This document discusses design guidelines and best practices for producing zinc diecastings for electroplating. It provides rules for minimum radii, recessed features, hole sizes and spacing to improve platability. It also covers factors that influence quality like alloy composition, melting practices, and die design. Defects that can occur like cold shuts, blisters, die soldering, shrinkage and laking are described along with techniques to prevent them.
Electroplating, Phosphating, Powder Coating and Metal Finishing Ajjay Kumar Gupta
Electroplating, Phosphating, Powder Coating and Metal Finishing (Electroplating Plant, Copper Plating, Electroforming, Brass Plating, Silver Plating, Tin-Nickel Alloy Plating, Gold Plating (Gilding), Cadmium Plating, Zinc Plating)
Electroplating is a process that uses electric current to reduce dissolved metal cations so that they form a thin coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate, as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.
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Email: npcs.ei@gmail.com , info@entrepreneurindia.co
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Electroplating Plant, Automatic Equipment, Surface Coatings and Treatments, Electroplating and Coating Plants, Electroplating Plant Equipment, Powder Coating Plants, Powder Coating Equipments, How to Start Powder Coating Business, Powder Coating Business Plan, Business Plan on Powder Coating, Start Powder Coating Business, Start High Profit Powder Coating Business, Starting Metal Polishing Business, Electroplating Business, Gold Plating Business, How to Start Metal Plating Business, Starting Zinc Plating Business, How to Start Electroplating Business, How to Start Metal Finishing Business, Starting Metal Polishing Business, Metal Finishing Industry, Business Plans for Metal Finishing, Zinc Plating Process, Zinc Plating Plant, Electroplating Plant for Acid Zinc, Electroplating Plant Equipment, Fixed Sequence Automatic Plating Plant, Trojan and Gem Type Automatic Plant, Vulcan Lattice Arm Type Automatic Plant, Titan Type Automatic Plant, Digit Pivoted Arm Type Automatic Plant, Straight-Through Type Automatic Plant, Methods of Transporter Control, Microprocessor and Computer Control, Semi-Automatic Plating Plant, Barrel Planting Plant, Suitability of Articles for Barrel Plating, Glydo/Glydette Barrel Plating Equipment, Calculation of Work Loads, Manual Planting Plant, Single Station Barrel Plating Units, Modular Plant and Specialised Equipment for Electronics Industry, Electroplating Equipment, Welded Steel Tanks, Plastic Tanks Reinforced with Glass Fibre, Tank Lining Materials, Glass Fibre (GRP) Tanks, Treatment of Rubber Linings, Ilex Grade Plastic Lined Tanks, Galvanised Steel Coils, Lead and Lead Alloy Coils, Titanium Coils, Metal Cased Heaters, Teflon Immersion Heaters, Silica Cased Heaters
The document discusses phosphating and chromating surface treatments. It describes the phosphating process as applying phosphoric acid to form a crystalline phosphate layer for corrosion resistance. The seven steps of the phosphating process are outlined. Chromating involves applying a hexavalent chromium solution to form a protective yellow-green layer and passivate metals like steel, aluminum, and zinc. The benefits of these processes are corrosion inhibition and providing an adhesive base for painting.
Passivation is a process that treats metals to form a protective oxide layer on the surface to make the metal less prone to corrosion. It involves cleaning the metal surface, then submerging it in a passivation solution like nitric acid, which removes any free iron or other contaminants and forms a chromium oxide layer. The key variables in passivation include time, temperature, acid concentration, and the type of metal. Effectiveness is tested using methods like the free iron test to ensure all free iron is removed and the protective layer is formed properly. At processing sites, systems undergo cleaning, passivation treatment, and testing before being put back into use.
Galvanization or galvanizing is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerged in a bath of molten zinc.
The document defines and categorizes various coating defects that can occur, including those related to surface preparation, application, and the coating film itself. It describes 13 common defects - blistering, bubbling, checking, cracking, corrosion, edge/corner failure, peeling/flaking/delaminating - and discusses their causes. The document is intended for internal use by AkzoNobel Protective Coatings to understand and address coating defects.
Steel is an alloy of iron and other elements like carbon, silicon, and manganese. Modern steelmaking involves two main processes: basic oxygen steelmaking (BOS) and electric arc furnace steelmaking. In BOS, molten iron from a blast furnace is refined in a converter vessel by blowing oxygen and maintaining a basic slag. Impurities like carbon, silicon, phosphorus, and sulfur are oxidized and removed. Electric arc furnace steelmaking uses scrap and direct reduced iron as the raw materials, which are melted using electric arcs. Secondary steelmaking and continuous casting then further refine the steel and cast it into final shapes.
Electroplating, Phosphating, Powder Coating and Metal Finishing Ajjay Kumar Gupta
Electroplating, Phosphating, Powder Coating and Metal Finishing (Electroplating Plant, Copper Plating, Electroforming, Brass Plating, Silver Plating, Tin-Nickel Alloy Plating, Gold Plating (Gilding), Cadmium Plating, Zinc Plating)
Electroplating is a process that uses electric current to reduce dissolved metal cations so that they form a thin coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate, as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.
See more
https://goo.gl/bKk1XU
https://goo.gl/5QasBV
https://goo.gl/sBmyLI
Contact us:
Niir Project Consultancy Services
106-E, Kamla Nagar, Opp. Spark Mall,
New Delhi-110007, India.
Email: npcs.ei@gmail.com , info@entrepreneurindia.co
Tel: +91-11-23843955, 23845654, 23845886, 8800733955
Mobile: +91-9811043595
Website: www.entrepreneurindia.co , www.niir.org
Tags
Electroplating Plant, Automatic Equipment, Surface Coatings and Treatments, Electroplating and Coating Plants, Electroplating Plant Equipment, Powder Coating Plants, Powder Coating Equipments, How to Start Powder Coating Business, Powder Coating Business Plan, Business Plan on Powder Coating, Start Powder Coating Business, Start High Profit Powder Coating Business, Starting Metal Polishing Business, Electroplating Business, Gold Plating Business, How to Start Metal Plating Business, Starting Zinc Plating Business, How to Start Electroplating Business, How to Start Metal Finishing Business, Starting Metal Polishing Business, Metal Finishing Industry, Business Plans for Metal Finishing, Zinc Plating Process, Zinc Plating Plant, Electroplating Plant for Acid Zinc, Electroplating Plant Equipment, Fixed Sequence Automatic Plating Plant, Trojan and Gem Type Automatic Plant, Vulcan Lattice Arm Type Automatic Plant, Titan Type Automatic Plant, Digit Pivoted Arm Type Automatic Plant, Straight-Through Type Automatic Plant, Methods of Transporter Control, Microprocessor and Computer Control, Semi-Automatic Plating Plant, Barrel Planting Plant, Suitability of Articles for Barrel Plating, Glydo/Glydette Barrel Plating Equipment, Calculation of Work Loads, Manual Planting Plant, Single Station Barrel Plating Units, Modular Plant and Specialised Equipment for Electronics Industry, Electroplating Equipment, Welded Steel Tanks, Plastic Tanks Reinforced with Glass Fibre, Tank Lining Materials, Glass Fibre (GRP) Tanks, Treatment of Rubber Linings, Ilex Grade Plastic Lined Tanks, Galvanised Steel Coils, Lead and Lead Alloy Coils, Titanium Coils, Metal Cased Heaters, Teflon Immersion Heaters, Silica Cased Heaters
The document discusses phosphating and chromating surface treatments. It describes the phosphating process as applying phosphoric acid to form a crystalline phosphate layer for corrosion resistance. The seven steps of the phosphating process are outlined. Chromating involves applying a hexavalent chromium solution to form a protective yellow-green layer and passivate metals like steel, aluminum, and zinc. The benefits of these processes are corrosion inhibition and providing an adhesive base for painting.
Passivation is a process that treats metals to form a protective oxide layer on the surface to make the metal less prone to corrosion. It involves cleaning the metal surface, then submerging it in a passivation solution like nitric acid, which removes any free iron or other contaminants and forms a chromium oxide layer. The key variables in passivation include time, temperature, acid concentration, and the type of metal. Effectiveness is tested using methods like the free iron test to ensure all free iron is removed and the protective layer is formed properly. At processing sites, systems undergo cleaning, passivation treatment, and testing before being put back into use.
