FOUNDRY PRACTICE

ISSUE

240

GIFA 2003

hall 12, stand 12 A 05

16-21 JUNE 2003 Dsseldorf Germany

IMPROVING FOUNDRY PROFITABILITY THROUGH THE USE OF RHEOTEC* XL COATINGS

THE

APPLICATION OF KALPUR* DIRECT POUR TECHNOLOGY IN THE PRODUCTION OF SAFETY CRITICAL STEEL CONSTRUCTION CASTINGS IN DIE COATING TECHNOLOGY
TM

DEVELOPMENTS FILTERCALC*

FOR STEEL A WINDOWS BASED PROGRAMME FOR SIZING FOAM FILTERS FOR STEEL

LOW DENSITY INSULATED LADLE LININGS AT SINCLAIR WORKS

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IMPROVING FOUNDRY PROFITABILITY THROUGH THE USE OF

page

Contents

RHEOTEC* XL

FOUNDRY PRACTICE
ISSUE 240 June 2003

COATINGS
BY NICK HODGKINSON FOSECO METALLURGICAL, INC.; USA & TIM BIRCH

FOSECO FOUNDRY EUROPE UNITED KINGDOM

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THE

APPLICATION OF

KALPUR*

DIRECT POUR

TECHNOLOGY IN THE PRODUCTION OF SAFETY CRITICAL STEEL CONSTRUCTION CASTINGS

BY

GERD STOTTMEISTER FOSECO GMBH GERMANY

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DEVELOPMENTS
Front cover: Moulding plant - pouring line, Friedrich Wilhelm Htte GIII, Mhlheim, Germany 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 by any means, including photocopying and recording, without the written permission of the copyright holder. All statements, information and data contained herein are published as a guide and although believed to be accurate and reliable (having regard to the manufacturers practical experience) neither the manufacturer, licensor, seller nor publisher represents or warrants, 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 available on request. FOSECO the logo, CERAMOL, DYCOTE, FERRUX, FILTERCALC, KALMINEX, KALPUR, KALTEK, MOLCO, RHEOTEC and STELEX are Trade Marks of the Foseco Group of Companies used under licence. Foseco International Ltd. 2003
BY

IN DIE COATING TECHNOLOGY

13

WOLFGANG HOPS FOSECO GMBH GERMANY

& ROGER KENDRICK FOSECO FOUNDRY EUROPE UNITED KINGDOM

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FILTERCALC*

FOR STEEL

WINDOWS

17
LOW

BASED PROGRAMME FOR SIZING FOAM FILTERS FOR STEEL

BY

TONY MIDEA & JOHN OUTTEN

FOSECO METALLURGICAL, INC.; USA

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DENSITY INSULATED LADLE LININGS AT

SINCLAIR WORKS

23

BY NICK CHILD FOSECO FOUNDRY EUROPE, UNITED KINGDOM

& SAM APSLEY, ENERGY CONSULTANT, UK ACTION ENERGY PROGRAMME

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Improving foundry profitability through the use of RHEOTEC* XL Coatings

Background
High production iron foundries everywhere are facing enormous pressures to produce increasingly complex, high performance automotive and other castings, to ever-increasing quality specifications while attempting all the time to reduce casting production costs. Refractory core coatings are fundamental to obtaining satisfactory casting surface quality and are used extensively on resin-bonded cores and core packages in production iron foundries. As the need for more complex, critical castings and higher quality standards grows, the function and performance of the core coating utilized in the process becomes critical. The impact of a high performance core coating on the overall production cost of a typical grey iron casting can be significant. Fettling, cleaning, and casting inspection operations can often contribute as much as 20 - 25% of the total production cost of an iron casting. While some of this time and cost is associated with the removal of gating systems and "flash", time-consuming repair of surface defects and the removal of adhered sand / coating residue from internal cavities are major cost components which can be directly affected by the core coating performance and application. The material cost of coating is typically a fraction of the total manufacturing costs and usually would be less than 1% of total production costs. The experience of production iron foundries in using the RHEOTEC XL range of premium core coatings in the past 3-4 years has been extremely positive. This paper provides an overview of the technology and provides examples of how RHEOTEC XL coatings have improved the profitability of foundries in many different markets and in different casting applications. As with the proven standard RHEOTEC products, RHEOTEC XL coatings are formulated and manufactured under tight quality control process conditions to provide excellent application behaviour and stability and consistency in use. Specially selected surfactants ensure controlled substrate wetting with no foaming tendency, for defect free core and casting surfaces and less remedial work on coated cores. Levelling of the coating layer is excellent, resulting in a consistent film thickness and a uniform layer that is free from runs, drips and curtain defects, even on complex core assemblies. The engineered RHEOTEC XL coating refractory system provides superior as-cast surface finish quality in the most critical applications - in particular the coating technology has been optimized to eliminate or dramatically reduce veining defects. Veining (or finning) defects (figure 1) occur when metal enters cracks in the core surface which result from thermal stresses generated by the expansion of silica sand during casting. In severe cases, the metal can actually penetrate the core completely causing a total blockage of an internal cavity, rather than simply causing a surface vein or fin defect.

Figure 1: Veining in a sectioned diesel cylinder head casting

Veining severity varies significantly, depending on core type, sand quality and type, casting configuration, and metal composition. The superior anti-veining and overall casting quality provided by RHEOTEC XL coatings is a direct result of the optimized application behaviour and the engineered refractory system which ensures that the thermal shock experienced by the core during casting is substantially delayed and diminished.

How RHEOTEC XL coatings function

RHEOTEC XL coatings are water-based slurries containing a special blend of refractory fillers that have been engineered specifically to meet the most stringent demands of grey and ductile iron casting producers.

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Controlled penetration of refractory fillers into the core substrate produces a high insulation value and a coating layer with an enhanced "hot strength" that inhibits the formation of core surface cracks at casting temperatures. The effect of RHEOTEC* XL coating chemistry on the temperature profile of a standard AFS compression core during pouring was studied through the use of thermocouples embedded in the core (figure 2).

Value to the User

In most cases, the use of RHEOTEC XL coatings will totally eliminate moderate veining, as well as adhesion of sand and core particulate matter (figure 4).

Figure 4. Penetration defect in 1.8ltr engine block oil gallery (left-hand section) eliminated through the use of RHEOTEC XL coating ( right-hand section )

Figure 2: Coated test piece cores

The highly insulating nature of RHEOTEC XL coatings is illustrated in Figure 3. The chart shows a comparison of core temperature vs. time after pouring, for a RHEOTEC XL coated core and a core coated with conventional aluminosilicate coating. The temperature increase at a 3 mm distance below the core surface was measured for a period of time after the test block had been poured.

The performance characteristics of RHEOTEC XL core coatings provide significant casting quality and operational benefits for production iron foundries, both in the core room and in the casting finishing area. Some of the benefits reported by RHEOTEC XL users include :Quality Improvements: Superior as-cast surface finish Reduced retention of sand and coating material particles Cleaner overall internal casting passageways. Operational Benefits: Elimination of costly anti-veining sand additives Elimination of double coating practices Reduced core dressing (remedial work) operations Simplified core room process control Reduced core room labour costs Lower casting scrap levels (due to reduced veining / metal penetration severity) Reduced shot-blasting costs (labour, equipment, energy, materials) Reduced fettling and grinding costs (labour, equipment, energy, materials) Reduced inspection costs Faster casting throughput - improved foundry productivity & capacity

Figure 3: Comparison of thermal behaviour of a RHEOTEC XL coated core vs conventional coated core

The time required for the core surface to reach the temperature at which sand expansion occurs (alphabeta phase change), is delayed by a short but significant period. This, combined with the high coating hot strength, significantly reduces the tendency for core surface cracking and subsequent vein formation.

