Neutec's 101 Most Frequently Asked Questions
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3.
Why should I buy the J-5 if the J-z is so much less?
Features of the
J-5 over the J-z:
a) Faster cycle times.4. What are the major differences between the Neutec/USA casting machines?
b) More automation that eliminates user errors.
c) Faster alloying and grain making.
d) More sophisticated controls, e.g., error messages.
e) Casting analysis software.
f) Higher flask capacity.
g) Optional flask temperature sensor.
h) More sophisticated IPS pressure system.
6.
Which machine is the most reliable?
All Neutec machines
are extremely reliable and robust. Every component of Neutec machines is
of the highest quality available and each machine goes through extremely
rigorous testing before it is sold. The J-I0b and the J-15 are top value
machines. They are built to be the most reliable, fastest and easiest to
use machines in the world. They have back-up systems in the electronics
that automatically take over if certain circuits fail. Operator control
is minimal so process repeatability is always high. The J-I0b and J-15
are favored where the environment is harsh. No other casting machine requires
as little operator training or supervision, or is as foolproof as the Neutec
J-I0b and J-15.
7.
Which is your most automated machine?
The J-15 and J-I0b
are the most automated.
8.
Since Neutec's machines are so sophisticated, how easy are they to use?
No one exceeds Neutec's
ease of operation. Even though the systems are very sophisticated, every
operation was designed with the customer in mind. Because of the expert
system (artificial intelligence), the computer is self-programming and
there are no complicated programs to be set. The machine does it all. Any
layman can be trained to use the machine in a short time. Programming a
VCR is more complicated than operating a Neutec machine. Yet one enjoys
precision and repeatability in casting that can only be achieved with sophisticated
computer automation.
9.
How long will it take me to learn how to operate a Neutec machine?
The J-2r and J-z
machines are owner-installed machines. They were engineered to be simple
enough to install, operate and maintain so that most jewellers are successful
with the instructions provided.
J-5, J-10b and J-15 machines are installed (unpacked, set in place, plumbed and wired) by the customer. Then a trained Neutec technician will arrive to start the machine, calibrate it and train the operator to use and maintain it. Usually the customer is trained to alloy, convert sprues to casting grain and, if flasks are ready, they can cast on the first day. The second day is used to watch the operator and reinforce the training and answer questions. Neutec and Lacy West Supplies are always ready to answer questions and provide any needed service after the sale.
10.
Can I upgrade my baseline machine with a pressure system?
J-5, J-10b and J-15
machines can be field upgraded. Parts are added but no parts require replacement.
J-z is difficult to upgrade in the field and several parts are replaced.
We do not recommend field installment of options. No pressure option is
available for the J-2r.
11.
How are Neutec machines sold and priced?
All Neutec machines
are sold through a network of dealers. Prices start at $6,300.00 USD and
can go above $80,000.00 USD for the machine. Accessories, consumable items,
CIF and technician travel and expenses are charged extra depending on what
is purchased. It is always necessary to get a current quotation to be sure
the price is correct.
12.
Why is Neutec more expensive?
Neutec is not "MORE"
expensive. Our largest and most expensive machines are comparable in price
to European and Japanese machines that are not as automated, not as fast,
do not have as much metal or flask capacity, and cannot be used for grain
making. Now Neutec has a full line of machines that cater to every casting
customer. All Neutec machines give great value for the money and have unique
technology that no other company can match. Of course, you pay for the
high quality and durability. The Return on Investment on Neutec machines
is greater than any other machine in the world.
13.
Does it take an expert caster to operate the machine?
No. Anyone can be
trained to operate any Neutec casting machine in a short time. Casting
is a process, and no casting machine can replace knowledge of one's profession.
The preparation steps leading to the invested flask and the metal that
are placed in any casting machine must be correct. No casting machine in
the world can correct mistakes made previous to the casting moment. One
advantage Neutec customers have is that we have a deep knowledge of the
casting process.
14.
Is your machine faster than the competitors' machines?
Yes, our machines
are faster than our competitors' machines. J-15 has a cycle time of less
than 3 minutes, measured flask to flask. The J-z has a cycle time 4 minutes.
In addition, our machines generally have larger metal capacity and flask
capacity than comparably priced competitors' machines.
