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R. Władysiak

Abstract

The paper presents the test results of a computerized control system the sequential cooling process of permanent mold with use of water mist in the gravity die casting process.

It describes the process for preparing high-quality casts made of AlSi7Mg alloy that achieves enhanced mechanical properties. A scheme of developed device and drivers for selected methods of sequence cooling for manufacturing of castings made in permanent steel mold was presented here. Also the microstructure and mechanical properties of received aluminium casts were described. It was shown that the use of a computer system to control the water mist cooling point of the mold not only accelerates the cooling of the cast and the gravity die casting cycle shortens, but also it has a positive effect on the microstructure and mechanical properties of castings made of unmodified AlSi7Mg alloy in a raw state.

Open access

R. Władysiak and P. Budzyński

Structure of Water Mist Stream and its Impact on Cooling Efficiency of Casting Die

The work is a continuation of research on the use water mist cooling in order to increase efficiency of die-casting aluminum alloys. The paper presents results of research and analysis process, spraying water and generated a stream of water mist, the effect of the type of nozzle, the nozzle size and shape of the emitting of the water mist on the wall surface of casting die on the microstructure and geometry of water mist stream and cooling efficiency. Tests were used to perform high-speed camera to record video in the visible and infrared camera. Results were used to develop a computerized image analysis and statistical analysis. The study showed that there are statistical relationships between water and air flow and geometry of the nozzle and nozzle emitting a stream of microstructure parameters of water mist and heat the incoming stream. These relationships are described mathematical models that allow you to control the generating of adequate stream of water mist and a further consequence, the cooling efficiency of casting die.

Open access

R. Władysiak

Abstract

The work is a continuation of research on the use of water mist cooling in order to increase efficiency of the die-casting process for aluminum alloys. The paper describes the multipoint sequential cooling system of the casting die and its computer control and monitoring. It also includes results of the tests and analysis of cooling methods during making of the casting. These methods differ from each other in the sequence of casting die cooling and cause effective changes in microstructure and mechanical properties of castings made of AlSi11 alloy. The study demonstrated that the use of multipoint sequential cooling with water mist affects the microstructure refinement and reduces the segregation in the cast as well as more than by 20% increases the mechanical properties of castings in the rough state. The study also demonstrates that the sequential cooling of casting die accelerates the cooling of the casting and shortens die-casting cycle.

Open access

R. Władysiak and A. Kozuń

Abstract

The paper presents the results of the crystallization process of silumin by the TDA thermographic method and the results of the cast microstructure obtained in the sampler TDA-10, that was cooling down in ambient air. The study was conducted for silumin AlSi11 unmodified. The work demonstrated that the use of thermal imaging camera allows for the measurement and recording the solidification process of silumin. Thermal curve was registered with the infrared camera and derivative curve that was calculated on the base of thermal curve have both a very similar shape to adequate them TDA curves obtained from measurements using a thermocouple. Test results by TDA thermographic method enable quantitative analysis of the kinetics of the cooling and solidification process of neareutectic silumin.

Open access

R. Władysiak and A. Kozuń

Abstract

The work is a continuation of research on the use water mist cooling in order to increase efficiency of die-casting aluminum alloys using multipoint water mist cooling system. The paper presents results of investigation of crystallization process and microstructure of synthetic hypereutectic AlSi20 alloy. Casts were made in permanent mold cooled with water mist stream. The study was conducted for unmodified AlSi20 alloy and modified with phosphorus, titanium and boron on the research station allowing sequential multipoint cooling using a dedicated program of computer control. The study demonstrated that the use of mold cooled with water mist stream allows the formation of the microstructure of hypereutectic silumins. A wide range of solidification temperature of hypereutectic silumins increases the potential impact of changes in the cooling rate on a size, a number and a morphology of preeutectic silicon and eutectic α+β (Al+Si).

Open access

R. Władysiak and A. Kozuń

Abstract

The work is a continuation of research on the use of water mist cooling in order to increase efficiency of die-casting aluminum alloys using multipoint water mist cooling system. The paper presents results of investigation on crystallization process and microstructure of synthetic hypereutectic AlSi20 alloy. Casts were made in permanent mold cooled a with water mist stream. The study was conducted for unmodified AlSi20 alloy and a modified one with phosphorus, titanium and boron on the research station allowing sequential multipoint cooling using a dedicated program of computer control. The study demonstrated that the use of mold cooled with water mist stream and solution heat treatment allows in wide range for the formation of the microstructure of hypereutectic silumins. It leads to the growth of microstructure refinement and spheroidizing of phases in the casting.

Open access

R. Władysiak, A. Kozuń, K. Dębowska and T. Pacyniak

Abstract

The work is a continuation of research concerning the influence of intensive cooling of permanent mold in order to increase the casting efficiency of aluminium alloys using the multipoint water mist cooling system. The paper presents results of investigation of crystallization process and microstructure of multicomponent synthetic hypereutectic alloy AlSi20CuNiCoMg. The study was conducted for unmodified silumin on the research station allowing the cooling of the special permanent sampler using a program of computer control. Furthermore, the study used a thermal imaging camera to analyze the solidification process of multicomponent alloy. The study demonstrated that the use of mold cooled with water mist stream allows in wide range to form the microstructure of hypereutectic multicomponent silumin. It leads to higher homogeneity of microstructure and refinement of crystallizing phases of casting.

Open access

R. Władysiak, T. Pacyniak and J. Trzoska

Abstract

The paper presents the technology and organization of the artistic cast production. On the basis of the actual cast production system, the manufacturing process was shown, in particular sand–piece moulding, which is a very important process and a time-consuming part of the entire manufacture of the casts. The current state of the production process as well as the organization of the work and production technology were analysed with the use of methods and techniques of production improvement, the Lean Manufacturing concept and computer systems. The results of the analysis and studies were shown with use of schemes and graphs of the layout of the production resources, a flow chart of the production process, value stream mapping, and a costs table for the production and modernization of the moulding stage. The work has shown that there are possibilities to improve the artistic cast production system. This improvement leads to increased productivity, lower production costs of artistic casts and increased competitiveness of the foundry.

Open access

R. Władysiak, A. Kozuń and T. Pacyniak

Abstract

The paper presents the results of the crystallization process of silumin by the TDA thermographic method and the results of the cast microstructure obtained in the sampler ATD-10, that was cooling down in ambient air. The study was conducted for silumins AlSi8 and AlSi11 unmodified. The work demonstrated that the use of thermal imaging camera allows for the measurement and recording the solidification process of silumin. Thermal curve was registered with the infrared camera and derivative curve that was calculated on the base of thermal curve have both a very similar shape to adequate them TDA curves obtained from measurements using a thermocouple. Test results by TDA thermographic method enable quantitative analysis of the kinetics of the cooling and solidification process of hypo-and neareutectic silumins.

Open access

R. Władysiak, A. Kozuń and T. Pacyniak

Abstract

The work is a continuation of research concerning the influence of intensive cooling of permanent mold in order to increase the casting efficiency of aluminium alloys using the multipoint water mist cooling system. The paper presents results of investigation of crystallization process and microstructure of synthetic hypereutectic alloys: AlSi15 and AlSi19. Casts were made in permanent mold cooled with water mist stream. The study was conducted for unmodified silumins on the research station allowing the cooling of the special permanent probe using a program of computer control. Furthermore the study used a thermal imaging camera to analyze the solidification process of hypereutectic silumins. The study demonstrated that the use of mold cooled with water mist stream allows in wide range the formation of the microstructure of hypereutectic silumins. It leads to higher homogeneity of microstructure and refinement of crystallizing phases and also it increases subsequently the mechanical properties of casting.