Papers by Author: Stanisław Roskosz

Abstract: The research presents methods for modern design and processing tools to be used in manufacturing process of castings in the aviation industry. In the study it is described how to use a computer simulation software and rapid prototyping / rapid tooling methods for manufacturing of drone’s micro-engine turbine rotor. The computer simulation of flow and solidification process and the investment casting technology were applied for manufactured elements.

Abstract: Paper presents results of quantitative evaluation of porosity conducted on big, thin walled airfoil turbine blades made from Inconel 713C alloy. To decrease mass, blades are design and manufacture like thin walled cored castings. Manufacturing of big thin walled casting airfoil blades is extremely difficult. During exploitation casting work undergo cycle fatigue. In that cause casting should be free of casting defects, including porosity. Conducted research focused on Inconel 713C superalloy pouring temperature effect on porosity level of cored casted turbine blade. Results were compared to porosity of solid casted turbine blade. It was found that porosity of cored blades is lower than solid blade porosity. In cored blades higher porosity is located on airfoil convex side. Airfoil concave side has lower porosity.

Abstract: The subject matter of the paper is the quantitative evaluation of gaseous and shrinkage porosity in the turbine blades using quantitative metallography methods. The research material consisted of blades with a polycrystalline structure made of IN 713C superalloys. Three different shell mould systems were used during the investment casting: shell A - typical industrial shell mould system and used in this work as the reference; shell B – similar to version A, but SiC grit was applied as back-up stucco; shell C – entirely SiC shell mould system. The blades of superalloy IN-713C cast into the wholly SiC shell mould system have revealed much lower porosity as compared to the blades cast into the typical industrial shell mould system.

Abstract: The paper presents investigations concerning causes of non-metallic inclusions forming in castings made of nickel-base superalloys. The most common reason of inclusions forming is erosion and thermal decomposition of crucibles and molds by the action of liquid alloy. In case of superalloys containing reactive elements (Hf), many reactions at the alloy-crucible and alloy-mold interfaces take place.

Abstract: The subject matter of the paper is the quantitative evaluation of gaseous and shrinkage porosity in construction elements of a low-pressure aircraft engine turbine using quantitative metallography methods. The research material comprised blades and blade segments with a polycrystalline structure made of IN 713C and MAR M247 superalloys. One of the major problems that occur in the precision castings is their porosity: gaseous, which is the result of emission of dissolved gases from the superalloy during solidification, and shrinkage, being the result of shrinkage of the superalloy and of insufficient feeding of the interdendritic space. The developed practical procedure of selective measurement of gaseous and shrinkage porosity enabling the examination of precision castings made of high-temperature creep resisting nickel superalloys is presented.

Abstract: Magnesium alloys are the lightest, widely used structural material. They are often used in aeronautical and automotive industries, where the weight savings are essential. Magnesium alloys present acceptable mechanical properties but their high temperature properties are unsatisfactory. This led to development of magnesium alloys with rare earth elements addition. To achieve good mechanical properties these alloys are modified with zirconium. Modification affects positively also corrosion resistance of Mg-RE alloys. It is important to study impact of modifier amount on the structure and properties of these alloys. Unmodified and modified alloys were investigated. Three variants of modification were: modification according to Magnesium-Elektron specification, 50% and 100% more modifier. Mechanical and structural properties were investigated. Fractures were observed on scanning electron microscope. Results showed that grain refinement and yield strength increase with increasing amount of modifier. Impact of modification on tensile strength is unclear, probably because of non-metallic inclusions in the material’s structure. The inclusions sources are oxygenated nappe of liquid metal and fluxes, used during smelting.

Abstract: Magnesium alloys, thanks to their low density, are characterized by very high specific strength and specific stiffness. Due to acceptable mechanical properties, these alloys are widely used in automotive and aerospace industries for the elements such as: gearbox and engine housings, steering wheel columns or wheels. The main problem of the most common magnesium alloys – such as AZ91 are their weak high temperature properties. This led to development of alloys containing rare earth elements. These alloys achieve their demanded mechanical properties after grain refinement with the zirconium. Because of a big responsibility of the elements made from Mg-RE alloys, it is important to investigate modification impact on properties of the magnesium alloys. The paper presents results of studies properties of the WE43 and Elektron 21 casting magnesium alloys, modified in three different ways – according to Magnesium-Elektron specification, 50% stronger modification and 100% stronger. For the comparison, unmodified alloys were also investigated. Investigations showed, that alloys modified according to MEL specification presents optimal set of structural and mechanical properties. Further increase of amount of modifiers doesn’t let to significant increase of mechanical properties. Fractographic investigations showed many non-metallic inclusions on the fractures surface, which are result of faulty smelting process.

Abstract: Magnesium alloys are the lightest, widely used structural material. They are often used in aeronautical and automotive industries, where the weight savings are essential. Due to high responsibility of the elements made from magnesium alloys it is important to achieve high quality castings without any defects. The paper presents results of investigations on impact of sand mould cooling rate on microstructure and quality of the castings. Six identical castings, fed and cooled in different ways were investigated. Studies consisted of: RTG investigations and SEM and LM observations. Microstructure was evaluated qualitatively and quantitatively. RTG investigations showed that casting without feeder and cooler, casting only with feeder and castings cooled with 20mm and 40mm thick cooler contains voids inside. Castings with feeder and coolers 20mm and 400mm thick were flawless. Microstructure evaluation showed that castings with and without defects have different structure. Castings with defects were characterized by higher volume fraction of Mg17Al12 intermetallic phase. Flawless castings were characterized by fully divorced eutectic.

Abstract: A quantitative description of overlaps on fractures in sialon ceramics, is presented in the paper. A conventional analysis, aiming at the determination of the percentage share of overlaps on the basis of quantitative fractography, was preceded by stereometric/fractal analyses. They enabled the selection of representative sections of samples and then, the production of transverse microsections in those places for an analysis of the fractures’ profiles using the light microscopy method and fractographic image analysis. Based on the compared results from both methods, a successful verification was made of the research methodology developed earlier for sintered carbides and proven for a chromium-molybdenum steel.

Abstract: Resistance to brittle cracking is one of the most important functional properties of sialon ceramics. Evaluation of the resistance requires an analysis of decohesion processes occuring in the material. Aiming at a comprehensive description of the morphology of typically brittle fractures, a quantitative characterization was made using different methods and techniques, regarding the surface of fractures formed in a three-point bending test. By using the parameter Sdr, determined via the surface stereometry method, the fracture surface development coefficient, RS, typical for fractography, was calculated. Analysis of the research results indicates a proportional relation between parameter RS and the sialon ceramics’ bending strength.