The outcome of lost foam casting

The X-ray radiography, used to measure the time of filling, as well as inspect for quality solutions / defects, recorded a series of video images. Developed strict list of optimal parameters describing the properties and behavior of coatings SMD expected as related to the quality of the final solutions from the complete data set. Ultimately, used the project data zones admissible apart of variables process control / quality given the rate of scrap lowest L61 Block and castings One (both castings most-prominent produced by GM Powertrain-Massena) to development. Moreover, it gave manufacturers specifications of the slurry to get new and improved formulations. Following guidance from the project team, the seller uses a ceramic slurry now consistent supply of raw material and ship the entire batch is divided into three 350 gallon totes.

Totes processing of all uniform, using a unique mix speed and mix-down era optimal as determined from tests with the new equipment acquired through the project. The changes in the process helped reduce scrap average of 8% – 10%. Further reducing switch manufacturer (strike at the supplier’s facility based on training from the project team), as well as improved coating, reduced scrap by another 4% -5%. This results directly in natural gas savings together and electrical energy of 1.63×1011 BTU / year (valued at $ 487,674 annual savings) and the combination of reduced emissions of particulate and volatile organic compounds different 3.21 tons / year.

With the cooperation of several private corporations, government and academic level, and through creative and innovative use of technology and staff analysis identified specific production issue, a solution achieved together and get important efficiency. This project will benefit not only economically vital New York factory, but it can be used by others across the nation and around the world in a variety of industries.

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