Technical University of Denmark

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Presentation transcript:

Technical University of Denmark Quantification of Feeding Effects of Spot Feeding Ductile Iron Castings in Vertically Parted Molds Nikolaj K. Vedel-Smith Technical University of Denmark

My PhD Project Improvement of Feeder Technologies for Energy Savings in Cast Iron Foundries

Agenda INTRODUCTION EXPERIMENT RESULTS CONCLUSIONS Why spot feeding? What are we testing? How do ram-up sleeves function EXPERIMENT Casting Geometry Test Variables and Configurations RESULTS Porosities Simulations Surface Shrinkage CONCLUSIONS

Why Spot Feeding? Feed heavy sections unreachable by traditional feeders Reduce melt use Improved yield and economy Melting accounts for approx. ¼ of the production cost for cast iron foundries

? We Want To Know… If spot feeding can feed closed off sections If spot feeding can prevent surface shrinkage How to model feeding properties correctly ?

Casting Geometry 20 x 25 mm 10 x 55 mm 30 x 50 mm

Casting Geometry Poured weight ≈ 8 kg Casting weight ≈ 4 kg Only w/ top feeder Only w/ center feeder Without feeders

Top feeder sleeve mounted Ram-up sleeve molded in Molding Pin for ram-up sleeve Top feeder Top feeder sleeve mounted Ram-up sleeve mounted Ram-up sleeve molded in 10 PPM foam filter

Molding The sleeve is mounted onto the pin (Can be automated) Sand fills the molding chamber As the mold is squeezed, the breaker core collapses and compacts the sand

Experiment All castings made on the same vertical molding line Three separate series Variables Top feeder Center feeder Sleeve material Alloy

Two near eutectic ductile iron alloys C Si Mn P S Mg Cu EN-GJS-500-7 3.67 2.73 0.50 0.015 0.005 0.049 0.025 EN-GJS-450-10 3.35 3.48 0.34 0.017 0.003 0.046 0.010 α β Cast through three series at: 1,401 ±5 °C (2,554 ±10 °F) 1,408 ±5 °C (2,566 ±10 °F) 1,392 ±5 °C (2,538 ±10 °F)

Feeder Configuration Mg = V/A Mt = MEF · Mg Exothermic Insulating (E/I) Insulating (Ins) Exothermic (Exo)

Trial Castings

Sectioning

Porosities Sectioned casting divided into 9 areas Liquid Penetrant Test according to EN 1371-1:2011 Of particular interest

Results Table

Simulations

Simulations

Surface Shrinkage Measurement Points α2C α5a β1C

Results Table

Conclusions The ram-up spot feeders successfully feed the boss section Without either of the two feeders, the castings were unsound Great casting reproducibility Top feeder influences solidification in boss section

For additional information, please contact: Nikolaj K. Vedel-Smith Produktionstorvet, Building 427A 2800 Kgs. Lyngby, Denmark Phone: 0045 23 61 69 77 Email: nikvs@mek.dtu.dk www.mek.dtu.dk