Wear Resistance Of Cast Iron Research Articles

Structural-phase state and properties of heat and wear resistant cast irons of Cr–Mn–Ni–Ti system additionally alloyed with Al and Nb

The paper presents the data on phase composition and structure forming for the alloys, on distribution of elements among the alloy structural components, on variation of wear resistance, scale resistance, growing stability and mechanical properties of cast iron of Cr–Mn–Ni–Ti–Al–Nb system depending on different aluminium and niobium content and thermal ac-cumulating capacity of a casting mould. Complex carbides (Nb, Ti)C are forming in white cast iron during niobium alloying. Quantitative metallographic analysis of (Nb, Ti)C carbides and (Cr, Fe, Mn)7C3 complex carbides was carried out on the samples with examined composition. Aluminium provides favourable influence on forming of the thin protective spinel-type films with minimal amount of defects; diffusion through such oxide film is very difficult. Joint alloying by aluminium and niobium leads to simultaneous increase of heat resistance and wear resistance. Wear resistance increased as a result of enlargement of the part of primary carbides (Nb, Ti)C with high hardness in the structure of cast iron. Composition of oxide films includes aluminium, which strengthens their protective properties and rises of the alloy scale resistance. It is found for the first time that niobium doping leads to secondary solidification during cooling in the casting mold. Dispersion particles of М7С3 carbides are forming in solid state, thereby no structure degradation occurs during testing at increased temperatures, and growing stability rises. On the basis of the complex of the conducted researches the rational composition of heat and wear resistant cast iron is offered at the following ratio of components, wt. %: 2.1–2.2 C; 4.5–5.0 Mn; 18.0–19.0 Cr; 1.0–1.2 Ni; 0.4–0.6 Ti, 2.0 Nb; 2.0 Al. Wear resistance increased 1.2 times compared to cast irons before the introduction of aluminum and niobium, and scale resistance – 2.4–4.5 times depending on the type of casting mold, the index of growth resistance is equal to zero for cast irons cast in dry SLM

Friction and Wear Performances of Materials for Wind Turbine Sliding Bearing Bushes

This study aimed to enhance the friction and wear characteristics of materials for wind turbine sliding-bearing bushes operating under low-speed and heavy-load conditions. To this end, a high-entropy CoCrFeNiMo alloy coating was applied to the surface of 9Cr18 bearing steel, and Ni-Cr-Mo-Si alloy coating was applied to MTCrMoCu30 wear-resistant cast iron using laser cladding. The effects of varying loads on the friction and wear properties of these coatings were investigated, and the friction and wear properties were compared. Furthermore, the overall priority indices for both groups of bearing bush coatings were assessed. The findings indicated that the friction coefficient, wear quality, and wear rate of CoCrFeNiMo high-entropy alloy coating initially decreased and then increased with the increase in applied load, dominated by abrasive wear. By contrast, the friction coefficient of the Ni-Cr-Mo-Si alloy coating increased, and wear quality and wear rate initially increased and then decreased, indicating the coexistence of adhesive wear and abrasive wear. Therefore, Ni-Cr-Mo-Si alloy coating exhibited a high overall priority index and favorable friction and wear properties.

Development of the hardness mathematical model of Ti-alloyed iron for cast parts used in conditions of intensive abrasive friction

The object of research is wear-resistant cast iron, intended for cast parts that work under conditions of intense abrasive friction during operation. Examples of such parts can be mixer blades of various functional purposes, the operational properties of which include stability, which depends on the hardness, determined on the HRC scale. To give such cast parts wear-resistant properties, the cast iron from which they are made is alloyed with elements that contribute to the formation of carbides of different composition: W, V, Mo, Ti, etc. The main problem that prevents the purposeful selection of materials is incomplete knowledge about the effect of chemical composition on properties, in particular, wear resistance, which prevents a justified selection criterion. Using regression analysis methods, a mathematical model was obtained, including a regression equation of the form HRC=f(C; Ceq; Ti), which relates the content of carbon, titanium and carbon equivalent in cast iron and hardness. The resulting model allows for purposeful selection of the chemical composition, which ensures a given value of HRC, on which wear resistance depends. Optimization of the chemical composition, performed according to this model, made it possible to determine that the chemical composition, which provides the maximum hardness of HRC=49, is outside the planning area: C=3.54 %, Ceq=3.95 %, Ti=3.56 %. It was established that the same value of hardness can be obtained inside the considered planning area, which has an arbitrary appearance, provided with available conditions of a passive experiment. According to the available experimental data, the values of the input variables equal to C=3.34 %, Ceq=3.727 %, Ti=0.73 % ensure obtaining hardness at the level of HRC=49. Such alternative options regarding composition and properties may indicate that the HRC=f(C; Ceq; Ti) response surface has a complex appearance that requires additional research.