15.
Who makes the Neutec machines?
Neutec is a division
of The Bell Group, Inc. Bell Group companies are employee-owned and have
been serving the jewelry industry since 1944.
16.
Where are they made?
Neutec machines
are manufactured in a modern 180,000 sq. ft. plant in Albuquerque, New
Mexico, USA.
17.
What are the site requirements for Neutec machines?
The dealer will
send written site requirements to each customer after a confirmed order
is placed.
18.
What is the machine's warranty policy?
Neutec/USA guarantees
the casting machines to be free of defects in material and in workmanship
for one year from the date of delivery, on all mechanical and electronic
components. This warranty does not include incidental or consequential
expenses. No other warranty is expressed or implied. All dealers stock
service parts for any model of machine present in their territory for fast
response service in or out of warranty.
19.
Does Neutec provide training with the machine?
Neutec takes its
dealers through a rigorous training and it certifies all its technicians
and its dealer technicians. Our dealers' technicians ensure that J-5, J-10b
and J-15 machines are completely installed and the operators trained. J-2r
and J-z are "self install" machines. Neutec provides comprehensive manuals
for start-up and training for these machines.
20.
Does Neutec send a technician to install the machine?
Neutec provides
full service through its dealers across the world. Trained and certified
dealer technicians start up the J-5, J-10b and J-15. J-2r and J-z are "self
install" machines. Neutec provides comprehensive manuals for start-up and
training for these machines.
21.
What service does Neutec provide regarding machine repair and maintenance?
Usually Neutec machines
are extremely robust and trouble-free. Neutec's dealers are fully trained
and certified to repair and provide after-sales maintenance. Neutec guarantees
full support in case our dealer technicians are unable to resolve a problem.
In that extreme and rare case, Neutec will send its technicians to correct
the problem.
22.
Can you give us the names of some of your customers?
A sample of Neutec
customers across the world are:
23.
Do you have leasing options?
All dealers may
be able to help you with your local leasing companies. Please ask the dealer
for more information.
24.
Where are the Neutec dealers located?
Currently Neutec
dealers are located in the following countries: Argentina, Australia, Brazil,
Canada, England, France, Germany, Greece, Hong Kong, India, Indonesia,
Israel, Italy, Lebanon, Malaysia, Mexico, Peru, Singapore, South Africa,
Spain, Sri Lanka, Taiwan, Thailand, Turkey, UAE, USA and Venezuela.
25.
To which countries have you sold your casting machines?
Some of the countries
where the machines have sold in the past are: Argentina, Australia,
Brazil, Canada, China, Costa Rica, England, France, Germany, Greece, Guatemala,
Hong Kong, India, Indonesia, Israel, Italy, Japan, Korea, Lebanon, Malaysia,
Mexico, Morocco, New Zealand, Peru, Portugal, Russia, Saudi Arabia, Singapore,
Spain, South Africa, Tahiti, Taiwan, Thailand, Turkey, UAE, USA, and Vietnam.
26.
How much space do I need in my shop for these machines?
Neutec engineers
know that space is not to be wasted. All Neutec machines are designed to
fit in as small a space as possible. The site requirements supplied by
the dealer will show the space needed for the machine and also the space
needed for the operator to work and service the machine.
27.
Can all the equipment/supplies needed for a complete factory set-up be
purchased from Neutec?
Neutec only manufactures
certain machines and accessories; Neutec dealers can supply everything
needed for a complete factory setup.
28. How much do the machines weigh?
30.
Must a grain-making tank be purchased with a Neutec machine?
The J-z comes with
the grain-making tank. The grain-making tank is sold separately with the
J-5, J-l0b and J-15 since many customers have multiple machines. The Neutec
Grain-making Accessory provides an oxygen-free environment for melting
metal for alloying and converting sprues to casting grain, so it is highly
recommended.
31.
Must a water cooler be purchased with the Neutec machine? What about a
water filtration system?
Neutec's RC-6 water
cooler is highly recommended. Some benefits of the cooler are:
33.
Do I have to use flux with this machine?
Since Neutec provides
a total system for preparing and casting metal in an oxygen-free environment,
no flux is required in the crucible.
34.
Will Neutec's machines eliminate my porosity?
