Kalminex-2000plus en

Revision No: 006
Date: 06/18
Steel Foundry • Iron Foundry
Product Datasheet - Feeding Systems
KALMINEX*2000plus
Accurately formed, low density, highly exothermic and insulating sleeves for insert or
ram-up application in iron and steel castings.
Product Description KALMINEX 2000plus are a range of highly exothermic and insulating feeder sleeves used to
feed all types of iron and steel castings in the modulus range between 9 and 40mm.
KALMINEX 2000plus feeder sleeves are available in both open and blind designs. Blind and
open sleeves are available in diameters from 25mm to 150mm with increments of 10mm.
The manufacturing process specifically developed for this unique feeder sleeve not only
ensures a low density of =0.60 gms/cc and a high grade of insulation but also ensures precise
& consistent dimensional accuracy and high strength.
Benefits • KALMINEX 2000plus sleeves extend the solidification time of feeder by 2.55 to 2.9 times
compared to sand feeders and thereby reduce feeder metal requirement by 75% to 80%;
substantially improving casting yield.
• KALMINEX 2000plus sleeve when used as a top feeder reduces the contact area, thereby
giving reduction in gas cutting and grinding area to the extent of 50% to 70% over sand
feeder; substantially reducing fettling cost.
• KALMINEX 2000plus feeder sleeves are also supplied with Breaker Core made of shell sand.
This will enable knocking-off of feeder; eliminating the need of gas cutting and further
reducing fettling cost. Figure-2 and 3 shows the sketch of a sleeves and standard Breaker core.
• KALMINEX 2000plus feeder sleeves improve foundry productivity as more number of moulds
can be poured in one heat. Labour productivity is also improved as gas cutting and fettling
work is reduced.
• KALMINEX 2000plus feeder sleeves have close dimensional tolerance and hence fit snugly in
the cavity and there is little or no metal penetration in the gaps. Small air gap between sleeve
and mould facilitates extra insulation and can prolong solidification time in the order of 8% -
10%.
• The inconsistency of shrinkage defect associated with sand feeder is eliminated with the use
of KALMINEX 2000plus feeder sleeve. Thus sound castings are ensured consistently by
extending the use of sleeves in automated molding lines.
• KALMINEX 2000plus feeder sleeves being highly exothermic in nature can also be used as a
cold feeder. Thus the gating system can be simplified. This is particularly beneficial in SG iron
castings.
• Unlike exothermic sleeves, KALMINEX 2000plus sleeves can be placed directly on the cast
surface without the need for sand collar, provided there is sufficient machining allowance.
• KALMINEX 2000plus feeder sleeves also have following additional features:
• Sleeve strength is higher by 50% - 70% than other conventional sleeves, means less
breakage during moulding.
• Sleeves are available in metric sizes, enabling easy sleeve selection.
• Sleeve has high permeability and low hygroscopicity.
• Sleeve has uniform wall thickness and William’s wedge is incorporated in the blind sleeve;
means improved insulation and feeding performance.
• Sleeve has consistent thermal and physical properties.
Foseco India Limited Gat Nos. 922 & 923, Sanaswadi, Taluka Shirur, District Pune - 412208, Maharashtra (INDIA)
Tel: +91 (0)2137 668100, Fax: +91 (0)2137 668160, www.foseco.com
KALMINEX*2000plus * Foseco, its logo and KALMINEX are trade marks of the Vesuvius Group, registered in certain countries, used under licence.
Page 1 of 8
Revision No: 006
Date: 06/18
Purpose
• Conventional sand feeders give poor casting yield and have large casting contact area leading
to high fettling cost.
• The principles of using exothermic and insulating sleeve as a method of increasing feeding
efficiency of a feeder have been well established for a number of years.
• KALMINEX 2000plus sleeves combine both approaches of exothermicity and insulation.
• KALMINEX 2000plus sleeve minimizes initial chill as the feeder gets filled. Gradually, as the
head settles, a vigorous exothermic reaction is initiated and a large amount of heat is made
available to the riser metal.
• On the completion of the exothermic phase, the insulating properties of the sleeve matrix
take over again ensuring the total solidification time of the riser metal is substantially
extended.
• KALMINEX 2000plus sleeve therefore has a triple action – initial insulation, an exothermic
second phase and final long-term insulation -thus offering optimum feed characteristics.
• With their exothermic / insulating nature, the feeding efficiency of KALMINEX 2000plus
feeder sleeve is high and so, a conventional sand feeder can be replaced by much smaller
KALMINEX 2000plus sleeve, whilst maintaining feed performance.
• Hence, casting yield is significantly increased and due to smaller contact area of the
KALMINEX 2000plus feeders, fettling cost is reduced.
Instructions for use
• Table-1 & 2(A) gives the effective modulus and the volume of metal in various sleeve sizes.
Table-3 gives the feeding efficiency (defined as percentage of metal that can be fed from the
feeder) of KALMINEX 2000plus feeder sleeves for various casting geometry. These tables
would enable selection of the appropriate sleeve size.
• While selecting the sleeve size, care should be taken to ensure that casting modulus, its feed
metal requirement and feeding distance criteria are satisfied.
• KALMINEX 2000plus feeder sleeves are suitable for insert and ram-up applications. For
insert applications a specially designed sleeve pattern should be fixed to the pattern plate.
The sleeve should be push-fit into the formed cavity inside the mould. The external sleeve
dimensions are given in Table-1 & 2(A).
• The sleeve pattern or drawings for different sizes are available from Foseco. For ram-up
application KALMINEX 2000plus feeder sleeves should be mounted on a suitable peg prior to
moulding so as to ensure correct placement. Internal sleeve dimensions are given in Table-1 &
2(A) to facilitate peg design.
• A metal pad of 6mm to 15mm thickness is recommended between sleeve and casting
surface when used as a top feeder. Alternatively, a breaker core can be placed between the
sleeve and casting surface.
• When open sleeves are used, metal should be poured upto its full height. The recommended
quantities of FERRUX 707F anti-piping compound must be used to prevent heat loss from the
open face of the feeder. Please refer to FERRUX 707F data sheet for further information.
• A vent hole is provided in the top cover face of blind sleeves as shown in Figure-3. This hole
should be punctured upto the top of the mould box to allow easy escape of mould air during
pouring.
Page 2 of 8
Revision No: 006
Date: 06/18
Application • KALMINEX 2000plus feeder sleeves has a favourable taper, which make it possible to insert
the sleeve into a preformed mould cavity. The close dimensional tolerance, higher strength and
excellent surface finish of the sleeve help to neatly push-fit it into the cavity.
• These features make KALMINEX 2000plus feeder sleeve suitable for the following
application, which otherwise would not have been possible.
• In automatic moulding lines, where pattern plates are not accessible, feeder sleeves have to
be essentially inserted after the mould is stripped.
• In high pressure moulding machines where pattern plate is accessible but squeezing
pressure makes it impossible to place sleeves while moulding and hence calls for insert
application.
• In vertically parted moulding system, like DISA.
• In shell moulding.
• In automatic moulding lines where cope is not accessible but drag is, sleeves can be placed
in a drag mould over a feeder base or on a cover core as a close-over application.
• In ram-up application where sleeves are placed on pattern plate prior to moulding in either
machine moulding or hand moulding. The sleeves have to be of high strength to withstand the
jolt-squeeze and ramming pressure.
Please refer to the method of inserting KALMINEX 2000plus sleeve shown in Figure-1.
Preformed cavity for inserting the feeder sleeve is formed by placing a specially designed
sleeve pattern on the pattern plate. The sleeve pattern, which forms the cavity in the cope,
provides equally spaced vertical sand ribs that are compressed/crushed by the sleeve as it
enters and it grips the sleeve tightly. No gluing or nailing is necessary. The use of specially
designed Foseco sleeve pattern is recommended as shown in Figure 1a.
Page 3 of 8
Revision No: 006
Date: 06/18
Technical Data KALMINEX 2000plus (open sleeve)
Table -1 : KALMINEX 2000plus sleeve selection table (open sleeve)

