Manufacturing Technology Journal, 2013 (vol. 13), issue 3
Influence of chemical composition, form and morphology of surface of NaCl grains on mechanical properties of water soluble cores
Eliška Adámková, Petr Jelínek, Soňa Študentová
Manufacturing Technology 2013, 13(3):255-261 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/255 
With development of a number of branches (automobile industry) the demand of increasingly more complex and more exacting castings that are mechanically cleanable with difficulties only is growing. Application of the technology of disposable water soluble cores from inorganic salts is one of solutions of troublesome problems of removing the cores from places hardly accessible for cleaning. Solubility in water enables reversal crystallization of the salt from the water solution what is a precondition for forming a closed ecological cycle of the core manufacture. Application of salt cores can be met in processes of low-pressure casting, gravity casting...
Production and properties of metal foams from non-ferrous metals alloys
Vlasta Bednářová, Petr Lichý, Tomáš Elbel, Ivo Lána
Manufacturing Technology 2013, 13(3):262-265 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/262
Metal foams belong thanks to their unique properties into the group of new and perspective materials. The paper deals with foundry procedures used for production of cast metal foams based on non-ferrous metals alloys. Individual procedures of production in lab and pilot conditions are described, which result in casting with certain structural regularity. Attention is paid also to the obtained microstructure of these cast materials and to evaluation of their properties. The experimental part summarises the existing research works in this area, including future possibilities of their use. Cast metal foams are not yet produced in Czech Republic on industrial...
Study of interactions between molding materials and magnesium alloys melt metal
Jaroslav Beňo, Petr Lichý, Michal Cagala, Kateřina Konečná, Marek Břuska
Manufacturing Technology 2013, 13(3):265-269 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/265
For production of castings from magnesium alloys it is necessary to use covering or protective materials, which prevent reaction of the melt with air (air oxygen). With respect to the surface quality of castings it is absolutely necessary to monitor also the mutual interaction of the alloy with material of the mould or the core. The objective of this paper consists in investigation of influence of cores based on inorganic salts on the structure and surface quality of the castings made of the magnesium alloy AZ91 at gravity casting. Within the frame of experiment we studied by metallographic and SEM analyses the surface quality of castings from the...
Offline Programming for Robotic Deburring Process of Aluminium Wheels
Ondřej Bílek, David Samek, Jana Knedlová
Manufacturing Technology 2013, 13(3):269-275 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/269
The paper presents application of Siemens RobotExpert software of industrial robot offline programming. The deburring process of aluminium wheel is described and developed. The robotic work-cell contains robot ABB IRB 1600id and two axes positioner ABB IRBP A 750 D 1000 H 700. The final robot tool path is checked using the collision viewer, the joint status monitor, the tool centre point speed viewer and tracker.
Effect of adding iron to the AlSi7Mg0.3 (EN AC 42 100, A356) alloy
Dana Bolibruchová, Lukáš Richtárech
Manufacturing Technology 2013, 13(3):276-281 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/276
Iron is the most common and harmful impurity in aluminum casting alloys and has long been associated with an increase of casting defects. While the negative effect of iron is clear, itsmechanism is not fully understood. In generally,iron is associated with the formation of Fe-rich intermetallic phases. This article deals with different iron content in aluminum alloy A356. After castingswere in test samples observed intermetallic phases and influence of iron on another elements in alloy. This alloy was not inoculatedor modified. The negative influence of iron wasn't eliminated by "iron correctors". The main objective of this experiment was to determine...
Effect of Germanium on Secondary Lead-free Tin Solders
Dana Bolibruchová, Marek Brůna
Manufacturing Technology 2013, 13(3):281-289 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/281
The paper deals with the lead-free soldering and influence of germanium amount in lead-free secondary solder Sn99. Lead-free soldering is an emerging area in the metallurgy of non-ferrous metals with a non-harmful effect on the environment. This method of soldering is very important for connecting materials in precision electrical engineering. In the experimental part of the paper are evaluated properties of lead-free solder Sn99 with graduated amount of Ge, compared with lead-free solder with the addition of nickel and silver. The goal was to provide knowledge on the impact of germanium on microstructure change, solderability and formation of oxides...
