Document xdb9QknB1o6omVKNk8azqKQXb

FILE NAME: Foseco (FOS) DATE: 1965 Apr DOC#: FOS007 DOCUMENT DESCRIPTION: Unpublished Internal Report Research & Development Steelworks Projects Foundry & Wrought Division Projects Rotes from Associated Companies k Other Projects Exothermica Profsx Mould Coatings Sands & Corebindera Fluxes Treatment of Molten Metal & Alloys Foaeco - Fordath Technical Scarvice (Miscellaneous Short-Teyra Development) Competitive Products Miscellaneous Circulation List 1- 6 7-13 14 - 17 14 - 15 17 - 20 20 - 21 21 22 2> 23 - 26 2d - 27 2? - 29 29 0315 T TECHNICAL DIVISION MONTHLY REPORT - APRIL. 1965 STEELWORKS PROJECTS 1. SPECIAL PEOXIPANTS (a) Steel Castings. Research _ Complex alloys based on the Briggs formulation have been added to a Steel melt in both lump form and as powder protected by a mild steel container. The resulting ingots are currently being examined and compared with a control ingot deoxidised with aluminium end silicon. (b) Steel Ingots. The method of deoxidation in which aluminium is -introduced to molten steel in mild steel containers has been extended to .larger ingots. The method again proved to be satisfactory, the resulting ingot3 after sectioning being observed to be fully killed. These ere now in process of Betallograuhic examination for the purpose of inclusion assessment. 2. INCLUSION REMOVAL (a) Powder Blowing Oun. Research Engineering modifications to the equipment have been made End consistant amounts of powder oan now be delivered. A possible disadvantage a that rather high flow rates of the carrier gas appear to be necessary. The equipment has been temporarily transferred to the Foundry Department for preliminary assessment by treatment of molten aluminium. (b) Tablet Additions to Mould. Experiments in which molten steel is teemed on to fluorspar in an ingot mould have been extended to larger ingots. Assessment of these is in progress. (c) Standard System of Inclusion Identifiestion, A comprehensive report dealing with the origin, effects and identification of non-metallic inclusions is being prepared. This will be available for reference in the Library and Metallurgical Service Laboratory. 0316 2 3. PKOFAX Research (a) Dust Free Profor. Trials axe still awaited at 3.K. Iron AJJteel. (b) Ifon-Toxic Fillers, etc. Samples of olivine 4 finer than the currently used R.M.lJJfiA, and of two grogs from Banpybridge, have been received. One of the grog samples is .claimed to he quartz-free, but X-ray diffraction measurements indicate that it contains 6$ quartz. Amitoc testa on Profax made with synthetic inorganic fibres Bhowed' the insulation to he slightly superior to that of production Profax. (c) Alternatives to Paper. Straw and chaff have been examined, but remain unchanged and floating after 2^-hours in the hydropulper. A literature search ia under way to determine the manner in which straw is used by the paper-making industry. (d) Reduction of Head Volume. Two boxes of silicate-bonded Profax, one with wire-netting rein forcement, were poured with steel, but failed prematurely due to opening of the Joints. The experiment is to he repeated, using "bridges" of COsand as supports for the vertical c b m e r B of the test boxes, A Profax assembly ha 3 been constructed with supporting ribs on the rear of the slabs Double-walled Profax slabs have been received from A.B. TSdnellhylsor for examination. (e) Fabrex. Further recipes have been tested by the method described in the March report, and it has been established that the maximum permissible silicate content to ensure freedom from blowing is 7 Recipes axe available for field testing. 0317 - 3 - 4- DESIGN OF HOT TOPS Research Profax Mould Lining. Nothing to report. 5. INGOT MOULD ADDITIVES Research (a) Stelotol 10 (Synthetic). Further recipes based on pumice with various auountB of soda ash have been tested in bottom pour ingot moulds in our foundry. Examination is in progress of surface and microBtructure of resulting ingots, and observations ere being correlated with physical properties of recipes tested. A refractory powder that is completely solid at molten steel temperatures has also been tried, but with extremely poor results. Our best recipe tested to-date i3 E.R.643* Results in the field, indicate that this provides a cover similar to that obtained with Thermofin 50X and an ingot surface which compares favourably with that achieved with Stelotol 10. (b) Stelotols 20 and 50- Field testing of the high temperature version of Stelotol 50. D.R.659. is still awaited. An alternative means of igniting Stelotol 50 has been developed, using a special fuse which prevents extinction of combustion during application. A visit has been made to Foseco S.p.A. and a Stelotol 50 recipe based on Italian raw materials formulated at the llaxcallo Vorks. (c) Coating of Metal Stream. N o t h i n g to report. 6. ANTI SCALE PAINTS Research (a) High Temperature Paints. The search for a silicon carbide-free water-based coating is nearing conclusion. Bauxite had proved to be a successful base for such a paint, but because bauxite iB a mineral of variable composition, 0318 T - 4 - aluminium hydroxide was considered as a substitute. The new aluminium hydroxide-based paint will shortly be released for field evaluation. (b) Low Temperature Paints. Development 1b proceeding of a water-based "paint using borax/ KBF. as the low temperature sintering agent. First indications of te3to conducted on cast iron for 16 houxB at 850C axe ^ h a t scaling protection is at least 90j and decarburiBation is prevented. (c) Applications. Present A.S.P'b are insufficiently tough to withstand much of the heavy handling they are likely to encounter in the field. Means of con taining them in greaBe or paint films are under consideration. (d) MechanlBm. (i) In controlled atmosphere tests at 1150C, wet air containing 1 .5$ S02 gives more rapid scaling of uncoated samples than wet air alone. However; E.P,2507-coated test pieces withstood these conditions satisfactorily (ii) Permeability tests indicate that a film of J.P.2510, previously heated for an hour ai 1150C, is slightly less permeable than E.P.2507 treated in the same manner. Results of replicate experiments show reasonable agreement, but so far insufficient data has been collected to draw any inference regarding the significance of permeability. (iii) A recording dilatometer has been constructed. (e) Comptitives. Foliac (a graphite suspension in I.M.S.) and Dow Corning 200 (a silicone oil) were examined. Both costings completely failed to prevent scale formation. 7. HOT TOPPING COMPOUNDS Research (a ) Schtnelzit. Nothing to report.