1.

Introduction:
Master alloys and alloying additives are alloy-element concentrates, grain refiners, hardeners,
deoxidants, and other agents added to a melt or metal-powder blend to produce a particular
alloy, modify a melt, or alter processing characteristics. They are designed to improve
processes in metallurgy by refining the final properties of different metals. Alloying agents
and elements are used as additions to modify or produce alloys in primary metal production
melts, foundry melts, and powder metal-blend manufacturing.

2. Alloy Systems
When working with a specific metal, it is important to know what materials can be alloyed to
ensure proper alloy selection.

Aluminum is a lightweight, non-ferrous metal with good corrosion resistance, ductility, and
strength. Typical alloyants for aluminum include copper, magnesium, manganese, silicon,
and zinc. Other elements that can be alloyed with aluminum include nickel, tin, vanadium,
molybdenum, chromium, titanium, antimony, bismuth, boron, calcium, and cobalt.

Iron is a soft, magnetic metal. It can be alloyed with carbon in various amounts to make steel.
Alloys typically added in addition to carbon include manganese, chromium, molybdenum,
vanadium, tungsten, cobalt, silicon, and nickel. Other elements that can be alloyed with iron
include titanium, copper, calcium, rare earth metals, zirconium, niobium, selenium, tantalum,
sulfur, phosphorous, and nitrogen.

Cobalt is a non-ferrous magnetic metal with high strength and toughness, excellent corrosion
and oxidation resistance, and high temperature strength. Alloys typically added to cobalt
include chromium, nickel, molybdenum, iron, tungsten, aluminum, manganese, silicon, and
titanium. Other elements that can be alloyed with cobalt include vanadium, boron, sulfur,
boron, carbon, and phosphorous.

Copper is a soft, conductive, non-ferrous metal with good corrosion resistance, ductility, and
strength. Main copper alloyants include zinc (brass alloys), tin (bronze alloys), aluminum,
nickel, tungsten, gold, silver, and manganese. Other alloyants of copper include lead, arsenic,
antimony, bismuth, chromium, cobalt, iron, magnesium, silicon, phosphorous, titanium,
vanadium, and zirconium.

Magnesium is a low density, non-ferrous metal with good ductility, moderate strength, and
good corrosion resistance. Primary magnesium alloyants include aluminum, zinc, copper,
silver, and zirconium.

Molybdenum is a refractory metal with avery high melting point and a relatively high
density. As a base metal, molybdenum is typically alloyed with titanium, zirconium, and
carbon. It also can be alloyed with tungsten.

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Nickel is a non-ferrous metal with high strength and toughness, excellent corrosion
resistance, and superior elevated temperature properties. Typical nickel alloyants include
chromium, copper, aluminum, manganese, molybdenum, silicon, iron, zinc, silicon, cobalt,
and magnesium. Other possible alloyants for nickel include tungsten, titanium, carbon,
niobium, phosphorus, tantalum, lanthanum, boron, and calcium.

Titanium is a non-ferrous metal with excellent corrosion resistance, good fatigue properties,
and a high strength-to-weight ratio. Elements in titanium-based alloys typically include
aluminum, tin, molybdenum, and vanadium and can also include chromium, manganese,
selenium, iron, silicon, columbium, tantalum, zirconium, and nitrogen.

Zinc is a moderately low melting, non-ferrous metal widely used in the production of die cast
components. Primary alloyants of zinc include aluminum, tin, magnesium, copper, and iron.
Other possible alloying elements are lead, cadmium, silicon, cerium, antimony, cobalt,
titanium, and vanadium.

For more detailed information on the properties of different types of metals and alloys, please
visit the Metals and Alloys section on GlobalSpec.

Grey cast iron

Grey cast iron is characterised by its graphitic microstructure, which causes fractures of the
material to have a grey appearance. It is the most commonly used cast iron and the most
widely used cast material based on weight. Most cast irons have a chemical composition of
2.5–4.0% carbon, 1–3% silicon, and the remainder iron. Grey cast iron has less tensile
strength and shock resistance than steel, but its compressive strength is comparable to low-
and medium-carbon steel. These mechanical properties are controlled by the size and shape
of the graphite flakes present in the microstructure and can be characterised according to the
guidelines given by the ASTM [8].

