EXACTCASTRisers and Sleeves
Product Line Overview

Market-leading feeding solutions for
perfect castings
EXACTCAST feeding solutions represent inno­

ASK Chemicals offers its customers an integrated

vative solutions and the highest process reliability inapproach that extends far beyond a mere range

the foundry. For instance, the min-riser technology

of products. Our applications engineering andcombining several patents offers unique effi­ciency.

technical sales experts keep an eagle eye on theThese productivity-enhancing developments areentire process stream and provide our customers

industry-leading solutions. Modern casting con­with solutions that are tailored precisely to thecepts are subject to ever-higher quality and cost-prevailing conditions and their needs at all times.

efficiency requirements that do not stop at foundry

This know-how embodied by our specialists is

auxiliaries. Our objective is to reliably support thesupplemented with a comprehensive range offoundry industry to maintain their strong position

services that benefit our customers with genuineon the global markets by refining feeding systems

added value. For instance, our design services

on a continuous basis.

can be applied specifically to the optimizationof the entire process stream – from the develop­

One crucial contribution is provided by our re­ment of the feeding and gating system to series

search and development. This can be described

production – thereby revealing to our customers

as the interaction between research powered by

key savings and improvement potential.

innovation and development based on market
and customer specifications. Our customers mustmeet requirements that are growing in complexity.
Just a few examples are the reduction of emissions,the elimination of casting defects, and the supplyof consistently high quality, not to mention thepressure of costs affecting many foundries. Theserequirements can be met not only with qualified,
motivated personnel and outstanding technologies,
but also top-level research and development
focusing on the elaboration of efficient and ecofriendly solutions, and without sacrificing key performance parameters.

2|Inventors of the mini-riser
Patented technology
Eco-friendly solutions
Local production facilities
Integrated services offering
added value|3Basic Information
EXACTCAST Products
Mini-risers
Riser caps
Sleeves

EXACTCAST TypesWater glass bonded risers

Cold Box bonded risers• Low emissions• Reduced weight• Simple handling• Simple handling• Free of organic materials• Patented Cold Box microspheres
technology

EXACTCAST Formulations
IN formulations	The IN formulation is an insulating
mixture developed for use with all
metals, including steel.

E X formulations	The EX formulation is a standard
exothermic mixture developed for
all ferrous materials. Feeders andriser caps with this mixture exhibit
a low fluorine content.

EXF formulations	These are fluorine-free, exothermic
mixtures. Fluorine-free mixtures not
only offer ecological benefits, butalso improve the quality of casting.

Custom solutions
Apart from the system solutions mentioned in this brochure, ASK Chemicals also offers you custom solutions to fit your individualprocess. Please contact us to discuss your specific needs.
4|The EXACTCAST mini-riser – the formula for success
One crucial factor affecting the productivity of a foundry is the fettling needed on the finished cast part.
EXACTCAST mini-risers, which offer here clear advantages over natural sand and exothermic feeder caps.

Parting surface
113 cm2Parting surface
232 cm2

Feeding weight 41.9 kg
Cast weight 49.5 kg

Feeding weight 12.6 kg
Cast weight 49.5 kg

Cleaning costs

Cleaning costs

Natural risers

Exothermic riser caps

Parting surface
33 cm2

Feeding weight 2.3 kg
Cast weight 49.5 kg

Cleaning costs

Mini-risers

Fluorine-free EXACTCAST risers for a clean environment and better casting
The fluorine-free risers from ASK Chemicals offer you crucial quality advantages and can eliminate fluorine contamination ofthe sand. This benefits both the environment and the foundry by reducing the quantity and disposal costs of the used sand.
Elimination of surface defects
The patented, fluorine-free risers fromASK Chemicals enhance productivity
by eliminating surface defects causedby fluorine reactions.

Reduction of graphite degradation
The patented, fluorine-free recipe helps
minimize graphite degradation in ductile
iron that is usually encountered in thefeeder’s zone of action.
Nodular graphite without degradation

Degraded nodular graphite|5Mini-risers

Mini-risers for standard applications
High-performance, versatile mini-risers for ideal results

EXACTCASTADS

EXACTCASTKMVEXEXFEXEXF

The ADS riser is a high-stability solution suitable for

The KMV mini-riser is a particularly low-weight

No-Bake and hand-mold applications. ADS risers

solution for use with a range of molding types.

are free of fluorine. The riser can also be fitted withThis versatile riser can be fitted with a spring pin

an open spring pin for use on automated green

or simply placed directly on the casting. The KMVsand molding lines.

is a highly exothermic solution available in a fluorinefree formulation.

