presentation conference opatija 2011 ml2
TRANSCRIPT
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Technical overview of Cored WireTechnical overview of Cored Wire
for Ductile Iron treatmentfor Ductile Iron treatment
ElFiCastElFiCast
Cored wire for iron foundriesCored wire for iron foundries
11th International foundrymenconference
Croatia, Opatija, April 28 29, 2011
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Brief history of Cored Wire processBrief history of Cored Wire process
The cored wire was introduced in the 1980s, first in the steelindustry, as a simple and economical way to introduce anyelement of addition or treatment in deep ladles of liquid metal.
The advantage of this method was quickly understood andapplications for the treatment of ductile iron was developed.
Several types of applications exist today in the elaboration of
ductile iron, cored wire can be used for desulfurization, for thetreatment of spheroidization, for inoculation in ladle or even
just before pouring, and some others applications linked tospecific requirements.
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Focus on theFocus on the
Nodularization of the ductile iron graphiteNodularization of the ductile iron graphite
Difficulties
=> Introduce the magnesium (boiling
temperature at 1090 C) in liquidiron at 1450 C
=> Limited sobubility of magnesium inthe liquid iron
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Metallurgical High Consistency
No Risk of Human Error
Cost Automation
High Productivity
Health & Safety Safe Use of Hazardous material Storage Clean & Easy Handling
Material Identified
Lower Dispersion Injection parameters adjusted
after the filling of the ladle
Reduction of Mg Targeted high metal quality
AdvantagesAdvantages ofofCoredCored WireWire processprocess
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Savings using Cored WireSavings using Cored Wire
SAVINGS
Unknow parameters(weigth)
Scattering
Cored Wire addition% min
Aim Using Lumps
Aim Using CW
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ComponentsComponents
of the Cored Wire treatment processof the Cored Wire treatment process
1) Consumable => wire + addition process
2) Equipment => Ladle + feedings equipment3) Liquid Iron
To highlight the benefits of Cored Wire process weneed to apply the best practices on these
components
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What do we need for to produceWhat do we need for to producean effective and efficient cored wire ?an effective and efficient cored wire ?
Choice and control of raw materials
Chemistry, sizing, flowability, ISO certified suppliers Homogeneous and consistent powder metric weight
weighting and blending in-situ
Automatic control of each individual powder feeding
& weighting system
Mixing just before filling the wire
Speed control of the profiling line
Prevention of lock seam opening hazards
Optimized final packaging
Full traceability
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Keys successKeys successto produce a consistent cored wireto produce a consistent cored wire
Homogeneity of encapsulated powder (blends)
The homogeneity of the composition of the encapsulatedpowder is guarantied by in-situ weighting and lateblending of the single components
Avoid to use pre-mix batches
Consistent filling rate The consistency of the weight of encapsulated powder
(grams of powder per meter of wire) all along the wire isobtained by using a permanent servo-controlled weightingsystem during filling
Avoid to fill the wire at constant volume
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Ferrostatic
Pressure
- Memory of coiling
- Flattening between feeder rolls
- high distance between guide tube and ladle
- low penetration into the liquid bath (twisting)
- Release of Mg on the top of the ladle => poor
efficiency nonnon--steady yieldssteady yields
FeedingFeeding equipmentequipment2
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FeedingFeeding equipmentequipment2
Cored WireCored WireInjectionInjectionPracticesPractices
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Straight and vertical injectionStraight and vertical injection
Straighten the wire to avoid residual constraint
Specific feeding equipment with adapted rolls
Guiding tube perpendicular to the bath (vertical)
Shorter distance between guiding tube and bath
No effect of ferrostatic pressure
Deeper penetration of wire into the melt
Deeper release of the product and longerreaction time with the molten metal
High and steadyHigh and steady yieldsyieldsDeep
penetration
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WireWire straighteningstraightening
Non-straightened wire Straightened wire
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GeometryGeometry of theof the treatmenttreatment ladleladle2
A ratio of H/D = 2 minimum is recommended in order to
have the highest metallo-static charge to oppose the
magnesium vapor pressure.
Also the height of the free board above the liquid surface
in the ladle before treatment, must be compatible with the
violence of the reaction.
H/D is the critical factor for the yield ofmagnesium, with the same cored wire we
can see a double consumption of wire withbad ratio
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WireWire diameterdiameter linklink to theto the ladleladle
Determinated by Mg content in the powder, requestedaddition of Mg, and speed of injection.
Economy is also a factor, typically higher diameter lead to lowprice. The goal is to find a wire whose ratio is: weight ofpowder/weight of wire is as high as possible.
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TemperatureTemperature ofofliquidliquid ironiron
This is the most important factor since temperature dictates
the vapor pressure of Magnesium (8 bars at 1400C, 17 barsat 1500C)
Consequently the speed of the Mg vaporization increases. Inaddition, the instantaneous flow rate of Mg is affected by the
injection speed (for a given Mg % in the powder)A greater Mg flow rate associated with liquid iron temperatureabove 1500C result in poor yields due to a formati on of biggerbubbles of Mg vapor.
And dont forget that solubility of Mg in cast iron decreases withtemperature.
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FactorsFactors toto bebe consideredconsidered whenwhen treatingtreating castcast ironiron
Liquid iron treatment temperature
Magnesium rate (for Mg treatment) Liquid iron weight
Liquid iron characteristics (oxidation, % S)
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Today we can achieve up to 60 % magnesiumrecovery with a pure magnesium patented cored
wire and consistent process
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Insulation which delays the heat transfer,
thus protects the Magnesium (~1 second)
deeper penetration of Mg into the liquidsteel. reduces the heat from thermalradiation. optimizes the wire guiding
Dramatic Improvement in Mg RecoveryDramatic Improvement in Mg Recovery
Very Steady ResultsVery Steady Results
Highly Predictable ResultsHighly Predictable Results
PAPMAGPAPMAGTechnologyTechnology
Deep
penet
ration
Externalsteel
sheath
Internalsteel
sheath
Insulation
Powder
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Pioneer, Leader, AFFIVAL is yourinnovative and sustainable partner.
Thank you for your attention
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Wire Feeding in FoundryWire Feeding in Foundry
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Wire Feeder for foundriesWire Feeder for foundries
Speed injection range: 0 to 120 m/min
Very accurate and steady injection speed (cm/min)
Very accurate length of wire fed (mm)
Light equipment easy to locate (ladle, mould ) Customizable equipment for any customer requirement
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Treatment booth for foundryTreatment booth for foundry
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Treatment BoothTreatment Booth
Wire feeder
Entry guides Exit guide tubes
Movable ladle cover
Sliding Door
De-dusting systemcompatible (not provided)
Possible full automation
All treatment Nodularization Inoculation
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Treatment booth for foundryTreatment booth for foundry