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HOME > FEATURE > MINI-RISERS ARE A BIG IMPROVEMENT FOR FEEDING PERFORMANCE

Mini-Risers are a Big Improvement for Feeding

Performance

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Mini-risers are a significant advance in feeding system technology, offering an

efficiency rating of 70% compared to cylindrical sleeves, which are roughly 30%
efficient.

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Mini-risers are a significant advance in feeding system technology, offering an efficiency rating of 70%
compared to cylindrical sleeves, which are roughly 30% efficient.

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Mini-riser products developed by ASK Chemicals are a

significant advance in feeding system technology, offering an
efficiency rating of 70% compared to cylindrical sleeves, which
are determined to be about 30% efficient. The development
provides an opportunity to reduce the overall size of the riser,
significantly increasing the casting yield and reducing the space
needed to apply them. Mini-risers also are seen as a step forward
in the continuous improvement of feeding systems.

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The first advance in mini-riser technology was the introduction

of a spring pin to support the mini-riser on green sand patterns,
and creating a sand layer between the riser and casting in order
This cross-section shows
to avoid contact between the exothermic material and the sand.
a riser sliding over a
This increased the surface quality of the casting, which may be
metal tube as sand is
compromised by the reactions of the exotherm during
compacted between the
sleeve and the pattern.
solidification. The introduction of shell-sand breaker cores,
The result is a small
which are in direct contact with the casting, reduces cleaning
riser neck with an
costs even more. However, as more modern, high-pressure
optimal breaker edge.
molding lines with higher compaction of the molding sand
became more popular, risers with breaker cores achieved their
limit. The pressure of the molding sand may destroy the breaker
core, which can create inclusion defects in the casting. Also, breaker cores can wear down
the pattern surface, which can be seen clearly on the casting surface.
Another important advance was the merging of ASK Chemicals Exactcast cold-box
technology into the mini-riser concept. The first mini-risers used a sand-based
exothermic formulation, as opposed to the traditional fiber slurry-based riser sleeves. The
sand-based exothermic sleeves provided higher compressive strengths, which was needed
to withstand the high molding pressures used to ram the sleeves into the mold. They were
also heavier and reacted more violently with the casting surface.
Replacing the sand with low-density refractory materials allowed a weight reduction of
nearly 75%, and replaced the sand with an insulating mix that improved the mini-riser
performance. Since the mini-risers weigh less, less exothermic material was needed to get
the sleeve to the same temperature. This helped to reduce the potential for aluminum
contamination and graphite nodularity degradation in the metal. ASK Chemicals
developed fluoride-free formulations too, for use in ductile iron applications, which
eliminated the potential for fish-eye defects and graphite flake formation.

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Ask the Expert

Mini riser with metal neck breaker

To take advantage of these details,
ASK Chemicals developed a mini-riser
with a metal breaker neck. This riser is
positioned on a pin with a conical metal
tube. When green sand falls into the
mold it builds up around the neck, and
during compaction of the mold the riser
moves down and slides over the metal
tube while sand is compacted between
A manganese steel casting fed with an Exactcast
the sleeve and the pattern. The result is a miniriser, taking advantage of the reduced
contact area on a particularly difficult-to-feed
very small riser neck with an optimal
breaker edge designed to simplify knock casting geometry.
off and cleaning of the casting: Many
foundries eliminated grinding completely after knocking off the riser, according to ASK.
The risers downward movement causes the molding sand under the riser to be very well
compacted, and the casting has a perfect contact surface.

NOV 30, 2014

ARTICLE

Comparing Warm-Box
Binders VOC
Emissions
A new laboratory method
for VOC estimates suitable for warm-box binder systems
is available....More
OCT 31, 2014
ARTICLE

The Advantages of
Floating Cover Lids
vs. Hot Toppings
Hot toppings are
frequently under-applied or inconsistently applied.

The low contact area of the new mini-risers allows for proper feeding of some very
difficult casting geometries. This is especially beneficial on castings that have a contoured
geometry, where the riser meets the casting and where a reduction in the contact area is
needed. In one example, a wear part casting produced in standard manganese steel, the
low shrinkage rate of the steel allows for the use of mini-risers that can lead to a reduction
in required feed metal of up to 3-5 times what a normal cylindrical riser sleeve can
provide, with little difference in feeding performance. This was first tested using
solidification modeling and then validated in a steel foundry. This also achieved a
significant reduction in surface contact with the casting, leading to the possibility of
simply knocking off the risers instead of the more costly method of arc-air cutting.

Floating cover lids fit inside open risers with consistent

Even more recent improvements in Exactcast riser design have led to newer mini-risers
that combine several optimal benefits into a single product. Now, the metalcaster is able
to reduce not only the size and weight of the riser but also the risers footprint on the
casting. These advancements improve casting yields significantly by improving feeding
performance. In some cases the result is more room in the mold for more castings to be
placed, significantly increasing the metal casters productivity.

Learn about the physics of seven

By combining functionality, performance, and cost reduction, ASK Chemicals new minirisers have raised the expectations for metal feeding performance and allow foundries to
produce highquality castings at a much lower cost.

effects on alloy metallurgy and strength.

thickness, for maximum coverage and optimal

thickness....More
View Morel

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