HUB Hamatetsu XD.

New Product Trial ReportForm No



Revision No Revision No Revision No

Issued Date Issued Date Issued Date

Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat :

Part No. : FCD 500 Part No. : FCD 500 Part No. : FCD 500

Trial Date Quantity : 5 Quantity : 48 Quantity :

Casting Date 29W Day Shift Mold 2X5 Day Shift 2 ladle Mold 2XA Day Shift 2 Ladle

Purpose Kirim Sample C/M core Fall at assy to mold Kirim Sample

Casting Condition

* New Pattern * Modify Core, using sealtape

Marking core side

C/M core fall

* Pattern : rough surface

C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P

3.85 3.17 0.316 0.011 0.027 0.026 0.02 0.038 3.88 2.9 0.38 0.01 0.021 0.026 0.024 0.043 3.73 3.11 0.31 0.01 0.027 0.031 0.019

PouringTemperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time

1384 sec 1410, 1407 sec 1405, 1409 sec

Result Result Result

Core

* Core : old brwon, grinding core to easy to core mask * Core old brown, assy sealtape

Old brown

Core Setting

* Core mask : core at assy core mask, dragging * not fall

* Mold : core at molding can't center, fall OK, not fall

Molding OK OK OK

Tolerance on progress

Hardness Nodularity Pearlite CarbideResult


Hardness Nodularity Pearlite Carbide

167 - 250 75% min actual - 167 - 250 75% min actual - 167 - 250 75% min actual -

165 - 193 90% 20 - 27% - OK 163 - 192 90% 35% - 167 - 199 90% 35% -

Visual Reject

% NG 85/182 : 46% % NG 61/176

aka 62 oshigomi 5 aka 50 KTC 2

gomi 1 KTC 17 gomi 9

Others

Chemical Composition

Item Check

Internal Defect

Material Structure

Trial DateCasting Date

Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure

46

Mold

Mg

0.036

Pouring Time

sec

Result

Result

OK


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure








Quantity : 21 Quantity : Quantity :

2XR Day Shift 1 ladle Mold 2ZB Day Shift 1 ladle Mold 2ZC Day Shift 1 ladle

* C/M Aka

* C/M Porosity Kirim Sample kirim sample

* C/M Aka, modify akatrap refers to HUB HAMATETSU regular

* C/M Porosity, additional chiller at core


3.8 3.01 0.28 0.011 0.029 0.02 0.019 0.037 3.69 3.16 0.3 0.015 0.023 0.03 0.018 0.041 3.78 2.93 0.23 0.01 0.023 0.027 0.018

Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time

1406 sec 1409 sec 1414 9.0 sec

Result Result Result Core keropos, area chiller core coating "SPARE OX" cavity 2, 4 chiller

core chiller for all cavity

OK, tidak jatuh OK ok

OK OK ok

add 2nd innoculant




167 - 229 75% min actual - 167 - 229 75% min actual - 167 - 229 75% min actual -

183 - 187 80% 35% - OK 183 - 187 90% 35% - OK 183 - 187 90% 35% -

% NG 3/73

gomi 3

Reaction Time 71 sec

add plate 0.5 mm at base plate

1 Pakai STD HAMATETSU,additional 2nd innoculant2

Core Coating "SPARE OX"cavity 2, 43

Release Riser at SqueezeC/M Porous

1

Spherodizer ELMAG 4911 : 6.5 KgInnoculant Ultraseed : 2 Kg2nd Innoculant Barinoc : 10gr, * 2mold awal * 1 mold akhir

2

2 mold not use core (full)Porous Check3


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure

21

Mold

Mg

0.043

Pouring Time

9.0 sec

Result

Result

OK

Spherodizer ELMAG 4911 : 6.5 KgInnoculant Ultraseed : 2 Kg2nd Innoculant Barinoc : 10gr, * 2mold awal * 1 mold akhir


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure









2ZD Day Shift 3.5 ladle Mold 2ZG Night Shift Process Mold 313 Day Shift 1 Ladle

Kirim Sample Kirim sample Kirim Sample


3.82 2.93 0.29 0.011 0.022 0.029 0.019 0.043 3.81 3 0.25 0.011 0.02 0.029 0.018 0.04 3.86 2.96 0.25 0.01 0.018 0.027 0.017


1412, 1409, 1410, 1405 sec 1404, 1419, 1427, 1405 sec 1410 sec

Result Result \ chiller Pakai Chiller, tanpa coating core pakai chiller

ok masih sering nempel ke core mask, pin harus dikikir

Masih ada yg nempel di core mask

ok OK

ok




167 - 229 75% min actual - 167 - 229 HB 75% min actual - 167 - 229 HB 75% min actual -

