Presentation on theme: "NETANYA PLASMATEC LTD Confidential 1 Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)"— Presentation transcript:
NETANYA PLASMATEC LTD Confidential 1 Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)
NETANYA PLASMATEC LTD Confidential 2 Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC) The PTC is an add-on patented technology, and does not change the end product The PTC is commercial as of 2007 The PTC reduces risers’ mass by 70-80% The PTC increases casting productivity by 20-25% The PTC improves the casting quality The PTC reduces casting process defects by 50%
NETANYA PLASMATEC LTD Confidential 3 Plasma Treatment Casting (PTC) PTC advantages Saving 30% of aluminum casting Increasing 20% of casting productivity Saving 35% of sand and binders Electrodes PTC System Sand and Binders saving Aluminum saving
NETANYA PLASMATEC LTD Confidential 4 The PTC process applies plasma arc during solidification process The rotating plasma arc moves along a prescribed path, defined by a special electrode The PTC Process Confidential
NETANYA PLASMATEC LTD Confidential 5 PTC multi plasma arcs system for complex casting shapes Parallel plasma arcs on top of the risers
NETANYA PLASMATEC LTD Confidential 6 Creates enormous shear forces by very effective stirring Plasma stirring Induces electric and magnetic fields in the molten metal Creates changing current density flow in the molten metal Breaks the growing dendrites and creates a new nucleation center on each fracture Creates smaller uniform dendrites and reduces significantly porosity and segregation levels
NETANYA PLASMATEC LTD Confidential 7 Saving 10kg of the riser’s mass Reducing casting weight 31kg 21kg.
NETANYA PLASMATEC LTD Confidential 8 Saving 10kg of the riser’s mass Reducing casting weight 31kg 21kg. Risers height reduction
NETANYA PLASMATEC LTD Confidential 9 Saving 10kg of the riser’s mass. Reducing casting weight 31kg 21kg.
NETANYA PLASMATEC LTD Confidential 10 Saving 13kg of the riser’s mass Reducing casting weight 42kg 29kg.
NETANYA PLASMATEC LTD Confidential 11 Reduction of risers mass by 17kg Reducing casting weight 54kg 37kg
NETANYA PLASMATEC LTD Confidential 12 The PTC system includes An electrodes gripper which can be adopted for each type of casting die A multi DC channel power sources A control cabinet A consumable electrodes The PTC system is a flexible add-on device for existing casting cells The PTC applies the plasma arcs after pouring and during solidification
NETANYA PLASMATEC LTD Confidential 14 8 kg casting weight reduction 31 Kg 23 Kg 70 sec solidification time reduction 240 sec 170 sec NP casting Normal casting
NETANYA PLASMATEC LTD Confidential 15 Bottom of the casting Column
NETANYA PLASMATEC LTD Confidential 16 Bottom of the casting Column
NETANYA PLASMATEC LTD Confidential 17 1 2 3 4 Mechanical properties in the bottom of the casting
NETANYA PLASMATEC LTD Confidential 18 Mechanical properties in the column area Column
NETANYA PLASMATEC LTD Confidential 19 Quality Conclusion Higher casting quality in addition to casting weight reduction by 30-40%. Solidification cycle time reduction by 30-35%. Mechanical properties Improvement by the PTC Elongation percentage (A% ) significant improvement: Form 3.48% to 5.70%, increase of 146% in the bottom From 2.62% to 5.95%, increase of 224% in the column (top) Porosity percentage significant improvement : From 0.012% to 0.0095%, reduction of 20% in the bottom From 0.08% to 0.027%, reduction of 66% in the column (top).
NETANYA PLASMATEC LTD Confidential 20 PTC’s Competitive Advantages in Aluminum gravity die-casting of GDC cylinder head. Production cost reduction of GDC cylinder head by 20%-25% Riser's mass reduction by 70% -90% and thus casting weight reduction by 35% Sand mass core reduction by 40% Foundry yield increase from 50% to over 80% Foundry productivity increase by 20%- 25% Melting and holding furnaces efficiency increase by 50% Foundry sand reclamation reduction by 30%-40% Environmental emission reduction by 35% Metal feeding improvement Defects ratio reduction Shrinkage and porosity elimination Mechanical properties improvement Microstructure refinement