ML20100N683
| ML20100N683 | |
| Person / Time | |
|---|---|
| Site: | Shoreham File:Long Island Lighting Company icon.png |
| Issue date: | 11/01/1984 |
| From: | Isleib C AFFILIATION NOT ASSIGNED |
| To: | Kascsar R LONG ISLAND LIGHTING CO. |
| References | |
| OL-I-S-008, OL-I-S-8, NUDOCS 8412130321 | |
| Download: ML20100N683 (11) | |
Text
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May 17o 1944 Ef r
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Euclear systems Engineering OLvision 4;Q
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Mr. Robert M. Kascsako Ma na ge r
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b Long Island Lighting Company m'J:. A :'
Post Office nos 618 Rotth Country Road Wading Rivero Eew York 11792 Dear Mr. Kascsakt O
Attached La my report of the Delaval foundry heat made on May to 1984 poured for LZLCo.and my essainatica of the gray iron block which was- -
In sensaryo Z observed the turance charge y
Casting procedures they were representative of very good aeltlago sad r
current. practice which would result La an excellent castlago metallurgically.
Chemical analysts of from which the block was pouredo the ladie of molten Arca af ter additions had been ande showed satisfactorg compositica.
Photoalcrographe vill be r
provided bg Delavalo as will results of nochanical testing of g
the test bars.
I inspected the block af ter cleanlag (but before patattag) on May 11 With the exception of one gate break =La the castlag appears to be excellent.
It is well formado without o
holes cra cks shrtakage or Laciustoast it has been thoroughly e
o p
cleaned and minor fian reins o
e and burnt on sand carefully groond off.
The gate break-La on the lower tLange between D2 and 84 cylladers o camshaft side o o appeared to have no cracks radLat-Lag 'f ron Les and can be ground smooth to ellataste possible 9
notch effects.
The Lategrity of the flat seallag surface of the flange is not violated by the breake and Les location between flange bolt holes and in front of a sa,1or reinforcing
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p seabeto plus the nachining stock which will ne removed from the flange make its effect on the casting probably insignificanto o
in my opinion.
A review of design stresses in this area should be ende to ascertain th:.s.
Some defects sech as sicroporosity. carbon flotation, and o
p slag inclusions, are often not visible on as~ cast s u rf a ces but can be seen after nachining.
I will inspect the casting for o
those detects at that tLae, if you so desire.
Please give ne as many days
- notice as possible if you want ne to do this.
I wLil be out of cova for 9 dayao June 1=10o but can be reached at 913=986-3503 during that time.
D Very truly yours, C.R.
Isleibo P.E.
9
.1. J. Reg. No. 13386 CRZeEMW Eac.
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i PRETACE i.ZLCO c o c ai s s t ored the writer to observe and review AeLaval heat 615K a nd to Laspect the t=cy1 Lader diesel engine block poured from that best.
This included a review of the melt sad f u rna ce cha rge obeetoutlea of the heat la progresso r
ladie additionsa tapptar, and castings discussicas rich foundry and quellty aneuranae essagement regarding tus11tg control and LanpectLon proceduress and visual, LaepectLon of the clasaed castlag.
The Leon wee to t,catern to ASTM Standard Specitica~
4f.
tion a 48, Class r
ca.sc:.us: ors - sstessa sua Cast:sc ESE
- :n x 3:-
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nele1as and Caaeing
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Q 2.
The furnace ch a tte was ',,ma de _ sp af good qualley virgia 8*,*o. '*f?.!...neiYn acaposttLoa.
- saw no asterials and purchased actor Meth* **EY. ewe ' heads or other scrap which p
might cont.ain Leed* *AREk$. 3 Ot'elEDiana Laserts which could be deleteriens to the*1raphite or satrix s t ruct u res th* L'?=R.=ih.
or caseaniastu *:
.m
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ortsest.c**%.&ic..s=1a=at <.aa >.
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asy e
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,ezadora us<, tappine ts== 7".i.*.*!* 4.
"us = = t e. sera t ar.
s o t,e e.r u* ~ Q 4=c nscro taoosn, e.. para-rescaed in nurs :s* css.=:=t..=s. *** su 1==~si.a eherso-e.ze was ano.t i s a C C W." -
$ 0.* *
- Pf**tA0*
nad should O
coagle.
