Foundry Technology Sand Casting. Cast Steel and Copper Casting Alloys

Transcription

1 Foundry Technology S Casting Cast Steel Copper Casting Alloys

2 S casting - Superior quality casting 02 // 03 The ZOLLERN Group ZOLLERN is one of the pioneers of the metal industry. 3,000 employees at 14 production locations seven subsidiaries in Europe, North South America Asia develop, manufacture supervise a range of innovative metal products. ZOLLERN supplies sophisticated solutions for diverse applications through its business units drive technology, plain bearing technology, foundry technology, mechanical engineering elements steel profiles. Contents Page S casting Superior quality casting S casting alloys 3 Cast steel for general use 4 Case-hardening steels 4, nitriding spring steels Heat-resisting cast steel 6 Stainless acid-resistant steels, ferritic/austenitic 6 Stainless acid-resistant steels, ferritic/martensitic 7 Stainless acid-resistant cast steel, austenitic 8 Heat-resistant cast steel 9 Special materials, non-magnetisable 9 Tool steels 10 Copper-tin copper-tin-zinc casting alloys 11 Copper-zinc casting alloys 11 Copper-zinc casting alloys 13 Copper casting materials 13 Copper-aluminium casting alloys (stardised) 14 Copper-aluminium casting alloys (non-stardised) 1 In Laucherthal, castings have been made from metallic materials since the founding of the company in. Apart from iron steel, a bronze foundry was added around 90. The emphasis today is on s castings made of copper copper alloys as well as high low alloy steels. For manually or machine formed parts, resin-bonded ss are used. This ensures a good surface, narrow tolerances as well as high-quality material. For special applications or requirements, we have the shell moulding process or utilisation of ceramic moulds ceramic cores at our disposal. Castings from copper alloys are possible to a delivery weight of approximately 7,000 kg, from steel to approximately 2,000 kg. Equipped with highly modern CNC machines, our machining shops pre-process or finish castings according to customer drawings. In the laboratory materials inspection, all stard destructive non-destructive tests examinations are available. Production is certified according to DIN EN ISO 9001 : For us, quality delivery reliability are the prerequisites for success on the national international market.

3 Cast steel for general use / Case-hardening steels /, nitriding spring steels 04 // 0 Cast steel for general use, nitriding spring steels DIN 1681 GE 200 EN DIN 1681 GE 240 EN A (%) annealed annealed (J) () General mechanical engineering; good weldability; magnetically soft for pressure-bearing components in accordance with AD-W up to 300 C General mechanical engineering; magnetically soft, at least 1. T at A/cm DIN 1681 annealed General mechanical engineering; magnetically soft, at least 1. T at A/cm (GE 260) DIN 1681 GE 300 EN annealed Case-hardening steels C NiCr WL CrNi 6 CrNi 8 17 CrNiMo Case WL hardened WL Cr Cr MnCr 16 MnCrS 20 MnCr DIN EN 84 A (%) () General mechanical engineering; magnetically soft, at least 1. T at A/cm Parts for general mechanical engineering with low core ; levers Components resistant to sudden, tough at subzero temperature; high core even with thick cross sections; pinion shafts, pins Parts subject to high with small wall thicknesses, inferior full hardening compared to 14 NiCr 14 Machine components subject to highest amounts of, better full hardening compared to 17 CrNiMo 6, therefore ly suited to larger parts Machine components subject to highest amounts of very good wear resistance Machine components subject to average, higher core compared to C 1; roller