How to improve sealing efficiency and reduce safety risks in a bottom pour forging application?

Once upon a time, in Canada, in the heart of Quebec, our experts know once more how answer to an industrial problematic. Sorel Forge, a large steel forgiving factory that is over 70 years old, produces a wide range of forged products.

This company is part of Finkl Steel, the world's leading supplier of forging die steels, a subsidiary of the Schmolz + Bickenbach Group.Sorel Forge facilities are able to produce blocks of molds up to 59 000 pounds or 27 000 kg.
 

The challenge

The customer uses steel to seal the runner and dish toolwhen making Ingots in a bottom pour application. However, the casting of steel and especially on large parts, creates a lot of pressure inside the liquid steel, which causes gaps and cracks between the different parts.

The application requires, depending on the size of its parts, about 100 kg of steel per pouring.

A way to package the material to reduce manipulation and cost was also needed in this case.
 

The solution

A meeting and an exchange took place between our team and our customer’s members.

First, the problematic was tackled in order to find suitable solutions. Then samples of steel grits and as casted materials were sent.

Quickly, our experts found that it was possible to use steel shots wisely because it aims to quickly freeze the leaking molten metal. In addition, it ensures steel leaks between the trumpet, runner, the dish tool and the sprue plate by filling the gaps and the edges with steel grit.

G18 size grit finally proved to be the best solution, not too small to float on the molten metal and not too large to leave path for leaks.  Because the hardness of the grit has no impact on the application and performance, any available hardness from stock is selected.
 

The result

The efforts of our team led to this operation, which was as instructive as it was conclusive. Indeed, it allowed our teams to realize that:

• A grit size between 0.6 mm and 2 mm is giving best sealing results.
• The use of 2MT supersacs reduces manipulation between the warehouse and the application area.

Yes, it is by forging that we become blacksmiths! Your problems are our solutions, and they are essential to our improvement, it is thanks to them that we reinforce our expertise, and offer the best solutions through our experiences.

How our services made the difference?
 

Our proximity:

Our multiple warehouses and our factory locations have allowed us to be competitive because we have proposed low cost sealing solutions.
 

Your savings:

About 20 hours per year are saved from using  2 tons of supersacs versus 1 ton.
Our teams have been able to innovate in the savings opportunities related to packaging.