Removal of Oxide Inclusions in Aluminium Scrap Casting Process with Sodium Based Fluxes
Total Page:16
File Type:pdf, Size:1020Kb
Load more
Recommended publications
-
Machining Accuracy of Machine Tools
Technical Information Machining Accuracy of Machine Tools Productivity and accuracy of machine tools are important competition aspects. Rapidly changing operating conditions for machine tools, however, make it diffi cult to increase productivity and accuracy. In the manufacture of parts, increasingly small batch sizes have to be produced economically, and yet accurately. In the aerospace industry, maximum cutting capacity is needed for the roughing processes, whereas the subsequent fi nishing processes must be executed with maximum precision. For milling high-quality molds, high material removal rates are required during roughing and excellent surface quality must be obtained after fi nishing. At the same time, maximum contouring feed rates are necessary to realize the required minimum distances between the paths within acceptable machining times. Thermal accuracy of machine tools is becoming increasingly important considering the strongly varying operating conditions in manufacturing. Especially with small production batches that require constantly changing machining tasks, a thermally stable condition cannot be reached. At the same time, the accuracy of the fi rst workpiece is becoming very important for the profi tability of production orders. Constant changes between drilling, roughing and fi nishing operations contribute to the fl uctuations in the thermal condition of a machine tool. During the roughing operations, the milling rates increase to values above 80 %, whereas values below 10 % are reached during fi nishing operations. The increasingly high accelerations and feed rates cause heating of the recirculating ball screw in linear feed drives. Position measurement in the feed drives therefore plays a central role in stabilizing the thermal behavior of machine tools. -
Introduction to Selecting Milling Tools Iimportant Decisions for the Selection of Cutting Tools for Standard Milling Operations
Introduction to Selecting Milling Tools IImportant decisions for the selection of cutting tools for standard milling operations The variety of shapes and materials machined on modern milling machines makes it impera- tive for machine operators to understand the decision-making process for selecting suitable cutting tools for each job. This course curriculum contains 16-hours of material for instructors to get their students ready to make basic decisions about which tools are suitable for standard milling operations. ©2016 MachiningCloud, Inc. All rights reserved. Table of Contents Introduction .................................................................................................................................... 2 Audience ..................................................................................................................................... 2 Purpose ....................................................................................................................................... 2 Lesson Objectives ........................................................................................................................ 2 Where to Start: A Blueprint and a Plan .......................................................................................... 3 Decision 1: What type of machining is needed? ............................................................................ 7 Decision 2: What is the workpiece material? ................................................................................. 7 ISO Material -
OVERVIEW of FOUNDRY PROCESSES Contents 1
Cleaner Production Manual for the Queensland Foundry Industry November 1999 PART 5: OVERVIEW OF FOUNDRY PROCESSES Contents 1. Overview of Casting Processes...................................................................... 3 2. Casting Processes.......................................................................................... 6 2.1 Sand Casting ............................................................................................ 6 2.1.1 Pattern Making ................................................................................... 7 2.1.2 Mould Making ..................................................................................... 7 2.1.3 Melting and Pouring ........................................................................... 8 2.1.4 Cooling and Shakeout ........................................................................ 9 2.1.5 Sand Reclamation .............................................................................. 9 2.1.6 Fettling, Cleaning and Finishing....................................................... 10 2.1.7 Advantages of Sand Casting............................................................ 10 2.1.8 Limitations ........................................................................................ 10 2.1.9 By-products Generated .................................................................... 10 2.2 Shell Moulding ........................................................................................ 13 2.2.1 Advantages...................................................................................... -
