NO.

268
JUNE 2019

FOUNDRY PRACTICE
The authoritative magazine for foundry engineers
- SINCE 1932 -

| METALLURGICAL AND POURING CONTROL

Theory and practice of grain refining for aluminium
alloys - Utilizing COVERAL* MTS 1582

| COATINGS, BINDERS, FILTRATION, METAL

TREATMENT
Working together in partnership - Excellence in
aluminium casting through cooperation

| MELT SHOP REFRACTORIES

Dosing furnace lining with INSURAL* pre-cast
shapes reduces downtime in foundries

| FEEDING SYSTEMS
Brand-new innovation for the non-ferrous sector:
The exothermic feeder FEEDEX* NF1
 EDITORIAL
Dear Readers,
Welcome to our 268th edition of our in-house technical journal of
Foundry Practice. The journal, now in its 87th year, is designed to inform
foundrymen of Foseco’s latest technologies and application techniques
to ensure the ongoing advancement of our customer’s foundry practice.

Non Ferrous is becoming more and more important in the daily world!
Lighter applications, beautiful and perfect haptic solutions are very
much in demand with the foundry‘s customers. Would you like to find out
more about our latest developments? You will find answers in this book.

Theory and practice of grain refining for aluminium alloys - Utilizing COVERAL MTS 1582
Salt form grain refining offers improvements in grain refining of aluminum alloys. These improvements can be
demonstrated via some industry standard techniques and then quantified for the technical and/or economic
benefit to a casting and to the foundry that pours them.

Working together in partnership - Excellence in aluminium casting through cooperation

For the production of high quality castings it is essential that the best decisions are made at every step of the
process from design and development of the component, the moulding practice, how the metal is prepared
and finally the pouring and solidification of the casting. A cooperative approach ensures that a broad range of
options can be considered and best practice is continually improved. This article details how this philosophy of
partnership between supplier and customer contributes to the production of best-in-class aluminium castings.

Dosing furnace lining with INSURAL pre-cast shapes reduces downtime in foundries
A completely dry lining system using INSURAL pre-cast shapes eliminates time-consuming sintering during
re-lining and the required aluminium melt density index is achieved immediately upon production start-up.
Significant energy savings can be realized due to the highly insulating nature of the INSURAL lining system.

Brand-new innovation for the non-ferrous sector: the exothermic feeder FEEDEX NF1
FOSECO* launches the first exothermic feeder for NE applications. Quick, steady and long-lasting reaction, high
strength and improved feeding effect characterize this recipe.

JENS OHM
Director Non-Ferrous EMEA
 CONTENTS
4.

13. 17.

21.

4. NON FERROUS FOUNDRIES

METALLURGICAL AND POURING CONTROL 17. NON FERROUS FOUNDRIES
MELT SHOP NON FERROUS
Theory and practice of grain refining for
Dosing furnace lining with INSURAL pre-cast
aluminium alloys - Utilizing COVERAL MTS
shapes reduces downtime in foundries
1582
Author: Dirk Schmeisser
Authors: Pascaline Careil, Brian Began

13. NON FERROUS FOUNDRIES

COATINGS, BINDERS, FILTRATION, METAL
21. NON FERROUS FOUNDRIES
FEEDING SYSTEMS
TREATMENT
Working together in partnership - Brand-new innovation for the non-ferrous
Excellence in aluminium casting through sector: the exothermic feeder FEEDEX NF1
cooperation Author: Arndt Fröscher
Authors: Enrique Pardo, Luis Merchan
THEORY AND PRACTICE OF GRAIN
REFINING FOR ALUMINIUM ALLOYS
- UTILIZING COVERAL MTS 1582
Authors: Brian Began, Foseco USA & Pascaline Careil, Foseco Europe

The need for smaller grains is vital to achieving the required properties when pouring most cast aluminum
alloys. Whether the desired results are high mechanical properties, leaker free castings, a cosmetic
appearance or improved structural soundness, smaller grains are impactfully beneficial. Accordingly, there
is a desire to improve both grain refining and the ability to quickly and effectively assess grain refinement
effectiveness. This paper discusses both the need for smaller grains and the principle fundamentals of
grain refining. Moreover, the paper reviews commercially-available grain refiner forms and currently
available methods for assessing grain refinement. Finally, the paper introduces a new and improved flux
form grain refiner (COVERAL MTS 1582) and documents two recently successful case studies where the
COVERAL MTS 1582 was utilized to improve castings in both a low pressure wheel foundry and a high
production sand moulding foundry, respectively.
Page 4
Foundry Practice No. 268
 INTRODUCTION In general, those castings with slower + 
Aerospace and military castings
cooling rates and larger variation requiring high mechanical
Grain refining is an essential part of the in casting thickness, require grain properties for difficult applications,
aluminium casting process which aims at refinement more than other casting grain refining is highly beneficial.
reducing the size of primary aluminium designs. + Sand and investment castings where
grains during the solidification phase. This There are several casting segments the long solidification times cause
process has many benefits for most hypo- where grain refining is critical including: large grain growth and difficult
eutectic aluminium alloys as it improves +  Wheel foundries where grain feed paths without optimized grain
feeding, elongation and mechanical refinement and cleaning are crucial refining.
properties, increases resistance to fatigue, for achieving the required feeding
improves casting machinability, reduces and cosmetic surface finished of the
hot tears, helps disperse micro-shrinkage, casting.
decreases the size of porosities and reduces + Safety critical automotive
thermal treatment cycles. Historically, castings such as suspension
grain refinement has been achieved using parts, turbochargers, and brake
master alloys, with the most commonly components which require good
used grain refiner mechanism involving fatigue properties.
the release of Titanium diboride into the +  General automotive castings like
melt. Grain refining is especially important cylinder heads, engine blocks,
in aluminium foundries using investment, manifolds in gravity diecast where
sand, gravity die, or low pressure die an intermediate level of grain
casting processes due to the potential refinement might suffice for the
for delayed cooling and complex casting mechanical property requirements,
designs with varying section thickness. but the improved feeding from grain
refinement helps prevent leakers.

