CPT International 01/2016

cptinternational

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

www.giesserei-verlag.de

March

2016

CASTING

PLANT AND TECHNOLOGY

INTERNATIONAL

CHINA

Special

1

Creating economical and

eco-friendly casting processes


SUSTAINABLE

TECHNOLOGY

––











ABP Induction Systems GmbH, Kanalstraße 25, 44147 Dortmund, Germany, Phone: +49 231 997-0, www.abpinduction.com


EDITORIAL

The Chinese dragon takes

a stand!

According to the latest World Census of Casting Production, China’s foundry

industry was again well ahead of other casting producers in 2014 – with production

of 46,200,000 tonnes. The Country Special in this issue focuses on

this far-eastern country. The Executive Vice President & Secretary General of

the Chinese Foundry Association gives his view on his country’s development

in this issue of CASTING: China wants to develop its foundry industry into a

post-industrial sector focusing on efficiency, productivity and environmental

protection (from P. 42). Reports of major orders recently received by German

foundry equipment producers for appropriate technologies had already pointed

towards this. The Beijing-based Association’s intentions were confirmed

and enlarged on by the President of the Hong Kong Foundry Association: in

“The impact of ‘Made in China 2025’ on China’s die-casting industry” in this

issue (from P. 45) he calls for a change in awareness away from single-minded

production and towards concentration on design, high value creation and

competitiveness – the Chinese dragon takes a stand!

Another highlight in this issue is the

report “Cast iron and e-mobility are

a perfect match” on the production

of castings for e-vehicles by Georg

Fischer in Herzogenburg (from P. 32).

It is illustrated with photos taken by

Warren Richardson, the current holder

of the World Press Photo Award

2015. Richard son has already collaborated

on several works reports in Hungary and Austria with the German-language

GIESSEREI and the English-language CASTING. He won the award with

a picture of a refugee passing a baby under a barbed-wire fence at the Serbian-Hungarian

border. We reprint the picture for you here again.

We also met Dr. Ioannis Ioannidis (Chairman of the VDMA Foundry Machine

Trade Association and CEO of the foundry machine producer Oskar Frech) at

the EUROGUSS trade fair in Nuremberg and talked to him about the current

situation in the die-casting industry, 3-D printing, and the trend towards Industry

4.0. You can read the interview from P. 6.

Other trailblazing articles in this issue include the report by Florian Hartung

on the installation of the Climatic exhaust system at Georg Fischer in Mettmann

(from P. 16), an article on Industry 4.0 technologies at Karl Casper Guss

in Remchingen (from P. 28), and the production of iron wind turbine hubs

weighing up to 30 tonnes at Heger Ferrit in Sembach (from P. 38).

Have a good read!

Robert Piterek, e-mail:

robert.piterek@bdguss.de

Casting Plant & Technology 1/2016 3


FEATURES

INTERVIEW

Ioannidis, Ioannis

“3-D printing opens doors for die casting which did not exist before” 6

MOLDMAKING

Gieniec, Anton; Hurkes, Natascha; Vietoris, Peter; Dieckhues, Harald



MELTING SHOP

Turner, Lynn


Cover-Photo:








ECO-FRIENDLY PRODUCTION

Hartung, Florian



QUALITY ASSURANCE

Schulz, Doris


CLEANING, FETTLING & FINISHING

Ibounig, Verena


AUTOMATION

Kramer, Olaf


Lüking, Malte; Throm, Stefan







28 32

Industry 4.0 is a hot topic in the media and in political discussions.

Most German foundries are still hesitant, but some

pioneers see it as a strategic objective (Photo: Casper Guss)

Light-construction specialist GF Automotive has received

orders amounting to 50 million euros to produce components

for e-vehicles (Photo: Warren Richardson)


CASTING

1 | 2016

PLANT AND TECHNOLOGY

INTERNATIONAL

COMPANY

Piterek, Robert


Junker, Pit




CHINA SPECIAL

Ping, Wen


Liu, Siong Song




Seidemann, Harald


Wibbe, Christine




Editorial 3

News in brief 56

Brochures 64

Fairs and congresses / Advertisers´ index 66

Preview of the next issue/Imprint 67

41

According to the latest World Census of Casting Production China’s foundry industry was again well ahead of the foundry industries of other

countries regarding casting production. And the Chinese dragon has many plans: efficiency, productivity and environmental protection are to

play a major role in future (Photo: BMW)


INTERVIEW

“3-D printing opens doors for die

casting which did not exist before”

Dr. Ioannis Ioannidis is Chairman of the Board of the Trade Association for Foundry Machinery of

the German Engineering Association and CEO of the die-casting machine producer Oskar Frech.

CASTING, PLANT & TECHNOLOGY met him at the EUROGUSS trade fair from January 12-14, 2016

Dr. Ioannidis, what is the current mood

among die casters and gravity die casters?

They are cautiously positive. They were

satisfied with 2015 and are starting 2016

with restrained optimism and the hope

that they will be able to continue last

year’s performance.

What is affecting the mood?

Well, we have already seen some investments

and larger projects. So a relatively

large amount has been invested. In general,

however, the world economic situation

is not exactly booming. So the two

factors come together and result in this

restrained optimism.

What is your forecast for 2016?

We completed 2015 with double-digit

growth and assume that we can maintain

this level. We naturally want to do

better on the earnings side. I am convinced

that the possibilities are there,

though we must also recognize that we

have already had several years that were

relatively positive. But overall I am optimistic.

What are the strengths of Germany’s

machine and plant constructors?

We are not just strong in mechanics.

What we are really good at is combining

electronics, electrics and mechanics.

There is, however, something else and

(Photos: A. Bednareck)

this is new: we are ahead in the fields of

energy and resource efficiency, as well

as regarding the topic of Industry 4.0,

where we are probably the only country

in the world that really understands

what is involved.

In the iron casting segment the socalled

‘smart factory’ opened recently

at Kurtz ersa in Hasloch. Is there also

something like a smart factory in the

die-casting sector?

There are many small smart factories

in the die-casting sector, in which the

experts’ experience has already been

adapted and combined with practical

data. As a result of this combination,

something like an automatic process

control is possible in these small smart

factories.

What opportunities do new IT technologies

offer die-casting machine and

plant constructors for increasing their

competitiveness?

We must always look at IT in combination

with modern data capture, i.e. sensors

that are capable of providing data

that can be processed with information

technologies. For this to work, of course,

you need someone who can recognize

what the data offer and what can be determined

with the assistance of IT. You

can detect a lot with IT, but whether

you can actually recognize it is another

matter. The opportunities are anyway

immense.

What improvements can German producers

of foundry and die-casting machines

make?

We must concentrate on the process.

When we do this, we can gain even

greater control over the process and

6 Casting Plant & Technology 1/2016


determine how we insert the hot metal

into the mold: at what speed, with

which turbulences. Then we can succeed

in working with less air and air inclusions

and thus achieve better structures.

On the other hand, I think that

modern Selective Laser Melting (SLM)

technology, i.e. 3-D printing, in combination

with die-casting technology

opens doors for die casting that have

never existed before.

How can die casting and additive technologies

be combined?

I’ll give you an example: we already

used 3-D printing six years ago during

the development of the Frech Gating

System (FGS), for low-sprue casting.

So there are parts used in this innovation

that were already created using

SLM. This smoothed the path for this

new innovation. Additive technologies

offer us the following opportunities:

they can help us, for example, to

almost eliminate critical areas in tools

by working on near-surface cooling,

which is only possible with the help

of the SLM process. Let me explain. A

core in a mold does not last as long as

the mold itself. If you now produced

this core with SLM technology and if

you designed the internal channels

differently it would last longer and you

would have considerably better productivity.

It is relatively easy to exploit this

technology. But you need modern scientific

knowledge and many years of experience

to exploit it optimally.

Where do you see the greatest dynamism

worldwide?

Europe now offers decent dynamism

and is strong. The USA is also developing

positively and I believe that India

will strengthen again. The Prime Minister

of India is changing and modernizing

quite a bit and that is valuable. The

market in China naturally continues to

offer major possibilities.

This year’s EUROGUSS has 110 exhibitors

more than in 2014. What is your

impression?

I think that the proportion of international

exhibitors has risen again. It is an

interesting trade fair, of which those in

the sector say, seven months after GIFA,

that it is worth going to! And one has

more time for discussions in smaller circles

there.

According to current information, 2018

will be a super-trade-fair year: EURO-

GUSS, GIFA and Aluminium will all

take place. How will the sector handle

this?

We like meeting in Europe and talk

about casting with great passion. And

I believe that the sector also recognizes

this and appreciates it. The management

of the EUROGUSS trade fair will

be thinking about this – there are many

possibilities both for EUROGUSS and

for GIFA. I would have nothing against

the foundry world meeting in Germany

more often.

An increasing individualization can be

observed in what the sector offers,

with many special customer requirements.

Will this development continue?

Yes, customers must continue to work

on their competitiveness. This results

in ideas that they want to implement

in order to stand out. As a supplier, if

one wants to support this one must also

take it into account. That is why we at

Oskar Frech have set up a dedicated department

in our R&D to deal with this.

How important do you think EURO-

GUSS is for recruiting young talent,

and what is the situation regarding

young talent in the die-casting sector

overall?

The world is changing. In the past, the

die-casting sector was not so conspicuous.

It is, however, becoming increasingly

interesting and attractive. We simply

feel that there are many people who

are interested and that this is increasing.

On the one hand, this is due to our manufacturing

tangible products while, on

the other hand, there is the combination

of our sector with IT. For us, however,

young talent is not just the trainee.

Young talent is also the engineer

– someone from the circle of employees

or someone from a different country.

The refugees also represent many potential

employees coming to us. Do

you think this will lead to anything?

Yes, we offer trainee positions and language

courses at Oskar Frech. We are

very open in this regard. We already

have personnel from numerous different

countries.

And what is the position regarding

specialists in the die-casting sector?

The situation here has improved I think

because we, together with the German

Engineering Federation (VDMA)

and the German Foundry Association

(BDG), have understood very well how

to get young people interested in metal

and machine construction. This can

also be seen from the growth in the

numbers of people studying mechanical

engineering.

Thank you very much for this interview

Dr. Ioannidis!

Casting Plant & Technology 1/2016 7


Production hall of Grunewald GmbH in Bocholt, Germany. For the last several years the company has particularly developed

the low-pressure casting of thin-walled aluminum sand castings (Photo: Andreas Bednareck)

Authors: Anton Gieniec, Business Line Manager No-Bake Europe, Natascha Hurkes, Head of Laboratory, Peter

Vietoris, Area Sales Manager Germany North West, ASK Chemicals, Hilden, and Harald Dieckhues, Foundry Manager,

Grunewald GmbH, Bottrop

mentally

friendly binder system

The demands of global competition are growing all the time. Besides high cost pressure and short

delivery times, foundries need to meet the highest quality requirements. In time for its 50th anniversary,

Grunewald, Bocholt, Germany, has taken account of these needs. With a new hall and

ultramodern process technology in the molding shop and reclamation plant, it has been able to

increase its capacities considerably. Meanwhile an inno vative Pep Set system, which is optimally

tuned to local processes, has been developed together with ASK Chemicals from Hilden, Germany

Next to tool and component construction,

the casting segment is the third

largest pillar of the international firm

of Grunewald company, which employs

240 staff at six sites worldwide.

Grunewald is one of Europe‘s leading

manufacturers of thin-walled aluminum

structural parts for the automobile

sector, the semiconductor

industry and machinery construction,

possessing excellent know-how in prototype

and small series production for

the different industries.

Owing to new and increasingly varied

customer demands and rising cost

pressure, the foundry was expanded to

a total 2800 m 2 in 2013. This was an important

step toward safeguarding the

future and enabled the company to

concentrate and restructure the whole

production at one site.

Already in the early stages, work was

carried out in conjunction with ASK

Chemicals on changing the binder

8 Casting Plant & Technology 1/2016


system in order to achieve further optimization

in terms of processing and

costs, such as improvement in the casting

quality and greater productivity in

mold making. The furan resin system

used hitherto was, first of all, unable

to satisfy the demands for an improved

casting surface with simultaneously

improved productivity. Likewise, the

reclamation of used furan sand is subject

to certain limitations: a thermally

reclaimed mold material produced by

an acid-hardening process has a high

proportion of metal oxides. These

metal oxides slow down the acid-catalyzed

hardening reactions on the reclaimed

material (Figure 1).

The use of a thermally reclaimed

mold material compared to fresh sand

and mechanically reclaimed sand prolongs

the strip time almost threefold.

To bring reactivity (the strip time) to

the level of mechanically reclaimed

sand, it is necessary to increase the acid

catalyst amount by approx. 30 %. An

increase of the acid catalyst, however,

leads to a considerable increase in SO 2

emissions and also comes along with

a deterioration of the casting quality.

Thermal sand reclamation was not

planned initially, but after extensive

analysis it offered the advantage of a

higher quality of reclaimed material

and, due to the increased proportion

of reclaimed sand, an almost 15 % reduction

in the waste sand requiring

disposal.

Due to its many outstanding advantages,

the polyurethane no bake

system, so-called Pep Set system, was

a potential alternative system for

Grunewald. Pep Set binders are based

on a polyaddition reaction between

a phenolic resin (polyol component)

and an isocyanate component. Pep Set

involves a 3-component system consisting

of a binder (Part 1), a hardener

(Part 2) and a liquid catalyst. Hardening

occurs without the formation

of elimination and by-products such

as water or formaldehyde (Figure 2).

