mandrel fabrication - TI International, Ltd.

Transcription

MANDREL FABRICATION
GUIDE LINES
International, Ltd.
(formerly Templeman Industries)
2260 Commonwealth Ave.
North Chicago, Il. 60064
Phone: (847) 689-0233
Fax: (847) 689-0238
TI SYSTEM WASH-AWAY CASTING COMPOUND
DESCRIPTION
TI System is the “State of the Art” hot melt casting compound that is non-toxic,
sets up in seconds, water soluble and remeltable. During casting it will pick up
the most complex details time after time and when washed out will offer
ecological benefits.
POURING INSTRUCTIONS
TI System pours and casts similar to low temperature metal combinations. For
any given core, by adjusting pour temperature, mold temperature and timing, the
ideal combination can be readily determined. By consulting the Physical
Properties sheet that applies to the material being used, the melt out, pour
temperature and casting temperature may be found as well as suggested mold
temperatures.
SOLID CORES
To eliminate pour lines in solid cores, raise the mold temperature to near
suggested maximum and pour TI System at near maximum temperature as
suggested on the Properties sheet.
HOLLOW CORES
1) On most hollow cores, pour TI System at approximately 15-20 degrees F
above minimum melt and pour temperature as indicated on the Properties
sheet.
2) Pour mold full and wait approximately 30-45 seconds.
3) Pour TI System out of mold and back into the melter.
4) Wait a few minutes then break open mold and remove core. (If pour lines
occur, heat mold to minimum temperature prior to pouring).
FOR GREATER WALL THICKNESS ON HOLLOW CORES
1) Pour mold full of TI System and wait 30-45 seconds.
2) Pour TI System out of mold and back into melter and wait 5 minutes, leaving
core in mold.
3) With core remaining in mold, repour material back into hollow core until full
and wait 30 seconds.
4) Pour material out of mold and wait a few minutes.
5) Break open mold and remove core.
Caution: Leaving the mold full of molten material too long could result in
uneven wall thickness.
EQUIPMENT REQUIREMENTS AND APPLICATION FOR
ULTIMATE PERFORMANCE
I. TOOLING REQUIREMENTS: TI System Casting Compounds are used at
elevated temperatures. Tools or molds must be constructed with the ability to
withstand high temperatures and initial thermal shock. Laminated high
temperature epoxy system tools are normally used, however, some users are
now moving to “cast to size” aluminum tools or molds as the shrink factor is
the same. The advantage being that aluminum will not degradate with
repeated cycling as do epoxy tools plus the surface finish of the cast mandrel
is far superior. Tooling is of the split flanged type with ribbed backing in any
case.
II. MELTING EQUIPMENT:
A) A good quality melting pot is very important to achieve optimum
performance from TI System compounds. The melter shall be electrically
heated, cylindrical with multiple circuit blanket type elements to apply
uniform heat to the entire bottom and up the side walls to approximately
75% of the wall height. Heat should be evenly distributed at a low watt
density (approximately 5 watts per square inch maximum), thereby
eliminating the danger of “hot “ spots.
B) TANK CONTROL: Accurate variable dial thermostats to control the wall
temperature are required and temperature range should be from 200°F550°F.
C) OUTLET VALVES: Great care should be used in the selection of the
outlet valve. It shall be electrically heated and thermostatically controlled.
Either slide or gate type is acceptable. Construction may be either brass
or stainless steel. Keep in mind that the outlet valve temperature must be
a minimum of 100°F hotter than the melted material. This is necessary to
prevent “freezing” of the material during evacuation because of the
eutectic nature of these compounds. Usually cartridge type heaters
perform the best.
D) AGITATOR: The purpose of agitating the material being heated is to
distribute heat more evenly , to maintain inert materials in suspension and
to reduce melt down time. Agitators are usually motor driven by right
angle reduction gear motors of the fully enclosed type. Agitator blades
are a simple 2 blade gate like which nearly scrape the sides of the tank
wall and with approximately a ½” clearance above the bottom.
CAUTION: R.P.M. IS TO BE NO FASTER THAN 20-30.
International, Ltd.
Phone: (847) 689-0233 Fax: (847) 689-0238
SUGGESTED IN-HOUSE PROCEDURES AND GUIDE LINES
1.0 EQUIPMENT
A) MAJOR EQUIPMENT
1) Industrial size melter
2) TI System #4150 Casting Compound
3) Tooling or Molds
B) SHOP SUPPLIED SAFETY EQUIPMENT
1) Impact Resistant Face Shields
2) Heavy Duty Heat Resistant Gloves
3) Lightweight Cotton Gloves.
