COPPER/ZINC/STEEL/IRON

1a (Copper Degaser)

Copper Degasser :

A briquette used for the removal of hydrogen from copper and copper base alloys

General Description

Loges comprises a granule material strongly bonded and formed into a weighed unit with high surface area to volume ratio to ensure maximum contact area with liquid metal.

Loges is used for degassing of molten copper and copper based alloys. In copper and copper base alloys, dissolved hydrogen and cuprous oxide combine to form water vapour by steam reaction. The solubility of hydrogen in copper and its alloy melts reduces as the temperature falls until the gas attains the solid solubility. The hydrogen which is expelled from solution tends to combine with cuprous oxide levels are very low after deoxidation, hydrogen may still be problematic and it is preferable to reduce it to negligible proportions. The easiest and most effective way of doing this is to bubble through the melt a stream of hydrogen scavenging gas which does not react with the alloy treated. Loges units comprise a mixture of chemicals which, on contact with the molten metal, decompose to give a continuous steady stream of non-reactive gas. Since Loges is very carefully dried and packed, the gas bubbles contain very little hydrogen and are able to flush out that gas and carry it to the surface where it is lost to atmosphere. cot Porosity Meter is easy to use and fast result. It is best applied to test the hydrogen before each cast, especially for cast the alloy ingot. Casting of aluminium, manganese and silicon bronze is very difficult because of those alloying elements great affinity for oxygen which during melting results in the formation of large amounts of oxide in the form of heavy drosses. These oxides are insoluble and if allowed to remain in the melt they tend to form upon solidification of the metal, a fine film at the grain boundaries when considerably weakens the structure of the alloy and the casting. Furthermore the natural and successful feeding of the casting is adversely affected by the oxides settling out in fine feeding channels restricting the flow of feed metal. The oxide formation is also the cause of the heavy build up which occurs or the crucible and furnace walls and therefore steps to cattails this build up essential.

Benefits:

  • Loges is an inexpensive, easy to apply and efficient method of removing hydrogen from copper and copper based alloys
  • Removal of hydrogen by Loges improves the mechanical properties in castings, minimizing porosity due to steam reaction
  • Ancillary equipment required to use Loges is simple and costs very little
  • Metal fluidity is improved due to degassing followed by deoxidation
  • Loges is robust, stores well and is safe and non-toxic in use

Application

Instructions for use :

Loges units are of annular shape, having a central hole into which a simple refractory coated and properly dried steel plunger can be inserted.

  • Melt down under the cover of an approximate flux like Culprit, Cuprex and Albaral.
  • For degassing, Plunge the Loges units to bottom of the melt. Maintain this position till the bubbling effect subsides totally. This would ensure maximum contact time between evolved gas bubbles and melt and obtain good hydrogen removal.
  • The degassing time should be at least 3 minutes. This is accompanied by a loss in temperature of 10-15 centigrade degrees. A correspondingly higher degree of superheat must therefore be allowed.
  • The metal should be deoxidized using DS tubes, skimmed and pouring immediately.

Specifications

Weight of each tablet : 110 grams

Packaging

Standard Packing :
96 Paces / Box
Shelf life : 1 Year
Store in cool and dry conditions



2b (Copper Degaser)

Copper Degasser :

A briquette used for the removal of hydrogen from copper and copper base alloys

General Description

Loges comprises a granule material strongly bonded and formed into a weighed unit with high surface area to volume ratio to ensure maximum contact area with liquid metal.

Loges is used for degassing of molten copper and copper based alloys. In copper and copper base alloys, dissolved hydrogen and cuprous oxide combine to form water vapour by steam reaction. The solubility of hydrogen in copper and its alloy melts reduces as the temperature falls until the gas attains the solid solubility. The hydrogen which is expelled from solution tends to combine with cuprous oxide levels are very low after deoxidation, hydrogen may still be problematic and it is preferable to reduce it to negligible proportions. The easiest and most effective way of doing this is to bubble through the melt a stream of hydrogen scavenging gas which does not react with the alloy treated. Loges units comprise a mixture of chemicals which, on contact with the molten metal, decompose to give a continuous steady stream of non-reactive gas. Since Loges is very carefully dried and packed, the gas bubbles contain very little hydrogen and are able to flush out that gas and carry it to the surface where it is lost to atmosphere. cot Porosity Meter is easy to use and fast result. It is best applied to test the hydrogen before each cast, especially for cast the alloy ingot.

