Keratuff has an exceptionally high strength to density ratio, which makes it suitable for thin walled shapes such as launders or runners.
Keratuff has a very fine microstructure of closed pores which, gives it excellent thermal insulation properties. Used as a launder, the heat losses of the molten metal are considerably reduced and skull does not form easily.
Ketatuff is non-wetting to aluminum, so that the metal flows cleanly, smoothly and rapidly.
The above factors eliminate metal freezing in a well-controlled operation, so that no cleaning is ever required.
Keratuff is very easily patched by hand, using keratuff. The bond is assisted by fibres which, protrude from broken surfaces. (Fibres do not protrude from the surface of cast or plastered surfaces.) Patching dries easily and rapidly. Preheat or drying is not deemed necessary.
Keratuff can easily be cut or machined. It is asbestos free and non-toxic.
From the above it will be clear that Keratuff is fundamentally superior to dense castables, has all the ideal characteristics for aluminium launders, and should be treated very differently. Keratuff should be treated as a permanent lining, not a short-lived consumable material.
Full technical specifications are available on the Keratuff data sheet.
1. Induction Coil Coating: A hard, strong, 93% alumina putty for protecting coils. Use it between coils and as a thin cover to prevent molten metal contact.
2. Kerasic: A hard strong, abrasion resistant material for inside the coils. Make it into a sleeve or skid rails.
3. Hollocast 1: An inexpensive, pleasure to install, quick setting insulation material. Use it as a support outside of the coils to keep them straight and in line. Easy to break out without destroying the coils.
4. Glyptal: A red insulating paint to prevent electrical shorting between coils.
5.Electrical Paint: A higher temperature resistant alternative to Glyptal. Use on slings. Dip the sling into the paint, switch it on for a few seconds and remove it. Switch on for another 10 seconds to dry and harden it.
6. Kerinduct 2: A dry spiking lining of spinel forming composition. Expands on sintering to make a tight lining. Use as a working lining in coreless induction furnaces for melting stainless steel and high temperature alloys.
7. Chloresist: A solid, almost impervious castable lining for channel induction furnaces. Use for zinc especially.
8. Mica sheet: Use for a slip plane between Kerinduct 2 and the Induction Coil Coating.
9. Asbestos Board: A durable, heat resistant board for the end plates of induction coils and the tops of coreless induction furnaces. stock boards 1m x 1m x 20mm.
10. Capping: A very fast setting material to give a decent hard capping against which a "gwala " can be levered. It requires no heat to set.
11. Kerapatch: An excellent hot patching material.
12. Slag Coagulant: To thicken the slag and enable its removal.
13. Keratherm: An insulation cover which spreads nicely. Carbon free.
14. Keraplas Ramming: An excellent ramming material with green chromic oxide.