At the Foseco booth, visitors will discover new, innovative solutions for iron, steel and non ferrous foundries. We look forward to seeing you on our stand in Hall 12 Stand no. 12A01.
Feeding Systems for Iron and Steel Foundries
The application of feeder sleeves is a major factor in reducing metal remelt and fettling costs in foundry customers. By working in close partnership with foundries, Foseco continues to deliver tailored solutions for specific applications and develop new process technologies.
In this year’s exhibition, we will showcase several new developments that advance the capabilities of the foundryman in optimising casting yield, minimising defects and reducing production costs. The new range of FEEDEK VAK spot feeders will be presented through a variety of ductile iron castings. This patented development provides an improved feeder neck pass-through on the most critical feeding applications.
The development of FEEDEX SCK (Sleeve Construction Kit) feeders opens up the application of spot feeding to the jobbing iron and steel sector where the modular product range enables our customers to optimise both casting yield and fettling costs on large steel and iron castings.
All relevant exhibits will feature simulations using the most recent version of the Foseco Pro Module for MAGMASOFT.
Mould and core coatings can significantly influence a foundry’s manufacturing costs. The displays will highlight specific examples of Foseco’s innovative approach to reduce casting manufacturing costs through product development and by enhanced coating application technologies. Highlights include the launches of an innovative new coating range for automotive foundries to fulfil most stringent demands on inner cleanliness and a state-of-the-art coating application control system to improve the consistency of coating at the point of application.
Coatings can have a direct influence on automotive engine performance and contribute directly to the achievement of the environmental aspects of Euro 6 and Euro 7 regulations. By optimising the inner cleanliness of critical cavities in castings such as cylinder heads and engine blocks, longer service intervals and reduced cooling and lubrication liquid exchange can be achieved. Foseco will showcase a new range of so called “inner cleanliness” coatings than enable automotive foundries to move from suppliers to engine design partners.
For the cleanest casting without scrap, the Intelligent Coating Unit (ICU) is the ultimate tool to control and automate coating dilution and application. Control, adjustment and preparation of coatings for foundries are the most important prerequisites for perfect casting without coating layer related defects. With its newly developed Intelligent Coating Unit, Foseco has set itself the task of eliminating such errors from the outset.
When the highest surface quality is required, coating quality cannot be left to chance. The process stability of the ICU completely eliminates both random and human errors. Real-time measurement of coating density ensures consistent application, thereby shortening drying times and reducing coating consumption such that a significant increase productivity can be achieved. In addition, coating layer related defects are reduced to a minimum and thus also the reject rate is notably reduced. The ICU operates in a closed system, which also enhances the entire working environment.
Ferrous Metal Treatment
The FERROLAB V thermal analysis system enable foundries to accurately monitor metallurgical process performance and take immediate corrective action by analysing base and final iron quality. FERROLAB V can be used on the melt deck to minimise variances in base iron by providing the operator information necessary to adjust the characteristics of iron within predetermined process specifications. It provides real time measurement of %Ceq, %C, %Si and the nucleation status of the iron. FERROLAB V can be used at the pouring station to provide real time measurement of the metallurgical quality of the final iron and highlight the possibility for defect formation.
The system is simple to install and has a user-friendly interface and real savings can be achieved from a reduction in scrap rate, and improvements in the quality and consistency of castings. FERROLAB V thermal analysis systems enhance the performance and value of the Metallurgical Solutions portfolio from Foseco.
Flow Control for Iron and Steel Foundries
Foseco will highlight the latest technologies available for controlling the metal flow in steel ladles and autopour iron applications.
We will show alternative steel ladle lining and flow control systems for both cold start and hot start ladle systems.
TRIAD Z lining system is a new generation of castables that bring long lining life. TRIAD Z are no-cement castables with superior hot strength properties and slag resistance. The drying procedure before usage takes half the time compared to conventional low cement castable.
Foseco will show the KALTEK board system for bottom pour ladles, a unique lining system that requires no preheating. The KALTEK board system is suitable for ladles up to 25T capacity and more for specific projects. A new generation of KALTEK board multi-life system has been introduced to the market to combine the KALTEK board properties (no pre-heating, metal cleanliness, insulation) with a KALTEK set that can be used up to 5 times and allow thermal cycles and nozzle exchange.
Foseco’s new, VISO isopressed zoned nozzle offers the steel foundry a multi-life nozzle for improved productivity. The zoned nozzle uses a combination of different refractory systems to enhance strength and performance, thereby enabling repeated use of the nozzle in a steel foundry ladle.
Furthermore, we will show the latest flow control technology for grey and ductile iron, especially for unheated pouring boxes. Here, we will show a range of design and refractory combinations to meet the requirements of a variety of autopour applications.