C) PERSONAL SAFETY CLOTHING
1)
2)
3)
4)
Steel Toed, High Top, Pull On Boots
Long Sleeved Shirts or Sleeves
Long Pants (Not tucked into Boots)
No Synthetic Clothing (Nylon, Rayon, Polyester, Etc.)
MATERIAL SAFETY DATA SHEET
REVISED 9-11-1996
SECTION I
MANUFACTURER'S NAME
TI INTERNATIONAL, LTD.(TM) (FORMERLY TEMPLEMAN INDUSTRIES, INC.)
ADDRESS
2260 COMMONWEALTH AVE.
EMERGENCY TELEPHONE NUMBER
(847) 689-0233
NORTH CHICAGO, IL. 60064
CHEMICAL NAME AND SYNONYMS
TRADE NAME AND SYNONYMS
TI HOT MELT CASTING COMPOUND
CHEMICAL FAMILY
POTASSIUM NITRATE, SODIUM NITRATE-NITRITE MIXTURES
FORMULA
SIMULAR TO HEAT TREAT SALTS
SECTION II -- HAZARDOUS INGREDIENTS
PAINTS, PRESERVATIVES & SOLVENTS
PIGMENTS
CATALYST
VEHICLE
SOLVENTS
ADDITIVES
OTHERS
%
TLV UNITS
ALLOYS AND METALLIC COATINGS
N/A
BASE METAL
N/A
ALLOYS
N/A
METALLIC COATINGS
N/A
FILLER METAL + COATING OR CORE FLUX
N/A
OTHERS - NITRATE-NITRITE MIXTURES
N/A
HAZARDOUS MIXTURES OF OTHER LIQUIDS, SOLIDS OR GASES
%
TLV UNITS
N/A
N/A
N/A
N/A
70
DO MIX WITH ACIDS
DO NOT IMMERSE OR CONTACT MAGNESIUM
SECTION III -- PHYSICAL DATA
BOILING POINT (F) - DECOMP. TEMP. APPROX
VAPOR PRESSURE (mm Hg.)
VAPOR DENSITY (AIR=1)
SOLUBILITY IN WATER 13.3/100cc @ 0 C
900 F
N/A
N/A
EXCELLENT
SPECIFIC GRAVITY (H20=1)
PERCENT, VOLATILE BY VOLUME (%0
EVAPORATION RATE __________=1
APPEARANCE AND ODOR:
POWDER-LIQUID-SOLID
2.1
LESS THAN 1%
N/A
SECTION IV -- FIRE AND EXPLOSION HAZARD DATA
FLASH POINT (Method used)
N/A
FLAMMABLE LIMITS
EXTINQUISHING MEDIA: Flood with water in early stages. Material may fuse or melt in large fires and water may result in scattring molten material.
SPECIAL FIRE FIGHTING PROCEDURES: Use NIOSH/MSHA approved self-contained breathing apparatus where this material is involved in a fire.
UNUSUAL FIRE AND EXPLOSION HAZARDS: Does not burn, but is an oxidizer. It can increase the intensity of existing fires.
N/A
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE:
NONE ESTABLISHED
EFFECTS OF OVEREXPOSURE: May cause eye, skin and mucous membrane irritation - Dizziness, Vomiting, Headache, Mental Impairment, Cyanosic.
EMERGENCY AND FIRST AID PROCEDURES: Skin: Flush thoroughly with water. Eyes: Flush with water for 15 minutes. Call physician.
Inhalation: Remove victim to fresh air. Call physician. Ingestion: Drink water, induce vomiting. Call physician.
SECTION VI - REACTIVITY DATA
STABILITY
CONDITIONS TO AVOID: Addition of any acid and avoid immersing magnesium into molten material.
UNSTABLE -- N/A
STABLE -- XXX
INCOMPATABILITY: (Materials to avoid)
N/A
HAZARDOUS DECOMPOSITION PRODUCTS: Oxides of nitrogen when reacted with acid.
HAZARDOUS POLYMERIZATION: Will not occur.
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED: Remove all sources of ignitation. Wear NIOSH/MSHA approved dust respirator.
Wear goggles, coveralls, impervious gloves and boots. Do not return material to original container. Do not contaminate streams or water supplies.
WASTE DISPOSAL METHOD: In event of spill, segregate contaminated material. Dispose of contaminated product and material used for cleaning spills in a manner
approved. Consult appropriate Federal, State, and local regulatory agencies to assure proper disposal procedures. After wash-out, filter water and dispose of sludge as per n
SECTION VIII -- SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (Specify type): NIOSH/MSHA approved duct respirator
VENTILATION: LOCAL EXHAUST: Use with localized ventilation, nothing special.
MECHANICAL (General): As dictated by airborne concentration, nothing else special.