Casting of aluminium, manganese and silicon bronze is very difficult because of those alloying elements great affinity for oxygen which during melting results in the formation of large amounts of oxide in the form of heavy drowses. These oxides are insoluble and if allowed to remain in the melt they tend to form upon solidification of the metal, a fine film at the grain boundaries when considerably weakens the structure of the alloy and the casting. Furthermore the natural and successful feeding of the casting is adversely affected by the oxides settling out in fine feeding channels restricting the flow of feed metal. The oxide formation is also the cause of the heavy build up which occurs or the crucible and furnace walls and therefore steps to cattails this build up essential.

Benefits:

  • Logas is an inexpensive, easy to apply and efficient method of removing hydrogen from copper and copper based alloys
  • Removal of hydrogen by Loags improves the mechanical properties in castings, minimizing porosity due to steam reaction
  • Ancillary equipment required to use Logas is simple and costs very little
  • Metal fluidity is improved due to degassing followed by deoxidation
  • Logas is robust, stores well and is safe and non-toxic in use

Application

Instructions for use :

Loges units are of annular shape, having a central hole into which a simple refractory coated and properly dried steel plunger can be inserted.

  • Melt down under the cover of an approximate flux like Cuprites, Cuprex and Albaral.
  • For degassing, Plunge the Loges units to bottom of the melt. Maintain this position till the bubbling effect subsides totally. This would ensure maximum contact time between evolved gas bubbles and melt and obtain good hydrogen removal.
  • The degassing time should be at least 3 minutes. This is accompanied by a loss in temperature of 10-15 centigrade degrees. A correspondingly higher degree of superheat must therefore be allowed.
  • The metal should be deoxidized using DS tubes, skimmed and pouring immediately.

Specifications

Weight of Each Tablet : 220 GrmsPackaging

Packaging

Standard Packing :
100 Pcs / Box
Shelf life : 1 Year
Store in cool and dry conditions



K-Slax 30

A slag coagulant for all forms of iron alloys including ductile iron.

General Description

For slag control on high duty grey and SG irons, where the metal temperature is high or where the metal surface is exposed to top heat, e.g. in covered ladles, reverberatory furnaces etc.

These alloys usually give a difficult slag that is awkward to handle and remove cleanly when the temperature exceeds about 1300ºC (2372ºF). Without control the possibility, therefore, exists that slag will be poured with the metal and give inclusions in the casting.

Purpose:

K-SLAX 30 coagulant will collect and coagulate these slag’s into a tough plastic crust. That can easily be removed or, alternatively, it may be left in place and the metal poured from beneath it. The crust will stay in place during pouring and will also provide an effective degree of heat insulation.

Application

Instructions for use :

These recommendations apply to the surface area of approximately 45 kg ladle.

Either (1) Add 30-90g, K-SLAX 30 coagulant to the existing slag, rabble until dry and skim off. Place a further 30-90g on the metal surface, with a view to forming a dam or bridge across the ladle lip. Allow to crust for a few moments before pouring. Do not break the crust formed. or (2) When tapping into carrying ladles, add 30-90g. K-SLAX 30 coagulant to the metal stream –not the empty pot. Rabble in when the pot is full and skim clean. Add a further 30-60g. as described under (1) above. or (3) Where the metal is melted under a dry cover, e.g. charcoal, it is not necessary to skim completely. The melting cover should be pushed back from the lip and 30-90g.K-SLAX 30 coagulant sprinkled on to the cleared metal so as to form a floating dam across the lip. This will effectively hold back charcoal etc. no matter how many times the crucible is tilted, provided the dam is not broken. Always remove the K-SLAX 30 crust before recharging the crucible or furnace.

