Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
Product Datasheet - Feeding Systems
KALPUR*
Exothermic-insulating or insulating direct pour system with ceramic foam filters for iron
and steel castings
Product Description KALPUR direct pour units are a combination of a feeder sleeve and a ceramic foam filter. Liquid
metal is poured through the KALPUR direct pour unit into the casting.
Benefits The KALPUR process entirely eliminates the need for a conventional running system. In addition,
by allowing the foundryman to pour directly into the casting, directional solidification is
improved.
Application Moulding system KALPUR direct pour system
Jobbing casting, moulding machines Ram-up feeder-filters (Table 1)
Horizontally parted moulding lines Insert feeder-filters (Table 2)
Vertically parted moulding lines Pour-down feeder-filters (Tables 3+4)
Notes on KALPUR Feeder-Filter Technique: The direct pour units must be chosen both by
modulus as well as shrinkage point of view.
Standard calculation:
Iron casting: Modulus feeder = Modulus casting
Steel casting: Modulus feeder = Modulus casting x 1.2
Non-metallic inclusions may cause blockage of the filter resulting in insufficient feeding.
Therefore clean metal and casting processes are also necessary for KALPUR casting technology.
When using an open top sleeve please always consider that in order to achieve desired feeding
modulus it is essential to cover the open top immediately after pouring with a proper amount of
FERRUX anti-piping compound. Please refer to FERRUX datasheet.
Technical Data Feeder / Filter material for the KALPUR system
KALPUR direct
Feeder Material Filter Material Casting Alloy
pour types
Ram-up KALMINEX* 2000 SEDEX*/STELEX* Iron and Steel
Insert KALMIN* S SEDEX/STELEX Iron and Steel
Pour down KALMIN S SEDEX/STELEX Iron and Steel
Packaging See Appendix.
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
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Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
Storage & Shelf Life Store dry. Shelf Life is 2 years. It is recommended to use within 3 months.
Health & Safety See Material Safety Data Sheet, copies of which are available on request.
Further Remarks For safety reasons the product mentioned above must only be used according to these
application guidelines. The above mentioned data are guidelines only and do not represent a
specification. All rights to make technical changes to improve the product are reserved.
Accordingly to DIN EN ISO 8062-3 KALPUR TA sleeves (table 1) have a dimensional tolerance of
grade DCTG 14, KALPUR Insert sleeves (tables 3, 4 and 5) have a dimensional tolerance of grade
DCTG 13.
Appendix Table 1: KALPUR Ram-up
Table 2: Filter Support Core
Table 3: KALPUR Insert
Table 4: KALPUR Pour down
Table 5: KALPUR Pour down
Table 1: KALPUR Ram-up
Protective pattern
Locating pin
Ram-up principle with fixed
locating pin and protective loose piece
extending to the cope height.
KALPUR Ram-up system
Feeder Modul Filter Ø Nominal Dimensions (mm) Vol. Packing units
Types (cm) (mm) Du N Do do H h T (dm³) (pieces/pallet)
ZTAE 10/12 2,50 70 76 48 136 100 120 43 4 0,68 288
ZTAE 12/15 3,00 90 96 60 157 120 151 45 4 1,29 160
ZTAE 15/18 3,70 125 120 70 191 152 181 55 5 2,57 96
ZTAE 18/20 4,30 150 130 86 221 174 200 80 6 3,78 72
XTAE 21/25 5,30 175 150 100 250 200 250 100 6 6,25 78
XTAE 23/25 5,80 200 160 110 278 225 250 110 6 7,75 66
ZTAE = KALMINEX 2000, KALPUR feeder-filters inserts
XTAE = KALMINEX, KALPUR feeder-filters inserts
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 2 of 8
Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
SEDEX Foam Filter for KALPUR FE Iron Casting Feeder-Filter
Filter nominal
dimensions (mm) Filter porosity 1) Filter area Flow capacity (kg/filter) 2) Packing units
Ø Height (ppi) (mm²) Ductile Iron Grey Iron (pieces/carton)
70 22 g/m 3848 40 - 80 80 - 160 264
90 25 g/m 6362 65 - 130 130 - 260 165
125 25 g 12266 115 - 230 230 - 480 121
STELEX PrO Foam Filter for KALPUR ST Steel Casting Feeder-Filter
Filter nominal
dimensions (mm) Filter porosity 1) Filter area Flow rate (kg/filter) 3) Packing units
Ø Height (ppi) (mm²) C-Steel High alloy Steel (pieces/carton)
70 25 g 3848 75 110 117
90 25 g 6362 125 185 117
125 30 g 12266 240 360 40
150 30 g 17671 345 520 16
175 35 g 24041 470 700 14
200 35 g 31400 610 910 9
1) Filter Porosity: g = coarse (10 ppi); m = medium (20 ppi)
2) Flow Capacity: 1-2 kgs/cm² for Ductile Iron; 2-4 kgs/cm² for Grey Iron
3) Flow Rate: 1.5 kgs/cm² for C-steel; 2.2 kgs/cm² for high alloy steel (>5%)
Purchase order Examples: Normally KALPUR ram-up filters are not ordered with the filter inside the KALPUR unit, since filters are
located after cope mould is completed.
