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FILE NAME: Foseco (FOS) DATE: 1965-1967 DOC#: FOS009 DOCUMENT DESCRIPTION: Advertisements in Trade Publications The Foseco- group of 19 companies is an international organization manufacturing,and marketing prod ucts under the trademark Foseco and serves the metal melting indus tries in most countries of the world. I t does not make castings, ingots or any other metal products, but it serves thoselhdustnes which do pro duce them, such as foundries, steel mills and wrought mills, producing aluminum and copper base products. Chemical and metallurgical products, and processes for the improvement oi molten metals, backed by world wide technical service enable Foseco to provide ideas, contributions, and know-how for these industries to: 1) Produce better castings, ingots, end billets a t lower cost. 2} Boost productivity. 3) Improve casting quality. 1) Simplify operations. ladel 0011 Fazttv, met. --1385 555 M ETA LLURG I CAL P RO D U C T S AND PROCESSE S .. . Cast metals often have defects due to incorrect melting or molding practice, but sometimes due to factors beyond a foundryman's control. By treating the molten metal in the furnace with certain Foseco chemical mixtures or by applying other Foseco products to the mold or core, most F O S E C O IN STEEL, M IL L S In steel mills the metal is first east into large ingots before it is rolled into slabs or blooms subsequently to be finished into sheets, tubes, bars or other type end products. The higher quality steels known as "killed steels" are prone to center line shrinkage. This results in lower yield of acceptable product unless "hot tops" are used during pouring of the ingot. Foseco produces numerous types of insulating (Frofmc) and exothermic (Feedex*) hot top- F O S E C O IN W R O U G H T N O N -F E R R O U S Technical developments and Foseco products are applied to the wrought non-ferrous producer. Tins industry melts large quantities of non-fer rous metals such as aluminum and copper-base for end usage in industries that manufacture electric wire, siding for homes, storm windows, PHOft&r -- light veijhl prehbncatei) n s i i a l f n g ^ ^ ^ ^ ^ ^ t e hot'topUahslofpradutingqaily.sfoal'Ing/vl^.i^'Aj''^^fe ...... ,,. Kradel 0012 of these defects cad be avoided. Foseeo makes a wide range of products including exQtherniies, fluxes, degassers, core and mold coat ings, feeding compounds and alloying additions for castings of most metals. Tiw porosity of holes in this isiOra2 cssting was caused by M orion molting practice. This sound cssting was made front metal treated with a Foseeo product, ping systems to control solidification of the steel. T here is little or no waste, and therefore the yield from ingot to finished product of slabs or blooms is improved by means of superior ingot quality (more sound metal per ton of metal cast), and therefore greater salable output from existing melting and railing plant w ithout additional capital investment by the mill. This is a sub stantial contribution to increased productivity and -steel mill .efficiency. This is the top or bend ol a filed ingot which lus been c.sst by e conventional meth od. (Inept has been sliced in two and dea rly shows the shrinkage cavity.) This is the top of an ingot cast w ith the aid of tho Foseeo PTOFAX insulating hot top, There is no shrinkago cavity in Ihu top o i this ingot N D U ST R IE S automotive trim and cigarette foil. In the production of non-ferrous sheet, strip, wire and extrusions, Foseeo contributes to increased productivity by improving mecal quality, as illus trated which show chill cast ingots of aluminum alloy 319. Ingot at the bottom shows the ellcctiveness ol 3 grain .-din ing treatment with a Foseeo product, ingot to the left is untreated m etal. Note the large, columnar crystals at edges -- a type ol structure highly detrimental to roiling or forging properties. Kradel 0013 :Exprimentt foundry itftclns':'Joe V rh V 'j tn^rmic: slattvs^T/ik:xp(!nm<:ntiijoiindry:-:-' :^^!{V*^thetml&^(npbhds'.'.t$it'o.tk^^{! ip urs iiew. products and techniques. . M el-Lety ta b . Technician a t tive.Sockmsn ,;SpectrophoWmter : which dtafiTiift'esVa^fi ^J*ili!:WtlS`anl,cloph.eWi':^'s-:o.r<j>8'i^ " ~an< the ~ ' ' 1 P ' ! '.: g*mz ^^iSt^gbr^phbrTrist'; hd>B pbtH 8nrri^ Quality'.Control;Analyst,- .inVcon.wal.qualit;; Con|rp.l-`..lah,Uwhich 'is; rsponihle for. .raw .iritrials -; control.j alohf! wim. tprodueriOn;- cbntrbVVof; paste - and liquid jprbdgctsirid,; fluxes. ; . . . .% ., > ?... W id e , W id e W o rld QUALITY and economy are essential in cast metals today. Castings must be Stronger,.dense', free from fatigue failures, close to dimensional tolerances to avoid needless machining, and, frequently, of X-ray soundness. Foseco, Inc., with a 30-year record of contributions to im proved foundry practice through formulations of metallurgi cal compounds and chemicals to males cast metals do a bet ter job oilers a specialized service co permit any foundry to produce better castings at a lower unit cost. Whether that foundry melts iron, steel, zinc, aluminum, magnesium, lead, tin, or copper, it can avail itself of competent technical serv ices based on complex international experience- The company;, now in process Of expanding its facilities for foundry research and development, has close "family" ties to a group of companies iii 19 countries around the world, all attuned to foundry research, Market demands of foundries naturally govern product re quirements, Through the Foseco sales force they are trans mitted to a research and development (R&D) group which initiates projects for investigation. Thin staff begins with an existing product, or with available information and expert-' ence, lit the case of an existing product, the effects of ingredi ents are known, and other suitable elements will be added to meet the necessary demands. The new formulations will be tried in