Foseco’s sand mold and core coating products help foundry operators achieve the best available casting surface finishes at the highest possible level of operational efficiency. Because we focus our efforts on advanced rheology and suspension technologies, and use only the highest quality refractory components, Foseco’s sand coating products provide “as-cast” excellent surface performance, particularly in critical applications. They are also noted in the industry for their ease of use and process productivity.

Foseco’s Sand Coating products provide:

• Reduced defects, particularly surface defects like veining, sand burn-in, and metal penetration.
• Increased productivity, because Foseco’s pioneering work in coating rheology and suspension technologies allows full-rate production of castings, minimizing coated core scrap and rectification, coating process variation and handling slow-downs.
• Improved quality, in addition to reducing defects, by acting as a robust element in a consistent foundry process and by improving the metallurgical properties and surface appearance of castings.

Water-based coatings

RHEOTEC coatings are water-based, slurry refractory formulations containing a carefully engineered blend of specialty refractory solids. They are used to coat cores for the high-production casting of gray/ductile iron and non-ferrous alloys. Typical casting components produced using RHEOTEC coatings include engine heads and blocks, brake rotors, gear boxes and axle housings. “Rapid Dry” and “Color Change on Drying” products are available. For foundries with demanding applications, RHEOTEC XL coatings provide exceptional resistance to veining and penetration defects.

• Superb dipping rheology (flow characteristics). No runs or drips. Highly uniform and consistent coating coverage.
• Low foaming tendency. Important in automated coating application systems.
• Outstanding suspension stability. Low level of settling in use. Sediment remains soft and easily re-mixed.
• Compatible with most core processes -- hot-box, shell, oil sand, the ECOLOTEC Process, Epoxy/Acrylic/Furan - SO2, Phenolic-Urethane and Phenolic - Methyl Formate.
• Excellent as-cast surface quality. Reduces or eliminates veining, burn-in and metal penetration defects.
• Highly cost-effective in use. Greatly reduced blast cleaning requirement. Can eliminate additional manual cleaning operations.
• Convenient form of delivery. Easily handled, mixed and diluted.
• Will not degrade core substrate.
• Durable coated surface resists abrasion during core handling.
  
  HOLCOTE coatings are water-based slurry refractory coatings for cores and molds. The principal refractory contained in these coatings is typically a high-purity zircon. HOLCOTE coatings are recommended for use in the casting of iron and steel alloys. These coatings should be used where metal casting sections are in the medium to heavy size range.
  
• Excellent rheology (flow characteristics) provides a highly uniform coating layer to molds or cores when applied via brush, spray or flowcoat methods.
• Outstanding suspension characteristics. Sediment is soft and easily re-dispersed.
• The resultant coated surface is hard and smooth, free from runs and drips.
• As-cast surface quality is excellent (no burn-in, burn-on or penetration defects), even with the heaviest casting sections.
• Strip/peel of sand from the casting surface at shakeout is significantly improved.
• Casting cleaning costs are greatly reduced.
• Compatible with all types of chemically-bonded sand and green sand.

Solvent-based coatings

ISOMOL coatings are flammable, solvent-based mold and core coatings. The principle refractory contained in these coatings is a high-purity zircon. ISOMOL coatings are recommended for use in the casting of iron, steel and non-ferrous alloys. These coatings can be used through a wide range of metal casting sections.

ISOMOL coatings provide excellent casting surface quality. Resultant casting finish is smooth and free from burn-in, burn-on and metal penetration defects. This coating is both easy to apply and economical to use. Casting cleaning costs are significantly reduced.

Related Case Studies:

Iron

• 4 & 6 Cylinder Head (Germany) Case Study (51.52 KB)  
• Flanged Pipe Fitting Case Study (64.4 KB) 
• Ford Ventilated Brake Disc Case Study (35.83 KB)  
• Gray Iron 4 Cylinder Block (Australia) Case Study (93.13 KB)
• Gray Iron 4 Cylinder Block (South Korea) Case Study (64.23 KB)
• Gray Iron 6 Cylinder Diesel Block (Brazil) Case Study (77.42 KB)
• Gray Iron 4 Cylinder Block (Brazil) Case Study (64.83 KB)
• Turbo Housing Case Study (182.89 KB) Ball Valve Body Case Study (53.76 KB)

Steel

• Ball Valve Body Case Study (53.76 KB)  
• Roof Node for Berlin Olympic Stadium Case Study (78.15 KB)

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