Optimization of the Brass Melting

Transcription

1 ARCHIVES of FOUNDRY ENGINEERING DOI: /afe Published quately as the ogan of the Foundy Commission of the Polish Academy of Sciences ISSN ( ) Volume 14 Issue 3/ Optimization of the Bass Melting S. Bienat a, A.W. Bydałek b, c * a PWSZ Głogów, Piota Skagi 5, Głogów, Poland b AGH Univesity of Science and echnology, Faculty of Non - Feous Metals, Mickiewicza 30, Kaków, Poland c Univesity of Zielona Góa, Faculty of Mechanical Engineeing, Z. Szafana 2, Zielona Góa, Poland *Coesponding autho. addess: adam_bk@poczta.onet.pl Received ; accepted in evised fom Abstact he aticle descibes the optimization of the melting bass. Basses, as one of the most popula alloys of coppe, deseve special attention in the context of the pocesses of melting, which in tun would povide not only poducts of bette quality, but also educe the cost of thei poduction o efining. Fo this pupose, seveal studies caied out deiatogaphic (DA) and themogavimetic (G) using deivatogaph. he esults wee confonted with the pogam SLAG - PROP used to evaluate the physicochemical popeties of the coatings extaction. Based on the suvey and analysis of the pogam can identify the most favoable physico - chemical popeties, which should be caied out teatments. his allows fo slag mixtues efeed configuations oxide matix containing specific stimulatos of the eaction. Conducted empiical studies indicate a convegence of the aeas poposed by the application. It should also be noted that the pogam also indicates additional aeas in which to cay out these pocesses would get even bette, to optimize the melting pocess, the esults. Keywods: Compute aided foundy, Optimization, Bass, Melting, Pogam, SLAG-PROP 1. Intoduction All poducts made of coppe and its alloys, also including basses [1-7], ae widely used in the moden wold. Because of its use of the coppe pat ecycled to the total consumption of the metal ove the yeas is a gowth. It is lagely dictated by economic conditions of obtaining the metal fom pimay souces elative to the souce of the waste. An impotant element of the whole pocess is adequate segegation of coppe fom its othe alloys. Paticulaly significant impact hee ae such alloys as bass o bonze, which, due to its popeties and the extensive use should be subject to a sepaate melting and efining pocesses [6-8]. 2. Optimization of efining basses 2.1. he concept of optimization In ode to optimize the melting pocess basses, including the best conditions efineies - educing agents, can be used vey widely used method of themogavimetic analysis (DA) and diffeential themal analysis (G) as poposed by A.W. Bydałek [7,8]. Using the method descibed above can be caied out studies aimed at educing facto appointment with an indication of the mass. Compaing the values epoted in the table can be used to detemine the popeties of educing efine as weak, stong, o an aveage of educing o even oxidation [9-11]. ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue 3/2014, 5-10 Unauthenticated 5

2 able 1. Aangements fo the desciption of the efineies [7] Value of Value of Intepetation 1 << 0 << -10 Stong impact of educing 2 << 0-10 < < -1 Weak impact of educing No impact of 4 > Results Of no account educing he impact of oxidative Based on the findings pesented in Chapte 2.1, made a seies of studies analyzing the impact of vaious chemical eagents on the ability to efine the extaction coating on the base of the oxide unde conditions of optimal melting pocess basses. Fist, the cicuit aangement has a base consisting of a mixtue of oxides: Al 2 O 3 (9%), SiO 2 (57%), CaO (22%), Na 2 O (8%) and MgO (4%). Fo the system as a non-metallic inclusions intoduced 30% oxides SnO, ZnO and PbO on the elative composition of 1:3:2. he following table shows the esults obtained. able 2. Selected esults fo the efining pocess modeling bass MO59 - inclusions SnO, ZnO and PbO Al 2 O 3 CaO SiO 2 Na 2 O MgO IN Othe 10%C 5%(NaCl + NaF 2 as 1:1) 5%(Na 2 CO 3 + NaCl as 3:1) 5%(Na 2 B 4 O 7 ) Analyzing these esults it can be seen that the best esults wee obtained when efines 4. he enegy index atio achieved at the level of -20 kj / mol, while the mass index was as high as -40%. A vey impotant effect is the fact that the esult was achieved aleady at a tempeatue of 1320 K, which is the lowest of the cases peviously analyzed. In the second case it was decided to examine the diffeent mix slag, this time composed of Al 2 O 3 (13%), SiO 2 (23%), CaO (52%), B 2 O 3 (8%) and MgO (4%). As the non-metallic inclusions wee intoduced to 20% Cu 2 O. he esults ae shown in the following table. able 3. Selected esults of tests fo the efining pocess modeling bass MO59 - inclusion of Cu 2 O Al 2 O 3 CaO SiO 2 B 2 O 3 MgO Othe %Al %Al, 10%C %Al, 2%(CaF 2 + NaF as 1:1) %Mn, 10%C %CaC 2, 20%Al %CaC 2, 20%Mn IN 1 20(Cu 2 O) > (Cu 2 O) > (Cu 2 O) > (Cu 2 O) > (Cu 2 O) (Cu 2 O) Also in this case, vey good esults wee obtained to optimize the melting bass. he best value obtained mixtue of slag in 5 cases whee the calculated enegy index was at the level of -370 kj/mol, while the mass index until -50%. he tempeatue of the pocess was caied out as the lowest of the analyzed fo this case and amounted to 1200 K. In the final stage of the study it was decided to examine seveal diffeent configuations mix Al 2 O 3 - SiO 2 - Na 2 B 4 O 7 in conjunction stimulatos with diffeent configuations in the fom of NaCl and NaF. Fist, the system was tested on the composition of Al 2 O 3 (50%), SiO 2 (10%) and Na 2 B 4 O 7 (40%), adding said stimulatos in vaious combinations. In addition, non-metallic inclusions wee used as oxides Cu 2 O and ZnO, with a total weight of 30% of the sample, while maintaining a atio of 1:2. he esults ae shown in the following table. 6 ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue Unauthenticated 3 /2014, 5-10

