High Temperature Erosion of Pig Casting Machine Mould

The purpose of this analysis was to find the reason for High temperature Erosion of Pig Casting machine mould in a Ferro alloy industry and to extend its life. The case study was done in Sarda Metals and Alloys Limited, Visakhapatnam, Andhrapradesh. The mould sample was initially tested by optical microscopy; its microstructure was analyzed to study the influence of microstructure to enhance erosion resistance. Hardness was taken by Rockwell Hardness testing machine and its effect was studied to increase erosion resistance. Elemental analysis was also done for new and rejected mould sample to study the effect of alloying elements in High temperature erosion resistance. Current operating condition was monitored and was compared with standard operating condition to remove some bottlenecks. Mould Temperature was measured at every point during operation and found that mould temperature was increased above 500ËšC at discharge point, which is one of the reasons for damage of the mould. New refractory coating was proposed in place of old lime coating for moulds to increase mould life, reduce fine generation and good cast quality. Design changes for moulds were suggested to increase the life of mould.