C O AT I N G S F I LT R AT I O N F E E D I N G S Y S T E M S M E LT S H O P R E F R A C T O R I E S M E TA L L U R G I C A L A N D P O U R I N G C O N T R O L B I N D E R S

FEEDEX K DISAMATIC Spot FeedingHIGH DENSITY EXOTHERMIC FEEDER SLEEVES

New Opportunities Spot feeding technology for vertically parted moulding lines enables the production of a new casting portfolio.

Existing barriers to certain casting typesWhile it is common practice to use highly exothermic spot feeders on horizontal greensand moulding lines, until now there have been limitations in applying this technology to vertically parted moulds. The traditional approaches of using sand feeders or feeder sleeves applied to the joint line of the mould via the core-setter, have technical and commercial limitations. The effort required to feed isolated heavy sections on a vertical moulding line frequently limits the customer to produce such castings in an economically viable way.

Break through obstaclesFoseco now provides a spot feeder concept which allows the foundryman to apply sleeves directly on the swing plate pattern during the normal moulding cycle, enabling sleeves to be positioned exactly where the feed metal is required no longer only on the joint line of the mould. To meet the requirements of minimum contact area and excellent sand compaction, the collapsible metal core concept was selected.

In order to maintain the high productivity of the vertical moulding line, it was clear that the coresetter could not be used. During the moulding process where the mould is moved forward out of the moulding chamber, the swing plate is available in the horizontal position for several seconds. In principle, this is sufficient time to enable placement of a feeder sleeve. The application of feeder sleeves to the swing plate can be automated by the introduction of a sleeve setter robot.

Central boss difficult to feed

Ram-up sleeve with collapsible

metal core

Metal padding to reach central area

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Proved Concept FEEDEX* K sleeves

Process validation Initial trials were conducted to test the moulding behaviour of spot feeder sleeves with collapsible metal breaker cores on a vertical moulding line. The results showed excellent sand compaction beneath the sleeve and a clean contact area of the metal core on the mould face.

Extensive tests have been conducted to evaluate the feeding performance of spot feeders in various applications to validate the concept. The main drivers for foundries to adopt this technology are:

+ Improved yield by increasing pattern plate utilisation, producing additional castings in one mould through elimination of sand risers

+ The ability to produce a new range of castings in an economical way, which are usually produced only on horizontal moulding lines

To highlight the potential of transferring castings which are usually produced on horizontal moulding lines to DISAMATIC* moulding lines a case study of a ductile iron bracket casting was developed.

By the use of exothermic FEEDEX spot feeders a Yield improvement from 48 to 59% could be achieved, giving the foundry a significant commercial advantage.

From simulation to realityPrior to further tests a fillingand solidification simulationwas conducted.

No feederShrinkage both at outside rimand in centre

Top feederShrinkage in centre

Top & side feederCasting is sound

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Well-proven FEEDEX K VSK sleeves

The proven FEEDEX K VSK and GK technology offers a wide range of products, covering a variaty of casting designs and feed requirements.

Tailored FEEDEX K GK types

For thin walled castings, with high volumetric feeding demand tapered GK sleeves were designed. The sloped design provides increased ferrostatic pressure to improve feeding in critical applications.

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Nock-offresult

Proven and tailored FEEDEX Product RangeHigh performance exothermic spot feeding technology

Application example

Feeding result

® MAGMA and MAGMASOFT are registered Trade Marks of MAGMA Giesserei technologie GmbH.*Foseco, the Logo, FEEDEX, KALMINEX, KALMIN, KALBORD, KALPUR, FERRUX, KAPEX, SEDEX, STELEX and FEEDERCALC are trade marks of the Vesuvius Group, registered in certain countries, used under licence. 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 or as expressly permitted by law. Applications for permission shall be made to the publisher at the address mentioned. Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, 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 nor 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 International Limited 03/19.

Foseco International LimitedDrayton Manor Business Park,Tamworth, Staffordshire,England B78 3TLPhone: +44 (0)1827 262021 Fax: +44 (0)1827 283725 www.foseco.comPlease contact your local Foseco team

FOSECO. YOUR PARTNER TO BUILD ON.