Document ypG16d2aQE26QNmpdYj21o0YV

EXAMINATION OF R.M. X3562 EX FOSECO INC.. U.S.A. IN PROFAX AND PPOFb'.'X. Int1rod- uc--ti--on-- : -- This material has boon used recently at Foseco Inc. in Profax and Proflex (Asbestos free) recipes with some success as an aid to improving *1 the.forming.characteristics.of these products. Since- It-was thought that- -- - - it could fulfil-' the dual' functlonsr^f''~^lbry~-and-flllcr^tu`boW extent',--the-- -- . material appeared to. be ldealf as.a_u-eans cf.simplifying.the^gxistinjg--m x^cipcs^-and^ts cheapneaii?.jCQulT;-bri^;jrpsp55WSBLETOdS^io^jLx>-*K)C*; ' _"7" costs. The`short investigation-vas"carried^ ouf" td'tesVthe properties of the two l-a-taratr-recipes received-from U.3-.Ar:f1;e."Proflex~XS 1500-and ,,r-----.- Profax XS 14-9-45 incorporating R.M. X3562- 7~ 1) Profax XS 1*94. a) Laboratory Scale Tests. Small tiles of XS 14{?4 and Profax J1 were formed on the Profox hand machine and the properties of each product compared. The recipes and mixing procedures are given in Appendix 1. (t) Experimental results. Solids content % Suspension clear liquid after 24 hours standing - 500 ml cylinder) Forma billty Fill time (secs.) Dewatering time (secs.) Tile thickness ' Nature of top surface Finished product Density (g/ar.3) Steel pour test Muffle furnace Shrinkage test (14XC) Pro fax 31 0 12.0 (clear supernatant) XS l*to4 23 4J.0 (clear supernatant) 20 15 l" - 2" Flat - no indents 20 30 1*" - 2"Flat - no indents 0.01 (See Appendix 2) 0.86 shrinkage practically nil in all cases (all samples of equivalent hardness when hot). 4. \ (it) Conclusions. XS 149^ appeared to be equivalent to Pro fax 31 in its main properties. In order to fully test the slurry fcrring properties, the above tests were repeated for X5 1494 on the SAM. (h) SAM tests. Large bonrds 1.5 metres x >7 cm were formed since these gave the most severe forming conditions. The properties of XS 1494 were compared with those of Profax 31 formed under similar conditions. (1) Experimental results. Solids content ?> Machine characteristics - Pressure (line) Pump ('form) time (secs.) Dewater time (secs.) Tile thickness (inches) Formabllity Green strength Profax 31 /. 18.9 XS 1494 30.0 40 p.s.i. 12.5 15 25 0.9 Very smooth top surface - very even fill - no cavitation 45 1.0 Reasonably smooth top surface - ever, fill - sliefit cavitation. Good Adequate for bcr.rd Ccr.r.lur.lons. Forna'dlity of XS 1494 was almost as pood as Profan .51, and most of the other prepyrtles were equivalent, with the exception of the dewatering tins which >ias longer. XS 14$4 therefore appears to be a satisfactory replacement for Profax 31* 2) Proflex XS 15?0. a) Laboratory sc'*.!? and SA?` tests. XS 1500 was compared with Proflex C3 using the Hand machine and the SAM 33 for Profax. Recipes and mixing procedures are given in Appendix 3\. L m 1726 (1) Tr.po rl r^ntn 1 result.?. Hand machine SAM olids content inability Al(pump)time (sees.) watering time (sees.) le thickness raability nished product nsity (s/cm3) exibility/Ccmpresslbility pour test 91 xs 1500 91 XS 1500 5-9 5-0 4.9 5.0 - 20 -6 - 20 njn Excellent flat Slight surface - no indentations indents. 20 20 15. 10 20-25 aim ca. 25 TM Flat surface - Board no indents. indented. Good 0.45 Excellent Conpressibilit y Slightly flexible Good 0.4(7 Flexible end compressible but pool' strength 0 strip (1 hour) la strip ' ^ rs ffvjwpj .