bearings, measuring tool As 1 Cr 3, but slightly higher core ; parts used in the construction of vehicles quality for components subject to average higher with cross sections that are not too large; cog toothed wheels, control components As 16 MnCr ; better more uniform machining possible due to modified sulphur content As 16 MnCr, but suitable for larger cross sections or higher core s C TL TL BWB C DIN EN 83 EN 1020 C DIN EN 83 EN C DIN EN 83 EN C 1.03 DIN EN 83 T1 - T2 CK DIN EN 83 T1 - T2 DIN EN CrNiMo EN CrNiMo DIN EN 83 T1 - T2 67 SiCr DIN EN T - T4 60 SiCr DIN EN % Proof A (%) Hardness/ Notched bar (J) () Reinforced cast steel; for components with high -treated toughness For components with small wall thickness subject to low ; mechanical engineering apparatus construction For thin-walled components subject to slightly higher in mechanical engineering Castings of higher with small cross sections subject to average For thin-walled castings of high ~ For components of high with small cross section/higher degree of purity cast steel for components subject to high with good full quenching subsequent drawing up to 0 mm wall thickness; parts subject to highest amounts of used in the construction of vehicles cast steel for large cross sections; full quenching subsequent drawing up to mm wall thickness possible; high toughness elasticity Castings subject to bending with small cross section Highly components with high requirements in terms of spring 2 CrMo DIN 1720 QT J Parts used in mechanical engineering G 26 CrMo EN QT J apparatus construction 34 CrMo DIN 1720 QT J High- cast G 34 CrMo EN QT J steel; wall thickness < 0 mm 42 CrMo 4 G 42 CrMo DIN 1720 EN QT1 QT J 37 J Universal, high- cast steel with average requirements in terms of toughness 42 CrMo S DIN EN 83 T1 - T2 0 CrMo DIN EN 83 T1 - T2 G 20 Mn EN CrMoV DIN CrV SEW 83 8 CrV CrMoV DIN WL Equivalent to material 1.722; good machinability due to modified sulphur content cast steel equivalent to 1.722; however with higher J with high toughness, also suitable for low temperatures N QT J Steel with good weldability even in ; nitriding steel for machine parts subject to wear Highly wear-resistant steel with good toughness Components with maximum wear resistance; also spring steel; cog toothed wheels, shafts & nitriding steel for wear parts subject to high up to approx. mm wall thickness

4 Heat-resisting cast steel / Stainless, acid-resistant steels, ferritic/austenitic ferritic/martensitic 06 // 07 Heat-resisting cast steel G X 20 CrCoMoV Thermal expansion between C 0.2% proof 20 C 90 C A (%) (J) α (10-6 K-1) C 2 DIN 1742 N GP 240 GH EN QT 40 G X 22 CrMoV 1 EN G X 23 CrMoV -1 EN G X 1 CrNiCo QT WL Cast ASTM A67 Or annealed 16 CrMo Heat-resisting castings resistant to pressurized hydrogen for the chemical industry; at least 340 MPa at 00 C 13.4 Fittings Turbine construction; components that are exposed to rapid temperature changes (temperature shock) Aeronautics; turbines/air blades, combustion chambers, valves; up to approx. 730 C; for further data, see supplement 1 to 1.497; non-scaling up to approx. 980 C; high-temperature; stainless For castings up to max. 30 C application temperature can also be used as case-hardening steel 17 CrMo EN QT G 17 CrMo - EN Turbine construction, pressure vessels, steam boiler construction 17 CrMoV EN QT G 17 CrMoV -10 Stainless acid-resistant steels, ferritic/martensitic G X 8 CrNi 13 DIN G X 7 CrNiMo -1 G X 20 Cr DIN 1744 X 46 Cr DIN G X 22 CrNi DIN 1744 A (%) (J) () QT ( HRC) Resistant to humidity, water, steam; pump parts, running wheels, running wheel blades; suitable welding filler For parts that must be resistant to humidity, steam, water