^ (b) Fonderit A.C.25. The thermal properties of this product have been compared with those of its nearest copy using FoBeco raw materials and with conventional 0319 T - 5 - Ferrux formulations. Ferrux 40 is itB closest match and cheaper formulations are also being assessed. Dry powder flowability of Ferrux recipes b reported to be inferior to that of Fonderit materials, and our product has to be spread over the metal surface. Experiments are in hand to improve this property by using additions of mica. 8. CONTINPOPS CASTINC PROJECTS Research * -- (a) Grain Refinement of Steel. Nothing to report. (b) Refractory Head. Shelton Iron and Steel have contacted Foaeco (F.S.)1Limited, with a view to co-operation on this development. (c) Refractory Erosion. (i) Self Fired Refractory, Following the conclusions of the Fulmer Research Institute reported in March, samples of both fused and dead burnt magnesite have been sent to B.C.R.A. for examination of contraction behaviour at 170CTC. (ii) Coatings. Tests in our foundry indicate that coatings containing green chromium oxide are fairly satisfactory. However, better results are obtained by the addition of calcium chromate end aluminium to the coating. Work continues. W St earn Film Formation. Practical experiments have been carried out using water contain ing various additives including substituted hydrazines and ureas to cool molten aluminium. Macro-examination of cast samples shows a marked reduction in length of columnar crystals at the surface cooled by treated water, indicating an improvement in heat abstraction. Work continues. (e) Mould Lubrication. (i) Oil Methods. Experiments have been carried out in which rape seed oil has been applied to a metal surface at 1200 C. Observations indicate that the lubrication achieved with this product is entirely gaseous, and that olive Oil may be a suitable alternative. 0320 T - 6- (ii) Slag Methods. A trial has teen carried out' at Sound Oak Steel using a synthetic slag copied from that Bed at the German plant at Dillingen. Eesults were inconclusive. Work on this project is also being carried out on a laboratory scale, using forculstiono derived from synthetic Stelotol 10 recipes. - 9. BOTTOM PLATE PKSSSIHGS Research " A new project has been opened to devise a means of treating the bottom plate of an ingot mould to reduce wear and the incidence of finning. Two possible solutions are being eonsideredr 1. Possible formulations for a refractory dressing are being examined. 2. Laminations of mild steel sheet and paper have been conatructed to fit between the bottom plate and the ingot mould. These will be tested in contact with a stream of molten steel. 0321 T - 7 POOHDRY ARD WROUGHT DIVISION 1. PARDIRG Research Ho thing- to report. 2. SAHD ADDITIVES Research Considerable data has been compiled on the effect of E.P.1893 on sands containing clays other then western bentonite. In general, little major variation in eand properties is apparent.- Of the polyacrylamides other than Bonaril 11 examined, Separar. MP10 and Separan PG2 showed promise as anti-scabbing additives. All ere manufactured by Row. Rata on relative costs of these materials is being obtained. Only marginal differences in green properties are apparent when E.P.189B is added as a solution compared with normal solid addition. Dry properties are worsened. Concentration of the solution has little affect. E.P.1898 appears to improve the properties of a mixture of old and new sand. When added to a 14$ cl By slurry as used by Fords, E.P. 1698 increases the viscosity to an unacceptable extent. Development E.P. 1B98 in Steel Foundries. Progress with this product is considered to be very satisfactory. Some twelve British steel foundries are still continuing with trials aimed at achieving unit eand working; in some cases the maximum practicable addition of returned sand has been reached and these foundries are now able tQ^alculate their possible savings using this E.P. For the period under review, 1 4 7 ewts. E.P.1698 were ordered in the D.K. compared nith 6? cwts. over the previous two months. Anti Finning Additives. E.P. 2396 and D.R. 601. Progress is slow and generally not very exciting with this project. It has been established that E.P.2596 is capable of reducing or eliminating finning on grey iron castings when used in oil sand cores: the same appears to be the case for D.R.601. Both materials, however, have given rise to a mottled cast surface appearance and as a result, the 0322 T - 8, - xuiexpanded perlite haB been sieved to eliminate the +40 mesh fraction. Since this change in formulation no further complaints of mottled surface have been received. An interim report on E.P.2596 has been issued and the material has been released for general Bale in the U.K. on oil sand cores only. The response to-date has not been very encouraging... On resin Bands, where tbe finning problem is more severe, neither material has been completely successful, although properly controlled trialo aSe still awaited. Coal Dust Replacement. Satisfactory trialo have been carried out with D.R.654 at four foundries before objections were raised by Qualoaot to the high wood flour content of this material. After considerable laboratory effort, D. R.661A has been developed which contains no wood flour and_Qualcast have agreed to a test run of one week involving e-tons of send daily which will contain no coal dust, but only D.R.661A. It is most probable that D.R.654 will now become redundant. Breakdown Agents (3.P.2497 and E,P.2499). Steel foundry trials confirmed by laboratory work indicate that E. P.2497 is inferior to Dexil 11 and that E.P.2499 is about equivalent to the standard Poseco product. In view of the unfavourable raw material price comparison no further work will be undertaken with either E.P. and the project is now considered closed. Liquid Sand Process. The G.K.N. Group wish to initiate trials at the Dowlais ingot mould foundry. They had already tested the B.C.I.R.A. technique on a Bmall scale and wished to compare it with-ours. The demonstration using a Vortek mill was satisfactory end a good casting with excellent breakdown was pro duced. G.K.N. personnel were very favourably impressed. A full testing programme has been provisionally drawn up depending on the availability of suitable mixing equipment. Corbicol. Kr. J.Beale visited the manufacturers of this potato starch. Prom laboratory work, this material which can be obtained in many countries, is equivalent to Mixad 61. Discussions are continuing and 5-tons of Corbicol have been ordered for field evaluation. 