The Pep Set system is characterized

by a relatively long processing time

with simultaneously very rapid curing

(Figure 3) and thus guarantees maximum

productivity thanks to very fast

cycle times.

Figure 1: Reactivity of a furan resin system with fresh sand, mechanically

reclaim ed and thermally reclaimed sand (Photos and graphics: ASK Chemicals)

Figure 2: Curing reaction of a Pep Set system

Figure 3: Hardening diagram of a Pep Set system compared to a furan resin

system

Casting Plant & Technology 1/2016 9


MOLDMAKING

Old

Figure 4: Strengths of a Pep Set system using silica sand H33

New

Dependency of reactivity on temperature

Figure 7: Comparison of casting surface;

sand molds manufactured: old

– with furan resin, new – with


Figure 6: Polystyrene model after demolding

The strengths are at a very high level

(Figure 4), enabling the addition

of binder to be significantly reduced,

which in turn reduces emissions of

10 Casting Plant & Technology 1/2016

the contaminants during molding

and casting. The standard addition of

a Pep Set system is very often below

0.6 % per part.

The curing speed is only negligibly

dependent on the ambient temperature

and / or sand temperature

( ) and can be controlled, almost

as preferred, with the quantity

and / or quality of catalyst (catalyst

amount specific to Part 1: 0.5 - 5.0 %).

Another important aspect for

Grunewald was that the binder system

does not interact chemically with their

polystyrene models (Figure 6). To fulfil

these needs solvent combinations and

manufacturing processes for Part 1 as

well as for Part 2 have been optimized.

In close collaboration, an innovative

Pep Set system was developed, which

can be applied directly to polystyrene

models in aluminum casting without

coating. Pep Set 10 Part 1, Pep Set 20

Part 2 and Catalyst 3595/20 have since

been successfully used for the series

production of molds with thermally

reclaimed sand. The castings are now

»


CASTING

PLANT AND TECHNOLOGY

INTERNATIONAL

International foundry competence –

printed or digital

As reader of CASTING, PLANT AND TECHNOLOGY you are

always on the cutting edge of technology! Supported by

the successful GIESSEREI family, the English- language

journal discovers the latest technology trends and offers

specialist knowledge and interviews with top decision

makers in the industry - read the CP + T in the

proven print format or as a free e-paper!

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CASTING, PLANT AND TECHNOLOGY –

online and mobile!

Access the website www.cpt-international.com

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GIESSEREI

VERLAG


Characteristics Thermal reclaimed sand Silica sand H 33

Average grain in mm 0.27 0.27

Fines content (< 0,125 mm) in % 0.30 0.40

AFS number 52 53

pH value 9.3 7.0

Electr. conductivity in μS/cm 49 11

Loss of ignition in % 0.15 0.00

Table 1: Characteristics of the thermally reclaimed material vs. silica sand H 33

Figure 8: Pep Set mold with thermally

reclaimed sand

created with such excellent surfaces

that the amount of reworking, especially

in deep pockets and cavities, has

decreased significantly (Figure 7).

Owing to the optimally adjusted

ratio of processing work time to strip

time, accompanied by very high final

strengths, it has been possible to increase

the cycle time in the mold shop

considerably. The excellent flowability

of the Pep Set mold sand enables even

the finest model contours to be formed

with maximum precision. Due to this

the need for proper models as well as

for high qualities in mold and tool

making processes even has increased

enormously (Figure 8).

The sand strengths also attain high

values with the thermally reclaimed

material. Despite the sometimes complex

geometries, it is possible with the

new system to work with a minimum

binder and catalyst amounts. The thermal

reclamation of the used sand proceeds

in a very stable way (Table 1) and

facilitates both resource-efficient and

cost-saving work.

Thanks to the efficient collaboration

of Grunewald and ASK Chemicals,

an innovative Pep Set system has

been developed, and both productivity

and casting quality have increased

considerably. At the same time, due to

the thermal reclamation of the used

sand and the possibility of binder and

catalyst reduction, not only cost savings

are made but also the health of

staff and the environment are protected

in the course of lower SO 2

emissions.

www.ask-chemicals.de

www.grunewald.de

Second-hand Foundry machines

FSG Giessereimaschinen GmbH

D-46147 Oberhausen

Im Quellgrund 38

Frank Stapelmann

Mobil: 0049-172-2052173


Modernized melting shop at a foundry in the UK: In record time the holding VIP (Inductotherm inverter technology)

was removed and the existing 2500 kW VIP repositioned and installed to run one 4 t furnace. Finally a new 3,500 kW

Dual Trak was installed (Photos: Inductotherm)

Author: Lynn Turner, Inductotherm Europe Ltd., Droitwich

A molten mission impossible


its melting facility without any loss of production. Such was the complexity of the project that it

was initially described by those involved as ‘mission impossible’. However, precise planning and

absolute collaboration between foundry and supplier saw the project completed on time and to

the satisfaction of all involved

Imagine the call from Thomas Dudley’s

foundry division director Mick

Cramphorn to Inductotherm Europe

Ltd., Droitwich, UK – “your mission

should you choose to accept it is to install

and commission new melting capabilities

in just one week.”

Cramphorn takes up the story: “It’s

been a six-year journey to transform

Thomas Dudley’s foundry division

into a world-class manufacturing facility.

Since 2009, we have proactively

doubled our turnover with 60 % of

the people, generating profit to support

further investment. Despite this

phenomenal turnaround, the two major

constraints going forward were that

we did not have enough molten metal

capacity or talent in depth. The project

has confirmed that we now have

enough metal and a team capable of

delivering on many fronts.”

A known commodity

With existing Inductotherm equipment

on the site – which has served

the foundry for 28 years – Cramphorn

and his team looked to the leading induction

melting supplier to take the

foundry into the next phase of its development

and ensure future demand

could be met. “The three existing furnaces

from Inductotherm were very

reliable and there was nothing wrong

with them. They had been well maintained

and serviced but they were only

giving us 4 t/h and our plan was to expand

to 6 t/h. The problem was that we

are growing at such a rate that we just

could not afford to lose any planned

production days so whatever we did

had to take place during our autumn

shutdown period.”

Working with their tried and tested

supplier, Thomas Dudley opted to increase

the existing 2,500 kw Power-Trak

single output to a 3.5 MW Dual-Trak

and integrate the system with the existing

4 t furnaces. The installation

would also include a new transformer,

cooling, hydraulic and control systems.

The whole project included moving

existing equipment to act as a backup

and excavating the metal melting area

14 Casting Plant & Technology 1/2016


MELTING SHOP

as an additional ten to twelve feet of

space was needed to accommodate the

larger equipment. The control room is

underground so much of the work was

undertaken by several contractors in a

confined space.

The timescale quoted – six weeks, the

timescale demanded – eight days! “Quite

frankly on paper it seemed impossible –

Mick even called it mission impossible,”

Craig Holdback, area sales manager at Inductotherm

Europe, said. “But the thing

is once we were on site and everyone was

working together I never once doubted

that we could do it. We all worked

around the clock and the Thomas Dudley

employees were amazing – it couldn’t

have happened if they hadn’t have integrated

well with Inductotherm and Emsco

engineers who worked a 24 h shift

pattern. The team at Thomas Dudley

were some of the best we have worked

with. They had a passion not to let their

customers down and it is a credit to all

involved that the team truly respects its

values of safety first, customer focus and

continuous improvement.”

Phased intervention

The only realistic way to achieve the

timescale of installation and commissioning

during the one-week autumn

shutdown was to pull four-five weeks

out of the project in advance. Thomas

Dudley had to undertake a huge civil

engineering project earlier in the year

whilst the foundry was still in full production

by expanding into the existing

scrap bay to acquire the extra space

needed, they built new oak-lined scrap

bays, replaced flooring to accommodate

charging cars, installed water

cooling and pipework.

Inductotherm worked with Thomas

Dudley to ensure all was in place for

the October shutdown deadline. “We

undertook the project in phases,” says

Craig Holdback. “On 16th June 2015

the radiator was delivered and we had to

crane that in over the roof of the foundry.

In July the rectifier/invertor panels

of Dual-Trak were delivered with pump

set hydraulics etc. to enable much of

the piping and wiring to be done. In

September we installed the transformer

so more wiring could be carried out.

Then came the October shutdown week

Figure 1: The first metal was poured a week after installation of the furnace

which we had all been working towards.

“The foundry closed on Thursday

night and we had to wait several hours

for the furnaces to cool down before

we started work at 6 am on the Friday

morning. The existing holding VIP was

removed and the existing 2,500 kW

VIP was repositioned and installed

to run one 4 t furnace. Then the new

3,500 kW Dual Trak was installed and

commissioned. The metal was being

poured a week later on 2nd November

(Figure 1). It really was a testament

to teamwork and dedication from all

concerned.”

The result is a project that everyone

involved with can be proud of and a

melting capacity lifeline for a tra ditio

n al foundry, which has expanded

to satisfy growing demand. “There’s

no other way of putting it but this was

a massive exercise and we didn’t lose

any production time or hurt anyone,”

said Cramphorn. “Inductotherm, Emsco

and the Thomas Dudley team were

great. It is a testament to great planning

and great people.”

Cramphorn says he was confident

from day one. “We were given the commitment

to the project from right at

the very top of the Inductotherm Europe

organization and I have to say the

superb project management and the

skill level of all parties to accomplish

this in a one-week shutdown is tremendous.

Everyone just knew what they

were doing and what was expected.”

A powerful position

The two constraining factors for the

foundry’s future melting ambitions

were that the existing melting bay

wasn’t large enough and the power on

site wasn’t sufficient. A higher than

expected quotation from the existing

electricity supplier to install more

power on site has meant the foundry

revised original plans but Inductotherm

has designed a scalable system

to allow Thomas Dudley to continue to

expand. “If we buy the power in the future

we can install another Dual-Trak,”

Cramphorn said. “You have to remember

that 20 % of our downtime was

caused by waiting for metal – this is

virtually eradicated now. We are now

getting around 5.6 to 5.8 t/h out of the

new plant and are working an extended

day shift. Metal is still our biggest issue

but now we are equipped to pursue

the market opportunities as we continue

to expand.”

Cramphorn and his team also have

confidence in the latest generation of

Inductotherm equipment – a company

that has provided the foundry’s

molten metal for three decades.

What was that word again? Impossible,

clearly not as far as the induction

melting specialists in Droitwich are

concerned.

www.inductotherm.co.uk

Casting Plant & Technology 1/2016 15


ECO-FRIENDLY PRODUCTION

Author: Florian Hartung, General Manager of Infuser Germany GmbH, Mannheim


reduces BTEX and other hazardous

substances in foundries

Successful implementation at Georg Fischer Automotive in Mettmann

ties

of the Earth’s atmosphere in a compact reactor by a hundred-thousandfold (Photos and graphics: Infuser)

Foundries (not only in Germany) are

under increased pressure to design their

manufacturing processes as environmentally

friendly and efficiently as possible

– not only because of the revision

of the German Technical Guidelines on

Air Quality Control (TA Luft). After successful

tests and a significant decrease

of emissions Georg Fischer Automotive

now examines the option of implementation

of the innovative Infuser exhaust

air purification system at the Mettmann

plant. Even the use of gas curing molding

materials such as Cold-Box, BetaSet

and other binders from Hüttenes-Albertus,

Düsseldorf, Germany, can be

further improved through the application

of the Climatic system, as it purifies

exhaust air in a powerful yet environment-friendly

manner.

In Germany, there are currently directives

and laws being developed or

transposed into German law, which

were developed on European level and

regard air pollution control. This includes

the CAFE programme (Clean Air

for Europe) launched in 2001 and the

Clean Air Policy Package from 2013,

both of which focus – amongst others

– on particulate matter, ground level

16 Casting Plant & Technology 1/2016


Cleaning procedure of the Climatic

ozone and nitrogen dioxide. In addition

to air pollution caused by transport,

heating and agriculture, the legislature

has particularly addressed

industrial emissions.

In addition and complementary to

numerous European regulations, a revision

of the Technical Instructions on

Air Quality Control (TA Luft) is being

developed at the German Federal Ministry

for the Environment, Nature Conservation,

Building and Nuclear Safety

(BMUB). The need for adjustments

was due to the further development of

the state of the art since the guidelines

were last amended in the year 2002. Alterations

are being expected for the entire

immission and emission part of TA

Luft. The integration of the list of particularly

carcinogenic substances such

as crystalline silica or formaldehyde is

expected, too.

C

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CM

MY

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HC_01_05_B2.pdf 1 01.03.16 13:15

Crude gas Clean gas

N.N-dimethyle thylamine

-89 % -98 %

Crude gas Clean gas

Tetraethyl Orthosilicate

moved by means of an electrostatic filter

and catalyst.

With this system, foundries can remove

exhaust air pollutants generated

in the core making process and along

the cooling conveyors such as amines,

methyl formate, phenols, formaldehyde

and BTEX up to nearly 100 %.

Due to the lowering of various limit

values, which is expected for TA Luft’s

amendment, this emissions reduction

is of particular relevance for the companies.

Especially for the expansion of

existing foundries and the construction

of new ones, the authorities are

expecting conclusive emission concepts.

These concepts will be significantly

easier and cost-efficient com-

cate

Innovative and patented


method

In joint cooperation with the University

of Copenhagen, the company Infuser

with its headquarter in Denmark

has developed an innovative, patented

method for exhaust air purification,

which removes a wide range of different

pollutants up to 100 %. This innovative

purification technology harnesses

and accelerates the natural self-cleaning

properties of the Earth’s atmosphere

in a compact reactor by a hundred-thousandfold.

