2014 issue 2 - home - ductile iron society · virtual tour of penticton foundry – chad gentes •...

FEATURES

• 2014 Annual Mtg. Highlights

• Controlling Slag Defects in GI & DI – Alan Patrick, Matt LaFramboise & Dave Williams

• 3D Printing for the DI Foundry Industry – Steve Murray

• Is the Growth of the Ductile Iron Industry at Risk – George Kokos

• High Silicon Molybdenum Cast Iron With Mixed Graphite (MG) Shapes for Elevated Temper-ature Applications – Delin Li

• Preventing Rust and Corrosion on Ductile Iron Using VCI Technology – Wayne Siefert

• Machining Ductile Iron: Benefits, Concerns and General Guidelines – Tim Heagney

• Virtual Tour of Penticton Foundry – Chad Gentes

•

Inoculation Method Panel – Mike Galvin, Riley Kerestes, Jim Csonka, Joseph Keske,, Kyle Rabine

DEPARTMENTS

• News Briefs• Back Issues• DIS Home Page

Ductile Iron News – Issue 2, June 2014

The Ductile Iron Society held their spring 2014 Annual Meeting in Lethbridge, Alberta, Canada at the Coast Hotel & Conference Center from June 4 to 6, 2014. On Wednesday June 4th, we started the 3 days with the DIS Research Committee meeting from 8am to 12 noon. There were 39 members and guests that attended in person and 7 members and guests that attended by conference calling. The rest of the other 4 operating committees held their meetings from 1:00pm to 3:00pm and the newly formed DIS MetalCasting Forum was held from 3:00pm to 5:00pm. At the same time the DIS Board of Directors held their meeting to review the past year’s financials along with approving the new budget for 2014/15, and the elections of 4 new directors and 1 new Vice President.

The Research Committee approved and the Board of Directors gave their approval for the funds for a new research project #53 on “Reducing the Casting Skin in Ductile Iron Castings” for $18,700.00. The research will be performed by UAB in Alabama. Also we are just waiting for the final report on research project #49 and as soon as it is complete you will find it on the DIS website.

On Thursday June 5th, the attendees were presented with 2 panels. One was on the continuing subject of, “back to the basics”, and this time it was on “Inoculation”. Also we had one smaller panel on “controlling Slag Defects in Gray & Ductile Iron”. We had 5 other individual presentations and one virtual tour of Penticton Foundry by Chad Gentes. As we have done in the past, you can find these presentations attached to this news edition. If not available you can contact Jim Wood, the Executive Director at [email protected] .

At the luncheon on Thursday, June 5th we held the Annual Meeting for the members who were in attendance.

http://www.ductile.org/back-issues/

http://www.ductile.org/

mailto:[email protected]

Susan

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Patricio Gil (DIS President) of Blackhawk de Mexico

Here are the notes from Patricio’s presentation; At this time i will recap the society’s activities during this past year before proceeding with the annual business meeting and the election of new officers. The Ductile Iron Marketting Group once again was out attending trade exhibitions throughout the year. They exhibited back in March at the 2014 Con/Ag show in Las Vegas, Nevada where it was reported that over 150,000 people attended. Thanks go out to the volunteers and their companies who made this a great success. They were; Vasko Popovski of Applied Process Henry Frear of Applied Process Carlos De La Graza of Blackhawk De Mexico Bob O’Rourke of Charter Dura Bar Chris Witt of Dotson Foundry Jim Wood of DIS Greg Selip of Ellwood Engineered Castings Brian Connell of Ellwood Engineered Castings Dylan Bruins of Lethbridge Iron Works Mark Mundell of Lethbridge Iron Works Vadim Pikhovich of Magma Corporation

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John Lewensky of Pure Power Technologies Dave Gilson of Sintercast The group of volunteers felt it was a great success and we were able to connect with design engineers as well as help out some consumers of ductile iron castings. In addition, the member services committee had our table top on display in April at the 2014 AFS CASTING CONGRESS in Schaumburg, Illinois. Our booth and the volunteers, who manned it, were very busy during the whole show. Thanks go out to Mark Beers of ASK, Jim Wood of DIS, Alan Patrick of Elyria Foundry, Patricio Gil of Blackhawk de Mexico, Alex Gyarmaty of Coorstek and other committee members and volunteers. We are striving to make our library available to the members through the website. There is now a link to the Lyle Jenkins Library under the Members Only area. These books were a collection of Art Spangler, Lyle Jenkins, P. H. Mani And Keith Millis. Also staying with the website, everyone should have now seen our new look. Thanks go to Susie for starting up the “Ask the Experts” program again and it too is under the Members Only area. Keep watch on the website periodically because you will stay in touch with up-to-date news and the calendar of events. The board approved increasing our scholarships from $2000 to $3000 each for 4 very awarding students. This past fiscal year we gained four new members. GENERAL MOTORS DEFIANCE OHIO (RESEARCH PATRON) PRODUCTORA DE HIERRO MALEABLE S.A. (FOUNDRY MEMBER-MEXICO) DITEMSA (ASSOCIATE MEMBER-MEXICO) CDB PROJECTS SERVICES LLC (ASSOCIATE MEMBER)

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During this past year we held two general meetings. The first one was our Annual Meeting held in Indianapolis, Indiana in conjunction with a tour of Pure Power Technologies plant (formerly Navistar) in Indianapolis with 143 attending including 20 guests. The second meeting held last fall, was the 5th Keith Millis Symposium in Nashville, TN. The attendance for that meeting was 218 including 26 guests. Thanks to the AFS for co-sponsoring this symposium. Also a special thanks go out to those corporate sponsors who donated $1000 each to help offset the costs of the reception & banquet. The Ductile Iron Society did hold a Production Seminar on February 11 & 12, 2014 at the Hilton Garden Inn at O’hare Airport in Chicago. The attendance was 30 for this seminar. We were very delighted to see so many people register. Thanks go out to our very special instructors, Kathy Hayrynen of Applied Process, Gene Muratore, DIS consultant and Don Craig of Selee Corporation. Also in march 2014 we lost a very good friend of the DIS. Fred Linebarger was a past director of the society, long time member of the DIS Research Committee and also a long time instructor at the DIS production seminar. We will all miss his humor and wit during future seminars. Also, I want to thank all of those that contributed to our “Hot Topics” publications and those who wrote articles for the “Ductile Iron News”. Four Keith D. Millis Scholarships were awarded at the 2013 FEF College Industry Conference held on November 15 & 16, 2013 at the Westin Hotel in Chicago. I would like to thank John Keough of Applied Process and Gary Gigante of Waupaca Foundry for selecting this year’s students. They were Erica Hill of The University of Northern Iowa, Steve Miller of The University of Wisconsin – Milwaukee, Connor Montgomery of The University of Wisconsin – Platteville and Matthew Wason of The University Of Northern Iowa. Each student received $3000. Once again this year’s CIC Conference is in November at the Westin Downtown Chicago and we will again hand out $12,000 in scholarships to 4 deserving students.

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Your society continues to make a donation to the Keith Millis scholarship fund every year so it will continue to grow. This past year we made a one-time donation of $20,000 and reached another goal of Chromium in donations to the fund. This $20,000 came as a result of the proceeds from the Keith Millis Symposium. AFS also donated $20,000 to their fund from the same Keith Millis Symposium.

Jim Wood attended this past year’s conference. We also had a table top booth for the industry information session where we distributed the “Doing It Spheroidal” T-shirts. Thanks go out to Kathy Hayrynen & Chip Keough of Applied Process who donated their time to help out at the table top.

Also we would like to thank those members who sponsored these T-shirts. They are Ask Chemicals, Applied Process, Allied Mineral Products, Buck Company, Bremen Castings, Blackhawk De Mexico, Dotson Iron Castings, Dura-Bar, Foseco, Globe Metallurgical, Green Packaging, Hitachi Metals Automotive Components, Hickman Williams & Company, Lethbridge Iron Works, Magma Foundry Technologies, and Waupaca Foundry. Also I should mention the hard work by your University Relations Committee members. Thanks go out to Bill Sorensen and Pam Lechner for their invitation to attend this important conference.

The Research Committee met three times during the past year. We completed one project in January 2014. It was #48 and was “Evaluation Of Normalizing Heat Treatment To Develop Improved Properties In Heavy Section Pearlitic Iron” by Rick Gundlach of Element Materials Technology. Also we are just waiting on the final report from #49 and it was “Analysis of Pearlitic Ductile Iron With Enhanced Mechanical Properties”. The Research Committee awarded two new projects, #51 – “Fatigue Resistance Of Weld Repaired Ductile Iron Castings” to Edison Welding Institute in Columbus, Ohio and #52 – “Evaluation Of The Influence Of Barium, Silicon And Inoculation In Counteracting The Effects Of Increased Manganese Levels On Varying Section Thickness Of Ferritic Ductile Iron” to Joyworks in Ann Arbor, MI and Element Materials Technology in Wixom, MI. This was a total of $77,000 of new research work.

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The Research Committee is looking for approval on 1 new project for the 2014/2015 budget year for $18,700 on “Reducing The Casting Skin In Ductile Iron Castings” by the University of Alabama. Thanks go out to Anhua Yu of HMAC for volunteering to be our Chairman of the Research Committee for the last 3 years and we welcome Brandon Reneau of Caterpillar as the new Chairman. Vadim Pikhovich of Magma will replace Brandon as the new Vice Chairman for the next 3 years. We will now proceed with the annual business meeting. We have 1 Associate member retiring from the Board of Directors as of June 30th. He is Alex Gyarmaty of Coorstek, ULC. We would like to thank Alex for his participation and dedication to the society over the past 3 years. We also have 3 Foundry members retiring from the Board of Directors as of June 30th. They are Tim Brown of Benton Foundry, Andy Franks of Hitachi Metals Automotive group and Greg Selip of Ellwood Engineered Castings. Also we would like to thank these 3 gentleman for volunteering their time and dedication to the society for the last 3 years. If there is anyone who would be interested in volunteering their time to join the DIS Board of Directors, please let Jim Wood know. To replace those retiring board members, the Nominating Committee recommends the following slate to serve on the Board of Directors for a 3 year term effective July 1, 2014; DAVE GILSON OF SINTERCAST - (ASSOCIATE MEMBER) MARK FIELDS OF GLIDEWELL SPECIALTY PRODUCTS – (FOUNDRY MEMBER) BRANDON RENEAU OF CATERPILLAR – (FOUNDRY MEMBER) JOHN LEWENSKY OF PURE POWER TECHNOLOGIES – (FOUNDRY MEMBER) Also this is my last Annual Report to the members as your President. Our next President of the society is Bob O’Rourke of Dura-Bar and to replace him as Vice President the Nominating Committee recommends Mike Galvin of Buck Company as our new Vice President.

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Ask the attendees to approve the slate. Those show their approval by saying yea, and those who disapprove signify by saying nay. The attendees voted unanimously to approve the slate. I declare that this annual meeting is now adjourned. Thanks, Patricio Gil June 5, 2014 At the banquet on Thursday evening, Patricio was the master of ceremonies for his last time. Patricio first introduced all the guests who came to attend this meeting. They were; Randy Penner, Darren Henaire, Neal McCain and David Correia of Ancast Foundry in Winnipeg, Manitoba Richard Pyper and Jason Brooks of Karrich Industries in Selkirk, Manitoba Kris Klynstra of Wesmat in Leduc, Alberta Bart Frauenfeld of Inproheat in Edmonton, Alberta Ike Wall of Monarch Industries in Winnipeg, Manitoba Ike Dyck and Jorge Bernal of Integra Castings in Winkler, Manitoba Ray Tyers of OCL in Vancouver, British Columbia Warren Geraghty of Robar Industries in Vancouver, British Columbia Rick Bell of Urbanmine Inc. in Winnipeg, Manitoba Patricio then presented membership certificates to the following new members of the DIS and the representative of that company in attendance.

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Patricio (L) & Mark Murphy of CDB Projects Patricio (R) & Haydn Parkin of Ditemsa Services LLC

Patricio (L) & Gabriel Trujillo of Prod- Patricio (L) & Walt Wan of Betz Ind. uctora De Hierro Maleable S.A. de C.V. Betz Foundry has been a member of the DIS since March 2009 but never received their membership certificate so we presented one at this meeting to Walt who was representing Betz Foundry. Patricio then introduced Kathy Hayrynen as the AM Technical Chair to assist in handing out our traditional speaker gift to each of the presenters.

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Kathy & Wayne Siefert of Green Packaging Kathy & Tim Heagney of Charter Dura-Bar

Kathy & Chad Gentes of Penticton Fdy Kathy & Jim Csonka of Hickman Williams & Company

Kathy & Mike Galvin of Buck Company Kathy & Riley Kerestes of Caterpillar, Inc.

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Joseph Keske of Waupaca Marinette Kathy & Kyle Rabine of Brillion Iron Works Patricio then asked Jim Csonka of Hickman Williams & Company, the PM technical chair to assist in handing out the speaker gifts.

Jim & Alan Patrick of Elyria Foundry Jim & Matt LaFramboise of Auburn Labs

Jim & Dave Williams of ASI International Steve Murray of Hoosier Pattern

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Jim & George Kokos of Caterpillar, Inc. Jim & Delin Li of Canmet Materials Canada Patricio then called the retiring Directors to the front of the room to receive their certificates of appreciation. They were;

Patricio and Andy Franks of Hitachi Metals Patricio and Alex Gyarmaty of CoorsTek, Automotive Group ULC

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Patricio and Greg Selip of Ellwood Engineered Castings

Also retiring is Tim Brown of Benton Foundry who was not in attendance. Thanks again to all these Board Members for volunteering their time to serve on the Board for the last 3 years. Patricio then introduced the new directors who were voted on the Board officially at the annual meeting at lunch earlier in the day. They are Mark Fields (Foundry Director) of Glidewell Specialties Foundry Company, Dave Gilson (Associate Director) of SinterCast, John Lewensky (Foundry Director) of Pure Power Technologies and Brandon Reneau (Foundry Director) of Caterpillar, Inc. Also Mike Galvin of Buck Company was elected the Vice President for the next 2 years. Congratulations to each gentleman and we look forward to their service to the DIS. Next Patricio handed out to Anhua Yu of Hitachi Metals Automotive Group, the certificate of appreciation for his retirement from the position of Research Committee Chairperson for the last three years.

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From Left Bob O’Rourke (Incoming President) Anhua Yu and Patricio Gil Also the society wishes to THANK Patricio for the last 2 years that he has been the President of the DIS.

From left are Bob O’Rourke, Patricio Gil and Jim Wood

On Friday June 6th the group was given a tour of Lethbridge Iron in Lethbridge, Alberta, Canada. John Davies gave a small presentation on Thursday evening about the history of Lethbridge Iron. Today it is still a family owned company and is the third generation.

Susan

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This concluded the Spring Annual Meeting in Lethbridge, Alberta, Canada. There were 120 in attendance and we wish to thank every one of them and their companies for allowing them the time to attend. We hope to see everyone at the fall T&O meeting to be held in Decatur, IL from October 29-31, 2014 at the Decatur Conference Center & Hotel with a tour of Decatur Foundry.

Susan

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FEATURES









•


DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

DIMG/ DESIGN WITH DUCTILE IRON SEMINAR

The DIS will hold the first ever Design with Ductile Iron Seminar on Tuesday, October 28, 2014 at the Decatur Conference Center & Hotel from approximately 9:00am – 3:00pm for any of our DIS Members who would like to invite their customers or any design engineers to attend. This is sponsored by the Ductile Iron Society and will be organized by the Ductile Iron Marketing Group. Here is a tentative schedule for this meeting 9:45 – 10:00am Introduction/ Video 10:00 – 11:30am Basics of Ductile Iron – Properties, Micro-structures,

Standards, Processing and Compacted Graphite Iron Overview

11:30 – 12:00 Ductile Iron Casting Design and Conversions 12:00 – 12:45pm Lunch 12:45 – 1:45pm Ductile Iron Casting Design and Conversions (Cont.…) 1:45 – 2:00pm Ductile Iron Machining 2:00 – 3:00pm Heat Treating of Ductile Iron 3:00pm Q&A, and Adjournment Keep an eye on the DIS website for more information and look for future notifications. There will likely be a limit to the number of attendees. Lunch and breaks will be supplied. This will be free to any attending. FUNDIEXPO

Please mark your calendar for the 2014 FundiExpo being held in Monterrey, Mexico from September 24-26, 2014. Some of our members will be making presentations. Gene Muratore will be making a presentation on behalf of the DIS and Dave Williams of ASI will be making a presentation on fluxes. Also the DIS Member Services committee and Jim Wood will be taking our table top booth to this show and exhibiting. The exhibit days are September 24 & 25 from 11:00 to 19:00 and September 26 from 11:00 to 18:00.



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Thanks go out to Fernando Morales of Fundicion Aguilas (a DIS foundry member) and Expo Chairman for giving the DIS this opportunity to exhibit. If any members speak English and Spanish and would like to volunteer to work the booth, please contact Jim Wood at the DIS office or [email protected] .