PROTECTIVE GLOVES: Impervious
EYE PROTECTION: Chemical goggles
OTHER PROTECTIVE EQUIPMENT: Coveralls and impervious boots.
SECTION IX -- SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING: Do not get in eyes, on skin, or on clothing. Do not take internally. Avoid breathing dust.
Use only with adequate ventilation. Protect against physcial damage.
OTHER PRECAUTIONS: Store in cool dry place. Separate from combustables, organic, or other readily oxidizable materials. Immediately remove and dispose
of any spilled or contaminated material.
Page 1
TI International, Ltd.(TM)
2260 Commonwealth Ave. *
(847) 689-0233 * Fax: (847) 689-0238 * E-Mail: [email protected]
WASHAWAY CASTING COMPOUNDS
Typical Physical Properties
Product Number
Form
TI2900
Powder
Heat Resistance
Melting & Pouring
Temperature
TI3800
Powder
TI4150
Powder
TI4750
Powder
290F
380F
415F
475F
315-415 F
410-500 F
440-540 F
505-600F
Coefficient of Linear
Expansion (IN/IN F)
2.8 x 10
2.6 x 10
2.6 x 10
2.4 x 10
Elevated Temp.
Comp. Strength
2,875psi
(@) 290F
2,950psi
(@)380 F
2,900psi
(@)415 F
1,580psi
(@)475F
Comp. Strength - 78F
17,500psi
18,250psi
18,500psi
19,000psi
Softening Point
300-315 F
390-395 F
425-440 F
485-490F
Mold Temperature
150-210 F
150-210 F
150-210 F
150-210F
-5
-5
-5
COMMON PROPERTIES OF ALL COMPOUNDS
Water solubility - Rate @ 135F
3 - 5 Min/Lb.
Density (Solid Cast)
142.5-143.5 Lbs/Cu. Ft.
Specific Volume ( Solid Cast)
14.2-14.3 Cu. In/Lb.
Specific Heat
.32 to .71 BTU/Lb.
Latent Heat Of Fusion
34.9 BTU/Lb. (Approximately)
Heat Conductivity
Same As Water
Thermal Shock and Impact Resistance
Equal to Ceramic
Decomposition Temperature
900 F
Tooling Shrinkage Allowage
.008 in/in
Modulus of Elasticity
-5
3.1 - 3.6 x 11
The TI System is the basis for all your complex composite needs!!
-5
International, Ltd. ™
P.O. Box 670
Phone:(847)689-0233 Fax:(847)689-0238 E-Mail:[email protected]
SUGGESTED MANDREL WASH OUT PROCEDURES
Steam is the best way to wash out the mandrels. A steam cleaner with a hose
wand is the most economical way.
1) Position hose around periphery between mandrel and duct until mandrel
dissolves enough to slide mandrel out if shape allows.
2) A wash-out tank should be made for this purpose. Once the compound is
washed out, the sediment will settle to the bottom of the tank. This sediment
can be scooped out and placed in the garbage as it is not toxic. The water
can be filtered and released into the normal sewer system.
3) Once water reaches the compound or mandrel, as the compound is
hydroscopic, the compound is no good and must be destroyed.
International, Ltd.
Phone: (847) 689-0233 Fax: (847) 689-0238
T.I. SYSTEM # 2900
SUGGESTED USE PROCEDURES
1)
MELTING POT TEMPERATURE SETTING AND AGITATOR R.P.M.
Pot thermostat should be set and held constant at 350°F +- 5°F.
Discharge valve should be set at least 100°F hotter (450°F +- 5°F) and
should be left on at all times to avoid it freezing up.
Agitator should travel at approximately 20-25 R.P.M
The agitator should always be in operation except when charging pot with
material and then when material is melted, started as quickly as possible.
MELTER MAINTENANCE
a) Melter should be checked frequently against burned out heater strips,
as well as proper thermostat operation.
b) Valve heaters and thermostats should be checked for proper
thermostat operation.
c) Melter should be cleaned at regular intervals (six months to one year)
to eliminate contaminate buildup on the screen and in the sump.
3)
CHARGING MELTER WITH TI SYSTEM COMPOUNDS
Remelt material is generally not recommended, however, a minimum of
50% new powder must be added to any remelt blend. If a high humidity
condition is present, remelt is definitely not recommended. Conditioned
use of only remelt material will always result in an overload of
contaminates, causing increased melter maintenance, lowered physicals
on finished mandrels, and general dissatisfaction of pour consistency and
texture.
CAUTION: ALWAYS WEAR HEAVY HEAT RESISTANT GLOVES,
FACE MASK AND EYE PROTECTION, ALONG WITH ARM SHIELDS,
HEAT RESISTANT APRON, FOOT AND LEG SHIELDS.
MOLTEN MATERIAL CAN CAUSE SEVERE BURNS!!!!