-inks 53 Test (lWV, (ii) Conclusions. Board residue fairly easily removed clean surface Each face glowing red before strip - apparent severe penetration Fairly rough surface with slight burr, on Very severe slagging and penetration. - Sample Intact Sample remains!. Poorer hot intact - good strength than hot strength. G3. Area Area shrinkage >3.7* shrinkage 10.9* XS 1500 is an inferior product to Proflex G3 aiui would be unsatisfactory both for boards and gaskets since the refractoriness is low. Apart from thin the SAM tests showed that fortiori lily was unsatisfactory and the dry strength of the cured product war. poor. 1727 3) Fv.rLl'~r cr~ri.it'.':L: un of X V . Further tests were c.wried out using X3p2 in previous Proflcx recipe" which had ;;!jov.ti some prs.vl se. and i:i modifications of X5 lVJO to try to overcome its ill sadvantium. ' a) Recipe PD 134. This v/as a board recipe which had previously Given satisfactory formatility usine H.M. 1J1A as filler but the cured boards were too friable. R.M. X3362 was used as a direct substitute for R.H. 131A. Recipe; (soe Appendix 4). Experimental results; (Hand machine). Slurry dispersion - (rood. Formabillty - good (flat surface). Cured tile - good compressibility but no flexibility. t b) Recipes P5 133 and PH 135. The resin content of F3 134 was reduced in order to improve flexibility (P3 135 contained Q.r~> 4665, and PB 136 1.0^ 4(3jB). There was t:o imorcv.r.nnt ir. fi1'. vibilivy ieh in^j cted that it ms the X35u2 rcth.er than the K.M. 4(3bi3 which was primarily responsible for tne Iovj flexibility. (Microscopic exarr.inr.tj on of the material snowed that it consisted of nt-calc like orjv.tais which it is thought probably interlock to form a ricio structure). It was al.ro observed during this test that the excessive form produced Appendix cJ' rAlu' ses scgrc'^ticn of fibres and filler. (For recipes see c) Reciecc ?5 7 37, l',S and 130. (Appendix 4). Recips P3 13T was made to confirm the apparent "inflexible" properties of R.I*. X35-52. The board was not flexible and strength it: poor. Tne forming properties v:cre also \;n3r.tisfac<.ory (a flat out indented surface was obtained). The compressibility was also low.- Tills test indicated thereforo several deficiencies of X35^2. Recipe 138 r.nd 139 were made to try to increase the flexibility of the previous series (PB 17/4-l>6) by using an intermediate X272 content between th?t used in XS 1500 *nd in PB 134-135. The results were again disappointinc - no improving in flexibility baing achieved. d) Recipe ~D 140 and 141. (Appendix 4). Because of the poor refractoriness of XS 1500 these formulations were tested to try to improve this. The formability of both mixes was not satisfactory - the boards hcln;; indented. Flexibility was also peer, but refractoriness an assessed by the Muffle Furnace shrinkage test at 1728 APFF.KDTX ] A. Pec ines - Profax 31 and XS 1494. (Hand i-*-chine tents). 131c * (131D) 447 468B * (177A) 265A 319 452 * (5*6) 122A * (X1790) X2782 117 X1281 X3562 Profax 31 ' 75.92 1.37 4.33 2.89 1.06 IO.63 3.80 - - XS 1494 61.9 1.0 3.0 - - - 2.5 0.5 1.0 0.1 30.0 * Since the original U.S.A. R.M1 s were not available, the nearest U.K. equivalents were used. Mixing procedure (Waste raix pulpcr). Profax 31; Solids weight - 3 Kg. Water addition 12 Kg. Solids - 20.0 1) Pulped R.M. 452 with 6 litres w3ter 1 itir.. 2) Pulped R.K. 319 26y 4 litres water ^ lain. 3) Pulped rest of R.M's (except 1230 J mir.. 4) Pulped R.K. 123V + 2 litres water 15 secs. XS 1494: Solicls weight - 3 Kg. Water addition - 10 Kg. Solids - 23.0 1) Pulped all R.M's except 117, X12S1 and 122A with 10 Hires water ? nin. 2) Sprinkled in R.M. 117 while pulping min. 3) + X12Q1 20 secs. 4) + 122A 10 secs. 1729 rv A PP'\ v.>r*v* : r* F.'!c.! rces - ire fix 31 and rj5 1494. (S/'.i* tests'). 