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FILE NAME: Foseco (FOS) DATE: 0000 DOC#: FOS047 DOCUM ENT DESCRIPTION: Company Sales Literature fot THE FDSCD ''PROFAX" INSERT ASSEMBLY FDR USE W PERMANENT TYPE HDT TOP CASTINGS Kradel 0088 THE US OF' FQSSCQ " P R Q F R X " H ' S c R T 5 IN Pt.RFiRliif.roT TYPE HPT TOP CASTINGS. Tha acceptance of numerous technological advances is rapidly changing the prccBdu-ea for manufacturing steal. The effects on steel production rates of (1) basic oxygan converters, sod (2) open hearths employing basic roofs and oxygen lancing are well known. The "Profax" system, of hot-topping big and up ingots io designed Bpecificially to give Htesl producers en efficient and economic method for hot-topping this increased production of steel into solid ingots. Due to increasing strict metallurgical specifications, mere of this tonnage is being mads as killed steel which mUBt ba hot-topped to produce a sound, acceptable product. A general survey of the Btasl industry indicates that a number of specific ations should ba mat to cope with the present steel hot-topping requirements. These specifications are as fallows: 1. Low volume hot-top do as to produce maximum yield at the rolling mill. 2. The assurance of producing consistently sound metallurgical product, 3. hinimunr capital Investment. t. Minimum number of permanent hot top units to conserve apses For prepar ation and storage. 5. The ability to prepare rapidly tbs hpt-top units between casts so that they may ba used severs! times per day. 6 ft system thst can bs used economically in periods of both low and peak production with ease and speed of preparation, at minimum cost. 7. Low mgintainence cost, and A system requiring a minimum of skilled labor for preparation. 6, Cleanliness at the hot-top preparation and pouring platforms and stripping area; minimum of dBbris and carry-over Into soaking pits, Ths steal Industries acceptance of "Profax" for hot-topping big-Bnd-dawn molds led to the usa of "Profax" as a liner in permanent hot-top castings for big-end-up molds. Its use in production provides a new hot-topping method thet meets all of the precseding opacifications. Kradel0089 T.hs "ProFax* liner is light walght, 3 / V thin. The finished liner is refractory, possesses insulating properties at eteel pouring- temperatures and does not adhere to either the ingot feeder-head or thB hot-top casting wall. This results lh both a smooth faadBr-hsad and clean hot-top interior walls upon stripping from the ingot* The permanent hot-top unit for the "Profax" liner is a special (movy-outy iron casting and completely eliminates costly back-up brick or castable, Two designs of casting are currently used: (!) a "3" shaped casting (Fig. l) which is bolted on to the top casting oF a conventional permanent hot-top unit or (2) a one piece casting which eliminates the nesd of assembling top and bottom units. Kradel 0090 IN PERMANENT TYPE HOT TOP CASTINGS 1. Lou volume hot top moans incroasBd yields. 2. Consistently Bound metallurgical product. 3. Good handling strength under normal steel mill conditions with no waste of materiel. A. Greatly reduced turn-around time of hot tops; permanent hot top available for use up to four titnse per day. 5. Fewer hot top castings heeded; less apace needed for given numhar of hot tops per day or increased hot top capacity with tbo eama number of hot castings. 6. improved flexability In scheduling of both the malt Bhop and rolling mill. 7. Leas labor needed-, no skilled labor required; improved working conditions in the hot tDp housa. B. Eliminates: (1) chipping out old lining; (2) clean up of brick or castable debris; (3) rslining of hot tops, 9, Less time neadsti for assembly of top and bottom castings due to the prolonged life oF the hattom casting with the "Pretax" process. ID. Eliminates use of slurry for linings or patches and drying of hot topa. 11. Reduced debris means cleaner hot top house; elimination of drying means reduced costs and batter working conditions. 12. Repid preparation of hot tops; 20 not lops par man hour possiblB. 