Blue Power. BLUE POWER. Casting Systems. Years of Top Class

Transcription

1 Blue Power. Years of Top Class Casting Technology BLUE POWER Casting Systems

2 A new brand, but with more than 20 years of experience: Blue Power, your partner for innovative metal casting solutions. A new company with 20 years of experience? Yes, in fact. Our established company Indutherm GmbH is developing and providing metal casting solutions since more than 20 years first for the jewellery industry, soon later for other sectors as well. By launching our new international brand Blue Power we are now taking the logical next step. In our new company BluePower Casting Systems GmbH we have concentrated our joint capability and expertise in metal casting and atomisation technology to support our customers even more focussed in their longing for the best fitting solution in metal processing. Capability based on experience and research We generally develop and test our systems in close collaboration with users from different sectors. The varying requirements and areas of use has been fundamental to our expertise. Numerous machines have also resulted from research projects that we frequently carry out in conjunction with well-known research partners. All of our clients can take advantage of this expertise, in the form of advanced technology and competent consulting and support. Solutions for four different categories of manufacturing Atomisation systems for production of metal powders as needed in additive manufacturing and other technologies Casting systems for vacuum pressure casting according to the lost-wax-casting principle Continuous casting and granulating machines for production of semi-finished material Melting and pouring systems Atomisation systems AU series page 4 Casting systems High temperature vacuum pressure casting systems (tilting principle) VTC series page 8 Table top vacuum pressure casting systems (tilting principle) MC series page 12 Vacuum pressure casting systems (sealing rod principle) VC series page 14 Continuous casting machines CC/VCC series page 22 Granulating Units GU series page 24 Melting and pouring systems Tilting furnaces TF series page 26 Melting machines for hand pouring MU/MUV series page 28 High temperature melting solutions TF C / MU C series page

3 The Powder Atomisation Plants AU series For fast and economic production of small batches of metal powder The BluePower atomisation plants have been particularly designed for the flexible and economic production of small-scale metal powder batches. Traditional large-scale production plants cannot provide this economic advantage. Frequently changing alloys in production require high cleaning efforts to avoid cross contamination. Particularly in R&D or precious metal powder applications small amounts of various kinds of powder are frequently required, often also new types of alloy powder not available on the market. Especially fast developing applications like SLM and MIM require more and more specialised metal powder. High quality metal powders in a wide spectrum of alloys and particle sizes Our atomisers produce spherical, flowable metal powders with mean particle sizes between ~10 µm and 200 µm for e.g. soldering, SLM or other innovative additive layer manufacturing processes, as well as MIM and other powder metallurgy processes. To obtain specific metal powder characteristics, the AU machines work with different easy-to-change nozzle systems: free fall and close coupled atomisation nozzles. Flow optimisation in the spray chamber ensures an increased powder quality (avoidance of satellites). The BluePower atomisers are generally suitable such as for example those based on Cu, Au, Ag or Sn (standard versions) as well as Fe, Co, Ni, Pd (high temperature versions). The inductive heating takes place in graphite crucibles (up to C) or in ceramic crucibles (up to C, up to C in development). The crucible volumes reach from 245 ccm to 12,000 ccm. Easy-to-clean concept Polished stainless steel surfaces prevent powder adhesions in spray chamber, cyclone and collector all parts are easy to clean without any residues. This way the risk of metal loss and for gas atomisation of a wide spectrum of alloys, cross-contamination is reduced to minimum. Ag-based solder alloy powder with an average particle size of ~60 µm Free fall nozzle fluid stream primary gas flow nozzle gas flow spray Close coupled nozzle Accumulated mass distribution 1 0,9 0,8 0,7 0,6 0,5 0,4 0,3 Free Fall Atomization; CuSn10; Free Fall Atomization; CuSn10; d50,3 = 106 atomization gas pressure p m; d84,3/d50,3 = 1.6 ; PGas gas = 2 MPa; 20 bar mass median diameter d 50,3 = 106 m; geometric standard deviation d 84,3 /d 50,3 = 1.6; Close coupled Atomization; CuSn10; Close Coupled Atomization; CuSn10; atomization gas pressure p d50,3 = 35 m; d84,3/d50,3 gas = 2.4 MPa; 1.7; PGas = 24 mass median diameter d bar 50,3 = 35 m; geometric standard deviation d 84,3 /d 50,3 = 1.7; fluid stream 0,2 gas flow 0,1 low pressure area spray Particle diameter dp / m Particle diameter dp / µm Easy change of alloy and atomisation nozzle for powder production in a wide range of particle sizes 4 5

