Blue power.€¦ · Vacuum pressure casting systems (sealing rod principle) VC series page 14 ... as well as MIM and other powder metallurgy processes. To obtain specific metal powder

Blue

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er.

BLUE POWERCasting Systems


Years of Top ClassCasTing TeChnologY

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A new company with 20 years of experience? Yes, in fact. Our established company Indutherm GmbH is developing and providing metal cast-ing solutions since more than 20 years – first for the jewellery industry, soon later for other sectors as well.

By launching our new international brand Blue Power we are now taking the logical next step. In our new company BluePower Casting Systems GmbH we have concentrated our joint capability and expertise in metal casting and atomisation technology to support our custom-ers even more focussed in their longing for the best fitting solution in metal processing.

A new brand, but with more than 20 years of experience:

Blue Power, your Partner for innovative metal casting solutions.

Capability based on experience and research

We generally develop and test our systems in close collaboration with users from different sectors. The varying requirements and areas of use has been fundamental to our expertise. Numerous machines have also resulted from research projects that we frequently carry out in conjunction with well-known research partners. All of our clients can take advantage of this expertise, in the form of advanced technology and competent consulting and support.

Solutions for four different categories of manufacturing

Atomisation systems for production of metal powders as needed in additive manufacturing and other technologies

Casting systemsfor vacuum pressure casting according to the lost-wax-casting principle

Continuous casting and granulating machines for production of semi-finished material

Melting and pouring systems

Atomisation systems AU series page 4

Casting systemsHigh temperature vacuum pressure casting systems (tilting principle) VTC series page 8

Table top vacuum pressure casting systems (tilting principle) MC series page 12

Vacuum pressure casting systems (sealing rod principle) VC series page 14

Continuous casting machines CC/VCC series page 22

Granulating Units GU series page 24

Melting and pouring systemsTilting furnaces TF series page 26

Melting machines for hand pouring MU/MUV series page 28

High temperature melting solutions TF C / MU C series page 28

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The Powder AToMiSATion PlAnTS – AU SerieS

For fast and economic production of small batches of metal powder

The BluePower atomisation plants have been particularly designed for the flexible and economic production of small-scale metal powder batches. Traditional large-scale production plants cannot provide this economic advantage. Frequently changing alloys in production require high clean-ing efforts to avoid cross contamination. Particu-larly in R&D or precious metal powder applications small amounts of various kinds of powder are frequently required, often also new types of alloy powder not available on the market. Especially fast developing applications like SLM and MIM require more and more specialised metal powder.

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high quality metal powders – in a wide spectrum of alloys and particle sizes

Our atomisers produce spherical, flowable metal powders with mean particle sizes between ~10 µm and 200 µm for e.g. soldering, SLM or other innovative additive layer manufacturing processes, as well as MIM and other powder metallurgy processes. To obtain specific metal powder char-acteristics, the AU machines work with different easy-to-change nozzle systems: free fall and close coupled atomisation nozzles. Flow optimisation in the spray chamber ensures an increased pow-der quality (avoidance of satellites).The BluePower atomisers are generally suitable for gas atomisation of a wide spectrum of alloys, ag-based solder alloy powder with an average particle size of ~60 µm

easy change of alloy and atomisation nozzle for powder production in a wide range of particle sizes

such as for example those based on Cu, Au, Ag or Sn (standard versions) as well as Fe, Co, Ni, Pd (high temperature versions). The inductive heating takes place in graphite crucibles (up to 1.600° C) or in ceramic crucibles (up to 1.750° C, up to 2.000° C in development). The crucible volumes reach from 245 ccm to 12,000 ccm.

easy-to-clean concept

Polished stainless steel surfaces prevent pow-der adhesions in spray chamber, cyclone and collector – all parts are easy to clean without any residues. This way the risk of metal loss and cross-contamination is reduced to minimum.

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Free Fall Atomization; CuSn10; d50,3 = 106 �m; d84,3/d50,3 = 1.6 ; PGas = 20 bar

Close Coupled Atomization; CuSn10; d50,3 = 35 �m; d84,3/d50,3 = 1.7; PGas = 24 bar

Free Fall Atomization; CuSn10; atomization gas pressure pgas = 2 MPa; mass median diameter d50,3 = 106 �m; geometric standard deviation d84,3/d50,3 = 1.6;

Close coupled Atomization; CuSn10; atomization gas pressure pgas = 2.4 MPa; mass median diameter d50,3 = 35 �m; geometric standard deviation d84,3/d50,3 = 1.7;

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The Powder AToMiSATion PlAnTS

oxidation-free processing

The AU machines offer the possibility of oxi-dation-free processing in the closed-chamber machine by means of de-gassing, vacuum and protective gas features.