8. "Test Method for Evaluating the Microstructure of Graphite in Iron Castings".

doi:10.1520/a0247-10.

Alloy Function
Alloys added to a base metal melt or powder can be classified as either master alloys or
alloying additives. These products can further be distinguished and selected by the specific
function they perform.

Modifiers include any materials added to enhance or alter certain properties in a melt or
alloy. Properties include corrosion resistance, fluidity, machinability, ductility, stability,
strength, hardness, and weldability.

Microalloying modifiers are additions added in small amounts that have a significant impact
on properties or processing. For example, rare earth element (RE) additions in small amounts
can dramatically alter surface energy and melt penetration in a weld pool,refinement of the
grain structure, and inclusion morphology.
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Deoxidizing or killing agents such as aluminum, silicon, or calcium are added into a steel or
iron alloy melt to absorb the melt, resulting in the absence of gas release during the
solidification process. In steel production, killing stops any additional reaction between the
carbon and oxygen, preserving the carbon content desired. Rimmed, unkilled, capped, or
semi-killed steels will have greater variation in composition across the cast ingot.

Desulfurizing agents reduce or control the morphology of sulfur in a steel or alloy. Sulfur
tends to wet the grain boundaries, resultingin hot shortness or brittle condition steel or iron
alloys during hot working processes. Manganese additions to steel or iron alloys form
manganese sulfides, which are nodular in nature resulting in strengthening of the grain
boundaries.

Grain refiners, nucleants, or nucleating agents promote rapid crystallization and a finer
crystal size by providing many points for crystals to start growing during solidification.

Inoculants, nodulizers,or spheroidizers are added to cast irons to form spherical shaped
graphite nodules, resulting in ductile cast iron. Without nebulization, graphite flakes form
resulting in a more brittle cast iron.

2. Additives and Modifiers

An alloying additive, agent, or modifier any alloy or element combined with a base metal to
impart additional specialized characteristics, or to enhance properties. Master alloys are
modifiers that contain one or more additives. Additives are pure metal constituents added to a
melt to change or enhance certain characteristics, such as manganese or chromium metal
additions for steel, which are added to increase hardness and strength.

REFRACTORY MATERIALS

These are the ceramic materials that are capable of withstanding high temperatures without
appreciable deformation under service conditions. For example, magnesia (with a melting
point of 2852˚C) and alumina (with a melting point of 2040˚C). Such materials are used for
lining of high temperature furnaces, boilers, crucibles, converters and supports for hot wires.
Other common examples of refractory materials are silica, magnesite, dolomite, silicon
carbide, zircon and graphite.

PROPERTIES OF REFRACTORY MATERIALS

(i) They do not fuse or soften at the temperatures at which they are used.
(ii) They have excellent resistance against thermal shock (i.e sudden changes in
temperature) and abrasion.
(iii) They do not crumble or crack under the prevailing pressure when in use at high
temperatures
(iv) They have low coefficient of thermal conductivity

3
 (v) They have high resistance to corrosion and therefore they do not react chemically
with the molten metal or slag in the furnace
(vi) They are impermeable to gases and liquids
(vii) They have extremely low values of electrical conductivity

………………………………………………………………………………………

CARBOLUX® G
CARBOLUX® G is used as recarburiser. It is a high purity and graphitic recarburiser.

Company Name: CS ADDITIVE

Technical Data

CARBOLUX® G
Carbon 98.0
Sulphur 0.03
Ash 1.2
Volatile
1.2
Matter
Nitrogen 0.02
Hydrogen 0.12
Moisture 0.4

Bulk density 750-900 kg/m3

Colour Shiny gray
Grain shape Pellet
Particle Shape 5.00 mm

Packaging: Packaged in 25 kg / pallet. Special arrangement upon request.

