Document ZB13GwGYp2Y3dLMvYOa8qVnE8

FILE NAME: Foseco (FOS) DATE: 0000 DOC#: FOS050 DOCUMENT DESCRIPTION: Company Sales Literature ZTODiafj THE FDSECO "PRQFflX" TldO 0 FOUR PIECE SEAS ASSEMBLY FOR USE In? SLAS TYPE SQUARE ftfUD BECTAPJGULfiR BIG-EMDDQlitW FiOLDSF During the pact few years important changes have taken place in re quirements Tor fist rolled products and plate products, Larger ingots have been mode to meet the demands of consumers for larger coils of aluminum killed deep drawing steel. At the same time consumers of plate product have found the economics end the metallurgy of big end down molds accept able, One of the major factors aiding these changes was the introduction -K- of Fosecc's "Feedtex" exothermic two side hot top. As pioneer of the exothermic hot top, Fd s b g o , Inc,, continually search for improved methods of not topping. Early in'1965, Fosecc, Inc, saw the advantages that the "Profax" hot top mould have ever the exothermic hot top. Soms of the advantages of the "Profax" hot tep have been listed. The following is 3 more detail ed explanation of the use and the benefits to be derived from the use of ins "Profe x " hot top on slab type ingots, The fact that a 3/h inch thickness of refractory insulating materia! can produce sound ingots of high quality is the characteristic of "Profax". The low density of "Profe x " has maos possible simple, compact packaging 3nd storage, ft typical example is the "Profax'' hot tap for a 3D" x 65" mold. A A2" x 60" pallet holds 60 hot tops; 3 truckload will hold A8Q hot tops and when shipped two pellets high, 360 hot tops can be shipped per truckload. By stacking the pallets two.high, 120 hot tops can be stored in sn area A2" x 60", Kate Figure 9, F<egistEred Trade Clark. Kradel 00108 Figure 9 Compact shipping and storing of "Profax" hot tops. Each pallet contains 6Q hot taps for 3 30" x 5" mold. Pallets are stacked two high with ease and s s f ety. 120 hot tops c a n he stored' in an erea -2" x 611". Because of the smell space required for a large number of hot tops and their esse Df installation, the "Profax" hot top can be put into the mold at the pouring pisiform if desired. The rapidity of installation is such that the pouring clstform is not tied up fox' any great length of time. Twenty af the 3D" * 65" "Profex" tops can be set by two men in about 3D minutes without the uss of 8 crane, kiote figures ID through Ik, Kradel 00109 Figure 11 Locating "Profax" hot top slabs agsinst mold walls, In shops where rig id safEty precau tions are taken, a light weight walk is placed between the molds for added saf Ely, Figure ID First step in the in stallation of "Profax" hot tops in a 26" X 59" big-end-down mold. Sections of oxygon lance era put through the hangers' so as to carry and also to sus pend the hot top in position in the mold. Easily inserted hangers are made of varying lengths so as to locate hot top at desired depth in mold. Mote one man is able to easily carry the entire hot top which weights 55 pounds. Kradel 00110 Figure 12 Putting spring clips in piece - the clips hold the hot top fii'mly a~ gainst mold wall, to pre vent metal penetration behind the hot top and also assures that the tap can not Float out of mold during pouring. It*6 imperative to have clean mold malls so that the "ProfsX" fits tight ly against the mold mall. Where "Profax" is ussd regularly on a particu lar mold, the hot top area is kepi clean by the "Profex" top itself and this area of the mold does not need any mechanical cleaning be tween bests, Figure 13 The last step in the "Profax" hDt top preparation is to remove the lifting or sospending rods; since the rods ere not needed during tracking or p-During, they are saved end usee! oyer again. The hot top is held sj firmly in place by the spring clips that they can be tracked over ins roughest of tracks without disturbing Dr harming lhs hot top Kradel 00111 Figure i*i Fully assembled "ProFax" 2~slb hot top ready must be taker, to assure that, ins spring clips tight contact et the bottom