The BluePower-Atomiser – at a glance:

•very simple handling via LCD-Display and neatly arranged control panel

•flexible and economic production of small scale metal powder batches

•easy-to-clean concept: minimum metal loss and cross-contamination

•high powder yield over a particularly wide particle size range via flexible, modular usage of different atomisation nozzles and hot gas atomisation

•particularly high process stability due to optimised nozzle systems

•anti-oxidation features

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Watch our atomization plant in action on .

The Air Classifier AC 1000

The ‚Air Classifier‘ AC1000 allows the economi-cal and flexible classification of metal powders (<200 µm particle diameter). It is suitable for the separation into fine and coarse powder fractions especially also in the range < 25 µm, where con-ventional sieving operations fail. The throughput is about 25 kg/h (bronze).

Low cleaning efforts with little metal loss and cross contamination, as well as high process stability qualify this plant for research, develop-ment and small scale-production with the need for frequent alloy changes, especially also for precious and other specialty metals*.

* Without additional safety measures not suitable for air classification of explosive metal or alloy powders, e.g. Aluminium-, Magnesium-, Zirconium- or Titanium alloys, or other alloys with increased content of these elements.

AU 500 AU 1000 AU 3000 AU 12000

crucible volume in ccm 245 - 386 1,500 3,400 12,000volume in kg bronze 2.1 - 3.3 9 22 80volume in kg steel* 1.6 - 2.5 6 16 60generator kw (400 V) 10 22 30 40* volume reduction with ceramic crucible inserts for the high-temperature versions

example 1: Before air ClassifiCaTionparticle size distributions obtained with atomiser aU1000 by gas atomization of a tin-bronze alloy (Close-coupled atomization)

example2: afTer air ClassifiCaTionparticle size distributions of a gas atomised tin-bronze alloy separated in coarse and fine powder fractions with air classifier aC1000

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The VTC SerieS: For eVery MeTAl or Alloy yoU wAnT To CAST

VTC vacuum/pressure casting machines

The VTC 100 V – VTC 800 V are extremely versa-tile casting machines suitable for a wide range of applications. While the VTC series was originally designed as a high-temperature casting machine for casting steel, palladium, platinum etc. (max. 2,100° C), large flasks also make it suitable for economically producing castings in each other material.

The machine combines a dual-chamber differential pressure system with a tilting mechanism. The casting process is achieved by rotating the entire melting-casting unit by 90°. One benefit of the tilting system is the use of economically priced

graphite or ceramic crucibles instead of crucibles with holes and sealing rods; these tend to have a longer endurance. Some alloys, such as copper beryllium, quickly cause crucibles with holes and sealing rods to become untight and therefore useless, and for this reason, many users have so far processed such alloys only in open systems – which means they can’t choose to optimise the process with overpressure or vacuum. With the VTC series, these handicaps no longer apply.

A vacuum can be produced in the melting chamber and the casting chamber to avoid oxidation pro-cesses during melting and air pockets in the casting mould.

casting pressing onmelting

vacuum

vacuum

vacuum

vacuumvacuum

overpressure

graphite crucible and ceramic crucible

The flask is automatically pressed against the melting chamber for casting, making it possible to switch to overpressure during casting for better mould filling; in addition, the vibration technology optimises the process even further. As well as casting with flasks, casting into ingot moulds is also possible.

Sweep mode vibration system for perfect results even in bad flowing metals

The VTC machines are equipped with the advan-ced sweep mode vibration system. It considers that each casting tree and even each item of a tree has a different resonance frequency, depending on its shape and size. Generating variable frequencies the sweep mode vibration ensures that the optimum frequency is covered. Read more about on page 15.

handling and control

Operation is simple and safe thanks to a clearly arranged and easy-to-use LCD display. All parameters, right down to the variable tilting speed, can be individually set and saved to ensure that recurring castings always produce consistent results.

The high vacuum casting systems VTC 100 V Ti - VTC 800 V Ti

Highly reactive metals such as titanium, copper beryllium, amorphous steel etc. pose particu-lar challenges when casting. Hence until now the only way to cast these metals was to use extremely expensive specialised machines. As part of a joint AiF ZIM research project, Blue-Power has collaborated with the FEM institute in Schwaebisch Gmund under the sponsorship of the Federal Ministry for Economics and Technology to develop a cost-effective solution for casting highly reactive metals: the VTC Ti machines. The ideal structural basis proved to be the VTC 200 V tilting casting machine. Following numerous modifications, such as completely reconstructed valves and hose connections, special seals and an evacuation and inert gas flushing process tailored to the machine, the prerequisites for the required vacuum of 10–3 mbar were met. Furthermore, special crucibles and inductors were developed, as the ceramic crucibles that are normally used also react with titanium. They also reduce melt-ing times – and the shorter the melting time, the less time there is for a possible reaction.

