by Julie | Jun 6, 2012 | Consulting, Efficiency
I love this time of the year when the warm weather finally appears! The plants are growing and life is good! However, it is also the time of the year when shell drying related issues start to creep up!
So, I thought I’d share a few items to check if you start to see an increase in shell cracking as the weather outside starts to warm up.
1) Check to make sure all your fans are operational. Regardless of the type of drying system you use, it is possible that a fan is not operating and as a result, some molds are seeing less air movement.
2) Look for hot spots in the room. The outside walls may start to radiate more heat and molds in that area may start to heat up.
3) Ensure that your RH sensors have been calibrated.
4) Evaluate your current intra-coat dry time against your standard. Changes in your throughput over time can impact dry time between coats.
5) Review your final dry procedures. Are the molds being exposed to enough air flow during final dry?
Obviously, there are a number of factors that can cause shell cracking. But, taking a little time to evaluate changes in your drying conditions will help in identifying the root cause of the cracking. If this review doesn’t resolve your issue, at least you can feel confident to move onto other potential causes of the cracking .
If you want to talk about where your process variability might be coming from, send me a quick email at Julie@keyprocessinnovations.com and I would be happy to help you troubleshoot your process.
by Julie | May 29, 2012 | Consulting
I am frequently asked how often should I test my slurry? I know you shouldn’t answer a question with a question, but what about a series of questions?
✓ How often do you have to make adjustments to your slurry?
✓ Are the adjustments with water, binder or a mixture of both?
✓ Do the components of the adjustment change every time?
✓ Do you have to add so many liquids that flour needs to be added to thicken up the slurry?
✓ Are these adjustments as a result of periodic viscosity checks or from the slurry testing?
The goal of your testing frequency should be as little as possible while ensuring the key parameters are in range. I have seen some customers test their slurries on a daily basis and some do no testing at all.
I firmly believe that if you control your inputs, slurry control will be much easier and a result, less testing is required. That means that you must monitor the material being fed into the slurry tanks and make adjustments prior to adding them into the dip tanks. If the make-up tanks are in range, it would stand to reason that the slurry dip tanks will also be in range. But, what if the make-up tanks aren’t maintained in range?
If you have questions about how to ensure the make-up tanks are in control, read Shark Teeth or an Iowa Cornfield?
If you start to understand why the adjustments are being made and take steps to correct those parts of the process which are causing the variability, then you will be on your way to having a more robust process which will allow the operators to spend less time testing the slurries and more time on production.
If you want to talk about where your process variability might be coming from, send me a quick email at Julie@keyprocessinnovations.com and we can discuss your situation in greater detail.
by Julie | May 23, 2012 | Employee Training
Stability of colloidal silica is important for the health and performance of an investment casting slurry. pH is one indicator as to the stability. Conductivity is another important indicator and information on that topic can be found here.
Accurate measurement of pH is critical. I have received numerous phone calls from customers stating that the pH of the slurry is 11.0 or even higher. If the pH of a silica-based sample is above about 10.5, the silica particles can begin to dissolve. Since the slurry additives typically lower the pH, a reading of 11.0 could indicate issues with your meter.
If you are unsure if the pH is giving accurate results, check the pH of the incoming colloidal silica and compare the reading to the supplier’s certification.
The trending of the pH over time is as important, if not more important, than an absolute value. For example, a pH of 9.2 could be a reason for concern. However, if the pH has been slowly drifting down to 9.2 and then settling there, the slurry stability may be fine. Checking conductivity is another way to confirm the health of the slurry.
Care of a pH meter will vary by manufacturer. Take some time to review the manual and ensure that the proper calibration and maintenance procedures are followed.
If you are still unsure of your readings, feel free to contact me for more information at Julie@keyprocessinnovations.com.
by Julie | May 16, 2012 | Employee Training
One of the most common slurry tests performed for investment casting slurries is SiO2 percentage. Insufficient concentration of SiO2 in the slurry creates a weak shell. However, having too high a concentration can also cause a weak shell while potentially gelling the slurry.
The two common methods for measuring binder solids are volumetric and through the use of a densitometer. For this discussion, we will focus on the volumetric method.
Ensure that the sample has been spun long enough to remove the refractory particles from the supernate (liquid on the top of the solids). If this isn’t done, the results will be inaccurate, regardless of the test method utilized.
Of the two methods, the volumetric procedure can lead to the most variability. This variability can come from the following:
1. Uncalibrated flasks
2. Dirty flasks
3. Fill line identification
Most foundries make the mistake of assuming that a 10 ml volumetric flask filled with water will weigh10 grams. Making this assumption could lead to inaccurate results. However, if you compound this error with a dirty flask and the results will be even further off. I have seen the percentage of silica be off by up to 3 percentage points by not calibrating a dirty flask.
The other challenge that operators sometimes face is knowing how to locate the meniscus. By going through the calibration process, this can help operators understand how a slight difference in the fill line can impact the results.
The ICI has outlined a procedure on how to calibrate your flasks every time the test is performed. Or, if you have questions, feel free to contact me for more information at Julie@keyprocessinnovations.com.
by Julie | May 7, 2012 | Employee Training
I had a wise customer comment to me once that he didn’t mind collecting data as long as the operators/engineers were going use it for slurry control. I completely agree with that statement but would add: make sure the data you are gathering is meaningful.
So, what does meaningful data look like? In my mind, it would be data that you could rely on to troubleshoot issues within your process. One of my favorite examples was a customer who was measuring the pH of a slurry but his pH probe would never stabilize prior to turning off. Instead of resolving the issue, he would record the last reading he saw before the meter shut off.
Then, his slurry gelled – all 250 gallons. In the tank.
So, I received the panicked call that his slurry had gone bad and he didn’t know why.
When I asked about the pH of the slurry and if it had been trending down, he said he didn’t know. I asked if he had been testing for bacteria and he said yes, but was out of biocide. I asked if he had been checking conductivity levels and he said no.
Though he did a great job recording his data and graphing it for all to see, his data wasn’t accurate and he couldn’t use it for its intended purpose. It was an expensive lesson for the engineer and the company.
Collecting data for the sake of compiling a graph does not help you achieve the ultimate business goal of making castings. And, if you don’t have any confidence in the testing method, the technician or the result, than you might consider utilizing your resources in another capacity.
In the next few weeks, we will discuss ways to ensure you have robust slurry testing procedures.
