V

Application considerations for KALPUR for steel direct pour units.

ouring steel castings directly down a riser has never been a desirable means of achieving a high level of casting quality until now. Fosecos patented KALPUR* for steel technology is one of the fastest growing innovations in the steel foundry industry. The KALPUR for steel unit an integrated insulating riser sleeve and filter provides clean, lessturbulent metal flow to the mold. This greatly reduces casting inclusions and improves casting surface finish, helping the foundry reduce welding and repair costs. Removal of conventional gating systems

of the metal being filtered and the method by which the metal is poured. Metal fluidity is affected by a variety of critical, and often hard to control foundry variables, such as: metal temperature, metal chemistry, and inclusion level (oxides of residual elements such as Al, Zr, Fe). Pouring rates vary widely by pouring method. Flow rates from most teapot ladles, over a course of a heat, vary less significantly than those of metal from bottom-pour ladles, simply because of variance in ferro-static head pressure in the ladle. No matter what the metal grade, metal temperature, pouring method,

In applying the KALPUR for steel unit to the casting, the engineer is encouraged to take the following steps to optimize performance.
Consider the feeding requirements for the casting section that is fed by the KALPUR for steel unit: First, determine the sleeve diameter and height that makes sense for the application. Then, check the KALPUR for steel Product Data Sheet for sleeve dimensions and riser modulus values in calculating the optimal size KALPUR for steel direct pouring unit. Consider which type of KALPUR for steel unit will be applied. For most ram-up applications, free-formed sleeves work best because the rough outer surface of the sleeve prevents it from floating up from the mold cavity during pouring. However, if molding with a jolt-squeeze table using green sand, consider using KALPUR for steel inserts. The inserts cannot be crushed during the molding cycle since they are inserted into the mold after the molding operation is complete. KALPUR for steel inserts are manufactured with a controlled outer surface dimension which ensures consistent feed performance. To prevent sleeves from floating during pouring, secure them to the mold using molding nails. Next, consider the desired contact area in selecting the sleeve. KALPUR for steel RND (Round-Neckdown) units provide reduced casting contact area, compared to conventional KALPUR for steel tube-shaped sleeves. An integral break-off notch formed in the RND unit promotes easy riser removal. Place the sleeve in a location desirable for feeding, as close to the casting surface as possible to minimize the distance the metal has to fall in the mold and to prevent high-velocity impingement on the mold surface or cores. After determining the size of the KALPUR for steel unit required to feed the casting, determine the size of filter necessary to provide sufficient metal to the mold in terms of flow rate and flow capacity. Again, reference the KALPUR for steel Product Data Sheet for flow rate and flow capacity data. It is helpful to quantify, in advance, the flow rate capacity of the ladle being used to fill the mold cavity before proceeding. If the filter contained in the KALPUR for steel unit will not allow for the required flow rate to be achieved, increase the diameter of the unit (in inches) until you achieve the desired mold fill rate. If the flow rate or flow capacity rating exceeds your capability to pour metal, the casting may not be suitable for direct pouring. If your casting or section requires a larger feed demand than any KALPUR for steel unit is able to provide even if the filter is able to provide sufficient flow rate and flow capacity the casting may not be suitable for direct pouring. Develop a clear understanding of your foundrys flow rate capacities before applying ANY direct pouring unit. The flow rates (and velocity) of metal from bottom-pour ladles varies significantly over the course of a heat. This needs to be considered in any direct pouring application.

reduces the thermal gradients in the mold, improving both the casting surface finish and the metallurgical consistency through a more uniform casting density. The performance of KALPUR for steel direct pouring units is greatly influenced by the fluidity

or inclusion level, the KALPUR for steel direct pouring unit must remain nearly full during pouring. If your ladle pouring rate capacity exceeds the potential flow rate of the filter, keeping the unit full should not be a problem. If your ladle pouring rate capacity is less than the potential flow rate of the filter, it will be more difficult to keep the cup full and filter breakage becomes more likely.

Continued next page

Application considerations for KALPUR for steel direct pour units. Continued from front...
Applications requiring special consideration:
Any stainless steel application. Since the fluid metal is generally poured well above its liquidus temperature, and since stainless steel by its very nature contains fewer elements of reoxidation, filters prime almost immediately. Consequently, pourers often find it difficult to keep KALPUR for steel units full of metal when pouring stainless steel. Applications pouring from small teapot or lip-pour ladles where it is difficult to keep the KALPUR for steel unit full of metal during filling. This is particularly a problem with small teapot or lip-pour ladles. The flow rate capacity of the ladle must exceed the flow rate capacity of the direct pouring unit. Applications pouring from large bottompour ladles where the metal velocity and flow rate are high at the beginning of a heat. While bottom-pour ladles generally provide enough metal to keep the KALPUR for steel unit full of metal during filling, the initial impact of the impinging metal stream can sometimes result in broken filters. Again, this can be particularly critical when pouring very fluid metal such as stainless steel where filter priming is immediate, difficult to maintain close proximity between the ladles pouring lip and the top of the KALPUR for steel unit; particularly early in the heat when the ladle is full. Any application where the metal is not fluid. Typically, KALPUR for steel units can be readily applied as long as the metal temperature remains at least 100 above liquidus and the metal is relatively clean. Dirty metal, typically as defined by the amount of oxides in the metal, can easily block filter pores and lead to premature blockage of flow. Foseco strongly recommends KALTEK* ladle linings in any application with direct pouring. KALTEK linings effectively improve metal fluidity by reducing the level of residual elements brought about by dirty ladles, and will maintain pouring temperatures over a narrow range. Foseco encourages its foundry customers to evaluate new direct pouring applications with KALPUR for steel units over the entire range of metal fluidity and pouring rates before converting the casting to KALPUR for steel units. Please contact your Foseco Account Executive for advice in applying KALPUR for steel units. Our experienced Product Applications Managers are also available to answer your questions.

