Blue Power Induction
Nothing improves the effective output of production more than a reduction of the rejection-quota. Therefore we have developed, together with external authorities, a new technology that clearly improves casting quality, even withdifficult moulds:
The advantages of our vibration technology at a glance:
- Higher and more consistent densities achieved with reduced porosity.
- Better material flow, better form filling, reduced risk of hot cracks.
- Up to 50% smaller grain size.
- Smaller dentrite formation.
- Consistently superior casting properties and less problems from later processing such as sizing of rings and setting of stones.
With a minimum of finishing work you will get jewellery with excellent surfaces and quality!
The vibration system is available with the MC and VTC series tilting casting machines and several VC series vacuum pressure casting machines.
Results of our metallurgic analysis:
Reduced porosity, higher and more consistent densities achieved.
- Reduced post-processing work.
- Reduced reject rate.
- Cast densities closely match the density of the alloy used, minimizing differences between designs and casting cycles.
Better material flow, better form filling, reduced risk of hot cracks.
- Vibration provides a better material flow.
- More dense structures achieved.
- Reduced risk of air inclusions.
- Improved form filling.
- Reduced danger of „hot cracks“
Up to 50% smaller grain size.
- Gold alloys solidify in a finer and more uniform structure.
- ~50 % smaller grain size in the analysed alloy.
Smaller dentrite formation.
- On solidification alloys will show a considerably smaller formation of dentritic structures most silver alloys).
- Leading to better material flow with reduced risk of hot cracks and better casting stability.
Consistently superior casting quality.
- Tensile strength is up to 25% higher
- Fewer problems from later processing such as sizing of rings and setting of stones.
Indutherm systems used in the recycling process
The demands on casting and smelting plants differ considerably in the field of analysis and recycling. In parts only a few grams have to be molten for sampling, and in parts large quantities have to be molten. Often a certain shape or size is required, such as ingots or pellets. Moreover, the metals and alloys themselves require different handling: Alloys containing copper, for example, should be molten in vacuum or inert gas atmosphere as they tend to strong oxide formation. For other metals or alloys, in turn, open plants are recommended as fumes have to be drawn off, for example.
The function principle of our continuous casting machines is based on similar ideas as our vacuum pressure casting machines. Instead of filling the liquid material into a flask you can produce (draw) sheet, wire or tube by using a graphite die.
Therefore we use a die cooler that cools down the material below solidification point. The so called drawing unit consists of a microprocessor controlled motor that pulls out liquid material in program- mable steps.
The drawing time, the stop time and the optional reverse time are variable.
All this happens without any air bubbles or shrinking porosity. The optional tools like hydraulic cutters, bending units or coiling systems proof the versatility of the machine, and material can be produced on demand.
All continuous casting machines operate on a lower frequency than usual on the market. This low frequency leads to a very high penetration of the electromagnetic field in the liquid melt. This physical effect called mixing or stirring effect prevents a sedimentation of materials with a higher specific weight e.g. gold in the liquid bath. The material is in most of the cases homogeneous up to 10th of a thousandth.
CONTINUOUS CASTING MACHINES CAN BE USED FOR
Casting
of wires and tubes up to 30 mm and casting of sheets up to 50×8 mm
Production of alloys
The low frequency of our continuous casting machines guarantees an intensive mixing of the molten material. This is the best basis for homogeneous alloys. In difference to many other systems, at the INDUTHERM continuous casting machines the crucible is closed by a stopper rod. That means, that no metal can flow out before all material in the crucible is completely molten and mixed. Your alloys will always be absolutly homogenous. So it’s possible to work with pre-alloys or with pure metals without any risk.
Casting of ingots
Diffusion welding (sintering)
With the new sintering kit, up to 6 rings can be sintered at the same time. The processing time including setting and removal takes 6 to 7 minutes. Pressure and temperature (a little bit below the melting point) can be regulated precisely to the requested data.