Possibilities of iron elimination in aluminium alloys by vanadium
Dana Bolibruchová, Mária Žihalová
Manufacturing Technology 2013, 13(3):289-296 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/289
Presence of iron is a common problem in Al-Si based alloys. Due to iron influence, mechanical and foundry properties of alloys are decreasing, so it is necessary to balance the influence in a certain way. One of possible solutions is addition of alloying elements, also called correctors of iron, into the melt. In this paper, the influence of vanadium on decreasing negative effect of iron in secondary alloy AlSi6Cu4 is assessed. In experimental part, properties of alloy with various addition of vanadium are evaluated. Microstructural and EDX analysis of selected structural parts are also a part of the experimental measurements. Based on statements from...
Prediction of the Porosity of Al Alloys
Marek Brůna, Lukáš Kucharčík
Manufacturing Technology 2013, 13(3):296-302 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/296
The main goal of the research presented in this paper is to gain a deeper understanding of solidification processes in terms of porosity formation in AlSi7Cu0.5Mg alloy through complex data evaluation obtained from thermal analysis, simulation software ProCAST and also from real melts. Formation of porosity (micro, macro porosity) was examined under different casting conditions, the pouring temperature varied from 730 °C to 650 °C. The experiment will attempt to analyze, how the pouring temperature effects the formation and character of porosity. For this purpose was various methods were used, not only real castings evaluation, but also advanced porosity...
Using the Design of Experiment Method to Evaluate Quality of Cuts after Cutting Aluminum Alloy by AWJ
Helena Čierna, Miroslava Ťavodová
Manufacturing Technology 2013, 13(3):303-307 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/303
The article deals with the use of the SPC method, specifically the DoE method - Design of Experiment method, during evaluation of a finished area of aluminum allow AlMg3 with an abrasive waterjet (AWJ). Design of experiment utilized a basic model, which presents a process as a change in input factors on an output characteristic. The basis of this method stems from the fact that the output characteristic, which expresses a specific measured qualitative attribute has its variability. We can identify numerous factors that affect the quality of finished area when cutting material with the help of an abrasive waterjet. With the help of statistical methods...
Fracture surface of recycled AlSi10Mg cast alloy
Mária Farkašová, Eva Tillová, Mária Chalupová
Manufacturing Technology 2013, 13(3):307-313 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/307
Recycled aluminium alloys are made out of aluminium scrap (new or old) and workable aluminium garbage by recycling. Due to the increasing production of recycled aluminium cast alloys is necessary to ensure their strict metallurgical control. The mechanical properties and the microstructure character depends on the chemical composition; melt treatment conditions, solidification rate, casting process and the applied thermal treatment. The mechanical properties depend on the morphologies, type and distribution of Si, Cu, Mg and Fe-phases, on the grain size, DAS and porosity distribution. Improvement of mechanical properties and structure of Al-alloys...
Plastic Deformation Properties of Magnesium Alloy AZ61
Ivana Hlaváčová, Peter Palček, Mária Chalupová, Zuzana Dresslerová
Manufacturing Technology 2013, 13(3):313-319 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/313
The main object of this research was the influence of plastic deformation on magnesium alloy AZ61 with 0.5 wt. % of Ca. Tested specimens were loaded by three - point bending test and by pressure deformation. Hardeing and softening were measured also. Specimens were studied in two structural states: as - cast state and in state after heat treatment. During three - point bending test specimens were plastically deformed by dislocation slip and twinning. The compression loading of experimental specimens after heat treatment led to slip and twinning plastic deformation. Cracks were created in the surrounding area of the indentation and there was also cracking...
The Influence of Porosity on Mechanical Properties of Casts Produced from Al - Si Alloys
Radek Honzátko, Štefan Michna, Jaromír Cais
Manufacturing Technology 2013, 13(3):319-324 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/319
The aim of the research was to evaluate influence of porosity size on mechanical properties of AlSi7Mg0.3 (EN AC 42 100) alloy before and after thermal treatment. For the analyses casts of the same production type (forms used for tires production) were used. They were casted employing low-pressure casting technology. Since the negative influence of porosity on mechanical properties of Al alloys is generally known there is no quantitative assessment. In this research relation of porosity size in the structure of AlSi7Mg0.3 alloy and its mechanical properties is verified and quantified. Static tensile testing has proven the relation between porosity...
