product information - Tennant Metallurgical Group Ltd

TENNANT METALLURGICAL GROUP LTD
PRODUCT INFORMATION
TENBLOC® & MONOBLOC
Established in 1794 the Tennant Metallurgical Group’s (TMG) main activity is
the worldwide sourcing, importation, sale and distribution of metallic ores,
pure metals and ferro alloys to the European steel, foundry, refractory and
ceramic industries. TMG has strong, long term relationships with major
mining houses and ferro alloy producers enabling us to maintain a consistently
high standard of service and product quality for our varied customer base.
PRODUCT PORTFOLIO
Chromium Alloys
High Carbon, Medium Carbon, Low Carbon, Nitrided
Manganese Alloys
High Carbon, Medium Carbon, Ultra Low Carbon, Silico, Ultra Low Carbon Silico, Nitrided
Silicon Alloys
Ferro Silicon, TENBLOC®, Monobloc, Atomised Ferro Silicon
High Purity Pig Iron
Sorelmetal
Calcium Alloys
Calcium Silicon
Refractory Materials
Zircon Sand / Flour, Microsilica
Noble Alloys
Ferro Boron, Ferro Molybdenum, Ferro Vanadium, Ferro Tungsten, Ferro Titanium,
Molybdenum Oxide
Pure Metals
Chromium, Manganese, Silicon, Nickel, Cobalt
Miscellaneous
Ferro Phosphorus, Ferro Sulphide, Ferro Silicon Zirconium, Ilmenite, Magnetite, Rutile,
Silicon Metal powder RG98®, Ferro silicon powder RG75®
Low Carbon Iron
MAXIMAG®
In order to fully develop this wide portfolio of products, strategically
placed warehousing has been established in conjunction with a
deep understanding of our customer’s needs both commercially
& technically. As part of this commitment to customer service
consistent quality and full traceability throughout the product supply
chain is maintained. This philosophy is fully supported by the ISO
9001 standard to which both TMG and our principles comply.
www.tenmet.co.uk Email: [email protected]
TENBLOC
®
TENBLOC® inoculant blocks are used for in the
mould inoculation.
TENBLOC® is available in a number of different
analytical grades, specifically formulated for both
grey and ductile iron applications.
TENBLOC® is produced by a unique powder
metallurgical method, giving very accurate
dimensions and weights, which also enables both
cylindrical and taper shapes to be produced from
5gm to 500gm.
The block has a very low thermal conductivity, which results in a rapid and
controlled dissolution during the casting time ensuring all metal, particularly
the first, is inoculated. As there is no chemical segregation, homogeneous
nucleation of the iron results, whilst complete control in the selection of raw
materials ensures freedom from extraneous materials. It is also free from
the problems of entrapped slag, blow holes and porosity.
TENBLOC® are available in a range of weight, shapes and sizes as detailed in the tables shown below. Whichever
TENBLOC® is selected, the weight and shape is tightly controlled.
Typical Shape & Weight Availability
Cylindrical
Diameter
Weights (g)
20.5 mm
5, 10, 15, 20
25.4 mm (1”)
15, 20, 25, 30, 40, 50
38.1 mm (1.5”)
50, 60, 80, 100
50.8 mm (2”)
80, 120, 150, 200, 220
76.2 mm (3”)
300, 350, 400, 500
ØA
C
(typ)
ØB
Taper
Dimensions (typical) mm
Description
Weights (g)
A
B
C
19.5
15, 20, 25
20.6
19.6
11
22.5A
25, 30, 40
24.6
22.6
14
22.5B
50, 60
26.1
22.6
21
26.5
60
27.2
26.6
20
28.4
50, 70, 80, 90
30.2
28.5
19
35.1
100, 110, 120, 150
38.2
35.2
28
35.6
150, 180
39.8
35.7
40
38
200, 240
43.3
38.1
50
52
200, 250, 300, 350, 400 55.1
52.1
30
TENBLOC
®
PROCEDURE FOR TENBLOC® USE
1. ADDITION RATE
4. POSITION OF PRINT
The recommended addition weight is between 0.08%
and 0.12% of the poured box weight. Generally most
applications utilise a 0.10% addition.
The block is normally printed at the base of the
downsprue. However, some foundries have placed
it in a print in the runner system to avoid the initial
impingement of metal.
However, a number of factors will affect this and these
can include:
1.1 Pour Time
1.2 Metal Temperature
1.3 Hold Time in Ladle
1.4 Degree of Inoculation Required
Excessive pour time can mean insufficient inoculant being
available and last metal being under inoculated. In such
cases it may be necessary to increase the percentage
addition above that recommended.
Care should always be taken when placing the block into
the runner system to avoid choking the metal stream.
Standard gating system ratios are recommended for the
use of TENBLOC®, with the most widely recognised as
being the ratio of 8:4:8:3 for the cross sections of A4
downsprue, A3 runner, A2 runner and ΣA gate areas
respectively.
Care should always be taken to ensure that the distance
between the block print and the ingate is sufficient to
provide adequate dissolution time.
2. PLACEMENT PRINT
The block should ideally be printed wherever possible
in order that the block remains in position during the
pouring period.
An incorrectly printed or unprinted block could be
washed through in the mould cavity resulting in the
possibility of undissolved material in the casting.
3. TYPE OF PRINT
Due to high dimensional accuracy of the pressed
block, standard core prints can be utilised. The normal
recommended printed depth is between 25% and 30%
of the block height.
The diagram shows the typical location of the TENBLOC® in a
horizontally parted mould.
Under certain pouring conditions, i.e. pressure pouring
or small pouring cup design, a print depth of between
30% and 35% is more suitable to prevent the block
from being dislodged because of the velocity of the metal
stream.