Appendix D – Machining Guidelines
Appendix D – Machining Guidelines A. Holding and Chucking When holding any composite billet or part it is important to remember that, unlike metallic materials, polymers will deform/distort under excessive holding pressures. This is very important when machining parts/billets with a thin cross-section (0.250 in / 6.35 mm or under) and for finish machining. Parts/billets that are held too tightly may spring back after release from the holding mechanism and result in parts that are not concentric and/or undesirable dimensions. 1. Standard Jaw Chucking Four or six jaw chucks are acceptable for thick cross-section parts and billets. Ensure medium chucking jaw pressure to prevent material distortion. 2. Pie Jaw Chucking Pie jaw chucking, contacting as close to 90% of the OD as possible, is a superior holding method over standard jaw chucking. This works well for any operation and is preferred over standard chucking for finish machine operations. 3. Adhesive Bonding / Gluing As an alternate to standard chucking directly to the composite, a billet can be glued to a fixture of alternate material prior to machining operations. If this method is used, it is recommended that guidelines from the adhesive manufacturer be followed to ensure sufficient quantity and coverage. Both Loctite® 4090 and 3MTM Scotch-WeldTM Acrylic Adhesive 8405NS have been successfully used. 4. Holding Fixtures Use holding fixtures to grip composite components during finish machining operations. Holding fixtures shall contact 100%of either the OD or ID and should be a snug fit (in/out by hand). PTFE is the best material of construction for fixtures with PVC being a close (slightly more rigid) second choice. -
Fire Protection of Steel Structures: Examples of Applications
Fire protection of steel structures: examples of applications Autor(en): Brozzetti, Jacques / Pettersson, Ove / Law, Margaret Objekttyp: Article Zeitschrift: IABSE proceedings = Mémoires AIPC = IVBH Abhandlungen Band (Jahr): 7 (1983) Heft P-61: Fire protection of steel structures: examples of applications PDF erstellt am: 06.10.2021 Persistenter Link: http://doi.org/10.5169/seals-37489 Nutzungsbedingungen Die ETH-Bibliothek ist Anbieterin der digitalisierten Zeitschriften. Sie besitzt keine Urheberrechte an den Inhalten der Zeitschriften. Die Rechte liegen in der Regel bei den Herausgebern. Die auf der Plattform e-periodica veröffentlichten Dokumente stehen für nicht-kommerzielle Zwecke in Lehre und Forschung sowie für die private Nutzung frei zur Verfügung. Einzelne Dateien oder Ausdrucke aus diesem Angebot können zusammen mit diesen Nutzungsbedingungen und den korrekten Herkunftsbezeichnungen weitergegeben werden. Das Veröffentlichen von Bildern in Print- und Online-Publikationen ist nur mit vorheriger Genehmigung der Rechteinhaber erlaubt. Die systematische Speicherung von Teilen des elektronischen Angebots auf anderen Servern bedarf ebenfalls des schriftlichen Einverständnisses der Rechteinhaber. Haftungsausschluss Alle Angaben erfolgen ohne Gewähr für Vollständigkeit oder Richtigkeit. Es wird keine Haftung übernommen für Schäden durch die Verwendung von Informationen aus diesem Online-Angebot oder durch das Fehlen von Informationen. Dies gilt auch für Inhalte Dritter, die über dieses Angebot zugänglich sind. Ein Dienst der ETH-Bibliothek ETH Zürich, Rämistrasse 101, 8092 Zürich, Schweiz, www.library.ethz.ch http://www.e-periodica.ch J% IABSE periodica 2/1983 IABSE PROCEEDINGS P-61/83 69 Fire Protection of Steel Structures — Examples of Applications Protection contre le feu des structures acier — Quelques exemples d'applications Brandschutz der Stahlkonstruktionen — Einige Anwendungsbeispiele Jacques BROZZETTI Margaret LAW Dir., Dep. -
A Comparison of Thixocasting and Rheocasting
A Comparison of Thixocasting and Rheocasting Stephen P. Midson The Midson Group, Inc. Denver, Colorado USA Andrew Jackson Arthur Jackson & Co., Ltd. Brighouse UK Abstract The first semi-solid casting process to be commercialized was thixocasting, where a pre-cast billet is re-heated to the semi-solid solid casting temperature. Advantages of thixocasting include the production of high quality components, while the main disadvantage is the higher cost associated with the production of the pre-cast billets. Commercial pressures have driven casters to examine a different approach to semi-solid casting, where the semi-solid slurry is generated directly from the liquid adjacent to a die casting machine. These processes are collectively referred to as rheocasting, and there are currently at least 15 rheocasting processes either in commercial production or under development around the world. This paper will describe technical aspects of both thixocasting and rheocasting, comparing the procedures used to generate the globular, semi-solid slurry. Two rheocasting processes will be examined in detail, one involved in the production of high integrity properties, while the other is focusing on reducing the porosity content of conventional die castings. Key Words Semi-solid casting, thixocasting, rheocasting, aluminum alloys 22 / 1 Introduction Semi-solid casting is a modified die casting process that reduces or eliminates the porosity present in most die castings [1] . Rather than using liquid metal as the feed material, semi-solid processing uses a higher viscosity feed material that is partially solid and partially liquid. The high viscosity of the semi-solid metal, along with the use of controlled die filling conditions, ensures that the semi-solid metal fills the die in a non-turbulent manner so that harmful gas porosity can be essentially eliminated. -
