Photo: The FEEDEX FEF product range will be showcased with best-in-class application examples
Source: Foseco Foundry Division Vesuvius GmbH
Covering more than 900m2 in Hall 12, the Foseco stand will feature many of our recent innovations for iron and steel foundries, including:
- Feeding systems
- Solutions to improve casting cleanliness
- New products for the melt shop
- Flow control
- Furnace refractory linings
Visit our global team of experts at Stand No. 12A01/12A02 to discover how we can help solve the most pressing challenges facing the foundry industry today.
Recent rises in energy and waste disposal costs is driving demand among iron and steel foundries for new feeding systems that improve process costs and casting yields, while minimising casting defects. Understanding this, we will present several new developments in feeding solutions at GIFA 2023.
With the development of FEEDEX* FEF, we now offer a complete range of feeding products that are either fluoride emission free or fluoride free. Available in all product geometries from our standard FEEDEX range, FEEDEX FEF is another milestone on our sustainability roadmap. And, alongside KALMINEX* 2000 FF and our fluoride-free KALMINEX SD formulation, it means we now offer a complete range of fluoride-free feeding systems.
Additional highlights at GIFA 2023 will include:
- Our patented FEEDEX VAK technology, which is specifically designed to meet the demands of more challenging castings, where neck modulus is critical to ensure casting integrity.
- FEEDEX K technology, which expands spot feeding with collapsible metal core technology beyond horizontal green sand applications to provide optimum feeding of isolated sections on vertically-parted moulds. To demonstrate this, we will show two DISAMATIC castings produced using FEEDEX K.
- Case studies demonstrating the SCK (sleeve construction kit) product range for jobbing iron and steel foundries. This modular product range enables foundries to optimise casting yield and reduce fettling costs on large steel and iron castings.
Where applicable, all exhibits will feature casting process simulations created in the recently-updated Foseco Pro Module 2.0 for MAGMASOFT. Visitors will also be able to try out our FEEDER CALCULATOR tool, which provides step-by-step assistance in selecting the perfect feeder sleeve from our extensive product range.
Solutions to improve casting cleanliness
Using the latest advances in additive manufacturing, we are developing the STELEX* Optiflow3D range of filters, which feature novel filter structures that were previously impossible to implement. The range will initially be available in gyroid and Voronoi structures, and with a range of pore sizes, but development work is continuing to evaluate the filtration performance of the wide variety of structures now available, as well as their impact on casting types and alloys.
STELEX Optiflow3D technology offers the opportunity to tailor filtration performance to the specific casting, including those which may not have been suitable for filtration in the past, e.g., high-capacity filters are expected to allow filtration of large iron and steel castings. Case studies presented at GIFA 2023 will demonstrate the application of STELEX Optiflow3D to both iron and steel castings.
The HOLLOTEX* EG runner for steel casting complements the existing system used to run iron castings. Lightweight and easier to cut, this innovative solution is easier, safer, and quicker to apply than conventional refractory systems. Casting quality can thus be improved by eliminating or reducing refractory erosion and cooling during mould filling.
Photo: New STELEX Optiflow3D filter rang
A number of recent coating developments will be on show at GIFA 2023, and highlight how we take a customer-centric approach to innovation.
The SEMCO* family of fast dry (FD), colour change (CC) and formaldehyde free (FF) water-based coatings takes aim at some of the most pressing challenges facing foundries today by reducing energy consumption, optimising drying times, improving core/casting performance, and reducing emissions to create a more sustainable working environment in foundries.
Meanwhile, SEMCO IC coatings help to reduce the risk of wear to new lead-free bearings from coating particles that are left over in engine components from the casting process. The coatings are designed to significantly reduce the amount such coating residues, while any coating particles that do remain are softer than the bearings.
Controlling the preparation and application of coatings is the most important prerequisite for eliminating coating-related defects. Our new continuous Intelligent Coating Unit (ICU) is designed to eliminate such defects from the outset. Real-time coating density measurement ensures consistent application for shorter drying times and reduced coating consumption – while enabling significant productivity gains. And, in a world first, we will showcase the first handheld density meter that can instantly display the current density or coating in use.
Photo: The Intelligent Coating Unit (ICU) is the most advanced coating control system in the industry and is Industry 4.0 compatible
ACTICOTE* 3D is a range of refractory coatings designed to overcome the limitations of moulds and cores produced by additive manufacturing (3D printing), including lower sand compaction and surface finish. To address these issues, the ACTICOTE 3D range:
- Provides excellent surface coverage, smoothing out the step-like surface inherent to 3D-printed cores and moulds, and so ensuring casting surfaces are smooth and free from discontinuities
- Improves the interface between the molten metal and the sand surface, preventing metal penetration and sand burn-on defects associated with lower sand compaction.
The range of ACTICOTE 3D coatings support varied application methods, with rheological properties adapted for both dipping and flow coat applications. The selection of refractory filler combinations is also optimised to casting application.