4 The Powder Atomisation Plants Oxidation-free processing The Air Classifier AC 1000 The AU machines offer the possibility of oxidation-free processing in the closed-chamber machine by means of de-gassing, vacuum and protective gas features. The BluePower-Atomiser at a glance: very simple handling via LCD-Display and neatly arranged control panel flexible and economic production of small scale metal powder batches easy-to-clean concept: minimum metal loss and cross-contamination high powder yield over a particularly wide particle size range via flexible, modular usage of different atomisation nozzles and hot gas atomisation particularly high process stability due to optimised nozzle systems anti-oxidation features Watch our atomization plant in action on. The Air Classifier AC1000 allows the economical and flexible classification of metal powders (<200 µm particle diameter). It is suitable for the separation into fine and coarse powder fractions especially also in the range < 25 µm, where conventional sieving operations fail. The throughput is about 25 kg/h (bronze). Low cleaning efforts with little metal loss and cross contamination, as well as high process stability qualify this plant for research, development and small scale-production with the need for frequent alloy changes, especially also for precious and other specialty metals*. * Without additional safety measures not suitable for air classification of explosive metal or alloy powders, e.g. Aluminium-, Magnesium-, Zirconium- or Titanium alloys, or other alloys with increased content of these elements. Example 1: BEFORE AIR CLASSIFICATION Particle size distributions obtained with Atomiser AU1000 by gas atomization of a tin-bronze alloy (Close-coupled atomization) AU 500 AU 1000 AU 3000 AU crucible volume in ccm ,500 3,400 12,000 volume in kg bronze volume in kg steel* generator kw (400 V) * volume reduction with ceramic crucible inserts for the high-temperature versions Example2: AFTER AIR CLASSIFICATION Particle size distributions of a gas atomised tin-bronze alloy separated in coarse and fine powder fractions with air classifier AC

5 The VTC series: for every metal or alloy you want to cast SweepMode Vibration Technology vacuum vacuum VTC vacuum/pressure casting machines The VTC 100 V VTC 800 V are extremely versatile casting machines suitable for a wide range of applications. While the VTC series was originally designed as a high-temperature casting machine for casting steel, palladium, platinum etc. (max. 2,100 C), large flasks also make it suitable for economically producing castings in each other material. The machine combines a dual-chamber differential pressure system with a tilting mechanism. The casting process is achieved by rotating the entire melting-casting unit by 90. One benefit of the tilting system is the use of economically priced melting vacuum vacuum pressing on graphite or ceramic crucibles instead of crucibles with holes and sealing rods; these tend to have a longer endurance. Some alloys, such as copper beryllium, quickly cause crucibles with holes and sealing rods to become untight and therefore useless, and for this reason, many users have so far processed such alloys only in open systems which means they can t choose to optimise the process with overpressure or vacuum. With the VTC series, these handicaps no longer apply. A vacuum can be produced in the melting chamber and the casting chamber to avoid oxidation processes during melting and air pockets in the casting mould. overpressure vacuum casting The flask is automatically pressed against the melting chamber for casting, making it possible to switch to overpressure during casting for better mould filling; in addition, the vibration technology optimises the process even further. As well as casting with flasks, casting into ingot moulds is also possible. Sweep mode vibration system for perfect results even in bad flowing metals The VTC machines are equipped with the advanced sweep mode vibration system. It considers that each casting tree and even each item of a tree has a different resonance frequency, depending on its shape and size. Generating variable frequencies the sweep mode vibration ensures that the optimum frequency is covered. Read more about on page 15. Handling and control Operation is simple and safe thanks to a clearly arranged and easy-to-use LCD display. All parameters, right down to the variable tilting speed, can be individually set and saved to ensure that recurring castings always produce consistent results. The high vacuum casting systems VTC 100 V Ti - VTC 800 V Ti Highly reactive metals such as titanium, copper beryllium, amorphous steel etc. pose particular challenges when casting. Hence until now the only way to cast these metals was to use extremely expensive specialised machines. As part of a joint AiF ZIM research project, Blue- Power has collaborated with the FEM institute in Schwaebisch Gmund under the sponsorship of the Federal Ministry for Economics and Technology to develop a cost-effective solution for casting highly reactive metals: the VTC Ti machines. The ideal structural basis proved to be the VTC 200 V tilting casting machine. Following numerous modifications, such as completely reconstructed valves and hose connections, special seals and an evacuation and inert gas flushing process tailored to the machine, the prerequisites for the required vacuum of 10 3 mbar were met. Furthermore, special crucibles and inductors were developed, as the ceramic crucibles that are normally used also react with titanium. They also reduce melting times and the shorter the melting time, the less time there is for a possible reaction. Graphite crucible and ceramic crucible 8 9

