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"


Pramod Gajare
Brembo Brake India Pvt Ltd Pune
Selection, Control Process Parameters
& Heat Treatment of GDC
02 March 2013
VI National Foundry Conclave Coimbatore
Prospering in New Abnormal
Pag. 2
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Pag. 2
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"

CUSTOMER EXPECTATIONS and ANSWERS

Achievable through
optimal management with
structured and disciplined
manner
This is possible through
strong Quality
Management System
(QMS)
Quality System is
developed, implemented
and its effectiveness is
improved by adopting
Process Approach


Pag. 3
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Pag. 3
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"

PROCESS APPROACH
Process : An activity or set of activities using resources, and managed in
order to enable the transformation of inputs into outputs, can be
considered as a process. (Many a time output from one process directly
forms the input to the next process)
Process Approach : Application of a system of processes within an
organization, together with the identification and interactions of these
processes, and their management to produce the desired outcome.
Process approach provides ongoing control over the linkages between
individual processes as well as over the combinations and interactions
The process approach emphasizes the importance of
Understanding and meeting requirements
The need to consider processes in terms of added value (Value addition)
Obtaining results of process performance and effectiveness, and
Continual improvement of processes based on objective measurement.
Pag. 4
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Pag. 4
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"

PROCESS APPROACH contd..

The evolution and analysis of each process has to be done in
disciplined manner; so that the interactions of the processes can be
identified without any ambiguity.
What is input
What output is expected
Who will execute the process (Competence / Skills / Training of the
person)
How to execute the process? ( Methods / Procedures / Work
Instructions )
With what the process is to be executed (Materials, tools,
equipment, consumables etc...)
With What Key criteria? ( Measurement / Test / Assessment )
The tool used for this evolution and analysis : Turtle Diagram

Pag. 5
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Pag. 5
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"

TURTLE DIAGRAM
PROCESS INPUT OUTPUT
With Who ?
(Competence /
skills / Training)
With What
Key Criteria?
(Measurement,
Assessment)
How?
(Methods /
Sequence /
Procedures)
With What?
(Materials /
Equipments)
Pag. 6
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Pag. 6
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"

TURTLE DIAGRAM

(Compare consecutive processes for output & input)
PROCESS INPUT OUTPUT
With Who ?
With What
Key Criteria?
How?
With What?
PROCESS INPUT OUTPUT
With Who ?
With What
Key Criteria?
How?
With What?
PROCESS # 1
PROCESS # 2
Pag. 7
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Pag. 7
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CHECK, INSPECT & CONTROL
Check :
to verify something
Inspect :
to look at something carefully in order to check that it is correct or good enough
Control :
the power to make decisions about something and decide what should happen ,
a law, agreement, or method that limits something
the process of checking to make certain that rules or standards are being applied,
to make people behave in the way that you want them to behave
to make a machine, system, vehicle, etc.. move or operate in the way that you
want it to
to keep something at the correct level
the ability to stop something from increasing or becoming dangerous,
to prevent something from increasing too much or too quickly
to prevent something harmful from spreading or becoming more dangerous

Pag. 8
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"

Pag. 8
"
S
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C
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f
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a
l
.

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b
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.
A
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w
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.
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,

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p
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s
"

UNDERSTANDING CUSTOMER REQUIREMENTS
Specified
Requirements
Not Stated but
necessary for
specified or intended
use
Statutory &
Regulatory
Requirements
Additional
requirements
considered necessary
by the organization
CUSTOMER
REQUIREMENTS
Pag. 9
"
S
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C
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"

Pag. 9
"
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C
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f
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.

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s
"

FEASIBILITY ANALYSIS
Detailed study & analysis of technical specifications and
test methods
Consider all aspects ( Monthly / yearly volumes, cost,
delivery mode etc...)
Gaps Identification : Comparison with what is
maintained / achieved for running product and what is
specified (expected) for the new product.
Actions for closing the Gaps : to make manufacturing of
new part (casting) feasible
Detailed feasibility Report always helps

Pag. 10
"
S
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f
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"

Pag. 10
"
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C
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.

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P
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.
,

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p
a
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s
"

SPECIAL CHARACTERISTICS
These are product characteristics or process parameters
which; if not complied with; may affect safety, conformity to
national/international regulatory standards, fitment,
function, performance, or subsequent processing of product.
Control on process parameters to ensure capability is often
missed out. Some examples of such parameters are
solutionising temperature, quenching delay time, quenching
water temperature , ageing temperature , etc...
Appropriate Statistical tools with correct measurement
system or suitable automation is expected for controlling the
manufacturing process parameters.

