Refractory lining reduces rework and lining wear by 50%. (Case History).Coreless induction furnaces and their refractories experience significant wear and tear, including thermal shack and erosion, voids caused by entrapped air, and chemical attack. In the case of one foundry, the costs associated with a rammed lining provided additional incentive to use a different type of lining. The foundry was using a 12,000-lb careless induction furnace to produce nickel-based super allay castings far the aerospace and turbine industries. It wanted an economic alternative to rammed lining that eliminated the costly fire out heats but still produced high quality metal. The foundry looked to Blasch Precision Ceramics, Albany, New York For other uses, see Albany. Albany is the capital of the State of New York and the county seat of Albany County. Albany lies 136 miles (219 km) north of New York City, and slightly to the south of the juncture of the Mohawk and Hudson Rivers. , and its lining systems. The refractory mixes alumina alumina (əl  `mĭnə) or aluminum oxide, Al2O3, chemical compound with m.p. about 2,000°C; and sp. gr. about 4.0. , mullite, zircon zirconSilicate mineral, zirconium silicate, ZrSiO4, the principal source of zirconium. Zircon is widespread as an accessory mineral in acid igneous rocks; it also occurs in metamorphic rocks and, fairly often, in detrital deposits. , silica and silicon carbide silicon carbide, chemical compound, SiC, that forms extremely hard, dark, iridescent crystals that are insoluble in water and other common solvents. Widely used as an abrasive, it is marketed under such familiar trade names as Carborundum and Crystolon. with binders, formulates the particle packing system for the specific application, and solidifies it with controlled time/temperature programming. After solidification and drying, it is fired, creating a material with high green strength and dimensional accuracy. The process allows the creation of refractaries in complex ceramic shapes with varying wall thickness, producing dimensional tolerances of [+ or-]0.5%. The resulting ceramic component requires little to no machining or finish work. The refractory also has law porosity (the average pore diameter is less than 5 mm), preventing metal penetration. The linings come in two different farms--monolithic crucibles with 5-5000 lb capacities and modular induction lining systems that use a tongue and groove tongue and groove n. A joint made by fitting a tongue on the edge of a board into a matching groove on another board. tile system for building large linings for air or vacuum induction furnaces. The modular design In the context of systems engineering, modular design — or "modularity in design" — is an approach aiming to subdivide a system into smaller parts (modules) that can be independently created and then used in different systems to drive multiple functionalities. features a monolithic base fitted with pre-fired tiles that interlock A device that prohibits an action from taking place. precisely with tongue and groove joints, eliminating the need for mortar. The system is complete with a compression hold-down plate specifically designed for the furnace. Installation of the lining system in the foundry increased service life by 50% (25-30 total heats). It also resulted in significant cost improvements in tons of metal produced as a result of increased capacity (breakeven point at 15 heats). The new material reduced rework by 50% because of inclusion reduction and reduced lining wear by 50%. Select No. 002 at www.moderncasting.com/info |
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