In addition, this

so-called atmospheric-photochem ical

acceleration ( ), consumes a lot

less energy than conventional processes

as it is based on natural chemical reactions.

One of Climatic’s practice-oriented

benefits is its modular design.

Each module has its specific function

in the purification process.

The contaminated air stream is

forced through the individual modules

and subjected to water vapour,

atmospheric reagents in various stages

and ultraviolet radiation. This way,

the gaseous pollutants are converted

into solids in the course of this process.

Then, these particles can be re-

Casting Plant & Technology 1/2016 17


ECO-FRIENDLY PRODUCTION

-85 % -97 % -96 % -97 %

Crude gas Clean gas Crude gas Clean gas Crude gas Clean gas Crude gas Clean gas

Benzene Toluene Ethylbenzene Xylene


Joint application of the Climatic with special binders offers synergies

piled and implemented when using

the Climatic system.



At the Georg Fischer Automotive plant

in Mettmann, the system is already

being tested and used to reduce the

amines and tetraethyl orthosilicate

present in the exhaust air. This process

is supported by experts from the

University Wuppertal, who monitor

and evaluate the tests. The Climatic

has been installed in the foundry together

with the also patented Cold Box

System by Hüttenes-Albertus. During

the tests completed in summer 2015,

the latter was installed in the core-drying

furnace in order to purify exhaust

air. The results obtained so far surpass

the expectations of all those involved.

For dimethylethylamine, the system

achieved a reduction by 89 % within a

response time of only 2 seconds. Tetraethyl

orthosilicate was reduced by

98 % (Figure 2).

„The protection of the environment

and sustainability are significant driving

factors in our entrepreneurial activities.

We see ourselves as supporters

of an innovative system helping to

make foundry technology more environmentally

compatible.” says Christoph

Stratmann, Foundry Manager at

Georg Fischer Automotive. Through

application of the Climatic system, it

was possible to achieve the reduction

of one emission point at the Mettmann

plant. Currently, tests on the production

lines are still ongoing, however,

previous test series revealed that benzene,

toluene, ethylbenzene and xylene

(BTEX) had been successfully removed

from the exhaust air. Benzene

was reduced by 85 %, ethylbenzene

could be decreased by 96 % and toluene

and xylene by 97 % (Figure 3).




The joint application of the Infuser exhaust

air purification system together

with binders from chemical company

Hüttenes-Albertus provide foundries

with profitable synergies (Figure 4). In

the Cold-Box process, it is thus possible

to eliminate emissions such as BTEX,

tetraethyl orthosilicate and amines

serving as catalyst in an energy- and

cost-efficient manner. „The joint application

with our 4th-generation silicate

Cold-Box systems allows an extended

usage in the foundry sector. Amorphous

silicon dioxide, which is generated in

the technical post-combustion process,

now can be avoided in an uncomplicated

manner. In future, using tetraethyl

orthosilicate containing Cold-Box systems

in thermal combustion processes

will not result in amorphous silicon dioxide

deposits and an reduced output“

explains Timm Ziehm, product manager

at Hüttenes-Albertus. A purification

performance that is unsurpassed so far

is achieved when employing the Climatic

system in conjunction with the

robust Hüttenes-Albertus Beta-Set used

in the core making process: Methyl

formate, which is used for curing purposes

in this binder system, can be removed

from the exhaust air. Therefore,

this combination enables utilization

of these systems even at critical and exposed

locations.

Joint employment of high-quality

binders and innovative exhaust air

purification is also possible in other

processes using organic binders,

which for most foundries is more simple

and cost-efficient than switching

to another binder. In addition, the

modular Climatic system offers efficient

and cost-optimized solutions, as

the used modules are tailored to the

required emission control. The system

entirely replaces conventional

filters and purification devices or can

be installed upstream of existing fil-

18 Casting Plant & Technology 1/2016


ters in order to improve purification

performance and reduce regular costs

for existing filter technology such as

activated carbon or scrubbers.

Furthermore, the pollutant load

is continually measured by the control

unit, which adjusts the purification

performance in a needs-oriented

way. Compared to other processes,

this feature also contributes to a great

reduction in energy costs and general

operational expenditures. The

amount of energy required for overall

foundry ventilation is also substantially

reduced when using the

Climatic system. This is partly due

to elimination of conventional static

filters, through which air has to

be forced, and hence a reduced pressure

drop in the exhaust air. Another

beneficial factor is the shorter channel

distance, meaning that smaller,

decentral and mobile systems can be

exploited economically. Overall, the

Climatic system offers a wide range

Infuser Climatic in operational use

of application in the foundry sector

without requiring the use of consumables

or hazardous substances, generates

only small quantities of waste

or none at all (i.e. better mass balance)

and provides economic and efficient

exhaust air purification, which

makes a substantial contribution towards

air pollution control (Figure 5).

http://infuser.eu/foundries

YOUR PARTNER

FOR TURNKEY PROJECTS

in no-bake moulding shops for:

• moulding lines

• continuous mixers

• mechanical and thermal reclamations

• chromite separations

Smooth pneumatic conveying system for:


QUALITY

MADE IN GERMANY

FAT Förder- und Anlagentechnik GmbH www.f-a-t.de


The combination of cleaning agent and additive increases the degreasing and cleaning capacity. The cleaned car

body components feature the cleanness required by the downstream processing steps (Photos: Stockmeier/Magna)

Author: Doris Schulz, Korntal

Cleaning of premium car body

components for the automotive

industry

No matter whether a casting will be heat treated, welded or joined by adhesives, a meticulously

clean surface free from any grease or metal grindings is an absolute must. A leading manufacturer of

pressure-die-cast aluminium car body components has changed over to a different cleaning medium

in order to extend the service life of the cleaning baths and enhance the process reliability of the pre-


When it comes to vacuum pressure die

casting of large series of premium car

body components made of aluminium,

Magna BDW Technologies Soest

GmbH, Germany, is definitely an address

of first choice. The company

was founded in 1993 as a subsidiary of

Alcoa. Acquired in 2010 by Bayerische

Druckguss-Werke (BDW), it is today

part of the Magna subsidiary Cosma

International. Numerous renowned

automotive producers, including Ferrari,

Jaguar, Land Rover, Mercedes,

Lamborghini, Nissan and Porsche, are

customers of Magna BDW. For Audi, a

customer of the early days, the company

is a partner in the development

and production of the Audi A8 Space

Frames, which is entirely made of aluminium.

Extremely exacting surface

quality standards

Initially, the company had produced a

great number of different castings for

car body applications. As a result of

the increasing functional integration

in automotive engineering, the castings

became ever larger and ever more

complex. Today, the production range

comprises between 150 and 200 differ-

20 Casting Plant & Technology 1/2016


Figure 1: After the degreasing / cleaning

process, the parts surface contaminated

by machining media, release

agent and metal grindings must be free

from any grease or metallic residues

Figure 2: The additive, which contains

emulsifying surfactants, binds the removed

oils and keeps them in solution.

This largely contributes to the

long bath life of 14 weeks

ent car body components, including

complete side bars, doors and absorber

pots, vacuum die-cast from six different

aluminium alloys. The castings

are machined, degreased and cleaned,

pickled and passivated. Many of them

are also heat treated.

The quality requirements on the castings

and their surfaces have been and

will continue to be extremely exacting

(Figure 1). They must be cleaned so as

to ensure that they are weldable and

suitable for joining by adhesives. Over

the years, both the diversity and the

number of castings requiring surface

treatments have increased. While back

in the past car body components used

to be joined after the surface treatment

by means of rivets and helicoils, today

joining usually takes place before the

surface treatment. With production

volumes becoming increasingly larger,

this has proved to be less time consuming.

However, care had to be taken that

no material at the joining elements was

removed. As a consequence, better performing

cleaning media were needed.

Extensive testing led to

the right medium

Magna BDW produces in three shifts

on six days a week. From 2006, when

the number of different parts, alloys

and release agents had risen as well as

the diversity of machining media, and

last but not least due to the requirement

that no material was allowed to be removed

during degreasing, the cleaning

process became a bottleneck in the

production chain. The bath life became

shorter every time. On the one hand,

it became increasingly challenging to

keep the degreasing and cleaning baths

stable for at least one week. There are

two degreasing baths with a volume of

16,000 l each. Setting up a fresh bath

of such volume is time consuming and

costly. On the other hand, the cleaned

parts showed areas of removed material

as well as deposits of foreign material,

all of which required time-consuming

reworking. Therefore, an alternative

cleaning medium was to be found. Requirements

on the new medium included

high degreasing efficiency and

good compatibility with the material

without any pickling attack and material

removal. In order to increase the economic

efficiency, a bath life of at least

ten weeks was envisaged and the cleaner

was to come in liquid form.

Altogether, the evaluation phase took

three years. During running operation,

products from four manufacturers

were tested, including Stockmeier Chemie

GmbH & Co. KG (formerly Dansotec

GmbH), Bielefeld, Germany, who

in addition to the tests at Magna BDW

Temperature Control.

Smart. Reliable.

Proven quality

& Swiss precision

Reliable Swiss quality, in use successfully

for 50 years. The temperature

control units from REGLOPLAS are

convincing because of their precision,

long service life and compatibility.

www.regloplas.com


QUALITY ASSURANCE

Figure 3: Feeding of the pretreament plant takes place automatically by means

of a conveyor system with transfer cars.

The cleaning quality is checked

every 24 h by means of test sheets

also conducted tests in their own laboratory.

These not only included the

verification of the cleaning properties

relative to all ten release agents applied

in the foundry, to the machining oils

and to the cooling fluids, but also the

adjustment of the cleaning medium to

these substances. As the tests with the

cleaning system from Stockmeier were

highly promising from the very beginning,

those responsible for this project

at Magna BDW decided to continue to

cooperate with Stockmeier.

Optimally tuned twocomponent

system

Based on the results from the cleaning

tests, Stockmeier defined a two-component

cleaner system. The actual

Figure 4: Make-up cleaning agent is

added in small quantities. This keeps

the concentration at a constant level

cleaning agent Dansoclean A 2100 is a

mildly alkaline, demulsifying formula

for spraying and flooding applications.

The cleaner can be used for all

aluminium alloys used at Magna BDW.

It is characterized by high degreasing,

cleaning and dirt holding capacities. A

typical effect occurring with demulsifying

cleaning agents is that when the

parts are removed from the tank of the

continuous dipping plant they pick up

the oil floating on the bath surface. In

order to avoid this effect, an emulsifying

agent was added. This surfactant

mixture binds the oil removed from

the castings and keeps it in solution

(Figure 2). While achieving a constantly

stable cleaning performance, the life

of the bath is markedly increased. The

new cleaning system is being used in

the pretreatment plant installed back

in 1993 and in the new plant commissioned

only two years ago.

Average bath life of 14 weeks

The car body parts contaminated with

release agents, machining media and

metal grindings are automatically fed

into the plants by chain conveyors or

transfer cars with supporting frames

(Figure 3). Every transfer unit has a

barcode which contains information

about the to be selected programme for

the specific casting. The programmes,

for example, cleaning only or cleaning,

pickling and passivating, are triggered

by a barcode reader. Depending on the

selected programme, the parts are either

removed from the plant after the

degreasing treatment or moved on to

the pickling and passivation sections.

During three shifts, between 120 and

180 frames, each loaded with 15 to 60

parts, pass the cleaning section of the

pretreatment plant. Make-up cleaning

agent is added at regular intervals

( Figure 4). Adding small amounts of

cleaning agent avoids that the concentration

becomes too high or too low.

The cleaning performance is checked

at short intervals. Every 24 h, test

sheets are sent through the plant and

used for checking water wettability

and the removal of material ().

Every day samples from the cleaning

and rinsing baths are analyzed in the

chemical laboratory. The Dansoclean

cleaning systems has meanwhile been

used for quite some time, achieving

an average bath life of 14 weeks. The

switch-over to a new cleaning system

has therefore above all paid off in terms

of higher plant availability, resulting in

higher productivity and improved economic

efficiency. Another advantage is

that the components can be joined before

the surface treatment.

www.cosma.com

www.stockmeier.de

22 Casting Plant & Technology 1/2016


CLEANING, FETTLING & FINISHING

Author: Verena Ibounig, Tyrolit - Schleifmittelwerke Swarovski K.G., Schwaz

Dry machining with diamond

cutting and grinding tools

Since 2002 Focur SA diamond cutting and grinding tools have proved successful in the dry machining

of grey and spheroidal cast iron. Diamond cut-off wheels by Tyrolit, Schwaz, Austria,

now complete the range for iron foundries

diameter of the grinding wheels (steel

core), no adjustment of speed and infeed

is necessary.

The Focur SA tools are practically

wear-free, which increases machining

quality and virtually no reworking

costs are incurred. Even the disposal of

grinding dust, consisting only of the

workpiece material, becomes considerably

more cost-effective than with conventional

tools. At the end of their lifetime,

the grinding wheels themselves

can either be replated or disposed of

relatively cheaply as scrap steel.

Whereas resin-bonded tools can

only be stocked for up to three years,

Focur SA diamond tools can be stored

indefinitely without compromising

their efficiency.

Off-hand cutting using a Focur SA diamond cut-off wheel, 230 mm diameter

(Photos: Tyrolit)

The foundry industry has always had

required grinding and cut-off wheels

for the removal of risers, feeders and

burrs. For a long time this demand

was met by conventional resin-bonded

tools. Only when the cost-effective

production of synthetic diamonds became

a reality could a new generation

of tools for working on castings be

brought to market.

