Number 9, 2006
Издательский дом «Литейное производство» выпускает два специализированных научно-технических журнала с периодичностью: «Литейное производство» – ежемесячно, «Металлургия машиностроения» – 1 раз в 2 месяца.
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Boldyrev D.A. et al. In-Mold Inoculation of High-Strength Cast Iron with Cast Inserts in the Production of Crankshafts
The work's aim is to optimize the parameters of the crankshaft casting production process using in-mold inoculation with cast inserts based on ferrosilicon under the conditions of operating production facilities. Preproduction and pilot batches of castings were cast with different ratios of spheroidizing to graphitizing inoculants. An optimum ratio of inoculant additions at ladle inoculation was chosen, crankshafts with required as-cast structure (without heat treatment) were cast. Bench tests and fatigue life tests have been conducted.

Karanik Y.A. Internal Combustion Engine Pistons Made of Iron-Based Alloys
The author suggests making ICE pistons from iron-based alloys instead of Al alloys while keeping their mass and outside dimensions (by reducing the wall thickness). Costs of materials for making such pistons are several times less. At the same time, quality of pistons, their reliability in operation and durability rise. Process of piston manufacture is described, including use of a flow line with a capacity of 1,800 pistons/h. Profit at the production of 1 million pistons a year on the flow line will amount to ? 10 million euros, with the costs of creating specialized equipment and mastering the new technology being ? 1million euros.

Voronin Y.F. System Analysis and Expert Judgement of Light Gas Holes in Castings
The article discusses problems of determining the kind of casting defects, their causes and methods of elimination. A system approach for quickly determining the kind of defects by the example of light gas holes is proposed. Discussed is a computer-aided mini-ES (for one casting defect) for eliminating the casting defect in question. The program considers the distinguishing characteristics of a defect as compared to others, asks questions concerning the casting production process, plots graphs of probability of the defect's emerging by the main causes, makes it possible to simulate the conditions of eliminating casting defects. Techniques for operating the system in the mode of simulating the elimination of a defect are set forth.

Deyev V.B. et al. Technologies of Treating Aluminum Alloys during Their Preparation
The article discusses actions on molten metals during the preparation of grade AK7ch cast aluminum alloy - thermo-temporal treatment, inert gas purging, mold vibration during pouring and crystallization. Mechanical and casting properties of the alloy subjected to variant treatments have been evaluated. The obtained results have shown that a combined treatment of a melt from low-grade charge materials allows to substantially raise the level of AK7ch alloy properties.

Gruzman V.M. et al. Water-Glass Foundry Washes
Results of testing protective coatings based on porous water glass are given. Absence of wash layer swelling during heat treatment is shown. Resistance of organic and water-glass mold washes to erosion within a wide range of melt's linear velocities has been investigated. Advantage of a water-glass coating, the target function in whose development was the protection of sand mold surface against erosion by the melt flow, is shown.

Belobrov Y.A. et al. Defect of Turbine Castings as a Result of Using Chromomagnesite Sand
Described is a surface defect of turbine castings in the form of grooves in the casting body when using chromomagnesite facing sand. It is stated that the cause of the defect is the hang-up of liquid metal splashes on the shaggy surface of the mold's chromomagnesite face during metal pouring. The splashes quickly oxidize and, when metal approaches them, already cannot merge with it because of having been oxidized. This defect can be eliminated by double coating the molds with a quick-drying corundum wash. Results of production tests of quick-drying aluminous and chromomagnesite washes are described.

Luzgin V.I. et al. Manufacturing Capabilities of Induction Melting Units
The article discusses new principles of constructing systems of two-station induction melting of metals in electromagnetic fields of medium and low frequency, wherein high manufacturing efficiency, versatility and adaptability in modular schemes of metalcasting are achieved.
Described are methods of controlling electromagnetic fields in the working volumes of induction furnaces providing extension of their manufacturing capabilities in making precision alloys of ferrous and nonferrous metals. Examples of modernizing induction furnaces of commercial frequency and crucible induction furnaces are given.

Dotsenko P. et al. Modernization of the Foundry of the Japanese Concern Mazda

Popov A. et al. Modernization of the Foundry of the Metalcasting Concern Montupet

Yevseyev V.I. Metalcasting Industry Today and Tomorrow

Degtyarenko G.I. et al. Rewiew of International Information

Shklyarov Y.V. et al. A letter to the Editors

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August 2006        October 2006

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