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Achievements in Foundry Materials and Technologies
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Achievements in Foundry Materials and Technologies

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 July 2025 | Viewed by 8474

Special Issue Editors

Prof. Dr. Marcin Stawarz

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Guest Editor
Department of Foundry Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, 7 Towarowa Street, 44-100 Gliwice, Poland
Interests: cast iron; intermetallic phases; crystallization process; electromagnetic stirring; quality of castings; corrosion of metal alloys; lost wax method; continuous castings; 3d printing process; reverse engineering
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Krzysztof Janerka

E-Mail Website
Guest Editor
Department of Foundry Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, 7 Towarowa Street, 44-100 Gliwice, Poland
Interests: cast iron; ductile cast iron; carburizing of iron alloys; carburizers; thermal derivation analysis; crystallization process
Prof. Dr. Jan Jezierski

E-Mail Website
Guest Editor
Department of Foundry Engineering, Faculty of Mechanical Engineering, Silesian University of Technology, 7 Towarowa Street, 44-100 Gliwice, Poland
Interests: cast iron; cast steel; crystallization process; quality of castings; high pressure die casting; gating systems; automation and robotization in foundry; pneumatic conveying; wastes management
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Foundry is one of the basic branches of production. In every industry of the modern economy, foundry products are used: parts of machines and devices, load-bearing elements, precision elements, etc. Throughout its history, the foundry industry has been constantly developing, introducing new molding materials, casting alloys, processes, foundry tools, quality control systems, energy-saving systems, environmental protection, etc.

Many innovations have not been adequately presented in the professional literature or have been presented locally at conferences and meetings. Therefore, the aim of this Special Issue will be to collect new achievements and progress in one place and to create a “platform” for discussion on new directions in the development of the foundry among authors, reviewers, and readers.

This Special Issue covers all foundry technologies and alloys (cast steel, cast iron, and non-ferrous alloys). Due to the topics covered in this Special Issue, articles on modern solutions in the technology of casting production are welcome. Topics covered may include optimization of foundry production, methods of metal preparation, crystallization, electromagnetic mixing of foundry alloys, quality control, printing 3D processes, reverse engineering, etc.

Once again, we invite you to submit your original research papers or review articles that describe the current state of the art within the scope of this Special Issue, “Achievements in Foundry Materials and Technologies”.

Prof. Dr. Marcin Stawarz
Prof. Dr. Krzysztof Janerka
Prof. Dr. Jan Jezierski
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • modern castings production process
  • environmental protection in foundry
  • reverse engineering in foundry
  • quality of castings
  • 3D printing process
  • molding materials
  • crystallization process
  • corrosion of metal alloys
  • casting alloys
  • continuous casting

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Published Papers (10 papers)

