NETANYA PLASMATEC LTD

Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)

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Plasma Treatment Casting (PTC) process for aluminum Gravity Die Casting (GDC)
The PTC is an add-on patented technology, and does not change the end product The PTC is commercial as of 2007 The PTC reduces risers mass by 70-80% The PTC increases casting productivity by 20-25% The PTC improves the casting quality The PTC reduces casting process defects by 50%

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Plasma Treatment Casting (PTC)

PTC System

Electrode s

PTC advantages
Saving 30% of aluminum casting Increasing 20% of casting productivity Saving 35% of sand and binders
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Aluminum Sand and Binders saving saving

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The PTC Process

The PTC process applies plasma arc during solidification process The rotating plasma arc moves along a prescribed path, defined by a special electrode

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PTC multi plasma arcs system for complex casting shapes

Parallel plasma arcs on top of the risers

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Plasma stirring
Creates changing current density flow in the molten metal Induces electric and magnetic fields in the molten metal Creates enormous shear forces by very effective stirring Breaks the growing dendrites and creates a new nucleation center on each fracture Creates smaller uniform dendrites and reduces significantly porosity and segregation levels
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Saving 10kg of the risers mass

Reducing casting weight 31kg

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21kg.
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Saving 10kg of the risers mass

Risers height reduction

Reducing casting weight 31kg

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21kg.
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Saving 10kg of the risers mass.

Reducing casting weight 31kg

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21kg.
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Saving 13kg of the risers mass

Reducing casting weight 42kg

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29kg.
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Reduction of risers mass by 17kg

Reducing casting weight 54kg

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37kg
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The PTC system includes

An electrodes gripper which can be adopted for each type of casting die A multi DC channel power sources A control cabinet A consumable electrodes

The PTC system is a flexible add-on device for existing casting cells The PTC applies the plasma arcs after pouring and during solidification

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PTC Quality Improvement

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8 kg casting weight reduction 31 Kg 70 sec solidification time reduction 240 sec 170 sec 23 Kg

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Normal casting

NP casting
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Micro-Porosity
0.09 0.08 0.07 0.06 0.05 0.04 0.03 0.02 0.01 0 column bottom
Normal casting

Bottom of the casting

porosity [%]

Column
Normal casting

NP1 0.02 0.02

NP2 0.05 0.007

NP3 0.008 0.001

NP4 0.03 0.01

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Average Dendrite Measurements (primary & secondary)
80 70 SIM [Microns] 60 50 40 30 20 column bottom NP1 66 44 NP2 65 49 NP3 66 44 NP4 66 47
Normal Casting Normal Casting

Bottom of the casting

Column

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Mechanical properties in the bottom of the NETANYA PLASMATEC LTD casting

1 4 2 3
7.00 6.00 5.00 e [%] 4.00 3.00 2.00 1.00 0.00 NP casting Normal casting Yield strength in the bottom of the casting 300 250 Sy0.2 [MPa] Suts [MPa] 200 150 100 50 0 NP casting Cut 1 252.5 265 Cut 2 256.5 265 Cut 3 254.33 267 Cut 4 253.25 262 NP casting Normal casting 300 250 200 150 100 50 0 Cut 1 306.67 307 Cut 2 305 305 Cut 3 306.33 304 Cut 4 301.5 299 Cut 1 6.22 3.44 Cut 2 6.5275 3.68 Cut 3 4.69 4.17 Cut 4 5.315 2.62

Elongation in the bottom of the casting

Ultimate tensile strength in the bottom of the casting

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Normal casting

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Mechanical properties in the column area

NETANYA PLASMATEC LTD
Elongation in the column area
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Tensile strength (Sy0.2 and Suts) in the column area

e [%]
300 250 St [MPa] 200 150 100 50 0 NP casting Normal casting Sy0.2-Cut 1 252.00 261 Sy0.2-Cut 2 252.5 259 Suts-Cut 1 306.75 302 Suts-Cut 2 301.5 297
NP casting

6 5 4 3 2 1 0

Cut 1 7.1225 2.91

Cut 2 4.78 2.34

Normal casting

Column

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Quality Conclusion
Higher casting quality in addition to casting weight reduction by 30-40%. Solidification cycle time reduction by 30-35%.

Mechanical properties Improvement by the PTC

Elongation percentage (A% ) significant improvement: Form 3.48% to 5.70%, increase of 146% in the bottom From 2.62% to 5.95%, increase of 224% in the column (top) Porosity percentage significant improvement : From 0.012% to 0.0095%, reduction of 20% in the bottom From 0.08% to 0.027%, reduction of 66% in the column (top).
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PTCs Competitive Advantages in Aluminum gravity die-casting of GDC cylinder head.

Production cost reduction of GDC cylinder head by 20%-25%

Riser's mass reduction by 70% -90% and thus casting weight reduction by 35% Sand mass core reduction by 40% Foundry yield increase from 50% to over 80% Foundry productivity increase by 20%- 25% Melting and holding furnaces efficiency increase by 50% Foundry sand reclamation reduction by 30%-40% Environmental emission reduction by 35% Metal feeding improvement Defects ratio reduction Shrinkage and porosity elimination Mechanical properties improvement Microstructure refinement
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