CPT International 01/2015

cptinternational

The leading technical journal for the
global foundry industry – Das führende Fachmagazin für die
weltweite Gießerei-Industrie

www.giesserei-verlag.de

12. March

2015

CASTING

PLANT AND TECHNOLOGY

INTERNATIONAL

30 years

CP+T

International

1

Centrifugal casting

machines for reliable

serial production


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EDITORIAL




The terms in the above title are always at the top of the foundries’ charts of

all-time hits worldwide. Many interesting technologies for optimizing production

are presented in this GIFA-year of 2015. We open the competition of ideas

in CP+T International with, among other things, two interesting articles from

the engineering companies Heinrich Wagner Sinto and Disa on the topic of

molding plants. Disa’s article compares flasked and Disamatic molding lines,

while the HWS contribution examines a Russian foundry that uses a molding

machine based on the Seiatsu airflow squeeze molding process. You should

not miss these articles, on P. 14 and P. 22, if your foundry is planning investments

on the molding lines.

As announced, CP+T is also celebrating its 30th anniversary with this issue.

The magazine, whose development can be traced from the covers used since

its founding in 1985 (see P. 39), has now left its youth behind it and from this

year will be presented with a new look – as a member of the GIESSEREI family.

The family includes the leading magazine GIESSEREI, GIESSEREI Erfahrungsaustausch,

the English-language CASTING, Plant and Technology, and the

research magazine GIESSEREI-Forschung. At the threshold to a familial future

we look back to the start of this technical magazine in the 1980s with engineer

Peter Haensel, the first Technical Editor of CP+T (from P. 40).

Further highlights in this issue include one of the world’s largest blasting

plants in Ukraine (from P. 26), the use of RFID chips for optimizing the charge

(from P. 30), and an interview with Dr. Ioannis Ioannidis, spokesman of the

management at die-casting machine producer Oskar Frech, on the upcoming

international foundry trade fair GIFA in Düsseldorf (from P. 6). And this is also

where the CP+T team will be expecting you: on 16 - 20 June.

Have a good read!

Robert Piterek, e-mail: robert.piterek@bdguss.de

Casting Plant & Technology 1/2015 3


FEATURES

INTERVIEW

Ioannidis, Ioannis

“GIFA is a unique opportunity for us!” 6

COREMAKING

Riker, Stefanie

Reconstructing cylinder heads for Porsche legends 8

AUTOMATION

Reimann, Sonja; Finzel, Klaus

Cast from the same mold 12

Colditz, Michael; Kang, Seong-Heon; Kim, Heung-Soo; Larsen, Per

Brake disc production - is optimization possible? 14

Geisweid, Steffen

A milestone for the modernization of a steel foundry 22

CLEANING, FETTLING & FINISHING

Schulz, Doris

One of the biggest shot blast systems in the world 26

Cover-Photo:

Küttner GmbH & Co. KG

Alfredstr. 28

45130 Essen/Germany

Tel.: + 49 (0) 201 7293 0

info@kuettner.de

www.kuettner.de

Dual turn table centrifugal casting machine by Küttner.

See page 50 for more details

14

26

Robot setting brake disc cores on a DIsa 240-C line. 3,5 of

the 6,5 million tons of brake disks manufactured annually are

produced on Disamatic molding lines (Photo: Disa)

One of the biggest shot blast machines in the world is in use in

a Ukrainian foundry, specialized in very big, heavy and complex

castings (Photo: Rösler)


CASTING

1 | 2015

PLANT AND TECHNOLOGY

INTERNATIONAL

QUALITY ASSURANCE

Gottsauner, Birgit

Raw materials according to recipe 30

POLLUTION CONTROL

Javadian Namin, Parisa

Clean up your act 34

ANNIVERSARY SPECIAL 37

COLUMNS

Editorial 3

News in brief 42

GIFA News 47

Fairs and congresses /Advertisers´ index 50/51

Brochures 52

Preview/Imprint 54

www.giesserei-verlag.de

12. March

2015 1

37

PLANT AND TECHNOLOGY

INTERNATIONAL

CASTING

30 years

CP+T

International

Centrifugal casting

machines for reliable

serial production

Casting, Plant and Technology International is 30 years old. The magazine has left its youth behind and is presented with a new

look – as a member of the GIESSEREI-family with German specialist magazines GIESSEREI, GIESSEREI Erfahrungsaustausch and

GIESSEREI Forschung. We look back to the beginnings in the 1980s with Engineer Peter Haensel, the first Technical Editor of CP+T


INTERVIEW

“GIFA is a unique opportunity

for us!”

Dr. Ioannis Ioannidis is Chairman of the Board of the VDMA Foundry Machinery specialist association

and spokesman of the die-casting machine producer Oskar Frech from Schorndorf in Germany.

In an interview with CP+T International Dr. Ioannidis speaks about his expectation regarding

the International Foundry Trade Fair (GIFA) in June 2015

Dr. Ioannidis, how do you assess the

development of the foundry machine

sector in the run-up to GIFA?

I am confident and expect a challenging

business environment at the GIFA.

But we have a very mixed sector: the situation

appears restrained for the steel

and iron casters while the die-casters

and permanent mold foundries are experiencing

a more positive business situation.

To what extent a positive development

in all areas will take place

remains to be seen.

tial

in the iron and non-ferrous foundries?

More materials will be combined with

one another in future and this will result

in new challenges for us. With

these composite materials, what matters

is using existing materials and

combining them in such a way that

components are created with better

properties but lower production costs.

The topic of resource and energy efficiency

is also becoming increasingly

important – we already saw this at

the last GIFA, with the sustainability

campaigns of the trade fair itself and

the ecoMetals and Blue Competence

campaigns launched by the German

Engineering Association – and they

will be exhibiting contemporary topics

again in 2015. Just like at Oskar

Frech, many companies are presently

considering energy and raw material

consumption, and where savings

can be achieved. The analyses that we

have carried out here in the company

are very promising. Light construction

in automotive production is another

important topic. Ever-smaller

Dr. Ioannis Ioannidis with a structural component made from die-cast aluminum

which was produced by a die-casting machine of Oskar Frech (Photos:

VDMA)

engines are being developed that have

to provide ever-increasing performance.

We need more resistant materials

for this. I am also convinced that

the SMEs here in Germany will invest

more in automation because even in

the Far East a lot is flowing into this

area now. There is a major potential

here, and a core topic is information

technology. Evaluating data from production

has not yet sufficiently penetrated

the SMEs.

6 Casting Plant & Technology 1/2015


Dr. Ioannidis with employees of Oskar Frech at the headquarters of Oskar Frech in Schorndorf

How are things at Frech? Machine cycle

times cannot be endlessly reduced;

the products must also be high quality?

We divide machines into their mechanics,

their electrics/electronics,

their IT (as an important integrative

component of increasingly high significance),

and the process technology.

I am convinced that process engineering

still offers more potential.

If you consider the low-sprue system

that Oskar Frech presented at the last

GIFA, fewer raw materials are used, less

energy consumed, but the cycle time is

20 % shorter. So you can produce more

parts in the same time. This shows the

potentials of process technology.

GIFA 2015 is coming up soon. Do you

expect a trade fair like that of 2011

for Frech and the foundry machine

producers? In 2011 GIFA was very


crisis.

In 2011 we were coming out of the worst

recession since the Second World War.

Growth and demand were very different

then. I expect satisfactory demand

and a good environment for 2015.

When I think about the sector, however,

I am not only curious about what

technology we will see, but also about

how we will come into contact with

interested parties and customers. How

will we win over the people who come

to the trade fair from far away? How

attractive is the world’s leading fair in

our sector: the GIFA? Because this is

important for the next time. The trade

fair is a platform, a location where the

whole world meets. And it takes place

in Germany. This is a unique opportunity

for seeing the technology of the

foundry machine producers and getting

to know the companies.

GIFA will focus on the competition of

ideas. What are you most looking forward

to?

To the trade fair program in its entirety

as well as to the presentations of the

competitors. This helps both the competitor

and us. The competitors see

how their ideas are received and can

receive inspiration themselves. We

look forward to all the interested parties,

the visitors and the young people,

but also to the representatives of the

companies and associations who will

see that the Foundry Machinery specialist

association makes the VDMA a

valuable contributor for the companies

and for business as a whole.

Read more on the innovations at the GIFA

exhibition on page 47!

www.gifa.com

Casting Plant & Technology 1/2015 7


Classical Porsche cars are popular but many special parts like cylinder heads

are no longer available (Photos: Por sche, Voxeljet)

Author: Stefanie Riker, voxeljet AG, Friedberg

Reconstructing cylinder heads for

Porsche legends

Anyone who owns a legendary Porsche

550 Spider, 904 or 356 Carrera can

count himself lucky. Unfortunately special

parts like cylinder heads are no longer

available. In the event of damage,

the only remedy is through customized

parts reconstruction or reverse engineering,

and 3-D printing turned out

to be the cheapest way.

Reconstructing complex components

(Figures 1-4) is a challenge for every design

engineer, because drawings are not

available in most cases. In this particular

case, the reconstruction of a Carrera

cylinder head made of aluminum started

with measuring and scanning of the

defective head.

Valve guides, seat rings, camshaft

bearing, intake and exhaust ducts, cylinder

head screws etc. had to be set up

as 3-D base bodies in a meticulous detailed

process. The next step was the

transfer to superordinate functional

models and the adding of design features

from casting technology like site

measuring, bevels, and fillets.

Affordable 3-D cores

After the geometric reconstruction

made by the company CAD Support

from Mössingen, Germany, the production

of the sand cores was the next item

on the agenda. The project implementation

with conventional cores based

on core-making tools was impossible

for cost reasons. The only solution was

creating the cores in a 3-D printer.

The order for printing the entire core

package with eleven cores in total went

to the voxeljet service center in Friedberg,

Germany, which has many years

of experience in project of this kind.

Thanks to the excellent printing quality

of the voxeljet printer, it was also possible

to outline the thin-walled cooling

8 Casting Plant & Technology 1/2015


Figure 1: 3-D data of the cylinder head by CAD Support

Figure 2: RPC mold package, 11 single cores, 5 insert

pipes by CAD Support

Casting Plant & Technology 1/2015 9


Manfred Sachse

DAMASCUS

STEEL

3rd Edition

Myth

History

Technology

Applications

3rd edition 2008. 25.6 x 31.9 cm.

304 pages, mostly in colour,

photographs and technical drawings.

ISBN 978-3-514-00751-2 79.00 €

For personal members

of Steel Institute VDEh: 71.10 €

Including VAT, excluding postage and packaging

Manfred Sachse

DAMASCUS STEEL

Myth | History | Technology | Applications

This book is a comprehensive and in-depth description of Damascus

steel and steelmaking. After the introduction “Magic and myth of sabres”

by Helmut Nickel, the author describes the development of the material

and the history of European, Middle Eastern and East-Asian forge-welded

composite steels used in the design of blades and fire arms.

A special chapter is dedicated to the great variety of Oriental dasmascus

steels (wootz steels). The author covers the topic of historical and

modern fakes and how they can be recognized as well as conservation

and restoration of Damascus steels. In one chapter he demonstrates

that not only weapons but also decorative articles of daily use and jewellery

can be made of Damascus steel.

Extensive research both into the history and theory of Damascus

steelmaking as well as practical work at the forge.

Distributed by Verlag Stahleisen GmbH

P. O. Box 105164 · 40042 Düsseldorf · Germany · Fon: +49 211 69936-264 · Fax: +49 211 69936-266

E-Mail: annette.engels@stahleisen.de · www.stahleisen.de


Figure 3: Raw part with gating system and risers

Figure 4: Reconstructed cylinderhead

rib measuring 2 mm without additional

supporting structure in the inner and

outer cores.

Foundry specialized in constructing

unique components

The molding was made by the

foundry Rauleder & Rudolf based in

Schwäbisch Gmünd, Germany, which

specializes in constructing unique

components. The hot isostatic pressing

(HIP) treatment led to a tremendous

improvement of the mechanical

properties, as well as a reduction of

pores. The final T6 heat treatment provided

the ultimate strength of the cylinder

head. The finishing of the components

was made on the basis of the

3-D CAD files in a 5-axis machining

center. After completion, the aluminum

cylinder head was ready for assembly.

www.voxeljet.de/en

Visit our booth in Hall 16 / A34

Working moment

to 12,300 kgcm

Working

moment

to

6,500 kgcm

FRIEDRICH Schwingtechnik GmbH

P.O. Box 10 16 44 · 42760 Haan · Germany

Phone +49 (0) 2129- 37 90-0

Fax +49 (0) 2129- 37 90-37

www.friedrich-schwingtechnik.de

info@friedrich-schwingtechnik.de

Unbalance Exciters

>> Extended product range for driving motors

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>> Centrifugal force from 29 to 482 kN

>> Working moment from 300 to 12,300 kgcm

Vibrator Motors

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>> Centrifugal force from 0.5 to 216 kN

>> Working moment from 1.2 to 6,500 kgcm


AUTOMATION

Authors: Sonja Reimann and Klaus Finzel, Communications Manager, Zeppelin Baumaschinen GmbH, Garching

Cast from the same mold


The mini-excavator hangs castings on a stand. (Photos: Zeppelin)

They are normally found when space

on a building site is particularly limited:

zero tail-swing mini-excavators.

But use of these compact construction

machines is not by any means limited

to the classic road construction, civil

engineering and landscaping applications.