Main Applications
RHEOTEC XL coatings are most suited to critical applications where dimensional accuracy and exceptional surface characteristics are required, where retained sand and coating particulate matter in internal passageways is a critical issue, and where veining is experienced. Typical casting applications include cylinder heads, engine blocks (water jacket, oil gallery), hydraulic castings, housings (differential, pump, etc.) and brake disc rotors. RHEOTEC XL coatings are most effective and provide the greatest benefit on phenolic-urethane cores. Phenolic-urethane cold-box cores are more prone to veining defects than other systems (hotbox, shell, etc.) because of the inherent lower hot strength of the binder system. However production tests have also confirmed that RHEOTEC XL coatings are effective when used on other binder systems such as SO2-epoxy, PF Hot-Box and Shell bonded cores.

Significant veining defects were typically encountered within the internal channels of the casting (figure 6) which required excessive cleaning times to eliminate, resulting in a production bottleneck within the finishing department of the foundry.

Figure 6: Extensive veining prior to use of RHEOTEC XL coating

Production experience with RHEOTEC* XL coatings

The following case-studies highlight the benefits of RHEOTEC XL coatings when targeted at the elimination of sand expansion defects such as veining and improving "strip and peel", to ensure a defect free surface without coating adherence and retained particulate. In all cases the benefits to the foundry are to be found in reduced overall cost per component. The cost savings are achieved through lower scrap and defect levels resulting in reduced processing times, both in the coreshop and the finishing shop. The overall effect is improved productivity and the elimination of production bottlenecks, with reduced labour requirements and no need for further capital investment in the finishing shop. Case Study 1. Grey iron diesel engine 6cylinder head The case-study is based on the experiences of a high production cylinder block and head foundry located in Brazil, whose main customers include Cummins, General Motors, Peugeot, Daimler Chrysler and Mack Truck. The foundry has an output of approximately 300,000 tonnes of finished castings per annum, with between 50 and 60 percent of these being for direct export. Details of the cylinder head casting and its manufacturing parameters are as follows : Weight Castings per mold : : 91.2 Kg 2 1400-1420C 144,000 Phenolic-Urethane Cold Box

The objectives of the customer were to remove this bottleneck by improving the as-cast quality of the internal channels by preventing the vein formation. This would reduce significantly the subsequent fettling and cleaning times and avoid further capital expenditure aimed at increasing the capacity of the finishing shop to accommodate the moulding line capacity.

Coating Application
The RHEOTEC XL coating was trialled against the current coating practice, as outlined in the table below. It should be noted that the RHEOTEC XL coating was applied as one layer by using an automated dipping machine, and that the layer buildup was equivalent to that achieved by a double dipping operation with the traditional coating. "Old" Practice Coating Core Sand Coating Method Graphite-based Silica 50/55 Water-Jacket manually pre-coated prior to auto dipping of core assembly 33 0.22 - 0.24 mm Gas Convection 180C for 40 mins. RHEOTEC XL Practice RHEOTEC XL No Change Single coat only of core assembly 34 No Change No Change

Baum Coating Thickness Drying Conditions

RHEOTEC XL coating performance

The internal channels were observed to be free from any veining defects, and there was also a reduction in the amount of retained particulate after the shot blasting operation (see figure 7). The total benefits to the foundry in using RHEOTEC XL coating are summarised below : Improved coreshop productivity through the elimination of the double dipping operation Elimination of the operator applying the "pre-coat"

Pouring temperature : Castings per year Core Package : :

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Reduced cleaning requirements would eliminate the production bottleneck within the finishing shop, allowing higher productivity and reducing overall production costs per unit. Coating Application A coating from the RHEOTEC XL range was compared directly with the established coating practice as outlined in the table below. Again it should be noted that the superior rheological properties of the RHEOTEC XL coating allowed for a one dip application. "Old" Practice Coating Sand Additive Coating Method Talc / Aluminosilicate product 3% anti-veining sand additive PF Hot-Box water-jacket core manually dipped, dried, assembled with slab core and re-dipped 28 - 32 0.45 - 0.65 mm (wet) Gas Convection 250C RHEOTEC XL Practice RHEOTEC XL-C coating supplied RFU at 34 Baum No Change Single coat of RHEOTEC XL-C coating to water-jacket/slab core assembly 32 - 35 Same Same (with no pre-coat cycle)

Figure 7: Defect free internal channels when using a single coating application of RHEOTEC XL

Reduced cleaning room labour from 12 to 4 operators Increased cylinder head output from 30 to 60 heads per hour Lower overall cylinder head production costs Zero expenditure on increasing cleaning shop capacity Case Study 2. Grey Iron 2.0 Litre Petrol Engine Block This case study is based on the development work that took place between FOSECO and a high production automotive foundry located in Australia. The foundry is producing approximately 63,000 tonnes per annum of finished castings and supplies customers such as General Motors, Daewoo, Isuzu and Opel throughout Australia and Europe. The problematic casting is shown sectioned in Figure 8, and highlights typical levels of both veining and retained particulate experienced when using the previous coating practice. Weight : 23 kg (2 per mold)

Baum Coating Thickness Drying Parameters

RHEOTEC XL coating performance

The single layer of RHEOTEC XL coating produced a clean, defect free internal water-jacket area with significantly less retained particulate (figure 9).

Pouring temperature : 1420C Castings per year Core Package : 600,000 : PF Hot-Box Water-Jacket

The objectives of the customer were to improve the internal finish of the water-jacket area, through eliminating the formation of veining defects and reducing the amount of retained particulate.

Figure 9: RHEOTEC XL coated water-jacket core and resulting defect free internal finish

The customer benefits resulting from this performance are summarised below : Less retained particulate and zero veining in the water-jacket area Reduced casting scrap 35% reduction in water-jacket related defects Overall 15 20% productivity increase

Figure 8: Veining and retained particulate levels prior to use of RHEOTEC XL coatings

Reduced labour in casting inspection and finishing

 Reduced labour in coreshop Finishing area bottleneck eliminated Lower drying oven energy costs, due to single dip operation

Conclusion
To maintain a competitive edge within the foundry market, production iron foundries need to produce increasingly complex, higher quality castings, at increased production levels and with lower overall costs. A key factor in achieving this goal is the reduction of costly cleaning and finishing operations that can also be a major process bottle-neck. This competitive edge can be achieved by using RHEOTEC XL coating to optimise casting surface integrity in a cost effective manner, and to help ensure the consistency and quality of the components being cast.

