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Plasma Casting treatment (PTC) Plasma Casting treatment (PTC) for Ductile Ironfor Ductile Iron

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Applying the Plasma Treatment Casting (PTC) process for Ductile Iron Sand Casting

Cast with PTC process:Total cast weight – 4.2 kg Net product weight – 3.4 kg Riser’s weight – 0.8 kg

Reduced riser without PTC:Total cast weight – 4.2 kgNet product weight – 3.4 kgRiser’s weight – 0.8 kg

Normal Casting:Total cast weight - 5.6 kgNet product weight - 3.4 kg Riser’s weight - 2.2 kg riser

The PTC process saves 80-90% of

the risers’ mass

The Camshaft Bearing Houses

shown in this presentation were

cast on DisaMatic line for ductile

iron sand casting, with and

without the PTC process

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Plasma Treatment Casting (PTC) process for Ductile Iron Sand Casting

•The PTC is patented technology worldwide.

• The PTC is a flexible add-on device for existing casting lines.

• The PTC does not change the end product.

• The PTC reduces risers’ mass by 80-90%

• The PTC refines the microstructure

• The PTC increases the ratio of product/casting weight

from about 50% yield to over 80%

• The PTC reduces defects and improves surface roughness

• The PTC reduces the feeding system weight

(In some cases also the internal risers)

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The PTC process applies plasma arc during solidification process.

The rotating plasma arc movesalong a prescribed path, defined bya special electrode.

The PTC process stir the molten in the sand mold during solidification, by replacing the risers’ mass with kinetic electric and magnetic stirring forces

The principle of the PTC Process

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Saving of 1.4 kg of the riser’s weight and 0.6 kg of the feeder in casting 3.4 kg product

Reducing risers’ weight from 2.2 kg 0.8 kg

Normal casting:Total casting weight – 6.8 kgNet product weight – 3.4 kgPouring feeder weight – 1.2 kg Riser’s weight – 2.2 kg

Casting with PTC process: Total casting – 4.8 kgNet product weight – 3.4 kgPouring feeder weight – 0.6 kg Riser’s weight – 0.8 kg

With an accurate pouring system, the PTC can save even 95% of the risers mass

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The PTC Reduces casting weight from 6.8 kg to 4.8 kg with better quality of the Camshaft Bearing House

Low risers without PTC Low risers with PTC

This product is most sensitive to shrinkage and porosity. Casting low risers without PTC process will result in lot of shrinkage under the riser and on the product’s sides

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The PTC process reduces total casting weight from 6.8 kg to 4.8 kg and improves quality of the Camshaft

Bearing House

Low risers without PTC Low risers with PTC

This product is sensitive to shrinkage and porosity. Casting low risers without PTC will result in lot of shrinkage under the riser and on the product’s sides.

With an accurate pouring system, the PTC can save even 95% of the risers mass

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Low risers without PTC Low risers with PTC process

This product is very sensitive to shrinkage and porosity. Casting low risers without PTC will result in lot of shrinkage under the riser and on the product’s sides

X-ray pictures position

X-ray photos taken of castings with and without PTC process

X - Ray

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Microstructure

•All specimens were taken from the upper middle part of each casting

•The chemical composition of the specimens were as follows :

C Si Mn P S Cr Cu V Mg Ti Al

Alloy A 3.88 3.002 0.324 0.011 0.004 0.045 0.19 0.005 0.051 0.006 0.011

Alloy B 3.35 2.588 0.338 0.013 0.004 0.041 0.1 0.004 0.044 0.006 0.013

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Alloy A

Alloy A - Normal casting Alloy A - PTC

100μm 100μm

50μm 50μm

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Alloy B

Alloy B - Normal casting Alloy B – PTC

100μm 100μm

50μm 50μm

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PTC’s Competitive Advantages in Ductile Iron sand - casting of automotive parts

• Production cost reduction by 20%-25%• Riser's mass reduction by 80% -90% and thus casting weight reduction by 35% • Sand mass core reduction by 40%• Foundry yield increase from 50% to over 80%• Melting and holding furnaces efficiency increase by 50%• Foundry sand reclamation reduction by 30%-40%• Environmental emission reduction by 35% • Metal feeding improvement• Shrinkage and porosity elimination • Mechanical properties improvement • Microstructure refinement