric parts in the flow and shear forming with laser heating. Parts were subjected to detailed studies focused on the analysis of changes in the mechanical properties and microstructure in the relation to the material in initial state. The analysis was based on the tests results of strength and plastic properties, hardness, microstructural observations and X-ray microanalysis in the areas where defects appear and beyond. The results are presented in the form of tables, charts, and photographs of the microstructure.