INTRODUCTION:
Exothermic Riser Sleeves (Any shape & Size)
- Available in both open & blind type.
- It carries both insulating & exothermic properties & offers close dimensional accuracy.
- It has Refractoriness 1400-1500°C & higher hot strength.
It offers higher casting yield & higher feeding efficiency due to it’s combined Insulating, Exothermic & higher refractoriness properties.
Riser Sleeves act as a reservoir of liquid metal in the sand mould for steel / iron castings in foundry. It keeps the metal in molten form and feed the metal to the casting body till solidification of casting gets completed by providing an exothermic reaction along with insulating properties and it solidifies at last.
APPLICATION:
It has close dimensional tolerance so it is used in insert application.
It is having high strength & good surface finish so it is suitable for ram up application also.
It is suitable for high pressure moulding line, automatic moulding line, vertically parted moulding line & shell moulding etc.
As the molten metal comes in contact with riser sleeves an exothermic reaction takes place that liberate enormous amount of heat which maintains the temperature of feed metal in the riser sleeves. This provides favorable temperature gradient and directional solidification. After the complete burning of sleeves it acts as an insulator to furnish above function. The performance of riser sleeves also depends on the quality and quantity of APC Powder used to cover the riser sleeves.
ADVANTAGES:
- Feeding efficiency is high due to the combined properties of Exothermic, Insulating & Refractoriness so percentage yield is very high.
- Reduction in fettling & gas cutting cost due to less contact area.
- It can be supplied with breaker core for ease of knocking off & thus reduces fettling cost again.
- Productivity is increased due to percentage yield improvement.
- Soundness of casting is improved.
- It is having high permeability & low hygroscopicity.
- Uniform wall thickness & William’s wedge offers effective insulation & feeding performance.
- Increase directional solidification.
- Avoid casting defects like shrinkage cavity / piping in castings.
USAGE GUIDELINES :
- Select size of sleeves, according to effective modulus & volume of metal in the sleeves.
- While selecting the sleeve size, care should be taken to ensure that the parametric requirements like casting modulus, casting feed volume requirement & the sleeve feeding distance are fulfilled.
- It is used for ram-up as well as insert application. For Ram-up & insert application, the peg should be manufactured as per the dimensions provided by us.
- In case of top feeder, sleeve should be used with breaker core or a metal pad of 6 to 12mm thick must be provided between the sleeve & the casting surface.