131D 447 4oSB * (177A) 122A * (X1790) X2782 X3562 117 X1281 131C * (1310) 265A 319 546 X1790 Prof:.-7. 31 0.68 4.36 - - - . 76.46 2.91 1.07 10.70 3.82 . XS 1404 61.9 1.0 3.0 2.5 0.5 30.0 1.0 0.1 .. - * U.K. equivalent R.H's. Mi/.in.- procedure (90 call- hydropul.se r). Profex 31: Solids weight 40 Kg. Water addition - 172 Kg. % Solids - 18.9 ) Pulped F..M. 447, 465B, 131C with Si litres water for 2 tr.ins. ) Added R.M. 26dA, 319/ 546. plus 60r litres v:ater - pulped 2 mins. ) Added X1750 plus 30* litres water - pulped 1-2 (tins. X5 14Q-'<: Solids weight - 50 Kg. Water addition - 117 Kg. % Solids - 305S1 2 3 4 1) Pulped all R.M's except 117, X128l, 122A with 110 litres water for min. 2) Sprir.i.Icd in P..M. 117 during rain, v.iiile pulping. 3) Added X12&1 plus 17 litres voter - pulped 15 secs. 4) Added F..i*. 122A - pulped 15 secs. r < C\J K N 1730 appendix Prcfax 31 and >.S 1^94. Steel Pour Test. \ One tile (10" x 9" x l") of each material wan used to line two sides of a steel box into which molten steel at ca. l600C was teemed. After one ho'ir, the box was removed and the tiles striDped from the casting. The surface characteristics of the metal were examined when the casting had cooled. Hot Strip (after 1 hour) Cold Strin Profax 31. Tile residue fairly easily removed clean surface. Fairly smooth surface Slight bum on. XS 1494 Tile more difficult to remove - considerable bum on. Smooth surface, no bum on. Tile residue next to mstol surface sintered. Easily removed. The performance of XS 1494 was considered to be equivalent to that of Profax 31* r 1731 Apreimtx 7.. Recipes - Proflcx G3 and XS 1500. (Hand r-tciijne tents). X2782 X.3562 468B 447 X1281 131D 265A X2286 Proflex 03 6.0 - 2.0 - 0.5 51.0 15.0 25.5 Xo 1500 4.0 94.6 0.8 0.5 0.1 - - Mixing procedure- (Mastermix pulper). Profler. C-3t Solids weight 1 Kq. Water addition 15 Kg. JS Solids - 5.956 T ' Pulped X27 2 - xi23i for 1 sin. (with 7-A litres water). -;\ Added R. H. 2C3A H- lit res water - eu? ;> 1 r.i Z) Added rest of R.H's plus 3 litres water, - pulp 1 ir.in. 4) Adieu 5 li t:es water - ulped sin. XS 1500: Solids wsi.-ht 800 rrar.. Water addition - 15 litres. Solids 5.055 1) Pulped r.eTiZ2 4- XI8l * 10 litres water - pulp 1 nin. 2) Added XJ562, 6SS. 447 - pulp * sin. 3) Added 5 litres water - pulped 15 secs. 1732 AP>~I/DTX Yx\. Recipes ProfIsa r:*> and XS 15r0. (TAA' tents). X2732 XJ362 468B 447 X1281 1310 265A X2286 Proflex C3. 6.0 - 2.0 0.5 51.0 15.0 25.5 xs 151 4.0 94.6 0.8 0.5 0.1 Mixing procedure (Masterraix pulper). Proflex G3; Solid3 weight Water addition 55 Solids 20 Kg. 585 litres. 4.9 ) Pulped XZ7C2 X12ul + 121 litres for 2 mins. ) Added 265A * 60 litres water - pulped 1 min. 3) Added rest of R.M's and 60 litres water - pulped 2 mins. 4) Added rest of water - pulped mir.. XS 1500: Solids weight Water addition 3 Solids 10 KC. 190 litres. 5.0 1) Pulped Xl'dSl YJZflte + 110 litres water for 2 mins. 2) r.ddcd rest of R.Ii!s and water - pulped 1 min. ru - 1733 O oo X3562 x2782 d4y X1281 PD 13* 85.7 2.0 12.0 - 0.3 135 87.2 0.5 12.0 - 0.3 136 86.7 l.G 12.0 - 0.3 137 23.0 1.0 - 133 22.6 0.8 * 6.0 0.5 0.1 Mixing procedure: (Masteraij: pulper). P 13*, 135, 136, 138, 139. 1) Pulped X1281 + XZfQZ + 10 litres water - 1 min. 2) Added other R.M's - pulped --r nln. 3) Added 5 litres water - pulped % min. P 137. 1) 2) Pulped X35S2 + 460b + 10 litres water - 1 min. Added 5 litres water - pulped nin. X3123 X3562 XT782 468d 447 X1281 PB 140 12.0 86.0 - 2.0 - 141 20.0 72.6 6.0 0.8 0.5 0.1 ML.tl r.r n'.