Materials Technology and Engineering Company

PRODUCTS FOR COPPER FOUNDRIES cfp en-copper29-cu-63-546 cfp en-copper-raw

 

I. PRODUCTS FOR CRUCIBLE FURNACES
A. Graphite crucibles (traders)  

A series of graphite crucibles of various types and sizes

Crucible catalogue and drawings

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

 

 

 

C. Products for melting copper and copper alloys

 
1. Melting fluxes

• Copper

 

  

HALCOREX

Oxidizing conditions flux that prevents the gas pickup in the melt.

  

• Brasses

cfp en-brasses

 

BRASSIT

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

• Bronzes

 

HALCOREX

Oxidizing conditions flux that prevents the gas pickup in the melt.

• Aluminium Bronzes

cfp en-aluminium-bronzes

 

  

BRONZAL

Flux for protection during melting and for the aluminium oxides removal from the melt.

• Manganese Bronzes

 

BRONZAL

Flux for protection during melting and for the aluminium oxides removal from the melt.

• Nickel Bronzes

 

HALCOREX

Oxidizing conditions flux that prevents the gas pickup in the melt.

• Fine brass melting

 

 

SCRAPIT

Reducing conditions flux that prevents oxidation and zinc losses during fine brass melting.

• Removal of excess aluminium from sand cast copper melts

 

ALUMINAL

Flux that removes excess aluminium from the melt.

 

• Slag removal

 

PERLAX

Coagulant flux for slag removal.

 

 

2. Degassing tablets

DEGASIT (traders)

Tablets for the removal of gasses from the melt and to prevent the formation of pores and inclusions in the castings.

 

 

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.

 

 

 cfp en-products-for-the-ladle
III. PRODUCTS FOR MOULDING

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
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.

  

 

 

 

Materials for the Copper Foundry

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

Melting and Casting Procedures

COPPER ALLOYS EN 1982 : 1998

ALLOY
TYPE

ALLOY
CHEMICALDESIGNATION

ALLOY
NUMBER

CASTING
METHOD

GS = SAND
GZ = CENTRIFUGAL
GP = PRESSURE DC

MELTING, METAL TREATMENT AND CASTING

COPPER

Cu

CC040A

GS / GM

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

COPPER -
ZINC

(BRASSES)

CuZn33Pb2

CuZn33Pb2Si

CuZn35Pb2Al

CuZn37Pb2Ni1AlFe

CuZn39Pb1Al

CuZn39Pb1AlB

CuZn15As

CuZn16Si4

CuZn25Al5Mn4Fe3

CuZn32Al12Mn2Fe1

CuZn34Mn3Al2Fe1

CuZn35Mn2Al1Fe1

CuZn37Al1

CuZn38Al

CC750S

CC751S

CC752S

CC753S

CC754S

CC755S

CC760S

CC761S

CC762S

CC763S

CC764S

CC765S

CC766S

CC766S

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

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.



ALLOY
TYPE

ALLOY
CHEMICALDESIGNATION

ALLOY
NUMBER

CASTING
METHOD

GS = SAND
GM= DIE CASTING
G Z= CENTRIFUGAL
GP = PRESSURE DC

MELTING, METAL TREATMENT AND CASTING

COPPER – TIN

(Bronzes)

CuSn10

CuSn11P

CuSn11Pb2

CuSn12

CuSn12Ni2

CC480K

CC481K

CC482K

CC483K

CC484K

GS / GM / GZ / GC

GS / GM / GZ / GC

GS / GZ / GC

GS / GM / GC / GZ

GS / GZ / GC

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

CuSn11P

CC481K

GS / GM / GC / GZ

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

COPPER - TIN - LEAD

(Leaded Bronzes)

CuSn3Zn8Pb

CuSn5Zn5Pb5

CuSn7Zn2Pb3

CuSn7Zn4Pb7

CuSn6Zn4Pb2

CuSn5Pb9

CuSn10Pb10

CuSn7Pb15

CuSn5Pb20

CC490K

CC491K

CC492K

CC493K

CC498K

CC494K

CC495K

CC496K

CC497K

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

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



ALLOY
TYPE

ALLOY
CHEMICALDESIGNATION

ALLOY
NUMBER

CASTING
METHOD

GS = SAND
GM= DIE CASTING
GZ = CENTRIFUGAL
GP = PRESSURE DC

MELTING, METAL TREATMENT AND CASTING

COPPER –
ALUMINIUM
(Auminium Bronzes)

CuAl9

CuAl10Fe2

CuAl10Ni3Fe2

CuAl10Fe5Ni5

CuAl11Fe6Ni6

CC330G

CC331G

CC332G

CC333G

CC334G

GM / GZ

GS / GM / GZ / GC

GS / GM / GZ / GC

GS / GM / GZ / GC

GS / GM / GZ

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

COPPER –
NICKEL
Nickel Bronzes

CuNi10Fe1Mn1

CuN130Fe1Mn1

CuNi3°Cr2FeMnSi

CuNi30Fe1Mn1NbSi

CC380H

CC381H

CC382H

CC383H

GS / GZ / GC

GS / GZ

GS

GS

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