the thermal analysis and derivative bronzes cast to ... · the plaster is the main component of...
TRANSCRIPT
A R C H I V E S
o f
F O U N D R Y E N G I N E E R I N G
Published quarterly as the organ of the Foundry Commission of the Polish Academy of Sciences
ISSN (1897-3310) Volume 9
Issue 3/2009
159 – 168
29/3
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 159
The thermal analysis and derivative
bronzes cast to plaster moulds
B. Pisareka,*, M. Pawlak
a,*
aDepartment of Materials Engineering and Production Systems, Technical University of Lodz
1/15 Stefanowskiego Str., 90-924 Łódź, Poland
*Corresponding authors. E-mail addresses:[email protected], [email protected]
Received 20.04.2009; accepted in revised form 24.04.2009
Abstract
It plaster moulds gets casted the alloys of following metals: Al, Cu, Ag, Au in precise and artistic founding. The investigation of the crys-
tallization of bronzes in hot plaster moulds the method of the thermal analysis and derivative (TDA) was not realized out so far. Probe
TDAg and tripod enabling the execution of measurements on inductive casting machine INDUTHERM-VC 500D were designed for this
technology especially. It was confirmed that one the method TDA can identify the crystallization process of the bronze in hot plaster
moulds.
The investigations of the superficial distribution of the concentration of elements in the microstructure of the studied grades of the bronze
on X-ray microanalizer were conducted. It results that they be subject to in bronze CuSn10-C (B10) and the CuSn5Zn5Pb5-C (B555) of
strong microsegregation from conducted investigations: Pb, Sn and Sb. The single separates of intermetallic phase κ was identified in the
bronze B10 rich first of all in Zn, Sn, Sb and Fe, and two intermetallic phase, one rich were identified in the bronze B555 first of all in Zn,
Sb, (Nor, Fe) and second rich in Sn, Sb, (Nor, Fe). The most homogeneous microstructure from the bronze CuAl10Fe5Ni5-C (BA1055) is
characterizes among the studied grades of the bronze in the cast state.
Keywords: Innovative materials and casting technologies, Method TDA, Casting bronzes, Plaster mould, Microstructure
1. Introduction
The plaster is the main component of plaster masses and their
binder also makes up [1]. Plaster masses are used on very exact
plaster moulds or models [1, 2]. One executes moulds to slip
casting from the plaster of Paris [3, 4]. Plaster moulds are used in
dentistry wide [5], jeweller's craft [6] and in the technology lost
models executed the method rapid prototyping [7]. Developmen-
tal investigations over the optimization of the processes of the
thermal processing of plaster moulds are make [8-10] and them
dylatometry changes [11]. It plaster moulds gets casts alloys: Al,
Cu, Ag, Au in precise and artistic founding [6, 7].
The investigation of the crystallization of bronzes in plaster
moulds the method of the thermal analysis and derivative (TDA)
was not realized out so far.
On precise casts as also artistic bronzes tin CuSn10-C (B10)
and tin-zinc-lead CuSn5Zn5Pb5-C (B555) are applied [12]. These
bronzes are resistant on corrosion, the abrasion and they can work
in the raised temperature: 280°C (B10) and 225°C (B555). They
are characterize good castability and machinability. They belong
to basic problems connected with their casting: the microsegrega-
tion of elements during crystallization (B10, B555) and the wide
range of the temperature of crystallization (B555).
Aluminium bronzes CuAl10Fe5Ni5-C (BA1055) belong to high-
grades materials constructional, applied on strongly the put under
load parts of machines, about good sliding, resistant properties on
corrosion both in the state the cast as and after the thermal proc-
essing. Manganese and nickel are characterize the comparatively
even distribution in all phase of the microstructure of the bronze
aluminum-nickel-iron, Al and Cu they place themselves first of all
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 160
in the metal matrix of the bronze ( , 2) however it is the basic
components of the phase of the type Fe and Si [13].
It results from the analysis of the binary alloys systems of the
alloys of the copper, that make additions to the tin bronzes of the
addition Pb, Zn, Ni, Fe rises its temperature liquidus, however he
reduces the addition of Sb and P its [14]. It was showed in Figure
1 the influence of chosen elements on the temperature liquidus of
alloys Cu-X (X={Sn,Zn,Pb,Ni,Fe,Sb,S,P,Mn,Al}).
In the comparison with tin bronzes, bronzes are characterize the
aluminum-iron-nickel the higher temperature liquidus.