an experimental foundry in minimum melts. If this is not practical, a test program will be conducted in cooperation with .a local foun dry with an R D engineer from .Foseco n3 supervisor. If the product idea warrants further investigation and seems to be formulated to meet requirements in accord with de mand. it is then taken to a local foundry for additional testing. Once it proves out in held trials, it becomes an ex perimental product of Foseco identified by an "3EP" number and can be purchased by metalcasters. The new product is under the cognizance of the R & D group, from market suggestion to EP number, including responsibility for direction of trials in foundries and suggest, ing and implementing the optimum manufacturing methods during the pilot plant stage. Exothermics Typical checks on raw materials made by the company's general analytical service section include control of alumi num fuel for the manufacture of exothermics. Percentages of aluminum, zinc, lead and chlorides arc critical. Also, sieve .analyses and related tests insure uniformity before mixes and finished products are- blended. In the manufacture of pastes and liquids for mold and core coatings, fluxes, and degassing agents, extensive tests on raw materials ore indicated. As an instance: a common ingredient for degassing aluminum melts is hexachloroethane, in which moisture is a contaminant. Laboratory tests are run on every batch of this product to guarantee that less than 0.10% moisture is present. Kradel 0014 Outgoing Product Control in the manufacture of foundry exothermic compounds, a primary product of Foseeo, aluminum fuel (metal) is the major ingredient. Each batch is individually formulated, be cause of the tight control on aluminum specifications -- and also because each exothermic grade is taiior-jnadB for the end use application. If used with copper, for example, the exothermic must ignite faster than for steel or iron, because of the variance in melting temperature of tire metals. To meat specifications, intensive quality control checks are made before, during, and after formulation, before release for shipment to customers as dry bulk material, or for in ternal fabrication into moldable exothermic shapes. A sam ple from each mix is brought into the experimental foundry for comprehensive testing. This includes dry-mix tests of powder sensitivity and burning rate, along with other investigations. Two corn sleeve samples from each batch then are molded and baked, and metal poured into them to record sensitivity, general burning characteristics and heat output. The batch is then approved for bulk shipment to customers or for in-shop fabrication into moldable sleeve shapes. The latter are 100% inspected by the quality control laboratory group of fosecu for (1) physical cracks, (2) soft spots, (3) friability, f4> sagging, (-5) wall thickness, (6) proper baking and f?) adequate vents. Accent on Service Foseco also helps serve foundries by offering what the com pany calis `'second opinion Services", Casting defect investigations, aid in risering critical jobs, and assistance- in setting up effective cupola operation for better hot rootal arc a few of the "second opinions" which the company strives to deliver, in conjunction with its field sales technical service stair. These product specialists can help larger foundries because of then: intimate knowledge of specific processes. At the same time, foundries benefit from these services because they free the metallurgical talent of the foundry for concentration, on problems unique to its particular operation. Small foundries realise benefits because they may not have skilled metallurgists to investigate operational problems. The help which Foseco can supply may be of primary im portance for those melters who cannot economically support their own investigations. Basic worldwide research and development, continuous new product development, exacting quality control techniques and customer oriented technical service enable FoSeco to provide products and services of considerable value to the foundrymroi in his never ending endeavors of producing higher quality castings economically. Ron Ruddle, Technical Manager o f Re search & Development at the board, and Ted dago, Supervisor o f Exothermic de velopment discussing the exothermic prop erties of experimental products. Sill Steln'man, Quality Control Supervisor of exotharmics at the Unitron metallograph viewing metal structure ol casting section. Jack Morgan, Technical Service Manager, and John Gotheridge, Sates Manager, foundry Division, risering a casting at the request of a steel foundry. One of the "sec ond opinion services" o^fegxj Igsj Foseco. IVIORE THAN QUALITY PRODU DEGASERI? 450 removes ttydrogon from molten aluminum. II Is vacuum friended during mnnufactufE to ensure freedom from moisture and Is shipped In waterproof heat sealed foil. S';-VTHE: f 6 s ECQ ' " '&$'-V'." :^J^TJhj,/osw6';njS6ft has-. v/q'fKStftinfouh - sties' and ecntribut-r-to tiift fund .of. -i.v,...g :yierfjfmYsfci ........ '& $ 8 8 f IDEAS, TECHNIQUES, IV1ETHOD FOSECO FOUNDRYMAN'S HANDBOOK 387 Pages of Foundry Technology The handbook contains facts and figures, charts and graphs, for the practical foundryman, metallurgist and apprentice. I t is pocket size with a flexible leatherette cover, and de signed for easy, daily reference in the foundry. Kradel 0016 n rs . , . P m fabricatod FDEX@ exotherm ic shapes ere available in a wide variety of design end are custom made in all sizes and shapes to meet a variety of east ing requirements. fiKeca pfodpcls are "engi neer packaged" in dags, drums, boxes., pails and pal lets for S3fe and speedy shipment. ft corner wedgo of a Profs hot top is being hsipmarsd into an ingot mold to secure the aids slabs. I KMOW-HOW FOR BETTER CASTINGS SSSSBSH 30 YEARS OF " FOUNDRY PRACTICE" One of the Most Widely Read Foundry Periodicals in the World This S page journal is now published in eight editions in seven languages w ith over 50,000 circulation. Containing articles on melting, molding, core making, feeding and other foun dry problems it gives useful hints and tips for everyday use, as well as information on the latest foundry developments. "EXTRA VALUE" SERVICE World-wide Research and Applicat ion Engineering Reports The latest developments and research projects of the Posero group of 19 companies are pub lished annualiv in FOSECO D E V E L O P MENTS. METHODS REPORT is a "case-history" ap plication engineering report sent regularly to metal casters to generate ideas and inform of proven worthwhile methods of producing quality castings economically. Kradel 0017 Th worid-wide business known today as Foseco had its beginning in 1932 in Birmingham, Eng land, In 1935, an American licensee was estab lished. Modest- foreign expansion continued until 1938, but the onset of World War II prevented further foreign development by Foundry Serv ices, Ltd., as Foseco was then known. After the war, overseas expansion resumed and manufacturing companies were established in France, Canada, Germany, Italy and South Africa between .1949 and 1952, In 1953 the American licensee was bought and the American Company reorganized. In 1959, Foundry Services, Inc,, as Foseco, Inc, was then known, moved from Columbus, Ohio into new offices and manu facturing facilities in Cleveland. The growth process has continued until there are now If) companies strategically located across the globe from Austria to Australia, from Brazil to Japan, and from. India to Spain. The largest are those in the United States, Great Britain, Japan and France. In addition, there are stocking dis tributors in 24 other countries of the world. This complex international experience, research, and new product development enables Foseco to be first to learn of new foundry and steel mill discoveries and ideas, quick to develop products for the American metal pouring industry, based on their needs and wants. CENTilAC RESEARCH ifffivitflute. snatesd Fseoo INTERHA'tfHAL LIMITED William? Wcnisn FOSECO WEERUND, K.V. MANUFACTURING COMPANIES Ar$en1ina Buenos Ailci FOSECO AP,GEWIHA 3.H.L. Aurtrl* S a lllw g Gl ESSEREI-QILSST CfcSEU SCHAFT. m.b.H. PjJsIop. Ne*SothVM& rDSEC PRDPR1E7ARY UMlTgD Dslgluru Brssels -fJSECO. 5.A. flwli S-So Paula rnsEco rfc rws. i.tda Canada GUfliph, Ontanu f 05 ECO CAMAOA. LTD. FVifiM CbUm S. i M..I, ffktee f SECO, S.A. Itfrl3irf POSECO 4.m.b.H. BAVE5 FOSCQ bi. Itely Milan KOSECO 5-p.A. Japan Osaka FOSECO JAPAN LIMITED Mexico Meai co City FOVNURr SERVICESda MEXICOS.A. d# .V juth Africa Jolismesbtrrg FOSECO SOUTH AFRICA (PTV.) UO. Spoilt Baictlont FOSECO ESPAn C-LA. S.A. 5witrerinr,il 2.-X FOSECO A.G United Xlniidum lav.wj|n FSF.CO if $ : UMHtD U-5.IV. Clffehind FOSECO. thC Kradel 0018 FOSECO. INC. 4 P.. BOX B72& - CLEVELAND. OHIO 44135 PkANT: 2020 SHELDON D. CLEVELAND, OHIO A 142 rc * p L i r c'-Omf PRODUCTS ; C m FOR THE ! STEEL '' INDUSTRY 4 } I r omr :c :0 t ) C. ( :.: o < j ,C i c lo i j L"@ C RiJW. T fild W i . I; Kradel 0019 For more thsn thirty years Foseco has served the rnetniluhjical inducirfxnnd tias . led the way in improving ingot yields with highly efficient axpentiablelinings to r ingot feeder heads, and surface feeding compounds. Maximum yields o f .Tii^did- killed and fully-killed steel in all steel quatlties^are obtained oimsSstently^anel economically, Pre-fabricated units or assemblies ready-for inyfSediate lise-jare supplied by your local Foseco company to designs made by FA'seco engineers, Foseco specializes in Supplying products wfuch aro feari to use and free from unpleasant and to x ic fumes, " f? * j :r f FEEDEX" exotherm ic head lining material, This mould able materia! is `-available In a wide variety of types of varying sensitivities and H^at output Chilling of the head metal Is delayed arid, after burning, the residual material inslllates the head to give maximum feeding efficiency from low volume feeders, Whilst It i& used on all sizes of ingots, it is of special benefit on smailer ipgots (see diagram,). The material can also be supplied as e powder for fabrication by the steelworks; thermo-setting, self-drying and silicate-bonded types are available. - r- r A N. j - '< ' /, I ` <. r r [ -- - y ------' .. . J, . - ...... - ------------- l y \ I `f '- j '-V~ j j - p p-. y X J P R O F A X f insulating head lining material On larger ingots, conservation oi the heat already present in the liquid Steel Is more important than the supply of external heat, Profax is a superior iighlwaight insulator which cart be supplied to almost any desired shape and gives yields which are similar to those obtained with Feedex.rHeads are fitted quickly and easily with no call on crane r capacity. Good surface condition of ihe head, and the absence of a pronounced -head/body demarca tion fine, makes possible the use of meiallureically. sound head meta! as prime yield. --------' X \, \ i \ . fi Where required, feeder heads.ban be designed for setting at difierent heights to give variable ingot lengths from the same mouirf, All Foseco proposals for hot- topping inciude the recommendation ot the most suitable anti-piping compound for the particular ingot, ...-v'. fPaicnte-J bjf S-6ndvlV:>-n JefitvcrV.* A 3 . M in u lc tlu riw i drids-f iiteftC-Jc, f Kradet 0020 .Oi,vi#Oi OS w&0 \ i FERRUX'* anti-piping compounds l Much oi the benefit of superior head lining materials can be lost by using Inefficient anti-piping compounds! The Ferrux range of products has been developed to mini mise heat losses by radiation. Types are available with varying sensitivities and heat output to meet the requirements of ingots oi ail weights. V-.