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  • 1. Campbell, John
    et al.
    Svidró, József Tamás
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting. Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Svidró, Judit
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Molding and Casting Processes2017In: ASM Handbook, Volume 1A: Cast Iron Science and Technology / [ed] Doru M. Stefanescu, Materials Park, Ohio: ASM International, 2017, p. 189-206Chapter in book (Refereed)
  • 2.
    Diószegi, Attila
    et al.
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Diószegi, Eva
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting. Diocore AB.
    Tóth, Judit
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Svidró, József Tamás
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Modelling and simulation of heat conduction in 1-D polar spherical coordinates using control volume-based finite difference method2016In: International journal of numerical methods for heat & fluid flow, ISSN 0961-5539, E-ISSN 1758-6585, Vol. 26, no 1, p. 2-17Article in journal (Refereed)
    Abstract [en]

    Purpose - The purpose of this paper is to obtain a finite difference method (FDM) solution using control volume for heat transport by conduction and the heat absorption by the enthalpy model in the sand mixture used in casting manufacturing processes. A mixture of sand and different chemicals (binders) is used as moulding materials in the casting processes. The presence of various compounds in the system improve the complexity of the heat transport due to the heat absorption as the binders are decomposing and transformed into gaseous products due to significant heat shock. Design/methodology/approach - The geometrical domain were defined in a 1D polar coordinate system and adapted for numerical simulation according to the control volume-based FDM. The simulation results were validated by comparison to the temperature measurements under laboratory conditions as the sand mould mixture was heated by interacting with a liquid alloy. Findings - Results of validation and simulation methods were about high correspondence, the numerical method presented in this paper is accurate and has significant potential in the simulation of casting processes. Originality/value - Both numerical solution (definition of geometrical domain in 1D polar coordinate system) and verification method presented in this paper are state-of-the-art in their kinds and present high scientific value especially regarding to the topic of numerical modelling of heat flow and foundry technology.

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  • 3.
    Svidró, Judit
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    New possibilities in the thermal analysis of moulding materials2018In: 73rd World Foundry Congress "Creative Foundry", WFC 2018 - Proceedings, Stowarzyszenie Techniczne Odlewnikow Polskich/Polish Foundrymen's Association , 2018, p. 25-26Conference paper (Refereed)
    Abstract [en]

    Moulding material related studies within research activities concerning foundry technology have always been limited, despite the significant effect of moulding mixtures on the quality of cast parts. One reason behind this trend is the difficulty in interpreting results of such complex systems like moulds and cores. This paper provides a new possibility to study the heat absorption performance of materials used as moulding media in metal casting processes. By further developing the Fourier thermal analysis method of cores and moulds introduced by earlier authors, the investigation of unbonded sand has become available. Heat absorption properties of the components can be hereby separated and studied respectively. Thermal analyses were performed on sphere shaped, resin bonded cores with various binder levels and on unbonded sand samples. The temperature data collected in two points of the samples were then used for the calculation of novel thermophysical properties. The results revealed not only quantitative but qualitative differences in the characteristics of binder decomposition processes, providing deeper understanding on the thermal behavior of moulding materials. The outcome of the research provides more accurate data, which is the key for improved simulation of casting processes.

  • 4.
    Svidró, Judit
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    New possibilities in thermal analysis of molding materials2018In: Journal of Casting & Materials Engineering, ISSN 2543-9901, Vol. 2, no 4, p. 67-70Article in journal (Refereed)
    Abstract [en]

    Molding material-related studies within the research activities concerning foundry technology have always been limited despite the significant effect of molding mixtures on the quality of cast parts. One reason behind this trend is the difficulty in interpreting the results of such complex systems like molds and cores. This paper provides a new possibility for studying the heat-absorption performance of materials used as molding media in metal casting processes. By further developing the Fourier thermal analysis method of cores and molds introduced by earlier authors, the investigation of unbonded sand has become available. The heat-absorption properties of the components can be hereby separated and studied respectively. Thermal analyses were performed on sphere-shaped resin-bonded cores with various binder levels as well as on unbonded sand samples. The temperature data collected from two points of the samples were then used for the calculation of the novel thermophysical properties. The results revealed not only quantitative but qualitative differences in the characteristics of the binder decomposition processes, providing a deeper understanding on the thermal behavior of molding materials. The outcome of the research provides more-accurate data, which is the key for the improved simulation of casting processes.