frequent hling. Suitable welding filler Heat-treatable cast steel for cutting tools, measuring tools, wear parts Corrosion-resistant, -treatable cast steel, e.g. for tow bars Stainless acid-resistant steels, ferritic/austenitic G X 4 CrNi G X 2 CrNiMoN G X 2 CrNiMoN J J9220 G X 2 CrNiMoCuN G X 2 CrNiMoN EN ASTM A 99 SEW 400 ASTM A 99 treated treated treated treated Thermal expansion between C A (%) (J) α (10-6 K-1) Parts that require toughness with higher proof compared to austenitic steels with partially identical or better corrosion resistance, suitable filler material , pump housing For heavy exposure to corrosion, sea or brackish water, operating temperature up to 300 C Chemical petro-chemical industry, high resistance to -crack corrosion in media containing chlorine; similar to Chemical petro-chemical industry, flue gas desulfurization; resistant to non-oxidizing acids, e.g. sulphuric acid X 14 CrMoS G X 3 CrMo G X CrNi 13 4 G X 4 CrNi 13-4 G X CrNiMo /4 PH 0.04C 16Cr 4Ni 3Cu DIN SEW 310 DIN SEW 400 Annealed or DIN 1744 QT QT WL G X 4 CrNiCuNb QT HRC HRC HRC QT QT2 0 1 As For castings that require elaborate, mechanical finishing. Welding not recommendable Parts for optical devices, medical instruments measuring devices Water turbines pump parts, suitable filler material For parts with increased corrosion resistance compared to ; suitable welding filler Precipitation-hardened, stainless cast steel of high ; aeronautical material

5 Stainless acid-resistant cast steel, austenitic / Heat-resistant cast steel / Special materials, non-magnetisable 08 // 09 Stainless acid-resistant cast steel, austenitic Heat-resistant cast steel 0.2% Proof A (%) (J) () A (%) (J) () X 8 CrNiS DIN EN 88 treated As For castings with extensive mechanical machining, primarily thread cutting; welding not recommendable G X 40 CrSi DIN 1746 EN 1029 annealed For parts subject to minimal in industrial furnace construction up to 80 C G X 2 CrNiN 9 X 2 CrNi EN 88 G X 2 CrNi G X 6 CrNi 9 DIN 1744 G X CrNi X CrNi X CrNiMo DIN treated AT AT Fittings parts for pumps, centrifuges, etc.; suitable welding filler , 1.41, ; food processing industry, dairies, beverage industry; similar to L Frequently used "V2A" quality; similar forging quality to ; fittings, pumps, food processing industry, dairies Castings with identical corrosion resistance forging quality, but lower ; as a casting material stardised under ; similar to 316 L DIN 1746 G X 2 CrNiSi EN 1029 G X 1 CrNiSi SEW 9 SEW 9 G X 40 CrNiSi EN 1029 DIN 1746 G X 40 NiCrSi EN 1029 Cast or annealed Cast or annealed Cast or annealed Cast or annealed For parts subject to minimal in industrial furnace construction up to 900 C For parts in furnace apparatus construction up to 1, C in oxidizing atmospheres For parts in industrial furnace construction with high temperature fluctuation resistance G X 2 CrNiMoN X 2 CrNiMo 17 2 EN 88 G X 2 CrNiMo G X 6 CrNiMo 10 DIN G X CrNiMo X 2 CrNiMoN17 13 DIN GX 2 CrNiMoN X 2 CrNiMo S31603 CF3M DIN MR 017 ASTM A 743 treated treated treated AT AT X 1 NiCrMoCuN ( 3) (80) treated SEW 400 G X 1NiCrMoCuN G X CrNiNb 9 DIN G X CrNiNb G X CrNiMoNb 10 DIN G X CrNiMoNb AT Castings for which resistance to intergranular corrosion is paramount. After welding, no renewed required; suitable welding filler , 1.476; similar to L Similar to 316 L; castings with increased resistance to intergranular corrosion after welding without further processing Castings for the pulp, textile chemical industry; fittings, pumps; suitable welding filler Good intergranular corrosion resistance, resistant in high chlorine concentrations temperatures, good pitting resistance, chemical industry in