Why Centrifugal Cast FeSi Anodes are Better than Die Cast or Sand Cast Anodes
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Centrifugal casting produces stronger, more corrosion-resistant anodes compared to die cast or sand cast anodes. Centrifugal casting spins molten metal at high speeds onto a mold, creating a dense, homogenous structure without imperfections from gates or cores. This uniform cooling and dense structure makes centrifugally cast anodes physically stronger, less prone to breaking during installation or corroding during operation, and able to pass more stringent quality tests. Overall, centrifugally cast anodes have improved performance and reduced lifetime costs compared to other casting methods.
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• Matrix materials testing
• Differs between matrix & steel body
• Matrix body bits manufacturing
• Steel body bits manufacturing
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• Weld strength of PDC bits and cutters
• PDC cutter manufacturing process
• Tsp cutter properties vs PDC
• The influences of bit profile and profile elements
• PDC forces
• PDC bit stability
• PDC bit steer-ability
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• Depth of cut
• Cutter exposure
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• Thermal damage and degradation of cutters
• Cutting mechanics
• PDC cutter substrate and its thickness
• Cutting structure elements
• Single set bladed cutting structures
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WL 112 Ch08 ch08 presentation
This document discusses various methods for producing steel products, including casting, forging, extrusion, and powder metallurgy. It provides details on the casting process, including melting steel, transporting it in ladles, molding techniques, and addressing issues like misruns and porosity. Forging is described as shaping metal through plastic deformation using hammers or presses. The document outlines the forging process and notes that forgings have very high toughness and desirable grain flow. Extrusion and powder metallurgy techniques are also briefly mentioned.
UNIT3-Special casting processmechanical.ppt
This document discusses various special casting processes including centrifugal casting, die casting, and investment casting. It provides details on:
1. Centrifugal casting can produce hollow cylindrical castings and has three main types - true, semi, and centrifuging. It works by pouring molten metal into a revolving mold.
2. Die casting uses metal dies to force molten metal into a mold cavity under high pressure. There are gravity and pressure die casting, with hot and cold chamber variations.
3. Investment casting, also called lost-wax casting, involves making a wax pattern, coating it, embedding in a refractory material, melting out the wax, and pouring molten metal. It produces
UNIT3-Special casting process mechanical.ppt
This document discusses various special casting processes including centrifugal casting, die casting, and investment casting. It provides details on the centrifugal casting process, including true centrifugal casting used to make hollow pipes and tubes, semi-centrifugal casting for more complex shapes, and centrifuging for precision castings. It also describes die casting processes like gravity die casting and pressure die casting methods. Investment casting involves making a wax pattern, coating it, and then melting out the wax to form the hollow mold. Common casting defects such as blowholes, shrinkage, cracks, and inclusions are also summarized along with their causes and remedies.
Casting
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Metal Casting ,its types and methods
1) Casting is a manufacturing process that involves pouring molten material into a mold and allowing it to solidify. The mold can be either permanent or temporary.
2) There are two main types of casting based on the mold: expendable mold casting, which uses sand casting; and non-expendable mold casting, which includes die casting and centrifugal casting.
3) Sand casting uses various types of sand as the mold material and is performed using either the green sand or air set method. Over 70% of metal castings are produced via sand casting.
ME3393 MANUFACTURING PROCESSES PPT FOR III SEMESTER
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WL 112 Ch14 ch14 presentation
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WL 112 Ch12 ch12 presentation
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Drilling Bit Introduction and bit Selection (Part 1)
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CENTRIFUGAL CASTING.pptx.pdf
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WL 112 Ch09 ch09 presentation
This document discusses various processes for working with steel, including cold rolling, annealing, forming, drawing, and joining. Cold rolling increases the strength of steel by introducing dislocations but reduces ductility. Annealing is then used to recover ductility by allowing dislocations to rearrange at high temperatures. Steel can be formed through bending, stretching, drawing, coining, and ironing. Small diameter wire is made by repeatedly drawing and annealing rod steel. Joining is done through welding, brazing, or soldering to form a metallurgical bond between pieces. Precautions like fluxes and shields are needed to prevent oxidation during high-temperature joining.
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Why Centrifugal Cast FeSi Anodes are Better than Die Cast or Sand Cast Anodes
- 1. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 Why are Centrifugal Cast FeSi Anodes Better than Die Cast or Sand Cast Anodes? How an improved manufacturing process can improve operational performance and reduce costs
- 2. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 How does Centrifugal Casting Work? • Molten metal taken in at the end • No need for in-gate • Rapid spinning forces metal onto the mould • No need for sand core • Cooling is uniform
- 3. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 Centrifugal Forces Ensure Homogenous Structure • Rapidly spinning mould - over 1500rpm • Pressures greater than 80 times gravity (80G) • Pressure much greater that die casting • High pressure ensures dense homogenous wall section structure • Denser wall structure means: – Less prone to breakages – Operationally less prone to corrosion
- 4. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 No Requirement for In-Gate or Feed Metal Pool • Feed metal immediately removed • All metal therefore directed at the anode • Differential cooling imperfections removed • Removal of in-gate improves structure and … • Removes faults that would fail x-ray test • Prevents premature failure through: – Corrosion – Cracking
- 5. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 Two Directional Solidification in Die Cast Anodes • Sand Core needed to form the inner bore of the Anode • Sand cores cause premature “freezing” of the metal at the surface • Also, two directional cooling creates structural weaknesses • Gas and particle impurities are trapped • Die Cast anodes may have a slight variance in wall thickness
- 6. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 One Directional Solidification • Centrifugal cast Anodes solidify in one directional only • Metal cools rapidly and uniformly • Creates a superior grain structure • Gas and solid impurities thrown to inside of bore • Metal with Improved structure and fewer impurities is: – stronger and less prone installation breakages – Less prone to corrosion
- 7. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 Summary Benefits of Centrifugal Cast Anodes • Physically stronger units reduce installation wastage • Denser material in the Anode walls reduces operational loss through corrosion • Capable of passing more stringent NDT requirements (e.g. X-ray) – fewer rejects • Overall installation and lifetime cost significantly reduced, while performance improved
- 8. www.specialistcastings.cominfo@specialistcastings.com +44(0)191 510 8843 Find Out More Specialist Castings Ltd Tatham Street Sunderland Tyne & Wear SR1 2AG United Kingdom Phone: +44 (0) 191 510 8843 Email: info@specialistcastings.com Web: www.specialistcastings.com