SweepMode Vibration

Technology

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VTC 100 V / Ti VTC 200 V / Tiperformance

power max. / electrical connectiontemperature max.

capacityvolume graphite crucible 25 ccm = 450 g Au 18 ct 145 ccm = 2.0 kg Au 18 ctvolume ceramic crucible 30 ccm = 600 g Pt / 250 g steel 180 ccm = 2.5 kg Pt / 1 kg steelfor use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h

handling+controlvibration technology sweep mode sweep modeautomatic tilting with motor driveautomatic flask fixingcasting programs 100 100temperature measurement thermocouple up to 1,300°C thermocouple up to 1,300°C

optical pyrometer up to 2,000°C optical pyrometer up to 2,000°C

quality managementRS 232 interface, diagnostic systemdata printerGSM-modem for remote service

accessoriespyrometer with video output

= standard equipment = optional



capacityvolume graphite crucible 25 ccm = 450 g Au 18 ct 145 ccm = 2.0 kg Au 18 ctvolume ceramic crucible 30 ccm = 600 g Pt / 250 g steel 180 ccm = 2.5 kg Pt / 1 kg steelfor use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h








capacityvolume graphite crucible 25 ccm = 220 g Cu 145 ccm = 1.2 kg Cuvolume ceramic crucible 30 ccm = 600 g Pt / 250 g steel 180 ccm = 2.5 kg Pt / 1 kg steelfor use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h






The VTC SerieSVACUUM PreSSUre CASTinG MAChineS

The new control system with lCDDisplay

The casting process is achieved by rotating the entire melting-casting unit by 90°.

flask size Ø125 mm x 220 mm

2100° C12 kW 3x400 V

2100° C15 kW 3x400 V



capacityvolume graphite crucible 300 ccm = 2.4 kg Cu 600 ccm = 4.8 kg Cuvolume ceramic crucible 300 ccm = 2.0 kg steel 600 ccm = 4.0 kg steelfor use of flasks up to ø 125 mm / 220 mm h ø 125 mm / 220 mm h






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2100° C20 kW 3x400 V

2100° C20 kW 3x400 V

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MC 15+ MC 20 V MC 60 MC 100 Vperformance


capacitycasting volume 60 g Cu 60 g Cu 260 g Cu 260 g Cu

110 g steel / 200 g Pt 110 g steel / 200 g Pt 300 g Ag 935 250 g steel / 500 g Ptfor use of flasks up to ø 30/50/65/80 mm x 80 mm h up to ø 30/50/65/80 mm x 80 mm h ø 100 mm x 120 mm h up to ø 80/100 mm x 120 mm h

handling+controlcontrol panel digital display by LCD-Display, full text readout digital display by LCD-Display, full text readoutautomatic vacuum function automatic overpressure functioncasting also under vacuum only – –vacuum or overpressure after casting –1 up to +2 bar –1 up to +3 bar –1 up to +2 bar –1 up to +3 barfunction washing by inert gasvibration system – –supply: cooling water, inert gas argon or nitrogentemperature measurement/control up to 1,300°C up to 1,600°C up to 2,000°C up to 1,300°C up to 2,000°C

quality managementRS 232 interface, diagnostic systemGSM-modem for remote service

accessoriesvacuum investment mixer Indumix 2furnace AK 20, 1,100°Csand blasting cabinetvacuum pump (min. 8 m3/h) (min. 8 m3/h) (min. 8 m3/h) (min. 21 m3/h)floor unit – – –


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1300° C3.5 kW 230 V single phase



2000° C8 kW 3x400 V

MC SerieS TABleToP CASTinG MAChineS

after pouring, the MC series automatically switch to overpressure in order to optimise the mould filling even for delicate parts. alternatively it is also possible to keep the vacuum (example shows MC 15+).

high-tech in most compact size

The MC series vacuum pressure casting machi-nes are compact yet highly professional casting systems for Rapid Prototyping studios and lab-oratories. They offer extremely short processing time from mould manufacturing to completed casting; simple, safe operation; high quality and reproducible casting results. The program controlled MC 20 V and MC 100 V are equipped with LCD control display and with the BluePower vibration system – for optimum mould filling even at filigree parts.

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A thoroughly thought-through concept with the finest details...

