The application of texturing on casting

admin

Texture or Texturing is a technology that forms specific textures by chemically etching or laser processing the surface of metal molds. These textures will eventually be transferred to the surface of plastic or metal products, achieving both decorative and functional effects. The texture process has clear feasibility in the casting field (especially die casting) . By improving the heat resistance of the mold, deepening the texture depth, and optimizing the draft angle , it can stably produce high-value-added metal parts. The future trend is to combine 3D laser engraving with mold temperature control technology to solve the problem of texture deformation caused by high temperature.

The following are its wide application areas and technical features:

🔧1 . Main application areas

🚗Automotive industry

  1. Interior parts : steering wheel (leather pattern), instrument panel, door panel (pear pattern or geometric pattern), etc., to enhance the touch and cover the mold line and shrinkage mark.
  2. Functional parts : non-slip footrest, crash bar surface (increases friction).

📱Consumer Electronics

  1. Mobile phone/computer cases (such as Galaxy S series, iPad protective cases) use laser biting to form delicate patterns (such as leather patterns and hair patterns), which are both beautiful and anti-fingerprint.
  2. The surfaces of household appliances (audio, camera) use fine grain or matte finish to reduce reflections and hide processing defects.

🏠Building materials and bathroom

  1. Bathroom tiles (imitation marble pattern, depth up to 3mm), door and window hardware (sandblasted pattern to resist scratching).
  2. The surface of flower pots and tableware (stone or wood grain) enhances texture and personalization.

🖥️Industrial equipment and daily necessities

  1. Office equipment (printers, keyboards) use satin texture, which is wear-resistant and comfortable to the touch.
  2. Medical device handles (anti-slip texture), toy surfaces (cartoon geometric patterns).

⚙️2 . Technical characteristics and trends

  1. 🔬Traditional crafts
    • Chemical etching : Use sulfuric acid, nitric acid and other solutions to corrode the mold to form leather grain, pear grain, etc. The disadvantage is that it relies on manual labor and has low environmental protection.
    • Sand blasting : quickly produces uniform sand patterns, low cost but poor durability.
  2. 💡Modern technology: Laser Texturing
    • Advantages :
      • No chemical pollution, precision up to 0.01mm (such as DMG five-axis laser equipment).
      • Supports complex 3D surfaces (such as automotive interior molds), and reduces working hours by 50% (a task that traditionally takes several days can be completed in 12 hours).
    • Application : high-end automotive leather texture, 3C product precision texture.

The molds of the biting process can be fully applied to the casting process, especially in the field of metal die casting and gravity casting , but the process parameters need to be adjusted according to the casting characteristics. The following is a specific analysis:

✅1 . The core application of biting in casting process

1. Die casting mold (aluminum/zinc/magnesium alloy)

  • Surface treatment : Laser biting or chemical etching is performed on the surface of the mold cavity to form a texture (such as leather texture, fine sand texture), which is then transferred to the surface of the die-casting.
  • Examples :
    • Automobile gearbox housing (anti-slip patterns improve operating feel).
    • Laptop shell (aluminum alloy die-casting + hairline texture, replacing plastic injection molding).

2. Gravity/low pressure casting mold

  • Biting is used in engine block and wheel hub molds to cover metal flow marks or parting lines.

⚠️2 . Technical difficulties and solutions

Challenge Casting process
Characteristics		 Countermeasures
High temperature corrosionHigh molten metal temperature (aluminum: 700°C)Use high heat-resistant mold steel (such as H13 surface nitriding treatment)
Texture wearStrong scouring power of molten metalLaser texturing depth ≥ 0.1mm (higher than 0.05mm for injection molding)
Demolding resistanceLarge metal shrinkage rate (aluminum 6~8%)Increase the draft angle by 50% (e.g. 5° or more for a texture depth of 0.1mm)
Surface AdhesionMetals tend to react with moldsChrome plating on mold surface (thickness 0.01~0.03mm)

