VSquare Foundry Products

Haveli, Pune, Maharashtra

The very widely used method of melting copper in foundries is with crucible furnaces. Gas, oil-fired or induction furnaces are the most common crucible furnaces used in copper foundries. Foseco offers a complete range of crucibles for all of these furnaces. TERCOD Crucibles : TERCOD crucibles have - 1. Excellent mechanical strength for handling and usage in heavy melting applications. 2. Excellent Thermal Shock resistance to sustain range of temperatures like melting and holding applications 3. Availability in a range of sizes and shapes 4. Better thermal conductivity giving better productivity and reduced energy consumption TERCOD DURATEK ER Crucibles : Premium, Specially engineered Oxidation resistant crucibles to minimize top oxidation. Offer increased service life in Aluminum holding furnaces, typical of High Pressure Die casting holding furnaces. It is designed to be easier to clean, resist cracking, and extend crucible life. TERCOD DURATEK FF Crucibles : TERCOD DURATEK FF* crucibles are long life erosion resistant crucibles engineered to maximize the mechanical strength and erosion resistance, peculiar to applications like Utensile manufacturing and Copper scrap melting. The are best suited for fuel fired applications and offer excellent flame attack resistance. The crucibles are easier to clean and resist cracking thereby extending life. They offer excellent resistance to attack by aggressive flux applications like Aluminium modification using Sodium. CORRUGATED Crucibles : TERCOD Crucibles with specially designed surface offer extended life spans and superior thermal conductivity The form of the crucibles has varied through time, with designs reflecting the process for which they are used, as well as regional variation. The earliest crucible forms derive from the sixth/fifth millennium B.C. in Eastern Europe and Iran. A crucible is a container that can withstand very high temperatures and is used for metal, glass, and pigment production as well as a number of modern laboratory processes. While crucibles historically were usually made from clay, they can be made from any material that withstands temperatures high enough to melt or otherwise alter its contents. Crucibles and their covers are made of high temperature-resistant materials, usually porcelain, alumina or an inert metal. One of the earliest uses of platinum was to make crucibles. Ceramics such as alumina, zirconia, and especially magnesia will tolerate the highest temperatures. More recently, metals such as nickel and zirconium have been used.

   Equal filling of the die + Controlled heat transfer + Good surfaces of the castings + Long life time INTRODUCTION: Although various aspects of the permanent mould casting process have been studied and developed, such as alloy selection, machine automation, etc., little attention has been given to the products and methods for preparing the surfaces of the die. It is often the operator that selects and prepares the coating material, and the final choice is based almost exclusively on practical experience rather than technical and theoretical considerations. This manual aims to provide foundry engineers and operators involved in die preparation with the information required for the correct use of coating materials, in order to optimise efficiency and so improve foundry production. This latest revised and illustrated edition of the Foseco DYCOTE Manual comprises: An analysis of the functions of coating materials, preparation and application methods, and examples of die preparation for the most common castings. The tables with the characteristics of DYCOTE products have been extended, rationalised and now include a new family of DYCOTE’s, the DURA group. This offers extended coating life, to improve productivity. Where a special coating is only available in some countries it has not been included in the table. Also not every mentioned coating is available in every country. For more details, please contact your local Foseco company. The manual is completed with appendices on cryogenic sandblasting, coating application defects and defects in die-cast parts. FUNCTIONS OF DYCOTE: 1  Control of the metal flow to ensure that it reaches all parts of the die at a sufficient temperature to prevent the formation of seams, cold laps, etc. 2  Control of heat transfer to obtain better solidification and ensure that the castings are properly fed. 3  Easy release: since castings are extracted at just below the solidification temperature, easy release ensures that castings do not come out deformed. 4  Good surfaces, and therefore a reduction in finishing costs. 5  Longer die life, therefore increased productivity and reduced maintenance. These results are directly in line with the characteristics of DYCOTE. Although various aspects of the permanent mould casting process have been studied and developed, such as alloy selection, machine automation, etc., little attention has been given to the products and methods for preparing the surfaces of the die. It is often the operator that selects and prepares the coating material, and the final choice is based almost exclusively on practical experience rather than technical and theoretical considerations. An analysis of the functions of coating materials, preparation and application methods, and examples of die preparation for the most common castings. The tables with the characteristics of DYCOTE products have been extended, rationalised and now include a new family of DYCOTE’s, the DURA section-grayoup. This offers extended coating life, to improve productivity. WIDE RANGE OF DYCOTE PRODUCTS FOR IMPROVING CASTING FILLING AND SOUNDNESS: DYCOTE 11 M Paste and Liquid :  Water base graphite dycote for lubrication and cooling of moving parts and metallic cores in GDC and LPDC applications. DYCOTE 140 Paste :  Versatile insulating die cavity coating with moderately textured surface finish.  DYCOTE 14 (ESS) :  Versatile insulating die coating with extra bonding and superior life. DYCOTE R 87 :  Base or primar dycote.  DYCOTE 34 Paste :  Insulating riser coating. DYCOTE 34 ESS :  Highly insulating riser coating with superior life.  DYCOTE 34 ESS :  Cavity and metallic core coating for excellent release and best possible surface finish. DYCOTE 34 ESS :  Medium surface finish, die cavity coating. SUPERIOR PERFORMANCE LONG LIFE DYCOTE PRODUCTS: DYCOTE 140 ESS :  Superior insulating die cavity coating with moderately textured surface finish and superior life.  DYCOTE 1400 :  Long life insulating cavity die coating for excellent productivity, with smooth surface finish. DYCOTE 3900 :  Long life die coating with excellent surface finish and better release. DYCOTE 3600 :  Long life insulating cavity die coating for excellent surface finish and productivity. DYCOTE 7029 :  Highly insulating long life riser coating paste for improving feeding of risers in GDC.

All Rotary Degassing Units from Foseco are backed by an experience of selling over 700 Units in India and 3000 Units globally. The knowledge of patented technology Rotor Geometries and apporpriate fluxes for specific applications and temperatures helps in maximizing the degassing and metal treatment results. All units are commissioned by a team of experienced and skilled team of Application Engineers using state of the art technologies for simulation of Degassing process and Hydrogen Measurement. HDU : Hoistable Degassing Units for easy handling and excellent degassing in small crucible furnaces. FDU : Stationary Degassing Units for best degassing results in ladles and furnaces. Foseco Degasser Model : Rotary degassing of liquid aluminium alloys is a widely used commercialm process to control levels of hydrogen, alkali metals and inclusions in the melt, prior to casting. A comprehensive theoretical understanding of the kinetics of aluminium degassing has been established in the past twenty years. A selection of different Foseco degas s ing rotor s has been characterised in a comprehensive experimental program. Tests have been carried out in both water model and foundry trials. The study results in an Internet based simulation software for degassing processes in foundries. MDU : Movable Rotary Degassing Units for superior degassing and in multiple furnaces located in different places. Rotary Degassing also helps in flushing out of suspended oxides. Available in a variety of tailor made sizes and transpor t modes, viz . Mounted on Manual Trolley, Battery Operated Pallet Truck, Electrical Motor Controlled Movement or Gear Box Controlled Horizontal Movement on a Battery of Furnaces in a line. MTS 1500 : MTS 1500 Units based on Vortex principle for best in class degassing and cleaning of Aluminium Alloys, with ROI of very quick return on investement. The MTS Units help reduce the process time and operator dependence. Results are consistent, reproducable, recordable and easily controlled and optimized.