MeltLab - the leader in thermal analysis for foundries since 1990

MeltLab Thermal Analysis System Description

The MeltLab system is a flexible thermal analysis instrument made for the difficulties of foundry production analysis. Ruggedly constructed with MTBF of over 5 years, and easily maintained, MeltLab has been running since 1990 in competition with QuickLab, DataCast , AluDelta , ATAS and other TA instruments. It consists of a PC software program melded with a very rugged analog converter with optional scoreboards, horn and light stacks.

Metal Types

It has been adapted to include options for

base irons
grey final iron
ductile final iron
aluminum
brass
steel
high temperature alloys such as cobalt
sterling silver

In addition, MeltLab Systems is dedicated to uncovering all information available through thermal analysis. This includes chemistry, microstructure, shrinkage, inoculation level, chill, nodularity, zero curve, and percent of phase. Custom programming and custom systems are available.

Hardware Description

PC running XP or Win7 provided by the customer (saves money, and conforms to corporate standards for computers)
Licensed MeltLab Software (CPU license)
Analog to Digital Converter box using industrial grade 16 bit zero pass, dual wire, non-multiplexed technology for the thermal couple greatest accuracy
Measuring station with either Pechiney stand for light metals, or a sand cup type stand for irons, steels and high temperature alloys
Shielded thermal couple cable to insure best signal to noise ratio

Software Description

32 Bit software compiled in Delphi Pascal
Threaded background processes for data collection
Nine (9) readings per second per station
Up to 10 inputs per MeltLab (cups or lances) - faster computers help with higher numbers
Fast access to the last 100 curves for each station
Up to 2000 curves can be archived per year
Curves and graphics can be exported to Excel or Microsoft Word, or printed
Results can be exported in comma or tab delimited files for various data bases
Fully Network compatible
Uses derivatives and other methods to determine points unavailable in any other foundry system
Special smoothing algorithm (trade secret) and instrument design provides the best signal to noise ratio even down to the 6th derivative
Rivals DTA instruments in accuracy and sensitivity but can be operated by foundry melters or technicians
Hands free operation in normal production. Input is only required to change metal types
Supports type K, B, R and S thermal couples using NIST standard equations
Typical precision with K-type thermal couples is 1/20 degree C
Display configuration menus allow the user to set the colors, font size, items to be displayed and much more
Configuration menus allow setting up of reports, equations, ranges, limits and more
Calibration menus allow for calibrations, tracking calibrations, and correcting for wire bias

Analysis Methods available (note: the number of methods provided will change the price)

Base iron chemistry using a tellurium cup: in addition to metastable liquidus, eutectic and solidus

Calculated carbon +/- 1% of concentration (Similar to combustion Carbon)
Estimated silicon with typical 1 sigma of 0.03% for normal irons. High chrome irons and irons that vary greatly in manganese have some problems.
Carbon Equalivant from liquidus temperature
Oxidation state of iron (reduces effectiveness of inoculant and Mg treatment)
Degree of micro-segregation (effects ADI treatment and possibly some physical properties such as impact strength)

Final Ductile Iron Microstructure in addition to liquidus, eutectic, solidus, recalesence and freezing ranges:

Shrinkage and suck-in tendency
Nodularity and Nodule count estimates (Note: actual values depend on section size. The equations can be calibrated to reflect a standard section size.)
Carbide detection
Solidification mode: eutectic, hypo-eutectic, hyper-eutectic and carbon flotation recognized
Ratio of pre- and post-eutectic periods (S2/S1 Ratio)
Percent late graphite
Estimates pearlite/ferrite content (values depend on section size, calibrate to a standard section size. This measurement depends on a full sample cup.)
Reports micro-segregation that is important in post ADI treatments.

Final Grey Iron Microstructure in addition to liquidus, eutectic, solidus, and recalesence

Final Grey Iron Microstructure in addition to liquidus, eutectic, solidus, and recalesence
Estimated chill
Flake type evaluation
Shrink
Carbides
Micro-segregation

Aluminum 200 series, 300 series, unmodified Aluminum-Silicon

Grain Size estimate for hypo-eutectic aluminum-silicon alloys
Beta Crystal detection down to 0.05% of volume
Degrees of modification for aluminum-silicon alloys
Zero curve plotted
Silicon Content for un-inoculated aluminum can also be used as an estimate for inoculated, but will not be as accurate
Copper phase detection and estimated percent volume
Magnesium-silicide phase detection and estimated percent volume

Steel and High Temperature Alloys including liquidus eutectic and solidus

Percent carbide for carbidic alloys
Phase detection for minor structures

Copper-Alloys including liquidus eutectic and solidus

Measures phosphorus at 12-15% content to +/- 0.02% using vapor phase detection
Measures Zinc in brass alloys if hypo- or hyper-eutectic is specified
Measures Tin in bronze alloys if hypo- or hyper-eutectic is specified

Special requirements
Other applications can be easily accommodated for special alloys if phase diagram or chemical analysis data is available. One example was a sterling silver manufacturer who needed to make sure his product contained at least 85% silver (the specification for sterling) but no more. Measuring the liquidus of his metal, we were able with the phase diagram to calculate the silver content, and allow him to adjust his heats to minimize costs.

Costs
The typical MeltLab system costs between 12 and 15k installed. Large systems can reach 25k. MeltLab holds a special niche in the market, offering a wide variety of analysis methods, superb accuracy and precision, long instrument life and is priced at or below similar systems, although with far more capability than the competition.