DELMER- Casting E catalog

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DELMER -E catalog for All type of Metal casting technology

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DELMER- Casting E catalog

  1. 1. C A T A L O G U E 1
  2. 2. Company Profile TOPCAST is a company specialised Product versatility to meet Areas of application are: Our technical office is available in casting machines design and different production needs, quality - Casting to evaluate any customer inquiry. manufacturing. Competence design, post-sales assistance and Please contact us for a personal developed in the investment technical help to satisfy particular - Melting quotation if you have any casting field, thermal processes, needs make TOPCAST the best - Heat treatment induction heating need. . induction heating and power company to count on in a global - Welding electronics set it as an ideal partner competition scenery. - Brazing also for custom applications. A group of qualified engineers and designers, constantly updated and oriented to the research of enhanced technological solutions, grants a product range definitely at the state of the art. Applications TVCd TVCs TCE-B TCE-A TMF TGEN TCF TSF-B Gold & Silver casting Platinum, Palladium and Steel casting Jewellery Field Melting Precious Metals Assay Titanium casting Precious Alloy and CrCo Medical casting and Dental Titanium casting Field Zirconia Sintering Lost-wax casting of Al, Bronze & Brass Lost-wax casting of Steel Industrial Melting Field Steel and Iron assay Hardening, Soldering and Brazing Titanium casting Page 4-5 6-7 8-9 8-9 11 10 - - Alloys and Machines TVCd TVCs TCE-B TCE-A TMF Ag Silver Al Alluminium Au Gold Brass Bronze Cu Copper Mg Magnesium Pd Palladium Pt Platinum Steel Super alloys Ti Titanio Page 4-5 6-7 8-9 8-9 11 2 Suggested - Possible
  3. 3. 3
  4. 4. Description TVCd is the pressure over vacuum and easy to fill with the investment flask is cooling down in protective casting machine designed to meet slurry (no tape needed around the gas for no oxidation, the next the more severe needs in lost wax flask). charge can be loaded into the casting production. Size of the flask can reach up to machine and melted, thus This machine works with a new, 400mm in height instead of the overlapping two cycles for no time revolutionary double chamber max 250 mm normally used while waste. concept. This innovative system working with conventional casting The machine is fully automatic gives you several advantages machines. having more than 100 programs compared with the traditional This will save more than 200g suitable for every kind of alloy. single chamber suction system of gold per flask and will save This amazing machine is the used by all ours competitors. more than 40% in consumables synthesis of the most advanced With TVCd you can use a simple as graphite and inert gas engineering and years of experience and plain steel pipe flask instead of consumption. in casting that only TOPCAST the perforated flask, which is safer The casting cycle takes only 3 can bring to your factory. (metal cannot spill out), cheaper minutes and, while the previous TECHNOLOGY & FEATURES Gas Wash Procedure Melting Injection and Compression Tree protection after casting - Crucible loading operation introduces - Advanced Self Tuning thermoregulation - When the stopper lifts up. it is very - Thanks to the double chamber concept, oxygen (AST™) with exact temperature control important to control the injection rate to after the solidification phase, the flask - The Gas Wash Purge procedure removes of the melted alloys avoid turbulences cools down in a protective atmosphere the oxygen (1) in a very fast and efficient - Two Set-Points available: Homogenization - TVC has the unique feature to have while at the same time you can load your way and then refills back the chambers and Casting Temperature the injection rate controllable and alloy in the melting chamber for the next with Argon or Helium gas (2) programmable (IRC™) melting. - Medium frequency induction heating - Compared with the traditional crucible stirs the melted alloy and leads to a - The metal enters smoothly inside the - This operation will allows an overlapping protection with flow-meter regulation perfect homogeneity mould (4). Then, after filling and of the casting cycles which will give you the consumption of gas is dramatically during the solidification phase, a strong the ability to protect longer the tree - Pulse Stirring Management (PSM™) for before removing it without loosing time reduced and the alloys oxidation is an extremely low frequency stirring compression takes place on the tree (5) minimized and productivity - Highest power density in the market - No turbulences in filling and high - Moreover the crucible life is increased: features strongest stirring and low gold compression rate lead to a large reduction TVC series crucible last up to 250 – 400 losses of shrinkage porosity phenomena casting cycles according to the graphite quality Air / Vacuum / Gas 1 2 3 4 5 6 4