4
CURBURON (PREMIUM

CURBURON (PREMIUM)
Carbon 98.50
Sulphur 0.02-0.06
Ash 0.5
Volatile
0.5
Matter

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 SILICON CARBID

Technical Data:
Chemical composition:

SILICON CARBID
SiC 2.50 % Max
Free C 2.50 % Max
Fe2O3 2.00 % Max
Al2O3 1.00 % Max
H2O
1mm - 8mm,
90% Min
Size

Origin China
Sizing 1mm - 8mm, 90% Min

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Packing: 25kg paper bag * 48 bags = 1.20mt/Pallet

Max load per container : 24mt per container

Ref. EMSB ENGINEERING MATERIALS SDN BHD, Jaya, Selangor D.

E., Malaysia, e-mail : engineering@emsbco.com

PRESEED™

A PRECONDITIONING AGENT FOR ALL CAST IRONS.

Preseed™ preconditioner has been proven to be an effective furnace addition for cast irons.
Small additions of Preseed™ preconditioner both increase the levels of nucleation in the base
iron and at the same time stabilise these crucial particles to give a long lasting effect that can
be measured right through to the final properties of the solidified iron. Increased nucleation
levels in the base iron can reduce the reliance on inoculant additions which, if the base level
of nuclei is low, may not have the power to give the desired structures and properties. This
can lead to inconsistencies which can be equalised through the use of Preseed™
preconditioner. Further, increased nucleation levels and subsequent improvements in graphite
morphology acts to reduce shrinkage tendency during the later stages of solidification and
improves mechanical properties such as tensile strength.

PRESEED™
Si 62 – 69%
Zr 3 – 5%
Al 3 – 5%
Ca 0.6 – 1.9%
Fe Balance

7
[c] PRESEED™ PRECONDITIONER, Elkem AS, Foundry Products,
www.foundry.elkem.com

……………………………………………………………………………………

SLAX 30*
Slag coagulant for all ferrous metals, also suitable for steel casting

Product Description: SLAX 30 is a high-quality, universal slag coagulant for all ferrous
metals, including steel casting.

SLAX 30

Benefits: SLAX 30 binds dry, liquid and tough slags. SLAX prevents slag build-up in
treatment, transport and pouring ladles and also in induction and pouring furnaces. The use of
SLAX 30 helps reduce the amount of slag inclusions in the casting.

Application: SLAX 30 is placed onto the bath surface and allowed to react for a short period
(there is an audible reaction). If there are large slag quantities or the slag is very liquid SLAX
should be briefly stirred in. As soon as the reaction has finished remove the slag. It is
important to remove the slag immediately after completion of the reaction, as the bound slag
regains its liquid state after a short period. The liquid slag could react with the induction
crucible lining for example or in the case of a magnesium-treated melt cause a return of
sulphur into the melt. SLAX is extremely economical in use - the kilogram price is not
necessarily the only criteria to be used in evaluating the economical use of a product!

Addition Rate: 50 to 150g dependent on slag quantity and size of bath surface

8
Packaging: 25 kg paper bags; 1000 kg per Europalette

[a] Product Datasheet – Ferrous Metal Treatment, SLAX 30*, FOSECO, Revision No: 00,
Date: 09/2015

FERROGEN® LF 10 X

General description:
FERROGEN LF 10 X is a product for cleansing of induction furnaces and ladles. It is useful
for furnaces and ladles used in the production of grey cast
iron,ductile iron or even steel.
FERROGEN® LF 10 X

Purpose of use:
Under certain conditions, the components of molten iron such as silicon, manganese, iron and
in case of nodular iron, magnesium, are prone to form oxides and other non-metallic
compounds. These compounds may also be formed during desulphurising, refining and
alloying treatments. The non-metallic compounds are insoluble in iron tending to remain
suspended in the melt. They have the tendency of floating to the surface when a number of
particles have coalesced. On the surface of the melt, the non-metallic materials form a slag
which, on contact with the cooler refractories of furnace or ladle, solidify and result in the
build-up which can reduce the efficiency of the operation and cause defective castings.

FERROGEN LF 10 X is designed to clean and remove the slag formed in induction furnace
and treatment or pouring ladles.

