CASTING INNOVATIONS
Dry Ice-Based Cleaning Method Cuts Costs, Improves Safety A metalcasting facility in Plym-
outh, Minn., specializing in precision diecasting and sand castings for the automotive, aerospace and defense industries, began exploring alterna- tive methods for cleaning tooling and coreboxes. Refractory coatings, resin spray buildup, sand casting compo- nents and core residues had been cleaned via sand blasting and manual brushes, but these processes were slow. Additionally, sand blasting destroyed the urethane and damaged the di- mensions on the molds and routinely destroyed the vents and screens on the coreboxes. Te company was searching for a
cleaning method that would easily remove the entire refractory coating and other residual material so it could achieve a consistent mold surface for a high quality finished product, while not damaging the dimensions of the mold or destroying the vents and screens on the coreboxes. It instituted a Cold Jet dry ice cleaning program that resulted in more cleaning online with less disassembly. In addition, the facility improved the asset utilization rates and asset life of its tooling and equipment, all while creating a safer and more environmentally respon- sible workplace. Dry ice cleaning eliminates equip- ment damage, reduces scrap product when compared to alternative clean- ing methods and allows for complete online cleaning so production time
The dry ice blast cleaning process significantly reduced the time needed to clean permanent molds.
can be maximized and touch-up cleanings are safe and easy. Te dry ice blast cleaning process is similar in concept to sand or soda blasting, where the respective media is accelerated through a pressurized airstream. Te main difference is that Cold Jet’s system uses recycled CO2 in the form of dry ice particles to clean and prepare surfaces. Dry, non-conductive CO2 particles are accelerated through a specialized hose and nozzle. Once the CO2 particles strike the surface, the combination of kinetic energy transfer, thermal shock
and gas expansion breaks the bond between the substrate and the con- taminant, flushing the contaminant away. Upon impact with the surface, the dry ice particles sublimate, leaving no secondary waste or residue. Te metalcaster tested the Cold Jet
i3 MicroClean MicroParticle system to clean its most delicate screen vents. Even at maximum blast aggression, there was no damage to the parts and the molds looked brand new. “Within two days, the system was
in our company and at work,” said the metalcaster’s tooling supervisor. “We estimated it would pay for itself in six months, but it only took one.” It used to take three
workers approximately 3-4 hours to clean one or two molds but now it only takes a single worker a total of 10 minutes. Te tooling supervisor estimated that they are saving as much as $500 per mold with a Cold Jet dry ice blasting system.
The Minnesota metalcasting facility used the Cold Jet cleaning process to clean refractory coatings, resin spray buildup and core residues from its sand casting components.
42 | MODERN CASTING June 2015
Visit
www.coldjet.com for more information.
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