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The application of KALPUR* direct pour technology in the production of safety critical steel construction castings
Introduction
The Olympic Stadium in Berlin is being renovated in readiness for the Football World Championships in 2006. Its design will be in keeping with that of a cultural monument yet at the same time cater for all the demands placed on a modern stadium. After completion, the stadium will have 76,000 covered seats. Until now the stadium has had a capacity of 75,000 seats but only 27,000 of these are covered by a roof (figure 1). Steel casting components can be optimised in their shape and wall thickness in accordance with load bearing requirements. Sharp corners and edges and variation in wall thicknesses can be virtually eliminated, thereby reducing stress concentration to the lowest levels. This is a decisive advantage for construction components subject to material fatigue. For these reasons, steel casting construction components are normally used for cable net structures, roof supports, pedestrian bridges, road and railway bridges as well as stadia such as the Berlin Olympic Stadium as described above. Steel castings were originally used in the roof of this stadium for the Olympic Games of 1972. The castings for the new roof are being manufactured by the Friedrich Wilhelms-Htte (FWH) steel foundry in Mlheim, Germany, who have been manufacturing castings for bridge, hangar and roof constructions for many years. FWH produced the first casting clusters for railway bridges in 1998/99 for the Humbold-Harbour Bridge in Berlin. Further major projects are the Lerther Railway Station in Berlin, the Nesenbachtal Bridge in Stuttgart, the Traunstein Bridge and hangars at the airports of Stuttgart and Leipzig.

Figure 1: Model of the Berlin Olympic Stadium after reconstruction

The new roof has been intentionally designed to have a different tone to the existing architecture of the historic stadium; and will consist of a filigree steel construction with a roof membrane over it. Only the roof over the Marathon Gate remains open so as not to obstruct the view of the bell tower. The main supports of this steel construction are steel casting clusters welded together with either pipes or solid material. The key advantages of steel castings over welded and screw-fixed components for construction are: The accurate production of even the most complicated geometrical cluster shapes is possible

Roof construction
The Berlin Stadium project comprises the supply of 254 different casting configurations with up to nine different exits and up to three additional connecting latches. The alloys used for the castings are G20Mn5V and G18NiMoCr3.6V (figure 2). Alloy G18NiMoCr3.6V with a wall thickness of 290 or 350 mm was chosen for the casting clusters of the uprights and the connecting exits of the cluster numbers 1 and 2. All other exits have a wall thickness between 14 and 45 mm (figure 3).

Figure 2: Initial roof construction. Architects: von Gerken, Mang and Partner. Photo: Heiner Leiska

The following case study concerns a cluster with 6 exits 3 latches and a wall thickness of 14 45 mm.

Pattern and Casting Data Conventional Casting System

Several parts had already been produced with a conventional feeding and running system. General Data: Part description: Alloy: Dimensions Nett weight: Poured weight: Running/Feeding system: Moulding system: Cores:

Node G 20Mn5V (mm) 1100 x 800 x 685 (kg) 792 (kg) 1298 (kg) 506 Furan resin (quartz/chromite sand) Coating: MOLCO* 246FA4 CERAMOL* 58 alkali phenolic resin (quartz/chromite sand) Coating: MOLCO 246FA4 CERAMOL 58

Figure 3: Casting cluster with cross-struts

Gating and Feeding Data: Downsprue: 1x dia 80mm Runner: 1x dia 80mm Ingates: 2x dia 60mm Filters: none Feeders: KALMINEX* X 12 - 500mm high (Modulus = 9.4) sleeves Casting Data Casting temperature: Casting time: Casting vessel: Melting furnace:

1610C 24-25 seconds 4t and 6t bottom pouring ladle nozzle diameter 70mm Arc furnace followed by VARP converter

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Figure 4: Computer simulation of solidification

A computer simulation of solidification was carried out before production, which resulted in the feeding method described above (figure 4).

Alternatives to the Conventional Casting System: KALPUR* Direct Pour Technology

It was suggested to cast the aforementioned cluster with the FOSECO patented KALPUR direct pour technique. The following is the technical data of the KALPUR direct pour casting product incorporating a STELEX* PrO filter. Application of KALPUR direct pour units: The FOSECO KALPUR product combines the use of feeders and filters and can replace the entire conventional casting runner system, as the mould is filled directly via the feeder. Because ingates are not necessary and filling is carried out into a suitable section of the casting, a directional or controlled solidification of the casting is achieved or improved. KALPUR direct pour units can either be positioned on top of the casting or used as a side feeder head. 1. Hand moulding and simple moulding machines

Bridging Pattern

Centering Support

Figure 5: Ram-up style with a fixed centering peg and a loose dummy reaching up to the cope

suitable for larger castings produced with the KALPUR direct pour units (figure 5). 2. Automatic moulding line with horizontal and vertical parting Use of the insert sleeve method enables highlyautomated repetition foundries to take advantage of KALPUR direct pour unit technology but will not be described here.

STELEX PrO Steel Filter

Open, neck-down shaped KALPUR direct pour units are used for this purpose and have a supporting surface on which the filter is located. They are either placed on the pattern or inserted later into the cavity created by an insert dummy. KALMINEX 2000 exothermic-insulating feeders are used for iron and steel castings up to a modulus of 4.3 cm. The neck-down KALMINEX TA feeding range is STELEX PrO is a new generation of ceramic foam foundry filters which have been developed especially for the filtration of carbon and low-alloy steels. Even materials such as manganese steel can be cast without problems. However, it is not recommended for steels with a carbon content below 0.15% or for high alloy stainless steels (figure 6).

Figure 6: The STELEX PrO filter

Some of the advantages of the STELEX PrO filters include: Consistent "Priming" even when pouring temperatures are low such that pouring temperatures normal for conventional gating systems are possible. Reduction of temperature related inclusions. Higher filtration capacity Excellent flow rate characteristics compared to zircon ceramics Flexible filter positioning - the filter can be placed horizontally and vertically and is ideally placed at the ingate The use of finer porosity filters is possible. When used in the KALPUR direct pour system the filter will easily float to the feeder surface after pouring, reducing the risk of secondary shrinkage and maximising feeding efficiency No difficulties during remelting of returns containing STELEX PrO filter material Lower energy costs Lower refractory materials costs

Clusters cast with KALPUR Direct Pour method

Because of the positive experiences with the KALPUR direct pouring unit, the suggestion to try to produce the cluster using this method was accepted. The first step was to create a computer simulation of the mould-filling and solidification in order to ascertain its feasibility. The simulation results indicated a successful result and casting trial was planned (figure 7).

Figure 7: Computer simulation for solidification

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KALMINEX TA 11 feeder sleeves were chosen as the feeder, but since the height of feeder was not sufficient a KALMINEX X 12 feeder sleeve was placed on top of it. A STELEX PrO 200 dia x 40mm /10ppi filter was used. The neck aperture of the feeder sleeve posed the risk of the filter being washed into the mould by the high ferrostatic pressure. To prevent this a shell sand core was used to provide a defined base for the filter.

The filled feeder, open at the top, was covered with FERRUX* 707G an exothermic, expanding powder. Covering the feeder with a suitable material is of prime importance for the KALPUR direct pouring system. Using FERRUX exothermic expanding powder, the dual effect of heating and insulation of the feeder surface facilitates the longest effect of the atmospheric pressure on the molten feeder metal. This leads to optimum use of the feeder, improvement of the later interdendritic feeding and consequently to a reduction of secondary shrinkage. After removal, shotblasting and fettling of the cluster, a cost comparison conventional casting method vs. direct pour method was carried out.

