MeltLab Thermal Analysis System Specifications

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1 MeltLab 1, a Production Tool for molten metals The MeltLab system is a flexible thermal analysis instrument made for the difficulties of foundry production analysis. Ruggedly constructed with MTBF of over 5 years, and easily maintained, MeltLab has been running since 1990 in competition with QuickLab 2, DataCast 3, AluDelta 4, ATAS 5 and other popular TA instruments. It consists of a PC software program melded with a very rugged analog converter with optional scoreboards, horn and light stacks. It has been adapted to include options for base irons, grey final iron, ductile final iron, aluminum, brass, steel, high temperature alloys such as cobalt, and even sterling silver. In addition, MeltLab Systems is dedicated to uncovering all information available through thermal analysis. This includes chemistry, microstructure, shrinkage, inoculation level, chill, nodularity, zero curve, and percent of phase. Custom programming and custom systems are available. Metal Types base irons grey final iron ductile final iron aluminum brass steel high temperature alloys such as cobalt sterling silver In addition, MeltLab Systems is dedicated to uncovering all information available through thermal analysis. This includes chemistry, microstructure, shrinkage, inoculation level, chill, nodularity, zero curve, and percent of phase. Custom programming and custom systems are available. Hardware Description PC running XP or Win7 provided by the customer (saves money, and conforms to corporate standards for computers) Licensed MeltLab Software (CPU license) 1 MeltLab is a Copyright of Sparkman Enterprises LLC dba MeltLab Systems, Winchester, VA. 2 QuickLab is a trademark of ElectroNite 3 DataCast is a trademark of ElectroNite 4 AluDelta is a trademark of Siedermes 5 ATAS is a trademark of NovaCast

2 Analog to Digital Converter box using industrial grade 16 bit zero pass, dual wire, nonmultiplexed technology for the thermal couple greatest accuracy Measuring station with either Pechiney stand for light metals, or a sand cup type stand for irons, steels and high temperature alloys Shielded thermal couple cable to insure best signal to noise ratio

3 Software Description 32 Bit software compiled in Delphi Pascal Threaded background processes for data collection Nine (9) readings per second per station Up to 10 inputs per MeltLab (cups or lances) - faster computers help with higher numbers Fast access to the last 100 curves for each station Up to 2000 curves can be archived per year Curves and graphics can be exported to Excel or Microsoft Word, or printed Results can be exported in comma or tab delimited files for various data bases Fully Network compatible Uses derivatives and other methods to determine points unavailable in any other foundry system Special smoothing algorithm (trade secret) and instrument design provides the best signal to noise ratio even down to the 6th derivative Rivals DTA instruments in accuracy and sensitivity but can be operated by foundry melters or technicians Hands free operation in normal production. Input is only required to change metal types Supports type K, B, R and S thermal couples using NIST standard equations Typical precision with K-type thermal couples is 1/20 degree C Display configuration menus allow the user to set the colors, font size, items to be displayed and much more Configuration menus allow setting up of reports, equations, ranges, limits and more Calibration menus allow for calibrations, tracking calibrations, and correcting for wire bias Analysis Methods available (note: the number of methods provided will change the price) Base iron chemistry using a tellurium cup: in addition to liquidus, eutectic and solidus Calculated carbon +/- 1% of concentration (Similar to combustion Carbon) Estimated silicon with typical 1 sigma of 0.03% for normal irons. High chrome irons and irons that vary greatly in manganese have some problems. Carbon Equalivant from liquidus temperature Oxidation state of iron (reduces effectiveness of inoculant and Mg treatment) Degree of micro-segregation (effects ADI treatment and possibly some physical properties such as impact strength)

4 Final Ductile Iron Microstructure in addition to liquidus, eutectic, solidus, recalesence and freezing ranges: Shrinkage and suck-in tendency Nodularity and Nodule count estimates (Note: actual values depend on section size. The equations can be calibrated to reflect a standard section size.) Carbide detection Solidification mode: eutectic, hypo-eutectic, hyper-eutectic and carbon flotation recognized Ratio of pre- and post-eutectic periods (S2/S1 Ratio) Percent late graphite Estimates pearlite/ferrite content (values depend on section size, calibrate to a standard section size. This measurement depends on a full sample cup.) Reports micro-segregation that is important in post ADI treatments. Final Grey Iron Microstructure in addition to liquidus, eutectic, solidus, and recalesence Final Grey Iron Microstructure in addition to liquidus, eutectic, solidus, and recalesence Estimated chill Flake type evaluation Shrink Carbides Micro-segregation Aluminum 200 series, 300 series, unmodified Aluminum-Silicon Grain Size estimate for hypo-eutectic aluminum-silicon alloys Beta Crystal detection down to 0.05% of volume Degrees of modification for aluminum-silicon alloys Zero curve plotted Silicon Content for un-inoculated aluminum can also be used as an estimate for inoculated, but will not be as accurate Copper phase detection and estimated percent volume Magnesium-silicide phase detection and estimated percent volume Steel and High Temperature Alloys including liquidus eutectic and solidus Percent carbide for carbidic alloys Phase detection for minor structures

5 Copper-Alloys including liquidus eutectic and solidus Measures phosphorus at 12-15% content to +/- 0.02% using vapor phase detection Measures Zinc in brass alloys if hypo- or hyper-eutectic is specified Measures Tin in bronze alloys if hypo- or hyper-eutectic is specified Special requirements Other applications can be easily accommodated for special alloys if phase diagram or chemical analysis data is available. One example was a sterling silver manufacturer who needed to make sure his product contained at least 85% silver (the specification for sterling) but no more. Measuring the liquidus of his metal, we were able with the phase diagram to calculate the silver content, and allow him to adjust his heats to minimize costs. Costs The typical MeltLab system costs between 12 and 15k installed. Large systems can reach 25k. MeltLab holds a special niche in the market, offering a wide variety of analysis methods, superb accuracy and precision, long instrument life and is priced at or below similar systems, although with far more capability than the competition.