Durable super abrasives – such as the

Tyrolit Focur SA diamond grinding

tools for the automatic grinding of grey

and spheroidal cast iron (developed in

2002 and since refined) – consisting of

a steel core on which a monolayer of

diamond grains is deposited. These diamond

grains are bonded to the core

via an electroplated me tal layer.

This results in numerous advantages

for grey and spheroidal cast iron grinding

applications. The significantly increased

lifetime is particularly beneficial:

the long tool life reduces tool

changing times and therefore increases

productivity. Due to the constant

Services & innovations

In addition to a comprehensive stock

range, the company also offers specialist

training courses and customer-specific

solutions as standard. It delivers

grinding tools throughout the world

and provides individual service packages:

experienced application engineers

optimize the machine parameters

and therefore the grinding process

directly at the customer’s premises.

This of course allows for new insights

gained since the market launch to be

passed on. Regular dialogue between

customers, application engineers and

the R&D department leads to new suggestions

and ideas for the further improvement

of Tyrolit products.

“We were mainly able to improve

two key parameters in the grinding

process: infeed and feed,” explains

Gebhard Melchior, Head of Marketing

24 Casting Plant & Technology 1/2016


Metal Fabrication at Tyrolit. “Especially

when grinding larger volumes such

as sprues, the infeed values were lowered

in order to reduce the load on the

grinding wheel and extend its lifetime.

When grinding burrs, Focur SA tools

reduce the cycle time through significantly

increased feed values.”

On the tool itself, the core has been

made lighter with no loss of stability in

order to protect machine components.

The Austrian company has developed

an edge shape with slots for grinding

large surfaces, which offers more chip

space and ensures cooler grinding. This

improves the lifetime and polishing behaviour

on the workpiece at the same

time. Ring wheels for the machining of

engine blocks have also receive an individual

edge profile to ensure that even

forces are applied when moving in and

round the engine block.

grinding. At the same time however,

the grain must be sufficiently embedded

in the bond.”

“The development process consists

of two steps. First, the revolutionary

approach with focus on innovation,



Since 2015, Focur SA snagging wheels

are offered as well for angle grinders.

In addition to the significantly longer

lifetime these grinding tools provide

Constructive cooperation

“These improvements to the Focur SA

diamond tools were inspired by analyzes

of our customers’ grinding processes,”

reports Adolf Lang, Manager

Product Development Metal Fabrication

at Tyrolit on the innovation process

jointly initiated by customers, application

engineers and developers. “A

consistent ideas management strategy

leads to feasibility and technology

studies. As a result we create customized

specifications. Our product development

projects are executed according

to a strict schedule and are

operated as stage-gate processes until

their market introduction, with both

internal and external usability tests

conducted with our customers.”

In addition to the new design innovations,

the diamond quality, grit

size and strength of the grain bonding

have been optimized. “The grain size

depends on the required stock removal

rate and desired surface quality,” explains

Adolf Lang. “When considering

the diamond quality, a suitable combination

of gain strength and grain

shape must be chosen according to the

application (grinding or cutting) in order

to achieve optimum results. With

regard to the bonding, a weaker bond

increases the chip space and promotes

high stock removal rates as well as cool

Figure 1: Focur SA diamond ring wheel for machining engine blocks

new requirements and new opportunities

and secondly the evolutionary

approach at which it comes to continuous

development “, Adolf Lang summarizes

the product development at

Tyrolit.

Higher productivity,


Since 2014 Focur diamond tools

have also been available for cutting.

A range of diamond cut-off wheels

(Figure 1) with diameters of 115 to

600 mm have been developed in collaboration

with specialists in the foundry

industry for both manual and automated

cut-off applications.

The diamond tools have an average

lifetime up to 25 times longer than conventional

resin-bonded cut-off wheels.

This value can even be exceeded when

cutting smaller cross-sections. The constant

external diameter allows work to

be carried out at an ideal speed and guarantees

a uniform depth of cut. The additional

reduction in dust and unpleasant

odours has been strongly welcomed, especially

in manual cutting operations.

noticeably improved working convenience

for the end user, especially due

to the low dust levels. Especially in diameters

115 mm, 178 mm and 230 mm,

the new range has been proven well in

field tests.

Whether grinding or cutting, Tyrolit

supports the companies of the foundry

industry. It de livers high quality, durable

products, but also caters for specific

customer requirements. This is supplemented

by the specialized expertise

of Tyrolit application engineers in analysing

and optimizing individual

grinding and cutting processes.

Focus diamond

grinding wheel

in use

http://bit.

ly/1WtieoQ

www.tyrolit.com

Casting Plant & Technology 1/2016 25


AUTOMATION

Author: Olaf M. Kramer, Heinrich Wagner Sinto Maschinenfabrik GmbH, Bad Laasphe

Attracting new customers with

modern molding technology

The bronze foundry Filthaut aims to sustainably produce quality castings to convince demanding

customers in terms of reproducibility, quality and price. Therefore the so-called FDNX-molding

machine from Heinrich Wagner Sinto, Bad Laasphe, Germany, was involved in the casting process

Pouring line with the poured cods of the FDNX. To stabilize the mold, wooden jackets are put on (Photos: HWS)

“Everything from one single source” is

the credo of the brass & bronze foundry

Josef F. Filthaut, at Iserlohn, Germany.

The family-managed company

has had more than 90 years of experience

in the process of sand casting

and lost wax technique and produces

high-quality castings made of light

and heavy metals.

With the highest level of craftsmanship,

the Filthaut brass foundry manufactures

art castings in single and small

batch production such as sculptures,

grave ornaments, memorial tablets,

crests, emblems, company signs and a

lot more.

Industrial castings are the second

source of income of the company.

Typical products of this sector are fittings,

safety relief valves, pump housings,

machine parts, friction rings or

marine propellers. In addition to their

production programme, the Filthaut

foundry also provides complete solutions

thanks to their own pattern making

and the in-house treatment of the

castings (Figure 1).

Expertise gained during many decades,

real passion for the skills and

craftsmanship of the metal foundry

are just some of the many qualifications

of our employees. Continuous

investments, and modern manufacturing

plants, are the factors of success

of the 2-generation company. For

example, the sand preparation plant

26 Casting Plant & Technology 1/2016


and the melting technology have been

modernized completely within the last

few years.

The growing demand for small series

and the vision to diversify their services

in the future encouraged Christina

Filthaut, head of the foundry and

daughter of the proprietor Michael

Filthaut, to strengthen the company

in the field of the sand molding technology.

The Filthaut family thus aims to

produce in a sustainable manner

high-quality castings that convince the

sophisticated customers with regard to

reproducibility, quality and price.

The target of the Heinrich Wagner

Sinto engineers was to integrate modern

molding technology as simply as

possible into the existing foundry process.

The ideal solution for this requirement

was the molding machine FDNX.

This molding machine operates with

the proven “Aeration” compaction process,

i.e. the molding sand is supplied

into the molding cavity by means of an

air flow. The air escapes through slotted

vents in the drag and cope. Hydraulic

pressing then gives the mold cod its

required stability. The hydraulic pressure

is generated by a hydroconverter

that is supported by a pressure amplifier.

The result is mold cods with horizontal

mold partition and a high mold

quality (Figure 2).

The FDNX machine does not require a

foundation. There is no spill sand as the

molding process is completely closed

and the dust emissions are minimal. The

design principles allow the machine to

operate in a manual environment or to

upgrade it gradually to a fully automatic

molding plant with an output of up

to 90 molds per hour (without core setting)

by means of modular plant technology.

At present, more than 70 FDNX

molding machines and molding plants

are being operated worldwide. The machine

is available in two versions for

cod sizes of 450 x 350 x 150/150 mm

and 500 x 400 x 180/180 mm.

The molding machine is extremely

compact requiring a space of just 5 m 2

and operates with low noise emissions

(approx. 75 dBA), low energy consumption

and operating costs. For these reasons,

the machine has been on show at

Figure 1: The heart of the brass foundry Josef F. Filthaut at Iserlohn

the “ecoMetals Trails“ at GIFA 2015 and

attracted lots of visitors.

Mrs. Filthaut gives a resume: “The

step from a purely manual molding

technology to modern machine molding

was an important step for us into

the future. Our aim is to realize the

wishes and ideas of our customers efficiently

with individual solutions in

a flexible, high-quality and reliable

way from the first pattern making until

readiness for series production. The

molding machine FDNX allows us to respond

now even more flexibly to customers’

requests. If we reach our capacity

limits, we will be able to increase

production at any time at short notice

by fully automating the line. The machine

fully satisfies us with regard to

the molding technology. It surprised

us that we could even mold sensitive

cement (gypsum) patterns in highest

quality. The FDNX is always working reliably.

Our employees confirm that the

workplace conditions have improved

significantly through the new machine.

We are confident that we will strengthen

our market position and attract new

customers with this investment.“



Figure 2: Foundry director Rainer



Casting Plant & Technology 1/2016 27


AUTOMATION

Authors: Malte Lüking, Technical Director Karl Casper GmbH & Co. KG, Remchingen, and Stefan Throm, Managing

Director, RGU Expert GmbH, Würzburg

Casper 4.0 – the supporting pillars

for a digital future

Industry 4.0 is a hot topic in the media and in political discussions. While most German foundries

are still hesitant, there are indeed some pioneers who are actively pursuing the concept of

Foundry 4.0 as a strategic objective

Foundry 4.0 pioneer

in the industry

The medium-sized foundry produces

a wide range of hand-molded castings.

Flexibility, on-time delivery and

good customer relations are the company’s

strengths. Under the term “Casper

4.0”, the company pursues clearly defined

targets and strategies leading to

the implementation of what is associated

with Foundry 4.0 and what is represented

by three supporting pillars

(Figure 1):

» VISU – network between all operating

assets

» ERP – planning / controlling of the

processes with 100 % trackability

» EXTRANET – the “transparent foundry”

– customers have access to information

related to the manufacturing

of their products

Industry 4.0 is omnipresent at the foundry Karl Casper Guss but without

good workmanship and well trained junior staff it would have been impossible

to implement the new technologies in practice (Photos: Karl Casper Guss)

The foundry industry is presented with

challenges of a new nature. “Industry

4.0” is a hot topic in the media and in

political discussions. Under the motto

“Safeguarding the future of Germany

as an industrial location”, various bodies

and organizations have set out to define

new standards for what is called the

fourth industrial revolution. The central

element is the concept of the “smart

factory”, in which humans communicate

with machines and products of

any kind. Also at GIFA 2015, “Foundry

4.0” was an omnipresent topic among

German foundry operators. For good

reasons, because international competitors

are not sitting back and just

watching. While most German foundries

are still hesitant, there are indeed

some pioneers who are actively pursuing

the concept of “Foundry 4.0” as a

strategic objective. Karl Casper Guss in

Remchingen is taking a pioneering role

VISU - networking of operating assets

Long before the current Industry 4.0

hype, had the Karl Casper foundry started

to link various equipment and operating

assets within a network. Casper decided

to use technology from Siemens.

The first project was started in 2010,

when network links and a control system

were implemented for a newly installed

continuous mixer and the existing sand

preparation plant. That first project was

started with mixed feelings, because the

company was entering entirely new territory

and success was not guaranteed.

What is more, in times of sluggish economy,

that was quite a remarkable investment

for a medium-sized company. Siegfried

Schlaak from the company SSSoft

and specialized in Siemens technology

was contracted to design and implement

the network solution. Once the

project “continuous mixer” and “sand

preparation plant” was successfully implemented,

the management at Casper

recognized the potential of such a net-

28 Casting Plant & Technology 1/2016


worked structure. Malte Lüking, Managing

Director Technology at Karl Casper

Guss, developed a concept of how to integrate

further plants and facilities into

the network. Meanwhile, Casper has implemented

an integrated network of all

operating facilities, including the building

infrastructure (e.g. charge make-up

with RFID connection, and can always

physically see what is going on. All links

are visualized and can be monitored and

controlled via a tablet or smart phone.

As the operators became increasingly experienced

with the new network-based

structure, the company realized the resulting

benefits, for example in terms

of energy saving, optimized equipment

use, as a fault early warning system and

for quality improvement. There is a constant

flow of important data coming

from the machines and facilities. These

data are directly stored in the MDC (machine

data collection) database of the

ERP system. This type of data management

supports the production managers

in preventing and analyzing defects.

Figure 1: Supporting pillars of the Casper 4.0 solution: Casper relies on

consist ent, integrated systems

ERP system serving as central planning

and management system with

100 % trackability

When it comes to planning and managing

orders and products, Casper believes

that consistent and transparent processes

are extremely important. Casper has

been closely working with the German

company RGU Expert, based in Würzburg,

specialists in software solutions

for foundries. More than 30 years ago,

Karl Casper Guss was one of the pioneering

foundries participating in a pilot

project involving the application of

the integrated foundry-specific ERP system

“structura FORM”. Ever since, the

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Casting Plant & Technology 1/2016 29


AUTOMATION

Figure 2: The system displays information on the current manufacturing status

and instructions at the start of every new job

foundry has constantly improved its

processes and expanded the application

of the systems.

Basic data must always be reliable: In

order to come up to this requirement, a

broad and consistent data base is needed.

Accurate planning data for the castings

and coherent cost calculations have

top priority for Casper. All descriptions

of castings and the associated calculations

are done in the ERP system. Detailed

planning of resources, such as

machines, tools, processing steps, raw

materials and auxiliary materials, relies

not only on the definition of the

technological features and specifications

but, most importantly, also on the

planning of the production methods.