Influence of Cutting Tool Material on the Surface Roughness of AlMgSi Aluminium Alloy
Júlia Hricová
Manufacturing Technology 2013, 13(3):324-329 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/324
Milling is one of the most universal operations in machining processes because it can remove the redundant part of material efficiently, and moreover, it can produce almost all kinds of contour surfaces with a high quality finish. Surface roughness plays an important role in determining the product quality since it strongly influences the performance of mechanical parts as well as production cost. Many types of cutting materials are used as tool materials in today's metalworking industry. Selecting the proper cutting tool material for a specific machining application can provide substantial advantages including increased productivity, improved quality...
Porous Ti-Si Alloys for Implants
Anna Knaislová, Matyáš Peterka, Pavel Novák, Dalibor Vojtěch
Manufacturing Technology 2013, 13(3):330-333 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/330
Porous alloys are very perspective materials for medical implants, particularly for surgical and dental applications. The reason - besides their biocompatibility - is their density. This is why the implants and bone replacements are lighter and more similar to a human bone in its structure and mechanical properties. Another advantage is good osseointegration, i.e. tissue growing through pores in the material, this makes the body accept the implant better and there is also no risk of rejection. New Ti-Si biomaterials were prepared by powder metallurgy using reactive sintering, during which the desired porous structure of the material is formed. In this...
Mechanical and corrosion properties of Mg based alloys considered for medical applications as biodegradable materials
Jiří Kubásek, Dalibor Vojtěch
Manufacturing Technology 2013, 13(3):334-341 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/334
Magnesium and its alloys are considered as suitable biodegradable materials which can be gradually dissolved in organism without production of toxic compounds. The present study is oriented on new group of possible biodegradable materials based on Mg-LMM (Mg- low melting metals) alloys. Due to the limited information about the effect of Ga, Sn and In on mechanical and corrosion properties, structure studies, mechanical and corrosion testing were performed. Corrosion behaviour of materials was studied using measuring of weight changes, Mg ions release and also by EIS technique in SBF (simulated body fluid) that is close in composition with human plasma....
Possibility of affecting the casting structure of magnesium alloys
Petr Lichý, Jaroslav Beňo, Michal Cagala
Manufacturing Technology 2013, 13(3):341-345 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/341
Magnesium alloys belong to materials, which are nowadays more and more often used for various technical applications. Their principal advantage consists in their low specific mass and high specific strength, while their drawbacks consist, among other, namely in low mechanical properties at higher temperatures. Obtaining of fine grained structure can be achieved by high cooling effect of the mould. This can be ensured by use of metallic mould, especially in combination for example with die casting, or with low-pressure casting or gravity casting. Some other casting procedures exist, however, such as casting into expendable moulds, the cooling effect...
Evaluation of vibration on technological devices
Petr Lukovics
Manufacturing Technology 2013, 13(3):345-349 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/345
Research paper discuss the possibility of vibration detection on production machine and also presents devices and methodology for evaluation of vibration amplitude using non-contact laser interferometer and contact piezoelectric vibration sensors. Experimentally determines the influence of technological conditions on the quality of functional surfaces. Furthermore, paper evaluates the influence of technological conditions during planar grinding on the vibration amplitude of the grinding spindle and presents correlation between grinder vibration amplitude and quality of the product.
The Effect of Chemical Elements on the Machinability of Aluminium Alloys
Jan Madl, Ludek Ruzicka, Michal Lattner
Manufacturing Technology 2013, 13(3):349-353 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/349
Machinability of materials is evaluated by different criteria. The basic evaluative criteria are based on tool wear. However, there are other criteria, for instance chip formation, cutting temperature, forces of cutting, etc. Machinability for different criteria depends on many factors, of which the most important is the chemical composition of the material. It is possible to divide machinability tests into two groups: Long-term tests and short-term tests. Short-term machinability tests are less objective than long-term ones, but they have the advantage of short duration and lower material consumption. This paper is focused on the experimental determination...
Properties of metallic nanocrystalline powders
Ivo Marek, Alena Michalcova, Dalibor Vojtech
Manufacturing Technology 2013, 13(3):353-358 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/353
Nanocrystalline metals are advanced materials with structural constituents smaller than 100 nm. With respect to structure, they are characterized by high strength and hardness, gas absorption capability, high specific surface area, catalytic activity or magnetic properties. These properties predispose them for using in wide spectrum of possible applications, namely advanced structural and functional applications, biomedicine, catalysis or electronics. Many methods have been developed for producing nanocrystalline metals or nanocrystalline metallic powders including precipitation from supersaturated liquids, severe plastic deformation, cryo-melting,...
