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KR WNMATIC Dosing Furnaces For High Quality Manufactured Parts in Comparison To Metal Chargers

KROWNMATIC dosing furnaces provide higher quality manufactured aluminum parts compared to traditional metal chargers by preventing aluminum oxide (Al2O3) contamination. The dosing furnace loads molten aluminum below the surface to avoid oxidation and doses the metal through a submerged tube, allowing only pure aluminum to be introduced to molds. This improves mechanical properties and eliminates defects in final products. Dosing furnaces also reduce electrical consumption by 1/3 and aluminum losses to less than 0.05%, lowering operational costs by thousands of euros per year compared to traditional furnaces. The quality control and cost savings provided by dosing furnaces make them preferable for meeting stringent customer requirements for industries like automotive and aerospace

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CLAYTON HENRIQUE STEPHANI REGIS DOS SANTOS
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144 views4 pages

KR WNMATIC Dosing Furnaces For High Quality Manufactured Parts in Comparison To Metal Chargers

KROWNMATIC dosing furnaces provide higher quality manufactured aluminum parts compared to traditional metal chargers by preventing aluminum oxide (Al2O3) contamination. The dosing furnace loads molten aluminum below the surface to avoid oxidation and doses the metal through a submerged tube, allowing only pure aluminum to be introduced to molds. This improves mechanical properties and eliminates defects in final products. Dosing furnaces also reduce electrical consumption by 1/3 and aluminum losses to less than 0.05%, lowering operational costs by thousands of euros per year compared to traditional furnaces. The quality control and cost savings provided by dosing furnaces make them preferable for meeting stringent customer requirements for industries like automotive and aerospace

Uploaded by

CLAYTON HENRIQUE STEPHANI REGIS DOS SANTOS
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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VICENTE MARTÍNEZ, M.A. and MARTÍNEZ ALCOLEA, A.

KROWNMATIC dosing furnaces for high quality


manufactured parts in comparison to metal chargers

The quality requirements of the parts manufactured through the injected foundry processes are
the highest. KROWN, S.A. is aware of this, and so is always developing new products and
technologies that solve the real problems that the market needs. This Company is characterized
by being a pioneer in the manufacture of new pressure casting furnaces which are based on the
constant improvement of the quality of manufactured parts, offering solutions to real problems
that we can find in the market, with new technologies. The general norm of the final customer
(automotive, communications, aeronautics ...) is to demand high quality products with high
mechanical capabilities and free of internal defects. In order to offer a product with such
requirements, the total control of the dosing process plays a key role in the Aluminum quality of
the final cast and will prevent Alumina (Al2O3) to penetrate.

Figure 1. Injected foundry process and components.

Oxidation Process
Aluminum as well as its alloys are highly oxidizable when they are in a liquid state and, even if it
is removed with traditional ladles, the Alumina always reappear immediately. The usual
problems related to Aluminum Oxide solidification inside the manufactured parts are:
1º. Reduced mechanical properties
2º. Likely to appear fissures in the final product
3º. Porous manufactured parts
4º. Hihg costs linked to the machining process
5º. Appearence of hard points

For all these reasons, it is important to avoid Alumina getting in touch with the manufactured
parts. This usually happens in one of two ways:

A) Inside the Mold


When the melted Aluminum (650 to 700 ºC) comes in contact with the mold, it generates water
vapor, breaking down into Oxygen and Hydrogen. Oxygen then reacts with the Aluminum and
produce Alumina (Al2O3). At the same time, Hydrogen will detach during the solidification
process forming the well-known pinholes.
Martínez Alcolea, Ángel (Technical Manager) angelmartinez@krownsa.com
Vicente Martínez, Miguel Ángel (Sales Manager) miguelavicente@krownsa.com
B) Inside the Furnaces.
Alumina appears during the melting, decanting and holding processes, since the metal is exposed
to Oxygen. It is at this last key moment when KROWN, with its KROWNMATIC dosing furnace
and its dosing system, prevents the entrance of Al2O3 inside the mold. KROWNMATIC is a
sealed Aluminum holding furnace which receives the melted metal conveniently treated. The
loading system is effected by means of a cone with a double
mission:

 To introduce the metal below the level broth and, in this


way, prevent the contact of Al2O3 with the melted
Aluminum (see Figure 2) and avoid the turbulences that
lead to trapped air and, therefore, oxidation.
 Loading the furnace continuously while it is working,
without needing to stop the loading or dosing processes.