In many test cycles this way of sintering has been optimized. The items to be tested, rings in different metal combinations, were checked thoroughly at wedding ring manufacturer E. Schwarz GmbH in Pforzheim. The sintered rings were widened up to 18 numbers, partially milled and then cut to control the quality of the welding under the microscope. According to E. Schwarz, the results were absolutely convincing in the case of low and high carat combinations as well as in the case of Pt/ 18 ct Au.
Drawing unit for 3 or 5 wires
For the simultaneous casting of 3 wires (CC 1000) or 5 wires (CC3000).
Bending unit
For the simultaneous casting of 3 wires (CC 1000) or 5 wires (CC3000).
Hydraulic cutter
The hydraulic cutter with a cutting force of 30 tons allows to cut easily sheet up to 10x100mm and wire.
GSM Modem
All INDUTHERM machines with an induction generator may be equipped with a GPS modem for remote service. INDUTHERM machines are in operation world wide, very often far away from INDUTHERM or from the next INDUTHERM sales representative. The GPS modem allows us to set up a remote connection with the machine and check all important parameters. That way the set up can be adapted in order to avoid operating trouble. In case of disturbances or complicated casting procedures we can help quickly and easily.
Granulating tank system
Every continuous casting machine can be modified into a granulating machine within a short time.
Crane
The crane can be very useful especially when granulating.
Platform
The movable platform is a reliable help for the operator.
Technical Features / Glossary Program control – Oxidation reduced casting – GPS Modem – Turbo-Pressure function – Flask temperature measurement
Program control system of the fully automatic VC machines
Thanks to a new control panel with real text LCD display, all programs and parameters are very easy and comfortable to set. 100 casting programs guarantee fast operation and consistent casting results. For all major alloys, e.g. for AGS, Alpha Plus, Heraeus, Legor and Pandora alloys, the parameters are pre-programmed. That means for you in practice: from the first flask on you can expect good casting results without making expensive pre-tests.
The control program does not only guarantee a high service comfort but it also renders the whole casting process in a quicker and safer way due to the exact reproducible casting results. The control of temperature, casting and overpressure/vacuum works automatically. All relevant parameters may be modified in the course of a casting cycle without interrupting the program. It is therefore possible to work out the optimal and reproducible process for every casting project. Hundred different processes may be programed and filed over the built-in printer. The turbo-pressure function starts precisely to a second and it guarantees optimal and regular results also in the case of filigree casting parts. The automatic mechanical functions as e.g. automatic opening and closing of the vacuum chamber enables the user to concentrate on the essential point: “the right casting”.
Oxidation reduced casting
Especially when casting silver and red gold, the high copper containts may cause oxidation of the casting tree. All machines from VC 400 onwards are equipped with a supplementary function which avoids this effect. All machines can be equipped with this option.
GSM-Modem
All INDUTHERM machines with an induction generator may be equipped with a GPS modem for remote service. INDUTHERM machines are in operation world wide, very often far away from INDUTHERM or from the next INDUTHERM sales representative. The GPS modem allows us to set up a remote connection with the machine and check all important parameters. That way the set up can be adapted in order to avoid operating trouble. In case of disturbances or complicated casting procedures we can help quickly and easily.
Turbo-Pressure function
The turbo-pressure function optimizes the casting of very small and filigree items and guarantees a perfect casting with stones in the jewelry production. Thanks to turbo-pressure a very quick and exactly defined pressure increasement is achieved during the cast out. In the case of all fully automatic VC machines the turbo-pressure starts automatically according to the program chosen and can always be started at the same time, precisely within a second.
Flask temperature measurement
Thanks to the digital control and recording over data printer as well as to the program control of our machines, we make it possible to reach a high process security and guarantee casting processes according to ISO Certificate.Up to now, the flasks with wrong or different temperature were a risk.
When casting very small or filigree parts, the flask temperature is decisive. Very often, the temperature indicated on the melting furnaces is not precise enough. The flask may also cool down between the removal from the furnace and the beginning of the casting process. The supplementary measurement of flask temperature (standard from VC 500 on) enables now the decisive security. The flask temperature can be precisely checked within 1° C.
More Articles ...
Blue Power Induction
9 Deforest St
Amityville, New York 11701
United States