  5. 5. Double Chamber Pressure Over Vacuum Casting Machine TVCd TVC5d TVC10d TVC12d TVC12d-Mg TVC25d TVC35d TVC45d Small labs Medium Large Magnesium Small Medium Large Application and research laboratories laboratories alloys Foundries Foundries Foundries departments Number of casting programs 100 100 100 100 100 100 100 Working Capacity of graphite crucible 1 kg Au 3 kg Au 5 kg Au 500g Mg 5 kg Al 10 kg Al 30 kg Al 0,5 kg Ag 1,5 kg Ag 2,5 kg Ag (AZ91) 9 kg Bronze 20 kg Bronze 80 kg Bronze Flask maximum diameter (mm) Ø150 Ø150 Ø150 Ø150 Ø300 Ø350 Ø600 Flask maximum height (mm) 300 / 400 300 / 400 300 / 400 300 / 400 600 600 800 Induction power 5 kW 10 kW 12 kW 12 kW 25kW 35kW 45kW Vacuum pump Built-in 25 Built-in 25 Built-in 25 Built-in 25 m3/h External External External m3/h m3/h m3/h Pressure over vacuum 3 bar 3 bar 3 bar 3 bar 1 bar 1 bar 1 bar Max. temperature 1600 °C 1600 °C 1600 °C 1600 °C 1400°C 1400°C 1400°C Shot maker Autotest with data report Monitoring system for process and production data collection Flask check before casting Vacuum leakage detector Oxygen Analyzer RS232 remote interface Main alloys Gold (Au), Silver (Ag), Copper (Cu), Brass, Bronze, Aluminium (Al) and their alloys 5 Provided - Available on request
  6. 6. Description TVCs is a fully automatic, robust, Moreover as soon as the metal easy (you simply have to load the easy to use pressure over vacuum has entered the mould a strong alloy and flask and then press the casting machine designed for small compression takes place on top START button). This will give you and medium casting laboratories. of the tree to reduce shrinkage the most consistent result flask to This machine works with the porosity. flask. well known pressure over vacuum Flask size can reach up to And remember, meanwhile the concept, thus preferring the 300mm in height and 160mm in machine is running the cycle, you perforated flask against the solid diameter. can do other important jobs in ones. Crucible graphite consumption is your factory. Alloy melting is achieved in greatly reduced thanks to the gas- wash procedure which remove the Having a consistent, robust and protective atmosphere (Nitrogen, oxygen in few seconds from the easy to use machine in your factory Argon or Helium) while a strong vacuum pump is provided in order charge loading operation. is the key factor for a reliable to boost the suction effect into the The machine is fully automatic casting production. mould. making the operator’s job very TECHNOLOGY & FEATURES Gas Wash Procedure Melting Injection and Compression Tree protection after casting - Crucible loading operation introduces - Advanced Self Tuning thermoregulation - When the stopper opens, as soon as the - After the solidification phase, the flask oxygen (AST™) with exact temperature control molten metal fills the flask, a trigger is cools down in a protective atmosphere to - The Gas Wash Purge procedure removes of the melted alloys launched to the over pressure valve which avoid oxidation. the oxygen (1) in a very fast and efficient - Medium frequency induction heating will make the gas flow enter smoothly and - A blinking lamp will signal the operator way and then refills back the chambers stirs the melted alloy and leads to a quickly to compress the tree during the that the cycle has ended and the flask can with Argon or Helium gas (2) perfect homogeneity solidification phase to reduce shrinkage be removed porosity - Compared with the traditional crucible - Pulse Stirring Management (PSM™) for protection with flow-meter regulation an extremely low frequency stirring the consumption of gas is dramatically reduced and the alloys oxidation is minimized - Moreover the crucible life is increased: TVC series crucible last up to 250 – 400 casting cycles according to the graphite quality Air / Vacuum / Gas 1 2 3 4 5 6
  7. 7. Single Chamber Pressure Over Vacuum Casting Machine TVCs TVC3s TVC4s TVC10s TVC10s-A Application Small labs Entry level model Mdium laboratories Brass Foundries Number of casting programs 1 1 8 8 Working Capacity of graphite crucible 1 kg Au 2 kg Au 3 kg Au 2.5 kg Brass 0,5 kg Ag 1 kg Ag 1,5 kg Ag Flask maximum diameter (mm) Ø150 Ø150 Ø150 Ø150 Flask maximum height (mm) 280 280 280 280 Induction power 3 kW 4 kW 10 kW 10kW Vacuum pump External External External External Pressure over vacuum 2 bar 2 bar 3 bar 3 bar Max. temperature 1400 °C 1400 °C 1400 °C 1400°C Shot maker Autotest Monitoring system for process and production data collection Flask check before casting Vacuum leakage detector Oxygen Analyzer RS232 remote interface Main alloys Gold (Au), Silver (Ag), Copper (Cu), Brass, Bronze, Aluminium (Al) and their alloys Provided - Available on request 7
