Naigai CERABEADS 60 for Any Kind of Metal

Transcription

1 ITOCHU CERATECH CORPORATION August 21 Artificial Sand made in JAPAN Spherical Ceramic Sand for Foundry Naigai 6 for Any Kind of Metal > Anti-Burn-On > Thermal Expansion Control > Reduced Waste and Health Hazard > Wide Choice of Particle size > High Reclamation Yield #65 MULLITE BALL mm mesh Particle Size Distribution, % (Typical Value) Mullite Ball mm #4 #5 #55 #65 #75 #85 #95 #145 #13K #17 μ m Tr AFS-GFN Frequency, % #4 #65 #5 #55 #75 #145 #17 # Particle Size Distribution, mesh 1 #95 #13K

2 Major Properties Typical Value Refractoriness (Japan) (Australia) (South Africa) Silica (Australia) SK37 SK37 SK39 SK33 (1825 C / 3317F) (1825 C / 3317F) (188 C / 3416F) (173 C / 3146F) Bulk Density *, g/cm 3 / lb/ft / / / / 99 ph Thermal Conductivity, W/m K Thermal Expansion, % *Measured after vibration Bulk Density is lighter than other special sand ) Bulk density is measured after vibration. 2) Volume ratio is calculated by following formula. Volume ratio = Cerabeads density / Other sand density Volume Ratio (Equal Wieght) Cerabeads Silica Heat Resistance has very High Heat Resistance. 1) Sand is heated at 15 C (2732 F). 2) Fused sand is separated by sieve. 3) Heat Resistance is calculated by following formula. Heat Resistance = weight under sieve/total weight x (%) Heat Resistance, % Cerabeads Silica Crushing Ratio has High Durability (= Low Crushing Ratio). It is possible to Reduce Sand Waste and Increase Sand Reclamation Yield. 1) Sand is crushed by pot mill with alumina ball. 2) AFS GFN is measured. 3) Crushing ratio is calculated by following formula. Crushing ratio = Crushed AFS-GFN / Original AFS-GFN x (%) Crushing Ratio, % Cerabeads Silica Thermal Expansion is good sand to control thermal expansion of core by mixing to silica sand. 1) Test piece is formed in shell process. 2) Thermal expansion is measured under C (1832 F). Thermal Expansion, % Silica Cerabeads Heated Time, sec 2

3 Major Properties Chill Effect provides good heat transfer when used with black iron oxide. Heat Transfer (W/m-K).79 1) Test piece is formed in sodium silicate process 2) The size of the test piece is 23 x 115 x 5mm. 3) Heat Transfer is measured under room temperature. #65+ Spherical Black Iron Oxide 4%.721 #65+ Spherical Black Iron Oxide 8%.849 # Customers Customer County Type of Metal Casting Weight Process Type of Purpose of using A U.S.A. Low Alloy Steel, Carbon Steel 1, to 7, lbs #85 Replacing zircon B U.S.A. Low Alloy Steel 4 to 15, lbs #85 Replacing zircon C U.S.A. 8, to 1, lbs #85 Replacing zircon D U.S.A. Stainless Steel 1,3 lbs #65 Replacing zircon E U.S.A. Gray Iron 7,7 lbs Phenolic Co2 #95 Replacing other ceramic sand F U.S.A. Ductile Iron 5 lbs #85 (Mixed with silica sand) Replacing zircon G Canada Stainless Steel 8,5 lbs Furan #65 Replacing zircon H Korea 66, lbs Ester-Cured Phenolic #65 & 85 Better surface finish and reducing sand disposal I Japan 22, lbs Ester-Cured Phenolic #85 Replacing zircon J Japan 15, lbs Ester-Cured Phenolic #65 Replacing chromite K Japan Stainless Steel 9 to 7 lbs Sodium Silicate #65 Replacing zircon In addition to the above mentioned customers, is used by more than foundries all over the world for various types of castings such as mining & construction machineries, automotive parts, gas & oil facilities etc, just as explained in the following pages. 3