Feeder

Core

Costs

Conventional Method 100.0% 100.0% 100.0% 100.0%

KALPUR Method 87.4% 100.0% 97.3% 80.1%

Molten material

Filter

Core-shop Moulding Pre-fettling/ sandblasting Manual cutting

100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

65.1% 88.1% 81.1% 94.7% 100.0% 100.0% 29.6% 82.9%

Figure 8: CAD illustration of casting method

The pattern was specially designed for use with the KALMINEX TA 11 feeder sleeve. This sleeve has the advantage of a base area four times less than the KALMINEX X 12 feeder sleeve this also means that cutting and fettling costs are significantly reduced (figure 8). Casting Data KALPUR- Direct Pour Method Casting temperature Casting time: Casting vessel: Moulding/Core practice 1612C 23-24 seconds 6 tonne bottom pouring ladle 70mm nozzle diameter no change The filter floated upwards immediately after casting and could be removed. Figure 9 shows the upper side of the filter after casting.

Arc Air Initial grinding Final fettling Tolerance grinding Heat treatment Finishing Production costs of raw casting

Figures 10 and 11 show the cluster after sandblasting, fettling and heat treatment.

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Figure 9: Filter after casting

Figure 10

The KALPUR direct pouring technique is just such an innovative production process, offering the foundry industry the following advantages: direct pouring of the casting complete elimination of conventional running systems directional solidification is improved or achieved increased yield reduction of fettling and grinding costs reduction of casting temperatures removal of fine inclusions

References:
Herion Mang Stahlbaukalender, Gu im Bauwesen S. 641 / Ausgabe 2001
Figure 11

The finished casting passed the customary ultrasonic inspection tests.

Karl-Josef Mller, The stadium roof for the football World Cup consists of 254 cast nodes. Glck auf Internal magazine of the Georgsmarienhtte Group; Edition: April 2002, page 20 STELEX PrO brochure, June 2003 KALPUR Direct Pour brochure, May 1999

Conclusions
The example described above illustrates a significant reduction in production costs, most noticeably in the fettling shop. Furthermore a significantly better casting surface can be achieved compared with conventional casting methods, especially where the new STELEX PrO ceramic foam filter is used. Depending on the geometry of the casting and the arrangement of the patterns in the mould, not all castings are suitable for the KALPUR direct pour technique, and a feasibility study should be carried out beforehand. The ability to manufacture high-quality castings whilst paying attention to economic and environmental pressures is a pre-requisite for a successful position in the market for many manufacturers. Demands are placed, especially in industrial Europe, for continuous improvement in productivity and the development of new and innovative production processes.

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Developments in die coating Technology

Background
Something in the region of 40% of aluminium castings produced globally are made via the gravity diecasting ( permanent mould ) and low pressure diecasting processes. It has always been accepted that a major contributor to the successful manufacture of quality parts is the coating which is applied to the die surface. FOSECO has had for many years a comprehensive range of coatings which give: Insulation control Release from the die Encouragement to fill thin sections fully Control of surface finish Soundness (feedability) The use of DYCOTE die coatings has been widespread in the foundry industry for more than 60 years with the traditional product range modified to satisfy specific customer requirements. The products have also evolved to reflect the change in casting requirements, however, no major developments have been made for some considerable period. Over the past 5 years the market demands regarding die coatings has been changing with productivity and plant utilisation becoming more important within the foundry industry. Any interruption in production and subsequent Type of Coating Typical Grain Size m Thinning Ratio down- time while cleaning and recoating is a major cost and inconvenience to the foundry so improvements in DYCOTE life will offer significant benefits. This has given FOSECO the opportunity to reassess its strategy towards the DYCOTE product range.

Traditional DYCOTE die coating range

The DYCOTE die coating range can be separated into three distinct product types: Insulating coatings Heat conductive coatings Lubricating coatings The insulating coating range is the largest of the three groups. These coatings help maintain metal temperature and therefore metal fluidity during the filling of the mould. The insulating characteristics of the coating will come partly from the constituents and partly from the surface roughness of the coating. The surface roughness is generated by the particle size of the refractory fillers and varies between 10 and 100 microns. In general the coarser the coating the higher the insulation effect. When selecting a die coating for each specific application there is always a compromise between surface finish of the casting and the filling of the mould cavities. Listed below are some typical coatings taken from the FOSECO Insulating coating range. Application, Description

Base Coat DYCOTE D R 87 Insulating Coatings DYCOTE D R 787 DYCOTE D 39 DYCOTE D BN 120 18 1:1 - 1:3 Primer, increases adhesion and thereby lifetime of the top coating Can be applied at higher temperature than standard coatings Where excellent surface finish is essential Coating containing boron nitride for smooth surfaces, although the coating itself has a rough surface, and long holding times Mid range coating for standard applications. Coarse coatings often used for thin walled automotive castings.

10 15 35

1:3 - 1:5 1:3 - 1:5 1:10 - 1:20

DYCOTE D 140 DYCOTE D 7039 DYCOTE D BN 7039 DYCOTE D 34 DYCOTE D 6 ESS

35 78 78 80 85

1:3 - 1:5 1:3 - 1:5 1:3 1:3 - 1:5 1:3 - 1:5

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In certain applications it is necessary to apply conductive coatings to increase heat transfer and encourage rapid cooling. These coatings are all graphite based and can also be used for lubrication. Below is a list of typical coatings from this range: Heat Conductive and Lubricating Coatings DYCOTE D 40 DYCOTE D 38 DYCOTE D 11 DYCOTE D 36 5 10 35 Typical Grain Size m Thinning Ratio Application, Description

Diluted with mineral oil 1:10 1:10 1:3 - 1:5

Graphite/oil ingot coating Colloidal graphite, lubricating coating for low tapers, without binder Semi colloidal graphite, for parts with low tapers, chill coating, without binder

As DYCOTE D 11, however, with additional binder All the above listed coatings are delivered in a concentrated form and have to be diluted with water, except for DYCOTE D 40, which has to be diluted with mineral oil. Selection of die coatings A number of factors must be taken into consideration when selecting a die coating. Firstly the section thickness of the casting. One of the main properties of a coating is its ability to aid the filling of the die. When the casting concerned has a thin section then a DYCOTE die coating with high insulation properties should be considered. Secondly there is the surface finish requirement of a casting. This is very important, however, coatings which give very good surface finish do not also give good insulation. The balance of surface finish and insulation will therefore always be a compromise. Another important factor is the geometry of the casting which can also be critical for efficient feeding. If a casting has isolated thick sections then a specific coating may be required to help directional solidification. Where a casting has small draft angles, then a coating with excellent release may be required. Finally the casting process may also influence DYCOTE die coating selection. For example low-pressure castings can be made with coatings which have different characteristics from gravity castings. By carefully selecting the DYCOTE die coating with the required features, then optimum performance can be achieved. Process control In order to achieve the optimum performance from a particular coating it is now accepted that the mixing and application of the coating is critical. To this end FOSECO have developed a DYCOTE die coating Management Station. This enables the foundry to mix the coating in ideal conditions by accurately measuring the water addition and also gives the option of pre-programmed dilution to eliminate operator error. The use of the FOSECO Carry&Mix mixer also ensures the coating is not only mixed well but is held in suspension during the working period. Cleaning of the Carry&Mix is simple and must be carried out thoroughly to avoid possible contamination with old coating. By creating a central, controlled mixing area then the preparation of the DYCOTE die coating will be given the level of importance and control which it deserves (figures 1 and 2).

