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LBBC Technologies Leaders in autoclave technology www.lbbctechnologies.com Core removal Howard Pickard LBBC Technologies.

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Presentation on theme: "LBBC Technologies Leaders in autoclave technology www.lbbctechnologies.com Core removal Howard Pickard LBBC Technologies."— Presentation transcript:

1 LBBC Technologies Leaders in autoclave technology Core removal Howard Pickard LBBC Technologies

2 Leaders in autoclave technology Core removal LBBC Technologies Suppliers of autoclave systems Dewaxing Boilerclave TM Core Leaching autoclave

3 LBBC Technologies Leaders in autoclave technology Core removal LBBC Technologies Suppliers of autoclave systems with Quicklock TM doors Independent family owned Established over 130 years Variety of autoclave applications Equipment development Service and support

4 LBBC Technologies Leaders in autoclave technology Shell removal vs Core removal

5 LBBC Technologies Leaders in autoclave technology Removal of the shell involves… Removal of a core involves… metal shrinkage assists the process large ceramic particles mechanical methods small ceramic particles complex geometry enclosed areas Shell vs Core removal

6 LBBC Technologies Leaders in autoclave technology Cores Used by a minority of foundries Increases applications for investment castings Implications throughout process Removal perceived to be the hardest stage Considering only Silica based cores

7 LBBC Technologies Leaders in autoclave technology Removal of core Key issues Geometry Is it possible to remove? Metal Alloy Susceptible to attack Cost Market potential, capital investment Health & Safety Exposure of operators, waste by-products Environment By-products of the process

8 LBBC Technologies Leaders in autoclave technology Removal of core methods Hydraulic cleaning Sand blasting Caustic bath / mechanical agitation Caustic autoclave Molten caustic Ultrasonics

9 LBBC Technologies Leaders in autoclave technology Removal of core methods Hydraulic cleaning Sand blasting Caustic bath / mechanical agitation Caustic autoclave Molten caustic Ultrasonics Best practice Large non complex cores Description High pressure water jets erode core particles then recirculate within machine Advantages Good method for simple core geometry. Low health and safety issues. Disadvantages Can be difficult and time consuming to remove the core.

10 LBBC Technologies Leaders in autoclave technology Removal of core methods Best practice Grade of shot/grit. Mechanical separation Hydraulic cleaning Sand blasting Caustic bath / mechanical agitation Caustic autoclave Molten caustic Ultrasonics Description Grit or shot is fired at the core passage within a cabinet either by compressed air or an impeller. Advantages Effective at removing large cores with low complexity. Low health and safety issues. Good casting finish Disadvantages High level of dust. High possibility of casting wear.

11 LBBC Technologies Leaders in autoclave technology Removal of core methods Advantages Low cost, simple method for removing cores. Minimises erosion of casting. Disadvantages Can take long time for large or complex cores. High level of health, safety and environmental risks Hydraulic cleaning Hydraulic cleaning Sand blasting Sand blasting Caustic bath / mechanical agitation Caustic bath / mechanical agitation Caustic autoclave Caustic autoclave Molten caustic Molten caustic Ultrasonics Ultrasonics Description Sodium or potassium hydroxide solution (35 – 50%) in a tank at room or elevated temperature. Parts placed into solution and left for liquid to break down the core material. Mechanical or air agitation may be added. Best practice Consider agitation Automate systems Drill holes first

12 LBBC Technologies Leaders in autoclave technology Removal of core methods Hydraulic cleaning Sand blasting Caustic bath / mechanical agitation Caustic autoclave Molten caustic Ultrasonics

13 LBBC Technologies Leaders in autoclave technology Core leaching autoclave

14 LBBC Technologies Leaders in autoclave technology Core examples Courtesy of Certech

15 LBBC Technologies Leaders in autoclave technology The process The Equipment

16 LBBC Technologies Leaders in autoclave technology The process Load Baskets

17 LBBC Technologies Leaders in autoclave technology The process Typically 120 psi 160 o C NaOH 20% KOH 40% Fill & Cycle

18 LBBC Technologies Leaders in autoclave technology The process Dump

19 LBBC Technologies Leaders in autoclave technology The process Wash

20 LBBC Technologies Leaders in autoclave technology Core leaching autoclave Best practice NaOH or KOH Speed, recycle Concentration High / low, temperature Component orientation Up or down, horizontal Cycle parameters Dwell, vent, mid way break Recycle caustic Cost, efficiency Post leach operations Water wash

21 LBBC Technologies Leaders in autoclave technology Removal of core methods Advantages Quick and effective at removing cores Disadvantages Many health and safety issues. Likely to attack the casting alloy surface Hydraulic cleaning Hydraulic cleaning Sand blasting Sand blasting Caustic bath / mechanical agitation Caustic bath / mechanical agitation Caustic autoclave Caustic autoclave Molten caustic Molten caustic Ultrasonics Ultrasonics Description Bath of molten concentrated caustic. Castings placed inside Best practice Take great care Check suitability of alloy

22 LBBC Technologies Leaders in autoclave technology Removal of core methods Advantages Speeds up the process Non contact Disadvantages Early development of the process. Untested. Hydraulic cleaning Hydraulic cleaning Sand blasting Sand blasting Caustic bath / mechanical agitation Caustic bath / mechanical agitation Caustic autoclave Caustic autoclave Molten caustic Molten caustic Ultrasonics Ultrasonics Description Use of ultrasonic rays to break down macroscopic structures Best practice Research phase – no commercial system

23 LBBC Technologies Leaders in autoclave technology Removal of core Consider the key issues Be aware of the alternative methods Review the operation Increase application of investment castings Increase yield Improve quality

24 LBBC Technologies Leaders in autoclave technology Shell and Core removal Special thanks to : Dr Brian Robson Casting Solutions Limited References Fettling and finishing, Dr Alan Clegg, EICF workshop 2004 Leaching of preformed ceramic cores, Miller & Eppink, Sherwood Refractories, ICI 1983

25 LBBC Technologies Leaders in autoclave technology Thank you


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