-; The diagram shows the thermal characteristics of firebrick, Feedex and Profax under 4he con ditions oi our standard revaluation te s t. The treat loss thro-ugh each 'material over a given period has been .related to approxim ate in g o t weights to indicate the weight ra n g e s w here Feedex and Profax are recommended. / '\ . '( | f V \ii . \ KALMEX* therm it anti-piping compounds Similar in application to Ferrux, but molten iron is produced by the reaction which develops heat approaching 2000C!C, (360Oc'F.) If for any reason there is not sufficient steel in the ladie to fill completely the last ingot in a cast, the addition of Kalrnex will give s yield high enough in the shortened Ingot to warrant ii being rolled instead of beino remelted. BOOO 6O0 w E -toco 0 u 2000 I----NETT HEAT LO r'' / / . &A 1 / "p* ->fAk ' 0 30 60 20 520 time elopied in miriules o ---------------------------------- 2 0 TO N 0 7 T O N arid a b o v e ------ > Kradel 0021 STELOTOL* for ingot surface improveiment Bad ingot surfaces result in difficult stripping, high dressing costs and direct material loss. The SfEJofot range of products reduces these and the costs of m&uid coating. There are types for both top and bottom pouring, including surface covering fluxes, and a jionveniently handled, ignitable product which deposits an t , even coating on the wails of the empty mould, 1 t I \ i f iN G O T O L * liquid mould coatings A range of water- and spirit-based costings for ingot moulds. ; 5 * ~ .! KORON" j ' wafer-based, heat-resistant coatings Grades have been developed to withstand the arduous service conditions of high temperature and liquid metal erosion. They are recom mended tor protecting ingot mould bottoms, ingot bottom plates, furnace iaunders, ladle and iundish linings, anti a1! metalwork exposed to intense raiianl heat. l I S TR 1M * rim m ing agents A good solid skin with deep-seated blowholes helps to make the ideal rimming steal ingot. Fast pouring tends to reduce the thickness of the skin. Strim promotes an early start to the rimming action and intensities it, giving a good solid skin even with fast pouring rates. It also has a cleansing action by coalescing nonmetaillcs and removing them to the slag. Types available include grades for rimming high carbon/iiigh manganese qualities, S L A X " slag conditioners These products are for the rapid chemical activation of sings. Among them is an aluminoth&rmic reducing agent tor improving yields of chrome additions to stainless and other Steel melts. Chromium is reduced from the chrome oxide in the slag to give maximum recovery ai minimum cost. .'Deoxidants, inclusion Removers and products for continuous casting are other i-Foseco developments. ' . L 3$. Kradel 0023 A N IS C O L * protective painte Scale termed on billets and slabs during re heating prior to further hot-working results in direct material loss. The type of scale termed on some steel qualities may cause defects in the end product, tor example in tube-making. Permissible limits of suriace decarburisation on some steels a r e very narrow, and critical on finished components. The Aniscol range d{ protective paints prevents excessive scare losses and greatly reduces decarburrsatlon. Watef- and spirit-based paints covering a i wide range of service temperatures are available tor spraying, brushing or dipping. . / 'I} i Kradel 0024 ii.- > L--^ r r i `r L l r - ^ r ^ Z LU POL* a lubricant ii>_pr&vgni.damageto-jcbeefirt>m' Bcraichiriij in the_>ret topping pris 'of jciTnlineoos pick- tine Tines. - ; l ;i i Uf | i *S ~ V y n i s r " t - i F* NOTAK* additives to pickling baths * ( r A range ol inhibitors and other addition? tor both static and continuous pickling. I ; P O W A X * waxing agents f Vaster soluble waxes tor application by spraying or dipping prior to up-coiling on continuous pickling Sines. Scratching is prevented and the dry coating is resistant to atmospheric corrosion -under normal works storage conditions. Also suitable tor dipping of components to prevent corrosion. : Other products for cold working include Wire Drawing Compounds, Degreosers i and Rolling Lubricants. FOSECO SERVICE j ' The experience accumulated tram our world-wide activities'is always ai the dis posal oi the industry we are proud to serve. Perhaps you have a problem where our products and service may be of assistanct-'-we would be pleased to discuss it with you, [ f Kradel 0025 Foseco research and product devel opment is continuous. This brochure is on outline of our current range erf products serving the steelmahlng and finishing industry, Further information in detail Dn these products and advice on how Foseco can be of service fo you is available from your local Foseco company. ~ rr" ' r' " *" i ' * X '> J <r;- 1 i -* \ F/ y \ .- V,- < \ \ y / ' fJ i / K \ N- o veS* srP4*?i / > -\\,i \ a*" y \ ' r ; \ y r r Ti V 1 r* A ftC E K T IH A Foste! Buenos AArtptiircia t i t i * 5.R.L., P-srtsBvsay 5, 16' Fiso, A U STR ALIA f-pseco P iopritriary Lim nd. S tu a rt S trepi, Pffdststw . New Srulh V / x h A U S TR IA G ic s ii? rif *D i? ri*i, G s s c iis c h s i .b.#;.. M I 2 P u c h , Possiteli li, B E IC I UM Fo*rC > S .A .. 4 ftv p L io . 'i L ip E D , f.5fvJSiili!R 1. B R A S lL F cte co rio BftiU - Frodate* par? a Melolurflifl L.lde-, Calia to stisi Ho. \S521, Sic- Paole*.. CANAPA F o te cr. C e n a li* L td .. & A tte * S (r c i, Gwiflph, O nleriO . FRANC Fosrco 5.A-, B o ltf Pesiate Ho. i t \ 78- CaCelle-SitiAt-CG:JJoGCtoft- DERMANV F oie co G eteUschoh n..b,H,e P o ilis c h 53-i, A2B Bo/aen. GsJsirnVirctvr/ifir 5ir. 10. BoAin. OLIANO F fcstco M f d i/ la ft t f W .V., O u flfiJtn jii.C '-wec i . P a l i b u i 5?.. W o f id & r .. P ijb -litb fri by T o te c o Snlcnsclio-nil Llrpitftd. 1006. Printed !>/ VV. Lche W Ifrr.tnoLam) Limited, En&lapi* F O S E C O U fN T E R N A T JO K A t LIM ITED 80S LO WG ACRE-, KHCHELLS, BIRMINGHAM 7 IN P i A G rcives P ecft L t,, i Porne* Sinici. 