Performance indicators of cutting tools from extra hard materials

Purpose. Establishing dependencies connecting the system of indicators of the processing process with technical limitations, on the one hand, and the area of existence of the parameters of turning wear-resistant cast iron with a tool made of superhard polycrystalline materials, reflecting the technical and economic indicators of the process, on the other. The methods. In the work, the structural-static dependence of the probability of non-destruction of the tool (composite) is proposed, which is a component of the mathematical model for calculating the parameters of the turning process. Findings. The most characteristic failures of blades from the point of view of the operational reliability of cutting tools are extreme wear as a result of natural wear (gradual failure) and destruction (painting) of the cutting edge as a result of the manifestation of hidden defects of the tool material or exceeding permissible loads and loss of fatigue strength during wear). According to these failure criteria, the initial indicators of the durability and failure-freeness of cutting tools in the theory of cutting and the system of operation of cutting tools are the period of stability. The efficiency of high-strength cast iron turning is inextricably linked to the wear resistance and strength of the tool materials used. The prospect of expanding the use of polycrystalline materials, taking into account boron nitride (composites), emerges from the comparison of the main performance indicators of tool materials. The analysis and experience of using ultra-hard polycrystalline materials showed that with the same cutting depth, lower feed, and high cutting speed, composites provide the largest volume work. The originality. The paper establishes the dependence of the parameters of the cutting tool made of superhard materials on the main parameters of the turning process of cast iron. With the use of grapho-analytical analysis, the primary influence of cutting depth on the period of stability and reliability of trouble-free operation of cutting plates made of superhard materials is substantiated. Practical implementation. It was established that when turning cast iron, wear occurs on both the back and front surfaces of the blade. The reason for the wear of the front surface is the presence of a large amount of wear-resistant chromium carbides and the higher hardness of the chips coming off.

Effect of Carbide Orientation on Wear Characteristics of High-Alloy Wear-Resistant Cast Irons

Both erosive and abrasive wear are common in mechanical systems and moving components in industrial production. Once they occur in machine parts, the task of breakdown maintenance should be carried out, leading to high production costs. Previous research has shown that high-chromium cast iron (HCCI), a commonly used wear-resistant material, experiences repeated particle impacts that break up the chromium carbides (M7C3) on its surface, resulting in the formation of fine fracture carbides. It has been reported that erosion wear occurs progressively due to the shedding of protrusions caused by the plastic deformation of the material’s matrix. Thus, the erosion wear characteristics of a material are strongly affected by carbides, which come in various shapes and can affect resistance. This research examined the orientation of carbides on the microstructure and their effects on erosion and abrasion properties. The wear tests showed that 27 wt.% chromium content high-alloy cast irons showed the best wear resistance properties due to the coarse strips of M7C3 carbides that effectively suppressed wear propagation. Additionally, the M2C carbides crystallized around the M7C3 carbides which support the M7C3 carbide to reduce plastic deformation and carbide peel-out. Consequently, the wear resistance properties of this material are significantly improved.

A Study of the Three-Body Abrasive Wear Resistance of 5V/5Nb-5Cr-5Mo-5W-5Co-Fe Multicomponent Cast Alloys with Different Carbon Percentages.

Since it is well known in the literature that transition metals can form extremely hard carbides and effectively strengthen a material's matrix, recently, some of them, such as V, Nb, Cr, Mo, and W, have been simultaneously added to cast iron. In addition, it is common to add Co to cast iron to strengthen the material's matrix. However, the wear resistance of cast iron can also be considerably affected by the addition of C, which is rarely discussed in the literature by the experts. Therefore, the effect of C content (1.0; 1.5; 2.0 wt.%) on the abrasive wear behavior of 5 wt.% V/Nb, Cr, Mo, W, and Co alloys was investigated in this study. An evaluation was conducted using a rubber wheel abrasion testing machine in accordance with ASTM G65 with silica sand (1100 HV; 300 μm) as abrasive particles. The results show that plural carbides (MC, M2C, and M7C3) precipitated on the microstructure of the material, which is not unlike the behavior of other types of carbides as the quantity of C increases. The hardness and wear resistance properties of 5V-5Cr-5Mo-5W-5Co-Fe and 5Nb-5Cr-5Mo-5W-5Co-Fe multicomponent cast alloys increased as the quantity of C increased. However, we observed no significant difference in the hardness between the two materials with the same C additions, while 5Nb presented better wear resistance properties compared to the 5V sample due to the larger size of NbC compared to VC. Therefore, it can be determined that, in this study, the size of the carbide plays a more important role than its volume fraction and hardness.