Modulus (mm) Nominal Dimensions (mm) FERRUX Pack Size
Sleeve Volume
707F Sleeve with breaker
Size Effective Geometric (cc) Ødb ØDb Ødt ØDt H Sleeve
(gms) core
30x75 9.6 5.4 37 27 47 23 43 75 25 240 -
40x75 13.8 7.7 87 41.5 62.5 35.5 56.5 75 25 144 128
50x75 16.7 9.4 147 52 73.5 48 69.5 75 25 104 84
50x100 17.7 9.9 193 52 73.5 47 68.5 100 25 104 42
60x75 17.9 10.0 178 57.5 80 52.5 75 75 30 84 72
65x100 20.6 11.8 297 64 88.5 59 83.5 100 30 66 36
70x100 22.0 12.6 355 69.5 94 65 89.5 100 30 60 25
80x100 23.6 13.7 445 79 104 71.5 96.5 100 50 50 20
80x125 25.0 14.5 556 79 104 71.5 96.5 125 50 25 20
80x150 26.0 15.0 668 79 107 71.5 100 150 50 25 20
90x150 28.1 16.6 852 89 118 81 111 150 70 20 16
100x150 30.4 17.9 1041 97 127.5 91 121.5 150 100 16 12
120x150 34.9 20.5 1505 116 148 110 142 150 150 12 9
130x150 36.1 21.5 1711 124 158 117 151 150 180 9 9
140x150 38.0 23.0 2084 136 171 130 165 150 250 9 6
150x150 39.8 24.2 2393 146 182 139 175 150 320 7 6
• Bottom surface of the sleeve feeder is taken as cooling surface.
• Full height of the sleeve is considered in calculating the volume of metal in the sleeve.
• Dimensions given above are nominal. Sleeves are precise in dimensions. Only minor variation to the extent of 1.5mm in
diameter and 2mm in height may occur.
• FERRUX 707F should be used for sleeves on all open sleeves to get the desired sleeve performance.
• Sleeves are shrink-wrapped in cardboard trays for ease of handling.
Page 4 of 8
Revision No: 006
Date: 06/18
Table-2(A) : KALMINEX 2000plus sleeve selection table (blind sleeve)
Modulus (mm) Nominal Dimensions (mm) Pack size
Volume
Sleeve Size
(cc)
Sleeve with breaker
Effective Geometric Ødb ØDb Ødt ØDt h H Sleeve
core
ZP 3.5/5 KE 9.1 5.30 31 35 47.5 30.5 44 39.5 49.5 360 -