8onvby, t- ITLV Fc te c o 5-fl.A.. MilanQ, Vie d e Amid s 53, JAPAN Foseco J a p a n Ltd.. Ceni/fll P.O- Bo; 52S*. O M E X IC O FP icco , 5 :A. tfe C.V.. Aprisde 150, Nnuebipxn ob Juarez. E sitcte da M l-j.co. SOUTH AFRICA Fiaico S o u th A irica (Ply.7 Liti., 20 Mfeioft fiend, Electron 7 o w i`>*hlp> J o b enne soiifp. SPAIN FoSfiCC Espoftoj S.A. CiHe Pedro lV a'34$ (inferior}, Barcelona {$). SWITZERLAND Fosi-cc A .G .. G x rJ e n s j *c 2, P o ilia c b &}, (301 2 tip. UNITED KINGDOM F o tecp fF.S.) Ltd-. Drayton M anor, Tfnmwcrfh, SteWorCshiia. U .S '.A . FoicCO 1ft,,20200 Shoftfon Rond. Clevelsnd <2, Ohio. PROFAX' E X P E N D A B L E , M EP IE C E , L O W V O LU M E HOT TOP SYSTEM Si PRODUCES CONSISTENT, HIGH QUALITY INGOTS m ASSURES MAXIMUM INGOT YIELD a SAVES LABOR a SAVES TIME m LOWERS COSTS a INCREASES EQUIPMENT USE a CUSTOM ENGINEERED TO YOUR PLANT'S SPECIFIC NEEDS ' k o v c c c --c >s> * i i S. P.'..b ! Nn/nottn Sa 25,'915`P.a 25,905, 3.237.29S tri 3tti*r palanti Kradel 0027 p p iN T so in ua.A 4 87 HOT TOP SYSTEM FOR B.E.U. INGOTS The unique, one-piece, FOSECO Profax Hot Topping System is a simplified, economical, Highly effi cient method of achieving greater benefits from the practice of hoi topping big fend up ingot moids. It consists of: 1. Art expandable, light weight, one-piece, Profax insulating. lin e r. 2. A permanent casting into which the Proiax hot iop is fitted and which requires no other refractory fining or treatment of any sort , . , NO BACK-UP REFRACTORY! . . , NO SLURRY! . . . NO SAND RfNC! 3. Fer.-ux* 107 exothermic-in sulating hot topping com pound added to the moid after teeming. PROFAX PRODUCES CONSISTENT, HIGH QUALITY INGOTS The prefabricated, FQSECO onepiece hot top is manufactured of the same efficient materials made famous throughout the steal mak ing wo.-Id as Profax insulating hoi top boards for B.E.D. ingots. The thin wail, one-piece B.E.U. Profax hot top liner Is produced on precision machines to to le r ances impossible with conventional refractories. Engineered with an integral base flange and steel wiper strip that assures a positive seal at the hoc top junction, the Profax liner ELIMINATES THE SAND RING. When Profax hot topped Ingots are stripped, residual materia! falls away as a powder avoiding any FERRUX 107 HOT TOPPING COMPOUND A cross sectional View of a big end up ingot mold equipped with the Profax hot top system. carry-over of refractory into soak ing pits or roiling mill. The FQSECO one-piece hot top is designed without ledges or re cesses into which molten steel could penetrate thus reducing the hazard of hanger cracks In the Ingot. FOSECO's Profax hot top system is TOTALLY DRY . . . eliminating ail dangers resulting From the residual moisture present in other hot topuing systems during pouring. PROFAX ASSURES M A X IM U M YIELD Because of its excellent insulating properties, the Profax liner does not require any back-up refractory material, The thin Profax wall alone provides the high thermal efficien cy needed for a low volume hot iop. The base of the Profax liner has a sloping shoulder instead of the conventional, wide, flat shoulder produced by a sand ring. This slope provides an improved rolling shape to the ingot and substantially reduces the extent of shoulder over.roll. The Profax liner's flared base provides an approximate 80% feed area. Other B.E.U. hot tops have vide flat base shoulders with a feed area of less than SQ%. The improved feeding charatteristies of FOSECO's Proiax liner enhances the segregation characteristics of the ingot and assures maximum product yield. Kiadel 0028 Profax is non-friable . . . has no spalling tendency , eliminates rejections from ncnme'nllie inclu sions during pouring. FOSECO's Profast material vvi/f not adhere to she ingot shoulder . , . unlike sand rings which can leave a residue to become entrapped during rolling and result in product loss. The Profax system assures a minimum top discard from the roiled ingot without endangering rneralfurgica! quality. PROFAX SAVES TIM E Use of the one-piece Profax hat cop invariably results in sizable savings of time. Assembly of the hot top is an easy, rapid, one-man operation. The lightweight Profax finer is simply placed in the casting and secured with wire dips. That's all there is to it! Assembling twenty tops per hour/ per man is a common accomplish* ment. The Pretax one-piece liner is compact, moisture resistant, has good handling strength and is not easily damaged under steelworks conditions No skilled labor is re quired and there is no need for special tools or handling equip ment. PROFAX SAVES LABOR At ail stages of hot topping pro cedures, the Pretax system pro duces significant savings in labor. With Profax, there is no tedious, costly, time-consuming re-bricking, patching, or application of slurry between pours . . .and no drying operation, The expended Profax material does not adhere to the hot top casting or ingot mold eliminating the need for cleaning after each use. The rugged FOSECO hot top cast ing is designed for longer life with proportionately lower cost per pour. It is engineered with smooth contours, both inside and out, for easy cleaning of steel splashes, Turning trunnions are located at the point of balance to insure sim ple one-man manipulation on the hot top assembly stand. PROFAX INCREASES EQ UIPM ENT USE The absence of semi-permanent back-up refractory aiiows the hoc top casting to cool much more rapidly after use. It also eliminates time spent on patching and drying. These facts, coupled with the rapid assembly of the Proiax hot top. result in a great improvement in turn around time. Three to four uses a day can be easily attained, which, in turn, permits a lower in ventory of hot top castings. PROFAX REDUCES COSTS Use of the Profax one-piece hot top system Invariably resuits in worthwhile reductions in the costs of finished product tonnage as a result of: * Low cost per ingot ton * Savings in time and labor * Economies effected in equipment use * Consistently high-quality product * Maximum yieid Installation of the lightweight Profax ilnor into tiia FOSECO casting