Figure 5: Dimensional Print for the Metal Treatment Station Additionally, the following


economic benefits were achieved upon adaptation of the new process:


• Elimination of the $28.80 daily spend on Hexachloroethane pills


• Grain refiner savings of $84.42 per day switching from metallic TiBor to the grain refining flux.


• Argon savings approximating $4.65 per melt.


for


The adaptation was reviewed potential


drawbacks and implications it may have caused.


other The


newer system was bulkier than the predecessor causing some requirements in the handling and there was a slight increase in spend on baffle plates


and graphite (when experiencing premature breakage). Regardless, it was unanimously agreed that the benefits of the new system far outweigh those few drawbacks that were introduced with the new procedure.


An approximate payback


appears in Table 6. chlorine


Table


savings in reduced argon spend, eliminating


After all the cost pills and lower


grain refining costs are offset by the slight increases in spend on graphite and baffle plates, a payback can be calculated and was determined to be approximately 16.5 months.


Summary A novel method for applying a combination salt-form grain refining flux and rotary degassing system was implemented at an investment casting operation in Clinton, NJ to great success. The new treatment method resulted in an improved grain refinement practice that lowered spend, increased productivity, improved hydrogen control, delivered environmental & safety benefits and eliminated waste.


The calculated


payback on a new MTS unit was calculated to be about 16.5 months.


The authors would like to thank Joe


Spadaccini of Weaver Materiel Services and Vernon Edwards of Atlantic Casting & Engineering for capturing much of the TA data.


May 2020 ❘ 31 ®


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