6 The VTC series Vacuum Pressure Casting Machines The new control system with LCD Display The casting process is achieved by rotating the entire melting-casting unit by 90. Flask size Ø125 mm x 220 mm VTC 100 V / Ti 12 kw 3x400 V 2100 C VTC 200 V / Ti 15 kw 3x400 V 2100 C VTC 400 V / Ti 20 kw 3x400 V 2100 C VTC 800 V / Ti 20 kw 3x400 V 2100 C volume graphite crucible ccm ccm = 450 = 220 g Au g Cu 18 ct ccm ccm = 2.0 = 1.2 kg kg Au Cu 18 ct volume ceramic crucible 30 ccm = 600 g Pt / 250 g steel 180 ccm = 2.5 kg Pt / 1 kg steel for use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h vibration technology sweep mode sweep mode automatic tilting with motor drive automatic flask fixing casting programs temperature measurement thermocouple up to 1,300 C thermocouple up to 1,300 C optical pyrometer up to 2,000 C optical pyrometer up to 2,000 C data printer GSM-modem for remote service accessories pyrometer with video output volume graphite crucible 300 ccm = 2.4 kg Cu 600 ccm = 4.8 kg Cu volume ceramic crucible 300 ccm = 2.0 kg steel 600 ccm = 4.0 kg steel for use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h vibration technology sweep mode sweep mode automatic tilting with motor drive automatic flask fixing casting programs temperature measurement thermocouple up to 1,300 C thermocouple up to 1,300 C optical pyrometer up to 2,000 C optical pyrometer up to 2,000 C data printer GSM-modem for remote service accessories pyrometer with video output = standard equipment = standard = equipment optional = optional = standard equipment = optional 10 11

7 MC series tabletop casting machines High-tech in most compact size The MC series vacuum pressure casting machines are compact yet highly professional casting systems for Rapid Prototyping studios and laboratories. They offer extremely short processing time from mould manufacturing to completed casting; simple, safe operation; high quality and reproducible casting results. The program controlled MC 20 V and MC 100 V are equipped with LCD control display and with the BluePower vibration system for optimum mould filling even at filigree parts. MC 15+ MC 20 V MC 60 MC 100 V 3.5 kw 230 V single phase 2000 C 3.5 kw 230 V single phase 2000 C 3.5 kw 230 V single phase 1300 C 8 kw 3x400 V 2000 C casting volume 60 g Cu 60 g Cu 260 g Cu 260 g Cu 110 g steel / 200 g Pt 110 g steel / 200 g Pt 300 g Ag g steel / 500 g Pt for use of flasks up to ø 30/50/65/80 mm x 80 mm h up to ø 30/50/65/80 mm x 80 mm h ø 100 mm x 120 mm h up to ø 80/100 mm x 120 mm h control panel digital display by LCD-Display, full text readout digital display by LCD-Display, full text readout automatic vacuum function automatic overpressure function casting also under vacuum only vacuum or overpressure after casting 1 up to +2 bar 1 up to +3 bar 1 up to +2 bar 1 up to +3 bar function washing by inert gas vibration system supply: cooling water, inert gas argon or nitrogen temperature measurement/control up to 1,300 C up to 1,600 C up to 2,000 C up to 1,300 C up to 2,000 C GSM-modem for remote service After pouring, the MC series automatically switch to overpressure in order to optimise the mould filling even for delicate parts. Alternatively it is also possible to keep the vacuum (example shows MC 15+). accessories vacuum investment mixer Indumix 2 furnace AK 20, 1,100 C sand blasting cabinet vacuum pump (min. 8 m 3 /h) (min. 8 m 3 /h) (min. 8 m 3 /h) (min. 21 m 3 /h) floor unit = standard equipment = optional 12 13