This
. t ainen s**bh.h-M,h.. **
- * = => 1-der sned,
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resu1e in t-complete caatinqe
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3 The heat was tapped Lato cae 30-ton kotton= pour ladle which had been prebested to red heat.
Ladle additione of Craphidox and 1:30 were made duttag the tap for graphitis=
Lag purposas, so delags were encountateds capping was 3
claan and complete 1" satisfactory.
4 Castlag was begun promptig at about 16007s no s toppe r tecuble was encountereds and the sold was filled la ander p
2=1/2 minutes o a very good time for this sise castlag.
Aa la-mold graphittslag hiock is norssi practice at Delavalo to alainize Laoculation fade.
p 3.
All sold vence wera LLC offs no gas explosions occurreds and the ris e rs all fede judging from esamlantion of the sold inter La the scratag.
4.
Et was reported by,superlatendent Dobrec that one o two o and 3=Lach test bars were cast Lategrelly la the solde off the same gating sgstas, and cooled La the nold along" with the casting.
Sepa ra t ely cast specimene were also poured.
D 1
Saaples for spectrographic analysis were poured as the heat approached finishing and just before tapplag.
The fLaal ladie ansignis is shown below.
D CORNENTS The furnace used was a 20= ton capacity three-phase direct arc turnace acid-lined, rated at 10 taas per hour seitlag o
rate.
The charge for heat 615K was as followes i
e 1
I tj 90d L2:10 t I /6_0 '7 9 x
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.O 5
'b)
Charte Lbs.
Delaval gray iron re tu rns (all shop scrap) 18.400 st ru ct u ral steel plate, etc.
13,800 sorel metal pig (4.2 C, 0.2 21, 0.01 Ma.
)
0.01 P. 0.02 K) 6,900 stasillan roundry pig (0.062 p) g,900 ELgh Carbon Ferromantene.se 170 Craphite..............................................
4go
)
Molybdeaue oxide briquetten (50% No) 175
!artcaolybdenna (625 no) 27 total 4g 842 Ladle Additions
)
SL80 Craphittser (80% e11 Leon) 144-Graphidos (305 stilcoa) gg Castjaa cosmosition
~
Aotwas Ladie A nal ueis (5)
TGtal carboa........................................
2.0:
)
........................................... 0.78 Silicon..............................................
1.82 Phospbstwo
........................................... 0.067 sultar..............................................
0.0$s Chromium
)
0.0J nicket 0.11 Roltbdenne........................................... 0.2g Copper..............................................
0.ggs
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s SI ae-
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=-
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f 3
Esasination et cleaned Casting I examined the casting on May 14, 1984 Lanediately after
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shotblast cleaning but before painting (and before shop inspec-l 3
cloa by Delaval) with the objective of locating and identifying any detects, especially those which would be hernful to the i
casting *s lategrity and intended service as an engine block.
p ny exacination was visuale aided by a 28L 3r hand eagnity=
Lag glass sensuring tape and scale supplementary lights and o
o o
a Newage pin brinell portable metal hardness tester.
(The purpose of the hardness tester was not to determine definitive 9
hardness Levels but staply to compare hardoess levels at e
several points on the casting and to help detect possible-porosity or other casting inhonagene t ties. )
Th a casting was set up on rails and blo:ks in a well=
lighted area no that ! was able to esaniae every surfaceo Laterior and esteriore cope and drag sides o as well as core cavities.
It was blown free of metal blasting shot for ny 9
Laspection.
Particular attention was given to the head sur-faces and each cylinder bore area.
The casting was eraniaed from the viewpoints and the 9
systen of organisation described in TDe Entstnational Atlas of CWkting Defects publ. 1974 by the A me rica n roundsynea's o
- society, Das Plainee 1111aciso and the Analysis of Casting r
Defects 4th ed.o ist revisloc publ. 1974 by the America n o
o e
roundrymen*e socieevo ces riaines 111Laois.