0323 5. INOCULATION Research Axi intensive programme of work hes been carried out to establish a technique of inoculating cast iron in the mould. Various methods heve been tried and assessed by measurement of chill reduction. Promising results have been obtained using tablets of paraffin war containing ferro silicon introduced into the mould cavity and paper coated with ferro Bilicon inserted into down-sprue. Loose powdered ferro silicon introduced to the'mould cavity has ^given variable and inferior results, and unsatisfactory chill reduction was obtained. When a technique hes been established, it iB proposed to extend the work to an examination of formulations devised by Short Term Development Depart ment. 4 . FLTJX WA5HIHS . Research (a) Solid Filter. Nothing to report. (b) New Flux Washing Tank. Extensive programme of work ha.B continued. No advantage has been found by pre-melting hygroscopic sodium-free fluxes in the tank and it is unlikely that such formulations will be acceptable. Examination of nonbygroscopic formuletions based on S.P.2074 is being made. Loss of magnesium from strong aluminium alloys which occurred when using this flux in the old flux washing process is unlikely to occur to the same extent in the new tank. Development The final results of trials carried out at H.D.A., Distington, with magnesite granules and Filtrox 1 in a flux washing crucible have now been obtained. The average inclusion counts of three trials is as follows!-- Filter only 17 oxide inclusions per field on three sections of extruded T bar. Filtrox 1 and Filter together 15 oxide inclusions per field on three sections of extruded I. bar.- This compares with normal material without special treatment. 37 oxide inclusions per field on three sections of extruded T bar. Chlorine degassed metal but 3 oxide inclusions per field on three not filtered. sections of extruded T bar. 0324 5 . TOCLBANT/GRAIN RBFBER - 10 Research This project has been transferred from Short Term Development Department. Work will he directed towards development of a product which utilises our theoretical understanding acquired to-date and matches the Kawecki hardener in ease of application. Examination of the powder blowing gun as a means of introducing a grain refining agent to. an aluminium melt has commenced. Development Grain Refiners with hifrh (20:1) Titanium : Boron Ratios (D.R.629 and 659.' Trials at the Aluminium Corporation, Dolgarrog, indicate that both development recipes are superior to Hucleant 2 when used at a. rB.te of 2-lbs. per ton on 99*5# aluminium for chill caBt slabs. The grain size was found to be finer and more uniform and the anodised finish superior. D.R.629 (with hexachloroethane) was preferred because of the objectionable dross obtained with D.R.639* Grain Refiner containing only Boron (D.R.646). Trials have been carried out on a number of aluminium foundry alloys and satisfactory grain refinement has been obtained by additions as low as 1 oz. per 100 lbs. Further tests are still required. 6 . F1HB GRIHDIHg .Research An interim report dealing with work so far carried out on coke and coal based dressings has been circulated to interested parties. Durrans 10 is found to give an X-rsy diffraction pattern similar to that of R.li.170. The water solubles contain sulphite lye, end it is possible that there may be a small amount of polysaccharide or related substance which would account for the superior suspension properties of Durrans 10 over a coke/sulphite lye mixture prepared by us. Mixtures combining coke dust, coal dust Bud Phumacite flash have been prepared for testing. A suggestion has been made that Durrans use an edge runner mill into which they chsrge all their re.w materials. The effect of auch a technique on suspension properties is under investigation. 0325 T 11 - 7 . DOXIDANT - POUIJDTtI ES Research Nothing to report. B. DIB COATINGS Research Field trials of D.R'b 655 and 656 have been arranged at Delta Dieoastinge. 9. 'COATINGS FOR SATO MOULDS Research The relative efficiencies of various binders for coatings are being examined and an apparatus to measure the abrasion resistance of coatings is under construction. A visit has been made to B.S.C.R.A. to observe tests in which ferro-ststic pressue is simulated by applying pneuma.tio pressure over the surface of metal in b mould. It is antici pated that our standard method for assessment of costings Cun be further improved by this technique and a similar apparatus is to be constructed. D evelopm ent Coatings based on Chromite Flour (DR.647. DR.645). A number of successful trials have nor been conducted and in all cases the results are equal to or sup-riox to the equivalent zircon or chromite sands. It is hoped to broaden the scope of tho trials end publish the information abroad, so that Foaaco companies csn tBke advantage of the present zircon shortBge. 10. COREBIKDBRS Research Two field trials have been carried out with D.R.660, but so far no reports are available on breakdorm properties of the sand. Cores produced nere slightly friable and this may necessitate modifying the recipe. This project is being extended to include an assessment of all potential systems able to function as sand binders. 0326 T - 12 Development "W" Process (D.R'g S04. 03AM. and 660) . Further trials have been carried out with-the silicate (D.H.SK4) and hardener (D.R.864A) supplied by J. Croafield and the latter has been compared with a hardener (33.H.660) developed by Foseeo. . The present position can be summarised as folloirsi. D.R.66O appears to be equivalent to Cxosfield's hardener (D.R.684A.). The soope of field trials is now being extended to gauge the market potential and to assemble the information required before Buch a process is introduced overseas. 11. FOAMED SARD Research (a) Both Teepol 514 and Teepol 610 have proved good substitutes for Empicol TLR as foaming agents. A premixed product comprising Teepol 514 , n-nonanol and calcium metasilioate has been issued as E.P. 2709A. (b) Mixers i. A petrol driven concrete mixer with variable speed has been hired and gives better results than the constant-speed electrically driven concrete mixer tried last month. Foaming osn be produced at a reasonable water level, but performance 1 b still erratic. ii. The 5-tilo Fordath mill has been further speeded to E0 r.p.m., which has further improved its foaming action. A mill so modified would, be suitable for field demonstrations. iii. Providing the Vortec mixer with a heightened paddle assembly hBS not improved its action. Speed is fax too high, and reducing it to the order of 60 r.p.m. would prove a difficult and expensive undertaking. iv. A spiral ribbon mixer has been tried end gives excellent fluidity. Tests with the Fordath mixer/slinger have not yet taken place. (c) Formulation, etc. i. It is established that a permeability of 300-400 A.F.S. units is developed after 2-J- hours. 