8 N/mm2 The VC series Vacuum Pressure Casting Machines Melting by induction technology: The crucible with the material is located in the core of the induction coil. By generating a strong alternating magnetic field, the result is a strong alternating current in the graphite crucible and in the metal. This leads to fast heating up and thorough mixing of the material. A thoroughly thought-through concept with the finest details......forms the basis of the technological advances made in our VC machines guaranteeing opti mal casting results whatever class of machine you opt for. A few examples of the additional features offered by BluePower machines: Vacuum Casting Automatic vacuum in the melting and flask chambers provides the de-gasing of the alloy and avoids undesired oxidation during melting (a low oxygen content is particulary important when casting silver or copper). Vacuum in the flask chamber during casting improves the form filling when casting filigree parts and avoids air inclusions. The special oxidation-reduced casting system... eliminates the danger of oxidation while the flask is cooling down. The Turbo Pressure function optimises the casting of very small and filigree objects. For the production of jewellery it guarantees perfect results when casting with stones. Turbo Pressure allows a precisely defined pressure to be achieved rapidly. For all program-controlled VC models, depending on the selected program the Turbo Pressure will start automatically exactly at the required time. Highest levels of safety for certified production The digital or program control of our machines and the integrated data printer (standard equipment for VC 650 V, VC 1000 V, VC 3000 V) ensure a high level of safety and the possibi lity of precise process documentation (important for ISO certified casting processes). During casting of very small or delicate parts the temperature of the flask is of utmost importance. By flask temperature measurement (standard for machines from VC 500 D onwards) the temperature of the flask can be monitored to within one degree. Overlapping casting All BluePower machines have separate lock systems for the melting chamber and flask chamber. This allows time to be saved by overlapping casting: while the flask remains in the flask chamber for several minutes after the casting, you may fill in and heat up the next charge. Vibration System Vibration during casting generally improves material flow and mould filling. Castings exhibit a higher and more consistent density Porosity is substantially reduced. Risk of hot cracks is reduced. 50% smaller grain size Castings have greater stress and elasticity properties, making them easier to process further. In practice this means: higher and more consistent quality, less waste, less postprocessing, better formability. Sweep Mode Vibration System The new sweep mode vibration system can do even more: it considers that each casting tree and even each item of a tree has a different resonance frequency, depending on its shape and size. The sweep mode vibration generating variable frequencies covers all natural resonances. porosity without vibration grain structure* without vibration Rm with V Rm without V Rp 0,2 with V Rp 0,2 without V tensile strength porosity with vibration grain structure* with vibration *Au 18 ct: 750 Au,128 Ag, 122 Cu 0,2% discharge elongination = with vibration = without vibration elongation limit ~12% better tensile strength ~25% better 14 15

9 The Vacuum Pressure Casting Machines for large casting parts VC 1000 VC 3000 VC VC 1000 V VC 3000 V VC V Capacity and power for large scale projects Our large vacuum pressure casting machines are mostly used for precise castings in aluminium alloys. They are always the first choice for parts with complicated geometry or when the number of pieces is not large enough for die-cast production. VC 1000, 3000 and offer the best pre-conditions for high quality castings in aluminium: the hydrogen content of aluminium alloys may be adjusted by regulating the vacuum during melting. This way, foaming of molten metal can be avoided without any melt additives. Overpressure in the melting chamber during and after casting and simultaneous vacuum in the flask chamber optimise form filling especially in filigree or thin-walled areas. The V-versions with vibration All our large VC machines are now equipped with a new program control system. The casting process is controlled via LCD full text display. Complete casting cycles may be stored for repeatable castings. Each machine is available in two versions: The standard versions offer 20 casting programs, the V-versions have 100 programs and as the most important innovation, they use the vibration technology for improved form filling. Magnesium casting versions picture: VC 1000 with feeding system picture: VC 3000 V picture: VC and window door with large flask chamber crucible volume 1,500 ccm = 3,5 kg Al 3,400 ccm = 8 kg Al 12,000 ccm = 25 kg Al optional up to 25,000 ccm = 60 kg Al for use of flasks up to ø 250 mm / 500 mm h ø 450 mm / 600 mm h ø 600 mm / 800 mm h optional up to ø 300 mm / 600 mm h 20 temperature programs program control (100 programs) VC 1000 V VC 3000 V VC V automatic flask and chamber lift VC 1000 V VC 3000 V dual temperature control flask temperature measurement data printer GSM-modem for remote service accessories granulation tank magnesium kit 25 kw 3x400 V 1500 C 30 kw 3x400 V 1500 C 60 kw 3x400 V 1200 C The magnesium casting versions are constructed according to strict safety requirements and guarantee safe and easy casting of magnesium and of course of many other metals, too. * Liquid metal up to top level of the crucible = standard equipment = optional 16 17

