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A B B M E A S U R E M E N T & A N A LY T I C S

The complete solution for

inclusion measurement
PoDFA

PHOTO À CHANGER
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Measurement made easy

PoDFA is a proprietary technology

for melt cleanliness evaluation that
provides information on the
composition and concentration of
inclusions in molten aluminum.

PoDFA has already demonstrated

its great potential for process
characterization and optimization,
as well as for product improvement.
 P o D FA T H E S O LU T I O N F O R I N C LU S I O N M E A S U R E M E N T 3

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PoDFA
The complete solution for inclusion
measurement

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01 Melt cleanliness Today’s global marketplace has compelled Inclusion
evaluation process aluminum producers and foundries to produce
the highest quality aluminum and shape castings.
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02 PoDFA technology
The most effective means of attaining superior
levels of quality is expertise in process coupled Filter Disc
— with systematic measurement for controlling the
03 PoDFA-f system
melt quality at all stages of manufacturing.

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02
Inclusion

PoDFA-f system
The PoDFA-f system includes all the equipment
required for PoDFA sampling in molten aluminum:
Filter Disc

a PoDFA-f sampling station, a crucible heater,

crucibles and filters as well as other facilitating
tools described below. The equipment is
compact, portable and economical. It can be
easily installed where the sampling is conducted.

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01
Sampling is straightforward: the operator pours
some metal in a crucible, presses the start button
PoDFA technology and that’s it! A vacuum forces the metal to flow
Two simple steps: sampling and metallographic through the porous filter. After the test, typically
analysis after five minutes, the metal sample is allowed
A predetermined quantity of liquid aluminum is to solidify and saved for metallographic analysis.
filtered under controlled conditions using a very
fine porosity filter. Inclusions in the melt are
concentrated at the filter surface by a factor
of about 10,000. The filter, along with the residual
metal, is then cut, mounted and polished before
being analyzed under an optical microscope by a
trained PoDFA metallographer.

The PoDFA technology has never been so

accessible. All you have to do is take metal
samples using the PoDFA-f system and then
choose between two analysis options. You can
either obtain a PoDFA license and perform your —
own metallographic analysis in house, or you can 03

employ ABB’s metallographic analysis service on

a per-sample basis with no license fee. The
second option enables you to access the PoDFA
technology at your own pace and capacity.
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01 Filter mounted
PoDFA reusable crucibles and filters PoDFA can effectively assess the effects of
on ceramic disk The PoDFA reusable crucible is designed to better various operating practices and melt treatments
meet the needs of cast houses and foundries by on metal cleanliness. The histogram shown on the
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02 Metallographic
decreasing operational costs and labor time. right is a good example of PoDFA results during
analysis the different stages of a process. Samples taken
Filter on ceramic disk at the furnace exit contain high levels of carbides,
We now offer filters mounted on a ceramic disk. magnesium oxides, refractory materials and oxide
These disks can reduce preheating time by 10 films. After degasser, the concentration of
minutes and the use of an expandable material as inclusions decreased while the concentration of
gasket greatly reduces the risk of leak when oxide films increased, most probably due to
pouring molten metal into the crucible. excessive turbulence in the degassing chamber.
Finally, results demonstrate that the ceramic
The patented reusable crucible can last for up to foam filter is effective in removing both
100 samples. It employs a ready-to-use filter for inclusions and oxide films. Inclusion
every test and can be installed in seconds. Thanks concentrations decreased from about 0.3 mm²/kg
to this leading-edge design, filter detachment to less than 0.1 mm²/kg and oxide films from
problems have been virtually eliminated as the about 100/kg to less than 10/kg.
filter is literally cast into the aluminum.
Practical accessories
ABB PoDFA metallographic analysis service • Reusable crucible trolley for safe cooling and
You do the sampling; we take care of the analysis. easy carrying
Use a PoDFA-f system to take samples quickly and • Metal sample holder for safe aluminum residue
easily. Identify each metal residue indicating the cutting on a band saw
sampling information and send all samples by
express mail to our PoDFA metallographic
analysis service. You will receive a report with key
residue pictures and a breakdown of each
inclusion type expressed in mm²/kg of aluminum.
All information is strictly confidential and reports
are produced in less than two weeks. There is no
license fee: you pay on a per-sample basis.

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01

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 P o D FA T H E S O LU T I O N F O R I N C LU S I O N M E A S U R E M E N T 5

— Annual contracts for volume users Metallographic analysis results

01 Metallographic
analysis results Volume customers who regularly employ ABB’s
PoDFA metallographic analysis services can take

Inclusion content (mm²/kg)

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02 Metal sample holder
advantage of significant price reductions by
signing an annual contract. Savings vary
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03 Inclusion
depending on the quantity, report content and
magnification sample preparation required. Annual contracts
also offer an excellent alternative to licensed
PoDFA users. As PoDFA metallographic analysis Exit furnace After degaster After CFF

calls for expertise, time and accuracy,

outsourcing to a highly specialized laboratory is —
01
the ideal solution for many aluminum plants.