The system supports the calculation of

times and quantities through planning

formulae, which in turn are the result

of the acquired production data (PDA).

Lüking is highly appreciative of the system

because he knows that a valid data

base and reliable calculations are indispensible

tools in today’s competitive environment.

Transparency in production: Increasingly

smaller inventories and ever shorter

delivery times demanded by their customers

require foundries to ensure pinpoint

deliveries. Given the wide range

of products made by Casper, this is a

genuine challenge and impossible to

cope with without the consistent use

of the production planning and scheduling

software “structura FORM”. At

Casper, on-time deliveries have top priority

- and the customers appreciate

that very much.

Single-item orders are immediately

scheduled and series parts are managed

via item accounts, i.e. the scheduling

module recognizes any shortages

and initiates corresponding production

orders. As part of order planning

and scheduling, the ERP system plans

the production cycle and performs a

feasibility check. Any bottlenecks will

be immediately indicated. When an

order is being planned, each casting

will be assigned a unique item number

(consisting of a part number and a

serial number). This code serves as the

central reference during production

and for tracking purposes. The item

number is cast into the product. Meanwhile,

Casper has installed a seamless

and consistent feedback system, which

allows the operators to know at any time

the exact position of each individual

product, identified by its specific item

number. Important tracking positions

include: collecting the pattern, making

the cores, filling, coating, assembling,

casting, ejecting, fettling, QA inspections,

priming/varnishing, contract

manufacturing, packaging and readiness

for shipment. The planned parts are

indicated on the feedback terminal according

to the first-in first-out principle

as work in stock. Depending on the specific

requirements, all tracking positions

are equipped with foundry-proof touch

PCs or normal thin-client PCs with bar

code scanners. This keeps the walking

distances for the operators short. Casper

also uses department-specific job tickets

which can be printed right at the production

line. Placed in dedicated magnetic

bags, the job tickets are assigned

to the respective flask or castings. This

organization requires a good deal of discipline

from the staff. However, this extra

effort will pay off soon in the form

of additional transparency, which provides

a much clearer view of what is going

on in the foundry. The feedback information

is checked for plausibility in

order for the production process to run

as planned. For example, the ejection

times and curing times defined for the

plausibility checks are accurate down

to the hour. Process supervision even

includes a function that automatically

triggers a complaint message indicating

that curing times have been exceeded or

QA inspections have been omitted. The

feedback system comes with an integrated

information system which sends

all relevant information about the production

process to the work places and

can be retrieved in text form, as images

or as video sequences. Or it may automatically

pop up as compulsory information

when logging in for a job. The

employees highly appreciate the added

value provided by the information system

and autonomously enter additional

useful data (Figure 2).

QA data are captured as part of the

feedback messages or are automatically

fed into the system as process-related

data by establishing a network

link to the testing device. In the background,

structura FORM compares the

actual QA data with the nominal values

from the inspection plan and will

indicate any deviation as an internal

complaint, which will be automatically

signalled to the QA department. This

procedure ensures that at the end of the

process chain the QA certificates can be

printed out together with the delivery

note without any extra effort simply by

pushing a button. Casper is proud of the

newly established logistics centre and

the modified organization in the dispatch

area. Picking is made at the terminals

of the system, which pre-plans the

castings based on deadlines and routes.

30 Casting Plant & Technology 1/2016


The system gives notice to the carrier

about a freight to be picked up via a

freight portal. The pick-up time schedule

is accurate down to the hour. Each

casting ready for shipment will receive

an adhesive label, which in the form of

a QR code may contain additional information

requested by the customer

concerning his product and order. This

service simplifies the incoming control

process for the customer. Such straightforward

organization of the production

chain and of the dispatch procedures

pays off in terms of good customer ratings

for delivery reliability. Also here,

Casper leaves nothing to chance but

constantly checks its own delivery performance

rating calculated by the ERP

module “delivery reliability” (Figure 3).

Integration of process data in the ERP

system: As mentioned above, the results

obtained from the network of

operating assets (VISU) are closely intermeshed

with the ERP system. All relevant

plant data are fed into the MDC

database of structura FORM. This process

runs automatically in the background.

Consumption data for sands,

resin, hardeners etc are transmitted to

the material management system. Technical

data such as operating times and

downtimes of the plants, energy input,

temperatures, emissions, etc. will be

used for evaluations. For example, the

calculations for the charge make-up,

including the cranes, are controlled by

VISU. The containers for making up the

charges are equipped with special RFID

tags (protection class IP 68). structura

FORM receives not only data about the

exact material consumption figures, but

also spectrometer data, data from the

thermal analysis and energy consumption

figures. structura FORM visualizes

all important information in graphical

form in a dashboard display, which can

be configured to meet the requirements

of the operator’s work place. Casper has

been constantly advancing the integration

of the two applications and will

continue to do so in the future.

Extranet – the transparent foundry provides

customers access to information

related to the manufacturing process

Karl Casper Guss is a “transparent”

foundry. It offers its customers access

Figure 3: The new mobile dispatch management system implemented at Cas-


to selected information concerning the

manufacturing process via a web portal

(Extranet). The customer may take

a look at his orders in process and see

in which processing state the products

are. He may enter additional information

or change deadlines and quantities

directly via the portal. In order to

exercise maximum data security, all relevant

manufacturing data from the productive

ERP programme are replicated

in a downstream web database. After

an initial phase of reluctance, this service

has been well accepted and actively

used by the customers. Managing Director

Malte Lüking knows that some of his

customers use the Casper Extranet as a

platform for their own planning.

Prospects and further projects

Casper does certainly not rest on their

accomplishments. Further projects are

being implemented or planned.

» Flask management via RFID. A new

building for the storage and management

of the flasks via RFID is under

construction. Besides optimized

manufacturing processes, the space

situation in the moulding shops will

be dramatically improved.

» Pattern managements via RFID. A

new high rack will be installed for the

management of the patterns. Today,

the management of the placements

and retrievals is still based on a procedure

that relies on the manual acknowledgement

of the activities at

the PC. In the future, this process will

be optimized by means of RFID tags

attached to the patterns and a mobile

touch PC on the forklift truck.

» Visualization of the manufacturing

process representing the plant layout

The linking of the feedback data

and the MDC database via an integrated

and realtime network provides

high-quality data. The information

provided by these data is to be used

for comprehensive evaluation procedures,

such as searches based on item

numbers, as well as for an enhanced

visualization of the manufacturing

processes in a plant layout setting.

The system will graphically indicate

the position of a certain casting at a

certain point in time (e.g. search for

a certain item number) or the jobs in

process in a department.

Summary

At the transition to the fourth industrial

revolution, the Casper foundry takes

on a pioneering role as it has already

implemented numerous technologies

that other foundries have just started to

think about. Especially for small to medium-sized

foundries, Casper may serve

as a positive example of how the challenges

of a digital future can be successfully

coped with.

www.casper-guss.de

www.rguexpert.de

Casting Plant & Technology 1/2016 31


COMPANY

Author: Robert Piterek, German Foundry Association, Düsseldorf

“Cast iron and e-mobility are a

perfect match”

The foundry sector can also make money with the production of components for e-vehicles. GF

Automotive, a Division of Georg Fischer AG, has received orders amounting to 50 million euros


What are the prospects for foundry

technology in the age of e-mobility?

This is one of the key questions

facing the sector in the 21st century

given the energy transition, increasingly

stringent environmental legislation,

falling CO 2

limit values, and declining

reserves of fossil fuels. While

some casters have put off examining

this question and ridicule the development

of e-vehicles in view of the

modest growth forecasts, the automotive

industry has hesitantly but

noticeably started producing the first

e-vehicles – Golf GTE, Audi e-tron,

BMW i3, Renault Zoe or Nissan Leaf

are just some of the models that are

on offer, largely as plug-in hybrids

with combustion engines. But cars

with all-electric drives are also gaining

ground – and with ranges of over

150 km are already penetrating domains

that exceed the potentials of

modest city cars.

e-mobility represents


On the supplier side, a few foundries in

Germany have already got involved in

this business – which is highly promising

in the long term. These include

the foundries of the major carmakers,

for example BMW’s light metal foundry

in Landshut, Audi Münchsmünster

and Volkswagen Kassel, as well as

foundry companies such as KS HUAYU

AluTech, Nemak, Magna, Handtmann,

32 Casting Plant & Technology 1/2016

Light-construction parts for weight-optimized vehicles on their way into the blasting plant (Photos: Warren Richardson)


Martinrea Honsel and, last but not

least, Georg Fischer. In addition to its

plant construction interests and business

with piping systems, the mixed

group (based in Schaffhausen in Switzerland)

is an important automotive

caster and has recently received orders

amounting to 50 million euros for

e-mobility components. While this is

less than 1 % of annual sales, it is still

an important milestone on the path

to the company’s e-vehicle future, as

is also demonstrated by the squad of

competent dialog partners available

when CASTING, PLANT & TECHNO-

LOGY visited the production site in

Herzogenburg in Austria. Klaus Decking

(Communication and Marketing

Manager as well as the Divisional Manager

of Business Development New

Markets), Claus Schepp (Sales Manager

and a member of the senior management

at the production sites of Herzogenburg

and Altenmarkt), as well as

Markus Rosenthal (Managing Director

in Herzogenburg and now also Manager

of the Light Metal Business Unit Europe)

have come.

Markus Rosenthal is the Manager of the Light Metal Business Unit Europe

and Managing Director of GF’s Herzogenburg works where structural castiron

doors are produced for numerous car models. The production of battery

trays and housings also started up recently

The lighter vehicles become,


be involved

“As a result of the investments required,

the SMEs that typify our sector

cannot simply start participating

in this segment,” Rosenthal comments

on the fact that so far the casters active

in the e-mobility market environment

have been large groups. Casting

and e-mobility, however, are a perfect

match in the opinion of Communication

Manager Decking – particularly

with the light construction and downsizing

that increasingly characterizes

automotive casters such as GF Automotive.

The company has already long

been producing large-scale structural

components such as vehicle doors,

as well as weight- and topology-optimized

drive housings made of aluminum.

The extent to which structural

castings have already gained ground

in the automotive industry can be

seen from the range of customers and

products: “We supply structural components

for all Maserati 4-door models

as well as for Audi’s A4 and A6 models

and BMW’s 5, 6 and 7 series,” says

Decking. “The more light construction

is required for a vehicle, the greater the

chance that casting will be the production

process chosen,” adds the engineer,

who was Managing Director for

GF Automotive in Canada before taking

up his current position.

With its light-construction competence,

his company has positioned itself

cleverly in the still-small market for

e-mobility components, and is reaping

the first rewards with these major contracts:

GF produces battery trays for the

Golf GTE and the Audi e-tron, while

project work is underway for a Bavarian

carmaker on battery housings with

function-integrated active cooling for

heat dissipation, as well as tank housings.

The BMW i3 is also receiving a

GF component (a mechanical part in

the drive train), while Georg Fischer is

in the race for the e-Smart with an instrument

panel made of magnesium.

Then there are structural parts for a

pure e-vehicle producer. The new orders

involve the production of six to

eight different components, totaling

about 30,000 to 40,000 units per year

(by comparison – the annual serial

volumes for iron castings ranges from

50,000 to a million units.



Production takes place at the Austrian

works in Altenmarkt and Herzogenburg.

At the latter site, about 800 employees

produce up to 22,000 t of aluminum

castings and another 40,000 t

of iron castings annually. This proportion

also excellently reflects the general

material distribution for automotive

components at Georg Fischer:

more than 60 % of the components delivered

are made of cast iron, the rest

from light metal.

Even if iron has a weight disadvantage

compared with aluminum and

magnesium, the metal is also used in

e-vehicles, particularly in areas where

high strength is required: “In the new

Golf GTE and in the e-Golf, where our

battery tray is also installed, a part

made of SiboDur (a material made of

cast iron with spheroidal graphite and

developed by GF Automotive) is used

as the wheel carrier,” Decking provides

an example and then stresses that: “A

lot is still possible, even in cast iron.”

Casting Plant & Technology 1/2016 33


COMPANY

Aluminum gearboxes in line on a conveyor belt

The Communication Manager sees opportunities

in the strength properties

of the iron, with which the light-construction

materials cannot compete.

People at GF Automotive, however,

are generally pragmatic: at the end of

the vehicle development path in the

next couple of decades lies a pure e-vehicle

which, with a completely new design,

will undoubtedly largely consist

of light materials – assuming that the

problems with range have been solved

and that car prices fall in the long term.

But weight-optimized combustion engines

will still play a significant role

until then (optimistic forecasts presume

that half of all cars will be e-vehicles

by 2050). According to Decking,

the electric motor or wheel hub motor

could be made in a single casting

in future: “Here, everything speaks for

casting because the e-motor has an extremely

complex geometry with a lot

of connection points and a complicated

inner life,” stresses Decking. Together

with ETH Zurich, the Georg Fischer

team has already developed a casting

with the gears integrated in the wheel

carrier for the Formula Student international

construction competition.

Fork-lift truck carrying a melting ladle

on its way to a die-casting cell

An industrial robot quenching an

aluminum component

Well positioned in the

e-mobility segment

In all these developments, however,

the main materials used in future will

be aluminum and magnesium, which

according to Decking is “the most underrated

light-construction material”:

“There is, of course, the example of a

rear axle cover that used to be made of

iron that is now produced using aluminum,”

admits Sales Manager Claus

Schepp, when asked about a possible

switch at GF in the wake of the material

change from iron to aluminum due

to increased light construction. Overall,

however, he does not see any major

trend towards large-scale substitution of

iron castings in the e-mobility segment:

“There didn’t used to be battery trays,

the same applies for structural components

– here we compete with sheet steel

or other materials,” he explains.