🔧3 . Key process adjustments

  1. Texture Design
    • Avoid sharp edges and corners (to prevent turbulence of the molten metal and cause porosity).
    • Anti-scour textures are preferred (such as cross grid texture > unidirectional straight texture).
  2. Mould pretreatment
    • The casting mold needs to be polished to Ra0.2μm or less before biting (to reduce the amplification of surface defects).
  3. Laser parameter optimization
    • The die-casting mold is suitable for high-energy-density fiber lasers (such as 1064nm wavelength, pulse frequency 20kHz) to ensure that the texture remains clear after thousands of castings.

🚀4 . Typical application scenarios

  1. Automotive Parts
    • Aluminum alloy door handles (anti-slip texture), center console bracket (matte fine sand texture).
  2. Consumer Electronics
    • Magnesium alloy camera body (leather texture), drone housing (geometric etching texture).
  3. Industrial Equipment
    • Hydraulic valve body (identification texture instead of marking), motor heat sink shell (pattern to increase heat dissipation area).

V. Comparison of economic benefits

Technology Traditional casting
smooth mold		 Texturing mold (die casting
application)
Secondary processing cost of productsNeed sandblasting/electroplatingDirect molding, eliminating the need for post-processing
Mold life300,000 times150,000~200,000 times (recoverable after texture repair)
Added valueBasic functions15%~30% premium (such as high-end tool handles)

In conclusion:

The texturing process has clear feasibility in the casting field (especially die casting). By improving the heat resistance of the mold, deepening the texture depth, and optimizing the draft angle , it can stably produce high-value-added metal parts. The future trend is to combine 3D laser engraving with mold temperature control technology to solve the problem of texture deformation caused by high temperature.

The application and casting process of AlMg5Si castings

admin

AlMg5Si (common grades such as EN AC-51400 or AlMg5Si1 ) It is a typical aluminum-magnesium-silicon casting alloy with excellent corrosion resistance, medium strength and good weldability , and is widely used in many industrial fields.

1. Main application areas and typical parts of AlMg5Si castings :

1. Shipbuilding and marine engineering

  • Hull structural parts (hatch covers, handrails, trusses, etc.)
  • Deck equipment (bases, housings, connections)
  • Offshore platform structures

Reason: Excellent seawater corrosion resistance, suitable for humid or salt spray environment.

2. Transportation (especially rail and commercial vehicles)

  • Railway vehicle body structure
  • Automobile chassis components (subframes, wheels, brackets)
  • Trailer structural parts

 Reason: Higher strength-to-weight ratio and impact resistance.

3. Energy and power equipment

  • Wind turbine cabin structural parts
  • High voltage switch housing, electrical connectors

 Reason: Certain strength, conductivity and corrosion resistance are required.

4. Building and structural parts

  • Curtain wall connection components
  • Aluminum formwork support system

5. Mechanical equipment

  • Pump body, housing
  • Industrial automation equipment parts

2. Characteristics and key points of AlMg5Si casting process

Compared with other cast aluminum alloys (such as AlSi7Mg , AlSi10Mg , AlCu4Ti , etc.), AlMg5Si has the following characteristics and points for attention during melting , pouring and solidification :

1. The oxide film is highly sensitive and requires a good protective atmosphere

  • The magnesium content is high and it is easily oxidized during the smelting process to form MgO .
  • Recommended use Inert gas protection (such as Ar ) or flux protection , especially during smelting and sub-packaging.

2. Strong air absorption, easy to produce pinholes

  • Mg reacts with hydrogen to increase the tendency to getter, thus:
    • Refining degassing (such as rotor degassing, Ar /Cl composite gas) must be sufficient ;
    • Melt processing should be carried out at low temperatures ( 690–720°C is recommended ) to avoid excessive temperatures that promote aspiration.

