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Metallurgy foundry alloys

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Course Unit Code618-2023/03
Number of ECTS Credits Allocated5 ECTS credits
Type of Course Unit *Compulsory
Level of Course Unit *First Cycle
Year of Study *Third Year
Semester when the Course Unit is deliveredSummer Semester
Mode of DeliveryFace-to-face
Language of InstructionCzech
Prerequisites and Co-Requisites Course succeeds to compulsory courses of previous semester
Name of Lecturer(s)Personal IDName
HAM33doc. Ing. Jiří Hampl, Ph.D.
LIC03doc. Ing. Petr Lichý, Ph.D.
Summary
The course focuses on broader theoretical and practical knowledge of metallurgy and technology for casting alloys and their application in smelting and casting. Emphasis is placed on knowledge and technology melting mimopecního processing and properties of casting alloys for castings.
Learning Outcomes of the Course Unit
Acquired knowledge
-student will be able to characterize the basic processes in the metallurgical processing of foundry alloys in electrical and fuel furnaces.
-student recieves theoretical and practical knowledge of secondary metallurgy processing foundry alloys and casting technology.

Acquired skills
-student will be able to use the knowledge of metallurgy foundry alloys to their optimal application.
-student will know the methods of production of castings of various alloys for castings.
- student will know the process and methodology of complicated and time-consuming tests ratings liquid phase metal materials based on visual methodology.
Course Contents
1. The division of foundry alloys for castings. Iron Cast. Steels for castings. Alloys of non-ferrous metals. Mechanical, physical, and technological properties of foundry casting alloys.
2. The division of cast irons, basic types and their application in industry. Equilibrium diagram of iron-carbon. The basic chemical composition, microstructure and foundry properties of cast iron with lamellar graphite.
3. Incoming raw materials and furnaces for melting of iron cast. Cupola furnace. Processes of melting in the CF, Melting of iron casts in an electric induction furnace and in an electric arc furnace. Rotary gas furnace. Holding furnace.
4. Crystallization of iron cast, eutectic of crystallization. The mechanism and kinetics of graphitization. Influence of crystallization of cast iron. Theory and technology of cast iron inoculation.
5. Foundry cast iron properties. Volumetric shrinkage of cast iron castings. The module of casting. Sizing of riser and gating system.
6. Metallurgical processing of spheroidal graphite cast iron. Manufacturing methods and technology modifications. Thermodynamics and kinetics of modification.
7. Steels for castings. Incoming raw materials and auxiliary facilities for the production of steel castings. Physical, mechanical and casting properties of steels for castings.
8. Melting of steels in electric arc furnace. Oxidation and reduction melting period. Vacuum degassed steel. Oxygen, sulfur, hydrogen, nitrogen and inclusions in steels.
9. Casting technology of steel castings. Gating systems, the metal flow, casting speed. Reoxidation processes of casting of steel castings.
10. Non-ferrous alloy castings. Aluminum alloy, silumin Al-Si, Al-Cu duralumin. Magnesium alloy. Bronze, brass. Mechanical, physical, and technological and foundry properties non-ferrous alloys.
11. Metallurgical processing of non-ferrous alloys. Furnaces for melting and refining of the melt. Influence of microstructure, inoculation. Degassing of melts.
12. Gravity casting of non-ferrous metals into permanent and non-permanent forms, precision casting. Centrifugal casting.
13. Low-pressure die casting, vacuum and pressure die casting in metal molds. Casting with crystallization under pressure and in semi-solid state. Heat treatment of castings.
14. Control and analytical methods in metallurgy, foundry alloys. Thermal analysis.
Recommended or Required Reading
Required Reading:
CAMPBELL, J. Castings practice: the 10 rules of castings. Oxford: Elsevier Butterworth-Heinemann, 2004. ISBN 0-7506-4791-4.
STEFANESCU, D.M. Science and Engineering of Casting Solidification. Alabama: Intrnational Pubishing Switzerland 2015. ISBN 978-3-319-15692-7, ISBN 978-3-319-15693-4.
VONDRÁK, V., HAMPL J. a A. HANUS. Metalurgie litin: mimopecní zpracování roztavené litiny. Ostrava: VŠB - Technická univerzita Ostrava, 2005. ISBN 80-248-0777-7.
VONDRÁK, V., PAVELKOVÁ A. a A. HANUS. Metalurgie litin: vtokové soustavy a nálitkování. 2. vyd. Ostrava: VŠB - Technická univerzita Ostrava, 2005. ISBN 80-248-0960-5.
MICHNA, Š. Encyklopedie hliníku. Prešov: Adin, 2005. ISBN 80-89041-88-4.
CAMPBELL, J. Castings practice: the 10 rules of castings. Oxford: Elsevier Butterworth-Heinemann, 2004. ISBN 0-7506-4791-4.


Recommended Reading:
GOODRICH, G.M. Iron Castings Enginering Handbook. Illinois: American Foundry Society. 2006. ISBN 0-87433-260-5

GEDEONOVÁ, Z. a I. JELČ. Metalurgia liatin. Košice: HF TU, 2000. ISBN 80-7099-516-5.

ELBEL, T. Vady odlitků ze slitin železa: (klasifikace, příčiny a prevence). Brno: MATECS, 1992.

GOODRICH, G. M., ed. Iron castings engineering handbook. Rev. and repr. Schaumburg: American Foundry Society, 2006. ISBN 0-87433-260-5.
Planned learning activities and teaching methods
Lectures, Individual consultations, Tutorials, Experimental work in labs
Assesment methods and criteria
Task TitleTask TypeMaximum Number of Points
(Act. for Subtasks)
Minimum Number of Points for Task Passing
Credit and ExaminationCredit and Examination100 (100)51
        CreditCredit30 20
        ExaminationExamination70 31