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5. PLACEMENT ON FILTER
7. FLOW RATE (cont’d.)
There are occasions when due to the mould design it is
more convenient to place the block on top of the filter in
the downsprue which can be glued in place, if necessary.
The following charts show typical pouring speeds
and times where TENBLOC® has provided effective
inoculation.
Typical Pouring Speeds
6. METAL TEMPERATURE
o
o
This is normally in the range of 1350 C to 1500 C
depending on the type/section thickness of the casting
being produced.
7. FLOW RATE
From experience we would recommend the following
flow rates:
WEIGHT OF METAL
POURED FLOW RATE
20 Kg
2 – 3 Kg/second
40 Kg
3 – 4 Kg/second
60 Kg
4 – 6 Kg/second
80 Kg
5 – 6 Kg/second
100 Kg
5 – 7 Kg/second
150 Kg
8 – 10 Kg/second
300 Kg
12 – 18 Kg/second
Typical Disolution Times
8. GENERAL
Whilst these guidelines will give the foundryman a basis
for use, account must be taken of the differences which
exist in operations from foundry to foundry.
It has been our experience that trials should always take
place utilising these procedures with modification if
necessary by the individual foundry in order to obtain
optimum results.
TENBLOC® Std Grade | ANALYSIS
Analytically formulated to achieve required metallurgical structures – nodule count, shape and freedom from
carbide for most ductile iron applications.
TENBLOC® Std
Si
65-75%
Al
3.3-5.0%
Ca
0.5-1.5%
TENBLOC® Std Grade + Zr | ANALYSIS
The addition of 1 - 2.5% Zr to the standard grade formulation has proven particularly useful for those ductile iron
castings where carbide has been a problem due to thin sections.
TENBLOC® Std + Zr
Si
65-75%
Al
3.3-5.0%
Ca
0.5-1.5%
Zr
1-2.5%
TENBLOC® Low Al Grade | ANALYSIS
The restriction on the aluminium content (a maximum of 1%) means that this analysis is particularly suited for
grey iron inoculation. The problem of Hydrogen pin-holing due to high moisture in green sand moulding systems
requires restrictions on the maximum Al content in the metal. The low Al grade TENBLOC® is ideal in this case.
TENBLOC® Low Al
Si
65-75%
Al
1% max
Ca
1% max
TENBLOC® Low Al Grade + Zr | ANALYSIS
The addition of Zr to the block eliminates the problem of carbide formation on thin section castings.
TENBLOC® Low Al
+ Zr
Si
65-75%
Al
1% max
Ca
1% max
Zr
1-2.5%
TENBLOC® MZ20 Grade | ANALYSIS
This grade is suitable for both grey and ductile iron applications and the controlled amounts of aluminium, calcium
and manganese give a strong inoculating effect. The excellent solubility of this block, due to the addition of Mn,
allows for much more controlled dissolution when metal pouring temperatures are lower.
TENBLOC® MZ20
Si
60-70%
Al
0.9-1.6%
Ca
0.5-1.5%
Zr
3.5-5.0%
Mn
2.5-4.0%
TENBLOC® BaMn Grade | ANALYSIS
The BaMn grade is ideal for both grey and ductile irons. It produces high cell counts in ductile irons with minimum
fade characteristics. The effect of the Ba addition in grey irons is also important, particularly for electrically melted
iron where S contents are generally lower than for equivalent cupola melted irons.
TENBLOC® BaMn
Si
60-70%
Al
0.5-1.3%
Ca
0.4-1.0%
Zr
0.6-1.4%
Mn
0.6-1.4%
Ba
0.2-0.6%
TENBLOC® Other Grade Availability
Specialist applications have resulted in other grades being produced. These are generally developed by discussions
between our technical personnel and the related foundry. However, due to the unique process of using powder
metallurgical techniques, special blends can be produced initially for trial purposes. These blends are often only
a few kilos, but are sufficient to allow the foundry the opportunity to run small samples trials to fine tune the
TENBLOC® analysis required.
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MONOBLOC
Quality and Versatility
Monobloc is produced using the same closely controlled
granular materials as are used when producing our
TENBLOC® range of in the mould inoculants. This
ensures that the same characteristics of low thermal
conductivity, homogeneous chemistry and consistent
nucleation are achieved as with TENBLOC®.
Monobloc is normally printed in the pouring basin of the
mould and would be set in a taper shape print between
20 to 25 % of its overall height.
Addition rates for larger castings, where Monobloc is
used, are recommended as 0.15-0.2%.
Monobloc addition rate is dependent upon whether there
are any other inoculants being used in the operation and
what other foundry or metallurgical considerations are
required.
Monobloc complements the weights offered by
TENBLOC® with blocks of up to 15 kg being available.
The same analytical grades mean Monobloc is suited for
both grey and ductile irons.
Weight
Dimensions (typical) mm
A
B
C
D
E
0.8kg
100
50
110
60
60
1Kg
100
50
110
60
65
2Kg
145
75
155
85
75
5Kg
185
110
200
125
100
10Kg
220
140
235
155
130
15Kg
230
155
245
170
175
20kg
250
180
265
190
205
30kg
250
180
270
195
310
For other sizes and shapes, please contact TM (Technology) to discuss.
All dimensions are provided as guide only.
TENNANT METALLURGICAL GROUP LTD
Suite 4 | Venture House | Venture Way | Dunston Technology Park
Chesterfield | Derbyshire | S41 8NR
Tel: +44 (0) 1246 263000 | Fax: +44 (0) 1246 263001
Email: [email protected] | www.tenmet.co.uk
May 2015