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SIMPLE SOLUTIONS THAT WORK! Committed to Sharing Best Practices for the Metalcasting and Die Casting Industry

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SIMPLE SOLUTIONS THAT WORK! Committed to Sharing Best Practices for the Metalcasting and Die Casting Industry ENGLISH / ESPAÑOL ISSUE 13 • FALL 2020 SIMPLE SOLUTIONS THAT WORK! Committed to sharing best practices for the metalcasting and die casting industry THE FOCUS OF THIS ISSUE: Defect Prevention WELCOME TO OUR “DEFECT PREVENTION” ISSUE With so many ways to make a bad casting, it’s no wonder that metal casters have taken a leadership position in the manufacturing world by building quality—in from the start. Unlike other manufacturing processes that rely heavily on final inspection as a primary means of ensuring quality, foundries understand better than others that you can’t wait until the casting is machined to test it. Over the past ten years, the foundry production floor has literally been upended with important changes, all designed to produce higher quality parts, at less cost—with reduced scrap. Six Sigma principles, robotic workcells, Additive Manufacturing, and Smart Technologies are all being deployed to deliver higher quality castings with repeatable processes. Today, everyone on the foundry floor is involved in the prevention of defects and this work is never, ever done. This issue is devoted to this subject because it’s something that you can’t talk about enough. We hope you find the defect prevention ideas in this issue (that range from binders and the mixing process, melting, analysis, materials, and molding) techniques you can use today. I would like to thank all of our contributors in this issue for their insightful articles. Special thanks to Innovative Casting Technologies, Dualtech Foundry’s Laboratory Manager Scott Gill for appearing on the cover of this issue. As always, thank you for reading our 13th issue of Simple Solutions That Work! GET THE FREE APP! Jack Palmer President, Palmer Manufacturing & Supply, Inc. [email protected] WANT TO SEE MORE? VISIT OUR WEBSITE TO GET PAST ISSUES! palmermfg.com/simple-solutions PALMER MANUFACTURING & SUPPLY INC. PUBLICATIONS © 2020 Palmer Manufacturing & Supply, Inc. All Rights Reserved TABLE OF CONTENTS ENGLISH ESPAÑOL Welcome to Our “Defect Prevention” Issue ..................... 02 Bienvenidos a Nuestra Edición Jack Palmer – Palmer Manufacturing & Supply, Inc. “Predicción de Defectos” .....................................................58 Jack Palmer – Palmer Manufacturing & Supply, Inc. Reducing Core Defects .........................................................04 Jerry Senk – Equipment Manufacturers International, Inc. Menos Defectos en Corazones ............................................ 60 Jerry Senk – Equipment Manufacturers International, Inc. The Use of Pre-Cast Monoform Liners (drop in liners) in Ladles. .................................................................................... 10 Utilización de Revestimientos Premoldeados Steven Harker – ACETARC Engineering Co. Ltd. (Monoforma Pre-Cast) en Cucharas.. ................................ 66 Steven Harker – ACETARC Engineering Co. Ltd. Grain Refinement and Thermal Analysis of Liquid Aluminum; Don’t Hurt Your Melt! ..........................................13 Afino de grano y análisis térmico del aluminio François Audet – Solutions Fonderie líquido; ¡no dañe a su metal líquido! ...................................69 François Audet – Solutions Fonderie Defect Prevention in Molten Metal Processing ................. 16 Jeff Keller – Molten Metal Equipment Innovations Puntos sobresalientes del artículo ......................................72 Jeff Keller – Molten Metal Equipment Innovations Turbine 30 Ton Steel Case Study ........................................ 20 Joe Howden – Eildon Refractories Ltd. Caso de Estudio Turbina de 30 Ton de Acero ..................76 Joe Howden – Eildon Refractories Ltd. Defect Prevention with a World Class Melt Shop ...........23 Richie Humphrey – The Schaefer Group Prevención de Defectos con una Fundición de Clase Mundial ......................................................................................79 Predicting and Eliminating Defects in Investment Richie Humphrey – The Schaefer Group Castings Using Computer Simulation .................................28 David C. Schmidt – Finite Solutions, Inc. Predicción y Eliminación de Defectos en Ceras Perdidas utilizando Simulación .......................................... 