PRODUCT RESOURCE FILE
Engineered Solutions for Tough Applications TECHNOLOGY IN ACTION
Z2 Syncarb Crucible Demonstrates Unmatched Reliability for MetalTek Division
Southern Centrifugal , a division of MetalTek International in Chat- tanooga, TN, was experiencing serious and costly problems directly related to poor crucible performance and abbreviated operational life. With a family of companies that combine the industry’s leading centrifugal, investment, sand, and continuous casting operations, MetalTek is unique in the diversity of casting and metalworking processes. Te company operates eight international facilities serv- ing customers in more than 25 countries, and could not afford the continued operational down time and lack of quality it was getting from its existing crucibles.
optimal life when melting copper and copper alloys as well as in induction furnace applications. Further, several applications have demonstrated that the new Z2 Syncarb performs exceptionally well in zinc distillation operations where a common mode of crucible failure is corrosive attack from zinc vapors.
MorganMMS has introduced the Z2 Syncarb crucible, offering major advantages in energy efficiency, higher thermal conductivity and other performance characteristics critical to the melting process. Te Z2 is an isostatically pressed clay-graphite crucible that provides
MetalTek was melting 30 different alloys - red brass, manganese bronze, monels, as well as high leaded, proprietary alloys - in their manufacturing process. However, erosion of crucible side walls was often taking the cru- cibles out of service, sometimes after as few as 25 days. In fact, the average service life overall was only 61 days. Applications like “melt and hold” or “melt and tap” were eroding the walls even faster. Tis led to excessive down time for crucible replacement, as well as a lack of consistent quality regarding melting and casting operations.
Te solution came from MorganMMS, specifically from its improved Z2 Syncarb crucible. Te Z2 Syncarb offers significant advantages in energy efficiency, higher thermal conductivity and other perfor- mance advantages critical to the melting process. It is a high pressure, isostatically pressed clay-graphite crucible that achieves optimal life when melting copper and copper alloys and in induction furnace ap- plications. Several customer applications have already demonstrated that the new Z2 Syncarb also performs exceptionally well in zinc distillation operations as well, where a common mode of crucible failure is corrosive attack from the Zn vapors.
“We’ve experienced a very dramatic improvement in average crucible life with Z2 crucibles versus other products used in the past - nearly four times the life in fact,” said MorganMMS customer, Carl Bednark of MetalTek International. “We expect the Z2 Syncarb to have a major impact on our operations.”
MorganMMS manufactures ceramic ladle bowls in sizes ranging from small bowls for taking molten metal samples to large bowls for ladling metal into molds. Teir ability to resist surface penetration from molten metal and slag keeps them free of dirt and contamination, allowing for cleaner samples and ensuring cleaner metal pours. Te thermal properties of the clay-graphite material also helps maintain the correct temperature for pouring accurate samples and molds. Also, the light weight of ceramic ladle bowls make them significantly better than metal skimmers where large quantities of material have to be removed over an extended period of time.
MORGAN MOLTEN METAL SYSTEMS 203/697-0808 Fax: 203/265-6267
www.morganmms.com
METALCASTING EQUIPMENT, PRODUCTS & SERVICES 2011-12 29
Performance comparison of the new MorganMMS Z2 Crucibles compared to MetalTek’s previous crucible in a 2000 pound 180Hz, 250KW induction furnace (Data provided by MetalTek International)
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