  8. 8. Description TCE is a consistent, robust and - Gas washing to remove oxygen - Centrifugal casting with speed easy to use vacuum centrifugal from the melting chamber and acceleration digitally casting machine designed for - Alloy Melting in Vacuum or controllable small and medium casting protective atmosphere - Cooling in inert atmosphere before laboratories. removing the flask - Induction melting and stirring TCE in Class B is particularly of the alloy to get perfect suited for Platinum, Palladium homogenization and Steel while TCE in Class A Casting is not only machines. For has been especially designed for - Accurate control of the this reason TOPCAST invests in Ti casting. temperature with a proprietary a deep and continuous research narrow band optical pyrometer on crucible and investment The casting process is fully materials to give to our customers programmable and consists of the - Vacuuming of the chamber before casting always the state of the art casting following phases: solution for any alloy. Class A and Class B The main difference between Regarding the mold size and TCE in Class A and TCE in crucible capacity, today with Class B is the degree of vacuum, TCE you can cast up to 1.7 kg Ti leak-back rate and ppm control and use flasks up to 140mm in of oxygen in the process chamber, diameter and 380mm in length. that makes the TCE in Class We are also developing larger A the best solution for casting machines under customized reactive metals like Titanium. specifications for what concerns Also the choice of the vacuum Ti crucible capacity and Flask pumps station and the induction mould size. In case you are power generator is different and interested in getting a quotation chosen to get the maximum result for non-standard casting machine in Ti cast parts. do not hesitate to send us your Hence, TCE machines conceived technical specifications. in Class A are suitable for fields TOPCAST also supplies special that require high quality control crucibles and investment powder and low interstitial pick-up on for Titanium casting particularly the Ti cast parts, like Aerospace, designed to avoid alpha-case Medical and Automotive. structure in the cast parts. TCE10 in Class B can instead Crucibles for Ti have been be used where the price of the designed to avoid alloy machines is an important factor contamination and to withstand and where no high quality control the high chemical and thermal of the metallurgy of the Ti cast shocks involved in Ti melting part is required, like in Jewellery, Eye-Glass and Leisure Industry (Golf Clubs, etc ...). TECHNOLOGY & FEATURES Gas Wash Procedure Melting Injection and Compression Tree protection after casting - Crucible and mould loading operation - Advanced Self Tuning thermoregulation When the charge is molten, the coil is After the solidification phase, the flask introduces oxygen (AST™) with exact temperature control retracted and the arm starts to spin. cools down in a protective atmosphere to - The Gas Wash Purge procedure removes of the molten alloys During the spinning the metal gets out avoid oxidation. the oxygen (1) in a very fast and efficient - Accurate control of the temperature from the crucible and enters the flask. A blinking lamp will signal the operator way and then refills back the chambers with a proprietary narrow band optical Rotational speed profile, which controls that the cycle has ended and the flask can with Argon, Nitrogen or Helium gas (2) pyrometer the injection rate, can be regulated digitally be removed Class A - Medium frequency induction heating for a consistent and reliable mould filling. stirs the melted alloy and leads to a The final speed will compress the tree - Level of vacuum reached is extremely perfect homogeneity high during the solidification phase to reduce - Magnetic field frequency has been studied shrinkage porosity. - Leak-back rate is carefully minimized for best coupling and energy transfer - Oxygen ppm in final atmosphere can be precisely controlled 8 1 2 3 4
  9. 9. Vacuum Centrifugal Casting Machine TCE TCE Class B TCE Class A TCE5 TCE10 TCE50 TCE8-Ti TCE12-Ti TCE50-Ti Application Small labs Medium labs Large labs Small labs Medium labs Large labs 500g Pt 1500g Pt Working Capacity 8 kg Steel 100g Ti 350g Ti 1700g Ti 250g Steel 1000g Steel Flask maximum diameter (mm) Ø110 Ø130 Ø140 Ø110 Ø130 Ø140 Flask maximum height (mm) 120 180 380 120 180 380 Induction power 8 kW 10 kW 50 kW 8 kW 10 kW 50 kW Speed 500 rpm 350 rpm 300 rpm 500 rpm 350 rpm 300 rpm Vacuum pump External External External External 1 External 1 External 1 Max. temperature 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C Monitoring system for process and production data collection Vacuum leakage detector Oxygen Analyzer RS232 remote interface Provided - Available on request 9 1 Vacuum performance, leak rate and oxygen content are sensitive data and cannot be discolsed in this catalogue. Please contact TOPCAST for more information.
