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Eliminating the Causes for Carbon Monoxdide Gas Defects in Cast Iron (05-06#01) |
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Coordinator Professional Metallurgical Services The presence of gas holes from carbon monoxide reactions has become an increasing problem in the past 15 years. As our casting processes have been altered with new binder systems, melting systems, metal handling systems and devices that are intended to control the introduction of foreign materials into the casting, seemingly, the problem with the development of carbon monoxide gas defects has increased. The consequence has been that returns have increased and production time has been lost in efforts to correct the problems and provide consistent quality iron castings. This project is intended to address the gas formation issue from the metal processing standpoint as well as the casting method standpoint, both of which are at the forefront in the AFS Division 5 Research Plan. Gas defects in cast iron and more specifically, carbon monoxide gas defects in cast iron castings, are simply not tolerated and this proposed research project is intended to identify the control factors needed to eliminate them. The characterization of carbon monoxide gas defects in cast iron has already been documented as part of the U.S. DOE funded project intended to model the formation of nitrogen in high alloy cast iron and specialty cast iron monitored through AFS Division 5 Special Irons Committee, (5D). The objectives of this proposed work would be to: determine the conditions that exist that are associated with the carbon monoxide gas defect; identify the cause of the conditions that existed when the carbon monoxide gas defect forms; eliminate or control the conditions that cause the carbon monoxide gas defect.
The project consists of five phases: evaluate the data from the 5D project as it relates to the presence of carbon monoxide; determine the conditions that were present when the carbon monoxide defect formed; identify the source of the constituents that caused the carbon monoxide to form; consult with participating foundries to devise experiments that would further isolate the cause of the carbon monoxide gas formation; conduct the experiments at research facilities or participating foundries to purposely create and eliminate the carbon monoxide gas defect.
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