Other industrial sectors have

long recognized the potential of the

compact devices, as has EMG Casting

from Waldkraiburg in Germany. A Cat

303.5E mini-excavator, complete with

sorting grab, has opened up completely

new possibilities for handling hot

cast-iron parts (at 300°C) at the medium-sized

foundry in southeast Bavaria.

Albert Tauschhuber, Director of

Tech nology and Human Ressources

(HR) at EMG Casting, has long played

with the idea of integrating a miniexcavator

in the production process.

He finally took the plunge in August

2013. When Zeppelin’s Munich

branch received the enquiry from

Waldkraiburg, its Regional Sales Manager,

Alexander Mayer, together with

his colleague Thomas Meier, Product

Manager for Attachments, analyzed

the applications and the demands to

be met by the mini-excavator and its

grapples. Then they presented a machine

to put it to the test (Figure 1).

Mini-excavator with standard

equipment and rapid-change

system

“We initially considered using special

grapples. But that is not at all necessary.

Standard equipment with a rapid-change

system is more than enough

here, because of the range and loads involved,”

was the recommendation from

Zeppelin. Now a Cat 303.5E uses its

grapples to take up cast-iron parts from

a discharge belt and place them either

in grid boxes or hang them from a stand

(Figure 2). The construction machine is

resupplied every 30 seconds.

“The decision to use the mini-excavator

was absolutely right. The excavator

fits perfectly into our workflow

and works faultlessly. Our initial

ideas about buying narrower claws

have long been discarded. I am convinced

that our solution is also a firstclass

option for reducing costs at other

works in our sector,” says Albert

Tausch huber.

A view that is also shared by the

two Zeppelin employees: “This opens

up a new segment for foundries. The

works in Waldkraiburg can be considered

a pioneer in this respect. I can well

imagine a mini-excavator for other

foundries.” Because thanks to the new

mini-excavator at EMG Casting there

is no longer any need for the manipulator,

which not only involves high investment

costs for purchasing but also

results in maintenance costs and expenditure

on spare parts, although the

works carry out many repairs themselves.

“Considered over a whole year

that results in quite a lot of bills,” says

the Managing Director. His thinking:

“For the same money we could buy five

mini-excavators. And, in fact, we have

not taken any risk at all with the new

excavator. We would have sold it again

if it hadn’t worked. But that is absolutely

unnecessary now.”

The works is well-protected if the excavator

breaks down. “We would get

a replacement device from Zeppelin’s

Munich branch within a few hours.

With the manipulator we often had to

wait for days until it started working

again,” according to Tauschhuber. In

order to be able to bridge the time with

a hired machine, a rapid-change system

was provided for the Cat 303.5E so that

the grapples remained compatible.

This solution is not just more economical.

The mini-excavator has made

the work process in the foundry more

efficient – the compact construction

machine can take on another work

step by also hanging finished castings

12 Casting Plant & Technology 1/2015


on a stand. This was not the case with

the manipulator.

Ability to use joysticks essential

The five employees, however, did have

to get used to their new tool – a process

that is still continuing. “It takes a while

until one has gained a certain routine in

its use,” according to the Managing Director,

responsible for technology and

the HR Department for 150 employees,

while Manuela Keller is Financial Director

and also responsible for marketing.

The employees have to learn how to

control the machine with two joysticks

– the manipulator, on the other hand,

only had a single lever to operate the

gripper. In the case of the Cat 303.5E,

the driver must also use the foot pedal.

According to Tauschhuber this is a

change, but just a matter of time.

Since it was bought in August 2013,

the Cat 303.5E has worked almost nonstop.

Thus about 800 operating hours

have been completed up to now because

production is running flat out in three

shifts – even on Saturdays. Delivery periods

are currently about eight weeks.


xible and rapid casting output

EMG Casting manufactures to order,

even if certain special parts have to be

kept in stock. Sales amount to around

27 million Euro per year. The customers

are from the drives, gears, pumps,

mountings, agricultural and rail technology,

automotive supply, general

mechanical engineering, and environmental

technology sectors.

“We naturally place great value

on the quality of our products. Our

standard is DIN EN ISO9001:2000.

But that is no longer anything special,

because today everyone has to deliver

top quality. Our best attribute is

speed, which not every works can offer.

Our strength is that we can also

make models at short notice,” says

Tauschhuber. 5,000 casting patterns

are available in the foundry’s warehouse.

The box sizes of the pat terns

are 700 x 800 mm², heights are

vari able at 170/170 or 300/300 mm. In

cast iron, unit weights of up to 150 kg

are possible, also allowing use of the

mini- excavator. Zeppelin is exclu sive

Figure 1: Zeppelin Regional Sales Manager Alexander Mayer (left) and

Zeppelin Product Manager for Attachments Thomas Meier (right) hand over

the new mini-excavator to the Managing Director of EMG Casting, Albert

Tauschhuber (second from left). It is the new workplace for Obazck Guegon

(second from right)

Figure 2: A Cat 303.5E uses its grapplers to pick up cast-iron parts from a

discharge belt

partner of Caterpillar in Germany,

Austria, the Czech Re pub lic, Slovakia,

Ukraine, Belarus, Russia, Turkmenistan,

Uz bekistan, Tajikistan and Azerbaijan.

www.zeppelin-cat.de/en

www.emguss.de

Casting Plant & Technology 1/2015 13


AUTOMATION

Authors: Michael Colditz, Disa, Duisburg; Seong-Heon Kang; Heung-Soo Kim, Hyundai Sungwoo Automotive, Pohang-Si;

Per Larsen, Disa, Copenhagen/Denmark

Brake disc production – is

optimization possible?

Robot setting ventilated brake disc cores on DISA 240-C line (Photos: Disa)

Each year brings new records in global

vehicle sales. These do not apply

equally to all parts of the world, however.

New auto manufacturers are moving

into the world market beside established

names with a view to exporting

from their home markets. And all auto

manufacturers producing vehicles

in other markets than their domestic

market are expecting their suppliers to

deliver locally.

Saturation in domestic markets has

led to unused production capacity in

industrialized countries. Prices are increasingly

under pressure as competition

grows. Auto manufacturers pass

the consequences on to their suppliers,

including foundries making automotive

components. Thus especially manufacturers

of brake discs and drums are

forced to develop new strategies.

The extreme and constant pressure

on the foundry industry is anything

but new. It is remarkable how production

is repeatedly scrutinized in detail

and how efforts are made all the time

to optimize every single process in the

foundry. There are, however, some fundamental

decisions that almost seem

to have “religious” roots. Once a molding

process has been decided it is unshakeable.

Truths and rumours about

the various molding processes vary

and are often mixed together.

An extremely obscure aftermarket

means that there are no detailed

data about worldwide sales of brake

discs. Based on our own market data

as well as information from automotive

system suppliers, it is estimated

that about 6.5 million tons of brake

disks are made every year worldwide.

14 Casting Plant & Technology 1/2015


This output comes from vertical parted

flaskless molding lines, horizontal

parted flask or flaskless molding lines

and floor molding. Currently 149 Disamatic-

and 6 Disa Match molding lines

at 91 foundries are making their contribution.

The share of world production

of discs and brake drums on Disamatic

lines is currently around 3.5 million

tons per year (Figure 1). Table 1 below

shows the Disamatic share of production

of these castings.

Of the last 50 molding lines commissioned

for the production of brake

discs, two thirds went to Asia, providing

a clear sign of where the market is

still growing.

Investment costs and future operational

costs carry most weight in new

investment decisions.

Figure 1: Large, ventilated brake drum (truck)

Investment costs

Foundation costs are easily overlooked

in the initial calculation, as plant supplier

quotations do not include civil

works. In many cases a simple foundation

plate with a surface deviation of

+/- 20 mm is sufficient for the vertical

molding process. The maximum deflection

should not exceed 0.1 mm, as this

could have an influence on the mold

mismatch. There is no need for pits below

the molding line, so the required

maximum bending plays a minor role

when installing in natural floor.

The simple and space-saving design

of vertical molding lines offers further

cost advantages, some of which

may only become apparent at second

glance. The great advantage of vertical

molding technology comes from simultaneous

molding of the two mold

halves into a sand mold and their immediate

merging with the previous

mold. This creates a very high production

density on the foundry floor. This

Figure 2: Disa 270 – service area

value is easy to quantify by examining

the relationship between the annual

production yield capacity and the area

required for the molding line plus service

areas. The calculation of the underlying

surfaces is shown in Figure 2.

In addition to the surface area of the

Disamatic molding line itself, service

areas must also be taken into account.

Molding lines developed by Disa for

the production of brake discs achieve

an annual production yield capacity of

more than 100 t/m 2 . Horizontally parted

high-performance lines with two

single or twin type molding machines

can only achieve about two thirds of

this capacity, even when using multifloor

cooling houses.

Energy savings

The reduction of energy consumption

in the foundry has played an import-

Europe North America South America Middle East Africa Asia

Disa 230/2013 24 20 15 1 2 43

Disa 240/250/2130 5 9 3 9

Disa 270/2070 5 4 2

Disamatic 2110 7

Sum 34 33 20 1 2 59

Table 1: The molding machine preference for brake disk production varies from continent to continent

Casting Plant & Technology 1/2015 15


AUTOMATION

Figure 3: Disa 270-A ventilated brake disc casting cluster

Average power consumption

in kW

ant role for many years. Until now discussions

have focused on reducing energy

consumption in the melting shop

where consumption is highest. While

the molding section may “only” account

for about 8 to 12 % of the total

production [1], there is still a significant

Connected load in

kVA

Disa 231 55 85

Disa 231 fast 60 85

Disa 240 75 105

Disa 250 90 145

Disa 270 110 155

Table 2: Electrical power consumption of Disamatic molding lines

savings potential to be found. Molding

shop energy consumption is split between

the sand plant and the molding

line. Depending on the type of molding

technology installed, the molding line

will account for between 30 and 55 %

of molding shop energy consumption.

Systematic use of robust vertical

molding lines based on lightweight design

criteria reduces energy consumption

significantly (Table 2). Here, too, it

is a good idea to address the average annual

consumption based on kWh per

ton of net castings. The drive for increased

efficiency demands working in

three shift production. Here we can set

off annual production hours and actual

energy consumption of the molding

line (molding machine, core setter, as

well as the pouring and cooling lines)

against net production showing a definite

potential for a consumption of less

than 10 kWh/t.

Given this result, Disa has nothing

to fear when comparing the Disamatic

vertical molding process with other

molding processes and energy consumption

is only about 20% of that of

flask lines.

The production of brake discs and

brake drums requires the highest possible

capacity at the lowest possible cost

– and thereby Lowering your cost per

casting. The Disamatic molding process

fulfils these requirements more

than any other. The machine design is

simple and robust and requires at most

only two additional main drives: one

for the molding machine and the other

for the pouring and cooling lines. Vertical

parting of molds enables placement

of the gating system, as well as venting

of the mold cavities, in the parting line.

Other systems or sources of disturbances

such as venting and drilling

devices (normal in flask molding) are

not necessary. Production normally re-

Single index Double index I Double index II

Amount of brake discs per mold 4 4 4

Brake disc diameter in mm 270 270

270

Weight per brake disc in kg 8,5 8,5

8,5

Pouring time in sec 10,4 13,3

13,3

Pouring speed in kg/sec ~4,5 ~3,5 ~4,5

Yield in % ~79 ~82,5

~79

Weight of the cluster in kg ~ 43,0 ~41,2

~43

Necessary melting capacity t/h ~12,5 ~13,3

~15,9

Brake discs per hour 1160 1288

1480

Use of energy for molding line kWh/t 12,4 10,0

9,7

Density of production t/m 2 ~95 ~105 ~120

Table 3: Example of the performance increase of a Disa 270-A using the double index

16 Casting Plant & Technology 1/2015


a

b

Figure 4: a) Ventilated brake disc pattern plate for DISA 240-C; b) Cores in the mold

Plant Production t/y Castings pieces/y Scrap total Molding line related scrap

Tight flask line 42,000 4,128,592 30,703 (0.8 %) 17,217 (0,40 %)

Disamatic 43,000 3,433,961 24,576 (0.74 %) 5,151 (0.15 %)

Table 4: Comparison of production on horizontal and vertical plant in 2013

Figure 5: Flaskline molds with ventilated brake disc cores

Figure 6: Machined brake disc of the

foundry Hyundai Sungwoo

quires only one cooling line, thus eliminating

the need for crossovers and the

drives required by these as well.

The absence of flasks means there is

no need for mold punch out, thus simplifying

separation from the greensand.

Neither is there a need for recirculation

and cleaning of pallets and flasks. The

array of additional machines and tools

required by tight flask lines mean higher

investment costs, which in some cases

can amount to the investment costs

of a Disamatic line, and that must be

taken into account when determining

the cost per casting. The interference

levels imposed by tight flask lines and

their drives also point to a higher uptime

of vertical parted flaskless systems.

Ongoing service and spare parts

costs vary from foundry to foundry,

but can be roughly estimated to account

for about 3 % of annual investment

costs based on external purchasing.

While the percentage amount is

likely to be similar for each process,

the absolute cost burden is certainly

not the same.

When considering investment costs,

production intensity, resource consumption,

uptime and maintenance

are all clearly cost advantages for vertical

molding technology. Another area

that is at least as important is the application

technology that determines net

production, castings quality and mold

surface texture.

