aluminum gravity die casting cost reducing ptc stirring process

NETANYA PLASMATEC LTD

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Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)


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Plasma Treatment Casting (PTC) Plasma Treatment Casting (PTC) process for aluminum Gravity Die process for aluminum Gravity Die

Casting (GDC)Casting (GDC)•The PTC is an add-on patented technology, and does not change the end product

• The PTC is commercial as of 2007

•The PTC reduces risers’ mass by 70-80%

•The PTC increases casting productivity by 20-25%

•The PTC improves the casting quality

•The PTC reduces casting process defects by 50%


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Plasma Treatment Casting (PTC)

PTC advantages PTC advantages

Saving 30% of aluminum castingIncreasing 20% of casting productivitySaving 35% of sand and binders

Electrodes

PTC System

Sand and Binders saving

Aluminumsaving


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The PTC process applies plasma arc during solidification process

The rotating plasma arc movesalong a prescribed path, defined bya special electrode

The PTC ProcessThe PTC Process

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PTC multi plasma arcs system for complex casting shapes

Parallel plasma arcs on top of the risers


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Creates enormous shear forces by very effective stirring

Plasma stirringPlasma stirring

Induces electric and magnetic fields in the molten metal

Creates changing current density flow in the molten metal

Breaks the growing dendrites and creates a new nucleation center on each fracture

Creates smaller uniform dendrites and reduces significantly porosity and segregation levels


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Saving 10kg of the riser’s mass

Reducing casting weight 31kg 21kg.


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Risers height reductionRisers height reduction


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Saving 10kg of the riser’s mass.



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Reduction of risers mass by 17kg

Reducing casting weight 54kg 37kg


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The PTC system includes•An electrodes gripper which can be adopted for each type of casting die•A multi DC channel power sources•A control cabinet•A consumable electrodes

•The PTC system is a flexible add-on device for existing casting cells•The PTC applies the plasma arcs after pouring and during solidification


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PTC Quality Improvement PTC Quality Improvement


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8 kg casting weight reduction 31 Kg 23 Kg

70 sec solidification time reduction240 sec 170 sec

NP castingNormal casting


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Micro-Porosity

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

po

ros

ity

[%

]

column 0.02 0.05 0.008 0.03

bottom 0.02 0.007 0.001 0.01

NP1 NP2 NP3 NP4

Normal casting

Normal casting

Bottom of the casting

Column


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Average Dendrite Measurements (primary & secondary)

20

30

40

50

60

70

80

SIM

[M

icro

ns

]

column 66 65 66 66

bottom 44 49 44 47

NP1 NP2 NP3 NP4

Normal Casting

Normal Casting

Bottom of the casting

Column


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1 2 3 4

Mechanical properties in the bottom of the casting

Yield strength in the bottom of the casting

0

50

100

150

200

250

300

Sy

0.2

[M

Pa

]

NP casting 252.5 256.5 254.33 253.25

Normal casting 265 265 267 262

Cut 1 Cut 2 Cut 3 Cut 4

Ultimate tensile strength in the bottom of the casting

0

50

100

150

200

250

300

Su

ts [

MP

a]

NP casting 306.67 305 306.33 301.5



Elongation in the bottom of the casting

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

e [

%]

NP casting 6.22 6.5275 4.69 5.315

Normal casting 3.44 3.68 4.17 2.62



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Mechanical properties in the column area

Column

Tensile strength (Sy0.2 and Suts) in the column area

0

50

100

150

200

250

300

St

[MP

a]

NP casting 252.00 252.5 306.75 301.5


Sy0.2-Cut 1 Sy0.2-Cut 2 Suts-Cut 1 Suts-Cut 2

Elongation in the column area

0

1

2

3

4

5

6

7

8

e [%

]

NP casting 7.1225 4.78

Normal casting 2.91 2.34

Cut 1 Cut 2


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Quality Conclusion

• Higher casting quality in addition to casting weight reduction by 30-40%.

• Solidification cycle time reduction by 30-35%.

Mechanical properties Improvement by the PTC

• Elongation percentage (A% ) significant improvement:Form 3.48% to 5.70%, increase of 146% in the bottom From 2.62% to 5.95%, increase of 224% in the column (top)

• Porosity percentage significant improvement :From 0.012% to 0.0095%, reduction of 20% in the bottomFrom 0.08% to 0.027%, reduction of 66% in the column (top).


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PTC’s Competitive Advantages in Aluminum gravity die-casting of GDC cylinder head.

• Production cost reduction of GDC cylinder head by 20%-25%• Riser's mass reduction by 70% -90% and thus casting weight reduction by 35% • Sand mass core reduction by 40%• Foundry yield increase from 50% to over 80%• Foundry productivity increase by 20%- 25%• Melting and holding furnaces efficiency increase by 50%• Foundry sand reclamation reduction by 30%-40%• Environmental emission reduction by 35% • Metal feeding improvement• Defects ratio reduction• Shrinkage and porosity elimination • Mechanical properties improvement • Microstructure refinement

aluminum gravity die casting cost reducing ptc stirring process

Documents

gdc cylinder

plasma treatment

casting weight

mechanical

saving 10kg

normal casting

risers mass

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