^occcu^e: ('.'asterviiis pulper). ?3 140 1) Pulped X319S - 10 litres water - 10 secs. 2) Added oU>er R.M's - 30 -ocr;. ?Ti 141 1) Pulped X31<?y + 10 litres water - 10 secs. 2) Added X272 * X1281 - 30 secs. 3) Added other R.M's - 30 secs. 173* APPTND7X 5. Muffle Furnace Shrinks,re Teat at 1.J>00C. XS lf.O:) and Pro**le.T G3 - Samples remained Intact after 1 hour although XS 15GO was more easily broken down. % shrinkage (area) - GJ JO.75* xs 1500 10.956 Recipe 137 - Melted in contact with the silicon carbide plate /.-t to a lesser extent than the fibre alone. Recipe 141 - completely melted. ^355? - partial melting in contact with silicon carbide- rlatr. 2 total of 32 sets were produced with no difficulties in manufacturing. The first five cycles were on the wet side but increasing the dewatering tine to 24 seconds corrected the problem. Some of the water entrapped in the tool came down on the pieces as they were blown off. This is a normal situation which shouldn't be but has existed from day one on the four cavity tools. Two ends and two side boards had a perfect fit in the jig with no shrinkage detected. The boards had a good appearance but wcrae undercured because one board contained approximately 5% moisture and two more were slightly wet when broken open in the center. The boards were to be held but were packaged and shipped. 8i11 Fletcher is aware and is handling the field tests at Copperweld. EP 5298 Proflex - #376 Rings on Chicago ffl one-piece Fifty rings were produced with much difficulty because of a mechanical problem which was not discovered until four hours after the run was dis continued. The vacuum lift was not operating at its full efficiency be cause of a malfunctioning air regulator. One hundred and fifty rings were produced the following day without supervision. The quality of these were very poor and probably should not have been shipped to the customer. The 50 rings which the Technical Department supervised were of good quality but these were lost and mixed with standard rings. About 50 rings'were tested and every one of these rings were sticking to the casting. Host of the castings had to be scraped at least a little to remove the ring pieces. It has not been determined definitely to what is causing the sticking. A microscopic examination showed that their is a layer of charred material at the surface which has not fully been combusted. The charred material is made up of paper and resin. The heat and casting pressure acting on the ring may be enough to fuse the surface resin to the casting. A high temoerature (1400^C) fusion test shoved that their were differences in the ring material produced three weeks ago and the recent rings all suposively from EP 5298. More rings are in the processof being tested for sticking which are of the earlier production lot. eo/lr .. . cc: U. J. Vandemark M. S. Wood 0. Lceian G. FitzGerald H. 0. Wright T. Levickl B. Fletcher 1736 TESTING rp.CCRAKS II? PROGRESS = t 9/28/73 Republic Canton Great Lakes Coppcrv/cld Harrisburg Steel Carpenter Steel Armco Kansas CityEdgewater Steel Laclede Steel Kaiser Steel Y. S. &T. Chicago Araco Eutier USS Homestead Sharon Steel USS Lorain Republic Chicago #669 currently testing EP 5465 #488, #490, #494, #144, #228 currently testing EP 5453A #68'5 currently testing EP 5465 #118 currently testing EP 5453A #357 and #75 currently testing EP 5453a #593 currently testing EP 5453A #897 currently testing EP 5453A and EP 5465 #579 currently testing EP 5453A #861, #636 currently testing EP 5453A #777 currently testing EP 5453A #373, #604 currently testing EP 5453a #708 currently testing EP 5453A #471 currently testing EP 5465 #376 currently testing EP 5465 #538 currently testing EP 5465 (modified