New Generation of Monolithic Inserts

Same high quality metallurgical performance you have been accustomed to over the years and now our mold inoculants are machined to higher tolerances, delivering even better consistency. The production of heavily stressed castings places ever-growing demand on the inoculation process and the inoculants used. With the new generation of monolithic inserts, our company offers a solution delivering improved tolerance and consistency to the end user. The machined surfaces guarantee good and uniform dissolution behavior of the inoculant. Thanks to the high-tolerance manufacturing process, the mold inoculants have narrower dimensional and weight distributions. Improved shape uniformity makes these products suitable for robot-assisted handling and automatic insertion into the mold, allowing our customers to prepare for the challenges of tomorrow.

The use of GERMALLOY type C improves the nodularity of graphite and optimizes ductile iron mechanical properties as cast. With OPTIGRAN C, the caster achieves a finer and more evenly distributed type-A graphite expression in the grey cast iron.

Mold inoculation is the addition of inoculant at the latest possible time in the casting process, and thus, is the most effective inoculation method in combating inoculant fading. This is particularly important in the production of thick-walled castings with long solidification times. In the mold inoculation process, the monolithic piece is inserted into either the pouring basin of a larger casting or directly into the sprue/gating system of a smaller casting. Such placement enables the dissolution of inoculant to take place directly in the iron and away from atmospheric exposure over the entire casting time. A fully submerged inoculation process results in cleaner metal and lower addition rates which means money back in your pocket. For mold inoculation to meet the needs of any casting design, monolithic inserts/tablets such as GERMALLOY C and OPTIGRAN C should be implemented. Solid single-block inoculants offer more consistent dissolution behavior and will not cause inclusions defects by flushing in undissolved inoculant granules.

Thin-walled castings with a nominal wall thickness of 5-50 mm solidify within seconds to a few minutes. However, the crystallization of heavy hand-molded castings with >60 mm wall thickness can take several hours, depending on the casting temperature. GERMALLOY C and OPTIGRAN C deliver good casting result even under extreme casting conditions due to their constant and long-lasting seeding properties.

We always think about our customers first and to make this transition easier for you, we chose the dimensions of the type-C inoculants in such a way that your existing core marks could be reused for the inoculant anchoring.

If required, the standard dimensions could be customized to a degree such that weight conditions are still satisfied.

Contact us today and learn more about our new generation of vaccines

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