10 The fully automatic VC machines Vibration Technology SweepMode Vibration Technology VC 450 VC 480 V VC 650 V VC 450 The VC 450 is equipped with a program control system with full text read out LCD display. With help of the step-by-step display information and many automatic functions, the machine is very easy to handle, even for less experienced users. The program control for 20 different casting cycles allow reproducible and consistent casting results. VC 480 V The construction of the VC 480 V is based on the VC 450 and offers the same melting. However, in addition to the technical equipment of the VC 450, the VC 480 V comes with 8 kw generator power, an advanced program control with 100 casting programs, variable vacuum in the flask chamber and the most important add-on the BluePower vibration system. VC 650 V The absolute State of the art -machine: the VC 650 V garantees highest efficiency through maximum speed and quality. New program control system Thanks to the control panel with full text LCD display, all programs and parameters are very easy and convenient to set. 100 casting programs guarantee fast operation and con - sistent casting results. Turbulence reduction software For faster and more laminar metal flow. Turbo Pressure PLUS Filling of the flask using fast overpressure allows casting of very filigree parts and casting with stones. HSC High Speed Casting HSC improves even more the filling and surface quality of filigree designs or those with large and flat surfaces. crucible volume 170 ccm = 1.5 kg Cu* 170 ccm = 1.5 kg Cu* 245 ccm = 2.1 kg Cu* 386 ccm = 3.3 kg Cu* 386 ccm = 3.3 kg Cu* 386 ccm = 3.3 kg Cu* 700 ccm = 6.0 kg Cu* for use of flasks up to ø 130 mm / 240 mm h ø 130 mm / 240 mm h ø 130 mm / 240 mm h optional up to ø 160 mm / 400 mm h vibration technology in sweep mode pneumatic bell lock maximum pressure 1.5 bar 1.5 bar 3 bar programs program control by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout dual temperature control flask temperature measurement automatic flask and chamber lift variable vacuum in flask chamber turbo pressure PLUS system turbulence reduction software HSC feature data printer GSM-modem for remote service 4.5 kw 3x400 V 1400 C 8 kw 3x400 V 1600 C 12 kw 3x400 V 1700 C accessories sintering kit (for diffusion bonding) granulation tank 18 * Liquid metal up to top level of the crucible = standard equipment = optional 19

11 The semi-automatic VC versions with an optional granulating tank VC 300 VC 200/300 VC 400 VC 500 Resistor heated casting machines VC 200 / VC 300 The resistor-heated vacuum casting machine VC 200 and the vacuum pressure casting machine VC 300 are very low priced casting machines for smaller productions. Nevertheless these machines offer a convincing casting quality. Both machines reach a maximum temperature of 1,200 C. Induction heated casting machines VC 400 The ideal machine for smaller companies producing moderate quantities but needing considerably more than that offered by the MC machines. Often, experienced casters are not particularly interested in automated functions or program control, and they can achieve the same quality with the VC 400 machine as with more advanced ones. Its induction generator guarantees fast heat-up and thorough mixing of the molten metal by inductive bath movement. VC 400 and VC 500 do not only provide the Turbo Pressure function, but in addition they also switch to overpressure automatically after casting. VC 500 For larger production quantities with continuous casting operation, greater (shorter casting times) with even larger crucibles and flask capacities (flasks up to 160 mm ø/400 mm H) is important. The high maximum temperature of 1,600 C extends the possible range of alloys. Temperature measurements in both the crucible and the flask mean the best possible repeat accuracy in the process. If alloys are changed frequently, 20 different temperature programs simplify working procedures. 2 kw 230 V 1200 C crucible volume 245 ccm = 2.1 kg Cu* 245 ccm = 2.1 kg Cu* 245 ccm = 2.1 kg Cu* 386 ccm = 3.3 kg Cu* (only for 4.5 kw version) 386 ccm = 3.3 kg Cu* for use of flasks up to ø 130 mm / 240 mm h ø 130 mm / 240 mm h ø 130 mm / 240 mm h optional up to ø 160 mm / 400 mm h dual temperature control flask temperature measurement flask and chamber lift temperature programs 20 temperature programs 20 temperature programs turbo pressure function GSM-modem for remote service accessories sintering kit (for diffusion bonding) granulation tank 3.5 kw 230 V or 4.5 kw 3x400 V 1400 C 10 kw 3x400 V / 3x208 V 1600 C 20 * Liquid metal up to top level of the crucible = standard equipment = optional 21