Fig. 1. The influence of chosen elements
on the temperature liquidus of binary alloys Cu-X, X={Sn, Zn,
Pb, Ni, Fe, Sb, S, P, Mn, Al} (1084,5°C the temperature
of melting Cu), the own study on the basis [14]
2. Methodic of research
Two species of tin bronzes were used to the investigations of the crystallization process in plaster moulds: CuSn10-C (B10) and CuSn5Zn5Pb5-C (B555) and bronze the aluminium-iron-nickel CuAl10Fe5Ni5-C (BA1055). Bronzes B10 and B555 contain these same elements in the chemi-cal composition (Cu, Nor, Pb, Sn, Zn, Fe, Si, Sb, Al, P, S). The approximate values of the maximum concentrations of elements occur in them:
Ni - ~1,8-2,0%,
Si - ~0,1-0,2%,
Al - ~0,01%.
They are elements differentiating their compositions:
Pb B555 - ~5%, B10 - ~1%,
Sn B555 - ~5%, B10 - ~10%,
Zn B555 - ~5%, B10 - ~0,5%,
Fe B555 - ~0,28%, B10 - ~0,18%,
Sb B555 - ~0,25%, B10 - ~0,18%,
Mn B555 - ~0,0%, B10 - ~0,1%,
S B555 - ~0,090%, B10 - ~0,045%,
P B555 - ~0,065%, B10 - ~0,125%.
Studied bronzes the largest difference in the composition are
characterize in the reference to concentration Pb, Sn and Zn.
The bronze BA1055 contains maximally to: 10,5% Al, 6% Ni,
5,5% Fe, 3% Mn, 0,5% Zn, 0,1% Sn, 0,1% Si, 0,03% Pb.
The bronze was smelted in the inductive casting machine of
INDUTHERM-VC 500D in the atmosphere of argon. Studied
bronzes were submitted the definite quantities of the batch the
granulation to weigh, being drowned cut up pieces of the pig sow
of the bronze in casting machine, and then pouring out they liquid
the alloy to granulator full the water about the temperature 20°C
±2 °C. The stream of the liquid metal was protected during the
granulation the stream of argon. The granulated product of the
studied grades of the bronze was introduced in Figure 2.
Fig. 2. The granulated product of the bronze
The process of the melting of the bronze B555 and B10 in the
furnace INDUTHERM-VC 500D characterizes oneself large
efficiency (the short time of the melting). The small surface of the
point of contact of the metal with argon limits to the minimum
absorbing O2 or H2 through the bronze. Bronzes after melting
were overheated to the temperature suitably 1200° C, cast the
mould then the probe TDAg.
Plaster moulds were executed from the mixture PRIMA-
CAST about the water-plaster relation 0,4. Special metal mold to
casting probe TDAg were flooded the plaster mass, and then the
probe was removed after binding the plaster from the metal mold.
The probe TDAg (after the extraction from the mold) before the
cast the liquid bronze, the thermal processing was subjected. The
program of the thermal processing of plaster moulds was showed
in Figure 3.
The probe TDAg before the cast was heated up to 500°C
±10°C initially. In the aim of making possible the execution of the
thermal analysis and derivative studied bronzes, cast to plaster
moulds, on the inductive casting machine INDUTHERM-VC
500D, it was designed especially for this technology the probe
TDAg and tripod. Cross - section the probe it was shown in Fig-
ure 4.
0 1 2 3 4 5 6 7 8 9 10
stężenie pierwiastka, %
700
750
800
850
900
950
1000
1050
1100
1150
1200
t, C
Sn
Zn
Ni
Fe
Pb
Sb
S
P
1084,5 C
Al
Mn
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 161
The general pattern of the measuring position was shown in Figure 5.
Fig. 3. The program of the thermal processing of plaster moulds
Fig. 4. The probe TDAg
They are the basic elements of the position measuring TDAg:
the position of casting the probe TDAg:
o the probe TDAg,
o the tripod,
o thermocouple Pt-PtRh10 the (type S) with the
line compensatory,
o Crystaldigraph – the transducer μV/Hz;
the position of the registration of measurements and
the visualization of analyses:
o computer with installed program TDA to the
registration of temperature and characteristic
curves t=f(τ) and dt/dτ=f’(τ),
o printer to the filing of characteristic curves
t=f(τ) and dt/dτ=f’(τ) and analyses in the form
of printouts (optional),
the line of the transmission of the data - connection
Crystaldigraph with computer for the aid of the line in
single isolation TLYp.