13. Inserts not friable - will not contaminate steel by introducing non- metallic inclusions. fo slurry present to fell into mold during insertion in mold or during subsequent tracking to pouring platform. Reduced sandring breakage and fall-off. Eliminates vacuuming molds at the pouring platf Drn, I k . Csn be trans parted over rugh "tracks without d;emage to hot top. 15. Totally dry 'Profax" system eliminatss boiling due to retained !moisture. 16. Refractory cnrry-ovsr to uoski-ng pit minimized 17. Fast, clean strip of hot tup ; fewer stickers. Fast, cunsi stent delivery of ingots to the soaking pite. IB, Clean, aimpi e compact aterage, Lqw density of "Prof ax * raducBs frsight charges. 19. Easily atispiable to all typss of permanent hot tops. Kradel 0091 K K U f A A LIITLK i l o i civi i \ j ,\ woi,, M * PERMANENT TYPE HOT TOPS \ T H E IRON C A S T IN G U SED AS P E R M A N E N T B A C K INC EOS T H E P R O T A X LIN ER S . 2 C O N V E N T I O N A L t o p C A S T I N G w h i c h IS B O L T E D p e r m a n e n t l y t o B O T T O M C A S T I N G . 3 SKO RING WHICH P R O T E C T S BO TTOM CASTING FROM LIQUID M E T A L. A S T E E L W I P E R S T R I P S U S E D T O A I D IN S E A L I N G M E T A L B E T W E E N M O L D A N D H O T - T O P . 5 AIR-SPACE BE T W EE N INNER AND O U T E R WALLS OF THE CASTING. 6 PRO FAX LINERS USED TO FORM HIGHLY INSULATING HOT-TOP 7 M E T A L C L I P S H O L D P R O F A X L I N E R S S E C U R E L Y IN P L A C E , B WISE SPITING C L I P S S E C U R E S SAND RING. flGlvRt ) Kradel 0092 Figure 2 Bottom C3oting of iron used in the "Profex Liner System" Df hot-topping. This casting act: as thE backing support far tbs "Profax" linars. "Profax* ie sue! an excellent insulator that the casting is only between B00 and 9DD degraEB F, at stripping. The metal walls of the casting enable the unit to cool very rapidly after stripping. Figura 3 A conventional permanent type top casting ia bolted to the "Profbx System" bottom casting. To keep costs at a minimum, the "Profax* bottom casting cen always be designed so ae to allow tne conventional top casting to bB bolted to the "Profax* bottom casting. The present permanent top castings in any ahop can be used with the "Profax System.0 Kradel 0093 Figure A Tdp view of the ''Profax* system pBrnsanant hot-top casting assembly. The top and bottom castings ere now bolted together to Form a single unit. Air Betting cement Ib usad. to Fill thB tap joint between the castings so as to prevent metal penetration during pouring. The^bolted-togethar' unit is bo rigid that the cement joint will rernein intact indefin itely and does not have to be replaced. Figure 5 Bottom view of the "Pro`'ax'1 systsi hoi-top casting assembly. The bottom portion of thB casting Port' Forms to the shape of the top uF thB sand ring. The unit is designed s o that it is impossible to have the hot-top head hang up in the hot-top. The design effects a decrease in the numbsr of hot-top stickera and permits faster, cleaner stripping of the hot-top from the head of the ingot. Kradel 0094 V. Figure S Tne specially designed sand-ring is used to protect the bottom casting from liquid metal during pouring. The eight wire springclips are used ta secure the sand-ring tightly to the bottom of the bottom tasting. Figure 7 The four wadgs-shapBd 'Profax' liners are inserted into ths iron casting to pro vide s highly insulating, low volume hot-top. The four metal clips are used to hold the "Profax" liners securely in place in the hot-top during insertion into the mold and during transit to ths pouring platform. Kradel 0095 Figure 8 Fig.urc-a B through 13 show steps required to assemble the "Profax" hot-top unit. The volume h.Dt-top shown is for 12,DDD IP. ingot wade in a 25n X 27" mold. At ths time of stripping from ingot, ths inner walls of the casting are about 900 P. Tbs unit takes about 1 hour to cool to AQD F, at which time the hot-top ia assembled. i\lata claanlinEsa of interior wallB of hot-top. The "Profax" strips clean from the casting anti no cleaning or other preparation must be made before raasgemhling the hot-top for use. Figure 9 The first step in the assembly is to place the sand ring on the bottom of ths casting in ths conventional manner. The unit Bhutan is being assembled on an automated hot-top lina; whan stanchions are used to BSaambie the hot-topB it ia often more convenient to turn the