0327 T - 13 - (ii) A reproducible fluidity test has been devised, based on allowing the mixture to escape through a two-inch hole in the bottom of a two-gallon tin. However, it bos been established in the course of this work that the density of the mix is an all important factor being inversely proportional to fluidity and proportional to final strength. A minimum density of 1,3 gm/cc., controllable by an-y.~foam addition, is required for adequate strength. Curiously the densities of a mix in foamed and set states are identical. -- (iii) Failure of aome mixes to harden was encountered, and was traced to an off-specification batch of E.K.504, which was low in SiO_ s Na^O ratio and in total solids. When this was allowed for in formulation, normal hardening times were restored. There axe indications that sodium silicate of 2 . - 2 .9 SiOg t Na-O weight ratio give the best results. Silicate Bamples of various ratios intermediate between 2 1 1 and 3 .3 f 1 have been received from Crosfields nnl are being assessed. (d) Demonstrations were given on our premises for personnel from Jackmans end Fordath, and our first outside demonstration was given at G.X.H. Group Research Department, Wolverhampton. Both the demonstretion and the subsequent casting were satisfactory, and we have been requested to produce a 6-ton ingot mould at their Dowlais works. 1 2 . PROFAX lit STSSD F0UHDR1ES Development Arrangements heve been made to carry out trials with hand-rammed E.P.2311 sleeveB {10" and 12" ID) at Jessr -.-Si>ville when compared with Feedex 50 and Feedex 723- In addition, it is hoped to be able to carry out trials with the oentrifuga-lly spun sleeves produced at Taaworth, in order to determine the comparable feeding efficiencies of exothermics and insulators. 0328 - 14 ROTES FROM ASSOCIATED COtffAKIES TO OTHER PROJECTS ` EXOTHERM! CS PROPAX Development - Foaeco Inc. Excellent progress continues to be made with the setting up of raw materials for ball mill dust Prefer production, it now appears that even high chloride materials, such es R.K.139 could be'used, et a pinch, although chloride contents of this level (27'/) are undesirable on account of the heavy fume evolved during burning. The need noc is to press on with field trials of the product Bnd s b b. first step in this direction, a number of 18" O.D. sleeves were made up during the month for .trial at foundries in the Birmingham, Alahame , eras.. Foundry Use. This month has been devoted to examining samples of ball mill dust. Samples have been received from welland Chemical, Aluminium Service Company, Hock: Creek and D.S. Reduction. Of all the samples tested, only the Kock Creek fines (7C -325) presented any difficulty in manufacturing, A test mix wss made using R.M. 159 ball mill dust. Very strong fumes were given off from the slurry, but no mechanical difficulty was encountered and the blind riser burned in two minutes and thirty seconds. Some obnoxious fume was emitted. The material received from TJ.S.Reduction looks very good, except that tha sensitivity is slightly slow. Tests showed that this could be increased by the addition of 1% of 7A to the Blurry. Development _ Foseco S.A., Frence. The tests o.t Vireux Molhain h8.ve given satisfactory results and an order for 500 sets has been placed. Mouldable Profax - EL.90. A reoeipe has been developed with expanded vermiculite base (21) end Lafarge cement. This recipe gives good results on the Amitec and in 0329 r - 15 the copper foundry. A teat on steel has been attempted giving a good eurfece condition and good stripping, hut unfortunately, we have had difficulties in shooting these sleeves on the F.8psr machine, Tests are at present in progress in order to reduce the grain size of the vermieulite which would he the cause of the trouble on the Rttper machine. Development - Foseco (F.5.) Limited- Silica and Asbestos free Profax. Tests have been carried out using grads (4) olivine sand from Norway, and to-date this material looks completely acceptable as a filler for Prefer. A 25-ton consignment of this material is due in tbia country any time now and further,.work will be continued as soon as the materiel is at Tamworth.. Two asmplea of mineral wool have been eveluatsd as possible replacements for asbestos !..15. 319J mixes have been made using both asmplea in concentrations of 1, 2, and 3$. Green strengths increased with the higher percentages, but there was little difference in transverse strength. Only one sample ha3 been tried on Amltee, trhich gave superior results to that from current Profax. Four samples of chopped fibreglass have been received and have been successfully evaluated. However, these materials are very much core expensive then asbestos. Development - Foseco Inc. Reformulation of most of the standard range of Feedex to deal with the current shortage of grindings is now almost complete. In the main, this has been accomplished without much disturbance of the quality of production, although some minor variations suoh as in the water requirement will be apparent in some cases. It is to be expected that * some complaints will be received from the field, and that some further minor adjustments to the recipes will be required in the light of experience. Work on American Steel Founders' Society. Although our test results hsv not as yet been able to fully substantiate'Foseco International's claim that English padding recipe No.3 gives consistently improved bend tests through lower aluminium" silicon contamination, there are so'rae indications tho-t the hypotheses of 0330 n - 16 - aluminium combined with sulphur as the main cause of the embrittlement may eventually be substantiated. FERRDX Development - Foseco S.A., France. Ferrux 40. "" In the last batches of Ferrux 40, we had to reduce the percentage of R.M.5 by 5O/0. We had thought that the main constituent of Ferrux 40, the calcined alumina, was responsible for this reduction, but after various changes in the alumina, this Ferrux was still very rapid. Tests have indicated that the grain size of the nitrate affects the sensitivity of the product. Ferrux without fume (121L etc.) This problem is at present at the forefront. A test at liont St. Martin of Ferrux EL.2764, has given excellent results from the point of view of fumes, but unfortunately, the product swells