179 - 187 90% 40% - OK 183 - 187 90% 35% - OK 183 - 187 80% 35% -

% NG 13/73

aka 11

gomi 2

Riser cav 1, 3 assy1 Spherodizer ELMAG 4911 : 6.5 KgInnoculant Ultraseed : 2 Kg2nd Innoculant Barinoc : 10gr

2 Pakai STD HAMATETSU,additional 2nd innoculant20 gr @mold

reduce akatrap4mm to 3mm

Cav 4

Cav 2


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure

22

Mold

Mg

0.038

Pouring Time

sec

\

Result

OK


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure









314 Night Shift 8 Ladle Mold Day Shift Mold Day Shift

Kirim Sample


3.73 3.16 0.29 0.011 0.018 0.027 0.02 0.047


1400 - 1420 sec sec sec

Result Result Result core pakai chiller

masih sering nempel ke core mask, pin harus dikikir

OK




167 - 229 HB 75% min actual -

183 - 187 85% 35% - OK

% NG 134/530

aka 61 KTC 1

gomi 34 Over G/D 1

reduce akatrap4mm to 3mm

cav 2

cav 1


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure

Mold

Mg

Pouring Time

sec

Result

Result


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure








Quantity : Quantity : Quantity :

Day Shift Mold Day Shift Mold Day Shift



sec sec sec

Result Result Result





Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure






Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD

Part No. : FCD 500 Part No. : FCD 500 Part No. :


Mold Day Shift Mold Day Shift Mold Day Shift

Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn

Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir

sec sec sec

Result Result Result Result

ResultHardness Nodularity Pearlite Carbide

ResultHardness Nodularity Pearlite Carbide

ResultHardness Nodularity Pearlite


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure






Mat : Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD

FCD 500 Part No. : FCD 500 Part No. : FCD 500 Part No. :



P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu

Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir

sec sec sec


CarbideResult



Hardness Nodularity Pearlite


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure



New Product Trial ReportRevision No Revision No Revision No




Quantity : Quantity :


Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S

Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir

sec sec sec


Pearlite CarbideResult



Hardness Nodularity


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure

Form No








Mold Day Shift Mold Day Shift Mold Day

Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn

Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal

sec sec sec


Pearlite CarbideResult



Hardness Nodularity


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure






HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat : Part Name:



Shift Mold Day Shift Mold Day Shift Mold

S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg C Si

Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time Temperature Awal

sec sec sec


Nodularity Pearlite CarbideResult



Hardness


Purpose

Casting Condition

Pouring

Core

Core Setting

Molding

Tolerance

Visual Reject

Others


Item Check

Internal Defect

Material Structure



Revision No Revision No

Issued Date Issued Date

HUB Hamatetsu XD Mat : Part Name: HUB Hamatetsu XD Mat :

FCD 500 Part No. : FCD 500

Quantity : Quantity :

Day Shift Mold Day Shift Mold

Mn S Cu Sn P Mg C Si Mn S Cu Sn P Mg

Temperature Awal Temperature Akhir Pouring Time Temperature Awal Temperature Akhir Pouring Time

sec sec

Result Result

Nodularity Pearlite CarbideResult


IN HOUSE REJECTION GRAPH : Casting MATERIAL FCD 500

PROJECT

Part Number Part Name Hub HAMATETSU XD CUSTOMER Hamatetsu

Date Code 2X5 2XA 2XR 2XY 2ZB 2ZC 2ZD 2ZG 313 314

% Reject 46.7% 34.7% 4.1% 15.3% 14.3% 17.5% 15.3% 24.1% 17.8% 18.3% #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

Inspection 182 176 73 72 49 57 189 158 73 530

Reject 85 61 3 11 7 10 29 38 13 97 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Aka 62 50 5 4 3 29 11 61

Gomi 1 9 3 6 1 1 28 7 2 34

Kataochi 17 2 6 1

Oshigomi 5

Yuzakai

Yumawari

Kusare

Hike

Mikui

Kake

Core 2

Bending

Dakon 1

GH 2

Over G/D 1

Others

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

others

Over G/D

GH

Dakon

Bending

Core

Kake

Mikui

Hike

Kusare

Yumawari

Yuzakai

Oshigomi

Kataochi

Gomi

Aka

SPV

Total

#DIV/0! #DIV/0! 22.7%

1,559

0 0 354

225

92

26

5

0

0

0

0

0

0

2

0

1

2

1

0

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

others

Over G/D

GH

Dakon

Bending

Core

Kake

Mikui

Hike

Kusare

Yumawari

Yuzakai

Oshigomi

Kataochi

Gomi

Aka

HUB Hamatetsu XD.

Documents

Transcript of HUB Hamatetsu XD.