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Metal Casting Technologies : March 2007
Trust your most complex cores to INCAST ®. The ideal combination of geometry, density and particle size distribution, INCAST improves critical core making and casting properties including binder utilization, permeability and dimensional stability. Higher strength cores, better surface finish and increased efficiency and yield are the INCAST advantages. These sands are engineered for the metalcaster. Optimize Core Performance Unimin Australia Limited Tel.: +613 9586 5400 Fax: +613 9586 5411 E-mail: email@example.com Worldwide: www.metalcaster.com CORE AND MOULDING SANDS ® ® INCAST is a registered trademark. All rights reserved. ©2003 d) Turbine discs, rotors. e) Nickel and cobalt based alloys for aerospace applications. f) Die casting dies, gears, tool and die parts. g) Pressure vessel, rocket motor cases. h) High strength structural steels. i) Super alloys for aerospace applications. ESR FEATURES Improvement in the quality and properties of steels and alloys can be done by improving the purity of the metal by reducing gases, sulphur, inclusions, etc and by improving the structure of the ingot i.e. by increasing its soundness, crystal structure and homogeneity. ESR improves the metal purity as well as the structure of the ingot obtained. Figure 5 shows conventional cast and ESR ingot. It can be seen that conventionally cast ingot is full of defects whereas the ESR ingot has no porosity. In conventional ingots the structure consists of columnar dendrites growing at right angles to the mould wall (radially) with equiaxed crystals in the central zone. Such a structure besides having poor transverse mechanical properties also shows macro and micro segregation and axial porosity. In ESR ingots due to directional solidification the structure consists of columnar crystals oriented in an axial direction. Figure 6 compares the structure of a conventionally cast electrode in a mould (A) with that of an ESR ingot (B). In the case of conventionally cast ingot, solidification of a large volume of liquid steel in the mould leads to ingot segregation, the extent of which depends on the solidification behaviour of the solidifying multiphase system. In this case, local accumulation of non-metallic Figure 5.