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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...

Computer simulation of foundry processes is an essential part of a modern foundry. The role of the gating system, its design and different elements are important in casting. Experimental verification of the designed gating system for new castings is costly, timeconsuming and economically inefficient. Therefore, these processes in the foundry are replaced by computer simulation. A detailed analysis of the simulation results makes it possible to predict various risks that may cause a failure in the quality of castin...

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...

Synthetic cast iron was introduced into production 60 years ago, just after the development and production of medium and low-frequency high-capacity of induction furnaces (1 to 20 tonnes). This allowed the production of a wide range of cast iron, especially alloyed. Another significant effect was the increase in the portion of steel scrap up to 100% and, in particular, the reduction of the consumption of deficient and costly pig iron. Its price is up to twice as high as steel scrap. In the long time, the negative ...

Tin is widely used in the electro-technical industry, mainly for the production of the solders and tin-sheets. Resources for the production of primary tin are currently limited. Therefore, the importance of secondary methods - the recovery of tin from waste - is growing. However, the recycling of tin is associated with many technological, economic and environmental problems. It is usually energy-intensive. One of the compromising methods is "dilution" - secondary tin is mixed with high purity primary tin. However,...

The purpose of this study is to identify relationships between the values of the fluidity obtained by computer simulation and by practically implemented tests. Three types of molds were used: 1. horizontal three-channel mold designed in the accordance with the methodology of the Measurement Systems Analysis which is useful for determining repeatability and reproducibility in the analysis, 2. vertical mold ? the lyre and 3. the spiral mold (Curry spiral). An aluminum - silicon - copper alloy was model material. The...

Cast iron, the oldest type of ferrous material for injection molding is also currently the most widely used material in foundries. In particular, this good technological properties (excellent fluidity, low tendency to shrinkage and their formation, low propensity for stress) as well as acceptable mechanical properties and good workability. Similarly, its physical properties and prefer it allows to produce castings with excellent specific characteristics, particularly heat and heat resistant, wear resistant and cas...

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 ...

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 ...

Castings production from gray cast iron is 55% of castings production around the world. Cupola furnace is the most used melting furn ace for the cast iron production. There is a counter current heat excha nge during melting process in the cupola furnace. Gases proceed upwards and charge and coke downw ards where they are heated. During this process the emission creation. These emissions come from coke and metallic parts of the charge. Another sources of contamination are particles created by abrasion of charge on ...