Galvanization or galvanizing is the process of applying a protective zinc coating to steel or iron, to prevent rusting. The most common method is hot-dip galvanizing, in which the parts are submerged in a bath of molten zinc.
The document defines and categorizes various coating defects that can occur, including those related to surface preparation, application, and the coating film itself. It describes 13 common defects - blistering, bubbling, checking, cracking, corrosion, edge/corner failure, peeling/flaking/delaminating - and discusses their causes. The document is intended for internal use by AkzoNobel Protective Coatings to understand and address coating defects.
Steel is an alloy of iron and other elements like carbon, silicon, and manganese. Modern steelmaking involves two main processes: basic oxygen steelmaking (BOS) and electric arc furnace steelmaking. In BOS, molten iron from a blast furnace is refined in a converter vessel by blowing oxygen and maintaining a basic slag. Impurities like carbon, silicon, phosphorus, and sulfur are oxidized and removed. Electric arc furnace steelmaking uses scrap and direct reduced iron as the raw materials, which are melted using electric arcs. Secondary steelmaking and continuous casting then further refine the steel and cast it into final shapes.
The document discusses the process of deoxidizing steel. During steelmaking, oxygen dissolves into the liquid steel but not in the solid steel. Deoxidation or "killing" of steel refers to reducing the excess oxygen content before casting to prevent blowholes and inclusions. This is typically done through precipitation deoxidation using elements like aluminum, silicon, and manganese that have a higher affinity for oxygen than iron and form stable oxides. These deoxidizers are chosen based on factors like stability, deoxidizing ability, oxide melting point and density. Aluminum is the most powerful deoxidizer but its oxide alumina must be modified to remain liquid during casting.
Anodizing is an electrochemical process that converts the metal surface of aluminum to aluminum oxide. It produces a coating that is very durable, corrosion resistant, and maintains the metallic appearance of the aluminum. The anodizing process involves racking parts for processing, cleaning, etching, anodizing in an acid bath using electricity, coloring or sealing the pores, and testing to quality check the coating. Anodized aluminum has advantages like durability, low maintenance, and an environmentally friendly process.
Electrochemical Protection or Cathodic Protection uses two methods to protect metal surfaces from corrosion. Sacrificial anodic protection connects the metal to a more reactive metal like zinc or magnesium that corrodes instead of the protected metal. Impressed current cathodic protection uses an electrical current to force the metal to behave as a cathode. There are also several metallic coating methods to apply a protective layer to metals including hot dipping, electroplating, metal spraying, metal cladding, and cementation. Organic coatings like paints, varnishes, enamels, and lacquers provide protection by forming a barrier film on the metal surface.
Ceramics and Glass Technology (Silicate Glasses, Boric Oxide and Borate Glass...Ajjay Kumar Gupta
Ceramics and Glass Technology (Silicate Glasses, Boric Oxide and Borate Glasses, Phosphorus Pentoxide and Phosphate Glasses, Germanium Dioxide and Germanate Glasses, Nitrate Glasses, Halide Glasses, Chalcogenide Glasses, Modern Glass Working, Monax and Pyrex Glass)
Glass-ceramics are mostly produced in two steps: First, a glass is formed by a glass-manufacturing process. The glass is cooled down and is then reheated in a second step. In this heat treatment the glass partly crystallizes. In most cases nucleation agents are added to the base composition of the glass-ceramic. These nucleation agents aid and control the crystallization process.
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applications of Ceramics, Boric Oxide and Borate Glasses, Business guidance for glass ceramics, Business Plan for a Startup Business, Business start-up, Ceramic and glass business, ceramic business ideas, Ceramic forming techniques, Ceramic Industry, Ceramic Material Manufacturing Methods, Ceramic processing, Ceramics and Glass Technology, Ceramics Based Profitable Projects, Ceramics Based Small Scale Industries Projects, ceramics business plan, Ceramics Forming Processes, Ceramics pottery Manufacturing, Ceramics Processing Projects, Ceramics Production Industry in India, Chalcogenide Glasses, Germanium Dioxide and Germanate Glasses, Glass & ceramics Business, Glass & ceramics Small Business Manufacturing, Glass and Ceramics, glass and ceramics industry, Glass and Ceramics Technology, Glass Based Profitable Projects, Glass Based Small Scale Industries Projects, Glass Ceramic Products, Glass Ceramics Industry, glass ceramics properties, Glass Forming & Processing, glass forming process, Glass Forming Technology, Glass making - Industry process, Glass Manufacture and Processing, Glass Manufacturing Process, Glass Processing Projects, Glass production, Glass Production Industry in India, Glass-ceramic materials, Glass-ceramics: their production, properties and potential, Great Opportunity for Startup, Halide Glasses, How to Start a Ceramic Business, How to Start a Ceramics Production Business, How to start a glass & ceramics business?, How to Start a Glass Production Business, How to start a successful glass ceramics business, How to Start Ceramics Production Industry in India, How to Start Glass Production Industry in India, Modern Glass Working, Modern Small and Cottage Scale Industries, Monax and Pyrex Glass, Most Profitable Ceramics manufacturing Business Ideas, Most Profitable Glass manufacturing Business Ideas, New small scale ideas in Ceramics Production industry, New small scale ideas in Glass Production industry, Nitrate Glasses, Phosphorus Pentoxide and Phosphate Glasses, Processing Glass and Glass-Ceramics, Production of Glass Ceramic, Profitable Small and Cottage Scale Industries
Non-destructive testing (NDT) allows inspection of materials and components without damaging them. Common NDT methods include visual testing, magnetic particle inspection, dye penetrant testing, radiography, ultrasonic testing, and eddy current testing. These methods are used to detect surface or internal flaws in materials and evaluate characteristics without impairing future usefulness or serviceability. NDT plays an important role in quality control and safety across industries such as aerospace, automotive, and energy.
Stainless steels contain 10.5-30% chromium which forms a passive oxide layer protecting the steel from corrosion. Common types include martensitic, ferritic, austenitic, and duplex stainless steels. Martensitic stainless steels can be hardened through heat treatment while ferritic stainless steels have higher ductility and corrosion resistance. Duplex stainless steels have a mixed austenite and ferrite structure providing high strength and pitting/stress corrosion resistance. Austenitic stainless steels have excellent ductility and toughness down to cryogenic temperatures and are widely used in chemical plants and food processing. Proper welding techniques are required to prevent issues like sensitization, hot cracking, and sigma
The document discusses various casting defects such as blows, blisters, scars, washes, cuts, sinks, shrinkage cavities, pinholes, blowholes, hot tears, and misruns. Blows are large cavities caused by gases displacing molten metal, while blisters are shallow blows covered by a thin layer of metal. Washes are low projections on drag faces that decrease in height. Pinholes and blowholes are small gas pockets on or just below casting surfaces. Hot tears are cracks from stresses during solidification. Misruns occur when cavities are incompletely filled.
A brief knowledge about surface treatment, which is a process applied to the surface of a material to make it better in some way, for example by making it more resistant to corrosion or wear. Shot peening is a surface treatment in which small hard pellets are shot against the surface of a metal to make it more resistant to fatigue.
This document discusses various surface treatment and coating techniques, including conversion coatings like oxidation and anodizing, thermal coatings like carburizing and nitriding, metal coatings using electroplating and electroless deposition, vapor deposition methods like PVD and CVD, and organic coatings like paint and powder coating. It provides details on common processes, their applications and benefits, comparing techniques like electroless nickel plating versus hard chrome plating. The document emphasizes the importance of coatings for improving properties like corrosion and wear resistance.
Surface coatings are used to protect metals from corrosion and improve their properties. Common coating methods include conversion coatings like oxidation, phosphatization and chromating which form protective oxide layers. Thermal treatments involve diffusion, carburizing and nitriding to enrich the surface. Metal coatings are applied by electroplating, electroless plating or metallizing. Vapor deposition techniques like PVD and CVD are used to deposit thin, hard coatings. Organic coatings such as paint provide decorative and protective functions. Coatings selection depends on the substrate material and desired properties.
