Figure 1 : Source 5 . |
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yield of 1 % up to 3 % results in significant cost savings and energy and emission reduction . A typical high-pressure diecasting facility could use approximately 6 million kWh of electricity and 18 million kWh of natural gas per facility per year . This facility would generate 60 million kg of CO 2 per year . 2 , 3 Each 1 % reduction in scrap would then result in a reduction in
CO 2 by 600,000 kg per facility annually .
This foundational work was applied to high-pressure die castings , which do have applications in some segments of the valve industry , typically in aluminum for solenoid valves and various components . This ML / AI approach has a track record in other manufacturing applications , including injection molding , extrusion , and stamping .
For sand castings , a two-pronged approach to process improvement can apply . The typical approach to casting optimization employs tools , like MagmaSoft ® for casting and mold design , and the casting process itself for both steel and die casting .
Supplementing the use of such existing tools by leveraging this predictive ML / AI approach for the sand-casting process , for example , is technically feasible . It would require designing the appropriate Internet of Things ( IoT ) system to monitor the key process parameters and linking these process parameters with quality data . Consideration should be given to extending the monitor parameters to include atmospheric conditions inside the work location and outside the facil-
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ity , sand humidity , and the other ( typical ) known variables .
The solution would utilize the process data to detect anomalous conditions at an early stage and recommend process adjustments to avoid sand casting defects ( porosity , pinhole , shrinkage , and more ) for future runs . Analogous to the high-pressure die-casting example , this technology would assist in reducing scrap , energy usage , and emissions .
A 1 % reduction in scrap may not seem like a significant amount , but a broader context exists . The global production of castings , of all materials , in 2020 was 105.5 million metric tons . 4 This was an increase of 40.8 million tons , or 63 %, from production levels in 2000 . China , the United States , and India are the “ Big 3 ” producers globally . China ’ s casting production volume exploded four times from 2000 to 2014 and is still growing . India ’ s production increased dramatically during the same period but has not reached China ’ s level and decreased slightly in recent history . The United States has seen a 14 % decrease over the 20-year horizon but retains the # 2 spot globally . With 49 % of current casting production volumes , China is the largest single casting producer overall .
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The output for cast steel production , a subset of total casting production , rose in line with the increase in total global output of all casting types . Throughout 2000 through 2014 , cast steel production was relatively steady at 8-10 % of the total . 5 |
The call to action is for metal casters and valve manufacturers to start planning their roadmap for sustainable manufacturing . Foundries should consider how IoT and AI solutions could be used to improve quality , reduce energy , and improve sustainability for sand-casting and other relevant processes . The place to start is with a digital transformation readiness assessment ( as-is state ), followed by an action plan to attain a future ( to-be ) state . Savings opportunities could be significant . Buyers of founder products should validate their supply base for programs and activities focused on improvement and sustainability . Long-term supply agreements and potential |
collaborative efforts , with savings sharing , are an established procurement practice in many industries .
REFERENCES
1 . https :// english . mee . gov . cn / Resources / Reports / reports / 202211 / P020221110605466439270 . pdf
2 . https :// www . energy . gov / eere / amo / articles / itpmetal-casting-energy-use-selected-metalcastingfacilities-2003
3 . https :// www . osti . gov / servlets / purl / 822409
4 . https :// www . statista . com / statistics / 237526 / castingproduction-worldwide-by-country /
5 . https :// www . researchgate . net / publication / 304402015 _ Trends _ in _ the _ Production _ of _ Castings _ in _ the _ World _ and _ in _ Poland _ in _ the _ XXI _ Century
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ABOUT THE AUTHORS |