Jim Wood DIS Executive Director


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FEATURES









•


DEPARTMENTS

• News Briefs

• Back Issues

• DIS Home Page

CONTROLLING SLAG DEFECTS IN GRAY & DUCTILE IRON

ALAN PATRICK, MATT LaFRAMBOISE, DAVE WILLIAMS

ALAN PATRICK

ALAN GRADUATED FROM THE UNIVERSITY OF PITTSBURGH IN 1973 WITH HIS BS IN METALLURGY AND MATERIALS ENGINEERING. HE BEGAN HIS PROFESSIONAL CAREER WITH HAYES-ALBION CORPORATION IN ALBION, MI FOLLOWED BY AUTO SPECIALITIES CORPORATION, BUCK COMPANY, ROCKWELL AUTOMATION, GREDE – IRON MOUNTAIN, BRILLION IRON WORKS, AND IS PRESENTLY EMPLOYED AT ELYRIA AND HODGE FOUNDRIES AS THEIR CORPORATE METALLURGIST. HE HAS HELD MANY POSITIONS IN METALLURGY AND QUALITY OVER HIS CAREER AND HAS BEEN A MEMBER OF MALLEABLE RESEARCH & DEVELOPMENT FOUNDATION, AFS, DIS AND ICRI. HE SERVED ON THE AFS 5L MOLTEN METAL PROCESS COMMITTEE AND AUTHORED CHAPTER 15 OF THE DUCTILE IRON HANDBOOK, “DUCTILE IRON PROCESS CONTROL”. ALAN HAS BEEN IN THE FOUNDRY INDUSTRY FOR 41 YEARS. MATT LaFRAMBOISE MATT GRADUATED IN CHEMISTRY FROM THE UNIVERSITY OF MICHIGAN AND SAGINAW VALLEY STATE UNIVERSITY. HE STARTED HIS CAREER AT AUBURN ANALYTICAL LABS AS AN ASSOCIATE TECHNICIAN IN 1988 AND HAS SLOWLY WORKED HIS WAY TO TECHNICAL MANAGER/PRESIDENT IN 2009 AND PART OWNER OF AUBURN LABS IN 2012. HE IS ALSO PARTNERED IN B&K CONSULTANTS SINCE 2009 AS A SLAG CONSULTANT.



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CONTROLLING SLAG DEFECTS IN GRAY & DUCTILE IRON, cont’d

DAVE WILLIAMS

DAVE GRADUATED FROM ILLINOIS INSTITUTE OF TECHNOLGY WITH HIS BS IN METALLURGICAL ENGINEERING IN 1978. HE STARTED HIS PROFESSIONAL CAREER WORKING AS PLANT METALLURGIST FOR 2 DIFFERENT FOUNDRIES. THEN HE WENT TO ALLIED MINERAL PRODUCTS FOR 21 YEARS BEFORE JOINING HIS CURRENT JOB AS VICE PRESIDENT OF TECHNOLOGY AT ASI INTERNATIONAL. DAVE HAS OVER 36 YEARS OF EXPERIENCE IN THE FOUNDRY INDUSTRY. HE HAS BEEN AN ACTIVE MEMBER OF THE DIS, SERVING ON THE DIS RESEARCH COMMITTEE AND CURRENTLY AS DIRECTOR OF THE DIS. HE HAS ALSO BEEN AN ACTIVE MEMBER OF AFS FOR 31 YEARS, SERVING ON THE DIVISION 8 MELTING METHODS AND INDUCTION MELTING AND POURING COMMITTEES. DAVE WAS THE KEY ORGANIZER OF THE RECENT FERROUS MELTING CONFERENCE AND ACTIVE INSTRUCTOR FOR THE AFS CAST METALS INSTITUTE.

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CONTROLLING SLAG DEFECTS IN GREY AND

DUCTILE IRONDUCTILE IRON

Alan Patrick, Rick Lewis, Hannah Lewis

Elyria Foundry

M tt L F b i A b A l ti l L b

DIS DIS Annual Annual Meeting, Meeting, June 4June 4--6, 20146, 2014Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Matt LaFramboise , Auburn Analytical Labs

David Williams, ASI International Ltd

CONTROLLING SLAG DEFECTS IN

GREY AND DUCTILE IRONIRON


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“Next to doing the right thing theNext to doing the right thing, the most important thing is to let people know you are doing the right thing.”

John D RockefellerJohn D. Rockefeller


0.70%

0.80%

0.90%

Monthly Slag Scrap for Grey and Ductile Castings

‐‐‐‐‐‐% Ductile, ‐‐‐‐‐% Grey

0.20%

0.30%

0.40%

0.50%

0.60%

Slag Percentage

‐0.10%

0.00%

0.10%

0.20%

Aug‐12

Sep‐12

Oct‐12

Nov‐12

Dec‐12

Jan‐13

Feb‐13

Mar‐13

Apr‐13

May‐13

Jun‐13

Jul‐13

Aug‐13

Sep‐13

Oct‐13

Nov‐13

Dec‐13

Jan‐14

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Employ Good Foundry PracticesReview and evaluate the foundry for the application of good foundry practices.

1. Use good gating practices that allow slag to separatefrom the metal flowfrom the metal flow.

2. Pour with low in-gate velocities, minimizingturbulence. (< 0.5 m/sec.)

3. Properly use filters in gating systems.

4. Use good pouring techniques to keep basins andpouring cups full during complete pour.

5. Eliminate conditions that allow a vortex in pouringcups or pouring basins.

6. Use separate ladles for grey and ductile iron.

7. Use controlled Flux additions to cleanse molten metal.DIS DIS Annual Annual Meeting, Meeting, June 4June 4--6, 20146, 2014

Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

Pouring Video

DIS Annual Meeting, June 2, 2011 DIS Annual Meeting, June 2, 2011 Dallas, TexasDallas, Texas

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Start at the Beginning1. Raw Materials should be free of excessive rust, oil, dirt,

etc. Inspect and reject all loads as appropriate.2 If preheating do not over heat Max temp should be2. If preheating, do not over heat. Max. temp. should be

<750oF to prevent excessive oxidation. Do not heatbeyond time necessary to reach temperature.

3. Furnace spouts should be round and well maintained tominimize oxidation, temperature loss and slag formation.

4. Keep furnace lids in good condition and tightly closed –prevents oxidation and slag generation. Also savesp g genergy.

5. Keep all molten metal containing vessels well covered.6. Remove all slag from furnace prior to tap and remove all

slag from ladles prior to pour.


Melt Cold - Pour Hot


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5

Melt Cold - Pour Hot

True ‐ Liesue es

Only ‐ Choice

Good ‐ Grief


Melt ColdDo not over-heat the melt, do not over-preheat the charge materials – this minimizes oxide generation and maintains optimal metal quality (generates a high level of nucleation with a reduced carbide forming tendency).

USE CHARGE MATERIALS THAT PROMOTE A QUALITY METAL

1. Use Graphitic Carbon raiser not Petroleum Coke2. Use Silicon Carbide in place of Ferro Silicon3. Use low rust charge materials

Confirm: Check furnace chill levels to validate that you have achieved a presence of strong nucleation. Pour chill wedges (Grey and Ductile) With an ASTM W3 wedge shoot for a 5/32” chill average or less.


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Pour Hot• Tap metal as fast as possible with as little

turbulence as possible. Minimizes oxidation(slag) and maintains metal quality (reduces(slag) and maintains metal quality (reducesnuclei loss and produces least carbideforming tendency) with minimal temperatureloss.

1. Reduces oxidation (slag)2 Reduces nuclei loss2. Reduces nuclei loss3. Reduces temperature loss4. Reduces carbide formation


Furnace Spout Design


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7

Square Spout Design

New Spout –temperature

Old Spout –temperature drop 150 to 200+oF

When square spouts are new this design typically has an

When square spouts are older they preferentially erode at the corners causing increased atmospheric exposure and splashing

drop 75 to 150oF

effective increased surface area greater than that of a round spout, with a rate of oxidation and temperature drop that is about 1.5 times greater.

which can result in oxidation rates and temperature drops that are as much as 3 times that of a round spout.


Round Spout Design

Level of oxidation is

Temperature drop is typically 50 to75oF depending on rate of tapping.

Spouts must be well i t i d t ll

minimal due to preferred geometry creating reduced exposure to atmosphere. Metal stream is compact and volume flow is maximized ll i id t i

POUR HOT

maintained to allow for a compact metal flow and minimal temperature drop.

allowing rapid tapping with minimal splashing and the smallest amount of temperature drop.


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Furnace Spout Design

All spouts

75 ‐200+oF temp. drop

should be made with a round trough to create a compact stream and i i i

50 ‐75oF temp. drop

minimize exposure to oxidation.


Cover Molten Metal


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Heat Loss of Liquid Iron in LadlesTypes of Heat Loss or Heat Transfer

1. Conduction2. Convection

Q = Ɛ * σ * (T14 ‐ T2

4)

Ɛ is the emissivity of the radiating body – 0.33σ is the Stefan‐Boltzman constant – (5.67 * 10‐8 W/m2 * K4) T1 is the temperature of radiating body ‐ 2700T2 is the temperature of receiving body ‐ 120 or 2550

177,302

31,271

20 000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

200,000

KW

KW Heat Loss3. Radiation

0

20,000

0 500 1000 1500 2000 2500 3000

ΔT oF

Experience has shown that immediately covering a ladle between fills with a good insulating material, the tapping temperature loss can be reduced to 50oF or less.


One Excuse After Another


Susan

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Why Perlite Works

Rapidly heating perlite ore to temperatures of about 900oC (1,700oF) softens the

Expanded perlite grows up to 20

Perlite is a volcanic glass that is mined,

HEAT

( )volcanic glass causing entrapped water molecules in the rock to turn to steam and expand the particles like popcorn.

times its original volume and takes on a foam like internal structure.

glass that is mined, sized and processed to produce a high temperature insulating product.


Perlite Structure

The expanded particles that result are actually clusters of minute, lightweight, insulating glass bubbles.

These glass bubbles are extremely good insulators that withstand very high temperatures.


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Perlite Properties

P lit i i i d b tibl• Perlite is inorganic and non-combustible.

• Very light weight, avg. bulk density, 6 lbs./ft3.

• Fusion point 2450oF.

• Low thermal conductivity, 0.35 Btu.in/hr.ft2.oF.

• 48% Oxygen, 34% Silicon, 7% Aluminum,48% Oxygen, 34% Silicon, 7% Aluminum,

4% Potassium, 4% Sodium


Use of Perlite

X


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Test Your Slag


2400

2600

2800

3000

3200

FNC 1 Melt Points

Mon

Thurs 2400

2600

2800

3000

3200

FNC 2 Melt Points

Mon

Thurs

2000

2200Linear (Mon)

Linear (Thurs)2000

2200Linear (Mon)

Linear (Thurs)

2800

3000

3200

3400

FNC 3 Melt Points

3000

3200

3400

FNC 4 Melt Points

2000

2200

2400

2600

2800 Mon

Thurs

Linear (Mon)

Linear (Thurs)2000

2200

2400

2600

2800 Mon

Thurs

Linear (Mon)

Linear (Thurs)


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Representative Slag Samples

Slag from Monday Slag from Thursday


Slag SamplingSlag Sampling Preparation


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Preparation of Slag Samples

Crush Slag into 1/4” to 3/4” Visually remove foreign material


Sample Preparation (Continued)

Separate Magnetic material ID and bag samples for lab


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Packaged and ID Slag Samples sent to Lab for Analysis


Relating Slag Chemistry Control to Production Problems

Three Important Physical Characteristics of Slag:

• Melt Point – The temperature at which slagbecomes a liquid.becomes a liquid.

• Viscosity – Measurement of slag thickness orfluidity.

• Wetting Ability – The slag/refractory interfaceenergy is required to be high to preventrefractory penetration and erosion.refractory penetration and erosion.

Are we able to modify and control thesecharacteristics through slag chemistry andreduce slag scrap?


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Summary of Oxide Effects on Slag Melting Point

M O F O B O C O M O d• MnO, FeO, BaO, CaO, MgO andNa2O reduce the melting point ofslag

• SiO2 and Al2O3 increase meltingSiO2 and Al2O3 increase meltingpoint


Summary of Oxide Effects on Viscosity

• MnO, FeO, BaO, CaO, MgO andN O d i itNa2O reduce viscosity

• SiO2 and Cr2O3 increase viscosity

• Al2O3 increase viscosity in neutraland acidic slagand acidic slag

• SiO2 reduce viscosity in basic slag


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Summary of Oxide Effects on “Wetting Ability”

• SiO2 and Al2O3 increase the interfaceenergy and therefore increase wettingcharacteristics

• MgO, CaO reduce the interface energyand therefore reduce wettingcharacteristics


What is more important ?

• the fluidity,

• the viscosity

• or the wetting ability of the slag?


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Slag Testing - Raw DataSample Date

FNC

Met Lab # Na2O MgO Al2O3 SiO2 P2O5 S K2O CaO TiO2 V2O5 Cr2O3 MnO FeO TCBasicity w/ Al2O3 Fe Removed

Report Date

Approx. Melting Point

8/16/2012 1 D12‐1970

0.00 1.88 13.64 52.71 0.08 0.03 0.25 3.28 0.44 0.01 0.21 3.03 20.31 4.12 3.45 8/28/2012 2610

8/23/2012 1 D12‐2029

0.00 2.23 7.57 51.33 0.06 0.04 0.47 4.04 0.27 0.02 0.40 4.10 22.01 7.47 16.29 8/31/2012 2710

8/30/2012 1 D12‐2075

0.00 3.01 9.02 53.52 0.08 0.03 0.46 8.96 0.36 0.00 0.38 3.22 17.29 3.65 8.9 9/7/2012 2700

9/5/2012 1 D12‐2101

0.00 2.07 24.71 25.72 0.10 0.08 0.22 3.59 1.07 0.03 0.35 5.47 35.87 0.71 2.54 9/18/2012 2640

9/6/2012 1 D12‐2105

0.00 2.54 8.79 42.58 0.06 0.08 0.43 4.33 0.40 0.03 1.38 4.64 19.50 15.24 18.27 9/18/2012 2610

9/20/2012 1 D12‐2194

0.00 2.52 14.99 52.78 0.07 0.09 0.36 4.68 0.43 0.01 0.30 6.78 14.08 2.91 4.70 9/27/2012 2590

9/27/2012 1 D12‐2277

0.00 3.35 10.22 64.70 0.06 0.04 0.63 3.49 0.38 0.02 0.51 4.20 11.30 1.10 3.03 10/5/2012 2730

10/4/2012 1 D12‐2330

0.02 1.98 5.85 61.68 0.05 0.11 0.69 3.48 0.33 0.02 0.80 4.83 14.80 5.36 28.38 10/16/2012 2860

10/11/2012 1 D12‐2409

0.00 2.43 18.95 40.78 0.06 0.02 0.34 3.52 0.77 0.02 0.32 9.15 22.92 0.71 1.09 10/19/2012 2190

10/18/2012 1 D12‐2445

0.00 2.88 18.21 50.41 0.06 0.08 0.74 6.80 0.63 0.02 0.36 6.32 12.34 1.14 4.11 10/25/2012 2390

10/25/2012 1 D12‐2495

0.00 2.96 18.96 54.33 0.06 0.03 0.41 6.55 0.69 0.03 0.51 7.06 8.07 0.34 1.15 10/31/2012 2530

11/1/2012 1 D12‐2553

0.00 3.23 16.71 53.07 0.06 0.06 0.55 5.71 0.53 0.02 0.47 5.37 12.56 1.66 6.00 11/7/2012 2530

11/8/2012 1 D12‐2629

0.00 3.28 25.85 45.97 0.06 0.11 0.39 6.38 0.58 0.01 0.18 5.08 11.44 0.67 6.62 11/14/2012 2710

11/15/2012 1 D12‐2664

0.01 2.26 15.65 40.90 0.06 0.04 0.37 4.32 0.61 0.04 0.45 8.47 24.01 2.80 2.37 11/21/2012 2150

12/6/2012 1 D12‐2769

0.00 2.67 11.64 56.32 0.05 0.11 0.55 4.45 0.33 0.01 0.36 4.33 10.60 8.60 8.19 12/17/2012 2700

12/13/2012 1 D12‐2835

0.01 3.58 17.31 44.20 0.06 0.10 0.40 4.48 0.48 0.02 0.41 7.22 18.53 3.19 8.15 1/2/2013 2200

Determine the Melting Temperature of Slag1. Analyze the slag chemistry

2. Use the FeO‐Al2O3‐SiO2 ternary phase diagram

3. For FeO use MgO + CaO + MnO + FeO(Basic Oxides)

4. For Al2O3 use reported % from laboratory

5. For SiO2 use reported % from laboratory

6. Using these three oxide percentages, normalizeeach oxide % (divide each of them by thepercentage that when they are added togetherthey fall short of 100%) so that when addedtogether they equal 100%

7. Plot the percentage line of each normalizedoxide % on the phase diagram as illustrated


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Normalizing Example

FeO+ (Basic Oxides) = 29.2%Al2O3 = 29.3%SiO2 = 39.1%

Where the Sum = 29.2+29.3+39.1 = 97.6%Then normalizing

29.2 / 97.6 = 30%29.3 / 97.6 = 30%39.1 / 97.6 = 40%

The normalized values add to 100%


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Introduction of

Matt LaFramboiseMatt LaFramboiseAuburn Analytical Labs

Slag Analysis for Various Melting Operations


Various Melting Operations

Where to take Slags

• Slags should initially be taken atevery point where slag is generated.


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Sampling Technique

• Samples should not be taken directly afteran alloy addition is takeny

• Samples should be retrieved in the sametime period of the process, and with thesame equipment

• The information gathered is only reliable ifThe information gathered is only reliable ifthe sampling technique is correct


Where slag analysis is useful

• Finding the “Normal” slag for your meltg g y

• Optimizing and extending refractory

lining life.

• Troubleshooting of casting defects.

• Solving operational issues.


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Preparing the slag

• Preparing the slag to a fine enough mesh• Preparing the slag to a fine enough meshto ensure a homogeneous mixture

• Proper mixing of the slag

• Weighing the sample with an inert bindingagent to form the pressed pellet.


Analysis for Slag

X-Ray Fluorescence Spectrometry

• Similar process to analyzing a metalp y gsample

• Measures the amount of various elementspresent

• Final results calculated with a computerprogramprogram

• Samples are either milled & pressed orfused into a disk


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X-Ray Fluorescence Spectrometer

Samples


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Things we look for

Analyzing the slag and the importance ofAnalyzing the slag and the importance of standards

• Alloy recovery issues• Tramp elements• Other operational issuesp


Back to:

Employ Good Foundry PracticesPractices

6. Use separate ladles for grey andductile iron.


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Changing the Slag Chemistry


Introduction of

Dave WilliamsASI I t ti l LtdASI International Ltd


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Change in Interpretation of Slags

Why do fluxes improve theWhy do fluxes improve the Metal Cleanliness?