...forms the basis of the technological advances made in our VC machines guaranteeing opti mal casting results whatever class of machine you opt for.A few examples of the additional features offered by BluePower machines:

Automatic vacuum in the melting and flask chambers…

…provides the de-gasing of the alloy and avoids undesired oxidation during melting (a low oxygen content is particulary important when casting silver or copper). Vacuum in the flask chamber during casting improves the form filling when casting filigree parts and avoids air inclusions.

The special “oxidation-reduced casting“ system...

…eliminates the danger of oxidation while the flask is cooling down.

The Turbo Pressure function…

…optimises the casting of very small and filigree objects. For the production of jewellery it guarantees perfect results when casting with stones. Turbo Pressure allows a precisely defined pressure to be achieved rapidly. For all program-controlled VC models, depending on the selected program the Turbo Pressure will start automatically exactly at the required time.

Melting by induction technology:The crucible with the material is located

in the core of the induction coil. By generating a strong alternating magnetic

field, the result is a strong alternating current in the graphite crucible and in

the metal. This leads to fast heating up and thorough mixing of the material.

Vacuum Casting

The VC SerieSVACUUM PreSSUre CASTinG MAChineS

highest levels of safety for certified production

The digital or program control of our machines and the integrated data printer (standard equipment for VC 650 V, VC 1000 V, VC 3000 V) en-sure a high level of safety and the possibi lity of precise process documentation (important for ISO certified casting processes). During casting of very small or delicate parts the temperature of the flask is of utmost importance. By flask temperature measure-ment (standard for machines from VC 500 D onwards) the temperature of the flask can be monitored to within one degree.

overlapping casting

All BluePower machines have separate lock systems for the melting chamber and flask chamber. This allows time to be saved by “overlapping” casting: while the flask remains in the flask chamber for several minutes after the casting, you may fill in and heat up the next charge.

Vibration System

•Vibration during casting generally improves material flow and mould filling.

•Castings exhibit a higher and more consistent density

•Porosity is substantially reduced.•Risk of hot cracks is reduced.•50% smaller grain size•Castings have greater stress and elasticity

properties, making them easier to process further.

In practice this means: higher and more consistent quality, less waste, less post-processing, better formability.

Sweep Mode Vibration System

The new sweep mode vibration system can do even more: it considers that each casting tree and even each item of a tree has a different resonance frequency, depending on its shape and size. The sweep mode vibration gener-ating variable frequencies covers all natural resonances.

porosity without vibration

porosity with vibration

grain structure* without vibration

grain structure* with vibration

*au 18 ct: 750 au,128 ag, 122 Cu

elongation limit ~12% bettertensile strength ~25% better

Rmwith VRmwithout V

Rp 0,2with VRp 0,2 without V

tens

ile

stren

gth

N/m

m2

➛discharge

0,2%elongination — = with vibration

— = without vibration

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The VACUUM PreSSUre CASTinG MAChineS For lArGe CASTinG PArTS

picture: VC 1000 with feeding system picture: VC 3000 V picture: VC 12000

and window door with large flask chamber

performancepower max. / electrical connectiontemperature max.

capacitycrucible volume 1,500 ccm = 3,5 kg Al 3,400 ccm = 8 kg Al 12,000 ccm = 25 kg Aloptional up to – – 25,000 ccm = 60 kg Alfor use of flasks up to ø 250 mm / 500 mm h ø 450 mm / 600 mm h ø 600 mm / 800 mm hoptional up to – ø 300 mm / 600 mm h –

handling+control20 temperature programsprogram control (100 programs) VC 1000 V VC 3000 V VC 12000 Vautomatic flask and chamber lift VC 1000 V VC 3000 V –dual temperature controlflask temperature measurement


accessoriesgranulation tankmagnesium kit

* Liquid metal up to top level of the crucible = standard equipment = optional

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VC 1000 VC 3000 VC 12000

VC 1000 V VC 3000 V VC 12000 V

1200° C60 kW 3x400 V

1500° C30 kW 3x400 V

1500° C25 kW 3x400 V

Capacity and power for large scale projects

Our large vacuum pressure casting machines are mostly used for precise castings in aluminium alloys. They are always the first choice for parts with complicated geometry or when the number of pieces is not large enough for die-cast production. VC 1000, 3000 and 12000 offer the best pre-conditions for high quality castings in aluminium: the hydrogen content of aluminium alloys may be adjusted by regulating the vacuum during melting. This way, foaming of molten metal can be avoided without any melt additives. Overpressure in the melting chamber during and after casting and simultaneous vacuum in the flask chamber optimise form filling especially in filigree or thin-walled areas.