Application

One of the major benefits of the Disamatic

is its high speed. On the other

hand, high speed demands a very short

pouring cycle time. The advantage of

high speed combined with pouring require

a correspondingly large-size gating

Casting Plant & Technology 1/2015 17


AUTOMATION

Plant Sand inclusions Mold cracks Mismatch Broken cores Flash Black skin

Tight flask line 76.55 % 16.32 % 0.2 % 6.52 % 0.37 % 0.13 %

Disamatic 93.32 % 5.49 % 0 % 1.06 % 0.11 % 0 %

Table 5: Percentage distribution of the scrap of both molding lines on basic of Table 4

Plant Uptime total Reason for downtime Downtime in %

Pattern change 1,4

Machine trouble 1,8

Waiting for iron (change of material) 1,2

Alloy change 1,0

Other reasons 0,6

Disamatic 94 %

Tight flask line 94 %

Table 6: List of downtime

Waiting for iron (change of material) 2,7

Machine trouble 2,5

Remove remain metal from auto pour 0,3

Pattern cleaning 0,1

Pallet car change 0,1

Other reasons 0,3

system. Higher pouring speeds could be

a reason for higher scrap rates. At GIFA

2011 Disa introduced the DIS system

enabling double index of the mold

string, thus extending the pouring time

by simultaneous pouring of two molds.

At the same time, several suppliers were

offering pouring solutions that enabled

foundries to make use of the advantages

offered by the double index.

This development gives us an increase

in performance that can be used

in different ways. The longer pouring

time can allow a reduction of the cross

sections of the gating system, while

freeing up space for additional castings

or enabling improved cavity cutting.

The longer holding time of the mold

string and simultaneous pouring of two

molds can mean that pouring time limits

the cycle time of the molding line.

Thus, there is more time for additional

molds to be poured, resulting in a further

reduction in the number of casting

defects. In this way, a partial combination

of the two advantages is possible.

These advantages are shown in Table 3.

Figure 3 shows the cluster forming

the basis of the information in Table 3.

The calculations for gating systems using

a single index are similar to those

for a double index. The differences lie

in the cross sections of the gating systems,

which is however very difficult

to see in the visual representation

( Figure 3). By extending the pouring

time using the double index from 10.4

to 13.3 seconds it was possible to reduce

the pouring speed from 4.5 down to

3.5 kg/s. This meant among other

things that the size of the pouring cup

could be reduced from no. 5 to no. 4.

The runner lengths and the cross sections

of the gating system to the pattern

could also be reduced. This enabled

a 3.5 % yield increase. At the same time,

molding capacity increased from 290 to

322 molds per hour. However, pouring

can also take place at 4.5 kg/s with a

yield of 79 %, thus increasing molding

capacity to 370 molds per hour using

double index.

Although the nature of the casting

defects is fundamentally different in

the production of brake discs using

horizontal and vertical molding processes,

rejection rates are comparable.

Microporosities occurring on vertical

lines correspond to blowholes in horizontal

lines. Any experienced foundry

man is aware of these issues in the respective

processes and knows how to

rectify the problem.

There are no detectable differences

after machining and mounting of

brake discs in cars between the two

production processes. A large globally

active automotive company has confirmed

that there are no qualitative

differences in long-term operation between

brakes discs made using a vertical

or horizontal process.

A common disadvantage, especially

of larger Disamatic molding lines,

is ferrostatic pressure arising during

pouring of the mold. These vertical

molding lines with mold heights of

700 and 800 mm have been present in

foundries since 1977. In 1979, the first

Disamatic 2070-A commenced operation

in a brake discs foundry with mold

dimensions of 700 x 950 mm. Thus, we

have 35 years of experience with issues

and solutions. The effects of ferrostatic

pressure can be handled via the gating

system, but there are limits. Mold

heights of more than 800 mm are not

recommended for brake disc production

by molding machine suppliers.

Double-sided squeezing of sand

molds via the pattern plates ensures

maximum hardness on the mold surface,

which decreases somewhat towards

the centre of the mold. Meeting

this natural process advantage of the

vertical molding process in a horizontal

flask process requires integration of secondary

filling frames with the pattern

bolster plate. Secondary filling frames

are used to increase mold stability in

the boundary areas of the flasks and to

ensure the desired low draft angles.

In tight flask lines, closing devices

are required to close the cope and drag,

however with the risk of mismatch by

mechanically determined clearance

in the adjustments. Wear and tear of

pins and bushings on all flasks must

18 Casting Plant & Technology 1/2015


www.gifa.com

www.tbwom.com

be continuously monitored. On the other hand, in vertical

parted lines the finished mold will be pushed out

of the mold chamber under the guidance of the pattern

plate and placed in contact with the previous mold. This

means that mismatch and consequent higher fettling requirements

are significantly reduced.

In the vertical process, glued strips on the surface of the

pattern plates ending at the top of the mold are sufficient

for venting the mold cavity during the pouring process.

Damage in the molded cluster by subsequent piercing or

drilling of vent holes is thus also eliminated.

worldwide

Greensand

The choice of molding technology also has a decisive influence

on the green sand circuit. In the horizontal process

the amount of sand can be regulated to a limited extent

by over-squeezing the cope. Metal-sand ratios in the

range from 1:3 to 1:12 are not uncommon. Problems with

sand-cooling and equalizing the sand in the sand plant are

correspondingly serious. The resulting quality problems

will considerably impact the production result. Used green

sand should be optimally prepared at a temperature of 40 °C.

Vertically parted mold systems with their adjustable mold

thickness prove to be advantageous in this respect. The PLC

of vertical molding lines calculates a constant iron-sand ratio.

The foundry can, however, take advantage of the low

pattern height in brake disc production to make adjustments

according to its own needs. In this case, however, the

above range is not reached. This constant ratio means that

the thermal load on the mold sand is relatively uniform –

an advantage for which any foundry quality department is

grateful. Sand overflow that occurs in horizontal flask molding

equipment is practically non-existent in the vertical

process, meaning that mold sand plants can be designed to

be smaller, thus also reducing energy consumption.

Experiences of Hyundai Sung woo Automotive

in South Korea

The South Korean foundry Hyundai Sungwoo Automotive

started production in May 1987 in Pohang / South Korea

with a flask molding system of dimensions 900 x 700 x250

/ 250 mm. 410 employees work in an area of 60,000 square

metres. The annual capacity of the foundry is 148,000

tons. In 2013, 121,000 tons of castings were produced, rising

to 127,000 tons in 2014. The foundry produces automotive

castings in GJL and GJS. The molding machine was

replaced in 2012, enabling a brake disc production cycle

time of 15,2 seconds. In 2005, two DISA 240-C molding

machines with a mold size of 600 x 850 x 150 mm to 500

mm and a cycle time of 9.3 seconds were commissioned for

brake disc production beside an additional flask molding

plant of the same size as the other with a cycle time of 20

seconds for other automotive castings. All plants producing

brake discs are directly connected to cooling drums and

continuous shot blast machines.

Similar production flow and about 4,500 hours production

time at both plants in 2013 mean that the perfor-

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Casting Plant & Technology 1/2015 19

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AUTOMATION

mance of the tight flask molding plant

and the older of the two Disa 240-C machines

can be compared directly. Both

systems make only brake discs, which

however are distributed differently between

the plants because of their dimensions.

The Disa 240-C features a rigid delivery

system including a filter core for

the transport of the cores to a core setting

robot. Both the cores and the filter

core are placed in fixed positions

( a and b). Brake discs are

manufactured in a range with diameters

between 260 and 325 mm on the

Disamatic in order to obtain acceptable

system efficiency. The smaller discs, as

well as a larger disc are made on the horizontal

molding line ( Figures 5 and).

The horizontal molding line makes two

large discs, or up to six small discs per

mold box (Table 4), while the Disamatic

always produces two discs per mold.

The percentage of scrap caused by

the molding lines, however, comes

very close to the desired zero error-production

(Table 5).

A comparison of the yield of each

plant and its scrap rate invites a comparison

of uptime. Again, the Hyundai

Sungwoo foundry is able to provide accurate

comparative data (Table 6).

Due to the excellent management of

the foundry, the production and maintenance

departments guarantee a very

high uptime on both plants. They employ

a preventive maintenance strategy

and educate their staff continuously

promising further increases in uptime

in the future.

Cast iron is used in both processes

for patterns and pattern plates. Their

expected service life in each process is

400,000 cycles before they are scrapped.

The costs of these tools for comparable

patterns vary considerably in the

South Korean market. This means that

the costs of core boxes producing the

cores for the Disamatic molding process

amount to only 70 % of those for comparable

core boxes for the tight flask

line. Prices of pattern and pattern plates

for the vertical process are also more favourable,

amounting to only 74 % of

those used on the tight flask line.

We lack detailed data in the area of

mismatch and dimensional accuracy

of the castings. There seem not to

be significant differences between the

two processes. 5 mm are added to the

diameter at all castings for machining,

which is performed 100 % in house enabling

direct feedback in the event of

quality issues.

The streamlined gating system developed

by Disa enabled a significant

optimization of the foundry in terms

of yield. The total weight of a poured

cluster of two discs using a conventional

gating technology was 35.9 kg. The

pouring cup and gating accounted for

12.9 kg, resulting in a yield of 64.7 %.

The introduction of new technology

reduced the share of the pouring

cup and the gating to 8.2 kg. The total

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20 Casting Plant & Technology 1/2015


weight of the poured cluster thus fell to

31.4 kg, increasing yield to 73.9 %. The

yield of the flask molding plant is 73 %.

A comparison of the power consumption

by the two molding machines is not

possible in this foundry. There is however

no doubt that the vertical molding

process has considerable advantages. It

is, however, possible to compare the energy

consumption of each production

line including filter units, vibratory conveyors,

sand supply units, belts and cooling

drums. The energy consumption per

hour of the tight flask production line

is 625 kWh, while the Disamatic production

line uses only 232 kWh. Neither

figure includes power consumption

by the heated pouring devices. Both systems

have their own green sand preparation

plant (120 t/h each) from different

manufacturers. This is necessary because

of the distances between the production

lines and different demands on

the greensand. In 2013, the power consumption

of the vertical parted line sand

plant averaged 530 kW/h, while the consumption

of the horizontally parted

sand plant was 540 kW/h.

Summary

The article compares different aspects

of brake disc production using vertically

parted flaskless molding lines and

horizontal parted tight flask molding

lines. In the first section the vertical

molding process demonstrates advantages

in terms of investment costs. The

discussion addresses annual production

density in tons per square meter

of the foundry area in use. Area use is

a significant factor in relation to production.

Furthermore, annual energy

consumption of the molding lines

in relation to castings produced is discussed,

again demonstrating clear benefits

from the Disamatic-technology.

Developments in vertical mold process

are tested for their effects on the application

of technology. The possible increase

in the yield or production volume

suggests further potential for cost

optimization in the foundry.

In the second section a comparison

between two molding technologies for

the production of brake discs is made

on the basis of production data from

the South Korean foundry Hyundai

Sungwoo. The two plants have been

in operation for several years, enabling

us to learn from maintenance experience.

Equipment performance as well

as respective scrap and uptime were

compared. In this case, no significant

differences in performance, yield and

quality between the technologies are

found. The Disamatic molding process,

however, offers advantages in

terms of tooling costs and energy consumption.

www.disagroup.com

References:

www.giesserei-verlag.de/cpt/references

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Casting Plant & Technology 1/2015 21


Pouring by stopper ladle

at the pouring line (Figures:

HWS)

Author: Steffen Geisweid, Heinrich Wagner Sinto, Bad Laasphe

A milestone for the modernization

of a steel foundry

In the Promlit foundry in the Russian city of Cheboksary the existing green sand molding system

has been replaced by a modern HWS molding machine. Instead of the jolt squeeze production


quality and is also able to mold larger patterns and to change them automatically

Historically grown foundries are often

well-established producers of

high-quality castings whose market

position is determined by a mixture

of experience, development and innovation.

Investments in this environment

are often oriented in the very

long term, considering the extraordinary

demands in foundry conditions.

This is the reason why investments on

replacements are often subject to lots

of restrictions that an existing company

together with its logistics prescribes.

The project definition of the present

case of the foundry Promlit was

to modernize the existing green sand

molding plant and to improve the existing

weak points. For this purpose,

particularly the so-called heart of the

foundry – the molding plant – was considered

because, for the investment examination

for a new automatic molding

machine, the existing molding

machine was subject to particular

specifications regarding increase of

the mold output, product variety and

molding quality.

The existing molding machine of

type Herman, installed in the early seventies,

did not provide a useful possibility

for an increase in production

with the formerly planned output of

seven complete molds. The layout of

the plant provides a separate transport

line for copes and drags as well as two

pouring and cooling lines each.

In order to achieve the above target

of a higher mold output, the new molding

machine from HWS ( ) has

been designed for a maximum output

of twenty molds per hour. Amongst

22 Casting Plant & Technology 1/2015


Automatic Seiatsu molding machine type EFA-S 8,5

Pattern shuttle at the automatic molding machine


others, one advantage for the exchange

of the molding machine was

the low degree of adaptation required

in the foundation area.

Furthermore, the inside dimension

of the flask was increased from 2500

x 1600 mm to 2630 x 1700 mm while

maintaining the former outside dimension;

cope and drag are 600 mm

high each. This enlargement opens

up the opportunity to the foundry to

mold bigger patterns and thus to extend

the variety of products.

