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Launders and Troughs

Launder and trough refractory shapes are critical for safe, energy- and cost- efficient molten aluminium delivery from the melting furnace to the casting table. Correct choice of refractory material for particular part of the launder system, shape design, insulation materials impact lifetime of the launder system, quality of the metal, and, eventually, maintenance and overall production costs of the Cast House.

Leveraging decades of experience and knowledge of PERMATECH, acquired by Vesuvius in 2019, we offer wide portfolio of trough refractory materials with excellent non-wetting properties and suitable for every part of a typical Aluminium casting line. For special and high purity applications, we offer sintered high purity fused silica materials. And disregarding the material, we offer capabilities to produce the most complex, customized shapes needed for a specific Cast House layout. 

Refractory Consumables

Transfer / discharge troughs

Transfer troughs, transporting molten aluminium from melting to holding furnace, are exposed to high metal flow, mechanical wear and thermal shocks. They typically require a more robust refractory material and proper insulation to prevent premature cracking due to temperature swings. Vesuvius typically offers SiC-based materials for those applications (e.g. Permatech’s Beta SC65, Onyx 80GR, or Beta 2 if proper insulation layer is not possible due to steel shell design or other limitations). For additional robustness, if customer requires, metallic mesh / fibers can be added to the mix.  

Today, transfer troughs in SiC mixes are regularly designed and produced at Vesuvius facility in the US (Graham, NC) and Rio de Janeiro (Brazil), with additional availability from Ras Al Khaimah (UAE) and Vizag (India).

Transport and casting launders / troughs

Transport, casting and distribution launders downstream of holding furnaces are less exposed to mechanical wear, so preference is typically given to a better thermal shock resistance, high SiO2 content material. Vesuvius produces those shapes using proven Permatech’s Sigma 2SL (~87% SiO2) or Zyacast IP (~80% SiO2) materials.

The critical aspect for those parts is complexity of the shapes and tolerances of the final precast parts, and that where Vesuvius leverages exceptional PERMATECH expertise.

Today, launders made of silica-based mixes are available globally from the original ex-Permatech site in Graham (NC, US), but also from Ras Al Khaimah (UAE) and Vizag (India) to support customers in EMEA, India, as well as from our Rio de Janeiro facility in Brazil.

In case of higher wear resistance needed, Permatech’s Beta SC65 and similar SiC-based materials, or Beta 2 can be used.

High purity applications

For special applications, like aerospace, where purity of the molten metal is the key, or in the final part of the casting line, after filtration, to make sure metal does not pick up any elements from the lining, Vesuvius offers Zyarock launders made of high purity sintered fused silica material (SiO2 > 99.5%) available globally from our location in Feignies, France.

Launder dams and screens

To control metal flow in the casting line, refractory dams and baffles are used typically. Those are made of the same material as the launder shape itself and are custom-designed to fit the launder shape perfectly.

Other launder-related products

For installation, assembly, maintenance and patching of launders and other cast house refractories, several types of Moldable (patching mastic) with excellent adhesion and non-wetting properties are available. 

And to ensure the best performance and life-time of launders, Boron Nitride coating should be applied regularly to the refractory surface.

 

Have issues with your current launders? Want to try Vesuvius quality? Any other questions?
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