GLASS
Touchstone has earned numerous awards as an industrial problem-solver,
new product developer, and applied research laboratory for hundreds
of manufacturers in a wide range of business sectors. Our unique
capability as an industrial problem-solver is based on the diversity
of our highly experienced technical staff, supported by over $10
million worth of in-house laboratory equipment and testing facilities.
The following examples illustrate some of our contributions to this
business sector:
- Touchstone was contacted by a glass manufacturer regarding a
problem concerning cracks in plungers that had been welded to
return the wear surface to original dimensions. The problem was
found to be caused by failure to properly pre-heat and post-anneal
the plungers in the welding operations. This improper practice
developed a brittle martensitic layer at the weld interface, which
led to crack initiation at this point. Additional recommendations
included changing the radius on the inside of the plunger to minimize
flexure of the highly stressed nose region during use.
- A manufacturer of glass mugs asked Touchstone to compare two
plungers in terms of metallurgy and chemical composition in order
to determine what may be the cause of poor performance. The examination
of the microstructure revealed that both plungers were composed
primarily of ferritic ductile iron, but one was found to contain
significantly more pearlite (12% vs. 3-4%).
- A manufacturer of glass street lamp covers occasionally found
inclusions in random locations on the pressed glass covers. SEM
evaluation using EDS found that the inclusions were iron rich
scale that probably dropped into the glass after introduction
into the mold. The inclusion was then pressed into the surface
during the forming operation. The source was found to be the old,
steel structural roof members. The problem was solved initially
by placing dust covers over the work area.
- Recommendations were provided to a manufacturer of glass novelties
for their color injection nozzles. The zirconium nozzles currently
in use appeared to be soluble in the molten glass and deteriorated
after only a short service life. The nozzle supplier offered to
provide candidate materials with potentially better service life.
The project manager also located suppliers for cast iron parts
for the forming equipment used in the operation.
- A manufacturer of thermopane windows was interested in the insulative
values of argon versus the nitrogen typically used in double glazed
windows. Touchstone adapted an existing apparatus to allow measurements
to be performed on windows. In addition, an evaluation of the
spacer/frame materials was made. The results helped the manufacturer
make decisions on their future window designs.
- Touchstone was asked to reverse engineer a high pressure sight
glass for one manufacturer to determine the type of metal used
to form the mounting ring, and to determine the method of sealing
the glass to the ring. The ring was formed from 430 stainless,
which was etched to produce a layer of chromium oxide on the bore.
Molten glass was then poured directly into the ring and the seal
was formed when molten glass dissolved and mixed with the chromium
oxide. 430 stainless steel is used in this application because
it has a coefficient of expansion nearly identical to glass.
- Finite element analysis was performed on iron plungers used
in a glass plant to determine what changes were needed to improve
production and service life.
The above examples are only a sample of our work in this area.
We would be pleased to provide any additional information you may
require. We also invite you to review examples on our website of
work that we have performed in support of other business sectors.
Please contact one of our Project
Managers to discuss your manufacturing problem. We would welcome
an opportunity to add you to our rapidly growing list of satisfied
customers.
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