Non-Ferrous

Hot Topping

Hotex 54

Product Description
HOTEX 54 is a quality hot topping compound, reddish in colour, comprised of carefully graded aluminum particles and chemical sensitizers, blended with selected refractory minerals.

Product Characteristics
When ignited, HOTEX 54 produces an exothermic reaction and a resultant self-heated highly insulating material. The physical and chemical reactivity of the product is scientifically controlled to make it ideally suitable for application to open molten metal surfaces of aluminum and non-ferrous metals. It can also be used with ferrous alloys and has proven to be very beneficial in the production of investment castings where a high heat output and sensitivity are important.

Product Application
1. Apply the product to the molten metal surface as soon as possible after pouring.
2. For open risers the thickness of the layer of HOTEX 54 applied to the surface should be at least 10% (0.1) of the riser diameter.
3. For application to molten metals in holding ladles, etc., the application thickness should be based on in-plant experience, but take into consideration:

a) the exposed surface area of the molten metal
b) the time the molten metal is to be held; the longer the time, the greater the thickness.

Advantages
• HOTEX 54 will improve riser performance by delaying the solidification time of the riser, thereby enhancing directional solidification. This is accomplished by preventing skin formation on the metal surface which allows the full influence of atmospheric pressure to remain in effect during the solidification of the casting.
• The permeable self-heating crusted insulating layer, produced by the exothermic reaction, can be easily removed from metal surfaces thereby minimizing the possible contamination of molding sand during shake-out.

Packaging
In cardboard drums @ 500 lbs.

Aluminum Fluxes

NS-511 Flux

Flux for Removing Oxides and Cleansing Molten Aluminum Alloys with Little Smoke and Fumes

Product Description
NS-511 flux is off-white granular mixture of inorganic salts.

Purpose
• Minimize oxidation and hydrogen pick-up during melting.
• Facilitate easy removal of dross. – Aid in the removal of oxides and non-metallic impurities.

Product Characteristics
A mild exothermic reaction with the dross takes place producing a surface cover or protective coating against molten metal oxidation, facilitating the removal of the aluminum oxide or other metallic oxides and producing a dry powdery dross low in metallic content.

NS-511 flux is used in wells, bull ladles, crucibles, holding and reverbatory furnaces and the middle of the operating temperature range.

Product Application
• Best results are obtained at metal temperatures of 1285ºF to 1390ºF.
• Do not expose flux to direct flames.
• Reverbatory furnaces: turn off burners before applying flux.
• Large furnaces: apply at the rate of ¼ lb. per ft2 of surface area of molten metal to be treated.
• Small furnaces: 4 ozs. per 100 lbs. of metal to be treated.
• A black dross indicates the use of too little flux.
• A white hot dross indicates the use of too much flux.
• A cherry red dross indicates the use of a sufficient amount of flux.
• Rabble or stir flux layer into the molten aluminum bath with a hoe to collect the oxides floating in the metal and accumulate these oxides at the surface.

Packaging
In cardboard drums @ 500 lbs.

SF-225

Sodium Free Flux for Oxide Removal and Cleansing of Aluminum Alloys and Aluminum/Magnesium Alloys

Product Description
SF-225 flux is an off-white to grayish colored powder comprised of a mixture of sodium (Na) free inorganic salts.

Purpose
• Facilitate the easy removal of oxide laden drosses from the surface of molten aluminum alloys without undue magnesium loss.
• Aid in the separation of aluminum and magnesium oxides from molten aluminum alloys.
• Produce drosses low in metallic content.

Product Application
• Before application, turn to low, or preferably shut off fire in melting furnaces.
• Apply SF-225, with a shovel or flux gun, in sufficient quantity…. (usually about ½ pound per sq. ft.) to the molten metal and oxide layer.
• Rabble the flux with a pre-heated tool coated with SFP specialty coating R-20, into the molten metal.
• Continue to “work” the flux until a dull cherry red dross is formed. Carefully remove any oxide build-up from the furnace walls and allow to remain in the dross.
• Remove the dross with a suitable skimmer or a ladle with 3/8 in holes drilled through it, allowing molten metal globules to drain back to the melt.
• Transfer the dross to a suitable dross container or dross wringer.

Packaging
In cardboard drums @ 500 lbs. or in 5 gallon pails @ 60 lbs.