oF the pads so as "Profax" pads firmly eosinst the mold mall. for use. Care ere making to hold the The installation of ihs "Profsx" hot top is cisen; the surfaces nf the "ProPax" era hard end not friable, and, as a result, no foreign debris falls into the mold during installation. The cleanliness of the "Profax" is such that no vacuuming of the mold is necessary after assembly; this is an im portant advantage when putting hot tops in place et the pouring platform. The strength and rigidity of the finished hot top assembly is such that the molds can be tracked without damaging or altering the position of tha hoi tops in tne molds. The "Profax" hot top cart be sat st varying heights in the mold to give a predetermined ingot insight. Kradel 00112 Ab soon as the hot top is filled, Foseco "Ferrvix 107'' ia added on top of the hot top metal to provide the necessary insulation. "Ferrux 107" has been especially compounded for use with Profax* hot tops and no other topping com pound has bean found thet will produce as. consistent results of high yields af segregation free step! The importance of following e prescribed hot top covering practice cannot be over-Eiriphasized, The proper amount of "Ferrcx 107" and its msthod of addition is recommended by Foseco and for optimum re sults this pr-actics should bs Followed, Wote Figure 16 and 17, Adding "Ferrux 107" top covering to the filled hot top - the addition is mads as soon S3 possible after the- hot top is full so as to preys" heat loss, ft carefully Followed top covering practice outlined by Fogecn engineers must be adhered to for maximum results. Kradel 00113 In eueh instances a specie! type spring clip is used to hold the top in plaCB, An important advantage Df the "Profax" hot top is the fact that the ingot and tha hot top can he filled with a full stream and no shut-off nr slow-down of the stresra ia necessary. Because of its tapered bottom edge which is characteristic to "Prof ax'', there is practically no up-thrust From the rising metal. This eliminates entrappment of slag and inclusions as so often happens when conventional thick hot tops are used. Because of the few er number of shut-offs per hs3t there is less chance of having a leaking cr running stopper; but, even in the case of 3 full running stopper, no damage is caused to the ingot. (Vote Figure 15. Figure 15 "Profax" hot tops are poured straight up with s full stream with out halt or slowdown until the hot top is foil - inis cuts down on the number of shut-offs per heat and helps prevent leaking or running stoppers. Kradel 00114 Figure 17 #PrDF3xn hot tupped ingots after' the hot topping process is complete. In this case, "Profax" boards mere put on top of an exothei'rriic topp ing compound cover. Until the development Df "Ferrux. 1D7", this was the only method to obtain maximum results with "Profax" hot topping. The use or "Ferrux ID?" assures maximum results and also is less cost ly than the duplex top covering method as shown. "Profex" hot topped inpots pen be moved immediately after pouring if the pouring bey is needed for another heat. The timing of the move is important as delaying it too long mill cause ingot pattern with "Profax" hot top use just as with any other hot topping method. The ingots should 5= moved care fully to prevent metal spillage. even though ths ''Ferrux 107" top cover crust may be broken by the move, it will weld together again and prpvipE Excellent insulation, fit stripping, the "Profex" hot top leaves very little debris, ft large portion of the "Profax" hpt top is consumed during tha solidification psnoc and only a small amount of light weight powder remains that falls easily from the hot top ares et stripping. There is less clean-up at the stripper with "Profax" than from any other hot top and there is little or no carry-over of refractory into the snaking pit. Note Figure 18, Kradel 00115 Figure: IS "Profex" hot topped ingot after stripping, "profex" has strip ped completely free of the hot top metsi with very little debris present. Mote