exactcast™ - ask chemicals · complicated disposal of used sand ... • plastic cap eliminates...

EXACTCAST™ Product Line Overview

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Industry Leading Feeding Solutions for the Ideal Casting

ASK Chemicals is your comprehensive provider of

premium fiber-free feeding solutions. Renowned for

quality and innovation, our EXACTCAST™ sleeves

and risers – based on patented technology – are

specially engineered to accommodate a multitude

of needs beyond exceptional performance. From

eco-solutions to formulations designed to satisfy

complex disposal requirements, ASK Chemicals

establishes a standard of excellence within the

marketplace. With manufacturing capabilities in

Europe, Asia and North America we guarantee

strict dimensional accuracy, uniform composition,

reliable logistics and superior consistent quality.

At ASK Chemicals we provide innovation driven

research through our product development approach.

We focus specifically on market trends and customer

demands because of the increasingly complex

requirements our industry faces: reduced emissions,

casting defect prevention, cost-efficiency, as well as

overall casting quality. Such requirements necessitate

more than just strong partnerships and outstanding

technologies; rather, we believe that first-class

research and development that focuses on efficiency,

environmentally friendly solutions and key performance

parameters is essential.

In addition we offer our customers a holistic approach

that goes well beyond merely offering products. Our

application technology and technical sales specialists,

in particular, always assess the entire production

process as a whole. Only this approach allows for

customer specific solutions that are precisely tailored

to meet customer requirements.

Finally, our specialists' expertise is complemented by

a broad range of services that offers our customers

real added value. In this way, for example, our

design services can be systematically

deployed to optimize the process as

a whole – from conceptual

development to actualized series

production – thereby offering

important savings and process

improvement for our customers.

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Original producers of the mini-riser

Global production facilities

Patented technology

Environmentally friendly solutions

Holistic value added services

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Basic Information

EXACTCAST™ types

Mini-risers

Riser sleeves

Pouring cups

Breakers & Cover lids

EXACTCAST™ styles

Waterglass-bonded feeders

• Low gas emissions

• Contains no organic materials

Cold Box bonded feeders

• Reduced weight

• Easy handling

• Utilizes ASK Chemicals Cold Box technology

EXACTCAST™ formulations

IN series

The IN series is an insulating formula designed for use with all metals including steel.

EX series

The EX series is a standard grade exothermic formulation designed for use with all ferrous metals. Our EX sleeves & risers contain low-fluorine levels.

EXF series

The EXF series is an exothermic fluorine-free variation. The elimination of fluorine allows for easier / less complicated disposal of used sand and a reduction of fluorine related defects. Several additional benefits can be realized with fluorine-free risers & sleeves: reduction of graphite degeneration, avoidance of surface flaws and overall cleaner workplaces.

Custom solutionsApart from the system solutions mentioned in this brochure, ASK Chemicals also offers you custom solutions to fit your individual process. Please contact us to discuss your specific needs.

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Mini-Risers for Standard Applications High performance versatile mini-risers for best results

Benefits

• Low emissions

• Available in fluorine free

• Improved yield via lower liquid metal content

Benefits

• Light weight

• Improved yield via lower liquid metal content

• Optimizes yield in steel castings

EXACTCAST™ ADS

The ADS riser is highly stable and suitable within

No-Bake molding and hand-molding applications.

Available in fluorine free, with or without a breaker

core. It is also usable with an open spring-pin on

automatic molding lines.

EXACTCAST™ KMV

The KMV mini-riser is especially light-weight and is

usable in multiple molding types. This versatile

riser may be used with a spring-pin, or simply placed

directly on top of the casting. The KMV is highly

exothermic, and is available in a fluorine free formulation.

Mini-Riser

Molding type Metal type Application

Green sand & HP Chemically bonded Iron GI Iron DI Steel Non-ferrous Ram-up Insertable

ADS

KMV

= recommended, = partially recommended

Open spring-pin Open spring-pin

EXEXF

INEXEXF

Recommendations only; please consult an ASK-representative for more information

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Mini-Risers for High Pressure ApplicationsDynamic mini-riser system with reduced neck diameter

Benefits

• Low emissions via inorganic materials

• Low finishing costs from smaller neck width

• Spring-pins reduce base size, surface imperfec-

tions and pattern wear

Benefits

• Low weight

• Low finishing costs from smaller neck width

• Plastic cap eliminates riser inclusions on the

mold surface

EXACTCAST™ KMV-QT

KMV-QT is a Cold Box bonded, economical and

light weight riser that has only a small base size

thanks to the use of spring-pins. The riser can also

be used directly on the casting. Available in fluorine

free.

Mini-Riser



FDS

KMV-QT


EXEXF

EXEXF


EXACTCAST™ FDS

By using spring-pins, FDS risers have small bases.