3.High requirements for the mold (mold)

  • The tendency of thermal cracking is relatively large, and the mold design should consider:
    • Reasonable cooling system distribution
    • Avoid combining thick sections with fast shrinking areas

4. The cooling rate needs to be controlled during the crystallization process

  • AlMg5Si alloy has a wide solidification range (about 30–40°C ) and shrinkage should be avoided:
    • Reasonable setting of gate system and riser
    • Sequential solidification control or pressure consolidation techniques can be used when necessary

5. Post-processing heat treatment methods are limited

  • T6 heat treatment (such as quenching + aging) is usually not possible because its strengthening mechanism mainly relies on solid solution rather than precipitation hardening;
  • Generally adopted Use in T5 or natural aging ( F ) state .

Summary of key comparisons :

Process AlMg5Si FeaturesDifferences from other aluminum alloys (such as AlSi10Mg )
Melting protectionEasy to oxidize, absorbHigh magnesium content → more inert gas protection is needed
Degassing treatmentHydrogen removal refining is requiredStronger than normal air intake AlSi Tie
Casting systemSequential solidification design requiredEasy to shrink and uneven cooling has a great impact
Heat TreatmentT6 is usually not performedNot suitable for precipitation hardening

The following are The recommended parameters of AlMg5Si casting process are suitable for process scenarios dominated by gravity casting (sand mold, metal mold). It is also suitable for low-pressure casting, such as when higher density is required for the production of structural parts.

1. Melting and insulation

Project Recommended parameters Illustrate
Melting temperature700–740 °CAvoid excessive temperatures to reduce oxidation and aspiration
Insulation temperature690–710 °CLong-term heat preservation requires protective atmosphere or flux
Protection methodArgon, nitrogen or flux ( NaCl+KCl )Prevent magnesium oxidation
Degassing treatmentAr+ Cl₂ Or degas the rotor for 10–20 minutesControl hydrogen content ≤0.15 ml/100g Al
Flux RecommendationSpecial magnesium aluminum alloy flux, such as Foseco MTS 158Anti-oxidation, anti-inclusion

2. Pouring

Project Recommended parameters Illustrate
Pouring temperature710–730 °C (sand mold) 
690–710 °C (Metal Type)		Fine-tune according to mold material and wall thickness
Mold preheating temperature (metal mold)250–300 °CPrevent cold shut and poor filling
Gate designBottom injection, flow rate control, sequential solidificationReduce oxidation slag and shrinkage
Riser / Feeding SystemIt is necessary to set up a heat preservation cap or pressurized shrinkage compensationThe alloy has a wide solidification range and large shrinkage
Cooling controlLocal chilling iron assisted solidification controlPrevent thermal cracking and shrinkage

3. Heat treatment recommendations

Heat treatment status Recommended
parameters		 Illustrate
T5 (artificial aging after casting)160–180 °C × 5–8 hoursImproved stability, slightly increased strength
F (Not heat treated )–Supplied in normal condition, maintain ductility
T6 heat treatment is not recommendedEasy to deform, no obvious reinforcementBecause its strengthening mechanism does not rely on precipitation phase

4. Reference values of cast properties (for comparison only)

Performance Indicators Numerical range Condition
Tensile strength (Rm)180–250 MPaCast or T5
Yield strength (Rp0.2)90–160 MPa
Elongation (%)5–12%
hardnessHB 50–80
density2.64–2.66 g/cm³

5. Precautions & Process Optimization Suggestions

  • Do not use iron tools to stir for a long time : high-magnesium aluminum alloys are prone to inclusion reactions;
  • The pouring system must be designed with an anti-eddy current structure to avoid inclusion of oxide film;
  • The mold or cavity should be kept dry to prevent explosion or holes;
  • Local reinforcement areas can be assisted by chill iron / pressurization to improve density .

against AlMg5Si is used for fire protection system parts (such as joints, flanges, housings, connectors, etc.) The riser size design suggestions and filling simulation scheme can be divided into two parts:

