Feature Article
Vacuum Precision Investment Casting Furnace Designs with the Aim of Sustainable Operation and Extended Machine Life
by Iñaki Vicario. Senior Process & Technology Specialist, Consarc Engineering 1.0 Abstract T
he biggest challenge faced by current and future generations is the issue of climate change. Investment Casting, as with many other industries, needs to face
this challenge by utilizing furnaces designed for green and sustainable operation with extended machine life. This philosophy offers the investment caster operational cost advantages in an environment of rising energy costs. Energy saving elements should be an important aspect
of the current vacuum precision investment casting furnace design, specially focused on the biggest energy consumption elements like induction power units and vacuum pumps. Several proven strategies for reduction of cycle time and
waste are the elimination of hydraulic systems and the use of high efficiency dry vacuum pumps, together with improved controls/automation. Moreover, clear, and optimized preventive maintenance plans form a critical part of the design of the furnace projects targeting extended machine life. This article describes the major features of the modern VPIC furnace designs, developed towards the target of a sustainable investment casting process with extended machine life.
2.0 Introduction Foundries represent an important example of circular economy, due to the very nature of their production process, which has always put into practice an advanced mechanism of circularity. Foundries and their technology make it possible to recycle and reuse a large portion of metal materials that have reached the "end of their life" to make new products. [1] The following are the main targets to concentrate on from the furnace design perspective: • Energy Consumers: first, identify biggest kW consumers, then implement smart solutions to reduce their energy consumption.
• Smart Process: determine the main process opportunities and identify key process optimization strategies.
• Waste & Fluids: find the main waste and fluid consumers and explore ways to eliminate or reduce them.
• Preventive-predictive maintenance: establish the best tasks-frequencies for preventive maintenance, and propose sensors and systems for predictive maintenance, thus controlling and reducing downtimes of equipment.
18 ❘ May 2024 ® Figure 1: Consarc vacuum precision investment casting furnace.
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