The prerequisite for good, reliable cooperation is an individual approach that guarantees knowledge of the customer's needs and expectations and thus the delivery of high-quality products. We are convinced that we can only achieve this through full synergy of activities, exchange of experience and continuous improvement of production technology. For this reason, we have developed and implemented the Q-AL Programme, which provides a platform for cooperation with our customers.
Utilising our many years of experience and knowledge of casting technology, as part of the Q-AL programme, we offer all our customers a wide range of industrial studies and tests aimed at optimising their casting processes.
Identification of causes of defects in foundry processes
optimisation of the melting process and management of process waste
selection of an optimal process for refining and filtering the liquid metal
selection and optimisation of the grain modification and grinding process
selection of the optimal alloy grade for the production technology used
selection of an optimum alloy grade with regard to the desired mechanical and service properties of the casting
The implementation of such an extensive research and testing programme is made possible through cooperation with an independent accredited laboratory.
The range of tests carried out includes, among others:
Observations are made to assess the structure of macro- and micro-section, and also serve to identify the size of phase separations, e.g. of the AlFeSi, AlFeMnSi, etc. types. These investigations are also used to assess the extent of porosity or the presence of inclusions (impurities). Using scanning microscopy observation in BSE mode, chemical analyses of micro-areas (e.g. inclusions) can be carried out, making it easier to determine their origin or the mechanism by which this type of defect was created in the casting.
They are carried out in a uniaxial tensile test and a hardness test. The purpose of the tests is to determine yield stress, strength, elongation and HB hardness of a sample cut from a finished casting or a sample cast in a special hardness die. The results of these tests allow an assessment to be made of the influence of the casting parameters, chemical composition of the alloy or heat treatment applied on the final properties of the finished product, i.e. the casting.
The tests allow the quality of the liquid metal to be assessed in real time. The possibility of carrying out tests directly in industrial conditions, during the production process, provides great opportunities to observe the influence of individual technological parameters on the quality of the liquid metal. This makes it possible to significantly shorten the time of necessary analyses and reduce the cost of testing in the laboratory. The tests include:
hydrogen content analysis with ALSCAN
liquid metal purity assessment with the PREFIL apparatus
thermal analysis of the solidification process using the TA 110 apparatus
These include tests using N-tec's Metal Health System die set. These tests make it possible to carry out comparative assessments of, for example, the influence of different temperature parameters of the mould and the liquid alloy, as well as the influence of different chemical compositions or the proportion of individual alloying elements on the leviability of the alloy and the susceptibility of the casting to the formation of porosity, shrinkage, hot cracking, etc.
They are carried out to determine the exact chemical composition of a casting alloy, mortar or alloying additive, e.g. for the purposes of demoulding analyses. These include:
We will be happy to answer any questions!