This document discusses inclusion control for clean steel production. It defines inclusions as non-metallic compounds that form separate phases in steel. Strict inclusion control is important for producing quality steel products. Inclusions are assessed and controlled by examining their source, shape, composition and distribution. Common inclusions include oxides, sulfides, and carbides. Modification techniques aim to make inclusions less harmful by modifying their shape, composition and dispersion in the steel matrix. Calcium additions are often used to modify alumina and manganese sulfide inclusions. Proper inclusion control is important at all stages of steelmaking and processing to achieve clean steel.
The document discusses various types of casting defects including gas defects, shrinkage cavities, molding material defects, pouring metal defects, and metallurgical defects. It provides detailed descriptions and characteristics of different specific defects such as blowholes, pinhole porosity, cuts and washes, penetration, fusion, rattails, swell, washout, misruns, and cold shuts. The document emphasizes the importance of properly identifying and classifying defects in order to determine their causes and implement appropriate corrective actions to control quality.
This document discusses electroplating methods. It begins by defining electroplating as a process that uses electricity to coat a thin layer of metal onto an electrode. It then discusses four common purposes of electroplating: appearance, protection, special surface properties, and engineering/mechanical properties. Four common electroplating methods are described: barrel plating, rack plating, vibratory plating, and reel-to-reel plating. The document provides details on the equipment and process for each method. It concludes by discussing effects of electroplating like changes to chemical, physical, and mechanical properties and examples of its uses in various industries.
For construction professionals and sales personnel.
The material will take you through the basics of raw materials and coatings as well as describes how to use them in different applications. After studying the material you will:
* Know the basics of raw materials and coatings
* Know the newest products in coatings
* Get introduced to how different coatings and steel grades are used in construction applications
* Know some technical performance of the coatings
* Get a deeper overview of the two newest coating options
* Get some important tips maintenance-wise
Read more about steel coatings:
ruukki.com/colourcoatedsteels
ruukki.com/metalcoatedsteels
In the process of heat treating steel, it is heated and cooled multiple times to achieve the desired microstructure and mechanical properties. There are three main steps to heat treatment (HT): heating, holding at temperature, and cooling. The time and temperature at each step are important. Different HT processes like annealing, normalizing, and spheroidizing are used to modify the microstructure and properties of steel in different ways. Controlled pickling of steel is important to efficiently remove oxides and produce a uniform surface while minimizing chemical usage and waste generation.
Vacuum degassing is commonly used in steel production to remove gases like hydrogen and nitrogen from liquid steel. It works by exposing the steel to vacuum conditions, which allows the gases to be readily removed. Specifically, vacuum degassing lowers the levels of dissolved gases to parts per million and improves the quality of the final cast product by preventing cracking defects. It is a critical process that improves both productivity and quality in continuous steel casting.
Billet defects off-corner cracks formation, prevention and evolutionJorge Madias
Presentation on a solidification defect in billets. After a characterization of the defect and a discussion on the mechanism for its formation, preventive measures are analysed, taking into account several plant experiences. The evolution of the defect during rolling and further processing and application is reviewed, too.
The document outlines the organizational chart and production processes of an engineering steel plant. It details the roles of leadership positions like the president and directors. It maps the flow of raw materials from storage through melting, refining, alloying and pouring processes. Key stages include loading scrap and alloys, melting in electric arc furnaces, secondary refining using AOD converters, heating ladles, and final pouring of liquid steel. Laboratories analyze raw materials and samples to control quality.
This document provides information on carbon dioxide (CO2) welding including:
- CO2 welding is a type of arc welding that uses CO2 gas to shield the molten metal from oxygen. No slag removal is required.
- It is suitable for thin sheet welding and has a high welding speed and low current requirement.
- Proper gas flow, current, voltage, wire feed rate, and tip-to-work distance are required to avoid defects like porosity, pinholes, cracks, and lack of fusion.
- Spot welding uses electrical current to generate heat and join metal sheets. Proper electrode alignment and pressure are needed to form strong nugget joints without defects like undersize spots
Its Is The Process By Which A Iron Nail Is Been Coated With Copper Plate.Electroplating is a process that uses electrical current to reduce dissolved metal cations so that they form a coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate, as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.
The process used in electroplating is called electrodeposition. It is analogous to a galvanic cell acting in reverse. The part to be plated is the cathode of the circuit. In one technique, the anode is made of the metal to be plated on the part. Both components are immersed in a solution called an electrolyte containing one or more dissolved metal salts as well as other ions that permit the flow of electricity. A power supply supplies a direct current to the anode, oxidizing the metal atoms that comprise it and allowing them to dissolve in the solution. At the cathode, the dissolved metal ions in the electrolyte solution are reduced at the interface between the solution and the cathode, such that they "plate out" onto the cathode. The rate at which the anode is dissolved is equal to the rate at which the cathode is plated, vis-a-vis the current flowing through the circuit. In this manner, the ions in the electrolyte bath are continuously replenished by the anode.[1]
Other electroplating processes may use a non-consumable anode such as lead or carbon. In these techniques, ions of the metal to be plated must be periodically replenished in the bath as they are drawn out of the solution.[2] The most common form of electroplating is used for creating coins such as pennies, which are small zinc plates covered in a layer of copper. [3]Process[edit]
Electroplating of a metal (Me) with copper in a copper sulfate bath
The cations associate with the anions in the solution. These cations are reduced at the cathode to deposit in the metallic, zero valence state. For example, in an acid solution, copper is oxidized at the anode to Cu2+ by losing two electrons. The Cu2+ associates with the anion SO42- in the solution to form copper sulfate. At the cathode, the Cu2+ is reduced to metallic copper by gaining two electrons. The result is the effective transfer of copper from the anode source to a plate covering the cathode.
The plating is most commonly a single metallic element, not an alloy. However, some alloys can be electrodeposited, notably brass and solder.
The document discusses the process of deoxidizing steel. During steelmaking, oxygen dissolves into the liquid steel but not in the solid steel. Deoxidation or "killing" of steel refers to reducing the excess oxygen content before casting to prevent blowholes and inclusions. This is typically done through precipitation deoxidation using elements like aluminum, silicon, and manganese that have a higher affinity for oxygen than iron and form stable oxides. These deoxidizers are chosen based on factors like stability, deoxidizing ability, oxide melting point and density. Aluminum is the most powerful deoxidizer but its oxide alumina must be modified to remain liquid during casting.
Anodizing is an electrochemical process that converts the metal surface of aluminum to aluminum oxide. It produces a coating that is very durable, corrosion resistant, and maintains the metallic appearance of the aluminum. The anodizing process involves racking parts for processing, cleaning, etching, anodizing in an acid bath using electricity, coloring or sealing the pores, and testing to quality check the coating. Anodized aluminum has advantages like durability, low maintenance, and an environmentally friendly process.
Electrochemical Protection or Cathodic Protection uses two methods to protect metal surfaces from corrosion. Sacrificial anodic protection connects the metal to a more reactive metal like zinc or magnesium that corrodes instead of the protected metal. Impressed current cathodic protection uses an electrical current to force the metal to behave as a cathode. There are also several metallic coating methods to apply a protective layer to metals including hot dipping, electroplating, metal spraying, metal cladding, and cementation. Organic coatings like paints, varnishes, enamels, and lacquers provide protection by forming a barrier film on the metal surface.
Ceramics and Glass Technology (Silicate Glasses, Boric Oxide and Borate Glass...Ajjay Kumar Gupta
Ceramics and Glass Technology (Silicate Glasses, Boric Oxide and Borate Glasses, Phosphorus Pentoxide and Phosphate Glasses, Germanium Dioxide and Germanate Glasses, Nitrate Glasses, Halide Glasses, Chalcogenide Glasses, Modern Glass Working, Monax and Pyrex Glass)
Glass-ceramics are mostly produced in two steps: First, a glass is formed by a glass-manufacturing process. The glass is cooled down and is then reheated in a second step. In this heat treatment the glass partly crystallizes. In most cases nucleation agents are added to the base composition of the glass-ceramic. These nucleation agents aid and control the crystallization process.