The V-versions with vibration

All our large VC machines are now equipped with a new program control system. The casting process is controlled via LCD full text display. Complete casting cycles may be stored for repeatable castings. Each machine is available in two versions: The standard versions offer 20 casting programs, the V-versions have 100 programs and as the most important innovation, they use the vibration technology for improved form filling.

Magnesium casting versions

The magnesium casting versions are constructed according to strict safety requirements and guarantee safe and easy casting of magnesium – and of course of many other metals, too.

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The FUlly AUToMATiC VC MAChineS

VC 450

The VC 450 is equipped with a program control system with full text read out LCD display. With help of the step-by-step display infor-mation and many automatic functions, the machine is very easy to handle, even for less experienced users. The program control for 20 different casting cycles allow reproducible and consistent casting results.

VC 480 V

The construction of the VC 480 V is based on the VC 450 and offers the same melting capacity. However, in addition to the technical equipment of the VC 450, the VC 480 V comes with 8 kW generator power, an advanced program control with 100 casting programs, variable vacuum in the flask chamber and – the most important add-on – the BluePower vibration system.

VC 650 V

The absolute “State of the art“-machine: the VC 650 V garantees highest efficiency – through maximum speed and quality.

New program control systemThanks to the control panel with full text LCD display, all programs and parameters are very easy and convenient to set. 100 casting pro-grams guarantee fast operation and con -sistent casting results.

Turbulence reduction softwareFor faster and more laminar metal flow.

Turbo Pressure PLUSFilling of the flask using fast overpressure allows casting of very filigree parts and casting with stones.

HSC – High Speed CastingHSC improves even more the filling and surface quality of filigree designs or those with large and flat surfaces.


capacitycrucible volume 170 ccm = 1.5 kg Cu* 170 ccm = 1.5 kg Cu* 245 ccm = 2.1 kg Cu*

386 ccm = 3.3 kg Cu* 386 ccm = 3.3 kg Cu* 386 ccm = 3.3 kg Cu* 700 ccm = 6.0 kg Cu*

for use of flasks up to ø 130 mm / 240 mm h ø 130 mm / 240 mm h ø 130 mm / 240 mm hoptional up to ø 160 mm / 400 mm h

handling+controlvibration technology – in sweep modepneumatic bell lock maximum pressure 1.5 bar 1.5 bar 3 barprograms 20 100 100program control by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readoutdual temperature controlflask temperature measurement – –automatic flask and chamber lift variable vacuum in flask chamber –turbo pressure PLUS system –turbulence reduction software HSC feature

quality managementRS 232 interface, diagnostic system data printerGSM-modem for remote service

accessoriessintering kit (for diffusion bonding)granulation tank

* Liquid metal up to top level of the crucible = standard equipment = optional 19

VC 450 VC 480 V VC 650 V

SweepMode Vibration

Technology

VibrationTechnology

1400° C4.5 kW 3x400 V

1600° C8 kW 3x400 V

1700° C12 kW 3x400 V

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The SeMi-AUToMATiC VC VerSionS

resistor heated casting machines

VC 200 / VC 300The resistor-heated vacuum casting machine VC 200 and the vacuum pressure casting machine VC 300 are very low priced casting machines for smaller productions. Nevertheless these machines offer a convincing casting quality. Both machines reach a maximum temperature of 1,200° C.

induction heated casting machines

VC 400The ideal machine for smaller companies producing moderate quantities but needing considerably more capacity than that offered by the MC machines. Often, experienced casters are not particularly interested in automated functions or program control, and they can achieve the same quality with the VC 400 machine as with more advanced ones. Its in-duction generator guarantees fast heat-up and thorough mixing of the molten metal by inductive bath movement. VC 400 and VC 500 do not only provide the Turbo Pressure function, but in addition they also switch to overpressure automatically after casting.

VC 500 For larger production quantities with contin-uous casting operation, greater performance (shorter casting times) with even larger cruci-bles and flask capacities (flasks up to 160 mm ø/400 mm H) is important. The high maximum temperature of 1,600°C extends the possible range of alloys. Temperature measurements in both the crucible and the flask mean the best possible repeat accuracy in the process. If alloys are changed frequently, 20 different temperature programs simplify working procedures.


capacitycrucible volume 245 ccm = 2.1 kg Cu* 245 ccm = 2.1 kg Cu* 245 ccm = 2.1 kg Cu*

386 ccm = 3.3 kg Cu* (only for 4.5 kW version) 386 ccm = 3.3 kg Cu*for use of flasks up to ø 130 mm / 240 mm h ø 130 mm / 240 mm h ø 130 mm / 240 mm hoptional up to ø 160 mm / 400 mm h

handling+controldual temperature control –flask temperature measurement – –flask and chamber lifttemperature programs – 20 temperature programs 20 temperature programsturbo pressure function –

quality managementRS 232 interface, diagnostic systemGSM-modem for remote service –

accessoriessintering kit (for diffusion bonding)granulation tank –

* Liquid metal up to top level of the crucible = standard equipment = optional 21