Preparation of Metallic Nanoparticles
Alena Michalcová, Dalibor Vojtěch, Ivo Marek, Petra Svobodová, Radka Nováková
Manufacturing Technology 2013, 13(3):358-361 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/358
Nanomaterials are substances with high application potential. It this article, the preparation technique are reviewed with aiming on selective leaching method. This method is based on preparation of conviniet binary alloy in form of supersaturated solid solution and consequent matrix dissolution. In the same time, the minor element forms nanoparticles. The need of rapid solidification of binary precursor before leaching is explained. Nanoparticles from Ni and Ag prepared by selective leaching form AlNi20 and MgAg10 alloys, were characterized by X-ray diffraction and by electron microscopy (SEM and TEM).
Analysis of Causes of Al2MgO4-Type Spinel Inclusions Formation in Al-Mg Alloys during Low-Pressure Casting
Štefan Michna, Radek Honzátko, Jaromír Cais
Manufacturing Technology 2013, 13(3):361-368 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/361
The aim of the research was to identify and analyze the nature and causes of black inclusions formation on a cast surface of AlMg3 alloy. Forms used in tires production are made of AlMg3 alloy by low-pressure casting technology. Four areas with the same shape and coloring of inclusions are marked on the figure Fig. 1. These areas underwent macroscopic and microscopic analysis. In regions of inclusions appearance several surface EDS analyzes were performed with the aim to determine chemical composition of the inclusions. EDS analyzes showed that the inclusions are in fact Al2MgO4-type spinel inclusions which appear for Al-Mg alloys with higher amount...
Influence of strontium in AlSi7Mg0.3 alloy on the tool wear
Nataša Náprstková, Jaroslava Svobodová, Jaromír Cais
Manufacturing Technology 2013, 13(3):368-373 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/368
Al-Si alloys are leading casting alloys based on aluminum. Machining of aluminum alloys is currently frequently used and it is an important area of production. The paper deals with an experiment that was conducted at the Faculty of Production Technology and Management, University of Jan Evangelista Purkyně in Ústí nad Labem, where was machined alloy AlSi7Mg0,3. Samples were made for processing from the master alloy AlSi7Mg0,3, subsequently unmodified and modified of strontium Sr. This paper describes the evaluation of tool wear in terms of how or strontium modification may affect (reduce) the tool wear.
Modification of AlSi7Mg0.3 alloy by strontium
Nataša Náprstková, Sylvia Kuśmierczak, Jaromír Cais
Manufacturing Technology 2013, 13(3):373-380 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/373
Alloy modifying is common practice for improving the structure of the material. One of often used material, where the modification is used is AlSi7Mg0.3 alloy. And modification of AlSi7Mg0.3 is often realized by strontium. The paper deals with an experiment that was realized at the Faculty of Production Technology and Management of Jan Evangelista Purkyně University in Ústí nad Labem, which dealt with the effect of modifications by strontium on the structure of AlSi7Mg0.3. In frame of its experiment were analyzed metallographic samples and were observed structures of unmodified and modified material on the microscope. Was evaluated result of modification...
The Effect of Modification by Strontium of the AlSi7Mg0.3 Alloy on the Surface Roughness
Nataša Náprstková, Jaromír Cais, Jaroslava Svobodová
Manufacturing Technology 2013, 13(3):380-384 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/380
Al-Si Alloys are a leading casting alloys based on aluminum. Machining of aluminum alloys is currently frequently used and it is an important area of production. The paper deals with an experiment, that was realized at the Faculty of Production Technology and Management, University of Jan Evangelista Purkyne in Ústí nad Labem, where was machined alloy AlSi7Mg0.3. Samples were made for machining because of the master alloys of AlSi7Mg0.3, where part of the castings was left in its original condition and part of the castings was modified by strontium. This paper describes the evaluation of surface roughness obtained after machining of these castings...