Page 5
Theory and practice of grain
refining for aluminium alloys
 GRAIN REFINEMENT Ceramic Angle
MECHANISM IN TiB2 60°
ALUMINIUM ALLOYS ZrB2 106°
HfB2 134°
TARGET OF ALL MELT TREATMENT PROCEDURES IS
AN IMPROVEMENT OF MECHANICAL PROPERTIES TaB2 125°
TiC 118°
Grain refinement affects the α-mixed crystal in the alloy.
At decreasing temperature those α-mixed crystals grow. ZrC 150°
Grain size depends on cooling rate during solidification. The SiC 135°
addition or formation of nuclei increases solidification speed
and decreases the grain size. HfC 148°
NbC 136°
TaC 145°
TiN 135°
ZrN 167°
NbN 156°
AlN 138°
Table 1: Contact angle of different ceramic materials [1]

MASTER ALLOY AND CHEMICAL PRODUCTS

COMPARISON

Considerations when using master alloy grain refiners

+ AlTi5B1 - AlTi3B1 - AlTi5B0,2 - AlTi10B1
+ TiB2 nuclei are pre-formed in an aluminium matrix
+ Easy to apply
+ Risk of oxides or impurities in the rod or waffle
+ Moisture and oxides on rod surface contaminate melt
Figure 1: Al-Si phase diagram

almost 180° approx. 60° almost 0°

non-wettable good wettable almost fully wettable
Figure 2: Nuclei needs a good wettability by melt Figure 3: Heterogeneous nucleation as a function of wetting angle

Benefits of chemical products are:

+ Contain metallic titanium and boron salt or titanium and
boron salt
+ TiB2 nuclei are in-situ formed in the melt – fresh
surface – higher surface energy and lower θ angle
+ No risk of impurities
+ Additional cleaning effect

Figure 4: Young‘s equation

Page 6
Foundry Practice No. 268
REASONS FOR BETTER MECHANICAL STRENGTH Both issues feature excellent articles on the MTS 1500
WITH CHEMICAL PRODUCTS technology [References 2 and 3].
MTS 1582 should be used with the melt at a temperature
We identified several reasons for archieving better mechanical
higher than 720 C. The reaction by-product from this treatment
strength with chemical products which are:
produces an extremely dry ash-like dross that is easily separated
+ Chemical products and master alloys with pre-formed
nuclei impact the contact angle θ differently from the liquid metal with a coated skimmer or similar tool.
+ θ for TiB2 = 60° is a theoretical value for an ideal
nucleus
+ θ for TiB2 from master alloys is significantly higher due E VALUATING GRAIN REFINEMENT
to reduced surface energy
+ θ for TiB2 from chemical products is close to 60° EFFECTIVENESS
or even below due to fluxing effect from chemicals Since grain refinement is critical to achieve the desired
(fluorides) properties of aluminium castings, it is important that there
are methods for assessing grain refinement effectiveness.
The most common methods for evaluating grain refinement
COVERAL MTS 1582 effectiveness are as follows:
FOSECO has developed a novel granulated flux COVERAL + Elemental spectroscopy
MTS 1582 that is capable of both grain refining and cleaning + Thermal analysis
aluminium alloy melts. COVERAL MTS 1582 is highly + Microstructural evaluation
concentrated in titanium and boron which form both titanium
diboride and aluminum boride in situ leaving fresh nuclei
ELEMENTAL SPECTROSCOPY
within the aluminium melt. These finely dispersed species
are highly efficient nuclei that promote a fine equiaxed grain Elemental spectroscopy is perhaps the most commonly
growth during solidification. employed method for assessing grain refinement, but
In addition to strong grain refining, COVERAL MTS 1582 flux it is also the least effective of the three methods listed.
is also a very good cleaning product that will react to remove Spectroscopy only determines the total concentration of an
oxides and inclusions from the melt. No additional cleaning/ element - however Titanium is usually present in other forms
drossing flux is required, resulting in lower overall process costs. and phases in addition to TiB₂ and these other phases do
COVERAL MTS 1582 is a sodium- and calcium-free granulated not impact grain structure. Foundries will measure Ti into the
flux suitable for all types of aluminium alloys except hyper- alloy range (typically 0.10-0.25% by weight) and assume that
eutectic alloys but including those alloys containing large because they are in range, they are achieving sufficient grain
amounts of magnesium. refinement. Consequently, given this issue, some foundries will
also measure boron (typical range 5-25ppm) as an additional
control. Tight controls of Ti and B do typically result in effective
APPLICATION OF COVERAL MTS 1582 grain refining; however, more advanced methods like thermal
analysis and microstructural analysis ensure higher probabilities
COVERAL MTS 1582 is specially designed for use with FOSECOs
of optimized grain refinement.
MTS 1500 rotary degassing and melt treatment equipment,
whereby controlled flux additions are made directly into a melt
vortex and mixed vigorously. PLC controlled additions of the THERMAL ANALYSIS
treatment flux are added into the vortex and mixed to complete
Thermal Analysis is perhaps the fastest growing method for
reaction prior to the vortex breaker baffle board re-engaging
assessing grain refinement as it is quick and more accurate
the melt, effectively stopping the vortex. After the vortex has
than elemental spectroscopy. The THERMATEST* 5000 NG III
been stopped, the MTS completes a standard rotary degassing
(pictured in Figure 5) is a widely used thermal analysis unit used
process and the treated metal in the ladle or crucible is used for
to quickly and accurately assess grain refinement effectiveness
transferring and/or casting.
in aluminium alloys. Thermal analysis involves collecting
For further information of the MTS 1500 process, readers are
data of temperature versus time of a solidifying melt sample
advised to review Foundry Practice Issue 247 (2007) or the
and comparing the curve to a set of known reference curves
Foundry Practice Special Edition for AFS CastExpo (2008).
algorithmically. The THERMATEST 5000 NG III unit’s algorithm
analyzes the sample curve liquidus and computes a score on
a scale from 1-9 for evaluating grain fineness (GF). A score of
1 references a curve that compares with curves exhibiting no
grain refining.

