COATINGS F I LT R AT I O N FEEDING SYSTEMS M E LT S H O P R E F R A C TO R I E S METAL TREATMENT BINDERS CRUCIBLES

H I G H P E R F O R M A N C E M O U L D A N D C O R E C O AT I N G S

COATINGS Tailored refractory engineering

FOR THE ELIMINATION OF SURFACE DEFECTS Optimum finish and reduced surface defects

Specialist application technology

Suitable for all coating methods

Application expertise and process knowledge

 High performance mould and core coatings
for the elimination of surface defects providing superior casting finish

Committed to foundries Specialist coatings

The foundry industry encompasses many metal types n lost foam and full mould processes
and production processes, producing an array of n spun pipe production
cast components in a multitude of different sizes. To n the enhancement of metallurgical properties
acknowledge this diversity, Foseco have developed n the protection of refractories and metal tools
a variety of coating ranges to ensure that product
and process are optimised. All Foseco products are Protection
supported by a team of technical experts who can A refractory coating provides a protective barrier
advise and help you to develop optimised coating between the molten metal and the mould or core
practices. substrate during the casting process, and ensures the
integrity of the as cast surface.
RHEOTEC*
A range of water-based coatings with superior Defect prevention
dipping properties, designed specifically to meet Through the use of carefully selected refractory
the demanding requirements of the production iron fillers, Foseco coatings are designed to deposit the
foundry. correct coating structure onto a given substrate, to
ensure cast surface integrity and help in the reduction
SEMCO / TENO and elimination of a number of casting defects:
SEMCO water-based and TENO solvent based
coatings are available in a full range of application n Metal penetration
rheologies and refractory combinations to offer n Poor casting strip
superior performance to individual foundry n Mould erosion
requirements. n Gas defects
n Metal / mould reactions
n Sand expansion defects
n Metallurgical defects
n Scabbing defects

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Application Control Flow coating
To deposit a consistent layer of coating, which is free The thickness of the coating layer, when dry, should Pioneers in the development of flow coating
of runs, drips and other discontinuities, products have be sufficient to supply the required protection. Within technology, Foseco’s Flow Coating Unit is specifically
been developed with specific rheological properties to a production environment it is recommended that dry designed to meet the needs of the foundry:
suit a wide range of application methods: layer thickness is related to:
n  onsistent, operator-independent application of
C
n Dipping n Wet layer - film thickness comb coating
n Flow coating n Viscosity - flow cup n Even coverage of all mould surfaces including
n Brushing n Baumé - baumé stick vertical walls and deep pockets
n Spraying n Reduced mould abrasion and subsequent sand
Equipment and refractory inclusions
Foseco offer a wide range of equipment for the n Absence of unsightly brush or swab marks
handling and application of refractory coatings, n Enhancement of finer detail such as numbering
ranging from containers and mixer units to spray and lettering
equipment and flow coating units.

Foseco flow coating unit Viscosity measured using a flow cup Baumé measurement Wet layer thickness measurement

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 High performance mould and core coatings
for steel, iron and non ferrous foundries

Steel
The high casting temperatures associated with steel These products are formulated to ensure rheology is
foundries requires careful selection of refractory optimised for specific application methods.
materials, to ensure full protection against metal
penetration and burn-on defects. The SEMCO and Jobbing iron
TENO range of coatings for steel applications This segment of the market is typified by the variety
utilise high purity zirconium silicate refractories to of size and shape of cast components, ranging from
offer protection under the most extreme casting many tonnes to less than a kilo. The processing
conditions. of such components in short runs requires flexible
manufacturing techniques. This variety and flexibility
A full range of specialist products is also available is reflected within the coating product ranges on offer
to cover specific applications, such as the high from Foseco.
demands of manganese steel, highly alloyed stainless
steels or metal penetration due to hot spots or high
metallostatic pressures.