1. Riser design suggestions (mainly for gravity casting)

Fire protection system parts usually require No leakage, no shrinkage, high density , so the riser design must consider the following points:

1. Riser design principles

Project Recommendations
Riser positionPlace in the last solidification area of the part (usually at the top of a thick section)
Riser shapeCylindrical or oval (easy to process)
Insulation treatmentInsulation riser sleeve + insulation covering agent
Feeding efficiency requirements≥30% and has a sequential solidification path
Is the riser open?Generally use open risers unless the pressure difference is well controlled

2. Riser size estimation method (based on Chvorinov’s law)

use Modulus​​ Method ) Design riser :

  • Modulus M ( Modulus ) = V / A
    • V = volume ( cm³ )
    • A = heat dissipation area in contact with air or die ( cm² )

Recommended size relationship:

Notice : The riser should use an insulating sleeve (such as an Exothermic sleeve ) to increase the effective shrinkage compensation volume by 30–50% .

3. Riser neck connection design

Parts module M ( cm )Riser modulus (need to be ≥ 1.2×M )Typical riser diameter × height ( mm )
M = 1.0≥1.2Ø30 × 35
M = 1.5≥1.8Ø45 × 50
M = 2.0≥2.4Ø55 × 60
M = 2.5≥3.0Ø65 × 70
  • The riser neck (the part connecting the riser to the casting) needs to be controlled to solidify slowly , with a modulus slightly lower than the riser but higher than the thickness of the casting.
  • Recommendation: Neck diameter = 1.2-1.5 times the wall thickness of the part , and the length should be controlled between 20-40mm to facilitate cutting.

2. Filling and solidification simulation scheme (simulation ideas)

It is recommended to use MAGMASOFT® or ProCAST ® For numerical simulation, the following are the simulation parameters for typical medium – sized flange joints (wall thickness 10-15mm ) in fire protection systems :

1. Simulation target

  • Confirm whether the solidification path is sequential
  • there porosity ?
  • Whether inclusions are generated ( Oxide Trap )
  • Is it cold shut or insufficient filling?

2. Simulation setup recommendations

Parameters Setting suggestions
Alloy ModelAlMg5Si (user defined or input data via thermal analysis)
Wall Thickness Area Mesh≤1.5 mm grid accuracy
Pouring temperature710 °C (metal type) or 730 °C (Sand mold)
Mold temperature250 °C starting
Gate speed0.3–0.8 m/ s (to prevent air entrainment )
Cooling methodLocal chilling (set temperature boundaries to 50–80°C )
Riser heat balance settingEnable the insulation sleeve data parameters to simulate the delayed solidification effect of the riser

3. Output analysis key diagram:

  • Solidification Time distribution diagram → Determine the solidification order
  • Porosity Map → Check whether the shrinkage compensation is successful
  • Velocity Field diagram → Analyze the filling path
  • Oxide Formation → Determine whether to switch to the bottom injection channel system

Conclusion Recommendation

  • For fire protection flange parts, using Ø50×60mm insulation riser + symmetrical arrangement of chillers can effectively compensate for shrinkage;
  • For large size connectors or housings, it is recommended to use Top injection + double riser system , with internal riser if necessary;
  • 2-3 times of scheme comparison and optimization in the early stage of development (different gate / riser combinations can be set);
  • If the casting is large and the thickness varies greatly, consider using Low pressure casting + local cooling channels optimize density.

MIM , Machining, or Hammering?

editor

Screw /Pin of hardware applied inn Kitchen or bathroom

For these kind of small stainless steel parts made of 304 with mirror effect of surface which is high end of hardware for kitchen and bathroom .Most of these kind of parts are plastic with zinc plating .The key process for this part is mirror polishing which makes the part looks more nicer surface and valuable. 

