International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

Paper presents experimental work focused on the application of the separating agent-lubricant SafetyLube 7815 on the surface of the tested samples: ground surface; polished surface; surface of the samples textured by laser in the mode stochastic texture mode. Duplex PVD coatings nACRo4, AlXN3 and AlTiN G were deposited on the surface. The aim of the experimental work was to approximate the breakin conditions of a new or renovated mould part for high pressure casting of aluminium alloys. The release agent-lubricant SafetyLube 7815 was applied to the surface of the specimens by dispersive spraying. The method of measuring the contact contact angle measurement, the influence of the finishing operations of the mould part surface on the surface wettability by contact angle measurement.

Paper presents results of an investigation aimed at determining optimum properties of the additive materials used. Laser welding technology was used for the creation of the clads. Single-layer clads with additive materials Dievar (1.2343), Dratec (1.6356) and UTPA 702 (1.6356) were realized on plates of Dievar material which were heat-treated to a hardness of 45-48 HRc. Their chemical compositions differed in the contents of C, Si, and Mn. The primary objective was to verify the possibilities of innovative use of additive materials based on maraging steels. The quality of the maraging agents was evaluated by stucture and EDX analysis in each selected maraging agent spectra. Due to the influence of the used surfacing technology and parameters, there was only minimal mixing of the surfacing metal with the base material, which is in agreement with the measured HAZ values. Using the energy beam laser welding method, there was no burning of the elements during their transfer to the filler metal, as occurs with arc methods. No oxidation or contamination of the additive metal due to insufficient protection of the cladding site was observed.

The paper presents the results of an investigation focused on the analysis of the wear of moulds for high-pressure casting with Al alloy. In order to repair and refurbish the mould parts of moulds for high-pressure casting of aluminium alloys, samples of experimental welds were prepared on the base material of grade 1.2343 (Dievar) of dimensions 150x130x30 mm refined to the hardness value of 44-48 HRC. A TruDisk 4002 solid-state disk laser with BEO D70 focusing optics was used for surfacing. Mat.No.1.2343 (Dievar), Mat.No.1.6356 (Dratec) and Mat.No.1.6356 (UTPA 702 and NIFIL NiCu7/Dievar) wires were used as additional material. Light microscopy technique was used to inspect the microstructures on the cross-sections of the welds. Microhardness measurements were performed with a Vickers indenter at a load of 500 g and a mutual indentation distance of 0.4 mm between the indenter impressions.

The paper presents the results of research focused on the application of innovative procedures for surface topography modification. The experimental work was aimed at adjusting the microgeometry and surface topography of new and renovated shaped parts of molds for casting aluminium alloys under high pressure. In the phase of experimental verification of suitable surface topography, a group of samples from Dievar material was prepared. A multilayer nanostructured PVD coating of the 4th generation duplex nACRo4 was deposited on part of the experimental samples. The surface of the samples was ground and polished. The microgeometry of the surface of the samples was modified by low-energy laser radiation – microtexturing. The maximum interval was chosen to create a stochastic texture, also called a random texture crater distance up to 200 μm. The aim of this surface treatment was to analyze the adhesion effect of commercially used ones of lubricants in the technology of treatment of shaped parts of molds when casting aluminium alloys under high pressure on machines with a cold filling chamber. In the run-in of the mold, after the first cycles of spraying with a separating agent, a compact layer was created to increase the technological life of the shaped parts of the molds.

The paper presents the results of research aimed at determining the quality of renovation layers using laser technology. In order to repair and renovate shaped parts of molds for casting aluminum alloys under high pressure, samples of experimental welds were prepared on the base material quality 1.2343 (Dievar). The renovation layers were created using additional materials Dievar, UTP A 7002 and NIFIL NiCu7 res. NiCu7 with Dievar combination. The microstructures on the cross-sections of the deposits were checked using the light microscopy technique. The technique of scanning electron microscopy and semi-quantitative EDX microanalyses were analyzed distribution of alloys in deposits. The microhardness of the deposits was determined.

The paper presents the results of research aimed at determining selected tribological properties of PVD nanocoatings. PVD nanocoating of the 4th generation duplex nACRo4 was applied to the surface of shaped parts of molds and cores for high-pressure aluminium casting. The surfaces were laser textured with a random texture. The tribological properties of the coating were determined by measuring the friction coefficient using the Pin on Disc method at a temperature of 300 °C. Confocal microscopy was used to determine the parameters of the microgeometry of surfaces with random texture topography. The aim of this surface treatment was to analyse the adhesion effect of commercially used ones of lubricants in the technology of treatment of shaped parts of molds when casting aluminium alloys under high pressure on machines with a cold filling chamber. By checking the integrity of textured surfaces with deposited with the duplex PVD coating of the 4th generation nACRo4, no damage to the integrity of the deposited material was detected PVD coating. Elements forming the PVD coating were detected on the surface by semiquantitative EDX microanalysis.

The paper presents the results of research aimed at determining surface wettability. The research was focused on microtexturing by low-energy laser irradiation of the surface of molded parts using innovative engraved surface treatment methods (LBT and EBT) to ensure a smooth distribution of the separation agent on the surface of high-pressure Al castings. The basic material was Uddeholm Dievar, which is used to make molds. PVD coatings were applied to the base material. The effect of laser texturing surfaces on the contact angle size was determined. Contact angle was evaluated on the base material, on PVD coatings without surface treatment and with the use of two types of separating agents.

The paper presents the results of research focused on the restoration of functional areas of products by the application of PTA technology. Hardfacing layers intended for the renovation of the surfaces of aluminum alloy injection molds were evaluated. The base material was medium alloy steel X38CrMoV5-1 (H11). Three types of powder additives were applied to form the functional layers: two types based on iron, designated HSS 23 and HSS 30, and one type based on nickel, designated DEW Nibasit 625 -P. The quality of the layers was evaluated using non-destructive and destructive tests. The surface integrity of the layers was assessed by visual and capillary tests. The microstructure of the materials and its hardness were evaluated. The tribological properties of the welds were determined by the pin-on-disc method.