Drip irrigation advantages for the cotton field in conditions of salty earth in Bukhara province region

Beginning with the existing irrigation technique used in cotton farming, this paper aims to compare the outcomes of using drip irrigation with traditional irrigation. There are drip irrigation advantages for the cotton field aimed at saving water and other resources, which is demonstrated by the example of decreasing the percent of losses and increasing the outputs and crop yields. Such irrigation conditions allowed collecting and saving water resources per hectare and increasing productivity, decreasing water consumption of surface irrigation thanks to wear-resistant cast iron parts that extended equipment life.

INFLUENCE OF THE CHEMICAL COMPOSITION OF HIGH-CHROMIUM CAST IRON ON THE CONTENT OF CHROMIUM IN NEAR-CARBIDE ZONES AFTER ANNEALING AT 720 °С

Purpose. Increasing the corrosion resistance of wear-resistant high-chromium materials operating in a liquid abrasive environment makes it possible to increase the service life of products made from these materials, which is an important task in materials science. One of the main reasons for the occurrence of damage during corrosion processes is the uneven distribution of chromium in the metal base, which leads to the formation of microgalvanic pairs on the surfaces of parts in an electrolytic environment. The creation alloys of wear-resistant high-chromium, in the metal base of which microgalvanic vapors are not formed, is a promising direction for increasing the corrosion resistance of such materials. Investigation of chromium distribution processes after heat treatment parts of high-chromium cast iron, namely the formation of metal base zones near carbides.
 Research methods. Analytical review of publications. Metallographic, microstructural and local X-ray microanalysis. Mathematical modeling of processes.
 Results. It was revealed that during the heat treatment in high-chromium cast irons, structures with significant segregation of chromium are formed. It has been established that after annealing of castings at 720 °C, the minimum chromium content in the metal base is observed in the zones near carbides, and the maximum in the central zones of the graids. The presence zones with a chromium content of more than 12 % (positive potential) and less than 12 % (negative potential) leads to the formation of microgalvanic couples, which is the main reason for the acceleration of corrosion damage in the metal base. The dependence of the chromium content in the zones near the carbides after annealing at 720 °C on the chemical composition of cast iron has been determined.
 Scientific novelty. The mathematical model is proposed for determining the chromium content in the zones near carbides after annealing at 720 °C with an exposure of 9 hours from the chemical composition of cast iron in the Fe-C-Cr-Mn-Ni system. This makes it possible to predict the chromium content in the zones near the carbides and prevent the formation of microgalvanic pairs.
 Practical value. The dependence (mathematical model) obtained can be used in the development of compositions of high-chromium wear-resistant cast irons with increased corrosion resistance and machinability.

Features of mechanical processing of wear-resistant cast iron

Features of mechanical processing of wear-resistant cast iron

Manufacture of wear-resistant cast iron and copper-bearing antibacterial stainless steel from molten copper slag via vortex smelting reduction

A novel method of preparing wear-resistant cast iron and copper-bearing antibacterial stainless steel by moderate dilution of molten copper slag and vortex smelting reduction is proposed in this paper. The reduction behaviors of different components during vortex smelting reduction after medium dilution of molten copper slag are systematically investigated. Thermodynamic analysis results show that lime (CaO) can promote the decomposition of the iron peridotite phase and strengthen the reduction of copper and iron in slag. Under the conditions of 1450 °C, slag alkalinity of 1.0, 0.13 wt% carbon addition, vortex stirring speed of 250 rpm, and sedimentation stirring speed of 63 rpm, the metallization rate of copper and iron is 91.76%. In addition, 97.90 wt% zinc and 14.79 wt% lead in copper slag enter flue gas to be recovered, and 94.11 wt% silver and 88.66 wt% gold are reduced into metal. HBW555Cr13 wear-resistant cast iron and 20Cr13Cu3 copper-bearing martensitic antibacterial stainless steel, which meet the requirements of Chinese national standards, are successfully prepared by this process, realizing the separation, enrichment, and recovery of valuable components in the copper slag. The Brinell hardness of wear-resistant cast iron is 575, and the antibacterial rate of copper-containing antibacterial stainless steel against Escherichia coli is more than 99%. The reduction slag can be used as the raw material for preparing cement clinker after water quenching. There is no secondary waste residue, which realizes the molten copper slag's large-scale, slag-free, and high-value utilization.