How do fluxes actually clean the insolubles emulsified in the molten iron?


What do Fluxes accomplish?

Fluxes will react with and modify the chemical composition of the complex compounds such as oxides, sulfides, phosphates, aluminates, etc, such that they will separate out, away from the metal matrix and be mechanically removed.


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Common Slag Inclusion Components:

Manganese Silicates, 2MnO∙SiO2 tephroite

Melting temperature: 2453F ( 1345C) g p ( )Considering the stability energy of formation(Gibbs Free Energy) at 2642F ΔGform = ‐ 4010 Cal/mole

2 MnO + SiO2 → 2MnO∙SiO2

Iron Silicates, 2FeO∙SiO2 fayalite

Melting temperature: 2223F ( 1217C)Considering the stability energy of formation(Gibbs Free Energy) at 2642F ΔGform = ‐ 3370 Cal /mole

2 FeO + SiO2 → 2FeO∙SiO2


MORE common Slag Inclusion Components

Alumino Silicates 3Al2O3∙2SiO2 MulliteAlumino Silicates, 3Al2O3∙2SiO2 Mullite

melt temp 3380F(1860C), ΔGform @2700F = ‐3177 Cal/mole3Al2O3 + 2SiO2 => 3 Al2O3∙2SiO2

Al2O3∙SiO2 Andalusite, kyanite, sillimanite

Magnesium Silicates, 2MgO∙SiO2 ForsteriteMagnesium Silicates, 2MgO SiO2 Forsterite

Melt temp 3434F(1890C), ΔGform @2700F = ‐13017 Cal/mole2MgO + SiO2 => 2 MgO∙SiO2


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4Al + 3O2 => 2Al2O3 Stable2Mg + O2 => 2 MgO Stable2Ca + O2 => 2CaO Stable2Ce + O2 => 2 CeO Very Stable


Ca + S => CaS Extreme Stability

Ce + S => CeS Extreme Stability

Mg + S => MgS Moderate StabilityDIS DIS Annual Annual Meeting, Meeting, June 4June 4--6, 20146, 2014


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2Ce + N2 = 2CeN Extreme Stability

2Al + N2 = 2AlN Extreme Stability

3Mg +N2 = Mg3N2 Not StableDIS DIS Annual Annual Meeting, Meeting, June 4June 4--6, 20146, 2014


Reactants in Fluxes

Strong Flux Reactants:gCa+2 ion included in CaF2 (Fluorspar)Na+1 ion included in Cryolite

Mild Flux Reactants:Na2O - Oxide compoundC O O id dCaO - Oxide compound


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Potential Reactions of Flux with Slag Components

Na2O + SiO2 -> Na2O•SiO2

Na2O + Al2O3 -> Na2O•Al2O32 2 3 2 2 3

CaO + Al2O3 -> CaO•Al2O3

CaO + SiO2 -> CaO•SiO2

CaO + Al2O3SiO2

N + S N SNa+ + S -> Na2SCa 2+ + S -> CaS

©2014 ASI International Ltd.

Potassium would behave similarly to Sodium.


The Effect of CaO on Complex Compounds

Calcium Oxide on Mullite, 3Al2O3∙2SiO2

3CaO + 3Al2O3∙2SiO2 => 3(CaOAl2O3)∙2SiO2 @2700F( )Anorthite, melt temp 2835F(1557C) ΔGform = ‐33,564 Cal/mole

Calcium Oxide on Forsterite, 2MgO∙SiO2

2CaO∙SiO2 + 2MgO∙SiO2 => 2(CaOMgO)∙2SiO2 @2700F

Diopside, melt temp 2536F(1391C) ΔGform = ‐33,922 Cal/mole

Calcium Oxide on Sulfur , CaO + 2S => CaS + O+2

Oldhamite, melt temp 4577F(2525C) Δ Gform = ‐86573 Cal/mole


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Effect of Na2O on Complex Compounds

Na2CO3 + SiO2 → Na2SiO3 + CO2

Sodium Oxide on Silica SiO ΔG 59 967 C l/ lSodium Oxide on Silica, SiO2 ΔGform = ‐59,967 Cal/mole

Na2O + SiO2 ‐> Na2O∙SiO2 Melt Temp 1990F (1088C)

Sodium Oxide on Alumina, Al2O3 ΔGform= ‐41,559 Cal/mole

Na2O + Al2O3 ‐> NaAlO2 Melt temp 3002F(1650C)Na2O + Al2O3 ‐> Na2O∙Al2O3 Melt temp 2469F(1353C)

Sodium Oxide on Alumino Silicate, 2Al2O3∙SiO2

2Na2O + 2Al2O3∙SiO2 => 2 (Na2OAl2O3)∙2SiO2

©2014 ASI International Ltd.


3,400 -8,045 **

** Educated Guess, need to verify by Calculation


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Challenge to any foundry struggling with Inclusions

Carefully examine the defect after sectioning, polishing and etching under various magnification.

Do X‐Ray Fluorescence on Slag and Inclusion for summary f O id d S lf t i hi tof Oxides, and Sulfur, compare to previous history

Do X‐Ray Diffraction for detection of complex compounds present, decide if melt, molding or agitation related

Possible SEM, i.e. electron probe microscopy to detect unique tramp elements. Evaluate potential source

Devise a recovery action plan to begin to address potential causes from X‐Ray results and SEM. Investigate all Tramps and considered dissolved gases.


For foundry applications, the metals involved are primarily Cerium (Ce)Lanthanum (La), Praseodymium(Pr), Neodymium (Nd). In most applications such as inoculation or magnesium treatment, Cerium and Lanthanum are the primary metals of choice.

Lanthanum Atomic Weight 138 9

What about Rare Earth Metals?

Lanthanum Atomic Weight 138.9Cerium Atomic Weight 140.1Praseodymium Atomic Weight 140.9Neodymium Atomic Weight 144.2

Barium Atomic Weight 137.3Iron Atomic Weight 55.85

The Molecular Weights of the Oxides and Sulfides of the REM’s will beThe Molecular Weights of the Oxides and Sulfides of the REM s will beheavy and eventually collect towards the lower portion of any holding /pouring vessel. (when compared the weight to iron compounds.)

Considering the melting points of these Oxides and Sulfides, these remainunmelted and insoluble at typical molten iron temperatures.


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Elyria Foundry found that using a patented fluoride‐free, chloride‐free flux, at a continuous rate of 1 lb/ton of molten iron within a transfer ladle, the benefits assisted in a cleansing process of the iron and reduced the slag inclusion defect.

Any flux addition , due to its cleansing nature, must require a slag removal step t f llto follow.

Elyria’s results were shown on the opening chart.


EXAMPLE: Treatment Ladle / Ductile Iron

Pictures illustrating the first and second addition of Flux crushed briquettes for two consecutive wash heats. Note the turbulence on top of the bath.


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Treatment Ladle / Ductile Iron

A Typical View of Ladle Slag after Treatment Process has been completed. Also pictured is the pouring spout of the ladle showing the build-up.



Views of the Treatment Ladle being subjected to the third 1000Kg wash heat with 0.43 Kg Flux treatment.


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Views of the fourth wash heat treatment with 0.43Kg Treatmentof Flux. Note the vigorous reaction with the slag. The Gas being released is carbon dioxide, NO Fluorine or Chlorine



Af fif fiAfter the fifth and final wash heat, the Ladle was drained to reveal significant improvement in cleanliness of the Ladle sidewalls, spout and treatment pocket.


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Flux in Mag. Treatment Ladles

Fluxing a 1 ton Treatment Ladle with 5 “Wash Heats” one Lb(0.4Kg) per Ladle

Initially, loss of pocket capacity due to Insoluble Build-Up.

After the 5 individual treatments, pocket capacity was restored as shown

Before Treatment After Treatment


A t i l i f T t t L dl Vie of the ladle after the 5 ash

This was achieved with minimal scraping, strictlythe addition of Flux to 5 different “wash heats.”


A typical view of Treatment Ladle after 72 hrs of operation

View of the ladle after the 5 wash heats in a cold state.

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2.00%

2.50%

Gray & Ductile Slag as a Percentage of No Bake Production by Cast Date Jul 29 2012‐ Sept 8 2013

% Ductile % Gray

1.44%0.33%

0.29%

0.83%0.17%

0.05%

0.45%

0.50%

0.19%

0.87%

0.94%

0.11%

1.32%

0.05%

0.25%1.22%

0 00%

0.02%

0.11%

0.06%

1.00%

1.50%

med

Red

uxFlux Additions

was red

uced

ut of Red

uxFlux Additions

Red

uxFlux Additions

0.61%0.58%

0.71%

1.01%1.10%

0.68%

1.44%

0.28%0.22%0.18%

0.13%

0.91%

0.73%

0.30%0.39%

0.18%

0.00%

0.74%

0.00%

0.30%0.39%

0.46%

0.07%

0.31%

1.17%

0.85%

0.44%

0.58%

0.05%

0.20%0.30%

0.17%

0.02%

0.15%0.12%

0.00%0.00%

0.72%

0.00%

0.19%

0.00%

1.22%

0.11%

1.06%

0.35%

0.10%0.18%

0.00%0.00%0.00%0.00%

1.33%

0.24%

0.02%

0.24%

0.08%0.08%0.15%

0.00%

0.29%

0.08%0.20%0.35%

0.19%

0.72%

0.13%0.46%

0.21%

0.36%

0.06%

0.00%

0.00%

0.03%

0.21%

0.20%

0.24%

0.06%

0.05%

0.26%

0.00%

0.00%0.00%

0.00%

0.00%

0.00%

0.07%

0.00%

0.03%

0.09%

0.51%

0.00%0.00%

0.54%

0.09%

0.19%

0.03%

0.10%0.32%

0.00%

0.00%

0.00%0.00%

0.50%

Resu

Red

uxad

dition w

Ran

o

StartedR

Melt Point vs Slag Defect

2800

3000

3200

3

4

5

FNC 1 - Ductile

2800

3000

3200

3

4

5

FNC 3 - Gray

2000

2200

2400

2600

0

1

2

3

3000

3200

4

5

FNC 2 - Ductile

2000

2200

2400

2600

0

1

2

3000

3200

4

5

FNC 4 - Gray

2000

2200

2400

2600

2800

0

1

2

3

4

2000

2200

2400

2600

2800

3000

0

1

2

3

4


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Oxide graphs Furnace #1

CaO

UCL 6.197

CL 4.415

LCL 2.6333.00

4.00

5.00

6.00

7.00

8.00

CaO

CaO

2.00

Sample Date


UCL 13.076

CL 6.432

LCL -0.2120 45

1.55

3.55

5.55

7.55

9.55

11.55

13.55

15.55

Mn

O

MnO

-2.45

-0.45

UCL 11.852

CL 6.396

8.00

10.00

12.00

14.00

Mn

O

LCL 0.940

0.00

2.00

4.00

6.00

M

Date

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2.50%

3.00%

Gray & Ductile Slag as a Percentage of No Bake Production by Cast Date Feb 10 2013‐ Feb 5 2014

1.22%

0.02%

0.11%

0.06%

0.18%

1.02%1.35%

2.14%

1.24%

1.00%

1.50%

2.00%

% 120‐544

% 53729

% Gray

ition was red

uced

0.20%0.30%

0.17%0.02%

0.15%0.12%0.00%0.00%

0.72%

0.00%

0.19%

0.00%

1.22%

0.11%

1.06%

0.35%

0.10%0.18%

0.00%0.00%0.00%0.00%

1.33%

0.24%

0.02%

0.24%0.08%0.08%

0.15%0.00%

1.01%

0.01%

0.41%

0.03%0.00%0.00%0.08%

0.28%

0.05%0.20%

0.00%0.00%0.00%

0.38%

0.00%0.00%0.00%0.14%

0.05%0.00%

0.39%

0.00%

0.24%

0.06%

0.05%

0.26%

0.00%

0.00%0.00%

0.00%

0.00%

0.00%

0.07%0.00%

0.03%

0.09%

0.51%

0.00%0.00%

0.54%

0.09%

0.19%

0.03%

0.10%0.32%

0.00%0.00%

0.00% 0.03%0.14%

0.35%

0.00%

0.00%0.18%

0.15%

0.00%0.00%0.00%

0.00%

0.00%0.00%0.11%

0.00%

0.00%0.00%

0.13%

0.00%

1.10% 1.28%

0.00%

0.50%

Red

uxad

di


Summary

• Employ Good Foundry Practices

M l C ld P H

Objective: Minimize Oxidation and Remove Oxides

• Melt Cold ‐ Pour Hot

• Confirm Nucleation with Chill Wedge Control

• Use quality charge materials SiC, GraphiticCarbon, clean steel, minimal rust on pig iron.

C ll M lt M t l• Cover all Molten Metal

• Keep ladles free of slag build up, use properfluxing agents.


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Conclusions1. The melt point of the slag fell as flux additions were made

due to increases in MnO and CaO. [In the first 6 monthsMnO began to rise as flux additions were made causing alower viscosity (higher fluidity) of our slag. In the next 6months when we introduced Silicon Carbide, the amount of,MnO began to fall.] Controlled additions of flux were foundto be very beneficial.

2. The increase in CaO from our flux addition reduced thewetting ability of our slag preventing build up in the ladlebetween gray and ductile taps. [This contributed to a majorimprovement in slag reduction].

3 Oth i ifi t i t i l d ti d3. Other significant improvements in slag reduction occurredas a result of initial employment of good foundry practices.Further improvements occurred as we identified problemjobs and then applied proper gating practices.


Questions?


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FEATURES









•


DEPARTMENTS


3D PRINTING FOR THE DUCTILE IRON FOUNDRY INDUSTRY

STEVE MURRAY

STEVE GRADUATED FROM INDIANA UNIVERSITY IN MATH. HE FOUND HIS CALLING WHEN HE STEPPED INTO A PATTERN SHOP AFTER GRADUATING AND IT WAS LOVE AT FIRST SPLINTER. OVERCOMING THE CHALLENGE OF HOW TO PRODUCE OR MANUFACTURE A CASTING IS ONE OF THE THINGS THAT KEEPS HIM INVOLVED AND INTERESTED IN THE METAL CASTING INDUSTRY. USING CIMATRON CAD SOFTWARE TO DESIGN WITH, ADDITIVE MANUFACTURING OF ALL SORTS TO CREATE WITH, AND 3D SAND PRINTING TO MAKE CASTINGS OF ANY ALLOY STIMULATES NEW CASTING DESIGNS. HE NOW HAS THE OPPORTUNITY TO MAKE CASTINGS THAT WERE NOT EVEN MANUFACTURABLE JUST A FEW YEARS AGO. AT THE 2014 AM-UG CONFERENCE IN TUCSON HE TOOK AND PASSED THE SME ADDITIVE MANUFACTURING CERTIFICATE EXAM.



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3-D Printing For The Ductile Foundry Industry

Steve MurrayHoosier Pattern


3-D Printing

Defined by the ASTM F42 CommitteeDefined by the ASTM F42 Committee as the fabrication of objects through the deposition of material using a print head, nozzle or other printer technology.

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 20146, 2014LethbridgeLethbridge, Alberta, Canada, Alberta, Canada

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3-D Processes

Material ExtrusionMaterial Extrusion

Material Jetting

Binder Jetting

Sheet Lamination

Vat Photo PolymerizationVat Photo Polymerization

Power Bed Fusion

Directed Energy Deposition


Ductile Foundry

Investment Casting

Sand Casting


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Printed Investment Casting Patterns

• Investment casting patterns built• Investment casting patterns builtusing an additive manufacturingprocess

• No tooling required

• Now used by more than 95% ofo used by o e t a 95% oinvestment foundries


Most Common Printed PatternsType Manufacturer Description

Q i kC t 3D S tHollow stereolithography models with an

i t l t t h t l iQuickCast 3D Systems internal structure– photopolymer resin solidified with a UV laser

Projet Wax 3D Systems Inkjet printed wax patterns

C tf 3D S tPolystyrene models built using selective l i t i (SLS) d i filt t d ithCastform 3D Systems laser sintering (SLS) and infiltrated with

wax

Voxeljet VoxeljetPMMA models built using finely ground

powder bound with a binder applied with inkjet technology

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Four Uses for Printed PatternsApplication Description

Prototype Create production quality castings without the cost or time required for tooling Several design alternatives to be tested

Castingsrequired for tooling. Several design alternatives to be tested

at the same time. Avoids tool rework.

Process Development

Optimizing gate location and pattern orientation, shrink confirmation, dip robot programming, straightening fixture

development

Bridge Enables limited production while waiting forBridge Production

Enables limited production while waiting for tooling to be delivered.

