PRODUCTS FOR COPPER FOUNDRIES |
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I. PRODUCTS FOR CRUCIBLE FURNACES |
A. Graphite crucibles (traders) |
A series of graphite crucibles of various types and sizes
Crucible catalogue and drawings
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B. Refractory materials
• REFCAST A series of castable and repairing refractory cement, high alumina based.
• REFPLAST Alumina based clay bonded or phosphate bonded plastic refractories for induction furnace spouts.
• REFCOTE Zircon based refractory coating for the top lining of the furnace, runners, spouts and other refractory surfaces to enhance refractoriness.
• PRECAST REFRACTORY SHAPES Ready to use for runners, spouts etc
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C. Products for melting copper and copper alloys
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1. Melting fluxes |
• Copper

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HALCOREX
Oxidizing conditions flux that prevents the gas pickup in the melt.
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• Brasses

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BRASSIT
Reducing conditions flux that prevents oxidation and zinc loss during brass melting.
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• Bronzes

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HALCOREX
Oxidizing conditions flux that prevents the gas pickup in the melt.
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• Aluminium Bronzes

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BRONZAL
Flux for protection during melting and for the aluminium oxides removal from the melt.
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• Manganese Bronzes

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BRONZAL
Flux for protection during melting and for the aluminium oxides removal from the melt.
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• Nickel Bronzes

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HALCOREX
Oxidizing conditions flux that prevents the gas pickup in the melt.
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• Fine brass melting

