EUREKA: Physics and Engineering

The basic stages of developing an information model of finishing work of the interior of industrial and housing buildings under the control of the developer agent on the construction site are considered in the article. The automation levels in modern CAD systems, which are necessary to ensure the implementation of each stage, are analyzed.
It is proposed a sub-system of formation of information model of decision-making for finishing work, which is able to provide automation of the use of standards, selection of the most optimal solutions based on the algorithm of greed, as well as design solutions to minimize execution time of finishing work with ensuring appropriate qualit

Koval, Volodymyr

CREATING A SYSTEM OF INNOVATIVE KNOWLEDGE MANAGEMENT OF FINISHING WORK ORGANIZATION

The paper proposes a new method of production of bilayer and double-sided&nbsp;castings with differentiated structure and properties using the technology of in-mold modification of the initial melt, smelted in a single melting furnace, which ensures formation of hard wear-resistant white iron as the working layer, and formation of ductile shock-resistant cast iron with nodular graphite as the core or the mounting part. Numerous laboratory studies confirm the feasibility of the proposed method and provide conditions ensuring differentiation of structure and properties in local parts or layers of castings. The prospects of the method for manufacturing a wide range of industrial castings are indicated

Fesenko, Kateryna

Mogylatenko, Volodymir

Fesenko, Anatoliy

Kosyachkov, Vyacheslav

Fesenko, Maksym

 
Reports on research  
projects 
 (2015), «EUREKA: Physical Sciences  
and Engineering» Number 1  
 
55 
 
 
 
 
 
MANUFACTURE OF TWO-LAYERS AND DOUBLE-SIDED 
IRON CASTINGS WITH DIFFERENTIAL STRUCTURE AND 
PROPERTIES  
 
Kateryna Fesenko  
Department of foundry of ferrous and nonferrous metals 
National Technical University Of Ukraine “KPI”  
Kyiv, Ukraine 
fesenkoev87@gmail.ru 
 
Volodymir Mogylatenko  
Department of foundry of ferrous and nonferrous metals 
National Technical University Of Ukraine “KPI”  
Kyiv, Ukraine, 03056 
foundry@iff.kpi.ua 
 
Anatoliy Fesenko  
Department of technology and equipment foundry production 
Donbass State Engineering Academy  
Kramatorsk, Ukraine 
prorector@dgma.donetsk.ua 
 
Vyacheslav Kosyachkov  
Department of foundry of ferrous and nonferrous metals 
National Technical University Of Ukraine “KPI”  
Kyiv, Ukraine 
foundry@iff.kpi.ua 
 
Maksym Fesenko  
Department of foundry of ferrous and nonferrous metals 
National Technical University Of Ukraine “KPI”  
Kyiv, Ukraine 
fesenkoma@mail.ru 
 
 
 
Abstract 
The paper proposes a new method of production of bilayer and double-sided castings with differentiated struc-
ture and properties using the technology of in-mold modification of the initial melt, smelted in a single melting fur-
nace, which ensures formation of hard wear-resistant white iron as the working layer, and formation of ductile shock-
resistant cast iron with nodular graphite as the core or the mounting part. Numerous laboratory studies confirm the 
feasibility of the proposed method and provide conditions ensuring differentiation of structure and properties in local 
parts or layers of castings. The prospects of the method for manufacturing a wide range of industrial castings are in-
dicated. 
Keywords: method, in-mold modification, bilayer and double-sided castings, white iron, high-strength iron 
with nodular graphite 
 
© Kateryna Fesenko,  Volodymir Mogylatenko, Anatoliy Fesenko,  
Vyacheslav Kosyachkov,  Maksym Fesenko 
 
 
1. Introduction 
Of major importance for many industries is the increase of reliability, durability and per-
formance of units, components of machinery and equipment with concurrent cost reduction. 
To ensure these requirements is possible by replacing monometallic parts by bilayer or dou-
ble-sided parts with different properties of some members. 
 
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The examples of bilayer components could be mill rolls, bushings, rollers, jaws crusher 
cheeks, armor plates, slide-ways for bulk materials; the examples of double-sided components are 
jackhammer bits, plowshares, excavator bucket teeth etc. 
The work area or operating surface of such parts should possess high hardness and wear re-
sistance, while the core or the mounting fastener should be resistant to impact, possess toughness 
and improved machinability, unlike the hard operating layer. 
It is known that high hardness and wear resistance of materials can be provided by white 
cast iron with carbide inclusions of iron, chromium and other alloying elements [1, 2], while im-
proved ductility and impact strength can be provided by ferrite high-strength cast iron [3–5]. 
At present, the production of cast iron parts with differential properties in separate areas 
(zones) is accomplished by various ways. Of greatest interest are the methods for producing such 
parts via injection by successive pouring of heterogeneous cast iron into a shared mold [6–8]. 
However, the need for smelting, for example, of white iron, synchronously with smelting 
and nodularizing of high-strength cast iron in two independent furnaces increases the cost of tech-
nological process and complicates the production of castings with differentiated properties of their 
parts or layers, which is a significant inconvenience of the existing production methods of such 
castings. 
 
