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Questions and Answers
What is the main application of Calcined Lime in the steel making process?
What is the main application of Calcined Lime in the steel making process?
Which consumable is used as a ladle addition for achieving final silicon chemistry in steel casting?
Which consumable is used as a ladle addition for achieving final silicon chemistry in steel casting?
What is the purpose of Silico Manganese in the Electric Arc Furnace steel making practice?
What is the purpose of Silico Manganese in the Electric Arc Furnace steel making practice?
In what application is Ferro Manganese primarily used?
In what application is Ferro Manganese primarily used?
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What is the role of Graphite Powder in the process of melting steel?
What is the role of Graphite Powder in the process of melting steel?
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What does Magnaglo Powder fluoresce under black light?
What does Magnaglo Powder fluoresce under black light?
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What is Fused Silica Powder used for in steel production?
What is Fused Silica Powder used for in steel production?
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What types of defects can Magnaglo Powder help locate?
What types of defects can Magnaglo Powder help locate?
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What is the main purpose of using Ferro Silicon in steel casting?
What is the main purpose of using Ferro Silicon in steel casting?
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What is a characteristic property of Magnaglo Powder?
What is a characteristic property of Magnaglo Powder?
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What is the primary purpose of the asbestos gasket in the casting of railway cast steel wheels?
What is the primary purpose of the asbestos gasket in the casting of railway cast steel wheels?
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What process is necessary for the clay graphite tapered ingate sleeve during preparation?
What process is necessary for the clay graphite tapered ingate sleeve during preparation?
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How much pressure is required for fixing the clay graphite tapered ingate sleeve during mould assembly?
How much pressure is required for fixing the clay graphite tapered ingate sleeve during mould assembly?
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What is the role of the ceramic pouring tube in the casting process?
What is the role of the ceramic pouring tube in the casting process?
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What is the primary function of the pouring tube glaze?
What is the primary function of the pouring tube glaze?
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Which material is used to prevent back flow of molten metal after pouring?
Which material is used to prevent back flow of molten metal after pouring?
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What happens to the ingate after each casting process?
What happens to the ingate after each casting process?
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During the manufacturing of steel wheels, what is the maximum pressure used for pouring?
During the manufacturing of steel wheels, what is the maximum pressure used for pouring?
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What type of environment is required for firing the clay graphite tapered ingate sleeve?
What type of environment is required for firing the clay graphite tapered ingate sleeve?
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What is a common sealant used in the casting of railway cast steel wheels?
What is a common sealant used in the casting of railway cast steel wheels?
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What is the primary application of steel shots?
What is the primary application of steel shots?
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What is the hardness range of the cast steel wheels that use steel shots?
What is the hardness range of the cast steel wheels that use steel shots?
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Which year showed an average of 22.75 heats cast per day?
Which year showed an average of 22.75 heats cast per day?
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What was the average number of good wheels produced per day in 2014-2015?
What was the average number of good wheels produced per day in 2014-2015?
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What was the wheel rejection percentage in August?
What was the wheel rejection percentage in August?
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How many average wheels were cast per day in the year 2015-2016?
How many average wheels were cast per day in the year 2015-2016?
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Which of the following is true about the trend in wheel rejection percentage over the years?
Which of the following is true about the trend in wheel rejection percentage over the years?
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What was the average wheels cast per day in the year 2014-2015?
What was the average wheels cast per day in the year 2014-2015?
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The average number of heats per day in the year 2015-2016 was approximately:
The average number of heats per day in the year 2015-2016 was approximately:
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Which of the following years had the highest average of good wheels per day?
Which of the following years had the highest average of good wheels per day?
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Study Notes
Consumables for Wheel Shop
- Consumables are used directly in wheel manufacturing (e.g., coke, graphite, ferro-silicon) or indirectly to aid in the process.
- Asbestos gasket is used as a sealant between drag and pouring tube in railway cast steel wheel casting to prevent liquid steel bleeding.
Ingate Sleeves
- Clay graphite tapered ingate sleeves are fired in a controlled reducing atmosphere.
- Kilns have mechanisms to control heating based on manufacturer's firing schedules.
- Sleeves are encased in graphite, calcined petroleum coke, or similar materials during firing to prevent oxidation.
- Used in steel railway wheel casting molds.
- Fixed in graphite drag against the tapered ingate sleeve.
- Retained in position using 52-56 kg/cm2 pressure.
Ceramic Pouring Tube
- Assembled with pressure pouring tank cover.
- Molten metal rises through the pouring tube into the mold.
- Controlled pressure (35 psi max.) is used in the pouring technique
Pouring Tube Glaze
- Used as a coating for ceramic pouring tubes.
- Coating is applied by dipping the tube to fill the pores and make it airtight.
Clay Graphite Stopper
- Made of clay graphite and used to prevent molten metal backflow during pouring into the mold.
- Set with cope at the required height.
- Used for cast steel wheel manufacture with molten metal rising through available gap between the stopper and mold box.
- Pressure pouring technique.
- Clay Graphite Stopper pressed down to close molten metal inlet port using pneumatic cylinders.
Calcined Lime
- Used as flux for slag production in steel making processes through Electric Arc Furnaces.
Ferro Silicon
- Used as a ladle addition to liquid steel tapped from Electric Arc Furnaces.
- Final silicon chemistry is achieved for railway steel wheel casting.
Silico Manganese
- Used as ladle addition to liquid steel from Electric Arc Furnace steel making practices.
- Final Manganese and Silicon chemistry is achieved.
Ferro Manganese
- Used as furnace addition in Electric Arc Furnace steel making process for railway steel wheels.
Graphite Powder/Granules
- Used in Electric arc furnace processes for railway wheel casting.
- Maintains carbon content in the steel during melting.
Magnaglo Powder
- Dry, free-flowing, speckled brown and white magnetic powder.
- Fluoresces bright yellow-green under black light (365 nanometers).
- Intended for use in high sensitivity wet method magnetic particle inspection on cast steel wheels.
Fused Silica Powder
- Used to prepare spray for graphite molds.
- Serves as an emulsion stabilizer, binder, organic gum modifier, etc.
- Used with other additives (CMC and veegum).
Steel Shots
- Used for cleaning and peening of cast steel wheels with 255-363 BHΝ hardness.
Wheel Shop Specifications
- Provides average wheel cast per day (13-14, 14-15, and 15-16)
- Charts and graphs showing the average wheels cast per day and per heat for the years 2013-2014, 2014-2015, and 2015-2016.
- Good wheels per day data presented graphically for specific periods.
- Wheel rejection percentages are shown graphically for relevant time periods.
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Description
This quiz covers the various consumables used in the manufacturing of railway steel wheels, including materials like coke, graphite, and specific components such as ingate sleeves and pouring tubes. Learn about their roles, specifications, and operational conditions during the casting process.