Pag. 11
"
S
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"

Pag. 11
"
S
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C
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f
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.

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P
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p
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s
"

TOOLS FOR PROCESS CONTROL
Optimum management of the manufacturing processes by
controlling all the special characteristics of process and the
product through following methodologies, tools, and
techniques.

Fool proofing /Mistake proofing
Automatic sequencing
Automatic detection and isolation
Control by variables
Control by attributes

This is applicable at all stages of manufacturing process; right
from receipt of ingots till the dispatch of the castings.

Pag. 12
"
S
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"

Pag. 12
"
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C
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f
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.

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.
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p
a
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t
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s
"

ALARMS, INTERLOCKS AND AUTOMATION
Alarm for non-operation
Alarm for premature operation
Alarm for malfunction
Alarms to remind about repetitive/ Scheduled activity
Interlock for Sequence
Interlock for subsequent operations.
Periodic check for proper functioning of the Alarms and interlocks is MUST.
Automation reduces human effort and fatigue substantially and removes any chance
of human error
Automation respects time, therefore, higher productivity is expected
Automation obeys logical sequencing, hence enables repetitive actions
Automation, due to its timer discipline, ensures consistency and therefore constant
quality!
Areas of Automation
Chemical Analysis of Melt
Temperature control of Melt , Die, Heat Treatment furnace
Metal Pouring
Fettling
Pag. 13
"
S
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"

Pag. 13
"
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P
.
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.
,

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p
a
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s
"

PROCESS DESIGN
Solely dependent on the technological competency of the
supplier.
The logical and systematic handling and monitoring of various
stages of design is important
Use of mathematical calculations always help to understand the
pros and cons of the concepts used.
All elements of the process must be addressed ( Time to reach
soaking temperature, Quenching delay time )

Consider all possible abuses, their effects and counter actions
(e.g. misuses, manipulations, mishandlings, misapplications,
mistreatments)
Make use of Gaps Identified during feasibility analysis & the
proposed actions for closing the gaps.

Pag. 14
"
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"

Pag. 14
"
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C
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f
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.

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A
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,

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I
.
P
.
R
.
,

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p
a
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t
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s
"

PROCESS FLOW, FMEA, CONTROL PLANS AND
WORK INSTRUCTIONS
Backbone of manufacturing process: extreme precaution has to be taken while
making and updating these documents.
Unambiguous definition of (a) Incoming source of variation, (b) special characteristics
of product and manufacturing process in the process flow.

FMEA : Identify ways in which a product / process can fail to meet critical customer
requirements and actions for avoiding the same. The past historical data about
Things gone wrong, things gone right (TGW-TGR) helps to make this task easy.

Control plan must be made available before performing the initial trials cycles. At
this stage the status of control plan is Pre-Launch control plan. The control plan
shall be finalized after the trial cycles are completed successfully.

Work instructions serve the expected purpose only when those are simple & easy to
understand. The pictures of accepted and not accepted working practices as well as
of the parts add value to them. The work instructions must be written in a language
which the operators can read and understand.

Pag. 15
"
S
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c
t
l
y

C
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f
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.

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.
A
.

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.
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.
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.
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p
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s
"

Pag. 15
"
S
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C
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f
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.

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.
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,

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w
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.
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.
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"

SIMULATION STUDY
This tool helps to great extent to find out the potential failures.
Sometimes corrections in the mould are either very costly or not possible,
which can be avoided by using simulation study.
Reduces the substantial work of doing the actual trials, checking the
samples, doing analysis and then doing corrections in the mould.
Few iterations of the simulation study and the changes in the design based
on the results of simulation , helps to have a good design output.
Simulation studies must be incorporated in the design program at
appropriate intervals.

Consider all aspects during giving inputs for simulation study. (e.g. Minimum
and Maximum limits for : metal temperature, important elements of the
alloy etc..)
Extract maximum possible outputs from simulation. (e.g. Mould filling
pattern, solidification pattern, fill time, trapped oxides, hot spots, air
pockets, areas of shrinkage, porosity, micro-porosity , mould temperature)

Pag. 16
"
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"

Pag. 16
"
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C
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f
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.