CR-1075

Product Description
CR-1075 is a granular, odourless, off-white to greyish coloured mixture of inorganic chemicals.

Purpose
• To facilitate the removal of small amounts of undesirable calcium form molten aluminum alloys, when its presence may be at levels of detrimental to the quality of the finished product.
• Aid in the separation and absorption into the dross of undesirable non-metalic impurities which may have been present in the charge material or formed during the melting cycle.

Guidelines For Use
• Due to the complexity of the reactions which take place with various alloying and trace elements present in molten metal at elevated temperatures, it is not possible to be precise as to the quantity of CR-1075 to use in a given application. However, practical experience has shown that about 4lbs. of CR-1075 will remove about 1lb. of calcium, with the initial calcium level in the order of the 0.008% and the final calcium content in the order of 0.002%.
• Use good melting practices – use AMCOR cover fluxes during melting keep furnaces clean – remove drosses before applying CR-1075.
•Use in the temperature range of 1320°F – 1480°F. Application of CR-1075 at temperature below 1320° reduces the efficiency of calcium removal.
• Spread CR-1075 over the melt surface and stir or rabble into the molten metal with the intent of exposing as much metal as possible to the flux. The taken time for the application will be from 5 – 15 minutes, depending upon the size and temperature of the melt.
• CR-1075 is very efficient when used as a surface cover, in conjunction with the INJECTAFLUX unit for introducing fluxes/composites into the molten metal and INJECTAFLUX IJ 5, Or INJECTAFLUX SF 5, fluxes for degassing and cleansing molten aluminum, with the latest molten metal treatment methodology.
• Read the MSDS before using.

AMLOX-39 and AMLOX-41

Fluxes for Protecting and Cleansing Molten Aluminum Alloys

Product Description
AMLOX-39 and AMLOX-41 are off white granular mixtures of inorganic salts.

Product Characteristics
These fluxes are grouped together because of their similarities in purpose  and application. However, AMLOX-39 will react quicker at lower temperature than AMLOX-41 and is preferred for use at a lower metal operating temperatures and AMLOX-41 is preferred at higher operating temperatures.

Mild exothermic reactions take place permitting globules of metal to fall back into the molten metal, or collect at the bottom of a dross pan. Working the flux/dross with a rake will increase the intensity of the reaction, while spreading it out will decrease (cool)  the intensity of the reaction.

Purpose
• Minimize oxidation during melting and holding periods
•Aid the removal of non-metalic impurities
• Minimize dross formation
• Minimize metallic content of drosses
• Reduce melt losses
• Soften oxide build-up on furnace walls, permitting easier removal
• Improve overall casting quality

Guidelines For Use
• Apply AMLOX in sufficient quantity to treat all of the metal being melted. Due to the differences in furnace operating procedures and type of charges being used (scrap/ingot ratios, dirty or clean returns) and the rate of metal withdrawal from the furnace makes it difficult to establish a specific amount of flux to be used. However, the following offer some guidelines as a starting point in a given operation.
• Cover the surface of the molten metal heel with about 1/4lb. of flux/sq. ft. of surface area and continue to charge the metal with a small amount of AMLOX (1/2 – 1 lb./ 1000 lb. of metal) until furnace is full.
• Rabble the flux into the immediate surface of the molten metal until it becomes cherry red.  Let stand for a short period of time.
• Remove the dross periodically, experience will determine how often to prevent excessive dross build-up and keep the metal clean.
• Consistent use of AMLOX will keep the furnace clean but in severe cases of oxide build up, AMLOX can be applied directly to the build-up, at the rate of 1/2 lb./sq. ft. of area.

 

INJECTAFLUX  IJ5,  SF5  and TB7

Aluminum Fluxes for Use with the INJECTA Autofluxing System

Product Description

INJECTAFLUX is AMCOR’s trade name for a group of aluminum fluxes developed for use in the flux injection process and in particular, for use with AMCOR’s INJECTA system for introducing fluxes into molten metals.

These fluxes are mixtures of inorganic salts formulated to be particularly effective when introduced into molten metal with an inert gas, such as nitrogen or argon.