Page 7
Theory and practice of grain
refining for aluminium alloys
In contrast, a GF score of 9 is achieved when the sample curve
compares with those curves known to have produced “perfect”
grain refining of melts with the same alloy composition. A
pictorial representation of the THERMATEST 5000 NG III grain
refinement levels is provided in Figure 7. Of note, THERMATEST
5000 NG III unit also provides the side benefit of helping to
assess eutectic modification effectiveness in Al-Si alloys
[References 4 and 5].

EVALUATION OF GRAIN SIZE WITH THERMAL

ANALYSIS
For a given cooling speed, the size of the grain depends on the
amplitude and duration of the undercooling, which appears at Figure 5: Photograph of a THERMATEST 5000 NG III unit
the formation of primary aluminium crystals.
+ When the undercooling is high and duration medium
THERMATEST 5000 NG III measures the following Liquidus
(Fig 6a), grain size is coarse.
parameters:
+ When there is no undercooling (Fig 6b), grain size
is very fine.
+ Temperature θ2 (°C)
+ When undercooling is low but duration is high, the + Undercooling Δθ (°C)
grain size is very coarse.
+ The duration of undercooling t1 (in seconds)

Fig 6a Fig 6b
Temperature Temperature
θ1: Temperature at which the solidification
begins
θ2: Maximum temperature reached at the end
of undercooling
Δθ: Apparent undercooling equal to θ2-θ1
t1: Duration of undercooling

Time Time
Figure 6a and b: Profiles of the cooling curve at the solidification of primary aluminium crystals in case of hypoeutectic alloy

Score 0.5 Score 1 Score 2 Score 3 Score 4 Score 5

Score 6 Score 7 Score 8 Score 9

Figure 7: Test of grain refinement - Standard plate with Grain Fineness (GF)

Grain refinement is considered fully optimized when the We recommend setting a minimum grain size index for each
undercooling is nil and grain size index is equal to 9. However, casting, correlated with desired elongation of mechanical
for certain alloys and thin shaped castings in permanent properties. For Al-Cu5%MgTi alloys, the absence of undercooling
moulds, a lower grain size index (5 - 9) would be expected and may not be sufficient to avoid hot tears. A stronger grain
is acceptable due to the higher cooling rate with permanent refinement is recommended to improve the alloy’s performance.
die casting.

Page 8
Foundry Practice No. 268
LIQUIDUS CURVES: COMPARISON OF TIB RODS
WITH COVERAL MTS 1582
The lower the undercooling at Liquidus, the stronger the grain
refinement. COVERAL MTS 1582, at much lower addition rate
(0.11 % vs 0.2 % for AlTi5B1 rods), performs better compared to
AlTi5B1 rods.

Figure 8: Thermal analysis curves

OPTICAL MICROSCOPY (BARKER TEST)

Alloy: AlSi7Mg0,3
Optical microscopy is the final methodology employed by COVERAL MTS 1582
foundries to assess grain refinement. Optical microscopy is Addition rate: 0,1%
considered the most representative method for assessing grain
refinement but is time-consuming and resource intensive. Optical
microscopy involves grinding and polishing test specimens
to microscopic levels to be evaluated for grain size under a
microscope. One popular method for optical microscopy is the
Barker test. The LectroPol-5 from Struers is used for electrolytic
etching with Barker reagent consisting of a 5% tetrafluoroboric Figure 9a: Before treatment. Grain size dm [µm] = 984
acid in distilled water. The sample to be tested acts as an anode
in a galvanic cell, which removes material from the sample
surface and an anodic layer can be formed. With the Barker
method, under a polarized light, a colored representation of the
grain structure of aluminum materials is achieved. It is possible
to carry out microscopic testing with up to 1000x magnification.
Figure 9b: After treatment. Grain size dm [µm] = 206

A B A Alloy: AlSi7Mg0,3
Rods AlTi5B1
0.08 % addition rate
Grain size Ø = 422 µm

B COVERAL MTS 1582

0.05 % addition rate
Grain size Ø = 237 µm

Figure 10: Comparison of TiB rods with Coveral MTS 1582: grain size

Page 9
Theory and practice of grain
refining for aluminium alloys
 CASE STUDIES
WITH COVERAL MTS 1582
1: European foundry
A European wheel foundry was interested in improving its melt
treatment practices by utilizing COVERAL MTS 1582 with a FDU
featuring MTS 1500 technology. This wheel foundry pours a
standard AlSi7Mg alloy and historically performed grain refining Figure 12: Microstructure before and after treatment with COVERAL MTS
1582.
by making manual additions of TiBor rod into a transfer ladle dur-
ing degassing. It was the foundry’s target to automate the grain
refining process all while capturing the typical benefits (drier Treatment parameters
dross, lower spend, smaller grain) achieved when grain refining INSURAL ATL 600 with 500 kg of
with COVERAL MTS 1582. The treatment parameters of the new Ladle
AlSi7Mg
process featuring COVERAL MTS 1582 can be found in Table 2.
Temperature 730 - 760 °C
After the new process grain refining with COVERAL MTS 1582 250 g COVERAL MTS 1582
was implemented, pictures were taken of the ladle dross (Figure Addition rate
(0.05 % of the melt weight)
11), thermal analysis curves (Figure 13) and microstructures
(Figure 12). Treatment time 6 minutes
Inert gas flow 20 l/min N2
Rotor speed 450 rpm for MTS FDR 190.70
Table 2: European Wheel Foundry (EWF) treatment parameters.