84 5 Keys to Reducing Casting Defects through David C. Schmidt – Finite Solutions, Inc. Refractory Coatings .................................................................31 Stanley Forehand – HA International 5 Claves en Pinturas Refractarias para Reducir Defectos en Piezas Fundidas ................................................87 Stop Making Excuses. Preventing Gas Porosity in Stanley Forehand – HA International Your Castings is Simple! ........................................................36 Brad Hohenstein – Porosity Solutions Basta de Excusas. ¡Prevenir la Porosidad por Gas en sus piezas Fundidas es Simple! ....................................92 3D Printing ..............................................................................39 Brad Hohenstein – Porosity Solutions Will Shambley – New England Foundry Technologies Artículo de Prevención de Defectos ..................................95 Moldmaking & Coremaking Automation Technologies Will Shambley – New England Foundry Technologies Reduce Variability To Increase Quality .............................. 41 Jack Palmer – Palmer Manufacturing & Supply, Inc. Tecnologías Automatizadas de Fabricación de Moldes & Corazones Reducen la Variabilidad para Aumentar Defect Prevention in Permanent la Calidad ...................................................................................97 Mold Casting Through Process Control ........................... 44 Jack Palmer – Palmer Manufacturing & Supply, Inc. John Hall – CMH Manufacturing Prevención de Defectos mediante Control de Better Sand Reduces Defects .............................................. 48 Procesos para Fundición en Molde Permanente ........100 Chris Doerschlag – Klein Palmer Inc. John Hall – CMH Manufacturing Casting Cooler Conveyors .....................................................52 Una Mejor Arena Reduce Defectos ........................... 104 Gaetano Coraggio – Magaldi Technologies, LLC Chris Doerschlag – Klein Palmer Inc. Cintas Transportadoras Enfriadoras................................. 108 Gaetano Coraggio – Magaldi Technologies, LLC SIMPLE SOLUTIONS Act Now to be considered for the Simple Solutions That Work Spring 2021 publication and reach over 27,000 THAT WORK! metalcasting/die casting industry contacts in North and South America. CALL 937.436.2648 or email [email protected] today. REDUCING CORE DEFECTS • What kind of finish is required? • Production rates; high runner or job shop? • Can core off-gas adversely affect the castings? JERRY SENK President • Is shake out of the cores going EQUIPMENT MANUFACTURERS INTERNATIONAL, INC. to be restrictive in any manner? ARTICLE TAKEAWAYS: • What are the environmental impacts? • Better Cores = Better Castings The core cost is usually the main • Five considerations for core quality driver to process selection, but all • Existing equipment improvements can minimize defects the variables listed above are inputs • New casting products may require new core production process to cost comparisons. Since the first castings were poured, foundry men have been working to eliminate scrap castings and improve product quality. This article will concentrate in one area of reducing casting defects and scrap by outlining five important considerations for reliable sand core production. There are many different sand core processes that metal casters can utilize. These can include; cold box (isocure), shell, warm box, inorganic, no-bake, among others. Any of these core processes can be used for just about any alloy. Selection is typically based on the size of the core, the production rate required, casting finish, tooling and capital investment. 1. CORE PROCESS Many times, the process will be defined based on the existing core process the foundry is familiar with, but as foundries add new castings to their portfolio; customer specifications may dictate a new core making process, or any of these considerations may impact the core process choice: 4 DEFECT PREVENTION 2. TOOLING DESIGN Tooling design is a critical consideration for accurately filled and well-defined cores that can meet the casting process requirements. Tooling can be made from a variety of materials; from a wood and resin coated core box for low production, aluminum can be used in cold box, inorganic or no bake cores, to iron/steel boxes that are used in medium to high production core runs, or shell, hot or warm box considerations. Minimizing core defects and improving reliability begins with tooling design. The filling and curing analysis can be done with trial and error, plain old experience, or with commercial simulation software. Success at launching new tooling usually requires a engineers will know where vents in advance. Just about every tool combination of these steps. are needed. Rules of thumb are will require some modifications and typically twice the vents in the only through patient trial and error cope than the drag in horizontally will the tooling engineer be able parted tooling scenarios. Never put to deliver consistent, high quality a vent directly below a blow tube. cores. Tool mounting and change out 3. CORE MACHINE AND should be considered up front, ANCILLARY SYSTEMS especially with a new machine or a retrofit. Any quick-change There are many core machine mounting features (automatic solutions to choose
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