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Current applications of thermal analysis in ductile iron production are largely limited to routine monitoring, while its potential for quantitative prediction and resource-efficient process control remains underutilized. This study addresses this gap by establishing direct relationships between melt composition, thermal parameters, and resulting material performance. Sixteen industrial melts of ferritic ductile iron were produced with systematically varied charge compositions and metallurgical treatments. Cooling ...

The foundry industry is a major producer of industrial waste, with used foundry sands (UFS) representing the largest share. While bentonite-bonded sands can be reused multiple times, sands with organic binders are typically single-use and are often landfilled due to limited regeneration capacity. Their valorization in construction materials represents an important pathway toward circular economy. This study evaluates the use of UFS from three different foundries, including bentonite- and furan-bonded systems, as p...

Particulate pollutants are generated at all stages of the preparation of the moulding and core mixture, during the handling of raw materials, during mixing and preparation of the moulding mixture in the mixers, during the moulding process itself, and during both manual and machine moulding. The reason for the generation of a relatively large amount of dust in all the operations associated with the manufacture of moulds and cores is the moulding mixture used, the basis of which is abrasive, i.e. sand, whether quart...

High demands on casting quality require modernization of technology and innovation of technological equipment. The growth of the cost of input raw materials for casting production forces manufacturers to rationalize production and reduce production costs. In addition to the manufacture of the mold, the metallurgy of liquid metal production is an important indicator of the efficiency of casting production. In terms of production costs, the global trend is towards increasing the share of steel scrap in the batch at ...

Cupola furnaces are still considered the most suitable furnace units for cast iron melting. Typical exhaust gas from a cupola furnace contains CO, SO2 and NOx. A relatively large amount of dust emissions are emitted from the cupola furnace. These are formed during melting in the cupola furnace. These emitted particles can contain CaO, FeO, Pb, MnO, MgO, SiO2 and Zn. Crushing and mechanical abrasion during charge preparation and charging generate particles, some of which are emitted immediately. Dust is also genera...

Gray cast iron is still the most used material for the production of castings. It can be made in several ways, but the most efficient and economical way to make gray cast iron is in a cupola furnace. A by-product in its production is slag, which arises from impurities that may be present in the charge, from coke, which is used as fuel for the cupola furnace and part of it also passes into the slag, from the lining of the cupola furnace as well as from oxides formed during of the smelting process, sulfides and phos...

Austempered Ductile Iron (ADI) is a promising material whose structure is obtained by isothermal processing, i.e. isothermal decomposition of austenite in the bainitic range. It is used in various industrial fields. It is characterized by an excellent combination of tensile strength and ductility, exceeding the properties of quenched and tempered steels in the strength range of 800 - 1500 MPa. Its production is problematic because the ferritic or ferritic-pearlitic ductile iron (SGI), which is the basis for the pr...

Briquetting is the pressing of dusty materials into pieces of the same shape and size. Briquetting can be done without a binder or with the addition of a binder to the briquetting mixture. Briquettes can have any shape, but the most common is the shape of a cylinder. The briquettes must be strong enough to eliminate the possibility of damage during transport and must be strong enough even at high temperatures. The briquettes have a regular shape, have the same weight, are more durable and easier to transport. They...

Cast iron GG30 (EN-GJL-300C) has excellent mechanical properties and good machinability. It can be used in many industries such as hydraulics, engineering, automotive, oil and gas mining, and processing. It is suitable for the production of compressor and pump components. Return material, technological residue, iron scrap, fractional cast iron, liquid metal, and alloying components can be used as input raw materials in the production of cast iron, the first three were taken into account in the analysis. In practic...

In the production process of cast iron and steel castings, a large amount of waste is generated. Each stage of production of castings generates a certain type or types of waste. The largest volume of waste is the used molding compound, followed by slags from melting processes and dust, the creation of which is copied by the entire foundry process. Dust waste is generated from the beginning to the end of the production cycle in the foundry. Finishing operations represent, in addition to a large source of noise, a l...

Concrete is a building material composed of aggregate, cement and water. Aggregate forms a filler, cement, after mixing with water, creates crystals that connect the aggregate with a firm and flexible bond. Cement slurry gradually loses its plasticity and begins to solidify and harden, until it finally turns into cement stone. Quartz sand is most often used as aggregate. Concrete is a building material composed of aggregate, cement and water. Aggregate forms a filler, cement, when mixed with water, forms crystals ...