is quickly and easily accomplished by one man. A 2 5 " x 2 ? " hot top lin e r weighs only 38 pounds. Securing the- Siner in the casting is accomplished with wire clips. The assembly is then inverted and is ready for placament on the B.E.U. Ingot mold. Kradel 0029 TOSECO Pi'of^i< h o t top liners are pro duced on FOSECO-developed automatic machines. The precision and performance of the finished product is assured by careful auaiity control measures enforced throughout each stage of manufacture. Supplies o f P raia* one-piece hot top liners are trucked to steel mills at a rate m atching mill production scncdutes. Stand-by supplies of Praia* liners a t the m ill insure against an inadvertent shortage of hot tops when needed. Empty racks from previous deliveries w ill be brought to the FOSECO plant on the truck's return trip. Kradel0030 r FOSECO 1 SCIENTISTS ARE PROBLEM SOLVERS IN ALL OF THESE PRODUCTION . AREAS f r f FOSECO MANUFACTURING PLANTS ARE LOCATED IN: Buenos Aires, Argentine * Bombay, India Salaburg, Austria Milan, Italy Padstow, New South Wales, Aus.traiia * Osaka, Japan Mexico City, Mexico Baissais, Selglum * Johannesburg, South Africa * Sao Pauio, B.-aul * Barcelona, Spain Gulph. Ontario, Canada Zug, Switzerland * Chelles (S. & M.), France Tamworth, England Borften/Westf., Germany Cleveland, Ohio. U.S.A. Woerdn, Holland * Mi. Brcdducit, Pa., U.S.A. (Eureka Fire Brick Works, Inc.) CENTRAL RESEARCH: * Birmingham, Eng'arui FOSECO, INC. P. 0. Sox 8728 Cleveland. Ohio 44135 234-3551 S7-* 7 Kradel 0032 W U JJim iM M M m 0 o i^ e s^L f i f i ASSEMaEY&m Mmm STr.t! M!Ll .-; iftoffieisifl iJ I liH E JC P iN B A B Li LOW 0 LUM i '^ J W HI ^ J p S ASSURE CONSISTENT HIGH PRODUCT YIELD m INCREASE EQUIPMENT USE # m IMPROVE INGOT QUALITY m DECREASE STORAGE SPACE NEEDS M SAVE LABOR SAVE TIME rn CUSTOM ENGINEERED TO YOUR ^ LOWER COSTS PER PRODUCT/TON PLANT'S SPECIFIC NEED fOSECO, INC 1987 f fas product or its rr-snifladofc ccvwed by a5 o# .'nor 61 tils foilii,i.'>g 1J.S, piM-ri! numbs; $e ii.V A . ms2l93S. 3..3.3,2*?.?%. J.Cqs.Cea su3 3,300,322, Kfadsl 0033 PRINTED IN U.SA. Profax Hot Topping Systems provide a simpli fied., economical, highly efficient method of achieving maximum benefits from hot topping ingot molds. There is a Profax System avail able for use with any type of ingot m old.'' Profax Systems are custom engineered to meet individual mills* production conditions. 1. Two-or four piece slab assembly: for use in square and rectangular big-end-down molds, o r. . . 2. Eight piece slab assembly; consisting of I four boards and four corner pieces for appli cation in square and rectangular big-end* down molds and . . . 3. FOSECO Ferrux 107: exothermie/insulating hot topping compound added to the mold after teeming, PROFAX ASSURES CONSISTENT. HIGHER QUALITY INGOTS Profax hot top boards are prefa brieatsd, insulating liners pro duced on precision machines to tolerances impossible with conventional refractories. The exceptionally high insu latin g efficiency of the Profax ma terial permits 3A" thin, tapered, low-volume hot top assemblies. The wider, flat feed of the Profax Hot Topping Systems (due to the very thin hot top wall), plus the thermal efficiency of Ferrux 107 Hot topping com pound, results in an ingot with consistently dependable sound metallurgical structure. Production experience at lead ing mills has shown that, with Prorax, certain grades of steel generally made big-end-up can be acceptably and consistently produced big-end-down. Profax is non-friable ar\d promotescleaner steel. When ingots are stripped, residual material falls away as a powder avoiding any carry-over of refractory ma terial into soaking pits or rolling mill. FOSECO's Profax system's are TOTALLY DRY . . . eliminating all dangers resulting from the resid ual moisture present in other hot topping systems during teeming, PROFAX ASSURES M A X IM U M YIELD Because of its excellent insulat ing properties, the thin Profax wall atone provides the high thermal efficiency needed for a 4 low volume hot top. The featheredged bottom of the thin Profax liners results in ingots which *FOSECQ 91so has a one-piece P/o-fos hot top tine/ In/ B.. u . iftyC/t molds- Rtxjuosi ripitvo Ulototura, Kradel 0034 ire. to all practical purposes, shoukicriess. Tills permits full use of sound portion of the ingot. During roll mg. the tapered shoulder dis- } appears, (See Figures 9 & 17.) The ef fectiveness of the Profs* Hot Topping Systems results in ingots with pipe and segregation confined to the uppermost por tion of the hot top metsl result ing in extremely high product yield. PROFAX SAVES TIME Use of P rofax Hof T op pin g Systems invariably results in significant savings or tim e. ' ;V- i : / U ,- !j // ; ; r i c - * J ~ S -, flLjUbiJ! 7 . -v C I J - J . J The lightweight Profax material results in significant savings in labor at atl stages of ingot pro duction. No cranes or other mechanical material handling equipm ent s required to instati Profax hot tops. Therefore, hot topping can be accomplished at the pouring platform. A change in production scheduling, from rimmed to killed steel, can be easily m et with rapid mold preparationavenafter the molds have been moved to the pouring site. Assembly of Profax hot tops is an easy, rapid, one-man opera tion. In the case of two or four shtb assemblies. Profax boards are suspended into the mold, at controlled depths, from hangar rods. They are than secured with wire clips, powder-driven nails or other suitable fastening m eth ods. (See Figures 1--4.) In eight piece assemblies, where ingot size may vary, the four side boards are held in proper position by a. collapsible jig. The locking corner wedges are then inserted and the jig removed, '//here molds are used only for maximum size ingots, Profax boards are available with integral ledges or attached hang ers to facilitate assembly. PROFAX REDUCES STORAGE SPACE REQUIREMENTS The compactness of Profax ma terials results in great savings of storage, space required for bulky, ordinary refractory materials. 120 palletized Profax hot tqps for a 30" x 65" ingot mold can b stored in an area only 42" x 60". PROFAX REDUCES COSTS Adoption of a Profax expendable hot top system reduces net cost per product ton as a result o>: - Low cost hot tops Assembling 20 Profax hot tops per man-hour is a common accom plishm ent! The Profax. boards are lightweight, moisture resistant, have good handling strength and are. not easily dam aged under steelworks condi tions. No skilled labor is required arid there is no need for cranes or other materia! handling toots. Rapid, easy installation Reduced labor costs * Elimination of installation cranes Reduced storage and freight costs Consistent, high-quality metallurgy * Maximum ingot yield FIG. 8, Typical four-slab P/ofax hot top Installa ho Recommended for use on large slab molds yd;ere i| length to width ralio is less than 2;i. FIG. 9, Slab flop) produced from an tngPl made wi a conventional hoi top. Mote over-roll and poor sit surfaces. Top discord of this slab was more than 7 fe long, Slab (bottom) produced from same type tngt but hot lopped with Praia,<, Mote excellent surface loch of over-roll, Sound product required a fop cut only 3VS feet. ingoi mold. Kradel 0035 COMPONENTS FOR A PROFAX FIG. IX. Components for a fr o tax B piece 22" square hot top. Each side sta b weighs 4Vi pounds; each corner post 1V2 pounds, Total waip.hu only 24 pounds, FIG. 15. Profax 3 piece hoi topped ingot treated with, ferryx 107 exothe'rmlc/insulntlng hot topping compound. Kata the unbroken crust anti absence oi smoke. FIG. 16. The same 22"' square ingols arc- shown above after strip, ping. Notice the absence pi any reflectory material In the hot Iqp area, the clean tapered shoulder ai (he hot top anti Ingot body [unction; the flat load which assures good center quality. FX3; 12. The 4 side slabs are held securely in place by an automa he jig as the 4 corner wedges are driven in. Complete assembly Of th 8 piece Protax hot lop Is accomplished in less than iwo minutes. FIG. 17. Blooms made from the Protax hoi lopped 22' square ingot. The (unction of the hot top and body is located approxi mately at She position of the rails, The lack of over-roll arid ab sence of any entrapped refractory results in higher product yield. 17VV5I: Discard [H c t-lo p rln g e t ^ lev si ^ju n ctio n ]3V i% Tap discard level | t T fe jg tiy in ....... *Vi- - r i ; FIG. 13. Praia* 8 piece hot top assembled 6" below the top oi the ingot mold (left) so produce a shorter hot topped ingot. FIG. 14. Cross Section view of lodged Profax boards which automatically position the hat top's depth loconon in the mold. This styie oi Profax is recommended where requited ingot size does not vary from heat to heal. FIG. 18. in is is a macro-etch made from the top bloom oi a 22 square, big-ebd-down Ingot. Note the complete absence ai pipe or segregation below the 3Vif% top discard area. Also Hole the cleanliness of the hot lop/ingoi Junction and the sound metal in the undiscarded heal area. Kradel 0036  ~ f- -*>**'> - :(ReconimendedioiHB;E.D;rriolds'w ith ,a lengthto ' w d t h ^ t - - igreat r t h r ;2:1 - mm 8S^^l^Wwte8fe i .. f^W jjgp T-othm-:lcnt0hn oT! thMn IJ: toA'<'-bonidp.i>*s;vnr a n ssp n i ^pi.a^<^r0Ainl[K^% ni,^^.{e|&aj)^p.oi S S # ^w M 2 ,# a |a o j sjmttmsstmmMS Vfl&otmxii^tnW&SDe^rSa^EBSK^a9SWx\f^iocrg gohiu bsa g^tig ni S ip ip t l't1^ ieJ^SSSil?0^ s ft M ni?c .1pE M mMm Kradel 0037 r FOSECO ^ SCIENTISTS ARE PROBLEM SOLVERS IN ALL OF THESE PRODUCTION , AREAS mm0mwm m ciim mimm L-5B72 FOSECO MANUFACTURING PLANTS ARE LOCATED IN: Birmingham, England Bombay. India Buenos Aires, Argentina > Milan, Italy Salzburg, Austria Osaka, Japan Padstow, New South Wales, * Mexico City, Mexico Australia Johannesburg, South Africa Brussels; Belgium Barcelona, Spain > Sao Paulo, Brazil Zug, Switzerland Sueiph, Ontario, Canada Tarnv/ortti, England Challes (S. & M,), France Cleveland, Ohio, U.S.A, * Borken/Wastf,. Germany M i. Braddocfc, Ps., U.S.A. Woerden, Holland (Eureka Fire Brick Wofks, Ini:.) CENTRAL RESEARCH: Birmingham, England FOSECO, INC. P. D. Box 8728 Cleveland. Ohio 44135 216/234-3551 Kradel0038 Kradei 0039 pro fa x* ME PIECE M O I P SYSTEM mn B E, D* IN G bTS > vV*: "SEAL-ON" . , ' - * , HOT TOP SYSTEMI C Another hot topping innovation from FOSECO research is the illustrated .pne-piece hot top for 8,.D. ingot.molds.. . . production tested and adopted by a rnidwestern steel m ill; Weighing oniy 14 lbs., this unit rests bn top of its 22 inch square by 34 inch high ingot mold supported by two nails inserted in each of two diagonal corners. With this thoroughly engi neered, uncomplicated Profax system, two men can hot top a drag of 40 molds in 15 minutes or less. Compare this to the 35 minutes, 3 men and s crane required tor the previously employed, !32 lb. exothermic hot tops. In addition, an aver age yield increase of 2-79% has been realized through use of the one-piecs Profax top and FOSECO Ferrux 107 exOthermic/insulsting hot topping compound. '4,.... ........... .... ... .......... 'asc\: results-'in ingots-wit-mpipe andSegrega Jined fo tpe uppermost prrtipn of,4 p : wsftmrcporext, m p l^Wh p ,c d u r ? ^ r 2 " . Kradel 0040 THERE m A Tm m m ? HOT TOP SYSTEM TO MEET EVERY m m TOUR PIECE ASSEMBLY EIGHT PIECE ASSEMBLY Profax Hot Topping Systems provide a simpli fied, economical, highly efficient method of achieving maximum benefits from hot topping ingot moids. There is a Profax System available for use with any type of ingot mold . , , custom engineered to. meet individual mills' production conditions.: 1. One piece Profax for big-end-up ingots : . . 2. One piece Profax for big-end-down ingots . , , 3. Two or four piece slab assembly: for use in square and rectangular big-end-down molds, o r.,. 4. Eight piece slab assembly: consisting of four boards and four corner pieces for applica tion in square, and rectangular big-end-down moids. 5. Five piece dry slab system far big-end-up molds, and . . . 6. FQSECO Femix 107: exqthermic/irisuiating hot topping compound added to the mold after teeming. The wider, flat feed of the Profax Hot Topping Systems (due to the very thin hot top wall), plus the thermal efficiency of Ferros 107 hot topping compound, results in an ingot, with consistently dependable sound metallurgical structure. Production experience at leading mills has shown that, with Profax, certain grades of steel generally made big-end-up can be acceptably gnri consistently produced big-end-down. Kradel 0041 ! ^oredbv ine Fteneb Gna^iJsSiicr, conducled' m d fstad oy: FOSECO, S)fiiu/f3rteot;3 icaiJSfsf/oit inio tour anguaks was emplcyen. - ' Four typoal FOSECO production stente; * . United Kingoht ; 3. India (ons of two factories) - ,4.. Westfiefmsny . v.;. ; - * - 5. Australia . . -A-'. .1... S IP ! Working niitlBl c/ a pioneering, in situ, automated, Praia jot top production line engineered and produced by FOSECO for a ma/or American sieel mill. A typical FOSECO technological "break compounds for removing ingot impurities. through" is the development of the PROFAX'5 Other FOSECO compounds control the be hot topping system. Utilizing compact, light havior of steel in its molten or solid state. weight, expendable refractory material, this Still other FOSECO materials are used to ex- ^ exciting FOSECO innovation brings many tend the useful life, and improve the per- w o rth w h ile b e n e fits to users, included form ance of, steel m aking tools arid among these are consistently high quality equipment. Ingots and increased product yield. FOSECO's dose contact with its customers The many advantages of the PROFAX hot throughout the world places its development topping system have made it, within a very teams in the advantageous position of being few years, the most widely used and copied on the scene wherever new techniques and hoi topping method throughout the free processes are being created. Our new-prod .voiid. However, FOSECO has continued to ucts department strives to keep ahead of widen its scope of interest in solving the these industry advancements and channels steel industry's problems. This brochure is its research efforts accordingly. This long- designed to give the reader a broader pic range planning places FOSECO in the unique ture of our many products and services all position of being able to supply both prod engineered with a single purpose in mind: to ucts and production experience of value to improve, simplify, speed-up and lower the its steel mill customers. cost of steel production. FOSECO is in a position to assist on many Founded and growing on the performance of of your mill's quality or production prob services to the industry, FOSECO has origi lems. Our research/development dep art nated solutions to numerous production ments will strive to quickly develop solutions ij problems. These include patented chemical that match your needs. Kradel 0044 Typical of FOSECO's highly competent staff of engineers and scientists are Vice President, Technology, Ron Ruddle, anti Ted Jago, TecJipicaJ Manager, Sieei Mill Products Division. They tira shown, hera discussing the exothermic properties of an experiment?! FGSECQ development. 2. FOSFCO Fiefd Engineers are wed known to production per* semriei of many sceei producers. They are available on an around-the-cicck basis Co serve as advisors when new FQSEGQ products and procedures are instituted. \ 3. Experimented foundries and metallurgical laboratories aid in tiie development and testing, of new FOSECQ products and techniques Quality control laboratories maintain a rigid check on all raw materials . . . assure the high level of consistency and d`e* ._ pendability for which FOSECO products am knows). v4fS- 5. A small section 0/ 3 FOSECO warehouse where stock prod ucts and custom eng/naared items i?r& inventoried tor "eft the shelf" delivery. 6, ftefracfory specialit/es produced by FOSECO Subsidiary, Eureka PoYraciorias, Inc. 7. FOSECO's Foundry Products Division nas a wide range of products to aid in the casting or most meteIs. These include exofce/mics, IIu x m . degassers, core and mold coatings, feed ing compounds. and afioying agents. PRODUCT GROUPS FOSECO Steel Mill- Products Division's extensive developments have been classified under the four general head ings shown at the right Each of the products within the group Is custom engineered to suit the user's needs, FOSECO field engineers and R /D staff jy. are at home in a steel mill and pride themselves on their ability to find the f 1 precise FOSECO product modification required for optimum performance und^r individualized mill situations. Trie's??-men are knowledgeable about mill practices, understand work-day problems, and can readily communi cate with production personnel, they are also available to observe, or . , . when requested . . . to supervise a FOSECO product's introduction into the .. mill's procedures. They are on the fob day and night, weekends and holidays, complying with the mill's schedules, In a single year, FOSECO's many tech nical staffs have developed 350 prod uct formulas. The expertise of the men who staff FOSECO's R/D departments and the great number of specialized skills they employ indicate FOSECO's dedication to retaining world-wide lead ership in its industry. ROLLING MILL PRODUCTS5 Kradel 0046 Beyond the ingot stages, FQSECO supplies steel mills with numerous compounds designed to improve the quality and reduce the price per ion oi finished product. For example: POWAXTM, a dry wax-like coating for steel sheet offers many advantages ever conventional Oil ing. LUPOLTM 2. 3 wet looping pit additive, in creases pi: capacity and product quality. 21 MOLTM provides a low cost method of re claiming zinc from hot galvanizing shimmings. Kradel 0047