Benefits

Benefits• Low emissions• Available fluorine-free• Reduced molten iron content for improved yield• Low weight• Reduced molten iron content for improveddischarge• Optimized yield for steel casting

Open spring pin

Open spring pin

Molding process
Green sand andhigh-pressure
molding lines

ChemicallybondedMetal type
GIDI

Steel

Application
Nonferrous
metalsPlaced on
the pattern

ADS
KMV

= recommended,= partly recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
6|Inserted in
the moldMini-risers in steel casting
New ways for metal feeding
Conventional sleeves encountered in steel casting fill the molds with fibers, including rice husks that can lead to casting
defects. Moreover, these slurry sleeves do not utilize their full volume for counteracting shrinkage defects. The yield effected
is only 30 %. The remaining 70 % of the volume is used to maintain the heat in the 30 % of the molten metal needed forfeeding.
This is exactly where the EXACTCAST KMV mini-risers come in, our fiber-free solutions for steel casting. The volume at theriser can be reduced without sacrifice to the feeding performance. The exothermic compound does replace the non-feeding
material and maintains the metal in its molten state. The KMV mini-risers therefore present an efficient and reliable alternative
to conventional slurry sleeves.
Casting defects caused by fiber sleeves
The photo shows surface defects caused by riser materialinclusions.

Casting defects caused by rice husks
The REM image clearly shows riser material residue, here
fibers (orange) and calcinated rice ash, leading to casting
defects. Casting defects caused by fibers are eliminatedwith fiber-free mini-risers from ASK Chemicals.

Reduced feeder volume
Thanks to its reduced feeding volume and its exothermic
formulation, the mini-riser offers interesting savings potential
in steel casting applications and yield improvements.

|7Mini-risers

Mini-risers with metal neck
Breaker cores are no longer needed

EXACTCAST BKS
EXACTCAST BKS C

EXACTCASTKMV-QM

EXEXF

EX
EXF

The BKS water glass bonded mini-risers and the organically bonded, lightweight KVM-QM make use ofa loose metal neck in the bottom part of the riser and the corresponding spring pin. These provide aspecially defined breaking point that makes it easier to detach the feeder. Fettling costs are reduced
considerably as a result. In some cases, there is no need at all for rework. The BKS C mini-riser featuring
a centering hole is designed for use on a rigid pin. Both variants are available in a fluorine-free formulation.

Benefits• No breaker cores needed• Extremely small contact areas to the casting• No contact between mold section and exothermic feeder material• A range of variants for your processes

Rigid pinMolding processGreen sand andhigh-pressure
molding linesChemicallybondedClosed spring pin

Metal typeGI

DI

SteelApplication
Nonferrousmetals

Placed on
the pattern

BKS
KMV-QM= recommended,= partly recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
8|Inserted inthe mold

Mini-risers

Mini-risers for automated high-pressure
molding machines
Dynamic mini-riser system with reduced riser neck diameter
EXACTCASTFDS

EXACTCASTKMV-QTEXEXF

EXEXF

FDS risers are used with spring mandrels, reducing

KMV-QT is a Cold Box bonded, cost-effective,

greatly their fitting surfaces. In addition, they dolightweight feeder that is used with spring pins for

not directly contact the casting. They are available

minimized contact areas. The riser can also be

fluorine-free.

used directly on the casting. They are available
fluorine-free.