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O lod
'L2:IQ 71/60'73
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conc:.us:o.vs - cxzu:ur :cx or rus cas :xc 1.
Meta 1 LLC Project 2one O
2 saw no evidence of thick fins or veine o swells not any o
significant washes crushes drope raises or scabs.
Thin 2Las e
e o
and thin velas la fillet areas had been carefully ground clean.
9 one alaer voland area (1-inch longo thin veia) was noticed la a corad slot on the water jacket side and some ainer seining La o
an entside flange-sidewall fL11et.
O 2.
cavittee I saw no evidence of surface or cornet blowholes or_
pinholes o
aos any shrinks or draws.
The castlag appears
^
sonad.
3.
Discontinuities O
Careful Laspection revealed no cold or hot cracks or tears o not any cold shuts visible to ny naked eyeo not under the Sr glass Z used.
Special attention was paid ca internal fL11sta sach as in the canshaft bearing saddle a reas.
O 4.
Surf ace Irregularities th2re are ao foldse seansa roughnesso buckins rac-ta11s o
o O
orange peel, alag laciusionso slaks or drawee or clamp-off defectso and no significant crushes bura=ons or buta-Las e
o metal penetration or scabs were visible.
Very ninor bura-ans or metal penetration had been carefully ground clean, one O
saali eartace irre9ula ri t y, 2 inches long by 1/2 inch wide and O
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m-a-n
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1/1 inch deepo in a cope side pocket tillet area near the de cylinder liner support ringo water jacket side Z judge r
inalgnitscant.
3.
Enconcleteness l
There is no sign of sistan short pouro o
or runous in this castinto aor should there be based on my obeervation of the o
molten iron t empe ra tu re and casting sequence on May 2.
Cates to the lower block flange (cope side of the casting as poured) nessure approminately 3-1/2 inches wide by 2-1/2 Laches high.
One of these gates between the f.? and 64 cy11aders camshaft o
o y
sideo suffered a break-in when the gating and riserlag system was renoved.
This break-in is between the flange bolt hole ~
l locations and in front of a major reinforcing aanhet.
Zt does..
not estead to the flat seallag surface of the flanges nachin~
(
ing stock to be renoved will help minimise the significance of this break-in.
20 cracks or incipient crocks were visible in or radiating from this break =la area.
9 A second san 11 (2 inches long by 1/2 inch deep) gate break-in esists in the flange below de cylladers this will probably be removed during nachining, and Z judge it to be insignificant.
D No break =in or porosits was visible at the test bar ingate acess o which are located inside the cores in the approximate center of the casting.
D 6
Encorrect Disensions Z anw no evidence of casting deformationa sold or core e
D 60d LE: IC tI/50 9a
D
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3 shitto or ran~ctf defects in this casting.
7.
Inclusions 3
saw no metallic Laciusions cold shoto slago dross o
o sendo refractoryo oside or graphite flotation defects.
Hardness Tests D
Za a test for any nafor unsoundness or inhonogenetties in the castiago 1 ande several hardness anosurements asi.n a Newage pin brinell kardness tester.
Because the surfaces 9
tested were shot-blasted but act groundo the impression zead-lags are act meant to be a eessure of actual brinell ha rdness -
level. A properly prepared surface would gleid higher valans. _
The pin ladentation diameters that were measured indicat-ed good homogeneity.
The heaviest sections which cooled o
slowesto showed sonawhat greater indentation diameters than the flanger which cooled f aster and would be expected to be harder.
There was no indicatica of micro = or gross shrinkage ftoe these observations.
B B
D s
n O!d L2:IO 7I/50'79 x
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3 Location Indentation Diameter (a ve rage reading) in willimetere Plange= Drag side =near ingace D
break-in staa 2.90 Test i
=
2.75 Tant 2
=
Read eurface
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between 14 and
,1 %
cylinders 3.20 Mead eurface beyond il cylinder 3.10 o
Head surface outside 65 cylinder 2.90 = Test 1 o
3.00 Test 2
=
Need surface between 87 and de o
y cylinders 3.00 Except for the flange break-in mentioned in conclusion s the casting as judged by ny visual Laspectica is of excellent o
quality.
D D
D
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9 f=r s:
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