considerably, collapsing on itself during cooling and adhering to the ingots after stripping. KALMBX Development - Posecp S.A., France. Kalaex I GS. Tests, are at present in progress on the grain size of this product in order to obtain s more uniform product. We have established that after pBclring into sacks and after having undergone a journey, considerable changes in the times of ignition Bnd combustion of this product ore observed, without appreciable change with regard to the grain size and the density of the product. This abnormal phenomenon would indicate a second control. EXOTHERM!CS Development - Poseco(F.S. Limited. Alternative production methods for exothermic sleeves by centrifugal spinning suction filter, etc. Considerable effort hes been put into producing exothermic sleeves by spinning techniques. A recipe containing 66> R.K.422D low, 4 -5?" R.M.2 6 7 , 4ft R.K.569A and Z.'xft exported "5 has been found suitable 0331 T - 17 - for spinning. A Blurry containing 40^ aolida has been made at a 1 gall. mix and produces a Bleeva with a wall thickness of 0 .6" and negligible' teper. Increasing the slurry addition to 1-J- gallons (maximum capacity of this spinning chamber) gives a wall thickness of 0,7". SleeveB mede from this recipe have been sent for field evaluation. Indications are that during the drying process of these sleeves, a'reduction of 2-35* in the outBide diameter of the sleeve occurs. The effect of reducing spinning time is also being studied and initial "teats indicate that spinning times could be reduced to approximately 30 seconds, and possibly further without much significant increase in water content. MOULD COATINGS Terrapaint Development - Foseco Inc. During the month of April, 107 batches of Terrapaint 5515 were produced. No batches were found to be defective. Thus, it would appear that the change to pre-.gelled bentonite combined with careful control of pH has completely eliminated the free liquid problem. The results of the shelf-life tests on theBe batches are not yet available, but preliminary indications are.that the majority of the compaction troubles have also been eliminated. Stelptol Development - Fp3eco Inc. Stelotol 5 0.. A sample of a new gelling agent was received from the present supplier of aluminium octoate. This product did not gel as fast as X.15B1, but when it finally did set, it formed a rather stronger gel. A larger quantity was ordered to make up a teat batch for field trials. Tests at Copperweld indicated that our present Stelotol 50 may give very poor deposits under certain conditions, i.e. tight moulds and poor air supply. E.P.2619/STL tested under similar conditions gave very good results. Because of the relatively poor performance of Stelotol 50 at Copperweld, present stocks were examined to see if they were up to pax, or whether performance might have fallen off. Extensive tests revealed little, if any, detectable change. Pinal conclusions were that laboratory tests may bear little- relation to field performance under Bone conditions. Seventeen new raw materials were examined for suitability in improved Stelotols. Two of these, Hi-flash na.ptho (Ohio Solvents) and "CycioBol 3S" (Shell Oil) hBve been selected for further study of partial 0332 - 10 - replacements for kerosene and xylene now used. Both gave much heavier quantities of Boot evolution for a. given weight than kerosene, end have higher flaBh pointB than xylene. A list has been compiled from the literature of 21 organic compounds, which yield from 25 to 65# carbonaceous residue when burned. These materials are mostly multi-bencene-ring structures, modified by various functional.groups and with high molecular weights. Mitromethene and nitropropane may offer a partial solution to formulating Stelotol gel which will burn in an oxygen-poor atmosphere. Both compounds have D.C. flash points above 100P.' Their compatibility is excellent with other Stelotol component as well as a large number of other organic materiels. Tests to establish the composition of the deposits produced from Stelotol 50 showed that regular Stelotol 50- yielded a soot containing 94# carbon and 35*> hydrogen and E.P.2619/^ST1> (containing xylene), yielded a deposit containing 96# carbon and 4# hydrogen. E . P .2619/STL gave an O.C. flesh point of 92F comparod with 120F for regular Stelotol 50 Stelotol Development - Foseco (F.S.) limited. Development of a foamed Stelotol 20 to improve and reduce BPittin? in the mould. This project has been tackled from two aspects, the first tu expand polystyrene snd mix together with the resin and bond to form low density tablets. The second to introduce Stelotol 20 to expandable liquid Polyurethane resin again to produce a low density of rigid spongey material. The most successful method of mixing Stelotol with foamed polystyrene has been to wet Stelotol with I.P.S.l and then mix the required quantity of expanded polystyrene. The dissolved resin gives a firm bond allowing the material to be rammed into a container that is sealed and ready for use. Several- recipes have been produced by foaming Stelotol 20 powder in Polyurethane; the maximum quantity of Stelotol which can be incorporated into a mix is 57-5#. The density of this material in its foamed stste has been found to be 0 .14 5 g/c.o. Samples have been prepared and are available for field evaluation. Self-drying Moldcote for Iron Castings - Foseco- International limited. One trial has been OBrried out, applying this coating on top of Moldcote 6 for large ingot mould core3 and moulds. Some improvement was observed over Moldcote 6 alone and further trials ere promised. The fumes have been objected to end these will probably have to be masked. 