Investigations on the metallographic and electron microscope
were carried out on samples low-cut from the probe TDAg. Met-
allographic microsection on the sample from the probe TDAg it
was made on the height „head” of thermocouple. Microsections
etch the reagent Mi15Cu. The superficial microanalysis of the
concentration of elements was executed on the microanaliser of
the firm Thermo Electro Corporation.
Fig. 5. The general diagram of the measuring position with aid of the probe TDAg
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 , h
0
100
200
300
400
500
600
700
800
t, C
4h 6h min 3h
200 C
720 C
500 C
the plaster mould
the quartz tube
vaulted one-sidedly
OPERATOR
of THE SYSTEM
Position
of the registration
of measurements
and visualization
COMPUTER
PRINTER
LINE
of THE TRANSMISSION DATA
INDUCTIVE
CASTING MACHINE
INDUTHERM
- VC 500D Position
of casting
the TDAg probe
TDAg
PROBE
TRIPOD
CRYSTALDIGRAPH
COMPENSATORY
LINE
SCREEN of THE DISPLAY
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 162
3. The results of investigations
The characteristic curves TDA of the bronze B10 were shown
in Figure 6. The identification on the characteristic curve dt/dτ
(the curve kinetics of the processes of crystallization) or d2t/dτ2
(the curve dynamics of the processes of crystallization) of charac-
teristic points makes possible delimitation of following quantity
describing the crystallization process of bronze (fig. 6):
kinetics dt/dτ
(e.g.: for the point K – (dt/dτ)K=KK, °C/s),
dynamics d2t/dτ2
(e.g.: for the point K – (d2t/dτ2)K=DK, °C/s2),
temperature t
(e.g.: for the point K – tK, °C),
time τ from the beginning of the visualization of the
measurement (e.g.: for the point K – τK, s).
The small addition Pb<1% crystallize on boundarys between
phase in the temperature approx. 326° C not creating identifiable
thermal effects on curve dt/dτ.
Individual points mark on curves the following stages of cooling
down, crystallization and phase transformation in the solid state:
from the beginning of the registration to the point Pk -
cooling down the liquid bronze - the giving back to
surroundings heat overheating,
Pk-A-B the crystallization of primary phase α,
B-C-D the peritectic reaction α+L→β,
D-E-F the partial transformation of phase β → α
along the solvus line,
I-J-K the eutectoid transformation β→α+γ and
γ→α+δ.
The maximum thermal effects of the process of the crystallization
of the bronze B10 mark the temperature:
A – tA of the liquidus (L→α),
C – tC of the peritectic transformation (α+L→β),
E – tE of the transformation of phase β→α,
J – tJ the eutectoid transformation β→α+γ and
γ→α+δ.
Remaining characteristic points mark the temperature of proc-
esses setting in the volume of the probe:
Pk – tPk of the beginning of the crystallization of
phase α,
B – tB of the beginning of the peritectic transforma-
tion,
D – tD of the beginning of the transformation of
phase β→α,
F – tF of the end of the transformation of phase β→α,
I – tI of the beginning of the eutectoid transformation
β→α+γ and γ→α+δ,
K – tK of the end of the eutectoid transformation
β→α+γ and γ→α+δ.
Appointed in the method ATD make possible characteristic
points delimitation of the time of duration of the following stages
of the process:
of the crystallization - phase transformation in the
solid state:
o of primary phase α,
from the point Pk to C – time SPkC,
o of the peritectic reaction (α+L→β),
from the point B to E – time SBE,
o of the partial transformation of phase β→α,
from the point D to F – time SDF,
o of the eutectoid transformation β→α+γ and
γ→α+δ, from the point I to K – time SIK;
of cooling down the bronze in the solid state:
o from the point F to I – time SFI.
Representative characteristic curves TDA of the bronze B555
were shown in Figure 7. The crystallization process of the bronze
B555 is similar how for bronze B10 (fig. 6), with this difference,
that:
the thermal effect of the peritectic reaction α+L→β he
is smaller than for the bronze B10 and he overlaps on
the thermal effect of the transformation of phase β
(β→α) creating the common „gibbosity” B-E-F on the
derivative curve,
the thermal effect of the transformation of phase β
(β→α) SEF is characterizes considerably longer time
than for the bronze B10,
the additional thermal effects occur F-G-H of inter-
metallic phase κ crystallizations.
The maximum thermal effect - the point G - it the process of the
crystallization of the bronze B555 marks temperature tG of the
crystallization of intermetallic phase κ (α+β→α+β+κ).