Rio Tinto Alcan metallographic analysis

technology transfer
PoDFA technology transfer and analysis trainings
are available from ABB. For those who prefer to
do more than just the sampling, the vast body of
knowledge of Rio Tinto Alcan is readily
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transferable to your organization. It includes
02
metallographic training and a CD-ROM that
contains a catalog of inclusions as well as
methods. This valuable information has been
optimized for over 30 years by Rio Tinto Alcan on
a wide variety of alloys.

Standard and advanced PoDFA training sessions

are available for PoDFA registered users.

Metallurgic spinel

Al4C3
MgO

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03
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Specification
PoDFA-f sampling station temperature, no forced convection around the equipment
Mass and use of an insulation blanket over the crucible.
Mass: up to 5 kg ±0.02 kg. Important: Mass over 8 kg can Lifetime: Up to 100 tests when following preparation and
damage the load cell. manipulation procedures described in the PoDFA-f system
Target mass: Selectable to 1.50, 1.25 and 1.00 kg user’s guide. Protective coating needs to be redone every
Display: 3 1/2 digits, 12.7 mm (0.56 in) high LEDs 15 to 20 tests. Important: Lifetime depends on the
protective coating. Carefully follow the procedure
Electrical described in the user’s guide.
Rated line voltage: 100 to 240 V AC
Rated line frequency: 50/60 Hz Physical
Rated line power: 11 VA at 100 V, 34 VA at 240 V Crucible
Fuse type: T2A/250V Outside diameter: 13.3 cm (5 1/4 in)
Height: 20.3 cm (8 in)
Compressed air requirements Weight: 1.36 kg (3 lb)
Inlet pressure: 5.5 to 8.25 bar (80 to 120 psig) Important: Materials:
To avoid damaging the solenoid valve, do not exceed 10 • outer shell: carbon steel
bar (150 psig) • inner shell: stainless steel
Air purity: dry air, minimum dew point –40 °C (–40 °F). • insulation: synthetic vitreous fiber (SVF) blanket
Clean, uncontaminated and filtered to Packaging information: 3 crucibles per box
40 µm or better. Filter
Air temperature: below 35 °C (95 °F) Materials:
Air fitting: 1/4 NPT female • outer shell: aluminum and silica
Air consumption (at 100 psi) Vacuum: 340 l/min (12 SCFM) Packaging information: 24 filters per box
Cooling: 665 l/min (23.5 SCFM)
Environmental
Physical Storage temperature: –10 to 75 °C (14 to 167 °F)
Overall dimensions (W × D × H): Storage humidity: up to 60 %, non-condensing
33.0 × 29.5 × 39.4 cm (13.00 × 11.63 × 15.53 in)
Weight: 18.0 kg (39.5 lb) Crucible heater
Heating
Environmental Heating time: 0 to 6 hours (adjustable timer)
Storage temperature:
–10 °C to 75 °C (14 °F to 167 °F) Electrical requirements
Operating temperature: Rated input voltage: 100 to 120/220 to 240 V AC
10 °C to 50 °C (50 °F to 122 °F) (factory set)
Storage humidity: Up to 60 % Rated input frequency: 50/60 Hz
(non-condensing) Earth leakage: less than 50 mA
Operating humidity: Up to 90 % Rated input current: 4 A at 230 V AC, 7 A at 115 V AC
(non-condensing) Fuse type: T4A/250 V at 230 V AC, T7A/250 V at
110 V AC
Sound pressure level
Approximate instrument sound pressure level in vacuum Environmental
mode Operating temperature: 10 to 50 °C (50 to 122 °F)
At the instrument: 118 dBA Storage temperature: –10 to 75 °C (14 to 167 °F)
At 1 m (39 in): 100 dBA Operating humidity: up to 90 %, non-condensing
At 5.1 m (17 ft): 85 dBA Storage humidity: up to 60 %, non-condensing

PoDFA reusable crucible Physical

General Overall dimensions (H × W × D):
Heating time, on the heater: When heater is hot: 20 to 25 35 × 29 × 21 cm (13 1/2 × 11 1/2 × 8 1/4 in)
min (typical). When heater is cold: 30 min (typical). Weight: 5.6 kg (12 lb)
Important: Typical times based on normal room
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ABB, Inc.
Measurement & Analytics
3400, rue Pierre-Ardouin
Québec (Québec) G1P 0B2
Canada
Tel: +1 418-877-2944 (worldwide)
1 800 858-3847 (North America)
Email: metal@ca.abb.com

abb.com/analytical

Additional information
We reserve the right to make technical changes or modify the
PB/PoDFA-EN Rev. A  06.2018

contents of this document without prior notice. With regard to

purchase orders, the agreed particulars shall prevail. ABB does not
accept any responsibility whatsoever for potential errors or possible
lack of information in this document.

We reserve all rights in this document and in the subject

matter and illustrations contained therein. Any reproduction,
disclosure to third parties or utilization of its contents – in whole or in
parts – is forbidden without prior written consent of ABB.

© ABB, 2018