Snam Alloys at International Trade Fairs Brazil I Mexico I Poland I Turkey

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1 Private Circulation only Volume - 1 I Issue - 2 October, 2014 Snam Alloys at International Trade Fairs Brazil I Mexico I Poland I Turkey Visit us at Stand : I -5, Hall 5 IFEX 2015 SNAM will be participating in the Indian Foundry Trade Fair (IFEX 2015) to be held at India Expo Centre & Mart, Greater Noida between 27th February - 1st March

2 Kielce Poland Trade Fair, Poland SNAM participates in annual metal fairs and exhibition along with their partners in respective countries every year. Metal Kielce: Held once in a year at Kielce - Poland. Sykofin - SNAM partner for Poland had a stall and SNAM marketing team were present at the exhibition stand as a Principal 2

3 Ankiros 2014 Turkish Trade Fair, Turkey ANKIROS International Iron-Steel & Foundry Technology, Machinery and Products Trade Fair, which is held biennially in Turkey, is the international exhibition on foundry and iron-steel industry, was held in Tuyap Fair & Congress Center from September, The exhibition ANKIROS is called to satisfy the vital requirements of Turkish iron and steel industry in modern technologies of production and trade in the world market. In this annual event, our Partner for Turkey Marmara Metal, had a Stall and SNAM represented it with its Marketing team. All leading foundries in Turkey visited the stall. 3

4 Metallurgia 2014 Brazilian Trade Fair, Brazil Metalurgia fair, attracts exhibitors and visitors from Brazil and abroad. For over 15 years it has integrated and developed the sector s supply chain by presenting innovative products with technological advances. Our Partner for Brazil, Buschle Lepper participated in the event and SNAM Marketing team were also present. 4

5 Fundiexpo 2014 Mexico Trade Fair, Mexico It is the leading event in the foundry industry in Mexico, organized by the Mexican Foundry Society for its different regions. For this 19th edition, the Mexican Foundry Society North Region, A.C. was the host for the attractive event. FUNDIEXPO Monterrey 2014 offered more than 5,700 square meters of space becoming an ideal platform for the launching of new product lines, technologies and positioning of the brand, in addition to being an excellent forum to create new business opportunities and increase commercial relationships with key people in the foundry industry. Our Partner for Mexico, Possehl participated in the event and SNAM Marketing team were present at the stall. 5

6 Cover Alloy for Ductile Iron Production Covering A dense material to delay the onset of Mg reaction to ensure less vaporization losses, high recoveries and better treatment. High density (with 50% Si) over regular FeSi ensures better covering action than regular inoculant. Presence of Barium controls loss of Magnesium due to oxidation. Less heat required for melting Allows low metal tapping temperature. Provided metallurgical benefits over regular Steel as cover. Promotes graphitization Controls shrinkage & Carbides in castings. Helps Foundries reduce the addition of Mg alloy and Post Inoculants. Case Study: Trials were conducted in ductile iron production to compare the effectiveness of SNAM Bacal50 as cover alloy in place of the regular treatment process. The process parameters and analysis results were as under: Parameters Regular Trial Bacal50 Trial Tapping Temperature FeSiMg addition 1.30% 1.20% Post Inoculation 0.40% 0.30% Covering CRCA: 1% Bacal50: 0.3% + CRCA: 0.4% Residual Mg 0.041% 0.043% Nodularity 85.30% 90.10% Nodule Count 217 / Sq.mm 274 / Sq.mm The micro-graphs for the trials are as under: Regular Trial Bacal50 Trial The Thermal analysis conducted for the same had cooling curve as under: Regular Trial Bacal50 Trial Sample TL TELow TEHigh TS R GRF1 GRF2 FeSiMg FeSiMg + Bacal Desired Depends on C-eqv High Close to TE Low High Low High Low Conclusion: It can be concluded from the trial and analysis that implementing Bacal50 as a cover alloy can help foundries improve the metallurgical quality and produce defect-free castings at same treatment cost. 6