  • 5.
    Svidró, Judit
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Tóth, L.
    University Of Miskolc, Department of Foundry Technology, Miskolc, Hungary.
    Svidró, József Tamás
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    The influence of thermal expansion of unbonded foundry sands on the deformation of resin bonded cores2017In: Archives of Metallurgy and Materials, ISSN 1733-3490, E-ISSN 2300-1909, Vol. 62, no 2, p. 795-798Article in journal (Refereed)
    Abstract [en]

    Depending on the preparation and the applied materials, moulds and cores can be of high rigidity or can be flexible. Although, chemically bonded moulding materials have relatively good flexibility, their high temperature behaviour determines the dimensional accuracy, the stresses in the castings and can induce several casting defects, such as rattail, veining, etc. The phenomenon is based on two major effects: the thermal expansion of the unbonded foundry sands and the deformation of the sand mixtures. The main objective of the present work was to study the relationship between these two effects, and to improve the knowledge related to the thermo-mechanical interactions between the casting and the mould. Dilatometric analysis of unbonded sand samples were performed and compared to the results of hot distortion tests of moulding mixture specimens. The results showed, that the thermal expansion of foundry sand largely influences the hot distortion behaviour, but depending on the type of binder used.

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  • 6.
    Svidró, József Tamás
    et al.
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Stevenson, David
    Exone GmbH, Augsburg, Germany.
    Tóth, Judit
    University of Miskolc, Hungary.
    Heat absorption capacity and binder degradation characteristics of 3D printed cores investigated by inverse Fourier thermal analysis2015In: Transactions Of The American Foundry Society, The American Foundry Society, 2015, Vol. 123, p. 135-143Conference paper (Refereed)
    Abstract [en]

    The application of 3D printing techniques is a recently developing area used within foundry technology. Digital production of sand molds and cores eliminates the need for hard tooling, drastically reduces lead times and offers design freedoms not possible in the traditional pattern making. Even though mold and core making technologies are refined from both scientific and practical points of view, casting defects may still occur in the final products. Thus, molding material related casting research is required to generate state-of-the-art methods and understandings to avoid the formation of casting defects. In this paper, a pioneering method is presented which is suitable to determine novel thermophysical and heat transfer properties of various types of molding materials. These properties are strongly connected to the cooling capacity and the gas evolution features of the cores used in casting production. The method is based on temperature measurements inside spherical shaped core sand specimens and evaluated by a special application of Fourier thermal analysis. Temperature measurements were performed in test samples produced by two different 3D core printing systems. The registered temperature data were processed by Fourier thermal analysis to calculate the thermal properties and the decomposition characteristics of the 3D printed cores. The experiments were executed under different heating conditions analogous to aluminium and cast iron production.

  • 7.
    Svidró, József Tamás
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Svidró, Judit
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Ferenczi, Tibor
    Department of Metallurgy, School of Engineering, University of Miskolc, Miskolc, Hungary.
    The effect of different binder levels on the heat absorption capacity of moulding mixtures made by the phenolic urethane cold-box process2017In: Journal of thermal analysis and calorimetry (Print), ISSN 1388-6150, E-ISSN 1588-2926, Vol. 130, no 3, p. 1769-1777Article in journal (Refereed)
    Abstract [en]

    The phenolic urethane cold-box (PUCB) process was first introduced to the foundry industry in the late 1960s. Since then, it has become one of the most popular methods to make foundry purpose sand moulds and cores, utilized in the manufacturing of aluminium and cast iron cast components. The factors to be considered, affecting the general performance of a PUCB moulding mixture, are the temperature of sand, the moisture content, the mixing conditions, etc. Moreover, there are variable production parameters such as binder level, to improve certain properties of the mould and/or the core based on their specific area of application. These are mainly mechanical properties such as tensile or splitting strength. They have significant influences on the behaviour of the moulding material and are usually tested at room temperature. Although the production phases of the PUCB system are refined to a high extent today, the effect of binder content on the quality of the mould/core and the final casting should be supported by new approaches also in thermal sciences, interpreted in high-temperature environment. In this work, different PUCB mixtures were produced to evaluate the effect of various binder levels on the thermophysical properties of sand cores. Thermogravimetry, differential thermal analysis and a novel application of Fourier thermal analysis were used to study the decomposition processes of the PUCB mixture and to reveal the impact of binder level on the heat absorption (cooling) capacity of sand cores at temperatures relevant in the manufacturing of cast iron parts (1300 ± 10 °C).