In addition, the automatic molding

machine type EFA-S 8.5 was equipped

with an automatic pattern change

( Figure 2). In running operation, the

following patterns can be prepared and

exchanged automatically which makes

the pattern change cycle shorter. The

arrangement of these preparation places

increases the accessibility at the stations;

so-called safety lifting gates ensure

a safe sequence during the pattern

change.

To improve the mold quality

( ), the foundry can, after the

modernization from jolt-squeeze

molding process, avail themselves of

the two-step airflow-squeeze molding

process Seiatsu (in combination with

squeezing from pattern side as an option)

– the currently most common

molding process in tight-flask green

sand molding plants. The two steps of

the molding process consist on the one

hand of the Seiatsu airflow that penetrates

the sand pre-dosed by the movable

sand hopper, aerates it and compacts

it by exiting through the vent

holes in the pattern (and/or the pattern

bolster) on the pattern side. In

addition, the second step provides a

hydraulic pressing of the sand back.

Here an homogeneous mold strength

is in the focus of the process control

to achieve optimum degassing during

the casting process (see lead picture).

In case of this project, the molding

machine is equipped with a so-called

multi-ram press that optimally adapts

the process of pressing to the pattern

geometry. Also many of the sand

touching flaps and ducts in the sand

dosing hopper are fitted with highly

porous plastic sheets which create

ventilation and an air cushion between

the molding sand and hopper

wall. This reduces wear, the sand does

not stick and thus creates a process reliable

sand filling process.

Furthermore, the function „squeezing

from pattern side“ enables an optimization

of the sand compaction at

the flasks’ limits by a levelling frame

that can be activated, especially in case

of patterns with an unfavourable ratio

of casting and sand in these areas.

In addition to reducing the number

of rejected molds, the foundry was able

to reduce additional costs, as the formerly

used stations for applying and

drying the black wash were not required

anymore.

The molding plant can be operated

in combination with two different

types of sand (filling sand and facing

Casting Plant & Technology 1/2015 23


AUTOMATION


Covering station (cope is setdown onto the drag)

sand) by each using an intermediate

hopper with precise weighing for the

exact dosage of the required amount

of sand. The maximum sand consumption

is 154 t per hour.

With the new supplied flask transfer

device (Figure 4) cope and drag are alternately

transported from the molding

line to the cope and/or core setting

line.

A new installed vent piercing and

drilling device allows a better degassing

of the mold during the casting

process and reduces the post-processing

effort on the casting. The working

area covers almost the entire mold

surface. A total of 32 vent holes can

be pierced and four vent holes can be

drilled. The drilling device produces

holes with a diameter of 32 mm.

The new closing device (Figure 5)

for copes and drags helps to reduce

the post-processing as well. It improves

the positioning of the molding boxes

to achieve an exact closing and minimizes

the reject rate caused by damaged

sand molds.

Furthermore, the molding plant got

a new central hydraulic station for the

new plant components. The new pushing

and braking units for the cope and

drag line have also been integrated in

the new central hydraulic station for

the molding plant.

All new supplied components are

designed for a plant output of 20

molds per hour. However, since some

remaining components (among others

in the pouring and cooling line)

are still being used, there is an overall

molding output of 16 molds per hour

– an increase in output of more than

100 %.

In general, the availability of the

entire molding shop is improved significantly,

which is among others

emphasized by the evaluation of the

plant software. The new HWS molding

plant control system based on Siemens

S7 has a plant monitoring system

(ALS 2010) and offers additional anal-

24 Casting Plant & Technology 1/2015


ysis capabilities to the foundry to increase

efficiency.

To illustrate the size of the equipment,

some data are listed below from

the truck dispatch of equipment in

2012: In total more than 30 vehicles

transported more than 500 t of material

to Russia, the heaviest single component

(base frame) had a weight of

17.5 t.

Together with the customer, the reconstruction

measure (installation

& commissioning) has been carried

out and the acceptance test has taken

place in time. It is worth mentioning

that the cooperation with the foundry

can already look back on years of

experience. In 2004, a vacuum molding

plant supplied by Heinrich Wagner

Sinto has already been installed. This

plant with a molding box size of 3000

x 1800 x 500/500 mm produces up to

20 molds per hour.

Promlit Cheboksary Foundry produces

all types of iron and steel castings

for the machine building and the

railroad industry. The company is located

in Cheboksary/Russia on the

right bank of the Volga River, about

600 km east of Moscow. The modern

production facility, built in the early

eighties, has extensive experience in

the manufacturing of complex steel,

cast iron and ductile iron parts having

weights from 10 to 6000 kg with

dimensions from 50 to 2000 mm and

more (see example in Figure 6). The

high quality of the castings is assured

by experienced staff and the EN-certification

ISO 9001.

The annual production capacity of

the foundry is 80,000 t.

The efficient production plants:

sand preparation, molding lines, core

production, pouring plants, molding

box cleaning, casting transport and

sand reprocessing, have been supplied

by leading foundry suppliers.

Promlit products are supplied to numerous

customers in and outside Russia,

e.g. in the USA, UK, Germany, Italy,

Spain, Israel, France and Canada.

www.wagner-sinto.de

Castings after shot-blasting

Casting Plant & Technology 1/2015 25


PJSC Energomashspetsstal (EMSS) manufactures complex castings like steam and hydro turbine housings, steam turbine

rotors, hydro rotors, trusses, ring gears, screw blades and hubs, support rollers for hot and cold rolling mills as well



One of the biggest shot blast

systems in the world

The foundry of PJSC Energomashspetsstal in Kramatorsk/Ukraine specializes in manufacturing

very big, heavy and complex castings. Considering the high value of the castings it is not surprising

that they are subject to comprehensive quality controls including – among other criteria –





space at the customer’s premises

The facilities of the iron and steel works

PJSC Energomashspetsstal (EMSS) are

located in the Ukrainian town of Kramatorsk

on an area of around 138 hectares.

Since 1964 this company has been

manufacturing castings and forgings

for the heavy, energy generating and

nuclear industries as well as for marine

and traffic engineering. Over the past

years the company has specialized on

components like steam and hydro turbine

housings, steam turbine rotors,

hydro rotors, trusses, ring gears, screw

blades and hubs, support rollers for hot

and cold rolling mills as well as diefixing

blocks. Because of their unique

function, as well as their size and

weight these components are generally

engineered and made as one-of-a-kind

products. EMSS has strict quality controls

in place to ensure the extremely

high quality and long service life

of these components. For example,

all external and internal surface areas

of the castings are visually inspected.

In addition, they undergo a magnetic

particle test or an ultrasonic inspection

to search for cracks in the material.

This requires a clean surface free of any

scale in compliance with the Swedish

surface preparation standard SA 2,5. In

the past this surface preparation operation

was done manually. Igor Sapetko,

foundry manager at EMSS comments:

“We invested in this new shot blast system

primarily because the stringent

26 Casting Plant & Technology 1/2015


Figure 1:

long, 7 m wide, 5 m high and up to 250 tons in weight

customer requirements for improved

casting and surface qualities forced us

to adopt the cold box casting method

for castings with complex geometries.

However, at the same time we wanted

to improve the working conditions for

our employees by eliminating the vibrations,

the dust and noise caused by

manual shot blasting. This, by the way,

also contributed to a much cleaner environment.”

Part size & weight and the onsite

space restrictions

The work piece dimensions which are

up to 12 m long, 7 m wide, 5 m high

and up to 250 tons in weight posed a

significant technical challenge for the

Rösler engineers (Figure 1). But the engineering

task became even more difficult,

because the customer specifications

called for integrating the shot

blast system into the overall EMSS

manufacturing line. The shot blast machine

had to be placed on the foundation

of an old water jet blast system in

a building with numerous support pillars.

At the same time, the Rösler engineers

had to ensure that the machine

design allowed utilization of the existing

rail part transfer system with turn

table for transporting the work pieces

from the foundry through the blast

machine to the quality control department

(Figure 2). Because of the high

weight of the castings a spinner/hanger

shot blast system was not feasible.

Igor Sapetko continues: “We looked

primarily for a simple but effective

shot blast system that guaranteed a

high functional reliability and was

easy to maintain. Of course, economic

aspects like the purchasing price and

operating costs played also a significant

role in our decision.”

With these requirements the project

team at EMSS contacted six shot blast

equipment manufacturers, among

whom three companies, including the

Rösler Oberflächentechnik GmbH,

were pre-selected. In the end, after visits

at the manufacturing facilities of

the three suppliers, inspection of various

reference shot blast installations

and review of the different technical

concepts, the customer decided to

place the purchase order with Rösler.

The comprehensive and extremely detailed

layout of the RDS 80/70 shot

blast system proved to the EMSS team

at a very early stage that the Rösler concept

met all its technical requirements.

Customer engineered to the

very last inch

The Rösler continuous rail shot blast

system RDS 80/70 is one of the biggest

shot blast machines ever built in the

world, and is certainly the biggest ever

built by Rösler. It had to be placed in

the building to fit exactly between the

support pillars. To prevent spillage of

blast media the blast machine inlet and

outlet areas are equipped with double

wing steel doors lined with wear resistant

rubber. The inside of the 30 m long

machine is divided into three sections:

Inlet and outlet chamber and the actual

blast chamber with inner dimensions

of 10.5 (L) x 8 (W) x 7 (H) m. The

large width of the blast chamber allows

complete rotation of parts with a length

of up to 7 m during the blast cleaning

process (Figure 3). The RDS 80/70 is

equipped with eight Hurricane H42

turbines mounted to the ceiling, respectively

one side wall, of the blast

chamber with an installed drive power

of 22 kW each, throwing over 2,000 kg

of blast media per minute. After their

first pass through the blast machine

parts longer than 7 m are picked up

from the transfer system turn table by

the existing bridge crane, rotated by

Casting Plant & Technology 1/2015 27


CLEANING, FETTLING & FINISHING

180 degrees and placed back on the

turn table for a second pass through the

machine. This ensures all around blast

cleaning of parts which, due to their

length, cannot be rotated on the turn

table. For optimum wear protection the

blast chamber is fabricated from manganese

steel and lined with easy to exchange

overlapping manganese wear

plates. To allow manual spot cleaning

of critical surface areas the RDS 80/70

is equipped with a pressure blast system

and lighting in the blast chamber.

A special technical feature of the

EMSS shot blast machine is the extra

large media hopper allowing the storage

of 30 metric tons of blast media.

This ensures that even in the case of

work pieces which are extremely cupshaped,

the shot blast process must not

be interrupted because of lack of blast

media in the system due to media carryout.

Figure 2: Work pieces with a length of up to 7 m can be rotated by 360° on

the turn table of the part transfer system

A blast machine consisting of

many more individual sections

than other machines

The blast media thrown by the turbines

is collected in two large hoppers

placed in the foundation pit

from where the media is transferred

to the transport system of the media

cleaning and classification unit. This

posed another technical challenge, because

the rails of the part transfer system

allowed an access opening of only

2 x 2 m for placing all these equipment

components in the foundation

pit. For this reason, the media collecting

hoppers below the blast chamber

had to be fabricated in 15 individual

sections instead of normally 4 sections.

A five storey high maintenance platform

allows quick and easy access to

all equipment sections requiring regular

maintenance work. Another significant

factor regarding maintenance is

the fact that Rösler maintains a service

center in the Ukraine.

Igor Sapetko concludes: “With the

new shot blast system from Rösler we

achieve the required surface cleanliness

with the blast media consumption

cut in half compared to our old

manual blast cleaning system. In addition,

we were able to significantly reduce

the blast cleaning process times.

Where previously several employees

needed weeks of manual blasting, we

are now completing the same blast

cleaning process within a few hours.”

Figure 3: The critical surface areas of very complex work pieces can be manually

spot treated with a specially installed pressure blasting system

www.rosler.com

28 Casting Plant & Technology 1/2015


www.sinto.com

16 th - 20 th June 2015

Duesseldorf,

Germany

Hall 17

Stand 17 B 20

• SEIATSU- / ACE-Moulding Machines and Plants

• FBO- / FDNX-Flaskless Moulding Machines and Plants

• VACUUM Moulding Machines and Plants

• POURING UNITS – semi and fully automatic

• SOFTWARE FOR MOULDING AND POURING LINES

HEINRICH WAGNER SINTO Maschinenfabrik GmbH

SINTOKOGIO GROUP

Bahnhofstrasse 101 · 57334 Bad Laasphe, Germany

Phone +49 (0)2752 907-0 · Fax +49 (0)2752 907-280

www.wagner-sinto.de


QUALITY ASSURANCE

Author: Birgit Gottsauner, Siemens AG, Process Industries and Drives, Nuremberg

Raw materials according to recipe






The RFID transponders at the charge containers survive the rough handling during the loading in the charging hall of

the foundry without damage (Photos: Siemens AG)

The Karl Casper GmbH & Co. KG headquartered

in Remchingen (in the German

state of Baden-Württemberg) is a

manufacturer of high-quality industrial

and art castings. From top-grade pig

iron and steel scrap, approximately 100

employees – in a two-shift operation –

fabricate sophisticated components for

machine tools and special machinery,

plastic injection molding machines

and railway vehicles. The workpieces

range from single parts to low-volume

batches of up to 1000 pieces – each

piece weighing up to nine tons.

“For many years, the data pertaining

to the composition of the melting

material was entered manually into a

PC, which made a precise production

planning and tracking and tracing difficult,”

explains technical manager Malte

Lüking. “An efficient solution for just

that now comes in the form of RFID

– Radio Frequency Identification enables

the automatic recognition of the

transport containers, the allocation of

the batches and the software modeling

of their relationships.” Lüking emphasizes

that a goal of the company management

was to also incorporate ideas

of employees in the implementation of

the new RFID application. “They are, after

all, working with the program day

in, day out – and know what is important,”

says the technical manager.