Low Volume Production

Cost effective production of jobs whose volume is too low to justify the cost of tooling


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DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 20146, 2014LethbridgeLethbridge, Alberta, Canada , Alberta, Canada

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3-D Printed Sand

CoresSolidSolidShellSolid / Shell Hybrid

MoldsSimulate Horizontal or Vertical Parting


g

Not An All Or Nothing TechnologyMix And Match

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DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 20146, 2014Lethbridge, Alberta, Canada Lethbridge, Alberta, Canada

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Why Use 3-D Printed Sand

PrototypePrototype

Sample Design Before Production

Sample Changes

Castings Till Production Comes On Line

Legacy Parts


Legacy Parts

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3-D Provider

Experience & KnowledgeAre They SME Additive Manufacturing Certified

Vendor Capabilities Match Your NeedsProcess Material Timing Quality

Changes

Proactive


Proactive

Response Time

For additional information, please contact:

• Steve Murray

• 906 North 10th Street• Decatur, IN 46733

• Cell 574-210-5934


• [email protected]• www.hoosierpattern.com

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FEATURES









•


DEPARTMENTS


IS THE GROWTH OF THE DUCTILE IRON INDUSTRY AT RISK

GEORGE KOKOS

GEORGE GRADUATED FROM IOWA STATE UNIVERSITY IN 1986 WITH HIS BS IN METALLURGICAL ENGINEERING AND IN 1988 HIS MS IN METALLURGY. GEORGE IS CURRENTLY THE SR CASTING TECHNOLOGY STEWARD AT CATERPILLAR INC. IN MOSSVILLE, ILLINOIS. GEORGE HAS 25 YEARS OF EXPERIENCE IN THE CASTING INDUSTRY IN WHICH THE MAJORITY OF TIME WAS SPENT AT THE MAPLETON FOUNDRY THAT MANUFACTURES BLOCKS, HEADS AND LINERS FOR CATERPILLAR ENGINES. HE HAS ALSO WORKED OVERSEAS IN THE ASIAN PACIFIC REGION PROMOTING CASTING EXPORTS TO THE USA AND MOST RECENTLY IN MEXICO WHERE HE SERVED AS TECHNICAL DIRECTOR FOR TECHNOCAST.

HE CURRENTLY SERVES AS THE CHAIR OF AFS 5B, THE CO-CHAIR OF 5A, AND ON THE EXECUTIVE COMMITTEE OF THE PEORIA CHAPTER OF THE AFS/ASM.



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Is the growth of ductile iron industry at risk?

George KokosCaterpillar Inc.


Burning PlatformDI components fail in the field

• Reduced fatigue life initiates crack growth

– Graphite skin reduces fatigue limit by 15%1

1 2– Dross reduces fatigue limit 20% to 33%1,2

• Crack grows until critical crack length

• Designers immediately change material tocast steel or forging

1=1983 BCIRA paper by K Palmer2=1982 International Journal of fatigue by M Starkey


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Outline• DI castings have dross and GI skin defects that effect

performance

• Variables that cause graphite skin and dross

• Foundry controls• Foundry controls

• Strategies to reduce DI failures

GI Skin can promote failures


Defect Type & Size / Location

m

Cast Surface

Dro

ss 3

-5 m

m

Fla

ke S

kin

0.5-

1.5

mm

Chu

nky

10 m

m-C

ore

Fer

rite

Who

le S

ectio

n

Gra

phite

Flo

at 5

mm

Section Centerline (Core)


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Graphite skin – why does it form?

50X

1.2 mm skin

Gray cast iron layer is present on as cast surfaceMg/RE from melt is tied up by oxygen and or sulfur from mold“Fading” is accelerated at the mold/metal interface


Performance Issues with Graphite Skin

• GI skin acts as a pre-existing crackpromoting fatigue failures

• Mechanical properties are reduced

• Other Issues– Machined surface have a patchy appearance

Part Spec

Hardness 4.5 mm 4.1-4.4mm

Yield (Mpa) 205 275 min

Ultimate (Mpa) 350 415 min

Elongation (%) 6 10 min


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Graphite Skin Variables• Mg/RE level in iron• Sulfur and Oxygen in mold coatings• Long turbulent runner system• Long turbulent runner system• Build up of S in furan (catalyst with

high sulfuric acid)• Build up of S in green sand (seacoal

with high sulfur)• Cooling rate


Validating Process Improvements(On Actual Castings)

• Low S catalyst in Furan mix

• Higher % of new sand in mix (initially 100%)g ( y )

– Reduced new sand with low S catalyst to 10%

• Goal of .05% max S in sand mix

• New Mg Silicate alcohol paint flow coatedOld Process New Process

Process Improvements

50X 100X

1.5mm skin 0.05mm skin


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Foundry controls to assure consistent results

• % new sand to furan mix

• % low S seacoal to green sand• % low S seacoal to green sand

• Measurement control of catalyst to furan

• Sulfur % in sand mix

• Correlate S% with GI skin depth in parts


Communicate engineering requirements to supplier

• Add a skin requirement to specificationsAdd a skin requirement to specifications

• Allow more skin for bigger castings

• Show example micros

Casting

Size

Casting

Size

Casting

Size GI/CGI to DI1 2 3

Allowed GI Skin Depth

X mm X+ mm X++ mm

GI/CGI to DI


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Dross Inclusions• Occurs inside the mold as a product

of magnesium-treated iron

• Identified by the shape of the oxide-film stringers and magnesiumcontent present Normally found oncontent present. Normally found oncope surface.

Element Weight% Atomic%

C K 14.02 21.86O K 41.56 48.68Mg K 24.88 19.18Al K 2.96 2.05Si K 8.37 5.58P K 0 31 0 19P K 0.31 0.19Ca K 0.34 0.16Fe K 6.40 2.15Ce L 1.17 0.16

Totals 100.00


Dross DefectsCast Surface • Dross occurs in 100% of ductile castings

• Dross volume increases with casting size

• Orientation (angle) of defect is random

• Dross location and volume (size) impacted by

Dro

ss 3

-5 m

m

( ) p ygating

– High stress area in drag reduces risk

~95% of

Section Centerline (Core)Gate

~95% ofDross

In These Areas


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Summary of variables effecting dross

• Location and amount of dross defects is process dependent. We have proven influence of the following:

• In-gate velocity - stay below 1 m/s (turbulence)

• Usage of filters

• Consistency and speed of pouring times

• Cannot put in gates at the parting line (fountaining)

• Riser size and position effects dross location but not quantity

• # of in-gates and their position effects sloshing of iron - needs to be smooth / even entry

• Extra stock and or flow offs also effects position of dross

• Quality of de-slag process prior to pouring

• Defect location is cope side


Filling VelocityFilling Velocity

Sloshing can be seen in the casting


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• Updated specifications to place limitations on dross and skin in DI

& CGI

Future or Ongoing Efforts to Apply to Future Product

• Updating defect criteria for critical locations to callout on print

• Develop training program (focus on castings for

designers/analysts)

• Review and update casting design guide

• Review fatigue de-rating factors for as-cast DI

• Document and deploy fracture mechanics tool and flaw tolerantDocument and deploy fracture mechanics tool and flaw tolerant

design guide for use by product groups

• PFMEA and control plan review on critical parts


Strategies to minimize effects of surface defects

• Work with supplier to assure high stress regionis not in the cope surface or near a riser

• Run oxidation models to minimize oxidation and• Run oxidation models to minimize oxidation andlocate in low stress region

• Add machine stock and remove defect layer (5mm)

• Mag particle all PPAP parts to assess risk– Minimum defect size that can be detectable = 2mm

• Note tensile test location on print in high stress• Note tensile test location on print in high stressregion


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Defect Location Matters

Same casting is used in 2 orientations•LHS defect area in tension•RHS defect area in compression


Special Inspection•Surface Requirements

•Defined by SCRATA plates

•Plastic replicas of several differentseverities for different defects (surface texture, gas)

•Dross

•3mm linear surface defect on machinedsurface

•Internal Requirements

•Several defects (gas, sand, shrink)

•Can saw cut and use liquid penetrant to

2.93 mm

identify the presence of defects

•Radiography is required for acceptance


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Special Inspection•Use in critical areas of a Ductile Iron Casting which require greater foundryinspection to ensure adequate reliability

•Applies only to sections of a casting

•Used in this case due to potential safety issue High Stress


Verification of Strength in Casting

• Best to have Y block cast attached to• Best to have Y block cast attached topart or check the actual casting– Assure connection does not promote

shrink

• Can get skin measurements and tensileresults from this sample (assure samecooling rate)


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QuestionsAll castings have defects that must be taken

into consideration for design and analysis. True or False


QuestionsDross defects (or any non-metallic inclusion—sand, slag,

etc) are generally located where:

A) CopeB) DragB) DragC) Under a coreD) Location cannot be predicted


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QuestionsHigh stress regions of the casting should not

be shared with the foundry due to IP concerns. True or False


QuestionsThe preferred method to reduce stress in

castings is to simply increase the section thickness. True or False


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For Additional Information, Please Contact:

• George KokosGeorge Kokos• Caterpillar Inc

– Advanced Materials Technology– Tech Center Bldg K - Room 185– PO Box 1875– Peoria, IL 61656-1875

• 309-578-6453• [email protected]• www. caterpillar.com


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FEATURES









•


DEPARTMENTS


HIGH SILICON MOLYBDENUM CAST IRON WITH MIXED GRAPHITE (MG) SHAPES FOR ELEVATED TEMPERATURE

APPLICATIONS

DELIN LI

DELIN IS A CASTING RESEARCH SCIENTIST FOR CANMET MATERIALS, A PART OF THE FEDERAL GOVERNMENT NATURAL RESOURCES CANADA IN HAMILTON ONTARIO SINCE 2012. FROM 2000 TO 2012, HE WORKED AT WESCAST INDUSTRIES INC. IN THE AREAS OF FERROUS ALLOY DEVELOPMENT AND FOUNDRY PROCESS IMPROVEMENT. HE WORKED AT WESCAST GLOBAL FACILITIES IN CANADA, USA, EUROPE, AND CHINA. HE IS ALSO AN ASQ SIX SIGMA BLACK BELT AND ASQ QUALITY ENGINEER.

DR. LI ALSO WORKED AT THE SPACE FLIGHT CENTER IN HUNTSVILLE, ALABAMA, GERMAN AEROSPACE RESEARCH CENTER AND QUEEN’S UNIVERSITY.



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Medium Graphite-nodularity High-Silicon Molybdenum (MG SiMo) Cast Iron for Elevated Temperature Applications

Delin Li CanmetMaterials, Natural Resources Canada

Clayton Sloss Wescast Industries Inc.

Presented at DIS Annual Meeting, June 4-6, 2014, Lethbridge, Alberta, Canada

ABSTRACT

Both spheroidal graphite (SG) iron and compacted graphite (CG) iron castings are currently produced for automotive applications. The graphite morphology nodularity is typically specified lower than 30% for CG and higher than 80% for SG. The so-called medium-nodularity graphite or mixed graphite (MG) cast iron has been proposed and developed, in which the nodularity was defined from 40 to 70%. A series of material and casting evaluations were conducted for the high-silicon moly (SiMo) iron with different graphite shapes, including SG, MG, and CG.

INTRODUCTION

Compositions, microstructures, material properties, and foundry practice of SiMo iron castings are well documented. As both SG SiMo and CG SiMo iron castings are applied to elevated temperature conditions, can SiMo cast iron with moderate or medium graphite-nodularity (MG) integrate advantages of both SG and CG microstructures? Thus, in this work, SiMo iron with MG microstructure was initiated and investigated.

EXPERIMENTAL PROCEDURES

There are four major melting casting facilities in CanmetMaterials as shown in Figure 1, including high pressure die caster, vacuum induction melting, air induction melting of up to 500 kg iron capacity, and twin roll caster.

All SiMo-related melting-casting trials and materials testing were performed at the Technical Development Centre of Wescast Industries Inc.

RESULTS AND DISCUSSION

The main results of high-Si cast irons from this work include microstructures, solidification curves, tensile testing data, thermophysical properties, hot oxidation and engine exhaust simulator (EES) testing.

MICROSTRUCTURES

Different amounts of nodulizers were added into SiMo iron to achieve a variety of graphite nodularity. The target chemistry was 4.0% Si, and the target carbon equivalent was from 4.40% to 4.70% dependent on the critical thickness of castings and the required graphite nodularity. Figure 2 displays the graphite morphology development from CG to MG and to SG by increasing the addition of Fe-Si-Mg nodulizer from 0.50% to 1.50%. The SG etched micrograph shows the moly-rich precipitates at the grain boundaries.

COOLING CURVES

The representative cooling curves are shown in Figure 3 for high-Si CG, MG, and SG irons respectively. Some parameters are listed in Table 1. The liquidus temperatures TL are approximately the same, which indicates the same carbon equivalent used among the three curves. The recalescence R, an indicator of undercooling, appeared to increase with increasing the residual magnesium. S1 stands for the primary solidification. The large S1 for CG sample was probably due to high carbon equivalent and less magnesium additions. Although the MG and SG samples had the same hypereutectic CE as the CG sample, a higher residual magnesium altered the CE effectively, promoted undercooling, and caused the MG and SG samples to solidify in a eutectic mode, as shown in Figures 4 (b) and (c) in which little primary solidification was detected.

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Table 1 – Solidification parameters of CG, MG, and SG SiMo samples determined from cooling curves.

Nodularity (%)

TL (°C)

R (°C)

S1 GRF1

CG ~ 30 1142 0.8 80 80

MG ~ 60 1140 1.0 1 101

SG ~ 90 1142 4.8 1 79

TENSILE TESTING

Table 2 presents some tensile testing results. As expected, the elongation at room temperature (RT E) and 0.2% offset yield strength (RT YS) were increased with increasing the graphite nodularity. The YS at 425 °C also slightly increased with nodularity. In contrast to RT elongation, lower ductility was observed for the SG samples, while higher ductility was obtained for the lower nodularity samples, tested at 425 °C. This may be explained as follows.

Table 2 - Tensile testing results at RT and 425 °C of SiMo iron samples with different graphite nodularity.

Nodularity

(%)

RT E (%)

425 °C E (%)

RT YS (MPa)

425 °C YS

(MPa)

30 5.0 5.0 450 360

50 8.0 8.0 480 380

70 10.0 6.0 500 390

90 14.0 2.0 510 395

The brittleness at medium temperature (BMT) has long been known as deleterious phenomena in ferritic ductile irons. One mechanism was suggested: the BMT is caused by the grain boundary segregation of impurities, which could be the magnesium assisted sulfur segregation. From Table 2, the BMT occurred for SG samples. CG samples exhibit low elongation at both RT and 425 °C. However, for MG samples, moderate elongation was achieved at both room temperature and 425 °C. The tensile elongation ranges at RT and 425 °C are schematically depicted in Figure 4 for CG, MG, and SG samples. Heat treating trials were also conducted. Little or no changes in BMT were found before and after heat treating, though the elongation at RT went up evidently after annealing heat treatment.

THERMOPHYSICAL PROPERTIES

SiMo samples with different graphite nodularity were sent to external laboratories for measurements of thermal conductivity, emissivity, and heat capacity, as a function of temperature. Graphite morphology does influence the thermal conductivity, as implied in Table 3. However, when the temperature is at 400 °C, the difference in thermal conductivity was decreased. The thermal conductivity of CG SiMo appears to decrease with temperature. But the thermal conductivity of SG SiMo increases or flattens with temperature. The CTE (coefficient of thermal expansion) and Ac1 (the critical phase transformation) temperature of CG, MG, and SG samples were also measured. No significant impact was detected of the graphite nodularity on CTE and Ac1.

Table 3 – Thermal conductivity (W/K.m) of SiMo iron.

Graphite Shape 100 °C 400 °C 700 °C

CG 36 33 30

MG Intermediate

SG 26 29 30

OXIDATION AND CORROSION RESISTANCE

A series of high temperature oxidation testing were conducted including static oxidation and thermal cyclic oxidation testing as shown in Figure 5. Table 4 briefly characterizes the hot oxidation behaviors of CG, MG, and SG SiMo samples, based on the testing results. More weight changes were observed for CG samples than SG samples. There was severe internal oxidation for CG samples because of the interconnected graphite structure, but less external oxide scales. For the SG samples, the opposite trend was observed. The MG samples exhibited hot oxidation behavior intermediate between that of CG and SG irons.

Table 4 – Brief summary of hot oxidation behaviors of SiMo irons with different graphite shapes.

Weight Change

External Scale

Internal Oxidation

Scale Adherence

CG More Thinner More Stronger

SG Less Thicker Less Weaker

MG Combined CG and SG

ENGINE EXHAUST SIMULATOR (EES) TESTING

Wescast has developed EES facilities for product testing, as shown in Figure 6. The thermal cycling profiles in EES testing include heating/cooling rates, peak/valley temperatures, and holding time. The cycles to failure determined from EES testing were expressed

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as the thermal durability, and were in turn influenced by a variety of factors such as product design, test parameters, chemistry, and microstructures.

From the testing results of manifold types 1, 2, and 3 (Table 5), the MG SiMo has shown equal or better EES performance than CG and SG SiMo parts. It also should be pointed out that CG, MG, and SG irons may have a different application scope in terms of product geometries and engine requirements.

Table 5 – Cycles to failure of different exhaust manifolds and materials evaluated by EES testing under different exhaust gas temperatures (EGT) and thermal profiles.

Product Type

Outlet

EGT

SG SiM

o

CG SiM

o

MG SiM

o

1 T1

190 150 270

2 265 250 330

3 T2

1140 1575

4 945 1335

5 T3

1800 2017

6 2287 2900

PRODUCTION OF MG IRON CASTINGS

MG can stand for moderate graphite-nodularity, medium graphite-nodularity or mixed graphite. Due to a moderate amount of nodulizers and inoculant added during the melt treatment, MG iron castings obviously have much lower tendency for formation of flake graphite, chunk graphite, and other degenerated graphite, shrinkage, inclusions, and other casting defects, as compared to CG and SG. In addition, the machinability, thermal fatigue life and brittleness at medium temperature of MG iron castings were improved as compared to SG and CG iron castings. Because of the benefits offered by MG iron, there has been production of MG iron castings in some companies as listed in Table 6, for example.

Table 6 – Production of MG iron castings in some companies.

Company Terminology Used

W (Canada) MG SiMo:

30% to 70% CG

K (Japan) FCV35 and FCV42

40% to 75% CG

S (Shanghai, China) Aim at

50/50 CG/SG

X (Henan, China) Medium Vermicularity

30% to 50% CG

CONCLUSIONS

SiMo cast iron has been intensively evaluated including SG, CG, and MG microstructures.

MG SiMo has shown appreciable improvements in materials properties and foundry process, as compared to SG SiMo and especially to CG SiMo.

