Post on 01-Apr-2015
CAST IRON SUPPORTS
OUTDOOR STREET LIGHTING
SUPPORTS OF CAST IRON TO OUTDOOR STREET LIGHTING1. Classification:
• As per application• As per materials
2. Manufacturing process:• Previous research.• Building Moulds.• Smelting pieces.• Mechanize• Finishing• Packing/Handling.
3. General Characteristics:• Differences between cast Iron/Aluminium
4. Quality control possible faults
5. Summary, comments & conclusions
SUPPORTS OF CAST IRON
APPLICATION
• Columns
• Brackets
MATERIALS
• Cast Iron.• Cast Aluminium• Others no ferrics
MANUFACTURING PROCESS OF CAST IRON LIGHT FITTING
Previous research.
Building Moulds
Smelting pieces
Moulding Positioning Closing boxes Fusion Rinding Fettled
MechanizeDrillWinchAdjustments
FinishingshotpeenedPutty / finishingPrimer coatingFinishing coated -
colourCamera de
polymerisation
Packing / handling.
• No norm no standardization / certified
• Research of R. to finite parts.
PREVIOUS RESEARCH
BUILDING MOULDS
SMELTING PIECES PROCESS
MODEL - MOULD - PIECE
Positive model
Negative Mould
positive part
Mold
Mold with inner part
MELTING / MELT DRAIN
RINDING
FETTLED
MACHINING
WINCH
DRILL
ADJUSTMENTS
• Energetic mechanical pickling – shotpeened.
• Primer coating - epoxy 2 components 50/60 μ
• application polyurethane 2 components 90 μ
• Polymerisation chamber
• Packing
FINISHING
SHOTPEENED
ENERGETIC MECHANICAL PICKLING
PUTTIED / FINISHING
PRIMER APPLICATION• Primer - epoxy 2 components 50/60 μ
• Application of polyurethane in 2 components 90 μ
POLYMERISATION CHAMBER
PACKING / HANDLING
GENERAL CHARACTERISTICS OF OUTDOOR STREET LIGHTING IN CAST IRON
• Reproduction of forms
• Great similarity of pieces
• Section & Strongest
• Texture
• Synonymous of quality
• Recyclable 100% without cost raw material
REPRODUCTION FORMS
PART
MODEL
GREAT SIMILARITY OF PIECES
SECTION & STRONGEST
BS 3000
TEXTURE
DETAIL OF
BS 3000
SYNONYMOUS OF QUALITY
MATARÓ, SPAIN PROJECT
SYNONYMOUS OF QUALITY
TARRAGONA, SPAIN PROJECT
SYNONYMOUS OF QUALITY
SEVERAL
PROJECTS
ALICANTE VALENCIA
RECYCLABLE 100% WITHOUT COSTRAW MATERIAL
PEAR
FURNACE LOADING
CHARACTERISTICS OF CAST IRON
• Type EN-GJL-200 As per norm: EN 1561
• Type EN-GJS-500-7As per norm: EN 1563
• Differents degrees R. of stretching.
• Good behavior to oxidation.
– Non reduction section.- Oxide = Protection
Grey cast iron (traditional)
Ductile cast iron (> R)
• Norm EN 1706
• Many alloys according to application.
• Great difference of €/Kg. Acording quality Danger
• In “normal” alloys, porous oxide Progressive
Oxidation• Galvanic Par with fastening bolts & Columns.
CHARACTERISTICS OF CAST ALUMINIUM
QUALITY CONTROL
• Metallurgical quality control • Thicknesses control with ultrasounds • Hardness control• Primer micron-size control & painting by
ultrasounds• Adherence control• Chamber control of foggy salt • Ultraviolet chamber control• Effort in point control in test machine.
POSSIBILITYOF FAULTS
METALLURICAL QUALITY CONTROL
THICKNESS CONTROL WITH ULTRASOUNDS
HARDNESS CONTROL
PRIMER MICRON-SIZE CONTROL & PAINTING BY ULTRASOUNDS
ADHERENCE CONTROL
CHAMBER CONTROL OF FOGGY SALT
ULTRAVIOLET CHAMBER CONTROL
EFFORT IN POINT CONTROLIN TEST MACHINE
SUMMARY, COMMENTS & CONCLUSIONS
• Historically, light fitting with gas were only of casting• Possibility of recovering old forms• Project quality• Possibility of mixed lamp post + slender + economic• Cast iron Lamp post
- Progression of oxidation- Galvanic Par
• Brackets of cast aluminium, thickness 1/3• Columns no approved Pay attention to the quality• Are hte supports “for all the life”• Sevilla, supports catenary tram with outdoor street lighting• Sculptures up to 8 Tn.• Differents pieces not catalogued• Class I. to control gear is essential earth wire.
BINEFAR
CASTING OF BIG PIECESBINÉFAR (SPAIN)
MONZÓN
HANDLING & LOGISTICMONZÓN (SPAIN)
SABADELL
CASTING OF SMALL PIECES & HEAD OFFICESSABADELL (BARCELONA-SPAIN)
R. ROS ALGUER S.A.CASTING & LIGHTING
Joan Ros CasanovasEngineer Metallurgical
Presentation at TECNICAT5 february 2009
www.fundicionros.com