castings on their Eideis and assemble tha unit horizont ally rather than vertically as ohowr. in thn abovB photo. Kradel 0096 Figure 10 This photo shows the location of the retains? straps which are bant over the bottom of tbs "Profax" liners to hold them SBcuraly in place dur ing handling and transport ation of the hot-top. Only one strap is uBEd on each side and it is located about 2" in From the corner of the "Profax" liners. ***3s**,r": Figure 11 The photo shows the securing of the sand ring to the botrom of the casting. Usually 2 wirB spring clips are used on each side of the hot-top. IF desired the sand ring can be secured to the casting at any time during the cooling period then as acson as the casting has leached M3DF ths "profax" liners can be inserted in the hot-top. Kradel 0097 Figure 12 Insertion of "Profax*1 liners into the iron casting. Complete time to Fit the liners in the hot tops is approximately 1 minute per top. The complete operation can bs dons by dos man. Ths "Profax" liners For the long sids of this hot top weigh only 11 lbs, each and the linsrs for the short side weigh 9 lbs, each. The wedge shapsd units slide easily into place and can us ually be secured tightly with the use of hand pressure. The only tool needed is a wooden bead mallet that may have to be used to tap the iinerB in place on e tioht fit. Figure 13 7ns last step of the assembly operation is to bend the retainer clips over ths bottom of the "Pretax* liners to secure them in the hot top. Although b hammer is shown being used in this picture, the clips are of light Enough gauge that they can bQ bent into place with finger pressure. This hot top was completely assemoled and back on e mold ready for use 1 hour and 15 minutes from the time it was stripped from the previous heat. Slurrying or drying of hot top between neats is not nucsGaary. Krade) 0098 Figure li: Typical Pallet of "PrDfax* liners For 32" square ingot There are 3D liners For hot tops per pallet and 26 pallets per truck load For a total of 7B0 hot tope per truckload. Figure 15 Open pallet of 'Profb x *liners 5hDutj.no the easy access forhandling, I h E "Profax" liners do not detBriorata under normal steel mill storage and are strong enough to withstand normal steel mill handling. Breakage has been less than 1/2% where this process has been used the longest time. Kradel 0099 INSTRUCTIONS FOR INSTALLING F O S E C O P R O F A X IN PERMANENT TYPE HOT TOP CASTINGS BiU&r cway any loose prolex powc-cr remaining from iW pt{?Yi:;?f. ft? end icjriovt- ony sJeel sploshes Fror. the m&xi? si the rc s lin c A-Mocl* s e llin g M a rk s T ih te stin g to 45" onpic. PFn<L<? s a n d ring ut, cisslin a . Kradel 00100 m m m f# Figure 3, 4 L ocate 4 re ta inin g strops n grooves. on sand ring approximately 3 in che s front edge. & n d rhe l e g s beck out oi the wey. ALLO W C A S T IN G TO C O O L B E F O R E P U T T IN G P R O F A X IN P L A C E . CASTING SHOULD BE MAX. <00* F BEFO RE SETTING PRO FAX- S:>un clip* mirV be attached during this cooiin period, or cf:e.' the Pit ta x h o * been set (see Fig ure }4, 15). Kradel 00101 Piece 1sI Profox slc-h on lower iocer cl casting. Allow approximately 2 inches lo ptotKidc. L e ii edge o{ slob should be touching Itit ioct oi costing, leaving a gep along right tape of slob. Figyre 6 ") P ie c e 2nd Proicx s-lafc ogoin&f It i l Joe* o l ce siin o . A llo w c&praxtniglely 7 inches id protrude. Th e lower edge oi 1he 2nd sla b w ill res: on ih r end ol the 1st Pretax slab. Kradel 00102 Fiq Picce 3ra Proox slab cq-osns ri obi foce o co ilin g . llo>* approximately 2 inches to prouue. Th bcrttom trice of. the 3rd sich w ill locale in she gei running d o ns sh fichi cage o the \ l slob.- P ia C t 4fH P fo ie x sla b cainsT top i o o costino. Keep rieht ecce ogoins- righi oc* o\ casting. P a s h in unsi! ever* w ith olhr Ih*ec labs. Kradei 00103 Fi^ir.'fr 10 T il* cditine- ic- ve rtica l pos-iiior one cover o il iob edges v>-iIK voodfrK iotKir.c plore. Tap locking plete evenly on dll *1 sitfei 1o cave itobi- Elysh with sond Kradel 00104 Kradei 00105 move Sockm plaie. R c lu/ft cestino ta 4* ano I' Figure l, 15 I Q c h sp r in g c l i p s --or c l i n c h s i n d straps i c Secure santi r in g sii place. Kradel 00106