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applications of Ceramics, Boric Oxide and Borate Glasses, Business guidance for glass ceramics, Business Plan for a Startup Business, Business start-up, Ceramic and glass business, ceramic business ideas, Ceramic forming techniques, Ceramic Industry, Ceramic Material Manufacturing Methods, Ceramic processing, Ceramics and Glass Technology, Ceramics Based Profitable Projects, Ceramics Based Small Scale Industries Projects, ceramics business plan, Ceramics Forming Processes, Ceramics pottery Manufacturing, Ceramics Processing Projects, Ceramics Production Industry in India, Chalcogenide Glasses, Germanium Dioxide and Germanate Glasses, Glass & ceramics Business, Glass & ceramics Small Business Manufacturing, Glass and Ceramics, glass and ceramics industry, Glass and Ceramics Technology, Glass Based Profitable Projects, Glass Based Small Scale Industries Projects, Glass Ceramic Products, Glass Ceramics Industry, glass ceramics properties, Glass Forming & Processing, glass forming process, Glass Forming Technology, Glass making - Industry process, Glass Manufacture and Processing, Glass Manufacturing Process, Glass Processing Projects, Glass production, Glass Production Industry in India, Glass-ceramic materials, Glass-ceramics: their production, properties and potential, Great Opportunity for Startup, Halide Glasses, How to Start a Ceramic Business, How to Start a Ceramics Production Business, How to start a glass & ceramics business?, How to Start a Glass Production Business, How to start a successful glass ceramics business, How to Start Ceramics Production Industry in India, How to Start Glass Production Industry in India, Modern Glass Working, Modern Small and Cottage Scale Industries, Monax and Pyrex Glass, Most Profitable Ceramics manufacturing Business Ideas, Most Profitable Glass manufacturing Business Ideas, New small scale ideas in Ceramics Production industry, New small scale ideas in Glass Production industry, Nitrate Glasses, Phosphorus Pentoxide and Phosphate Glasses, Processing Glass and Glass-Ceramics, Production of Glass Ceramic, Profitable Small and Cottage Scale Industries
Non-destructive testing (NDT) allows inspection of materials and components without damaging them. Common NDT methods include visual testing, magnetic particle inspection, dye penetrant testing, radiography, ultrasonic testing, and eddy current testing. These methods are used to detect surface or internal flaws in materials and evaluate characteristics without impairing future usefulness or serviceability. NDT plays an important role in quality control and safety across industries such as aerospace, automotive, and energy.
Stainless steels contain 10.5-30% chromium which forms a passive oxide layer protecting the steel from corrosion. Common types include martensitic, ferritic, austenitic, and duplex stainless steels. Martensitic stainless steels can be hardened through heat treatment while ferritic stainless steels have higher ductility and corrosion resistance. Duplex stainless steels have a mixed austenite and ferrite structure providing high strength and pitting/stress corrosion resistance. Austenitic stainless steels have excellent ductility and toughness down to cryogenic temperatures and are widely used in chemical plants and food processing. Proper welding techniques are required to prevent issues like sensitization, hot cracking, and sigma
The document discusses various casting defects such as blows, blisters, scars, washes, cuts, sinks, shrinkage cavities, pinholes, blowholes, hot tears, and misruns. Blows are large cavities caused by gases displacing molten metal, while blisters are shallow blows covered by a thin layer of metal. Washes are low projections on drag faces that decrease in height. Pinholes and blowholes are small gas pockets on or just below casting surfaces. Hot tears are cracks from stresses during solidification. Misruns occur when cavities are incompletely filled.
A brief knowledge about surface treatment, which is a process applied to the surface of a material to make it better in some way, for example by making it more resistant to corrosion or wear. Shot peening is a surface treatment in which small hard pellets are shot against the surface of a metal to make it more resistant to fatigue.
This document discusses various surface treatment and coating techniques, including conversion coatings like oxidation and anodizing, thermal coatings like carburizing and nitriding, metal coatings using electroplating and electroless deposition, vapor deposition methods like PVD and CVD, and organic coatings like paint and powder coating. It provides details on common processes, their applications and benefits, comparing techniques like electroless nickel plating versus hard chrome plating. The document emphasizes the importance of coatings for improving properties like corrosion and wear resistance.
Surface coatings are used to protect metals from corrosion and improve their properties. Common coating methods include conversion coatings like oxidation, phosphatization and chromating which form protective oxide layers. Thermal treatments involve diffusion, carburizing and nitriding to enrich the surface. Metal coatings are applied by electroplating, electroless plating or metallizing. Vapor deposition techniques like PVD and CVD are used to deposit thin, hard coatings. Organic coatings such as paint provide decorative and protective functions. Coatings selection depends on the substrate material and desired properties.
This document discusses inclusion control for clean steel production. It defines inclusions as non-metallic compounds that form separate phases in steel. Strict inclusion control is important for producing quality steel products. Inclusions are assessed and controlled by examining their source, shape, composition and distribution. Common inclusions include oxides, sulfides, and carbides. Modification techniques aim to make inclusions less harmful by modifying their shape, composition and dispersion in the steel matrix. Calcium additions are often used to modify alumina and manganese sulfide inclusions. Proper inclusion control is important at all stages of steelmaking and processing to achieve clean steel.
The document discusses various types of casting defects including gas defects, shrinkage cavities, molding material defects, pouring metal defects, and metallurgical defects. It provides detailed descriptions and characteristics of different specific defects such as blowholes, pinhole porosity, cuts and washes, penetration, fusion, rattails, swell, washout, misruns, and cold shuts. The document emphasizes the importance of properly identifying and classifying defects in order to determine their causes and implement appropriate corrective actions to control quality.
This document discusses electroplating methods. It begins by defining electroplating as a process that uses electricity to coat a thin layer of metal onto an electrode. It then discusses four common purposes of electroplating: appearance, protection, special surface properties, and engineering/mechanical properties. Four common electroplating methods are described: barrel plating, rack plating, vibratory plating, and reel-to-reel plating. The document provides details on the equipment and process for each method. It concludes by discussing effects of electroplating like changes to chemical, physical, and mechanical properties and examples of its uses in various industries.
For construction professionals and sales personnel.
The material will take you through the basics of raw materials and coatings as well as describes how to use them in different applications. After studying the material you will:
* Know the basics of raw materials and coatings
* Know the newest products in coatings
* Get introduced to how different coatings and steel grades are used in construction applications
* Know some technical performance of the coatings
* Get a deeper overview of the two newest coating options
* Get some important tips maintenance-wise
Read more about steel coatings:
ruukki.com/colourcoatedsteels
ruukki.com/metalcoatedsteels
In the process of heat treating steel, it is heated and cooled multiple times to achieve the desired microstructure and mechanical properties. There are three main steps to heat treatment (HT): heating, holding at temperature, and cooling. The time and temperature at each step are important. Different HT processes like annealing, normalizing, and spheroidizing are used to modify the microstructure and properties of steel in different ways. Controlled pickling of steel is important to efficiently remove oxides and produce a uniform surface while minimizing chemical usage and waste generation.
Vacuum degassing is commonly used in steel production to remove gases like hydrogen and nitrogen from liquid steel. It works by exposing the steel to vacuum conditions, which allows the gases to be readily removed. Specifically, vacuum degassing lowers the levels of dissolved gases to parts per million and improves the quality of the final cast product by preventing cracking defects. It is a critical process that improves both productivity and quality in continuous steel casting.
Billet defects off-corner cracks formation, prevention and evolutionJorge Madias
Presentation on a solidification defect in billets. After a characterization of the defect and a discussion on the mechanism for its formation, preventive measures are analysed, taking into account several plant experiences. The evolution of the defect during rolling and further processing and application is reviewed, too.
The document outlines the organizational chart and production processes of an engineering steel plant. It details the roles of leadership positions like the president and directors. It maps the flow of raw materials from storage through melting, refining, alloying and pouring processes. Key stages include loading scrap and alloys, melting in electric arc furnaces, secondary refining using AOD converters, heating ladles, and final pouring of liquid steel. Laboratories analyze raw materials and samples to control quality.
This document provides information on carbon dioxide (CO2) welding including:
- CO2 welding is a type of arc welding that uses CO2 gas to shield the molten metal from oxygen. No slag removal is required.
- It is suitable for thin sheet welding and has a high welding speed and low current requirement.
- Proper gas flow, current, voltage, wire feed rate, and tip-to-work distance are required to avoid defects like porosity, pinholes, cracks, and lack of fusion.
