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The automated robotic shell mould-dipping line |
The unique investment casting facility of the CSIR has been upgraded to facilitate research and development (R&D) on the casting of titanium alloys.
An automated robotic shell mould-dipping line has been completed and is operational.
This casting facility is unique in South Africa and positions the organisation for intensive, well-controlled and systematic R&D in particular shell systems for reactive metals such as titanium.
The metals and metals processes competence area of the CSIR is developing a titanium investment casting competency for South Africa. The research is funded by the Department of Science and Technology's Advanced Manufacturing Technology Strategy, which is hosted by the CSIR. One of the ultimate research objectives of this project is to develop casting processes for aerospace components. The CSIR and Boeing Phantom Works in the USA have an active working relationship.
As part of the titanium investment casting technology chain, a state-of-the-art robotic dipping line has been installed for the manufacture of the ceramic moulds has been installed. The moulds are used in the investment casting process.
Although robotic dipping is commonly used in investment casting foundries internationally, the robotic dipping line at the CSIR facility is uniquely dedicated to research. The robotic shell mould-dipping line ensures repeatability for R&D purposes and is not used, as elsewhere, for increased production.
According to Pierre Rossouw of the CSIR, "The line is set up for R&D, and is equipped with various monitoring and recording systems that are designed to give maximum information on the process parameters." In developing novel shell systems for reactive alloys such as titanium, it is important not only to investigate the technological aspect of the technology, but also the economic aspects. "In this way we ensure that implemented processes are cost-effective and competitive," he says.
Rossouw explains that the dipping line incorporates load cells that monitor total material consumption, including losses, and load cells that monitor each mould passing through the process. The data are then compared with statistical data obtained in a casting quality analysis and the shell system can be optimised for maximum yield and casting quality.
The system also has total environmental monitoring and data-logging capabilities. Rossouw says the system is currently being expanded to include other parts of the casting process, such as boiler de-waxing and vacuum casting.
The primary theme of the CSIR's metals and metals processes for the next three years is light metals with development focused on titanium, aluminium and magnesium. The CSIR's encompassing research in metals includes primary processes (primary titanium metal production), titanium processing through powder metallurgy techniques, powder alloying, processing through semi-solid metal forming of aluminium and magnesium, investment casting of titanium and light metal alloy modification for advanced processing. Product and process design activities focus on the design and optimisation of moulds for metal casting and forming, as well as numerical analysis of products and systems.
The primary research partners on these projects are South African universities. These include the universities of Cape Town, Stellenbosch, Pretoria, Limpopo, the Witwatersrand and KwaZulu-Natal, the Central University of Technology in the Free State and the Nelson Mandela Metropolitan University. Other collaborators are the CSIR National Laser Centre, as well as the science councils, Mintek and Necsa, and the company Thermtron.
Enquiries: CSIR Communications
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