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Metal Casting Technologies : March 2009
Automobiles NewWorldOF THE should reduce energy consumption, improve the work environment, and protect workers’ health. Regulatory pressure and restriction can come from various casting materials and processes. For example, foundry sands and additives can be identified as carcinogens. Odour pollution may warrant expensive scrubbers for core rooms. Therefore, there is a need for a new generation of low emission chemical binders, organic mold additives, and refractory coatings. In addition, batch melting practices are better than continuous melting in terms of energy efficiencies. Yet both may use holding furnaces which produce carbon monoxide and carbon dioxide. Stricter air toxic limits on benzene and formaldehyde are aimed at reducing hazardous air pollutants. Melt charge materials of galvanized, oily turning, heavy-metal components and fluxing must be eliminated or reduced as this can result in expensive controls for ventilation systems, bag-houses, and cupolas. New market development is an engineering challenge that requires matching the product needs to the casting design. Consumers have needs for casting performance and price/value. The metal casting producers need casting soundness and recyclability. Government regulators are looking for zero emissions, energy efficiencies, and an energy champion. Some of the markets worth penetrating are the electronics, semi conductor industries, aerospace (stabilizers, instrument panel console and wing supports), military (ground and air mobility), and energy (non-renewable such as oil, natural gas, coal, and nuclear and renewable such as biomass, hydro, wind, solar, and geothermal). To provide a better future requires the metal casting industry to penetrate markets requiring tighter casting tolerances. This requires certain improvements within the metal casting industry: 1) Metal casting producers need to take charge of the design process of casting by improving the “casting design rules” and taking away designer uncertainty. For example, certain testing standards are out dated and do not reflect the specification and performance of castings. More accurate testing methods are needed for mold, melt, and fill. 2) Labor costs in the metal casting process need to be reduced. This means replacing workers with automation in areas of highest cost such as in shakeout and finishing. Further, we need to remove workers from heat, dust, fumes, and repetitive motions to Profit from the superior capabilities of the SPECTRO metal analyzers for higher speed, lowest argon consumption, virtually no consumables and very little maintenance requirements - as well as unmatched analytical performance. SPECTROMAXx – Rapid analysis of all common elements in all common bases – Low maintenance spark stand with very low argon consumption – No recalibration or profiling required due to ICAL logic system – Available as benchtop or floor model with several versions to choose Metal Analyzers that Meet Your Demands Swamped with samples? Fighting high analysis costs? In need of extraordinary analytical performance? Please visit us at: Metal Tech Malaysia, 7-10 May 2009, Kuala Lumpur, Malaysia Butech, 20-24 May 2009, Busan, South Korea Asia Steel, 24-27 May 2009 Busan, South Korea Nippon Casting Congress, 29 May-1 June 2009, Tokyo, Japan Tel. +852.2976.9162 Fax +852.2976.9542 firstname.lastname@example.org www.spectro.com SPECTROLAB – High-performance metal analysis for demanding requirements – Unique hybrid optic with analog detectors and digital sensors, recording the complete spectrum from 120-780 nm – Digital plasma generator for exact control of the plasma conditions – New kind of readout system for detailed and flexible evaluation of each individual discharge TECHNOLOGY FEATURE Talk with SPECTRO and find out why SPECTRO’s analyzers and monitors are an investment in better efficiency and higher profitability. METAL Casting Technologies March 2009 31