Quality and Efficiency through an Automated Charge Correction

To manufacture a sound casting in a foundry, the melt needs to contain the correct composition of specified grade non-metallic and metallic elements. Sound foundry practices, such as careful mold design and melt preparation, can reduce the risk of defects.

Nonetheless, a procedure to enhance or correct the composition may be unavoidable due to the source materials used (sorted scrap, raw material or leftovers from earlier melts). Making this process automatic with charge correction software for OES analysis can provide an extensively powerful tool for the foundry process.

The challenge of melt correction is that it can prove to be a metallurgically complicated and lengthy process. As the industry is constantly looking for ways to reduce savings in material and energy costs, and methods to increase efficiency, the laborious process of charge correction can cause major disruptions.

In the past, the charge correction method entailed utilizing a pocket calculator to carry out complicated calculations. This is not only a long process, but is also subject to human error.

Hitachi High-Tech has made the charge correction process automatic with a state of the art software solution, so calculations only take a matter of seconds. However, the software doesn’t only reduce melting time; it can bring a range of alternative benefits to foundries.

Increasing Quality

The Adjcalc software in combination with the very intuitive Hitachi SpArcfire operating system, allows a foundry to automate the key aspects of melt correction.

When the Hitachi OES analyzer demonstrates that the material in the production process does not meet specifications, the software can calculate the adjustments needed automatically and propose a plan of action.

There is no longer a need for calculators or excel spreadsheets. Simply an efficient, accurate analysis with direct instructions on how to correct the melt composition.

The OES can automatically compare the analysis with grade specifications by accessing the Hitachi High-Tech GRADE Database which has recent data on over 340,000 metal grades, meaning that charge corrections receive the best results as quickly as possible to ensure melt quality.

Reducing Costs

Along with making all the calculations needed in a matter of seconds, Adjcalc can help to make the charge correction process more efficient.

The software calculates and chooses the quickest and least costly combination of source materials necessary to create the desired melt specification. This may help the customer to use scrap more economically rather than purchasing expensive raw materials.

Reducing Errors

The complex nature of manual charge correction calculations results in a strong possibility for human error. The slightest mistake in calculation can create a massive amount of disruption when dealing with incredibly small margins in a high-volume environment.

By enabling software to deal with this step of the process, operators can significantly decrease the amount of charge correction errors. Balancing all the elements in a metal, instead of only one, lessens the potential of needing additional costly rounds of corrections.

Increasing Efficiency

The software is intuitive and simple to use meaning that years of technical experience in metallurgy is no longer needed to carry out a melt correction. A goal for Hitachi High-Tech’s software is to enable even the most technical of processes to be finished in a few easy steps.

With charge correction no longer a disruptive process demanding significant staff resources, process efficiency and productivity are much easier to maintain.

Combining Adjcalc software with SpArcfire allows foundries to take the complexity and lack of certainty out of charge correction and make sure materials are manufactured to the correct specification.

Hitachi High-Tech has been developing solutions that enable foundries to deliver the greatest results in the most safe and efficient way possible for more than four decades. Utilizing the power of software is the next exciting step for several metal production companies internationally.

This information has been sourced, reviewed and adapted from materials provided by Hitachi High-Tech Analytical Science.

For more information on this source, please visit Hitachi High-Tech Analytical Science.


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