Figure 11: Photograph of extremely dry dross in transfer ladle after Figure 13: Thermal analysis curves
treatment with COVERAL MTS 1582.

2: American foundry The first part of the project involved using a THERMATEST 5000 NG
Littlestown Foundry is a sand and low-pressure (LP) mould III unit to assess the incumbent procedure and then developing
aluminium foundry in Littlestown, Pennsylvania in the USA. The an optimized procedure using the MTS 1500 and COVERAL MTS
main alloy poured by Littlestown Foundry is a standard 356 alloy 1582. The results of the THERMATEST 5000 NG III evaluation are
(AlSi7Mg). In the sand foundry, Littlestown casts some difficult presented in Table 3.
castings that are subjected to pressure testing with air to make
sure they are leak free for application. After reducing scrap Average
Sample #
through improved grain refining in the LP foundry from 13.6% to Grain Fineness (GF)
2.7% by converting from metallic TiBor (10%Ti, 1%B) to COVERAL Sample before treatments 5.8
MTS 1582, a similar project was undertaken in the sand foundry.
The aim was that by improving the grain refining using COVERAL Standard TiBor Additions 6.8
MTS 1582 - introduced via an MTS 1500 unit - in place of metallic COVERAL MTS 1582 9.0
TiBor rod, the sand foundry would see similar benefits in the form
of reduced leakers and lower spend. Table 3: Results of THERMATEST 5000 NG III evaluation with the COVERAL
MTS 1582 grain refining flux.

Page 10
Foundry Practice No. 268
The THERMATEST 5000 NG III evaluation confirmed that The results of the mechanical testing evaluation are shown in
the metallic TiBor rod was successful in raising the Grain Table 4. The results exhibited positive improvement in all three
Fineness value from insufficient (5.8/9.0) to an improved and metrics evaluated, i.e., ultimate tensile strength (UTS), yield
more acceptable level of grain refining (6.8/9.0). However, strength (YS) and % Elongation. Accordingly, the decision was
the THERMATEST 5000 NG III unit also confirmed that a made to convert to the new process to make a full assessment
huge improvement to a fully optimized level of perfect grain of the new process featuring COVERAL MTS 1582 and a FDU
refinement (9.0/9.0) was possible with the COVERAL MTS featuring MTS 1500 technology.
1582. Hence, mechanical test bars were poured and evaluated
to assess any potential impact of the new process featuring the
COVERAL MTS 1582.

Incumbent New Process Featuring MTS 1500

Test
TiBor Process & COVERAL MTS 1582
UTS in psi (MPa) 40,000 (276) 41,290 (285)
YS in psi (MPa) 34,500 (238) 35,100 (242)
Elongation (%) 4% 5%
Table 4: Results of mechanical testing of preceding treatment samples and samples collected after the implementation of a MTS 1500 with COVERAL MTS 1582.

Finally, after four months in production, the new process change SUMMARY &
was evaluated economically. The following economic benefits
were achieved after implementation: CONCLUSIONS
COVERAL MTS 1582 is a universal grain refining and cleaning
+ Reduction in annual projected spend on grain refiners and flux for treating aluminium alloys. It forms in situ Aluminium
cleaning flux by $276 per day, $1,380 per week, $5,750 per boride and Titanium boride which are the most suitable
month or more than $69,000 per year. nuclei, within aluminium melts. Creating TiB2nuclei in situ is
+ A ten-fold reduction in projected impregnation costs from more effective than releasing pre-made TiB2nuclei into a melt.
a starting point that exceeds $1,500 per month to less Elemental spectroscopy, thermal analysis with a THERMATEST
than $150 per month. 5000 NG III and optical microscopy are three methods for
+ The calculated payback for the MTS 1500 unit when assessing grain refinement effectiveness within a melt; the
factoring in the lower grain refining spend, the lower latter two methods being the most efficient. Experience in
flux cleaning flux spend and offsetting it with the slightly both a low pressure wheel foundry and high production
higher spend on filters is just over 6 months. greensand foundry has confirmed the benefits of superior
casting mechanical properties and lower overall process costs
A full peer-reviewed paper (paper #19-015) on the Littlestown when grain refining using COVERAL MTS 1582 through an MTS
Case Study was published with the AFS 123rd Metalcasting 1500 unit.
Congress Proceedings in April 2019 and is available for a more
extensive review.

Page 11
Theory and practice of grain
refining for aluminium alloys
 REFERENCES
CONTACT
1. G. Samsonov, A. Panasyuk und G.
Kozina, Poroshkovaya Metallurgiya,
Nr. 11, pp. 42-48. (1971)

2. Careil, P., & Simon, R. MTS 1500

Automated Metal Treatment Station.
Foundry Practice Issue 247. p. 15-20.
(June 2007)

3. Careil, P. & Simon, R. MTS 1500 PASCALINE CAREIL

Automated Metal Treatment Station.
EUROPEAN PRODUCT
Foundry Practice Special Edition for
Cast Expo 2018. p. 1-6. (May 2008) MANAGER NFMT

4. Stonesifer, J. & Began, B. Degassing and

Flux Grain Refining in a Continuous [Link]@[Link]
Well at Littlestown Foundry. AFS 123rd +33 6 23 17 02 25
Metalcasting Congress Proceedings.
Atlanta, GA : American Foundry
Society. (2019)

5. Careil, P., & Kientzler, P. Thermatest

5000 NG III: thermal analysis
equipment designed to predict and
control the structure of aluminium
alloys before casting. Foundry Practice
Issue 250. p. 2-6. (September 2008)
BRIAN BEGAN
APPLICATION MANAGER
NFMT
[Link]@[Link]
+1 440 863 2755

DISCOVER MORE

Want more info about

grain refining with COVERAL?

