Objective
Heat treatment installation for parts manufactured in spheroidal foundry to be replaced advantageously from traditional manufacturing processes, involving power savings and others such as reduction in production costs.
Modifications to the original design of the furnace have favourably influenced the foreseen performances :L% 1. The electric heating of the austenized furnace has been substituted by natural gas heating with radiant pipes.L% 2. Load travelling speed increases from the austenized furnace to the salt bath.L% 3. Heat isolation improvement of the salt tank by means of installing a double fibre layer and building a refractory lid.L% 4. Removal of the oil washer and tank. All parts are salt treated and washed in one single installation.L% 5. Introduction of pressure washing (200 bar), which reduces the water consumption and allows a 93% salt recovery.L% Although productivity of the furnace is below the foreseen amounts (ranging from 1,500 Tn/year to 1,128 Tn/year), the final energy saving amounts up to 400,86 TOE/year. These data are obtained after comparing the actual forging and foundry consumptions for producing the mentioned tonnage.L% Forging : 1,017 TOE/TnL% Foundry + T.T = 0.66 TOE/Ton.L%
1. Innovation of this project relys in the fact that by means of a specific treatment a certain spheroidal foundry material may obtain much better mechanical properties.
2. It has been first designed for automotion parts in spheroidal foundry with treatment, replacing the same parts from forging.
3.Economical comparison between the traditional forging manufacturing system and the austempered spheroidal foundry may be as follows :
FORGE Pts/K Foundry
Raw Material 38.6 46
Power 43.2 27.2
Man Power 106.4 58.5
Indirect costs 71.8 63.3
TOTAL 260 195
The economical advantage of the new material may be deduced from above table, independently from mechanical cost savings whichmay be considered as 50 % favourable to the cast part compared with the forged part.
4. Testing consists of monitoring both the optimun metallurgical quality of parts to be treated and the prefixed energy consumption. This is achieved in two phases. First phase takes two months and serves for starting up the installation. The second phase analyses the metallurgical and energy results obtained and lasts 10 months.
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Programme(s)
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Coordinator
20009 San Sebastian
Spain
The total costs incurred by this organisation to participate in the project, including direct and indirect costs. This amount is a subset of the overall project budget.