Designed to reduce brush marks and improve surface finish

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The SEMCO and TENO product ranges utilise can be introduced to improve insulation properties
precise blends of refractory fillers to ensure ultimate and help to eliminate sand expansion defects, whilst
protection of both mould and core. In the case of maintaining excellent strip and casting surface finish.
heavy sectioned castings a combination of high A full range of specialist products is also available to
purity zirconium silicate and graphitic fillers provide cover specific applications, such as prevention of flake Flow coating ensures
optimum refractoriness and prevention of metal reversion in ductile iron. even coverage of all
mould surfaces
penetration, whilst maintaining a good strip and
reducing “white shining”. As section thickness is All these products are formulated to ensure rheology
reduced, alternative fillers such as alumino silicates is optimised for specific application methods.

Protection for even

Optimal interaction of moulding material and coating Operator independent application the largest castings

Fast and consistent

coverage of
mould surfaces

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 High performance mould and core coatings
for production iron and specialist applications

Production iron
High production foundries with a large proportion of Refractory filler combinations are carefully selected
cored castings, typify this segment. The production and controlled and rheological properties are designed
unit is typically highly automated and the application to apply a controlled coating layer. Specific coatings
of coating is normally via a dipping operation. The are available to offer superb protection against a
RHEOTEC, SEMCO and TENO range of coatings number of common defects.
are focused on providing exceptional dipping
characteristics, whilst ensuring internal surfaces are An example of this is RHEOTEC XL which offers
free from casting defects. unparalleled protection against the formation of
veining defects.

Even coverage without runs or drips Fast and consistent application

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Metallurgical coatings
A full range of specialist products is also available to Permeability and composition have been specifically
Protection from flake
cover specific applications, such as localised chill and designed to meet the requirements of lost foam. The reversion in ductile iron
grain refinement. TELLURIT chill-promoting coatings coatings can be applied by spray, dipping or brush.
for grey cast iron are ideal for producing a wear
resistant surface. Spun pipe
SPUNCOTE are specialist products formulated to
MOLCO 50 dressings are designed for the localised provide a permeable coating with very low gas
densening of grey cast iron. They can eliminate the evolution for the centrifugal casting process. They can
use of metal chills and are useful for treating heat also assist metal flow and promote easier stripping of
centres affected by open grain structure that are the finished casting.
difficult to feed. Coatings for highest
Tools and refractories thermal demands

Full mould and lost foam processes FRACTON coatings are used for the protection of
SEMCO perm is a range of water based coatings refractory surfaces, metal dies and launders, pig
designed to promote excellent surface finish and moulds and other metal tools.
dimensional stability whilst avoiding common
problems such as lustrous carbon formation, metal
penetration and premature mould collapse.

Net shape castings

using the lost
foam process

Optimised
process
control

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 For highest casting quality

Research and development Consistency Reduction in

As the quality demands from end-users of castings Controlled and automated manufacturing processes finishing costs
through improved
increases, it is essential that coating technology ensure that products are supplied to a highly surface finish
keeps pace. Foseco continually invest resources in consistent specification, eliminating batch to batch
the research and development of innovative solutions product variations.
to the problems of today and tomorrow. Coating
development laboratories work closely with in-house Quality assurance
casting facilities to ensure new product developments Accredited quality assurance systems ensure optimal
fully meet the customer’s needs. testing of finished product, and provides a framework
for continual improvement and further process
optimisation.
Customer focused
research &
Flexibility development

A broad range of delivery options are available to suit

the needs of the individual customer.

Service
For further information and specific recommendations
on the full range of Foseco coatings for ferrous and
non ferrous foundries, please refer to the local Foseco
For highest representative.
quality Quality assured
demands processes

*FOSECO, the Logo and RHEOTEC, SEMCO, TENO, TELLURIT, MOLCO, FRACTON and SPUNCOTE are trade marks of the Vesuvius Group, registered in certain countries, used under licence. All rights reserved. Foseco International Limited
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Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are Tamworth, Staffordshire,
published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants,
expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not England B78 3TL
authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request. Phone: +44 (0)1827 262021
© Foseco International Limited 05/11.
Fax: +44 (0)1827 283725
05/2011 · re 750 e

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