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Research

19 pages, 15506 KiB  
Article
The Analysis of Plastic Forming in the Rolling Process of Difficult-to-Deform Ti + Ni Layered Composites
by Dariusz Rydz, Sebastian Mróz, Piotr Szota, Grzegorz Stradomski, Tomasz Garstka and Tomasz Cyryl Dyl
Materials 2025, 18(9), 1926; https://doi.org/10.3390/ma18091926 - 24 Apr 2025
Viewed by 125
Abstract
The article presents the results of experimental studies on the symmetrical and asymmetrical rolling process of composite laminate sheets consisting of difficult-to-deform Ti and Ni materials. Composite sheets joined by explosive welding were used for the tests. The aim of the research was [...] Read more.
The article presents the results of experimental studies on the symmetrical and asymmetrical rolling process of composite laminate sheets consisting of difficult-to-deform Ti and Ni materials. Composite sheets joined by explosive welding were used for the tests. The aim of the research was to determine the impact of plastic shaping conditions in the rolling process on the quality and selected functional properties of the materials constituting the layered composite. The rolling process was carried out cold on a duo laboratory rolling mill with a roll diameter of 300 mm. During the rolling process, the influence of the rolling process conditions on the distribution of metal pressure forces on the rolls was determined, as well as the shear strength and microstructural studies of the joint area of the layered composites. As part of the conducted considerations, residual stress tests were carried out using the Barkhausen noise method. The scientific aim of the presented work was to determine the optimal conditions for the plastic processing of multi-layer Ti-Ni sheets. The results presented in the work allowed for determining the most favorable conditions for the rolling process. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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15 pages, 15656 KiB  
Article
Oxidation of the Alloy Based on the Intermetallic Phase FeAl in the Temperature Range of 700–1000 °C in Air and Possibilities of Practical Application
by Janusz Cebulski, Dorota Pasek, Maria Sozańska, Magdalena Popczyk, Jadwiga Gabor and Andrzej Swinarew
Materials 2025, 18(8), 1835; https://doi.org/10.3390/ma18081835 - 16 Apr 2025
Viewed by 249
Abstract
The paper presents the results of oxidation tests on the alloy based on the intermetallic phase, Fe40Al5Cr0.2TiB, in the air at 700–1000 °C temperature. The kinetics of corrosion processes were determined, the surface condition after oxidation was assessed, and the type and morphology [...] Read more.
The paper presents the results of oxidation tests on the alloy based on the intermetallic phase, Fe40Al5Cr0.2TiB, in the air at 700–1000 °C temperature. The kinetics of corrosion processes were determined, the surface condition after oxidation was assessed, and the type and morphology of the oxides formed were determined. In addition, the paper presents the possibility of applying the technology of surfacing Fe40Al5Cr0.2TiB alloy on the surface of steel grade S235JR as a protective coating that is resistant to high temperatures. The process was carried out using the TIG method by direct current (DC). After the surfacing, the structure of the surfacing weld made of the tested material on the base of structural steel grade S235JR was determined. It was found that a protective Al2O3 oxide layer is formed on the surface of the oxidized alloy based on the intermetallic phase from the FeAl system, and the oxidation kinetics have a parabolic course. Moreover, it was found that the morphology of the oxides formed on the surface varies depending on the oxidation temperature, which clearly indicates a different mechanism of oxide layer formation. The formation of a stable α-Al2O3 oxide variety on the surface of the Fe40Al5Cr0.2TiB alloy protects the material from further corrosion, which favors the application of this alloy on structures and fittings operating at elevated temperatures. The aim of the research was to use the Fe40Al5Cr0.2TiB alloy with very good oxidation resistance as a layer overlay on ordinary quality S235JR steel. In this way, conditions were created that fundamentally changed the surface condition (structure and physicochemical properties) of the system: steel as a substrate—intermetallic phase Fe40Al5Cr0.2TiB as a surfacing layer, in order to increase resistance to high-temperature corrosion and erosion (in the environment of gases and solid impurities in gases) often occurring in corrosive environments, especially in the power industry (boilers, pipes, installation elbows) and the chemical industry (fittings). At the same time, the surfacing method used is one of the cheapest methods of changing the surface properties of the material and regenerating or repairing the native material with a material with better properties, especially for applications in high-temperature corrosion conditions. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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15 pages, 3576 KiB  
Article
Effect of Solidification Direction on the Freckle Formation in Single-Crystal Superalloy Castings
by Dexin Ma, Hongyuan Sun, Yunxing Zhao, Weitai Xu, Zaiwang Huang, Bowen Cheng, Yang Liu, Fu Wang, Qiang Yang, Lv Li, Yangpi Deng, Fuze Xu, Haijie Zhang and Menghuai Wu
Materials 2025, 18(7), 1534; https://doi.org/10.3390/ma18071534 - 28 Mar 2025
Viewed by 325
Abstract
Solidification experiments in two opposite directions were conducted to investigate the buoyancy effect on freckle formation during directional solidification in single-crystal superalloy castings. During conventional upward solidification with the superalloy CMSX-4, severe freckles were observed in castings of various geometries. By reversing the [...] Read more.