Remaining characteristic points make possible delimitation of the
temperature of characteristic for processes setting in the volume
of the probe:
F – tF of the end of the transformation of phase β→α
and the beginning of the crystallization of phase κ,
H – tH of the end of the crystallization of phase κ.
Appointed in the method ATD for the bronze B555 additional
characteristic points (G, H) make possible the qualification of the
times of duration in the volume of probe TDAg of the stage of the
crystallization of intermetallic phase (α+β→α+β+κ), the time
SFH.
Addition of 5% Pb to the bronze B555 cause the maximally
crystallization intercrystalline Pb in the temperature approx. 326
°C creating on curve dt/dτ, comparatively insignificant thermal
effect, highly elongated in the time.
The primary and secondary crystallization of the bronze
BA1055 causes on the curve derivative (dt/d ) creation of follow-
ing thermal effects (fig. 8):
Pk-C-H the primary crystallization of phase ,
P-Q-R the crystallization of intermetallic phase κ,
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 163
J-K-L the partial transformation ,
M-N-O the eutectoid transformation + 2.
Analysing created in the plaster mould macrostructure of the
studied grades of the bronze (fig. 6 ÷ 8) it results that the bronze
B10 characterizes oneself the largest grain. Analysing created in
the plaster mould macrostructure of the studied grades of the
bronze (fig. 6 ÷ 8) it results that the bronze B10 characterizes
oneself the largest grain.
Pk A B C D E F I J K
τ, s 26 58 381 404 411 421 440 750 792 822
t, °C 1031 992 774 758 754 750 735 507 485 470
K, °C/s -2,092 0,006 -0,858 -0,473 -0,538 -0,308 -1,089 -0,552 -0,432 -0,511
D, x10-3
°C/s2 26,8 34,0 0,4 14,1 10,7 -18,1 -9,1 -0,0 0,5 -0,8
Fig. 6. Example characteristic curves TDA for the bronze B10 (t=f(τ), dt/dτ=f ’(τ), d2t/dτ2 = f ”(τ)) and the macrostructure of the cast
0 200 400 600 800 1000
, s
300
400
500
600
700
800
900
1000
1100
t,
C
-4.0
-3.0
-2.0
-1.0
0.0
dt/
d
, C
/s
-0.10
-0.05
0.00
0.05
0.10
d t
/d
,
C/s
t=f( )
d t/d =f ''( )
dt/d =f '( )
2
2 2
22
A CDE J K
Pk I
KK
tK
K
DK
B F
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 164
Pk A B E F G H I J K
τ, s 30 56 250 307 422 440 462 674 721 746
t, °C 1024 996 895 854 753 736 714 540 512 498
K, °C/s -1,904 -0,021 -0,871 -0,425 -1,024 -0,868 -1,028 -0,649 -0,497 -0,590
D, x10-3
°C/s2 35,1 42,7 -1,8 -7,5 3,1 -1,5 -0,0 0,1 0,3 0,5
Fig. 7. Example characteristic curves TDA for the bronze B555 (t=f(τ), dt/dτ=f ’(τ), d2t/dτ2 = f ”(τ)) and the macrostructure of the cast
0 200 400 600 800 1000
, s
300
400
500
600
700
800
900
1000
1100
t,
C
-4.0
-3.0
-2.0
-1.0
0.0
dt/
d
, C
/s
-0.10
-0.05
0.00
0.05
0.10
d t
/d
,
C/s
t=f( )
d t/d =f ''( )
dt/d =f '( )
2
2 2
22
A B E FGH J K
Pk I
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 165
Pk C H P Q R J K L M N O
τ, s 22 48 262 306 369 413 449 544 631 1127 1159 1196
t, °C 1085 1058 1013 961 903 867 838 775 727 485 473 460
K, °C/s -1,771 0,029 -1,367 -1,079 -0,790 -0,842 -0,786 -0,544 -0,564 -0,403 -0,342 -0,357
D, x10-3
°C/s2 30,1 42,2 -9,0 3,0 -0,5 -1,0 -0,0 -0,8 -1,0 -0,1 1,0 0,1
Fig. 8. Example characteristic curves TDA for the bronze BA1055 (t=f(τ), dt/dτ=f ’(τ), d2t/dτ2 = f ”(τ)) and the macrostructure of the cast
The crystallization of the bronze BA1055 in the hot plaster
mould is characterizes the small growth of the size of primary
phase β. However despite this in the comparison with the bronze
B10, if also B555, its macrostructure is characterizes the smallest
grain.