The top vent hole provided on the sleeve should be opened to the top surface of cope mould to allow mould air to escape during pouring.
SELECTION OF SLEEVE (OPEN) 180 M SIZES:
Highly Exothermic Sleeves used for feeding S.G. Iron & Steel Castings having modulus in the range 6-7 mm & 32-34 mm.
| Sr. No | Sleeve size – Blind (mm) | Modulus (mm) | Modulus (mm) | Volume of metail (cc) | ID (mm) | Height (mm) | |||
|---|---|---|---|---|---|---|---|---|---|
| 1 | 25×50 | (1”x2”) (B) | 9.4-9.8 | 5.2-5.4 | 18-20 | 28 | 52.50 | ||
| 2 | 25×75 | (1”x3”) (O) | 9.8-10.1 | 5.4-5.6 | 28-32 | 25 | 77 | ||
| 3 | 25×75 | (1”x3”) (B) | 14.8-15 | 8.2-8.3 | 86-88 | 28 | 75 | ||
| 4 | 40×75 | (1.5”x3”) (O) | 13.6-13.8 | 7.5-7.6 | 86-88 | 37 | 75 | ||
| 5 | 40×75 | (1.5”x3”)P(B) | 13.6-13.8 | 7.5-7.6 | 86-88 | 40.8 | 74 | ||
| 6 | 50×75 | (2”x3”) (O) | 16.5-16.8 | 9.3-9.4 | 140-150 | 50 | 75 | ||
| 7 | 50×75 | (2”x3”) (B) | 17.7-18 | 9.8-10.00 | 140-150 | 54 | 77 | ||
| 8 | 60×75 | (2.5”x3”) (O) | 17.8-17.9 | 10-10.1 | 192-195 | 63 | 75 | ||
| 9 | 60×75 | (2.5”x3”) (B) | 18.9-19.1 | 10.5-10.6 | 192-195 | 63.5 | 80 | ||
| 10 | 50×100 | (2”x4”) (O) | 17.5-17.8 | 9.8-9.9 | 180-190 | 50 | 100 | ||
| 11 | 50×100 | (2”x4”) (B) | 18.5-18.7 | 10.3-10.4 | 180-190 | 50 | 100 | ||
| 12 | 65×100 | (2.5”x4”) (O) | 20.5-20.7 | 11.8-11.9 | 295-300 | 63 | 100 | ||
| 13 | 65×100 | (2.5”x4”) (B) | 22.2-22.4 | 12.3-12.4 | 295-300 | 64.25 | 95 | ||
| 14 | 65×150 | (2.5”x6”) (O) | 23.5-24.0 | 14.6-14.8 | 595-600 | 62 | 150 | ||
| 15 | 75×75 | (3”x3”) (0) | 26.6-27.0 | 14.8-15.0 | 260-265 | 76.5 | 75 | ||
| 16 | 75×75 | (3”x3”) (B) | 28.4-28.8 | 15.8-16.0 | 260-265 | 78 | 80 | ||
| 17 | 75×100 | (3”x4”) (O) | 21.8-22.4 | 12.4-12.6 | 345-355 | 75 | 100 | ||
| 18 | 75×125 | (3”x5”) (O) | 24.5-25.0 | 14.2-14.4 | 550-560 | 75 | 125 | ||
| 19 | 75×125 | (3”x5”) P(B) | 26.8-27.2 | 14.9-15.1 | 550-560 | 75 | 127 | ||
| 20 | 75×150 | (3”x6”) (O) | 25.8-25.9 | 14.8-15.0 | 660-670 | 76 | 152 | ||
| 21 | 75×150 | (3”x6”) P(B) | 27.9-28.4 | 15.5-15.8 | 660-670 | 74 | 148 | ||
| 22 | 90×150 | (3.5”x6”) (O) | 28.0-28.2 | 16.6-16.8 | 850-860 | 91 | 150 | ||
| 23 | 100×150 | (4”x6”) (O) | 29.8-30 | 17.6-18 | 1030-1040 | 102 | 152 | ||
| 24 | 100×150 | (4”x6”) P(B) | 33.8-34.0 | 18.5-18.9 | 1030-1040 | 97 | 150 | ||
| 25 | 125×150 | (5”x6”) (O) | 34.5-35 | 20.2-20.5 | 1550-1600 | 127 | 152 | ||
| 26 | 125×150 | (5”x6”) P(B) | 38.2-38.8 | 21.2-21.5 | 1550-1600 | 124 | 150 | ||
| 27 | 150×150 | (6”x6”) (O) | 39-40 | 23.5-24.0 | 2350-2400 | 156 | 152 | ||
SELECTION OF SLEEVE 180 HM SIZES:
Highly Exothermic Sleeves used for feeding all grades of Iron & Steel Castings having high modulus and available in diameter from 150 to 650 mm & in heights of 150 mm & 200 mm.
| Sr.
No.