The use of a combination of a chemically reactive flux in combination with an inert gas, preferably nitrogen, offers the latest advance in metal treatment technology whereby undesirable elements are removed by chemical and physical means at the same time. Conversely desirable elements to bring about metal structure refinement and modification can also be effectively added.

Purpose
• Efficient removal of hydrogen
• Efficient removal of oxides
• Efficient grain refinement
• Effective modification of silicon in eutectic alloys
• Effective magnesium removal
• Reduce treatment times by approximately 1/2 when compared with straight gas treatments of nitrogen, argon on SF6.
• Reduce dross and metal retained in the dross by 1/2

 

 

 

Copper Based Alloys – B Series Fluxes

B12

Copper -Commercial (copper content in excess of 95% with small amounts of tin and zinc)

Product Application
Oxidizing atmosphere and protective cover to prevent hydrogen pick-up and cleanse the metal during melting. Deoxidize with phosphor-copper immediately before pouring.

Guidelines for Use 
1 lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge . Skim thoroughly before pouring.

Brasses – Red and Leaded Red (typically 2-8% zinc, tin less than 6% and lead up to 7%)

Product Application
Oxidizing atmosphere and protective cover to prevent hydrogen pick-up and cleanse the metal during melting. Deoxidize with phosphor-copper immediately before pouring.

Guidelines for Use 
1 lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge . Skim thoroughly before pouring.

Brasses – Semi Red and Leaded Semi Red (typically 8-15% zinc, tin less than 6% and lead up to 7%)

Product Application
Oxidizing atmosphere and protective cover to prevent hydrogen pick-up and cleanse the metal during melting. Deoxidize with phosphor-copper immediately before pouring.

Guidelines for Use
1 lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge . Skim thoroughly before pouring.

Bronzes – Tin and Leaded Tin (typically up to 20% tin, up to 5% lead, 0-5% zinc, and 0-5% nickel)

Product Application
Oxidizing atmosphere and protective cover to prevent hydrogen pick-up and cleanse the metal during melting. Deoxidize with phosphor-copper immediately before pouring.

Guidelines for Use 
1 lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge . Skim thoroughly before pouring.

Copper – Nickels – Cupro Nickel, Nickel Silver, Leaded nickel silver and Monel (typically nickel over 10%, zinc less than nickel and lead up to 25%)

Product Application
Oxidizing atmosphere and protective cover to reduce the undesirable effect of sulphur and carbon contamination. In the case of alloys free of zinc, also to prevent hydrogen pick-up. Deoxidize before pouring.

Guidelines for Use 
1½ – 2 lb. per 100 lb.’s
1½ lbs. to molten heel or with first charge. ½ lb. to be stirred into (plunged) 5-10 mins before pouring. Skim thoroughly before deoxidization and pouring.

B15

General Purpose Flux for Brass, Bronze and other Copper Alloys

Product Description
B-15 flux is off-white granular mixture of inorganic salts. The ingredients of the flux will not attack the crucible or furnace lining.

Purpose
• Minimize oxidation and hydrogen pick-up during melting.
• Facilitate easy removal of dross.
• Aid in the removal of oxides and non-metallic impurities.

Product Characteristics
B-15 flux provides a metal cleaning action, a neutral protective barrier to reaction with the atmosphere and releases the metal entrained in the dross layer. The flux melts about 1370ºF and covers the dross-metal surface with a molten flux layer that resists zinc loss from the melt oxidation and pick-up of hydrogen from the atmosphere over the melt. The flux layer provides a cleaning action to remove accumulated build-up from the sides of the crucible or furnace lining. With the presence of a film of liquefied flux the metal trapped in the dross is essentially released into the metal bath. After the metal separation the formed oxides and other impurities retained in the dross can be easily removed.

Product Application
B-15 flux is suitable for all copper alloys melted in crucible, electric induction or reverbatory melting furnaces. From ¼ to ½ pound of flux is required per 100 pounds of metal in the furnace. Larger amounts of flux are necessary when fines and returns are melted; smaller amounts are required for ingot melting. About one-half of the flux is charged with the metal and one-half added to the bath surface after melt down is complete. After the required alloy additions are made and the melt brought to pouring temperature, the dross layer formed by the flux is then skimmed from the surface in collected segments.

Packaging
In cardboard drums @ 500 lbs.