Grinding and inspection work on

aluminum vehicle housings

34 Casting Plant & Technology 1/2016

»


COMPANY


Markus Rosenthal studied foundry

technology at Duisburg University

and has recently become Manager

of GF Automotive’s Light Metal Business

Unit Europe

And does GF Automotive have a

Plan B in reserve if a game-changer

were to come along, abruptly changing

the situation from one day to the

next – for example, a Chinese government

decision to subsidize e-vehicles

in future? The professionals at GF have

faith in their expertise: “If China really

made such a decision it would lack the

production expertise. Then they would

also have to think about how to substitute

sheet steel with structural castings,

for example. That would be good for GF

– we would still grow!” according to a

confident Managing Director Markus

Rosenthal.



At first sight, the foundry in Herzogenburg

is not so very different from other

light-metal foundries in Germany

like KSM Castings, the AE Group or Nemak

Dillingen: whirring robots in the

die-casting cells remove the finished

castings and cool them, hissing, in

quenching basins while fork-lift trucks

loaded with melting ladles drive along

the aisles between the melting shop

and the casting cells. From the heart

of this bustling atmosphere one suddenly

hears the muffled thud of a tilting

sliding table press which is deburring

a structural die-cast door. But when

one examines the plants in greater detail

one becomes aware of their size –

both the massive permanent molds,

of which one half weighs 24 t, and the

trimming presses from Kurtz in Kreuzwertheim

in the casting cells. The works

tour starts by passing 3,300-t die-casting

machines, followed by the premiere

class: die-casting machines with clamping

forces of 4,400 t and a mold weight

of 60 t, with which battery trays and

structural parts are cast (from die-casting

plant producer Bühler in Uzwil,

Switzerland).

“Our works here in Herzogenburg

is one of the sites within the group

with the most heavy machinery. In

future, we will have nine machines of

over 4,000 t operating here. This is really

quite a lot compared to our competitors,”

describes Rosenthal. These

machine sizes, however, are necessary

given the component weights:

“This type of structural die-cast door

weighs 2.5 kg, and large clamping surfaces

are needed because of the dimensions

of the part. And a 30-kg gearbox

needs clamping power,” adds the Manager,

who studied foundry technology

in Duisburg and wrote his thesis at GF

Mettmann. Rosenthal has been active

in management at Herzogenburg for

six years – first in charge of Permanent

Mold Casting and Die-Casting, then he

added management of the Altenmarkt

foundry, and he is now also Manager of

the Light Metal Business Unit Europe.

While foundries like Volkswagen

Kassel are pleased with their interlinked

process chains, casting cells and

raw casting cells for casting and finishing),

here in Herzogenburg the processes

are no longer completely linked

together because it resulted in lower

productivity. “If one cell stops, both

stop,” explains Rosenthal. The melt for

the die-casting process is supplied by

a 10-t gas-fired shaft melting furnace

from Strikowestofen in Gummersbach.


production

On moving to a new hall one immediately

notices numerous installers and

half-constructed die-casting machines.

This will be the center for e-mobility

36 Casting Plant & Technology 1/2016


A vehicle door made of structural

cast iron suspended on measurement

scanners is compared with

customer requirements. This inspection

step is also used for documentation

components. Three 4,400-t die-casting

machines are currently being installed

– a double-digit million investment.

One machine will soon be commissioned.

The installers are busily discussing

technical details while switching

circuits are being laid down and tested.

Regardless of whether e-vehicle parts

or some other light-construction components

will be produced in Herzogenburg

in future, the problems of a typical

automotive foundry also play a role

here. For example, the topic of young

talent: the Austrian foundry sector is

quite small with about 7,500 casters, of

which 2,500 work for Georg Fischer. So

New installation work in the hall for e-vehicle components: the permanent

mold for battery trays has already been inserted into the die-casting

machine

GF Automotive considers its own training

very important: 50 trainees – from

foundry mechanics, through automation

specialists and mechatronics engineers,

to designers – learn their trade

at the major automotive supplier from

the bottom up.

GF Automotive also has little leeway

in its price structuring for vehicle producers

and, like other automotive suppliers,

the group must also adapt to the

carmakers’ desire to reduce stocks by

exploiting just-in-time deliveries from

foundries.

Decking and Rosenthal therefore remain

pragmatic when considering the

future strategy: weight reduction and

the substitution of materials by castings

will remain on the group’s agenda

– with e-vehicle components as part

of the product strategy.

www.gfau.com

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Casting Plant & Technology 1/2016 37


COMPANY

An aerial view of the HegerFerrit foundry in the Palatinate region in Germany. Its own single wind turbine has been covering

about one-third of the foundry’s annual electricity consumption since May 2013 (Photos: Gesamtmetall/Pit Junker)

Author: Pit Junker, Cologne

Heavy castings roll off the

conveyor belt

The Heger Group runs one of the world’s most innovative foundries. The concept was revolu-

-



The table is laid. A single steel cylinder

is all that is on it. This, though, has a

diameter of almost 5 m and is a good

7 m tall. A rail-borne elevating platform

truck hums quietly as it slides between

the table legs and lifts the entire

ensemble, weighing about 130 t, a

few centimeters. It enters a large hall at

walking speed. A few minutes later, beneath

a shower of sparks, molten iron

weighing more than 30 t and at a temperature

of about 1,500 °C is poured

into the cylinder (Figure 1). While this

is going on, about 50 m away on another

table, the parts for the next mold –

for a wind turbine rotor hub – are being

assembled.

Conveyor belt casting. This is nothing

special for smaller parts of up to

100 kg, e.g. engine blocks or gearboxes

for the automotive industry. But

what is taking place at Sembach (near

Kaiserslautern, Germany) is unique regarding

both the magnitude and the

processes. Johannes Heger, the Managing

Partner of HegerGuss GmbH,

a company with a 110-year tradition

based in the neighboring town of Enkenbach-Alsenborn,

is responsible for

this. In 2009 the entrepreneur created

a foundry concept, HegerFerrit

GmbH (on a greenfield site) for

large hand-molded castings that is

“unique” worldwide and whose technology

is “the unchallenged number

one” in Germany.

Exploiting the momentum

of wind power

“As a family-run company, we had the

good luck of being able to act at the right

time without any major delays once the

decision had been made,” says Heger.

The right time was when the wind energy

sector had momentum and one of

Germany’s largest wind turbine producers

signed a five-year contract with

Heger. This secured the investment of

more than 25 million euros. Since then,

everything in the new works has literally

revolved around these heavy cast-

38 Casting Plant & Technology 1/2016


ings in serial production (Figure 2). Because

a circular railway with a dia meter

of 110 m forms the heart of the works.

This central structure is pierced by four

elongated halls that break through the

circle like thorns. The castings are transported

by rail to the particular workstation

in the circular hall – as if they

were on a conveyor belt. Whereby the

innovative idea is that the workpiece

comes to the employee. This is exactly

the opposite to the current way of

working in foundries. “Only one type

of activity takes place in each hall,”

says Heger. Thus processes cannot interfere

with one another. For the first

time, the workstations are stationary

“and can be correctly designed for productivity,

safety and ergonomy.” This

concept allows the production of up

to 2,000 large wind turbine hubs per

year ( Figure 3). The planning, and the

managing partner is particularly proud

of this, was entirely carried out by engineers

from HegerGuss. “The innovative

idea at HegerFerrit is that the workpiece

comes to the employee. Thus the

particular partial processes cannot interfere

with one another.”

Figure 1: Pouring the iron melt into the casting ladle

Figure 2: Removing casting residues from a hub

Conveyor belt castings

up to 30 t

The exclusive contract with the wind

turbine producer came to an end last

year, opening up completely new possibilities

for the foundry. “They are

still our largest customer,” says Heger,

“but since the contract expired we

have also gained other producers as

customers – so we now supply three

of Europe’s leading wind turbine

constructors.” This was not the original

plan. But as a result of the rapid

growth of the wind turbine sector

Heger is now happy that the commitment

to a single producer has lapsed.

The very large components were also

not part of the original plan. “The unit

Non-contact and wear-free

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Casting Plant & Technology 1/2016 39


COMPANY

Figure 3: The prototype of a new hub is measured

weight was originally 8 to 10 t, with a

maximum of 15 t possible,” according

to Heger. But this was not enough for

the rapidly expanding wind energy sector

and for the wind turbines that were

growing with it – larger hubs are now

required (). “Our engineers and

highly qualified specialists succeeded

in doubling the maximum weight to 30

t,” says a pleased Johannes Heger. “This

is possible with two casting ladles and

two cranes in simultaneous operation.”

Productivity and jobs double

The new factory concept has resulted

in double the productivity. “The possibilities

created by the now higher

unit weight have enlarged the potential

market, improved our competitiveness

and further increased productivity

compared to other conventional

competitors,” stresses Heger. This has

also had a corresponding effect on

jobs. We started in Sembach with 50

new employees in 2009 – we now have

80. “The workforce will increase to 100

during the coming months,” predicts

Heger, “because sales are continuing

to grow.” With the orders already received

by the end of 2015 the company

has achieved sales growth of almost

70 % during the last two years.

While Heger is participating in regenerative

energies and in Germany’s

energy transition with the casting

of wind turbine hubs, an enormous

amount of energy is consumed at the

Sembach works. Although the energy

needed for the new foundry concept

– 200 kWh per tonne of castings produced

– is lower than at other foundries,

about 20 million kWh is required

every year. This is about as much as a

small town with 20,000 inhabitants

consumes. “Apart from personnel

costs, the main Achilles’ heel of German

foundries in international competition

is the high price of electricity,”

says Heger. But the company not

only consumes a lot of energy, it also

produces some. About one-third of the

foundry’s annual electricity requirement

has been covered by its own wind

turbine – a highly visible emblem for

HegerFerrit – since May 2013. The hub

was, of course, made by HegerFerrit itself.

In addition to the wind turbine

hubs, the family-run group (in its

fourth generation) with its 270 employees

also produces other high-quality

iron castings for the world market.

Some time ago, the largest and heaviest

engine block in the company’s history

– more than four meters long and

weighing 13,000 kg – was cast at the

main facility, HegerGuss in neighboring

Enkenbach. The V16 motor constructed

from it was a prototype with

a great future and was used for stationary

energy generation. “A new mold

process, developed in-house, was used

to produce the mold which, with an

extremely complex component geometry,

permitted considerably improved

dimensional accuracy of the

casting,” explains Heger. Long longitudinal

channels no longer required

elaborate drilling, but were formed directly

during the casting process. The

component was, however, still cast using

traditional processes – not on travelling

tables.

A 30-t hub is fastened to a low-loader for transport

www.hegerferrit.com

40 Casting Plant & Technology 1/2016


Casting

China

Special

Photo: BMW


SPECIAL

Author: Wen Ping, Executive Vice President & Secretary General of China Foundry Association

Status and outlook of China’s

foundry industry

Figure 1: Total castings output of China from 2000 to 2014, in thousand tons

Steady growth in the “new

normal” era

The Chinese foundry industry has

grown steadily since the turn of the

century. However, the growth rate

has significant slowdown since 2011.

Just as other industries in China, the

foundry industry has entered the “new

normal” era.

Data shows that the total castings

output reached 46.2 million tons

in 2014, which reflected an annual

growth of 3.8 % compared to the

figures of 2013. Actually the growth

rate between 2011 and 2014 was rather

steady, ranging from 2.4 % to 4.8 %

(Figure 1).

For casting output breakdown by

materials, the growth rate of aluminum

and ductile cast iron has shown

an annual increased of 12.5 % and

6.9 % respectively. The ductile iron

and aluminum alloy had a nearly

high-speed growth, while gray iron

showed no significant change. Among

all castings, the proportion of aluminum

including magnesium alloy castings

accounts for 12.7% of the total

output, and the ductile iron accounts

for more than a quarter, or 26.8 %

(Figure 2).

In 2014, the rapid growth in demand

for automobile, agricultural machinery,

rail transportation, communications

and other industries stimulated

the need for related castings. It was also

one of the major reasons for the rapid

increase of aluminum alloy castings.

Automobile castings now account for

more than a quarter of industrial needs

(up to 27.3 %). It is generally expected

that the industry will continue to focus

on production related to the automobile

industry (Figure 3).

But at the same time we saw decline

of demands related to machine tools,

engineering machinery, mining and

metallurgical industries.

Future growth governed by

regulations

To strengthen the macro-management

of the industry, and stabilize the market

order, the Ministry of Industry and

Information Technology has issued

“The Access to Foundry Industry” in

May, 2013. It covers nine aspects:

» construction conditions and layout

»production process

»production equipment

» company scale

»product quality

» energy consumption

» environment protection and resource

comprehensive utilization

» job health, safety and protection

» personnel ability

Implementation of the “The Access to

Foundry Industry” is to promote the

structural adjustment and upgrading

of foundry industry; to promote energy-saving

and emission reduction;

42 Casting Plant & Technology 1/2016


educe outdated capacity; to contain

low level and repeated construction,

to avoid “blind” expansion, to protect

the environment, and lead to the sustainable

development of the industry

in long term.