MG SiMo iron castings are produced in some companies. A new ASTM standard specification for SiMo with SG, MG, and CG microstructures was initiated.

ACKNOWLEDGMENTS

SiMo related work in this paper was conducted in Wescast Industries Inc. under the skillful contributions of N. Heap, D. Aitchison, R. Milord, F. Yu, and B. Makarski. The company permission is greatly acknowledged.

This paper was partially based on 2007 SAE paper 2007-01-1227 (selected for SAE’s 2007 Transactions) about MG SiMo.

Delin acknowledges the financial support by Natural Resources Canada and Mark Kozdras of CanmetMaterials program manager for the review.

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Figure 1: Four major mleting casting facilities in CanmetMaterials. HPDC – high pressure die casting, AIM – air induction melting, VIM – vacuum induction melting, and TRC – twin roll caster.

Figure 2: Micrographs of SiMo iron with different graphite morphologies. The SG etched micrograph shows the moly-rich precipitates at the grain boundary.

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048

12162024

0 7RT 425 C

Elon

gatio

n (%

)

CG SG MG

Figure 4: Tensile elongation ranges at RT and 425 °C (~ 800 °F) for SiMo irons with different graphite shapes, SG, MG, and CG. The SG samples show low ductility at 425 °C. The CG samples show low ductility at both room temperature and 425 °C. For the MG samples, moderate ductility was achieved at both room temperature and 425 °C (~ 800 °F).

Figure 3: Selective cooling curves measured from high-Si cast iron trials: (a) CG, (b) MG, and (c) SG.

(a) (b)

(c)

(a) (b)

(c)

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Figure 5: High-temperature oxidation testing of SiMo samples, a- mufffle furnace used for static oxidation tests, b- thermal cyclic oxidation tests developed in Wescast, c- SiMo samples after static oxidation testing, d- samples used for dimesnsion stability tests at high temperature, and e –tensile samples used for oxidation tests to study the mechnaical properties before and after oxidation tests.

Figure 6: Engine exhaust simulator (EES) facility developed in Wescast.

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FEATURES









•


DEPARTMENTS


PREVENTING RUST AND CORROSION ON DUCTILE IRON USING VCI TECHNOLOGY

WAYNE SIEFERT

WAYNE STARTED HIS CAREER AS DIRECTOR OF SALES AND MARKETING FOR DIFFERENT DISTRIBUTORS OF VCI PRODUCTS. HE THEN MOVED ON FOR ANOTHER 4 YEARS AS THE NORTHEAST REGIONAL MANAGER FOR DAUBERT VCI, A LEADING MANUFACTURER OF VCI PRODUCTS. WAYNE HAS A TOTAL OF 25 YEARS OF EXPERIENCE IN THE PACKAGING INDUSTRY, SPECIALIZING IN RUST PREVENTATIVE PACKAGING. SINCE 2007, WAYNE HAS BEEN THE PRESIDENT OF HIS OWN COMPANY, GREEN PACKAGING, INC. IN HARLEYSVILLE, PA., STOPMYRUST.COM, AND GREEN-VCI PRODUCTS. HE IS ALSO AN AUTHOR OF A BOOK, “A COMPLETE GUIDE TO RUST PREVENTION USING VCI”.

WAYNE IS RECOGNISED AS AN AWARD WINNING LEADER IN THE FIELD OF ANTI-CORROSION PACKAGING, ROUTINELY SOLVES CORROSION AND RUST ISSUES FOR HUNDREDS OF THE COUNTRY’S LEADING METAL PARTS MANUFACTURERS, INCLUDING FOUNDRIES, METAL STAMPING, HEAVY EQUIPMENT MANUFACTURERS, SPRING MANUFACTURERS, POWDERED METAL PARTS PRODUCERS AND MANY OTHERS WITH VCI PRODUCTS.



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Preventing Rust and Corrosion on Ductile Iron

Using VCI Technology

Wayne SiefertGreen Packaging, Inc.


What We Will Cover Today

• What is Rust?What is Rust?

• How Does Rust Form?

• Different Types of Rust

• Condensation and its Affects

• Seasonal Climate and How it Affects Metal

• VCI (Vapor Corrosion Inhibitors)( p )

• “The Dirty Dozen-The 12 Most Common MistakesThat Can Lead to Rust and Corrosion”


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Question?

• How much does rust and corrosion costHow much does rust and corrosion costAmerican industry on a yearly basis?


Why Should You Care About Rust?

According to the National gAssociation of Corrosion Engineers, last year, rust and corrosion cost American Industry $360 Billion Dollars! Of that amount, nearly $30 Billion Dollars was lost by American Metal Parts Manufacturers.

T d ill h 12 tToday, we will show you 12 ways to prevent this tremendous loss of money in your company and increase your company’s profits.


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How Much Does Corrosion Cost

Your Company?• The Average Ductile Iron Foundry Loses $76,350

in costs related to Rust and Corrosion

• Re-Working Parts

• Transportation

• Labor in Sorting

• Scrapping• Scrapping


How Can YouBenefit From NO RUST?

• What’s In It For ME?

• No More Angry Customers Calling toComplain About Rust

• No More Lost Money and Labor inRe-Working Rusty Parts

• No More Money Lost in Scrappingy pp gRusty Parts

• More Time to Deal With MoreImportant and Productive Activities


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What Is Rust?

We should take a look at exactly what corrosion is. According y gto Wikipedia, “Corrosion means the breaking down of essential properties in a material due to chemical reactions with its surroundings.

In the most common use of the word, this means a loss of electrons of metals reacting with water and oxygen. Weakening of iron due to oxidation of the iron atoms is a well-known example of electrochemical corrosion. This is pcommonly known as rusting.”


Corrosion Basics

Metal + H2O + O2 = CorrosionMetal + H2O + O2 Corrosion

65% Relative humidity is sufficient to cause corrosion

Objective is to:

• Eliminate O2 OR H2O• Create a Barrier Between Metal and H2O and O2• Inhibit the Electron Flow


• Inhibit the Electron Flow• VCI Creates a Barrier AND Inhibits the Electron Flow

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Corrosion Basics: Types of Corrosion

Color of Rust Can Determine Cause

Red rust hydrated oxides - high oxygen & water exposure

Yellow rust oxide-hydroxide - very soluble iron oxide

Brown rust ferric oxide - high oxygen lower moisture

Black rust from limited oxygen - Iron (II)oxide


Corrosion Basics

High & low energy areas create electric potential g gy p

• Metals which have higher electric potential are moresusceptible to corrosion. i.e. Highly Machined parts, partssubjected to high heat, excessive forming, stamping, etc.

• Metal grains and micro structure are a major influence.


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Corrosion Basics

What Causes RUST and CORROSION?

Corrosion is influenced by PART & PROCESS factors:• Type and nature of the metal• Ductile Iron is very porous

Metal and part processing

A d i t l f tAnd many environmental factors: Relative humidityContaminantsTemperature


Corrosion Basics

Process Corrosion Factors

MachiningExposes grain boundaries and creates microscopic peaks and valleys.

Heat TreatingCreates differences in electrical

potentialand can be a source for contaminates.


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Corrosion Basics

Process Corrosion Factors

Cleaning Poorly maintained cleaning solutions

are a source of corrosion and may cause “flash rust”.

Handling & Packaging Contamination from human handling g

or contact with untreated packaging materials.


Condensation

Wikipedia: Condensation is the change of the physical state of matter from gas phase intophysical state of matter from gas phase into liquid phase, and is the reverse of evaporation. It can also be defined as the change in the state of water vapor to water when in contact with any surface.

• Water that collects as droplets on a coldsurface when humid air is in contact with it.

• The process by which a gas cools andbecomes a liquid

• Small drops of water that form on a coldsurface


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Condensation

• Warm air has the capability of holding moremoisture than cool airmoisture than cool air.

• As the air (or your metal part) cools,condensation forms

• Condensation can form when parts go fromwarm to cold OR cold to warm

• Condensation becomes an electrolyte• Condensation becomes an electrolyte


Common Forms of Condensation

• Morning Dew Air gets colder at• Morning Dew – Air gets colder at

night

• Glass of Iced Tea or Bottle of

Beer from the refrigerator

• On the Windows in your Home

• On your Car on a Cool Morning

• Moisture on Your Metal Parts


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Spring• Warm Days

• Cool Nights• Cool Nights

• Can Have High Humidity

• Condensation can form on all metalsurfaces in plants that are notclimate-controlled

• Condensation can form on metal parts being shippeddue to temperature fluctuations in the truck during


due to temperature fluctuations in the truck duringshipping

• Condensation can form on metal parts going fromwarm plant to cool truck or cool truck to warm plant

Summer• Hot Days and High Humidity

• Cooler Nights• Cooler Nights

• Condensation can form on allmetal surfaces in plants thatare not climate-controlled

• Condensation can form on metal parts being shippeddue to lower night time temperatures in the truckduring shipping


• Condensation can form on metal parts going fromwarm truck to cooler customer plant if A/C

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Fall• Warm or Cool Days• Cool or Cold Nightsg• Condensation can form on all metal

surfaces in plants that are notclimate-controlled

• Condensation can form on metalparts being shipped due to lowernight time temperatures in the truckduring shippingC d ti f t l• Condensation can form on metalparts going from cool truck to warmercustomer plant


Winter• Cool or Cold Days and Nights

• Condensation can form on all metalf i l t th t t li tsurfaces in plants that are not climate-

controlled

• Condensation can form on metal partsbeing shipped due to lower night timetemperatures in the truck during shipping

• Condensation can form on metal partsgoing from warm plant to cold truck

• Condensation can form on metal partsgoing from cold truck to warmer customerplant


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How to Combat the Effects of Condensation

• Acclimate Parts to Ambient Temperatures

Slowly

• Protect Parts From Corrosion as Soon as

Possible

• If Using a VCI Bag, Keep the Bag Open

Until Parts Reach Room Temperaturep

BEFORE Sealing the Bag

• Add a Sheet of VCI Paper to Your Package

for Additional Protection


Prevention• Traditionally, the following products have been used in an

attempt to prevent rust and corrosion:attempt to prevent rust and corrosion:

• Rust Inhibiting Oils• Rust Inhibiting Greases• Tectyl• Cosmoline• Motor Oil• WD-40WD 40• Desiccants• NEWER TECHNOLOGY:• VCI Paper and VCI Bags


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OK, So What Is VCI?• VCI is an abbreviation for Vapor Corrosion Inhibitor or Volatile

Corrosion Inhibitor These corrosion inhibiting compounds areCorrosion Inhibitor. These corrosion inhibiting compounds arecoated on paper or polyethylene bags, and have sufficientvapor pressure to release molecules into the air.


OK, So What Is VCI?• Due to their polarity, the VCI molecules are attracted to the

surface of metal just like a magnet VCI molecules move fromsurface of metal, just like a magnet. VCI molecules move fromthe paper or film directly to the surface of metals. When thesecompounds come in contact with metal surfaces they form avery thin molecular layer. This thin layer effectively inhibitscorrosion on the metal surface by preventing air and moisturefrom coming in contact with the surface of the metal.


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Rust Prevention Methods Using VCI

• VCI Bags

• VCI Paper

• Combination of Both is Best• Increase the Amount of VCI molecules in

Package• VCI Poly Bag creates a Moisture Barrier• VCI Paper formulation is Water-SoluableVCI Paper formulation is Water Soluable• Our VCI Paper is Coated on Both Sides, so a

Sheet in the Middle of the Package will do aGreat Job


Rust Prevention Methods (Including VCI) Work Best

When…• They are Performed Consistently Throughout the PlantThey are Performed Consistently Throughout the Plant

(Standardized Procedures)

• They are Performed Consistently Throughout the Year

– When Are Your Parts Produced?

– When Are They Actually Shipped?

– When Are They Actually Used by Your Customer?y y y


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OK, So What Is VCI?• Our VCI packaging products include VCI papers, VCI poly

bags VCI poly sheeting VCI stretch film VCI foam VCIbags, VCI poly sheeting, VCI stretch film, VCI foam, VCIEmitters, VCI Wire, VCI chipboard, and many others.

• VCI products are environmentally-friendly, cost-effective, andsimple to use. These advantages, along with many othersmake VCI products an excellent choice for corrosioninhibition, eliminating the need for messy grease, oils,protective coatings and other ineffective methodsprotective coatings, and other ineffective methods.


Benefits Of VCI• Our VCI packaging products include VCI papers, VCI poly

bags VCI poly sheeting VCI stretch film VCI foam VCIbags, VCI poly sheeting, VCI stretch film, VCI foam, VCIEmitters, VCI Wire, VCI chipboard, and many others.

• VCI products are environmentally-friendly, cost-effective, andsimple to use. These advantages, along with many othersmake VCI products an excellent choice for corrosioninhibition, eliminating the need for messy grease, oils,protective coatings and other ineffective methodsprotective coatings, and other ineffective methods.


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Top Twelve Reasons For Rust and the Answers

1. Gloves, Gloves, Gloves!!2 Wood is NOT Good!2. Wood is NOT Good!3. Cover Up!!4. If You Can’t Stand the Heat, Stay Out of the Heat

Treat Area!!5. “Dry Up!”6. Keep it Clean!!7. Water is Water is Water….Right? No!8 It Doesn’t Take a PhD to Adjust the pH!8. It Doesn t Take a PhD to Adjust the pH!9. Keep Your Cool!!10. Oil is SO 1990’s!!11. The Right Stuff12. Finally! Use Enough VCI!


1 Gloves, Gloves, Gloves!

The #1 mistake is employees touching metal parts with their bare handswith their bare hands.

Acids, oils, and contaminants on human hands can cause and accelerate corrosion.

SOLUTION: All employees who handle metal parts including production workers, inspectors, and packaging personnel should wear gloves whenpackaging personnel should wear gloves when handling metal parts. Simple solution: wear gloves…..every time!


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2 Wood is not goodThe 2nd biggest mistake is having metal parts in direct contact with any of the following:

Corrugated cardboard cartons Wooden Pallets Wooden CratesCorrugated cardboard cartons Wooden Pallets Wooden CratesWooden Boxes Untreated Paper or Plastic

All forestry products (wood, paper, corrugated) contain moisture, acids, and chlorides that can cause corrosion. Most commonly, this mistake causes “contact corrosion” where parts that are in contact with the wood, cardboard, or paper will have rust or corrosion on the spots that were in direct contact. This often causes sporadic rust, where some parts in a particular shipment are rusty and some are not rustyrusty.

SOLUTION: Create a barrier between your metal parts and any wood or corrugated boxes and/or line boxes, crates etc. with a VCI poly bag, or VCI paper. This creates an effective barrier between your metal parts and the wood products that cause rust.


3 Cover upThe 3rd most common mistake is leaving metal parts uncovered in the plant. Leaving metal parts uncovered, unprotected while they are in your plant, waiting for secondary operations, or in queue for additional machining drilling tapping or other operations or while those partsmachining, drilling, tapping, or other operations, or while those parts are waiting to be packaged or shipped, leaves those parts susceptible to rust and corrosion.

Leaving metal parts uncovered and unprotected in the plant and making those parts susceptible to corrosion from forklift exhaust. Chlorides, Sulfides, and oxides from fork truck exhaust all contribute to corrosion of metal parts.

SOLUTION: Cover all metal parts with VCI paper or VCI poly bags to protect them from oxygen and contaminants that are in the plant atmosphere.


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4 If You Can’t Stand the Heat…Stay Out of the Heat Treat

Area!!Number 4 is storing metal parts near your manufacturing areasNumber 4 is storing metal parts near your manufacturing areas, especially heat-treat processing areas. The heat treating process causes by-products that can cause corrosion on metal parts.

SOLUTION: Move stored metal parts away from the heat treat area, and cover all of your metal parts with VCI paper or VCI poly bags to protect them from heat treat by-products.


5 Dry Up!The 5th most common mistake is not allowing metal parts to dry after taking them out of cleaning solution. Stacking metal parts on top of each or packing them in boxes after taking them out of the cleaning p g g gsolution without thorough drying is a recipe for rust. If you are washing parts, make sure that you do not stack metal parts on top of each other or pack them into boxes until the parts are completely dry. Wet parts can rust when stacked on top of each other because the fluid will act as an electrolyte and form a galvanic cell between the two parts.

SOLUTION: Make sure your metal parts are thoroughly dry before stacking them or packing them in boxes. Place metal parts in a wire basket to allow the parts to air dry. Vibratory action, forced air, and h t d th t i kl Wh k i d t kheat can dry the parts more quickly. When packaging dry parts, make sure to package the parts quickly into VCI paper or VCI bags.

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 20146, 2014Lethbridge, Alberta, CanadaLethbridge, Alberta, Canada

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6 Keep it clean!The 6th most common mistake is dirty metalworking fluids and dirty cleaning solutions. Small metal particles, also called “swarf” in the solution can end up on metal parts and if not properly washed away p p p p y ycan form a galvanic corrosion cell, and corrosion will occur underneath the swarf.

SOLUTION: Keep your metalworking fluids and cleaning solutions clean and free of dirt and swarf. Fluids and solutions should be checked on a regular basis, and kept free of contaminants that can cause corrosion.


7 Water is water… right? No!The 7th most common mistake is using public water sources for cleaning fluids and for water-based rust inhibitors. Public water can contain high chlorine levels, and can contain other chemicals that can g ,cause corrosion. The pH of public water can also vary greatly. As we will see in the next most common mistake, proper pH plays an important part in preventing rust and corrosion on metal parts.

SOLUTION: Switch from public water to distilled or deionized water. For water-based rust inhibitors, consider a ready-to-use product, like our Dry Coat Rust Preventative.


