MOLTEN METAL TRANSFER - Foseco

The performance required from a ladle and mouldtransfer system depends on many considerationsfrom within the foundry.These include:• Casting type• Alloy• Ladle type and size• Mould shape and size• Casting quality specification• Pouring line• Casting preparation requirements• Health and safety• CO 2and environmental legislation• CO 2and environmental strategy• Casting fill time• Production requirementsFoseco has a wide range of ladle lining and flow controlsolutions available to provide the properties your foundryrequires. We can assist you in selecting and implementingthe system that best suits your foundry.CastableOptimisedsafetyEasy installation Highly insulatingRammableBottom pourHighly refractoryFosecoLadleTechnologyTeapotHighly inertLow densityNo pre-heatSingle useLong lifeEasy cleanReducecontaminationRapid fill3

Refractory lining systemsFoseco supplies a comprehensive range of hightechnology lining systems to provide the propertiesyou require from your ladle and molten metaltransfer devices.KALTEK*Low density ladle lining systems that require almostno drying and pre-heat.KALTEK boards – preformed ladle liningPredominantly, this system is applied to steel foundryladles up to 25 tonnes in capacity. The system isused for up to 5 heats.KALTEK shanks – preformed ladle liningUsed in iron and steel foundry applications for ladlecapacities up to 1000 kilos.KALTEK ISO* – powder refractoryUsed in iron and steel applications for ladles up to7 tonnes. KALTEK ISO is cast using a former as a drypowder and hardened using heat.Benefits of KALTEK• Insulation• Temperature control• Easy application and removal• Energy efficient• Clean ladle systemCRITERION* and DURAFLO*A range of low cement and high strength refractories,suitable for iron and steel application. CRITERION isapplied by mixing with the optimum amount ofwater and vibrocasting behind a former.DURAFLO is applied in a similar way, but due to theself flowing properties, no vibration is required.Benefits of CRITERION and DURAFLO• Long life• Clean ladle system• Easy slag removal• Simple to repair• Thermal shock resistance• High hot strength• Minimal hot load deformation4

TRIAD*A range of cement free, high strength refractories,ideally suited for iron foundry lining applications.TRIAD is applied by mixing with water and castinginto place behind a former with vibration.Benefits of TRIAD• Easy to install• Short and simple drying schedule• Long shelf lifeRefractory bricksDimensionally accurate refractory shapes areavailable in a variety of sizes and materials whichoffer properties including low heat conductivity,high strength and high temperature resistance.SILLMAX* and STEIN* bricks are prefired, highalumina dense shapes ranging from 42% to 85%alumina content.ALRO* bricks are a range of high alumina, denseshapes ranging from 42% to 85% alumina content.Mouldable refractoriesFoseco’s range of mouldable or rammed refractoriesinclude DURACRETE*, BLURAM* and X9 PLASTER*.These products can be applied by hand or pneumatictools according to the application and consistencyof the product.Foseco’s mouldable products are ideal forapplication to launders, ladles, spout and generalrefractory repairs.These materials are generally easy and quick toapply whilst offering excellent refractoriness,durable performance, resistance to slag and metal,and ladle cleanliness.• Ready to use• Hand forming• Easy to dry (chemical bonding)• Good thermal shock resistance• High performance• Easy to repairFormer placementRefractory applicationFitting a KALTEK shank5

The selection of the correct material and shapes forthe flow control system in a ladle or pouring box hasa significant impact on the pouring of the castings.Inadequate flow control devices can result inmany problems. The stopper / nozzle can leak andoccasionally fail, resulting in uncontrollable flow ofmolten metal from the ladle - this is an obvious safetyissue. A worn or blocked nozzle will give inconsistentflow rates and mould fill times. Incorrect shape ofthe stopper and nozzle will result in poor metal flowattributes. The metal will not flow in a consistentstream and may spray out of the nozzle, resulting incasting defects from oxidation, air entrapment anderosion of the pouring cup by the metal stream.The use of VAPEX cross bore nozzles improves theintegrity and consistency of the metal flow into themould.Gas diffusersThe technology associated with purging of molteniron and steel with inert gasses is becomingincreasingly important as the demands on castingintegrity continue to rise. The purging process istypically undertaken in the induction furnace or thetreatment and pouring ladles, and generates manybenefits including:• Reduction in scrap rate• Improved quality of castings• Reduction in pin holing• Removal of inclusions• Reduction in gas content• Temperature homogenization• Distribution of alloying agents and de-oxidantsTo facilitate the optimum purging process, gasdiffusers are available in a range of materials andshapes.VAPEX cross bore nozzlesMetal stream from a crossbore nozzleBottom pour ladle readyfor useGas diffusers available in arange of shapes7

Quality, consistency and flexibilityResearch and developmentAs the quality demands from end-users of castingsincreases, it is essential that foundry technologykeeps pace. Foseco continually invests resourcesin the research and development of innovativesolutions, to the problems of today and tomorrow.Development laboratories work closely with inhousecasting facilities to ensure new productdevelopments fully meet the customer’s needs.Quality assuranceAccredited quality assurance systems ensureoptimal testing of finished products, and providesa framework for continual improvement and furtherprocess optimisation.ConsistencyControlled and automated manufacturing processesensure that products are supplied to a highlyconsistent specification, minimising batch to batchproduct variations.05/2011 · re 750 e*FOSECO, the Logo and ALRO, BLU-RAM, CRITERION, DURACRETE, DURAFLO, KALTEK, KALTEK ISO, ROTOLOK, SILLMAX, STEIN, TRIAD, VAPEX, VISO, and X9-PLASTER are trade marks of the VesuviusGroup, registered in certain countries, used under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or byany means, including photocopying and recording, without the written permission of the copyright holder or as expressly permitted by law. Applications for permission shall be made to the publisherat the address mentioned.Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein arepublished as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents norwarrants, expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation.The seller is not authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale availableon request.© Foseco International Limited 05/11.C O M M I T T E D T O F O U N D R I E SFoseco International LimitedDrayton Manor Business Park,Tamworth, Staffordshire,England B78 3TLPhone: +44 (0)1827 262021Fax: +44 (0)1827 283725www.Foseco.comPlease contact your local Foseco team