C OAT I N G S F I LT R AT I O N FEEDING SYSTEMS M E LT S H O P R E F R A C TO R I E S M E TA L L U R G I C A L A N D P O U R I N G C O N T R O L BINDERS CRUCIBLES

FDU FOUNDRY DEGASSING UNIT

EQ U IP M EN T & C O N SU MA BLES

+ Hydrogen removal

+ Oxides and inclusions removal

+ Controlled upgassing

+ Highly efcient rotor designs

+ Reliable and consistent equipment

 FDU Foundry Degassing Unit
For the improvement of quality of non ferrous castings

FDU foundry degassing units are a melt treatment The advantages

system for the degassing and cleaning of aluminium
alloys in foundries. + Reproducible results
+ Short treatment time
All FDU units use the impeller principle with + Reduced gas porosity and hard inclusions in
patented rotor designs which mixes fine inert gas castings
(usually Nitrogen or Argon) with the melt. The gas + Reduced machining costs
bubbles are distributed widely through the melt + Consistent mechanical and physical properties
whilst maintaining a smooth melt surface. This + Environmentally friendly
results in short treatment times, effective degassing
and melt cleaning.

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The FDU product range covers a number of machines FDU ROTOSTATIV FDU
for transport by crane or fork-lift truck, mobile and Compact assembly ROTOSCHWENK
static units. The degassing equipment is used for on the ground; For assembly on
transport ladles and free standing crucible furnaces. a manual arm the ground and
All machines are custom-made and adapted to swivel (optional) electrically arm
foundrys requirements and needs. An advanced provides easy movement for
control system enables the operator to program acces to furnace or process automation
various parameters; the degassing treatment runs transport ladle. and multi-position
automatically without any operator involvement once use.
the process has been started.
A team of Foseco specialists commissions the
equipment, optimises the treatment parameters and
trains the operators.

FDU FDU MARK 10 FDU ROTODRIVE

MINIDEGASSER For treatment in Battery operated
Compact design transport ladles trolley for moving
for placing on top or furnaces, easily into treatment
of a crucible or pushed manually position and for
ladle by means of into position. long-distance
crane or fork-lift movement.
truck.

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 Degassing consumables
For the improvement of quality of non ferrous castings

Graphite shafts Graphite shafts

+ 
Graphite rotors are used in connection with the - 45 mm, 700 mm long
corresponding graphite shafts. Various rotor designs - 75 mm, up to 1200 mm long
and diameters can be combined with shafts in - 95 mm, up to 2300 mm long
different lengths and types. This procedure provides
maximum flexibility to suit almost all crucible and INSURAL* baffle plates
transport ladle designs. Vacuum impregnation of the A baffle plate is placed near to the graphite shaft
graphite consumables ensures a long life. and guarantees a smooth melt surface during
treatment. It is available in different shapes and
Graphite shafts are available with two different lengths.
connections to the degassing unit:
Quick-lock or clamp coupling for BKF type shafts
and screw coupling for DSK type shafts.

FDU graphite shaft and INSURAL baffle plate

FDU BKF types of shaft

45

75

95

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 hydrogen content (ppm)

temperature
The rotor design is the key for optimal cleaning and The degassing effect has been plotted online
degassing the melt; rotors must fulfill the following with Fosecos ALSPEK* H hydrogen analyser. The
functions: diagram illustrates a typical curve for hydrogen treatment time (min)
+ small size of purge gas bubbles concentrations in aluminium. The rate of degassing SPR
+ homogeneous bubble distribution across the under consistent test conditions in achieving a Curve for XSR
temp. (C)
whole volume target level of 0.08 ppm of hydrogen in the molten hydrogen content
in aluminium
+ good melt movement and mixing material was 0.03 ppm H2/min with the XSR rotor.
+ low melt surface movement The degassing rate for the SPR rotor was 0.02 ppm
H2/min, 50% less.
Foseco intensively investigate existing rotor designs
combined with theoretical studies, simulations, For detailed information refer to Foundry Practice
extensive modelling and practical tests to further 241 (2004).
improve the degassing performance.
MTS FDR high-performance rotor
FDU XSR graphite rotor The MTS FDR high efficiency rotor is a further
The XSR rotor type can be combined with all development of the SPR and XSR types range.
graphite shafts. Different diameters from 140 to An innovative design is the key for its advanced
250 mm fit nearly all geometries and sizes of functionality for good degassing performance and
treatment vessels. Turbo cuts in the upper section optimal melt homogenisation during MTS 1500 FDU XSR rotor
of the rotor further reduce the size of the inert gas application. Furthermore it is suitable for degassing
bubbles thus maximising the surface area of the of ladles or crucibles with difficult geometries.
bubbles for a given volume of treatment gas. Degassing runs at reduced speed in order to extend
the service life of the graphite shaft as abrasion is
reduced.

MTS FDR rotor

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 Degassing simulation
Software to analyse batch degassing processes

Rotary degassing of liquid aluminium alloys is a A selection of different Foseco degassing rotors has
widely used commercial process to control levels been characterised in a comprehensive experimental
of hydrogen, alkali metals and inclusions in the program. Tests have been carried out in both water
melt, prior to casting. A comprehensive theoretical model and during foundry trials. The study results in
understanding of the kinetics of aluminium an Internet based simulation software for degassing
degassing has been established in the past twenty processes in foundries.
years.

Screen shot

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The software enables the operator to characterise Diagram 1
the degassing process with an extended parameter The curves in diagram 1 compare the degassing
list for data input: efficiency of different rotor designs.

+ Pre-set crucible and ladle sizes Diagram 2

+  Pre-set alloy compositions The curves in diagram 2 compare the degassing
Diagram 1
+  Different ambient conditions efficiency of different FDU XSR rotor diameters.
+  Starting level of hydrogen
+  Operating conditions like melt temperature, gas Diagram 3
flow rate, rotor speed and diameter Diagram 3 shows an upgassing process using an inert
Treatment time
+  gas-hydrogen-mix.

Based on input data the software calculates a

degassing curve hydrogen content vs. time. It is
possible to draw degassing curves of different rotor
design and rotor diameters in one diagram. The
software compares the hydrogen removal efficiency
and total consumption of inert gas for each rotor.
Diagram 2
A full report about the batch degassing software is
available in Foundry Practice Issue 256.

For more information and a demonstration please

contact the local Foseco representative.

Diagram 3

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 FDU
Service and further options

MTS 1500 automated metal treatment process is A temperature measurement system is an option
available for nearly all types of FDU. to enable foundries to monitor and control the
degassing process. In many cases it is therefore
possible to save both energy and costs. Additionally
a PLC interface can be provided to collect and
transfer treatment data.

The use of Mass Flow Controllers provides a

temperature and pressure independent control
of the inert gas flow during the rotary degassing
process. A separate setting of flow rates for each Flow rate display

program provides high flexibility, the actual flow

MTS 1500 automated Metal Treatment Station rate is displayed on a touch screen. The N2-H2 mixed
gas addition for upgassing melt is also availble with
mass flow controllers.

Foseco is continually developing new and improved

products and services to boost melt treatment
efciency and effectiveness. Our service team would
be pleased to answer any further questions you may
have.

Training and service N2-H2 mixed gas control

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05/2015 e

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