ZP 3/8 K 9.3 5.10 34 27 47 23 43 72 80 240 -
ZP 4/7 K 12.5 6.90 68 41.5 62.5 35.5 56.5 62 71.5 144 128
ZP 5/8 K 15.8 8.70 131 52 73.5 48 69.5 70 80 104 84
ZP 5/11 K 17.0 9.40 184 52 73.5 47 68.5 100 110 104 42
ZP 6/9 K 17.3 9.60 177 57.5 80 52.5 75 78.5 91 84 72
ZP 7/10 K 20.7 11.50 294 69.5 94 65 89.5 87 99 60 25
ZP 8/11 K 23.1 12.90 410 79 104 71.5 96.5 96.5 109 50 20
ZP 8/14 K 25.0 13.90 537 79 104 71.5 96.5 125 138 25 20
ZP 8/17 K 26.0 14.50 646 79 104 71.5 96.5 150 163 25 20
ZP 9/12 K 25.4 14.40 567 89 115 81 106 104.5 120 20 16
ZP 9/17 K 28.2 15.90 821 89 115 81 107 150 164 20 16
ZP 10/13 K 28.4 16.10 785 97 127.5 91 121.5 118 133.5 16 12
ZP 10/17 K 30.4 17.20 1002 97 127.5 91 121.5 150 165 16 12
ZP 12/15 K 33.2 19.20 1302 118 154.5 112 148 130 150 10 9
ZP 12/17 K 34.3 19.80 1457 116 148 110 142 150 165 12 9
ZP 13/17 K 35.8 20.80 1660 124 158 117 151 150 165 9 9
ZP 14/17 K 38.3 22.30 2018 136 171 130 165 150 165 9 6
ZP 15/17 K 40.2 23.40 2322 146 182 139 175 150 165 7 6
Page 5 of 8
Revision No: 006
Date: 06/18
• Bottom surface of the sleeve feeder is taken as cooling surface. Effect of surface of William
wedge is not considered in calculating geometric modulus.
Volume of William wedge is deducted from sleeve volume.
• Dimensions given above are nominal. Sleeves are precise in dimensions. Only minor variation
to the extent of 1.5mm in diameter and 2mm in height may occur.
Table-2(B) : KALMINEX 2000plus (blind sleeve) William’s wedge & Vent Hole
Dimensions
William’s Wedge
Vent Hole Dimensions (mm)
Sleeve Size Dimensions (mm)
a b ØD1 ØD2
ZP 3.5/5 KE 12 2 - -
ZP 3/8 K 10 2 5 4
ZP 4/7 K 14 2 7 5
ZP 5/8 K 16 2 10 8
ZP 5/11 K 18 2 10 8
ZP 6/9 K 18 2 10 8
ZP 7/10 K 20 3 12 10
ZP 8/11 K 22 3 14 12
ZP 8/14 K 22 3 14 12
ZP 8/17 K 24 3 16 14
ZP 9/12 K 24 3 16 14
ZP 9/17 K 26 3 18 16
ZP 10/13 K 26 3 18 16
ZP 10/17 K 28 3 18 16
ZP 12/15 K 28 3 18 16
ZP 12/17 K 28 3 18 16
ZP 13/17 K 28 3 20 18
ZP 14/17 K 30 4 20 18
ZP 15/17 K 30 4 22 20
KALMINEX 2000plus ND sleeve
KALMINEX 2000plus ND sleeves are suitable for top feeder applications in steel and iron
castings as the smaller contact area substantially reduces gas cutting and grinding work. It
combines the advantage of breaker core and in many instances it is possible to knock off the
feeder. The contact diameter of the sleeve is less than 50% of the original sleeve, which gives a
reduction in area more than 75%. Hence it will be ideal where the casting contact area is
limited. It will avoid sleeve projecting out and the need for a metal pad.
Page 6 of 8
Revision No: 006
Date: 06/18
Table-2 (C) : KALMINEX 2000plus ND sleeve selection table (ND sleeve)
Nominal
Sleeve Modulus (mm) Volume FERRUX 707F Pack
Dimensions (mm)
Size (cc) (gms) Size
Effective Geometric Ødt ØN h’ H
ND2 14.4 8.1 86 50 20 15.7 60 30 104
ND2 L 16.7 9.8 176 57.2 20 15.7 100 30 104
ND 3 21.6 12.4 291 75 30 26.5 87 50 54
ND 4 28.2 16.6 697 100 40 37 115 100 16
ND 5 34.9 20.6 1310 127 50 49 135 200 10
ND 6 40.3 24.4 2193 150 60 58.5 160 320 8
• Bottom surface of the sleeve feeder is taken as cooling surface.
• Dimensions given above are nominal. Sleeves are precise in dimensions. Only minor variation
to the extent of 1.5mm in diameter and 2mm in height may occur.
• FERRUX 707F should be used for sleeves on all open sleeves to get the desired sleeve
performance.
Table-3 : Typical Feeding efficiency of KALMINEX 2000plus feeder sleeve
% Typical Feed efficiency*
Casting type Thickness Width Length H/D ratio of