Benefits:
1. FERROGEN LF 10 X prevents side-wall slag build-up in induction furnaces resulting in
longer furnace life and increased furnace conductance. Thus FERROGEN LF 10 X
increases the efficiency of induction furnace.

9
2. Slag build-up in ladles can be removed by regular applications of FERROGEN LF 10 X.
This results in greater ladle life and ladle spouts are kept clear.

3. Regular use of FERROGEN LF 10 X reduces the downtime consumed in cleaning up

the slag build up on side walls of ladles or incution furnaces.

4. FERROGEN LF 10 X retains the furnace volume and facilitates furnace operation close
to its rated power input.

5. FERROGEN LF 10 X increases the life of refractory lining by protecting it from

chemical attack by slag buildup.

6. FERROGEN LF 10 X reduces the possibilities of inclusion of slag into the castings.

………………………………………………………………………………………

GROUT 163ACF

General Information
GROUT 163ACF is a tabular alumina-based, refractory trowelling mix recommended for
application to the inside face of coreless induction furnace coils. What makes this
product unique from our traditional grouting products, such as Grout 663A or Grout
563A, is the addition of ceramic fibers. This design allows for improved mechnical
behavior of this refractory body by deflecting and minimizing macrocrack propagation.
This product offers the following features and benefits:

> Excellent trowelling properties

> Reduced slumping during tapering applications

> Micro-toughening fibers for crack resistance and deflection

GROUT 163ACF
Al2O3 91.0%
CaO 5.3%
SiO2 3.1%
Fe2O3 0.2%

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Material Required 2.51 g/cm3 (160 lb/ft3)
Grain Size 2 mm (10 mesh) and finer
Installation Method Trowel
Procedure (Heat-up) CL-37

Hydraulic Set and Casting Data

Water Required: 16 - 18%

Working Time: Up to 30 minutes
Initial Set: 1-4 hours
Final Set: 2-6 hours

Packaging: Packaged in 25 kg (55 lb.) multi-wall paper bags. Palletized 64 bags (1600 kg or
3520 lb.) per 42" x 42" pallet protected with stretch wrap. Storage beyond 12 months is not
recommended. Store in a dry location to avoid moisture pickup.

[a] PRODUCT BULLETIN, GROUT 163ACF, ALLIED MINERAL PRODUCTS, INC.,

USA

Dorit DF 4 G Q
Technical Data:

Dorit DF 4 G Q
SiO2 99.0%

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Main Raw Material Quartzite
Required Material 2 (t/m3)
Type of Bonding Hydraulic
Field of Application Dry vibration
Grain Size 0 – 6 mm

Grey iron
Boron oxide 1.0% Boric acid 2.0%
1300 - 1450 °C
Grey iron
Boron oxide 0.8% Boric acid 1.6%
1450 - 1550 °C
Ductile iron
Boron oxide 0.6% Boric acid 1.2%
1550 - 1600 °C
Steel
Boron oxide 0.4% Boric acid 0.8%
1600 - 1650 °C

Packaging: Paper bags each 25 kg or Big Bags. Limit of storage time: 24 months for masses
without sintering agent, 12 months for masses with boric acid and 6 months for masses with
boron oxide.

[2] Technical Data Sheet, Dorit DF 4 G Q, Edition: 0213St rev 2, Dörentrup

Feuerfestprodukte GmbH & Co. KG, www.doerentrup.de, email: info.dfp@doerentrup.de

12
 1. V-CAST® 699A

General Information

V-CAST® 699A is a coarse-grained, ultra low-moisture, low-cement, mullite-based

castable recommended for use in tundish back-up linings, ladle linings, trough linings,
and other similar applications. This product offers the following features and benefits:

> Coarse aggregate for improved thermal shock and abrasion resistance

> Outstanding hot and cold strength

> Volume stability

V-CAST® 699A
Al2O3 68.5%
SiO2 28.2%
TiO2 1.6%
Fe2O3 0.9%

Casting Data:
Water Required: 5.0 - 5.5%
Working Time: Up to 45 minutes
Initial Hydraulic Set: 1 - 2 hours
Final Hydraulic Set: 3 - 4 hours
Form Removal: 18 hours after casting