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.
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.
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p
a
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t
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s
"

TRIAL CYCLES (INITIAL TRIALS)
The trial cycles should be performed to understand following;
adequacy of the process and mould to meet the Quality and productivity
requirements of the part.
effectiveness of equipments used for manufacturing , inspection , testing
and material handling
effectiveness of Pokayoke (mistake proofing) provided
effectiveness of training of all involved personnel
effectiveness of controls for traceability
limits of Aesthetic appearance
inputs for revising the Process Flow, FMEA , control plan and work
instructions

Do not forget to document the results, actions identified, and actions
taken for each trial cycle.
Pag. 17
"
S
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"

Pag. 17
"
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f
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.

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.
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s
"

PEOPLE: IMPORTANT ASSET

Clearly documented Job description for each function in the organization
specifying responsibilities & authorities
Competency level (related to function handled) is always important
In GDC industry human elements are more involved for controlling various
parameters; hence this competency has an added value.
The team working on shop floor in various functions therefore must have
awareness of the relevance and importance of metallurgical aspects of
aluminum alloy apart from knowledge related to the foundry process.
Behavior of alloy at various temperature levels, cooling patterns, effects of
alloying elements, effects of contaminations , sensitivity to high
temperature etc.. are some of the aspects.
Knowledge of Statistical techniques ; appropriate to the function of the
person is essential.

Pag. 18
"
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"

Pag. 18
"
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f
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.

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.
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.
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s
"

TRACEABILITY
Traceability is the series of links that exists between a part and data
recorded previously during its development, manufacturing, and control
processes.
Enables all links necessary to identify causes of possible product variations
during a well-defined time frame.
Immediately provides the data necessary to analyze and resolve problems
and to isolate the defective products.
Enables appropriate, timely, and less costly action to be taken to resolve
problems arising at customer end or in the market.
Enables that the quantity, sorting or reworking of recalled products to be
limited
Enables identification of the responsibilities in a clear and unmistakable
manner
Must cover the entire development stages and manufacturing stages which
are related to the critical characteristics of the process, special
characteristics of the part, and any other characteristic specified by
customer.
Pag. 19
"
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"

Pag. 19
"
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"

ALLOY

Controlled specifications for some elements view of further processing. ( e.g. Fe,
Mg, Zn etc...).
Your own Standard for the Alloy ( Aluminum grade Primary / secondary,
Chemistry, Appearance , Heat No. Identification, Fracture Test , Test certificate, Lot
size etc...)
Quality agreement with Alloy Supplier
Test Facility to check the Chemical composition (Spectrometer with Master standard
samples)
Clear cut SOP (Standard Operating procedure ) for inspection and acceptance of the
Alloy.
Explicit Inspection Check Sheet for inspection of the Alloy received.
Alloy wise separate storage location for ingots ; to prevent mix up.
FIFO (First in , first Out) at all the stages.
Separate location for foundry returns from each type of Alloy
Traceability (Documented & Physical) during issue of the material

Pag. 20
"
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"

Pag. 20
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"

MELTING
Best Control : Separate melting furnace for each alloy.
In case above is not viable (Less volumes, use of many alloys); use of dedicated
crucibles with distinct identification on the crucibles.
Identification of dedicated melting furnaces with colour same as colour code of the
particular alloy.
Controls to keep the charge Dry and free from oil and grease
Protection of flux from moisture pick up
Operator friendly definition of charge ratio (e.g. 200 /220 Kg. ingot and 80 /100 Kg.
foundry returns)
Physical weighing of the ingots, foundry returns and flux
Definition of melting sequence . (e.g. charging of scrap, melting of scrap, flux
addition, charging of ingots, melting of ingots, flux addition, rabble, dross removal )
Definition of the Maximum metal temperature (e.g. 750 Deg Max), tapping Temp.
High temperature alarm to avoid Over heating of the alloy
Coating and preheating for melt handling tools.
Traceability : Date, Furnace number, shift, Operator, Melt No, weight of ingots ,
weight of foundry returns, weights of flux, time duration, Max. temp. & Temp at
tapping etc...

Pag. 21
"
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"

Pag. 21
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p
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"

METAL TRANSFER
Transfer ladles of appropriate capacity
Dedicated transfer ladles for each alloy
Identification of dedicated transfer ladles with colour same as colour code of the
particular alloy.
Distinct location for keeping ladles meant for different alloys
Definition of Preheating of ladles (e.g. Type of Burner/ Jig, heating time,
measurement/judgment criteria etc...)
Definition of crucible cleaning (e.g. Time interval, judgment criteria, type of flux
etc...)
Mechanism to ensure transfer to specific holding furnace when more than one alloys
are used . ( e.g. Line layout, route card etc...)
Filtering of molten metal at the time of pouring to holding furnace
Skilled operator : takes care of turbulence and thereby, oxide movement into melt
Traceability : Date, shift, Operator, Melting Furnace number, Holding furnace
number, Melt No, time of transfer, weight of metal transferred.
Pag. 22
"
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"