Without exact temperature
control, there is no hope of eliminating porosity in jewellery casting.
Metal temperature too hot can cause gas porosity and a kind of dendritic
porosity. Temperature too low can cause another kind of dendritic porosity.
Casting with metal not properly prepared can cause gas porosity and dendritic
porosity, too. Neutec induction casting machines employ advanced computer
technologies to control
the melt temperature
more accurately than any other machine in the world.
The Neutec induction casting machine is so repeatable, it can be used as a diagnostic tool to discover what the cause of porosity is in a casting by deductive reasoning. Often the true source of porosity is found in the preparation for casting. The master model, the feed sprue design, the tree design, and the investing and burnout must be correct before bringing the flask to the casting machine if high quality, high yield production is to be achieved.
35.
Will I still have to over-karat?
Neutec machines
have two unique technologies, Pulsed Power Stirring (PPS) and Power Stir
Casting (PSC), which guarantee homogeneity of the metal from the top to
the bottom of even the largest trees, and for any karat gold. Neutec customers
do not find it necessary to over-karat. This benefit alone can pay back
the price of the machine in a short time.
36.
Is the vacuum pump built in the Neutec machines?
Only the J-z has
the vacuum pump built inside the cabinet.
37.
Can platinum be cast in the J-series machines? Can Neutec machines be modified
to cast platinum?
Platinum cannot
be cast in the current models of Neutec machines, and they cannot be modified
for platinum casting. There are great differences in the requirement needed
for gold and silver casting versus platinum casting. In order to have a
truly optimized machine, it cannot do both.
38. Can bronze be cast in Neutec casting machines? Yes.
39.
Can stainless steel be cast in Neutec casting machines?
Our induction machines
can go up to 1510° C or 1750° F, which is hot enough to cast some
steel alloys. However, the graphite crucible may be a problem. Graphite
is ideal crucible material for silver and gold casting, but it is not recommended
for melting most steel and stainless steel alloys. Also, special precautions
would need to be made to insure safety in case of a flask blowout. Liquid
stainless steel could eat through the flask chamber and allow the cooling
water to come in contact with the hot metal. The steam generated could
explode the machine and kill the operator.
40.
Can ingots be cast in the J-series machines?
No. The pouring
angle of any investment casting machine is not conducive to pouring good
ingots. Special ingots have been successfully cast in investment molds.
A wax pattern the shape of the desired ingot is invested and burned out.
The mold is cast hot, taken out of the machine and a torch is used to control
the solidification. Rod and tube shapes work best. Large flat ingots don't
come out well.
41.
Can titanium be cast in Neutec casting machines?
No. Titanium requires
special equipment, crucibles and investment. Titanium is a very reactive
metal and is easily contaminated by almost anything it touches when it
is liquid.
42.
What is the difference between nitrogen, argon and helium gases?
Argon is one of
the so-called noble gases. Because it is less than 1 % of air (0.934%),
it is somewhat expensive. At the time of writing, the price is $10.50/m3
USD. Advantage: It is inert to all metals and at 1.7840 grams per liter,
it is heavier than air. There is some evidence that silver may absorb argon
and some gas could be trapped, causing subsurface porosity, but evidence
is not conclusive. The specific heat capacity of argon is low: 0.520 J
g °K. The atomic radius is the largest of these three gases, large
at 1.53 A.
Helium is the lightest of the noble gases and it is found in air in only trace amounts. Commercial helium is derived from gas wells and transported. It is the most expensive of these three gases at $13.12/m3 USD. Helium is much lighter than air: 0.1718 grams per liter, and it is inert to all metals. The specific heat capacity of helium is 5.193 J g °K, which is about 5 times higher than nitrogen. The atomic radius is surprisingly large considering its weight, 0.93 A.
Nitrogen is about 78% of air, making it the low cost winner of these three gases at $2.40/m3 USD. Nitrogen is slightly lighter than air (1.251 grams per liter), requiring a well-engineered delivery system such as Neutec has to make it work well in a casting machine. It is inert to all commonly used gold and silver alloys. Nitrogen will react with iron, magnesium, titanium and aluminum. The specific heat capacity of nitrogen is moderately low at 1.04 J g °K. The atomic radius is the smallest of the three, 0.75 A. In its natural state, nitrogen atoms share the 2p electrons in a very strong covalent bond to form a diatomic molecule.