Although “The Access to Foundry

Industry” is a nation-wide guidance,

setting up the general guidelines for

the foundry industry, management

and governing bodies at local level can

carry out its own policies according to

individual local conditions when the

mainframe guidelines were followed.

The core and essence of economic

“new normal” era will be “Transformation”

and “Upgrade”. In the 13th

Five-Year Foundry Plan (2016-2020),

the China foundry industry will go

through the most critical period for

industry development, with four major

changes to be expected:

1. The industry will transform from

development by speed to efficiency;

2. Emphasis will shift from output volume

to product quality

3. Development will change from extensive

to intensive

4. Last by not least, development will

be driven by innovation, not tradition.

In other words, the 13th five-year

foundry plan will be a critical five year

period for China’s foundry industry

to move from the mid and late stages

of industrialization to post-industrialization.

It has to comprehensively implement

the innovation-driven development

strategies, promote industrial

transformation, upgrade with information

technology and prioritize the

development of modern producer service

sector.

According to the forecast of development

of the equipment manufacturing

industry of China, the total output of

castings will grow at a medium, steady

pace, and is expected to exceed 55 million

tons by the end of the decade, i.e.

2020.

Change to adapt and survive

Re-building foundry cluster is one of

the solutions for sustainable development

in China’s foundry industry. The

Figure 2: Total castings output, by materials

Figure 3: Output requirement, by industries

process will base on remodelling of the

existing local foundry clusters through

the process of industrial restructuring

and upgrading. At the same time, the

process will take into the accounts of regional

economy consideration, brand

building/re-building, product development,

platform construction, etc. With

the overall target evaluation system and

relevant standards being set, the rebuilding

of new foundry clusters could

be accomplished as soon as possible.

It was hope that based on the nearly

30 existing foundry clusters, the experience

drawn from overseas foundry

clusters, the construction of foundry

clusters with Chinese characteristics

will be accelerated.

Geographically speaking, the Eastern

part of China has been taking a leading

role in industrialization and modernization

in the past decades. With

more stringent environmental protection

policies being implemented in this

area and the upsurge of labour cost, an

increasing number of foundry enterprises,

together with other equipment

manufacturing industries, will move

Casting Plant & Technology 1/2016 43


SPECIAL







The 13th Five-Year Plan also set down the

framework of lowering cost. Industrial energy

conservation is the grim – nationwide.

It is estimated that the high energy-consuming

industry in industrial circle

will be more strictly supervised. For adapting

to requirements of national environmental

protection regulation and the demand

of reducing product manufacturing

cost, casting industry will pay more attention

on energy management by promoting

technical and management energy

saving simultaneously.

Advanced energy-saving technology and

equipment have broader space in foundry

enterprise application. Per ton comprehensive

energy consumption of casting will be

further reduced.














to the Middle and the West of the country

to stay competitive in the market. It will

change the all-over geographical industry

layout of the country.

Meanwhile, it is expected some casting

orders from overseas will be transferred to

other countries in which labour cost are

comparatively lower.

All these factors will speed up the transformation

of the traditional industry into

modern enterprise through innovation.

In general, the number of foundry companies

will be reduced as less competitive

enterprises will fall out from the market.

Through economies of scale, some larger

enterprises may enjoy a better margin of

business, and further enhance the industry

concentration ratio. It may turn out

that 20 % of the companies will produce

80 % of the castings available in the market.

The implementation of the latest national

environmental protection act was

just the starting point. It was expected that

subsequent supporting regulations will

follow, and national environmental legal

enforcement will be further enhanced.

Casting industry has always been under

the monitoring pressure from environmentalists

in the aspects of smoke

and dust emission, waste gas treatment,

etc. All enterprises should abide the latest

environmental protection regulation

requirements by implementing the latest

environmental protection equipment

for production. The sooner they can fulfill

it, the higher chance they can stay competitive

in the market, and in turn expect

growth in profit.

The 3-D printing and rapid prototyping

technology will further improve the

development of new products at much

lower cost. Rapid prototyping technology

can produce some castings in small batches.

Breakthrough will be made with the application

of the semi-solid forming technology

in aluminium alloy casting, which

is expected to be applied on a large scale in

the industry.

The domestic foundry equipment manufacturing

level will be further improved,

capable to produce world-class key foundry

equipment such as high-pressure automatic

molding lines and large die-casting

machines to meet domestic needs.

With technological transformation of

foundry enterprises, efficient, energy-saving

and highly automatic foundry equipment

will be used in a much wider perspective.

To cope with the ever-rising labour cost

and production in harsh environment,

some enterprises that produce a large bulk

of castings will gradually extend the use of

robots in core making, pouring, and cleaning.

It is our hope that the foundry equipment

produced in China will become

more competitive in the international

market.

www.foundry-china.com


SPECIAL

Author: Siong Song Liu, President of the Hong Kong foundry Association and Founder of the L. K. Group, Hong Kong

The impact of “Made in China

2025” on China’s die-casting

industry

German foundry groups like Handtmann,

one of the major German casting

enterprises, want to participate

in China’s economic growth: Handtmann

Light Metal Foundry (Tianjin)

Co., Ltd., was founded in Tianjin Airport

Economic Zone at the end of

2015. With a total investment of 75

million euros, the company is equipped

with 12 die-casting machines

and two smelting furnaces. Annually,

27,000 t of aluminum ingots will be

produced, and two million transmission

and clutch housings will be provided

for the German carmaker

Volkswagen (Photo: Handtmann)

As the global landscape of industrial

competition experiences significant

change, China is confronted with huge

challenges as it makes new efforts to develop

its economy. Through dozens of

years’ rapid development, China has

emerged as a global leader in the manufacturing

industry, with an independent,

complete system that spans all

fields of manufacturing, thereby laying

a solid foundation for China’s social

and economic development. However,

China is still in the early stages of industrialization,

and lags far behind developed

countries. In fact, China’s manufacturing

industry is large in scale but

not strong, lacks the ability to develop

innovations independently, and relies

too heavily on core technologies and

high-end equipment imported from foreign

countries. The deep fusion of the

new generation of information technology

and the manufacturing industry is

bringing about profound changes within

the industry, creating new modes of

production, industrial forms, business

models and areas with great potential

for growth. With every country around

the world intensifying its effort to encourage

scientific and technological

innovation, China’s manufacturing

industry is expected to have many opportunities

as it tries to transform itself

and develop through innovation.

A review of the development

of China’s die-casting industry

In 1947, China’s first die-casting plant

came into being in a small alley in

Shanghai. Before 1949, only a few Chinese

plants had a small number of imported

cold- or hot-chamber die-casting

machines, mainly used for producing

zinc alloy castings. In the 1970s, the

development of China’s motorcycle

industry propelled the die-casting industry,

and a large number of die-casting

producers emerged, with the most

rapid development taking place in Jiangsu

Province, Zhejiang Province and

Chongqing Municipality. In the 1980s,

China began to introduce reforms and

open itself up to the outside world,

causing industries like automobile,

hardware, motorcycle and wristwatch

to experience rapid growth in the process.

The die-casting businesses began

to flourish. In the last 20 years, the diverse

development of the die-casting

industry has helped China go from a

large die-casting country to a die-casting

power. Except for Jiangsu Province,

Zhejiang Province and Shanghai Municipality,

Guangdong Province and

Chongqing Municipality have experienced

the fastest growth, with their

numbers of die-casting plants and

their production capacities continuing

to grow. As China’s die-casting industry

advances, so does its die-casting

equipment industry, at an even faster

pace. What follows is a review of the

Casting Plant & Technology 1/2016 45


SPECIAL

and Honda Motor Co., Ltd. began to

use Chinese-made die-casting equipment.

» From 2007 to 2010, Foxconn and BYD

purchased many large die-casting production

units from domestic producers.

» In 2009, 3,500-t die-casting installations

were included in the national

list of critical scientific and technological

tasks.

KSM Castings Qinhuangdao Co., Ltd., also one of the major German casting

enterprises, was founded in Qinhuangdao Economic Development Zone in

mid of 2013. With a total investment of more than 70 million euros, the company

is equipped with high pressure die-casting production lines for engine

parts and counter pressure casting production line for chassis parts. Total capacity

is more than 20,000 t of aluminum annually. More than 2 million parts

of engine and chassis are supplied for German OEM and also various domestic

Chinese brand car makers (Photo: KSM Castings)

13 milestones in the history of China’s

die-casting equipment industry. The

milestones are as follows:

» During the 10th five-year plan period,

the Ministry of Science and Technology

included “Research and Development

around cold- and hot-chamber

die-casting machines for magnesium

alloys” in the national list of scientific

and technological tasks.

» During the 10th five-year plan period,

the Ministry of Science and Technology

included “Research and Development

around large-scale die-casting

machines for magnesium alloys

(3,000 t)” in the national list of scientific

and technological tasks.

» In October 2001, during Shanghai International

Industrial Exposition, the

model DCC1600 die-casting machine

for magnesium alloys, a machine developed

solely by a Chinese business,

was revealed to the public for the first

time (as the result of a state-funded

scientific or technological task)

» The model DCC2000 die-casting machine

for magnesium alloys was successfully

developed.

» In Shenzhen, a base was set up under

the auspices of the state for the

industrialization of die-casting machines

for magnesium alloys and for

the production of such machines for

sale overseas to earn foreign exchange

» In 2001, a task force was set up in

Shenzhen to promote the cooperation

on magnesium alloy industrialization

and application among three

cities on both sides of the Taiwan

Strait.

» In 2002, a special program was

launched in Shenzhen to provide

funds to the effort to industrialize the

die-casting equipment industry. Starting

2003, L.K. Group became a principal

equipment supplier for Aisin Seiki

of Japan.

» In 2007, the National Technical Committee

on Hot Metal Forming Standardization

settled in Shenzhen.

» In 2007, GM ordered several dozen of

3,000 t die-casting production units

from Chinese manufacturers for the

first time.

» From 2005 to 2008, Japanese automakers

Toyota Motor Corporation

The current status of China’s

die-casting industry

As the trend toward a lighter automobile

continues, the automotive industry is

increasing its use of aluminum or magnesium

die-castings, including complicated

components like the gearbox, engine

housing, steering wheel, seats and

dashboard. As a result, market demand

for large die-casting machines (with a

minimum capacity of 1,000 t) has risen

drastically. At present, the dies produced

in China for use in household appliance

and motorcycle industries can

fully satisfy domestic demand, the ratio

of local dies in the automotive industry

keeps on increasing, and magnesium

alloy dies have begun mass production.

Same Chinese producers are now selling

their products overseas, while China

still needs to import large, precise, sophisticated

dies.

The impact of “Made in China

2025” on the development of

the die-casting lndustry

The document “Made in China 2025,”

released in 2015, points out a direction

for China’s manufacturing industry including

the die-casting industry to follow.

The manufacturing industry needs

to make the following three transformations:

the transformation from Made in

China into Created in China, from the

Chinese breakneck speed into Chinese

quality, and from Chinese products into

Chinese brands.

1. The transformation from Made in

China into Created in China

To promote innovation in the die-casting

industry and make it develop, it is

vital for China to develop its own technology

while introducing foreign advanced

technology. For example, China

46 Casting Plant & Technology 1/2016


may improve the performance of its domestic

die-casting machines, improve

the quality of its dies and the level of

its die-casting technology, and improve

the quality and performance of die-casting-related

auxiliary equipment products

and materials. The “model plants”

will play an important role in guiding

the transformation from Made in

China into Created in China. In the aspects

of policies and R&D funds, the

government should encourage and support

the creation of “model plants” and

“model projects” by domestic die-casting

businesses, so that they may increase

the added-value of their products

and help make the process of transforming

from Made in China into Created in

China faster and steadier.

2. The transformation from the

Chinese breakneck speed into the

Chinese quality

Insisting to make quality as the lifeline

in the effort to transform China

into a manufacturing powerhouse,

the industry must stress the responsibilities

of all parts of the business concerned

with quality and intensify the

effort to make quality and technological

breakthroughs and cultivate domestic

brands. lt is also vital to build uniform

standard and quality supervision

systems and create a quality-conscious

culture and a market environment characterized

by credibility and honesty. In

a mature market environment, quality

assurance depends not only on compliance

with standards but also on the

company’s willingness to follow all

rules. In other words, it is important

to change the quality requirements of

standards and the consumer’s reasonable

expectations for quality into the

company’s willingness to improve quality.

How can this goal be achieved? The

only way is to build up a brand system.

3. The transformation from Chinese

products into Chinese brands

This transformation comes naturally

after the previous two. For years many

domestic OEM businesses have run

into trouble and even come close to

bankruptcy. Why has this happened?

There are many reasons, but the most

important reason is that these businesses

were able to produce products

but they lacked a brand consciousness

and could not do marketing weil. lt is

therefore natural to come to the conclusion

that it is important for China’s

foundry and die-casting industries

to improve design, increase the added-value

of their products, enhance

their brand awareness, increase the

competitiveness of their products, and

build up their Chinese brands. Tue document

“Made in China 2025” will turn

out to be a new driving force behind

the development of China’s die-casting

industry and it will offer a host of

opportunities.

www.foundry.org.hk

www.lktechnology.com

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SPECIAL

Author: Harald Seidemann, Managing Director, IPS Expert GmbH, Würzburg

Guss Expert – the foundry ERP system

is ready for China

The Sino-German Green Foundry

Summit Forum in Qingdao – attended

by association representatives, numerous

Chinese foundry representatives,

and specialists from Germany’s

foundry sector – took place for the second

time in September 2015.