Page 12
Foundry Practice No. 268
WORKING TOGETHER IN PARTNERSHIP
– EXCELLENCE IN ALUMINIUM
CASTING THROUGH COOPERATION
Authors: Enrique Pardo & Luis Merchan, Foseco Iberia

Aluminum gravity casting production continues to grow, in many cases replacing ferrous materials, with
increasing demand in industrial sectors such as energy, defense, medicine and transport. The reduction in
the weight of the components is a very attractive point, and the latest technological advances, which have
helped aluminum alloys to provide more mechanical strength, has opened up even more opportunities for
cast aluminium components. The majority of these pieces for industrial applications require a very high
level of quality control and quality assurance procedures.
To ensure sound castings it is essential that strict procedures are followed in the casting methods (feeding,
filtration & simulation), manufacture and preparation of the moulds and cores and the pouring of molten
metal, with its special treatments, to obtain final castings without inclusions, defects or shrinkage.
Aluminium components produced by gravity casting are manufactured in medium or large series, where
if a defect appears, it affects many parts and directly incurs an increase in manufacturing cost. Therefore,
it is essential that within all parts of the process the correct raw material choices are made, and these
decisions are critical to the successful and repeatable production of defect free castings and must be
combined with the correctly applied application, technical and manufacturing process knowledge.

Page 13
Excellence in aluminium
casting through cooperation
 INTRODUCTION
Grupo Aluminio de Precision (GAP) is
an aluminium foundry based in Burgos,
Spain. It is a gravity, sand foundry and
produces castings ranging from 0.2kg up
to 300kg using either the greensand or
no-bake moulding process. Production
capacity is in the region of 12,500 tonnes
per annum and castings are supplied to
a diverse range of market sectors on a
global basis.
To serve these demanding industries,
GAP is providing their customers with a
full supplier service, from casting design
and development to production and
delivery of fully machined, painted and
tested cast components.
Throughout the design and Figure 1: MAGMA simulation of casting
implementation stage GAP works
together with Foseco to optimise the
casting methodology and subsequently
utilizes the superior properties of Foseco
consumable products to optimise casting
quality, improve yield and reduce overall
production costs.
This paper focuses on the partnership
between Foseco and GAP throughout
the development process and across
several internal departments, and in
doing so demonstrates the value created
by undertaking such close cooperation.

DESIGN &
DEVELOPMENT
When a new casting is to be produced in
the foundry the involvement of FOSECO
starts in the design and development
stage. The main criteria are how to Fig. 2: Coreshop & cores coated with TENOTEC 7804A (inset) using the flow coating process
produce a sound casting without defects
and with optimum yield to ensure cost-
Typically, there is more than one potential
MOULDING &
effectiveness. Initial discussions focus
on the method of producing the casting; solution and by using metal flow and COREMAKING
how the metal will flow into the casting solidification modelling these solutions
After the design stage is complete
with minimal turbulence, where filters can be evaluated and optimised to
the required designs are passed to
will be placed to reduce turbulence and focus in on the most cost-effective
the pattern workshop where skilled
eliminate inclusions and where to place method of production, whilst delivering
patternmakers will produce the pattern
feeders / feeding aids to ensure there is the customer’s quality and integrity
equipment to produce the moulds and
no shrinkage in the casting itself. There requirements. It is at this stage that many
the coreboxes for core production.
are many variables to consider including of the consumable products that enhance
The high-quality production of pattern
the orientation of the casting and the the casting process will be selected to
tooling is essential to the casting
subsequent implications on moulding optimise the casting process, such as:
process in that any discrepancies at
and core making. + KALMIN* insulating sleeves – to
this point will be reflected in the ease
prevent shrinkage defects
of production of the moulds and cores
+ SIVEX* foam filters – to remove
and subsequently in the dimensional
inclusions and reduce turbulent
accuracy of the final casting.
metal flow

Page 14
Foundry Practice No. 268
For the production of cores GAP have a highly automated The POLISET AL binder system has been specifically developed
manufacturing line, which allows the mass production of cores for the needs of aluminium sand foundries to reduce gas
without compromise of integrity or dimensional accuracy. The emissions, provide high production rates through reduced
sand cores are bonded using a special polyurethane coldbox stripping times and easy core breakdown and shake-out after
binder system supplied by FOSECO (POLITEC* AL320/420). The casting.
benefit of this system is that it requires very low addition rates to The second line is for smaller casting up to 80kg in weight and
give high strength cores. The low binder addition rate minimizes is based around a greensand system. To avoid sticking of the
the production of gases during thermal decomposition on greensand to the pattern plates, small amounts of a highly
pouring, thereby avoiding the potential for gas pinhole defects effective release agent (PARTISAL* 421) are sprayed on to the
at the surface of the finished casting. To improve productivity pattern at regular intervals. PARTISAL is an environmentally
the coreboxes are coated with a highly effective release agent friendly product without aromatic solvents.
(ACMOS* 118-63) that has superior release properties without
the build-up of residues that need to be removed on a regular
basis, taking the corebox out of service. Where cores are joined MELTSHOP
together a refractory putty (TAPA PLAST 41) is used to seal any
The quality of the molten aluminium alloy is paramount to
gaps or small breakages. To further enhance the surface finish of
producing consistent castings to the correct metallurgical
the casting and to avoid sand adherences the cores are coated
specification and free from defects such as inclusions and gas
with a refractory coating from Foseco (TENOTEC* 7804A).
porosity. GAP uses a Foseco Degassing Unit (FDU) melt treatment
After casting the binder breaks down readily, allowing for
system for the degassing and cleaning of the aluminium alloys.
the easy removal of the core material during the shake-out
The FDU rotary degassing units utilize patented rotor designs
process, ensuring no damage to the casting. The casting
to ensure rapid and efficient distribution of nitrogen or argon as
surface finish is free from sand adherence, gas pin-hole defects
finely dispersed bubbles to ensure effective degassing in short
or any other metal/mould reactions. GAP utilizes two modern
treatment cycles. Advantages are:
moulding lines; the first utilizes a no-bake binder system based
+ Reproducible results
on polyurethane chemistry (POLISET* AL 6A & 6B), for high
+ Short treatment time
dimensionally accurate castings up to 300kg in weight.
+ Reduced gas porosity and hard inclusions in castings
+ Reduced machining costs
+ Consistent mechanical and physical properties
+ Environmentally friendly