Everything considered, assuming the N2 is smaller than the helium in one direction, the flow rate might be a little better than the helium, or close to the same. The very high heat capacity of helium is offset by the low mass, suggesting that the cooling effect on the investment wouldn't be that different. So it looks like the main difference between using helium and nitrogen is the cost. Refill of a 250 cubic foot cylinder of nitrogen costs $17.01 USD and the same size cylinder of helium costs $92.91 USD to refill, more than five times higher.
43.
What kinds of inert gas can I use?
We recommend technical
grade nitrogen or argon.
44.
Why is inert gas used in Neutec machines?
Inert gas protects
the graphite crucible and sealing rod from burning and keeps the metal
being melted clean and oxide-free.
45.
How much inert gas does the machine consume?
Inert gas usage
is approximately 5 liters/minute. A 250 cubic foot cylinder (7000 liter)
will last 18-24 hours of operation. Based on 6 hours of use per day and
the current highest retail price of nitrogen in Albuquerque, nitrogen would
cost $4.25 USD per day.
46.
What optional casting related accessories are available?
Some accessories
that Neutec offers are:
47.
Must a different crucible be used for casting different metals?
That depends on
the alloys you use and the change. Strictly speaking, if you change the
crucible when you change metal alloy, you have the safety of limiting possible
contamination or karat change. In practice, any alloy that does not leave
a residue in the crucible should not cause any problem to the next alloy,
except when changing from white gold to any other color. The wise caster
casts the highest karat of a color first and then casts the lower karats
progressively. If the crucible must be changed, it can be removed hot and
placed in a Neutec cooling jar.
48.
What is the life of a graphite crucible? Does it last longer in one machine
from another machine?
The life of a graphite
crucible is 150-250 casts. The life of the crucible does not depend on
the machine. It depends on the care taken with the crucible during use.
It is critical to change the crucible bottom gasket when it turns half-white
to avoid damaging the crucible. The crucible cooling jar helps eliminate
oxidation of the crucible during crucible changes. The crucible stand inner
gasket should be changed when it becomes hard or frayed. The crucible shield
should be changed when it fails to fit snugly in the crucible stand. All
these steps will ensure a long life of the crucible. When the crucible
is hot in the machine, the inert gas must be on until the crucible is cool
enough so it will not bum. Keeping the flask chamber closed during preheat
and cool-down will extend the life of the crucible and the crucible bottom
gasket.
49.
Why must I use a graphite crucible?
Graphite is a good
oxygen scavenger. Liquid copper oxide will react with carbon and make carbon
monoxide gas, leaving oxide-free copper. Silver and gold alloys do not
stick to the graphite crucible (except when there is too much silicon in
the alloy) and graphite heats fast in induction heating, allowing rapid
cycles.
50. Can Nickel Silver be cast in a graphite crucible? Yes.
51.
Can ceramic crucibles be used in lieu of graphite crucibles?
So far we have not
had any call for ceramic crucibles, so we do not have any available.
52.
Does using a graphite crucible contaminate white gold alloys?
No. In fact, we
have found that white gold casts extremely well in Neutec casting machines.
One customer, who has several J-10b machines now, transferred all his white
gold to his first J-10b shortly after he discovered how well it worked.
Neutec C50 grade graphite crucibles should be used for melting any white
gold alloy.
53.
Won't the graphite crucible cause inclusions on my pieces?
Graphite inclusions
are not a problem with Neutec casting machines if they are used correctly.
If graphite inclusions are present, the crucible bottom gasket has not
been, changed when required.
54.
When are the AutoValve crucible and the AutoValve disk used? What are their
benefits?
Processing tree
sprues into casting grain is best performed with our patented Auto Valve
crucible. The Auto Valve crucible is easy to load because no sealing rod
is required. A special thermocouple inserted in the sidewall of the crucible
provides temperature control. The inside bottom of the crucible is machined
to receive a graphite disk that regulates the flow of metal out of the
crucible. The Auto Valve crucible automatically maintains a liquid pool
of metal, which hastens the melting of sprues and prevents the clogging
of the pour holes. Sprues are fed at a constant rate into the top of the
crucible and the grain is constantly being formed below.
