US3326273A - Exothermic hot top - Google Patents
Exothermic hot top Download PDFInfo
- Publication number
- US3326273A US3326273A US517132A US51713265A US3326273A US 3326273 A US3326273 A US 3326273A US 517132 A US517132 A US 517132A US 51713265 A US51713265 A US 51713265A US 3326273 A US3326273 A US 3326273A
- Authority
- US
- United States
- Prior art keywords
- aluminum
- dust
- ballmill
- metal
- dross
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000203 mixture Substances 0.000 claims description 30
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 27
- 239000002657 fibrous material Substances 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 7
- 239000002245 particle Substances 0.000 claims description 7
- 239000007800 oxidant agent Substances 0.000 claims description 4
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 4
- 230000003647 oxidation Effects 0.000 claims description 3
- 238000007254 oxidation reaction Methods 0.000 claims description 3
- 239000000428 dust Substances 0.000 description 27
- 229910052751 metal Inorganic materials 0.000 description 20
- 239000002184 metal Substances 0.000 description 20
- 229910052782 aluminium Inorganic materials 0.000 description 17
- 238000005266 casting Methods 0.000 description 14
- 239000002002 slurry Substances 0.000 description 13
- 239000000463 material Substances 0.000 description 11
- 238000000034 method Methods 0.000 description 11
- 239000007787 solid Substances 0.000 description 10
- 239000011230 binding agent Substances 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- 230000008901 benefit Effects 0.000 description 6
- PUZPDOWCWNUUKD-UHFFFAOYSA-M sodium fluoride Chemical compound [F-].[Na+] PUZPDOWCWNUUKD-UHFFFAOYSA-M 0.000 description 6
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 4
- 239000004615 ingredient Substances 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 239000011819 refractory material Substances 0.000 description 4
- 235000002639 sodium chloride Nutrition 0.000 description 4
- 239000011701 zinc Substances 0.000 description 4
- 229910052725 zinc Inorganic materials 0.000 description 4
- XTEGARKTQYYJKE-UHFFFAOYSA-M Chlorate Chemical compound [O-]Cl(=O)=O XTEGARKTQYYJKE-UHFFFAOYSA-M 0.000 description 3
- 238000000498 ball milling Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 238000002485 combustion reaction Methods 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000005058 metal casting Methods 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 229920001568 phenolic resin Polymers 0.000 description 3
- 239000011775 sodium fluoride Substances 0.000 description 3
- 235000013024 sodium fluoride Nutrition 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 238000003809 water extraction Methods 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 2
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000010425 asbestos Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229910001610 cryolite Inorganic materials 0.000 description 2
- 150000002222 fluorine compounds Chemical class 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 239000003292 glue Substances 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- -1 halide salts Chemical class 0.000 description 2
- 239000011810 insulating material Substances 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- NUJOXMJBOLGQSY-UHFFFAOYSA-N manganese dioxide Chemical compound O=[Mn]=O NUJOXMJBOLGQSY-UHFFFAOYSA-N 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 229910052895 riebeckite Inorganic materials 0.000 description 2
- 238000005029 sieve analysis Methods 0.000 description 2
- 239000000377 silicon dioxide Substances 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L sodium carbonate Substances [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 239000004094 surface-active agent Substances 0.000 description 2
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 229920001131 Pulp (paper) Polymers 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 201000010001 Silicosis Diseases 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- GZCGUPFRVQAUEE-SLPGGIOYSA-N aldehydo-D-glucose Chemical compound OC[C@@H](O)[C@@H](O)[C@H](O)[C@@H](O)C=O GZCGUPFRVQAUEE-SLPGGIOYSA-N 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 description 1
- 229910001634 calcium fluoride Inorganic materials 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 229910001959 inorganic nitrate Inorganic materials 0.000 description 1
- 229910052909 inorganic silicate Inorganic materials 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 239000000025 natural resin Substances 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 229910021652 non-ferrous alloy Inorganic materials 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000001103 potassium chloride Substances 0.000 description 1
- 235000011164 potassium chloride Nutrition 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000011044 quartzite Substances 0.000 description 1
- 150000003242 quaternary ammonium salts Chemical class 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 230000035945 sensitivity Effects 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 229910001388 sodium aluminate Inorganic materials 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229940032158 sodium silicate Drugs 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 235000019794 sodium silicate Nutrition 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical compound [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 238000007666 vacuum forming Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/10—Hot tops therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D7/00—Casting ingots, e.g. from ferrous metals
- B22D7/06—Ingot moulds or their manufacture
- B22D7/10—Hot tops therefor
- B22D7/104—Hot tops therefor from exothermic material only
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
- C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
Definitions
- molten metal may feed to the body of the ingot or casting to compensate from the shrinkage which occurs on cooling since otherwise the ingot or casting may be formed with internal cavities or fissures.
