Preliminary Agenda Abstracts WEDNESDAY, AUGUST 24, 2022
7:00 a.m. – 12:00 p.m. REGISTRATION – Disneyland Center Lounge
8:00 a.m. – 8:05 a.m. GENERAL SESSION – Disneyland Center Ballroom Greeting
8:05 a.m. – 8:40 a.m. Process Cycle Time Analysis And Optimisation for Efficient Vacuum Precision IC Furnaces Iñaki Vicario, Consarc Engineering, Booth No. 324 The production of advanced superalloy components for applications in aerospace, power generation, automotive etc industries is accomplished in Vacuum Precision Investment Casting (VPIC) furnaces. Consarc recognises the technical and commercial importance involved in optimising modern VPIC operation efficiency, and apply these to their state of art VPIC furnace technologies. The Vacuum Precision Investment Casting process
includes many activities to perform a complete casting cycle. There are many sensitive and complex operations, including: mould loading into the furnace, mould pump down stage, mould raise to heating/pouring position, mould heating (DSSX process), liner and ingot loading, alloy melting, mould pouring, casted mould unloading and used liner removal. Among each of these operations, there are many subtasks that should be identified, analysed and optimised. Proper cycle process time analysis enables a view of the time consumption of each process stage, and the best synchronisation strategies to avoid wasted time and ensure the fastest cycle time is achieved. This work will show how furnace design principles can permit the operator to achieve the fastest, most productive, most efficient, and reliable casting process.
8:40 a.m. – 9:20 a.m. Shifting the Engineering Focus of Back-up System Design, George Salomon, Nalco Water – An Ecolab Company, Booth No. 320 As investment casting foundries strive to improve the manufacturing process and reduce cost, the need to increase throughput without compromising shell integrity is a common area of interest. Reducing the amount of time required to dry shells, increasing shell thickness and uniformity per dip, and using regional refractory flours in the slurry formulation are some of the benefits that can be gained using the latest modified colloidal silica binder for backup slurries. In this presentation, we aim to present data corroborated by foundry trials demonstrating increased shell room throughput, achieved through back up dip reduction and decreased shell dry time.
9:20 a.m. – 10:00 a.m. Meet The Challenge Jack Ziemba, Aristo Cast For a process that’s approximately 6000 years old, it never
ceases to amaze me the refinement that has taken place in the last 15 years. We’ve gone from rudimentary injection molds to a sophisticated tooling in use today. We’ve gone from machinable wax being utilized for one off patterns to the ability to use additive manufacturing equipment to print complex patterns in a variety of materials which are all compatible with the IC process. The advent of metal printing has encroached into the investment casting market. We intend on showing you how to meet the challenge,
head on! As the owner of Aristo-Cast Inc. and a member of the Additive Manufacturing Users Group, we’re going to get that business back using the P.I.C.S. (Printed Investment Casting Shells), a method that revolutionizes the traditional investment casting process. This is accomplished by printing the ceramic shell directly from CAD data, eliminating the need for wax injection molds to create the patterns and the skill to dip the critical early coats of ceramic shell. P.I.C.S. allows even the most complex interior design to be cast successfully.
10:00 a.m. – 10:20 a.m. BREAK
10:20 a.m. – 11:00 a.m. Advanced Analysis Techniques of Slurry Stability Utilising Zeta Potential Testing of Colloidal Silica Gavin Dooley, Remet UK, Booth No. 217 Zeta
potential
testing is a common measurement
technique of colloidal dispersions. The test can be used to quantify the charge on the particle of colloidal silica at different states. The stability of a colloidal silica can affect many aspects of a slurry within the shell room including binder viscosity, shell strength, gelling of the slurry and slurry life. The longevity of the slurry and replacement costs are directly related to this important property within the colloid and therefore, should be understood further. REMET® UK has recently acquired a zeta potential measurement kit to understand the effect of this property on slurry performance. First, a defined test method was established and is presented within this paper, which reduces error within the test and allowed for repeatable tests. A review of the effect of pH on colloids was also conducted. Furthermore, binders resistant to pH changes are presented within this paper. Following this, the lifecycle of the binder was measured
over time utilizing accelerated aging tests within the REMET® UK Laboratory. Finally, the effect of freezing was conducted using the zeta potential equipment. Samples were shown to have different charges when subjected to freezing conditions within the lab. This offers the opportunity to assess if a colloid has been frozen during its lifecycle during transport and storage.
30 ❘ May 2022 ®
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