|
Sleeve size
(mm) (ID x Height) |
Modulus (mm) | Volume of
metal in sleeves (cc) |
ID (mm)
|
Height (mm) |
||
|---|---|---|---|---|---|---|---|
| Effective | Geometric | ||||||
| 1 | 150×200 | 43-43.5 | 27.5-28 | 3750-3775 | 150 | 200 | |
| 2 | 150×225 | 51.8-52 | 33.4-33.6 | 4320-4330 | 155 | 225 | |
| 3 | 180×150 | 44-44.5 | 28.5-29 | 4000-4050 | 180 | 150 | |
| 4 | 175×200 | 48-48.5 | 31.5-32 | 5350-5400 | 180 | 200 | |
| 5 | 200×200 | 52-52.5 | 33.5-34 | 6550-6600 | 200 | 200 | |
| 6 | 225×200 | 54.5-55 | 36-36.5 | 8300-8350 | 225 | 200 | |
| 7 | 250×200 | 58-58.5 | 38.5-39 | 10200-10225 | 250 | 200 | |
| 8 | 275×200 | 62-62.5 | 41-41.5 | 12300-12325 | 275 | 200 | |
| 9 | 300×200 | 64.5-65 | 43-43.5 | 14600-14625 | 300 | 200 | |
| 10 | 325×200 | 67.5-68 | 45-45.5 | 17100-17125 | 325 | 200 | |
| 11 | 350×200 | 69-69.5 | 46.5-47 | 19775-19800 | 350 | 200 | |
| 12 | 375×200 | 72-72.5 | 48.5-49 | 22675-22700 | 375 | 200 | |
| 13 | 400×200 | 73-73.5 | 50-50.5 | 22750-25775 | 400 | 200 | |
| 14 | 425×200 | 75.5-76 | 51.5-52 | 29025-29050 | 425 | 200 | |
| 15 | 450×200 | 77-77.5 | 53-53.5 | 32500-32525 | 450 | 200 | |
| 16 | 475×200 | 76-76.5 | 54-54.5 | 36175-36200 | 475 | 200 | |
| 17 | 500×200 | 77.5-78 | 55.5-56 | 40050-40100 | 500 | 200 | |
| 18 | 525×200 | 80-80.5 | 56.5-57 | 44100-44125 | 525 | 200 | |
| 19 | 550×200 | 81.5-82 | 58-58.5 | 48375-48400 | 550 | 200 | |
| 20 | 575×200 | 80.5-81 | 59-59.5 | 52825-52850 | 575 | 200 | |
| 21 | 600×200 | 81.5-82 | 60-60.5 | 57475-57500 | 600 | 200 | |
| 22 | 625×200 | 82.5-83 | 61-61.5 | 62325-62350 | 625 | 200 | |
| 23 | 8”x12” (open) | 60.5-61 | 39-39.5 | 10550-10575 | 8” | 12” | |
SELECTION OF SLEEVE 180 ND SIZES:
These Sleeves are used as top feeder for feeding all grades of Iron & Steel Castings. Due to the smaller contact area, it will reduce gas cutting & the grinding work.
It offers benefit of the breaker core & in many cases, it is possible to knock off the feeder. The contact diameter of the sleeve is less than 50% of the original diameter of the sleeve thus contact area is minimized. Hence it is suitable where the casting contact area is limited.
| Sr. No.
|
Sleeve size (mm)
(ID x height) |
Modulus (mm) | Volume of metal in sleeves (cc) |
ID (mm) |
Height (mm) |
||
|---|---|---|---|---|---|---|---|
| Effective | Geometric | ||||||
| 1 | ND 1.5 | 9-10 | 6-6.5 | 52-57 | 20 | 60 | |
| 2 | ND 2 | 13.7-14.7 | 7.5-8.5 | 80-90 | 20 | 60 | |
| 3 | ND 3 | 21-22 | 12-13 | 285-295 | 30 | 87 | |
| 4 | ND 4 | 27.5-28.5 | 16-17 | 690-700 | 40 | 115 | |
| 5 | ND 5 | 34.5-35.5 | 20-21 | 1300-1320 | 50 | 135 | |
| 6 | ND 6 | 40-41 | 24-25 | 2180-2200 | 60 | 160 | |
| 7 | ND 150 (150×200) | 42-42.5 | 27-27.5 | 3075-3100 | 150 | 200 | |
| 8 | ND 180 (180×200) | 47-47.5 | 30-30.5 | 4200-4225 | 180 | 200 | |
| 9 | ND 200 (200×200) | 49.5-50 | 31.5-32 | 4975-5000 | 200 | 200 | |
| 10 | ND 225 (225×200) | 51-51.5 | 34-34.5 | 6150-6175 | 225 | 200 | |
| 11 | ND 250 (250×200) | 53.5-54 | 35.5-36 | 7300-7325 | 250 | 200 | |
| 12 | ND 300 (300×200) | 56.5-57 | 37.5-38 | 9575-9600 | 300 | 200 | |
| 13 | ND 350 (350×200) | 57-57.5 | 39-39.5 | 12225-12250 | 350 | 200 | |
| 14 | ND 400 (400×200) | 57.5-58 | 39.5-40 | 14650-14675 | 400 | 200 | |