Refractory Linings for Iron and Steel Foundries
Foseco will highlight the latest developments in foundry lining technology including the launch of the TRIAD Z no cement castable range for iron and steel foundry applications.
No cement castable have been available for many years and are attractive for minimising the furnace downtime during the relining process. The recent development of the TRIAD Z range bring added advantages in terms of superior slag resistance and enhanced hot properties of the castable system.
TRIAD Z can be cast, pumped and shotcreted is now available for most of iron and steel foundry applications such as long campaign cupola melting, channel holding and pouring furnaces as well as iron and steel ladle applications.
On the stand Foseco will present a complete package of lining and purging refractories designed for long life and improved metal cleanliness in coreless induction furnaces melting steel grades. The portfolio consists of high quality KELLUNDITE lining systems suitable for melting a wide range of steel alloys and purge plugs utilising integral earth protection and precise gas flow control systems to ensure safe and optimal operation.
Finally, Foseco will also show a complete package of long-life linings for long campaign cupolas melting iron grades. The cupola portfolio consists of high quality RAMWELL ramming mixes and HYDRA-MAX low cement castable lining systems enriched with silicon carbide and graphite aggregates to improve slag resistance.
Feeding and Filtration for Aluminium Foundries
The methoding area will highlight the optimal use of foam filters, die coating and feeding systems in sand and gravity die casting applications. Applications will be shown for aluminium and copper base castings demonstrating excellent yield combined with improved casting quality.
Foseco will launch the FEEDEX NF1 range of exothermic feeders designed for aluminium applications. The sleeve material is highly exothermic, provides a quick ignition and has a high strength and due to its excellent feeding performance, manual application of exothermic powders is avoided thereby reducing emissions.
The new range of DYCOTE SAFEGUARD products are nano-ceramic top coatings to be applied on top of the existing insulating DYCOTE base coating to increase the lifetime up to 300% (depending on application). The longevity of a die coating is essential for the die casting process. The longer lifetime leads to reduced interruptions for touch-up and therefore increased productivity.
Finally, new case studies of a filter and sleeve combination with conventional running and gating systems used in high quality, technically demanding applications will be displayed. All relevant exhibits will feature simulations using the most recent version of the Foseco Pro Module for MAGMASOFT.
Non Ferrous Melt Shop
INSURAL multi-part and highly insulating dosing furnace linings for aluminium foundries combine energy savings with long-service life and resistance to oxide build-up.
The use of energy efficient dosing furnaces in Aluminium foundries is seen by many as the best available technology today. Foseco is now able to supply a new multi-part and highly insulating lining made of INSURAL which is delivered ready to install. Installation can be achieved in 3 days with no ongoing hydrogen issues and due to a totally dry installation process no sintering of the lining is necessary. Energy saving can be as high as 17%.
Non Ferrous Metal Treatment
Controlled Melt Quality is Key for Aluminium Foundries
In recent years, a number of new features and technologies have been added to the Foseco FDU and MTS equipment range – the state of the art in technology for the automated treatment of an aluminium melt. SMARTT software offers various programs for rotary degassing and the operator simply defines a melt quality after treatment. SMARTT predicts the best treatment practice based on ambient conditions, melt temperature, rotor design and alloy composition. The treatment parameters are automatically transferred into the FDU MTS.
In conjunction with innovative rotor designs Foseco guarantees a constant quality level and reliable results. SMARTT not only controls degassing but together with forming gas any defined hydrogen level can be reached. A customised report system records all parameters.
The chemical grain refiner in granulated form can be added through the automated Metal Treatment Station. This grain refiner offers many advantages such as improved melt fluidity during casting, reduced inclusion level and better mechanical properties. The dross remaining after the treatment is low in metal which additionally saves costs. The dosing equipment uses a gravimetric load cell to ensure highest dosing precision for best metallurgical results as well as repeatability and traceability.
Shaft and rotor design are continuously improved to offer high efficiency in degassing at long service life.
Crucibles for Non-Ferrous Foundries
Foseco offer a complete range of silicon carbide and clay graphite crucibles, retorts and other specialised shapes for use in fuel fired, induction and electric resistance furnaces and new crucibles with a THERMACOAT external coating layer offering enhanced insulation and reduced power consumption in induction furnace applications.
In the Non Ferrous metal transfer area ENERTEK ZnO will be featured highlighting the energy and cost saving potential in melting and metal processing furnace applications.
Refractories for Non-Ferrous Foundries
Monolithics also now play a significant role in modern aluminium foundries. Foseco’s ALUGARD low-cement castables and TRIAD no-cement castable contain a new aluminium “non-wetting” additive giving excellent resistance to corundum development across a wider temperature band, while the dry-vibratable lining KELLUNDITE is ideally suited to coreless induction melting furnaces.