- the usual method is to provide that the solidification of the head metal in an ingot mould, or in a hot top provided thereon, or in the risers and feeder heads of a casting mould is delayed, so providing a reservoir of molten metal which may feed to the ingot or casting proper.
- This delay may be achieved by setting up a barrier to the loss of heat from the head metal by lining the head of the ingot mould or the hot top, risers, feeder heads and the like with a refractory heat-insulating composition, or by using a composition of which the ingredients are ignited by the heat of the molten metal to react exothermically.
- shaped bodies or linings made of castable compositions which contain predominantly a refractory filler material, usually with minor amounts of an organic fibrous material and of a binding medium.
- the organic fibrous material is usually a paper pulp, e.g. rep-ulped old newsprint.
- the binding medium may be based on any of a wide variety of materials, e.g. a natural or synthetic resin or glue, elg. a silicone resin, ureaor phenol-formaldehyde resin, a cellulose glue, sulphite lye, or sodium-silicate.
- the refractory material used in the said compositions is generally a siliceous material such as sand, quartz, quartzite, inorganic silicate, or may be a material such as dolomite.
- the refractory material may also include a fibrous refractory, e.g. asbestos, glass fibre, or rock wool.
- composition suitable for lining the inner surface of a casting mould for casting metal or of a hot top for such a mould which comprises a predominant amount (i.e. at least about 50%) of ballmill dust, advantageously together with about 2 to 30% by weight of organic fibrous material, about 1 to by weight of a binding medium and optionally from about 1% up to 10% fibrous refractory material.
- Preferred compositions are those containing 78 to 94% ballmill dust, 3 to 9% of organic fibrous material and 1 to 8% of binding agent.
- the organic material and the binding agent may be any of those referred to above or mixtures thereof.
- compositions since it contains finely divided aluminum metal this tends to burn exothermically when linings of the composition are contacted by the molten mould metal.
- the compositions being thus self-heating, they tend to improve the feed characteristics of the molten metal with which they are used. It is to be noted in this connection that various ingredients present in ballmill dust, e.g. halide salts, may tend to facilitate the combustion of the aluminum.
- hot tops or risers of the invention are highly exothermic without requiring the presence of chemical oxidizing agents.
- an oxidizing agent such as iron oxide, manganese dioxide, or an inorganic nitrate or chlorate.
- the present invention by eliminating the need for such agents, avoids the possibility of iron or manganese altering the molten metal composition, and reduces moisture absorption caused by deliquescent nitrates or chlorates.
- Ballmill dust is obtained from the skimming and drosses formed during the metling of aluminum and aluminum alloys in an oxygen-containing atmosphere.
- the skimmings and drosses pass to the secondary melters for pulverizing by ballmilling or grinding.
- the dross may need to be reduced in size in a jawcrusher but generally it is sufliciently fine for ballmilling Without any pretreatment.
- After ballmilling it is usual to screen the residue.
- the coarse material normally +10 or +16 mesh
- the fine material which is called ballmill dust, may be washed by the producer in order to remove water-soluble salts.
- the dross usually is composed mainly of aluminum oxide (resulting from the oxidation of the molten metal) and particles of aluminum or aluminum alloy, together with a few percent each of metallic contaminants such as copper, silicon, iron, zinc, magnesium, and/ or their compounds.
- Some silica is generally present, as are fluorides and chlorides of sodium, potassium, and/or other metals (from fiuxing ingredients and their various reaction products).
- Aluminum nitride is also usually present, resulting from the reaction between aluminum and atmospheric nitrogen.
- the fluxes used with aluminum or mixtures containing one or more of the following components sodium fluoride, sodium chloride, sodium sulphate, potassium chloride and cryolite.