0333 rr - 19 - Development of s Dressing similar to Thiem Satinkote - Foseco (F.S.) Ltd. Although triels with D.R.669 have not been completed by Ford as yet with thin material, which is being offered in competition to Satinkote, it has bean renamed E.F.2713/TP for coating purposes. Development of Improved Hot Bor Coatln,1? for Ford Motor Company - Foseco (F.S. Plaited. Verbal comments from the Ford Motor Company indicate that agglomerates of powdered material are etill present which render the coating difficult to use. Ford aleo express a desire that the viscosity curve of the dressing should be flattened within the 15-16 second range. The covering power of this coating was found to be from 23-24 (a Ford Motor Company standard) and is satisfactory for their use. Work is continuing with this project. Comparison and Evaluation of South African Coke Blacking end Morgan Blacking Foseco (F.S. )' Limited 23 drums containing two types of blacking have been sent in by G. A vJ.Base Minerals Limited. There were two types available in these 23 drums, the only difference being the grades of coke used. All resulta so far tie in well with those obtained on the previous small samples, apart from the self-aevere applied coa.ting. A Bimilar Beries of tests have been carried out with a blacking obtained from the Morgan Crucible Company Limited again to compare its properties with Durrans 10'. Findings to-date are that this Morgan material is coarser than the South African, but slightly finer than Durrans. It has the following mesh grading:- 95* +200 11% +300 Balance -300 Coating tests revealed ths.t the material had a. similar hardness characteristic to Durrans 10. Test castings have been prepared and are a.t present being shot blasted prior to examination. Development of a. Coating to compete with Durrans Steslciol 15 - Foseco (F.S.) Limited. This product has had satisfactory field tests, but British Roll Makers Limited have at the same time carried out gas evolution tests on this dressing and compared their results with Durrans 1 5 . Discrepancies between results obtained by ourselves end British Roll Makers are believed to be due to differences in procedure. Our apparatus is, th.-rofore, being modified to overcons these discrepancies and further tests ere being carried out. 0334 T - 20 - Development of Synthetic Dycote II - Foseco (F.S.) Limited. D.H.761G has been evaluated, but faulted In that it adhered too well to the die face. This was presumably due to the ljfe R.M.110 addition. A further D.R, has been issued containing 0.245* R.M.110 and without any H.M.110 being preaent and these are currently being evaluated. Dry Powder Spuncote for Grey iron Liners - Foseco TF.S.) Limited. Attempts to use the grades of calcined anthracite mentioned in last month's report to eliminate ferro silicon at Harold Andrews limited, Halesowen, have been unsuccessful but the present grade of enthracite is much superior to prsviouB consignments end the introduction of ferro silicon to this has given very satisfactory results. Production trials with E.P.269$A/SCT are now in hand. SARDS & CORSBIKDDRS Oorflx Development - Foseco (F.S.) limited. Modification of Corfix 40 for Morris Motors, Wellingborough. As a result of a. successful trial with D.R.754/iXt this material has been renamed E.P.I56SF and the above company have placed an order. Coresesl 4 Development - Foseco (F.S.) Limited. A thinner version of E.P.2590A/CRS has been prepared and has been called D.R.387B/CRS, uork is also in hand to study complaints made by customers regarding the quality of V.-.P.2590A. Evaluation of B.H.F. Process 3d, Glucose ba.se Breakdown A.rent - Foseco (F.S.') Limited. A considereble amount of time has been spent in evaluating this process and our findings have been published in Technical Report Ho. UK.42. Briefly conclusions were as followss- 1. Process 54 justified the claim that it facilitates breakdown and core knock-out without adversely affecting physical end mechanical properties of cores. 2. At conventional levels of sodium silicate, i.e. yl,cores are no better than those containing Dexil 11 at the same level of addition, i.e. lj. 33s T~1 21 - 3. At reduced levels Bodiura silicate binder, i.e,, 25, Process 34 aliona manufacture and use of corea which ere otherwise impracticable, therefore, knock-out properties are excellent with both copper and cast iron. 4 . At these reduced levels of silicate binder, satisfactory cores cannot be made with Dexil 1 1 . mam 5. Process 34 enables a savin? to be made in the cost of silicate binder because of the small amounts used. Senerally, Process 34 is end may be classed as rather a sodium silicate binder extender, rather than a breakdown agent. Mixad Development - Foseoo (F.S.) Limited. Mixad 61 is now being used on a regular basis. It has taken approximately six weeks to show that the addition rate of liixad 61 for this particular plant, purely as a replecement, is between cwts. per day. A detailed scrap analysis over the months of March end April indicates that some saving may be expected following the considerable reduction in expansion defects. An improvement has aleo been observed in the casting finish. Corfix Development - Poseco Inc. In view of the excellent results and sales in Mexico of Ccrfix 4,it was decided to try this product. Tests were run with Corfix 4, Corfix 40, and a powdered version of Corfix 4 . Respective tensile strengths were 225, 110 and 165 p.s.i. In view of the relatively low raw material cost snd the results obtained, it was suggested thet this product be evaluated in the field. FLUXES Zinc Coverai Development - Poseco lac. Improved Zinc Coversi for General Use. Since General Motors, Trenton, Hew Jersey, have already tried Zinc Coveral e7 in the past, it was decided to try the new English high temperature recipe. Experiments in the foundry indicated that R.D.S01 (E.P.2621) flux would work well, without giving noticeable fuses at a temperature of 950 F. A sample was submitted for trials early next month. 0336 T - 22 TRBATtSWT OF MOLTEN KGTALS & ALLOYS Dry Cuprex (3.P.2493) - Foseco International Limited. Development ,, Trials have been completed and . Bummaxy of field experience and recommendations is being: prepared. It is considered that .?. 2493 in both powder and block form is .technically at least as good as, if not superior to its standard Cuprex equivalents, and in addition, it has a rar ms.terial price advantage. It is intended to seek approval for this product at the next approval committee meeting prior to releasing the trial information abroad. Anti-Radin? (PeraiBhlock. E.P. 2734 tablets. Coveral 6/0 - Foseeo Internationa'. Limited. Development It has only been found possible to produce small (4-oa.) tablets of E.P. 2734 and Coveral 64 end for one trial these were glued together with sodium silicate and dried in order to compare the materials directly with the prefused Permablock. The letter prevented reversion successfully for two hours, whereas, the other tabletted materials were only satisfactory for half that time. Attempts to press E.P.2734 and Coveral 64 into blocks on an 000-ton hydraulic brick press produced blocks which were bo delicate thst they could not be handled. 'Work will, therefore, be concentrated on the prefused Permablook. Albral tyre Flux not containing either Fluorides or Boron (D.R.65:1 Foseco International Limited. Development At J. Stone & Company, one trial with 14;* manganese bronze has been completed. Flux characteristics and melting losses were the same as for Cuprit 1. Providing metal is free from hard spots, trials in the large reverberatory furnace have been agreed. 