Alteams had clear ideas for the new machine, and the requirements differed significantly from the existing systems on site. Ultimately, however, the final decision-making aid was practical experience and thus the inspection of a machine during production. The main focus of the practical test was on the furnace exchange: process and costs, how is an exchange carried out and how much time is required? In contrast to the existing systems, Alteams decided to work with crucible furnaces in future. The main reason for this was the requirements for the cast part, for which an appropriate melt quality was a key factor. Refilling, cleaning, density index and melt analysis are all carried out in the crucible furnace. In order to increase production and be able to cast continuously, the decision was also made in favor of an exchange furnace concept. The furnace is changed using a crane. Centering and coupling systems are installed on furnace and casting machine so that the exchange itself can be carried out as quickly and safely as possible. The furnace has a capacity of 1,100 kg and can be operated with one to five riser tubes. The riser tube is the direct interface to the mold, and temperature losses are avoided thanks to Kurtz´s “DOM technology”.
Alteams´ main low-pressure products include electric housings with high quality requirements. Die cooling is another key factor in achieving such requirements. 16 regulated water-cooling systems are used as main cooling systems, supported by 16 air cooling circuits. The water-cooling circuits can be blown out with air independently of one another at the end of each cooling cycle. The fact that cooling is controlled not only by time, but also and above all by temperature, is relevant to the process. In addition to the cooling time, 12 thermocouples determine the use of cooling. Recording the temperature prevents a cold mold from being cooled further.
Quality assurance is a top priority at Alteams. The function “Quality Management Sheet” enables the documentation of every single casting. Recording the data is not only the “birth certificate” of the casting, but also a reflection of the results and is used for process optimization. The machine was installed and commissioned in Laihia, Finland, at the end of October and casting has been taking place since the beginning of November. We would like to thank Alteams for the trust they have placed in us and wish them every success for the future. Good luck!
Highlights of the Kurtz/Alteams machine AL13-13SC
- Crucible exchange furnace with 1,100 kg capacity
- Use of 1 to 5 riser tubes via DOM system
- Manual on-site panel for teaching furnace filling level and pre-pressure determination
- 16 regulated water-cooling systems
- 16 air cooling systems
- Cooling circuits can be used as mixed circuits
- Blowing out the water circuits with air
- All machine axes via measuring systems, no mechanical adjustment of initiators
- Recipe management for machine and casting parameters
- Parallel guidance
- Kurtz ejector system
ABP is a leading manufacturer of induction furnaces and systems for inductive melting and holding for the metal and metalworking industries. ABP is an expert in melting, pouring, holding and heating iron, steel and non-ferrous metals with design, production, assembly and services for foundries, forges and steelworks. The ABP Induction Group with over 400 employees has companies in the USA, Mexico, Sweden, Germany, South Africa, Russia, India, Thailand and China. It is represented by service and sales partners in most of the world's industrialized countries.
