Partners

Advance Solutions from John Winter & Co. Ltd. Of United Kingdom

AF2Mg

1. AF2 is John Winter leading anti-veining powder additive. It is very effective even at low levels in preventing fins in castings. Finning or ‘veining’ can be a severe problem inside castings, hard to reach and hard to remove. AF2 is a class leading product sold globally. 
2. Small additions to the core sand of typically 0.5-0.7% of AF2MG at the sand mixing stage has helped to eliminate Veining, Sand fusion and Metal penetration defects
3. They are very potent but not suitable for components in which gas is an issue

AF6 & AF7

1. AF 6# & AF 7# is a powdered sand additive specifically developed to eliminate Silica sand expansion defects
2. Small additions to the core sand of typically 3-4% of AF 6# & AF 7# at the sand mixing stage has helped to eliminate Veining, Sand fusion and Metal penetration defects
3. No gas and does not reduce the core strength
4. Improve compaction and definition of the core and reduce blowing pressures/times
5. Eliminates veining in wide range of castings such as turbocharger, manifolds, axle housing and pumps etc.
6. Reduces metal penetrations

AF 182B

1. AF 182B it is an in inorganic blue powder sand additive
2. AF 182B is design for use with the cold box process and resin coated sand to eliminate fusion and veining, reducing rework and scrap.
3. AF 182B is having very low gas evolution, and minimal effects on core strength.

AF 194D

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ASI International, USA

Incorporation of EF40L with the charge can greatly improve melting efficiency and metal quality and is successfully used in all types of electric melting furnaces such as arc, coreless induction, as well as channel induction furnaces.

Redux EF40L flux additions improve melting efficiency and productivity.

EF40L eliminates slag build up on furnace walls, thereby providing a more constant furnace volume. Improved electrical efficiency resulting from reduced slag buildup can allow faster melting rates and reduce electrical loads.

EF40L is also very effective in reducing slag and spinel buildup in the inductor throats of channel furnaces.

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Chesapeake Specialty Products, INC. U.S.A

SphereOX, the Best Sand Additive for No-Bake Moulds and Cores, Resin Coated Shell Sand and Cold Box

SphereOX keeps resin use to a minimum and maintain tensile strengths while significantly reducing the amount of resin. (Cost savings from 17 – 34% can be expected).

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Carborundum Universal Limited (CUMI), Mumbai

Forace Group is an exclusive partner for India market with Carborundum Universal Limited, Mumbai for their complete range of Advance Refractory products including Neutral Ramming Mass.

Advance Refractory Solutions for Reducing Defects in Foundry

Refractories for Induction Furnace

1. Patch repair mass for side wall: Same chemistry for better adherence
2. DVM for sidewall working lining and top cap: Alumina based High CCS and TSR criteria
3. Plastic masses for spout
4. Precast shapes any requirement
5. Coil coating mass Alumina based fine coating mass

Neutral Ramming Mass for Induction furnace

Castables for Holding furnace

CUMICRETE CA 66
Maximum Service Temperature (oC)	1800
Bulk Density (g/cc) dried at 110°C/24 hr	2.80 Min.
Cold Crushing Strength (kg/cm2)	__
@ 110°C	600
@ 1000°C	450
@1550°C	750
Chemical Analysis (%)	__
Al2O3 (min.)	88
Fe2O3 (max.)	0.10

Refractories for Press Pour

1. DVM for Sidewall working lining & Top cap- Alumina, Zircon based. High CCS and TSR criteria.
2. LC/ULCC for upper case sidewall, spout, receiver, throat and floor.
3. Conventional castable 94% Al2O3 for working lining.
4. Plastic masses, Castables for spout.
5. Precast shapes for any requirement.

Castables for Ladles

	CA 392S	CA 85M
Maximum Service Temperature (oC)	1700	1650
Bulk Density (g/cc) dried at 110°C/24 hr	2.70	2.6
Cold Crushing Strength (kg/cm2)	__	__
@ 110°C	550	500
@ 1550°C	550	550
Chemical Analysis (%)	__	__
Al2O3 (min.)	87	84
Fe2O3 (max.)	1.5	1.8

Pour boxes, Launders, Tundish and Consumables

Castables for Tundish and Autopour

Precast Pre-Fired Refractories

1. Special Alloy Pouring Cups – CUMILOX 45V
2. Small Tundish for Special Alloy – CUMILOX 45V
3. Small Ladles/ Crucible – CAST CUMILITE HF
4. Tundishes – CUMI CAST EF 951M
5. Precast Pad – CUMI HICAST SUPER
6. Collar and Top Block – CUMILOX 45V
7. Top block – CUMI HICAST SUPER
8. Bottom block – CUMI HICAST SUPER

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MCM Foundry, Italy

Forace Group is an exclusive partner for India market with MCM Foundry, Italy for their Foundry Equipment Solutions.