2. Experimental procedures 
Foundry departments of the National Technical University of Ukraine «KPI», (Kyiv) and of 
the Donbass State Machine-Building Academy (Kramatorsk) perfecta fundamentally new way of 
differentiating the structure and properties of cast iron in different parts of castings, devoid of 
these inconveniences [9–25]. 
The method is based on the technology of intra-mold treatment of the melt in a reaction 
chamber of gating system, in other words it is the so-called in mold-process [26–28]. 
The idea of the new method lies in the smelting of the initial white cast iron in a melting 
furnace and pouring it into the bottom of the lower part of the mold cavity where the hard working 
layer of casting crystallizes. The remaining part of the mold cavity is filled with the same initial 
cast iron through a second independent gating system with a reaction chamber where the white 
cast iron is modified by nodularizing and graphitizing inoculants subsequently forming a soft ma-
trix layer of ductile iron casting (Fig. 1, a). 
                       
                    a                                                                               b 
                           
                   c                                                                                d 
 
Fig. 1. Scheme of technological options for obtaining bilayer (a, b) and double-sided (c, 
d) castings of white cast iron (WCI) and high strength cast iron (HSI) on the basis of the initial 
white cast iron (WCI) or gray cast iron(GCI), with partial modification of metal in the mold by 
nodularizing (NI) or carbide-stabilizing (CSI) inoculants 
 
Reports on research  
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Gating systems possessing two reaction chambers with nodularizing and carbide-
stabilizing inoculants allow the mold to be filled with conventional gray cast iron of eutectic com-
position (Fig. 1, b). 
For obtaining double-sided castings the mold is poured with the initial white cast iron via 
two independent gating systems, thus separating the melt by two streams. The first melt flow of 
the initial cast iron fills the mold cavity, where hard solid working layer crystallizes, and the sec-
ond melt flow is modified in the reaction chamber by nodularizing inoculant and subsequently 
crystallizes in the mold, forming the second part of the casting with nodular graphite (Fig. 1, c). 
Fundamentally it is possible to fill in the mold with conventional gray cast iron with subsequent 
modification of two separate streams – one by nodularizing, and the other one by carbide-
stabilizing inoculants (Fig. 1, d). 
 
3. Results 
Early laboratory testing of the new method showed negative results. Instead of the ex-
pected bilayer or double-sided iron castings all experimental castings crystallized to yield plain 
conventional gray cast iron with flaked graphite. The reason for this was the hydrodynamic mixing 
of dissimilar flows when filling forms with liquid metal and subsequent convective and diffusive 
redistribution of inoculants between the layers in the liquid-solid alloy, which led to blending and 
homogenization of the structure and properties of cast iron throughout its entire volume. 
The issue of prevention the problem of hydrodynamic mixing and redistribution of ele-
ments when obtaining double-sided castings (Fig. 2, b) was solved by installation of a partition 
wall of galvanized iron sheet into the mold cavity (Fig. 2, a). At a certain combination of the parti-
tion thickness and the cast melt temperature, the dissolution (fusion) time of the partition coin-
cided with the time of cast iron in liquid and liquid-solid state, preventing mixing of the melt and 
providing obtaining castings with differentiated properties in different sections. In some cases, the 
partition is not completely melted, but is securely welded to the both parts of the casting  
(Fig. 2). 
 
              
a                                                          b 
 
c                                                            d                                                                      f 
Fig. 2. Mold with inserted steel wall (a), double-sided castings (b), fracture (d) and microstructure 
of the left (c) and right (f) parts of double-sided casting (×100) 
 
The same problem with obtaining bilayer (Fig. 1, a, b) castings was solved by pausing 
time between the two phases of casting. At a certain pause, sufficient for the formation of a layer 
of separating solid crust on the surface of the lower plate, hydrodynamic mixing and diffusion re-
distribution of inoculant elements is prevented. As a result, white iron casting crystallizes in the 
lower layer (Fig. 3, f) and high-strength cast iron in the upper layer respectively (Fig. 3, c). 
 
    
 
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                      a                                                       b 
            
   c          d        f  
Fig. 3. Mold (a), two-layers iron castings (b), fracture (d) and microstructure of the upper 
(c) and lower (f) parts of two-layers casting 
 
4. Conclusion 
Thus, this work confirms the possibility of implementation of the proposed method of cast 
iron structure and properties differentiation in local parts or layers of parts by using in-mold inocu-
lation technology of the initial smelt melted in single melting furnace. 
The results of numerous laboratory studies indicate the prospects of applying the proposed 
method at industrial enterprises for manufacturing parts, operating under unstressed-abrasive or 
impact-abrasive wear instead of steel castings, e.g. steels C120G13 (X120Mn12), or other high-
alloy steels, as well as special alloyed cast irons. 
The proposed method allows to considerably, simplify the process of producing castings 
with differentiated properties, to reduce the consumption of scarce and expensive alloying ele-
ments, as well as to reduce the cost of casting; also it does not require installation of additional 
equipment in a foundry shop. 
 
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CREATING A SYSTEM OF INNOVATIVE KNOWLEDGE MANAGEMENT OF FINISHING WORK ORGANIZATION

MANUFACTURE OF TWO-LAYERS AND DOUBLE-SIDED IRON CASTINGS WITH DIFFERENTIAL STRUCTURE AND PROPERTIES

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