4 Cast Steel Anti-Burn-on (Good alternative to and sand) Molten Metal Metal penetration due to higher head pressure can be avoided with, Burnt Layer Still Easy to be Shaken out - Choice of Finer size - Black Iron Oxide (BIO) addition (BIO helps to keep core/mold stable at hot spot.), etc Heat by Molten Metal Burn on Difficult to be Shaken out Heat Resistance, % Temperature, F 2,192 2,372 2,552 2,732 SiO2(79%) SiO2(95%) 1,2 1,3 1,4 1,5 Temperature, deg. C Cerabeads SiO2(%) Applications Process Compatibility Alkid Isocyanate Furan Green sand Phenolic Ester & CB - NB & CB Sodium Silicate etc Low alloy 47 t (Max. 25 t) Phenolic Ester, #85 Carbon Steel 8 t, Phenolic Ester, #65 Weight Stainless 4.5 t, Phenolic Ester, #65 Carbon Steel 4.3 t, Phenolic Ester, #65 Cr-Mo Steel 4 t, Phenolic Ester, #65 Hi-Mn Steel 2 t, Phenolic Ester, #65 Carbon Steel 74kg, PU-NB, #85 Low alloy 6kg, PU-NB, #85 Alloy Heat Resistant Steel 7 kg,, #75 4

5 Automotive Engine Parts & Others Thin-Walled Casting and Complex Thermal Expansion, % ratio in silica, % + Frequency, % #4 #5 #55 #65 #75 #85 #145 #95 # Particle Size Distribution, mesh Expansion Control by Mixing Ratio Proper choice in size from AFS 4 to 17 = Net Shaping Less Defects (Gas & Vein) Smoother Surface Applications Cylinder Block,, #65 Process Compatibility Alkid Isocyanate Furan Green sand Phenolic Ester & CB - NB & CB Sodium Silicate etc Weight Cylinder Block,, #95 Cylinder Block, Green sand & PU-CB, #55 Exhaust Manifold Green sand &, PU-CB, #65 Cylinder Head, #4 - #75 Hydraulic Valve,, PU-CB #4 - #85 Hollow Camshaft,, #145 Turbo Charger Housing,, PU-CB #65, #75 Aluminum Cast Iron Steel 5

6 One Sand Loop System ( %) Benefits Less Cleaning time Because of high heat resistance of Less Dust in Work-Space Less dust generation due to high durability. No SiO 2 crystalline dust from. Shaking Out Pouring Breaking down to Sand Particles with Vibration and/or Drum Mold Fine Particles Mold, Thermal And/Or Mechanical New Sand Removing Binder Reclamation Dust Collection Reduction of New Sand Only for compensation of lost sand (spilling and duct collection) Simple Molding No Facng / Backing sand molding. All the reclaimed sand is special sand. Reduction of Waste Reduction of sand waste cost Advantage of Crushing Ratio, % After heating at 1,3C (2372F) Silica X-Ray Intensity M M Mullite Corundum γ-al2o3 C Crushing Time, min 3 5 times 3 5 Thermal Spray Ceramic sand Number of Heating at 15C (2732F) Mechanical Durability under repeated reclamation Chemical Stability under repeated heating Choice in Size Stable Supply Technical Support 6

7 Applications (One Sand Loop System) Green Sand Line Products Process Effect of Contents 1, cc Cylinder Brock (Gray Iron) Mold: Green Sand : Cold Box (with paint) High dimensional accuracy Thickness (Wall of Product): 3 mm Reduction of Sand Waste Process flow Reclamation of Sand Sand Preparation of Green Sand Sand Recovery Product Cooling Finishing Making (PU-CB) Green Sand Shakeout Cooling in Flask Automated Pouring Quality Check Taking product out Molding Setting Flask Closing To the Nest Process (PU-CB) Phenolic Ester Line 1.The Purpose for using Cerabeads, and Effects Purpose Effect Reduction of New Sand -2 % and Resin Cost Reduction of Sand Waste -92 % -2 % ( Working Hour ) Simplification of Molding 3 Layer Molding 1 Layer Molding (1 sand 1 process) 2.Products and Molding condition Contents Products: Turbine casing for Thermal power generation The pump runner for Hydropower generation, etc. Products Metal : Carbon steel, Low alloy steel, Stainless steel Weight : 1 t 25 t/piece Thickness: ave.15 mm (5-1, mm, Specialize Max 5 m) Amount of Resin Phenolic Ester 1.7 % Sand /Metal Weight Ratio ave Turbine Casing ( 47 t ) Other Typical Applications Product Process Type of CB Reclaimer L.O.I. Yield Hi-Mn, Hi-Cr Steel Phenolic ester #65 USR.9 % 97 % Mining tool #95 Thermal system Tr. - Stainless pump parts New Furan #65 Sand Shiner 1.6 % - Mining tool Phenolic ester & #95 Thermal & NRR Tr. 99 % Vessel parts Phenolic ester #65 #85 NRR type -.6 % 97 % Waterworks Phenolic ester #65 2 Pattern Shiner.8 % 98 % Stainless impeller VRH #65 Sand Fresher.3 % 98 % Hydraulic valve Lost Form #4 Non - >99 % Exhaust manifold Green Sand & #65 outside suppliers - - 7