Kärntner Montanindustrie - Tecmos...Kärntner Montanindustrie GmbH (KMI) is an Austrian company,...

KÄRNTNER MONTANINDUSTRIE

MIOX® as core sand additive

KMI Presentation - MIOX® as moulding material additive rev02 EN

© 2017 KMI 1

The Company

Kärntner Montanindustrie GmbH (KMI) is an Austrian company,founded in 1932. The company owns micaceous iron oxide minesand mineral processing facilities. The headquarters are in the castleof Wolfsberg, the regional capital. The mine and processing plantare located not far from that in Waldenstein, both in the State ofCarinthia.


© 2017 KMI 2

The Waldenstein Mine

KMI‘s mine at Waldenstein is

a well-known source of Micaceous Iron Oxide (MIO)

with characteristic lamellar structure and high purity.

The reserves are sufficient for the next decades. The mine is anunderground operation, which enables an all-season excavation.


© 2017 KMI 3

The Mineral

Waldenstein ore contains a naturaliron oxide (Fe2O3) whichdistinguishes it from other iron oreswith its metallic grey lustre.

Its lamellar structure – resembling that of mica – has also given it its name:

Micaceous Iron Oxide (MIO)


© 2017 KMI 4

The Processing Plant

KMI‘s processing plant is in vicinity

to the MIO mine.

The crude ore is sorted, sieved and classified by specialtechniques. Through continuous development of the beneficiationknow-how, the distinguish lamellar structure of the MIO – gradesis secured – independent from fineness.


© 2017 KMI 5

KMI – an Expert in Micronization

KMI has long-term expertise in

delamination of minerals. Further

investments in state-of-the-art grinding

technology enabled the micronization of

micaceous iron oxide.

These products are the finest on world markets.

Today, KMI is acknowledged as the world leader in MIO-technology, research and development.


© 2017 KMI 6

Typical applications

Coatings

Heavy dutycorrosionprotection

Decorativemetal

protection

Partial replacementof Zinc-Dust

Thin film corrosionprotection

Powdercoatings

Coil coatings

Polymers

Automotive

Technical parts

Packaging

Building & construction

Furniture

Electrical & electronic

Ceramics

Tiles

Sanitary-ware

FrictionMaterials

Brake pads forpassenger cars

Brake pads forcommercial

Brake pads formotor cycles

Brake pads forrail industry

Industrial Friction linings

Foundry

Core sandadditives

Coatingadditives

Special Applications

Welding rods

Paper


© 2017 KMI 7

MIOX® - the Brand of the Market Leader

MIOX® is the registered

tradename of KMI for its

micaceous iron oxide products.

For decades KMI have been renowned as worldwide leader in thesupply of iron ore pigments for anti-rust protective coatings.

Export rate of more than 95%

Customers in more than 80 countries


© 2017 KMI 8

Quality counts first

ISO 9001:2015 & ISO 14001:2015

Product quality, consistency andsupply reliability are the pillars ofKMI’s commitment.

KMI is aware of the stringent quality demands of their internationalcustomers.

We are aware of the importance for the environment and the futureof our children. KMI is committed to ensuring that all industrialpractices and products are socially, environmentally and economicallysustainable.


© 2017 KMI 9

MIO – a rare Mineral

Mineralogy: Hematite

Chem. formula: Fe2O3 (iron-III-oxide)

Form: lamellarColor: grey to reddish brown

metallic

Density: 4,8 g/cm³

Hardness: 6,0 – 6,5 MohsSafety: natural mineral, harmless

Micaceous iron oxides (MIO) are a rare mineral. Significant resources areknown in Europe (Austria), Asia (China), Australia and Africa. There aremajor differences in mineralogy, lamellarity and iron content betweenthese sources.


© 2017 KMI 10

MIOX® as inorganic core sand additive

Sand expansion defects like veining still rise to cost-intensive challenges for foundries due to rework or rejects

MIOX was tested for this application as core sand additive for the reduction of veining

With its lamellarity MIOX is significantly different to usual iron oxides which are partly used as

veining additives


© 2017 KMI 11

Source: www.giessereilexikon.com

MIOX® as inorganic core sand additiveVeining can occur in all foundrymaterials. Cast iron with nodulargraphite, malleable cast iron andbronzes containing lead are particularlyprone to veining, whereas aluminumand magnesium alloys are less prone toveining.


© 2017 KMI 12

Source: www.giessereilexikon.com

Veining is likely to occur on the inner contours (cores) of the cast partswhen chemically hardened mold materials are used. Its formation iscaused by cracks in the surface of the mold part that can be penetratedby the liquid metal. Since veining must primarily be attributed to the heat-induced expansion of the mold materials, mold parts made of silica sandare particularly at risk. The molten metal surrounding the core causes atemperature gradient between the surface and the center of the core,which leads to stress.

