Plasma Casting treatment (PTC) for Ductile Iron

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• Plasma Casting treatment (PTC) for Ductile Iron

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Applying the Plasma Treatment Casting (PTC)
process for Ductile Iron Sand Casting
The Camshaft Bearing Houses shown in this
presentation were cast on DisaMatic line for
ductile iron sand casting, with and without the
PTC process
Normal Casting Total cast weight - 5.6 kg Net
product weight - 3.4 kg Risers weight - 2.2 kg
riser
Reduced riser without PTC Total cast weight
4.2 kg Net product weight 3.4 kg Risers weight
0.8 kg
The PTC process saves 80-90 of the risers mass
Cast with PTC process Total cast weight 4.2 kg
Net product weight 3.4 kg Risers weight
0.8 kg
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Plasma Treatment Casting (PTC) process for
Ductile Iron Sand Casting

• The PTC is patented technology worldwide.
• The PTC is a flexible add-on device for
  existing casting lines.
• The PTC does not change the end product.
• The PTC reduces risers mass by 80-90
• The PTC refines the microstructure
• The PTC increases the ratio of product/casting
  weight
• from about 50 yield to over 80
• The PTC reduces defects and improves surface
  roughness
• The PTC reduces the feeding system weight
• (In some cases also the internal risers)

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The principle of the PTC Process
The PTC process applies plasma arc during
solidification process.The rotating plasma arc
movesalong a prescribed path, defined bya
special electrode. The PTC process stir the
molten in the sand mold during solidification, by
replacing the risers mass with kinetic electric
and magnetic stirring forces
Confidential
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Saving of 1.4 kg of the risers weight and 0.6
kg of the feeder in casting 3.4 kg product
Normal casting Total casting weight 6.8 kg Net
product weight 3.4 kg Pouring feeder weight
1.2 kg Risers weight 2.2 kg
Casting with PTC process Total casting 4.8
kg Net product weight 3.4 kg Pouring feeder
weight 0.6 kg Risers weight 0.8 kg
Reducing risers weight from 2.2 kg
0.8 kg
With an accurate pouring system, the PTC can save
even 95 of the risers mass
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The PTC Reduces casting weight from 6.8 kg to
4.8 kg with better quality of the Camshaft
Bearing House
Low risers without PTC
Low risers with PTC
This product is most sensitive to shrinkage and
porosity. Casting low risers without PTC process
will result in lot of shrinkage under the riser
and on the products sides
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The PTC process reduces total casting weight
from 6.8 kg to 4.8 kg and improves quality of
the Camshaft Bearing House
Low risers with PTC
Low risers without PTC
With an accurate pouring system, the PTC can save
even 95 of the risers mass
This product is sensitive to shrinkage and
porosity. Casting low risers without PTC will
result in lot of shrinkage under the riser and
on the products sides.
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X - Ray
Low risers with PTC process
Low risers without PTC
X-ray photos taken of castings with and without
PTC process
X-ray pictures position
This product is very sensitive to shrinkage and
porosity. Casting low risers without PTC will
result in lot of shrinkage under the riser and on
the products sides
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Microstructure

• All specimens were taken from the upper middle
  part of each casting
• The chemical composition of the specimens were as
  follows

C Si Mn P S Cr Cu V Mg Ti Al
Alloy A 3.88 3.002 0.324 0.011 0.004 0.045 0.19 0.005 0.051 0.006 0.011
Alloy B 3.35 2.588 0.338 0.013 0.004 0.041 0.1 0.004 0.044 0.006 0.013
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Alloy A
Alloy A - Normal casting
Alloy A - PTC
100µm
100µm
50µm
50µm
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Alloy B
Alloy B - Normal casting
Alloy B PTC
100µm
100µm
50µm
50µm
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PTCs Competitive Advantages in Ductile Iron sand
- casting of automotive parts

• Production cost reduction by 20-25
• Riser's mass reduction by 80 -90 and thus
  casting weight reduction by 35
• Sand mass core reduction by 40
• Foundry yield increase from 50 to over 80
• Melting and holding furnaces efficiency increase
  by 50
• Foundry sand reclamation reduction by 30-40
• Environmental emission reduction by 35
• Metal feeding improvement
• Shrinkage and porosity elimination
• Mechanical properties improvement
• Microstructure refinement