- Spot welding uses electrical current to generate heat and join metal sheets. Proper electrode alignment and pressure are needed to form strong nugget joints without defects like undersize spots
Its Is The Process By Which A Iron Nail Is Been Coated With Copper Plate.Electroplating is a process that uses electrical current to reduce dissolved metal cations so that they form a coherent metal coating on an electrode. The term is also used for electrical oxidation of anions onto a solid substrate, as in the formation silver chloride on silver wire to make silver/silver-chloride electrodes. Electroplating is primarily used to change the surface properties of an object (e.g. abrasion and wear resistance, corrosion protection, lubricity, aesthetic qualities, etc.), but may also be used to build up thickness on undersized parts or to form objects by electroforming.
The process used in electroplating is called electrodeposition. It is analogous to a galvanic cell acting in reverse. The part to be plated is the cathode of the circuit. In one technique, the anode is made of the metal to be plated on the part. Both components are immersed in a solution called an electrolyte containing one or more dissolved metal salts as well as other ions that permit the flow of electricity. A power supply supplies a direct current to the anode, oxidizing the metal atoms that comprise it and allowing them to dissolve in the solution. At the cathode, the dissolved metal ions in the electrolyte solution are reduced at the interface between the solution and the cathode, such that they "plate out" onto the cathode. The rate at which the anode is dissolved is equal to the rate at which the cathode is plated, vis-a-vis the current flowing through the circuit. In this manner, the ions in the electrolyte bath are continuously replenished by the anode.[1]
Other electroplating processes may use a non-consumable anode such as lead or carbon. In these techniques, ions of the metal to be plated must be periodically replenished in the bath as they are drawn out of the solution.[2] The most common form of electroplating is used for creating coins such as pennies, which are small zinc plates covered in a layer of copper. [3]Process[edit]
Electroplating of a metal (Me) with copper in a copper sulfate bath
The cations associate with the anions in the solution. These cations are reduced at the cathode to deposit in the metallic, zero valence state. For example, in an acid solution, copper is oxidized at the anode to Cu2+ by losing two electrons. The Cu2+ associates with the anion SO42- in the solution to form copper sulfate. At the cathode, the Cu2+ is reduced to metallic copper by gaining two electrons. The result is the effective transfer of copper from the anode source to a plate covering the cathode.
The plating is most commonly a single metallic element, not an alloy. However, some alloys can be electrodeposited, notably brass and solder.
Power point presentation based on electroplatingShah Virangi
Electroplating is a process that uses electricity to coat an object with a thin layer of metal. It involves using a cathode, anode, electrolyte, and power source. The metal ions in the electrolyte solution are attracted to the cathode due to the electric current, reducing and plating the metal onto the cathode. Electroplating is widely used in industries like automotive, aerospace, electronics, and jewelry to protect objects from corrosion, improve appearance and surface properties, and reduce friction.
Electroplating is a process that uses an electric current to coat an electrode with metal by transferring metal ions in a solution onto the electrode. The document provides instructions for electroplating a copper coating onto a key using a copper sulfate solution, copper anode, and battery. When current is applied, copper ions in solution are oxidized from the anode and travel to the cathode/key, where they are reduced and deposited as a copper coating on the key's surface. Electroplating can coat many metal items like ornaments and coins.
Electroplating is a process where a metal coating is produced on a surface through the action of an electric current in an electrolyte solution. Key factors that influence the quality of electroplating include current density, cathode efficiency, agitation of the plating bath, bath composition/concentration, water quality, and presence of impurities. Hydrogen embrittlement can occur during electroplating and negatively impact the metal's fatigue and mechanical properties.
The document discusses electroplating, which involves using electrolysis to coat a thin layer of one metal onto another. It explains that electroplating can be used to protect against corrosion or improve appearance. It then provides details on the electroplating process, where the metal to be plated is the cathode and connects to the negative terminal, while the metal used for plating is the anode and connects to the positive terminal. Ions of the anode metal dissolve and deposit onto the cathode. Copper plating of other metals like copper is provided as an example.
Zinc and zinc nickel plating provide corrosion protection for steel. Zinc plating is an electrochemical process that deposits a thin layer of zinc onto steel. It protects against white and red corrosion but government regulations and industry standards have increased minimum corrosion protection requirements. Zinc nickel plating deposits both zinc and nickel onto steel, providing greater hardness and minimum 750 hours to white corrosion and 2000 hours to red corrosion. It has become a replacement for zinc plating and cadmium plating due to its superior properties and compliance with environmental regulations.
The presentation takes into account widely used surface finishing processes including electroplating, anodizing, alodining, cadmium plating, zinc plating, phosphating, passivation
Este documento describe la toxicidad de compuestos de plomo, incluyendo su toxicocinética, efectos a la salud, diagnóstico y medidas de prevención. Explica las consideraciones ocupacionales del plomo inorgánico y sus exposiciones comunes en diversas industrias. Describe la absorción, distribución y excreción del plomo, así como sus mecanismos de acción y efectos hematológicos, neurológicos y renales. Finalmente, recomienda medidas ambientales, de vigilancia médica y protección
The document describes the design of a chemical vapor deposition (CVD) system. It discusses the working principles of CVD, the key components of a CVD system including the reactor chamber, gas distribution system, heating elements and vacuum system. It outlines the functional, performance and reliability requirements for the CVD tool, as well as environmental health and safety considerations. The document also discusses the product lifecycle and costs associated with developing, operating and disposing of the CVD system.
Reporting involves presenting metrics at face value within a limited context, which does not provide actionable insight. Analysis requires understanding why results occurred in order to inform decisions. To succeed, organizations must set strategic objectives and empower analysts, using the right tools, people, and processes to become truly data driven. Moving from only reporting to a data-driven culture of analysis and action can help organizations get more value from their data investments.
Visual Workflow Management is a highly effective method for implementing lean product development that provides quick wins to build momentum for improvement initiatives. It consists of daily stand-up meetings of 15 minutes or less to check status and plan work, combined with a visual project board to capture information in real-time. These frequent yet brief synchronization points help prevent team members from drifting and promote collaboration, issue resolution, and productivity. Visual Workflow Management benefits any group that must work as a team to achieve common goals.
The document provides a detailed summary of the plot and characters of the memoir "When I Was Puerto Rican" by Esmeralda Santiago in 12 chapters. It also analyzes the key elements of the story such as its exposition, rising action, climax, resolution, conflicts, themes, and the author's use of figurative language.
Electroforming is an additive manufacturing process that uses electrodeposition to precisely create metal parts on a micron scale. It involves submerging a mandrel and anode in an electrolyte bath containing metal salts and applying a direct current, which causes a metal such as nickel to deposit on the mandrel in thin layers. Once the desired thickness is reached, the part is removed from the mandrel. Electroforming can produce parts as thin as 0.0005 inches with holes as small as 0.0002 inches in diameter and tight tolerances of 0.0001 inches. It is commonly used to create screens, molds, and microelectronics components when conventional machining is impossible at the required precision levels.
This document discusses antireflection coatings. [1] Antireflection coatings are applied to optical surfaces to reduce reflection and improve efficiency. [2] They work through destructive interference between light reflecting off the coating surface and light reflecting off the underlying surface. [3] Common techniques for depositing antireflection coatings include chemical vapor deposition, physical vapor deposition, and plasma-enhanced chemical vapor deposition.
Ultrasonic bone scalpels are a novel surgical device that can be used for spinal decompression. The device cuts bone using ultrasonic vibrations while sparing soft tissues like the dura mater. A study of 35 patients undergoing spinal decompression with an ultrasonic bone scalpel found that it reduced operation times, blood loss, and hospital stays compared to traditional techniques. It also lowered post-operative disability scores and had only one minor complication of a dural tear. While the bone scalpel offers advantages over power drills and rongeurs, surgeons must develop tactile feedback and plan bone cuts in advance due to its selective cutting of bone only.
The document discusses various types of casting defects including their forms, causes, and prevention methods. It covers shaping faults from pouring like misruns and cold shuts caused by low metal temperature or moisture in sand. Shrinkage defects from inadequate gating and risering are described. Contraction defects like hot tears occur when thin and thick sections cool at different rates. Gas defects result from entrapped gases or gases evolving during solidification. Inclusions and sand defects enter the melt during pouring. Dimensional errors occur from mold distortions. Compositional errors and segregation vary the alloy composition.