Cupola Practice in Modern Gray Iron Foundry
Scholars' Mine Professional Degree Theses Student Theses and Dissertations 1924 Cupola practice in modern gray iron foundry George E. Mellow Follow this and additional works at: https://scholarsmine.mst.edu/professional_theses Part of the Mechanical Engineering Commons Department: Recommended Citation Mellow, George E., "Cupola practice in modern gray iron foundry" (1924). Professional Degree Theses. 56. https://scholarsmine.mst.edu/professional_theses/56 This Thesis - Open Access is brought to you for free and open access by Scholars' Mine. It has been accepted for inclusion in Professional Degree Theses by an authorized administrator of Scholars' Mine. This work is protected by U. S. Copyright Law. Unauthorized use including reproduction for redistribution requires the permission of the copyright holder. For more information, please contact [email protected]. CUPOLA PHAC11ICE IN MODERN GRAY IRON FlOUNDRY BY GEORGE E. MELLOW A "THESIS submitted to the faculty of the SCHOOL OF MINES AND ~~TALLURGY OF THE UNIVERSITY OF MISSOURI in partial fulfillment of the work required for the Degree Of' Mechanica.l Engineer St. Louis, Mo. 1924 Approved by.?f'..Q... .. Cupola Practice in Modern Gray-Iron Ii'oundry Cupola practice, as described in this paper, 'will include only the practical operation or a cupola and the details of the work necessary in daily routine, and very little of the theory of combustion,or history of cupola development, is presented. A brief ~escription of the cupola will give an idea of its construction, and the names of the parts may be found on the sketch herewith. The cupola consists of a steel shell, cylindrical in shape, which stands veDtically on four cast-iron legs, about four feet off the floor; it is open at the top, and has SWinging cast-iron doors at the bottom. -
Implementation of Metal Casting Best Practices
Implementation of Metal Casting Best Practices January 2007 Prepared for ITP Metal Casting Authors: Robert Eppich, Eppich Technologies Robert D. Naranjo, BCS, Incorporated Acknowledgement This project was a collaborative effort by Robert Eppich (Eppich Technologies) and Robert Naranjo (BCS, Incorporated). Mr. Eppich coordinated this project and was the technical lead for this effort. He guided the data collection and analysis. Mr. Naranjo assisted in the data collection and analysis of the results and led the development of the final report. The final report was prepared by Robert Naranjo, Lee Schultz, Rajita Majumdar, Bill Choate, Ellen Glover, and Krista Jones of BCS, Incorporated. The cover was designed by Borys Mararytsya of BCS, Incorporated. We also gratefully acknowledge the support of the U.S. Department of Energy, the Advanced Technology Institute, and the Cast Metals Coalition in conducting this project. Disclaimer This report was prepared as an account of work sponsored by an Agency of the United States Government. Neither the United States Government nor any Agency thereof, nor any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any Agency thereof. The views and opinions expressed by the authors herein do not necessarily state or reflect those of the United States Government or any Agency thereof. -
STAINLESS STEEL Flux Coated
U.S. ALLOY CO. STAINLESS STEEL dba Washington Alloy 7010-G Reames Rd. Charlotte, NC 28216 Flux Coated Tig www.weldingwire.com Quality Management System in accordance with ISO 9001:2000 Cert # 05-R0925 ALLOY DESCRIPTION AND APPLICATION; These flux coated rods are primarily used for the root pass on piping where backing and purging gas may not be possible or desirable. This 39” rod should be used as a basic tig rod on DCEN, however caution is advised due to the easily removable slag covering that must be removed prior to addition welding. TYPICAL GTAW WELDING PROCEDURES; DCEN Wire Diameter Amps Volts 5/64” 90-180 12-13 3/32” 150-250 12-13 1/8” 200-375 12-14 Procedures may vary with change in position, base metals, filler metals, equipment and other changes. TYPICAL UNDILUTED METAL CHEMISTRY (%) per AWS A5.22; Chemistry Grade 1) Intended Use C Cr Ni Mo R308L 0.03 18.0-21.0 9.0-11.0 0.50 Welding of 18Cr & 8Ni such as 304, 304L R308H3) 0.04-0.08 19.5-22.0 9.0-11.0 0.50 Welding of 18Cr & 8Ni such as 304, 304H R309L 0.03 22.0-25.0 12.0-14.0 0.50 Welding of carbon steel to austenitic stainless R316L 0.03 17.0-20.0 11.0-14.0 2.0-3.0 Primarily use on 316 or 316L R347 2) 0.08 18.0-21.0 9.0-11.0 0.50 Primarily use on 347 1) All grades has the following : Mn=0.50-2.5, Si=1.2, P=0.04, S=0.03 Cu=0.50 Single values are maximum 2) R347 also has Cb+Ta =8xCmin. -