0337 - 23 - FOSZCO - FOHDATH Tbe ETR/ 1 7 resin is meeting with considerable success in many of the larger foundries in the country. An improved catalyst system containing a much lower nitrogen content has been developed for UBe cith FPR/1 7 . This will reduce the possibility of pin-holing even further. The cold-set equivalent to PFR/17, which is to be named CS. 60, has now been successfully completed, and. field trials are at present being conducted. Early indications are very promising, and it is hoped to release this product for general sales in the immediate future. It should be noted that this is not completely fuxfuryl alcohol free, but contains a substantially lower percentage than other cold setting resins. A sample of HBJl manufactured byAdryzyl, Brasil, has recently been received, and is being evaluated by the Fordath Engineering Company. TECHNICAL SZRVICi: Miscellaneous Short-Term Development. (a) Pickling Inhibitors. The size/Teepol inhibitor manufactured by G.F.Powell(E.P.2681) was only Lightly effective at the recommended concentration of O.IJi; it permitted considerable metal loss together with heavy Btaining. At 1.0$, inhibition was improved to 81$, but staining persisted. A further very slight improvement resulted from increasing the size/Teepol ratio. The competitive Armohib 25, at 0 .04$,`gave 96$ protection and a bright finish. , Dowfax 2AI, a commercial detergent, had some inhibiting properties and .formed a stable foara on the surface o f the bath, thereby suppressing acid spray- At 1% it .g-ave an inhibition of 797*9 with metal staining* A mixture of 1$ Dowfax 2AI and 0.01$ phenylthiourea gave 90$ protection and s bright finish. All the inhibition figures are for 20$ H2S0^ at 90C. (b) Development of Inoculln for High Strength Irons. Further experimental foundry trials give continued confidence in R.Jfi'a X1463 and 115C. in respect of both chill reduction and tensile 0338 T - 24 - strengths. In respect of tensila strength, the combination of the two R.M's on a 50/50 basis is particularly encouraging and a recipe fox field trial which includes this combination is being considered. The single field trial already conducted with R.M.XI483 and reported last month as not having given the high degree of chill reduction erpeoted haB, after all, produced generally encouraging results. Chill reduction can. be described as adequate only, but Tensile strengths obtained were", higher than for Xnoculin 10 used under similar conditions. (o) Steel Terranowder for Suspension in Water or Alcohol. Teats are being finalised with a reoipe which differs from other existing Terrapowders in this field, b&Bieally in that chromate flour is the filler and colloidal ailica is used to give quite good suspension properties in alcohol. (d) Works Control of R.M.252 Solution Viacosity - Terrauaint 55. Currently, the 2.C.X. Rotothinner is recommended for this purpose. It has been thought that some of the smaller companies may find this instrument too expensive and consequently, efforts are being made to con struct a cheaper but adequately reliable apparatus. One Buch apparatus has been prepared,, but may require modification before its suitability can be assessed. Companies who are interested are invited to write to Technical Service Department. (e) Crain Refinement of Magnesium Base Alloys. A Technical Service Report, on the use of calcium cyanamide has been issued. (f) Terrapaint 5 5 . The reported suspicion that R.M.239 effects breakdown of R . M .252 gels, apparently substantiated last month, has been further examined. Substantiation appeared to come from tests in which s concentrated R.M.252 solution was diluted with water end R.M.239 solution. The latter produced substantially greater decreases in viscosity. Subsequently, batches of Terrapaint 55, with and without R.M.239 solution were prepared. Better suspension' properties were obtained where R.11.239 bod been used. There is some agreement here with the comments of a TT.K. manufacturer of H.M.239, who says that its advantageous properties as a dispersion agent should outweigh any deleterious effects on R.M.252 solution. 0339 n - 25 - (s) Moldcote 35. The claim of Foseco, Australia, that the use of R.U.40& instead of R.M.I29 in hentone el improves Btorsge/transport&tion (suspension) properties of Moldcote 33 has "been upheld in laboratory tests Foseco (F.S.) Limited, Foseco Espaola S.A. and Foseco G.m.b.H., who have all expressed recent interest in this field recently trill, it is hoped, comment Bhortly on their findings. (h) Mixed 61. 1. A B&mple of material for potential use s b R.U.269 in Mixed 61 has teen examined for Foseco, Italy. It tree found to he of some value hut not up to the standard of U.K. fl.li.269* 2. Five samples of potential I..M.269 ere examined for Foseco Inc, Only one appeared of any great value and this wb.s not completely up to standard. 3. results. R.U.269Z from Foseco, France, has heen examined with sstisfactory 4. Tests arc in progress to-reproduce a metal/mould reaction l.M.4 aluminium alloy which has heen reported in the field here Mixed 61 is used in the moulding sand. There are some small signs of success and the phenomena, will he studied in conjunction with Foseco (F.S.) Limited. with (i) Inoculin 1 0 . Two samples of Inoculin 10 from Foseco, Germany, which contained slightly coarser than recommended graphite, have heen examined. Because the graphite was of very good quality, the oversize grading was considered tolerable when normal supplies were not available. Two samples of R.M.427B have been examined for use in Inoculin 10. Both are already in use. One material from Foseoo, France, was felt to be not quite up to the standard of U.K. R.11.4273, the other from Foseco, Argentina, w s b only lacking in respect of size grading. (j) Konserver. This is a competitive product for addition in the cold-set furane resin sand -process. Its -chief arttribute is in water proofing cores but in view of the fact that the ^ addition replaces some of the resin, it hes economic value, also. It is being examined together with other materials which might do the same job. Results are not yet available. (k) Profax - Fabrex. Foseco, Japan, have experienced serious stripping problems with emo T - 26 - with their Profax. Samples were examined and found to exhibit some slagging tendency. Proa permeability measurements it was felt that the filler might be a little too coarse and could result in localised cracking. Contraction at 600C was rather high. Fabrex from Foeeeo, Spain was examined. Dry and green strengths were down by comparison with .K. 13.P . 