aluminum gravity die casting cost reducing ptc stirring process
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NETANYA PLASMATEC LTD
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Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)
NETANYA PLASMATEC LTD
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Plasma Treatment Casting (PTC) Plasma Treatment Casting (PTC) process for aluminum Gravity Die process for aluminum Gravity Die
Casting (GDC)Casting (GDC)•The PTC is an add-on patented technology, and does not change the end product
• The PTC is commercial as of 2007
•The PTC reduces risers’ mass by 70-80%
•The PTC increases casting productivity by 20-25%
•The PTC improves the casting quality
•The PTC reduces casting process defects by 50%
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Plasma Treatment Casting (PTC)
PTC advantages PTC advantages
Saving 30% of aluminum castingIncreasing 20% of casting productivitySaving 35% of sand and binders
Electrodes
PTC System
Sand and Binders saving
Aluminumsaving
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The PTC process applies plasma arc during solidification process
The rotating plasma arc movesalong a prescribed path, defined bya special electrode
The PTC ProcessThe PTC Process
Confidential
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PTC multi plasma arcs system for complex casting shapes
Parallel plasma arcs on top of the risers
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Creates enormous shear forces by very effective stirring
Plasma stirringPlasma stirring
Induces electric and magnetic fields in the molten metal
Creates changing current density flow in the molten metal
Breaks the growing dendrites and creates a new nucleation center on each fracture
Creates smaller uniform dendrites and reduces significantly porosity and segregation levels
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Saving 10kg of the riser’s mass
Reducing casting weight 31kg 21kg.
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Saving 10kg of the riser’s mass
Reducing casting weight 31kg 21kg.
Risers height reductionRisers height reduction
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Saving 10kg of the riser’s mass.
Reducing casting weight 31kg 21kg.
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Saving 13kg of the riser’s mass
Reducing casting weight 42kg 29kg.
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Reduction of risers mass by 17kg
Reducing casting weight 54kg 37kg
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The PTC system includes•An electrodes gripper which can be adopted for each type of casting die•A multi DC channel power sources•A control cabinet•A consumable electrodes
•The PTC system is a flexible add-on device for existing casting cells•The PTC applies the plasma arcs after pouring and during solidification
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PTC Quality Improvement PTC Quality Improvement
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8 kg casting weight reduction 31 Kg 23 Kg
70 sec solidification time reduction240 sec 170 sec
NP castingNormal casting
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Micro-Porosity
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0.09
po
ros
ity
[%
]
column 0.02 0.05 0.008 0.03
bottom 0.02 0.007 0.001 0.01
NP1 NP2 NP3 NP4
Normal casting
Normal casting
Bottom of the casting
Column
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Average Dendrite Measurements (primary & secondary)
20
30
40
50
60
70
80
SIM
[M
icro
ns
]
column 66 65 66 66
bottom 44 49 44 47
NP1 NP2 NP3 NP4
Normal Casting
Normal Casting
Bottom of the casting
Column
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1 2 3 4
Mechanical properties in the bottom of the casting
Yield strength in the bottom of the casting
0
50
100
150
200
250
300
Sy
0.2
[M
Pa
]
NP casting 252.5 256.5 254.33 253.25
Normal casting 265 265 267 262
Cut 1 Cut 2 Cut 3 Cut 4
Ultimate tensile strength in the bottom of the casting
0
50
100
150
200
250
300
Su
ts [
MP
a]
NP casting 306.67 305 306.33 301.5
Normal casting 307 305 304 299
Cut 1 Cut 2 Cut 3 Cut 4
Elongation in the bottom of the casting
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
e [
%]
NP casting 6.22 6.5275 4.69 5.315
Normal casting 3.44 3.68 4.17 2.62
Cut 1 Cut 2 Cut 3 Cut 4
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Mechanical properties in the column area
Column
Tensile strength (Sy0.2 and Suts) in the column area
0
50
100
150
200
250
300
St
[MP
a]
NP casting 252.00 252.5 306.75 301.5
Normal casting 261 259 302 297
Sy0.2-Cut 1 Sy0.2-Cut 2 Suts-Cut 1 Suts-Cut 2
Elongation in the column area
0
1
2
3
4
5
6
7
8
e [%
]
NP casting 7.1225 4.78
Normal casting 2.91 2.34
Cut 1 Cut 2
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Quality Conclusion
• Higher casting quality in addition to casting weight reduction by 30-40%.
• Solidification cycle time reduction by 30-35%.
Mechanical properties Improvement by the PTC
• Elongation percentage (A% ) significant improvement:Form 3.48% to 5.70%, increase of 146% in the bottom From 2.62% to 5.95%, increase of 224% in the column (top)
• Porosity percentage significant improvement :From 0.012% to 0.0095%, reduction of 20% in the bottomFrom 0.08% to 0.027%, reduction of 66% in the column (top).
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PTC’s Competitive Advantages in Aluminum gravity die-casting of GDC cylinder head.
• Production cost reduction of GDC cylinder head by 20%-25%• Riser's mass reduction by 70% -90% and thus casting weight reduction by 35% • Sand mass core reduction by 40%• Foundry yield increase from 50% to over 80%• Foundry productivity increase by 20%- 25%• Melting and holding furnaces efficiency increase by 50%• Foundry sand reclamation reduction by 30%-40%• Environmental emission reduction by 35% • Metal feeding improvement• Defects ratio reduction• Shrinkage and porosity elimination • Mechanical properties improvement • Microstructure refinement
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