Marek Wojtaszek

T-Shape Connector Hydroforming Process Analysis

The work is focused on hydroforming of T-shape connector for high temperature applications. A seamless part for use in industrial applications was formed in a high pressure liquid extrusion process. Due to the occurrence of faults in the final products, numerical simulations were conducted to reveal the possible sources of such failures. The numerical simulation took into account precisely determined boundary conditions allowing proper selection of processing parameters. The microstructure of charge material as well as that of the final product was also examined. Numerical simulations of the investigated extrusion process showed the possibility of obtaining good quality product, however, the quality of final part is strongly influenced by properly designed heat treatment schedule.

Design and Verification of the Parameters of Hot Forging of Ti10V2Fe3Al Alloy Compacts

This research work was focused on the application of powder metallurgy technology to the production of high-quality products from Ti10V2Fe3Al alloy. For the purpose of investigations hot compaction and hot closed-die forging processes were used. As an initial material a mixture of elemental powders was applied. As a result of hot densification, fully densified semi-products were obtained (99.4 % relative density). Numerical modelling of forging of a selected forging was performed using finite element method. Various options of forging process conditions were applied. The designed parameters of forging technology were verified by means of trials performed in industrial conditions. The quality of the product was estimated by microstructure observations. It was found that hot forging of compacted mixture of elemental powders resulted in obtaining defect-free gear wheel showing the relative density of 99.8 ±0.2 %.

Properties of Al-Si-Fe-Cu-Mg Alloy PM Composites Obtained by Closed -die Forging and Heat Treatment

Aluminium RAl-1 and its alloy Al17Si5Fe3Cu1.1Mg0.6Zr composite materials were manufactured from powder mixtures by cold pressing, hot closed-die forging at 480oC and heat treatment. Powders ranging in composition in 20 wt.% steps of the alloy were mixed in a Turbula mixer for 1 h. The preforms with alloy concentrations of 80 and 100 % were hot consolidated at 480oC and closed-die forged at the same temperature. The effect of chemical composition on microstructure and mechanical properties in bending and compression was examined. Bend strength ranged from 400 to 540 MPa, compression strength from 415 to 744 MPa and hardness from 32 to 203 HB. Simulated distribution of component materials for a cross-section of the forging and shapes of the materials were analysed using LARSTRAN/Shape finite element program and are qualitatively comparable with the results obtained by forging.