As a primary innovator in the foundry industry globally, Foseco regularly publishes information on new products and enhancements, process developments and new techniques, and state-of-the-art papers on new thinking in foundry practice.
With the commencement of the international GIFA 2015 exhibition scheduled to begin in little over two months, Foseco have released a number of new products that will be on display for the first time. Below are some of the products that visitors can expect to see.
Metal treatment for iron and steel foundries
The manufacturing cost of ductile iron castings is a major limiting factor for foundries to compete against alternative materials such as welded components or steel castings.
The Foseco Initek process, which was launched at GIFA 2011 and has seen many improvements, can enable your foundry to produce the metallurgical properties and quality ductile iron castings demanded by your customers at a lower cost, and with greater productivity.
The Foseco Initek process, which was launched at GIFA 2011 and has seen many improvements, process can enable your foundry to produce the metallurgical properties and quality ductile iron castings demanded by your customers at a lower cost and with greater productivity
The Initek process addresses the inherent problems of conventional ductile iron production by eliminating the undesirable side effects of the inescapable, but harmful addition of Mg into the metallic matrix (carbide promoter / dross generator).
The Initek process permits a significant reduction of Mg alloy addition and ensures a consistent, reliable, and productive nucleation event. Furnace and pouring temperatures are brought back to grey iron operating temperatures generating savings across the whole casting process.
Introduction to the “initialising” principle of the Initek process, an advanced nodularising technology for ductile and compacted graphite iron grades
The production of magnesium treated iron castings is witnessing a radical change in the way liquid metal treatment practices are performed. The nodularising and inoculation practices are being fundamentally reviewed in the light of findings that are declared in a new Foseco patent named “improved method of producing ductile iron” and designated as the “initialising practice”.
This new metal treatment practice makes good use of the base liquid iron oxygen activity of your melt shop process. The active oxygen is utilised to facilitate an effective and long lasting inoculation event prior to the conventional spheroidisation treatment.
For the first time, the timing and sequencing of both nodularising and inoculation practices are implemented within your melt shop process. Results are spectacular and reproducible as the fundamental oxygen variable is deactivated and utilised efficiently to improve your ductile iron quality. To achieve this, Foseco has developed new know-how, new products and a new metal treatment converter.
The many benefits of the Initek initialising process are centred around the considerable reduction of the ductile iron pouring temperature achievable. Not only is the associated energy saving obtained; but further benefits related to productivity, quality, and consumable consumption are also achieved. The pouring temperature is a strong cost indicator of your overall foundry practice – the lower the temperature, the lower your casting production costs will be.
The Foseco convertor is a prism shaped treatment ladle that can also be used for pouring. The Foseco converter is lined with Kaltek ISO and pre-loaded with Inodex, a FeSi based initialiser and Nodulant, a FeSi based nodulariser.
The converter is delivered as a shell assembly together with Kaltek lining formers. The rotation can be manual or assisted for automation. The converter can be handled by crane, forklift or fitted on a fixed station below furnaces.
ITACA (Incremental Thermal and Chemical Analysis) software is a comprehensive system for measuring and controlling liquid iron metallurgy
Nodulant Mg alloy is loaded into the chamber at a rate ranging from 0.65 to 1% maximum.
The Foseco converter is then orientated into a horizontal position and the Inodex initialising alloy is placed into the ladle.
The molten iron is then tapped into the ladle and mixes with the Inodex but does not reach the level of the reaction chamber. The treatment reaction is started by rapidly bringing the ladle into the vertical position. The molten metal comes into contact with the Nodulant and a head of metal above the reaction chamber is established. Using this technology, a magnesium recovery of up to 97% is achievable.
The metal in the converter is then deslagged and then transferred to an automated pouring unit or poured directly into the moulds.
The Initek process is part of the Foseco Ferrous Melt Shop (FMS) concept for improved quality, productivity and melt capacity. This concept includes and combines the benefits of a thermal analysis device (ITACA), and a new “state-of-the-art” metal stream inoculation technology (MSI DC+) framing the potential for increased metallurgical process control in the melt shop.
ITACA – a thermal analysis system for iron foundries
ITACA (Incremental Thermal and Chemical Analysis) software is a comprehensive system for measuring and controlling liquid iron metallurgy.
ITACA shows how the metal solidifies, giving critical information on metal quality such as sources of shrinkage, graphite flotation and poor graphite structure. A range of key process control measures can be analysed over time, generating essential quality control information.
The ITACA thermal analysis systems help foundries monitor metallurgical process performance by analysing base and final iron quality. The ITACA Melt Deck minimises 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.
ITACA 8 provides real time measurement of the metallurgical quality of the final iron to provide a prediction of defect formation tendency and as-cast mechanical properties.
Real savings arise from a reduction in the cost of the charge and in the cost of metallurgical additives, a lower scrap rate, and improvements in the quality and consistency of castings.
ITACA is a product of ProService srl, Padua, Italy and they joined forces with Foseco to drive the development of thermal analysis as the leading metallurgical control tool for iron foundries.
Foseco opens dedicated foundry research and development facility
Vesuvius plc has announced that it has invested £4.5 million in the establishment of a new, dedicated R&D Centre for its Foundry Business Unit, Foseco. The facility, which is located in Enschede, the Netherlands, covers an area of 4 500 m² and is equipped with state-of-the-art analytical equipment, a chemical lab, and a test foundry.
Vesuvius plc has announced that it has invested £4.5 million in the establishment of a new, dedicated R&D Centre for its Foundry Business Unit, Foseco. The facility, which is located in Enschede, the Netherlands, covers an area of 4 500 m² and is equipped with state-of-the-art analytical equipment, a chemical lab, and a test foundry
Pavel Holub, Global R&D Director Foundry commented, “This exciting new centre offers a world class innovation environment which will allow us to attract the best talents from all around the world, helping us to drive the creation of innovative solutions, new products and services for the foundry industry.”
George Coulston, Chief Technology Officer for Vesuvius plc said “This represents a significant step forward in the Vesuvius strategy of maintaining its technology and innovation leadership position across all business lines and further demonstrates our commitment to providing our foundry customers with the leading edge innovations they require.”
The facility will bring together Foseco’s metal treatment, feeding, filtration, binders and coatings research and development activity under one roof. Crucible and refractory R&D will remain in a second facility in Pittsburgh, USA.
Enno Krueger – Foseco’s Business Unit Manager in South Africa stated, “Foseco has a proud history of innovation through the introduction and development of technologies such as metal filtration, feeding systems and automated metal treatment processes, which have gone on to become industry standards. With our unique combination of technology, application expertise and foundry process know-how, we are ideally positioned to work even closer with our customers to develop the iron, steel and non ferrous foundry technologies of tomorrow.”
For more information contact Foseco on TEL: 011 903 9500 or visit www.foseco.com