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8 It doesn’t take a PhD to change the ph

The 8th most common mistake is improper pH of cleaning solutions. Failure to maintain proper pH levels in your cleaning solutions can p p p y gquickly lead to corrosion. Proper pH levels depend on the type of metal parts you are producing. For ferrous parts, you should maintain a pH level of at least 9.0. For non-ferrous metal parts such as copper, and alloys like brass and bronze, a pH level of 7.0 – 7.5 should be maintained.

SOLUTION: Regularly check and correct pH levels of all your cleaning solutions. Adjust according to manufacturer’s instructions.


9 Keep your cool!The 9th most common mistake is failure to maintain proper temperature in manufacturing and shipping areas. For every 10 degree Celsius increase in temperature, corrosion rates can double. g p ,Fluctuations in temperature can cause metal pores to open, and also can cause condensation to form on your parts. Condensation becomes an electrolyte, allowing corrosion to occur. High humidity can cause electrolytes to form on the surface of metal parts, enabling the corrosion cell to form, and allowing corrosion to propagate. When you package your parts in high humidity, you lock that atmosphere into your packaging.

SOLUTION: Maintain lower temperatures and lower humidity levels by installing climate controls, air conditioning and/or dehumidifiers. Al b t l t l t i t VCI b VCIAlso, be sure to place metal parts into VCI bags or VCI paper as quickly as possible.


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10 oils is so 90’s!!The 10th biggest mistake is using Rust Preventative Oils or R.P Oils instead of VCI packaging. R.P. Oils are the traditional method of preventing rust and corrosion. However, R.P. Oils are messy, labor p g , y,intensive, and bad for the environment. R.P. Oils are also less effective than VCI products when it comes to preventing rust.

• Lower labor costs: Simply place your parts in a VCI Bag or wrap them in a sheet of VCI Paper. No coating, spraying, dipping or brushing necessary

• No need for messy oils and greases • VCI molecules reach all recessed areas of your parts for complete corrosion

protection • Your customer receives your product in a clean dry state • VCI protected parts can be used immediately with no need for removal of oils

and greases VCI molecules evaporate into the air when parts are removed from


and greases. VCI molecules evaporate into the air when parts are removed from VCI packaging

• More environmentally-Friendly • No employee health and safety issues as with oils: No slip and fall accidents • No disposal fees (VCI is completely repulpable and recyclable) • Lower insurance costs (due to no flammable liquids)

11 the right stuff!The 11th most common mistake is using VCI products improperly, such as using a VCI paper designed for non-ferrous p p gmetals on ferrous metal parts. Some VCI manufacturers incorrectly state that one VCI formulation will work for every application. This is simply not true. Other mistakes include facing the wrong side of the VCI paper toward the metal, although our VCI papers are coated on BOTH sides to eliminate the possibility of making this mistake.

SOLUTION Al f ll f t ’SOLUTION: Always follow manufacturer’s instructions when using VCI products. Consult with a VCI expert like Green Packaging, Inc. to design a VCI system for your specific application, and help you implement the usage of VCI products properly.


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VCI For Ductile IronDuctile Iron is very porous and rusts very quickly

S di Nit it i t i ll d i f VCISodium Nitrite is typically used in ferrous VCI formulationsSodium Nitrite is not very effective as a vapor phase inhibitor

Nitrites have been classified as carcinogens

Always choose a NITRITE-FREE VCI formulation for complete protection of Ductile Iron parts NaNO2for complete protection of Ductile Iron parts

Contact a VCI specialist to determine the best VCI formulation for your specific needs.


NaNO2

12 Finally, use enough VCIThe final mistake is not using enough VCI paper. The formula is to use at least 1 square foot of VCI paper or VCI poly for every 1-3 square feet of metal surface. Or use at least one square foot of q qVCI for every cubic foot of void space.


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SummaryAs we have seen, there are many factors that can contribute to the formation and acceleration of corrosion and rust. Some of these factors such as temperature, humidity, manufacturing by-products, and even the types of metals you are processing are beyond your control. But there are procedures that you can put into place to lessen the possibility of corrosion.

Using VCI poly bags, and VCI paper are a great way to reduce or eliminate corrosion and rust on your metal parts. VCI chemistry

i t f th l d d itmigrates from the paper or poly and deposits on all of the metal surfaces of your parts, including hard-to-reach recessed areas, holes, etc., leaving your metal parts clean, dry, and corrosion-free for years.


Questions


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Thank you!Thank you for your time and participation!



• Name: Wayne SiefertAdd 1527 G h Rd• Address: 1527 Gehman Rd.

Harleysville, PA 19438 • Phone: Toll Free 1-855-4-NO-RUST (1-855-466-7878)• Fax: 215-368-7269• Email: [email protected]• www.green-vci.com


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FEATURES









•


DEPARTMENTS


MACHINING DUCTILE IRON: BENEFITS, CONCERNS AND GENERAL GUIDELINES

TIM HEAGNEY

TIM HAS OVER 35 YEARS OF EXPERIENCE IN PRECISION MACHINING AND MANUFACTURING OPERATIONS WORKING WITH MANY FERROUS AND NON-FERROUS MATERIALS. HE BEGAN HIS CAREER AS A MACHINE SETUP/OPERATOR, PROGRESSED THROUGH PROCESS AND MANUFACTURING ENGINEERING, AND ON THROUGH GENERAL PLANT MANAGEMENT.

HE IS CURRENTLY IN THE POSITION OF “PROCESS OPTIMIZATION MANAGER” WITH DURA-BAR, SERVING AS TECHNICAL SUPPORT TO THE SALES FUNCTION WORKING WITH CUSTOMERS TO IMPROVE MACHINING PROCESSES WITH EMPHASIS ON IMPROVED PRODUCTIVITY AND REDUCED OPERATING COSTS.

THE DIS WELCOMES TIM WHO IS HERE TO TALK ABOUT “



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Machining Ductile Iron:Benefits, Concerns and General

Guidelines

Tim HeagneyDura-Bar


1 Reduced weight of component

Benefits –Machining Castings vs. Steel

1. Reduced weight of component

2. Intricate profiles and shapes

3. Free machining characteristics ofDuctile Iron

4 Superior chip management4. Superior chip management

5. Improved productivity resulting inlower overall cost


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Cost of ProductivityTypical Manufacturing Facility

Manufacturing Cost includes:

Labor,Machining, plus

Building &Building & Administration Costs


Typical Concerns –Machining Ductile Iron

Hard to machineHard to machine

Dirty and causes damage to my machine

Requires too much horsepower

Burns through tooling


g g

Can’t achieve surface finish

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Machining Speed


Machinability Ratings (speed)

• 1212 Steel - 100%

• 12L14 Steel - 170%

• 1050 Steel - 54%

• 4140 Steel - 66%

• 60-40-18 Ductile - 61%

• 65-45-12 Ductile - 61%

80 55 06 D il 40%


• 80-55-06 Ductile - 40%

• 100-70-03 Ductile - 30%

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Machining Feed / revolution


Machining Feeds

The specific cutting force is the force (F ) needed to shear off a

Ft

force (Ft) needed to shear off a specific chip cross-section, under certain conditions.

•Steel – 217,000 to 450,000 lbs./inch2

•Ductile Iron – 114,550 to 195,750 lbs./inch2


•Aluminum – 50,000 to 100,000 lbs./inch2

Based on the lower cutting force required, Ductile Iron can be machined at higher feed-rates than steel.

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Guidelines for Successful Machining

• Design the casting with machining in mind

• Use tooling designed specifically formachining cast iron

• Rigidity, (machine, fixture, and tooling) iscritical

• Use proper machining approach (speed,


feed, depth of cut)

• Proper filtration, chip evacuation, andmachine maintenance

Any Questions?


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• Tim HeagneyD B• Dura-Bar– 1800 West Lake Shore Drive– Woodstock, Illinois 60098

• Phone: 815-206-6770• Fax: 815-338-1549• [email protected]

d b


• www.dura-bar.com

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FEATURES









•


DEPARTMENTS


VIRTUAL TOUR OF PENTICTON FOUNDRY

CHAD GENTES

CHAD OBTAINED HIS MATERIALS ENGINEERING DEGREE FROM THE UNIVERSITY OF ALBERTA IN EDMONTON, ALBERTA. HE HAS BEEN WORKING AS THE QUALITY ASSURANCE MANAGER AND METALLURGIST AT PENTICTON FOUNDRY IN PENTICTON, BRITISH COLUMBIA SINCE NOVEMBER 2006.

SINCE SOME OF OUR FOUNDRY MEMBERS ARE HARD TO GET TO, WE HAVE DONE THIS IN THE PAST A FEW TIMES WITH GREAT SUCCESS.



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Penticton Foundry Virtual Tour

Chad GentesPenticton Foundry


Penticton, British Columbia Canada

DIS Annual Meeting, June 4, 2014 DIS Annual Meeting, June 4, 2014 LethbridgeLethbridge, Alberta, Canada, Alberta, Canada

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Penticton, British Columbia Canada

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 2014 6, 2014 LethbridgeLethbridge, Alberta, Canada, Alberta, Canada

History of Penticton Foundry

• 1935 Wilkins Machine shop and Foundry started producing castings indowntown Penticton near City Hall. Melted with a cupola furnace and

ld d ith dmoulded with green sand.

• 1951 Ray O’neal and Harry Hughes purchased the foundry and renamedit to Peach City Foundry.

• 1976 Peach City Foundry moved to a new location in the new industrialarea of Penticton on Commercial way, switched to Induction melting andadded in no bake moulding


added in no bake moulding.

• 1984 Name change to Penticton Foundry and moved to the currentlocation.

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L.L. Wilkins Machine Shop and Foundry

• First Foundry was• First Foundry wasowned and run byMr. Cliff Wilkins onWestminster avedowntownPenticton


• Foundry waslocated rightbehind thisbuilding

Mr. Wilkins

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--66, 2014 , 2014 LethbridgeLethbridge, Alberta, Canada, Alberta, Canada

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Original Location

• First location• First locationwas positionedclose to the railline

• Coking coalrailed in from St.Louis,droppedat the back door


Penticton in 1950’s• Rail line

going throughtown.

• Packinghouses on thewaterwater.Shipping vialake or Railline


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Peach City Foundry

• Municipal• Municipalcasting foundry.

• Green sand andCupola melting,all Grey Iron.Manhole coversand tree grates

• 5-7 employeesDIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 20146, 2014


Original Foundry in the 1970’s and in May 2014


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June 22, 1976 removal of the Cupola, May 2014


Cupola Melting Peach City Foundry

• Mr O’Neil• Mr. O Neiltapping out theCupola Furnace


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Peach City Foundry

• Green Sand• Green SandFloor Moulding

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6, 2014 6, 2014 Lethbridge, Alberta, CanadaLethbridge, Alberta, Canada

1976 Peach City Foundry

• 2 5 ton Induction• 2.5 ton Inductionmelting

• NobakeMoulding

• Municipalu c paCastings


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• Jim O’Neil had• Jim O Neil hadtaken over forhis father

• Written up in thepaper for thenew foundryexpansion



• Very first pour at• Very first pour atnew Peach Cityfacility.


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• Jim O‘Neill and• Jim O Neill andRusty Pettinger

• Early pour atPeach CityFoundry.


Current Location of Penticton Foundry

• 568 Dawson Ave• 568 Dawson AvePenticton BC

• Location since1984.


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Penticton Foundry568 Dawson Location 1950’s

568 Dawson Location May 2014


Penticton Foundry


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Penticton Foundry

• Canadian, Privately Owned, y

• 80 Full time employees

• Long time employer• Employees 10-15 years = 12

• Employees 15-20 years = 10

• Employees 20+ years = 12

• Pouring 50% Ductile and 50% HCWI


Penticton FoundryPattern Shop- Randy and Jim

Pattern Shop- Colin

DIS Annual Meeting, June 4DIS Annual Meeting, June 4--6 20146 2014LethbrigeLethbrige, Alberta, Canada , Alberta, Canada

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Penticton Foundry

• 3 5000 lb• 3- 5000 lbInductionfurnaces.

• Currently 55000lbs per day avg.


Penticton FoundryNew Core Room 2012-New Palmer mixer and Table

Old Core Room- - Palmer mixer


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Penticton Foundry

• Gaylord Core• Gaylord Coreblow mould.


Penticton Foundry

AMC- Mixer Wulf AMC Closing- Glen & Dale


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Penticton Foundry

1000 lb Jobbing MixerNew 1000 lb Jobbing Mixer 2013


Penticton FoundryPouring lines, floor jobbing moulding in back ground

Pouring Lines, breakout, Grinding in background


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Penticton Foundry

Heat Treat Oven 1 Heat Treat Oven 2


Penticton Foundry

• New Pattern• New PatternStorage Facility2014


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Penticton Foundry


Worked at all 3 Facilities

Jim O‘Neill Wulf Reinert


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Worked at all 3 Facilities

Rusty Pettinger


Penticton from up highApex ski hill in the background/Penticton down low

Penticton and Okanagan lake from up high


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Other Reasons People Live in Penticton

Brian Rock Climbing Skaha Bluff’s


Other Reason’s to live in Penticton

• Cycling


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Canadian Wines


Thank you to the following

Penticton Museum & Archives

Jim O‘Neill

Penticton Foundry


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• Chad Gentes568 D A• 568 Dawson Ave.

• 250 492 7043• 250 492 6933• [email protected]• www.pentictonfoundry.com


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FEATURES









•


DEPARTMENTS


INOCULATION METHODS PANEL

MIKE GALVIN – LADLE INOCULATION

MIKE GRADUATED FROM MONTANA TECH IN 1986 WITH HIS B.S. IN METALLURGICAL ENGINEERING. HE GREW UP IN PHILLIPSBURG, NJ. HE STARTED HIS CAREER WITH VICTAULIC IN EASTON, PA FROM 1988 TO 1998 AS A METALLURGIST THEN MOVED ON TO ALLIED MINERAL PRODUCTS IN FORT WASHINGTON, PA FROM 1998 TO 2000 IN REFRACTORY SALES. HIS NEXT STOP WAS WITH ELECTRO-NITE IN PHILADELPHIA, PA FROM 2000-2001 AS FOUNDRY PRODUCT MANAGER AND THEN BUCK COMPANY IN QUARRYVILLE, PA FROM 2002 TO PRESENT AS TECHNICAL DIRECTOR. MIKE WAS ON THE DIS BOARD OF DIRECTORS FROM 2005 – 2008, CHAIRMAN OF THE PROCESS SUBCOMMITTEE FROM 2009 TO 2011 AND IS CURRENTLY A VOTING MEMBER OF THE RESEARCH COMMITTEE. MIKE WAS THE AFS KEYSTONE CHAPTER CHAIRMAN FROM 2007-2008 AND THE AFS 2008 EAST COAST REGIONAL TECHNICAL CHAIR.

RILEY KERESTES – IN-BASIN INOCULATION

RILEY GRADUATED FROM THE UNIVERSITY OF ILLINOIS IN 2004 WITH A DEGREE IN MATERIALS SCIENCE ENGINEERING. RILEY STARTED HIS FOUNDRY CAREER WITH GREDE ST. CLOUD AS A METALLURGIST. RILEY IS CURRENTLY THE METALLURGIST FOR CATERPILLAR IN MAPLETON, IL. HE IS ALSO THE SECTRETARY FOR THE AFS 5P COMMITTEE AND IS A 6 SIGMA BLACK BELT. RILEY IS CURRENTLY ATTENDING THE UNIVERSITY OF ILLINOIS TO OBTAIN HIS MBA.



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JIM CSONKA – INOCULATION ALLOYS

JIM GRADUATED FROM CASE WESTERN RESERVE UNIVERSITY WITH A DEGREE IN METALLURGY AND MATERIAL SCIENCE ENGINEERING. HE HAS WORKED AS THE PLANT METALLURGIST AT EMI COMPANY AND WARD MANUFACTURING BEFORE TAKING A JOB WITH AMERICAN ALLOYS AS THEIR TECHNICAL SERVICE ENGINEER. IN 1993, JIM JOINED HICKMAN WILLIAMS & COMPANY AS A TECHNICAL SALES ENGINEER AND IS CURRENTLY LOCATED IN PITTSBURGH. JIM IS A MEMBER OF HICKMAN, WILLIAMS & COMPANIES TECHNICAL SUPPORT GROUP AND ALONG WITH CUSTOMER SERVICE; HE IS ALSO RESPONSIBLE FOR SOURCING THE MgFeSi, INOCULANTS AND CERAMIC FILTERS FOR THE COMPANY. JIM IS CURRENTLY THE CHAIRMAN OF THE DIS COLLEGE AND UNIVERSITY RELATIONS COMMITTEE AND AN ACTIVE MEMBER OF THE RESEARCH COMMITTEE. JIM WAS A MEMBER OF THE DIS BOARD OF DIRECTORS AND A PAST CHAIRMAN OF THE PROCESS SUB COMMITTEE OF THE DIS RESEARCH COMMITTEE.

JOSEPH KESKE – IN STREAM INOCULATION

JOE GRADUATED FROM MIGHIGAN TECH WITH HIS B.S. IN METALLURGY AND MATERIALS ENGINEERING IN 1997. IN 1999, HE WENT TO THE COLORADO SCHOOL OF MINES AND RECEIVED HIS M.S. IN METALLURGY AND MATERIALS ENGINEERING.

JOE STARTED HIS CAREER WITH BETHLEHEM STEEL CORPORATION IN SOUTHFIELD, MI AS AN APPLICATION ENGINEER IN THE STAMPING DEPARTMENT. HE THEN MOVED ON TO POWERLASERS CORPORATION IN PIONEER, OH IN SALES, AND AS APPLICATION

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ENGINEERING & PRODUCTION MANAGER FOR 5 YEARS. THE NEXT STOP WAS KS KOLBENSCHMIDT PISTONS IN MARINETTE, WI AS SENIOR METALLURGICAL ENGINEER AND FINELY TO HIS CURRENT POSITION AS PLANT METALLURGIST AT WAUPACA FOUNDRY IN MARINETTE, WI.