4)
CASTING PROCEDURE
A) Stabilize tool or mold at “Preheat “ temperature. This may be done in
oven, or using heat lamps or gun. A simple method is to fill tool with
casting material and leave for a period of time and then remove. This
will usually provide sufficient heat to eliminate pour lines and chill
imperfections.
B) Casting material from melter discharge valve directly into mold is not
preferred, as air entrapment is almost always present. Rather, use of
a steel pail or other suitable container to transfer material from melter
into a pail then stirring gently to remove air bubbles that may be
present prior to casting into mold.
C)
SOLID CORES:
When casting T.I. System compounds in mold, always try to “slide”
material down the side of the mold. This means the mold must be tilted at
the start of the pour and then gradually moved back to an upright position
as the mold fills. If the material is poured directly into an upright mold, the
casting material will splash when it hits bottom and cause serious
imperfections. Pouring technique is only accomplished by practice and by
following these simple guide lines. After casting material has solidified, do
no wait too long to demold, especially if the part has complicated
geometry, as thermal contraction may cause difficulty
in removal, as well as possible cracking. Usually 5-15 minutes is
sufficient. Large parts will require an additional 5-10 minutes. In any
case, demold time must be monitored for each different part.
D)
HOLLOW CORES:
Producing hollow cores is easily accomplished. First the timing will be
different with a metal tool than with an epoxy laminate one. Starting with
the epoxy tool, fill the mold full the same way as outlined for solid cores.
Make sure that the mold has sufficient preheat before casting.
When mold is full, wait 60 seconds on an average size tool, and about 3-5
minutes on a larger tool, then pour material out of mold back into melter or
pail and wait 5-10 minutes, leaving core in mold. This will usually produce
about a .250” wall thickness. A good rule of thumb to remember is a .250”
wall thickness every 30 seconds. If a greater wall thickness is desired,
repeat the same procedure for an extra .250” thickness required. Timing
is very important because in most every case, leaving the mold full of
molten material too long will result in uneven core thickness. Now, using
aluminum tooling, the tool should definitely be preheated to eliminate pour
lines. With either type of tooling, the material should not be poured more
than 575°F, otherwise, the dwell time will be too long to solidify and in
addition, cause an uneven wall thickness.
Ideally, a log should be kept on each tool as proper dwell times are
achieved, keeping in mind that constant pouring temperatures are very
important and must be maintained.
E)
FINISHED MANDRELS:
Completed mandrels may be placed in poly-bags of any mil thickness
(preferably .006) for storage. The need for oven storage is not required.
Room temperature storage is preferred, and when ready for lay-up, may
be heated to facilitate faster lay-up with prepreg materials. Barrier
coatings are recommended and should be applied to bare mandrels prior
to lay-up.
We recommend Miller Stevenson (MS143DF) as it acts as a barrier coat
and a release agent combined.
International, Ltd.
Phone: (847) 689-0233 Fax: (847) 689-0238
T.I. SYSTEM # 3800
1)
MELTER MAINTENANCE
3)
CHARGING MELTER WITH T.I. SYSTEM COMPOUNDS
texture.
4)
CASTING PROCEDURE
imperfections.
C)
SOLID CORES:
D)
HOLLOW CORES:
E)
FINISHED MANDRELS:
to lay-up.
International, Ltd.
Phone: (847) 689-0233 Fax: (847) 689-0238
T.I. SYSTEM # 4150
1)
MELTER MAINTENANCE
3)
CHARGING MELTER WITH T.I. SYSTEM COMPOUNDS
texture.
4)
CASTING PROCEDURE
imperfections.
C)
SOLID CORES:
D)
HOLLOW CORES:
E)
FINISHED MANDRELS:
to lay-up.
June 17, 2005
REPORT OF:
Compression Testing
REPORT TO:
TI International, Ltd.
North Chicago, IL 60064
DATE RECEIVED:
June 16, 2005
IDENTIFICATION:
3 ea. Mandrels (made with TI #4150 Material) identified as:
A) Large
B) Medium
C) Small
PROCEDURES:
Compression testing was performed on Sample C using a Satec
Model 120HVL, S/N: 1263, with a calibration due date of June 16, 2006. Rate of
loading was 0.020 in/min using double spherical bearings.
RESULTS: Compression Test –
Sample ID
C
Modulus of Elasticity, psi
407,000
These results are based on the tests performed and are subject to change upon the
receipt of new or additional information.
Respectfully submitted,
Douglas A. Stolk
President
DISTRIBUTION OF REPORT:
(1) Ms. Judith Krotz
Purchase Order No. 2005-78
Lab No. 20152
Page 1 of 1

mandrel fabrication - TI International, Ltd.

Transcription

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