corso di tecnologia meccanica - my.liuc.itmy.liuc.it/matsup/2017/n91328/industrial technologies...
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LIUC - Ingegneria Gestionale 1
Foundries
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Overview
EU foundry industry facts
The foundry process
A. Melting
B. Moulding
C. Casting
LIUC - Ingegneria Gestionale 2
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EU foundry industry facts
3rd largest in the world for ferrous casting and
2nd largest for non-ferrous.
In 2005, 11,7 million tonnes of ferrous.
Germany, France and Italy: top producers.
Predominantly still an SME industry, 80% of
companies employing <250 people.
Serves automotive (50%), general engineering
(30%) and construction (10%) sectors.
LIUC - Ingegneria Gestionale 3
Source: European Commission, 2005, Reference document on Best Available Techniques in the Smitheries and Foundries Industry, p.ii
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Foundries
Foundries melt ferrous and non-ferrous metals and
alloys and reshape them into products at or near
their finished shape through the pouring and
solidification of the molten metal or alloy into a
mould.
LIUC - Ingegneria Gestionale 4
Source: Ivi, ii
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LIUC - Ingegneria Gestionale 5
Source: Ivi, p. 13
The
foundry
process
A
B
C
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Mass stream
overview of the
foundry process
LIUC - Ingegneria Gestionale 6
Source: Ivi, p. 97
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A) Melting and metal treatment
LIUC - Ingegneria Gestionale 7
Applicability of furnace types, for melting (m) and holding (h)
Different melting and metal treatment for each material
For instance, for steel:
Source: Ivi, p. 28
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Electric arc furnace (EAF)
It is a batch-melting furnace consisiting of
a large bowl-shaped refractory lined body
with a dish-shaped hearth.
It is covered by a refractory roof, which
has ports for three graphite electrodes.
Typically the shell diameter is 2 to 4 m.
Most furnaces use roof charging.
Capacities from 2 to 50 tonnes.
Low refining abilities if acidic lined EAF,
high if basic lined.
LIUC - Ingegneria Gestionale 8
Source: Ivi, p.34; HUT, 2003
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Coreless induction furnace
It is a batch-melting furnace containing a water-cooled copper
coil, the inside of which is internally refractory lined.
It is charged by a lifting magnet, bucket skips, a vibrating
conveyor or manually.
Furnace capacities
range from 10 kg up
to 30 tonnes.
LIUC - Ingegneria Gestionale 9
Source: European Commission, 2005, Reference
document on Best Available Techniques in the
Smitheries and Foundries Industry, p.37
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Process Flow diagrams for the melting and
metal treatment of steel
LIUC - Ingegneria Gestionale 10
Source: Ivi, p. 18
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B) Moulding techniques
The process of making a mould in which the
molten metal will be poured.
Special cares include:
Get dimensional precision
Get a smooth skin
Avoid casting defects, e.g. cracks, pinholes, etc.
Types of moulds: lost and permanent, i.e. single
and multi use.
LIUC - Ingegneria Gestionale 11
Source: Ivi, p. 61
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Lost moulds vs Permanent m.
Single use, i.e.
destroyed after
pouring.
Generally made out of
sand (different types),
which can be
chemically bonded,
clay-bonded or
unbonded.
LIUC - Ingegneria Gestionale 12
Multiple uses.
Typically metallic.
Used for gravity and
low-pressure casting,
pressure die-casting
and centrifugal casting
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Example: Vacuum
moulding (sand)
Sand moulding involves
the use of large sand
volumes, with sand-to-
liquid-metal weight ratios
generally ranging from 1:1
up to 20:1.
LIUC - Ingegneria Gestionale 14
Source: Hoppenstedt, 2002; European Commission, 2005, Reference document
on Best Available Techniques in the Smitheries and Foundries Industry, p.ii, 64
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C) Casting
Pouring is the central activity in casting
production.
The finished mould is filled with the liquid
metal under the effects of gravitational or
centrifugal forces or pressure.
After pouring the casting is cooled to
allow solidification and is then removed
from the mould for further cooling and
treatment.LIUC - Ingegneria Gestionale 16
Source: European Commission, 2005, Reference document on Best Available Techniques in the Smitheries and Foundries Industry, p.79
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Pouring
LIUC - Ingegneria Gestionale 17Source: HUT, 2003
Lip pour ladle for
molten metal
pouring.
Teapot ladle for
molten metal
pouring.
Bottom pour ladle
for molten metal
pouring.
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Pouring
Automatic
casting lines
are often
equipped with
a pouring
furnace.
Metal is
poured during
a fixed period
by elevating a
stopper
LIUC - Ingegneria Gestionale 18
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Solidification (1st cooling)
The length of the cooling line determines the
final temperature of the casting at the point of
shake-out.
This temperature must be low enough to
provide the casting with sufficient strength
during shake-out and further manipulation.
Big moulds are not moved during cooling.
The cooling time can be up to several days
LIUC - Ingegneria Gestionale 19
Source: European Commission, 2005, Reference document on Best Available Techniques in the Smitheries and Foundries Industry, p.81