<p>This paper documents a project in which a metal treatment station (MTS) unit guided by SMARTT (Self-Monitoring, Adaptive, Re-calculating Treatment Technology) degassing was implemented to optimize the melt treatment process in the production of A356 aluminum. It also briefly discusses the background model for adaptive degassing and the rationale for using adaptive degassing and other combined treatments including upgassing and flux form grain refining to fully automate the melt treatment process at Harmony Castings, LLC in Harmony, PA. Moreover, this presentation reviews the unique considerations involved in jobbing type production where many different castings are made to multiple different specific gravity ranges. A comparison to the experience using the Industry 4.0 style process at a higher production environment is made, and a review of testing evaluation methods and the corresponding results achieved, are provided. The paper will also document some expected benefits achieved during the first year after implementation, which include significantly improving mechanical properties (i.e., 13.4% in elongation, 10.1% in yield strength, 7.5% in ultimate tensile strength, and 3.28% increase in Brinell hardness). Finally, the presentation reviews the project’s primary objectives of higher productivity and lower metallurgical scrap, which were accomplished relative to historical standards, by reducing the degas cycle four times over and reducing scrap by 50%.</p>

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Implementing an Industry 4.0 Style Degassing Procedure into a V-Process Foundry Making A356 Aluminum Alloy Castings

  • B. Began,
  • E. Baker,
  • J. Johnson

摘要

This paper documents a project in which a metal treatment station (MTS) unit guided by SMARTT (Self-Monitoring, Adaptive, Re-calculating Treatment Technology) degassing was implemented to optimize the melt treatment process in the production of A356 aluminum. It also briefly discusses the background model for adaptive degassing and the rationale for using adaptive degassing and other combined treatments including upgassing and flux form grain refining to fully automate the melt treatment process at Harmony Castings, LLC in Harmony, PA. Moreover, this presentation reviews the unique considerations involved in jobbing type production where many different castings are made to multiple different specific gravity ranges. A comparison to the experience using the Industry 4.0 style process at a higher production environment is made, and a review of testing evaluation methods and the corresponding results achieved, are provided. The paper will also document some expected benefits achieved during the first year after implementation, which include significantly improving mechanical properties (i.e., 13.4% in elongation, 10.1% in yield strength, 7.5% in ultimate tensile strength, and 3.28% increase in Brinell hardness). Finally, the presentation reviews the project’s primary objectives of higher productivity and lower metallurgical scrap, which were accomplished relative to historical standards, by reducing the degas cycle four times over and reducing scrap by 50%.