3 able 4. Selected esults of tests fo the efining pocess modeling bass MO59 - inclusions of Cu 2 O and ZnO Composition of basic slag Additional factos - stimulatos Al 2 O 3 SiO 2 Na 2 B 4 O 7 NaCl NaF Othe IN Cu 2 O/ZnO as 1: , , As can be seen, the best efining capacity shows a mixtue of the composition of the thid. his is achieved hee enegy index kj/mol, and the component to 30% by mass. he blend obtained using the above values of the two stimulatos in an amount of 25% by weight of the sample while maintaining a 3:2 aspect atio. It should be noted hee that the tempeatue of the pocess was now 1300 K, which fom an economic point of view is highly desiable. In the second case the sample was examined meely consisting fom Na 2 B 4 O 7 (60%) and SiO 2 (40%) using a simila amount of non-metallic inclusions and a combination of the stimulatos. In the conducted study, the esults obtained in the following table. able 5. Selected esults of tests fo the efining pocess modeling bass MO59 - inclusions of Cu 2 O and ZnO Composition of basic slag Additional factos - stimulatos Othe Al 2 O 3 Na 2 B 4 O 7 SiO 2 NaCl NaF IN Cu 2 O/ZnO as 1: It tuns out that the same composition as the pomotes in the pevious study has allowed to obtain the best esults. Enegy index was -45 kj/mol, while the mass index = -20%. Hee too, the pocess tempeatue was the lowest, and it amounted to 1350 K. Conducting these studies indicated that the most favoable conditions fo melting bass ovelapped with the best efining abilities slag mixtues. Is this allows, howeve, daw the thesis of the close and the associated coelation of these two values. A ecent study caied out fo the composition of Al 2 O 3 (50%) and SiO 2 (50%) answes this question by giving a negative answe. he esults of a ecent study ae pesented in the following table. able 6. Selected esults of tests fo the efining pocess modeling bass MO59 - inclusions of Cu 2 O and ZnO Composition of basic slag Additional factos - stimulatos Othe Al 2 O 3 SiO 2 Na 2 B 4 O 7 NaCl NaF IN Cu 2 O/ZnO as 1: ,0-2, , , Also in this case tuned out to be the most pefeed composition of the pacemake using the same amount as in the pevious examples. he enegy index, in this case, was -65 kj/mol, while the mass index -10. It should be noted that the pocess tempeatue in this case was 1480 K, and it was the highest pesented duing the eseach. Should theefoe apply fo the selection of components of slag-foming mixtues, which will minimize the melting tempeatue, and hence the cost of pefomed pocesses Summay of laboatoy tests o summaize the above expeiments it can be concluded that the best blend of slag composition to optimize the pocesses of melting bass sample was detemined by the numbe 5 in the second study. Only this sample eceived the lowest tempeatue pocess at 1200 K and the best popeties efines: enegy index -370 kj/mol and the mass index -50%. Conducting these studies aises the question. Is obtaining empiical eseach confims bass melting pocess optimization ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue 3/2014, 5-10 Unauthenticated 7

4 with application SLAG - PROP to assess extaction of physicochemical popeties of coatings [11-14]. 3. Analysis of pogam optimization using SLAG - PROP Afte the pogam had to choose a use inteesting bounday conditions associated with the exploation aeas. hen select the base point stop fo efining, melting atmosphee and the seach citeion with espect to tempeatue. Because of the above consideations limit tempeatue was 1480 K value, this tempeatue was taken as the maximum, while maintaining the appopiate value changes 1207 C. As the minimum tempeatue was also adopted minimum tempeatue taken fom empiical eseach which is 1200 K, and theefoe appoximately 927 C. Afte the filtation of a database povided the following esults. Fig. 1. Sceenshot fo the selection of aeas that meet the citeia I 8 ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue Unauthenticated 3 /2014, 5-10