In addition, they do not come into direct contact with

the casting. Available in fluorine free.

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Mini-Risers with Metal Necks Eliminates the need for applying breaker cores

Benefits

• No need for breaker cores

• Extremely small base area

• No contact between the casting and the exothermic riser material

• Multiple versions to fit your process

EXACTCAST™ BKS EXACTCAST™ BKS C

EXACTCAST™ KMV-QM

Breaker edge risers use a loose molded part in the bottom area of the riser and the corresponding spring-pin

to create a specifically defined breaking point, which makes it easier to break off the riser and significantly

reducing fettling costs and can in some cases completely eliminate the need for finish grinding. Available in

fluorine free. The BKS C mini-riser – including a center hole – is usable with a rigid pin. Both varieties are

available in a fluorine free formulation.

Mini-Riser

Fixed Closed spring-pin



BKS

KMV-QM


EXEXF

EXEXF


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Mini-Risers with Free-Moving Metal Necks The most efficient & high performing mini-risers

Benefits

• No need for breaker cores

• Extremely small base area

• No contact between the casting and the exothermic riser material

• Multiple versions to fit your process

• Prevents riser particles falling into the mold

EXACTCAST™ Optima KL

EXACTCAST™ Optima KMV-CC

Breaker edge risers use a loose molded part in the bottom area of the riser along with a corresponding spring-pin

to create a specifically defined breaking point. This, in turn, makes it easier to break off the riser and significantly

reduce fettling costs. In fact, in some cases one can completely eliminate the need for finish grinding.

An incorporated cap and loose tube prevents riser particles falling into the mold. Both styles are available in a

fluorine free formulation.

Mini-Riser



Optima KL

Optima KMV-CC


EXEXF

EXEXF


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Insertable Risers with the Efficiency of Mini-Risers Optimized yield with insertable sleeves

Benefits

• Improved yields

• Additional high insulation effect

• Available in multiple sizes

EXACTCAST™ KIM Insertable

EXACTCAST™ KIM-QM

The new EXACTCAST™ KIM insertable mini-riser line was created to service customers looking for options

that didn't come at the expense of high metal usage. The "KIM" accomplishes this by doubling the riser

wall thickness. In addition, by incorporating a conical shape less metal is required to fill the space. Total riser

weight is also of little concern due to the lightness of the refractory material composition. Available in a fluorine

free formulation, with or without a breaker core and with metal neck reduction.

Mini-Riser



KIM

KIM-QM


EXEXF

INEXEXF

Recommendations only; please consult an ASK-representative for more informationKIM insertable mini-riser is also available with a breaker core (KIM-GP)

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Riser Sleeves for Insertion Precise dimensional stability with no deformation

Benefits

• Low gas evolution

• Consistent thermal properties & performance

• Available in custom shapes & sizes

• Can be used with a breaker core

Benefits

• Improved feeding consistency

• Reduced segregation

• Available in all formulation types

EXACTCAST™ Insertable Riser Sleeves & Covers

Riser covers and sleeves are available in highly

exothermic and insulating versions. They are

characterized by their high level of strength and

dimensional accuracy. Suitable for inserting into

molds as well as automatic casting systems and being

placed in DISAs using core setters. They can also

be used with breaker cores. Available in fluorine free,

with or without a breaker core.

EXACTCAST™ Cover Lids & Floating Cover Lids

With ASK’s cover lids you replace the need to apply

the typical powdered hot topping to open risers. In

fact, they are much more consistent in performance

to standard hot toppings due to their predetermined

size and weight. The floating cover lids, for reference,

are placed inside the feeder when the mold is closed

and float up as the riser fills with molten metal.

Available in fluorine free.

Riser-Sleeves



Insertable sleeves

Cover lids

= recommended

INEXEXF

INEXEXF


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Riser Sleeves for Open Riser Applications Precision grade designs for multiple applications

Benefits

• Low gas evolution

• Consistent thermal properties & performance

• Available in custom shapes & sizes

• Can be used with a breaker core

Benefits

• Reduced contact area

• Dimensional accuracy

• Consistent thermal properties and performance

EXACTCAST™ Cylindrical Sleeves

EXACTCAST™ cylindrical sleeves are used primarily

in open riser applications. They are available in

insulating and exothermic / insulating formulations.

For your added benefit ASK Chemicals provides

cylindrical sleeves with our patented measuring

markers for easy cutting. Available in fluorine free,

with or without a breaker core.

EXACTCAST™ Neckdown Sleeves

ASK Chemicals EXACTCAST™ neckdown sleeves

are used primarily in open riser applications. They

are available in both insulating and exothermic /

insulating formulations. Also available in tapered

designs. Available in fluorine free, with or without

a breaker core.