Increasing wear resistance of the protective bush-ing of the centrifugal pump made of gray cast iron by chemical-thermal treatment

Problem. The weak link that reduces the warranty time of centrifugal pumps is a unit that includes protective bushings and seals. The purpose of the bushings is to protect the rotor shaft from erosion, corrosion and wear. The bushing works under conditions of abrasive wear by elements of the seal packing and abrasive particles entering the liquid pumped by the pump. Due to accelerated surface wear, cast iron protective bushings do not satisfy the requirements service life. Goal. The purpose of the work is to increase wear resistance of pump parts made of gray cast iron by chemical and thermal treatment. Method. Metallographic studies of the structure were performed under a UIT MicroMet-D-101 microscope. Wear is studied using the roller-pad method on a friction machine. Sulfocyanation of cast iron samples was carried out in molten salts (K2CO3, CO(NH2)2, Na2S at 560°С at the bottom of the bath. Results. In the cast state, the microstructure of gray cast iron consists of ferrite, pearlite, double phosphide eutectic and lamellar graphite inclusions. The influence of exposure time during sulfocyanation in a bath with molten salts on the structure and properties of the formed surface layer was studied. The exposure was carried out for 2 hours, 3 hours 30 minutes and 6 hours. After exposure in the bath, a thin carbonitride layer is formed on the surface of the cast iron, and a layer consisting of iron sulfide is formed on top. Conducting wear tests showed that sulfocyanation increases the wear resistance of gray cast iron. An increase in the wear resistance of cast iron is provided by a hard carbonitride layer, and good workability – by a layer of iron sulfides, which acts as a lubricant. Scientific novelty. Increasing the exposure time during sulfocyanation in the bath for more than 3 hours 30 minutes does not affect the thickness of the carbonitride layer. Practical significance. As an optimal mode of sulfocyanation, exposure for 3 hours 30 minutes can be recommended, which provides a 4.8-fold increase in wear resistance.

Polymer materials used to reduce waterjet wear of pump parts

The article presents the results of studies of the degree of influence of the operating mode of the centrifugal pump on the intensity of the water jet at constant values of the sediment concentration P = 20 kg/ m3, particle diameter d = 0.25…0.5 mm, test duration T = 2 hours and shaft speed n0 = 2900 rpm. Experiments were carried out on pump feeds from 0.5 Qopt to 1.25 Qopt with various materials and polymer coatings that were applied to the surfaces of the blades made of St.3. The best adhesion of the polymer coating is obtained at a metal temperature of 21°C. Polymer materials based on epoxy resin with silicon carbide have the highest wear resistance, while silumin shows low wear resistance. When testing ground pumps, it was found that parts made of electro corundum on an epoxy-phenol-formaldehyde bond, in comparison with parts made of wear-resistant cast iron, increases the service life of pumps 3 - 8 times.

A Thermodynamic and Experimental Assessment of the Recovery of Copper, Iron, Zinc, and Lead from Copper Slag

With the increases in the costs of iron and copper ores, the incongruity between the significant imports of these ores into China and the ongoing accumulation of unused copper slag has greatly increased. Even so, there are few low-value methods for the utilization of copper slag. The present work demonstrates the processing of this material via reduction whilst smelting wear-resistant cast iron. This system is able to recover copper, iron, zinc, and lead. The FactSage software package was used to calculate the reduction thermodynamics of the copper slag, and suitable conditions for the processing of this slag were experimentally investigated. The thermodynamic calculations indicated that copper, zinc, and lead oxides could all be readily reduced whereas the reduction of sulfides was more difficult than that of oxides. The most suitable conditions for the reduction of copper slag comprised a temperature of 1450 °C, an alkalinity of 1.2, and a reducing agent ratio of 0.225. This newly developed process was found to recover 95.49% of copper and iron from the slag along with 83.54% of lead and 98.30% of zinc. The copper-containing molten iron obtained could be used to create wear-resistant cast iron.