H/D ratio of feeder
feeder
2.0 : 1.5
1.49 : 1.00
Cube 1 1 2 25 20
Bar 1 2 8 30 25
Semi plate 1 3 10 35 30
Plate 1 10 10 45 40
Rangy 1 15 30 55 50
*% Feed efficiency: Values are indicative only. May vary depending on metal grade, moulding
sand, sand binder and other process parameters.
Page 7 of 8
Revision No: 006
Date: 06/18
Precautions
• KALMINEX 2000plus feeder sleeves should be stored in a cool and dry place. The sleeves
should be removed from its packing only at the time of use. This is to prevent sleeves from
picking up moisture.
• Sleeve should be kept away from open flames or other source of ignition.
• While making molds, care should be taken to avoid damage or displacement of sleeves.
• Torching and coating of sleeves must be avoided inside the mold.
• In SG iron castings, there could be a possibility, in few instance only, of reversion of
microstructure (upto 5mm depth) from SG iron to CG/grey iron beneath the top feeder. Hence
it is advisable to use top feeders where machining allowance has been provided or use breaker
cores.
• In steel casting composition having very low carbon ( below 0.10%), there could be
possibility of carbon pick up on the riser face in contact with Kalminex 2000plus sleeve, up to
the depth of 2mm to 4mm.
Packaging KALMINEX 2000plus feeder sleeves are available in shrink wrapped cardboard trays. Shrink-
wrapped packing is done for the ease of handling and for reducing moisture pick-up in
sleeves.
Storage & Shelf Life KALMINEX 200plus sleeves should always be stored under dry conditions.Shelf-life is 1 years,
however it is recommended to use the sleeves within 3 months.
Health & Safety See Safety Data Sheet, copies of which are available on request.
Further Remarks For safety reasons the product mentioned above must only be used according to these
application guidelines. The data provided above is for guidance only and does not represent a
specification. All rights to make technical changes to improve the product are reserved.
Page 8 of 8

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Revision No: 006

Steel Foundry • Iron Foundry

Product Datasheet - Feeding Systems

Steel Foundry • Iron Foundry

Instructions for use

Steel Foundry • Iron Foundry

Steel Foundry • Iron Foundry

Technical Data KALMINEX 2000plus (open sleeve)

Table -1 : KALMINEX 2000plus sleeve selection table (open sleeve)

Steel Foundry • Iron Foundry

Table-2(A) : KALMINEX 2000plus sleeve selection table (blind sleeve)

Modulus (mm) Nominal Dimensions (mm) Pack size

ZP 3.5/5 KE 9.1 5.30 31 35 47.5 30.5 44 39.5 49.5 360 -

Steel Foundry • Iron Foundry

KALMINEX 2000plus ND sleeve

Steel Foundry • Iron Foundry

Table-2 (C) : KALMINEX 2000plus ND sleeve selection table (ND sleeve)

Table-3 : Typical Feeding efficiency of KALMINEX 2000plus feeder sleeve

% Typical Feed efficiency*

Casting type Thickness Width Length H/D ratio of

Steel Foundry • Iron Foundry

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