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THERMAL ANALYSIS OF FOUNDRY METALS
Quick answers for Chemistry, Inoculation and Microstructure
Presented by MeltLab Systems2010
THE PROCESS
Molten metal is poured into a sampling cup containing a thermal couple
Takes about 30 seconds of operator time, results in 2 to 6 minutes
THE THEORY
Phase diagrams measure the transition points from liquid to solid, from one structure to another.
Iron-Carbon phase diagram
DATA PRESENTATION
As simple or as complex as you like
Includes all phase diagram information
And alloy correction calculations
DATA SELECTION
Turn displayed items on or off
DATA STORAGE
User controlled files Connects with our GSPC system for
On the floor monitoring SpectrometerLab to include results with
Chemistry Long term historical files for record keeping
and, with GSPC, graphic analysis
METHODS OF ANALYSIS
Iron Chemistry Ductile Microstructure Grey Microstructure Aluminum 300 Series Steel & High Temperature Alloys Copper Alloys Other Metals – Sterling Silver
NECESSARY IMPROVEMENTS
Higher precision to get 16 fold improvement
Invented new data smoothing methods Researched TA for better understanding
of data Redesigned instrument for the foundry
environment Evangelized to try to get the word out
FOUNDRY REQUIREMENTS
Shielded wiring to prevent furnace power from getting into the measurement
Proper electrical grounding to provide a reference to measure from
Proper Metal Sampling Hot enough that all alloys are dissolved
(1400˚C) If final metal, then fully inoculated/treated Full sample cup
MELTLAB CAPABILITIES
The following slides are meant to show the capabilities of MeltLab. They show details that may be more complex than you would want to display to the melters. But they can be useful to the quality of the metal. Our philosophy is that it is better to have more than you need rather than to have less than you need. The graphs have been shrunk for this presentation.
IRON CHEMISTRY FOR GREY & DUCTILE
IRON MICROSTRUCTURE FOR DUCTILE
ALUMINUM MICROSTRUCTURE
STEEL & HIGH TEMP ALLOYS
COPPER ALLOYS
OTHER ALLOYS
If you have any particular alloy you need to measure, MeltLab has the capability to:
Measure any arrest point or phase change
Based on phase diagram or chemical analysis, develop equations to convert arrest points into chemistry
Measure and quantify the amounts of the different phases detected.
CONCLUSION
Thermal analysis is now giving faster results than any lab can do
Gives feedback in time to make corrections
MeltLab is already two generations beyond what any other TA unit can do.
Visit www.meltlab.com for more information on what can be done.
Presented by MeltLab Systems2010
MeltLab Systems based in the United States of America is the inventor of the MeltLab system, Graphic Statistical Process Control and other software designed for foundries.
CONTACT INFORMATION
MeltLab Systems www.meltlab.com General Information: [email protected]
David Sparkman: [email protected]