Casting defects can be classified into general defects common to all casting processes and defects related specifically to sand casting. General defects include misruns where the mold is not fully filled, cold shuts where two metal flows fail to fuse, cold shots where metal splatters during pouring, and shrinkage cavities caused by solidification shrinkage. Sand casting defects include sand blows caused by trapped gases, pin holes of small gas cavities, and penetration where molten metal enters the sand mold. Proper design and production processes seek to eliminate defects and ensure casting quality.
The document discusses design considerations for castings. It notes that casting involves pouring molten material into a mold to create complex shapes. Successful casting requires controlling variables like the material, casting method, cooling rate, and gases. The document outlines design considerations like designing parts for easy casting, selecting suitable materials and processes, locating parting lines and gates, and including features like sprues and risers. It also discusses designing parts to avoid defects from things like shrinkage, stress concentrations, and uneven cooling. The document concludes by mentioning some common casting defects and factors in the economics of casting like costs of molds, materials, and production rates.
The document discusses casting quality and defects that can occur during the casting process. It describes general defects that can happen with any casting method as well as defects specific to sand casting. It also covers casting materials, including ferrous alloys like cast iron and steel, and nonferrous alloys such as aluminum, copper, and zinc alloys. Product design considerations for castings are outlined such as simplifying geometry, avoiding sharp corners, and allowing for tolerances and machining.
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
Direct gold foil restorations involve building up gold incrementally using various forms of gold foil, powder, or electrolytic precipitate. Key steps include tying opposing walls, banking walls, shoulder preparation, overfilling the cavity, surface hardening, burnishing, margination, contouring, finishing, and polishing. Direct gold provides advantages like corrosion resistance and biocompatibility but requires skill for manipulation and has disadvantages like poor esthetics and a high coefficient of thermal expansion. The quality of a direct gold restoration depends highly on the dentist's technique.
The document discusses welding processes and their importance, types of welds and weld defects, including causes and methods of detection. It examines the microstructure of welds and defines features like the fusion zone, heat affected zone, and unaffected base metal zone. Various weld defects are described such as cracks, cavities, inclusions, lack of fusion/penetration, imperfect shape, and miscellaneous faults.
Lamellar tearing is commonly observed in fusion welding and occurs near the heat-affected zone in flange plates of T-butt joints. It is due to segregation caused by excessive dilution from filler metal or improper heat input. Dilution and heat input must be controlled to minimize lamellar tearing.
Porosity appears as dark round or elongated indications in radiographs and is caused by gas inclusions from inadequate shielding or moisture contamination. It represents voids in the weld metal.
Lack of penetration occurs when weld metal fails to fully penetrate the joint, leaving a linear discontinuity. In radiographs it appears as a dark line along the weld centerline.
The document discusses the design of gating systems for sand casting. It describes the key components of a gating system including the pouring basin, sprue, runners, ingates, and riser. It explains the functions of each component in filling the mold cavity with molten metal while preventing defects. The document also discusses factors like gating ratio, pressurized vs non-pressurized systems, and formulas for calculating freezing ratio between the casting and riser.
RAW MATEIAL and Heat Treatment process .pptSameerSutar8
This document provides an overview of a training programme on raw materials and heat treatment. It discusses the objectives of the training, which are to provide awareness of different raw material types, their characteristics, advantages, and examples used in the division. It then describes common product types like rolled products, forgings, castings, tubular products, and extrusions. The remainder of the document discusses these processes and material types in further detail, including definitions, considerations, defects, inspection methods, and more. It aims to educate participants on raw materials and manufacturing processes.
The document discusses various traditional and nontraditional machining processes. It describes grinding as a traditional machining process that uses abrasive particles to remove small amounts of metal. It then discusses several nontraditional processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, and ultrasonic machining. Each of these processes removes material using methods other than traditional cutting, such as through chemical or electrical erosion, melting with lasers or electrons, or erosion with high-pressure water or abrasive particles. The document provides details on the mechanisms and applications of each of these nontraditional machining methods
Special Casting Processes
Centrifugal Casting
Semi centrifugal casting
Centrifuging
Die Casting
Gravity Die Casting
Pressure die casting
Hot chamber die-casting:
Submerged plunger die casting
Air blown or goose neck die casting machine
Investment Casting
Defects in Casting
Blow holes Casting Defects
Shrinkage
Crack
Inclusions
Lift and shift
Swell
Fins
Misrun and cold shut
Metal Penetration
Hard spot
Run out
Drop
Warpage
Casting Sensitization Process and Details.pptxJAYARAMPRABHU3
Sensitization occurs when chromium depletes around carbides that precipitate at grain boundaries in stainless steel or alloys held at temperatures from 425-815°C. This makes the metal susceptible to intergranular corrosion or cracking. Welding is particularly prone to sensitization due to temperatures in the heat-affected zone. Preventing sensitization involves reducing carbon content, adding stabilizers, or shortening exposure time in the critical temperature range.
- Lamellar tearing is commonly observed discontinuity in fusion welding that occurs near the heat-affected zone in flange plates of T-butt joints. It is caused by factors like dilution and heat input during welding.
- Dilution is affected by the melted parent metal, melted filler metal, and weld width to depth ratio. Too low or too high heat input can both be detrimental.
- Solidification cracks can form due to the bead factor, which is the ratio of weld width to depth. A ratio greater than 1 or less than 1 can both result in cracks.
Nitriding is a heat treatment process that diffuses nitrogen into the surface of metals like steel to create a hardened case. There are three main nitriding methods: gas, salt bath, and plasma nitriding. Nitriding increases properties like wear resistance, fatigue strength, and corrosion resistance while minimizing distortion compared to other hardening processes. Common applications of nitrided parts include use in the aircraft, automotive, and tooling industries.
This document discusses various types of coatings used to protect metals from corrosion. It covers metallic coatings such as those that are more or less noble than the base metal. It also discusses organic coatings and how they provide protection through barrier properties and active inhibition. Various coating application methods are outlined. Finally, common corrosion issues that can occur with coatings like blistering, rust, and delamination are described along with examples of how coatings can solve corrosion problems in applications.
The document discusses various joining processes including welding, brazing and soldering. It explains that brazing and soldering involve melting of a filler metal with brazing using higher temperatures and stronger fillers, while soldering uses lower temperatures and weaker tin-lead fillers. Welding involves melting the base metals. The document then goes on to describe various welding techniques like stick welding, MIG welding, TIG welding and spot welding. It also discusses factors like distortion and flaws in welds. The document also provides details about brazing and different types of solders, fluxes used and joint designs for soldering.
The document discusses various casting methods including sand casting, investment casting, and die casting. It provides brief descriptions of each process, including typical metals used, size ranges, tolerances, surface finishes, draft requirements, section thicknesses, ordering quantities, and lead times. It also discusses topics related to casting such as solidification, shrinkage, heat transfer considerations, and environmental issues. Pattern design guidelines are presented for factors like shrinkage allowance and minimum thicknesses.
The document summarizes corrosion of weldments. It discusses the microstructure of weldments and the distinct regions that form. It then covers the various forms of weld corrosion including galvanic, pitting, crevice, intergranular, stress corrosion, and hydrogen cracking. Factors that influence weld corrosion like material selection and welding parameters are presented. Testing methods for weld corrosion like linear polarization resistance and corrosion potential measurements are briefly described.
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
The document discusses Hevi Sand, a processed chromite product created by AMCOL. It begins with an overview of AMCOL and its global mining operations. It then discusses the traditional chrome ore supply chain and issues with traditional processing methods. The document outlines the development of the H.S. Process for processing chromite, including identifying customer needs, researching chromite formation and impurities, developing plant requirements, and addressing issues like yield and quality. It provides details on the H.S. process plant, technology used, and end product results and issues identified.
The document discusses a new process called the Hevi-Sand Process for producing foundry-grade chromite sand from mines in South Africa. Traditionally, chromite sand production has involved crushing, screening, and washing ore using Humphrey spirals to separate out lower-grade material. This process is variable and inefficient. The Hevi-Sand Process was developed to maximize the yield of high-quality foundry sand through advanced separation techniques. It aims to convert over 65% of the mined ore into consistent chromite sand while reducing water usage by 80% compared to traditional methods. The document suggests this new technology could support changing quality standards for chromite sand.
This document summarizes a presentation on improving energy efficiency in foundries. It discusses the South African foundry industry and provides definitions related to energy efficiency. It then examines opportunities for energy savings across various foundry processes like melting, holding, tapping, and maintenance. These include using batch melting, avoiding holding metal, preheating scrap, improving refractory maintenance, and more. The conclusion is that continuous small improvements can achieve energy savings and there are retrofitting options available for many furnaces.
