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LINING SYSTEMS
HIG H P ERF O RMAN C E L INING T ECH NOLOGY FOR A LUMINIUM FOUND R I ES

++ Excellent refractoriness

++ Consistent performance

++ Clean furnace systems

++ Quick installation

++ Dross resistance
 Aluminium foundry linings

The aluminium foundry melting plant was once even better corundum resistance across a wider
dominated by crucibles, however, bulk melting by temperature band whilst Foseco’s dry-vibratable
coreless induction and tower melting furnaces is lining KELLUNDITE* is ideally suited to coreless
increasingly important. Consequently monolithics induction melting.
now play a significant role in modern aluminium The products listed in this brochure represent
foundries. Foseco’s ALUGARD* low-cement the best-in-class products for typical foundry
castables and TRIAD no-cement castable now applications. Foseco offers an extensive portfolio of
contain a new aluminium resistant additive giving monolithic and precast refractory solutions to meet
your specific needs. Please contact your local Foseco
team for more information.
Typical aluminium foundry layout

Coreless induction Tower & reverberatory

furnace melting furnace

 
Casting furnace



Transfer & treatment ladles

Crucible melting &

casting furnace

2
Melting furnaces
in aluminium foundries

Tower melting furnaces This leaves a clean refractory furnace lining,

Tower melting furnaces are commonly used in optimising the client’s furnace service life.
aluminium foundries. They consist of a vertical
melting shaft with a connecting holding bath. The ALUGARD CE-S high alumina low-cement castable
solid ingot is charged into the top of the tower, with offer excellent aluminium resistance. This is the
pre-heating in the stack followed by melting in the perfect general purpose product, with good strength
Tower melting furnace
melt chamber hearth. and all round performance.

The melt then flows naturally into the holding ALUGARD HS85 high alumina, super tough
chamber. Here the metal resides until it is tapped aluminium resistant castable has been specially
into a ladle, treated and then delivered to the developed to combat aggressive erosion and
casting furnaces. These furnaces are complex in their mechanical damage around charge areas.
geometry and most customers look for a full supply
and installation maintenance package. QUICK FIX ALUGARD EXP 2-part phosphate bonded
system contains a non-wetting additive and is ideal
Reverberatory melting furnaces for patch repairing furnaces. This material can also
Unlike tower melters, reverberatory furnaces are be used for thin veneer repairs due to the fact
usually single chambered furnaces. The solid ingot that it sticks very well to existing, used and new
is charged into the furnace through the charge door refractories. Cup test of ALUGARD CE-S
opening, then melted within the furnace bath. The
melt is then charged into the holding furnace. TRIAD*
TRIAD 70AL high alumina cement-free castable
ALUGARD offers exceptional resistance to aluminium wetting
ALUGARD aluminium resistant castables are used and penetration. It has all the characteristics of
to line these types of furnaces. There are a variety normal TRIAD castables:
of grades, specifically developed for different ++ Easy to mix
applications and conditions found in aluminium ++ Easy to install
handling and containment. ALUGARD materials are ++ Reduced bake-out time.
termed “non-wetting” due to their ability to “repel”
molten aluminium, resulting in no reaction between The product is suitable for all metal contact areas;
Sample of ALUGARD
the metal and the refractory. including bath, lower sidewall, ramp and sill. CE with ARA (right) and
without ARA (left)

3
 Melting furnaces
in aluminium foundries

Coreless induction melting Ancillary products

Coreless induction furnaces are the ideal foundry KELLUNDITE 707 dry topping prevents crack
tools for batch melting scrap. propagation and ensures a seamless transition from
the furnace body to capping area.
Coreless induction furnace linings for aluminium
melting are required to exhibit excellent non- Coil Protection
wetting properties and operate successfully over COILCOTE high alumina grouts provide a protective
a range of melting and casting temperatures for semi-permanent refractory screed to the power coil.
aluminium alloys.
Spout Materials
KELLUNDITE 703 high alumina dry-vibration ++ 
BLU-RAM* HS and BLU-RAM HSW granular
refractories are used for induction furnaces melting phosphate bonded material with good installation
aluminium. properties
++ ALUGARD CE-S precast refractory
They include the addition of a special aluminium
resistant agent to provide a clean furnace lining
with minimum dross build-up and sticking, enabling Lid Materials
easy and non-aggressive cleaning. ++ CERCAST 1500AL castable with good volume
stability and non wetting additives
KELLUNDITE 703 linings are based upon andalusite,
which is expansile through the aluminium alloy
melting temperature ranges and therefore reduces Crucibles
the risk of metal penetration. The most widely used method of melting aluminium
in foundries is with crucible furnaces. Foseco offer
a wide range of crucibles for all types of furnaces.