Pag. 22
"
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"

METAL TREATMENT
Treatment in holding furnace is the BEST CONTROL
Definition of temperature ,sequence, time and amount of the agents (e.g.
refinement, degassing, modification, )
Physical weighing of refiners (e.g. AlTiB) and modifiers (e.g. AlSr)
Definition of degassing parameters (Rotor speed, gas Flow, Pressure, Time etc...)
Defined criteria for setting degassing parameters with reference to the seasonal
changes in atmosphere ( e.g. Rainy season, winter, summer etc...)
Measurement of the Relative Humidity on daily basis is always helpful
Automation in degassing (e.g. rotary degassing with programmable settings)
Purity of the Nitrogen gas.(e.g. Ultra High Purity Nitrogen)
Checking of chemical composition after treatment for every melt
Testing of density / density index for every melt
Coating and preheating for melt handling tools.
Traceability : Date, Furnace number, shift, Operator, Melt No, weights refiners and
modifiers, time of addition of refiners, and modifiers, Degassing start time, degassing
end time, degassing temperature, gas flow (LPM), Flux used, Chemical composition,
Density/ density index before degassing , Density/ density index after degassing etc...






Pag. 23
"
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f
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"

Pag. 23
"
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"

DIE MAINTENANCE & DIE COAT APPLICATION

Check sheet for maintenance instructions together with time cycle (frequency)
Being a crucial activity, skilled & trained operator
Check the last casting of the previous run meticulously
Strip or clean coating properly (Use of Glass Bids Blasting Machine)
Open and clean each and every vent plug and gas venting tubes
ENSURE ALL THE VENTS AND TUBES WERE PLACED AT THEIR LOCATIONS
Repair/polish the profiles that showed drag marks/rubbing in the previous run
Preparation of the die coat as required. Use of measuring jars to ensure requisite
amount of water & die coat is used.
Use of a sieve (strainer) to ensure only fine particles of die coat to pass through.
Do not forget to close the lid of the can of supplier tightly. This ensures prevention
of dust particles mixing with the solution.
Check the functioning of the spray gun BEFORE transferring the freshly prepared die
coat into it
Stir the prepared coating solution well before transfer to the gun.
Do not forget to close the lid of the storage can. This ensures prevention of dust
particles mixing with the solution.

Pag. 24
"
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"

Pag. 24
"
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"

DIE MAINTENANCE & DIE COAT APPLICATION
contd
Pre-heating the die to required temperature. Use of profile burners to ensure that
there is no concentration of heat due to flame direction.
Do not forget to check the die temperature before spraying the die coat. (Infra-red
digital thermometer is very convenient to measure die temperature)
Spray the die as per desired thickness on the given slide.
CONDUCT DRY RUN TRIAL AFTER ASSEMBLY AND GET SATISFIED
When the Die coat mixture is to be used during the production, vigorous stirring
must precede transfer to gun. Thin particle size of the coating ensures superb
surface finish of the casting. Use of mechanical stirrer is Practically Best Solution
Traceability : Die history card indicating part number, die No, Operator who
performed maintenance, No of castings produced, observations on the last shot,
details of work carried out & parts replaced etc..


Pag. 25
"
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"

Pag. 25
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"

DIE CASTING

Control mechanism for updating the traceability code (when specified )
Interlock to avoid use of wrong programme in case of automatic die operation
Metal Temperature : Control through immersion type thermocouple & temperature
controller (e.g. Thyristor or PID controller )
Interlock for High/Low metal temperature to stop machine operation
Die pre-heating : Use of profile burners to ensure that there is no concentration of
heat due to flame direction.
Interlock for Minimum die temperature to stop machine operation.
Skilled operator : controlled & consistent pouring rate (e.g. 250 grams per second)
Provision of support point /pivot point on the die to facilitate easy pouring
Auto ladling is the BEST CONTROL
Control to protect sand cores from moisture pick up
Protection of flux from moisture pick up
Coating and preheating for melt handling tools.
Definition for maximum time for melt holding and repeating the degassing
Audio alarm for repeating the degassing after specified time is lapsed




Pag. 26
"
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"

Pag. 26
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"