MCM Foundry Provides

1. Designing and manufacturing of machines and plants for No-Bake foundry
2. Designing and developments of new equipment for foundry 4.0
3. Refurbishing of second hand machines and plants
4. Technical service and commissioning of existing plants
5. Maintenance service for machines and plants for foundries
6. Spare parts for existing machines and plants
7. Technology and process consulting for foundries
8. Engineering of new projects

Product Range

1. Single arm mixers (Capacity from 1 to 20 MT/h)
2. Double Arm Articulated Mixers (Capacity from 10 to 100 MT/h)
3. Vibrating tables for sand compaction
4. Moulding lines
5. Manipulators for flask and/or mould handling
6. Shake out grids
7. Sand reclamation systems
8. Sand pneumatic transport systems
9. Special machines

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VIBROPROCESS, Italy

VIBROPROCESS Vibratory equipment are utilized for the simplest up to the most challenging continuous processes where the handled products have 1000°C temperature.

1. Extracting
2. Feeding
3. Conveying
4. Dewatering
5. Drying and cooling

…and many others challenges inside the process plant are carried out by Vibroprocess vibratory equipment.

Their equipment is used in various areas of the foundry: from feeding the furnace, to cooling and transporting the castings, passing through green sand or sand-resin shakeout. They also offer applications for the processing lines, that collects and cools the sand before delivering it back to the sand plant.

Forace Group is an exclusive partner for India market with Vibroprocess, Italy for their Vibrating Machines.

Vibroprocess handle

1. Cast Iron
2. Steel
3. Copper
4. Brass
5. Aluminum
6. Ferro Alloys
7. Foundry Sand
8. Castings
9. Scraps

Equipments they provide

1. Melting Charging Feeders
2. Continuous Shake out
3. Casting Coolers
4. Shake Out Tables
5. Shake Out Drums
6. Sand Feeders
7. Sand Coolers
8. Casting/ Sand Resonance Conveyors
9. Vibrating Screens

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Filters

Complete Solution to Metal Filtration- Silicon Carbide Foam Filter

1. Silicon foam filters helps to enhance quality of castings and reduce cost
2. Designed for filtering ductile iron, grey iron and copper alloy castings
3. High porosity (80% – 90%), high thermal shock resistance and large specific surface, compared with other traditional filters
4. Reduce defect rate of castings
5. Improve mechanical properties of castings
6. Simplify pouring systems and increase ratio of mould

SiC Filters Reduce

1. Gas and Inclusions
2. Turbulence Level
3. Surface Defects
4. The rejection rate of castings

SiC Filter improves

1. Mechanical properties of castings
2. Surface finish of castings
3. Filling capacity of melt
4. Casting yield

Complete Solution to Metal Filtration- Zirconia Foam Filter

Drache, Germany

Forace Group is an exclusive partner for India market with Drache, Germany for their Zirconia Foam Filter.

Drache has been offering innovative and sustainable products and systems in foundry technology. They pay attention to the highest quality standards and innovative technologies.

Flow Modification

1. Aid in the homogenous filling of the mould. This reduce the risk and erosions and minimises the reoxidations of metals

Removal of Impurities

1. Removes both small and big inclusions
2. The large inclusion is held back on the surface of the filter and the smaller ones get trapped in its complex structure

Solution for inclusion problem

1. Cerazirk ZrO2 Filter
2. Cerazirk LD Filter

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Ceramic Sand

Forceram Spherical Ceramic Sand for Foundry

1. Replacement of Chromite Sand with 20% Cost Saving
2. Prevent Sand expansion defects
3. Less resin consumption and gas defects
4. Wide choice of particle size

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Chromite Sand from South Africa

1. Providing particles size as per customer requirement
2. Available in ready stock

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High Performance Long Life Die Coats for LPDC and GDC from John Winter, U.K.

1. Dytek range of insulated coatings are for use in low pressure and gravity die casting applications.
2. Helps to increase productivity and reduce the downtime
3. Give a “Longer Life” (LL) protection of the die – more shots per application
   • Made from highly insulating refractory materials, bonded together with a higher heat resisting binder gives longer protection to the die from wear and erosion caused by repeated exposure to hot molten metal.
4. Provide insulation enabling control of cooling and solidification – reduced porosity
   • A range of coatings that can be used to insulate specific parts of the die to promote directional solidification.
5. Lubricate enabling easier release of the casting from the die – less damage to die.
   • In difficult cases Dytek G is specifically designed solid lubricant based costing to be applied on top of an insulating coating to ease release of the casting from the dye.
6. Provide a smooth surface – producing a high quality surface finish
7. Textured to enable enhanced metal flow reducing cold shuts and entrapped gas.
   • Using an engineered blend of refractory and or insulating components of specific particle size creates the surface texture required for the specific customer application.