The pictures of microstructure of the studied grades of the
bronze after the etching the reagent MiCu15 show in Figure
9 (a ÷ c). The microstructure of the bronze B10 (Fig. 9 a) it is
built-up from phase: α+eutectoid (α+δ)+Pb. It characteristic is
arrangement intercrystalline eutectoid α + δ, how also small
quantities Pb. Microstructure of bronze B555 (Fig. 9 b) is built-up
from phase: α+eutectoid(α+δ)+κ+Pb. Eutectoid α+δ, intermetallic
phase κ and Pb nucleation and grow up on the boundary of the
intercrystalline grains of phase α.
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
, s
400
500
600
700
800
900
1000
1100
1200
t,
C
-4.0
-3.0
-2.0
-1.0
0.0
dt/
d
, C
/s
-0.10
-0.05
0.00
0.05
0.10
d t
/d
,
C/s
t=f( )
d t/d =f ''( )
dt/d =f '( )
2
2 2
22
C H Q R K L N
Pk P J M
O
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 166
a)
b)
c)
Fig. 9. The microstructure of the bronze: a) B10, b) B555 and c) BA1055
Microstructure of bronze BA1055 (Fig. 9 c) is built-up from
phase: α+κ+eutectoid(α+γ2). Intermetallic phase κ they are spread
in the microstructure of the bronze comparatively evenly, both
inside former phase β, how and on her intercrystalline bounda-
ries. The bronze BA1055 the most homogeneous microstructure
of the studied grades of the bronze is characterizes.
In Figures 10 (a, b) and 11 (a, b) shown microstructure ob-
served on the electron microscope suitably (a) and the results of
the investigations of the distribution of elements (b) in the micro-
structure of the bronze suitably B10 (Fig. 10) and B555 (Fig. 11). a)
b)
Fig. 10. Microstructure (BSE) and the maps of the superficial
distribution of the concentration of elements in the bronze B10
50 μm
50 μm
50 μm
α
α+δ
Pb
α
Pb
κ
α+δ
α α+γ2
κ
α
Pb
α+δ
κ
A R C H I V E S o f F O U N D R Y E N G I N E E R I N G V o l u m e 9 , I s s u e 3 / 2 0 0 9 , 1 5 9 - 1 6 8 167
It results that Sn and Sb be subject to, in the bronze B10, of
the strongest microsegregation from the carried out analysis.
These elements are „pushed aside” in front of the front of the
crystallization of phase α, enriching highly they the liquid bronze.
Rich in these elements phase δ crystallizes in the result of phase
alternatively peritectic, and then eutectoid from the liquid staying
in intercrystalline spaces.
a)
b)
Fig. 11. Microstructure (BSE) and the maps of the superficial
distribution of the concentration of elements in the bronze BB555
Small quantities Pb crystallize on intercrystalline boundaries.
Identify single, in the microstructure of the bronze B10, the sepa-
rates of intermetallic phase κ in the composition which the ele-
ments: Zn, Sn, Sb and Fe come in. The lead undergoes, in the
bronze B555, of the strongest microsegregation and similarly
how in the case of the bronze B10, Sn and Sb. These elements are
„pushed aside” in front of the front of the crystallization of phase
α enriching highly they the liquid bronze. Rich in these elements
phase δ crystallizes, in the result of phase alternatively peritectic,
and then eutectoid, from the liquid staying in intercrystalline
spaces. The lead, being characterizing the lack of dissolubility in
Cu and the lowest temperature of crystallization, it crystallizes as
last phase from the liquid bronze in intercrystalline spaces. Two
kinds of intermetallic phase κ were also identified in these spaces.
One of them rich is first of all in Zn, Sb, Ni and Fe second
meanwhile in Sn, Sb, Ni and Fe.
4. Conclusions
From carried out investigations, in the reference to the bronze solidifying in hot plaster mould, following conclusions result:
one the method of the thermal and derivative analysis
(TDA) can identify the crystallization process of the
bronze,
they be subject to, in bronze B10 and the B555, of
strong microsegregation: Pb, Sn and Sb,
single was identified, in the bronze B10, the separates
of intermetallic phase κ rich first of all in: Zn, Sn, Sb
and Fe,
two intermetallic phase κ were identified in the
bronze B555, one rich first of all in Zn, Sb, (Ni, Fe)
and second including Sn, Sb, (Ni, Fe),
the bronze BA1055 the most homogeneous micro-
structure in the cast state is characterizes.
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α
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