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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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)
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
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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
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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
KMI Presentation - MIOX® as moulding material additive rev02 EN
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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
KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 16KMI Presentation - MIOX® as moulding material additive rev02 EN
MIOX® as core sand additive -Recommended MIOX® products
MIOX® Micro 40RMIOX® AS
© 2017 KMI 17KMI 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
x 200
x 200 x 700
x 200 x 200
© 2017 KMI 18KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 19KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 20KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 21KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 22KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 23KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 24KMI Presentation - MIOX® as moulding material additive rev02 EN
No significant influence on wet tensile strength
MIOX® as core sand additive -Wet tensile strength
© 2017 KMI 25KMI Presentation - MIOX® as moulding material additive rev02 EN
No significant influence on the sintering point with addition under 15 % core sand
MIOX® as core sand additive -Begin of sintering
© 2017 KMI 26KMI Presentation - MIOX® as moulding material additive rev02 EN
No significant influence on green tensile strength
MIOX® as core sand additive -Recycled core sand - Green tensile strength
© 2017 KMI 27KMI Presentation - MIOX® as moulding material additive rev02 EN
No significant influence of gas permeability
MIOX® as core sand additive -Gas permeability
© 2017 KMI 28KMI Presentation - MIOX® as moulding material additive rev02 EN
MIOX® as core sand additive -Results production trial: non-coated cores
Core 1 Core 2
© 2017 KMI 29KMI Presentation - MIOX® as moulding material additive rev02 EN
MIOX® as core sand additive -Results production trial: coated cores
Core 2
without MIOX®
with MIOX®
© 2017 KMI 30KMI Presentation - MIOX® as moulding material additive rev02 EN
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
© 2017 KMI 31KMI Presentation - MIOX® as moulding material additive rev02 EN
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.
KMI Presentation - MIOX® as moulding material additive rev02 EN
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Contact
KMI Presentation - MIOX® as moulding material additive rev02 EN
© 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
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