Benefits

Benefits• Low emissions• Reduced riser neck diameter for reduced• Low weight• Reduced riser neck diameter for reduced

fettling costs

fettling costs• The spring pin helps reduce contact areas,• Plastic caps eliminate feeder inclusions on thesurface defects, and pattern wear

mold surface

Molding process
Green sand andhigh-pressure
molding lines

Chemicallybonded

Metal typeGI

DI

Steel

Application
Nonferrous
metalsPlaced on
the pattern

Inserted in
the mold

FDS
KMV-QT= recommended,= partly recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
|9Mini-risersP

Mini-risers with freely
moving metal neck

AT

ENTE

D

ASK CHEMICALS

SY

STEM

The most efficient and effective mini-risers
EXACTCAST
OPTIMA KL

EXACTCAST
OPTIMA KMV-CCEX
EXF

EX
EXFThe EXACTCAST OPTIMA risers offers all the advantages of the BKS and KMV risers with a loose integra­
ted metal neck in the bottom part of the riser and the corresponding pin. These act as a precisely defined
breaking point. In addition to the benefits provided by the BKS and KVM-QM feeder, the virtually friction­less sleeve and the integrated riser cap prevent crumbling particles from falling into the mold. Both variants
are available fluorine-free.

Benefits• No breaker cores needed• Extremely small contact areas• No contact between mold section and exothermic riser material• A range of variants for your applications• Riser particles are prevented from falling into the mold• A 100 % inorganic variant of the OPTIMA KL riser with metal cover is available on request.

Molding process
Green sand andhigh-pressure
molding lines

Chemicallybonded

Metal typeGI

DI

Steel

Application
Nonferrous
metalsPlaced on
the pattern

OPTIMA KLOPTIMA KMV-CC= recommended,= partly recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
10 |Inserted inthe moldOptima KL in competition
Increased productivity of the molding line
Riser applications with rigid pins usually destroy the riser during the compaction process, and the crumbling riser particles canfall into the mold. This can also be the case when spring pins are used under high compaction pressures. The OPTIMA KL andOPTIMA KMV-CC risers are fitted with a cover of non-friable material. Mold contamination and the associated casting defects are
therefore eliminated, raising the cycle times on molding systems. There is virtually no need to purge the molds with air afterwards.

Problems encountered with various risers articles of riser material onP
the pattern surface
 urging the molds with airPtakes time

Result: Reduced productivity of the molding system

Solution in the form of EXACTCAST OPTIMA
Time savings
Shorter cycle times

Result: There is virtually no need to purge the molds with air afterwards| 11

Riser caps

Riser caps with the efficiencyof mini-risers
Improved discharge with feeder caps
EXACTCASTKIM insertable

EXACTCASTKIM-QMEXEXF

EXEXF

The new, insertable mini-riser series EXACTCAST KIM was developed for customers seeking to reduce
their circulating material and hence the associated costs. The solution is the KIM risers, which exhibit
double the wall thickness of conventional riser caps, and so require less metal as a result.
Thanks to the special combination of its material, this riser exhibits a very low overall weight. Available
in a fluorine-free formulation, with or without breaker core, or with a reduced metal riser neck diameter.

Benefits• Improved yield• Additionally high insulating effect• Available in a range of sizes

Molding process
Green sand andhigh-pressure
molding lines

ChemicallybondedMetal typeGI

DI

SteelApplication
Nonferrous
metalsPlaced on
the patternKIM
KIM-QM= recommended,= partly recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
12 |Inserted in
the mold

Riser sleeves

Riser sleeves for openriser applications
Precision designs for a range of applications
EXACTCAST
neck-down risers

INEXEXFASK Chemicals EXACTCAST neck-down risers are designed primarily for open riser applications. They
are available in insulating and exothermic / insulating formulations. They are also available with a tapered
geometry and fluorine-free, with or without breaker core.

Benefits• Smaller contact area
• Dimensional accuracy• Constant thermal properties and performance

Molding process
Green sand andhigh-pressure
molding lines

Chemicallybonded

Metal type
GIDI

Steel

Application
Nonferrous
metalsPlaced on
the pattern

Inserted in
the mold

Neck down= recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
| 13

Riser sleeves

Insertable riser caps and sleevesExcellent dimensional accuracy

EXACTCAST
Insertable riser caps and sleeves

INEX
EXF

Riser caps and sleeves are available in highly exothermic and insulating designs. They are characterizedby high strength and dimensional accuracy. They are suitable for inserting into molds and automatedmolding lines with core setters. They can also be used together with breaker cores and are available
fluorine-free, with or without breaker core.