VC 200/300 VC 400 VC 500

VC 300

with an optional granulating tank

1200° C2 kW 230 V

1400° C3.5 kW 230 V or 4.5 kW 3x400 V

1600° C10 kW 3x400 V / 3x208 V

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The ConTinUoUS CASTinG MAChineS – The only oneS wiTh VACUUM And qUATTro driVe

More flexibility, lower costs

BluePower continuous casting machines help you to save production costs. With only one machine, you can produce your own alloys or semi-finished products in different shapes and sizes in the shortest time, for example: •wires or bars in every diameter you need, up

to ø 85 mm (CC 1000/3000)•sheets and strips, e.g. ring production, for

stamping and pressing•tubes, perfect as basic material for cutting in

sections for wedding ring production•granulates (with granulation tank, available as

option)As the desired parts and alloys can be produced within minutes, you can reduce your investment for material in storage. Your processes will get faster, more flexible and more efficient.

Semi-finished materials in highest quality

To reduce the risk of oxidation during melting and during drawing, the machines are equipped with inert gas function, vacuum system for the melting chamber (VCC), optical die temperature measurement, die cooler with inert gas flushing and additional secondary cooling system. All these measures are ideal especially for alloys containing copper such as red gold or for silver as these materials tend to oxidise easily. Degasification under a vacuum results in a sub-stantially improved – because of the absence of oxidation – semi-finished product.Thanks to the control panel with full text LCD display, all functions and parameters are very easy and convenient to set (100 casting pro-grams).

optional quattro drive system

The optional drawing unit with four instead of two motor driven feed rolls produce smoother tubes and sheeting with reduced marks of transportation.


capacitycrucible volume 285 ccm = 2.2 kg Cu* 1,500 ccm = 12 kg Cu* 3,400 ccm = 27 kg Cu*

400 ccm = 3.2 kg Cu* 700 ccm = 5.6 kg Cu*

wire / tube production up to ø 15 mm / ø 45 mm ø 30 mm / ø 85 mm ø 40 mm** / ø 85 mm**sheet production 50 x 8 mm / 60 x 8 mm 100 x 10 mm 130 x 12 mm

handling+control100 programs by LCD-display, full text readout by LCD-display, full text readout by LCD-display, full text readoutvacuum/inert gas overpressure – CC 400 / VCC 400 – CC 1000 / VCC 1000 – CC 3000 / VCC 3000neutral inert gas atmosphere optical die temperature measurement die cooler with protective gas flushing secondary cooler end bar sensor

quality managementRS 232 interface, diagnostic system data printer GSM-modem for remote service

accessoriesQuattro-drawing unit center alignmentsintering kit – –granulation tankbending-unitsimultaneous casting of several wires – 3 wires *** 5 wires ***

* Liquid metal up to top level of the crucible ** Standard sizes – special dimensions or *** not in combination = standard equipment = optional profiles for watch cases etc. on demand with Quattro Drive 23

picture: VCC 1000with Dual Drive

picture: CC 3000 with optional Quattro Drive

picture: VCC 400with optional Quattro Drive

CC 400

VCC 400

CC 1000

VCC 1000

CC 3000

VCC 3000

1500° C12 kW 3x400 V / 3x208 V

1500° C20 kW 3x400 V

1500° C30 kW 3x400 V

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GU 500 GU 1000 GU 3000 GU 12000 GU 25000

crucible volume in ccm 245 - 700 1,500 3,400 12,000 25,000volume in kg Cu 2.1 - 3.3 13 30 105 215generator kw (400 V) 10 20 30 40 40

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SolUTionS For GrAnUlATinG

These shotmakers are developed especially for granulating bullions, sheet metal or casting residues into proper grains. The granulating tanks are very easy to remove for clearing. The GU machines are available with crucible sizes from 245 ccm up to 12,000 ccm.

The major applications are•Preparation of alloys or alloy components •Preparation of alloys from components •Cleaning up of already casted metal … each under inert gas atmosphere or

under vacuum

The Granulating Machines GU 500 - GU 25000

gU 12000

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The Micro Shot Systems GU 500 micro, GU 1000 micro and GU 3000 micro

The GU micro series was developed for the pro-duction of micro granules with a grain size of between 0.1 and 1 mm. The systems are based on the BluePower granulation units as shown on the left but all key components, particularly the jet system, are special developments. The main areas of application for the micro-granules are in metal laser sintering processes, in jewel-lery surface design and in soldering technology.

gU 500 micro

The Granulating Tank for casting machines in the VC and CC series

The optional equipment of a vacuum pressure or a continuous casting machine with a granu-lating tank is a suitable solution for occasional granulating. Granulating tanks are available for all machines in the VC series from VC 400 up to the VC 12000 and for all CC machines.