- the ballmill dust may contain up to 50% sodium chloride and values of 10 to 15% total fluorides (Water-soluble and water-insoluble) have been noted.
- the residual aluminum content of ballmill dust depends therefore on the source and on the type of processing it receives but normally is between 10 and 30%. It may however contain as little as 5 or as much as 60 or 70% metallic aluminum. For optimal exothermic performance when pouring ferrous metals, it is preferred that the ballmill dust contain from about 5 to about 45 weight percent aluminum metal (e.g. about to and accordingly it may in some instances be desirable to fortify aluminumlean dust with blown or ground aluminum metal. With non-ferrous metal casting, a higher aluminum content may be desirable.
- ballmill dust used herein means a product as thus defined.
- composition of the ballmill dust preferably used in the practice of the invention may vary widely, e.g. within the ranges shown below:
- Percent Aluminum 5 to 70 Aluminum oxide 15 to 60 Zinc 0 to 5 Chloride 0 to lead 0 to 1 Most preferably, however, the composition contains approximately 15-45% aluminum, about 1% chloride and not much more than 0.1% each of zinc and lead. A minimum aluminum content of 15% seems to provide a suificiently intensive reaction to make feeding of steel castings efficient in riser sizes down to about a 3 inch diameter. However, improved efficiency can beobtained by using higher aluminum contents in the feeding of both ferrous and non-ferrous alloy castings. Generally speaking, the advantage of higher aluminum contents is most marked with the smaller diameter risers, but advantage is to be expected with all sizes.
- Impurities such as zinc, chloride, and lead are detrimental in that they cause the evolution of excessive or toxic fumes during combustion of the product. They do not eifect the resultant castings however.
- the presence of some fluoride is beneficial since it increases the sensitivity of the mixt-ure; for example, the addition of 2% sodium fluoride /2% in the finished product) results in improved burning especially on small diameter risers.
- the 'ballmill dust should preferably not contain large particles of dross since, if included, these tend to increase the density of the final product, and reduce the efficiency of the aluminum combustion.
- a 22. 34 10. 00 31. 00 9. 40 0. 75 0.50 1. 00 0.50 0. 10 0. 10 0. 10 0. 10 1.30 0. 10 1. 70 0. 45. 25 24. 35. 28 41. 43 5. 50 2. 0O 2. 62 8. 96 0. 0. 21 0.98 0. 35 1. 15 1. 89 4. 28 0. 89 0. 13 Nil 2 86 2. 83 15. 40 3. 01 0.70 0.80 1. 4. 00 0.75 0.75 0.77 0. 98 0. 55 O. 50 0. 39 0. 64 1. 73 48. 9 2. 34 14. 76 0. 10 2. 5O 0. 30 1. G6 0. 02 0. 10 0. 63 3. 54 1. 16 7.25 Trace Truce TABLE II.-TYPICAL SIEVE ANALYSIS OF BALLMILL DUSTS Sample A l B l o Sieve Analysis:
- Ballmill dust particle size distribution depends both on the extent of grinding and on the screens used to recover the aluminum. It is preferred however that more than half, optimally more than 95%, of the dust pass a 10 mesh screen, and optimally more than pass a 20 mesh screen.
- compositions of this invention are preferably preformed as slabs or sleeves for use in lining the head of an ingot or casting mould or in lining a hot top for a metal casting mould.
- An especially useful shape in the practice of this invention is that of a slightly coned sleeve having at its narrower end a wall across it provided with a vent, substantially the same shape as, for example, an inverted flowerpot.
- exothermic riser sleeves or sleeves of refractory insulating material to cover the top layer of molten metal, after pouring, with exothermic or refractory heat-insulating powder.
- This method has several disadvantages, such as inhomogeneity and inconvenience to the user, and heat loss due to the splitting of the powder layer during cooling.
- fabrication of sleeves in the shape indicated above eliminates the need for powder, increases the insulation of the top metal and makes the casting operation easier. In addition, sleeves thus formed are stronger and easier to store.
- the slabs or sleeves may conveniently be formed by a slurry technique as follows:
- the ingredients of the composition are made up to an aqueous slurry.
- a small quantity of a surfactant known per se is included in the composition to facilitate this.
