Monitoring the temperature of the pouring melt in foundries is a challenging task due to the varying measuring conditions and characteristics of the metal.
In most foundries, the temperature of the metal melt is usually measured by thermocouple immersion probes. These immersion measurements can only be made in the crucibles or the transfer ladles where the melt is stationary, but not in the pouring stream where insertion of a probe would disturb the flow into the cast. However, the direct temperature of the pouring stream is critical to the quality of the final casting. By continuous monitoring of the pouring steam temperature and pour quality for each cast, the foundry is able to better control of the casting process.
An undisturbed temperature measurement of the pouring stream can only be obtained by non-contact infrared pyrometers. Where castings are made of different alloys, conventional pyrometers and ratio pyrometers often cannot be used for the measurement of the pouring stream due to considerable differences in the measuring conditions and the characteristics of the metal.
LumaSense offers specialized solutions to address these issues and to provide robust temperature measurement by using both a portable as well as a fixed measurement system.
The IMPAC IS 8-GS pro represents a dedicated, portable solution for non-contact measurement of liquid metals in the temperature range between 1000 and 2000°C. Our model ISR 12-LO/GS incorporates a fixed system solution for measuring the exact casting temperature of each pouring process.
This rugged, industrial pyrometer system was designed to overcome many of the issues that complicate the temperature measurement of the pouring steam such as changes in stream location and width, start and stop time variation, and slag interference.
An accurate temperature of each pour is displayed online and corrective action can be taken immediately if defined limits are exceeded. In this way, the narrow process window for quality castings can be maintained. Especially for accurate measurement of pouring streams the IMPAC ISR 12-LO/GS provides special features and functionalities, based on these applications:
By using armored fiber optics cables with high temperature precision optics lens head, this fixed Pyrometer can be used for non-contact measurement in difficult installation areas.
Its line spot shape optical beam minimizes effects of pour stream location variation. An integrated laser targeting function serves for ease of alignment.
Via a short wavelength ratio detector the signal is maximized from low emissivity metals and systematic errors due to emissivity changes are minimized, as well as interference from dust and vapor. Moreover the Pyrometer provides an integrated lens contamination warning system.
The exact pouring stream temperature is determined via an advanced algorithm. This robust tuning procedure includes start and stop pour signals, pouring time calculation and is immune to random slag events, and pre/post pour drips.
By using LumaSense instrumentation for temperature measurement of pouring streams, process engineers can take advantage of following system benefits:
Accurate measurement data & automatic recording of the pouring temperature
Documentation of the temperature of each single pouring process
Replacement or reduction of immersion lance measurements with thermocouples
Minimum system maintenance required
Increased safety with reduced employee interactions