Conversions to Castings - There are many reasons to convert a fabrication or other wrought product to a casting. Cost is usually the most obvious one, but flexibility of the design is a very important characteristic of castings that is not always explored. The casting design can often be the lowest weight option with the critical sections not being associated with weld joints, unlike many fabrications.
Failure Analysis - Whether a casting fails in the foundry, at the machine shop, during assembly or in the field, it is essential to determine the reason QUICKLY!! CMPT is extremely competent and experienced in determining reasons for failures. We know what anomalies are in the casting microstructure and we know the reasons for them. We also understand various casting embrittlement phenomena. With this knowledge, we can determine if the problem is likely to be associated with one or more castings. If the casting is deemed to be defective we shall quickly investigate and implement corrective/preventative foundry procedures. We can also help the OEM by preparing casting purchasing procedures and specifications to ensure that the correct alloy and quality level is selected for the casting.
Defect Reduction - Reduction of defects is possible when the correct identification is made. The discontinuity can then be characterized. After observation of the foundry practices, a solution can usually be recommended, sometimes within a few days.
Melting Heat Treatment and Welding Metallurgy - Operators and supervisors having a basic knowledge of metallurgy can often be beneficial to prevent costly processing shortcuts. CMPT conducts training on site and in the classroom. On-line courses can also be conducted. This is very cost effective since many employees from different shifts can be trained in a short time frame.
Maximize Toughness and Strength of Steels - As the strength of steel increases, the toughness generally decreases. CMPT are experts at maximizing the properties form a particular grade of steel such that the toughness will be met at higher strengths.
Achievement of Hardness and Microstructure in Grey Iron By careful control of chemistry, inoculation and pouring temperature, CMPT are able to achieve the desired results (or explain what is attainable).
Assessment of Plant Operations - When this study is conducted at foundries, all the tough questions are asked and answered, for example, why is the machine producing at 70% uptime, why are the furnaces taking 3 hours tap to tap, why is scrap at 10% and rework at 10%. Why is the same defect occurring on different castings (or different defects on the same casting). The entire operation is surveyed and critiqued to find answers to the questions and solutions to the productivity problems.
Process and Practice Enhancement - This type of study usually involves a walk through the foundry followed by observation of the practices and recommendations for improvement.
Clean Steel Development and Implementation of Procedures - CMPT are experts at Clean Steel practices. We can recommend the practice most suitable to the foundry and follow up with the implementation of procedures. In most cases, capital equipment is not necessary but the foundry usually has significant changes to make to the process in order to reap the benefits from the Technology. Clean Steel is produced by standard melting practices with or without secondary refining.
Cost Benefit Analysis Studies - CBA studies can be performed for many casting operations, but a very detailed analysis will be produced by CMPT to accurately and objectively evaluate the (potential) benefits of a particular process modification.
Development and Implementation of Preventative Maintenance Programs - A good PM program is essential to operate an efficient foundry. Rather than having unplanned breakdowns occurring at the worst moments, planned maintenance schedules are beneficial. CMPT and its associates offer PM programs, tailored to the individual foundry.
Ladle Metallurgy to Improve Quality and Melting Efficiency - The quality of foundry steel can be improved significantly by modifying melting and refining practices. There are many benefits to "Clean Steel" resulting from the practice modifications. Mechanical properties are improved, machining is enhanced, casting appearance is improved and there is less welding. These benefits usually outweigh the costs associated with the practice modifications. In addition to practice modifications, CMPT president has been involved with the development and operation of a Plasma Ladle Refiner for the American Foundry Society.
NON DESTRUCTIVE TESTING & EVALUATION OF CASTINGS
Preparation of NDE Procedures Specifically for Castings - Many NDE technicans who receive training from approved labs are not properly qualified to test and evaluate castings. This is because the focus of the lab training is to components other than castings. CMPT are experts at training operators in casting NDE methods. Included in the training is a basic but valuable understanding of characteristics of casting discontinuities. Proper procedures are written and tested to ensure they are capable of detecting the various types of discontinuities that are problematic to client.
EXPERT CONSULTANT (WITNESS)
Legal services for the foundry, component manufacturer or the end-user - CMPT has been involved as an expert witness in casting failure cases and other foundry related litigation. The broad and in-depth practical knowledge of foundry operations and understanding of metallurgical principles are the keys to being a successful expert for foundries, OEM and other industries associated with castings.