55.
When purchasing a graphite crucible, what determines the size of hole (8
mm or 9.5 mm)?
The sprue size determines
the size of the hole. Crucibles with 8 mm holes are used with 8 mm (1/4
inch) sprues. Crucibles with 9.5 mm holes are used with 9.5 mm (3/8 inch)
or larger sprues.
56.
What accessories does the average customer buy?
Some accessories
that we highly recommend and most customers buy are:
58.
How often do we have to replace the consumable items?
It depends on the
item. A general guideline on some consumables is:
60.
Does Neutec always have consumable items in stock?
Yes. Neutec ensures
ready stock of all consumables and parts, both at the factory and with
the dealers.
61.
How quickly can I get parts?
Parts can be sent
overnight the same day of the order.
62.
Since the flanged flasks are more expensive, can flangeless flasks be used
in the Neutec machines? Why do we need the flask with flange?
Only flanged flasks
may be used in Neutec machines. Well-made flanged flasks, such as Neutec
standard flasks, may cost more than non-flanged flasks, but in use they
are proved to give the best value because they perform better and last
longer. Non-flanged flasks depend on the edge of the tube to make a vacuum
seal. As the metal corrodes or gets bent from handling, the vacuum seal
is compromised.
63.
How many flasks can be cast in one day?
It depends on the
machine. For example, the J-15 has a cycle time of less than 3 minutes.
That means 20 flasks per hour. The J-10b can cast 20 flasks per hour. The
J-5 can cast 15 per hour, the J-z 12 per hour, and the J-2r can cast 6
per hour.
64.
What is the least amount of metal I can cast per flask?
We recommend at
least 100 grams of metal.
65.
What is the smallest and largest flask size used for each machine?
Flask size chart:
| J-2r: | 2.5" x 3" to 4" x 9" | 63.5 mm x 76.2 mm to 101.6 mm x 228.6 mm |
| J-z: | 3" x 4" to 5" x 9" | 76.2 mm x 101.6 mm to 127 mm x 228.6 mm |
| J-5/10/15: | 3" x 4" to 6" x 10" | 76.2 nm x 101.6 mm to 152.4 mm x 254 mm |
66.
What are the different applications for different flasks/gaskets ( ie.
silicone, graphite,woven)?
Flask gaskets are
used to make a vacuum seal between the flask and the flask chamber. Neutec
carries 3 kinds of gaskets: woven, silicone & graphite. Each of these
has their pros and cons:
Woven: Flexible and conforms to irregularities. They are best with flask temperatures below 600°C (1100°F). Woven gaskets become fragile quickly but can last for several days if left undisturbed.
Silicone: These gaskets make the best seal, but they work best for flask temperatures below 500°C (900°F). Silicone expands a lot, so at fast cycle rates, they tend to grow.
Graphite: They are not as flexible but they are strong. They work best with flask temperatures below 650°C (1200°F). They, however, do not conform to irregularities as well as the others.
67.
What is the maximum casting temperature for each machine?
J-2r: 2200°F
(1204°C)
All other machines:
2750°F (1510°C)
68. Can I program the temperature into the machine? Yes.
69.
How accurate are the temperature readings?
Temperature readings
are within the 0.3% range - the most precise anyone can get.
70.
How does the computer assist in temperature accuracy?
The Neutec exclusive
ADC technology is self-programming and a self-learning computer. The lag
time caused by heat transfer from metal to sealing rod to thermocouple
to the readout on the controls causes inaccurate metal temperature readout
in all other machines. If one casts the same alloy and the same load every
time, one could program the time lag. However, in practical applications
that never holds true. Our advanced computer system can detect the characteristics
of the metal and the amount of metal in the crucible and adjust the heating
cycle automatically to give the most accurate temperatures.
71.
What are the differences in the regular and in the slim NeuSprueTM
sprues?
The regular NeuSprueTM
has a diameter of 10 mm. The Slim NeuSprueTM has a diameter
of 9.5 mm.
72.
Why should we use the NeuSprueTM in lieu of the "C" style sprues?
