AGENDA CONTINUED...
1:00 p.m. – 1:45 p.m. Novel Regular Ceramic Filter for The Lost Wax Applications Ladislav Tomek, LANIK s.r.o. Booth 301 Presented paper describes novel regular ceramic filter
type for usage in the lost wax foundries. Vukopor HT RS presents a new type of filter determined for the filtration of molten metals as superalloys and steels. Its unique structure is made of circular elements that create the paths labyrinth. It gives a high efficiency to calm the turbulent molten metal flow and provides metal laminarization. There have been tests done on the water simulator proving that behaviour, as well as numerical simulations. Thanks to its regular structure, the HT RS filter enables a repeatable way of application giving almost the same conditions for mould filling - pouring time, dynamic conditions, filling speed. The unique structure of the RS filter is printed on a 3D printer by the SLA technique and final ceramic body is coated on the resin structure. In order to achieve a strong structure, it needs to apply several coatings.
1:45 p.m. – 2:30 p.m. Effect of Depressurization on Dimensional Expansion of Turbine Blades Casting Process Lütfi Yakut, Tubitak Marmara Research Center In this study, improvement studies carried out with the
aim of reducing the dimensional expansion in turbine blades after casting are done. In the production of turbine blades, the process of forming a shell by coating ceramic slurry on the turbine blades which are produced with the help of wax injection and the discharging the wax from the shell with the autoclave system without damaging the ceramic coating directly affects the casting result in terms of dimensions. The shell layers that separated or cracked from the blade surface after autoclave cause dimensional differences and reduce production efficiency. In order to eliminate this problem, first of all, studies will be carried out to determine the problem and the measures to be taken to eliminate and it will be determined. Especially the cracking or expansion of the first layer of ceramic shell causes dimensional differences as well as many other defects such as surface defects and flashes, and their removal is necessary in order to comply with aviation standards in turbine blade production. For this purpose, a study has been planned to improve the process and reduce the scrap rate.
2:30 p.m. – 5:00 p.m. EXPO
6:00 p.m. – 8:00 p.m. RECEPTION
26 ❘ August 2023 ®
WEDNESDAY, AUGUST 16, 2023 7:00 a.m. – 12:00 p.m. REGISTRATION
8:00 a.m. – 8:15 a.m. WELCOME - GENERAL SESSION Ty Ueland, SeaCast, Inc., ICI Director
8:15 a.m. – 9:00 a.m. Advanced Electrode Melting for Highest-Purity Cast Parts Dr. Samuel Bogner, ALD Vacuum Technologies GmbH Booth 113 In the Electrode induction melting for Inert Gas
Atomization (EIGA) process the lower end of the vertically hanged pre-alloyed electrode is continuously fed into the region of high-frequency electromagnetic (EM) field created by a conical coaxial induction coil located below. Induction melting takes place and a flow in a thin layer is formed at the conical tip of the electrode resulting in a metal down-stream on the axis. Application of reviewed electrode induction melting for investment casting applications could be exceptionally beneficial for achieving the highest cleanliness of the cast parts. However, the electrode induction melting for metallic powder production is currently a well-established technique only for relatively low melt rates (such as <2 kg/min for Ti-alloys). On top of that, the melt cannot be significantly superheated due to the small thickness of the liquid layer at the conical electrode tip and the fact that material instantly leaks out of the zone of EM heating as it turns liquid due to the gravity and pinching Lorentz forces. In the present work, we are using numerical modelling and experimental validation to demonstrate how the high-melt-rate and high-superheat electrode induction melting can be designed for investment casting applications.
9:00 a.m. – 9:30 a.m. An Approach Utilizing Technology to Restore the Metal Casting Industry to a New Level of Pre-eminence Donald Deptowicz, Aspen Hybrid Technology Solutions, LLC, ICI AM Subcommittee Chair The metal casting industry is one of the oldest, most
challenging, and energy-intensive manufacturing processes. It has experienced swift and significant headwinds due to the pandemic. Massive changes in raw material prices, utilization spikes, OEM backlogs, and lack of maintenance availability and human resources are the themes that challenge us today. Further, worldwide developments are continuously changing our operational dynamics. While our society is excellent at responding to a crisis, we need to be pre-emptive in our approaches and prevent
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