4
Casting furnaces
in aluminium foundries

There are three main types of casting furnaces pick-up. Crucibles also ensure that the aluminium
found in aluminium foundries, each using different is uniformly heated through the crucible wall by
furnace technology: electric resistance heating. Foseco offer a wide
range of crucibles for all types of furnaces.
++ L ow pressure furnaces
++ D osing furnaces
TRIAD 70 AL cup test
++ B ale-out furnaces Dosing furnaces
Refractory lined dosing furnaces have traditionally
Low pressure furnaces low moisture rammed linings. However these
Refractory lined low pressure furnaces have furnaces are usually small and can be cast in a
traditionally cast linings. These furnaces are usually single pour. This is so that there are no construction
small and the cast furnace bath is done in a single joints below metal level that could allow aluminium
pour. This is so that there are no construction joints penetration during the pressurised casting operation.
below metal level that could allow aluminium
penetration during the pressurised casting operation. The bath linings can be cast in TRIAD 45AL castable,
TRIAD 70AL castable and precast INSURAL*
The bath linings can be cast in one of the following refractory.
materials:
Low pressure furnace with
accessories
++ T RIAD 70AL castable Bale-out furnaces
++ A LUGARD CE-S castable Most bale-out furnaces are crucible furnaces and
++ A LUGARD A95 castable are either electric resistance, gas or oil fired.
Lifetimes can be many months, depending upon
the application and metal treatment conditions.
Many furnaces use crucibles to hold aluminium. The Foseco offer a wide range of crucibles for all types
main advantage is that the crucible can be easily of furnaces.
changed and casting can commence immediately,
without the need for prolonged drying of the
furnace linings and reducing the risk of hydrogen

Dosing furnace with

accessories

5
 Ladles and launders
in aluminium foundries

Ladles in aluminium foundries are used to tranfer INSURAL ATL ladle linings are precast and supplied
the metal from the melting unit to the casting fully fired. The non-wetting properties ensure that
unit, therefore minimum temperature loss is very aluminium skull formation is reduced and simple to
important. remove, preventing cross contamination between
metal transfers. Oxide build-up is avoided, reducing
The following products can be used: the risk of hard inclusions in the melt.

TRIAD 45AL low density no-cement castable has Furthermore, traditional linings frequently require
exceptional resistance to aluminium wetting and the melt to be superheated to offset temperature
penetration and is very user-friendly. It is easy to loss, promoting oxide formation and higher dissolved
mix, easy to install, easy to dry and easy to break hydrogen levels.
out. Suitable for all transfer ladles and launders, it
has the added advantage of a 12 month shelf life. The use of CERAMOL* 258G or TERRACOTE 7667
refractory coatings can further improve the ladle
lining cleanliness.

Refractory concrete INSURAL REFRACTORY

Wall thickness: 150 mm Wall thickness: 90 mm
Heat Loss: 9069 W/m² Heat Loss: 2583 W/m²
Boundary temperature: 308 °C Boundary temperature: 152 °C

Thermal Boundary
Layer Thickness Material
conductitvity temperature
No. mm W/mk °C

1 150 Refractory 3,140 741

concrete
2 0 1,000 308

1 60 INSURAL 140 0,460 747

2 30 INSURAL 10 0,300 410
3 0 1,000 152

6
Repair and maintenance
for furnaces and ladles in aluminium foundries

Foseco offers a wide range of repair mixes and INSURAL 700 and INSURAL 800
mortars. INSURAL insulating pastes are hardened by heat
and are used especially for aluminium and zinc. They
QUICK FIX* ALUGARD EXP are self-adhesive, ready-to-use and free of classified
QUICK FIX ALUGARD EXP is a phophate bonded synthetic fibres.
castable with 85% alumina providing: QUICK FIX ALUGARD EXP
repair
++ excellent non -wetting caracteristics INSURAL 700 and 800 pastes are used for the
++ good mechanical resistance assembly of INSURAL shapes, joining of INSURAL
++ rapid instalation and dry-out insulating bricks, repair of fissures and lining of
++ excellent sticking properties to old refractory ladles.
++ long shelf life (12 month)
KALSEAL* 1
X-9 PLASTER KALSEAL 1 sealing compounds are used for INSURAL
X-9 PLASTER is a thermally stable, putty consistency lining assemblies, but can also be used as a general
refractory, suited for all ferrous and non ferrous purpose mortar for repairs of brickwork refractories,
applications providing: etc. The motar will dry and harden by air-setting in
++ Excellent refractoriness 30-40 minutes depending on ambient temperatures.
++ Durable performance X-9 PLASTER and
BLU-RAM HS repair
++ Non-wetting characteristics BLU-RAM HS material
++ Resistance to slag and molten metal BLU-RAM HS phosphate bonded mouldable
++ Easy and clean application refractories are based on mullite and can be used
as a repair material.
X-9 PLASTER is designed for hand patching and
repairing applications.

INSURAL ATL
precast ladle linings

7
 Design and engineering service

Foseco offers a full refractory lining design and engeneering service, including:
++ Technical specifications
++ T hermal calculations
++ I nstallation instruction
++ P roduct datasheets
++ M aterial safety datasheets
++ D ry-out and commissioning schedules

Full aluminium furnace revamp dry-out

1000°C
900°C
800°C
Temperature (deg. C)

700°C
600°C
500°C
400°C
300°C
200°C
100°C
0°C
0 20 40 60 80 100 120 140
Furnace
Elapsed time (Hours)
drawings

*FOSECO, the Logo, ALUGARD, BLU-RAM, CERAMOL, DURACRETE, INSURAL, KALSEAL, KELLUNDITE, TRIAD and X-9 PLASTER are trade marks of the Vesuvius Group, registered in certain countries, used Foseco International Limited
under licence. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system of any nature or transmitted in any form or by any means, including photocopying and recording,
without the written permission of the copyright holder or as expressly permitted by law. Applications for permission shall be made to the publisher at the address mentioned. Drayton Manor Business Park,
Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are Tamworth, Staffordshire,
published as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants,
expressly or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not England B78 3TL
authorised to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request. Phone: +44 (0)1827 262021
05/2015 · e

© Foseco International Limited 05/15.

Fax: +44 (0)1827 283725
www.Foseco.com
COMMITTED TO FOUNDRIES Please contact your local Foseco team