Main advantages:•Easy installation of the granulating tank•Fast changing between casting process and

granulating•Ergonomically and perfectly balanced design

for safe and easy handling•Optimised streaming behaviour of the cooling

water•Reliable separation of water and granules

CC 3000 with optional granulation tank

granulation tanks in different sizes: left: gU 500, option for VC 400 - VC 650 V and CC 400middle: gU 1000, option for VC 1000 and CC 1000right: gU 3000, option for VC 3000 and CC 3000

Simple handling of the granulation tanks

pull-out handle for easy removal of the tank insert.

pour off the residual water... ... and then pour off the granules.

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TilTinG FUrnACeS For MelTinG And CASTinG lArGe qUAnTiTieS inTo inGoTS or Shell MoUldS

Power, efficiency and safety

The TF series tilting furnaces are equipped with 32-bit induction generators providing 15 - 60 kW output power (depending on version). Low-frequency tuning means excellent through- mixing of the molten material. All versions are now controlled via a console with an LCD dis-play with full text readout. Efficient thermal insulation and elec-tro-magnetic shielding ensure a high level of effectiveness. Comparison tests carried out by a customer proved that the TF 12000 has a higher level of productivity than a competitor model with twice the performance and correspondingly twice the energy costs.

The compact and highly cost-effective tilting furnaces TF 2000 and TF 4000

The new „small“ TF machines have been deve-loped with the focus on least possible energy consumption and on safe and ergonomic handling. The melting unit and crucible can be tilted and locked in position by the user at multiple angles for gentler filling. Such “soft pouring” also prevents damage to the crucible. Pouring off is continuous and gradual, using a pivot lever. The operator is forced to stand to

the side of the machine – away from the dangers of the pouring off area. In the rare event of a crucible breaking, the machine is not damaged – all of the assemblies are covered by a separate protective housing. A large collecting tray under the smelting unit prevents potential loss of metal.

our large tilting furnaces TF 6000 and TF 12000

Because of the potentially large weight of the inductor/crucible unit tilting is effected by motor drive with a stable shaft. Use of a joystick enables the tilting process to be controlled easily and sensitively.

high temperature tilting furnacesTF 2000 C/TF 4000 C

These tilting furnaces have been specially de-signed to melt large quantities of steel or other metals with a high melting point. They are basing on TF 6000/TF 12000 and as these they are equipped by motor drive tilting mechanism. The special low frequency tuning of the induction generator means very good mixing of the metal can be achieved.

TF 2000 / 4000 TF 6000 / 12000 TF 2000 C / 4000 Cperformance


TF 2000: 20 kW TF 6000: 40 kW TF 2000 C: 40 kWTF 4000: 30 kW TF 12000: 40/60 kW TF 4000 C: 60 kW

temperature measurement by thermocouple

capacitycrucible volume TF 2000: 2,000 ccm = 17 kg Cu* TF 6000: 6,000 ccm = 52 kg Cu* TF 2000 C: 2,000 ccm = 5 - 14 kg steel*

TF 4000: 4,000 ccm = 34 kg Cu* TF 12000: 12,000 ccm = 105 kg Cu* TF 4000 C: 4,000 ccm = 8 - 30 kg steel*

handling+controltilting by lever – –tilting with motor drive (remote control) –temperature control by LCD-Display temperature measurement by pyrometer – –temperature programs 20 100 20


* real capacity for casting = standard equipment = optional

27

TF series

Tf 12000

1500° C20-30 kW 3x400 V

1500° C40-60 kW 3x400 V

1700° C40-60 kW 3x400 V

ideal for melting large parts: no sealing rod construction reduces the available space.

some metals develop a lot of smoke and oxides during melting. it is better to melt them in open systems, with use of an air absorber.

no limitation in the material size.

Tf 4000

2928

MelTinG MAChineS For hAndPoUrinG And reCyClinG

With the MU-, MUV- and MU C-series we offer melting machines for many different needs and with crucible capacities from 155 ccm up to 1,200 ccm. The material is molten in open crucibles and poured by hand into the casting mould or ingot mould.

Melting Units MU Series

Flexible melting furnaces designed to melt aluminium, bronze, brass, gold and silver alloys. Due to the strong induction generator (up to 15 kW) and the low induction frequency the stirring effect of the metal is excellent.