the very slight shoulder on the ingot and the ab sence of hot top material at the junction between the hot top and the body o.f ingot, and also the very flat feed produced by the "Profex" het topping msthod. The practically srouldarless "Prefax" ingot provines many advantages to the rolling mill opsratpr, During rolling, the small snoulder disappears without any roll-over after a couple of passes through xna 111. The slab has all the appssrsnoes of an open-topped ingot an the vurfanG, Bs c e u b b there is no adhering refractory there is no flying debris. There are no rolled-in surface inclusions from the "Profax" hot top end it is impossible to tell by visual inspection where the hot top junction was located except in rare instances when light metal flashing gets behind the "Profax" when dirty molds ere used. Ever, in the case where soma metal flashing is rolled into the surface of the ingot, the scab can easily be removed by hot scarfing as it contains no refractory. See Figure 19 and 20. Kradel 00116 t Figure 19 Slab produced From ingot maria with a convention al hot top. Note overfall of hot top junction and poor aide surface even below the hot top junction. Top discard from this slab was nvEr 7 fa s t lo n g. Figure 20 Slab produced from same type ingot as that shown in Figure 19 but using nPrpfax" hat top. ftote good surface and absence of hot top joint demarc ation. Sound product was made with s top cut of only 3-j- fB6t. The surfacs in the head mstel srEa is as good as that of the body cf the ingot. Kradel 00117 The steelmaker should metallurgically study the heed metal of tho "ProFax" topped ingots. This head mstsl is as clean Bnd es frse d F segregates as the body of the ingot. Except for about 3 ^ top discard, the head metal is superior to much af the metal in the center third of a conventionally topped ingot, Head metal can now be used as prime product with much higher yields because: 1..) There is no defective hot top junction metal due to rolled-in inclusions or scabs 2) The head metal is metallurgically sound. Dost users of "Profax" taka advantage of this. See Figures 21 through 24 h.. Figure 21 Longitudinal macro-etch through the hut top portion of a 24" tdida bic-anrf-doun ingot hot topped with "Profax", .`c-> carbon steel. Note absence of both carbon and r.on-metallics segregation. Kradel 00118 Figure 2k Transverse macro-etch sections taken from the center of top discards of slabs of aluminum killed deep drawing stBel made in 23 x 56 x 85 ingots using "Profax" hot tops. In every ness the Et.ee! is sound at the 85?~ ingot level and al so up to the ingot level. With well controlled "Profax" hot topping prac tice e total oT 7>i top discard will assure sound metallurgically acceptable high quality steel. Kradel 00119 -XT' I W I \J-J THERE IS A HOT TOP FOR ANY INGOT MOLD m SYSTEM Slab M old Liners Kradel 00121 O nc-Pieee B.E.D. Wh/:t> tlpci.' uhe r t o :--.:on>. s i--;"eco ' vjTi:.:' Onii-Piec-e D.E.U. The h ig h ly ve rsa tile . PITOFLEX h o t to p p in g system s are sn In n o va tio n that in tro d u ce new sim plicity, new economy, new ef ficie n cy in achieving the m axi mum benefits from hot lopping in got m olds. PROFLEX systems ere custom engineered to meet in d iv id u a l m ills ' p ro d u c tio n requirement: te O N E -P IE C E PRE-FORMED NO T TOP FOR S.E.'J. INGOTS e GN5-PiL.CE PPS-rORMRO H O T T O " FOR B.E.O. INGOTS t ONE TVVO-!ECF FDwO:-Ofb\i SEi-' -nlNGE.O LINER c POUR-PIECE SLAB MO; D Li.NEK PROFLEX HOT TOP SYSTEMS BRING YOU THESE ADDED BENEFITS: BETTE''" FIT . . m ey its * or com press lo c o r IDim ;o mpot m old mte rip/ contours . . minim ize molten metal by-pass and naoors. BETTER STRENGTH PROFLEX'S a ljii vy to w ith sta n d abuse e lim inates bieeV.age lcr.se; LIGHTER W E IG H T .. PRO FLEX it 40% tighter the.-, she next lightest hoi top linar This increases ease oi hanoiing. testuces la'ooi and ship ping costs. Kradel00122 ^ROFLEX ASSURES. CONSISTENT, HIGHER QUALITY NGOTS 'ROFLEX has an exceptionally hibh isolating efficiency that permits 1' hiii, tapered, low volume hoi top issemWies. 