Computer simulation has a significant application in the field of metallurgy. It is primarily an issue that deals with the issue of casting. The simulation of casting and solidification makes visible the foundry phenomena that take place in the gating system and the casting when the mold is filled with liquid metal and during its solidification. The article deals with the design of the gating system and the simulation of the filling and solidification of a real casting made of ductile iron. In the next production ...

The paper deals with the ? + ? titanium alloys, due to their good properties such as low specific weight and high values of mechanical properties have found wide application as a construction material. Their disadvantage is high price and complicated production of the basic material - titanium but also alloying components (molybdenum, chromium), associated with high energy demand and undesirable effects on ecology. The inhomogeneity of the deformation with formation of deformation bands are typical for these alloy...

In the context of the recycling of waste from wrought aluminum alloys, especially food packaging, these were re-melted and cast into bars. The alloy thus obtained contains up to 2.0% Si, 0.8% Cu, 2.0% Fe, 2.5% Mn and other elements in tenths of %. The problem in its further processing is the porosity. Several methods were used to quantify it, of which the most accurate method was weighing. The disadvantage of this method is the requirements of the competence of the personnel as well as technical equipment. Other m...

Ductile iron is currently one of the most popular construction materials. Its mechanical properties are close to those of steel. The basic material in the production of ductile iron is gray iron, which can be produced in a cupola or in an electric induction or electric arc furnace. After tapping the gray cast iron from the furnace, the gray cast iron is processing into ductile iron. This process is called modification. Magnesium and its alloys and cerium are most often used as modifiers. In addition to the modific...

ADI (Austempered Ductile Iron) - a bainitic ductile iron in which the resulting structure is obtained by the isothermal decay of austenite in the bainite region is currently a very promising material, which has a very wide application in various industries. It is characterized by a particularly favorable combination of strength and ductility, which exceeds the properties of heat-treated steels in the strength range of 800 - 1500 MPa. Its production is problematic because the ferritic or ferritic-pearlitic SGI (sph...

Production of castings plays an important part in the global and in the national economy. The main recipient of the foundry production is the automotive industry, but castings find application also in other branches of industry, in civil engineering, in farming, in medicine, and can as well serve art production. In 2016, worldwide casting production reached 104.1 million metric tons, a shade over the 103.7 million metric tons produced in 2015. The remaining 2015 top 10 casting nations by tonnage are Japan at 5.4 m...

The increasing computing power of modern hardware systems opens new possibilities for simulating complex solidification phenomena as well as the overall simulation of the casting process. Although the simulation of filling and solidification can be considered to be state of the art, the simulation of residual stresses and distortion is still the object of intensive research. Distortion is one of often found problems of castings, especially large castings with thin sections such as frame shape or those with curved ...

The property that influences the binding properties of slag is its hydraulicity. The term ?hydraulicity? is now used internationally to describe cements and other binders that set and harden as a result of chemical reactions with water and continue to harden even if subsequently placed under water. There are a few exceptions but these chemical reactions generally involve calcium, silica, and aluminum constituents that react with water to form a whole family of calcium silicate and calcium aluminate hydrates. The c...

At present, increasingly high demands on the quality of the manufactured castings, which are used in the automotive industry. The foundry respect there are a number of advanced technologies, which are used for the casting. These include the technology of production castings by investment casting. It is used particularly where in view of the complex shape casting technology is the production of other more expensive, respectively, it is not at all possible. Such casting is the rotor of the turbocharger to be used in...

The manufacturing and processing of metals is connecting with large number of different types of wastes. One kind of these wastes are dusts and sludges which arise as a result of the melting processes or in the machining of castings. Flue dusts from melting processes are captured most often on filters, scrubbers or in Venturi scrubbers. Dust particles resulting from the machining of castings (grinding and blast cleaning) remain in the grinding rooms or they are sucked and collected on filters. Whereas these dusts ...

Various metallurgical slags are generated in metal extraction, refining and alloying processes. Due to the large slag quantities and the strict erenvironmental regulations, recycling and utilization of these slags are an attractive alternative in order to reduce and eventually to eliminate the disposal cost, to minimize the related environmental pollution, and to save the resource conservation.The global warming effect and natural resource saving are the general environmental topics nowadays. In addition, the land...

In a large competitive environment in which today foundry exist are more important is production of castings with high quality and high economic efficiency. Therefore, the use of 3D software and simulation programs is necessary in the pre-production stages. In them it is possible to design, construct and simulate filling and solidification of castings in the foundry mould, design ingate system and feeder system. A properly designed and calculated ingate and feeder system is the first prerequisite for producing of ...