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SCRAPIT
Reducing conditions flux that prevents oxidation and zinc losses during fine brass melting.
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• Removal of excess aluminium from sand cast copper melts
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ALUMINAL
Flux that removes excess aluminium from the melt.
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• Slag removal
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PERLAX
Coagulant flux for slag removal.
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2. Degassing tablets
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DEGASIT (traders)
Tablets for the removal of gasses from the melt and to prevent the formation of pores and inclusions in the castings.
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3. Metal deoxidisers (traders)
For the removal of oxygen and oxide inclusions.
Copper (commercial) Copper (conductivity) |
Copper tubes filled with CuP Copper tubes filled with CuP and then CaB tubes |
Brasses |
Copper tubes filled with CuP |
Bronzes |
Copper tubes filled with CuP |
Al-Bronze |
Copper tubes filled with MnB |
Mn-Bronze |
Copper tubes filled with MnB |
Ni-Bronze |
Copper tubes filled with Mg |
II. PRODUCTS FOR THE LADLE |
Refractory materials
• REFCAST A series of castable and repairing refractory cement, high alumina based.
• REFCOTE Zircon based refractory coating for the top lining of the furnace, runners, spouts and other refractory surfaces to enhance refractoriness.
• Precast refractory shapes Ready to use for runners, spouts etc.
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III. PRODUCTS FOR MOULDING
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A. Binding materials for sand moulding
• Furanic resins (resin + catalyst system) • Waterglass (waterglass + catalyst system or CO2)
Β. Core binders
• SOLBIND Silicate for core making with breakdown properties • Furanic resins
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C. Coatings
For smooth surfaces and for the protection of the metal from moulding sand defects.
Coatings for sand moulding
• GRAFICOTE ZG 290 Zircon + Graphite / Isopropyl alcohol
• STEELCOTE ZR 185 Zircon / Isopropyl alcohol
Coatings for die casting
Dilute in water and apply by spraying.
• METALCOTE DC 61 Water based graphite coating.
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Metal treatment: |
Fluxes |
for Copper |
HALCOREX - Oxidising atmosphere fluxes |
for Brasses |
BRASSIT - Reducing atmosphere fluxes |
for Bronzes |
HALCOREX - Oxidising atmosphere fluxes |
for Aluminium Bronze |
BRONZAL - Inclusions of Alumina and oxides removal fluxes |
for Manganese Bronze |
BRONZAL - Inclusions of Alumina and oxides removal fluxes |
for Nickel Bronze |
HALCOREX - Oxidising atmosphere fluxes |
for melting fin scrap |
SCRAPIT - For fine scrap melting protection fluxes |
for Aluminium removal |
ALUMINAL - Aluminium removal fluxes |
for deslagging |
PERLAX - Deslagging after melting fluxes |
Degassing Tablets (for gas removal) |
DEGASIT |
Deoxidants |
Tubes |
for Copper |
Phosphor based deoxidants |
for Brasses |
Phosphor based deoxidants |
for Bronzes |
Phosphor based deoxidants |
for Aluminium Bronze |
Manganese/Boron based deoxidants |
for Manganese Bronze |
Manganese/Boron based deoxidants |
for Nickel Bronze |
Magnesium based deoxidants |
Master Alloys |
Phosphor (Cu-P 15%) |
Manganese (Mn) in 1 Kg tablets |
Rotary Degassing Units |
Rotary Degassing units fixed or mobile with Nitrogen gas supply |
Coatings |
sand moulds |
STEELCOTE 185 (Zircon/alcohol based) |
FERROCOTE 290 (Zircon/Graphite/alcohol based) |
μεταλλικά |
METALCOTE 61 |
Coatings for metallic Tools protection |
TOOLCOTE |
For refractory surfaces |
launders |
REFRACOTE |
surfaces |
Sand mould Binders : |
Furane Resins |
RESIN 140 |
Silicates for moulding |
SΟLBIΝD |
Silicates for core making |
SΟLBIΝD |
COPPER ALLOYS EN 1982 : 1998
ALLOY TYPE
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ALLOY CHEMICALDESIGNATION
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ALLOY NUMBER
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CASTING METHOD
GS = SAND GZ = CENTRIFUGAL GP = PRESSURE DC
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MELTING, METAL TREATMENT AND CASTING
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COPPER
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Cu
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CC040A
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GS / GM