Figure 1: DYCOTE die coating management station

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Figure 2: FOSECO Carry&Mix mixer

New Developments As productivity in foundries became ever more important over the years FOSECO were continually asked to develop new ranges of coatings which would improve die life. The original development work was carried out by FOSECO Japan. It was soon evident that by moving to a different binder and more carefully graded fillers then significant improvements could be made in die coating performance. By making these changes a range of coatings were developed equating to the current range, and sold in Japan. A key feature in the improved performance of these products has been the final curing of the coating. The finished die is soaked for 60 minutes at 450C to drive off any chemically combined moisture, reducing the tendency to pick up moisture during storage. This also hardens the surface thus increasing the coating life in service. European Experience When the first trials were made in Europe, using the Japanese developed products, it soon became clear that these very fine coatings were not suitable for European casting techniques. Problems with mould filling were experienced and it was found that a coarser range of Long Life DYCOTES die coating were required for the European market. The European product range to date includes; DYCOTE DYCOTE 1450 DYCOTE 2040 DYCOTE 2050 DYCOTE 3950 DYCOTE 3975 Description General purpose coating. Coarser version of DYCOTE 2050 - for thinner walled gravity die applications such as cylinder heads. Successful for automotive castings. Excellent for low pressure wheel production Good surface finish, excellent release.

Application Best results are achieved with dilution rates of around 1 : 3 Spray on to the die at 200 - 250C To achieve the optimum life time of the Long Life DYCOTE the die has to be cured at 450C for just over one hour Advantages of Long Life DYCOTE die coatings Improved Productivity - Dies run for longer and so the frequency of stopping production to change to a newly coated die is reduced. A reduction in scrap on start up of a newly coated die. It is common when a newly coated die is first cast that the temperature profile may not be correct. Shrinkage or mis-running sometimes results. Again the less frequently a newly coated die is introduced, the fewer problems are created. Reduction in frequency of coating leads to a reduction in labour required in die preparation. As the Long Life DYCOTE die coating is tougher and more wear resistant then the die will run longer at the optimum thickness and condition of the coating, resulting in better quality castings. With the special composition of Long Life DYCOTE die coatings there is less likelihood of settling and segregation during mixing. Reduction in frequency of die cleaning will result in less die wear, improved die life and consistent casting definition. A lower frequency of die cleaning means a reduction in cleaning consumables and less DYCOTE die coating being consumed. Foundries will traditionally touch up the coating on the die to extend the coating life, without removing and recoating. Again the amount of touching up required will be far lower with Long Life DYCOTE die coating.

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Case Studies
Europe In the following table a selection of castings produced throughout Europe using various DYCOTE die coating products are shown.

Casting
Suspension arm Cylinder head Wheel Customer A Wheel Customer B Wheel Customer C Housing

LLDYCOTE
DYCOTE 2050 DYCOTE 2040

Dilution
1:3 1:3

Spray temp
200C 200C

Curing
400C 300C for 3 hours None None None None

Performance
12 shifts 3 days

DYCOTE 3950 DYCOTE 3950 DYCOTE 3950 DYCOTE 1450

1:5 1:5 1:5 1:3

300C 300C 300C 225C

10 shifts 4 shifts Double l4fe. 5 shifts

Conclusion
The developments in DYCOTE die coatings have now given diecasting foundries a wider and more sophisticated range of products from which to choose. The products need to be able to perform such that they satisfy the requirements placed on the industry by casting designers and buyers. By careful product selection, preparation and application better performance can be achieved with subsequent improvements in casting quality, consistency, finish and productivity.

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FILTERCALC* for steel a Windows based programme for sizing foam filters for steel
TM

Abstract
The widely accepted benefits of ceramic foam filters for steel casting include removal of non-metallic inclusions, reduction of turbulence to minimize reoxidation and simplified gating (1,2). However, the filter must be properly sized and applied for maximum effectiveness and cost efficiency. Filter selection historically has been based on tables of flow rate and filtration capacity ranges derived from foundry experience under general melting, pouring and moulding conditions. This has often required interpolation and extended foundry trials to determine proper selections for specific applications. Elaborate methods already exist to design successful filter gating systems, but they are not widely used due to economic and/or time constraints. A new computer programme simplifies and increases the accuracy of filter selection. It uses physical principles herein described governing fluid flow and empirical data from extensive water modelling studies to determine the pressure drop effects of introducing ceramic foam filters into the molten metal stream.

The maximum flow rate of the system is determined by the system choke. For direct pouring systems, the choke is always the exit area of the direct pour unit (KALPUR unit). For in-line gating, determining the location of the choke is more complex, and could be affected by the exit area of the sprue, the filter print, the filter flow characteristics and the foundry process conditions. Depending on the above constraints, the in-line system choke will either be located at the sprue exit or at the filter print exit. Ideally, choking before the filter should be avoided due to the increased potential for turbulence and mould erosion.

Current Filter Selection Methods

Existing filter sizing methods utilize tabular data from general foundry experience. Ranges, rather than specific flow rates and filtration capacities, are normally given for each filter size. It is difficult to adjust these values to account for variations in alloy type, metal cleanliness, moulding conditions and pouring practices found at an individual foundry. Using current methods, once a filter size is selected, the sprue is simply sized by using a recommended sprue-to-filter-area ratio. However, this technique is approximate because clogging of the filter is proportional to the quantity of metal passed through the filter, not the sprue-to-filter-area ratio. Filtration capacity is based on several considerations. Major limiting factors include clogging at which filter flow rate is significantly affected, or failure of the filter structure due to exceeding the filter capacity. Current filter selection methods are severely limited and generally result in over sizing and higher filtration costs. This could conceivably prohibit the use of filtration on a particular casting. To simplify and improve ceramic foam filter sizing accuracy, a unique computer programme has been developed. It is an advanced application tool that considers filter behaviour within, and as part of, the specific gating system to be used.

Introduction
A properly sized filter for a casting meets a maximum mould pouring time requirement while adhering to a filter capacity limitation, which is defined as the amount of metal that will pass through prior to blockage. The pouring time is influenced by the geometry of the casting and mould, alloy type, mould and core materials, pouring temperature, and pressure drop as flow passes through the filter. Filtration capacity is influenced by alloy composition, deoxidation practice, metallostatic pressure, pouring temperature and the filter porosity and frontal area. Besides removing inclusions from steel through filtration, filters modify metal flow and reduce turbulence. The flow modification produced is a function of the filter material, thickness, pore size and inlet flow velocity.