Fig. 3: Assembly of POLISET bonded moulds and POLITEC bonded cores

Figure 5: Effective degassing process using a Foseco Degassing

Unit (left) and the patented impeller rotor (right)
Figure 4: Greensand line

Page 15
Excellence in aluminium
casting through cooperation
The benefits of best practice in terms of melting, melt treat- CONCLUSION
ment and pouring of the molten aluminium are observed in
the non-destructive testing laboratory with the cast materials FOSECO offers the aluminium foundry a full range of equipment
having optimum metallurgical structures and soundness. Fose- and consumables that support the production of quality castings.
co supply testing equipment and consumables that support the In the sand foundry binders, coatings and moulding materials
quality assurance procedure such as GASTEC PRO and DENS- supplied by Foseco ensure the integrity of the moulding
ITEC devices for measuring density. GASTEC PRO allows for the process and enable complex castings to be manufactured
creation of a partial vacuum (up to 10 mBar) under one glass with superior surface finish. The preparation and transfer to
bell, in order to highlight the presence or absence of dissolved the mould of the liquid aluminium is equally important and
hydrogen which has a negative influence on the tightness and again Foseco products are used to improve metal cleanliness
mechanical characteristics of aluminum castings. DENSITEC and metallurgical structure, with product performance ensuring
provides a direct measurement of density, a ticket can be print- energy costs are minimized and casting quality is maximized.
ed, or values are recorded to a computer for traceability. The benefits of this focus on process and consumable technology
is observed in the high quality, defect free castings produced,
with Foseco developed test methods providing the end user
with quality assurance data.
Above all the benefits of the products themselves, it is
the relationship with foundries such as GAP that elevates
performance to a higher level. By working in partnership to
deliver best in class solutions and creating value for the end-
user a sustainable relationship is developed that ensures future
success for all parties.

CONTACT

Figure 6: GASTEC PRO (left) and DENSITEC (right) density

measuring equipment

GAP is also using Thermatest 5000 NG III thermal analysis

equipment. These units are designed to predict and control
the structure of aluminium alloys before casting, including the ENRIQUE PARDO
grain refinement and the type of eutectic structure that will TECHNICAL MANAGER IBERIA
be formed. Within only a few minutes, it assesses the melt
quality, allowing for specific additions to be made to the melt
before casting, therefore avoiding costly scrap due to shrinkage, [Link]@[Link]
leakage, porosity, and hot tears. +34 6396 76 86 8

LUIS MERCHAN
PRODUCT MANAGER NF

[Link]@[Link]
+34 946 20 25 00

Figure 7: Thermatest 5000 NG III thermal analysis unit

DISCOVER MORE

Want to know more about the casting

Page 16 and related products
Foundry Practice No. 268
DOSING FURNACE LINING WITH INSURAL PRE-CAST
SHAPES REDUCES DOWNTIME IN FOUNDRIES
Author: Dirk Schmeisser, Foseco Europe

By using INSURAL pre-cast shapes for furnace relining, sintering can be dispensed with and a
constant density index can be achieved. The use of high-quality insulating materials in the lining
process enables significant energy savings and thus a reduction in CO₂ emissions.

Page 17
Dosing furnace lining with
INSURAL pre-cast shapes
 INTRODUCTION
Furnace atmosphere with O₂ ~ 700°C
The relining of a dosing furnace in aluminium foundries is
always labour-intensive and particularly time-consuming. In
Corundum Al2O3/Al Refractory lining
the case of a monolithic lining, the sintering phase in particular
extends the downtime of the furnace. A market analysis among
relevant customers shows that there is a need for optimisation
in the area of furnace lining and cleaning of dosing furnaces in Aluminium melt Al
connection with corundum formation.
Penetration
The solution for your dosing furnace in pressure and low-
pressure die casting foundries: A completely dry lining with
INSURAL pre-cast components combined with high-quality
Figure 1: Schematic of corundum formation
insulation materials.

THE FORMATION OF CORUNDUM THE INSTALLATION

There are basically two types of corundum formation: external The new lining consists of INSURAL pre-cast parts, which are
and internal corundum generation. assembled according to a modular principle. The time required
for a furnace installation using a clean and empty steel shell is
External corundum formation occurs on the bath surface by
between two and four days, depending on the furnace type. In
oxidation of liquid aluminium with oxygen from the furnace
addition to the INSURAL pre-cast parts, high-quality insulation
atmosphere. Aluminium is sucked upwards through pores
materials are used. The insulation materials are mounted
and oxides on the metal surface and forms corundum-lumps.
between the INSURAL parts and the steel shell. After insulating
This process is accelerated by a high proportion of oxygen, the
the bottom area and the side walls, the main liner is inserted.
presence of certain alloying elements and high temperatures.
The gap between the bassin and the insulation is then filled
and the heating and ceiling blocks are placed on top. The
In addition, there is internal corundum formation, also called
remaining insulation work is then carried out and the holes for
penetration. In the contact area of the refractory lining with
the thermocouple and the compressed air supply are drilled.
the liquid aluminium, a substitution reaction occurs due to
The last step is closing the furnace with the lid.
the higher affinity of oxygen to the aluminium in the molten
melt and the free oxygen from the SiO₂ in the refractory lining.
This reaction takes place within the refractory structure and
below the melt surface. A dense black zone is formed. This
is accelerated by a high bath temperature and an increase in
the pre-baking temperature, which burns out non-wetting
additives.
Roof block - maintenance door end
In order to solve this problem, extensive tests were carried out
with various INSURAL recipes. Suitable compositions were then
determined and new formulations developed. FOSECO offers
a completely dry lining with INSURAL pre-shaped parts for all Blocks
common dosing and low-pressure furnaces, which is not only
economically attractive but also offers the following further
advantages:
+ Direct installation on site possible
+ No time-consuming sintering required
+ Stable density index after relining is achieved in a much
shorter time Liner
+ Corundum formation is reduced to a minimum
+ Easy cleaning, thus alloy change with little effort possible
+ Larger filling volume for some furnace types due to Heater element blocks
optimized design
+ Energy saving during operation
+ Reduction of CO₂ emissions Roof block - dosing tube end

