product news/產品新聞 Ferrosad Low Carbon Steel Shot Case Study Isselburg Guss & Bearbeitung GmbH is a medium size
company employing 240 people in Isselburg, Germany, that specialize in the development, design and manufacture of pre-finished gray vermicular (CG) and ductile cast iron components. Tese components include housings, shafts, flywheels, brake discs and oil pans. To improve the efficiency of the production process and the surface finish, IsselburgGuss embarked on a project “Blasting Process Optimization” with the help of Metalltechnik Schmidt GmbH (MTSD). Te unprocessed casting was picked up on an AGTOS sus-
pension system and passed through a Wheelabrator Berger ma- chine for de-sanding and blasting. After initial discussions and detailed inspection of the process in 2010 with foundry manager Markus Vißer and MTSD engineer Hans-Jürgen Werner, a nine-month trial was agreed with Ferrosad Low Carbon (LC) SteelShot supplied by Metalltechnik Schmidt. Previously the company had used a high carbon (HC) steel shot with carbon content of 0.89%. With a carbon content of 0.1% and a bainitic microstructure Ferrosad LC can reduce shot consumption and machine wear. Teoretical advantages were shown prior to the trial
through laboratory tests with respect to chemical analysis, bulk density, carbon content and the life of the abrasive in terms of impact cycles. Both, Ferrosad and the HC under- went a K50/K100 procedure that tests small quantities of abrasive inside a turbine with a launch velocity of 65m/s. Tese tests showed the Ferrosad lasted more than 20% longer than the HC previously used, which suffered from a cracked Martenitic structure. Te trial on the two machines at IsselburgGuss was regu-
larly monitored by engineers with assistance from the cus- tomer’s staff. Tis monitoring included regular sieve analysis of the operating mix to ensure the best ratio of new material to part used material thus giving the best surface coverage and clean. Since Ferrosad is free of cracking and does not crack in use, it gives a higher kinetic energy on impact compared with HC. Following the trial, savings on shot consumption and machine wear (specifically blades and linings) had been achieved in full, and the trial was extended through 2011.
Ferrosad 低碳钢丸使用分析 德国伊塞尔堡的Isselburg Guss&Bearbeitung公司 是家有240名员工的中型企业，专注于开发、设计、生 产和加工各类灰铁、蠕铁、球铁零部件。这些零部件包 括壳体、曲轴、飞轮、刹车盘及油底壳。 为了提高生产效率和铸件表面光洁 度，IsselburgGuss公司在Metalltechnik Schmidt公司 （MTSD）的帮助下实施了“抛丸工艺优化”项目。 待清理的铸件被挂在AGTOS的悬挂系统上，通过 Wheelabrator Berger的清理设备除砂和喷丸。2010 年，在铸造车间经理Markus Vißer和MTSD公司的工程 师Hans-Jürgen Werner对工艺的初步讨论和仔细检查 后，双方同意使用Metalltechnik Schmidt 公司的Fer- rosad低碳（LC）钢丸并进行为期9个月的试验。 此前，公司曾使用碳含量为0.89％的高碳（HC）钢 丸。而用碳含量0.1％的低碳贝氏体Ferrosad 钢丸可以 减少钢丸的损耗和抛丸机的磨损。
理论上的优点在实际生产前，通过实验室测试关于化 学成份，容积密度，碳含量和根据冲击周期得出的磨料 可使用时间就显示出来了。Ferrosad钢丸和高碳钢丸经 过K50/K100程序测试，少量的磨料由抛丸轮以65米/秒 的速度抛出。试验表明，Ferrosad钢丸比之前用的高碳 钢丸的使用时间多20％，高碳钢丸容易受损开裂。 IsselburgGuss公司的两台设备上的试验在客户方工 作人员的协助下，定期由MTSD公司的工程师进行监 测。这些监测包括混合磨料定期的筛分分析，以确保补 充的新材料与重复使用材料的最佳配比，从而得到最佳 的表面清洁度。由于Ferrosad钢丸在使用中不开裂，与 高碳钢丸相比，它的冲击动能更高。试验结论表明减少 磨料损耗和机器磨损（特别是叶片和衬板）的目标全部 实现，该试验持续到2011年。
Impeller Cast Using SLA-Printed Patterns 使用SLA打印技术生产铸造叶轮
Needing to replace two double suction impellers with 30-in. diameters, SPX, Charlotte, N.C., decided to explore alternative casting processes to improve perfor- mance and limit lead times. It contacted Tech Cast LLC, Myerstown, Pa., a producer of large (up to 500 lbs.), pre- cision engineered investment castings using stereolitho- graphic (SLA) rapid prototype technology, an additive manufacturing process that produces objects from CAD models by printing successive layers of curable resin that
为了替代2个直径达0.762米的双吸叶轮，美国北卡 罗来纳州夏洛特的SPX公司决定开发不寻常的铸件工艺 来提高性能并缩短交货期。他们联系了宾夕法尼亚州的 迈尔斯敦的Tech Cast LLC公司，其是使用SLA（液态光 敏树脂选择性固化技术）快速成型技术生产大型（重达 226.8千克）精密工程用精铸件的制造商，该技术是一 项通过打印经紫外线硬化的连续光固化树脂层，从CAD
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2014
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