Specifications

Advantages:

K-SLAX 30 coagulant allows positive control of difficult slag’s to be obtained at the Most effective point - the lip of the crucible. Manual holding back can be dispensed with. Castings are cleaner and crucibles stay clean and last longer. K-SLAX 30 coagulant is entirely safe to use, is free from dust and fume, does not trap metal and does not contaminate the melt in any way. Good slag control means cleaner castings and easier working.

Packaging

Blue Color Powder

Standard Packing :

25 Kg HDPE Lined bags
1 M.Ton Jumbo Bags



E1 / E2 / E3

For controlled deoxidation and improvement in the fluidity of copper base alloys.

General Description

K- DEOXIDISING TUBES comprise of a range of various reducing agents contained in pure copper and brass tubes for controlled deoxidation of copper and its alloys

Benefits:

  • Dissolution of deoxidant is rapid and uniform thus melt treatment time is reduced.
  • Very convenient and accurate method of deoxidation which prevents casting rejection due to oxygen blow holes.
  • Metal fluidity is improved and major causes of porosity in the castings are eliminated.

Application

Purpose:

  • Oxides are formed during melting of copper and its alloys. These oxides, if allowed to remain in the melt, cause sluggish and gassy metal leading to low mechanical properties of the cast parts.
  • These oxides are reduced from the melt by the introduction of K- DEOXIDISING TUBES.
  • K- DEOXIDISING TUBES contain very reactive reducing agents which form stable oxides by combining with oxygen. Such oxides can be easily separated from the melt and thus the metal quality is improved.
  • K- DEOXIDISING TUBES offer an easy method for making controlled and correct addition of deoxidising agents to the melt. The dissolution of K- DEOXIDISING TUBES is rapid and uniform hence it results incomplete and efficient deoxidation of the metal.

Specifications

Instructions for use:

  • Melt down under the cover of an appropriate flux like KUPRIT, KUPREX, REKUPEX or K-ALBRAL.
  • Degas with CU DEGASER blocks
  • Immediately before pouring, plunge K- DEOXIDISING TUBES right to the bottom of the melt. Stir the melt well, skim and pour. Standard packing: 500 Nos. in CB box. Other KAVITA INDUSTRIES products for casting copper and its alloys Melting fluxes : K-ALBRAL, K-CHROMBRAL, KUPREX, KUPRIT Speciality fluxes : K-ELMINAL, REKUPEX Degassing fluxes : CU DEGASER.

Packaging

Standard Packing

100 PCS / BOX
Store in cool and dry conditions
Use within 1 year from date of manufacturing



CB 3

For controlled deoxidation and improvement in the fluidity of copper base alloys.

General Description

K- DEOXIDISING TUBES comprise of a range of various reducing agents contained in pure copper and brass tubes for controlled deoxidation of copper and its alloys

Benefits:

  • Dissolution of deoxidant is rapid and uniform thus melt treatment time is reduced.
  • Very convenient and accurate method of deoxidation which prevents casting rejection due to oxygen blow holes.
  • Metal fluidity is improved and major causes of porosity in the castings are eliminated.

Application

Purpose:

  • Oxides are formed during melting of copper and its alloys. These oxides, if allowed to remain in the melt, cause sluggish and gassy metal leading to low mechanical properties of the cast parts.
  • These oxides are reduced from the melt by the introduction of K- DEOXIDISING TUBES.
  • K - DEOXIDISING TUBES contain very reactive reducing agents which form stable oxides by combining with oxygen. Such oxides can be easily separated from the melt and thus the metal quality is improved.
  • K- DEOXIDISING TUBES offer an easy method for making controlled and correct addition of deoxidizing agents to the melt. The dissolution of K - DEOXIDISING TUBES is rapid and uniform hence it results incomplete and efficient deoxidation of the metal.

Specifications

Instructions for use:

  • Melt down under the cover of an appropriate flux like KUPRIT, KUPREX, REKUPEX or K-ALBRAL.
  • Degas with CU DEGASER blocks
  • Immediately before pouring, plunge K-DEOXIDISING TUBES right to the bottom of the melt. Stir the melt well, skim and pour. Standard packing: 500 Nos. in CB box. Other KAVITAINDUSTRIES products for casting copper and its alloys Melting fluxes : K-ALBRAL, K-CHROMBRAL, KUPREX, KUPRIT Speciality fluxes : K-ELMINAL, REKUPEX Degassing fluxes : CU DEGASER.

