CASTING TECHNOLOGY May - August 2010 Issue
A Complete Global Publication on Ferrous and Non-Ferrous Foundries
Effects of Core Materials on Solidification Time and Pattern in Steel Castings
Frederick A. “Fritz” Henderson joins Sunoco to lead SunCoke Energy
Sunoco, Inc. has announced that Frederick A. “Fritz” Henderson has joined the company
as a senior vice president to help prepare for the previously announced separation
of SunCoke Energy from Sunoco.
Indian aluminium manufacturer oppose spot pricing of alumina
India’s aluminium manufacturers are against the proposal to shift to spot pricing
for alumina due to slow Chinese demand and sharp price fluctuations. They prefer
the present method of price discovery through long-term contracts.
Copper and Copper Alloys - Newer Materials and Processes†
Copper and copper alloys are versatile in their application and are economical for
the manufacture of engineering components. There is a copper alloy for mundane applications
like plumbing and also for sophisticated electronics uses and a suitable method
for making them.
The review highlights some details of newer materials, their applications and innovative
processes which enhance strength, quality and saleable yields. New materials include
high conductivity Cu-Fe-P-Zr, Copper MMC, Cu-Mg-Fe etc.; spinodal alloys, heat-treated
aluminium bronzes, high strength manganese bronzes and lead-free bronzes.
India's foundry industry holds opportunities & new challenges
India's foundry industry is now the fourth largest in the world and booming at a
rapid pace in shaping the country's economy. India has improved its casting production
by more than 100 percent since the year 2002. No other nation has achieved that
growth during that period.
Monolithic Refractories in Casting House of Blast Furnace
Trough system of a blast furnace (BF), consisting of main trough, iron runner, slag
runner, skimmer and tilting runner, serves the function of providing channels for
the hot metal and slag flowing out of the BF to the transporter. They are among
the most important facilities of iron-making as their durability affects production
circulation. As pointed out in Fig. 1, large capacity and long campaign life have
been the trend of modern blast furnace. Higher blast temperature, higher tapping
temperature and higher utilization factor have imposed much tougher working conditions
on BF troughs and runners, principally because of higher temperature of hot metal
and larger flow, which sets more stringent requirements on refractories not only
in performance but also in installation.
Effect of Core Materials on Solidification Time and Pattern in Steel Castings†
Castings are often required to have holes and recesses of various sizes and shapes.
These impressions in castings can be obtained by using cores. In the present work,
a numerical study of heat transfer during the solidification of steel casting with
core has been presented. A conjugate conduction based finite element heat transfer
analysis of metal, mould and core with interfacial air gap has been performed. The
heat transfer through the air gap has been modelled using the coincident node technique.
Effect of core materials on solidification times and patterns of square shaped steel
castings has been studied. The solidification time and sequence of solidification
pattern is different when zircon is used as core material in comparison to silica.
Sunoco reports results of second quarter 2010
Sunoco, Inc. has reported net income attributable to Sunoco shareholders of $145
million ($1.20 per share diluted) for the second quarter of 2010 versus a net loss
attributable to Sunoco shareholders of $55 million ($.47 per share diluted) for
the second quarter of 2009. Excluding special items, Sunoco had income for the 2010
second quarter of $158 million ($1.31 per share diluted) compared to 2009 second
quarter loss of $31 million ($.27 per share diluted).
Influence of Microstructure and Turning Inserts on Machinability and Surface Characteristics
of Hypereutectic Al-Si Cast Alloys
The microstructures, machinability and surface characteristics of hypereutectic
Al-Si cast alloys were studied after various melt treatments like refinement and
modification. Results indicate that combined refined and modified Al-17Si-4.5Cu
cast alloys have microstructures consisting of uniformly distributed primary silicon,
interdendritic network of fine eutectic Al-Silicon and fine CuAl2 particles in the
interdendritic region. These alloys exhibited better machinability and surface finish
in the cast condition as compared with the same alloy subjected to only refinement
or modification. Performances of the turning inserts (Un-coated, PVD and Polished
CVD diamond-coated) were evaluated in machining hypereutectic Al-Si cast alloys
under dry environment using a lathe. The Polished CVD diamond-coated insert outperformed
the Un-coated or PVD-coated cutting inserts which suffered from sizeable edge buildup
leading to higher cutting force and poor surface finish. The Polished CVD diamond-coated
insert shows a very small steady wear without flaking of the diamond film during
cutting. This paper attempts to investigate the influence of refinement, modification
and combined action of both on the microstrutural changes in the hypereutectic Al-Si
cast alloys and their machinability and surface finish when different turning inserts
Role of Process Control in Aluminium Casting Foundry for Global Business
The true enlightenment came from measuring the stability of the process conducted
to carry out series production. Relationship between stability of process with rejection
percentage could then be defined and established. The more stable the process, the
lesser is the rejection. Conversely, it was also determined that the more the deviation
from established process, higher the rejection.
Computer-Aided Simulation and Optimisation of Casting - A Case Study
Casting is the fundamental process of manufacturing. In this process, most important
factor is to get the shrinkage-free product which needs proper design of runner,
riser and its neck. Though these elements are not the part of the actual casting
but they are essential components of a casting. The sizes of these elements are
to be optimised properly to get maximum casting yield as this reduces the re-melting
cost of the component and also reduces energy requirement by a huge amount because
of lower hot metal. In this study, a cast iron pan has been identified which is
one of the oldest components of Howrah cluster. It is expected that this work will
be of great importance to the small-scale entrepreneurs and to the professionals
who are working in this area.