KYLE RABINE – WIRE INOCULATION

KYLE GRADUATED FROM SOUTH DAKOTA SCHOOL OF MINES AND TECHNOLOGY WITH A METALLURGICAL DEGREE. KYLE STARTED WITH BRILLION IRON WORKS AFTER HIS GRADUATION IN 2012. CURRENTLY KYLE IS A METALLURGIST WITH BRILLION IRON WORKS IN BRILLION, WI.

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Ladle Inoculation ofDuctile Iron

Mike GalvinBuck CompanyQuarryville, PA


Buck CompanyQuarryville, PA

• Non Ferrous Foundry• Non Ferrous Foundry

• Ferrous Foundry

• Heat Treat

• Pattern Shop CNC

• 220 000 ft²


• 220,000 ft²

• 345 employees

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Went from this …


… to this!


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Non Ferrous Foundry

• Aluminum• Aluminum

• Brass and Bronze

• 3 Automatic Molding Machines

• 7 Aluminum Resistance Furnaces

• 9 Coreless Induction Furnaces


• 9 Coreless Induction Furnaces

• T6 Heat Treat Capability

Ferrous Foundry

• Malleable Gray and Ductile Iron• Malleable, Gray and Ductile Iron

• 60-40-18, 65-45-12, 80-55-06100-70-03 & ADI

• 9 Automatic Molding Machines

• 2 C&D


• 2 C&D

• 2 Sand systems

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Melt

• 5 Coreless• 5 CorelessInductionFurnaces

• Each with 6 toncapacity

• 2400 lb tap &


• 2400 lb tap &charge

Melt

• 2700ºF tap temp• 2700 F tap temp

• 1000 lbs. steel, 1400 lbs. sprue

• Alloys and Carbon

• Tap, charge, melt, verify chemistry


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Melt

• 2700ºF tap temp• 2700 F tap temp

• 1000 lbs. steel, 1400 lbs. sprue

• Alloys and Carbon

• Tap, charge, melt, verify chemistry

• Melt Deck Theory of Spectroscopy


• Melt Deck Theory of Spectroscopy• The accuracy of a spectrometer is directly linked to whether

it is in spec or not in spec.

MgFeSi Treatment

• Covered Tundish• Covered Tundish

• 4.5% MgFeSi

• 50% FeSi

• Cover (spill iron)

• Trim FeSi


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MgFeSi Treatment

• Covered Tundish• Covered Tundish

• 4.5% MgFeSi

• 50% FeSi

• Cover (spill iron)

• Trim FeSi


• 2600ºF

• Slag & Wedgecheck

Ladle Inoculation

• Transfer iron from• Transfer iron fromBull ladle topouring ladle

• Add other alloysas needed

• Full pouring ladle


• Full pouring ladle

• Slag ladle

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Pouring

• Iron distributed to• Iron distributed toseveral pouringladles

• Automatic moldhandling

• Fade Timer


• Fade Timer

• Nodularity check

Ductile Iron

• 65-45-12• 65-45-12


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Alloy Additions

• 65-45-12• 65-45-12

• Copper - 80-55-06,100-70-03


Alloy Additions

• 65-45-12• 65-45-12

• Copper - 80-55-06,100-70-03

• Monel


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Ladle Inoculation

• 300 400 600 900• 300, 400, 600, 900,1500 lb pouringladles

• Scoops sized perladle

• 1 lb per 300 lb Fe


• 1 lb per 300 lb Fe

• 50% FeSi w/ Ba

• .5 x 10mm sizing

Ladle Inoculation Procedure

• Do not add FeSi tooDo not add FeSi tooearly

• Add to stream, notbull ladle

• Add evenly to stream

• Add grade alloys atth ti


the same time

• Fill ladle completely

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Pros and Cons


Pros - Versatility of Ladle Inoculation

• Start with 65 45 12• Start with 65-45-12

• Produce several grades at one time

• Add grade changing alloys easily

• Add Ba, Bi, La, RE … on a need basis

• Add 20 x 70 FeSi in the down sprue


• Add 20 x 70 FeSi in the down spruefor carbides

• A395

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Cons – how to combat them

• Cup size heaping• Cup size – heaping

• FeSi sizing

• Poor addition

• Slag build up in ladle

• Under filled pouring ladle


• Under filled pouring ladle

Ladle Inoculation Review

• Versatile – Start with a standard 654512 grade,Versatile Start with a standard 654512 grade,add alloys, add different types of FeSi


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• Simple addition that can be done manually





• Need a set procedure to do it correctly


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• Don’t over fill, under fill the cup or the ladle

• Don’t add FeSi too early, too late

• Don’t add FeSi too quick, too slow






• Don’t over fill, under fill the cup or the ladle

• Don’t add FeSi too early, too late

• Don’t add FeSi too quick, too slow

• Produces good Ductile Iron!


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Acknowledgements

• Dick McMinn

• Dave Sharkus

• Every Alloy guy I ever met


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In-Basin Inoculation Best Practices

Riley KerestesCaterpillar, Inc. Foundry

Mapleton, IL


• 600 employees

Caterpillar Mapleton Foundry

• 600 employees

• Produce engine components(Blocks, Heads, Liners, Flywheels)

• Pour Gray, Ductile, CG iron

• Molding with Green Sand Cold box


• Molding with Green Sand, Cold box, Air set, Furan

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In-Basin Inoculation Chemistry

• In-Mold Inoculants can be used for any type of iron

• Ductile Iron – High Al & Ca

• Grey Iron – High Ca and Mn (helps inoculant go intosolution due to lower pour temp)

CGI Low Al


• CGI – Low Al

• Specialty Additions – Bi, La & Ce for certainapplications and casting issues

In-Basin Inoculation Delivery Method

• Anchored into pouring basin or into drag mold sand

Can be placed loosely in sprue well• Can be placed loosely in sprue well

• Proper sizing can be calculated with charts available fromsuppliers

• Variety of sizes is important for initial iron poured and toprovide inoculation during the entire duration of casting


provide inoculation during the entire duration of castingpour time.

• Pouring basin capable of holding 20-30% of mold weight toencourage good stirring and mixing

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In-Mold Inoculation Advantages

• Uniform inoculation throughout the pour

• Addition rate is easily adjusted to varying pour weights and timesy j y g p g

• Inoculant goes into solution in the absence of an atmosphere

– Reduces Atmosphere generates oxides and potentially slag

• Latest stage inoculation – minimizing fade effect – use less inoculant

• Pouring more than one mold in ladle – inoculation effect varies though


Pouring more than one mold in ladle inoculation effect varies thoughout ladle with ladle inoculation

• Pouring Flexibility – floor molding or basins in different locations

• Higher nodule counts - very important for riserless ductile iron castings

In-Mold Inoculation Options

• Powdered in-mold – first iron inoculated very well – duration ofpour can be suspects – less expensive method

• Pressed Inserts – go into solution very quickly – more inoculationeffect in the beginning – dissipates much faster than the castinserts - can generate some slag (binder is needed)

• Cast Inserts – more consistent delivery through the pour – smalland large inserts needed to achieve uniform inoculation – more


and large inserts needed to achieve uniform inoculation moreexpensive

• 15g-50kg sizes available

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In-Mold Inoculation Best Practices

• Pour Time, Pour Weight, Pour Temp are critical variables to figure propersizing

• Typical pour temp 2450°F-2575°F – key for first inoculant in mold – toocold no reaction – too hot use up inoculant before pour is over

• Usually a 0.1% addition rate 8-25mm – Heavy section (50-200mm) 0.15%

• Do not want to over inoculate – the iron only has so much energy toabsorb the inoculant – additional concerns at lower temperatures


p

• Can greatly improve final microstructure if there is a long time betweenfurnace tap into ladle and actual pour into mold – long fade times

In-Mold Inoculation Best Practices

• Using this method filters are highly recommended – especially if added in the well or drag – pouring basin iron travels further for both mixing and avoiding any undissolved silicon

Smaller inserts are more important hen not sing a stopper rod plate or some dela• Smaller inserts are more important when not using a stopper rod, plate or some delay method – if you delay fill until basin is full then smaller inoculant tabs can be avoided

• Ideally inserts are placed on pattern and anchor and secure it into the sand (~1/3 in sand or 2/3 exposed to metal) or placed loosely into a chamber in the drag


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In-Basin Examples –C175 Engine Block & Liner

12,500 lbs.


50 lbs.

In-Basin Examples –3600 Engine Block


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Real Life Cost Savings–C175 Flywheels

• C175 Ductile Flywheel housings were the largest

scrap hitter for 2012 on Line 6 by dollars.

• A majority of this scrap (68%) was due to improper

microstructure and chemistry and failing to meet the

customer specified mechanical property

requirements.

• The goal of the project is to reduce the overall

i ti i th i t t d h i l t


variation in the microstructure and physical property

performance of these castings that is causing us to

reject the parts as scrap and reduce the scrap rate for

this defect to 0% without significantly increasing the

cost of the casting.

Real Life Cost Savings

Old Inoculation Process MapAdd 0 3% Ladle

•Improved Inoculation by adding in-basin inoculation to maximize latestage property enhancement and minimize inoculant fade

Add 0.3% Ladle inoculant at transfer

New Inoculation Process Map

Cost per Treatment = $14.13


Add 0.1% SO Coated ladle FeSi

at transfer

Add 0.1% Ca bearing ladle FeSi

at transfer

Add 0.1% In-Basin Inoculation

Cost per Treatment = $13.88

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Real Life Cost Savings•Quality Improvement – Castings are displaying improved physicalproperties and microstructure due to the late stage inoculation method and more versatile inoculation process. Fade time is irrelevant now.

NormalHistogram of 7687 Ultimate Strength, psi

NormalHistogram of 7687 Yield Strength, psi

NormalHistogram of 7687 Elongation, %

90000840007800072000660006000054000

0.00009

0.00008

0.00007

0.00006

0.00005

0.00004

0.00003

0.00002

0.00001

0.00000

Ultimate Strength, psi

Den

sity

60190

79655 4512 5673974 6966 198

Mean StDev N

NO

Method

Normal

540005100048000450004200039000

0.00025

0.00020

0.00015

0.00010

0.00005

0.00000

YieldStrength, psi

Den

sity

44960

48499 1833 5647105 2618 198

Mean StDev N

NO

Method

Normal

181614121086

0.35

0.30

0.25

0.20

0.15

0.10

0.05

0.00

Elongation %

Den

sity

5

12.85 1.206 5612.27 2.493 198

Mean StDev N

NO

Method

Normal


g , p YieldStrength, psi Elongation, %

Tensile Strength Yield Strength Elongation•Increased by 8%

•St Dev decreased 35%

•Increased by 3%


•Increased by 5%



LSLProcess Data Within

Process Capability of 7687 Yield Strength, psi - Old Method

LSLProcess Data Within

Process Capability of 7687 Yield Strength, psi - New Method

4000

1000

8000

5000

2000

9000

LSL 44960Target *USL *Sample Mean 47177.3Sample N 190StDev(Within) 2124.21StDev(Overall) 2605.78

Cp *CPL 0.35CPU *Cpk 0.35

Pp *PPL 0.28PPU *Ppk 0.28Cpm *

Overall Capability

Potential (Within) Capability

Overall

2000

0000

8000

6000

4000

LSL 44960Target *USL *Sample Mean 48241.4Sample N 63StDev(Within) 1296.1StDev(Overall) 1901.36



Overall Capability


Overall


540

510

480

450

420

390

PPM < LSL 157894.74PPM > USL *PPM Total 157894.74

Observed PerformancePPM < LSL 148278.67PPM > USL *PPM Total 148278.67

Exp. Within PerformancePPM < LSL 197403.27PPM > USL *PPM Total 197403.27

Exp. Overall Performance

520

500

480

460

440





Yield Strength CpK increased 2.4x!

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LSL

LSL 60190Process Data Within

Overall

Process Capability of 7687 Ultimate Strength, psi - Old Method

LSL

LSL 60190Process Data Within

Overall

Process Capability of 7687 Ultimate Strength, psi - New Method

9000

084

000

7800

072

000

6600

060

000

5400

0

Target *USL *Sample Mean 74102.2Sample N 190StDev(Within) 5606.21StDev(Overall) 6989.12



Overall Capability


Overall

8800

084

000

8000

076

000

7200

068

000

6400

060

000

Target *USL *Sample Mean 78909.1Sample N 63StDev(Within) 3021.11StDev(Overall) 4792.42



Overall Capability


Overall





Exp. Overall PerformancePPM < LSL 0.00PPM > USL *PPM Total 0.00




Tensile Strength CpK increased 2.5x!


• What did we achieve? – Continuous Process Improvements

• Process Robustness – The castings are now less susceptible tobeing scrap for Magnesium and ladle inoculant fade due to thebeing scrap for Magnesium and ladle inoculant fade due to thelate stage in-basin inoculant addition.

• Three castings have been poured with lower than desiredMagnesium levels of 0.030-0.035%. In the past this chemistry haslead to castings being scrap for failing to meet physical propertiesdue to poor microstructure.

• However these castings all met physical property andmicrostructure requirements and were useable castings using the


new inoculation method.

• We have achieved 0% Scrap since the new inoculation methodwas implemented in March 2013 (vs. ~3 per month previous)

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• What did we achieve? – Cost Reduction & Avoidance

• Quality Improvement – Our castings are more robust due to thelate stage inoculation This quality improvement was done withoutlate stage inoculation. This quality improvement was done withoutincreasing the inoculation costs by adding in late stage in-moldinoculation in addition to the ladle inoculation.

• Cost avoidance Internal – Reducing scrap to zero for this kind ofdefect represents an annual savings of $111,000 for the twoFlywheels. The more robust process makes this possible!

• Cost avoidance External – Reducing salvage repair work at themachine shop represents an additional annual savings of for the


two Flywheels.

• Total Project Annual Savings = $111,000

• Savings per Casting = $74.00 : Savings per pound=$0.05


• Riley Kerestes• Caterpillar, Mapleton Foundry• 309-633-8507• [email protected]


Thank you for your attention.

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Choosing an Inoculant, what options to consider.

Jim CsonkaHickman, Williams & Company


Where do Inoculants come from?

• Are they mined in the desert or some• Are they mined in the desert or somemountainous region?

• Do they come from the bottom of theocean?

• Produced in a Submerged Arc


oduced a Sub e ged cFurnace, what is that?

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Ferrosilicon Ingredients


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Furnace layout, typical FeSi plant.


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5 ton ladles used to pour into 8 foot pig molds.


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Cooling of 4 inch thick, 8 foot diameter molds.


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Taken to Crushing and Screening system.


How do you pick an inoculant that is right for you?

• Is the silicon in the inoculant the key• Is the silicon in the inoculant the keyfactor?

• Does the silicon percentage play arole?

• Endothermic vs. Exothermic?dot e c s ot e c

• Melting Temperature vs. Dissolutionrate?


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Melting points, Thermal values.

• Si level Liquidis Thermal effectqTemperature (1#/ton steel 2,902F)

• 75% FeSi 2,430 F + 0.4 F

• 65% FeSi 2,320 F - 0.1 F

• 49% FeSi 2,240 F - 0.8 F

• 15% FeSi 2,280 F - 1.6 F

• Ferroalloys & Alloying Additives Handbook, P.D. Deeley, 1981, page 121,


Dissolution study based upon Silicon percentage.

• 1983 study by C. Dremann of Foote Mineral.y y

• Part of a study to improve In-Mold MgFeSi.

• Alloys were sized to 10 x 30 mesh.

• 110 cm3 of alloy varying in Si % was added to a chamber.

• 23 to 25 second pour time at 2550 +/- 10 F.

• Filmed using quartz glass window as side of chamber.

• Used a point grid to determine volume percentagedissolved.

• Calculated dissolution rate by counting frames of Super 8film at 2.36 frames per cm and 18 frames per second.

• Wide angle lens recorded pouring and clock.

• AFS Transactions, 83-108, pages 263 to 268


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Dissolution study based upon Silicon percentage.

• Silicon Grams Pour Volume % Dissolution• percent time dissolved time rate

• 36 315 24 2% 0.1 cm3/s

• 46.9 277 25 23 1.0

• 59.9 201 23 78 2.6

• 75.6 169 23 100 21.3 5.4

• 88.3 135 23 100 14.6 7.3

• 99.1 138 23 28 1.3

• Alloys had 0.3% Ca, 0.7% Al unless noted below.

• 36% Si alloy had 13.4% TRE.

• 59.9% Si alloy had 3.4% Ca, 4% Ba, 12% Mn.

• 75.6% Si alloy had 1% Ca, 1.5% Al.

• 99.1% Si alloy had 0.1% Ca, 0.2% Al.


What role do Ca, Al, Ba, Sr, TRE etc. play?

• Does FeSi inoculate or just bring the• Does FeSi inoculate, or just bring theinoculating elements to the party?

• Widely believed that at the center of anodule is an oxide or sulfide particle.

• Not all oxide or sulfide particles are thesamesame.

• Oxide or sulfide particles form at varyingrates, and stay suspended for differentlengths of time.


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What role do Ca, Al, Ba, Sr, TRE etc. play?

• Gibbs Free Energy of Formation• Gibbs Free Energy of Formation.

• Ellingham Diagrams.

• More negative the number the• More negative the number, thegreater chance of formation.



The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson, 1979 AFS Casting Congress

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The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson, 1979 AFS Casting Congress

Free Energy of Formation

• Oxides • Sulfides• Oxides• Al2O3 -730

• BaO -737

• CaO -903

• CeO2 -693

• Sulfides• CaS -723

• CeS -815

• MgS -389

• Ellingham Diagram Web Tool, San Jose State University

• Values in kJ/mole at 1800K• = 1527 C = 2780 F

• K = C + 273.16


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Oxide or Sulfide Density

• Oxides or Sulfides with higher• Oxides or Sulfides with higherdensities, in theory, will stay insolution longer thus will be availablefor nucleation.