accordance with NACE MR 017. Similar to , 316 L Good resistance to pitting -crack corrosion; full austenite; especially suitable for use in sea water; similar to 1.484/1.429 Castings in the food processing, film, photo, paint, soap, paper, textile saltpetre industries; suitable welding filler 1.41 AT As 1.42; suitable welding filler Special materials, non-magnetisable G X2 CrNiMoN G X CrNi G X2 CrNiMnMoN Nb SEW 39 WL SEW 39 WL 1.39 SEW 39 WL treated treated treated A (%) (J) () Non-magnetic casting material (VG 836); resistant to intergranular corrosion; can be welded Non-magnetic casting material (VG 836), can be welded Non-magnetic casting material (VG 836); very good corrosion resistance; ly resistant to intergranular corrosion; can be welded, subsequent not required

6 Tool steels / Copper-tin copper-tin-zinc casting alloys 10 // 11 Tool steels Copper-tin copper-tin-zinc casting alloys Chemical composition (approximate values %) C Si Mn Cr Mo V W Properties (HRC) () s Rm A % Cr DIN EN ISO 497 Hardened Wear-resistant tool steel, also for parts with high Hertzian contact, telescopic type ball bearing travellers, etc. RG EN 1982 CC491K CuSnZnPb-C DIN G-CuSnZnPb USA ~ C83600 UK LG2 F U-EPbZ Thin-walled castings, water steam fittings up to 22 C RG 6 EN 1982 CC492K CuSn7Zn2Pb3-C DIN G-CuZn6ZnNi UK ~ LG Suitable for pressure-tight parts due to additional Ni content fittings pump housing up to 22 C G X 38 CrMoV DIN EN ISO 497 Hardened High-temperature tool steel for all non-cutting functions; ing RG 7 EN 1982 CC493K CuSn7Zn4Pb7-C DIN USA ~ C93200 F U-E7ZPb Through higher Pb content good emergency running properties, sliding strips, sliding plates slide bearing shells or bushings up to 4kN/cm 2 maximum load, unhardened steel as shaft is an option G X 40 CrMoV DIN EN ISO 497 Hardened High-temperature wear-resistant tool steel; ing N/ mm 2 GBz 10 EN 1982 CC480K CuSn10-C DIN 1 2. G-CuSn10 USA ~ C900 GB CT Tin bronze with relatively high fittings pump housing guide, running paddle wheels for pumps water turbines GBz EN 1982 CC483K CuSn-C DIN G-CuSn USA ~ C900 GB PB Good sliding properties wear resistance, hinged blocks, hydraulic parts, sliding strips spindle nuts, cylinders for axial pistons G X CrMoV Hardened Cutting punching tools for average material thicknesses, cutting dies GBz Ni EN 1982 CC484K CuSnNi2-C DIN G-CuSnNi USA ~ C As GBz, but higher wear resistance high-speed, low-noise transmissions subject to higher, in endurance runs up to 1.2 kn/ cm 2, over short periods also kn/cm 2, ly suitable for worm wheels through additional Ni content, but also for same applications as GBz 10 G X 1 CrVMo DIN EN ISO 497 Hardened X 16 CrMoV Hardened MnCrV DIN EN ISO 497 Hardened Dimensionally stable, super-speed steel for higher toughness Steel resistant to corrosion to a limited extent for plate, wire, punching cutting tools. Tools for moulding ceramic shells Cutting punching tool, small shear blades, higher toughness compared to , , , , yet slightly reduced wear resistance GBz Pb mechanical properties pursuant to EN 1982 EN 1982 CC482K CuSn11Pb2-C DIN G-CuSnPb Young's modulus ~ k Electric conductivity ~ -8 MS/m Density ~ kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.01 µ r Good emergency running properties through higher Pb content high wear resistance, for slide bearings subject to -type up to kn/cm 2 crank toggle bearings, highly ed high-speed spindle nuts, sliding parts, sliding strips but not suitable for worm wheels = s casting (values also for shell-mould casting) = centrifugal casting All alloys are resistant against drinking water, sea water, oils, soap solutions, milk