 

B16

Copper – High Conductivity (copper content in excess of 98%,  and electrical conductivity greater than 85% I.A.C.S)

Product Application
Reducing the atmosphere and protective cover to minimize oxygen pick-up and reduce deleterious effect on electrical conductivity. Use calcium boride or lithium for deoxidation.

Guidelines for Use 
1½ – 2 lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge. Skim thoroughly before pouring.

B89

Brasses – Yellow and Leaded Yellow (typically over 15% zinc,  tin less than 6% and lead under 3%)

Product Application
Minimize or prevent zinc fuming and metal loss. Provide a cover for absorbing and agglomerating non-metallic impurities during melting and holding.

Guidelines for Use 
½ – 1½  lb. per 100 lb.’s
One half the required amount to molten heel or with first charge. Remainder with final charge. Skim thoroughly before pouring.

B91

For Aluminum, Manganese and Silicon Bronzes

General Description
Aluminum, manganese and silicon as alloying agents in copper base alloys have a strong attraction to oxygen and if not controlled, they form heavy dross. In addition to melt loss, oxidation and dross formation will result in reduced fluidity during casting and can also contribute to poor mechanical properties.

B-91 FLUX forms a protective fluid cover on top of the melt, reducing or preventing oxidation. It dissolves oxide films, releasing entrapped metal back to the melt, thus reducing melt losses. Agglomeration of these oxide films facilitates their easy removal from the crucible or furnace. By collecting these oxides from the metal bath, B-91 Flux improves the fluidity of the melt increasing the feeding properties of the alloy.

The reduction of dross formation reduces the build-up on crucibles which is usually associated with these alloys.

Application
When melting in crucible furnaces, about ½lb. of B-91 Flux per 100lbs. of melt is added to the charge. This should be enough to form the protective cover over the molten metal. About ten minutes before casting, plunge about ¼lb. B-91 FLUX per 100lbs. of melt to the bottom of the crucible. Stir thoroughly to bring as much metal as possible into contact with the flux. All the dross and oxides can then be skimmed off. B-91 FLUX produces skimmings with a low metallic content.

When melting in electric induction furnaces, about 0.5% by weight of the charge is added to the heel of the previous melt. B-91 FLUX will form protective cover while the melt-down is taking place. After charge material has melted, enough B-91 FLUX is added to maintain a reasonable cover on the surface. B-91 FLUX is skimmed off just before pouring.

Packaging
B-91 FLUX is available in 150lb. and 500lb. polyethylene lined fiber drums.

 

B93

Bronzes – High Leaded Tin (Typically up to 20% tin, over 10% lead and sometimes up to 3% of zinc)

Product Application
Protective cover to prevent hydrogen, hydrocarbon and sulphur pick-up during melting. Cleanse the metal of tin and lead oxides. Prevent lead segregation.

Guidelines for Use
½ lb. to molton heel or with first charge: superheat and thoroughly stir in (plunge) remainder ½ lb., wait 5 mins. before skimming and pouring.

 

Zinc

Z-33

Flux for Protecting and Cleaning Molten Zinc Alloys

Product Description
Z-33 Zinc Flux is an off-wite granular mixture of inorganic salts.

Purpose
• Remove oxide and non-metallic impurities from molten zinc alloys.
• Minimize magnesium loss from zinc alloys containing magnesium.
• Produce a dry dross at temperatures between 800°F – 900°F
• Maximize release of metallic globules from the dross to the molten metal bath.
• Produce a dry dross with sufficient retained heat to permit further processing in a mechanical dross wringer

Application
• Apply Z-33 in small increments up to approximately 3 lbs./1000 lbs. of molten metal to be treated. More flux will be required to treat oily, dirty, nickel and chrome plated scrap to produce a powdery dross.
• Work the flux into the dross layer with a hoe that has a blade about 10 inches  wide and 5 inches deep. If necessary, a 1 H.P. mixer with an 8 inch, 3 blade propeller can be used to further reduce the broken-up dross
• Rake the dross with a suitable tool to release metallic globules from the dross back into the molten metal bath. If the dross layer is not a powdery condition an insufficient amount of Z-33 has been used.
• Remove the dross, with a perforated skimmer or a ladle with holes drilled through the ladle, and place it in a dross container, a reclaiming dross pot or a mechanical dross wringer.