The project team, consisting of

Malte Lüking, Uwe Wilhelm – manag-

30 Casting Plant & Technology 1/2015


er of maintenance at Casper, and Siegfried

Schlaak –managing director of

the consulting firm SSSoft specializing

in foundry technology, began roughly

18 months ago with the selection of

the new hardware and the design of the

software. One decision criterion was the

lasting operational suitability: The RFID

transponders had to survive the rough

handling during loading and unloading,

be unaffected by interference caused by

strong electromagnets mounted to the

crane, and withstand high furnace temperatures

without damage despite continuous

use ( ). For the identification

of the charge containers, the use

of the low-cost, heat-resistant Simatic

RF680T transponders by Siemens, Munich,

Germany, suggested itself. The

transponders are designed for operating

temperatures up to 220 °C and feature

a rugged construction with IP68 degree

of protection; they are thus ideal for applications

in harsh industrial environments.

Heat-resistant Simatic RF680T RFID transponders identify the charge

containers; a sturdy metal frame protects them against mechanical stresses

Due to limited space on the furnace platform, a rugged RF630R RFID

reader with external RF640A UHF antenna is employed, which also offers a

high interference resistance in metallic environments

Highly resistant to interference

in metallic environments

The radio signals are evaluated by a Simatic

RF630R reader. “We chose Siemens

products, since they best matched

our ideas and requirements,” stresses

Lüking. Due to limited space on the

furnace platform, a reader with an external

Simatic RF640A UHF antenna is

employed (Figure 2). The unit operates

in the ultra-high frequency (UHF) range

and is unaffected by external influences

such as dust or moisture. In addition,

the unit is characterized by a high interference

resistance in metallic environments

– as found in the steel constructions

around the furnace platform. For

the communication and supply of power,

the reader is connected to a PLC or a

fieldbus communication module.

Prior to the introduction of the identification

solution, it was time-consuming

for employees of the so-called

charging plant to meter the contents

of the charge containers in accordance

with the recipes to achieve the

called for product properties. Since

then, ten charge containers equipped

with transponders – for the transport

of the melting material to the induction

furnace – have been put into rotating

operation at Casper. To feed the

melting furnace, the crane operator of

the charging plant selects an empty

charging box and fills it with pig iron,

steel scrap, stacks of sheet metal, etc. as

specified by the production planning.

As soon as the charge is complete, the

crane operator sends the data to the

control and monitoring software; the

container is then ready for the transport

to the furnace platform (Figure 3).

The requirements placed on the accuracy

of the melting processes are very

high and may deviate only slightly from

the specifications. This highlights the

advantage of the new RFID installation:

The RFID reader/writer mounted to the

furnace platform reads the transponder

data of the charging box and forwards it

to the control and moni toring system.

During the melting process, a spectrometric

and thermal determination of

Casting Plant & Technology 1/2015 31


QUALITY ASSURANCE

The charging software informs the melting foreman about the

charge container – and the components contained in it for the steel melt –

to be fed into the furnace

The production processes are controlled and monitored by Simatic

S7 controllers; sensors and actuators are connected by means of ET200S I/O

-


the alloying elements takes place. The

software calculates the difference between

reference and actual values, and

informs the melter whether other additives

(carbon, silicon, etc.) are needed

on the basis of the recipe. Thanks to

the batch tracking and tracing, it is precisely

documented what has been processed.

At the end of the month, material

quantities as well as the melting loss

can thus be accurately accounted for.

Setup of an RFID-based casting

pattern management

In the electric induction furnace, temperatures

reach roughly 1,600 °C. It

takes about an hour for the raw materials

and additives to liquefy into a homogenous

iron melt. While the shift

supervisor prepares for tapping the

crucible holding the molten iron, employees

in the light-flooded casting

and molding hall are already making

arrangements for the next steps. After

melting down and mixing all components,

the melt flows into a treatment

ladle by tilting the crucible, where it

is adjusted to the desired quality using

additional alloying elements. Afterward,

the ladle is transported to the

casting hall, where experienced casters

fill the iron melt into molding boxes.

An expansion of the identification

solution to provide an RFID-based casting

pattern management is planned.

The modern high-bay warehouse of the

foundry holds patterns made of laminated

wood, synthetic resins or polystyrene

foam for repeat orders, pattern

changes or pattern adjustments. “We

are warehousing roughly 8,000 casting

patterns, of which about 4,000 are

recurring shapes,” describes Lüking.

In the future, every pattern plate will

receive an RFID tag, on which component

and job data, attached parts,

storage location, materials and other

information are noted. “Employees

can then read out the data with a handheld

scanner. The uniform and always

up-to-date information greatly facilitates

the identification of the patterns.

Lengthy searches thus become a thing

of the past,” Lüking is convinced.

Casper not only makes and “sells”

high-quality products, but also is pursuing

the goal of a clean environment –

the company calls itself “weiße Gießerei

im Grünen” – meaning an ecological

foundry preserving the environment.

Among the measures are a newly installed

co-generation plant that generates

power and heat in an environmentally

friendly manner and significantly

lowers the operating costs. To further

optimize the energy consumption, the

company management has tackled the

project of energy management. In particular

the high power consumption of

the electric melting furnaces represents

an enormous cost factor for foundries.

In other places as well, e.g., the production

hall cooling and ventilation, molding

plants, shakers, sandblasters and

sand preparation, considerable energy

savings can be realized.

In a first step, the technicians have

started to install Sentron PAC4200 power

meters by Siemens in the control cabinets

of the various production areas, and

32 Casting Plant & Technology 1/2015


consolidated the measured data in CSV

files. As next step, the Sentron units will

be integrated into the automation and

energy management software “powermanager”,

which conveniently visualizes

all measured data. The solution will

then clearly depict the current status of

the plants and the power grid quality;

and by more efficiently utilizing the systems,

the energy use and costs are lowered.

The real-time display of connected

consumers enables a weak point analysis

and thus a quick power reduction at

individual production plants.

tly

with notebook and smartphone

To comprehensively automate the production

operation, the foundry management

decided to install the production

monitoring system DCAS (Data by

Concentration and Analysis System)

by SSSoft. It monitors, among other

things, the pass-through rotary mixers,

the sand regeneration, the electric

furnace and the air compressors. The

signal parameters are tapped at the Simatic

controllers by means of Profinet

and forwarded to the software. A visualization

computer prepares the data

and provides it in real-time for the

monitoring and control of the plants.

If, for example, a fault occurs, the employee

can immediately locate the

problem and initiate the proper steps.

A location-independent, secured system

access via the Internet using a

notebook, iPad or smartphone is also

possible, e.g., to remotely control processes

and avoid interruptions through

early intervention (Figure 4).

The diverse automation tasks at

Casper have been carried out by Simatic

controllers for years. The Simatic

S5 controllers used so far are now

being replaced by new Simatic S7-300

modular controllers. In this context,

the process visualization is also advanced

to allow processes to be controlled

and monitored from different

operator control and monitoring stations.

As distributed I/O modules, signal

and function modules as well as

Simatic ET200S communication processors

are employed for the user-specific

automation tasks of the S7-300

controllers, which greatly simplifies

the wiring and commissioning.

Casper is a compelling example of a successful

implementation of an integrated

automation philosophy. Thanks to

its complete product portfolio of Totally

Integrated Automation (TIA), with

which Siemens denotes the transparency

and interoperability of its systems,

the individual automation components

are always matched to each other. From

medium-voltage transformer to drive

and control technology to sensors and

visualization, the foundry solely utilizes

standard components from the

same vendor. The integrated TIA Portal

engineering environment for PLC,

HMI and network provided great flexibility

during the system development,

which considerably reduced the time

required for the integration. According

to the pro ject team, the development

and commissioning times were greatly

shortened and the requirements optimally

met with the TIA Portal software,

unlike with other solution approaches.

Positive summary

“The production of high-quality casting

alloys requires a lot of experience,

the mastery of all production processes

and an optimal composition of the

source materials. RFID is the right solution

here. In the six months since its

commissioning, it has truly proven itself

and been running trouble-free,”

judges Lüking. Thanks to the transponders,

the loading of the charging boxes

with pig iron and steel scrap can be accomplished

in a precise manner, which

helps in putting together the melt with

a minimized use of resources. Compared

to the manual entry of data, sometimes

during frantic operations, the paperless

storing of the raw materials data ensures

that nothing is ever lost. “Together

with the analysis values, the data forms

a comprehensive batch profile, which

provides information about the respective

metallic composition. A complete

history is generated that makes a gapless

tracking and tracing of the process

progression and a certified quality management

easy,” concludes Malte Lüking.

www.siemens.com/ident

Casting Plant & Technology 1/2015 33


POLLUTION CONTROL

Air pollution in the Chinese metropolis Shenzhen

(Photo: Oliver Zwahlen)

Author: Parisa Javadian Namin, KMA Umwelttechnik GmbH, Königswinter

Clean up your Act

Cleaning the air in your factory can save operational costs – and the environment

The new World Health Organization report

was released in March 2014. It stated

2012 around 7 million people died -

one in eight of total global deaths – as a

result of air pollution exposure. Awareness

and responsibility towards air pollution

is needed more than ever, in particular

in the industrial sector. Especially

in the mega cities of the People´s Republic

of China, where smog hangs heavy

over Beijing and Shanghai alone, where

children grow up with asthma and other

respiratory illnesses.

In many factories the exhaust air is

captured and (often without being filtered)

transported to the outside. This

provides a small improvement of the air

quality inside the hall, but only means

a shift of air pollutants to outdoors. In

addition, letting polluted air disperse

in the hall before being filtered allows

aerosols to be deposited on products

and expensive machinery. This means

high maintenance costs and in most

cases short life expectancy for the machinery.

And the large amount of exhaust

air movements implicates high

energy consumptions for the exhaust

and inlet ventilation systems. At the

same time, this method causes heating

costs during the winter period, because

the transported air to outdoors must be

replaced with the same amount of fresh

air from outside. These facts increase

the company´s operation costs and

carbon dioxide (CO 2

) emissions. The

use of energy efficient air filtration systems

can lead to a significant improvement

in the company’s balance sheet.

Besides, clean air at the workplace increases

productivity, motivation and

overall health of employees.

Methods of exhaust air treatment

An interesting aspect about modern

solutions for air purification is the energy

efficiency. Air treatment systems

with a disadvantageous layout can cause

enormous investment and running

costs. A modern solution can, how ever,

help to reduce the energy consumption

and the operating costs significantly,

permitting a short payback period on

air filtration installations.

A comparison between the

exhaust air treatment systems

To give a better idea about the differences

in the energy demand of different ex-

34 Casting Plant & Technology 1/2015


haust air treatments, a practical example

for several methods of air purification

will be explained in the following.

We assume that there is a die casting

foundry in Changchun, because it’s

particularly interesting to direct the

attention to energy efficiency in provinces

with significantly high or low

temperatures, where heating or cooling

of make-up air is required.

Die casting machines create highly

greasy and polluted smoke. Changchun

has a median daytime temperature

of -4.4 °C degrees during the

winter period (October to the end of

April). The desired inside temperature

is with 17 °C degrees around room

temperature. The manufacturing hall

of the foundry has a total volume of

78,000 m 3 and is equipped with 20 die

casting machines in several sizes (from

640 tons up to 2500 tons machines).

The management has now several air

treatment options to purify the waste

air of the die casting machines.

First method: Conventional

exhaust air ventilation system

A conventional exhaust ventilation system

works in a very easy way: the waste

air is led outside through complex exhaust

ducts and chimneys at the roof

of the building and fresh air from outdoors

is led inside through the inlets.

This method ensures clean air at the

workplace but creates high follow-up

costs. The main reason: allowing

fumes to get dispersed in the hall first

a nonessential increase of the exhaust

air volume is created, which needs to

be purified. And a high air volume always

means high energy consumption.

Practical examples show that generally

the ambient air inside the hall has

to be changed by a conventional ventilation

system 10 to 12 times per hour

by air from outdoors to keep it clean.

In our example this means an air volume

exchange of at least 781,200 m 3

per hour, plus high pressure loss (generated

by the exhaust air ducts) and

high heating costs of the incoming

air. This results in an annual operation

cost of 19,056,770 Renminbi

(2,490,615.39 Euro) and carbon dioxide

emissions of about 3,500 tons per

year.

Figure 1: -



stay clean (Photos: KMA Umwelttechnik GmbH)

Second method: Exhaust air


ing air mode

Today´s most energy-efficient principle

of exhaust air treatment is the recirculating

air mode. For the comparison:

in the exhaust air mode the waste air is

led outside, either with or without air

purification. This method ensures clean

air at the workplace but creates high

follow-up costs, especially during cold

winter periods or hot summer periods.

The reason: the same amount of air that

is led outside has to be replaced by incoming

fresh air from outdoors, which

has to be heated up first or cooled down

first before it is led inside. Heating up

or cooling down the fresh air to room

temperature will cause high amounts

of energy consumption and operation

costs for the company. At the same time

the environment gets polluted by high

CO 2

emissions caused by energy consumption

processes. In a recirculating

air mode the exhaust air will be filtered

very effectively by the use of highly efficient

electrostatic filter units. After

the filtration the purified air will be led

back into the production hall. As the

purified air is led back into the manufacturing

hall, there is no need of maintenance-intensive

exhaust air ducts,

which cause high pressure loss and increase

the energy demand.

