Morgan Molten Metal Systems GmbH Berkatal Germany Dr Dieter Heumannskämper Mirco Pavoni What is a crucible Crucibles Melting refining non ferrous metals such as aluminium ID: 935567
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Slide1
Coating on performance
Morgan
Molten
Metal
Systems GmbH
Berkatal
, Germany
Dr. Dieter
Heumannskämper
Mirco Pavoni
Slide2What is
a
crucible?
Crucibles Melting, refining non ferrous metals such as: aluminium, copper, zinc, precious metals.
Slide3What is
a
crucible?
Crucibles Melting, refining non ferrous metals such as: aluminium, copper, zinc, precious metals.
Important properties
Performant
Crucible
Slide4What is the purpose of coatings?
Coatings
Increase performance
of crucibles
Case studies show
- Increased
erosion
resistance
-
Less
dross
adhesion - Increased purity of melted metal - Increased crucible lifetime
Slide5Star Coating
Nano
Boron
Nitride CoatingCrucible with STAR coating
Bonding : Nano ZrO
2 or Phosphate
Main ingredient: Boron Nitride particles within the matrix
Application temperature: Up to 1000°C
Crucible
with
STAR coating
Slide6Star Coating
Nano
Boron
Nitride CoatingTypical
application
- High purity aluminium metal production (99.999% purity)
- High purity aluminium alloy melting
- Precious metal melting
Slide7Star Coating
Nano
Boron
Nitride CoatingKey benefits: STAR coating
- Low dross adhesion
- Low impurities leak into molten metal
- Low porosity, high density coat
- Protection against aggressive compounds
STAR
coating
as viewed under the microscope
Slide8Star Coating
Nano
Boron
Nitride CoatingCase study: Laboratory trial with aluminium (99.999%)
- Holding melted AL5N at 710°C for 48 hours
- Tested for boron and silicon impurities before and after holding
Slide9Star Coating
Nano
Boron
Nitride CoatingCase study results: Laboratory trial with aluminium (99.999%)
Very
low adhesion
of
the
metal
Easily
removable
even when solidified
1mm
0.4mm
Microscope pictures
b
efore and after holding
Al5N in crucible with STAR coating
Slide10Star Coating
Nano
Boron
Nitride CoatingCase study: Induction furnace with aluminium (99.999%)
Cylindrical
crucible
with STAR coating
Induction
furnace
300 Hz, 300 kW
- Melting and casting Al5N
Cylindrical crucible ZYLS 1300 x 760
with
STAR coating
Slide11Star Coating
Nano
Boron
Nitride CoatingCase study results: Induction furnace with aluminium (99.999%)
-
Coating is still
present on the
crucible
surface
High
purity
sputtering targets with melt right out of the crucibleVery low dross adhesion, easy cleaning
Slide12SiCH Coating
Nanoscaled
Sic Coating
Crucible with SiCH coating
Bonding: Carbon +
SiC
Main ingredient: Micro and
nano
sized
SiC
particles
Colour: Grey
Application temperature: Up to 1600°C
Crucible with
SiCH coating
Slide13SiCH Coating
Nanoscaled
Sic Coating
Typical application
Copper and copper alloys melting, with & without high fluxes usage
Precious metal refining
Zinc distillation
Slide14SiCH Coating
Nanoscaled
Sic Coating
Key benefits:
SiCH coating
Exceptional erosion resistance
High non-wettability leading to low dross adhesion
Low porosity, high density coat due to
nano
-scaled ingredients
SiCH
coating under the microscope
Slide15SiCH Coating
Nanoscaled
Sic Coating
Case study:
Cylindrical crucible
with SiCH
coating
SnPbZn
copper
meltingIsostastically pressed cylindrical crucible with SiCH coatingLow frequency (180Hz) metal movement erosionCrucible failure due to erosion (thin walls)
Cylindrical crucible
ZYLS 815 x
610
with
SiCH
coating
Slide16SiCH Coating
Nanoscaled
Sic Coating
Case study
results: SnPbZn copper
melting
Output increase by 20% over the crucible lifetime
Lower erosion rate
Increased crucible lifetime
Melting of
SnPbZn
copper alloy
Slide17SiCH Coating
Nanoscaled
Sic Coating
Case study
results: Stabil E323 VO with SiCH
coating Gold Refining
Increased
amount
of
refined
gold by 20 – 25%Decreased erosionIncreased resitance to
borax flux
penetration
Slide18SiCH Coating
Nanoscaled
Sic Coating
Case study:
Stabil TPC 587 HT with SiCH coating Bronze
Gas
fired
furnace
Usual
lifetime
: 60
chargesFailing due to erosion (copper alloy, fluxes)
Case study
results:Increased
performance
by
83%
with
coating
(111
charges
)
Slide19Si3N4 Coating
Silicon
Nitride Coating
Crucible with Si3N4 coating
Main ingredient: Nano silicon
nitride (Si3N4)
particles
Colour: White
Application temperature: Up to 1500°C
Crucible with Si3N4 coating
Slide20Si3N4 Coating
Silicon
Nitride Coating
Typical application
Copper melting
Zinc distillation
Slide21Si3N4 Coating
Silicon
Nitride Coating
Key benefits: Si3N4 coating
Exceptional erosion resistance
High non-wettability leading to low dross adhesion
Low porosity, high density coat due to
nano
-scaled ingredients
Si3N4 Coating under Microscope
Slide22Si3N4 Coating
Silicon
Nitride Coating
Case study: FUS 750 Z2 with Si3N4 coating
Zinc distillation
Isostatically pressed crucibleHigh amount of iron impurities
Increased dross adhesion, difficult to remove
Crucible volume decreased by 30 – 40%
FUS 750
Z2
Zinc
distillation with a thick layer of dross
Slide23Conclusion
Coatings
improve
specific and
add
new
performance
characteristics