Transcript NETANYA PLASMATEC LTD Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC) Confidential NETANYA PLASMATEC LTD Plasma Treatment Casting (PTC) process for aluminum Gravity.

NETANYA PLASMATEC LTD
Plasma Treatment Casting (PTC) process
for aluminum Gravity Die Casting (GDC)
Confidential
NETANYA PLASMATEC LTD
Plasma Treatment Casting (PTC) process
for aluminum Gravity Die Casting (GDC)
•The PTC is an add-on patented technology, and does not change the end product
• The PTC is commercial as of 2007
•The PTC reduces risers’ mass by 70-80%
•The PTC increases casting productivity by 20-25%
•The PTC improves the casting quality
•The PTC reduces casting process defects by 50%
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Plasma Treatment Casting (PTC)
PTC System
Electrodes
PTC advantages
Saving 30% of aluminum casting
Increasing 20% of casting productivity
Saving 35% of sand and binders
Aluminum
saving
Sand and Binders
saving
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The PTC Process
The PTC process applies plasma arc
during solidification process
The rotating plasma arc moves
along a prescribed path, defined by
a special electrode
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PTC multi plasma arcs system for complex casting shapes
Parallel plasma arcs on top of the risers
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Plasma stirring effects
Creating changing current density flow in the molten metal
Inducing electric and magnetic fields in the molten metal
Very effective stirring which creates enormous shear forces and feeding
Breaking the growing dendrites, each fracture create a new nucleation center
Smaller and more uniform dendrite arm spacing (DAS) and significant porosity
ratio reduction
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Saving 10kg of the riser’s mass
Reducing casting weight 31kg
21kg.
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Saving 10kg of the riser’s mass
Risers height reduction
Reducing casting weight 31kg
21kg.
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Saving 10kg of the riser’s mass.
Reducing casting weight 31kg
21kg.
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Saving 13kg of the riser’s mass
Reducing casting weight 42kg
29kg.
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Reduction of risers mass by 17kg
Reducing casting weight 54kg
37kg
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The PTC system includes
•An electrodes gripper which can be adopted for each type of casting die
•A multi DC channel power sources
•A control cabinet
•A consumable electrodes
•The PTC system is a flexible add-on device for existing casting cells
•The PTC applies the plasma arcs after pouring and during solidification
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PTC Quality Improvement
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8 kg casting weight reduction
31 Kg
23 Kg
70 sec solidification time reduction
240 sec
170 sec
Normal casting
NP casting
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Bottom of the casting
Micro-Porosity
0.09
Normal casting
0.08
porosity [%]
0.07
0.06
0.05
0.04
0.03
Column
0.02
Normal casting
0.01
0
NP1
NP2
NP3
NP4
column
0.02
0.05
0.008
0.03
bottom
0.02
0.007
0.001
0.01
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Average Dendrite Measurements (primary &
secondary)
80
Bottom of the casting
Normal Casting
SIM [Microns]
70
60
Normal
Casting
50
Column
40
30
20
NP1
NP2
NP3
NP4
column
66
65
66
66
bottom
44
49
44
47
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Mechanical properties in the bottom of the casting
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1
2
3
4
Elongation in the bottom of the casting
7.00
6.00
e [%]
5.00
4.00
3.00
2.00
1.00
0.00
Cut 1
Cut 2
Cut 3
Cut 4
NP casting
6.22
6.5275
4.69
5.315
Normal casting
3.44
3.68
4.17
2.62
Ultimate tensile strength in the bottom of the casting
300
300
250
250
200
Suts [MPa]
Sy0.2 [MPa]
Yield strength in the bottom of the casting
150
100
200
150
100
50
0
NP casting
Normal casting
50
Cut 1
Cut 2
Cut 3
Cut 4
252.5
256.5
254.33
253.25
265
265
267
262
0
NP casting
Normal casting
Cut 1
Cut 2
Cut 3
Cut 4
306.67
305
306.33
301.5
307
305
304
299
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Mechanical properties in the column area
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Elongation in the column area
8
7
Tensile strength (Sy0.2 and Suts) in the column
area
6
e [%]
5
300
4
3
250
St [MPa]
2
200
1
150
0
NP casting
100
Normal casting
50
0
NP casting
Normal casting
Sy0.2-Cut 1
Sy0.2-Cut 2
Suts-Cut 1
Suts-Cut 2
252.00
252.5
306.75
301.5
261
259
302
297
Cut 1
Cut 2
7.1225
4.78
2.91
2.34
Column
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Quality Conclusion
• Higher casting quality in addition to casting weight reduction by 30-40%.
• Solidification cycle time reduction by 30-35%.
Mechanical properties Improvement by the PTC
• Elongation percentage (A% ) significant improvement:
Form 3.48% to 5.70%, increase of 146% in the bottom
From 2.62% to 5.95%, increase of 224% in the column (top)
• Porosity percentage significant improvement :
From 0.012% to 0.0095%, reduction of 20% in the bottom
From 0.08% to 0.027%, reduction of 66% in the column (top).
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PTC’s Competitive Advantages in Aluminum gravity diecasting of GDC cylinder head.
• Production cost reduction of GDC cylinder head by 20%-25%
• Riser's mass reduction by 70% -90% and thus casting weight reduction by 35%
• Sand mass core reduction by 40%
• Foundry yield increase from 50% to over 80%
• Foundry productivity increase by 20%- 25%
• Melting and holding furnaces efficiency increase by 50%
• Foundry sand reclamation reduction by 30%-40%
• Environmental emission reduction by 35%
• Metal feeding improvement
• Defects ratio reduction
• Shrinkage and porosity elimination
• Mechanical properties improvement
• Microstructure refinement
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