Packaging

Standard Packing

100 PCS / BOX
Store in cool and dry conditions
Use within 1 year from date of manufacturing



DS 1 / 2 / 3

For controlled deoxidation and improvement in the fluidity of copper base alloys.

General Description

K- DEOXIDISING TUBES comprise of a range of various reducing agents contained in pure copper and brass tubes for controlled deoxidation of copper and its alloys

Benefits:

  • Dissolution of deoxidant is rapid and uniform thus melt treatment time is reduced.
  • Very convenient and accurate method of deoxidation which prevents casting rejection due to oxygen blow holes.
  • Metal fluidity is improved and major causes of porosity in the castings are eliminated.

Application

Purpose:

  • Oxides are formed during melting of copper and its alloys. These oxides, if allowed to remain in the melt, cause sluggish and gassy metal leading to low mechanical properties of the cast parts.
  • These oxides are reduced from the melt by the introduction of K- DEOXIDISING TUBES.
  • K- DEOXIDISING TUBES contain very reactive reducing agents which form stable oxides by combining with oxygen. Such oxides can be easily separated from the melt and thus the metal quality is improved.
  • K- DEOXIDISING TUBES offer an easy method for making controlled and correct addition of deoxidising agents to the melt. The dissolution of K- DEOXIDISING TUBES is rapid and uniform hence it results incomplete and efficient deoxidation of the metal.

Specifications

Instructions for use:

  • Melt down under the cover of an appropriate flux like KUPRIT, KUPREX, REKUPEX or K-ALBRAL.
  • Degas with CU DEGASER blocks
  • Immediately before pouring, plunge K- DEOXIDISING TUBES right to the bottom of the melt. Stir the melt well, skim and pour. Standard packing: 500 Nos. in CB box. Other KAVITA INDUSTRIES products for casting copper and its alloys Melting fluxes : K-ALBRAL, K-CHROMBRAL, KUPREX, KUPRIT Speciality fluxes : K-ELMINAL, REKUPEX Degassing fluxes : CU DEGASER.

Packaging

Standard Packing

100 PCS / BOX
Store in cool and dry conditions
Use within 1 year from date of manufacturing



K-PlumBral 2

K- Plumbral 2 is a covering and drowsing flux used for Copper based alloys (mainly Bronze)

General Description

K- Plumbral 2 provides a cover during melting of high lead bronze. This flux is used to prevent oxidation loss during melting. The plunging of K- Plumbral flux before pouring scavenges the melt, removing impurities and assisting in the dispersion of the lead phase.

Application

Instructions for use:

In crucible melting 0.5% is added about 5 minutes before deoxidising the melt. Before pouring, the fluid slag formed is skimmed off, thickening it with dry silica sand if necessary.

In Tilting, rotary or reverbratory furnaces, 0.5% of Scot- Plumbral flux is added when the charge begins to melt. A further 0.5% is placed at the bottom of the preheat ladle, along with deoxidants, and the metal tapped onto them. Before poring the slag may be thickened with a coagulant to form a crust and the metal poured from beneath it.

Packaging

Standard Packing

25 / 50 Kg HDPE Lined bags
Shelf life : 1 Year



ReKupex

REKUPEX range of fluxes for melting copper and nickel alloys in swarf, skimming and scrap forms.

General Description

Swarf, drowses, residues and small scrap of copper and such alloys as brass, gun-metal, phosphor bronze, tin bronze, nickel silver etc. are frequently dirty, oily and heavily oxidised. When melted down, problems may arise if adequate steps are not taken to cleanse the melt. REKUPEX fluxes are present during melting and form a continuous fluid cover dissolving and removing the dirt, impurities and oxide and preventing further oxidation.