causing the filter to remain exposed directly to the impinging metal stream, with little to no build-up of metal head above the filter component. Any application where the distance between the pouring lip or pouring nozzle is greater than 12 inches. This condition is generally limited to large teapot ladles where it is

KALPUR for steel RND.

provide enough filtration capacity for the poured n recent years the steel foundry indusweight? And, is the flow rate through the filter suftry has benefited greatly from Fosecos ficient to pour the casting within the optimum direct pour technology. This technology time? If any of these criteria are not met, the next has resulted in significant yield improvements, larger size KALPUR for steel unit should be used. reduced defects, and improved metallurgical consistency. For those castings requiring a higher feed KALPUR for steel tubes have a fixed feed volume but not a large flow rate or filter capacity, the answer is the new KALPUR for steel RND unit volume and flow rate capacity and a large contact surface making the tube-shaped unit ideal for side riser applications. However, when a casting requires a large modulus or feed volume, KALPUR Contained Volume and when contact area on the surface of the for steel Modulus Weight (lbs.) (In3 ) RND casting is limited, it may not be economical (4 x 1.8 x 6) .92 10.5 42.6 to use KALPUR for steel tubes. To address these applications, Foseco has developed (5 x 2.4 x 8) 1.20 23.8 95.3 the KALPUR for steel RND (Round (6 x 3.0 x 10) 1.44 45.9 185.7 Neckdown) unit. This innovative new shape (7 x 3.5 x 12) 1.70 80.2 325.0 expands the Foseco line of KALPUR for steel units to a more extensive range of castings. In selecting a direct pour unit for a given which combines a larger feed volume than that casting, three criteria must be considered: feeding of the tube direct pour unit with flexibility in capacity, filter capacity, and flow rate. Does the filter size. The RND shapes provide a feed metal sleeve contain enough modulus and volume to volume of 100-350 cubic inches and a filtering feed the casting or section? Does the filter size capacity of over 1000 pounds.

The KALPUR for steel RND unit is a free-formed insulating riser sleeve with a notch formed at its base to create a knock-off point. This eliminates the need for breaker cores and allows for lower cleaning costs. In addition, the lower portion of the KALPUR for steel RND unit has seats for two consecutive filter sizes, making it more versatile and in certain applications more economical than KALPUR for steel tubes. This design allows for a wide range of feed requirements in a variety of casting geometries. KALPUR for steel RND units should be considered for castings or sections that require a larger volumetric feed demand, due to casting size or alloy, than is offered with the standard direct pour units. Also, where it is difficult to find a flat area where a full contact sleeve of the proper modulus or volume will fit, reducing the contact area allows the riser to be located over a smaller area, enabling the reduction or elimination of padding. KALPUR for steel RND units can also be used in applications where a standard round neckdown riser sleeve is currently being used to feed the casting.

KALPUR for steel molding plugs and filter insertion tools.

any foundries have come to realize significant savings and improved quality through the introduction of the KALPUR for steel direct pouring system. KALPUR for steel units have been used with many high production molding systems. Among the most demanding of these molding systems have been jolt squeeze molding applications which require the feeding unit to withstand high molding pressures without breakage. Until recently, this has presented a unique challenge to the molder when applying KALPUR for steel units.

Molding plugs are available to fit the full range of KALPUR for steel direct pouring units. They are available individually or as a set to suit your particular requirements. The product codes and descriptions are outlined in the accompanying chart. Foseco has also developed a filter insertion tool set for KALPUR for steel units. This set features a filter insertion disk suitable for use with each of the KALPUR for steel direct pouring units. The filter insertion tool goes where fingers often cannot reach, seating the filter within the KALPUR for steel direct pour unit. The insertion tool set will save time and prevent difficulties associated with incorrectly seated filters. Simply place the selected filter in the KALPUR for steel direct pour unit. Using the appropriate insertion tool, press down gently on the filter, seating it into the direct pour unit. A light tap with the plastic-tipped hammer ensures the filter is seated and fully engages the holding strips.