S Foundry Solutions By: Ricardo Volkmann Index
Issue #2 Adolf′s Foundry Solutions by: Ricardo Volkmann www.foundrysupply.com Index: Mission Statement & History 3 Style ~A~ Alignment Inserts 4 Alignment Core Prints 4 Wood Cutting Tools 4 Style ~B~ Alignment Inserts 5 Alignment Core Boxes 5 Single Cavity Filtering Basins 6-7 Double Cavity Filtering Basins 6 Pouring Basins 6 Riser Rings 7 Filtering Runner Basins 7 14 Inch Sprues 8 Filtering Sprue Plugs 8 Pop-up Sprue Basins 9 Single Faced Basins 10-11 Pyramid Style Basins 10-11 Three Faced Basins 10 Sprue Pins 10-11 Filtering Basin 10 Four Faced Basins 11 Test Bar Basins 12-13 Inter-Changeable Test Bars 12-13 Test Wedges Basins 12-13 Inter-Changeable Test Wedges 12-13 Test Coupon Basins 12 PIG Boxes 13 Photo Gallery 14-15 Silent Adjustable Vibrator 16 DuraTech Tooling Material 16 Buy direct and save... No sales tax in Oregon 2 www.foundrysupply.com Mission Statement “Doing it Right the First Time” Our mission is to provide new lean manufacturing practices to the foundry industry. Adolf’s Foundry Solutions are products made with the highest integrity, they are dependable, exteremly durable and very cost effective. History 1949 Adolf started his pattern maker apprenticeship in Berlin, Germany during 1949. Trained by German master craftsmen, Adolf excelled as an apprentice and completed a four year apprenticeship program in three years, allowing him to graduate at the top of his class with honors. In Germany, at that time, it was mandatory practice for all apprentices to spend six weeks working in a foundry doing piece work on the molding line. -
Molding & Machining: Metalwork in Geneva
MOLDING & MACHINING: METALWORK IN GENEVA This is a story of change. In the mid-1800s, Geneva claimed the most foundries in western New York State. The metal industry accounted for almost 70% of the city’s jobs in the 1950s and remained strong until the 1970s. Today, Geneva has only one major metal fabrication company. Geneva was not near iron ore or coal but 19th-century canals and railroads allowed access to raw materials. Demand for new products, from farm equipment to heating systems, allowed foundries to flourish. New factories changed Geneva’s landscape and affected its environment. Ultimately, 20th-century changes in technology and economics – and failure to adapt to change – caused most of the city’s metal industry to disappear. A foundry melts refined iron and pours it into molds to create cast iron. It is brittle but, unlike wrought iron pounded out by a blacksmith, objects can be mass produced in intricate shapes. Molding room at Phillips & Clark Stove Company Machining is the shaping of metal, and other materials, through turning, drilling, and milling. Machining tools were powered by steam engines in the 19th century and later by electricity. Machinists bent sheet metal to make cans, stamped metal for tableware, and milled stock to create machine components. Tool Room at Herendeen Manufacturing Company, 1907 This is a companion exhibit to Geneva’s Changing Landscapes in the next gallery, which has more information and artifacts about local industry. Support for this exhibit is provided by Rosalind Nester Heid in memory of her grandfather Samuel K. Nester, Sr. The First Geneva Foundries Refineries require iron, sand, water, fuel, and people. -
General Purpose Liquid Soldering Flux
Weldcote Metals 842 Oak Grove Rd. Kings Mountain, NC 28086 704-739-4115 www.weldcotemetals.com WELDCOTE GENERAL PURPOSE LIQUID SOLDERING FLUX General Purpose Liquid Soldering Flux Formulated for soldering Stainless Steel and High-Chrome Alloys. Excellent across a broad range of base metals, solders, and temperatures. Exhibits excellent capillary action. DESCRIPTION Weldcote Liquid Soldering Flux is a water-based, general purpose, inorganic-acid flux formulated for soldering stainless steel and other industrial metals. The flux contains Zinc Chloride, Ammonium Chloride, and Hydrochloric Acid, that make this flux active at room temperature where it begins to clean metals and remove oxides. The flux exerts a strong scavenging action to remove oxide coatings and other impurities from the metal surface to produce strong joints. Pre-cleaning is not necessary under most conditions. APPLICATIONS Weldcote Liquid Soldering Flux is excellent for use on Stainless Steel, Monel, High-Chrome Alloys, Inconel, Nickel, Copper, Brass, Ferrous Alloys and many more metals. It is not recommended for Aluminum and Magnesium. DIRECTIONS Weldcote Liquid Soldering Flux may be applied with a brush, swab or by dipping. The flux exhibits the best activity between 93°C/200°F and 315°C/600°F. Post-solder residues are water-soluble and hot water rinses (140°F or higher) may be adequate for most applications. The following steps are recommended for optimum soldering results: • Remove any oil, grease, or other contaminants from the surface to be soldered. • Apply flux to joint by dipping, spraying, dragging, swabbing or brushing to area being soldered. • Preheat or air-dry area to be soldered after flux has been applied to activate the flux and yield optimum soldering characteristics and reduce or eliminate spattering.