Here, each die casting machine is

equipped with specially adapted extraction

hoods. These extraction devices

capture fumes efficiently and directly

at the die casting machines, avoiding

fumes get dispersed into the production

hall and therewith, no high air volumes

for the exhaust air treatment. In

our example the exhaust air volume decreases

to 215,400 m 3 per hour. Low air

volume always means less energy consumption.

Each die casting machine is

Casting Plant & Technology 1/2015 35


POLLUTION CONTROL

Figure 2:

-



also equipped with one decentralized

compact filter system. The filter units

are electrostatic precipitators, which

ensure highly effective separations of

smoke, dust, and fine mist whilst using

little energy. Unsuitable filter types

can quickly clog and become ineffective,

leading to excessive costs associated

with filter replacement and disposal.

However, changing the electrostatic filter

cells is not necessary and they never

obstruct the air flow through the exhaust

system. The electrostatic filter is

an economical and durable filter medium

for many applications. In our model

( Figure 1) case the exhaust air filter system

with a recirculating air mode leads

to very low energy consumption. Hence,

the foundry in Changchun has now just

operation costs of 1,098,791 Renminbi

(143,648.94 Euro). That’s more than

90 % less compared to a conventional

ventilation system. Also the carbon dioxide

emissions are reduced to 416 tons

per year.

According to these, the recirculating

air mode includes the most energy-saving

potential. Although this principle

is used in many modern and newbuilt

foundries, it is a fact that in some

foundries the demand for exhaust air

mode systems still exists. For those cases

there is an energy-efficient exhaust

air alternative, explained below.

Third method: Centralized ex-


with heat recovery system

At some winter days in Changchun the

ambient median temperature is going

down to -16 °C. By using a conventional

exhaust ventilation system, the temperature

inside the hall will also turn

cold. Therefore, many foundries in that

region have to heat up the production

halls to keep the productivity high. But

due to the high energy costs that are

caused by heating systems, some foundry

managers see this proposition as an

incapable solution. What often is not

considered is the fact that in most production

processes high amounts of heat

and energy is created, which can be used

for follow-up processes. The centralized

exhaust air filtration system (Figure 2),

equipped with an integrated heat recovery

system, enables an energy-efficient

heating or cooling of the hall by perform

in an exhaust air mode.

Here, the multiple machines are

connected to one centralized large exhaust

air filter system. That means the

waste air from the machinery is extracted

through exhaust ducts and led

to the centralized filter system, which

is equipped with electrostatic precipitators

as well as integrated fin tube

heat exchanger. After filtering aerosols

out of the exhaust air, the heat pump,

which is connected to the filter system,

extracts the energy out of the purified

air. The energy is transferred in the condenser

of the heat pump to a heating

water circuit. Afterwards the heating

water is led to a second heat exchanger,

which is installed in the incoming

air duct. With this method the incoming

cool air is heated up in an energy-efficient

and economical way before

it flows into the production hall.

With the help of the highly efficient

heat pump the foundry in Changchun

increases the temperature inside the

hall up to a room temperature just by

using the heat recovered out of the exhaust

air. By an energy demand of 352

kW per hour, the heat pump is creating

almost 1,500 kW per hour for follow-up

processes. Here the foundry

in Changchun is having annual operation

costs of 4,235,717 Renminbi

(553,750.66 Euro), which goes along

with an annual carbon dioxide emission

of almost 1000 tons. These energy-savings

are less than the foundry

in Changchun would reach with the

recirculating air mode, but still much

higher than the conventional exhaust

ventilation system with a simple and

energy-intensive heating system would

reach.

Take action on air pollution

The energy consumption in foundries

is strongly depending on the energy

input of the exhaust and supply

air systems. High energy consumptions

always mean high amounts of

CO 2

emissions. Through the use of energy-efficient

exhaust air filtration systems

the air gets clean and significant

reductions in carbon dioxide emissions

can be done. Die casting foundries

and other metal processing industries

can easily improve the company´s

“Carbon Footprint” and make an important

contribution to climate protection.

Therefore, a change in thinking

for each factory is worthwhile.


36 Casting Plant & Technology 1/2015


www.giesserei-verlag.de

1985-2015

Special of

CASTING

PLANT AND TECHNOLOGY

Anniversary edition


www.giesserei-verlag.de

12. March

2015

CASTING

1

PLANT AND TECHNOLOGY

INTERNATIONAL

30 years

CP+T

International

Centrifugal casting

machines for reliable

serial production

U 1.indd 1

1985-2015

30 years

Foundry technology at first hand


SPECIAL

“CP+T is an excellent worldwide

platform for foundry technology”

Engineer Peter Haensel edited CP+T for almost 20 years from its founding in 1985 until 2004.

The foundry specialist came from Austria originally and had studied at the prestigious Leoben

University of Mining and Metallurgy. On the occasion of the magazine’s 30th anniversary he

spoke to CP+T about developments in foundry technology in his day, and why the English-language

foundry magazine was founded. He also takes a look at the future of foundry technology

Looking back at the beginnings: CP+T-Editor Robert Piterek with Dipl.-Ing. Peter Haensel (r.) who managed the specialist

magazine for 19 years from 1985 to 2004 (Photos: BDG/Soschinski)

Mr. Haensel, how long did you produce

CP+T for?

From 1985 to 2004, so almost the first

twenty years of the existence of this

English-language specialist foundry

magazine. I was Technical Editor from

1985 to 1997 then, as Editor-in-Chief

of GIESSEREI, I was also the top editor

at CP+T until 2004.

How was the magazine produced in

those days?

It was much more difficult: there were

a lot more production steps than now,

corrections were made in different colors

to keep the costs apart – each proofing

cost 4 deutschmarks, and correcting

the format cost 10 deutschmarks.

The specialist articles, for example,

were translated by Robert Vinall, an

engineer who had learnt in cleaning

shops in England and supplied excellent

translations for our international

magazine.

What function do you think CP+T


world?

40 Casting Plant & Technology 1/2015


In an interesting talk

across generations

Haensel pointed out

that foundry technology

since 1985 has

mainly developed in

the areas of material

optimization and IT

technology in foundries

In those days we got several letters from

the USA and Canada, in particular,

praising the excellently translated specialist

articles. In my time the magazine

was particularly appreciated in China

and America (including Canada). The

magazine was also popular in Brazil.

German companies see it as a publishing

platform for presenting their technology.

When you look at the CP+T from then

and from now what is particularly noticeable?

The major difference is that the layout

used to be more related to the content.

Today’s layout is picture-oriented. It’s

similar in GIESSEREI. I like it. It reflects

modernity. In the past the magazine

was mainly intended for specialists and

maybe interested students who already

knew something of the subject. Now

both magazines are more interesting

and appeal to a broader circle of readers.

What important developments took

place in foundry technology while you

were working for GIESSEREI and CP+T?

Mainly it was the change in materials

and in the concentration and optimization

of materials for particular

parts. And then, of course, the changes

in foundry technology caused by electronic

data processing and simulation

– the use of computers throughout the

foundry.

What is your background and how

did you become an Editor and Editor-in-Chief

of GIESSEREI and CP+T?

I am Austrian and studied at the Leoben

University of Mining and Metallurgy.

That’s why I still go to the Austrian

Foundry Congress every year. I

was active in the Research and Development

Department of the Institute

of Foundry Technology in Düsseldorf,

which I got to via Buderus, already one

of Germany’s largest foundry companies

then. After five years at the Institute

I started work in the Editor’s Office

of GIESSEREI and CP+T. That was 1980,

five years before CP+T was founded.

What was the reasoning for launching

CP+T 30 years ago?

It was founded as a counterpart to the

English-language magazine MPT for

the steel industry. The initiative came

from the foundry suppliers, who were

interested in finding a platform for

publicizing their technologies abroad.

What role did the GIFA – where CP+T

was always on display – have in this?

The International Foundry Fair GIFA

in Düsseldorf has been organized in its

present form since 1956. Since its start,

CP+T has always been available there

and has been sought-after by foundry

specialists from all over the world.

Today, in 2015, the foundry world has

changed a lot compared to before.

What directions are developments

taking?

Yes, the changes have been great. Development

will continue in the direction

of material optimization. I think

there will also be further developments

in light construction materials, e.g. towards

the use of magnesium.

And where do you see CP+T in 2020?

The magazine goes to so many countries

that it is an excellent platform

for companies that want to inform

the whole world about their foundry

technology. So the magazine should

also have a bright future.

Casting Plant & Technology 1/2015 41


NEWS

ALCOA, TITAL

Alcoa completes acquisition

of Tital

Lightweight, highperformance metals

leader Alcoa, New York, USA, announced

that it has completed the acquisition

of privately held Tital. The acquisition

will strengthen Alcoa’s global

position to capture increasing demand

for advanced jet engine components

made of titanium.

Germany-based Tital is a leader in

titanium and aluminum structural

castings for aircraft engines and airframes.

Its revenues from titanium are

expected to increase by 70 % over the

next five years as manufacturers of

next-generation jet engines look to titanium

solutions for engine structural

components. Titanium can withstand

extreme high heat and pressure, and is

a lighter weight alternative to steel,

providing increased energy efficiency

and improved performance. These engines

are used on large commercial

aircraft, including wide- and narrow-body

airplanes. Engines for narrowbody

aircraft are among the top

selling jet engines in the world.

“This acquisition is the next step in

building a powerful aerospace growth

engine,” said Klaus Kleinfeld, Alcoa

Chairman and Chief Executive Officer.

“As a fast-growing innovator, Tital will

increase our share of highly differentiated

content on the world’s best-selling

jet engines. The company’s talent

and customer relationships will boost

Alcoa’s expanding global aerospace

leadership as we meet the future needs

of our customers. We have the highest

respect for our future colleagues and

look forward to welcoming them

wholeheartedly into the global Alcoa

family.”

Philipp Schack, CEO of Tital said,

“Alcoa is widely recognized for its innovation

and manufacturing expertise,

which is fully in line with Tital’s

philosophy. We look forward to joining

the Alcoa family, and to combining

our world-class technologies and processes.

Alcoa was and is our desired

partner. We are glad to join this impressive

company at an exciting time.”

This transaction will further position

Alcoa to capitalize on strong growth

in the commercial aerospace sector.

Alcoa projects a compounded annual

commercial jet growth rate of 7 %

through 2019 and sees a current 9-year

production order book at 2013 delivery

rates. Almost 70 % of Tital’s revenues

are expected to come from commercial

aerospace sales in 2019. In 2013,

the company generated revenues of

approximately 71 million Euro, more

than half of which came from titanium

products.

The acquisition will establish titanium

casting capabilities in Europe for

Alcoa, while expanding its aluminum

casting capacity. Tital’s strong connections

to European engine and aircraft

manufacturers such as Airbus,

SNECMA, and Rolls-Royce, will enhance

Alcoa’s customer relationships

in the region, and beyond.

Tital’s engineers are known and

highly respected experts in manufacturing

advanced, single-piece components,

often delivered ready for the

customer to install, which lower

weight and reduce complexity. These

products, such as engine gearboxes,

nacelles and fan frames, are used on

current and next-generation jet engines

and airframes. Tital will add capabilities

in casting titanium airframe

structures, such as titanium castings

for pylons. Pylons mount engines onto

airframes and are a highly-engineered

part because they must bear the load of

the engine and its thrust.

In addition, Tital is a leader in process

technology. It employs advanced

techniques needed to manage titanium’s

reactive properties, including

cold hearth melting and centrifugal

and gravity casting. Its teams also use

3-D-printed prototypes, enabling customers

to test designs and bring a finished

product to market faster. Tital

employs more than 650 people, primarily

in Bestwig, Germany.

Alcoa has been aggressively growing

its aerospace business as part of the

company’s broader transformation. In

November, Alcoa completed the acquisition

of global jet engine component

leader Firth Rixson, announced in

June. This was the first of two announced

acquisitions in 2014, including

the Tital transaction. Earlier this

year, Alcoa announced investments to

expand jet engine parts production in

Indiana and Virginia, opened the

world’s largest aluminum-lithium facility

in Indiana, and in Michigan,

plans to expand its coatings capabilities

for jet engine components. In addition,

the company announced plans

to install advanced aerospace plate

manufacturing capabilities in Iowa.

It also announced more than 1,8 billion

Euro in supply deals with Boeing

and Pratt & Whitney, which included

the world’s first forging for an aluminum

fan blade for Pratt & Whitney’s

PurePower jet engines. The PurePower

engine will be used to power some of

the world’s highest volume aircraft,

including the next-generation Airbus

A320neo.

Alcoa’s aerospace business holds the

number one global position in aluminum

forgings and extrusions, jet engine

airfoils and fastening systems and

is a leading supplier of structural castings

made of titanium, aluminum and

nickel-based superalloys and aluminum

sheet and plate. It also holds the

number one global position in seamless

rolled jet engine rings, engineered

from nickel-based superalloys and titanium,

and is one of the world’s leading

suppliers of vacuum melted superalloys

used to make aerospace, industrial

gas turbine, oil and gas products and

structural components for landing

gear applications. It also has entered

into a highly specialized segment of jet

engine forgings that require isothermal

forging technology.