KALPUR for steel units improve steel casting surface finish.

asting surface finish can be improved

using the KALPUR for steel direct pouring process. The process allows for more uniform casting temperatures in the mold after pouring. Fewer inclusions enter the mold, and a less turbulent metal stream results in fewer inclusions generated in the mold. Mold filling times are dramatically reduced. To illustrate this point, the WCC grade casting on the left was poured using conventional gating practice. A popular flow and solidification modeling program was used to model the casting

As with most tasks, the job is made easier if you have the right tools. Foseco has recognized the challenge and, in response, developed molding plugs for jolt squeeze and conventional molding applications. Made from highly resilient epoxy resin, the molding plugs will stand up to the most demanding molding operations and allow KALPUR for steel direct pouring units to be molded in place. All molding plugs are cast to exact dimensions, ensuring a reliable fit inside all of the KALPUR for steel direct pouring units. The molding plugs also feature an integral dirt trap that forms a shallow ring around the outer circumference at the top of the KALPUR for steel direct pouring unit. This shallow ring is designed to retain stray sand particles, preventing them from entering the mold cavity. Used in combination, the molding plug and direct pouring unit produce cleaner castings.

KALPUR for steel direct pouring units are proven to be the best solution for many casting jobs. Now with Fosecos new molding plug and insertion tools, they are even easier to apply to many castings. Your Foseco sales representative can provide further details regarding molding plugs and insertion tool sets. Dont hesitate to discuss these unique products at your next meeting.
Molding plug and filter insertion tool sets for KALPUR for steel direct pouring units
Product Code Description Size

before it was poured, in order to optimize mold filling and feed performance. The same casting shown on the right, when poured using a KALPUR

223100 321450 415700 515950 145350 423350 528200 158100

Molding plug Molding plug Molding plug Molding plug Molding plug Molding plug Molding plug set of 6 Filter Insertion tool set

2.0 x 6.0 2.5 x 6.0 3.0 x 6.0 4.0 x 6.0 5.0 x 8.0 6.0 x 9.0 2.0 x 6.0 through 6.0 x 9.0

for steel direct pouring unit, had markedly

better surface finish.

Using KALPUR for steel on jolt squeeze molding equipment.

any steel foundries use jolt-squeeze molding equipment for making green sand molds. With the right tooling and a few additional steps shown in the photos, it is easy to to use the KALPUR for steel Direct Pouring Process when using jolt-squeeze molding equipment. The obtainable benefits include increased yield, higher pattern plate utilization, and cleaner castings, to name a few. Figure 1 shows the cope pattern plate mounted on the molding machine. The orange post on the background is a loose-piece vent. The KALPUR for steel unit will be rammed up in the mold on the pad (left side of casting). Since the unit effectively functions as a gating system and an active feeder, the pad supporting the unit is raised above the parting line by Figure 1 the height of the feeder neck. Before placing the filter component in the sleeve of the KALPUR for steel unit, the sleeve component is placed on the pattern, then a molding plug is placed in the sleeve. Figure 2 shows the cope pattern with the unit and the molding plug in position. The flask is positioned ready for sand filling. Molding plugs are available in sizes to fit the KALPUR for steel units. The Figure 4 specially designed plugs keep sand out

of the sleeve during filling and also protect the sleeve from being crushed by the squeeze head. The mold is filled with sand. The molder exercises caution so as not to tip the KALPUR for steel unit. Sand is hand-tucked around the unit (Figure 3). After the jolt-squeeze cycle is completed, the molder cuts the sand away from the top of the molding plug (Figure 4) and lifts it from the mold (Figure 5). Using a slick, the molder shapes

the sand in the form of a basin above the sleeve component. The cap on the top of the plug makes a gutter around the top of the sleeve to keep any loose sand from falling into the mold cavity. The final step before mold closing is to insert the filter in the unit. The filter insertion tool makes this step easier, as shown in Figure 6. Note the smooth opening in the sand above the KALPUR for steel sleeve.

Figure 2

Figure 3

Figure 5

Figure 6

Feeding Systems Facts are intended to promote the exchange of information, to contribute to the fund of available knowledge in the foundry industry and to promote good feeding system practice. Foseco will also use Feeding System Facts to highlight new products and concepts and to provide application tips and guidance.
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 implied: (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 requested to meet local legislation. The seller is not authorized to make representations nor contract on behalf of the manufacturer/seller. All sales by the manufacturer/seller are based on their respective conditions of sale, available on request. *KALPUR and KALTEK are Trade Marks of the Foseco Group of Companies.

KALPUR direct pouring units are covered by U.S. patents #4,928,746 and 4,961,460 and Canadian patents #1,304,599; 1,304,560; 1,304,561; and 1,304,562. KALTEK ladle linings are covered by U.S. patent #4,330,107 and Canadian patent #1,195,472.

A NEW PERSPECTIVE ON PERFORMANCE

Foseco, Inc. Foseco Metallurgical Inc 20200 Sheldon Rd. Cleveland, Ohio 44142 Phone: 440-826 -4548
Printed in the U.S.A. Foseco, Inc. 1997

1M/