7 Get the best out of your Magnesium Treatment! 1. Base Metal Chemistry: a. Silicon: Silicon pick-up after Mg treatment in ductile iron is between 0.7% - 1%. To achieve the final desired Silicon level, alloy for Mg treatment can be chosen as per the base Silicon level. With common Mg alloys containing 40-45% Silicon, Alloy with Mg content of 5-10% can be selected accordingly. b. Sulphur: Sulphur, though an important element for nucleation, may reduce the nodularizing effect of Mg by decreasing the surface tension at Liquid metalgraphite interface. High Sulphur (more than 0.02%) in base iron requires increased Mg alloy addition. c. Oxygen: Oxygen content in the metal should be low, high oxygen content leads to oxidation losses, slag and Inclusion defects. Oxidation losses can be prevented by tapping metal at low temperature, avoiding metal holding for long time and by avoiding excessive usage of rusted scrap. 2. Treatment temperature: Tapping at temperatures above 1540 C leads to loss of Mg and hence, poor Mg recovery. By treating the metal at less superheated temperature, foundries have been able to achieve higher Mg recoveries with reduction in Mg alloy addition. 3. Treatment & Pouring Time: All inoculants and nodulizers fade with time. Fading of nodulizer results in degenerate graphite shapes and hence poor nodularity. Hence, foundries should ensure control over pouring time (generally not more than 10 minutes) after treatment. There are some inoculants which are specifically designed to work even at extended time periods Barium based. 4. Clean Metal Treatment: Foundries should ensure minimal slag. Metal, ladle and ladle pockets that are free of slag result in less oxidation losses and efficient Mg treatment. 6. Pre-conditioning & Inoculation: Metal with high nucleating potential and controlled amount of tramp elements can achieve high Nodularity. Pre-conditioning to rejuvenate the base metal by creating stable nucleating sites and Inoculation in the treatment ladle helps control oxidation losses of Mg and decreases carbide formation tendency. 7. Treatment Ladle Design: Well insulated treatment ladles with minimum height: diameter ratio of 2:1 and preferably a tundish as cover, allow foundries to achieve better metal head for Mg pick-up, low treatment temperature and high Mg recoveries. 8. Alloy composition: For higher Mg recovery, it is always advisable to use alloys with low Mg reduced reaction violence & extended reaction time. Also, the presence of elements having higher oxygen affinity, for e.g. Ca, helps reduce the oxidation losses of Mg during treatment. Rare earth elements in controlled amount in the alloy negates the effect of tramp elements and hence controls degenerate graphite formation. 9. Size range: Size distribution of alloy should always be with respect to the amount of metal to be treated. Varied size distribution gives better alloy packing and hence extended reaction time less violence and high Mg recovery. 10. Alloy Storage & Charging: Alloys stored in moisture free closed containers result in consistent and effective treatment. Alloy addition in ladles should be done as late as possible to avoid exposure to hot ladle wall and/or atmosphere to avoid oxidation of Mg alloys. 5. Treatment Technique: Mg Treatment using Tundish cover on ladle and Sandwich method delays Mg reaction resulting in lower Mg loss. Different covering agents steel scrap and punchings, specialized flux materials etc., help in effective treatment. High metal tapping rate ensures sufficient metal head for Mg pickup during reaction. 7

8 Members of IIF, Coimbatore Chapter visit to Snam R&D Centre Members of IIF Coimbatore chapter, visited SNAM R&D centre on 26th September, 2014 as a part of their factory visit. A presentation was made to the members highlighting the SNAM R&D capabilities and services on offer to the foundries. Additionally, the presentation described some of the projects undertaken in collaboration with the foundries. Apart from the presentation, a trial melt was conducted at the in-house foundry, demonstrating correct melting practices and modern quality inspection tools. During the interactive session held later, some of the members of IIF shared their experiences and expectations with SNAM Alloys R&D Centre. Their kind words about the work culture, cleanliness, dedication, knowledge and commitment practiced at SNAM were very pleasing and will encourage and motivate the team to achieve new endeavours in future. IIF Members at SNAM Alloys R&D Centre IIF members during the Melt IIF, Coimbatore Chapter s Factory Visit - Memento 8

