The handling of molten metals requires the use of refractory materials, which protect „man and machine“ from the high temperatures of these metals and which also ensure the quality of the melt is maintained or even improved; they also keep the machines in good condition, enabling the foundryman to work in a clean and efficient way over an extended period of time.

These refractory materials must be adapted to fulfil the various requirements of the metals. The name INSURAL stands for a group of materials which have proven to be effective especially for aluminium and zinc, for several years now. These materials can also be used for other molten metals, provided the temperature lies below 1000°C.


INSURAL is available both as a paste and as pre-formed shapes. The INSURAL pastes are highly insulating and can be used for example not only as adhesives but also or the repair of cracks and the sealing of joints etc. In the production of ready-to-use shapes, several INSURAL material types are used with differing degrees of strength and insulating properties. Examples of use are launders, nozzles and pre-fabricated pouring ladles for 40 – 1100 kg of aluminium.


Small shapes with very accurate dimensions are also produced, which are suitable as permanent feeders in die-casting (e.g. pistons for combustion engines) as gate linings for wheel production and many other applications. INSURAL 50 is mainly used for these smaller shapes. Because INSURAL is a paste which is poured, very complicated geometrical shapes can be manufactured economically . All INSURAL materials are free from hazardous materials as defined in the „Gefahrstoffverordnung“ (= regulations governing the handling of hazardous goods).


INSURAL140 and INSURAL180 are used for most larger shapes which require a higher strength together with a slightly lower insulating effect. This is often the case when relatively large quantities of metal react only slowly to the slightly lower insulation, or when the contact time between metal and INSURAL is short. Typical applications are ransport ladles, pouring basins, transfer launders or filling funnels.

INSURAL 50 insulating sleeves are highly suitable for use as permanent feeders in die-casting. Dependent on the casting they can be used for 500 to several thousand casting operations.

Applications of INSURAL shapes are extremely varied, which is why only the most typical ones can be described in this brochure. Wherever you may need an insulating, non wetting product, please get in touch with us – together we will find a solution to your casting problem.

Low-pressure casting is the most often used casting process for the production of aluminium wheel rims. The connection between riser tube pipe and die is frequently formed by the upper bush and the intermediate bush, which are made from steel. For the casting process these must be heated to a high temperature. Because of its highly insulating properties, when INSURAL is used in this sector there is no need for further heating.

The upper bush is produced in very many different dimensions and is additionally wrapped in mineral fibre paper, which on the one hand further increases the insulating effect and on the other hand enables a good fit in the steel casing. The intermediate bush is also available in many different dimensions and versions. Special sizes are available.

Advantages:

	No need for heating: Gas savings of up to 25m3 /machine*day
	No rising heat, more die chill
	Higher productivity due to shorter cycles
	Better working conditions due to less heat, less noise, cleaner air

A further application sector for INSURAL shapes is its use in dosing furnaces. In this case the typical consumables - upper filling cone, riser tube and launder - have
proven their effectiveness.

They are a low-cost alternative to claygraphite parts.

The upper filling cone, flow-optimized in accordance with Nielsen principles, is especially of note – it guarantees the turbulence-free filling of the furnace, thereby reducing oxide inclusions in the melt.

Pre-fabricated INSURAL shapes for transport ladles are already in use for metal quantities between approximately 40 kg to more than 1300 kg. Their installation
in existing steel shells is swift and simple.

The newly lined ladle is ready for use once more after a brief period, as a timeconsuming drying operation is not necessary.