IMPROVEMENT OF WEAR COMPONENT'S PERFORMANCE BY UTILIZING ADVANCED MATERIALS AND NEW MANUFACTURING TECHNOLOGIES: CASTCON PROCESS FOR MINING APPLICATIONS Page: 3 of 5
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In this reporting period, we continued the effort to manufacture a full disc prototype. We
increased the thickness of the disc pattern and the resulting discs had the correct dimensions. We
carefully welded the HIP cans and performed leak checks before sealing. There were no can-
blowing problems encountered in this quarter. We increased the off-gas temperature from 5000C
to 10500C in an effort to eliminate the cracking problem. Unfortunately, cracking still occurred
on the H13 body and H13/WC insert interface. Microstructure examination showed an oxidation
film existing on H13 particle boundaries. This is an indication of improper off-gassing.
It is planned in the next quarter to check the vacuum system for the off-gassing, increase
stem size, use argon for purge and cooling, add a steel mandrel to the sand mold to reduce
shrinkage restriction, add a copper coating between H13 and WC insert, and add an oxidation
prevention agent in the sand mold.
Discs produced last quarter were not thick enough on the disc hub section. Two 1/8"
thick steel rings were prepared and bonded on the pattern hub to increase its thickness. We used
the modified pattern to make the 6.5" discs this quarter.
The HIPping cans were made of 1/16" thick low carbon steel sheet by cutting, rolling,
bending and welding. It required excellent welding to prevent vacuum leaks. Can leaking has
happened several times in the past and was a problem in making the discs. In this quarter, we
carefully cleaned the welding regions of cans before welding, using sand blasting and wiping
with alcohol. We also did a vacuum leak check before final sealing the can.
We increased the off-gassing temperature of the cans from 5000C to 10500C in this
quarter to reduce potential oxidation of H13 powder inside of a can. The off-gassing temperature
was high and lasted for 3 hours at temperature. Severe oxidation took place on the can surface
and a lot of scale formed. To reduce the risk of leaking due to potential oxidation though the thin
steel, we started to look for an oxidation resistant glazing material. We identified a protective
coating, named "CeramGuard" for heat treating metal protection. This coating is supplied by
A.O. Smith Corporation, Holton Road, Florence, KY 41042, Tel: 606-727-3500. CeramGuard is
a group of coatings for heat treating at different temperatures. We selected and ordered CG-27
based on A.O. Smith Corp's recommendation. CG-27 is supposed to be used around 11000C. We
applied this coating to the cans before off-gassing. To further reduce oxidation scaling, fly ash
residual carbon was added to the off-gassing furnace to react with oxygen and reduce oxidation
of the cans.
Results and Discussions
The cans did not leak during HIPping. This showed that our measures to solve the can
vacuum leakage were effective. Figure 1 shows the cans after HIPping.
CastCon Process for Mining Applications 2 Michigan Technological University
12' Quarterly Technical Report (Oct-Dec, 2003) February 2, 2004
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Huang, Xiaodi & Gertsch, Richard. IMPROVEMENT OF WEAR COMPONENT'S PERFORMANCE BY UTILIZING ADVANCED MATERIALS AND NEW MANUFACTURING TECHNOLOGIES: CASTCON PROCESS FOR MINING APPLICATIONS, report, February 27, 2004; [Houghton, Michigan]. (https://digital.library.unt.edu/ark:/67531/metadc781079/m1/3/: accessed March 23, 2019), University of North Texas Libraries, Digital Library, https://digital.library.unt.edu; crediting UNT Libraries Government Documents Department.