Volume 3, Number 3

 

 

Nothing keeps a piece of equipment operating efficiently over a long life like proper maintenance. Furnaces are no exception. In fact, they may be in greater need of regular maintenance than most other equipment.

 

Consider what the burnout, preheat or FlashFire Dewax furnace has to go through, many times 24 hours per day. High temperatures, high velocities, smoke and fumes, temperatures cycling constantly, doors opening and closing continuously and operators moving molds in and out of the furnace, all day long. All this activity takes its toll in the form of shrinking and cracking refractories and insulation, worn components (particularly in the door area), burner and control adjustment, and specifically for FlashFire Dewax, wax build-up in the drain tubes and extinguishing chamber.

 

Nearly all areas of a furnace are subject to wear and tear, but regular preventative maintenance can prevent failure or identify in advance those components that need attention or replacement. This translates to less down time, higher productivity and consistent quality. A quick look at each furnace, each week can prevent costly down time. Key areas to inspect are:

 

Insulation and Refractories:

  • Fiber Insulation: Look for shrinkage. This will show up in corners, joints and ends. Pack these areas quickly to avoid heat leakages to the exterior.
     
  • Door Systems: Keep your door adjusted properly so that it seals evenly around the entire refractory jamb. Cam adjusters, chain adjusters, compressed door fiber, and cracked or broken jamb refractories are the main culprits in an improperly operating door system.
     
  • Door Jambs: Inspect door jamb refractories for loose blocks, shifted blocks, cracks etc. These can cause rapid wear and deterioration of the door fiber.
     
  • Burner System: Keep your burners firing efficiently. This can be done with visual inspection as well as atmosphere analysis. Poorly adjusted burners can give incomplete burnout, poor heat distribution and waste of fuel.
     
  • Temperature Control & Safety: Check thermocouples, igniters, valve linkages, wire connection etc. Keep these things clean and in good repair. They can shut you down and be hard to find after the fact. 
     
  • Flame Safety System: Inspect Fireye system and verify operation by performing "Flame Safety Test".

FlashFire Dewax Systems:

  • Bed Refractories: Car blocks can crack, shift and fall apart. Be sure they are in good repair and positioned properly. They can cause poor car operation and, heat, pressure and atmosphere leaks.
     
  • Drain Tubes: The drain tubes in your bed may look clean on top but down where it is cooler they can build up with wax, plastic or filler and cause severe drainage problems which may result in wax overflow onto the bed and resultant fire. Periodically pull these tubes out and thoroughly clean them. This can save you a bad experience.
     
  • Extinguishing Chamber: Same goes here. Wax, plastic and fillers can build up a deposit on the bottom of the chamber creating a dangerous situation. Regularly clean this deposit out to avoid wax fire. Inert Gas: Very important. Keep your inert gas at the proper pressure and flow, and periodically inspect/clean the nozzles in the extinguishing chamber. This is fundamental to the safety and correct operation of the FlashFire Dewax System.

 

We're here to help you. Refer to your instruction manual or give us a call if you need information to help you properly maintain your furnace equipment. This is the best investment in your furnaces you can make.

 

Recent Orders

North America:

  • Lamothermic - "New Generation" Wax Burnout Furnace
  • Joseph Bronze - "Economy" Slurry Mixer
  • GSC Foundry - "Economy" Slurry Mixer
  • Oakley Inc. - (2) 42" Barrel Rain Sanders
  • Coast Cast Corp. - (2) 30" Barrel Rain Sanders
  • KomTek - (2) "New Generation" Burnout Furnace
  • KomTek - FlashFire Dewax System

 

Recent Installations

North America:

  • PCC Portland - (4) 60" Barrel Rain Sanders
  • MCM Precision - "New Generation" Preheat Furnace
  • AMT Inc. - "Standard" Wax Burnout Furnace
  • PCC Airfoils/Douglas GA. - (2) "New Generation" Car Bottom Burnout Furnaces
  • GSC Foundry - "Economy" Slurry Mixer
  • Coleco - "Deluxe" Slurry Mixer

 

Foundry Facts

 

Dear Pyro

We're currently using a water blast cabinet to remove the shell from our castings. It's slow, messy and water is expensive. I'd like to try a pneumatic Knock-out Machine, but i'm afraid it will damage my thin wall parts.

Not-sure about Knock-out

Dear Not-sure,

Pacific Kiln's Pneumatic Knock-out Machines have been used to clean thin wall and Aluminum castings for over 15 years. Proper hammer selection and accurate pressure control are the keys to success.

 

Still Not-sure? Pacific Kiln has just completed construction of a demonstration Knock-out Machine. We would be glad to test clean some of your castings. Please call to arrange a visit or send us some parts. We'll run the tests and send you the results (along with the clean parts).

The Pyro Maniac