Please state the following description(s) when ordering:
KALPUR ram-up feeders and separate foundry filters
KALPUR ram-up feeder, e. g. ZTAE 10/12
ceramic foam filter for iron casting, e. g. SEDEX Ø 70x20 / 10ppi
ceramic foam filter for steel casting, e. g. STELEX P Ø 70x25 / 10ppi
KALPUR feeder-filters with ceramic foam filters
for iron castings e. g. KALPUR FE ZTAE 10/12 L10
for steel casting e. g. KALPUR ST ZTAE 10/12 P10
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
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Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
TA Sleeve
Filter Support Core
D d
Type T [mm] Ø Filter TA Sleeve
[mm] [mm]
FSC 3/75 81 61 25 75 TA 3
FSC 4/100 106 75 25 100 TA 4
FSC 5 / 125 132 98 30 125 TA 5, TA 6
FSC 6/150 158 131 30 150 TA 6, TA 7
FSC 7/175 184 151 35 175 TA 7, TA 8
FSC 9/200 209 175 35 200 TA 9, TA 8
FSC 10/250 260 220 40 250 TA 10, TA 11
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 4 of 8
Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
Table 3: KALPUR Insert Feeder-Filters
Special insert application patterns have
been developed to insert the KALPUR unit.
3D models of these patterns are available
on request from local Foseco
representative.
KALPUR FE / KALPUR ST Insert System
Nominal dimensions (mm) Packing units (pieces)
Feeder types Modulus (cm) Filter Ø (mm) Vol. (dm³)
du Du Do H without bc with bc
KSET 4/7 1,20 40 31,0 62,0 58,0 71,5 0,07 2120 1908
KSET 5/8 1,50 50 44,0 74,5 66,5 81,0 0,16 1404 1404
KSET 6/9 1,70 60 50,0 81,0 73,5 91,0 0,23 1056 1056
KSET 7/10 2,00 70 60,0 94,5 86,5 99,0 0,38 672 672
KSET 8/11 2,25 80 70,0 102,5 96,0 109,5 0,50 560 560
KSET 9/12 2,50 90 78,5 116,0 106,5 120,5 0,70 360 360
KSET 10/13 2,80 100 87,0 129,0 116,0 134,0 0,92 288 240
KSET 12/15 3,20 125 110,0 154,0 148,0 151,5 1,55 160 160
KSET = signifies KALMIN S KALPUR units.
Breaker cores and application patterns for KALPUR Insert System
Nominal dimensions (mm) Application pattern types
Breaker core types
D1 D2 t N F1) (cm²) without bc with bc
BK 4/7/16 65,5 66,5 8,0 25,0 4,9 DEE 4/7 DEE 4/7/16
BK 5/8/16 75,5 76,5 8,0 30,0 7,1 DEE 5/8 DEE 5/8/16
BK 6/9/16 83,0 84,0 8,0 30,0 7,1 DEE 6/9 DEE 6/9/16
BK 7/10/16 97,0 98,0 9,0 40,0 9,6 DEE 7/10 DEE 7/10/16
BK 8/11/16 106,5 107,5 9,5 40,0 12,6 DEE 8/11 DEE 8/11/16
BK 9/12/16 119,0 120,0 10,0 45,0 15,9 DEE 9/12 DEE 9/12/16
BK 10/13/16 131,0 132,0 11,0 50,0 19,6 DEE 10/13 DEE 10/13/16
BK 12/15/16 158,5 159,5 12,0 60,0 28,3 DEE 12/15 DEE 12/15/16
1) F= Feeder fracture area
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 5 of 8
Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
SEDEX Filter for KALPUR FE Feeder-Filters
Filter dimensions (mm) Filter porosity 1) Filter area Flow capacity 2) (kg/Filter)
Ø Height (ppi) (mm²) Ductile Iron Grey Iron
40 22 g/m 1256 15-30 30-60
50 22 g/m 1964 20-40 40-80
60 22 g/m 2827 30-60 60-120
70 22 g/m 3848 40-80 80-160
80 25 g/m 5026 50-100 100-200
90 25 g/m 6362 65-130 130-260
100 25 g 7854 80-160 160-320
125 30 g 12266 115-230 230-480
STELEX Filter for KALPUR ST Feeder-Filters
Filter dimensions (mm) Filter porosity1) Filter area Flow rate 3) (kg/Filter)
Ø Height (ppi) (mm²) C-Steel High-alloy Steel
50 25 g 1964 29 43
60 25 g 2827 43 63
70 25 g 3848 58 85
80 25 g 5026 75 111
90 25 g 6362 95 140
100 25 g 7854 118 173
125 30 g 12266 240 270
1) Filter Porosity: g = coarse (10 ppi); m = medium (20 ppi)
2) Flow Capacity: 1-2 kgs/cm² for Ductile Iron; 2-4 kgs/cm² for Grey Iron
3) Flow Rate: 1.5 kgs/cm² for C-steel; 2.2 kgs/cm² for high alloy steel (>5%)
KALPUR insert filter feeders are supplied only with integrated filters.
