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Abstract
Low pressure casting is a very well established process for the casting of aluminium alloys. In the field of ferrous materials, however, the process has so far only found a few applications. The crucial reasons for this are the low flexibility and poor economic efficiency of the existing technologies. Since 2016, a new technology has been developed at the Foundry Institute of the TU Bergakademie Freiberg, in which an induction crucible furnace can be used as a melting unit and, in combination with a cover including a casting pipe, as a casting unit. The new technology stands out from existing low-pressure casting technologies for ferrous materials, particularly in terms of its flexibility and cost-effectiveness. The main focus of the activities was the development of a casting pipe as well as the verification of its lifetime, the elaboration and verification of process parameters and sequences as well as the upscaling of the technology for an industrial application. In all considerations, the focus was on both the technical feasibility and the economic efficiency of the process. The result is extensive expertise that can be used in the future to offer a finished product for industrial applications as a plug-and-play solution together with an induction furnace construction company.
Highlights
Low pressure casting is a process that is widely used in industry
Since 2016, a new technology has been developed at the Foundry Institute of the TU Bergakademie Freiberg, in which an induction crucible furnace can be used as a melting unit and, in combination with a cover including a casting pipe, as a casting unit
Processes that operate in the pressure range above atmospheric pressure are more accurately referred to as low pressure counter gravity casting (LPCGC) processes, while systems that operate below atmospheric pressure are referred to vacuum counter gravity casting (VCGC) processes
Summary
Low pressure casting is a process that is widely used in industry. To date, it has been used primarily with the material aluminium. One of them is the fact that the flow velocities of the melt can be influenced and the turbulence of the flow can be kept low by a controlled and rising mould filling This is of extraordinary importance for the casting of high-quality and safety-relevant components, which have to meet high standards with regard to the absence of defects. The advantages of the low pressure casting process, apart from the controlled and lower-turbulent mould filling, which apply in their entirety to both aluminium and steel materials, are counterbalanced by higher https://journals.agh.edu.pl/jcme plant and operating costs for technologies currently available on the market. Additional advantages of the low pressure casting technology compared to gravity casting of steel alloys are often regarded as so called soft facts because their monetary effect cannot be obviously quantified. This article presents the developed technology in comparison to already existing systems and evaluates the economic aspects of some of the relevant soft facts
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