C O A T I N G S F I LT R A T I O N F E E D I N G S Y S T E M S M E LT   S H O P   R E F R A C T O R I E S M E T A L L U R G I C A L A N D P O U R I N G C O N T R O L B I N D E R S C R U C I B L E S
MSI+
M ETAL STREAM I N O C ULAT ION S YS T E MS
++ Highly reliable
++ Controlled addition
++ Consistent distribution
++ Reduced casting defects
++ Lower costs
MSI+
MSI In-Stream Inoculant Dispensing Systems for Fixed-Station Pouring
MSI In-Stream Inoculation Systems
MSI represents a range of in-stream inoculant
dispensing systems from Foseco. MSI systems are
designed specifically for use with Foseco’s range of
INOCULIN* alloys. MSI systems can be customised
to meet the unique needs of foundries and can be
integrated with most automated pouring systems
to achieve the highest level of metallurgical process
control across a full spectrum of iron grades.
Over the past 25 years, having sold over 600 MSI
systems worldwide, Foseco has been a leading
innovator in the field of in-stream inoculation
dispensing technology. It has filed a variety of
in-stream inoculation patents and contributed
significantly to the application of related technology
in the industry.
Importance of in-stream inoculation
The influence of ferro-silicon alloy additions changes
over time based a phenomenon commonly called
“fade”. The rate of fade depends on the composition
of the inoculating alloy, metal casting process
temperatures, and the chemical composition of base
iron. In order to achieve consistent solidification
and physical properties of iron, inoculating alloys
are ideally added to the melt immediately before
solidification. The efficiency of an inoculant is
highest when it is added to the pouring stream as it
enters the mould cavity.
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The economical and effective application of
inoculating alloys places stringent demands on
both inoculation alloy and dispensing systems.
Consistent dissolution and nucleation in the melt
requires inoculating alloys with relatively low melting
points and a consistent grain size distribution. The
composition of inoculating alloys should be closely
aligned with the specific grade of iron to which it is
applied. MSI systems are applicable to flake graphite,
spheroidal graphite and compacted graphite iron
grades.
MSI+ 900
MSI+ 900 inoculant dispensing systems incorporate
basic ferro-alloy dispensing features that can be
successfully applied in the majority in-stream
applications. The system is comprised of:
++ control panel with power supply
++ communications interface
++ gravity feed “hot-box” dosing unit
++ inoculating pipe
++ cable package for compressed air and electrical
supplies.
MSI+ DC Dynamic Inoculant Dispensing System
The most recent innovation in the area of in-stream
inoculation is a concept called “Dynamic Inoculation
Control”. Advanced MSI+ DC systems create value for
foundries by delivering the right about of inoculating
alloy, in the right place, at the right time, and at the
lowest possible overall cost.
MSI+ DC (“Dynamic Control”) dispensing systems
incorporate novel control features designed for the
most demanding in-stream applications. The base
model system is comprised of:
++ control panel with power supply
++ communications interface
++ vertical screw feeding “hot-box” dosing unit
++ inoculating pipe
++ cable package.
Optional features include:
++ INOCHECK visual sensing control system – assures
that INOCULIN alloy is being dispensed into the
metal stream at the desired time, location and rate
++ INOCELL dynamic weight control system – measures
a predetermined mass of INOCULIN alloy to assure
accuracy in alloy dispensing weight
++ ITACA thermal analysis system – assures that the
desired nucleation state of iron is achieved and
maintained
++ MSI+ DC can be controlled using an electrical
signal from the stopper control system or through
the use of an optical camera sensing system.
Assuring the accuracy of inoculating alloy dispensing
The INOCHECK visual sensing system continuously
monitors and controls the position and dispensing
rate of INOCULIN relative to the metal stream as it
enters the mould. INOCHECK analyses visual images
acquired from a camera sensor at an imaginary
vertical plane formed by the iron stream and the end
of the dispensing tube. At the instant that the camera
sensor is activated by the presence of the iron stream
during the pouring cycle, INOCULIN is dispensed and
the system detects and quantifies the presence of
grains of inoculating alloys visible in the iron stream.
The system measures the concentration of inoculating
alloys in the metal stream and immediately alerts to
any deviation from predefined norms.
To ensure perfect traceability, the INOCHECK system
stores images of each pouring operation. The data
can be easily sorted by category and displayed
on the control panel or remote monitor. In the
event of virtually any casting problem, INOCHECK
characterises the relative quality of inoculation for
each mould poured. The INOCHECK system thus
enables:
++ validation that each mold has been sufficiently
inoculated
++ assurance by the operator that inoculating alloys
have been synchronised with the metal stream
++ assurance by the operator that the inoculating
alloys are directed at the metal stream using the
alignment feature
MSI+ DC
control unit
MSI+ DC dosing
equipment (Hot Box)
Internal view of the
dosing equipment
INOCHECK
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MSI+
MSI In-Stream Inoculant Dispensing Systems for Fixed-Station Pouring
Controlling the weight of inoculating alloys
An optional dynamic load cell feature called INOCELL
assures a high level accuracy and control of the
INOCULIN dispensing rate.
Stabilising the nucleation state of iron via thermal
analysis
Key foundry process variables like inoculation rate,
holding time, and process temperatures strongly
influence the nucleation state of iron. Consequently,
constant inoculation rates – normally seen as a
controllable process parameter – can result in
variability in the nucleation state of iron and thus
iron metallurgy and physical properties (free-carbide,
graphite-shape, shrinkage tendency, nodule count,
nodularity, ferrite/pearlite ratio).
MSI+ DC can be equipped with an optional, fully
integrated, thermal analysis system, called ITACATM.
Foundries can leverage the advantages of an
integrated ITACATM system to control the influence
of in-stream inoculation. This is accomplished by
periodically sampling the melt to measure its real-time
carbon equivalent value (CEV) and nucleation state
which is automatically derived from the cooling curves
and first derivative analyses. ITACATM then calculates
the appropriate addition rate for inoculating alloys
allowing the operator to make necessary adjustments
using the MSI+ DC control panel thus minimising
variation in inoculation state and the consumption
rate and cost of INOCULIN alloys.
ITACATM thermal
analysis
04/2015 · e
ITACATM cup
testing
*FOSECO, the Logo and INOCULIN are trade marks of the Vesuvius Group, registered in certain countries, used under licence. ITACATM is a trademark of ProService. All rights reserved. No part of this publication
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expressly permitted by law. Applications for permission shall be made to the publisher at the address mentioned.
Warning: The doing of an unauthorised act in relation to a copyright work may result in both a civil claim for damages and criminal prosecution. All statement, information and data contained herein are published
as a guide and although believed to be accurate and reliable (having regard to the manufacturer’s practical experience) neither the manufacturer, licensor, seller nor publisher represents nor warrants, expressly
or impliedly: (1) their accuracy/reliability, (2) that the use of the product(s) will not infringe third party rights, (3) that no further safety measures are required to meet local legislation. The seller is not authorised
to make representations nor contract on behalf of the manufacturer/licensor. All sales by the manufacturer/seller are based on their respective conditions of sale available on request.
© Foseco International Limited 04/15.
COMMITTED TO FOUNDRIES
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