  10. 10. TGEN Induction Frequency Converters TOPCAST designs state of the art In our generators, galvanic An accurate study of the coil Temperature control can be chosen generators for induction heating insulation between coil and guarantees a very high heating between IR optical pyrometer and application. power mains gives the maximum efficiency while medium thermocouple while the electronic The design approach uses both safety for the user, while digital frequency magnetic field stirs the board implements an advanced configurations: parallel and series technology makes our furnaces molten metal and leads to high self-tuning thermoregulation resonant typology adopting the soundless, versatile and reliable. homogeneity of the alloys algorithm with exact temperature latest and most advanced IGBTs Fibre optics connections give control. and SCRs modules available to our electronics the highest Melting plants can be provided worldwide. immunity to electrical noise also with one or more melting stations in harsh environment. using a power switch to drive one station or the other. TGEN5 TGEN15 TGEN50 TGEN100 TGEN150 TGEN200 Induction power 5 kW 15 kW 50 kW 100 kW 150 kW 200 kW Frequency range 5 – 50 kHz 5 – 50 kHz 5 – 50 kHz 5 – 25 kHz 5 – 25 kHz 5 – 25 kHz MF voltage 550 V 550 V 550 V 550 V 550 V 550 V Monitoring system for process and production data collection Remote control 10 Provided - Available on request
  11. 11. High Power Induction Melter TMF Maintenance of the furnace is very Touch screen display in provided easy and allows rapid changing for a fast and user-friendly of the crucible and the safety interface. refractory shell. A water cooling plant is needed to Inert gas or gas-flame are cool the induction heating coils foreseen to protect the melt from and the power generator. oxidation. TMF5 TMF7 TMF10 TMF12 TMF-10P Graphite crucible 6 kg Au 8,5 kg Au 13,5 kg Au 17 kg Au 1 kg Steel SiC crucible 4 kg Au 12 kg Au 12 kg Au 12 kg Au (for steel assay purpose) Power 5 kW 7 kW 10 kW 12 kW 10 kW Max. temperature 1300 °C 1350 °C 1400 °C 1450 °C 1800 °C Melting time 15 min. 15 min. 15 min. 20 min. 3 min. TMF10-R TMF15-R TMF25-R TMF35-R TMF45-R TMF60-R TMF100-R TMF150-R TMF200-R Power 10 kW 15 kW 25 kW 35 kW 45 kW 60 kW 100 kW 150 kW 200 kW Zirconia crucible 1 kg Pt 2 kg Pt 8 kg Pt 12 kg Pt 22 kg Pt 30 kg Pt 40 kg Pt 80 kg steel 120 kg steel Max. temperature 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C 2000 °C Alumina crucible 2 kg steel 5 kg steel 10 kg steel 15 kg steel 25 kg steel 50 kg steel 60 kg steel 80 kg steel 120 kg steel Max. temperature 1700 °C 1700 °C 1700 °C 1700 °C 1700 °C 1700 °C 1700 °C 1700 °C 1700 °C 20 kg Au 20 kg Au 40 kg Au 40 kg Au 40 kg Au 100 kg Au 200 kg Au 500 kg Au 800 kg Au SiC crucible 10 kg Ag 10 kg Ag 25 kg Ag 25 kg Ag 25 kg Ag 50 kg Ag 100 kg Ag 300 kg Ag 500 kg Ag Max. temperature 1450 °C 1450 °C 1450 °C 1450 °C 1450 °C 1350 °C 1350 °C 1350 °C 1350 °C 11
  12. 12. w w w . t o p c a s t . i t Loc. San Zeno, Strada C, 6/D - 52100 Arezzo (AR) - Italy Tel.: +39 / 0575 / 441 341 - Fax: +39 / 0575 / 441 222 e-mail: info@topcast.it - web: www.topcast.it 12

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