12 The Continuous Casting Machines the only ones with vacuum and quattro drive picture: VCC 400 with optional Quattro Drive picture: VCC 1000 with Dual Drive picture: CC 3000 with optional Quattro Drive CC 400 VCC 400 CC 1000 VCC 1000 CC 3000 VCC 3000 More flexibility, lower costs BluePower continuous casting machines help you to save production costs. With only one machine, you can produce your own alloys or semi-finished products in different shapes and sizes in the shortest time, for example: wires or bars in every diameter you need, up to ø 85 mm (CC 1000/3000) sheets and strips, e.g. ring production, for stamping and pressing tubes, perfect as basic material for cutting in sections for wedding ring production granulates (with granulation tank, available as option) As the desired parts and alloys can be produced within minutes, you can reduce your investment for material in storage. Your processes will get faster, more flexible and more efficient. Semi-finished materials in highest quality To reduce the risk of oxidation during melting and during drawing, the machines are equipped with inert gas function, vacuum system for the melting chamber (VCC), optical die temperature measurement, die cooler with inert gas flushing and additional secondary cooling system. All these measures are ideal especially for alloys containing copper such as red gold or for silver as these materials tend to oxidise easily. Degasification under a vacuum results in a substantially improved because of the absence of oxidation semi-finished product. Thanks to the control panel with full text LCD display, all functions and parameters are very easy and convenient to set (100 casting programs). Optional quattro drive system The optional drawing unit with four instead of two motor driven feed rolls produce smoother tubes and sheeting with reduced marks of transportation. crucible volume 285 ccm = 2.2 kg Cu* 1,500 ccm = 12 kg Cu* 3,400 ccm = 27 kg Cu* 400 ccm = 3.2 kg Cu* 700 ccm = 5.6 kg Cu* wire / tube production up to ø 15 mm / ø 45 mm ø 30 mm / ø 85 mm ø 40 mm** / ø 85 mm** sheet production 50 x 8 mm / 60 x 8 mm 100 x 10 mm 130 x 12 mm 100 programs by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readout vacuum/inert gas overpressure CC 400 / VCC 400 CC 1000 / VCC 1000 CC 3000 / VCC 3000 neutral inert gas atmosphere optical die temperature measurement die cooler with protective gas flushing secondary cooler end bar sensor data printer GSM-modem for remote service 12 kw 3x400 V / 3x208 V 1500 C 20 kw 3x400 V 1500 C 30 kw 3x400 V 1500 C accessories Quattro-drawing unit center alignment sintering kit granulation tank bending-unit simultaneous casting of several wires 3 wires *** 5 wires *** * Liquid metal up to top level of the crucible ** Standard sizes special dimensions or *** not in combination 22 = standard equipment = optional profiles for watch cases etc. on demand with Quattro Drive 23

