Of great importance in the selection of materials for cast structures is keeping a proper balance between the mechanical and plastic properties, while preserving the relevant casting properties. This study has been devoted to an analysis of the choice and application of high-strength aluminium-based alloys maintaining sufficient level of casting properties. The high level of tensile strength (Rm > 500 MPa) matched with satisfactory elongation (A > 3%) is important because materials of this type are used for cast parts operating in the aerospace, automotive, and military industries. These beneficial relationships between the high tensile strength and toughness are relatively easy to obtain in the Al-Zn-Mg-Cu alloys subjected to plastic forming and proper heat treatment. In gravity cast products, on the other hand, whether poured into sand moulds or metal moulds (dies), obtaining this favourable combination of properties poses a number of research problems (mostly resulting from the alloy chemical composition) as well as technical and technological difficulties.
During the processes of copper production, post-reaction slags are formed and must be transported to storage sites as waste. The working conditions of the slag ladles are extreme, incl. due to the high reactivity of copper slag and the cyclicality of the operation of the slag ladles. The material of the vat walls is exposed to intense factors: chemical in the form of a liquid phase and temperature in the form of high gradients (thermal shocks). Which leads to a reduction in the campaign length of a single vat. The paper discusses the issues related to the operation of smelting slag pots depending on the insulating material. The aim of the work is to analyze the thermal interactions during the filling of the pots. The conclusions from the presented research are a proposal of actions aimed at extending the working time of the slag pots between repairs related to operation, as well as in terms of the total working time. The analyzes of thermal decomposition on the external and internal surfaces of slag pots with "artificially compressed" calcium milk Ca(OH)2 on the entire surface of the slag pots, which were carried out in the presented work, gave very similar results as during the modeling of steel slag pot. The use of a heat-resistant concrete layer at the bottom of the pots significantly reduces the damage zone and extends the working time.
The article presents the analysis of properties of the high-strength AlZnMgCu (abbr AlZn) aluminium alloy and estimates possibilities of its application for responsible structures with reduced weight as an alternative to iron alloy castings. The aim of the conducted studies was to develop and select the best heat treatment regime for a 7xx casting alloy based on high-strength materials for plastic working from the 7xxx series. For analysis, wrought AlZnMgCu alloy (7075) was selected. Its potential of the estimated as-cast mechanical properties indicates a broad spectrum of possible applications for automotive parts and in the armaments industry. The resulting tensile and fatigue properties support the thesis adopted, while the design works further confirm these assumptions.
The new research trends are moving away from research works that are not directly connected with industrial applications. The Integrated Computational Materials Engineering (ICME) is an excellent example of the relationship between scientific research and the industrial sector.As an example of the design development of construction of a suspension component, an overview of the changes of a welded part replaced with cast component is presented. The identification of boundary conditions and forces operating on the nodes of the suspension element allowed determining the critical areas in the existing welded construction. Then the new design of casting for high performance applications was developed. Analysis of the kinematics of the suspension components also revealed the need for changes in the design of the mounting points of the suspension components to reduce the maximum values of forces and enforced moments. As a result of successive stages of the topology optimization of analysed cast, control arms with significantly lower values of maximum stresses were obtained. The material conversion of welded part with high strength AlZnMgCu aluminium alloy allowed the reduction of the weight by 25% for the lower control arm and 30% for upper control arm.
The article discusses some of the issues associated with the use of topology optimization in shaping of the strength of castings. This kind of optimization is performed in the preliminary design phase, when the shape of the constructed part is not yet defined. The limitations that apply to the designing process concern the dimensions, boundary conditions, loads, forces, and cooperation with other structural elements. Topology optimization determines the arrangement of the material in space, so that under the conditions of loads, exploitation, and the design assumptions, the construction will have smallest possible weight. The article presents a few methods of optimization and provides simple examples. The computer calculations were carried out based on, the Finite Element Method (the Abaqus software), and the authors’ subroutines optimization algorithm that uses the results obtained in FEM. The example of the method to optimize the shape of mine shaft tubing is presented. The verification of the casting technology was conducted in MAGMASoft, taking into account the influence of the topology optimization on the production possibilities.
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