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1. We melt the metal under a cover of an oxidizing atmosphere flux HALCOREX in proportion 1%. HALCOREX flux is added during the initial stage of melting. 2. The slag that was formed upon completion of melting is removed using the deslagging PERLAX flux. 3. We deoxidize the melt using a deoxidant CuP15% by immersing tubes with this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. 4. We cast the metal in sand moulds resin bonded with the minimum possible resin content to avoid possible gas defects. 5. W e cast at the following recommended temperatures : Small Casting section < 15 mm 1250 °C Medium casting section 15 – 40 mm 1200 °C Heavy casting section > 40 mm 1150 °C
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COPPER - ZINC
(BRASSES)
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CuZn33Pb2
CuZn33Pb2Si
CuZn35Pb2Al
CuZn37Pb2Ni1AlFe
CuZn39Pb1Al
CuZn39Pb1AlB
CuZn15As
CuZn16Si4
CuZn25Al5Mn4Fe3
CuZn32Al12Mn2Fe1
CuZn34Mn3Al2Fe1
CuZn35Mn2Al1Fe1
CuZn37Al1
CuZn38Al
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CC750S
CC751S
CC752S
CC753S
CC754S
CC755S
CC760S
CC761S
CC762S
CC763S
CC764S
CC765S
CC766S
CC766S
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GS / GZ
GP
GM / GP
GM
GS / GM / GZ
GM / GP
GS
GS / GM / GZ / GC
GS / GM / GZ
GS / GP
GS / GM / GZ
GS / GM / GZ / GC
GM
GM
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SAND CASTING 1. We melt the metal under a cover of a reducing atmosphere flux BRASSIT in a proportion 1% to avoid Zinc losses due to oxidation. 2. If Brass alloy has been contaminated with Aluminium up to 0.5%, we can remove the Aluminium from the melt by adding and stirring ALUMINAL flux in a proportion 0.5 Kg for every 100 Kg melt. 3 We deoxidize the melt using a deoxidant CuP15% by immersing tubes with this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. 3. We cast at the following recommended temperatures :
Casting section < 15 mm 15-40 mm > 40 mm Cu/Zn 60/40 - 65/35 1100 °C 1050 °C 1020 °C Cu/Zn 80/20 – 70/30 1150 °C 1100 °C 1070 °C
DIE CASTING 1. Brasses cast in metallic dies always contain Aluminium that is readily oxidized to oxides inclusions that reduce fluidity and for this reason it is necessary to remove these non metallic inclusions. 2. We melt the alloy under a cover of a flux BRONZAL in proportion 1 Kg for every 100 Kgs melt. BRONZAL is added during the initial stages of melting (pasty condition). 3. We deoxidize the melt using a deoxidant CuP15% by immersing tubes with this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. 4. We cast at temperatures between 1150 0C to 1200 0C . 5. The die face is spray coated by using a refractory and lubricating coating ALUCOTE.
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ALLOY TYPE
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ALLOY CHEMICALDESIGNATION
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ALLOY NUMBER
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CASTING METHOD
GS = SAND GM= DIE CASTING G Z= CENTRIFUGAL GP = PRESSURE DC
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MELTING, METAL TREATMENT AND CASTING
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COPPER – TIN (Bronzes)
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CuSn10
CuSn11P
CuSn11Pb2
CuSn12
CuSn12Ni2
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CC480K
CC481K
CC482K
CC483K
CC484K
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GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GZ / GC
GS / GM / GC / GZ
GS / GZ / GC
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GENERAL Bronzes are sensitive to absorb Hydrogen gases during melting. These gases are expelled during solidification and appear as holes and pores in the castings. Hydrogen gases are removed from the melt by degassing the melt with ring type tablets of DEGASIT. These tablets disintegrate in the melt and produce a huge inert gas stream that expels Hydrogen gases out. Aluminium is a deleterious element in sand casting since it is easily oxidized forming non metallic inclusions oxides that are trapped in the melt resulting pores and pressure leakage casting defects. Aluminium is removed treating the melt with ALUMINAL flux in a proportion 0.5 Kg for every 100 kgs melt.
SAND CASTING (GS) 1. We melt the alloy under a cover of an oxidizing atmosphere flux HALCOREX in a proportion 1 Kg for every 100 kg melt. HALCOREX is added during the initial stages of melting. 2. We degas the melt from dissolved gases by immersing deep inside DEGASIT tablets. 3. Immediately before casting we deoxidize the melt using a deoxidant CuP15% by immersing tubes with this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. 4. We cast at the following recommended temperatures :
Casting section Cu/Sn/Zn/Pb < 15 mm 15-40 mm > 40 mm 83/3/9/5 1180 °C 1140 °C 1100 °C 85/5/5/5 1200 1150 1120 86/7/5/2 1200 1160 1120 88/10/2 1200 1170 1130 90/10 (P-Bronze) 1120 1100 1030 |
PHOSPHOR BRONZES
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CuSn11P
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CC481K
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GS / GM / GC / GZ
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MELTING PROCEDURE