NeuSprueTM
is one of the latest Neutec innovations. Some advantages of NeuSprueTM
over traditional sprues are:
73.
What is the difference between a two-part sealing rod and a one-piece sealing
rod?
Two-piece sealing
rods have a ceramic rod with replaceable graphite ball. Metal temperature
reporting is slower than with the one-piece sealing rod, but they cost
less to use since the rod can be fitted with a replacement graphite sealing
ball. They are mainly used for alloying. The one-piece sealing rod is made
out of a solid piece of very high-density flake graphite. These have the
fastest temperature transfer rate to the thermocouple and the least temperature
loss from metal. These are perfect for casting. The computer must be set
for the sealing rod type in use. If the computer 200 code is set for one-piece
sealing rod, the temperature will be off if a two-piece rod is in use and
vice versa.
74.
What type of thermocouples do the Neutec machines use?
Two types of thermocouples
are used in the Neutec machines. They are Type K (for temperatures up to
1200°C) and Type S (for temperatures up to 1510°C), except for
the J-2r, which can only use Type K. Note: Neutec thermocouples cannot
be used in any other casting machines without damage to the temperature
control unit.
75.
How often must I change the thermocouple?
Thermocouples last
a long time. The average life of Type K thermocouples is 4800 casts. The
average life of Type S thermocouples is 2400 casts.
76.
Is a voltage stabilizer needed in countries where there are frequent fluctuations
in the power lines?
No, voltage stabilizers
are not needed with Neutec machines.
77.
What is the operating frequency of the Neutec machines?
Operating frequency
of Neutec machines is in the medium range of 4-9 KHz.
78.
What are the Neutec machines' power requirements?
J-2r: 208-240 Volts
AC, 50/60 Hz single phase, 1.5KW.
J-z: 200-240 Volts
AC, 50/60 Hz single phase, 5KW.
J-5: 208-240 Volts
AC, 50/60 Hz single phase, 5KW.
J-10b: 208-240 Volts
AC, 50/60 Hz three phase, 10KW.
J-15: 208-240 Volts
AC, 50/60 Hz three phase, 10KW.
79.
What machines are CE certified?
Presently the J-2r,
J-z and the J-5 are CE certified.
80.
What is the difference between the R46 and the R81 graphite sealing rods?
The one-piece graphite
rod is sold in two different grades: R46 and R81. R46 is the lower-grade
sealing rod. It is used for alloys that leave residues. R81 is the sealing
rod that we recommend the most. It is a high-grade sealing rod used for
long-life application. If the sealing rod is not attacked by some dross
from the metal, this rod is the best value muse.
81.
What are the differences in POV, IPS and DPS?
The Neutec machines
have three different pressure systems:
82.
What is the difference between the Pulsed-Power Stirring technology and
the Power Stir Casting?
Pulsed-power stirring
is a feature on Neutec induction machines that allows manual stirring during
grain making. It is also used when the metal overshoots the set point and
power turns off to bring it down to the set point. Pulsed-power stirring
can be used at that point to stir the metal since the regular induction
power stirring is turned off. Power stir casting is a unique way that Neutec
machines make sure that the alloy is well stirred just before casting.
These technologies assure that every cast is homogeneous from the top to
the bottom of the tree.
83.
Do I need a computer to operate Neutec machines?
No. You need a PC
only for the data collection option.
84.
How does the Advanced Dynamic Computer technology work?
Neutec Advanced
Dynamic Computer (ADC): The ADC adaptive programming adjusts power and
frequency for any size load of alloy to achieve a fast, consistent casting
cycle. ADC maintains a metal profile for every metal you cast and improve
the timing of the profile every time you cast. Neutec's ADC is a self-programming
and self-learning computer. The lag time caused by heat transfer from metal
to sealing rod to thermocouple to the readout on the controls causes inaccurate
metal temperature readout in all other machines. If one casts the same
alloy and the same load every time, one could program the time lag. However,
in practical applications, that never holds true. Our advanced computer
system can detect the metal characteristics and the amount of metal and
adjust the time automatically to give most accurate temperatures.
Question numbers from 85 to 100 have yet to be assigned.
101.
What hardware equipment do I need to allow me to use the data collection
graphing software?
One needs a P1 or
greater PC for installation and operation of the software.
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