CD-101

Melt Quality Control In Induction Furnace
Mr. Prakash K. Basutkar
Dr. Basutkar explains in this lecture:
Various factors which determine the melt quality of cast iron (including S.G. Iron) and How to control these various factors. This lecture gives very specific information and technical details, which will be immensely useful for practicing foundrymen.
Contents - Furnaces used : Advantages of medium frequency furnace over mains frequency furnace.

Objectives of Melt Quality Control:Quality of charge materials used such as steel scrap, foundry returns ferro - alloys used, carburisers. Charging methods and sequence to reduce melting losses and give required chemical composition and temperature of liquid metal.

Desulphurization:Steps in desulphurisation, Quality of desulphurisers, temperature of melt, deslagging etc.

Metal Chemistry:Melt composition and temperature of metal. Various ranges of Carbon, Silicon, Manganese, Phosphorus, Chromium and other submersive elements like Pb, Bi, Sb, Ti and Al. Carbon Equivalent.

Magnesium treatment:Control of base liquid metal, temperature of liquid metal, nodulizing agents i.e. ferro - silicon Magnesium alloys, its composition. Controls required in Magnesium treatment - viz. temperatures method of Mg treatment recovery of Mg etc.

Control for producing S. G. Iron.

Metal temperature which controls Magnesium recovery.

Weight of liquid metal treated.

Composition of nodulizer - percentage Mg in alloy.

Pouring techniques to give minimum fading effect.

Proper residual Mg to give desired microstructure in as cast condition.

Productivity Improvement In Foundry Industry
Mr. B. S. Pendse
In this lecture Mr. Pendse describes:
Productivity in foundry.
Factors on which productivity depends and
How these factors can be controlled.
This lecture will be very useful for the managerial level personnel and entrepreneurs in foundry industry in evolving their strategies and implementing them.
Success of any business is essentially dependent on management's ability to maximize output of all types of inputs in a coordinated manner. Foundry industry is not an exception. But being labour intensive discussions about productivity in foundry tend to concentrate on only "labour productivity". In the current wave of liberalization measures for enhancing various day to day operations become important and are focussed in this lecture. Money, materials and Men are basic inputs which control productivity in small / medium scale foundry in particular.
Contents - Furnaces used : Cost competitiveness - through a comprehensive long term approach of maximizing outputs.

Productivity of capital.

Productivity of materials and equipment.

Productivity of Human Resources.

In conclusion, it must be emphasized that a "do or die" situation is going to be thrust on all small / medium level business serving small niche markets - either domestic or export or both in the near future. It would be essential to realise the irreversibility of this process and to have a sense of extreme urgency in tacking the problems. The complacent approach so far would have to yield to "permanent" and "united " effort to meet the challenges ahead for foundry industry.