Results of study of the structure of castings from white wearresistant cast irons

The article considers white wear-resistant chrome cast iron used for making castings used in the mining industry, in particular, for parts of centrifugal grinders. Parts are made at the Navoi Machine-Building Plant (Uzbekistan). The white wear-resistant cast irons 280CrNi29 1, 300CrNiMoTi32 2 2 and experimental cast iron 330Cr17 used at the plant were studied. To conduct research on the above-mentioned cast irons, «Feeding disk» parts with a diameter of 380 mm, a thickness of 38 mm, and a weight of 35 kg were cast into earthen molds. The microstructure in the cast state of all the studied cast irons is a trostiteaustenitic metal matrix with eutectic colonies. The content of carbides in pre — eutectic cast iron 280CrNi29 1 was 30–32%, the hardness on the surface of castings 50–51 HRC, and in the center 45–46 HRC, the amount of carbides in cast iron 300CrNiMoTi32 2 2 was 35–37%, the hardness on the surface of castings 56–57 HRC, and in the center 52–53 HRC, the amount of carbides in eutectic cast iron 330Cr17 was 39–40%, the hardness on the surface of castings 53–54 HRC, and in the center 50–51 HRC. The cost of the 330Cr17 alloy is 1.3 times lower than the cost of the 280CrNi29 1 alloy, and 4.5 times lower than the cost of the 300CrNiMoTi32 2 2. To obtain parts from a cheap alloy 330Cr17, a technology for manufacturing castings using metal refrigerators is proposed, in this case, the hardness of castings from the alloy 330Cr17 is 58–61 NRC on the surface and 55–56 HRC in the center of the castings. The size of carbides is reduced by 3–4 times. By obtaining a directional structure and grinding carbides during casting using metal refrigerators, the wear resistance of cast parts increases by at least 20%. In this case, you can use cheaper grades of chromium cast iron, containing less alloying.

Development and Introduction of a New Composition of Wear-Resistant Cast Iron with Improved Performance Properties for Castings of Pump Parts

Improving the quality and reliability of machines is a necessary condition for the development of mechanical engineering. Most often, the main reason for the failure of machines is the wear of working parts. The reliability of the machines is ensured primarily by achieving high-quality materials of the working parts with the required level of mechanical properties.The short service life of parts reduces the economic efficiency of many machines and industrial equipment and results in irretrievable metal losses.Under conditions of wear that are not associated with large impact loads, white wear-resistant cast irons, which wear resistance is 5-10 times greater than structural steels, have shown themselves well.Grinding and the main processes of non-ferrous and ferrous metal ore-dressing, as well as coal, mining and chemical raw materials are associated with the need to process large volumes of ore slurry (pulps). For the implementation of complex dressing technological schemes at modern factories and the removal of refuse materials, centrifugal sand and soil pumps are widely used, the service life of which is limited. Impellers, bends, and sealing elements are the first to break down, resulting in significant repair costs and reduced productivity due to forced downtime [1-3].To replace worn out parts, it is necessary to remove the pumps from the operation, or install redundant pumps for the main technological stages, which takes up to 20-25 % of the productive time. If we take into account the fact that due to the wear of these parts, the pumps have lower productivity, then the total losses on a national scale are enormous.The low durability of the cast working parts of the pumps is related to the fact that the properties of used alloys do not always correspond to the operating conditions. But even parts made of the same cast iron composition and working under the same conditions have a different service life. This is due to the fact that changes in the concentrations of alloying elements within the grade composition strongly affect their properties [4-6].

THE OPTIMISING OF CUTTING MODES FOR MACHINING PARTS MADE OF CHROMIUM CAST IRON

The purpose of this work is to analyze methods and means to reduce labor intensity of machining wear-resistant cast irons. The investigation of the stability of variable carbide inserts considering different factors of cutting process at machining of expensive parts when tool failure can lead to irreparable defect is the actual problem.