2511. Increased resin and decreased wood flour contents were suggested (l) Dycote 4.2 - Janan. Blowing troubles from Pycote (Chilcote) 42 on iron chills in the roll-making industry appear to have prompted Foaeco, Japan, to enquire about gas evolution from their product. Samples of the product have been examined in this respect together with raw materials. G&b evolution was higher than for U.K. Dycote 42, and the nature of the B.M.3O4 was deemed likely to be the cause. It was not, however, positively concluded that gas evolution was dangerously excessive and technique of drying was suggested likely to be inadequate. (m) Perrux Evaluation - Prance. Seven Ferrux type Bamples were evaluated from Poseco, Prance from the insulation and fume evolution aspects, particularly the latter. An order of merit was established. COMPETITIVE PRODUCTS Fourteen competitive products were analysed during the month. Twenty-nine miscellaneous samples were also dealt with. Two Rimrite rimming agents from America and Australia were found to contain iron oxide, fluorspar, sodium cryolite, sodium nitrate and a- small addition of metallic aluminium. The only product competing with Profax which was analysed this month was a hot-top manufactured in America, by Gilliam ?ackaying. Although of orthodox exothermic composition, this product naa stated to be cheaper than Pro fax.-, Exotherm grade A, a hot-topping compound manufactured in South Africa by Foundrex, was stated to be causing severe competition to the various grades of Ferrux. An Amitec assessment of this material shored that it gave a very rapid and hot reaction, but this reaction wa3 not prolonged. As fluorspar is the only Bource of fluorine and appreciable 0341 T-- T - 27 amounts of sodium nitrate and sodium sulphate were present, this is not surprising. Ihe main exothermic reactions are the uncontrolled, direct, reactions between aluminium and the alkali nitrate and sulphate. Exomold MLD=R, the latest light-weight resin bonded exothermic material from the Exoraet Corporation, contained the usual ingredients favoured by this manufacturer; I.R. epectron analysis indicated that the resin was a partially solubilised phenolic novolac" without an addition of hexamine. Other materials analysed this month were as follows: 1. A flux for aluminium alloys from Italy which is stated to dross off satisfactorily as low as 620C. 2. Pour Japanese mould dressings which are in competition with Terraoote 46. 3. Coremol, a water-based zircon paste from America. This was competing with Terrapaint 5 5 . 4. A n Archer-I'sniels-Midland mudding compound from Poboco Inc, 5. An insulating1 sleeve prepared from perlite and calcined alumina and also submitted by Poseco Inc. 6 . A combined wetting agent and pickling inhibitor obtained in Italy by Ur. D, V7.Leonard. MISCELLANEOUS Metallurgical Laboratory. Humber of Customer Service items received Humber of Cuetomer Service items completed Humber of Metallurgical Reports issued Humber of A n a l y t i c a l Reports issued Humber of Outstanding items Date of oldest outstanding item Number of Internal Service items received Humber of Internal Service items completed Humber of Internal Service items oustanding Date of oldest oustanding item 14 12 6 1 c 15-3-S5 41 47 10 10.3.65 0342 T - 20 - ' Metal Analysis. 124 Baaplea were analysed this month. 63 of these were internal aervice, 17 customer service and 44 competitive products or miscellaneous B&mples. 19 samples were examined by X-ray diffraction end 52 epectrographically. The analysis of Briggs deoxidant was completed. Analytical Development. X-Ray Diffraction. The generator broke down early this month and. cannot be readily repaired. A Rayraax 60 generator baa been ordered and arrangements made to use the generator at the C.A.T., Gosta Green until the new one arrives. Spectrograph. The calibrations for white and grey iron have been checked. Aprocedure for the determination of niobium in Bteel has been developed. Coloured M a r k i n g Crayons for High Temperature Appliestion - Foseco (F.5.) Limited. Samples of micronised barytes, titania and mica have been evaluated and are showing some promise, A sample of polypropylene melting at 150C has been located and a quantity ordered for trial purposes. This material is considerably cheaper than the polyethylene at present being used and with its higher melting pointio suitable in the formulation of the higher temperature sticks. Production o the S.P.2711 series (marking crayons suitable up to temperatures of 750 c) has been fairly successfully carried out in the laboratory mixing rooms. Development of Improved Pattrex 5 Pith built-in resin binder - Poseco (P.S.) Limited, This plaster ha.B now been designated E.P.272l/?T. A further 1-cwt. has been ordered by Barton Conduits Limited following their success of the Bample previously evaluated. flon-Exothermic Bulk Mixes - Poseco Inc. Detailed examination on some batches of dry mixes indicates that incomplete mixing was being obtained in the "3,000 lb" vs.cuum blender. As & result of this finding, a survey has been made of all materials which have 0343 TT been blended in -this blender, and recommendation hsa been made to revise batch weights. In some instances, thiB reduction in weight amounts to 50$ of the quantity previously mixed. The possibility of this problem arising again has been eliminated by insisting that no batch weights ore assigned to new formulations without ail initial determination of the powder density on an experimental basis. NO REPORTS WERE ISSUED DURING THE PERIOD - 1ST APRIL - 30TH APRIL. 1965. WOA/DKH 14th June, 195. Mr. E. Weiss Dr. D. V. Atterton Mr. R. A. Miller Dr. K. Strauss Mr. D, T. liorgenthaler (2) Mr. G. L\ Cobby Mr. If. R. Owen Mr. A. G. T. Chubb Mr. J. C. Noon Mr. E. A. Jinks Mr. R. W. Ruddle (2) Mr. D. Todish Mr. E. J. Heel (4) Mr. T. Okamoto (4) Hr. R. S. Moore Mr, R. C. Cross Mr. R. Flint Mr. P. H, Stein Mr.. D. A. Dodscn Mr. K. Schneider Mr. A. B. Smith Mr. C. C, Andrews Mr. R. Hontells Mr. B. Yentian W .0.ALEXANDER. CIRCULATION LIST Ur. S. Cross Mr. D. W. Leonard Miss R . Feibusch (5) Mr. A. J . Inghe.o Mr, A. Lebeau Mr, K. Hauschultz Mr. R. D. Eume Ur. W. D. Cutler Professor G. Vf. Aust: Mr. K. Provencio Hr. R. F. Boddey Mr. A . T. Andren Hr. U. CI. Neu Mr. F. S. G. Ravsult M r . R. 5. Harke 11 Hr. A. S . Godbehere Hr. F. H. Bunbury Hr. L. T. Johnson Hr. B. M. Horgan Kr. G. R. Anderson Hr. R. S. Bushneil Mr. H. Jordan Mias H . D. B r o m Library 0344