Please state the following description(s) when ordering:
KALPUR FE insert feeder-filters for iron castings
KSET 5/8 L10: (L10 = SEDEX filters 10ppi)
KSET 5/8 L20: (L20 = SEDEX filters 20ppi)
KSET 5/8 L10/16Q: (16Q = silicia sand breaker core)
KALPUR ST insert feeder-filters for steel castings
KSET 5/8 P10: (P10 = STELEX PrO filters 10ppi)
KSET 5/8 P10/16Q: (16Q = silica sand breaker cores)
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 6 of 8
Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
Table 4: KALPUR Fe Poured-down System, Opposite Conical Shape
Principle of a two-part pattern print with
securing wedge and larger insert half for
KALPUR Feeder-Filters for vertical parting
line.
SEDEX Filters for KALPUR FE Units
Nominal
dimensions (mm) Filter porosity 1) Filter area Flow capacity 2) (kgs/Filter)
Ø Height (ppi) (mm²) Ductile Iron Grey Iron
50 22 g/m 1964 20 - 40 40 - 80
60 22 g/m 2827 30 - 60 60 - 120
70 22 g/m 3848 40 - 80 80 - 160
80 22 g/m 5026 500 - 100 100 - 200
1) Filter Porosity: g = coarse (10 ppi); m = medium (20 ppi)
2) Flow Capacity: 1-2 kgs/cm² for Ductile Iron; 2-4 kgs/cm² for Grey Iron
Feeder Modulus Filter Ø Nominal dimensions (mm) Vol. Packing units
Types (cm) (mm) du Du do Do H (dm³) (pieces/palett)
KSE 6/7 1,50 50 42 80 55,0 76 71 0,15 1320
KSE 6/9 1,70 50 43 80 57,5 75 93 0,21 1056
KSE 7/10 2,00 60 50 95 69,0 88 101 0,34 672
KSE 8/11 2,20 70 63 104 79,0 98 108 0,46 560
KSE 9/12 2,50 80 72 115 89,0 108 123 0,66 360
KSE = signifies opposite conical KALMIN S KALPUR Poured-down feeder-filter
Please state the following description(s) when ordering:
Opposite conical KALPUR FE unit is supplied with integrated filter at the base of the unit.
When ordering, please state the following, e. g.:
KALPUR FE poured-down feeder-filter
KSE 6/7 L10 (L10 = SEDEX Filter 10ppi)
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 7 of 8
Revision No: 017
Date: 04/22
Steel Foundry • Iron Foundry
Table 5: KALPUR Fe Poured-down System, Opposite Conical Shape
SEDEX Filters for KALPUR FE Units
Filter Flow capacity 2)
Filter porosity 1) Filter area
dimensions (mm) (kgs/Filter)
Ø Height (ppi) (mm²) Ductile Iron Grey Iron
50 22 g/m 1964 20 - 40 40 - 80
60 22 g/m 2827 30 - 60 60 - 120
1) Filter Porosity: g = coarse (10 ppi); m = medium (20 ppi)
2) Flow Capacity: 1-2 kgs/cm² for Ductile Iron; 2-4 kgs/cm² for Grey Iron
Feeder Modulus Filter Ø Nominal dimensions (mm) Vol. Packing units
Types (cm) (mm) du Du do Do H (cm³) (pieces/palett)
KSPE 5/7 1,5 50 40 67 55 73 70 0,17 1560
KSPE 5/11,5 1,7 50 40 67 58 77 115 0,26 792
KSPE 5/15 1,8 50 40 68 64 80 150 0,37 660
KSPE 6/15 2,0 60 50 78 74 91 150 0,51 480
KSPE = signifies parallel conical insulating KALMIN S KALPUR Pour-down feeder-filter
Please state the following description(s) when ordering:
Opposite conical KALPUR FE unit is supplied with integrated filter at the base of the unit.
When ordering, please state the following, e. g.:
KALPUR FE poured-down feeder-filter
KSPE 5/15 L10 (L10 = SEDEX filter 10ppi)
Vesuvius GmbH Gelsenkirchener Str. 10 • 46325 Borken
Telefon +49 (0)2861/83-0 • Telefax +49 (0)2861/83-338 • www.foseco.de
KALPUR* * Foseco, its logo and KALPUR, KALMINEX, SEDEX, STELEX and KALMIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
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