7 Copper-zinc casting alloys / copper-nickel casting alloys / copper casting materials // 13 Copper-zinc casting alloys Copper-nickel casting alloys s s Rm A % Rm A % BZG Non-stardised bearing casting material better sliding properties (Si, Pb) ~ CuZn37Mn2Al2Ni1SiPb-C composition similar to CW713R ~ 10 Preferred for sliding-ed parts, up to 10 m/s sliding velocity, average compressive loads per unit area spindle pressure nuts, bearing guide bushings, bearing rings, worm wheel rims cast or produced from centrifugal casting GN 10 GN 30 EN 1982 CC380H CuNi10Fe1Mn1-C DIN G-CuNi10 USA C96200 F U-N10Fe1M EN 1982 CC383H CuNi30Fe1Mn1NbSi-C DIN G-CuNi30 USA C96400 F U-N30M1Fe Very good resistance against sea water, brackish water, chloride-containing wastewater, brine solutions for power plants, refineries, desalination plants, chemical industry, drilling platforms, petroleum production fittings, valve parts, oil water cooling tanks mechanical properties pursuant to EN 1982 = s casting (values also for shell-mould casting) = centrifugal casting PB EN 1982 CC76S CuZn3Mn2Al1Fe1-C DIN G-CuZn34Al1 USA ~ C8600 UK HTB Moderate sliding properties, tough pressure nuts for rolling mills spindle presses with higher additional Ni content also for ship superstructures, on-board tableware, propeller hubs blades Young's modulus ~ 0-14 k Electric conductivity ~ 2-6 MS/m Density ~ 8.9 kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 2 µ r ZB37 EN 1982 CC764S CuZn34Mn3Al2Fe-C DIN G-CuZn34Al2 USA ~ C86200 F U-Z36N Statically ed construction parts, valve control units, bevel only with good lubrication for bearing, guide rings, sliding blocks, pressure adjustment nuts with low sliding velocities, low emergency running properties Copper casting materials ZB 80 ABG EN 1982 CC761S CuZn16Si4-C DIN 19 G-CuZn1Si4 USA C80 EN 1982 CC762S CuZn2AlMN4Fe3-C DIN G-CuZn2Al USA ~ C86300 GB HTB3 F ~ U-Z19A Very good casting capability, good sea water resistance, low permeability < 1.01, suitable for pressure-tight, thin-walled parts such as sea water pump housings fittings, water tanks, exchanger parts, also parts for mechanical engineering, the electronics industry precision engineering Bearing material with high capability, only for low sliding velocities, moderate sliding properties, bearing bushings in construction machines, such as excavator arms, slow-running worm wheel rims, slide guide rails WKG L4 CCG s EN 1982 CC040A Cu-C, Type B DIN G-Cu L4 USA ~ C80 UK HCC1 F ~ Cu/c1 EN 1982 CC140C CuCr1-C DIN G-CuCr F3 USA ~ C8 UK CC!-WP F U-Cr0.8Zr Rm A % Electric conductivity 4 MS/m thermal conductivity 3.09 W/cm.K parts with higher conductivity in electrical mechanical engineering, general mechanical engineering, smelting technology, power supply, contact parts, cooling elements Electric conductivity 4 MS/m thermal conductivity ~ 3.14 W/cm.K As WKG, but higher wear resistance also for welding guns, electrode holders, clamping jaws for resistance welding equipment mechanical properties pursuant to EN 1982 = s casting (values also for shell-mould casting) = centrifugal casting mechanical properties pursuant to EN 1982 = s casting (values also for shell-mould casting) Young's modulus ~ k Electric conductivity ~ 3-8 MS/m Density ~ kg/dm 3 Thermal conductivity ~ 0.42 W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.03 µ r Young's modulus ~ k Density ~ 8.9 kg/dm 3 Thermal expansion coefficient ~ /K Permeability < 1.01 µ r

