Foseco showcases 6 new Technologies for Die Casting at EUROGUSS

Visitors will discover new, innovative solutions for cost effective melting and holding of aluminium, optimized melt treatment, transfer and dosing at the Foseco booth in Hall 7A, stand no. 523.

Controlled Melt Treatment & Quality is Key for Aluminium Foundries
In recent years, several 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. COVERAL MTS fluxes are a range of new granulated treatment agents to cover the principal foundry operations of cleaning, drossing, modification and grain refinement. They have been specially formulated for use in conjunction with FDU and MTS which keep smoke and fume to a minimum.
Shaft and rotor design are continuously improved to offer high efficiency in degassing at long service life.

Non Ferrous Die Coatings
The longevity of a die coating is essential for the die casting process. Short lifetime leads to interruptions for touch-up, problems with mould filling and surface quality of the casting.
The 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 longer lifetime leads to reduced interruptions for touch-up and therefore increased productivity.

Methoding for Aluminium Foundries
Foseco has recently launched 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.
 
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. In the Non Ferrous metal transfer area crucibles from the ENERTEK and DURATEK family highlight the energy and cost saving potential in melting, holding, 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 castables 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.

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 less than 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%.