by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
button in toolbar for more information.
Metal Casting Technologies : September 2010
● Measuring instruments having virtually no human intervention. ● Recorder and analyzers with no human intervention. ● Sensors based on solar energy. ● Artificial intelligence. ● Use of solar thermal heaters/coolers for sand heating/cooling processes. ● Core drying tunnels based on solar thermal stoves/ovens operating at 200 deg C. Equipment & systems for future viability Melting furnaces, ladle refiners, moulding lines, pouring systems, mixers, sand reclaim machines ,shot blasting machines, fettling tools and so on will undergo radical change in terms of having lower inertia materials, high strength, minimal moving parts and this that move will have significantly reduced friction. The objective will be to reduce energy consumption in various unwanted drives. Use of composite and nano technology materials in addition to the inbuilt materials of very high tolerance for thermal shocks will be developed. Metallurgical properties/alloys ● Castings having metallurgical properties which will need no heat treatment or reduced annealing cycle time. ● Deliberately included inclusions and oxides that will enhance strength of consumer choice. ● Food grade and antibacterial surface properties within alloy matrix. Need no external and additional coatings. ● Scratch free and corrosion resistant metal components and machine exteriors that will need no additional paints. ● Alloy melts compositions that will have least shrinkage after solidification. Revolution in skill-set: Interdisciplinary talent inputs Future foundry layouts and operations will attract talent from fashion, architecture, IT, telecommunication and art institutions in addition to the core team of metallurgists, material engineers, scientists, and mechanical electrical and civil engineering specialists. The future training needs will therefore be cross discipline and multi collaborative type 28 www.metals.rala.com.au Fig 7. 3 Rs: Reduce, Reuse and Recycle: A typical foundry layout and our possible conservation areas Mold production Casting Foundry residuals Shakeout Recycled sand Recycled scrap metal Finishing Melting Core production (In-house) Virgin sands Graphite wash Organic additives (phenolics, isocyanates, petrolium distillates, amines, formaldehydes. etc) Fines Core butts Excess sand Slag Finishing wastes Finished castings Virgin sands Clays Water Organic additives (sea coal, cellulose, starch) Externally Produced Cores Scrap Metal Scrap metal storage RAW MATERIALS: MATERIALS PREPARATION: CASTING: MATERIALS SEPARATION: PRODUCTS AND WASTES: