Document k9bbDJbMZGRKoeRg3a7JZMLVy

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. It does not make castings, ingots or any other metai products, but it serves those industries 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 foT the improvement of 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, and billets at lower cost. 2) Boost productivity. 3) Improve casting quality. 4) Simplify operations. 7cf:: r; -- :?*: METALLURGICAL PRODUCTS AND PROCESSES... Every metallic object, at one or more stages of its fabrication, has been molten and all Foseco products are applicable to metals while they are in this state. The majority of them are patented chemical mixtures suitably bonded, packaged and supplied in forms for convenient application to furnace, ladle or mold. These products, which number over 200, perform a variety of functions all of which lead to improvements in efficiency in the casting of metaL Some control the manner in which the metal solidifiesin the mold, some remove impurities by chemical action, some add minute traces of important elements and some pro tect the metal surface during the melting period. In each of these, Foseco offers products for applica tion to iron, steel, bronze, brass, copper, aluminum, zinc, and magnesium. TYPICAL FOSECO PRODUCTS FOSECO IN FOUNDRIES Cast metfcls 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 FOSECO IN STEEL MILLS In steel mills the metal is first cast 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 (Profax) and exothermic (Feeder) hot top- Fomco foundry products art designed for easy ap plication and offer foundries exact chemical additions for uniformity of metal analysis. PROFAX -- fipit-weifh* prefabricated insulating bo: top slabs lor producing duality steel ingots FOSECO IN WROUGHT NON-FERROU Technical developments and Foseco products are applied to the wrought non-ferrous producer. This 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, 0297 of these defects can be avoided. Foseco makes a wide range of products including exothermics, fluxes, degassers, core and mold coat ings, feeding compounds and alloying additions for castings of most metals. ping systems to control solidification of the steeL There 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 rolling plant without additional capital investment by the mill This is a sub stantial contribution to increased productivity and steel mill efficiency. This is the top or head of a steel ingot which has been car. by a conventional meth od. (Ingot has been sliced in two and clearly shows the shrinkage cavity.) This is the top of an ingot cast with the aid of the PftOFAX1!' insulating hot top. There is no shrinkage cavity in the top of this ingot. JUSTRIES automotive trim and cigarette foil. In the production of non-ferrous sheet, strip, wire and extrusions, Foseco contributes to increased productivity by improving metal quality, as illus trated which show chill cast ingots of aluminum alloy 319. Ingot at the bottom shows the effectiveness of a pain refin ing treatment with a Foseco product. Ingot to the let; is untreated metal. Note the large, columnar crystals at edges -- a type of structure highly detrimental to rolling or forging properties. 0298 Experimental foundry technicians Joe Vrh and Jim Austin pouring copper into exo thermic sleeves. The experimental foundry not only contributes to the production con trol of exothermic compounds but also spurs new products and techniques. Mel Leeb, Lab. Technician at the Beckman Spectrophotometer which determines al kali metals and colorimetric traces of iron, manganese, chromium, titanium, boron and the like. Jey Steiger. Chemist and Bob Henning, Quality Control Analyst, in central quality control lab. which is responsible for raw materials control, along with production control o( paste and liquid products and fiuxes. i.ju'.iuj'jiuLaua W Wide, Wide Worlc f QUALITY and economy are essential in cast metals today. Castings must be stranger, denser, free from fatigue failures, cloae to dimensional tolerances to avoid needless machining, and, frequently, of X-ray soundness. ~ Foseco, Inc., with s 30-year record of contributions to im proved foundry practice through formulations of metallurgi cal compounds and chemicals to make cast metals do a bet ter job offers a specialized service to 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 in 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. This staff begins with an existing product, or with available information and experi ence. In 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 L D engineer from Foseco as 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 field trials, it becomes an ex perimental product of Foseco identified by an "EP" 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. Exothermic* 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 are 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 are 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. A W *!B. jew 0299 ^ULIWVr sseco's Market Outgoing Product Control In the manufacture of foundry exothermic compounds, a primary product of Foaeco, 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 tailor-made 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 the metals. To meet specifications, intensive quality control checks are made before, during, and after formulation, before release for shipment to customers as dry built 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 core 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 Foseco for (I) physical cracks, (2) soft spots, (3) friability, (4) sagging, (5) wall thickness, (6) proper baking and (7) adequate vents. Accent on Service Foseco also helps serve foundries by ofiering what the com pany calls "second opinion services". Casting defect investigations, aid in risering critical jobs, and assistance in setting up effective cupola operation for better hot metal are a few of the "second opinions" which the company strives to deliver, in conjunction with its field sales technical service staff. These product specialists can help larger foundries because of their 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 realize benefits because they may not have skilled metallurgists to investigate operational problems. Tne 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 ioundryman in his never ending endeavors of producing higher quality castings economically. Ron Ruddle. Technical Manager of Re search A Development at the board, and Ted Jago. Supervisor of Exothermic de velopment discussing the exothermic prop erties of experimental products. Bill Steinman, Quality Control Supervisor of exothermic* at the Unitron metallograph viewing metal structure of casting section. Jack Morgan. Technical Service Manager, and John Gotheridge. Sales Manager. Foundry Division, risering a casting at the request of a steel foundry. One of the "sec ond opinion services" offered by Foseco. 0300 MORE THAN QUALITY PROD' DEGASER41 450 removes hydrogen from molten aluminum. It is vacuum blended during manufacture to ensure freedom from moisture and is shipped in witeiproof heat saalcd foil. THE FOSECO MAN Tne Foseco man has worked in foun dries. Many are recognized authori ties and contribute to the lund of available knowledge in the foundry and mill industry. The Foseco man is knowledgeable about foundry prac tice. can communicate with its peoole. and understand its everyday worK problems. He car. offer ideas and solutions--and most important, learn from his customers, mo*- coes this benefit Fosecc customers' Fosecc can adapt its plus 30 years of ex pedience in chemical proouct formulations tc fit the practical requirements of any cus tomer in terms of wnatthat customer needs. IDEAS, TECHNIQUES, METHO FOSECO FOUNDRYMAN'S HANDBOOK 3B7 Pages of Foundry Technology The handbook contains facts and figures, charts and graphs, foT the practical foundryman. metallurgist and apprentice. It is pocket size with a flexible leatherette cover, and de signed for easy, daily reference in the foundry. 0301 ) 3. Fomco products in *ir paekpfcd" In bags, drama, bom, paila nnd pal lets ter sata and spnady shipment. * <NOW-HOW FOR BETTER CASTINGS 30 YEARS OF "FOUNDRY PRACTICE" One of the Most Widely Read Foundry Periodicals in the World n This 8 page journal is now published in eight editions in seven languages with over 50,000 circulation. Containing articles on melting, molding, core making, feeding and other foun3 dry problems it gives useful hints and tips for everyday use, as well as information on the latest foundry developments. The latest developments and research projects of the Foseco group of 19 companies are pub lished annually in FOSECO DEVELOP 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. 0302 WORLDWIDE FACILITIES .. . TO SERVICE THE METALCASTING INDUSTRY J.S.A. 200,000+ Square feet ENGLAND The world-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 193S, 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 19 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 leam of new foundry and steel mill discoveries and ideas, quick to develop products for the American metal pouring industry, based on theiT needs and wants. CENTRAL RESEARCH ilTMIftfMm. England FOSECO IKTCRHATtOHAL LIMITED MANUFACTURING COMPANIES Argentina Soenoi Awi FOSCCO ARGENTINA S.A.l. Austria Saitew'C OESSERCIDICNST Ctsat SONAFT, M.b.H. Amtralia Fadstew. Now South Walts FOSCCO PROFfttriAltY LIMITED SoJgiirfn IrauiH rostco. s.a rttil Sao Fa ole FOSCCO de WASH ITOk Canada Cvttbh. Ontario FOSCCO CANAOA. LTD Fnatt CMUti (S. A V ), FrtnCt FOSCCO. S.A. Carman? FOSCCO G.m.t.n MIM FOSCCO KCDCRUKD. N.V. AoNttay CItCAVCS FOSCCO LTD. itoir Milan FOSCCO S.a.A. Oukl FOSCCO JAFAN LIMITED Moaico Moiico Cin rOUNORY SERVICES t* MEXICO S.A. -- C-V. South Africa janiMNibtti| FOSCCO SOUTH AFRICA (PTY.) LTD. Shorn SorcoloM FOSCCO CSFAAOLA. S.A. SoiliorliM 2i FOSCCO A.fi. Untied Kingdom To mvorrh FOSCCO tF.S.) LIMITtO U.S.JL Cortland FOSCCO. INC 0303 FOSECO. INC. P.O. BOX *728 CLEVELAND. OHIOAA13S PLANT: 20203 SHELDON RO. CLEVELAND. OHIO *A]42 * l \ fi * * i; .{ t t J J O O O U T L IQ .