- the slurry is charged into a vessel having a perforate wall or walls and pressure or vacuum is applied to cause the slurry to be urged against the perforate walls.
- the liquid me dium of the slurry passes through the perforate walls as eflluent and the solid constituents are compacted against the perforate walls as layers of desired thickness.
- the internal diameter of the sleeve formed may only be controlled by the amount of slurry added to the mould, and the solids content thereof.
- the solids content of the slurry is preferably to 50%, most preferably 30 to 35%.
- Typical spinning times and speeds are 1200 to 1400 r.p.m. for 1.5 to 3 minutes.
- the compacted sleeves may be withdrawn from the mould, and are fairly easily handleable.
- the slabs or sleeves Before use the slabs or sleeves must be dried. This is generally effected by drying on vented core plates in normal ovens through which air is passed.
- any binder which is soluble in the liquid medium will be largely lost in the effluent (from which if desired it may be recovered) and it is therefore necessary to employ sufiicient binder to ensure that enough is present in the liquid which is retained by the compacted solid contsit-uents to provide the necessary composition as earlier described.
- a water-insoluble, thermo-softening binder may be employed in solid powder form (e.g. phenolic resins in a suitable state of polymerization). In such case losses with the efiluent will be negligible.
- a mixture of insoluble and soluble binders may be employed.
- the ballmill dust used contain not more than 50 to 60% of material of particle size 200 mesh (Tyler) since slurries made using dust with these or even higher fine dust contents tend to be nonporous and tend to require longer spinning or compacting to extract the water. Where long water extraction times are acceptable, however, materials containing up to 85%, or over, of 200 mesh particles may be used.
- Permeability in formulations containing unwashed ballmill dust may be increased by incorporating a small amount, e.g. 1 to 5% of Wood flour in the mix. This amount brings the permeability to at least about 4 or 5 A.F.S. units in order to avoid blowing during metal pouring.
- the preferred range of permeabilities is about 812 A.F.S. units.
- calcium fluoride or cryolite may be used, each in amounts of 0.1 to 2%.
- a major advantage of the invention is that the exothermic refractory of the invention becomes a relatively soft, frangible material after completion of the exothermic reaction. It thus may easily be removed from the solidified metal in the mould cavity, allowing facile recovery of the riser metal and clean rolling of hot topped ingots.
- compositions are essentially nonsmoking, and may be used without discomfort to near-by workers.
- an exothermic hot top, riser, or the like having a molten-metal-contacting surface comprising a shaped body composed dross obtained by the atmospheric oxidation of molten aluminum metal, said dross having a composition comprising from about 5 to about weight percent aluminum metal and from about 15 to about 60 weight percent aluminum oxide and being of a particle size which will pass through a 10 mesh screen, said shaped body being substantially free of oxidizing agents and from about 2 to about 30 weight percent of an organic fibrous material.
- said shaped body comprises about 78 to 94 weight percent of said dross, about 3 to 9% of organic fibrous material, and about 1 to 8% of binding agent, wherein all of said dross passes through a 20 mesh screen and not more than about 60% passes through a 200 mesh screen, and wherein said shaped body has an A.F.S. porosity of at least about 4.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Mold Materials And Core Materials (AREA)
Priority Applications (12)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US517132A US3326273A (en) | 1965-12-28 | 1965-12-28 | Exothermic hot top |