As a first order after the merger Tital

announced that it is going to produce

for the Chinese aircraft manufacturer

Comac. The twin-jet aircraft Comac

C919 is the second passenger aircraft

entirely developed in the People’s Republic

of China. Tital secured firm orders

to supply 80 different parts made

from aluminum and titanium investment

casting. These orders also cover

the so-called Hinge Arm, the connecting

element or hinge between the fuselage

and the passenger door.

www.alcoa.com

42 Casting Plant & Technology 1/2015


TRANSVALOR

Improved software for the

simulation of steel and metal

casting

Thercast is Transvalor’s tried and tested

3-D finite element software for the

simulation of metal casting, solidification

and heat treatment processes.

It excels thanks to its proven ability

to forecast real-world results, thus allowing

plant operators to reduce time

and expenditure for planning, starting

up and running casting processes.

The software has now been thoroughly

revamped. The greatly enhanced

8.2 version includes important

new functionalities as well as

significant improvements to many of

its existing features. It can be used for

steels just as well as for other technical

metals such as copper or aluminum.

The outstanding highlight is a new

comprehensive model of the flow

characteristics based on real viscosity

data making it possible to predict the

rheological behaviour of the melt

during casting processes as well as

when solidifying with a much higher

degree of precision. Another remarkable

feature is the degree of accuracy

with which the transformation processes

within the microstructure

during heat treatment can be depicted.

The results thus comprehensively

match real-world conditions.

The software permits computing

processes governing the casting of ingots

with the same ease and accuracy

as those applying to continuous casting

operations.

Another aspect worth mentioning

relates to substantial enhancements

of the man-machine interface. Access

to and use of different modules and

features has been greatly improved,

thus facilitating the easy and efficient

implementation of variants to simulation

tasks as well as significant improvements

with respect to the time

spent by operating staff. Processed

data can directly be shared with the

Forge software package.

Transvalor, a scientific software editor

and service provider headquartered

in France, provides manufacturing

and engineering intelligence to a

wide range of industries such as automotive,

aerospace, energy, medical,

oil and gas and many others. It has

Illustration through a cut plane of

the grain structure of a quarter solid-


developed an extensive suite of cutting

edge simulation software for materials

science that addresses a wide

and varied range of forming processes

for metallic solid and liquid materials

as well as for polymers: Forge for hot,

warm and cold metal forming, Coldform

for cold metal forming, Thercast

for casting applications and Rem3D

for plastic injection molding.

www.transvalor.com

100% inline

Automated visual inspection of castings, cores and molds.

New capabilities in quality

assurance: flexible laser gauging

of complex castings –

now 100% inline

Hall 16,

Stand D 01

www.inspectomation.de

Casting Plant & Technology 1/2015 43


NEWS

TRIMET FRANCE

New continuous caster in operation

Since December 10, 2014, Trimet has

been producing aluminum rolling ingots

at the Saint-Jean-de-Maurienne

location. After a test phase lasting

several months, the Trimet plant in

Saint-Jean-de-Maurienne put a vertical

continuous caster into full operation.

With an annual production capacity

of around 60,000 t of rolling

ingots, the system represents a strategic

addition to the product portfolio

of the facility in the French Alps.

Around 145,000 t of primary aluminum

is produced here annually. In

addition to rolling ingots, aluminum

wire for the energy and automotive

industries is mainly produced by

some 500 employees in Saint-Jean-de-

Maurienne and the sister plant in

Castelsarrasin, in Southwestern

France. Trimet took over the plants at

the end of 2013 and has since consistently

worked toward full utilization

of the production capacity. The recommissioning

of the continuous

caster after more than five years marks

The vertical continuous caster at the Trimet plant in Saint-Jean-de-

Maurienne produces up to 60,000 tons of rolling ingots annually


an important step on the road to full

utilization of the plant. Last autumn,

the electrolysis production was returned

to near maximum capacity

with the recommissioning of production

line “F.”

www.trimet.eu/en

ULTRASEAL INDIA

Lightweight castings to support

the automotive supply

chain

Suppliers to automotive OEMs were

shown how to ensure that lightweight

aluminium components remain leakfree

when they visited the Ultraseal

India stand at Alucast India 2014 in

Bangalore, India.

The global trend towards making

lighter, more fuel efficient vehicles by

designing thinner, more complex

parts in lightweight materials such as

aluminium alloys was a key theme of

the show.

An eternal problem with cast metal

parts is that microscopic holes called

porosity can form during the casting

process itself and this can create a leak

path which causes a part to fail.

With thinner walls and more castin,

as opposed to bolt-on, features,

lightweight components can be more

susceptible to porosity.

Stephen Hynes, Marketing Director

of Ultraseal International, said: “One

of the most serious problems is when

through porosity occurs – it stretches

from one side of a casting to the other.

“The thinner the walls of a part, the

more likely it is through porosity will

occur and cause a leak path, leading to

the component failing under pressure.

“That is why many OEMs and suppliers

are now using vacuum impregnation

with a porosity sealant such as

PC504/66 or Rexeal 100 as a routine

quality enhancement.

“The process is easily incorporated

into a modern just-in-time production

line and offers a reliable and permanent

solution to porosity.”

Coventry-based Ultraseal has been a

pioneer in the field for decades. It entered

the Indian market more than 25

years ago when it established a Joint

Venture (JV), Ultraseal India Pvt. in

Pune, in collaboration with Devindra

Nath.

With another JV in China, an office

in Japan, an operation in the United

States, a job processing shop in Germany,

and a host of OEMs and Tier 1 suppliers

as customers, Ultraseal has a truly

global reach.

www.ultraseal.co.uk

44 Casting Plant & Technology 1/2015


SPECTRO

New Arcos high-resolution

ICP-OES Spectrometer

Spectro Analytical Instruments, Kleve,

Germany, announced its new Spectro

Arcos high-resolution ICP-OES

spectro meter, the first and only spectrometer

featuring the fast and convenient

selection of axial plasma or

radial plasma observation in a single

We look after every

grain of sand

Pneumatic conveying

technology

For dry, free flowing, abrasive

and abrasion-sensitive material

Spectro Arcos

ICP-OES

Spectrometer


Core sand preparation

technology

Turn-key systems including sand

and binder dosing and

core sand distribution

instrument – without any optical compromise.

Designed for use in the most demanding

elemental analysis applications

in industry, science, and academia,

the new Spectro Arcos easily

surpasses the performance limitations

of conventional ICP-OES instruments

– dramatically improving sensitivity,

stability, and precision, while lowering

operating costs with the introduction

of innovative components, unique capabilities,

and optimum flexibility.

The new Spectro Arcos establishes a

new ICP-OES performance class for

complex analytical tasks – resolving a

wide array of inherent problems in traditional

spectrometer design – and caps

30 years of Spectro experience in developing

advanced solutions for the elemental

analysis of metals, chemicals,

petrochemicals and other materials.

Features include:

» Axial or Radial Plasma Observation:

Spectro’s unique new MultiView capability

delivers unmatched performance

improvements in accuracy

and stability and allows for the

fast and convenient selection of axial

plasma or radial plasma observation

with no optical compromise.

» Orca Optical System: The CCD optic

system with a Paschen-Runge

mount assembly delivers a matchless

resolution of 8.5 picometer in

the wavelength range from 130 to

340 nm.

» Innovative Power Generator: A

unique new solid-state generator design

that provides the highest plasma

power available for extreme or

quickly changing plasma loads.

» Elimination of the Need for Purge

Gases: SSpectro’s UV-Plus sealed optical

chamber ends the need for the

purging of argon or nitrogen gases

– along with the related supplies,

maintenance costs, and downtime.

» No External Cooling System: Aircooled

interface technology and the

completely air-cooled generator eliminates

the need for an external cooling

system – along with the associated,

and often substantial, equipment,

power, and maintenance costs.

Spectro Analytical Instruments is a

leading global supplier of analytical

instruments employing XRF, Arc/

Spark, ICP-OES, and ICP-MS technology

for the elemental analysis of materials

in industry, research, and academia.

www.spectro.com

Reclamation technology

Reclamation systems for

no-bake sand and core sand

GIFA 2015

Hall 16 / C11

Konrad-Adenauer-Straße 200 · D-57572 Niederfischbach

Phone ++49 27 34 / 5 01-3 01 · Telefax ++49 27 34 / 5 01-3 27

e-mail: info@klein-ag.de · http://www.klein-ag.de

Casting Plant & Technology 1/2015 45


NEWS

AGTOS

chine

at „Surface Technology”

After a need for blasting machines

was indicated for smaller factories

in the steel industry, Agtos, Emsdetten,

Germany, reacted by developing

a machine that fulfils this need. The

goal was to develop a roller conveyor

shot blasting system for operators

that have halls often with low ceilings.

The “Ocean Blaster” fulfils this

and other additional requirements.

The machine is presented by the company

during this year´s show “Surface

Technology” in Hannover, Germany,

on April 13-17.

The Ocean Blaster is a very compact

roller conveyor shot blasting machine

for smaller factories for which a turbine

wheel shot- blasting machine

was not profitable due to the capacity.

From now on, these users can profit

from the advantages of the Agtos

blasting technology. An in-house

blasting system allows for more flexible,

independent operation and transport

channels and costs are not incurred.

The work pieces to be

processed can be up to 1000 mm high

and 500 mm wide.

The Agtos engineers have designed

the Ocean Blaster to be much more

compact than other commercial machines.

It was thus possible to generate

space advantages. Even the height

of the system is extremely low at

4.1 m. Thus, the machines can also be

used in smaller production halls without

a foundation. In addition, the machine

is designed to be operator-friendly.

A maintenance platform

allows quick access to the wind sifter;

appropriately dimensioned maintenance

openings ensure easy access to

wear and tear parts in case of maintenance.

Prior to starting the blasting process,

using the rotating potentiometer,

the operator sets the feed speed

which corresponds to the degree of

impurity, respective to the desired degree

of cleaning for the work pieces.

For processing surfaces that are to



have a purity grade of BSa 2.5 after the

blasting process, the flow-through

speed is generally approx. 1.0 m per

min when using round-grain abrasives.

An additional aspect of the design

was energy efficiency. The powerful

Agtos high-performance turbines

with increased abrasive throughput

thanks to the one-disc technology

and the cartridge filtration system

with differential pressure-independent

cleaning of the filter cartridges

offer concrete advantages. As a result,

the Ocean Blaster consumes a comparatively

low amount of energy and

abrasives in comparison to other commercial

systems. Thus, the operating

costs are kept low.

To keep the height of the blasting

machine low, the bucket elevator was

separated into two parts. The first part

cleans the abrasive. The second part is

responsible for supplying the abrasive

to the high-powered turbines.

So the wear and tear costs are kept

low, a work piece tracking system on

the intake of the blasting machine ensures

that abrasives are only introduced

to the turbines if a work piece is

in the blasting area. When the fully

cleaned part has passed the blasting

area and no more work pieces have

been fed into the blasting chamber,

this is detected and the abrasive supply

is closed and the second part of

the abrasive circuit is shut off with the

turbines.

If no additional work piece is detected

at the intake light barrier within

15 min, the first part of the abrasive

circuit shuts off. For an additional

blasting process, the system must be

restarted by pressing the button.

After the work pieces run through

the blasting zone, they go to the blowoff

system which is also activated by

the slide register. A high-pressure bellows

supplies air nozzles that are

aligned so they blow off residual abrasive

from the work piece surfaces and

feed it back into the abrasive circuit.

The outlet sluice, in accordance with

the intake side, has several rows of

sealing blades. The discharge of stray

blasting grains is thus reliably prevented.

In a service case, these blades

are replaced in only a few steps.

This and other advantages allow economic

processing of the work pieces.

www.agtos.de

46 Casting Plant & Technology 1/2015


FOSECO

Pouring temperature measurement

for cast iron

The temperature measurement of cast

iron is quite a complex subject. The

temperature of a bath of molten metal

is by essence not homogeneous. You

can have in the same molten bath, discrepancies

of temperature that can

reach 100 °C, due to location and flux

motion of cast iron. For this reason, an

instantaneous punctual measurement

is not the most effective way to appreciate

the temperature of molten metal.

Foseco, Borken, Germany, has developed

a range of different technologies

for temperature measurement in order

to help the foundry man to appreciate

his pouring temperature range. These

technologies can be applied to a pressurized

furnace or bottom pour ladle

with various types of cast irons.

Temperature measurement system by Foseco. The company has developed a

range of different technologies for temperature measurement (Photo: Foseco)

Itaca - Thermal analysis system

for iron foundries

Itaca thermal analysis systems help

foundries monitor metallurgical process

performance by analysing base

and final iron quality.

Itaca Melt Deck minimizes variances

in base iron by providing the operator

information necessary to adjust the

characteristics of iron within predetermined

process specifications. It provides

real time measurement of % Ceq,

% C, % Si and the nucleation status of

the iron.

Itaca 8 provides real time measurement

of the metallurgical quality of

the final iron to provide a prediction of

defect formation tendency and as-cast

mechanical properties. Real savings

arise from a reduction in the cost of the

charge and in the cost of metallurgical

additives, a lower scrap rate, and improvements

in the quality and consistency

of castings.

The Itaca thermal analysis systems

enhance the performance and value of

the metallurgical solutions portfolio

from Foseco.

