High silicon alloys present important peculiarities in comparisson to standard grades, especially in terms of feeding capacity and tendency to contraction. For this reason, their behavior differs significantly from the behavior modeled by the simulation systems available in the market.
The system for the Industrial Manufacture of High Silicon Iron Castings developed by AZTERLAN makes it possible to mass-produce this type of components, overcoming the usual difficulties presented by their development:
- Significant tendecy to contraction of these alloys
- Variability in the soundness of the parts produced under industrial conditions
- Lack of precission of standard simulation tools to predict defect and their location
Advantages
- Know how the quality of molten metal of your plant affects to the apparition of defects in your products
- Get a direct correlation between the parameters that influence the most in the apparition of manufacturing defects
- Obtain and implement a single control predictive model for each reference
- Develop a robust and stable manufacturing process
- Manufacture at industrial level, without defects
Implementation phases
Initial study of the solidification characteristics of each reference in the mold, based on the actual quality of the metal, using the Thermolan® and Kasandra® systems.
Sorting of the defects by causes, zones and incidence to determine the subsequent adjustments to be made on the metal and the predictive model to be developed.
Determination of the appropriate process ranges (temperature, composition, etc.) for defect-free manufacturing, metallurgical optimization and customization of the Thermolan® thermal analysis system.
Development of an application that integrates the criteria or models of the shrinkage tendency of the alloys studied with the results of standard solidification simulation tools or integration in Kasandra® software.
“The Foundry of the Future is that of connected processes that is able to take advantage of the knowledge generated inside the company at the same time that it keeps learning from its manufacturing and market experience.
Along with a deep knowledge of metallurgy, Industry 4.0 technologies, advanced data management systems and machine learning technologies have landed in this industry to transform the way castings are conceived”.
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