Recycling is the method used to reduce the environmental impact of large volumes of materials, the sparing use of resources is another relevant factor here. The waste materials which occur in the foundry and st eel industry alongside the target products most be used elsewhere or returned to the foundry and steelmaking processes. The result will be that the need to dispose of material s will be greatly reduced , so alleviating the demand for landfill capacity. In addition, raw material depo sits will be conserved a...

The foundry industry, itself, is one of the wo rldВґs first recyclers. Foundries have been making new metal objects by remelting old ones. An estimated 15 to 20 million tons of scrap metal that would otherwise be sent to overcrowded landfills are being remade into new castings each year. As with most industries, the foundry industry generates its own by-products. Typical by-product streams from the foundry indus try include foundry sand, foundry slag, baghouse dust, and furnace and ladle refractory. In order to co...

Slag from pig iron, steel and cast iron production belong to metallurgical slag. A blast furnace slag is from pig iron production, slag from electric arc furnace and electric induction furnace are from steel production and stag from cupola furnace proceeds from cast iron production. There are given basic information about chemical composition and physical properties of slag in this contribution (melting temperature). As another properties basicity, content of free lime and structure of slag will be determined. Che...

Castings production cover different technologies of mouls and cores production, different technologies of metal melting (depended on casting material) and technologies of pouring. All these technologies have got some advantages, disadvantages and generate some kinds of by products.There are described in the contribution the basic technologies of moulds production (sand casting, shell moulding, investment casting, lost foam casting, shaw process, vacuum process), pouring technologies (gravity casting, die casting,s...

Fly dusts creates by steel and cast iron melting. Their properties depends on a type of melting aggregate. For steel it is first of all a fly dust from electric arc furnace, its chemical composition is depended on the kind of produced steel. A cupola furnace is the most used furnace for cast iron production. Fly dusts from steel and cast iron production contain some part of FeO that is reducible in a cupola and blast furnace. It is a very fine material and it has to be pelletized or briquetted before its next use....

Foundries produce metal castings from ferrous or non-ferrous alloys and they operate in various locations around the world. A typical foundry workplace is composed of furnace area, pouring area, core making area, shaking out area and fettling area. The manufacturing process involves the melting of metal into a liquid, the pouring of molten metal into a cast, the removing of casting and the cleaning / finishing of the cast piece. Dusts arise almost in every of these steps of foundry processes. Solid waste streams f...

Returnable and non-returnable losses rise during melting and casting of molten metal. Non – returnable losses arise by melting and metallurgical treatment of molten metal as a back wash of evaporation, chemical reactions between molten metal and refractory lining, molten metal and air and between molten metal and refining additions. Value of these losses depends on the kind of alloy, on used furnace and charge quality. Except non-returnable losses, the returnable losses creates by melting. They represent a diffe...

Slag are by-products by metallurgical processes. The most famous slag are blast furnace slag and steel slag. Their treatment and using are known and their using is very extensive. Cupola slag formats by cast- iron production in cupola furnace. In some countries it is used by roadway building but in Slovakia it is waste only. In some European countries it is granulated and granulation product is used in building industry. Cupola slag is after tipping from cupola furnace casted in to slag dip and put in to waste dep...

Dusts arise in every step of foundry process. A lot of dust create by mould sands and core sands preparation. Their composition depend on used binder. The main compound of these dusts is SiO2 and by mould sands with organic binder it is carbon too. A melting process is connected with formation of flue dust, its composition depends on charge composition. Cupola furnaces, electric arc furnaces and induction furnaces are used in foundry. The most quantity of dust is produced from cupola furnace. It is very fine-grain...

Return material consists of gating, risers and residues from cold chamber, defective castings and another residues from die casting. This material has to be degreased from the fatty and separating agents that are usually of oil origin. In common praxis the clean and contaminated material is put in to melting furnace, it is melted and new alloys are added in the form of small pieces. Within the frame of experiments the influence of contaminated return material in the charge on quality die castings was observed. The...

Foundries melt ferrous and non-ferrous metals and alloys and reshape them into products at or near their finished shape through the pouring and solidification of the molten metal or alloy into a mold. The foundry industry is a differentiated and diverse industry. It consists of a wide range of installations, from small to very large, each with a combination of technologies and unit operations selected to unit the input, size of series and type of product produced by the very specific installation. The foundry proc...

The European foundry industry is the third largest in the world for ferrous castings and the second largest for non-ferrous ones. the annual production of castings in the enlarged European Union amounts 11.7 million tonnes of ferrous and 2.8 million tonnes of non-ferrous castings. The foundry industry is a major player in the recycling of metals. steel, cast iron and aluminium scrap is remelted into new products. The most possible negative environmental effects of foundries are related to the presence of a thermal...