Дослідження та порівняльний аналіз зносостійкості литих мелючих тіл з хромистих чавунів

A study was made of the impact-abrasive wear resistance and impact resistance of grinding bodies cast in a multi-place mold. Three types of chromium cast irons were adopted for the study: low chromium (~1% Cr), medium chromium (up to 5% Cr) and high chromium (up to 20% Cr). The macro- and microstructure of these alloys as a material for cast grinding balls has been studied. Installed an increase in the impact-abrasive wear resistance and impact resistance of such products with an increase in the mass fraction of chromium in cast iron due to the formation of carbides of the (Fe, Cr)3C and especially (Fe, Cr)7C3. Balls were cast in multi-seat chill molds. Cast iron was smelted in a medium-frequency induction furnace, such as IChT, with the main lining on a charge of pure pig iron and steel low-carbon scrap. The temperature of cast iron production was 1500 °C. Liquid cast iron was subjected to alloying with medium carbon ferrochrome. The wear resistance of cast irons was determined on samples cut from balls in the radial direction. The tests were performed in a laboratory mill When tested for impact resistance, the grinding ball received a striking blow of mass 50 kg, falling from a height of 0,5 m. The frequency of application of dynamic loads was 10 beats per minute. Impact resistance was determined by the average number of impacts sustained by the grinding body prior to destruction. Nevertheless, significant excess of the cost high-chromium over low-chromium cast iron forces us to agree with the opinion of the majority of researchers and the practice of production of such metal products. In today's conditions, low-chromium white cast iron is an economically viable material for grinding media.

Influence of structure and mechanical properties on hydroabrasive wear resistance of cast Iron

Results of study of hydro abrasive wear resistance of unalloyed and micro alloyed Sn and Sb cast irons with different forms of graphite and metal base structure are presented. It is shown that high-strength ductile cast iron with spherical graphite andpearlitic-ferritic base (P70) with high ductility and high impact toughness has the greatest resistance to hydro abrasive wear.

Influence of aluminium and niobium alloying on phase composition, structure and properties of heat- and wear-resistant cast iron of Cr-Mn-Ni-Ti system

The paper presents the data on phase composition and structure forming for the alloys and oxide layers, on distribution of elements among the alloy structural components and oxidation surface through the depth of oxide and sub-oxide layers, on variation of wear resistance, scale resistance, growing stability and mechanical properties of cast iron of Cr-Mn-Ni-Ti-Al-Nb system depending on different aluminium and niobium content and thermal accumulating capacity of a casting mould. Complex carbides (Nb, Ti)C are forming in white cast iron during niobium alloying. Quantitative metallographic analysis of (Nb, Ti)C carbides and (Cr, Fe, Mn)7C3 complex carbides was carried out on the samples with examined composition. The tests for scale resistance were conducted, structure and properties of cast iron were investigated. It was determined that chemical composition and structure of oxide layers depend on distribution of alloying elements among the alloy structural components. It was established that the areas of oxide film surface layer, which were formed on eutectics, contain mainly manganese; its concentration is more than 65 %, while Al is 4 % and Cr is 1 %. Manganese leads to increase of defects amount, such as pores, micro-cracks and vacancies, in oxide film during high-temperature gas oxidation; penetration ability of this film also increases, what has a negative effect on metal resistance to further destruction caused by oxidation. The film becomes porous, its thickness enlarges. Aluminium provides favourable influence on forming of the thin protective spinel-type films (dense substance with good metal adhesion) with minimal amount of defects; diffusion through such oxide film is very difficult. The areas of oxide layer, which were formed on austenite dendrites, contain mainly aluminium; its concentration is more than 24 %, while Mn is 16 % and Cr is 12 %. High aluminium content provides small film thickness. Joint alloying by aluminium and niobium leads to simultaneous increase of heat resistance and wear resistance. Wear resistance increased as a result of enlargement of the part of primary carbides (Nb, Ti)C with high hardness in the structure of cast iron. Composition of oxide films includes aluminium which strengthens their protective properties and rises of the alloy scale resistance. Alloying by niobium leads to secondary hardening during cooling in a casting mould. Dispersion particles of М7С3 carbides are forming in solid state, thereby no structure degradation occurs during testing at increased temperatures, and growing stability rises.

Development of Data-Driven Machine Learning Models for the Prediction of Casting Surface Defects

This paper presents an approach for the application of machine learning in the prediction and understanding of casting surface related defects. The manner by which production data from a steel and cast iron foundry can be used to create models for predicting casting surface related defect is demonstrated. The data used for the model creation were collected from a medium-sized steel and cast iron foundry in which components ranging from 1 to 100 kg in weight are produced from wear and heat resistant cast iron and steel materials. This includes all production-relevant data from the melting and casting process, as well as from the mold production, the sand preparation and component quality related data from the quality management department. The data are tethered together with each other, the information regarding the identity and number of components that resulted in scrap due to the casting surface defect metal penetrations was added to the dataset. Six different machine learning algorithms were trained and an interpretation of the models outputs was accomplished with the application of the SHAP framework.