1. We melt the alloy under a cover of an oxidizing atmosphere flux HALCOREX in a proportion 1 Kg for every 100 kg melt. HALCOREX is added during the initial stages of melting. 2. The oxidizing conditions during melting prevent the absorption of Hydrogen gases. If for any reason the melt needs degassing we immerse deep inside DEGASIT tablets for gas removal. 3. We add the necessary quantity of Phosphor in the form CuP15% tubes or Phosphor master alloy wafles. 4. We deslag the melt surface using PERLAX flux. 5. Recommended casting temperatures :
Casting section < 13 mm 13-38 mm > 38 mm 1100 – 1200 °C 1080 – 1100 °C 11020 – 1030 °C
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COPPER - TIN - LEAD (Leaded Bronzes)
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CuSn3Zn8Pb
CuSn5Zn5Pb5
CuSn7Zn2Pb3
CuSn7Zn4Pb7
CuSn6Zn4Pb2
CuSn5Pb9
CuSn10Pb10
CuSn7Pb15
CuSn5Pb20
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CC490K
CC491K
CC492K
CC493K
CC498K
CC494K
CC495K
CC496K
CC497K
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GS / GZ / GC
GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GM / GC / GZ
GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GC / GZ
GS / GC / GZ
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MELTING PROCEDURE
1. We melt the alloy under a cover of an oxidizing atmosphere flux HALCOREX in a proportion 1 Kg for every 100 kg melt. HALCOREX is added during the initial stages of melting. 2. If needed we degas the melt from dissolved gases by immersing deep inside DEGASIT tablets. 3. Immediately before casting we deoxidize the melt using a deoxidant CuP15% by immersing tubes with this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. 4. We bring the melt at the correct temperatute , we deslag with PERLAX FLUX. 5. We cast at the following recommended temperatures :
Casting section Cu-Sn-Zn-Pb < 15 mm 15-40 mm > 40 mm 83/ 3/ 9/5 1180 °C 1140 °C 1100 °C 85/5/5/5 1200 1150 1120 86/7/5/2 1200 1160 1120 88/10/2 1200 1170 1130
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ALLOY TYPE
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ALLOY CHEMICALDESIGNATION
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ALLOY NUMBER
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CASTING METHOD
GS = SAND GM= DIE CASTING GZ = CENTRIFUGAL GP = PRESSURE DC
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MELTING, METAL TREATMENT AND CASTING
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COPPER – ALUMINIUM (Auminium Bronzes)
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CuAl9
CuAl10Fe2
CuAl10Ni3Fe2
CuAl10Fe5Ni5
CuAl11Fe6Ni6
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CC330G
CC331G
CC332G
CC333G
CC334G
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GM / GZ
GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GM / GZ / GC
GS / GM / GZ
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GENERAL Excellent Copper-Aluminium alloy with high mechanical properties and resistance to corrosion. Aluminium Bronzes are susceptible to Hydrogen pick-up and heavy dross formation through melting, so good melting and casting practice is necessary for sound and defect free castings.
1. We melt under a cover of BRONZAL flux in a proportion 1 Kg for every 100 Kg melt. BRONZAL flux is added during the initial stages of melting. 2. When completely melted we add some more BRONZAL flux and we stir very well and deep inside in order to remove Alumina and oxides inclusion up to surface. 3. We leave the melt still for 2-3 minutes. Then we immerse deep inside the melt Deoxidant MnB based in Manganese/Boron. The tools must be painted with the protective coating TOOLCOTE.
Recommended casting temperatures : Casting section < 13 mm 13-38 mm > 38 mm 1250 °C 1200 °C 1150 °C
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COPPER – NICKEL Nickel Bronzes
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CuNi10Fe1Mn1
CuN130Fe1Mn1
CuNi3°Cr2FeMnSi
CuNi30Fe1Mn1NbSi
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CC380H
CC381H
CC382H
CC383H
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GS / GZ / GC
GS / GZ
GS
GS
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1. We melt under a cover of HALCOREX flux in a proportion 1 Kg for every 100 Kg melt. HALCOREX flux is added during the initial stages of melting in proportion 1 Kg HALCOREX for every 100 Kg melt. 2. We degas the melt from dissolved Hydrogen gases by immersing deep inside DEGASIT tablets. 3. We deoxidize the melt using a Deoxidant Magnesium based by immersing this deoxidant deep inside the melt. We always should care to paint the metallic tools with the protective coating TOOLCOTE. (ATTENTION : We should not use Copper Phosphor deoxidants since Copper-Nickel alloys harden with the addition of Phosphor.
Recommended casting temperatures : Casting section < 15 mm 15-40 mm > 40 mm 1400 °C 1350 °C 1280 °C
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