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Physics of Flow
Applied physics can significantly improve filter sizing accuracy. Several methods exist to physically model the flow through a filter. The most accurate and complex require iterative solution of the NavierStokes equations. They employ sophisticated software, are computationally intensive, and generally require user expertise. They are not simple application tools. A less rigorous method is to apply the Conservation of Energy (Bernoulli) (3) equation to solve for fluid flow characteristics. Simply stated, Bernoullis equation defines the relationship between pressure, head height and velocity of a fluid in a system. For simple gating systems, this method is adequate and significantly better than previous filter sizing methods. Complex gating systems require more complete flow analyses. In all cases, physics-based models of filter flow require empirical data describing pressure drop characteristics of the filter as a function of filter inlet velocity. Pressure drop data describes the restrictiveness of the filter and can be measured using water modelling. A detailed report on the development and validation of water modelling data for steel filtration devices can be found in the literature (4,5). The head height, system losses, pouring temperature, alloy density and viscosity, filter type, exit area and thickness all play a role in determining the velocity at the exit of the filter. System losses include not only pressure drop, but also flow losses from turning and contraction/expansion of the gating system. By balancing head height and system losses against one another, the velocity at the exit of the filter can be determined. The flow rate of the system can then be calculated using the filter exit velocity, metal density and filter exit area. While filtration capacity for a given filter is still determined from empirical tables based on alloy type, metal cleanliness and pouring conditions, this more precise calculation of flow rate significantly improves filter selection accuracy.
Figure 2: Steel filter print designs Figure 1: Filter design screen

FP1

FP3

FP4

FP6

FP7

For the Direct pour method, there are several sleeve component shapes to choose from in the drop down menu, including Tube, Insert and Round Neckdown (RND). The entire mould cavity Pour Weight is input, even if there is more than one casting per mould. The number of filters is asked for later, thus allowing the programme to establish the requirements for capacity and flow rate per filter. Note: The programme will assume that the same amount of metal is required to go through each filter. The Maximum Pour Time can be input, or by using the Calculate button, can be determined using the equations from the 1958 US Naval Research Report, "Pouring Times for Steel Castings" (6). The Delay Time input accounts for foundry-specific pouring behaviour. At the start of pouring, the initial flow rate is generally low and increases to steady state flow until the end of pouring. Using an average flow rate to calculate pour time could undersize the filter. Therefore, proper filter sizing requires that the maximum flow requirement be considered.

The FILTERCALC

TM

for Steel Programme

Inputs To use the programme, the user simply inputs already known or easily calculated information in the windows provided on the Filter Design screen (figure 1). Filtration Method can be chosen as In-line or Direct pour. If the In-line method is chosen, there are several filter print types to choose from, as shown in Figure 2.

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The Delay Time is the variable time occurring before and after the steady state flow, resulting from filter priming and human variations in pouring. If a foundry pours hard, or uses automated pouring, this input can be ignored or set to zero. This is the default setting. The Delay Time input is subjective, and is most critical for small castings. The pouring time for sizing is the input Maximum Pouring Time minus the Delay Time. Then, the required mass flow rate is calculated as the metal weight per filter divided by the pouring time for sizing. The Pour Temperature is input, or can be calculated from metal chemistry inputs (using the Calculate button). For the Effective Head Height of the system, a known value can be input or the user can select Calculate to determine it, as shown in Figure 3.

The Alloy Type can be chosen from several alloys. Within the programme, each alloy has its own thermophysical data as a function of temperature, and this information is used to calculate the flow rate. Finally, the Ladle Type (Lip or Bottom pour) and the metal Deoxidation Practice (CaSi/Al or Zr/Ti) are input. These values affect the Maximum Capacity of the Standard Filter Recommendation.

Filter Recommendations
Once the inputs are entered, the recommended filter appears in the Standard Filter Recommendation panel of the screen. The default filter recommendation is 10ppi STELEX ZR. Alternate filter types can be chosen from the drop-down menu, and the resulting size recommendation is given. (Note: The filter size is given for in-line applications, and the KALPUR unit size is given for direct pour applications). The Maximum Capacity and Maximum Flow Rate of the filter are shown, and the programme identifies whether the filter (or unit) was Sized By filter flow rate, filter capacity constraints, or sprue exit area (in-line applications only). The Predicted Pour Time is calculated using the maximum flow rate for the recommended filter and the delay time. This value will always be lower than Maximum Pour Time plus the Delay Time. The Critical Choke Area and Diameter dimensions identify the minimum Sprue Exit Area that can be used before the sprue becomes the choke of the system and reduces the flow rate (inline applications).

Figure 3: Calculating effective head height

This input is very important to determining the metal flow rate, so care should be taken to input correct values. Increasing the head height will result in higher flow rates, and potentially smaller filter size recommendations. See the Direct Pour discussion below.
Figure 4: Filter size options

The optional Sprue Diameter and Sprue Exit Area inputs only apply to in-line systems. The user may choose to allow the programme to calculate these dimensions as described in the Filter Sizing Logic section below. The Capacity Factor input is applied to the Maximum Capacity shown for the Standard Filter Recommendation. It enables the user to adjust the capacity based upon metal cleanliness and foundry experience.

If the recommended in-line filter or direct pour unit was Sized By filter flow rate, it may be possible to evaluate smaller filter/unit options that still satisfy the filtration capacity requirements. However, these options will result in lower Maximum Flow Rates and higher Predicted Pour Times. Options (figure 4) can be evaluated by selecting the Size Options button, next to the Filter recommendation. In this figure, two additional filters are shown that can also satisfy the filtration capacity requirements if the Max. Pour Time constraints can be relaxed.

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The Standard Filter Recommendation is for a STELEX ZR 125 x 125 x 30 mm filter, which would result in a predicted pour time of 8.02 seconds (6.02 actual + 2.0 delay). However, if a slightly longer pour time is acceptable, a 100 x 100 x 25 mm filter could be used, with a total pour time of 11.18 seconds (9.18 + 2). A 75 x 75 x 25 mm filter could be used as well, but the predicted pour time would increase to 18.47 seconds (16.47 + 2).

when the sprue has become the system choke (Sized By). Caution should be exercised whenever the Sprue Exit input constrains the flow rate. A better approach is to leave the Sprue Exit input blank, and allow the programme to output the sprue exit dimensions. If Sprue Exit Area or Sprue Diameter inputs have been entered, check to ensure that the Predicted Pour Time does not exceed the Max. Pour Time. It should also be noted that actual pouring times could be longer than predicted pour times when an adequate pouring rate cannot be maintained. For example, pour rates in excess of 16 kg/s (35 lb/s) are generally difficult to achieve with a lip or teapot ladle, and thus would be difficult to model using this programme.

Filter Sizing Logic

First, the programme sizes the filter to satisfy the Max. Pour Time requirements (maximum flow rate); then it considers filtration capacity.

Direct Pour
For direct pour configurations, the exit area of the KALPUR unit is the choke. First, the smallest KALPUR unit in the database is chosen. The programme calculates the exit velocity as described above; then it calculates the required flow rate, using the KALPUR unit exit area. If the calculated flow rate does not meet or exceed the required flow rate, the programme chooses the next largest size KALPUR unit and recalculates. This continues until a KALPUR unit that meets the flow rate (Max. Pour Time) constraint is found. Care must be exercised in determining the effective head height for a KALPUR unit. When pouring rapidly from a lip pour or tea pot ladle with a large diameter metal stream, the effective head height may be closer to the pouring height of the ladle than any liquid level in the direct pouring unit. In pouring where a smaller metal stream is dissipated into a built-up reservoir of metal above the filter, the metal height in the KALPUR unit would be the effective head height. If the KALPUR unit also meets the filtration capacity requirements, then the programme is done. If not, the programme recalculates, using the next largest KALPUR unit, until the filtration capacity requirement is met.

Filter Prints
The programme allows the user to view the various filter print designs. Examples are shown in Figure 2. Once a filter has been recommended, the user can view the filter print drawing and print out its dimensions (figure 5).