The high temperature Melting Units MU 100 C and MU 200 C

By the special generator tuning and extremely heat-resistant ceramic crucibles the MU 100 C and MU 200 C are ideal for melting metals with a high melting point, such as steel, palladium, platinum, chrome- cobalt etc.

The MU as vacuum casting machine: MUV Series

The V-versions include one or two additional extra large capacity vacuum chambers. Evacuating the flask immediately after pouring improves the form filling, reduces porosity and avoids oxidation of the hot metal.

old golddental gold

remains from production and

recyclinga.s.o.

ingots granulesfl akes

melting down melting down Raffi nation

Subsequent processing of the pure precious metals as new alloys into…

GU CC VC 400 B/P TF / MU

…granulate …semi-fi nished material(sheets and stripes,

wires and tubes)

…ingots or pellets with defi ned quantities

…ingots

TF MU GU

Indutherm systems used in the recycling process

MU/MUV series MU/MUV C series

MU 700 MUVV 700

MU 200 MU 400-1200 MU 100 C MU 200 CMUV 200 MUV 400-1200 MUV 100 C MUV 200 C


MU 400: 10 kWMU 700: 12 kWMU 900: 15 kWMU 1200: 15 kW

capacitycrucible volume 155 ccm = 1.3 kg Cu* MU/MUV 400: 400 ccm = 3.5 kg Cu* 50 ccm = 1 kg Pt * 155 ccm = 2.5 kg Pt *

MU/MUV 700: 700 ccm = 6.0 kg Cu* –MU/MUV 900: 900 ccm = 7.5 kg Cu* –

MU/MUV 1200: 1,200 ccm = 10.0 kg Cu* ––

perforated flasks with/without flange up to ø160 mm/400 mm h (MUV) ø 160 mm / 400 mm h (MUV 100 C / MUV 200 C)

handling+controltemp. measurement by thermocouple –temperature controltemperature programs 20 –


* real capacity for casting = standard equipment = optional

1300° C or3.5 kW 230 V or 6 kW 3x400 V

1500° C 1500° C 10-15 kW 3x400 V

29

BluePower machines used in the recycling process

MU 200 C

2000° C 8 kW 3x400 V

2000° C 15 kW 3x400 V

30 31

AlwAyS in FoCUS: The MoST eConoMiCAl SolUTion For yoUr deMAndS

original BluePower consumables: quality pays off!

Our own high quality consumables, such as crucibles, dies or sealing rods, are specially developed for BluePower machines. Only using original BluePower consumables makes sense for a number of reasons:

1. Compact graphite ensures greater durability for crucibles and sealing rods

2. Higher quality casting results•Less contamination from extraneous

material like lead etc•Less graphite contamination in alloys and

castings •Less gas porosity => reduced post-

production costs, less material loss3. Less stress for the casting machines

•Our crucibles have lower electrical resistance, meaning that there is less stress on the inductor, condenser assembly, transformer and generator – resulting in greater durability for these components

•Less power consumption4. An extra two years of warranty for free if you only use original BluePower consumables.

The casting process from start to finish from a single supplier – and perfectly tuned to your needs

We offer not only perfectly tuned casting machines, but also competent consultation in the various moulding, casting and finishing processes.

Moreover we can support you in planning and equipping your complete foundry.

Casting simulation: know what you’re doing before you do it!

Professional computer simulation of the casting process offers you peace of mind before em-barking on complicated casting jobs: instead of tedious and costly failures, we can determine all the relevant parameters beforehand – mould construction, positioning of sprues, temper-ature, pressure relationships – based on your CAD data.

energy efficiency that goes that bit further

The induction generators and inductors in our machines are designed with the highest possible level of effectiveness in mind. Efficient insulation ensures that the induction generated loses as little energy as possible for fast melting of the metal. The thermal insulation around the inductor and crucible effectively reduces heat radiation; the melting chamber acts like a Faraday cage to prevent the radiation of electromagnetic waves. The infused stainless steel coolant water lines further improve the shielding effect.

Less energy for cooling Efficient energy use also reduces energy consumption for water re-cooling in the machine and the potential need for air-conditioning in the foundry.

Blue Power Casting Systems GmbHBrettener Strasse 32 · 75045 Walzbachtal/Wössingen · Germany

Fon: +49 (0) 7203 9218 - 0 · Fax: +49 (0) 7203 9218 - 70e-mail: [email protected]

www.blue-power.deAll machine descriptions and technical data published in this leaflet make no claim to be complete.

They are subject to change and therefore they are not basis of contract. No liability for printing errors. Reprinting and publishing, even as excerpts, are only permitted with the prior consent of BluePower.

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