Riser-Sleeves



Cylindrical

Neckdown


INEXEXF

INEXEXF


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Pouring Cups for Filtration & Feeding Ideal designs alongside superior filtration

Benefits

• Promotes directional solidification

• Improves metal cleanliness, yield & productivity

• Close over design available for high production

green sand

EXACTCAST™ Pouring Cups

EXACTCAST™ pouring cups are used in direct pouring applications, promoting directional solidification

and increasing metal cleanliness. Containing high quality ASK Chemicals’ filters: UDICELL™ & EXACTFLO™

they are available for use in multiple metal applications, including aluminum. They are also available in sizes

ranging from 2" to 7" diameter (50.8 to 177.8 mm).

Pouring Cups



Poring cups

= recommended

INEXEXF


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Added Value for our Customers

Benefits

• Improved decision-making via greater transparency

• Reliable recommendations

• Quick response

• Customized solution development

• Cost in-use reporting (i.e. savings)

• Casting defect analyses

• On-site training sessions

Application technology and technical sales – for complete process transparency

Application technology and technical sales at ASK Chemicals offer our customers comprehensive expertise

in all areas of foundry technology and metallurgy. We offer a comprehensive service that focuses on the

production process as a whole and helps customers not only to cut costs but also to enhance their processes.

ASK Chemicals also conducts casting defect analysis and offers tailored training sessions on the customer’s

own premises.

EXACTCALC™

EXACTCALC™ software, which is exclusive to ASK Chemicals, was specifically designed to assist the foundry engineer with riser & gating system design. With EXACTCALC™ you'll receive critical and comprehensive calculations: casting weight, modulus, riser feeding distance, riser size, riser neck contact dimensions, gating system dimensions and filter size.

Benefits

• Accurate recommendations

• Customizable “learning feature” – specific to your foundry

• Printable results

Cores / Molds

Simulation Prototypes

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Benefits

• Higher productivity and optimized catalyst

consumption

• Manufacturing process design, including inorganic

technology

• Calculation of optimal feed

• Optimized design and manufacture of model

plates, core boxes and molds

• Less scrap

• Shorter product launch times

• Quicker time-to-market

Design Services – for perfect casting results

Our Design Services team monitors the entire casting development process from initial design to final production

of actual cast parts (i.e. prototypes). Our highly experienced engineers enjoy a wide range of knowledge

within all aspects of foundry technology and metallurgy. In addition, we use only the most advanced simulation

software offered today: MAGMA, Novacast, FLOW-3D and Arena-Flow®. Beyond fully optimized designs

and simulation expertise, the Design Services team cooperates with external companies and service providers

to assure proper project alignment for unparalleled results and guaranteed customer satisfaction.

Simulation services

The simulation of casting processes provides foundries with invaluable casting mold information. Specifically, this benefit allows for the optimization of gating & feeding systems, overflows, venting design and risers. Moreover, it provides critical insight into the influences and effects directly related to casting integrity such as, cooling & heating measurements and filling & solidification times.

From the idea to the prototype

ASK Chemicals supports your entire process from concept to prototype production. How you benefit: comprehensive expertise from a single source.

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Benefits

• Highly experienced researchers

• Global presence and availability

• Comprehensive knowledge of the regional sand

types and technological requirements

• Short response times for our customers

• First class equipment

Pilot foundry

• Fully equipped research foundry

• Mold production, mold / core package assembly and casting

• "Real World" foundry process representation

Metallurgical investigations

• Comprehensive examination of the graphite structure and metallic matrix: Graphite size, Number of nodules, Degree of dispersion, Nodularity, Ferrite / pearlite ratio

• Preparation of metallurgical reports

Sand laboratory

• Examination of high temperature materials

• Testing of tensile strength, compression and transverse loading

• Sand characterization and analysis

Product development and technical support

• Casting defect analysis

• Full spectrum chemical & polymer analysis

• Product, process and test method development

Comprehensive research and development services

Research and development – for innovation near you

Our R&D department performs innovation driven groundwork as well as market and customer driven

development. Interaction between these three areas is of fundamental importance in offering our customers

technologically sophisticated products and efficiency enhancing solutions at all times. Through close

cooperation and the constant exchange of ideas with our application technology and technical sales specialists,

R&D at ASK Chemicals is always in tune with the market and also has a presence on the customer's own

premises itself.

ASK Chemicals L. P.495 Metro Place SouthSuite 250Dublin, OH 43017Phone: +1 800 848 7485Fax: +1 614 761 [email protected]

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Global Feeding Systems ManagerCalogero VasalloPhone: +49 211 71 [email protected]

exactcast™ - ask chemicals · complicated disposal of used sand ... • plastic cap eliminates...

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