Material Required 2.65 g/cm3 (165 lb/ft3)

Grain Size 6 mm (3 mesh) and finer
Maximum Application Temperature 1705ᴼC (3100ᴼF)

13
Installation Method Vibration
Procedure(s) CH-23, G-33

Packaging: Packaged in 25.0 kg (55-lb.) multi-wall paper bags. Palletized 60 bags 1500 kg
(or 3300 lb.) per 42" x 42" pallet protected with stretch wrap. Also available in bulk
packaging. Storage beyond 12 months is not recommended. Store in a dry location to avoid
moisture pickup.

[b] PRODUCT BULLETIN, GROUT 163ACF, ALLIED MINERAL PRODUCTS, INC.,

USA

1. QUICK CAST® 62
General Information
QUICK CAST® 62 is part of a complete family of products that offer a wide range of
installation methods: pumping, pouring, shotcreting or vibrating. QUICK CAST 62 is a
mullite-based low cement castable designed for applications including upper sidewalls,
jambs, and roofs in aluminum melting and holding furnaces. Other applications include, forge
and heat treating furnaces, kiln car tops, rotary cement kiln linings, ladles, covers, coreless
furnace rings, non-ferrous uppercases, and launders. For more severe applications, the
QUICK CAST family includes QUICK CAST 72 and QUICK CAST 82. QUICK CAST 62
offers the following features and benefits:
> Excellent hot strengths
> Tolerates a wide water range without sacrificing physical properties
> Excellent abrasion resistance
> Resistant to thermal shock

Technical Data:
Chemical analysis/composition

QUICK CAST® 62
Al2O3 66.1%
SiO2 27.2%
CaO 2.1%
TiO2 2.4%
Fe2O3 1.2%
Others 1.0%

14
Material Required 2.64 g/cm3 (165 lb/ft3)
Grain Size 7 mm (3 mesh) and finer
Maximum Application Temperature 1705ᴼC (3100ᴼF)
Installation Method Self-flow/Vibration/Shotcrete

Packaging: Packaged in 25 kg (55 lb) multi-wall paper bags, protected with stretch wrap.
Also available in bulk packaging. Storage beyond 6 months is not recommended. Store in a
dry location to avoid moisture pickup.

Hydraulic Set

Vibrated Pouring and Pumping Self-flow

Water Required: 5.4% 6.0% 7.1%
Working Time: 40 minutes 50 minutes >60 minutes
Initial Set: 2-6 hours 2-6 hours 2-6 hours
Final Set: 8-24 hours 12-24 hours 16-24 hours

N.B: Storage beyond 6 months is not recommended.

15
[a] PRODUCT BULLETIN, GROUT 163ACF, ALLIED MINERAL PRODUCTS, INC.,
USA

DORICAST RC 1750 0-1

Technical Data:

DORICAST RC 1750 0-1

Al2O3 92.5%
SiO2 0.3%
Fe2O3 0.2%
CaO 5.5%

Size <1mm

Main Raw Material Corundum

Required Material 2.5 [t/m3]
Type of Bonding Hydraulic
Field of Application coil trowelling mass
Grain Size <1mm
Maximum of Service Temperature 1750 ᴼ C
Mixing Liquid Water, 12 L/100 kg

Packaging:

[2] Technical Data Sheet, DORICAST RC 1750 0-1, Edition: 05/11Kli rev3, Dörentrup
Feuerfestprodukte GmbH & Co. KG, www.doerentrup.de, email: info.dfp@doerentrup.de

Doriflow ULC 1600

Technical Data:

Doriflow ULC 1600

16
 Al2O3 80%
SiO2 9%
Fe2O3 1.7%
CaO 1.7%

Main Raw Material Bauxit

Required Material 2.75 (cm3)
Type of Bonding Hydraulic
Field of Application cast
Grain Size 0 – 6 mm
Maximum of Service Temperature 1600 ᴼ C
Mixing Liquid Water, 7.5 L/100 kg

