68th Annual Technical Conference & Exposition 1:00 p.m. - 1:40 p.m.
Paper No. 15: Pattern Cleaning Mark Oles, Pine Tree Castings Why clean a wax assembly prior to the application of the prime coat? A pattern cleaning operation involves labor, materials and disposal costs that can be significant. This operation would not be performed unless there was some benefit in casting quality. The most common reason is to improve prime coat wax adhesion to prevent shell buckle.
The adhesion of a prime coat to a wax pattern is dependent on the ability of the prime coat to wet the wax. For successful bonding to occur, the surface tension of the prime coat must be lower than the surface energy of the wax pattern.
This collaborative paper will demonstrate several methods of measuring the surface energy of wax patterns and show the relationship between surface energy and prime coat bond strength.
1:40 p.m. - 2:00 p.m.
Paper No. 16: Investment Castings with Unique Levitation Melting Technology FastCast Dr. Sergejs Spitans, ALD Vacuum Technologies, Booth 202 Crucible-free Levitation Melting (LM) and single-batch casting of titanium alloys (e. g. for turbocharger impellers up to 500 g) has many advantages over multi-piece casting from ceramic- or Cold-Crucible (CC) induction furnaces.
First of all, electromagnetic (EM) levitation prevents contamination of the melt with the crucible material and results in a superior and reproducible quality of alloy. Heat losses from the liquid metal are reduced and limited to radiation and evaporation that permits fast melting and high overheating at much higher thermal efficiency. Additionally, contact-free single-shot casting of the levitated melt can be precisely controlled by the current in the inductor. Apart from that, the new method breaks down the statistical nature of a single product quality in case of a multi-piece casting and advances production to the “one-piece-flow” concept.
A novel method for the large-scale LM of metals is developed to transfer this technology from lab use into industrial sphere. Numerical simulation has been used to verify the new method and to design a pilot LM furnace capable for a contact-less melting of metallic samples with increased weights. The designed prototype has been successfully validated by experiments with Ti-6-4 and other alloys up to 500 g.
This presentation gives an update on recent achievements to the FastCast demonstrator which is in operation at ALD.
AGENDA 2:00 p.m. - 2:20 p.m.
Paper No. 17: Steel Performance Initiative (SPI) and Digital Innovative Design (DID) Raymond Monroe, Steel Founders’ Society of America, Booth 503
National security and advanced manufacturing depend on a robust specialty steel industry. Steel Founders’ Society of America’s (SFSA) has collaborated with the Defense Logistics Agency (DLA) to organize efforts to invest in steel production and performance. This effort is intended to improve the supply chain capability and provide the most capable steel parts for commercial and national security using technology developed in partnership with the leading universities. This presentation will show DID successes and SPI strategic research objectives, including alloy and modelling capability development, hybrid steel components, and automation.
August 2021 ❘ 19 ®
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