The heating elements and control thermocouples located close to the liner makes the outside of the mantle cooler than the liner, and the container housing even cooler. This maximizes support and mantle life. The built-in thermal gradient allows heat to dissipate from the liner without using auxiliary cooling or air, making it possible to maintain the liner 30oC (50oF) below the billet temperature
With a QR Container, the response to a demand for heat is therefore almost immediate. The liner is heated when and where necessary; and an improved liner temperature consistency is maintained, which is key to achieving product consistency both metallurgically and dimensionally. The QR Container reduces energy usage by over 50% from standard containers.
The container mantle is made of AISI 4340, which is 100% tougher, and has 80% better thermal conductivity than W.Nr 1.2344 (H-13) or 1.2343 (H-11) steel. This mantle is tougher and has better heat dissipation. The sub-liner is either 4340 or 1.2344 (H-13).The container liner is typically made of 1.2344 (H-13) which has high vanadium carbide and provides superior wear resistance or 1.2367 / E40K / Inconel 718 etc depending on the application.
“It is only when the conversion system, which includes the die, stem, dummy block and container is optimized that maximum productivity can be reached.” Paul Robbins
REPLACEABLE RING BLOCK
Replaceable ring block for standard long stroke presses up to 100,000 psi. The combinations of the ring hoop strength and the yield strength of the mandrel and holder have been carefully designed. The ring expands to pre-determined size at a pre-determined pressure. It provides long-lasting dummy block elastic expansion and contraction.
MARATHON (H-13 OR TUFF-TEMPER)
This extra strong 2-piece block emphasizes quality of product plus length of operating life. The sturdy design provides excellent long elasticity life and rigidity. Tuff-Temper is a patented steel developed by Castool. It has 3 times more Molybdenum than H-13. The amount of Molybdenum increases the yield strength from 156,000 psi to 165,000 psi, elongation from 6.5% to 8.5% and the ultimate tensile strength from 184,000 psi to 196,000 psi at extrusion temperature (800 oF).
This makes Tuff-Temper stronger and tougher for the dummy block. Tuff-Temper produces two times more carbides, so it has better wear property than H-13 as well. The single-use marathon dummy block has no replaceable parts and is not rework-able. It is simply replaced when it loses its ability to retract at the end of each cycle, and remains permanently expanded.
Castool uses a unique bayonet-type coupling which locks the dummy block quickly and securely to the stem. This makes it much easier and faster to replace a very hot block than with a conventional screw-type or rod coupling. Castool uses a secondary stabilizing stud (behind the bayonet), to limit the amount of lateral movement of the block on the stem. The stabilizing stud can reduce the lateral movement from 0.7 mm to 0.2 mm.
STEM AND SPACER
Existing stems can be adapted to the Castool bayonet system by attaching a spacer. The stem is cut and thread machined in the bore to accept the spacer stud. It is important that the stem and spacer faces match exactly, and that there are no gaps. A dowel pin must be installed on the diameter of the stem/ spacer to prevent rotation. If a gap develops between the stem and the spacer, the stud will then bear the full pressure of the ram, threads can foul and removal becomes difficult or impossible.
- Maintain liner 30 oC (50 oF) below billet temperature to reduce direct surface inflow onto the profile, reducing scrap from surface finish.
- Increase the billet/container differential towards the back end, and controlling shape, especially waving of wide thin extrusions.
- Reduce container and die slide effect on die temperature and resulting profile run-out, reducing scrap from shape deformation.
- Stabilize container and container housing temperatures which effect hot press alignment.
- Minimize energy usage and extend life of container mantle, liner and dummy block.
The container withstands extrusion pressure while billet is pushed through the extrusion die by the dummy block. The container maintains liner temperature at +5 oC of desired temperature throughout the process. When using taper heated billets intended for isothermal extrusion and higher productivity, the container liner temperatures can be set appropriately to enable best isothermal extrusion conditions.
- Provides uniform flow of alloy through the die.
- Reduces cost of operation.
- Reduces scrap.
- Reduces downtime.
- Increases productivity.
- Makes isothermal extrusion attainable.
- Increases operating life
With QR Containers, Castool again sets a new standard of excellence in the extrusion industry.
Results may vary depending on individual press characteristics and setup.