The Capping (Top Cap) and Spout (Runner) are the areas requiring the most frequent maintenance. Berikutnya, we will analyze the differences in mechanical impact resistance and thermal shock resistance of different refractory materials in these specific areas.
Choosing between Dry Vibration Mix Dan Wet Ramming/Patching Mass for the Capping Dan Spout is a common pain point for foundries trying to balance cost with durability.
The operating conditions for these two areas are distinct: The Capping primarily faces mechanical impact from cold charge materials, while the Spout primarily faces severe thermal shock and erosion.
Below is a detailed comparative analysis:
Capping (Top Cap/Collars)
The capping is the sealing area connecting the upper part of the furnace lining and the induction coil; it is the first line of defense at the charging opening.
Core Operating Conditions
- Mechanical Impact (Major Challenge): During charging (especially with scrap steel or heavy returns), the capping endures significant physical impact and abrasion.
- Kejutan Termal: Frequent opening of the lid and the addition of cold material cause extreme temperature fluctuations in this area.
Material Comparison: Dry vs. Wet
| Dimension | Wet Ramming/Patching Mass | Dry Vibration Mix |
| Typical Composition | Silica sand/High Alumina aggregate + Sodium Silicate (Water Glass) or Phosphate binders. | Same material as the furnace lining (Dry Silica or Neutral Ramming Mass) + Low-temperature sintering agents. |
| Impact Resistance | Miskin. Wet materials have higher porosity after drying, resulting in relatively lower strength. Under heavy impact, they are prone to spalling or crushing, leading to premature exposure of the upper coil. | Excellent. Compacted via vibration to achieve high density. After sintering, it forms a hard ceramic body with compressive and abrasion strength far superior to wet mass, effectively resisting scrap impact. |
| Resistensi goncangan termal | Moderate/Poor (Depends on baking). High moisture content. If baked too quickly, water evaporation causes micro-cracks which expand rapidly under thermal cycling. | Excellent. Contains no water, eliminating the risk of steam explosions. Dry mix possesses a “micro-crack toughening” mechanism, allowing it to better adapt to thermal expansion and contraction. |
| Overall Assessment | Suitable for short-term repairs or applications with low longevity requirements. Prone to “delamination,” causing the capping to separate from the working lining. | Suitable for long-campaign furnace linings. It sinters with the working layer below to form a monolithic structure, preventing molten metal from penetrating between the capping and the coil grout. |
Expert Recommendation: For Capping, Dry Vibration Mix (or specialized high-strength castables) is strongly recommended. Although installation requires a former (mold), it significantly reduces the risk of “loose capping” and metal run-outs. Many modern foundries have phased out the old “Sodium Silicate + Sand” method for capping.
Spout (Runner/Launder)
The spout is responsible for guiding the high-temperature molten metal out of the furnace, serving as the channel from the furnace to the ladle.
Core Operating Conditions
- Kejutan Termal (Major Challenge): Instant contact with molten iron (1500°C+) during tapping, followed by rapid cooling. This rapid heating/cooling cycle is the main cause of spout failure.
- Mechanical Cleaning: Frequently requires manual chipping to remove slag buildup.
Material Comparison: Dry vs. Wet
| Dimension | Wet Plastic/Ramming Mass | Dry Vibration Mix |
| Workability | Excellent (Key Advantage). The spout has a complex, open shape. The high plasticity of wet materials allows for manual shaping and patching, making repairs very convenient. | Very Difficult. Dry mix relies on molds and vertical vibration for density. It is extremely difficult to set up molds and vibrate effectively on an open spout, so it is rarely used directly for the spout working face. |
| Resistensi goncangan termal | Excellent (Key Advantage). High-quality wet spout materials are typically Phosphate-bonded High Alumina or Corundum plastics. Phosphate binders provide high strength at low temperatures and offer excellent resistance to thermal spalling, making them ideal for intermittent tapping. | Average/Not Applicable. If dry mix lacks density (due to installation difficulties), thermal shock resistance drops significantly. Lebih-lebih lagi, dry mix requires high heat to sinter; spout surface temperatures often fail to reach the optimal sintering range, leading to a loose surface prone to erosion. |
| Impact Resistance | Good. High-quality plastics possess a certain degree of toughness, preventing brittle fracture when chipping away cold slag. | Not Applicable. Difficult to achieve high density in spout applications. |
Expert Recommendation: For the Spout, Wet Plastic Refractories (specifically Phosphate-bonded High Alumina Plastic/Patching Mass) are the absolute mainstream choice. Dry mix is almost never used for spout repairs unless it is in the form of a pre-cast block.
Ringkasan & Decision Guide
| Area | Recommended Material | Core Rationale | Next Step |
| Capping (Top Cap) | Dry Vibration Mix | Impact resistance is the #1 priority. High density and strength allow it to integrate with the lining, preventing mechanical damage during charging. | Stop using “Sodium Silicate + Sand” metode; switch to a dry capping mix compatible with your lining material. |
| Spout (Runner) | Wet Plastic Refractory | Thermal shock resistance & Workability are #1 priorities. Must withstand rapid cooling/heating and allow for manual shaping. | Choose Phosphate-bonded High Alumina Plastics rather than ordinary refractory mortar. |