'he. wider. Itai feed of the PROFLEX lo t topping system (due to very thin no! top wall), plus ill thermal efli* ;Ivnay of Ferrux. hot lopping compound, results in an ingot with consistently dependable sound ms! allurgical structure. -Vhen PSOFLEX hoi to p pe d ingots 5re stripped, residua; m aterial tails away as g pow der avoiding any car ry-over o f refractory into soaking cits o r ro llin g m;M. t'ROFl.EX hat top system s are to tally a ry , . e lim in a tin g ail dangers re s u ltin g irons re s id u a - m o is tu re present in other hot topping systems during teeming. PROFLEX ASSURES MAXIMUM YIELD Because of tis excellent insulating properties, the PROFLEX hot tops do not require any back-up refrac tory material. The thin PRO FLEX wail atone provides the high thermal effi ciency needed tor a tow volume hoi top. The improved feeding cherscieristics of s PROFLEX ho! topped ingot, enhances its aggregation characterlslics and assures maxi mum yield. PROFLEX is non-friable . . . has up spalling tendency . . . eliminates rejections from non-me tallic inclusion during pouring; The thin taper-bottomed PROFLEX gives practically shoulriertess ingots and s u b s t a n t ia lly re d u c e s loss to Shoulder over-rail resulting In ex tremely high product yield. PROFLEX SAVES TIME. SAVES LABOR At all stages of ingol production, the lightw eight PROr.LEX material aiiows significant savings in lime and iahc-:. Assem bly oi p r o f l e x hot tops is an easy, rapid, one-man operation. Assembly ol 2.0 one-piece or m ulti part hot lops per hour/pe r man is a common accomplishment.No skilled labor is .required, here is no need fa r .spe cial to o ls or ha nd lin g equipment. PROFLEX REDUCES COSTS A doption ol a PROFLEX expendable hot lo p system invariably reduces costs o l finished product tonnage as a result of: * Lower hot top cast per ingol ton - Savings in installation lime and labor Reduced stotage and height costs Consistent, h.gh-niialiiy' proouct 1-iaIXM D:Wi;ii6ii -It-ifuluci*.'iiid ARE TAILORED TO YOUR MILL'S NEEDS Kradei 00125 f INSTRUCTIONS FOR INSTALLING FOSECO PROFAX IN PERMANENT TYPE HOT TOP CASTINGS Figy.re 1 Brush ovvuy ony loose PToesje powdtr rcjJitth'ig {fern .{he previews and remove or,y .sled sploshes it oik the ut side c*l the cas ring. Attach selling blocks. T ilt casting to 45* angle Place sand ring V.'.-, costing Kraclel 00126 L o c a te 4 re ta in in g straps in grooves an sand ring approxim ately 3 inches from edge. Bend llte legs bock out o f the wcy. ALLO W C A S TIN G TO COOL BEFO RE P U T T IN G PROFAX IN P LA C E . CASTING SHOULD BE MAX. 400" F BEFORE SETTING PROFAX, Spring c lip s rotfy be attached during th is c o o lin g period, or o ile r the Prcdax has been se t (see F ig u ie 14, 15), Kradel 00127 Figure 5 Place 1st Pretax slab on lower face- oi costing. Allow approximately 2 inches lo protrude. Left edge o f slab should ho touching ta il (gee of costing, leaving s gap d a n g right edge o f slab. Figure 6 Ptace 2nd Praia slob agoiftSl left foce of casting. Allow upproxinvaiedy 2 inches bo protrude. The tav.er edge ol Ihe 2nd slob will rest or, the Ciid of the h i Prof* slob. Kradel00128 Plane 3rd Profax slob- agoins! glil iocc* oi ta ilin g . Allow approximately 2 inches to protrude. The bottom edge of 1he 3rd slab w ill locate in the gap fanning along the right edge of the 1st stab. Place 4th Profax stab again si top loco of casting. Keep rig hi edge against rioht face of casting. Push in until evert with other live slabs. Kradel 00129 Push oil 4 slobs, in evenly by Hand until they lock* Slabs w jll extend about 1 inch above bottom of send ting. Figure 10 l ilt easting to vertical position and cover oil slob ?dg<*s with wooden locking plaSc?. Tap lacking'plate even*y c-n all 4 sides io live slabs flush with sand ring. Kradel 00130 Remove lockitig piare. Reium ca iltog io 45* ongle. Figure 12, 13 Bt-nd 4 relomlr.g sraps inwo.-d orni downwoid io lock Profox slabs In posstion. Kradel 00131 Kradei 00132