In this paper is presented an analysis of a comparison of particular non-destructive techniques: radiographic, ultrasonic, eddy current and pulsed infrared thermography to detect flaws in pressure die casting. Furthermore, a new way of the image segmentation method for porosity detection in aluminium pressure die casting using results from X-ray analysis and public domain software is proposed. The results of the research allowed verifying the possibility of using the aforesaid methods in controlled technological parameters of the casting process, and thus permitted confirming the quality of the manufactured castings. It was found that the radiographic method was the most preferred means for evaluating the quality of products and for optimizing the technological process for aluminium pressure casting. It permits a fast analysis of casting defects in the finished products, and when combined with the computer image analysis (the porosity segmentation algorithm as described in the article) it allows drawing conclusions regarding their causes (e.g. based on the size and shape analysis of the pores detected). The ultrasonic testing method can also be used to evaluate the quality of the casting (to detect it but without the possibility of interpreting the size or source of origin). The results obtained via this method allow for proper control of die casting parameters.

This paper presents the results of laser welding of dissimilar joints, where low-carbon and stainless steels were welded inthe lap joint configuration. Performed welding of austenitic and ferritic-pearlitic steels included a sealed joint, where only partial penetration of lower material was obtained.The authors presented acomparative study of the joints under different configurations. The welding parameters for the assumed penetration were estimated via anumericalsimulation. Moreover, a stress–strain analysis was performed based on theestablished model. Numerical analysis showed significant differences in joint properties, therefore, further study was conducted. Investigation of the fusion mechanism in the obtained joints wascarried out using electron dispersive spectroscopy (EDS) and metallurgical analysis. The study of the lap joint under different configurations showed considerable dissimilarities in stress–strain distribution and relevant differences in the fusion zone structure. The results showed advantages of using stainless steel as the upper material of a microstructure, and uniform chemical element distribution and stress analysis is considered.

Magnesium alloys, due to their unique properties, low density and high strength properties, are becoming more frequently used in industrial applications. However, a limitation of their use may be the need to ensure high abrasive wear resistance and corrosion resistance. Therefore, magnesium alloys are often protected by applying protective coatings. The paper presents the influence of the modification of the electrolyte composition, with or without the addition of borax, on the morphology (observed by SEM method) and phase composition (analyzed by EDS and XRD) of the formed layers on the AZ91 magnesium alloy, and their abrasive wear (determined with Ball-on-Disc method) and corrosion resistance (evaluated using the immersion method and by electrochemical tests), especially in chloride solutions. It has been clearly demonstrated that the modification of the electrolyte composition significantly impacts the final properties of the protective coatings on the AZ91 alloy formed by the plasma electrolytic oxidation (PEO) process. On the basis of the results, it was found that the new type of PEO coatings with the borax addition, compared to base PEO coatings, showed significantly higher abrasion resistance and an order of magnitude lower corrosion rate.

Designers’ efforts to use the lightest possible materials with very good mechanical properties mean that in recent years magnesium alloys have been increasingly used. It is well-known that the use of various plastic working processes allows achieving even better strength properties of the material, often without significant loss of plastic properties in relation to the properties of products obtained in the casting process. The article presents the results of research on microstructural changes and mechanical properties of the alloy AZ91 (MgAl9Zn1) occurring in samples subjected to conventional plastic deformation and the KOBO method. The obtained results were compared to the properties of reference samples, i.e., cast samples. The article presents the advantage of using the low-temperature KOBO method compared to the high-temperature deformation in a conventional manner. Moreover, it has been shown that the use of KOBO extrusion allows the alloy AZ91 (MgAl9Zn1) to obtain superplasticity properties with an elongation of up to 577% compared to the cast reference sample, which is generally classified as difficult for plastic deformation.