Once the melted metal is inside the furnace chamber, we


introduce pressurized air (or gas), never at a higher than 200
mbar, which makes the liquid Aluminum rise through the Figure 2. KROWNMATIC loading process
dosing tube during a predetermined time, providing the
precise dose required at each time. The non-inclusion of Aluminum Oxide is because the dosing
tube is inside the metal, leaving the Oxide layer outside the tube, so that only the quality
Aluminum, without oxide. S allowed
through. Furthermore, with this system we
can perfectly control the casting temperature
as we place the thermocouple at the exact
point where the Aluminum is removed
during the dosing process, avoiding oxidation
and Aluminum loss because of high
temperature, (see Figure 3).

Figure 3. KROWNMATIC Dosing process

KROWNMATIC dosing furnace and quality


KROWNMATIC dosing furnaces finds its competitors in the traditional injected metal chargers
sector. In this type of furnaces, Aluminum comes in
direct contact with Oxygen, Alumina is created; the
more Alumina there is, more problems are created
since the loading ladle breaks the Al2O3 layer in the
mold in each cycle and it appears again instantly in the
furnace.
The KROWNMATIC dosing furnace, as well as its
components, are designed to reach the objectives
mentioned and thereby obtaining high quality parts.

Figure 4. KROWNMATIC dosing furnace


In addition to the metallurgical advantages listed above, and therefore the quality of the parts, we
have to consider the economic conditions that today make necessary the use of this type of dosing
furnace compared to the traditional metal chargers. These advantages are worthy of consideration
as they can make a difference in profits. They are essentially two:

.- 1/3 less electrical consumption


.- Aluminum loses by oxidation less than 0,05%.

Operational cost comparison between KROWNMATIC dosing furnaces (KM)


and holding furnaces plus traditional automatic metal chargers.
The following estimates are based on KROWN experiences with facilities with similar
characteristics.

Energy and labour cost estimated:

Cost Kw/hour (0,15 €/hour)


Cost labour worker (21,00 €/hour)
Change crucible (1500 hours)
Change refractory in KRB 1200 (5 years)
Change refractory in KM 900 (10 years)

1. Comparison between a 900 Kg Dosing Furnace (Ref. KM 900) and a KRONW Crucible
Furnace (Ref. KME 900). Both working to a 900Tn BÜLHER machine.

Extraction regime approx. 3,2 Kg every


50 sec. in working conditions
equivalent to 230 Kg/hour and
121,44 Ton/month (24 hours/day and
22 days/month) KME 900 KM 900

Electrical consumption working 30 Kw/hours 8 Kw/hours


Electrical
Costs

Consumption Kw/month 15.849 Kw/month 4.224 Kw/month


Total Operating Costs 2.376,00 €/month 663,60 €/month

Consumption Crucible and 4 units/year 0


Stand
Maintenance

Cost of the crucible and Stand 1.500 €/unit 0


Costs

Cost labour Replebishment 672 € 210 €


Costs of spares in KM900 0 2.000 €/year
Refractary Materials 0 1.300 €/year
Total Maintenance Costs 6.672 €/year 3.510 €/year

Using the KM Dosing Furnace we can get 1.742,40 € of electrical savings and 264 € maintenance
savings. Therefore, we can save 2.006 € each month or, what means the same, 24.071 € per year.
If we consider these amount during the whole shelf life of the furnaces (25 years), at the end we
are saving 601.770,00 € every 25 years if we use dosing furnace instead of the Crucible one.

2. Comparison between a 900 Kg Dosing Furnace (Ref. KM 900) and a KRONW


Reverbetory Furnace (Ref. KRB 1200). Both working to a IDRA DGK800 machine.

Extraction regime approx. 5 Kg every


57 sec. in working conditions
equivalent to 316 Kg/hour and 167
Ton/month (24 hours/day and 22
days/month) KRB 1200 KM 900

Electrical consumption working 20 Kw/hours 8 Kw/hours


Electrical
Costs

Consumption Kw/month 10.560 Kw/month 4.224 Kw/month


Total Operating Costs 1.584,00 €/month 663,60 €/month

Costs of spare parts 1.880 €/year 2.000 €/year


Mainten.
Costs

Refractary Materials 2.600 €/year 1.300 €/year


Total Maintenance Costs 4.400 €/year 3.300 €/year

Using the KM Dosing Furnace we can get 950,40 € of electrical savings and 92 € maintenance
savings. Therefore, we can save 1.042 € each month or, what means the same, 12.505 € per year.
If we consider these amount during the whole shelf life of the furnaces (25 years), at the end we
are saving 312.620,00 € every 25 years if we use dosing furnace instead of the Reverbetory one.

Conclusion
The quality requirements of melting pieces are at the top level of the injection sector because the
customer demands a great quality product with high mechanical benefits and free of internal
defects. In order to be able to offer a product with these requirements, it is necessary that the
smelter apply the dosing furnaces technology.

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