This sector is typified by the variety of size and shape of cast components, ranging from many tonnes to less than a kilo. The processing of such components in, typically, short runs requires flexible manufacturing techniques. This variety and flexibility is reflected within the coating product ranges on offer from Foseco.
The SEMCO and HOLCOTE water based and ISOMOL and TENO solvent based product ranges utilize precise blends of refractory fillers to ensure ultimate protection of both mould and core. These water and solvent based refractory coatings for semi-automated and hand moulding short run production in iron foundries and deliver superior casting results.
SEMCO FD faster drying coating products can help to transition customers to water-based products. For those foundries that have already implemented the change, they can help to improve productivity, reduce drying costs and CO2 outputs. SEMCO FD is a range of water-based coatings designed for flow coating applications that will dry quicker than traditional water-based products.
Find out more about SEMCO FD fast-dry coatings that help to reduce energy consumption
The high casting temperatures associated with steel foundries requires careful selection of refractory materials, to ensure full protection against metal penetration and burn-on defects. The SEMCO and HOLCOTE water-based coatings and TENO and ISOMOL solvent-based coating range for steel applications utilize high purity zirconium silicate refractories to offer protection under the most extreme casting conditions.
A full range of specialist products is also available to cover specific applications, such as the high demands of manganese steel, highly alloyed stainless steels ormetal penetration due to hot spots or high metallostatic pressures. These products are formulated to ensure rheology is optimised for specific application methods.
Foseco developed a new family of refractory coatings to minimise the use of zircon in the formulation. TENO Tec ZA coatings maintain the technical properties of zircon-based products, but by significantly lowering the use of zircon, they reduce exposure to radiation. In some cases, zircon is eliminated altogether. These coatings do not therefore trigger radiation warnings in the foundry. TENO Tec ZA coatings also do not suffer from the same variability in production costs as zircon-based products.
Learn more about improving casting quality in steel casting applications in our white paper Casting clean: today’s solutions and opportunities. This paper cuts through the noise and brings clarity to the clean steel debate: an overview of common casting defects is followed by a detailed review of the technologies currently on offer to reduce casting defects and improve cast quality at each stage of the steel casting process.
The choice of coating will depend on the type of moulding material used, the alloy being cast, casting dimensions, weight and component part requirements.
To comply with all these different requirements Foseco have developed a wide range of coating products.
SEMCO, HOLCOTE or SEMCO water-based coatings with a full range of application rheologies and refractory combinations that offer superior performance for individual foundry requirements. They are suitable for moulds and cores made from all types of foundry binder systems.
TENO or ISOMOL alcohol-based coatings with a full range of application rheologies and refractory combinations that offer superior performance for individual foundry requirements. These coatings are designed for moulds and cores which do not require drying.
MOLDCOTE or MOLCO a comprehensive range of flash-drying and airdrying coatings for use on sand moulds and cores in the casting of copper alloys.