Does your Foundry comply with current Environmental Legislation requirements?SAIFoundry
EnviroKey Management Services cc.
Does your Foundry comply with current Environmental Legislation requirements?
South African Institute of Foundrymen
17 April 2012
Austempered ductile iron production properties applicationsSAIFoundry
Austempered ductile iron (ADI) is an engineering material with good mechanical properties due to its unique microstructure of acicular ferrite and carbon-enriched stabilized austenite (ausferrite). The austempering process involves two stages - the first produces ferrite and high-carbon austenite, while the second decomposes austenite and forms carbides. Controlling the austempering time within the "process window" between these stages results in optimum properties. The microstructure and properties depend on factors such as austempering temperature, alloy content, and heat treatment parameters.
This document discusses various methods to enhance the properties of austempered ductile iron (ADI), including:
1. Carbidic ADI (CADI) which has improved abrasion resistance through the addition of carbides.
2. Cold-rolled ADI which has enhanced toughness from transformation induced plasticity during rolling.
3. Bainitic-martensitic ADI which has a dual-phase microstructure for higher toughness and hardness.
It also discusses ausforming ADI to produce very fine ausferritic microstructures with dramatically increased strength, hardness, and wear resistance compared to conventionally processed ADI.
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2. Relative costs of fabricating, finishing and plating
zinc diecastings
3. Some Design Rules
Mimimum crown of 0.15cm per cm
If flat surfaces required, use satin instead of bright finish to hide waviness
All edges should be rounded off to radius of at least 0.4mm, preferably
0.8mm
Reduce depth of concave recesses as much as possible, avoid depths greater
than 50% of width
If sharply angled grooves are needed, paint the bottom of the grooves, it is
cheaper than plating the bottom of the grooves
Slots and holes shown have widths at least 2X their depth
Spaces between slots should be spaced so that spacing between their
centers is 4X their width
Blind hole depths should be less than ½ their width and blind holes <5.6mm
diameter should be avoided
Threaded holes should be countersunk to minimize buildup on their outside
The height of fins and ribs should be reduced as much as possible with
radius>1.6mm at base
Parallel fins should be spaced so distance between centers is >4X fin width
Recessed letters preferred to raised letter. Raised letter heights should be
<50% of their width
If studs threaded before plating, max thickness is 5µm
Drain holes should be provided in cup-like contours to avoid hand rinsing
6. Checklist for High Quality Castings
Properly designed and constructed dies
Smooth working, run-in casting machines
Correct alloy composition
Good melting and delivery practice, proper die
lubrication
Correct injection and trimming procedures
7. Die Design Guidelines
Plan for location of ejector pins to prevent marks
in visible areas, or place on areas that can be
easily polished
Fill thick sections before thin to allow progressive
cooling
Alloy should reach vents and overflows last to
allow complete die cavity filling
Place vents at parting line to allow easy removal
of flash
Surfaces required to slide on cavity during
ejection should be tapered
Castings with defects >50µm are not salvageable
8. Cross sections of rough
surface diecastings
plated with bright copper
in cyanide and acid
baths, then with leveling
duplex nickel
9.
10. Casting Fluidity
• Zamak Alloys are more fluid than ZA
Alloys.
• Aluminum increases fluidity for Zamak
Alloys – keep Al to high side of range.
• Magnesium decreases fluidity, but not as
much as aluminum changes.
11. Fluidity of Zinc Die Casting Alloys
Ragone Fluidity, Inches
Aluminum, Weight Percent
12. Solidification Ranges
Zamak alloys have smaller freezing ranges than ZA alloys
Alloy Solidification Range ºC ( ºF )
Alloy 3 6 (11)
ZA-8 29 (52)
ZA-12 55 (100)
ZA-27 112 (202)
Therefore, shrinkage porosity rarely occurs in
Zamak alloys
13. Casting Limits
Integranular corrosion can be caused by high levels of Pb, Cd, Sn
Casting Limits
Zamak 3 Zamak 5
Pb (max) 50 ppm 50 ppm
Cd (max) 40 ppm 40 ppm
Sn (max) 30 ppm 30 ppm
ZA contaminant levels are similar
14. Effect of humidity test on zinc-aluminum
alloy containing cadmium
Discolored &
As cast plate Cracked
humidity-tested
panels
15. As-polished structure of humidity-tested zinc
aluminum alloy containing cadmium showing a
crack and intergranular corrosion
16. Intermetallics
• Intermetallics are mostly Fe-Al:
– Leave “comet tails” after buffing.
– Can be removed by stirring, letting the
bath stand and skimming.
– Machining (tool wear) problems can also
result.
18. Tool Wear – ZA-27 Die Casting
Many large FeAl3 particles
Mean Wear Land Width (mm )
(0.07% Fe)
Mean Wear Land Width (in.)
Many small FeAl3 particles
(0.22% Fe)
Drilling Time (min.)
19. Cosmetic Defects
• Cold Shuts • Flaking or waving
• Blisters • Solidification
• Die Soldering cracking
• Surface Shrinkage • Hot tearing
• Internal porosity
20. Cold Shuts
• Defined as surface lappings of
solidified metal on die castings.
• Caused by premature solidification of
flowing metal.
• Results in line defects at stream
intersections
21. Cold Shuts
• Important Control Variables:
– Cavity fill time
– Gate velocity
– Die & metal temperatures
– Flow pattern in cavity.
• Cold shuts cannot be removed by
intensification.
22. Cold Shut Regions
( a) (b)
(a)Surface view of a cold- (b) Higher Magnification
Shut region of a casting view of center field in
“(a)”
23. Cold shut in a zinc Cold lap in a zinc
diecasting diecasting electroplated
conventionally conventionally after
electroplated after mechanical buffing
polishing and buffing
24. Eliminating Cold Shuts
• Cavity fill time should be 20 ms or less for
casting 2 mm (0.080 in) or thinner for
chrome plating.
• Painted castings can tolerate fill times up
to 40 ms.
• Die temperature should be at least 200ºC
(390ºF) on the surface.
• Runner and gates should be designed to
produce uniform cavity fill.
25. Eliminating Cold Shuts
• Heat transfer can be retarded by auxiliary
heaters, textured dies & die coatings.
• Cold shuts shallower than 0.05 mm (0.002
in) can be removed by buffing.
• Excessive buffing or sanding can expose
subsurface porosity.
• Cold shuts act like “notches” can cause
brittle fracture.
28. Blisters
• Caused by expansion of gases or
corrosion products trapped in pores near
plated surface.
• Gas in pores is nitrogen or hydrogen
(from mold lubricant).
• Usually form during premature ejection
from die or baking or heat treatment of
casting.
• Blisters can also occur if a lap is not
completely removed – plating stresses lift
off the poorly-bonded joint.
29. Exfoliation of a zinc Skin blister in a zinc
diecasting diecasting
conventionally plated conventionally
after mechanical electroplated after
buffing polishing and buffing
30. Surface Porosity: Blisters
• Minimize blistering due to subsurface porosity
by limiting ejection temperature.
• Minimize blistering due to gas porosity by
minimizing trapped gases in casting. Improve
feed system, eliminate sharp corners.
• Gas should be forced into less critical regions of
the casting.
• Increase gate velocity to decrease size of
pores.
• Cooler dies will make pores form more in
center of casting.
31. Small surface pores in a Large surface pores in
zinc diecasting a zinc diecasting
conventionally conventionally
electroplated after electroplated after
polishing and buffing polishing and buffing
33. Views of Castings with Extensive
Surface Lapping
As-Cast and Plated After a paint baking
heat treatment
34. Die Soldering
• Defined as fusion of cast metal to die steel
during casting – sometimes referred to as
buildup.
• Can be caused by direct impingement of
molten metal stream on a flat surface, die
erosion, high die temperature or
insufficient draft angles.
• Soldering due to die erosion usually occurs
near the gate – eroded or pitted areas
occur.
35. Die Soldering
• Insufficient draft angles or high die
temperatures can also roughen the die
surface, encouraging soldering.
• Best solution is to use a good die
lubricant, combined with good metal flow
and uniform die temperatures.