Monitoring of the microstructure and mechanical properties of the magnesium alloy used for steering wheel manufacturing
Iva Nová, Jiří Machuta
Manufacturing Technology 2013, 13(3):385-390 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/385
The article presents the microstructure and mechanical properties of magnesium steering wheels. These steering wheels are manufactured by high pressure die casting. High-pressure die casting (HPDC) is a very good process for making complex mechanical parts out of light metals like magnesium and aluminium alloys. However, in recent times, another light metal has come to the forefront in the quest for lighter vehicles and improved fuel economy. The most commonly used magnesium alloy for die casting automotive components is of the Mg-Al-Mn type. MgAl5Mn is a good purity magnesium alloy with good corrosion resistance, very good mechanical properties and...
Preparation of aluminium-based quasicrystals
Pavel Novák, Milena Voděrová, Robin Hendrych, Tomáš Kubatík, Alena Michalcová, Dalibor Vojtěch
Manufacturing Technology 2013, 13(3):390-394 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/390
This paper describes the methods that are applicable for the preparation of aluminium-based quasicrystals. Application of rapid solidification of the melt, mechanical alloying and reactive sintering of metallic powders are presented. Based on the conducted experiments, mechanical alloying seems to be the most promising technology, since it enables to yield nearly pure quasicrystalline powder in Al-Fe-Cu alloy system.
Magnesium Alloys for Implants
Pavel Salvetr, Pavel Novák, Dalibor Vojtěch
Manufacturing Technology 2013, 13(3):395-399 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/395
Extraordinary properties of magnesium alloys, biodegrability and low density guarantee that these alloys are suitable for using in medicine as bone implants. So far there have been used alloys of titanium, cobalt and stainless steel for this purpose. Among the mentioned materials the magnesium alloys are winning because of their mechanical properties, which are more similar to human bones and at the same time there is the possibility to reduce the number of surgeries because of the spontaneous implant disintegration. Pure magnesium reaches neither the requested mechanical properties nor the corrosion resistance. That is why people are searching for...
Coefficient Thermal Expansion of Fe3Al and FeAl - type iron aluminides
Martin Švec, Pavel Hanus, Věra Vodičková
Manufacturing Technology 2013, 13(3):399-404 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/399
The iron aluminides appear to be suitable materials for use in high temperature applications. Knowledge of thermal expansion of the machine parts is prerequisite for their use in industrial applications. The study of expansion properties of iron aluminides in temperature range 400 - 1200 °C is the subject of this article. There were investigated four FeAl - type alloys, four Fe3Al - type alloys and two reference materials. Tests were carried out in the furnace on a horizontal dilatometer on cylindrical or cuboidal specimens with a length of approximately 15 mm. An absolute and relative expansion was measured. The coefficients of thermal expansion (CTE)...
Research of Corrosion Properties of Al-Si Alloys Antimony Alloyed
Jaroslava Svobodová, Jaromír Cais, Štefan Michna, Martin Brůha
Manufacturing Technology 2013, 13(3):404-409 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/404
This paper evaluates the influence of different amounts of antimony addition on the corrosion resistance of the alloy Al-Si. The corrosion of aluminium alloys, methods of testing and evaluation of corrosion and the influence of antimony in alloying of Al-Si alloys is described in the introduction of the paper. The alloy Al-Si specifically AlSi7Mg0.3 alloyed by 0; 0.001; 0.005; 0.01 and 0.05 wt. % of antimony was chosen for the experiment. The prepared alloys were subjected to the two types of corrosion tests in the environment - atmosphere and corrosion chamber. The corrosion attack of experimental samples was evaluated from both the macroscopic and...
Corrosion properties of the superelastic shape memory Ni-Ti alloy for medical implants
Dalibor Vojtěch, Jiří Kubásek, Pavel Novák
Manufacturing Technology 2013, 13(3):409-414 | DOI: 10.21062/ujep/x.2013/a/1213-2489/MT/13/3/409
The Ni-Ti alloy (Nitinol, approx. 50 at. % Ni) is a biomaterial showing the shape memory and superelasticity effects. These characteristics make this material of interest for biomedical applications, especially for manufacture of stents, i.e., tubular implants for restoring damaged blood vessels, oesophageus etc. The corrosion resistance in the human body environment is a very important factor determining the life time of implants. An insufficient corrosion resistence may lead to fractures of implants, formation of dangerous fragments and to serious health problems for patients. The corrosion behavior is influenced mainly by the surface structure and...