Our customer, a manufacturer of cast metal product, faced potential safety issues when workers visually monitored molten material through a view port during the casting process. MS Technology designed and fabricated an automated temperature measurement and inspection device that improved both safety and accuracy. As often happens in MS Technology projects, as our team worked on the original customer problem, other innovations were identified leading to valuable improvements in the overall process.
Operators of a molten metal casting process were manually measuring material temperature using a system that created safety risks for the individual and liability exposure for our customer.
MS Technology designed and fabricated a system for accurate temperature measurement and inspection of vacuum induction melters and a microwave furnace. This system for automated temperature measurement of molten material replaced visual inspection, greatly increasing safety of this critical process.
While addressing the safety improvement needs of this project, MS Technology engineers identified three methods to increase accuracy of pyrometer readings.
- Graphite pour valve allows a positive mechanical attachment between the mold and the crucible. This is important for reasons of pour containment and prevents criticality events that could result from an unplanned release of material to areas other than the mold.
- Connection between the crucible and mold allows heat transfer from the crucible to the mold, which is essential to avoid premature freezing of the liquid metal during casting operations.
- Incorporation of the pour valve into the pyrometer system allows for accurate melt temperature measurement. The valve is designed with a well into which the pyrometer is focused. The graphite pour valve serves as a “black body” with an emissivity of very nearly 1.0. Since the behavior of graphite is well documented over a wide temperature range, pyrometer calibration is greatly simplified.