Application

Instructions for use:

The application rate of the selected grade of REKUPEX depends to a large extent on the type and condition of the material being melted and is a matter of Experience. It is very important that slag cover formed should be kept reasonably fluid throughout the melting period. The slag tends to thicken as it absorbs impurities and oxides from the melt and further additions of flux should be made from time to time as required, to maintain fluidity. It may be necessary to remove some of the existing slag before making further additions, but these later applications should be rabbled well into the melt.

Reverberatory and Electric Melting. The required quantity of REKUPEX should preferably be mixed thoroughly with swarf, grindings, sawings, scrap, etc. and charged into the furnace. The application rate of REKUPEX is approximately 3% of the charge weight. Where REKUPEX is not pre-mixed with the scrap it is particularly important to rabble the slag well into the metal during melting and immediately before tapping. If part of the charge is heavy scrap, this can be melted first with the required amount of REKUPEX. The remainder of the metal, finely divided swarf etc. is then passed through the liquid slag into the molten heel. It is very important that further additions of flux should be made as required to maintain the fluidity of the slag, each new addition being well rabbled into the melt.Crucible. REKUPEX FLUX ADDITIONS ARE USED AT A RATE OF 1.5% by weight pre-mixed with fine materials such as swarf, grindings etc. and charged into a pre-heated crucible, the subsequent melting down being done as rapidly as possible. To maintain slag fluidity, further additions of REKUPEX may be necessary, in which case these should be well mixed with the molten metal by rabbling.

Specifications

Advantages :

REKUPEX increases yield, recovering metal which otherwise would be lost as drosses. The protective cover given by REKUPEX minimises oxidation during melting and reduces melting losses.

REKUPEX removes oxides and non-metallic impurities from copper and nickel alloy charges during melting and refining.

Packaging

Standard Packing

25 / 50 Kg HDPE Lined bags
Shelf life : 1 Year



K-ELEMINAL 2

Additions for the reduction of aluminum in copper-based alloys.

General Description

The presence of aluminium in copper-based castings can result in the occurrence of alumina inclusions at grain boundaries. These may give rise to porosity, loss of pressure tightness and low tensile strength. In addition, surface aluminium oxide films cam be problematic in welding, soldering and brazing techniques. The removal or significant reduction of aluminium content of these alloys largely eliminates the problems.

K-ELIMINAL is a product which is designed to fulfil the purpose of aluminium removal without otherwise affecting the melt. When the aluminium content has been reduced to very low levels. K-ELIMINAL will then remove silicon and manganese from copper alloys but at a much slower rate than aluminium.

Application

Product Selection and Application:

Two forms of K-ELIMINAL are available as follows:

  • K-ELIMINAL 2 is recommended for foundry use when metal temperatures any be relatively low
  • K-ELIMINAL 8 is primarily intended for use in refineries

K-ELIMINAL should be used to treat melts containing less than 0.5% aluminium. Where higher levels exist the alloys should be diluted with aluminium free material until the content is reduced to 0.5% or less. When the aluminium content is high, approximately 0.5%, it is recommended that the charge be melted down under a cover of 0.5% by weight of K-ELIMINAL. This will also protect the zinc content of the melt . Before poring the metal should be brought to a temperature slightly higher than that required normally and 0.5% of K-ELIMINAL should be added to the surface and rabbled in or plunged to ensure maximum mixing. The degree of mixing is very important if efficient removal is to be obtained.

The treatment is repeated with further additions of K-ELIMINAL until the aluminium content of the melt is reduced to the required level. The melt is thoroughly deoxidized immediately before pouring



The following figures give a guide to the effect of K-ELIMINAL on melts of varying aluminium content:

  • Where melts contain 0.4% aluminium an addition of K-ELIMINAL will remove approximately 40% of its own weight of aluminium
  • When melts contain 0.2% aluminium an addition of K-ELIMINAL will remove approximately 25% of its own weight of aluminium
  • When melts contain 0.1% of aluminium an addition of K-ELIMINAL will remove approximately 25% of its own weight of aluminium

Advantages:

  • K-Eliminal reduces the aluminium content of copper-based alloys by a simple flux treatment
  • The handle effects of aluminium are eliminated by K-ELIMINAL without contamination or unwanted compositional changes in the melt
  • Casting made with K-ELIMINAL-treated metal exhibit greater cleanliness
  • Pressure tightness and tensile strength. In addition the lend themselves to easier welding, brazing and soldering

Specifications

Packaging

Standard Packing :
25 / 50 Kg HDPE Lined bags
Shelf life : 1 Year
Store in cool and dry conditions



K-AlBral 2

A range of fluxes for reducing oxide formation and inclusions in copper base alloys containing aluminium manganese or silicon.