8 Copper-aluminium casting alloys (stardised) / copper-aluminium casting alloys (non-stardised) 14 // 1 Copper-aluminium casting alloys (stardised) Copper-aluminium casting alloys (non-stardised) s Notes Rm A % Rm A % AB 9 EN 1982 CC330G CuAl9-C Low permeability < 1.01 also resistant against diluted sulphuric acid, castings for the chemical food industry, such as screw conveyors, feed-in trays, mixing arms, pickling racks hooks TZB 28 TZB 32 TZB 36 Al content > 13% frequently not possible only is guaranteed very brittle Deep drawing tools for reshaping of titanium, Hastelloy austenitic steel, low friction coefficient, no welding profile straightening rolls, bending tools TUBG EN 1982 CC331G CuAl10Fe2-C DIN G-CuAl10Fe USA ~ C9200 UK AB1 F ~ U-A10Fe Low temperature dependency of the properties between -200 und +200 C, good corrosion resist. paddle wheels, pump wheels, fittings, bevel wheel sea water applications if Al < Ni (%) SMBG Sliding material, similar to forged material For parts subject to sliding, oil lubrication required, worm wheels, sliding blocks, spindle nuts, guide rails, also suitable for refrigeration technology EBG 9 EBG VBG EN 1982 CC332G CuAl10Ni3Fe2-C DIN G-CuAl9Ni EN 1982 CC333G CuAl10FeNi-C DIN G-CuAl10Ni USA ~ C900, ~ C9800 UK ~ AB2 F U-A10N EN 1982 CC334G CuAl11Fe6Ni6-C DIN G-CuAl11Ni USA ~ C Sea water resistant copper-aluminium bronze, no risk of -crack corrosion, as bearing material for parts subject to high slower sliding velocities < 1 m/s good lubrication required good weldability, also with composite constructions, with increasing aluminium content greater wear-resistance cavitation resistance, but also less running wheels, pump housing blades, ship propellers, ship superstructures, on-board tableware, turbine wheels, supered steam fittings, engine components, stirrers, pickling hooks, mixing arms for the chemical industry, exchangers, worm wheels, toggle bearings, sliding pressure parts, wear parts AMBG Sliding material, similar to forged material (CW306G) mechanical properties pursuant to EN 1982 or WL DIN Young's modulus ~ k Electric conductivity ~ 3-6 MS/m (SMBG, AMBG) Density ~ 7.6 kg/dm 3 TZB ~ 7.2 kg/dm 3 Thermal conductivity ~ 0.4 W/cm.K (SMBG, AMBG) Thermal expansion coefficient ~ /K (SMBG, AMBG) For parts subject to sliding, MoS lubrication required, worm wheels, sliding blocks, bushings, bearings subject to -type oscillating es also for higher temperatures such as roller conveyors of continuous casting plants, foundry machines = s casting (values also for shell-mould casting) = centrifugal casting EBG 9 - very good weldability MEBG WL G-CuAl9Ni EBG - most often implemented, very good combination of toughness MEBG, AMB3 for special requirements in shipbuilding low permeability < 1.02 or < 1.0 AMB3 DIN G-CuAl8Mn VBG - highest wear resistance capability mechanical properties pursuant to EN 1982 or WL DIN Young's modulus ~ 90 - k Electric conductivity ~ 2-9 MS/m Density ~ kg/dm 3 Thermal conductivity ~ W/cm.K Thermal expansion coefficient ~ /K Permeability < 1.01 to < 1.9 µ r = s casting (values also for shell-mould casting) = centrifugal casting For s shell-mould casting, the mechanical properties are determined from separately or integrally cast rods, with centrifugal casting (only copper alloys), directly from the casting, in doing so, the specified values apply only for wall thicknesses up to 0 mm. All information presented in this brochure was prepared with great diligence. Any warranty of quality or qualities is not connected therewith. does not assume any guarantee or liability. Applicable are the provisions stipulated in arrangements /or provisions as agreed on in the individual contract or in the General Terms Conditions.

9 Subsidiaries & local offices Plants ZOLLERN GmbH & Co. KG Hitzkofer Strasse Sigmaringendorf-Laucherthal Germany T F info@zollern.com ZOLLERN I I 081 I Errors amendments excepted. Pictures illustrations similar. Group headquarters