FR69134A FR1494838A (fr) | 1965-12-28 | 1966-07-12 | Perfectionnements apportés aux moules de fonderie |
GB44722/66A GB1117977A (en) | 1965-12-28 | 1966-10-06 | Mould linings |
JP41085257A JPS4948618B1 (fr) | 1965-12-28 | 1966-12-28 | |
BE691923D BE691923A (fr) | 1965-12-28 | 1966-12-28 | |
GB03587/67A GB1218568A (en) | 1965-12-28 | 1967-03-22 | Mould linings |
US707471A US3567667A (en) | 1965-12-28 | 1968-02-23 | Mould linings composition comprising ball mill dust and calcium silicate,aluminum silicate or calcium alumino silicate fibrous refractory material |
NL6803645A NL6803645A (fr) | 1965-12-28 | 1968-03-14 | |
BE712197D BE712197A (fr) | 1965-12-28 | 1968-03-14 | |
ES351881A ES351881A2 (es) | 1965-12-28 | 1968-03-22 | Perfeccionamientos en la preparacion de composiciones para revestir la superficie interior de utiles para fundicion. |
FR144965A FR94641E (fr) | 1965-12-28 | 1968-03-22 | Perfectionnements apportés aux moules de fonderie. |
JP43018305A JPS5248932B1 (fr) | 1965-12-28 | 1968-03-22 |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US517132A US3326273A (en) | 1965-12-28 | 1965-12-28 | Exothermic hot top |
Publications (1)
Publication Number | Publication Date |
---|---|
US3326273A true US3326273A (en) | 1967-06-20 |
Family
ID=24058495
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US517132A Expired - Lifetime US3326273A (en) | 1965-12-28 | 1965-12-28 | Exothermic hot top |
Country Status (5)
Country | Link |
---|---|
US (1) | US3326273A (fr) |
JP (1) | JPS4948618B1 (fr) |
BE (1) | BE691923A (fr) |
FR (1) | FR1494838A (fr) |
GB (1) | GB1117977A (fr) |
Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3385717A (en) * | 1966-01-19 | 1968-05-28 | Armsted Ind Inc | Mold wash composition |
US3622536A (en) * | 1968-10-17 | 1971-11-23 | Foseco Int | Exothermic hot tops |
US3876420A (en) * | 1969-08-20 | 1975-04-08 | Foseco Trading Ag | Thermal insulation molten metal |
US3878142A (en) * | 1971-12-03 | 1975-04-15 | Tidd Chemisch Tech Produkte G | Compositions for lining casting moulds and related articles and method of making such articles |
US4031046A (en) * | 1974-04-02 | 1977-06-21 | Firma Tido Chemisch-Technische Produkte Gmbh | Exothermic lining for metallurgical purposes and method of making the same |
US4119468A (en) * | 1970-11-12 | 1978-10-10 | Air Products And Chemicals, Inc. | Particulate metallurgical hot topping compositions and method of use |
JPS5651539A (en) * | 1974-10-29 | 1981-05-09 | Shoichi Sasaki | Slag making lump material for metal refining |
US4274869A (en) * | 1979-04-19 | 1981-06-23 | Foseco International Limited | Desulphurization of metals |
US4440575A (en) * | 1979-06-11 | 1984-04-03 | Daussan Jean | Granular insulation product and process for its preparation |
USRE31589E (en) * | 1969-08-20 | 1984-05-22 | Foseco Trading A.G. | Thermal insulation molten metal |
US4659056A (en) * | 1983-09-19 | 1987-04-21 | Societe Nationale Industrielle Et Aerospatiale | Electrically heated light-weight concrete mold |
US6972059B1 (en) * | 1999-06-01 | 2005-12-06 | As Lungen Gmbh & Co. Kg | Exothermic feeder |
WO2006091105A1 (fr) * | 2005-02-03 | 2006-08-31 | Elkem As | Compositions refractaires |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4041199A (en) | 1974-01-02 | 1977-08-09 | Foseco International Limited | Refractory heat-insulating materials |
JPS5278924U (fr) * | 1975-12-11 | 1977-06-13 | ||
SE434352B (sv) * | 1976-11-04 | 1984-07-23 | Foseco Int | Forfarande och anordning for forvermning av samverkande delar av ett munstycke och en stopparstang i ett for smelt metall avsett kerl |
GB9308363D0 (en) * | 1993-04-22 | 1993-06-09 | Foseco Int | Refractory compositions for use in the casting of metals |
DE10149876B4 (de) * | 2001-10-10 | 2013-01-10 | Georg Fischer Gmbh & Co.Kg | Exotherm reagierende Werkstoffzusammensetzungen für Speiserheizmassen |
