Use of arc plasma in metal casting as a new approach towards energy efficient manufacturing

Abstract

Foundries constitute a segment that influences the supply chain of a several industrial segments by defining the quality and cost of manufacturing metallic primary products. Within this context, the encouragement of seeking for energy efficient processes is extremely encouraged, also to minimize the environmental collateral damage inferred by foundries. The present article explains and demonstrates the elaboration of a mechanism to compensate the temperature drop of the poured cast iron by pre-heating the cast iron pouring channel with the heat transfer from an arc plasma source placed above it. Besides requiring less energy to heat the post-poured molten metal, which impact has been measure after one year of operation of this innovative solution, it was possible to improve the metallurgical quality of the cast alloys and reduce defects thanks to a more accurate control of the molten metal temperature. The result obtained regard the design and implementation of a pioneer solution of heater inside a conventional sand casting foundry.