How’s the price for this part? Depends on different quantities , it has different process . For example , if the quantities is less than 50,000pcs, it will be considered to be machined directly . If the quantities is over 400,000pcs, it will be considered to be hammered .

As the high cost of the mould compare to hammering, these kind part is not competitive made by MIM .

If you have some question for these kinds of parts , send email to alina@tcc-casting.com. The technician team will be happy to discuss with you .

WHICH PROCESS IS THE MOST COST-EFFECTIVE FOR SMALL PARTS, MIM ,COLD HEADING AND COLD EXTRUDING?

editor

WHAT’S THE DIFFERENCE ON MIM , COLD HEAD AND COLD EXTRUDING?

Which process is the most cost-effective for those small parts less than 50g, MIM , cold heading or cold extruding?

The cold heading process which is a branch of cold extrusion is most right way to manufacture the bolts, screws, nuts, nails, pins and other standard fasteners.

During the process of manufacturing bolts, the forming of the hexagonal head is made by cold heading, and the reduction of the rod part is cold extruding(extrusion). The non-cut hexagonal flange bolts (multi-station forming) are done by both cold heading and cold extruding, the hexagonal nut has only be done by cold heading before forming, and the extruding hole in the post process by cold extruding (positive and negative extrusion).

Cold heading process is a kind of processing method by the plastic deformation of the metal under the action of external force, and with the help of the mold, the volume of the metal is redistributed and transferred, so as to form the required parts or blanks.

At present, cold extrusion technology has been widely used in fasteners, machinery, instruments, electrical appliances, light industry, aerospace, shipbuilding, military and other industrial sectors, and has gradually become the development direction of small and medium-sized forgings refined production.

Cold extruding is the process by the metal blank in the cold extrusion cavity, at room temperature, through the press fixed punch to apply pressure to the blank, the metal blank produce plastic deformation and the processing method of parts. Cold extrusion is one of the machining processes of parts with no chips and less chips.

Cold extrusion is also divided into positive extrusion, reverse extrusion, composite extrusion, radial extrusion and so on.

MIM (Metal Powder Injection Molding Technology), The injection molding process can directly form thin-wall and complex structural parts, and the shape of the product is close to the requirements of the final product, and the dimensional tolerance of the parts is generally maintained at about ±0.1-±0.3. In particular, it is of great significance to reduce the processing cost of cemented carbide, which is difficult to be machined, and to reduce the processing loss of precious metals.

MIM is suitable for mass production of parts. Due to the use of injection machine molding product blank, greatly improve the production efficiency and reduce the production cost.

MIM has wide range of applicable materials and application field (iron base, low alloy, high speed steel, stainless steel, hard alloy).

If you have some small parts and not sure which is the best way to manufacture , please feel free to contact Alina@tcc-casting

Surface treatment on the Aluminum with high content of Silicon

editor

Microarc Oxidation（ MAO) VS Anodic oxidation

Microarc Oxidation on A380

Microarc Oxidation（ MAO), It is also been called Plasma electrolytic oxidation(PEO) or  Microplasma oxidation(MPO ).It is a high technology of in-situ growing ceramic layer on the surface of aluminum, magnesium, titanium and other metals and their alloys .

The characteristics of micro-arc oxidation

•(1) The appearance of the ceramic membrane layer is uniformly dense and the combination is firm. It is matte and the color is consistent. The thickness of the film can be controllable from 10UM to 300UM; 

•(2) Good wear resistance; The Hardness is HVA400 to 2500, the highest to 3000HV; The wear resistance is improved to 30% than the original material. 

•(3) Good heat resistance. High temperature impact resistance of 2500°C for 20 seconds (the matrix melts and the ceramic layer is intact after 20 seconds) with strong flexibility , even the matrix is bending, The ceramic layer does not crack or fall off during fracture . 

•(4) Strong corrosion resistance. The salt spray test >1000 hours. 

•(5) Good insulation performance, electrical breakdown strength 5KV/mm, electrical .

