Is it possible to improve the quality of castings and reduce the cost price?

Published on: 11.07.2017

SmartScrap team pays great attention to methods of increasing the efficiency of our customers’ production through the use of alternative materials produced from industrial waste.
We came to the conclusion that raw materials produced from waste materials are not only inferior to those produced by traditional methods, but even have several additional benefits. For example, let’s consider the production of cast-iron railway brake pads.

      Russian candidate of Technical Sciences Mr Marshev V.I. in his dissertation work “High-phosphorus cast iron for brake shoe of high-speed locomotives” has considered in depth the fact that phosphorous cast iron has better adaptability, compatibility and stability of friction coefficient than conventional gray cast iron, which is widely used at present.
Let’s get back to the theory. Due to the presence of a phosphide eutectic in the structure, the amount of which increases as the content of phosphorus increases in cast iron, the frictional heat resistance of tribocoupling increases. In this case, the phosphide eutectic has a positive effect during friction, by reducing the intensity of destruction by reducing the number of large setting points, and at the same time by increasing the coefficient of friction.
Full-scale bench and operational tests revealed that the use of brake pads made of high-phosphoric cast iron increases their validity period in 2.5-3.0 times.
Let’s turn up to the economic value. For today the price of cast iron including delivery to the European consumer is $ 350. The price of ferrophosphorus with phosphorus content of 20% is about $500-900.
In total, the cost of pig iron and ferrophosphorus for the production of 1 ton of castings with 3% phosphorus content will be $350 + $75 = $425.
We offer cast iron scrap with phosphorus content of 3-4% (Fe 90%+), formed at the foundry, at a price of approximately $200-220 (the final price depends on the delivery to the consumer plant.)
As you can see from this example, there are some options for improving efficiency through the use of alternative materials. And what is also important, this solution helps to make the planet cleaner! After all, for today the pig iron industry appears to be one of the most polluting industries in the world.

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