Solidification experiments in two opposite directions were conducted to investigate the buoyancy effect on freckle formation during directional solidification in single-crystal superalloy castings. During conventional upward solidification with the superalloy CMSX-4, severe freckles were observed in castings of various geometries. By reversing the solidification direction from upward to downward, freckle-free castings could be obtained. To visually verify the effect of the solidification direction, an in situ observation experiment by varying the solidification direction was performed using a Ga-In alloy. In the upward solidification process, strong solutal convection was visually observed due to the decrease in the density of the interdendritic liquid. Conversely, a stable condition without visible flow was established during downward solidification, due to the stable state of the top-light, bottom-heavy liquid system. A new Rayleigh-number model was successfully applied to characterize the freckle features in superalloy cluster castings. When the solidification direction was reversed from upward to downward, the driving force for solutal convection was suppressed, leading to the complete elimination of freckle formation in single-crystal superalloy castings. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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19 pages, 13112 KiB  
Article
The Effect of Mold Flux Wetting Conditions with Varying Crucible Materials on Crystallization
by Muhammad Anwarul Nazim, Arezoo Emdadi, Todd Sander and Ronald O’Malley
Materials 2025, 18(5), 1174; https://doi.org/10.3390/ma18051174 - 6 Mar 2025
Viewed by 628
Abstract
Understanding mold flux crystallization is essential for assessing heat transfer during steel casting. The complexity of the mold gap presents challenges in identifying the optimal testing method and nucleation type. This study investigates how variations in wetting properties influence nucleation dynamics, in particular [...] Read more.
Understanding mold flux crystallization is essential for assessing heat transfer during steel casting. The complexity of the mold gap presents challenges in identifying the optimal testing method and nucleation type. This study investigates how variations in wetting properties influence nucleation dynamics, in particular the wetting behaviors of mold flux in platinum and graphite crucibles and how they affect crystallization temperatures and solidification mechanisms. Advanced analytical techniques, including confocal laser scanning microscopy (CLSM), and differential scanning calorimetry (DSC) were employed to analyze nucleation under different conditions, with calibration using synthetic slag, Li2SO4, and thermodynamic equilibrium simulations. The findings highlight the crucial role of crucible materials in modifying nucleation energy barriers and undercooling requirements. These insights enhance the understanding of mold flux behavior, contributing to the refinement of testing methodologies and the optimization of heat transfer and solidification processes in continuous casting. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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16 pages, 4154 KiB  
Article
Optimisation of Hot-Chamber Die-Casting Process of AM60 Alloy Using Taguchi Method
by Tomasz Rzychoń and Andrzej Kiełbus
Materials 2024, 17(24), 6256; https://doi.org/10.3390/ma17246256 - 21 Dec 2024
Cited by 1 | Viewed by 772
Abstract
This paper presents the effect of hot-chamber HPDC (high-pressure die casting) process parameters on the porosity, mechanical properties, and microstructure of AM60 magnesium alloy. To reduce costs, a Taguchi design of the experimental method was used to optimise the HPDC process. Six parameters [...] Read more.
This paper presents the effect of hot-chamber HPDC (high-pressure die casting) process parameters on the porosity, mechanical properties, and microstructure of AM60 magnesium alloy. To reduce costs, a Taguchi design of the experimental method was used to optimise the HPDC process. Six parameters set at two levels were selected for optimisation, i.e., piston speed in the first phase, piston speed in the second phase, molten metal temperature, piston travel, mould temperature, and die-casting pressure (the pressure under the piston). Signal-to-noise (S/N) ratios were used to quantify the present variations. The significance of the influence of the HPDC parameters was assessed using statistical analysis of variance (ANOVA). The results showed that the die-casting pressure had the most significant influence on the porosity of the AM60 alloy. Moreover, piston speed in the first phase, second phase, and die-casting pressure had the most important effects on tensile strength. It is well known that porosity determines the mechanical properties of die castings; however, in AM60 alloy, changes in the HPDC parameters also contribute to microstructural changes, mainly through the formation of Externally Solidified Crystals. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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21 pages, 8615 KiB  
Article
Evaluating the Appropriateness of Selected Foundry Sands for the Casting of Reactor Housings: A Study Based on Physicochemical Characterization Outcomes
by Paweł Gara, Ewa Wisła-Walsh and Tomasz Bajda
Materials 2024, 17(24), 6068; https://doi.org/10.3390/ma17246068 - 12 Dec 2024
Viewed by 579
Abstract
In the case of desulfurization and spheroization of cast iron using the in-mold method, in which the treated cast iron is poured into the reaction chamber and placed in the casting mold, the mineral raw material of the mold should support these processes. [...] Read more.
