NETANYA PLASMATEC LTD Confidential 1 Plasma Casting treatment (PTC) for Ductile Iron.

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Presentation transcript:

NETANYA PLASMATEC LTD Confidential 1 Plasma Casting treatment (PTC) for Ductile Iron

NETANYA PLASMATEC LTD Confidential 2 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 kg Net product weight – 3.4 kg Riser’s weight – 0.8 kg Normal Casting: Total cast weight kg Net product weight kg Riser’s weight 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

NETANYA PLASMATEC LTD Confidential 3 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)

NETANYA PLASMATEC LTD Confidential 4 The PTC process applies plasma arc during solidification process. The rotating plasma arc moves along a prescribed path, defined by a 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 Confidential

NETANYA PLASMATEC LTD Confidential 5 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 kg Net product weight – 3.4 kg Pouring feeder weight – 1.2 kg Riser’s weight – 2.2 kg Casting with PTC process: Total casting – 4.8 kg Net product weight – 3.4 kg Pouring 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

NETANYA PLASMATEC LTD Confidential 6 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

NETANYA PLASMATEC LTD Confidential 7 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

NETANYA PLASMATEC LTD Confidential 8 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

NETANYA PLASMATEC LTD Confidential 9 Microstructure All specimens were taken from the upper middle part of each casting The chemical composition of the specimens were as follows : CSiMnPSCrCuVMgTiAl Alloy A Alloy B

NETANYA PLASMATEC LTD Confidential 10 Alloy A Alloy A - Normal castingAlloy A - PTC 100μm 50μm

NETANYA PLASMATEC LTD Confidential 11 Alloy B Alloy B - Normal casting Alloy B – PTC 100μm 50μm

NETANYA PLASMATEC LTD Confidential 12 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