RU2454294C1 (ru) * | 2010-12-13 | 2012-06-27 | Государственное образовательное учреждение высшего профессионального образования "Московский государственный университет путей сообщения" (МИИТ) | Комплексная экзотермическая смесь |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2390500A (en) * | 1942-07-30 | 1945-12-11 | Ferro Eng Co | Low volume sinkhead |
US2500097A (en) * | 1947-10-14 | 1950-03-07 | Peter J Soffel | Exothermic composition for controlling the fluidity of castings |
US2891293A (en) * | 1956-01-20 | 1959-06-23 | Foundry Services Ltd | Method of initiating an exothermic reaction in a mold by chemical means |
US3039158A (en) * | 1960-09-22 | 1962-06-19 | Oglebay Norton Co | Highly thermally efficient hot top and preformed protective refractory and exothermic unit therefor |
US3171173A (en) * | 1962-05-04 | 1965-03-02 | Frank J Ingala | Composite slab for hot tops |
US3212749A (en) * | 1964-03-24 | 1965-10-19 | Bate Micheal Donald La | Consumable hot top with inserts of exothermic material |
-
1965
- 1965-12-28 US US517132A patent/US3326273A/en not_active Expired - Lifetime
-
1966
- 1966-07-12 FR FR69134A patent/FR1494838A/fr not_active Expired
- 1966-10-06 GB GB44722/66A patent/GB1117977A/en not_active Expired
- 1966-12-28 JP JP41085257A patent/JPS4948618B1/ja active Pending
- 1966-12-28 BE BE691923D patent/BE691923A/xx not_active IP Right Cessation
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2390500A (en) * | 1942-07-30 | 1945-12-11 | Ferro Eng Co | Low volume sinkhead |
US2500097A (en) * | 1947-10-14 | 1950-03-07 | Peter J Soffel | Exothermic composition for controlling the fluidity of castings |
US2891293A (en) * | 1956-01-20 | 1959-06-23 | Foundry Services Ltd | Method of initiating an exothermic reaction in a mold by chemical means |
US3039158A (en) * | 1960-09-22 | 1962-06-19 | Oglebay Norton Co | Highly thermally efficient hot top and preformed protective refractory and exothermic unit therefor |
US3171173A (en) * | 1962-05-04 | 1965-03-02 | Frank J Ingala | Composite slab for hot tops |
US3212749A (en) * | 1964-03-24 | 1965-10-19 | Bate Micheal Donald La | Consumable hot top with inserts of exothermic material |
Cited By (14)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3385717A (en) * | 1966-01-19 | 1968-05-28 | Armsted Ind Inc | Mold wash composition |
US3622536A (en) * | 1968-10-17 | 1971-11-23 | Foseco Int | Exothermic hot tops |
USRE31589E (en) * | 1969-08-20 | 1984-05-22 | Foseco Trading A.G. | Thermal insulation molten metal |
US3876420A (en) * | 1969-08-20 | 1975-04-08 | Foseco Trading Ag | Thermal insulation molten metal |
US4119468A (en) * | 1970-11-12 | 1978-10-10 | Air Products And Chemicals, Inc. | Particulate metallurgical hot topping compositions and method of use |
US3878142A (en) * | 1971-12-03 | 1975-04-15 | Tidd Chemisch Tech Produkte G | Compositions for lining casting moulds and related articles and method of making such articles |
US4031046A (en) * | 1974-04-02 | 1977-06-21 | Firma Tido Chemisch-Technische Produkte Gmbh | Exothermic lining for metallurgical purposes and method of making the same |
JPS5651539A (en) * | 1974-10-29 | 1981-05-09 | Shoichi Sasaki | Slag making lump material for metal refining |
JPS5638659B2 (fr) * | 1974-10-29 | 1981-09-08 | ||
US4274869A (en) * | 1979-04-19 | 1981-06-23 | Foseco International Limited | Desulphurization of metals |
US4440575A (en) * | 1979-06-11 | 1984-04-03 | Daussan Jean | Granular insulation product and process for its preparation |
US4659056A (en) * | 1983-09-19 | 1987-04-21 | Societe Nationale Industrielle Et Aerospatiale | Electrically heated light-weight concrete mold |
US6972059B1 (en) * | 1999-06-01 | 2005-12-06 | As Lungen Gmbh & Co. Kg | Exothermic feeder |
WO2006091105A1 (fr) * | 2005-02-03 | 2006-08-31 | Elkem As | Compositions refractaires |
Also Published As
Publication number | Publication date |
---|---|
GB1117977A (en) | 1968-06-26 |
JPS4948618B1 (fr) | 1974-12-23 |
FR1494838A (fr) | 1967-09-15 |
BE691923A (fr) | 1967-06-28 |
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