Microarc Oxidation on ADC12

Microarc Oxidation VS Anodic oxidation

SpecificationMicroarc OxidationAnodic oxidation
Working time（min ） 10-3030-60
Thickness of film（um ） 10-30030-60
Hardness（HV）1500-2500300-400
Surface Porosity（%） 0-40>40
Insulativitygood uninsulation
Solution PH neutral or alkalineacidic
Flexibility Good Fragile
Uniformity Uniform  on an internal and external surface. Relatively uniform
Wear resistance GoodPoor
Process flowdeoiling – Microarc oxidation – sealingAlkali etching – pickling – chemical polishing – anodizing – sealing
Working temperature（°C）10-9013-26
Choose the right surface treatment

TCC has experienced with surface treatment on on the Aluminum with high content of Silicon, eg. ADC12 and A380. If you have such requirement , please contact us by email .

Aluminum Alloy Casting Valve

editor

12 inch pressure valve material A356

A356 alloy is a typical Al-Si-Mg ternary alloy which is a cast aluminum alloy with excellent comprehensive properties. It not only has good casting performance at good fluidity, line shrinkage, no hot cracking tendency, but can cast thin wall and complex shape castings, also it can achieve the ideal synthesis of high strength, good plasticity and high impact toughness by heat treatment.

A356 is widely used to cast components like aircraft parts, pump housings, impellers, high velocity blowers and structural castings .

A356 alloy is a class of alloys in the Alcoa Standard series. This series has three alloys: A356.0, A356.1, and A356.2, which are part of the 356 Series. Its composition is shown in Table 1.

Table 1 Comparison of chemical composition between Alcoa 356 series alloy and domestic ZL101 series aluminum alloy Unit: %

-The 356 series is the American standard brand, and the ZL101 series is the Chinese standard brand;

-S-sand casting, P-metal casting;

-The Chinese standard also makes separate provisions on the content of Pb and Sn impurities (the American standard classifies them as other impurities) : Pb<0.05 Sn<0.01(corresponding to ZL101), Pb< 0.03 Sn< 0.01(corresponding to ZL101A);

-356.2 alloy has a maximum Fe content of 0.25%.

It can be seen that the chemical composition design of Al-7Si-Mg series alloys has the following characteristics: no matter the American standard or the Chinese standard, the common feature is the same composition range of Si elements: (SI-6.5/7.5); For magnesium, the Mg required for casting material is 0.25~0.45; In the American standard, the requirement of magnesium element in the ingot is increased by 0.05%, namely 0.30~0.45, mainly considering the burning loss of magnesium element during smelting.

The main difference in the chemical composition of this series lies in the regulation of impurity content. For the American standard, the first letter of the brand indicates its performance grade, so that the user according to different application requirements to determine the brand. The first letter of the letter B is the highest performance, so the requirements for impurities are also the most stringent. Alloys without a first letter have poor performance and are mainly used in common applications. The A356 series is an in-between material. The number at the end of the brand (0,1,2) is the limit of various impurities according to different occasions. A356.0 is the material composition specified for the material of the castings produced; A356.1 and A356.2 are two kinds of components formulated for the production of raw materials for castings, namely ingot, according to different requirements of use.

ZL101 series mainly defines the material of castings, with high requirements for ZL101A; ZL101 is generally required. The Chinese standard does not specify the composition of the raw material used for casting, namely the ingot.

TCC has rich experience in producing cast aluminum to meet your design. If you have any inquiry on custom parts, Please feel free to send us the CAD drawing and let’s discuss!

Iron Oxide Desulfurizer loading , Filling and Use Plan

editor

Index Parameter:
1. Saturated sulfur capacity: greater than or equal to 600 mg/g
2. Industrial sulfur capacity: 20%~35%
3. Penetrating sulfur capacity: more than 30%
4. Desulfurization accuracy: generally less than 0.05PPM
Uses: For the removal of H2S in various gases such as urban pipeline gas, water gas, semi-water gas, coke oven gas, steel mill raw material gas, biogas, petrochemical and other gases.