Figure 5: Filter print design drawing

In-Line
The in-line case is more difficult because it requires determination of whether the system choke is the filter or the sprue. If the filter is the choke, the calculations are identical to the direct pour situation. However, if the sprue exit area is the choke, the system is constrained by the sprue, and not the filter. Here, the recommended filter is sized according to the flow rate constraint determined by the sprue exit area. The filtration capacity calculations are then done, as described above. The programme will tell the user

Validation
The FILTERCALC for Steel programme results compare very well with those obtained using published datasheet information. However, because the programme allows for significant adjustment of input variables, recommendations are more accurate than would have been possible using datasheet information. Two production casting examples were analyzed to see if the programme could accurately predict filter sizes and pouring times recorded during actual production. For in-line filtration, a 2-up oil tool casting was selected. For direct pour, a 2-up valve body was selected.

20

In-line Figure 6 shows the cope and drag patterns for the 2-up oil tool casting. Note that the FP1 filter print design is used.

Figure 7 shows the inputs and recommendation. The programme recommends a 100 x 100 x 25mm filter for the FP1 filter print. The filter has a Maximum Capacity of 225.8 kg and Maximum Flow Rate of 16.03 kg/s. (A 224.5 mm head height is input, calculated from the gating system dimensions.) This configuration is Sized By filter flow rate, thus the filter print exit area is the choke of the system. In actual practice, a 100 x 100 x 25 mm filter is used with an FP1 filter print. The actual casting configuration is poured in an average of 8.85 seconds, with a standard deviation of 1 second. This agrees well with the Predicted Pour Time of 8.83 seconds, well within the standard deviation of 1 second. In addition, the measured flow rate of 16.25 kg/s agrees well with the predicted Maximum Flow Rate of 16.03 kg/s, well within the standard deviation of 2 kg/s. Direct-pour Figure 8 shows the cope and drag patterns for the 2-up valve body casting.

Figure 6: Cope and Drag patterns for 2-up oil tool casting

The actual poured weight of the mould is 141.5 kg and the net weight of each casting is 45 kg, for a net yield of 64%. The pouring temperature of the carbon steel is 1602C. The chemistry is: (0.16% C, 0.56% Si, 0.96% Mn, 0.038% Al, 0.07% Cr, 0.08% Ni, 0.02% Mo, 0.019% P and 0.014% S). Electric arc melting is employed. A teapot ladle is used; the desired maximum fill time for this unpressurized runner system is 14 seconds.

Figure 8: Cope and Drag patterns for 2-up valve body casting

The actual poured weight of the mould is 169 kg. The net weight of each casting is 40 kg, for a net yield of 48%. The pouring temperature of the carbon steel is 1606C. The chemistry is: (0.26% C, 0.38% Si, 0.79% Mn, 0.058% Al, 0.16% Cr, 0.06% Ni, 0.05% Mo, 0.015% P and 0.008% S). Electric arc melting is employed. A tea pot ladle is used; the maximum pour time for this unpressurized runner system is 20 seconds.

Figure 7: Filtercalc for Steel inputs and recommendation for oil tool casting

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Figure 9: FILTERCALC for Steel inputs and recommendation for valve body castings

Figure 9 shows the inputs and recommendation. The programme recommends a 4 x 6 direct pour unit (with 100mm STELEX ZR filter). The filter has a Maximum Filtration Capacity of 177.3 kg and Maximum Flow Rate capability of 12.74 kg/s. (This is based on a 117.8 mm head height, assuming the KALPUR unit is 3/4 full, standard practice at this foundry.) This configuration is Sized By filter flow capacity. In actual practice, a 4 x 6, 100 mm direct pour unit is used. The actual casting pouring time averages 14.5 seconds. This agrees well with the predicted fill time of 13.28 seconds. In addition, the actual measured flow rate of 11.65 kg/s agrees well with the predicted Maximum Flow Rate of 12.74 kg/s. The predicted flow rate results are within 8% of actual practice for this direct pour configuration. These results are consistent with other in-line and direct pour configurations that have been evaluated.

References
1. J. Svoboda, "Filtration of Liquid Steel", Steel Founders Society of America Research Report No. 98, May 1986. 2. "Development of Casting Technology to Allow Direct Use of Steel Castings in High Speed Machining Lines", Steel Founders Society of America Report, May 1987. 3. D.R. Poirier, G.H. Geiger, "Transport Phenomena in Materials Processing", TMS, USA, (1994), pp. 79-82 and 119-124. 4. T. Midea, B. Alquist, C. Blackburn, "Increasing the Accuracy of Metal Flow Results in Steel Castings", Steel Founders Society of America Technical and Operating Conference, Chicago, IL, November 2001. 5. T. Midea, "Increasing the Accuracy of Metal Flow Results", Foundry Management and Technology, August 2001. 6. E.A. Lange, A.T. Bukowski, "Pouring Times for Steel Castings", U.S. Naval Research Report, Washington, D.C., 1958.

Summary and Conclusions

To reduce the complexity of sizing filters for steel castings, a unique, advanced filter application tool has been developed. This computer programme generates more-accurate recommendations because filter behaviour is considered within, and as part of, the gating system; because it is based on physical principles governing fluid flow; and because it utilizes foundry-specific inputs. The result is less-conservative recommendations than those derived from flow and capacity ranges traditionally found in datasheets. This offers the potential for more-cost-effective filtration solutions.

22

Low density insulated ladle linings at Sinclair Works

Introduction
The Sinclair Works of St. Gobain Pipelines produces drainage castings in both grey and ductile iron. There are three foundries on site, one producing larger fittings using an airset system, one making rainwater products in metal moulds and the third using a Disamatic machine to make smaller fittings. Metal is melted in coreless induction furnaces in the rainwater and Disamatic shops, whilst the airset foundry receives its metal by transfer ladle from the rainwater foundry. Typical Products are shown in Figure 1. Clearly, the operations involved vary slightly depending upon the size, variety and performance required of the ladle, but a typical sequence is: Clean the ladle shell of all lining material Pour about 75 mm of KALTEK* ISO powder onto the base Coat the internal former with release agent Set the former in place (it is fitted with lugs which engage with sockets on the shell) Feed the powder from its 25 kg bags directly into the gap between former and shell (figure 2)

Figure 2: KALTEK ISO powder being applied Figure 1: Typical products of Sinclair Works

Fill the gap to the desired level Apply a gas torch to the inside of the former for 1 to 2 minutes to initiate the exothermic reaction (figure 3)

Staff and operators are well aware of the importance of controlling the temperature and cleanliness of the iron poured into moulds and ladle linings play a vital part in maintaining this control. KALTEK* ISO is a lightweight, highly insulating and easy-to-use lining material. It was first introduced into the airset and rainwater foundries, and advantages identified there have led to its being used also in the Disamatic foundry. The material is now employed for all pouring ladles throughout the works. These ladles range in capacity from 250 kg to 450 kg of iron. The advantages will apply to many other iron foundries and the prime purpose of this Case Study is to explain what the system is, how it is used and the benefits that can be expected from it.

Lining a ladle with KALTEK ISO

The lining process consists essentially of pouring KALTEK ISO, a dry powder, around a former suitably located within the ladle shell, igniting the powder, allowing the resulting flame to spread throughout the mixture, and removing the former a few minutes later from the hardened body of refractory.