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  • 8.
    Svidró, József Tamás
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Svidró, Judit
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Ferenczi, Tibor
    Department of Metallurgy, School of Engineering, University of Miskolc, Miskolc, Hungary.
    Thermophysical aspects of reclaimed moulding sand addition to the epoxy-SO2 coremaking system studied by Fourier thermal analysis2017In: Journal of thermal analysis and calorimetry (Print), ISSN 1388-6150, E-ISSN 1588-2926, Vol. 130, no 3, p. 1779-1789Article in journal (Refereed)
    Abstract [en]

    The most important advantage of foundry purpose moulding sand is that it can be reclaimed and reused through the casting manufacturing process. Supplying the foundry with a new source of material, sand reclamation brings along both environmental and economic advantages. Utilization of used sand can be considered as a common technological routine in the production of most types of chemically bound moulding materials. The epoxy-SO2 process is prevalent in the processing of cast iron engine components worldwide. Based on its excellent properties, it is mainly suitable for producing internal sand cores with complex geometry. Even though reclaimed sand addition is an active and well-functioning feature in ferrous foundries, the scientific and thermophysical background of its effects on the casting process is yet to be explored. In this work, the thermal aspects of different reclaimed sand levels in the epoxy-SO2 moulding system were examined. Thermogravimetry and differential thermal analysis of the epoxy-SO2 and reclaimed sand in focus were carried out to obtain basic understandings about their high-temperature behaviour. A state-of-the-art Fourier thermal analysis method presented in a recent paper was used at temperatures corresponding to actual cast iron production (1300 ± 10 °C), contrary to the previous tests at the typical temperature range of aluminium melt processing (660 ± 10 °C). By the right of the method, the effects of reclaimed sand addition on the heat absorption (cooling) capacity of the epoxy-SO2 moulding mixtures were investigated.

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    Fulltext
  • 9.
    Svidró, József Tamás
    et al.
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Tóth, Judit
    University of Miskolc, School of Material Science.
    The novel application of Fourier thermal analysis in foundry technologies2014In: Journal of thermal analysis and calorimetry (Print), ISSN 1388-6150, E-ISSN 1588-2926, Vol. 115, no 1, p. 331-338Article in journal (Refereed)
    Abstract [en]

    The process of casting in sand moulds is used for a large volume of castings manufactured in the world. Internal channels and complex geometries of these products are formed by the placement of cores within the mould cavity. Resin-bound sand mixtures are essential ingredients in engine component manufacturing. In this study, a state-of-the-art application of Fourier thermal analysis in foundry technologies is presented. Investigation of decomposition phenomena of resin-bound moulding materials during casting production is a brand new area to use the potential of thermal sciences. Temperature measurements in test samples of standard types of moulding mixtures were performed. The registered cooling curves were processed by a numerical iteration algorithm to determine the amount of heat absorbed during degradation of the moulding material. Thermogravimetric analysis (TG) and differential thermal analysis (DTA) of sand mixtures were carried out to compare the results of the Fourier thermal analysis with TG and DTA curves.

  • 10.
    Tóth, Judit
    et al.
    University of Miskolc, Miskolc, Hungary.
    Svidró, József Tamás
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing. Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Diószegi, Attila
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing. Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting.
    Stevenson, David
    ExOne GmbH, Augsburg, Germany.
    Heat absorption capacity and binder degradation characteristics of 3D printed cores investigated by inverse fourier thermal analysis2016In: International Journal of metalcasting, ISSN 1939-5981, E-ISSN 2163-3193, Vol. 10, no 3, p. 306-314Article in journal (Refereed)
    Abstract [en]

    The application of 3D printing techniques is a recently developing area used within foundry technology. Digital production of sand molds and cores eliminates the need for hard tooling, drastically reduces lead times and offers design freedoms not possible in the traditional pattern making. Even though mold and core making technologies are refined from both scientific and practical points of view, casting defects may still occur in the final products. Thus, molding material related casting research is required to generate state-of-the-art methods and understandings to avoid the formation of casting defects. In this paper, a pioneering method is presented which is suitable to determine novel thermophysical and heat transfer properties of various types of molding materials. These properties are strongly connected to the cooling capacity and the gas evolution features of the cores used in casting production. The method is based on temperature measurements inside spherical shaped core sand specimens and evaluated by a special application of Fourier thermal analysis. Temperature measurements were performed in test samples produced by two different 3D core printing systems. The registered temperature data were processed by Fourier thermal analysis to calculate the thermal properties and the decomposition characteristics of the 3D printed cores. The experiments were executed under different heating conditions analogous to aluminium and cast iron production.

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