Development and implementation of synthetic cast iron casting technology for the manufacture of a friction wedge

Abstract

The article presents a step-by-step technological process for manufacturing a friction wedge for freight cars,
designed to damp vibrations, using synthetic cast iron casting. Special attention is given to the preparation of
molding and core mixtures, the formation of a disposable sand mold from compacted sand, and the preparation
of charge materials. The study examines experimental results of synthetic cast iron production using various
proportions of steel scrap in an induction crucible furnace. Methods for chemical composition control,
assimilation coefficients of alloying elements, energy consumption indicators, and hardness data based on melt
certificates are analyzed. An improved method for melting synthetic cast iron using steel scrap and ferroalloys
for carburization and alloying is proposed, along with a detailed scheme for producing the friction wedge in a
disposable sand mold. The development and implementation of this technology are especially relevant under
conditions of limited access to high-quality cast iron scrap and the need to reduce production costs. The use of
single-use sand molds, along with the careful selection and control of molding mixtures, ensures consistent
casting quality and compliance with current standards.