Wheel blast machine assists with new production of superalloy bars

Citation

(2001), "Wheel blast machine assists with new production of superalloy bars", Anti-Corrosion Methods and Materials, Vol. 48 No. 6. https://doi.org/10.1108/acmm.2001.12848fad.012

Wheel blast machine assists with new production of superalloy bars

Wheel blast machine assists with new production of superalloy bars

Keywords: USF Surface Preparation Group, Casting

Capitalising on the success of its "superalloy" bar products supplied to the investment casting industry worldwide, the UK's Sheffield-based Ross & Catherall has recently invested £7.8m in an expansion of its production facilities, including the development of a novel, combined vacuum induction melting and continuous casting process.

"Superalloy" bars in the 41mm to 100mm diameter range, produced continuously by the new process are initially cut to 4 metre lengths before being quench cooled, and dried. Subsequently, in order to achieve the desired surface quality and cosmetic appearance, a final finishing operation is necessary to remove light oxidation and heat discolouration.

The company set up a study group to consider the alternative methods of achieving this finish.

Headed by project development engineer Steve Salisbury, the group eventually selected a USF Spencer Halstead diablo conveyor wheel blast machine – a decision taken after an extensive study of the alternative cleaning methods, equipment and following discussions with leading manufacturers and end users.

Said Mr Salisbury: "The USF proposal, although not the cheapest option, was 'head and shoulders' above the rest. The equipment offered the best performance and we knew from discussions with other users that it would be rugged, reliable and efficient."

The alloy bars are processed in the blast chamber of the USF Spencer Halstead shotblast machine where diablo rollers rotate them for a predetermined cycle under a stream of steel shot projected by a blast wheel (Plate 6).

Plate 6 USF wheel blast machine assists with new production of superalloy bars

According to USF a high efficiency dust filter guarantees a clean working environment and an integral air wash separator ensures that only abrasives within acceptable size tolerances are retained within the working mix. Push button controls give a high degree of automation, saving production time, reducing labour costs and ensuring optimum blast performance.

The machine was delivered fully assembled, wired and tested and capable of meeting its objectives – 6 tonnes of cleaned bar every four hours.

"Our new blast cleaning facility has produced excellent results," concluded Mr Salisbury. "The new production process puts us in a much more secure and competitive position in the market place."