Volume 12, Number 1

 

At this years 56th Annual Technical Conference & Expo in Indianapolis,Indiana sponsored by Investment Casting Institute (ICI);Doug Marion of MCM Precision Castings presented a paper on Comparisons of Dewax Processes. The following are some highlights of his findings that show the FlashFire de-wax process has been proven to be more energy efficient,safer,easier,“greener” and more economical; versus the autoclave de-wax process.

 

Energy Efficient - The autoclave de-wax process is longer and less productive because it requires a boiler, with or without an accumulator, to feed steam to the pressure vessel, as well as a burnout furnace to burn off the residual wax left in the shell.The FlashFire Dewax system requires a single furnace,which performs both the de-wax and burnout in a single cycle.The energy consumption per cycle for the two operations in an autoclave cycle uses 57,900 more BTU's per cycle compared to the FlashFire Dewax cycle. This represents a 24.8% increase over the single FlashFire cycle.

 

Safer - Improved FlashFire de-waxing technology has revolutionized the de-wax process. Today's FlashFire de-wax technology combines the same principle of entering molds into a pre-heated furnace,employing fully automated or semi-automated systems that are operator safe. Fire hazards are essentially eliminated as the hot molten wax is protected by an inert gas shield as it drains so it cannot burst into flame.

 

Easier -The automated type system assures that each mold receives identical,repeatable processing. The wax is recovered without moisture, so it can be easily reclaimed or reused in house. The mold is not only de-waxed, but also burned out and fired cleanly in onethermal cycle.Smoke is eliminated through the use of an afterburner.Stateof the art controls assure the closest possible process variables.The same system can be used to preheat molds for pouring,in fact it is possible to pull shells right out of the oven and pour them in one thermal cycle.

 

“Greener” -In general the regulations set in place do not affect investment casting foundries using our FlashFire Dewax equipment.The release of Hazardous Air Pollutants (HAP's) is virtually non-existent due to the use of a well designed afterburner that will destroy benzene and other HAP's. Unfortunately even when using a quality built autoclave it is still a source of Volatile Organic Compounds (VOC) and HAP emissions.A properly built and sized FlashFire Dewax system,fitted with an appropriately sized afterburner will eliminate VOC's and HAP's with an efficiency of 99.9%.

 

Economical - The research shows that the FlashFire process of de-waxing ceramic investment casting shells provides the foundry with the most benefits. It isplain to see that it's more economical and provides the operator and foundry staff with a cleaner, safer atmosphere inside the foundry and for the environment. It is safe to say that it is better for the ceramic shell to be cast because of the thermal cycles and all pattern materials being removed in a single cycle. 

 

Thank you MCM Precision Castings and Doug Marion for your continued support.If you would like to find out more about the FlashFire Dewax Systems and how they can benefit your foundry process, please contact us here at Pacific Kiln.

 

 

HOT TIPS
Most people associate heat distribution in the load area with the burners that fire into it; while this is obviously an important part, just as significant as allowing the heat to properly flow around the shell. Proper shell stacking or placement can be just as crucial as burner input.

 

Don't pack them so tight as to block the heat and circulation. Leave room between each mold. Give plenty of room around the flue exit so heat can easily get out.

 

Thermo-Flo Floor Tiles will allow the heat to circulate under the molds, which aids in complete burnout as well as thorough heat distribution.

 

 

Facts
Dear Pyro Maniac,
We have the proper temperature and time, but our shells aren't burning out clean. There's a lot of carbon left after the cycle.

 

What's wrong?

 

Dear What's Wrong,
You probably don't have enough oxygen in the atmosphere to combust the carbon and burn it away. Increase the air-to-gas ratio until you have 8-10% oxygen in the atmosphere.
This can be checked with an oxygen analyzer. Your gas company might check it for free.

 

The Pyro Maniac

 

 

Recent Installations

  • Engineered Precision Casting, Middletown, New Jersey - “New Generation” Double Door Wax Burnout Furnace
  • Alcoa Howmet-Hampton Casting, Hampton, Virginia - (2) Barrel Rain Fall Sanders
  • Buddy Furnace, Balch Springs, Texas - “Standard” FlashFire Dewax System
  • Barron Cast, Inc, Oxford, Michigan - “New Generation” Double Door FlashFire Dewax System
  • Unison Industries, Dayton, Ohio - “New Generation” Double Door FlashFire Dewax System
  • School of Art Chicago, Chicago, Illinois - “Elevator” FlashFire Dewax System
  • Intermountain Precision Casting, Lindon, Utah - “Standard” Double Door Wax Burnout Furnace
  • Chromalloy, Carson City, Nevada - Barrel Rain Fall Sander
  • Ametek Chemical Products, Nesquehoning, Pennsylvania “Economy” Slurry Mixer
  • GE Global Research, Niskayuna, New York - “Deluxe” Slurry Mixer
  • Castco Precision Casting, Cape Town, South Africa (2) “Deluxe” Slurry Mixers
  • Turbine Technologies, Chetek, Wisconsin - “Deluxe” Slurry Mixer

 

New Orders

  • Picatinny Army Arsenal, Picatinny, New Jersey - “Elevator” FlashFire Dewax System
  • Academy of Art University, San Francisco, California “Elevator” FlashFire Dewax System
  • TPM, LTD-Texas Precision Metalcraft, “Standard” FlashFire Dewax System
  • Carley Foundry, Blaine, Minnesota - “New Generation” High Temperature Wax Burnout Furnace
  • Pacific Business Development, Beijing, China - “New Generation” FlashFire Dewax System
  • CIFM, Trois Rivieres, Quebec - “New Generation” FlashFire Dewax System
  • Chromalloy Castings, Tampa, Florida - (3) “New Generation” Car Bottom Wax Burnout Furnaces

ThermoFlo Pusher Tiles – New Orders

  • Pine Tree Castings, Newport, New Hampshire
  • Hitchiner Mfg. Co., Milford, New Hampshire
  • Signicast, Hartford, Wisconsin
  • Howmet, Wichita Falls, Texas

 

Pacific Kiln Upgrades Automation and Control Systems.When Pacific Kiln decided to upgrade their furnace controls and automation platform the choice was not easy,with all the new control systems available on the market.Opto-22 proved to have all the answers for all of our high end furnace controls and automation needs.With a HMI (Human Machine Interface) touch screen and simple flow chart programming and FM,CE,and CSA approved interface modules in the PAC control product line.With the PAC brain and interface modules we were able to combine our temperature controllers and automation needs all in one control package. The new controls are simply easier to use with better control and alarm settings.All in-formation is displayed on a single touchscreen with access to any individual control sections at the touch of a button.With the new system our customers can integrate the system with there shop floor net-work for real time temperature and oxygen profiles from any where in the plant.The system can also contact engineers via e-mail or send text messages if there is a problem or alarm has occurred.