In the case of desulfurization and spheroization of cast iron using the in-mold method, in which the treated cast iron is poured into the reaction chamber and placed in the casting mold, the mineral raw material of the mold should support these processes. Therefore, it is important to know the physicochemical properties of the materials selected for the production of casting molds and to learn about the phenomena occurring during their pouring. The research presented in this paper was carried out on quartz, magnesite, chromite, and olivine sands. The results not only provide a comprehensive understanding of these materials but also have significant implications for reactor housing casting. Two of the three tested quartz sands meet all the standards, allowing quartz raw materials to be foundry sands. Marked by the authors of this work, P11 sand, which is classified as 1K grade by the seller, does not meet the requirements of the Polish standard PN-85/H-11001 for this grade and should be classified as 2K grade. At the same time, attention was drawn to relatively considerable weight losses at 1350 °C for the tested quartz raw materials. More significant losses on ignition were found for magnesite sand than the value permitted by the Polish standard, which should be associated with the fact that derivatographic tests were carried out in an oxidizing atmosphere. In the analysis made for olivine sand, the obtained data indicated that the magnesium content is slightly below the requirements of the relevant standard; on the contrary, the iron content exceeds the standard requirements. Analytical data obtained for chromite sand indicated that it meets the PN-91/H-11007 standard regarding chemical composition, but X-ray diffraction tests showed that the tested sample is not chromite but magnesiochromite. The results of grain size distribution, chemical composition, X-ray diffraction, SEM/EDS, and TG/TG presented in this paper show that before starting the production of a specific molding mixture, each time most of the parameters characterizing sand used should be controlled because the properties may differ from the manufacturer’s declaration. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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13 pages, 10836 KiB  
Article
Microstructure of the Working Layer of X46Cr13 Steel in a Bimetal System with Gray Cast Iron
by Natalia Przyszlak, Tomasz Wróbel, Agnieszka Dulska, Paweł M. Nuckowski, Dariusz Łukowiec and Marcin Stawarz
Materials 2024, 17(23), 5933; https://doi.org/10.3390/ma17235933 - 4 Dec 2024
Viewed by 619
Abstract
The research conducted in this study aimed to determine whether the production of a layered casting in the material system of X46Cr13 steel (working part) and gray cast iron (base part) can be integrated with the hardening process of this steel within the [...] Read more.
The research conducted in this study aimed to determine whether the production of a layered casting in the material system of X46Cr13 steel (working part) and gray cast iron (base part) can be integrated with the hardening process of this steel within the conditions of the casting mold. Accordingly, a series of layered castings was produced by preparing the mold cavity, where a monolithic steel insert was poured with molten gray cast iron with flake graphite. The variable factors in the casting production process included the pouring temperature Tp and the thickness of the support part g. Importantly, given that the hardening of the X46Cr13 steel insert occurred directly within the mold, the selection of casting parameters had to balance the ability to heat the insert to the austenitization temperature Tγ≥950°C while also creating thermokinetic conditions conducive to the rapid cooling of the system. Therefore, chromite sand—commonly regarded as a rapid-cooling material—was selected as the matrix for the molding material. Based on the conducted studies, it was determined that the thermokinetic properties of this material allowed the surface of the cast working part to be heated to the austenitization temperature. The microstructure consisted of Cr(Fe) carbides within a martensitic-pearlitic matrix, with martensite filling the grains of the primary austenite and pearlite situated along their boundaries. The carbides were primarily located at grain boundaries and, to a lesser extent, within the primary austenite grains. Through transmission electron microscopy and X-ray diffractometry, the type of Cr(Fe) carbide in the microstructure of the working part was identified as M23C6. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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21 pages, 5241 KiB  
Article
Regression Analysis and Optimum Values of Austempering Affecting Mechanical Properties of Compacted Graphite Iron
by Aneta Jakubus, Marek Sławomir Soiński, Piotr Mierzwa and Grzegorz Stradomski
Materials 2024, 17(20), 5024; https://doi.org/10.3390/ma17205024 - 14 Oct 2024
Viewed by 1095
Abstract
The study examined the effect of heat treatment parameters of compacted graphite iron (CGI) on the mechanical properties of the material. The microstructure was characterized using optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Three levels of heat treatment parameters [...] Read more.