Benefits• Low gassing• Constant thermal properties and performance• Suitable for use with breaker core

Molding process
Green sand andhigh-pressure
molding lines

ChemicallybondedMetal typeGIDI

SteelApplication
Nonferrousmetals

Placed on
the pattern

Insertable sleeves= recommended

These are solely recommendations. For more details, please consult your ASK Chemicals contact.
14 |Inserted in
the moldAdded Value for our Customers
Application technology and technical sales – for complete process transparency
Application technology and technical sales at ASK Chemicals offer our customers comprehensive
expertise in all areas of foundry technology and metallurgy. We offer a comprehensive service that focuseson the production process as a whole and helps customers not only to cut costs but also to enhancetheir processes. ASK Chemicals also conducts casting defect analyses and offers its customers theopportunity to have tailored training sessions on the customer’s own premises.

Benefits• Improved decision-making thanks to greatertransparency• Reliable recommendations• Quick response• Customized solution development• Cost-in-use reporting (i.e. savings)• Casting defect analyses• On-site training sessions

EXACTCALC
EXACTCALC software, which is exclusive to ASK Chemicals,
was specifically designed to assist the foundry engineer withriser and gating system design. With EXACTCALC you will
receive critical and comprehensive calculations: casting weight,modulus, riser feeding distance, riser size, riser neck contact
dimensions, gating system dimensions and filter size.
Benefits• Accurate recommendations• Customizable “learning feature” specific to your foundry• Printable results| 15

Design Services – for perfect casting results
Our Design Services team monitors the entire process from the development of the designconcept and validation right up to the production of the cast part prototype. Our engineers havea wide range of experience and a clear understanding of all aspects of foundry technology andmetallurgy. Our Design Services team has the right combination of design, production andsimulation expertise, co-operates with external companies and service providers, and enjoys
extensive industry experience. ASK Chemicals' simulation service offers wide-ranging technicalknowledge and understanding combined with state-of-the-art simulation programs (MAGMA,Novacast, FLOW-3D and Arena-Flow®).

Benefits• Higher productivity and optimized
catalyst consumption• Optimized design and manufacture ofmodel plates, core boxes and molds• Manufacturing process design,including inorganic technology• Calculation of optimal feed

• Less scrap• Shorter product launch times• Quicker time to market

Simulation services
The simulation of casting processes provides foundries with invaluable casting mold information. Specifically,
this benefit allows for the optimization of gating and feeding systems, overflows, venting design and risers.
Moreover, it provides critical insight into the influences and effects directly related to casting integrity, such as
cooling and heating measurements, filling and solidification times.

From the idea to the prototype
ASK Chemicals supports your entire process from the concept to prototype production. Your benefit:
you enjoy wide-ranging expertise from a single source.

Simulation

Cores /Molds

Prototypes| 16

Research and development – for innovation near you
Our Research and Development department performs both innovation-driven groundwork as
well as market and customer-driven development. Interaction between these three areas isof fundamental importance in terms of offering our customers technologically sophisticatedproducts and efficiency-enhancing solutions at all times. Through close cooperation and theconstant exchange of ideas with our application technology and technical sales specialists,
research and development at ASK Chemicals is always in tune with the market and also
maintains a presence on the customer’s own premises.

Benefits• Many years of experience• Global presence and availability• Comprehensive knowledge of the regional• Short response times for our customers• First-class equipment

sand types and technological requirements

Comprehensive research and development services
Pilot foundry

Product development and technical support• Fully equipped research foundry• Casting defect analysis• Mold production, mold / core package assemblyand casting• Full spectrum chemical and polymer analysis• Product, process and test method development• "Real world" foundry process representation
Metallurgical investigations• Comprehensive examination of the graphite structure
and metallic matrix: graphite size, number of nodules,degree of dispersion, nodularity, ferrite / pearlite ratio• Preparation of metallurgical reports
Sand laboratory• Examination of high-temperature materials• Testing of tensile strength, compression andtransverse loading• Sand characterization and analysis| 17

www.ask-chemicals.com/locations

This information is based on our current state of knowledge and does not represent assurance of the properties of the products described. We are only liable for
product-related advice and information within the scope of duties of disclosure included in collateral contractualagreements unless expressly agreed otherwise. (03/ 24)

Visit www.ask-chemicals.com/trademarks for a complete list of our trademarks.
Please contact ASK for any questions concerning the usage of these marks.