Implementation of Metal Casting Best Practices - EERE - U.S. ...

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Another alternative for the facility is to evaluate the benefits of replacing traditional crucible furnaces with induction furnaces. Induction melting has a thermal efficiency of 59-76%, which is significantly more efficient than a crucible furnace at 7-19%. Induction melting also has a significantly lower melt loss when melting aluminum (i.e., 0.75-1.25%). 66 This is much lower than the 6-7% loss currently experienced at the facility. The analysis that the facility conducts should examine its current and projected alternative fuel costs (i.e., natural gas versus electricity), and should factor in the following: • Number & size (exposed diameter) of the melting crucibles • Crucibles that use blowers vs. compressed air • Actual pounds of castings sold per year vs. purchased ingots • Number and size of air compressors • Data on natural gas use for melting (if it is available) in summer vs. winter This analysis will enable the facility to make a business decision as to whether it would be in its financial advantage to undertake such a large project. Heat Treating Furnaces Aluminum Casting Facility-2 heat treats approximately 90% of its castings using conventional natural gas-fired furnaces. The assessment team recommended that Aluminum Casting Facility-2 perform a combustion gas analysis on these furnaces. The facility should also examine using heat exchangers to capture waste heat from the furnaces. In the past, heat exchangers have been a capital-intensive investment and their economics were not attractive. However, rising natural gas prices could change that conclusion. Sand Heater The no-bake line at Aluminum Casting Facility-2 does not utilize a sand heater. The assessment team recommended that the facility reconsider installing one of these heaters because of the potential differences in summer versus winter cure times caused by low sand temperatures. Chemical reaction rates double with each 10ºC increase in temperature. Cold sand temperatures in the winter will either slow down production while waiting for sand to cure or, if cure times are not adjusted, cause castings to be poured into under-cured molds which often causes gas-related defects. Die Steels Currently Aluminum Casting Facility-2 utilizes H-13 die steels for its permanent mold and die material. The assessment team recommended that the facility consider some of the die steel research performed by Case Western Reserve University that has identified a number of commercially available steels that can outperform conventional H-13 steel. 3. Conclusion Aluminum Casting Facility-2 has actively participated in DOE-sponsored research. Participating with CANMET in their E-SMARRT activity has proven beneficial to the facility by bringing a 86
new alloy to the facility’s production line. Also, the facility’s work with Case Western is improving its crucible melting facility and lowering its natural gas bill. The facility does have areas it could improve upon, and has the drive to take on these projects. In particular the facility could improve their energy efficiency by improving their efficiency of all their crucible furnaces. 87
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Implementation of Metal Casting Bes
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Executive Summary Since 1995 the U.
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summarized comments regarding the t
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• Metal casters must investigate
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F. Iron Foundry-2..................
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As part of this project, an assessm
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1.3 Report Organization This report
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energy needs, primarily to the larg
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As a result of this strategy, ITP h
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All of the facilities that particip
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A number of the facilities visited
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Steel Foundry Aluminum Foundry Alum
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4. Methodology for Assessing Indust
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5. Overall Assessment Observations
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samples and measurements from vario
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the Metalcasting Congress and other
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single in-line memory module (SIMM)
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application can offer tangible bene
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7. Common Energy-Saving Solutions T
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7.4 Installing Radiant Panels in Cr
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7.8 Installing Energy-Efficient Lig
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8. Conclusion The ITP Metal Casting
Page 46 and 47: Appendix A: Plant Assessment Case S
Page 48 and 49: Scrap Rate The scrap rate at the pl
Page 50 and 51: Dross Management Metal dealers and
Page 52 and 53: B. Die Casting Plant-2 Plant Profil
Page 54 and 55: Quality Control The assessment team
Page 56 and 57: C. Steel Foundry-1 Plant Profile St
Page 58 and 59: also enables foundries to understan
Page 60 and 61: Automated Molding Line Steel Foundr
Page 62 and 63: D. Steel Foundry-2 Plant Profile St
Page 64 and 65: subsequent machining operations. Ex
Page 66 and 67: motor, with an older piece of equip
Page 68 and 69: 1. Implemented Best Practices Age S
Page 70 and 71: Treating Sand Iron Foundry-1 reclai
Page 72 and 73: F. Iron Foundry-2 Plant Profile Iro
Page 74 and 75: Working with the Utility Iron Found
Page 76 and 77: G. Lost Foam Foundry-1 Plant Profil
Page 78 and 79: work yielded a 0.85% reduction in s
Page 80 and 81: Stack Melter Like many plants melti
Page 82 and 83: tools. Like many of the other facil
Page 84 and 85: will require that the facility have
Page 86 and 87: 1. Implemented R&D and Best Practic
Page 88 and 89: V-6 blocks, the gating system was c
Page 90 and 91: During their site visit, the team f
Page 92 and 93: J. Aluminum Casting Facility-2 Plan
Page 94 and 95: promoting a product line for the fa
Page 98 and 99: K. Copper Foundry-1 Plant Profile C
Page 100 and 101: The facility also stays abreast of
Page 102 and 103: Electric Arc Furnace (EAF) - A stee
Page 104 and 105: Sprue - Metal that fills the conica
Page 106 and 107: 23 Stratecast, Inc. AFS Metalcastin
Page 108: 99 Ibid. pg. 335. 100 http://www.go
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