9 Enlighten your knowledge on better practices The schedule of the training program is designed such that the participants are introduced to the technical aspects of all the foundry activities and their impact on the final casting quality.in due course, the participants find themselves home with the feel of what they do, with more technical inputs. The later sessions include theory cum practical oriented classes where properties of the raw materials and the metal treatment is explained in a broader manner. The participants are then provided with the knowledge of modern laboratory equipment to check and validate the metal and casting quality. Highlight of the training is the melt at the in-house shop floor simulating the melt practices at a typical foundry. The melt aims at equipping the participants with proper melt practices like charging, preheating, melt treatment, tapping and pouring, etc. Hence, the training program is a full-fledged package aimed at turning the improper/deficit practices into one with proper knowledge. Training is the kindling of a flame and not just filling the vessel. - John.F.Kennedy It s all to do with the training: you can do a lot if you re properly trained. - Queen Elizabeth-II Continuing with the success of earlier training programs, in the last quarter, SNAM marched towards providing improved and specialised trainings as a service to our customers. The improved training module provides a clear picture of correct and effective foundry practices and its impact on final casting product. The training is aimed at detection and solving of problems faced at the shop-floor. As a next step towards progress, SNAM offers a specialised training program on 3D modelling, Simulation and Thermal analysis. As these have become key tools for quality assurance in modern foundries, SNAM has stretched its hands to assist foundries in the same. The first specialised training on 3D Modelling and Simulation and Thermal Analysis was held on: 2nd to 4th July, The next training session will be conducted at the SNAM R&D Centre in the month of November. Kindly book your slots and help us serve you better. Foundrymen during the training session Three training sessions were conducted and 27 foundrymen from across the country attended the sessions. The Training programs conducted at SNAM Alloys Pvt. Ltd., R&D Centre: 7th to 9th July, Foundry-men 17th to 19th July, Foundry-men 18th to 20th September, Foundry-men 9

10 Tech Quest 1. Brittle materials when subjected to tensile loads, fractures without any sensible elongation. (a) Yes (b) No 2. Which type of cast iron requires least risering in the design? (a) White Cast Iron (b) Malleable cast iron (c) Grey Cast iron (d) Ductile Iron 3. The effect of improper cooling of the system sand in the green sand moulding cycle (a) Increase in the compactability of the sand (b) Increase in the dead clay content of the sand (c) Increase in the grain fineness number of the sand (d) Increase in the moisture content of the sand Kaizen CII In September: CII in association with the Institute of Quality organised the 14th TPM National Chennai. SNAM participated in the event and Mrs K Nirmala - Manager from our Quality and Process Department represented SNAM in the event and presented the Kaizens executed at SNAM. 4. Which is the alloy with least melting point in the Fe-Fe3C diagram (a) Peritectic alloy (b) Eutectic alloy (c) Eutectoid alloy (d) Fe-C Alloy with 1.9% C 5. Which among the following is not a factor for lower Mg recovery in DI? (a) High tapping temperature (b) High Sulphur and Oxygen content in melt (c) High Carbon content in melt (d) Low L/D ratio of treatment ladle ANSWERS: 1. (a); 2. (c): 3. (b); 4. (b); 5. (c). Mrs K Nirmala - Manager (Q & P) at extreme right Our New Partners M/s Ergarda: For Russia and Ukraine M/s Dickinsons: For Australia and New Zealand M/s Envoy : For Taiwan 10

11 Crossword Across 1 Degree of roundness of graphite in ductile iron (10) 5 Iron carbide is also known as (9) 6 Material used to accelerates solidification in a particular portion of mould (5) 8 A casting defect (7) 9 Element in white cups for C% detection in melts (9) Down 2 Property of a material to elongate is known as (9) 3 Structure of pearlite (8) 4 Connects Down sprue and In-gates in the mould (6) 6 Supports cores inside a mould (7) 7 Element causes Carbides in ductile iron (8) 11

12 Snam s Global Network Unit 1 Kariamanickam Village Nettapakkam Commune Pondicherry , India Unit 2 Damalacheruvu Village Pakala Andhra Pradesh, India R&D Centre 138, SIPCOT Industrial Complex Hosur Tamil Nadu, India Ph: / Fax: marketing@snam.co.in / gmmktg@snam.co.in