• Reduce inoculant fade.

• Extend inoculant life.


Sulfide Densities

• Aluminum Al2S3 2.02Aluminum Al2S3 2.02

• Barium BaS 4.25

• Calcium CaS 2.18

• Cerium Ce2O2S 6.00

• Cerium Ce2S3 5.19

• Lanthanum La2O2S 5.872 2

• Lanthanum La2S3 4.99

• Magnesium MgS 2.85

• Strontium SrS 3.20• The Control of Particles and other Precipitates Formed in Cast Iron and their Effects on Structure, W.G. Wilson.


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Inoculating Potential

• Look at each inoculant by the potential of• Look at each inoculant by the potential ofcreating oxides or sulfides per pound ofmaterial.

• Add up the percent of each oxide orsulfide former per individual inoculant.

• Take into account the FeSi percentage• Take into account, the FeSi percentagemay change the amount of oxides/sulfidesavailable.


Inoculating Potential

• Examples, considering a constant % FeSi.Examples, considering a constant % FeSi.

• FeSi with 1% Ca, 0.7% Al = 1.7%

• FeSi with 1% Ca, 0.7% Al, 2% Ba (or TRE) = 3.7%

• FeSi with 1% Ca, 3.5% Al = 4.5%FeSi with 1% Ca, 3.5% Al 4.5%

• FeSi with 1.25% Ca, 0.925% Al, 4% Zr = 6.17%


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Inoculant Choices

• Many things to consider:• Many things to consider:

• Silicon percentage of inoculant.

• Oxide/Sulfide formation potentials.

• Oxide/Sulfide densities.

• Potential based upon percentage of• Potential based upon percentage ofnucleating elements.


Thank you!

• Jim Csonka• Jim Csonka

• Hickman, Williams & Company

• [email protected]

• Mobile: 216 233 3143• Mobile: 216-233-3143

• Office: 724-772-3334


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Evolution of In-Stream Inoculation Practice

Joseph S. KeskeWaupaca Foundry – Plant 4


Overview

• Cause & Effect (6M approach)

• Method

• Machine(s)

• Measurement

• Material – General Comments


• Pros and Cons

• Conclusions

174

Cause & Effect

ManMaterial

Mother

In-Stream Inoculation

Man

M hi M

Mother Nature


Machine

Method

Measurement

Method• Minimize Impact of Operator – Only

metallurgists can make changesg g

• Centralized location for raw material– services all molding machines

• Low-level sensors

• Integrate equipment


• Treat every job as safety critical andstop pouring when operatingparameters are not within range

175

Cause & Effect

ManMaterial

Mother

In-Stream Inoculation

Man

M hi M

Mother Nature


Machine

Method

Measurement

Machine(s) & Integration• Vertical Molding Machine (VMM) &

mold mapping

• Pressure Pour Furnace

• Hot-Metal Carrier

• Inoculant Feeder


Feeder must run under any circumstance where iron could be

released into molds

176

Machine (Feeder)

• KISS Philosophy (Keep It Simple…)

• Motor, Auger, Air Pressure

• Feed Rate set by Motor RPM (voltage)

• Inoculant is hopper-fed into augerchamber


• Inoculant exits auger and is blownthrough a pipe, directed at iron stream

Measurement• Condition of tube and position of

inoculant stream must be monitoredinoculant stream must be monitored

• Inoculant needs to be added ininverse proportion to section sizes

• Chill/carbide-prone parts requirehigher additions – insurance!


Complete integration to VMM allowsfeeder to operate at settings dictated

by part number

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Measurement – Stopping Pouring

• Low inoculant situations must beid tifi d ith bl i blidentified with measurable variables.

• Motor Voltage (low V = low RPM)

• Incoming Pressure (low P = low inoc.)

• Back Pressure (low P/high P)Pi Mi i i l t t fl i


– Pipe Missing, inoculant not flowing

– Pipe blockage

VMM MUST STOP POURING!

Measurement – Testing Controls

• Conditions that trigger the VMM toConditions that trigger the VMM tostop pouring must be tested

• During scheduled down time, thesystem integration is checked byintentionally creating feeding


scenarios that should trigger alarms

• Feed rate to motor voltage calibration

178

Method• Time Stamp and Store Data

• Identification of Suspect Product ispparamount to success

• Every piece of data pertaining topressures and motor rpms is in adatabase.


• Every time a delivery tube isreplaced, the metallurgist is notifiedand tube alignment verified

Material• Waupaca Foundry has not changed

inoculant material since about 1998

• Inoculant has performed consistently– Bi/Ba and RE blend

• Other materials have been tested

• Current methodology makes trials of


new inoculants almost impossible

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Pros/Cons• System integration

is complex andproblems can be

• Highly automated

• Feed rates done byproblems can betough to diagnose

• New material trialsare almostimpossible andpose risk (entire

part number!

• PLCs and alarmsprovide protection

• Resulting iron isconsistent, few


pose risk (entireplant would runtrial)

• No visual - YET

issues withnodularity oreutectic carbides

Method

• Even with all of the alarms,l i id f i l tconclusive evidence of inoculant

hitting the iron stream, 100% of thetime, does not exist

• Waupaca Foundry’s most recentinoculant project is looking at the


inoculant project is looking at thevarious camera technologies to beadded to our list of checks.

180

Summary – Success at Waupaca• Take a 6M approach

• Focus on Methodology &Focus on Methodology &Measurement

• Machine integration so pouring stopsautomatically

• Store data - tracking suspect product


is simplified


J K k• Joe Keske• 805 Ogden St. Marinette, WI 54143• 715-735-4986• [email protected]• waupacafoundry.com


181

Wire Inoculation

Kyle Rabine


Brillion Iron Works

Brillion Iron Works

• Foundry operations since 1900

• Complex, highly-cored ductile andgray iron foundrygray iron foundry

• In-house pattern shop

• Complex core assembly in-house


Brillion Iron Works

• 2 plants– Peters and Gabler

• Induction melting• Induction melting

• Wire Mg treatment

• TS16949 & QS9001 Certified

• ISO-14001 Certified


Brillion Iron Works

Gabler

Peters

Direct HWY 10 AccessCustomer Warehouse

Office

Brillion Campus=138acres/ 56 Hectares


Larsen

Types of Inoculation

• Ladle inoculation

• Wire inoculation

• In mold inoculation• In-mold inoculation

• In-stream inoculation


What is Wire Inoculation?

• Cored steel wire containing apowdered inoculant– Same concept as Mg wire treatmentSame concept as Mg wire treatment

• Can use any kind of inoculant in thecored wire


183

Wire Inoculation Items

Wire feeder Cored wire coil


Wire Inoculation Uses

• In treatment ladle

• In pouring ladle



• In pouring launders



• In mold


Wire Inoculation Pros

• Inoculant goes into solution underthe surface

• Less chance for inoculant to dissolveLess chance for inoculant to dissolvein an atmosphere

• Able to add any inoculant to wire


Wire Inoculation Pros Cont.

• Adapts well to automation

• Reduces need to transfer ladles toinoculate ironinoculate iron– Treating, alloying, inoculating all-in-one

ladle


184

Wire Inoculation Cons

• Cost of equipment– Wire feeder machines

• Maintaining machineg

• Calibration

• Extra cost to add inoculant in wire– Have to pay for the wire sheath


Questions?



• Kyle Rabine• 200 Park Ave, Brillion, WI 54110• 920-756-6439• [email protected]


• www.brillionironworks.com

185

FEATURES









•


DEPARTMENTS


NEWS BRIEF

News Release 24 June 2014

Global molybdenum production and use at new high

Global production of molybdenum in 2013 reached a new high of 539.2 million lbs, up from the previous year’s record of 535.2 million lbs. Full year figures from the International Molybdenum Association (IMOA) also show global molybdenum use at 537.7 million lbs, breaking the previous year’s record high of 522.5 million lbs.

The greatest usage of molybdenum in 2013 was in China, where use increased from 188.4 million lbs in 2012 to 196.2 million lbs in 2013. Europe recorded the second biggest share with 140.4 million lbs, up from 135.9 million lbs in 2012. Japan and USA were the third and fourth largest users of molybdenum by region, recording 57.4 and 56.1million lbs respectively. Usage in the CIS was 23 million lbs, with other countries together totalling 64.6 million lbs.

China was also the biggest molybdenum producing area in 2013, although output fell slightly to 194.9 million lbs, compared to the previous year’s record high of 207 million lbs. Production in North America rose from 176.5 million lbs in 2012 to 180.5 million lbs in 2013. South America was the third largest producing region, accounting for 128 million lbs in 2013, up from 118.7 in 2012. Production in other countries increased slightly from 33 to 35.7 million lbs in 2013.



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New figures for the fourth quarter of 2013, also released, saw total molybdenum production rise from 134.9 million lbs in Q3 to 141.4 in Q4. China’s molybdenum production increased slightly from 49.7 in the third quarter of 2013 to 51.2 million lbs in Q4. North American production fell slightly, from 44.5 million lbs in Q3 to 43.2 in Q4. Production in South America increased from 31.7 million lbs in Q3 to 38.1 in Q4.

Global usage increased from 137.5 million lbs in Q3 to 138.2 in Q4. Usage in China decreased slightly from 52.9 million lbs in Q3 to 51.6 in Q4. Usage in Europe increased 34 million lbs in Q3 to 35.1 in Q4. Japan and USA used 14.4 and 14.2 million lbs respectively in Q4.

Tim Outteridge, IMOA’s Secretary-General, commented: “These figures indicate that molybdenum use remained buoyant throughout 2013, with production keeping pace or slightly exceeding demand. Figures for both production and use reached new highs once again in 2013.”

For more information contact:

Alan Hughes T: +44 (0)1606 852011 M: +44 (0)7759 243969 E: [email protected]


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NEWS BRIEFS

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NEWS BRIEF

For more information, contact: Charlotte Zang 410-810-8862

[email protected] For immediate release …

Michigan Manufacturing International (MMI) Completes New Plant in Hosur, India

MMI adds Worldwide Quality Control Manager in India and Supply Mgr in China.

Stevensville, Md., June 17, 2014 - Jacob Prak, CEO of Michigan Manufacturing International (MMI) recently returned from Hosur, India where the new MMI plant has been completed. This stop was part of Prak’s annual visit to MMI locations in Mumbai, Coimbatore, and Bangalore, India, and Shanghai, Fuyang, Ningbo, Jinan, Shenzhen, Dongguan, and Hong Kong, China.

The MMI Hosur facility is primarily an assembly plant that receives its inputs from a highly qualified local supply base. “We estimate that approximately 65% of our sales in India come from the Hosur location, making this plant very important for us. It is vital to our ability to offer the best and most cost-effective supply options to our customers,” Prak said.

Prak estimates that MMI purchases 10% of the company’s total volume from South Korea, 10% from the Pearl River delta region in China, 50% from the Yangtze delta region in China and 30% from India.

http://www.michmfg.com/

http://www.michmfg.com/

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During the trip to Asia, MMI filled two key positions. Prabhu Rajendran was chosen as the new Worldwide Quality Control Manager. His primary focus will be implementing and managing quality assurance processes. Jarbo Lu was named as the new Supply Manager for Shandong province in China.

“These new MMI team members will be instrumental in ensuring that MMI products meet the highest quality control standards,” Prak said. “I am very pleased to have them join our growing company.”

Founded in 1991, Michigan Manufacturing International (MMI) specializes in supplying manufactured to print assemblies and components to original equipment manufacturers (OEM). Products include assemblies, castings, stampings, machined parts, gears, bearings and more. Services include product engineering, manufacturing, inventory management and stocking programs — all designed to streamline client operations and increase profitability. MMI designs the most effective, highest quality solutions from anywhere in the world.

For more information about MMI, visit www.michmfg.com or call 800-677-0504.

http://www.michmfg.com/capabilities/assemblies/

http://www.michmfg.com/prod-services/shaping/

http://www.michmfg.com/prod-services/shaping/

http://www.michmfg.com/capabilities/engineering/

http://www.michmfg.com/capabilities/manufacturing/

http://www.michmfg.com/prod-services/stocking-2/

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NEWS BRIEFS 1695 N. Penny Lane, Schaumburg, Illinois 60173

FOR IMMEDIATE RELEASE

Contact: Shannon Wetzel, [email protected]

June 2, 2014 847/824-0181 ext. 266

AFS Issues Call for Papers for 119th Metalcasting Congress

Schaumburg, Ill. The American Foundry Society (AFS) has issued a call for papers for its 119th Metalcasting Congress to be held April 21-23, 2015, at the Greater Columbus Convention Center, Columbus, Ohio.

AFS is seeking papers covering all issues relating to metalcasting, diecasting and foundry management and operations, including unique in-plant procedures, new technologies, equipment, products and other innovations that have contributed to enhanced metalcasting productivity and quality.

Technical paper abstracts are due Aug. 15 and complete papers are due Sept. 15. Paper number assignment, offer and abstract form and authors guide will be available July 1, 2014 on the Metalcasting Congress website (www.metalcastingcongress.org).

For more information, contact Pam Lassila, Metalcasting Congress administrative assistant, at 800/537-4237 Ext. 240 or [email protected] or visit www.metalcastingcongress.org.

Headquartered in Schaumburg, Ill., AFS is a not-for-profit technical and management society that has existed since 1896 to provide and promote knowledge and services that strengthen the metalcasting industry for the ultimate benefit of its customers and society.


http://www.metalcastingcongress.org/


http://www.metalcastingcongress.org/

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NEWS BRIEFS

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NEWS BRIEFS Family-Owned Bremen Castings Welcomes

Fifth Generation to Company Bremen Castings Has a Lot to Celebrate in Its 75th Year

Not only did Indiana-based Bremen Castings just celebrate its 75th milestone, the family owned and operated machine shop and foundry is welcoming another one of its own to the team. Jordan Brown, a 5th generation member of the Brown family, will join Bremen Castings as Inside Sales Manager.

Daughter of President James (JB) Brown and granddaughter of Chairman and CEO James E. Brown, Jordan graduated from Indiana University Bloomington with a Bachelors degree in Management and a Minor in Business and Human Resources. Jordan interned at BCI the past three summers, working in various roles within BCI and BCI Defense to learn about all aspects of the business.

“Bremen Castings is a family business and Jordan needs to learn how it operates from the ground up. My grandfather, James L. Brown, my father, and I, all started this way,” adds JB Brown. “We are excited to see Jordan grow and bring her ideas into BCI. The metal casting industry has been male dominated for years and its time for a change; we look forward to seeing this within BCI and the foundry industry as a whole in the years to come.”

Please contact me if you would like to speak with James (JB) Brown about Bremen Castings Inc.

Carolyn Blackman | Vice President Empower Public Relations 625 N. Michigan Avenue- Suite 2500 Chicago, IL 60611 O: 312.854.8830 C: 312.375.4106 [email protected] www.empowerpr.com


http://www.empowerpr.com/

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NEWS BRIEFS Aarrowcast Wins AFS/Metalcasting Design &

Purchasing Casting Competition Schaumburg, Ill. Aarrowcast Inc., Shawano, Wis., has won the 2014 American Foundry Society (AFS)/Metal Casting Design & Purchasing Magazine Casting of the Year award for its ductile iron oil pan produced for a John Deere 9-liter engine. The 842-lb. casting is the result of collaborative effort between supplier and customer to achieve weight reduction while meeting the application’s strength requirements.

The agriculture component combined a frame casting, two fabricated brackets and a stamped steel oil pan. Through a combination of finite element analysis and solidification simulation, the design team achieved a 77-lb. weight reduction while still accommodating a 60-horsepower increase in the engine. Because of the compact design of the oil pan casting, the package allowed for a lower engine position in the tractor chassis and eliminated a 2-degree angle. The volume of oil accommodated by the oil pan was increased over the original steel stamping.

Aarrowcast used 11 interlocking cores to establish dimensional repeatability and designed a gating strategy that provided low velocity and turbulence during feeding of molten metal into the casting to achieve quality requirements.

The casting illustrates an increased use of castings that are structural and functional into one piece,” said one of the casting competition judges. “It combines parts from several processes into one casting with complex coring.”

The AFS/Metal Casting Design & Purchasing Magazine Casting Competition is held every year to give North American metalcasting facilities the chance to show the engineering and purchasing community what a cast metal part can accomplish.

Aarrowcast was recognized for its winning casting during the President’s Brunch April 10 at the 118th AFS Metalcasting Congress in Schaumburg, Ill.

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Six other castings were honored as Best in Class or Honorable Mention winners.

Best in Class:

• Aristo-Cast Inc., Almont, Mich., for a magnesium investment castelectronics mount for the aerospace industry.

• Pier Foundry & Pattern Shop, St. Paul, Minn., for a ductile iron greensand cast hub used in the mining industry.

• Signicast Investment Castings, Hartford, Wis., for a steel investmentcast knife blade holder for a thresher used in farming.

• Tooling & Equipment International, Livonia, Mich., for an aluminumwater passage cast via low pressure permanent mold casting thatintegrates cooling system parts for an automotive application.

Honorable Mention:

• O’Fallon Casting, O’Fallon, Mo., for a aluminum fan housing used on acommercial helicopter.

• Meritor Design, Troy, Michigan, for a ductile iron green sand castsubframe used in a military application.

The American Foundry Society is a not-for-profit organization formed in 1896. With its headquarters in Schaumburg, Ill., AFS provides members and consumers with information and services to promote and strengthen the metalcasting industry.

Shannon Wetzel MODERN CASTING Metal Casting Design and Purchasing

800/537-4237 ext. 266 [email protected]

www.moderncasting.com www.metalcastingdesign.com


http://www.moderncasting.com/

http://www.metalcastingdesign.com/

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2014 issue 2 - home - ductile iron society · virtual tour of penticton foundry – chad gentes •...

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