Itaca 8 provides real time measurement of the metallurgical quality of the


Hall 12, Stand A1 + A2

www.foseco.com

Video: Itaca thermal analysis system

foseco-at-gifa.com/en/highlights-2015/

videos

Casting Plant & Technology 1/2015 47


MICHENFELDER

Controlled molding sand

quality

Michenfelder (ME), Mainz, Germany,

stands first of all for a maximum of expertise

concerning the process-technical

procedures of molding sand

preparation and of the factors influencing

sand quality. This knowledge

is based on experience gained during

more than 50 years with the installation

of Michenfelder-designed control

systems in sand preparation machinery

of major manufacturers in

foundries world-wide. There are very

few in the industry who can rely on

such a wide basis of experience with

machinery and plant-specific – positive

as well as negative – specialities

and characteristics. The ME expertise

is therefore highly regarded in connection

with molding sand plant analyses

or preparatory investment consultancy,

because planning or optimization

of sand preparation plant covers more

factors then just throughput per hour.

ME also stands for the technically

leading FoMaSys conception of networked

moisture measuring, sand testing

and process control systems for

real-time monitoring and control of

molding sand quality. In the range of

moisture measuring and control systems,

integrated into mixers and coolers,

which are the key elements of any

FoMaSys introduction, there is a new

type series, Micomp 5, ready to take

off. The Online-Sandlab, which is also

new, is generating fully automatically

and in real time a so far unmatched

multiplicity of quality-relevant measured

values, directly at the molding

machine. These include compactability,

shear and compression strength,

moisture and temperature, fines content,

the bentonite equivalent and, for

the first time worldwide, permeability.

Combined with the central process

FoMaSys – The modular process-integrated molding sand management system

with Online-Sandlab, process control system MiPro and the latest system

generation Micomp 5 for continuous sand moisture measurement and control

in coolers and mixers (Photo: Michenfelder)

control system MiPro, the measured

values and process data are prepared

and analysed in a comprehensible

manner and the connected system are

remotely controlled and serviced. In

addition, Michenfelder supplies various

systems for sand-premoisturizing

on conveyor belts.

The outstanding performance in the

market with regard to consistency of

the most important sand parameters

at the decisive points of the sand

preparation process makes the difference

to ME competitors. ME is asking

to demand a guarantee for the performance

data and accuracies when the

application of measuring and control

technology is decided on. ME guarantees

the following control accuracy

values:

» Output moisture at cooler: ±0.1 -

0.2 %

» Output moisture at mixer: ±0.05 -

0.1 %

» Compactability directly at the molding

machine: ±2 % (frequently even

better values with ±0.9 - 1.5 % are

achieved in daily routine).

These data apply in first standard deviation

and when basic processing rules

in sand preparation are observed.

Hall 16, Stand A12

www.michenfelder.com

48 Casting Plant & Technology 1/2015


AGTOS

Reliable cleaning and deburring

of (die) cast work pieces

Agtos, Emsdetten, Germany, is going

to show interested visitors of this year’s

Gifa a compact blast machine in particular

for aluminium parts.It requires a

relatively small installation area and distinguishes

itself by a low loading height.

Loading and unloading is possible manually

as well as fully automatically. This

machine is especially designed for companies

treating the products with aluminium-

or stainless steel shot.

The work pieces to be blasted – the

blasting task may be finishing, cleaning

or deburring – are placed manually or by

using a manipulator onto the wire mesh

belt which transports the work pieces

through the machine. First of all they

pass through the inlet sluice, which

seals the sub sequently installed blast

Compact blast machine in particular for aluminium

parts (Photo: Agtos)

chamber towards the

outside. High-per forman

ce turbines installed

in the blast chamber are

throwing the shot onto

the work pieces at a high

speed. Thanks to the design

of the wire mesh

belt the work pieces can

ideally be treated with

shot from above and below

at the same time. At

the end of the blasting

process, shot and dust

are blown off from the

work piece surface.

The Agtos wire mesh belt shot blast

plants are designed for highest demands.

By means of the installed

high-performance turbines an optimum

covering of the surface is achieved.

This guarantees short blasting times and

high-quality blasted products.

The automatic abrasive dosing device

installed above the turbines ensures

that blasting only takes place

when there are work pieces in the blasting

area. This minimizes the wear of

the shot blast plant. A blower unit removes

any shot remaining on the work

piece surface.

Hall 16, Stand A39

www.agtos.com

CHEM-TREND

High part quality at reduced

production costs

Die lubricants and other chemical process aids play a decisive role in part


In die casting, die lubricants and other

chemical process aids play a decisive

role in part quality and post-cast finishing.

At Gifa 2015 Chem-Trend, Howell,

USA, will present its latest solutions to

support die casters in improving part

quality and reducing production costs.

Technology highlights include Chem-

Trend’s Micro-Dose-System, designed

to minimize the amount of plunger lubricant

applied. The combination of

liquid lubricants and a special dosing

system work together to provide superior

plunger lubrication while reducing

the propensity of entrapped lubricants

in the casting. This helps minimizing

surface defects and reduce time and effort

in post-cast finishing. Another new

development is Chem-Trend’s CP-406,

a highly efficient corrosion protection

for tooling in storage. The product

forms a thin protection film that

also adheres on vertical surfaces. In addition,

Chem-Trend will present new

solutions that reduce the formation of

bacteria, slime and fungus in contaminated

die lubricant systems.

Hall 11, Stand D59

www.chemtrend.de

Casting Plant & Technology 1/2015 49


KÜTTNER

Dual turn table centrifugal

casting machines

Since 2014, Küttner Gmbh & Co. KG, Essen,

Germany, has fully integrated the

centrifugal casting team from its former

joint venture with Düker, Lau fach, Germany.

As a first milestone, Küttner designed

and delivered a dual turn table

centrifugal casting machine to customers

in Eastern Europe.

The project purpose has been to design

a machine, which will be suitable

for high volume production of heavy

duty cylinder liners in constant quality,

with high degree of automatization.

The heavy duty liners are typically cast

with a flange, close to net shape. Machine

allowances are reduced to minimum

at highest material yields, due to

no gating and feeding systems.

In order to maximize the machine capacity

at minimal costs, the dual turn

table concept was developed. Both machines

are running independently but

sharing one automatic pouring furnace.

The central control station enables a

one man operaton for both machines.

Each turn table is equipped with 10

frequency-controlled spinning heads.

Dual turn table centrifugal casting machines (Image: Küttner)

The number of heads is determined

mainly by the number of cooling stations,

which will be necessary to achieve

the desired capacities. The spinning

heads are rotated around the work stations,

from pouring, cooling, extracting,

mold cleaning up to mold coating.

The demand for high qualities and process

stability required a consistent mold

treatment, which requires sufficient

cleaning and a consistent coating before

each cycle. For that reason, the typical

mold wash was avoided and the coating

is sprayed in defined layers into the

mold. The mold covers are removed before

the casting extraction, are cleaned

and separately coated in intermediate

working positions and set into the

molds after the coating station.

Hall 16, Stand: G26

www.kuettner.de

Fairs and Congresses

16th Global Foundry Sourcing Conference 2015

March, 20, 2015, Shanghai/China

en.fsc86.com/FSC

Metal + Metallurgy China 2015

March/April, 31-3, 2015, Shanghai/China

www.mm-china.com/En

Hannover Messe 2015

April, 13-17, 2015, Hannover/Germany

www.hannovermesse.com

119. Metalcasting Congress

April, 21-23, Columbus/USA

www.afsinc.org

Aluminium Two Thousand

May, 12-16, Florence/Italy

www.aluminium2000.com

International Foundry Trade Fair GIFA 2015

June, 16-20, Düsseldorf/Germany

www.gifa.com

50 Casting Plant & Technology 1/2015


Surface quality with impregnation coating (left) and traditional production

(right) (Photo: Hüttenes-Albertus)

HÜTTENES ALBERTUS

Innovative coating to prevent


Foundries are increasingly faced with

a rising demand on the quality of

castings, the dimensional consistency,

and importantly the surface quality.

For many years foundrymen have

been struggling with the casting defect

“white film”, which appears on the

casting surfaces of thick-walled castings

made of nodular graphite cast iron.

This is a pockmark-like, rough area on

the casting surface, which is covered

with a white film.

The film is removed by sandblasting

the castings; however the irregular surface

remains and often leads to graphite

degeneration. The only corrective

measures described in literature [1] are

as follows:

» Lower the pouring temperature

» Increase the addition of new sand

» Examine the loss on ignition, electrical

conductivity, nitrogen content

and if necessary the phosphorous

content of the reclaimed

material

» Increase gas permeability

» Reduce the amount of curing agent

for furan resin bonded moulds

» Minimize the oxygen-affine elements,

examine the melt additives

Unfortunately the above measures

are either insufficient or cannot be

fully implemented by the customer.

For this reason, this casting defect

leads to higher fettling costs e.g. due

to rework, additional wall thickness,

and in some cases higher appraisal

costs.

The team from Hüttenes-Albertus,

Düsseldorf, Germany, has investigated

in great detail the cause of this problem.

Working in close collaboration

with selected partners from the foundry

industry, a group of R&D chemists

and product managers examined

through research the causes and conducted

field trials. An innovative impregnating

coating was developed by

closely analyzing the causes for the

emergence of the film and carrying out

individual process steps to overcome

the defect. This coating is applied to

the affected areas within an existing

process (binder system/reclaim/material)

by means of brushing. This leads

to a complete suppression of the white

film.

The HA team will present this and

other developments and solutions in

detail at the GIFA 2015.

Literature:

[1] 2. Edition: Guß- und Gefügefehler

– Stephan Hasse: Berlin - Schiele &

Schön, 2003

Hall 12 - Stand C 50

www.huettenes-albertus.com

Advertisers‘ Index

AGTOS Ges. für technische

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Casting Plant & Technology 1/2015 51


BROCHURES

Aluminium sand and die casting

4 pages, English

A brochure summarizing the activities and competences of aluminium foundry

1.Guss Maulburg. Castings made by the foundry are used in a wide range of applications

and industries, including automotive, railway, vacuum pumps, drives,

machine tools, electric motors, general mechanical engineering, packaging etc.

www.alucasting-germany.com

Lifting platforms

4 pages, English

This brochure outlines the programme of lifting platforms offered by SLF Ober-


platforms. Technical data are given in the form of tables. Photos illustrate the versatile

uses of the platforms.

www.slf.eu

Aluminium-based modules and parts

12 pages, English

A brochure providing an overview of the activities of aluminium sand casting

specialists Eurotech. It covers the aspects of engineering and prototyping, tooling

development, vacuum and hand moulding, mechatronic assembly, testing facilities

and quality assurance.

www.eurotechgroup.eu

Safety technology for melting and holding equipment

28 pages, English

This comprehensive brochure summarizes the line of refractory monitoring and

measuring solutions offered by Saveway. These include systems for continuous

monitoring of the remaining lining thickness, hot spot measurements, monitoring


temperature measurements.

www.saveway-germany.de

52 Casting Plant & Technology 1/2015


Specialists for carbon and sulphur

6 pages, English, German, French, Spanish

This concise brochure outlines the range of carbon and sulphur products made by

CS Additive for customers in the iron, steel and chemicals industries. The products

include sulphur recarburizers, carbon products, metallurgical coal and coke, lump,

granulated and powdered sulphur, slab and roll sulphur, sulphur balls, etc.

www.cs-additive.de

Industrial furnace engineering

8 pages, English, German


systems engineering. The systems are used in regenerators and burners, in casting

systems, for thermal metal and waste treatment. The equipment includes solutions


www.jasper-gmbh.de

Specialist suppliers of chemical materials

4 pages, English, German

ence

materials, SUS and recalibration samples, consumables, etc. The supply range

includes environmental samples, pharmaceuticals and metals. An interactive data-


www.labmix24.com

Castings for the industry

8 pages, English

A brochure outlining the range of cast products supplied by CASTService to industries

such as automotive, furnace engineering, mechanical engineering and steel

plant technology. The demanding applications call for customized concepts ranging

from consulting, design, pattern making, casting, machining through to service.

www.castservice.de

Casting Plant & Technology 1/2015 53


BROCHURES

Preview of the next issue

Publication date: 1 June 2015

Photo: Messe Düsseldorf

Selection of topics:

Special: GIFA 2015

The International Foundry Trade Fair GIFA – “Bright World of Metals”

– is about to begin. The preliminary work is completed successfully,

the companies have signed up and the fair organization


all back on board. So far, a total of about 43 000 square meters of

exhibition space are booked – again with a very high international

share. GIFA is divided into the areas patterns, molds and cores,

foundry chemicals, feeding technology and foundry machines and

equipment. For details please refer to the GIFA special in the next

issue

F. Hansen: Fully linked inorganic core production

of the cylinder head production at Volkswagen

Inorganic core production has meanwhile been introduced in numerous

foundries in Germany, especially in the automotive sector.

After producing intake manifolds and cylinder heads for 10 years

in serial production with inorganic cores the Volkswagen foundry

in Hanover in 2012 started a fully linked inorganic core production

I. Schruff : Die-cast structural components for

lightweight vehicles

A prerequisite for a successful competition of structural components

made of die-cast with alternative methods are powerful

and trouble-free operating molds. Die-cast structural components

can be manufactured almost ready-to-install. Compared

with stamped welded components many production steps can

be eliminated as well

Imprint

Pub lish er:

Ger man Foundry As so ci a tion

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ISSN 0935-7262

54 Casting Plant & Technology 1/2015


www.giesserei-verlag.de

12. March

2015

CASTING

PLANT AND TECHNOLOGY

INTERNATIONAL

30 years

CP+T

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Centrifugal casting

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04.03.15 13:35 13:3

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