Figure 2: INSURAL precast components

Page 18
Foundry Practice No. 268
 1 2 3 4

Figure 3: Empty steel shell Figure 4: Insulating materials Figure 5: Installation of the liner Figure 6: Installation of heating
for floor and side walls into the steel shell and roof blocks

ADVANTAGES In addition, a constant density index is achieved much faster

with an INSURAL lining. As a result, the furnace can return to
After complete assembly, the furnace can be put into operation the production process faster due to the shortened integration
immediately and is ready for operation once the desired furnace time.
chamber temperature has been reached. A sintering program
as with a conventional installation is not necessary. As can be The use of INSURAL prefabricated parts minimizes corundum
seen from Diagram 1, this step saves a great amount of time. formation and facilitates furnace cleaning. For this purpose, the
method of corundum formation will be discussed once again.
800 750 Parameters that can influence the formation of corundum are:
700 700 700
700
+ High proportion of O₂
600 + Pores
500 500 + SiO₂ ratio in refractory material
Temperature in °C

500

400
+ Temperature
+ Wetting properties
350 350

300 250 250

200 Traditional lining Based on these points, the INSURAL 270 recipe was developed
120 120
100 INSURAL in 2015, which has a small amount of SiO₂, low porosity and
0
good non-wettability with liquid aluminium. With the INSURAL
0 6 31 36 48 64 70 98 104 134 140 166
270 recipe, dry lining with pre-cast parts for dosing furnaces
Time in hours
has been successfully introduced to the market in recent years
Diagram 1: Comparison of preheating curves and excellent results have been achieved with a large number
Depending on the casting process and quality requirements, of customers.
the density index plays an important role in the availability INSURAL 270 has a SiO₂ content of 22 %, a porosity of
of the dosing furnace. After reaching the furnace chamber about 17 %, a cold compressive strength of 50 N/mm²
temperature, a constant low density index value can be and excellent non-wetting properties compared to liquid
measured after only two days (Diagram 2). The availability aluminium. In order to meet the growing demands of the
of the system by lining it with INSURAL pre-cast parts has market, another INSURAL formulation has been developed,
clear advantages over conventional lining. With conventional which has extended the product range since April 2019.
installations, the sintering process takes seven days. If INSURAL The INSURAL 290 recipe has a SiO₂ content of less than 10 %
prefabricated parts are used, this part is completely obsolete. only, a porosity of around 16 % and a higher cold compressive
strength of 100 N/mm². The non-wetting properties remain
18
excellent.
16,2
16 15,9
Traditional lining Another important point is the temperature in the furnace,
14
12,4
12,9
INSURAL which is a decisive factor for the formation of corundum.
The compensation of temperature loss in dosing furnaces is
12 12,1 11,2
Density index in %

10 9,3

8
controlled by the heaters and can be readjusted depending on
6
6 6,2
the insulation. Since the heating takes place via radiant heat,
4 4,1 3,5 the heating elements become significantly hotter than the melt
2 bath temperature. This is a major reason why the formation
0
0 24 48 72 96 120 144 168 169 170
of corundum accelerates and good insulation therefore has a
Time in hours positive influence on corundum avoidance.
Diagram 2: Density Index

Page 19
Dosing furnace lining with
INSURAL pre-cast shapes
 INSURAL

905

384
Traditional lining

905

30

529

0 100 200 300 400 500 600 700 800 900 1000

Time in hours
Measuring in hours Max. level (14,3 KW/h) Min. level (10,7 KW/h)

Diagram 3: Power consumption Figure 7: Condition of furnace after 3.5 years

FOSECOs insulation concept can counteract corundum

formation and also save energy costs (Diagram 3). The power
consumption measurements carried out in a foundry using
a 650 kg dosing furnace show a lower energy requirement
compared to conventional lining. The heating power remains
at the lowest level for almost 98% of the time, which avoids
overheating and effectively prevents corundum formation.
Operation at low heating output levels also has an influence on
the peak shutdown in the foundry’s energy management and
reduces weekly average consumption.

CONCLUSION Figure. 8: Furnace surface temperature (left: conventional lining,

Furnace lining with INSURAL pre-cast parts offers a number right INSURAL 270)
of advantages over conventional lining. On the one hand, the
actual lining process requires considerably less time, and on the
other hand, time-consuming sintering is no longer necessary.
Furthermore, the dry lining avoids the absorption of hydrogen
by the melt in the first days after commissioning. The formation
CONTACT
of corundum is minimized and furnace cleaning is simplified.
Furnace cleaning remains important, so a weekly cleaning
interval is recommended. Depending on the insulation concept
selected, energy and CO₂ output can be significantly reduced.
The current electricity mix in Germany indicates that for 1 kWh
an average of 511.2 grams CO₂ are released to atmosphere.
With a furnace that saves 48,000 kWh per year, the foundry
achieves a reduction of 24.5 tons of climate-damaging CO₂. DIRK SCHMEISSER
EUROPEAN PRODUCT MANAGER
INSURAL & REFRACTORIES NF

[Link]@[Link]
+49 2861 83 369

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Want more info about our INSURAL

linings system?

