netanya plasmatec ltd confidential plasma treatment casting (ptc)
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NETANYA PLASMATEC LTD
Confidential
Plasma Treatment Casting (PTC)
NETANYA PLASMATEC LTD
Confidential
PTC’s Competitive Advantages for high grade steel ingot
•Production cost reduction by 10%-20%•Ingot casting yield increase from 80% to 90% •Segregation reduction•Grain refinement •Mechanical properties improvement•Enables ingots casting with larger dimensions •Shrinkage and porosity elimination•Environmental emission reduction by 15%
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The Effects of PTC Process
•Replacing hot isolation- feeding the liquid metal with a concentrated energy•Reducing heat gradient - intensive heat exchange in liquid metal•Stirring liquid metal while solidification- through multi-dimension electric and electromagnetic fields•Producing additional pressure in risers - reducing risers height by exchanging potential energy with kinetic energy
NETANYA PLASMATEC LTD
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The PTC process applies plasma arc during metals and metal alloys solidification process.
The rotating plasma arc movesalong a prescribed path, defined bya special electrode.
The PTC Process
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1.6 Ton steel ingots Casting Yield increase from 80% to 93%
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Microstructure )center ( of 10 ton P-20 tool steel ingot
Middle
Top
Bottom
Plasma treated ingotConventional ingot
M x 50 Confidential
NETANYA PLASMATEC LTD
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Microstructure )R/2 ( of 10 ton P-20 tool steel ingot
Middle
Top
Bottom
M x 50
Conventional ingot Plasma treated ingot
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NETANYA PLASMATEC LTD
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Microstructure) Surface (of 10 ton P-20 tool steel ingot
Middle
Top
Bottom
Conventional ingot Plasma treated ingot
M x 50 Confidential
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0
200
400
600
800
Surface 0.5R Center
Auste
nite g
rain
siz
e,
m
Top Middle Bottom
PTC improves austenite grain size of P20 tool steel
NETANYA PLASMATEC LTD
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Microstructure )Bottom (of 12 ton AISI 4130 steel ingot
PTC
Conventional
150mm from surface10mm from surface 75mm from surface
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Microstructure )Middle (of 12 ton AISI 4130 steel ingot
10mm from surface 75mm from surface 150mm from surface
PTC
Conventional
NETANYA PLASMATEC LTD
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Microstructure )Top (of 12 ton AISI 4130 steel ingot
10mm from surface 75mm from surface 150mm from surface
PTC
Conventional
NETANYA PLASMATEC LTD
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0
20
40
60
80
10 75 150
PTC conventinal
PTC improves grain size of AISI 4130 steel
Bottom
0
20
40
60
80
10 75 150
location from surface [mm]
Gra
in s
ize
[mic
ron]
Middle
0
20
40
60
80
10 75 150
location from surface [mm]
Gra
in s
ize
[mic
ron]
Top
0
20
40
60
10 75 150
location from surface [mm]
Gra
in s
ize
[mic
ron]
NETANYA PLASMATEC LTD
Confidential
0
20
40
60
80
10 75 150
PTC conventinal
PTC improves hardness variation of AISI 4130 steel
Middle
170
180
190
200
210
surface 80% R 60%R 40%R center
location from surface
Har
den
ess
HD
Bottom
170
180
190
200
210
surface 80% R 60%R 40%R center
location from surface
Har
den
ess
HD
Top
170
180
190
200
210
surface 80% R 60%R 40%R center
location from surface
Har
den
ess
HD
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600
700
800
900
1000
Ingotedge
R/2 Ingotaxial
R/2 Ingotedge
Conventional ingot after cast
Conventional ingot after heat treatment
Plasma treated ingot after cast
Plasma treated ingot after heat treatment
700
750
800
850
900
950
1000
Ten
sile S
tren
gth,
MPa
Relative Ingot height
Average in cross-section
Bottom Top
600
700
800
900
1000
Ingotedge
R/2 Ingotaxial
R/2 Ingotedge
Average along the ingot
PTC Improves Tensile strength
Tensile strength variation in Conventional and Plasma Treated 1.6 ton steel ingots after heat treatment
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280
290
300
310
320
0% 20% 40% 60% 80% 100%
Relative ingot height
Har
dnes
s, H
B
Conventional ingot Plasma treated ingot
280
290
300
310
320
0% 20% 40% 60% 80% 100%
Relative ingot heightBottom Bottom Top Top
Metal Hardness variation in Conventional and Plasma Treated 1.6 ton steel ingots as cast
PTC Improves Hardness variation As cast
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0
2
4
6
8
10
12
ingot 20% 40% 60% 80%
elon
gation
, %
Conventional ingot after castConvntional ingot after heat treatmentPlasma treated ingot after castPlasma treated after heat treatment
Relative elongation variation in Conventional and Plasma Treated 1.6 ton steel ingots after heat treatment (average along the ingot from top to bottom)
PTC Improves Relative Elongation Variation
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The PTC equipment
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The PTC equipment
NETANYA PLASMATEC LTD
Confidential
The PTC equipment
PTC position during the PTC process