Features:

1. High desulfurization accuracy: when the imported H2S is 1000ppm, the export H2S is 0.05ppm, which is 20 times higher than the desulfurization accuracy (1ppm) of ordinary Fe2O3;

2. Fast reaction speed: the air velocity of 1000-20000h-1 is 3-6 times higher than that of ordinary Fe2O3;

3. Large working (penetration) sulfur capacity: under the conditions of 1 and 2, the one-time fine H2S sulfur capacity is 20%-25% when O2 is contained, which is 3-6 times that of ordinary Fe2O3 desulfurizers.

4. Good strength and good water resistance. Boiled in water for 2 hours or soaked for 30 days without pulverizing or mudding, and the strength remains unchanged after soaking in water and drying.

5. Wide applicable temperature range, it is better below 100℃

1. Filling

  1. Filling with grain suction machine

2. Hoisting and filling with a crane

3. Hoisting and filling with electric hoist

The quality of the desulfurizer filling directly affects the use effect, and it must be paid enough attention. The entire desulfurizer filling process should be in charge of a special person, and the following points should be paid attention to:

1) Lay two-layer meshes smaller than 8-10 mesh stainless steel mesh on the grate board of the desulfurization tower.

(2) Lay another layer of 20-30mm, Φ20-30mm thick porcelain balls on the wire mesh.

(3) Since dust will be generated during transportation and loading and unloading, it needs to be screened before loading.

(4) Using special filling tools, the discharge pipe should be able to rotate freely, so that the material can be evenly filled around the reactor, and it is strictly forbidden to pour the desulfurizer from the middle to prevent uneven filling.

(5) The strength of the desulfurizer increases with the increase of the amount of sulfur absorbed during the use process, so it should be packed in layers in the desulfurizer. Each layer is marked according to the filling height of the desulfurizer to ensure full, level and even filling.

(6) During the filling process, it is strictly forbidden to step on the sulfur agent directly. The wooden board can be placed on the material layer, and then enter the material and check the filling situation.

(7) At the inlet of the desulfurization raw material gas, a grid plate or crushed coke block should be installed to prevent the desulfurization agent from being blown away.

2. Use

(1) The desulfurization tower generally does not need to be specially heated and consumes energy, but the outdoor desulfurization device must be kept warm in winter to prevent the gas from being overcooled, reducing the activity of the desulfurizer and the accumulation of water on the bed and worsening the operation.

(2) Try to remove tar and water before desulfurization.

(3) The desulfurizer can be replaced all at once, or it can be replaced segment by segment according to the direction of airflow.

(4) Regularly discharge the water in the water separator in front of the desulfurization tower and the bottom of the desulfurization tower, and it is strictly forbidden for the gas to enter the desulfurization tower with liquid.

(5) The operation should be stable and the use should be reasonable in order to exert its excellent performance.

3. Clean up

1. Wet cleaning

①Close the inlet and outlet pipeline valves of the desulfurization tower before cleaning, (three desulfurization towers are alternately cleaned to ensure that there are desulfurization towers that can be used normally during the operation).

② Open the manhole at the top of the tower and inject water into the desulfurization tower. The water level is based on the submerged desulfurizer, and the soaking time is more than 8 hours. 

③ Drain the soaking water in the tower from the drain at the bottom of the desulfurization tower, first take out the desulfurizer in the lower layer of the desulfurization tower, and then take out the desulfurizer in the upper layer.

④ On-site must be ventilation, operators wear gas masks or long-tube ventilators. Monitor the concentration of hydrogen sulfide and combustible gas at any time on site.

⑤ Clean out the waste desulfurizer, lay it flat on the ground to dry, and then bag it (woven bag with inner film) to monitor the temperature of the desulfurizer after bagging to prevent spontaneous combustion.