13 Solutions for Granulating GU 500 micro GU The Granulating Machines GU GU These shotmakers are developed especially for granulating bullions, sheet metal or casting residues into proper grains. The granulating tanks are very easy to remove for clearing. The GU machines are available with crucible sizes from 245 ccm up to 12,000 ccm. The major applications are Preparation of alloys or alloy components Preparation of alloys from components Cleaning up of already casted metal each under inert gas atmosphere or under vacuum GU 500 GU 1000 GU 3000 GU GU crucible volume in ccm ,500 3,400 12,000 25,000 volume in kg Cu generator kw (400 V) Simple handling of the granulation tanks Pull-out handle for easy removal of the tank insert. Pour off the residual water and then pour off the granules. CC 3000 with optional granulation tank The Granulating Tank for casting machines in the VC and CC series The optional equipment of a vacuum pressure or a continuous casting machine with a granulating tank is a suitable solution for occasional granulating. Granulating tanks are available for all machines in the VC series from VC 400 up to the VC and for all CC machines. Main advantages: Easy installation of the granulating tank Fast changing between casting process and granulating Ergonomically and perfectly balanced design for safe and easy handling Optimised streaming behaviour of the cooling water Reliable separation of water and granules The Micro Shot Systems GU 500 micro, GU 1000 micro and GU 3000 micro The GU micro series was developed for the production of micro granules with a grain size of between 0.1 and 1 mm. The systems are based on the BluePower granulation units as shown on the left but all key components, particularly the jet system, are special developments. The main areas of application for the micro-granules are in metal laser sintering processes, in jewellery surface design and in soldering technology. Granulation tanks in different sizes: left: GU 500, option for VC VC 650 V and CC 400 middle: GU 1000, option for VC 1000 and CC 1000 right: GU 3000, option for VC 3000 and CC

14 Tilting Furnaces for melting and casting large quantities into ingots or shell moulds TF 4000 TF TF series Some metals develop a lot of smoke and oxides during melting. It is better to melt them in open systems, with use of an air absorber. No limitation in the material size. Power, efficiency and safety The TF series tilting furnaces are equipped with 32-bit induction generators providing kw output power (depending on version). Low-frequency tuning means excellent throughmixing of the molten material. All versions are now controlled via a console with an LCD display with full text readout. Efficient thermal insulation and electro-magnetic shielding ensure a high level of effectiveness. Comparison tests carried out by a customer proved that the TF has a higher level of productivity than a competitor model with twice the and correspondingly twice the energy costs. The compact and highly cost-effective tilting furnaces TF 2000 and TF 4000 the side of the machine away from the dangers of the pouring off area. In the rare event of a crucible breaking, the machine is not damaged all of the assemblies are covered by a separate protective housing. A large collecting tray under the smelting unit prevents potential loss of metal. Our large tilting furnaces TF 6000 and TF Because of the potentially large weight of the inductor/crucible unit tilting is effected by motor drive with a stable shaft. Use of a joystick enables the tilting process to be controlled easily and sensitively. High temperature tilting furnaces TF 2000 C/TF 4000 C temperature measurement by thermocouple TF 2000 / 4000 TF 6000 / TF 2000 C / 4000 C kw 3x400 V 1500 C kw 3x400 V 1500 C kw 3x400 V 1700 C TF 2000: 20 kw TF 6000: 40 kw TF 2000 C: 40 kw TF 4000: 30 kw TF 12000: 40/60 kw TF 4000 C: 60 kw crucible volume TF 2000: 2,000 ccm = 17 kg Cu* TF 6000: 6,000 ccm = 52 kg Cu* TF 2000 C: 2,000 ccm = 5-14 kg steel* TF 4000: 4,000 ccm = 34 kg Cu* TF 12000: 12,000 ccm = 105 kg Cu* TF 4000 C: 4,000 ccm = 8-30 kg steel* tilting by lever tilting with motor drive (remote control) temperature control by LCD-Display temperature measurement by pyrometer temperature programs Ideal for melting large parts: no sealing rod construction reduces the available space. The new small TF machines have been developed with the focus on least possible energy consumption and on safe and ergonomic handling. The melting unit and crucible can be tilted and locked in position by the user at multiple angles for gentler filling. Such soft pouring also prevents damage to the crucible. Pouring off is continuous and gradual, using a pivot lever. The operator is forced to stand to These tilting furnaces have been specially designed to melt large quantities of steel or other metals with a high melting point. They are basing on TF 6000/TF and as these they are equipped by motor drive tilting mechanism. The special low frequency tuning of the induction generator means very good mixing of the metal can be achieved. GSM-modem for remote service * real for casting = standard equipment = optional 26 27