Page 20
W AT C H V I D E O
Foundry Practice No. 268
BRAND-NEW INNOVATION FOR THE NON FERROUS
SECTOR: THE EXOTHERMIC FEEDER FEEDEX NF1
Author: Arndt Fröscher, Foseco Germany

In aluminium foundries, the use of insulating sleeves in a wide variety of materials has been common
practice for many years. FOSECO is now launching an exothermic sleeve material for aluminium
casting applications for the first time. The new recipe FEEDEX NF1 was specially developed for the
aluminium sector and adapted to the existing requirements there. It ignites quickly, the exothermic
reaction takes place slowly and steadily and ensures a considerable improvement in the feeding
effect. This results in only low emissions. FEEDEX NF1 feeders are available in numerous different
versions and eliminate the need for manual addition of exothermic powders.

Page 21
The exothermic feeder FEEDEX NF1
 INTRODUCTION THE SOLUTION
The use of insulating feeders is common practice in aluminium With the new product line FEEDEX NF1, FOSECO now provides
foundries. In this segment, many different products are for the first time exothermic feeders for aluminium applications.
available. In most cases, the products are made of fibres or These products are made of a new developed exothermic recipe
spheres. In both cases, organic or inorganic binders are being and make the application of exothermic powders obsolete.
used. When in contact with liquid aluminium, ignition starts within
30 seconds.
This exothermic reaction goes on slowly and steadily and
provides a significantly delayed solidification of the metal in the
THE CHALLENGE sleeve and therefore a long lasting feeding performance.
The module extension factor which is between 1.3 and 1.5 for
If the insulating property is not sufficient or if the size of the
insulating sleeves is between 1.55 and 1.65 for FEDEX NF1.
sleeve is limited, very often so called exothermic powders are
These facts lead to a number of benefits: First of all, the
applied. These powders start an exothermic reaction when in
manual application of exothermic powder becomes obsolete.
touch with liquid aluminium and provide their energy to the
In addition it is now possible to mould the feeders completely,
melt in the feeder to slow down the solidification. Also this
which leads to reduced emissions. But also at open FEEDEX NF1
technology is common practice.
sleeves, reduced emissions can be observed. Due to the better
However, this process contains a number of disadvantages:
feeding performance, sleeve dimensions can be reduced which
First of all, the application of the powder has to be done
leads to reduced re-melting costs. Figure 1 shows a typical
manually, therefore the amount is often unstable. At big
cooling curve of a FEEDEX NF1 sleeve. The exothermic reaction
castings with a number of feeders, it is difficult for the operator
is clearly visible. The released energy leads to a strongly delayed
to apply the powder to all feeders in an acceptable time frame.
solidification. FEEDEX NF1 sleeves are available in all common
The exothermic reaction of the powder creates smoke, which
dimensions. In all cases, the combination with a breaker core is
(although it is not harmful) should be extracted. As the surface
possible. The use of breaker cores provides an easy knock-off
of the feeder must be open to apply the powder, users face
of the sleeves from the casting and therefore reduces the costs.
limitation during the moulding process.

Fraction liquid %
Temperature °C

Time in seconds
FEEDEX NF1 Speiser KALMIN S

Figure 1: Comparison between cooling curve of an exothermic feeder sleeve FEEDEX NF1 MAGMA simulation - Fraction liquid in %
and insulating feeder sleeve KALMIN* S

Page 22
Foundry Practice No. 268
Figure 2 shows the risers in the core box. Due to the high
strength of the FEEDEX NF1 recipe it is possible to use the
feeders on automated moulding lines without any problems.
On the opposite, feeders with lower strength can break or
deform during the moulding process.
Figure 3 shows the FEEDEX NF1 risers during casting. The
exothermic reaction is clearly visible in contrast to the insulating
risers. The reaction starts only a few seconds after filling with
the melt and continues slowly and evenly. This makes the
addition of exothermic powders such as FEEDOL* obsolete.

Figure 3: Clearly visible exothermic reaction of the FEEDEX NF1 riser

Figure. 2: Exothermic and insulating risers positioned in the moulding box

CONTACT

Figure 4. Constant burn-off of the FEEDEX NF1 feeder ARNDT FRÖSCHER

EUROPEAN PRODUCT MANAGER
CONCLUSION NON FERROUS METHODING
FEEDEX NF1 is a new recipe for the non- errous sector. The fast,
steady and lasting reaction makes it an excellent alternative to [Link]@[Link]
conventional insulating feeders. The high strength of the risers
+49 2861 83 259
makes them suitable for use on automated moulding lines. The
improved feeding effect can lead to a reduction of the feeder
size and thus to a saving of recycled material. The manual
addition of blowhole powders is no longer necessary, which
increases process stability. DISCOVER MORE

Want more info about our

FEEDEX NF1 sleeves

Page 23
The exothermic feeder FEEDEX NF1
 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 manufacturer’s practical experience)
neither the manufacturer, licensor, seller nor publisher represents
or warrants, expressly or impliedly:

or e
(1) their accuracy/reliability
(2) that the use of the product(s) will not infringe third party rights
m
d in t ice?
(3) that no further safety measures are required to meet local

t e legislation

t e r e s pr ac The seller is not authorised to make representations nor contract

in ndry on behalf of the manufacturer/licensor.

F ou
All sales by the manufacturer/seller are based on their respective
conditions of sale available on request.

*FOSECO, the logo, ACMOS, COVERAL, FEEDEX, FEEDOL,

F
SUES O INSURAL, KALMIN, PARTISAL, TENO, POLISET, POLITEC, SIVEX and
F U R T H E R IS AT THERMATEST are Trade Marks of the Vesuvius Group, registered
IN
E IN T E R
E ST E D E TO U S
O U A R P L E A S E W R IT in certain countries, used under licence.
IF Y E,
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U R F O UNDRY ©Foseco International Ltd.
O om
o s e c o .c
u n ic a t io n s @ f COMMENT
omm
f o s e c o .c 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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