36. Defects Cause by Hot Spots
• High die temperatures used to improve surface
quality.
– Each increase in die temperature of 11ºC
(20ºF) above 200ºC (390ºF) has same effect as
increasing fill time by 2 ms.
• Defects include:
1. Surface Shrinks 3. Solidification cracking
2. Laking or Waving 4. Hot tears
37. Surface Shrinkage
• Usually coincides with hot surface spots on
die.
• Caused by delayed solidification in this
area compared to surrounding
areas, hence increased contraction.
• Shrinkage areas are shiny on Zamak
alloys, frosty on ZA alloys.
38. Views of Surface Shrinks on a ZA Casting
Surface Shrinks Close-up View of
Surface within a
Shrinkage area
39. Laking or Waving
• Defined as large, irregular patches on die
casting surface – can be sunken or raised.
• Vary in size & shape, but always in same
general area of casting – can have height
difference of 0.025 mm (0.001 in.)
• Higher lakes are more rapidly cooled than
surrounding areas.
40. Laking or Waving (Cont’d.)
• Buffing reveals transition lines between
different solidified zones.
• Usually caused by over-heated
dies, inadequate filling, poor die
lubrication.
• Better fill times can also reduce laking
41. Views of Lake Areas in Casting
A B
Example of a lake Microstructure in
on a plated casting lake area of
casting in Fig. “A”
42. Surface waviness on a Small nodules on a zinc
zinc diecasting after diecasting
electroplating with electroplated with
leveling copper and leveling copper and
nickel nickel
43. Solidification Cracking
• Occurs if feeding of area is restricted.
• Usually occurs when thick sections are
fed by thin ones – shrinkage occurs in
the last area to freeze (hottest area).
• Rare in Zamak alloys because of low
freezing range & normal presence of
entrapped gas. Gas maintains pressure
and feeding
44. Solidification Cracking
A B
Solidification cracking Solidification cracks at
of a bulky & complex inside surface of
casting casting in Fig. “A”
45. Hot Tearing
• Begins along inside corners of casting if
thermal contraction is hindered
• Occurs when an outside corner of the die
is over-heated
• Solidification of the corner is retarded,
freezing & contraction of metal on either
side applies stress, resulting in cracks to
semi-solid metal
46. Hot Tearing (Cont’d.)
• Can occur with bosses and along length of
a gate, where it is confused with trimming
damage
• To eliminate, control die temperature, die
cooling methods, make part inside radii as
large as possible
• A minimum radius of 2 mm (0.08 in.) is
desired
47. Hot tear crack along the base of a ridge on
a casting
A B
As-polished Higher magnification
View of crack etched view of crack
at lower arrow
location in Fig. “A”
48. Hot tear cracks
B
A
Edge view of hot-tear crack View of similar casting
along the length of a gate as shown in Fig. “A” but with
after trimming gate attached
49. Internal Porosity
• Distinct from subsurface porosity that
causes blisters
• Internal porosity revealed by trimming,
machining. Must be removed before
plating
• Can also cause leaks in fluid handling
components.
• Important factors for porosity size and
distribution are metal flow system,
venting & die temperature
50. Internal Porosity (Cont’d.)
• Fill patterns must be uniform.
• Gate velocity should exceed 35 m/s (115
ft/sec) for atomized flow
• Vents remove entrapped gas.
• Die & metal temperature, together with
cooling system, also affect porosity.
• Rapid solidification traps gas throughout
the casting.
51. Gate pores exposed
By trimming
Gate pore with
small opening; no
plating of inner
surface
Gate pore with
plating of inner
surfaces & corrosion
lower down
52. Gate Pores (cont’d.)
B
Large gate pores in water
Original small gate pore
Hose gun casting exposed
Enlarged by action of
By machining to create a
Accelerated corrosion test.
“leaker.” (X10)
Upper polished view (X100); lower
Etched view (X200)
53. The depth of surface defects in a sample of
defective zinc diecastings
54. Inspecting Zn Diecastings
Need to identify defects requiring excessive polishing or
buffing
Inspection should be nondestructive and rapid
Dye penetrant is best of non-visual methods, but
improved lighting techniques allow visual inspection to
be preferred method
Best for first inspection to occur after trimming. Need to
sort into
-Diecastings with no plating problems
-Salvageable castings using economical
polishing, buffing or vibratory milling
-Castings that would still show defects after finishing
and plating that should be scrapped
55. Evaluation of 9 nondestructive methods for
inspecting zinc diecastings for surface defects
58. As-cast surface illuminated to a
level of more than 2700 Lux (250
foot candles) with a mixture of
direct and diffused light
59. Well-diffused light source Patterned light source
Buffed surface illuminated to a level
of more than 2700 Lux (250 foot
candles) with a mixture of direct
and diffused light
60. Visual Inspection
Almost all fissures and pits on a typical
diecasting are< 50µm, at limit of human eye,
but good lighting can allow visual inspection
Polarized light reduces glare but prevents
viewing of fissures and pits
Laser lighting produced granular surface
appearance, limiting its sensitivity
Smooth castings, including those inspected
after polishing and buffing, give high reflectivity
surfaces and therefore different lighting
requirements than as-cast surfaces.
62. Design for Finishing
Position parting line, gates, vents, overflows
and ejectors on insignificant surfaces
Locate gates to produce sound castings with
good surface quality, in locations avoiding
marks left after breaking or shearing
Avoid sharp edges, corners or protrusions that
can cause excessive wear on polishing wheels
or belts
For barrel plating, avoid plain flat surfaces that
hay cause castings to stick together
Design for fixturing to allow use of automatic or
semi-automatic equipment
63. Die Preparation
Polishing of die to reduce roughness to maximum of
0.2µm will increase die cost moderarately but can
substantially reduce expensive polishing and buffing
Oxide films on the die surface are beneficial for
eliminating soldering and reducing heat loss
A thin crack-free Cr plating layer can be inexpensively
stripped and replaced. Cr plate must be compressively
stressed to prevent cracking and spalling. Solutions of
chromic, sulfuric and fluosilic acid used at 40-43°C to
deposit compressively stressed Cr with minimum
thickness of 10µm
Electroless Ni on clean die surfaces can also produce
durable surface
64. Polishing Belts and Wheels
Removal of metal with abrasive, especially rough edges
after trimming
Slurry finishing involves rapid movement of castings, ie
by spinning, in abrasive
Use of coarser (240 grit) abrasive followed by fine
allow for polishing of both jagged, wide burrs and finer
parting lines etc
Vibratory finishing faster than barrel tumbling
(abrasive-loaded plastic chips)
Finishes of 3-5µm possible with vibratory finishing, can
be reduced to 1-2µm by level plating
66. Buffing – moves metal from microprojections to
microdepressions
Surface temperature must be >120°C, preferably
>150°C
Surface roughness after buffing is 2-3µm
Good vibratory finishing and levelling plating can
make buffing unneccessary
Removal of buffing compound from recesses can be
difficult
Electropolishing can be used to remove burrs and
fissure-like defects up to 50-75µm, but can expose
subsurface pores
Subsurface pores can be completely filled with
leveling copper
67. Surface roughness variations resulting from some
polishing and buffing operations
Surface roughnesses after plating refer to
leveling electroplate in all cases
1 microinch= 0.0254µm
68. Metal removal rate for salvaging defective
diecastings in vibratory machines
69. Metal removal rate during vibratory finishing with
chemical accelerators
78. Effect of anode size and position on the thickness
variations on electroplate
79. The cathode robbers
of each corner of the
workpiece are in
electrical contact
with the workpiece
4 curved plastic
shields are
placed one at
each corner of
the workpiece
80. Plating rack with integrated, hinged current
shields for improving coating thickness of
electrodeposits
81. Integrated plating rack showing auxiliary anode
for obtaining uniform coating thickness on a
diecasting
82. Section of plating
Section of rack rack equipped
equipped with auxiliary with auxiliary
nickel anodes nickel anodes to
to increase coating improve thickness
thickness of Ni and Cr uniformity on
around automobile
headlamp doors handles
83. Distribution of nickel on an automobile door
handle resulting in 400% waste of metal on high
current density areas
84. Copper-nickel-chromium coatings on zinc
diecastings (ASTM B456)
All applied on undercoat of copper or yellow brass
with thickness of at least 5µm (0.2mil)