The study examined the effect of heat treatment parameters of compacted graphite iron (CGI) on the mechanical properties of the material. The microstructure was characterized using optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Three levels of heat treatment parameters were adopted considering the orthogonal test plan 24. The effects of austenitizing temperature and time and austempering on tensile strength, yield strength, and elongation were analyzed. Polynomial regression was chosen because it extends linear regression and allows for modeling more complex, nonlinear relationships between variables. Total regression models were determined for each dataset. The models for tensile strength (Rm) had an approximately 82% coefficient of determination, for yield strength (R0.2) around 50%, and for elongation (A5) around 80%. For optimization, the response surface method (RSM) was used. The results obtained were compared with the proposed mathematical models. The ANOVO results showed that austempering temperature (Tpi) had the greatest effect on each parameter studied. The optimal conditions for the analyzed parameters, assuming tensile strength and yield strength at the maximum level and an elongation of about 0.7%, are obtained for the following heat treatment parameters: Tγ = 890 °C; Tpi = 290 °C; τγ = 120 min; τpi = 150 min. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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26 pages, 19322 KiB  
Article
Role of Quenching Temperature Selection in the Improvement of the Abrasive (Al2O3) Wear Resistance of Hybrid Multi-Component Cast Irons
by Yuliia Chabak, Vasily Efremenko, Ivan Petryshynets, Michail Golinskyi, Kazumichi Shimizu, Bohdan Efremenko, Vadim Kudin and Alexander Azarkhov
Materials 2024, 17(15), 3742; https://doi.org/10.3390/ma17153742 - 28 Jul 2024
Cited by 2 | Viewed by 1924
Abstract
In this paper, enhancing the tribological characteristics of novel cast metallic materials—hybrid multi-component cast irons—by applying a strengthening heat treatment is described. The experimental materials were the cast alloys of a nominal composition (5 wt.% W, 5 wt.% Mo, 5 wt.% V, 10 [...] Read more.
In this paper, enhancing the tribological characteristics of novel cast metallic materials—hybrid multi-component cast irons—by applying a strengthening heat treatment is described. The experimental materials were the cast alloys of a nominal composition (5 wt.% W, 5 wt.% Mo, 5 wt.% V, 10 wt.% Cr, 2.5 wt.% Ti, Fe is a balance) supplemented with 0.3–1.1 wt.% C and 1.5–2.5 wt.% B (total of nine alloys). The heat treatment was oil-quenching followed by 200 °C tempering. The quench temperature (QT) varied in the range of 900–1200 °C, with a step of 50 °C (with a 2-h holding at QT). The correlation of the QT with microstructure and properties was estimated using microstructure/worn surface characterization, differential scanning calorimetry, hardness measurement, and three-body-abrasive wear testing (using Al2O3 particles). The as-cast alloys had a multi-phase structure consisting of primary and/or eutectic borocarbide M2(B,C)5, carboborides M(C,B), M7(C,B)3, M3(C,B), and the matrix (ferrite, martensite, pearlite/bainite) in different combinations and volume fractions. Generally, the increase in the quenching temperature resulted in a gradual increase in hardness (maximally to 66–67 HRC) and a decrease in the wear rate in most alloys. This was due to the change in the phase-structure state of the alloys under quenching, namely, the secondary carboboride precipitation, and replacing ferrite and pearlite/bainite with martensite. The wear rate was found to be inversely proportional to bulk hardness. The maximum wear resistance was attributed to QT = 1150–1200 °C, when the wear rate of the alloys was lowered by three to six times as compared to the as-cast state. With the QT increase, the difference in the wear rate of the alloys decreased by three times. The highest abrasive resistance was attributed to the alloys with 1.1 wt.% C, which had a 2.36–3.20 times lower wear rate as compared with that of the reference alloy (13 wt.% Cr cast iron, hardness of 66 HRC). The effects of carbon and boron on hardness and wear behavior are analyzed using the regression models developed according to the factorial design procedure. The wear mechanisms are discussed based on worn surface characterization. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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18 pages, 18765 KiB  
Article
Compound Castings for the Coke Industry
by Tomasz Wróbel
Materials 2024, 17(14), 3539; https://doi.org/10.3390/ma17143539 - 17 Jul 2024
Cited by 1 | Viewed by 899
Abstract
In this paper, issues related to the technology of compound castings composed of two parts, i.e., the working layer and the supporting part, made of X46Cr13 high-chromium steel and EN-GJL-HB 255 grey cast iron, respectively, in a liquid–solid system by pre-installing a monolithic [...] Read more.
In this paper, issues related to the technology of compound castings composed of two parts, i.e., the working layer and the supporting part, made of X46Cr13 high-chromium steel and EN-GJL-HB 255 grey cast iron, respectively, in a liquid–solid system by pre-installing a monolithic insert in the mould cavity are presented. As a part of the research, the mechanism of formation of transitional zones in the bonding area of the above-mentioned two alloys was identified and described. It was shown that the phenomenon that determines the formation of a permanent bond between the joined materials is the transport of C and heat from the “high-carbon and hot” material of the supporting part poured into the mould in the form of liquid cast iron to the “low-carbon and cold” material of the working layer placed in the form of a steel monolithic insert inside the mould cavity. In the paper, the suitability of the compound castings technology developed for use in the coke industry is also presented. Full-size high-chromium steel–grey cast iron compound casting plates designed for the coke quenching car lining were positively verified in real coke plant operating conditions. Full article
(This article belongs to the Special Issue Achievements in Foundry Materials and Technologies)
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