Finally, ACTICOTE TS is an insulating coating that provides better control of solidification at lower castings weights, while maintaining excellent surface finish, free of common defects. It thus allows foundries to improve the metallurgical properties of current castings, while also developing designs that minimise casting wall thickness to further reduce total weight – improving yield and reducing energy consumption
Photo: ACTICOTE TS coating for thin section castings
With growing concern over the environmental impact of fossil fuels and from petrochemical products based on phenol, much recent research has gone into exploring renewable alternatives to phenol-based organic binders. Biopolymers are one possible solution, as they possess many of the characteristics needed of foundry binders, but can be obtained from renewable raw materials. For example, lignin – which is considered to be a promising substitution for phenol – is available as a by-product of the pulp and paper industry.
A recently developed biopolymer-based binder for foundries, based on our proven ECOLOTEC concept, will be presented at GIFA 2023. Cores produced using this binder were characterised by excellent strength, high dimensional accuracy, and excellent surface. The castings made with these cores were sound and dimensionally accurate, while surface quality was at least equivalent to that of conventionally-manufactured components based on binders made from purely fossil fuel raw materials.
Photo: Biopolymers offers a potential alternative to phenol sourced from fossil fuels for the production of binders
New products for the melt shop
ROTOCLENE is a new process for producing the highest quality, inclusion-free steel for casting. We will display the whole process at our stand, with an hourly presentation to introduce the theory, practice, and benefits.
The process uses rotary action to stir the metal and disperse fine argon bubbles through the melt. These bubbles are highly effective at catching any inclusions and bi-films, floating them to the melt surface, where they are trapped in the slag layer. The rotary action also homogenises melt temperature and eliminates cold spots. This allows the steel to be poured at lower temperatures, reducing shrinkage and promoting finer microstructures. This is all possible in a standard bottom pour ladle.
Photo: Steel metal treatment with the new ROTOCLENE process
Having cleaned the steel, it is important to avoid further inclusions developing in the melt during pouring – the job of our HOLLOTEX shroud filtration system. Combining the benefits of STELEX filters with shrouding technology, the HOLLOTEX shroud allows pouring of large castings quickly and effectively, without the turbulence that creates these oxide inclusions. The latest incarnations of the HOLLOTEX system will be on show at GIFA 2023, including demonstration of an improved and simplified method of achieving an air-tight seal.
Photo: The HOLLOTEX shroud provides turbulence control and filtration for large steel castings
Finally, we will display new temperature sensing and analysis equipment from Vesuvius’ Sensors and Probes division. The FERROLAB V thermal analysis system provides real-time measurement of %Ceq, %C, %Si, and the nucleation status of the iron. This provides the operator with the insight needed to take immediate corrective action, within predetermined process specification, to protect the quality of the iron. Benefits include reduced scrap rate, as well as improvements in the quality and consistency of castings.
Photo: FERROLAB V thermal analysis system for iron foundries
At GIFA 2023, we will highlight the latest flow control technologies for steel ladles and auto-pour iron applications, which save time on maintenance and repair, as well as extending life.
The VAPEX FosFlow is an alternative nozzle system for bottom pour ladles for steel and runners/tundishes for casting iron. The system allows nozzle change from the bottom, without any refractory maintenance. Nozzle change is thus achieved more quickly and safely – important when time is key or a different inner diameter of the nozzle is needed.
We will also introduce two new mixes of our VISO stopper technology, which extend stopper life and/or eliminate the need for preheating. VISO stoppers are the ideal choice when using a KALTEK ladle lining, allowing foundries to reduce their environmental footprint and cut CO2 emissions.
Photo: VAPEX FosFlow is an alternative nozzle system for bottom pour ladles for steel and runners/tundishes for casting iron
Furnace refractory linings
A complete lining package, designed for long life and improved metal cleanliness in coreless induction furnaces melting steel grades, will be on display at GIFA 2023. The portfolio consists of high-quality KELLUNDITE lining systems, suitable for melting a wide range of steels, in combination with an optimised sintered profile that allows enough powder at the back to run the furnace safely.
Photo: Full package of KELLUNDITE lining and purge plug for steel induction melting
In addition, we will show a complete package of long-life linings for long campaign cupolas melting iron grades. The cupola portfolio consists of high-quality RAMWELL ramming mixes and HYDRA-MAX low cement castable lining systems, enriched with silicon carbide and graphite aggregates, to improve slag resistance.
John Sutherland, Foseco International
*FEEDEX, KALMINEX, STELEX, HOLLOTEX, SEMCO, ACTICOTE, ECOLOTEC, ROTOCLENE, VAPEX, FERROLAB, KALTEK, KELLUNDITE and HYDRA-MAX are trademarks of the Group Companies of Vesuvius plc, registered in certain countries, used under license.
Source: Foseco Foundry Division Vesuvius GmbH