CASTING TECHNOLOGY March-June 2011 Issue
A Complete Global Publication on Ferrous and Non-Ferrous Foundries
Sand-Casting: An Overview
Effective usage of innovative technology will prove profitable for foundry industry
The Indian Metal casting (Foundry Industry) is well recognized in the
global market. The various kinds of castings that are produced are
ferrous, non-ferrous, Aluminium Alloy, graded cast iron, ductile iron,
Steel etc. The foundry industry is the key feeder to all engineering
sectors including auto, railways, power, textile machinery, sanitary
castings, earthmoving machinery and many more.
Sand Casting-An Overview
Sand casting is comparatively less expensive while standing
as a sufficient refractory even for the usage of steel foundry.
An appropriate bonding agent (generally clay) is mixed or
occurs with the sand. The mixture is then moistened with
water to develop potency and plasticity of the clay while making
the aggregate suitable for molding. More than 70% of
all metal castings are produced by sand casting
ATI completes acquisition of Ladish Co.
Based in Pittsburgh, PA, Allegheny Technologies
Incorporated (ATI) has completed the acquisition of Ladish
Co. Inc., Cudahy, Wis., owner of investment casting industry
leader Pacific Cast Technologies (PCT), Albany, Ore.
ARI to resume operations at Ohio Castings
Directors at American Railcar Industries Inc. (ARI) have
approved plans to resume their Ohio Castings operation in
Martinrea International signs agreement for Metalcaster Honsel
Martinrea International Inc., a leader in the production
of high quality metal parts, assemblies and modules and fluid
systems focused primarily on the automotive sector, has
signed a purchase and transfer agreement for all of the assets
of Honsel AG, a German-based leading supplier of aluminium
components for the automotive and industrial sectors.
Bradken increases capital to fund Chinese, Domestic growthBradken Ltd., Newcastle, Australia, has decided to
increase $100 million to establish a metalcasting facility in
Xuzhou, China, and fund two U.S. foundry expansions
announced earlier this year.
IBC Advanced Alloys inks exclusive
IBC Advanced Alloys Corp. has inked an exclusive
supply contract to provide investment-cast engineered
components to a global leader in the design and manufacture
of high-technology assembly equipment.
Grede acquires two Mexican
Grede Holdings LLC has acquired two Grupo Proeza
foundries in Mexico. The cost of the acquisition was
undisclosed. Both the NovoCast and Teknik foundries are
located near Monterrey, Mexico.
General Aluminium plans to idle
General Aluminium Manufacturing Co., a unit of
Cleveland-based Park-Ohio Industries, is planning to idle the
Rome, GA, diecasting plant, which it acquired from the former
Rome Die Casting in October 2010.
Modification of a Cast Al-Si-Cu Alloy by Heat
Treatment in the Semisolid State and Evaluation of
Its Wear Characteristics
Heat treatment of an as-cast Al-10Si-3.2Cu alloy in the semisolid state at 600°C resulted in rounding off of the a-Al grains and
spheroidisation of the eutectic silicon particles. A sample with the modified microstructure suffered more wear than an ascast
sample under moderate loads in pin-on-disc sliding wear test. A steady state of wear was attained when the wearing
surface was work-hardened. At this stage, the coefficient of friction also dropped sharply in case of both the as-cast and
semisolid heat-treated samples. SEM-EDS studies indicated that wear proceeds by oxidation and delamination of the workhardened
surface. Iron ( 0.5%) present in the alloy as an impurity diffused into the oxide scale during the wear test denuding
the work-hardened subsurface of its iron content.
Refractories industry in India-present scenario,
issues and way forward
The Indian refractory industry has witnessed sustained
growth in the past few years buoyed by the growth in the iron
& steel, cement and non-ferrous industries. Refractories play
an extremely important role in the development of the core
sector, a fact which mostly remains unnoticed. Although,
turnover-wise it is miniscule compared to the GDP of the
country, it is critical to the production process and as well as
quality. The industry, which is now at the advanced stage of
growth has the capability to address the increased challenges
posed by the user industries like stringent operating parameters,
demand for clean steel etc.
Role of nanometric titania on the properties of
Nanometric titania is synthesized through inorganic sol-gel route followed by ultrasonification. Addition of this nano titania
in low cement spinel castable refractories improves the bulk density, compressive strength and spalling resistance due to
formation of consolidated flexible matrix of castables at high temperature. In the present investigation, white tabular alumina
aggregate, dead burnt magnesia, calcium aluminate cement bond material, microfine alumina, microsilica and nanometric
titania are utilized in the formulation of the castable batch. The important properties like bulk density, apparent porosity,
linear change, cold crushing strength before and after thermal spalling of castables are investigated. Atomic force microscopy
is used to characterize nanometric titania. Phases formed in the castables are identified by X-ray diffraction studies. SEM
analysis has been done to understand the microstructure of the castables.
Simulation of a Rectangular Object with Shrinkage Defect
Gating system design is one of the most important factors that ensure the quality of casting by controlling the mould filling pattern. In this study, the effect of gating design including gate geometry and importance of riser was incestigated by pouring ductile iron into a sand mould. The direct observation method was used with and without riser and various stage of stimulation is recorded by a computer system and compared with each other.
Making Casing History
Top-quality jumbo slabs are essential for high-grade
pipe and plate steels. Siemens VAI is the first anywhere, to cast
ultra-thick slabs of 400 mm on a straight mold machine with
the proven concept of bending and unbending during the liquid
state while keeping the strand temperature above the critical
ductility trough. The machine with its straight mold has an
extremely long metallurgical length of 45 m. The 11 m bow
radius is an essential aspect of the machine’s design and
contributes to product quality. The single-strand machine is
designed for a yearly capacity of 1.1 million tonnes.
GIFA, METEC, THERMPROCESS, NEWCAST - A
global leading trade fairs point the way forward
After 4 years of long waiting, finally the world’s biggest
trade fairs have punched the clock! Arrangements for the
four international technology trade fairs GIFA, METEC,
THERMPROCESS and NEWCAST are now in high gear.
Visitors and exhibitors from around the world are much
excited to flock to these trade fairs in Düsseldorf.