5 Fig. 2. Sceenshot fo the selection of aeas that meet the citeia II he pogam offeed 11 aeas that meet the citeia specified by the use. he optimal tempeatue fo melting bass by application aea is maked with an index of 180. Meanwhile, the designated aea duing the expeimental pogam was on the second place. If the use will look at the aea indicated by the desciption of the pogam will ecognize that the melting tempeatue of the aea, depending on the composition of an additional in the ange fom 977 C to 1700 C, wheein it appeas that at a tempeatue of 977 C can be obtained enegy index KJ/mol and a mass index = -15%, with the exact composition of Al 2 O 3 and slag mix (9%), SiO 2 (57%), CaO (22%), Na 2 O (8%), MgO (4%). As can be appeciated, the database pogam is so boad that it is easy aeas with even bette conditions, in the context of pocess optimization melting bass. Going theefoe futhe illustated couse of the poceedings, changed the seach citeia, the pogam asking if you can get an even bette line-ups slag mixtues fo optimization of melting bass. As the minimum tempeatue limit value is enteed 419 C, while the maximum value specified at a level that peviously descibed as the maximum, o 927 C. In esponse, obtained a list of the 4 aeas shown in the figue below. In this case, it is woth noting the aea maked numbe 368 Afte getting acquainted with his accuate desciption can eceive infomation that a sample can be melted aleady at a tempeatue of 970 K, which is about 697 C, to give the aveage eduction effects. Enegy index eaches a value of 12.5 kj/mol, and the mass index = -10%, with the exact composition: with the following composition: Al 2 O 3 (18%), B 2 O 3 (6%), CaO (12%), Na 2 O (22%), SiO 2 (42%). 4. Summay Summing conducted eseach and analysis on how to optimize the melting pocess basses can be seen excellent coincidence with the esults pesented by the application SLAG - PROP with the esults deived fom empiical eseach. It should also be noted that the pogam can also indicate additional aeas woth attention, which optimize these pocesses meet the citeia posed. Using theefoe poposed compositions of blends of slag poduced by the pogam, as well as confimed expeimentally can be lagely melting pocess optimization, and hence significant economic savings. Refeences [1] Góny, Z. (1992). Casting of non-feous alloys. Waszawa: WN. [2] Kozana, J., Rzadkosz, St. & Piękoś, M. (2010). Influence of the selected alloy additions on limiting the phase fomation in Cu-Zn alloys. Achives of Foundy Engineeing. 10(1), ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue 3/2014, 5-10 Unauthenticated 9

6 [3] Kluska-Nawaecka, S., Mzygłód, B., Duak, J. & Regulski, K. (2010). Analysis of the applicability of domain ontology in coppe alloys pocessing. Achives of Foundy Engineeing. 10(2), [4] Kondacki, M. & Szajna, J. (2007). Possibilities fo leaded bass eplacement with multi-component bass. Achives of Foundy Engineeing. 7(2), [5] Kaczma, J.W., Ganat, K., Pietzak, K., Naplocha, K. & Godzka, E. (2010). Manufactuing and micostuctue of MMC based on CuZn38Al2Mn1Fe bass stengthened with δ-alumina fibes. Achives of Foundy Engineeing. 10(SI1), [6] Bydałek, A.W., Bydałek, A. (2007). Basics of casting metallugy in efining pocesses. Zielona Góa: Univesity of Zielona Góa. [7] Bydałek, A.W. (1998). Slag systems oxygen cabon in the pocesses of melting coppe and its alloys. Zielona Góa: Univesity of Zielona Góa. [8] Bydałek, A.W (2001). Assessing the efining abilities of slags by modelling a eal pocess of metal melting. Jounal of hemal Analysis and Caloymety. 65(2), [9] Kluska-Nawaecka, S., Góny Z., Mzygłód, B., Wilk- Kołodziejczyk, D. & Regulski, K. (2010). Methods of development fuzzy logic diven decision-suppot models in coppe alloys pocessing, Achives of Foundy Engineeing. 10(SI1), [10] Bienat, S. & Bydałek, A.W. (2010). he estimation of quality efining coves. Achives of Foundy Engineeing 10(SI1), [11] Bienat, S., Bydałek, A.W. & Schlafka, P. (2011). he popiety estimation of the coppe alloys efining slag with the stimulatos addition use the database. Achives of Foundy Engineeing. 11(2), [12] Bienat, S., Bydałek, A.W. & Schlafka, P. (2012). Analysis of the possibility of estimation ecological slag popiety with use the DAABase. Metalugija-Metallugy. 51(1), [13] Bienat, S., Bydałek, A.W. & Schlafka, P. (2013). he analysis of the chloide and fluoide influences one the educe efinement pocesses (Cabo N Ox) Aluminum Alloys. Achives of Foundy Engineeing. 13(3), [14] Bienat, S., Bydałek, A., Bydałek, A.W. & Schlafka, P. (2013). Assessment of the possibility of utilising waste mateials fom the aluminium poduction in the coppe alloys efining pocesses. Achives of Foundy Engineeing. 13(4), ARCHIVES of FOUNDRY ENGINEERING Volume 14, Issue Unauthenticated 3 /2014, 5-10