15 Melting machines for handpouring and recycling Indutherm systems used in the recycling process old gold dental gold remains from production and recycling a.s.o. ingots granules melting down melting down flakes Raffination TF MU GU Subsequent processing of the pure precious metals as new alloys into BluePower machines used in the recycling process GU CC VC 400 B/P TF / MU MU 700 MUVV 700 MU 200 C granulate semi-fi nished material (sheets and stripes, wires and tubes) ingots or pellets with defi ned quantities ingots MU/MUV series MU/MUV C series With the MU-, MUV- and MU C-series we offer melting machines for many different needs and with crucible capacities from 155 ccm up to 1,200 ccm. The material is molten in open crucibles and poured by hand into the casting mould or ingot mould. MU 200 MU MU 100 C MU 200 C MUV 200 MUV MUV 100 C MUV 200 C 3.5 kw 230 V or 6 kw 3x400 V kw 3x400 V 1300 C or 1500 C 1500 C 8 kw 3x400 V 2000 C 15 kw 3x400 V 2000 C Melting Units MU Series Flexible melting furnaces designed to melt aluminium, bronze, brass, gold and silver alloys. Due to the strong induction generator (up to 15 kw) and the low induction frequency the stirring effect of the metal is excellent. The high temperature Melting Units MU 100 C and MU 200 C By the special generator tuning and extremely heat-resistant ceramic crucibles the MU 100 C and MU 200 C are ideal for melting metals with a high melting point, such as steel, palladium, platinum, chromecobalt etc. The MU as vacuum casting machine: MUV Series The V-versions include one or two additional extra large vacuum chambers. Evacuating the flask immediately after pouring improves the form filling, reduces porosity and avoids oxidation of the hot metal. MU 400: 10 kw MU 700: 12 kw MU 900: 15 kw MU 1200: 15 kw crucible volume 155 ccm = 1.3 kg Cu* MU/MUV 400: 400 ccm = 3.5 kg Cu* 50 ccm = 1 kg Pt * 155 ccm = 2.5 kg Pt * MU/MUV 700: 700 ccm = 6.0 kg Cu* MU/MUV 900: 900 ccm = 7.5 kg Cu* MU/MUV 1200: 1,200 ccm = 10.0 kg Cu* perforated flasks with/without flange up to ø160 mm/400 mm h (MUV) ø 160 mm / 400 mm h (MUV 100 C / MUV 200 C) temp. measurement by thermocouple temperature control temperature programs 20 GSM-modem for remote service * real for casting = standard equipment = optional 28 29

16 Always in focus: the most economical solution for your demands Casting simulation: know what you re doing before you do it! Professional computer simulation of the casting process offers you peace of mind before embarking on complicated casting jobs: instead of tedious and costly failures, we can determine all the relevant parameters beforehand mould construction, positioning of sprues, temperature, pressure relationships based on your CAD data. Energy efficiency that goes that bit further The induction generators and inductors in our machines are designed with the highest possible level of effectiveness in mind. Efficient insulation ensures that the induction generated loses as little energy as possible for fast melting of the metal. The thermal insulation around the inductor and crucible effectively reduces heat radiation; the melting chamber acts like a Faraday cage to prevent the radiation of electromagnetic waves. The infused stainless steel coolant water lines further improve the shielding effect. Less energy for cooling Efficient energy use also reduces energy consumption for water re-cooling in the machine and the potential need for airconditioning in the foundry. Original BluePower consumables: Quality pays off! Our own high quality consumables, such as crucibles, dies or sealing rods, are specially developed for BluePower machines. Only using original BluePower consumables makes sense for a number of reasons: 1. Compact graphite ensures greater durability for crucibles and sealing rods 2. Higher quality casting results Less contamination from extraneous material like lead etc Less graphite contamination in alloys and castings Less gas porosity => reduced postproduction costs, less material loss 3. Less stress for the casting machines Our crucibles have lower electrical resistance, meaning that there is less stress on the inductor, condenser assembly, transformer and generator resulting in greater durability for these components Less power consumption 4. An extra two years of warranty for free if you only use original BluePower consumables. The casting process from start to finish from a single supplier and perfectly tuned to your needs We offer not only perfectly tuned casting machines, but also competent consultation in the various moulding, casting and finishing processes. Moreover we can support you in planning and equipping your complete foundry

17 Blue Power. standard BLUE POWER Casting Systems Blue Power Casting Systems GmbH Brettener Strasse Walzbachtal/Wössingen Germany Fon: +49 (0) Fax: +49 (0) All machine descriptions and technical data published in this leaflet make no claim to be complete. They are subject to change and therefore they are not basis of contract. No liability for printing errors. Reprinting and publishing, even as excerpts, are only permitted with the prior consent of BluePower. BluePower en