John Winter has multiple grades for various applications

Sno.	Dytek	Application
1	S	High insulating smooth coating.
2	S LL	High insulating smooth coating with enhanced Long Life.
3	M	Textured Insulated coating designed to promote metal flow and reduce entrapped air. Ideal for the production of thin and flat surfaced castings.
4	G	Graphitic based coating used to enable release of the casting from the die. Designed to be applied on top of insulated coating.
5	T	Titanium Oxide coating produces a very smooth surfaces. Predominantly used in the production of alloy wheels on top die faces which produce the visible part of the wheel.
6	V	Highly insulating textured coating for the production of thin sectioned castings.
7	SI	Smooth Low-cost general-purpose coating.
8	D	Two part smooth insulating coating exhibiting excellent durability ideal for high volume general purpose castings.
9	Zr	Zircon / Red Iron oxide primer used to protect the dies and help with the adhesion of insulted top coating. The red colour enables visual confirmation when the top coating has worn.
10	Hardner	Used to increase bonding strength in cases of high dilution rates.

Boron Nitride Coating – BNH2O

JW BN H2O is a water-based Boron Nitride Coating.

Main applications are within aluminium cast houses and foundries as well as magnesium casting.

JW BN H2O can be applied to refractory parts, ceramic parts as well as metal surfaces.

The coating may be applied to components like e.g.: transition plates, thimbles, filterboxes, launder segments, header plates, distribution troughs, ladles, etc.

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JODOVIT S.r.l., Italy

The whole range of JODOVIT materials for non-ferrous foundry is totally free from:

1. nonylphenol formaldehyde
2. fluorine

LUBRAX SOLUTION FOR HIGH PRESSURE DIE CASTING

1. LUBRAX COLATE (release agent)
2. LUBRAX OIL (start-up oil)
3. LUBRAX Graph (anti-solder paste)
4. LUBRAX OIL (plugger oil lubricants)
5. LUBRAX POW GRAPH (plugger wax lubricants)
6. LUBRAX CUPRUM (high temperature grease)
7. LUBRAX Cleaner (cleaner for all machines parts)
8. LUBRAX Paste TW (protection coatings for cup)
9. LUBRAX TW 201 SW (protection coatings for cup)

LUBRAX

New generation of Lubricants for the production of Aluminum castings in high and low pressure die-casting.

Benefits:

1. improvement of casting efficiency
2. reduction of impact on casting porosity
3. increase shot component life
4. Lower usage rates to minimize costs
5. High degree of thermal stability
6. Smooth defect free surfaces

Boron Nitride Coating

SCHELL:X BN 33 is a product that, after the evaporation of water, forms a lubricating, detaching and protective film based on boron nitride, resistant to high temperatures. This film is resistant to the aggression of molten non-ferrous alloys and, in addition to a protective action, performs a good lubricating power.

It is an excellent release agent for high temperatures towards aluminum, magnesium, zinc and lead alloys, used to protect cups, pouring channels, pressure heels and all ferrous surfaces that come into direct contact with these melted alloys.

It adheres well to metal, ceramic and aluminum-titanium surfaces.

LUBRAX BOROCOMPOUND R is a product that, after the evaporation of water, forms a lubricating, detaching and protective film based on boron nitride, resistant to high temperatures (about 1000 ° C in natural atmosphere). This film is resistant to the aggression of molten non-ferrous alloys and, in addition to a protective action, performs a good lubricating power.

It is an excellent release agent for high temperatures towards aluminum, magnesium, zinc and lead alloys, used to protect cups, pouring channels, pressure heels and all ferrous surfaces that come into direct contact with these melted alloys. It adheres well to metal, ceramic and aluminum-titanium surfaces.

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SUMA Robotic, Turkey

SUMA specialists offer training about the operation and optimal use of our machines, aimed to plant managers and machine operators.

Core Shooters: Fast, Precise & Eco-Friendly

For Cold Box, Inorganic & Hot Box Processes

1. Vertical and Horizontal Core Production
2. Hydraulic and Electric driven option for machines with shoot volume of 15 to 40 Litres
3. Hydraulic option for machines with shoot volume of 40 to 150 Litres