⑥ Loading and shipping.

2. Dry cleaning

①Close the inlet and outlet pipeline valves of the desulfurization tower before cleaning, (three desulfurization towers are alternately cleaned to ensure that there are desulfurization towers that can be used normally during the operation).

② Open the manhole in the lower layer of the desulfurization tower, take out the desulfurizer with tools, and monitor the site environment.

③ On-site filling, on-site forced ventilation, operators wear gas masks or long-tube ventilators, and monitor the concentration of hydrogen sulfide and combustible gas at any time.

④ Pack the bag, monitor the temperature of the desulfurizer, and prepare for fire extinguishing in the event of spontaneous combustion.

4. Gas replacement

  The use of inert gas to replace the biogas in the desulfurization tower was not used due to cost issues.

[contact-form-7 id=”1022″ title=”Message”]

EN1.4405 , Small Parts , Investment Casting Or Metal Injection Molding(MIM)?

editor

The most cost-effective for the small metal parts which are less than 50g.

For some small metal parts which are less than 50gram, they used to be casted directly in the past. Since there is another process called metal injection molding which is focusing on the small parts in recently years, which process is the most cost effective way?

Mostly the MIM is more suitable than the investment casting, however, It still need  to be analyzed case by case.

Let’s take the wear segment like above image as an example.

The weight is 36 Grams.

The structure of this part is simple.

The dispatch condition is blank casting or raw part.

The tolerance is referred to  VDG-Sheet P690 D1

The annual quantity for this part is around 30,000/ year.

According to this information, It is concluded that the investment casting is most cost- effective process to manufacture this part. For the molding cost of this part , metal injection molding(MIM) is three times than the investment casting.For the unit cost of this part, Metal injection molding is 2.5 times than the investment casting.

The advantages of metal injection molding compare to investment casting are follows.

  1. The High working efficient .
  2. No machining or less machining 
  3. Better tolerance and surface requirement.
  4. Complicated structure.

So you can see none of these advantages are applied on this part .

If you have some small parts to OEMs, let’s discuss case by case and  we will give you the best solution. Please send email to alina@tcc-casting.com

Aviation casting

editor

Aerospace Investment Castings

When aeronautical engineers design aircraft ,considering the safe, perform well, and can be built and sold at a competitive price, for certain parts with unusual or complicated shapes it is often by casting with appropriate heat treating and machining rather than forging .Investment casting is more economically and technically feasible on aerospace industry.Parts ranging from high to low complexity which are made from durable and corrosion resistant materials are possible. TCC understand the quality and precision that the industry demands which enable us to provide a wide range of investment cast parts for applications in both commercial and military aerospace sectors.

At TCC, we have a proven track record of producing some investment cast parts for aerospace applications that meet strict industry standards , eg bracket for J-10CE. Some of our capabilities in this sector are as follow:

In depth knowledge in working with a vast number of standard and super alloys such as stainless steel, PH stainless steels (17-4 ), carbon steel, and Nickel based super alloys like Inconel 718, Inconel 625, and alluminum alloy.
Use of the latest 3D modeling (SolidWorks) and solidification analysis (Pro-Cast) software’s.
In house rapid prototyping technologies with the ability to print 3D waxes.
When necessary we can design and implement soluble and ceramic cores into our tooling and workflow.

With a high level of casting expertise, stringent process control and certified quality systems of AS9001, we proudly provide reliable and cost-effective aerospace investment castings for the following applications:

Valves
Mounts
Swirl Nozzles
Engine Blades
Engine Rings
Vanes
Engine Impellers
Aircraft fluid management systems
Interior components
Hydraulic fluid system components

Quality is always the top priority at TCC. Certifications and compliances we adhere to for the aerospace industry is EN ISO 9001:2015 and EN9100:2018 .

For more details , please contact us with email : alina@tcc-casting.com