MIOX® as core sand additive -Cold box casting trials

© 2017 KMI 13

PUR-Cold-Box – core sand

Quartz sand H 32 (SiO2 = 99,8 %)

PUR-Cold-Box-Binder0,8 % Binder 7241 0,8 % Activator 6324

Core sand additivesComparison without additiveComparison with commercial additives, 1 % and 2 % addition:

- MIOX® AS- MIOX® Micro 40R- comparison-additive A - inorganic- comparison-additive B - organic- comparison-additive C - organic


© 2017 KMI 14

Performed Tests *)

Microscopy of additives

Flexural strength of core

Casting test for veining

Influence on bentonite-bound recycled molding material (green sand): - green compression strength- green tensile strength- gas permeability- beginning of sintering- electrical conductivity- content of active clay

*) carried out at Gießerei-Institut, TU Bergakademie Freiberg and Österreichisches Gießerei-Institut ÖGI


MIOX® as core sand additive -Cold box casting trials

© 2017 KMI 15KMI Presentation - MIOX® as moulding material additive rev02 EN

MIOX® as core sand additive -Compared materials

MIOX® AS inorganic

MIOX® Micro 40Rinorganic

Additive Ainorganic

Additive Binorganic/organic

Additive Cinorganic/organic


MIOX® as core sand additive -Recommended MIOX® products

MIOX® Micro 40RMIOX® AS


MIOX® as core sand additive -Compared materials

MIOX® AS inorganic

MIOX® Micro 40Rinorganic

Additive Ainorganic

Additive Binorganic/organic

Additive Cinorganic/organic

x 200

x 200 x 700

x 200 x 200


MIOX® as core sand additive -Core sand with compared additives

Core sandwithout Additive

Core sandMIOX® AS inorganic

Core sandMIOX® Micro 40R

inorganic

Core sandAdditive Ainorganic

Core sandAdditive B

inorganic/organic

Core sandAdditive C

inorganic/organic


MIOX® as core sand additive -Phenol Index and Loss on Ignition

Standard Unit MIOX® Additive A Additive C

Dry residue(105°C)

DIN EN 14346

% 99,8 99,6 98,6

Phenol-Index(in eluate)

DIN 38409-16

mg/kg TS < 0,1 - -

Gas evolutionof core

sandml gas / l sample 30 40 400

Loss on ignition % < 3 < 3 13


with addition of 1 % MIOX minor reduction of a maximum of 5 %

with addition of 2 % MIOX moderate decrease by roughly 10 %

MIOX® as core sand additive -Bending strength


Casting trial for veining

Cast iron GJL-250 at 1400 °C / 2550 F

Casting height approximately 500 mm

Additon of 1 % additive

- MIOX® AS

- MIOX® Micro 40R

- Comparison-additive A – inorganic

- Comparison-additive B – organic

- Comparison-additive C – organic

MIOX® as core sand additive -Casting trial for veining

MIOX® as core sand additive -Result casting trial


Result: significant reduction of veiningMIOX Particle size: finer type shows best result

Value Veining

0 no veining

1 low veining

2 medium veining

3 strong veining

4 very strong veining

4

without Additive

3 - 4

Additive A

2 - 3

MIOX® AS

2 - 3

Additive B

0 - 1

MIOX® Micro 40R

0 - 1

Additive C


Circulation tests with addition of core sand (with 2 % additive) to the bentonite-bound green sand in 5 %-steps up to 25 %

Simulation of adding broken cores with thermally untreated cold-box-core sand

Simulation of adding casted cores with thermally stressed cold-box-core sand (800 °C / 1472 F)

Measurement of

- Wet tensile strength - Electrical conductivity - Green compression strength - Active clay content- Begin of sintering - Gas permeability- Green tensile strength

MIOX® as core sand additive -Influence of used core sand on green sand


No significant influence on wet tensile strength

MIOX® as core sand additive -Wet tensile strength


No significant influence on the sintering point with addition under 15 % core sand

MIOX® as core sand additive -Begin of sintering


No significant influence on green tensile strength

MIOX® as core sand additive -Recycled core sand - Green tensile strength


No significant influence of gas permeability

MIOX® as core sand additive -Gas permeability


MIOX® as core sand additive -Results production trial: non-coated cores

Core 1 Core 2


MIOX® as core sand additive -Results production trial: coated cores

Core 2

without MIOX®

with MIOX®


MIOX® as core sand additive -Production trials: calculation cost-savings

* plus savings due to non-coating of the cores

WeightCost

compared organic additive

CostMIOX

Micro 40RCost-savings

Cold-Box kg % % %

Core 1 3,0 100 71 * 29

Core 2 0,96 100 70 * 30

Further examples

Core 3 5,2 100 85 15

Core 4 1,5 100 80 20

Core 5 1,75 100 75 25


MIOX® as core sand additive

Less expansion defects – significantly less veiningCost savings – less finishing work requiredLess gas blister defects (binding nitrogen)Good core strengthOnly inorganic components – no degassingLess adhesion to boxes and mixersCompatible with core sand binders and bentonite bound sandLow influence of used core sand on mechanical properties of green sandExcellent processabilityEco-friendly (no odour or pollutant emission)Unlimited shelf life

without MIOX with MIOX

Recommendation for application:Addition of 1 - 5 % to core sand

KMI‘s Business Objective

Kärntner Montanindustrie wants to be seen by itscustomers as a synonym for product innovation andcustomer orientation.

We always appreciate to work on newdevelopments together with our customers.

It is the company's objective to further extend itsposition as a major player and to develop newapplication fields and markets for functionalindustrial minerals.


© 2017 KMI 32

Contact


© 2017 KMI

Kärntner Montanindustrie GmbH

Schloss 1A-9400 Wolfsberg, AUSTRIA

Tel: +43 (4352) 54 5 35 – 0Fax: +43 (4352) 54 5 35 – 135

www.kmi.at

33

Kärntner Montanindustrie - Tecmos...Kärntner Montanindustrie GmbH (KMI) is an Austrian company,...

Documents

Transcript of Kärntner Montanindustrie - Tecmos...Kärntner Montanindustrie GmbH (KMI) is an Austrian company,...