General Description

ALBRAL helps in removing and preventing the formations of harmful oxides of aluminium, silicon and manganese. Forming a protective cover over the melt, reducing oxidation and also Zinc fuming to minimum. Increasing fluidity and feeding proportions of the alloy. Improving pressure tightness and mechanical properties of the castings.

Reducing dross formation and curtailing crucible build up normally associated with melting of theses alloys. Lowering the metallic content in skimming.

Casting of aluminium, manganese and silicon bronze is very difficult because of those alloying elements great affinity for oxygen which during melting results in the formation of large amounts of oxide in the form of heavy drosses. These oxides are insoluble and if allowed to remain in the melt they tend to form upon solidification of the metal, a fine film at the grain boundaries when considerably weakens the structure of the alloy and the casting. Furthermore the natural and successful feeding of the casting is adversely affected by the oxides settling out in fine feeding channels restricting the flow of feed metal. The oxide formation is also the cause of the heavy build up which occurs or the crucible and furnace walls and therefore steps to cattails this build up essential.

Application

How to use Albral

Crucible Furnaces :

The quantity of K-ALBRAL 2 varies according to the quantity and amount of scrap used in the charge. A high proportion of dirty scrap requires the use of larger quantities of flux, but for normal conditions addition upto 1 Kg. Per 100 Kg of melt will be found sufficient. As soon as the first part of the charge begins to melt sufficient K-ALBRAL 2 is added to form a cover, usually ¾ kg per 100 kg of melt. About five to ten minutes before casting a further small quantity (about ¼ kg per 100 kg melt) is plunged slowly to the bottom of the melt and is stirred well in to bring the flux into contact as much as possible with the metal. Where necessary the fluid slag can be thickened with dry sand to facilitate skimming.The treatment is repeated with further additions of ELIMINAL until the aluminium content of the melt is reduced to the required level. The melt is thoroughly deoxidized immediately before pouring


Tilting Furnaces : As soon as the first part of the charge begins to melt add ½ kg K-ALBRAL 2 per 100 kg of melt and complete the charge. When ready for pouring into the transfer ladle introduce a further ½ kg of flux in the ladle and pour onto it.


Electric Furnaces : For electric melting furnaces such as Ajax Wyatts. K-ALBRAL 2 is usually added in two stages, using a total of ½ kg per 100 kg of melt. The major portion is added to a heel of metal from the previous melt and the remainder used for final drossing off. The slag may be skimmed off or thickened up with dry silica sand and the metal poured from beneath it.


Bale – Out Furnaces : The charge is treated as described for the crucible furnace but using K-ALBRAL 3 instead. The dry dross formed may be either pushed aside during baling out or skimmed off cleanly. As metal is added from time to time replenish the melt, further small quantities of K-ALBRAL 3 should be plunged occasionally and stirred well.


Reverberatory Furnaces : Sufficient K-ALBRAL 16 to form a fluid protective cover with charge. It is important than the flux cover be maintained in a fully fluid condition, and to achieve this, further additions may have to be added from time to time, particularly if the charge melt is very dirty. A total quantity of upto 5 kg per 100 kg to melt may have to be used. The fluid cover should be stirredwell into the melt to bring it into contact as much as possible with the metal. Where necessary the fluid slag can be thickened with dry sand to facilitate skimming. In all cases, immediately before casting, the melts should be treated by plunging K-DEOXIDING TUBES to coalesce any oxide particles and assist their removal with slag.

Specifications

Packaging

Standard Packing :
25 / 50 Kg HDPE Lined bags
Shelf life : 1 Year
Store in cool and dry conditions