Figure 3: The KALTEK ISO reaction being initiated with a gas burner

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Remove the gas torch and allow the reaction to go to completion (15-20minutes) (figure 4) Remove the former (figure 5) Top off the lining and make up the spout with rammable material

Excellent heat retention Reduction in energy consumption Reduced labour Lining a ladle with the KALTEK* ISO lining is far simpler and quicker than using conventional casting/ramming techniques. For example, a 330 kg ladle used on the Disamatic line at Sinclair works requires some 85 minutes total labour time to remove a used KALTEK* ISO lining and replace it completely. This compares with a labour time of 175 minutes using a rammed refractory. In each case, approximately half the labour time is needed to remove the old lining, a task which involves the use of a pneumatic chisel. The reduction in time for which the chisel has to be used is of considerable benefit in reducing the risk of Vibration White Finger. Rapid replacement of ladles In many foundries, ladles lined with "conventional" materials are frequently kept in use despite the lining being in a poor state and almost certainly resulting in "dirty metal", simply because of the length of time required to replace the lining or effect major repairs. The speed with which a ladle can be lined with KALTEK* ISO and brought back into use contributes to increased productivity and improved quality. Reduced overall costs Although the KALTEK* ISO lining material price per kilogram is higher than that of a rammable refractory, the fact that ladles can be kept in use for far longer without replacement or major repairs means that lining costs are lower, as seen from the table below. This is based on the ladles in use in the Disamatic foundry.

Figure 4: The KALTEK ISO reacting

Comparative costs of lining individual ladles at Sinclair Works 250 kg capacity KALTEK* ISO _ Material Labour
Figure 5: The finished KALTEK ISO lining

330 kg capacity KALTEK* ISO _ 181.50 25.20 0.45 207.15 Rammed _ 99.15 52.65 2.70 154.50

Rammed _ 82.65 36.00 2.70 121.35

163.05 12.37 0.45 175.87

Heating Total

The ladle in use

Before being put into use, the ladle is usually preheated for an hour. The ladle then undergoes no further heating during the shift unless there has been an unusually prolonged stoppage. Lining life varies with the duty, but, for example, on the Disamatic line at Sinclair works, which works a 3shift day, it averages 5 shifts (This compares with 3 shifts on ladles lined with castable material). It is noteworthy that the useful life when working on ductile iron is about two-thirds that achieved on grey iron, because of build-up on the lining. Nevertheless, the life achieved is greater than that of linings made of castable refractory.

Ladle lining costs over 3 shifts KALTEK* ISO _ 250 kg ladle 330 kg ladle 105.52 124.29 Rammed _ 121.35 154.50

Note: KALTEK* ISO lined ladles average 5 shifts before replacement Conventionally lined ladles average three shifts before replacement or major refurbishment. Consistent ladle capacity The fact that ladles stay clean for a longer time when lined with the new material is an additional benefit. The foundry produces SG iron by a process in which a measured amount of a proprietary treatment alloy, based on the nominal capacity of the ladle, is added to the metal stream as it passes through a refractory-lined vessel. Metal is tapped from the electric furnace until the ladle is filled. Variations in ladle capacity can result in the fixed quantity of alloy treating different amounts of metal. Since ladle capacity does not vary to the same extent as with previously-used refractories, greater metallurgical consistency is achieved in the SG iron.

The benefits
Use of the system has many benefits, including: Reduction in overall costs Rapid replacement of linings

24

Consistent ladle capacity

Heat retention The rate of loss of heat from a pouring ladle depends upon a number of factors, hence it would not be possible without a prolonged and detailed study to make precise comparisons of the difference between the rate of temperature loss from a KALTEK* ISO lined ladle and that from a ladle lined with an alternative material. Observations to date, however, indicate that the temperature loss rate of the ladle lined with KALTEK* ISO is about one-third that of the alternative, typically 5C per minute compared to 15C. A model of the comparative metal temperature losses of a KALTEK* lined and cement lined ladle is shown in Figure 6. The prediction was made using a "Ladle Transient Temperature Calculation Program" based on the following assumptions: 350 kg capacity ladle 40mm lining thickness The ladle is in use, the lining is therefore at high temperature The ladle is not covered

The Managers view

" I am a firm believer in the use of KALTEK* ISO lined ladles. It enables us to bring ladles into service more quickly, reduces temperature loss rates, reduces energy consumption and contributes to the reductions in foundry scrap levels we have achieved in recent months. It also has several less obvious advantages. For example, the consistent ladle capacity has simplified the control of metal treatment, whilst the easier removal of linings at the end of their life helps significantly to reduce the hand-arm vibration problem which can arise in carrying out this task". Steve OBrien Plant Manager.

Opportunities for other foundries

350kg of grey iron is tapped into the ladle at 1400C The excellent results obtained at Sinclair Works have already been confirmed at a number of other plants throughout Europe and should encourage many iron foundries to examine their present ladle lining practice and experiment with this simple and effective system. The benefits they obtain will inevitably vary. Some will gain from reductions in the number of defective castings produced e.g. misruns and inclusions are likely to be fewer others will find the saving in labour very valuable and a few may even discover that the lower weight of refractory will enable them to use larger ladles on existing runways. The energy savings possible are another important feature, since lower heat losses and better yield lead to energy savings in melting. Many foundries use considerable (but unmetered!) quantities of gas to cure and preheat ladle linings and should consider the new material as an opportunity to reduce this cost. The knocking out of conventional linings can be a dirty and strenuous activity and has serious Health and Safety implications. The ease of removal of the KALTEK* ISO linings is therefore an important benefit. In carrying out trials, it should be remembered that the very property which makes removal of the lining so easy also makes it more prone to mechanical damage than a rammed or cast lining of denser refractory. It is for this reason that the tops and lips of the ladles, which need frequent cleaning of buildup, are occasionally made of a denser refractory.

Figure 6: A model of heat loss from molten iron contained in a KALTEK ISO lined ladle compared with a refractory cement lined ladle

Metal quality
Good ladle practice is an important feature of practical metal control. The KALTEK* ISO lining system now in use contributes to the reduction in levels of foundry scrap, thanks to cleaner linings, better control of ferro-alloy addition levels and reduced temperature losses during pouring. Reduced energy With the need for foundries to meet their obligations under the Climate Change Levy Agreement, any reduction in the use of energy is welcome. Whilst a gas torch is used to ignite the refractory powder, to dry any topping refractory and to pre-heat the KALTEK* ISO lined ladle for up to one hour before initial use, the amount of gas used in more conventional systems, where the ladle is likely to be under a pre-heater for 5 to 6 hours , is far greater. It is also worth noting that improved ladle practice helps to improve overall yield of good castings, thereby reducing the amount of metal which has to be melted to produce a given output of good castings and resulting in a lower electricity consumption.

Acknowledgement
The authors would like to acknowledge the assistance provided by the employees of Sinclair Works St Goban Pipelines in the preparation of this paper.

COMMENT Editorial policy is to highlight the latest Foseco products and technical developments. However, because of their newness, some developments may not be immediately available in your area. Your local Foseco company or agent will be pleased to advise.

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GIFA 2003

hall 12, stand 12 A 05

Registered in England No. 468147

ISSN 0266 9994 Printed in England 40006355

Design & Production: Warwicks UK Limited, Coventry, England.

Foseco International Limited P.O. Box 5516 Tamworth Staffordshire England B78 3XQ