DIE CASTING contd

Arrangement to avoid damages to the casting (e.g. Trolley with separators to keep
the shots)
Explicit method / control for physical separation and disposition of initial shots. (e.g.
Cage with lock & key arrangement and a pigeon hole to drop the rejected shots in
the cage)
Definition of inspection parameters, frequency & use of inspection check sheet.
Do not forget to define HOT INSPECTION for visual parameters which includes
inspection of feeders, risers etc..
Identification on the shots for respective Melt Number (E.g. Label, Route card etc.)
Definition of casting of the test bars
Traceability : Date, Furnace number, shift, Operator, Melt No, Die temperature,
Metal temperature, Production start time & end time for each & every melt, No of
initial shots scrapped, Degassing start time, degassing end time, Density/ density
index after second degassing,, No of castings produced, No of castings rejected &
reasons of rejection
Periodic Calibration of the thermocouples and the temperature controllers


Pag. 27
"
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"

Pag. 27
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"

GATE CUTTING AND FETTLING
Mostly neglected for controls in many industries
Ensure Line start approval with check sheet to confirm condition & availability of
the respective tools at each station.
In-process inspection helps to reduce operator error as well as rework and
rejection.
Melt wise Movement of the shots with identification to ensure traceability
Human oriented activity ; hence possibility of errors. Use of gate cutting machines
and fixtures help to reduce the errors.
Explicit and distinct definition of activities to be done, tools to be used ,
methods/ sequence to be followed and acceptance limits
Visual Aids with Dos and Don'ts always help
Provision of separate bins/pallets for input and output at each station to avoid
mix-up, missing operation .
Low cost Automation helps to get consistency and productivity
Use of Robotics is an emerging trend
Timely and systematic maintenance of the dies and discipline during die casting
reduces the fettling work.
Traceability : Melt No, Operator, Qty rejected & reasons
Pag. 28
"
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"

Pag. 28
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"

HEAT TREATMENT

Suitable Furnace : Capacity (volume & weight of charge, temperature range),
capability (temperature range & uniformity).
Definition of complete Heat treatment cycle (Time and temperatures for
Solutionising , quenching and ageing with allowable tolerances)
Explicit and distinct definition of Reaction plan in case time and/or temperature
exceeds the specified limits
Temperature control mechanism to suit the tolerance on temperature (e.g. PID
controller)
Position & number of control thermocouples (depends on furnace type & capacity)
Temperature recording graphs for each thermocouple
High temperature alarm and interlock
Interlock/alarm for working of air circulating fan
Control on time temperature cycle through PLC or micro processer.
Definition & control of charge (e.g. Loading pattern, Qty of castings per layer, No. of
layers, No. of Test bars & their position etc..)


Pag. 29
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Pag. 29
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HEAT TREATMENT contd

Definition and control of tank water level in quenching tank
Definition and control for decanting used water & filling fresh water
Definition of quenching water temperature & control mechanism (e.g. 40 Deg. Max,
temperature indicator , addition of fresh water etc..)
Controls for effective quenching (e.g. quenching delay time, water agitation,
minimum time for charge in the water etc..)
Verification and certification of the graph for correctness & completeness of the
cycle for each batch
Inspection & Checks : Hardness, Microstructure , physical properties
Traceability : Date, Furnace number, shift, Operator, HT Batch No. No. of castings
loaded and their Melt Nos, Loading time, Soaking start time, Soaking end time,
Soaking temperatures at every hour, Quenching delay time, Water temperature
before quenching, Hardness Microstructure, physical properties etc..
Periodic Calibration of the thermocouples and the temperature controllers
Periodic validation for the temperature uniformity inside the furnace



Pag. 30
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Pag. 30
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FINAL INSPECTION, PACKING AND DISPATCH
Distinct & explicit definition of inspection check sheets confirming to agreement
with customer.
Mechanism with check sheet to ensure that all the testing / inspection related to
previous operations is completed and results are in acceptable limits (e.g. Physical
tests, micrographic inspection etc..)
Quantitative and qualitative results recording for acceptance , rejection and rework
Definition of packing standard with pictures for primary and secondary packing,
sequence , Qty, Dos and Don'ts, labeling, etc..
Consider use of Silica Gel or similar means for protection of castings from getting
affected by humidity.
Mechanism to monitor preservation and traceability of the left out pieces after the
packing.
Mechanism for periodical control to check the preservation condition of the
available stock
Interlock at Invoice preparation stage for availability of respective documents and
confirmation of correct packing is the Best Control.
Traceability : Part Name & No. Inspector name, Packing operator name, Melt No &
Qty, No of boxes, Qty per box, Customer Name, Invoice No & date etc
Pag. 31
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Pag. 31
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