Packaging:

[2] Technical Data Sheet, Doriflow ULC 1600, Edition: 05/11Kli rev3, Dörentrup
Feuerfestprodukte GmbH & Co. KG, www.doerentrup.de, email: info.dfp@doerentrup.de

17
 COLD START FOR MEDIUM & HIGH PREQUENCY
CORELESS INDUCTION FURNACE
Cold start is for

 Closing small cracks before melt

 Reduce thermal shock
 Length of cold start time depends on time required to close the small cracks
based on size of furnace

Procedures to start cold start for Silica Refractory & ferrous melting operation,

 Prepare clean & densely packed charge, fill the furnace

 Don’t allow too much power during cold start which lead premature melting
may cause thermal shock , crack lining
 Use gas burner at the top to heat up charges pilled in ‘Free board’ area. Free
board area is the area above power coil
 Use ‘K’ type thermocouple to monitor the temperature changes
 For cold start heat the charge raise the temperature up to 1093°C for 2 hours.
Hold the temperate for next one hour. Total cold start cycle is for 3hours.
 During this holding period any molten metal is not desirable.
 After cold start melting down the charge using normal procedures

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STEP BY STEP DFP IMF LINING
1. Coil Grout patching & bottom patching with Allied Grout 163 ACF (Recommend water
addition 16-18%, we have added 20% water). Patching by hand palm & finally lap the surface
with water.
2. Drying the wet coil grout has carried out for 1 hour & 30 min. Gas burner has turned on
(1.30 hrs) to dry out the remaining moisture content from applied patching.
3. Cleaning the furnace with vacuum cleaner
4. For the bottom both asbestos & mica sheet will be placed for better insulation as slip plane
5. At the bottom 15 bags of DF 4 G 0.6% B2O3 in needed to pour in two steps.. Forking 15min
and manual ramming for 10min. For the next step forking for 15min and lastly using bottom
vibrator for 6min
6. Checking, leveling with spirit level, GLD, place the former. Center the former with wooden
edge
7. Side lining will be done by pouring such amount of dry ramming mass which will be forked &
locked with the bottom layer easily
8. Run the vibrator in auto mode

STEP BY STEP LINING PROCEDURE (IMF)

1. Slip plane has to be placed around furnace wall & bottom with suitable method
2. Bottom base asbestos is needed to be placed at the bottom of furnace. 10 inch
ramming mass has to be placed ---- fork, ram upto 1 hour each. Upto 210 mm the
bottom refractory height should be maintained.
3. GLD antenna has to be observed from the top of the 210mm formed refractory base &
end of antenna is necessary to bend like inverted ‘L’
4. Lining former has to be placed upon 210 mm bottom refractory base. With the help of
spirit level former bottom level has to be checked from several orientations. From
inner side of the former one steel pipe has to be placed to accommodate
thermocouple. After that certain quantity of pig iron lumps has to be placed to
increase the self-weight of former arrangement whether the former will not deflect
during ramming from its original position

19
 5. Eccentricity in between former center & furnace center has to be eliminated by
suitable measuring tape or gauge or scale
6. Five inch layer of ramming mass has to be poured in-between lining former & slip
plan, 20 min forking, 10 min ramming has to done for each 5” layer. Same process
has to be continued up to the top of the furnace
7. Before furnace power turning on former in needed to be filled around 250mm down
from the top.

3. Conclusion:
In this report basic sections of Melt Shop are described. Melting shop is very hazardous area.
Major foundry health risks encountered by people working in foundries may occur from
scrap, molten metal, heat, sound and power supply unit. Personal protective equipment
should be worn by every workers as well as education and training should be provided to
minimize the foundry hazard.

4. References:
1. Bhattacharya, S.K. (2009). Fundamentals of Power Electronics. Vikas Publishing House Pvt.
pp. 142–143. ISBN 8125918531.

Silicon carbide:

EMSB ENGINEERING MATERIALS SDN BHD, Jaya, Selangor D. E., Malaysia, e-mail :
engineering@emsbco.com

20