The event provided an opportunity

to discuss a very interesting topical

subject: development towards Foundry

4.0, the information technologies

that will be necessary for this, and a

suitable communication platform.

Industry 4.0, and particularly Foundry

4.0, involves the setting-up of a

network to provide all the necessary

information in real time to every entity

involved in the value-creation chain

for the production of castings. It also

means the possibility and ability to extrapolate

and automatically adjust the

further flow of production and values

on the basis of the information obtained.

Foundry 4.0 is characterized by a

wide-ranging and comprehensive human-machine

and machine-machine

dialog. Access to the relevant data and

results takes place both via the internal

company network as well as via secured

communication paths, such as

VPN and the internet.

In addition to PCs (which can already

be described as ‘classic’), increasing

numbers of iPads, tablets and

smartphones are being used here. The

foundry manager is thus always kept

informed about the general situation

in production; current processes in

production; the state of individual aggregates

and, not least, the stage of processing

of the customers’ orders.

The exchange of all data with customers,

suppliers and external workers

also takes place digitally via electronic

data exchange and web access.

Sino-German Green Foundry Summit Forum in Qingdao: At the event the development

towards Foundry 4.0 was dicussed (Photos and Graphics: IPS Expert)

The foundry’s customers can check out

the state of processing of their orders at

any time via the web, with the help of a

browser-enabled device, e.g. on an iPad

or smartphone.

For the foundries this means that

their machines and aggregates must

be equipped with networking capability,

and a comprehensive internal

network constructed by means of cables,

WLAN, switches, etc. If this is

already a major task when building a

foundry from scratch, it is a disproportionally

greater challenge in the

case of an existing foundry. In addition

to the enormous tasks facing the

hardware and the technical solutions,

the software used – the Enterprise Resource

Planning system (ERP) – must

be designed in such a way that networking

in the sense of Foundry 4.0

is possible.

Guss Expert – the special ERP system

for foundries – achieves this and

is therefore the solution for foundries

on the way to Industry 4.0, in particular.

Following use in Germany and Europe

the system can now also be employed

in Chinese foundries.

In addition to resource planning,

costings and sales it is, in particular,

the areas of production planning and

production/machine data acquisition,

as well as electronic data interchange

(EDI) with customers and suppliers

that are responsible for the real-time

processing of data in Industry 4.0.

The timing of the start and end of

a work sequence as defined during

throughput scheduling and capacity

planning is the prerequisite for placing

the production order on the planning

grid for weekly or daily planning. Feedback

from production via production/

48 Casting Plant & Technology 1/2016


The different modules of the ERP-/

PPS-software Guss Expert

machine data acquisition is compared

with the defined schedules – and particular

events that are important for

further work steps are triggered.

Guss Expert and the consulting services

of IPS Expert GmbH, Wurzburg,

Germany, or its Chinese partner company

Qingdao Forward Green Foundry

provide support for foundries regarding

permanent process monitoring as

well as the reorganization of processes

in the sense of Industry 4.0.

www.ipsexpert.de

Competence and Innovation.

DEVELOPMENT AND MANUFACTURING OF

PROTOTYPE AND SERIAL PRODUCTION TOOLS

FOR ALL CASTING PROCESSES

Meissner AG

35216 Biedenkopf-Wallau

Germany

Phone +49(0)6461 802-0

info@meissner.eu

www.meissner.eu

Casting Plant & Technology 1/2016 49


SPECIAL

Author: Christine Wibbe, Communications Production Network BMW Group, BMW Munich

BMW Brilliance Automotive opens

new engine plant with light metal

foundry in China

Engine plant to produce three and four-cylinder petrol engines – light metal foundry sets the

benchmark for sustainable production

Opening ceremony of the new BMW Brilliance engine plant with light metal foundry in Shenyang: Oliver Zipse,

Board Member for Production BMW Group, Olaf Kastner, President BMW Group Region China, Dr. Anton Heiss, President

BMW Brilliance (from left; Photos: BMW)

On the 22nd of January 2016 BMWBrilliance

Automotive (BBA) opened a new

engine plant with a light metal foundry

in Shenyang. The new location will produce

the latest generation of the BMW

TwinPower Turbo three and four-cylinder

petrol engines and forms part of

the BBA production network based in

Shenyang in Northeastern China. BBA

is a long-standing joint venture between

the BMW Group and Brilliance China

Automotive Holdings Ltd. A total of

around 2,000 BBA employees will work

at the engine plant over the long term.

Oliver Zipse, Board Member for Production

BMW Group, stated during

the opening ceremony: “This is another

milestone in the history of our

joint venture and further confirms the

success of our cooperation. The new,

groundbreaking engine plant, complete

with a light metal foundry, will

play an important role within the BMW

Group’s worldwide production net-

50 Casting Plant & Technology 1/2016


work. It forms part of our strategy for

globally balanced growth with production

capacity in the respective regional

markets.”

Yumin Qi, Chairman of Brilliance

China Automotive Holdings Ltd., expressed

his gratitude: “During the last

years BBA has made considerable progress

and set up an excellent, state-of-theart

production location in Shenyang.

With these facilities we are able to deepen

our presence in the Chinese market

and to continue our success. We do appreciate

the great achievements of BBA

as well as the good cooperation with our

partner BMW Group.”

BBA President Dr. Anton Heiss also

announced the next groundbreaking

step for the joint venture at the event:

“BMW Brilliance is recognized as one of

the most successful premium manufacturers

in China. Three new models are

already in the pipeline for local production.

One of these models, the BMW 2

Series Active Tourer, will be launched in

the first quarter of 2016.”

Both the engine plant and the light

metal foundry incorporate the latest

state-of-the-art production standards

and will supply BMW Brilliance’s

Dadong and Tiexi automotive plants.

Factory gate of the new BMW engine plant in Shenyang in Northeastern China

Capacity, which currently stands at up

to 300,000 units per year, is tied to production

volumes at the two automotive

plants. In 2015, local automotive

production reached more than 287,000

units. BBA funded the necessary investment

from its own resources; no additional

capital was needed by the two

joint venture partners.

The opening ceremony was attended

by Oliver Zipse, Member of the Board

of Management of BMW AG, Production;

Olaf Kastner, President and CEO of

BMW Group Region China; Yumin Qi,

Chief Executive Officer of Brilliance China

Automotive Holdings Ltd.; Xiaoan

Wu, Chairman of BBA; Dr. Anton Heiss,

President of BBA; Ilka Horstmeier, Senior

Vice President of Production: Engines

and Electric Drive Systems; Ralf Hattler,

Head of Purchasing and Supplier Network,

Drive Trains; as well as representatives

of Brilliance China Automotive

Holdings Ltd. and the local government.


Pneumatic conveying

technology

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Core sand preparation

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KLEIN Anlagenbau AG

Konrad-Adenauer-Straße 200

57572 Niederfischbach

Fon +49 2734 501 301

Fax +49 2734 501 327

info@klein-ag.de

www.klein-ag.de


BMW TwinPower Turbo petrol engines are

characterised by an especially high level of

efficiency and low emissions and represent

the latest development in the BMW EfficientDynamics

engine family. Using a high

percentage of aluminium has significantly

reduced the weight of drive trains. Heat

management and acoustic features were also

improved. At the heart of this engine range

is the award-winning TwinPower Turbo

technology, combining variable load control

with state-of-the-art direct injection.

A special feature of the new engine generation

is standardized, location-independent

production using a so-called modular

system. All engines of this generation are inline

engines and every derivative is produced

on the basis of a core engine and a modular

kit. This principle increases the proportion

of identical parts used within each combustion

type, i.e. petrol or diesel, to up to 60 %.

Even around 40 % of the parts used in petrol

and diesel engines are identical.

The standardized production system for

modular engines forms synergies with the

international BMW Group engine production

locations in Munich (Germany), Steyr

(Austria) and Hams Hall (UK): Value stream

optimization and economies of scale benefit

production processes and make them more

economical. These locations, which serve

as competence centres for various engine

types within the global engine production

network, are able to share their know-how

with other engine plants at any time.

A further advantage of a standardized production

system is uniform, stable processes

that enhance quality. At the same time, location-independent

modular production

is highly flexible: Its standardized systems

and processes allow the company to respond

quickly to changes in market and customer

demand.

All production processes at the BMW Brilliance

engine plant meet the BMW Group’s

high global standards for quality, safety and

sustainability. Know-how from the BMW

Group’s global engine production network

not only benefitted planning and construction

of the new plant, but also helped with

the introduction of sustainable production

processes and technologies for the latest

generation of modular engines: Following

the example of the BMW Group Plant

Steyr (Austria), machining work uses a water

recovery system, resulting in completely

wastewater-free production. This process

uses innovative combined membrane technologies

to treat all wastewater from mechanical

production and feed it back into

manufacturing.

-


The foundry sets new standards for sustainable

production and has a capacity of up to

15,000 t of aluminium per year. It is modelled

on its partner plant in Landshut, Germany,

whose wealth of experience was integrated

into production processes.

Innovative manufacturing processes enable

nearly emission-free production of sand

cores. For the first time in China, inorganic

binders are used and lead to a reduction of

emissions of combustion residues by 98 %

compared with the organic casting processes

typically used in the industry. In addition,

90 % of the sand used for casting can be recycled

to reduce waste to a minimum. In 2009,

the BMW Group became the first to use this

state-of-the-art, eco-friendly technology

completely in series production of castings

worldwide.

The aluminium needed for casting will

continue to be delivered in solid form and

then liquified to around 760 °C in the on-site

smelter. The “returns” from the casting process,

i.e. metal residues separated from the

raw cast during cleaning, are melted down

in the foundry’s own smelting and holding

furnaces and are reused.

Innovative wire arc spraying technology

(LDS) is also being introduced for production

of cast-aluminium crankcases: The cylinder

faces of all crankcases are coated with

a wafer-thin layer of iron particles sprayed

on in liquid form. This results in a lower

weight and less friction in the engine leading

to lower fuel consumption.



In addition to combustion engines, the new

engine plant will also produce high-voltage

batteries for future Plug-in Hybrid models.

As with the organization of engine assembly,

this project will entail close cooperation

between BBA and the BMW Group to ensure

knowledge transfer from high-voltage battery

production in Germany.

http://iframe.bmw.com.cn/cn/en

52 Casting Plant & Technology 1/2016


VOXELJET

3-D-printing specialist

expands to China

voxeljet, Friedberg, Germany, has announced

the signing of the agreement

to form a joint venture with Suzhou

Meimai Fast Manufacturing Technology

Co., Ltd. (“Meimai”) to pursue opportunities

in the industrial 3-D printing

market in China. The joint venture

shall be called voxeljet China Ltd. and

will be controlled by the headquarter

in Germany. New Managing Director

is Tianshi Jin. He brings more than

fifteen years of 3-D printing and rapid

casting experience and a thorough understanding

of the Chinese market to

the company. Prior to joining the company,

Tianshi Jin was General Manager

of Wenzhou Product Innovation Center

Co. Ltd., a state-owned company.

In 2013, Tianshi Jin founded Suzhou

Meimai Fast Manufacturing Technology

Co., Ltd. which specializes in sand

printing and rapid casting services. He

was also a long standing distribution

partner of voxeljet in China.

voxeljet China Ltd. will be headquartered

in the city of Suzhou, near Shanghai,

and is expected to begin providing

on-demand part services from a temporary

facility in the second quarter of

2016. The joint venture parties are in

the early planning stages for a larger facility,

which is expected to be similar in

size to voxeljet’s existing service facilities

in Germany and the United States.

Dr. Ingo Ederer, Chief Executive Officer

of voxeljet, commented, “We are

excited to announce our joint venture

partnership with Meimai in China as

part of our ongoing growth strategy.

Our long standing relationship with the

principals of Meimai makes them the

ideal local partner for us to establish a

direct operating presence in the market.

Their experience with our printers coupled

with their existing customer base

and relationships with end users of industrial

3-D printing applications in

Tianshi Jin, the new Managing

Director of voxeljet China, and

Dr. Ingo Ederer, CEO of voxeljet (r.),

making the start for the subsidiary in

China (Photo: voxeljet)

China is a great benefit. This is a great

opportunity for us and we look forward

to growing together in the market.”

www.voxeljet.de/en

May 17-20, 2016

China International Exhibition Center

(New Venue) • Beijing

Metal MMeeettaallll ++

etal

Metallurgy MMeee

ttaalllluurrrrgy

ggggy 016

China China

CCCCCC 2016

hhiinnaa 2200011666

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etal

The 16 th China International Metallurgical Industry Expo

The 14 th China International Foundry Expo

The 14

th China International Industrial Furnaces Exhibition

The 12 th China International Refractories and Industrial Ceramics Exhibition

Review

2014




CIEC Exhibition Co., Ltd.

Lydia Sun T: +8610 8460 0341

F: +8610 8460 0325

E: sunying@ciec.com.cn

www.mm-china.com

Casting Plant & Technology 1/2016 53


SPECIAL

MUSCHNA GIESSEREI-MASCHINEN

Automatic molding machine MGM-SM in action (photos: MGM)

Automatic pouring unit MGM-PU

Successful start-up of automatic

molding and pouring

unit

Chinese foundry “Jilin Province Boqiang

Machinery Manufacturing Co.,

Ltd.” successfully started up their

new automatic molding machine

MGM-SM 9 and automatic pouring

unit MGM-PU 100 supplied by the

German start-up company Muschna

Giesserei-Maschinen GmbH, Bad

Laasphe. The machines are made in

Germany and are complemented by

equipment from SUZHU Foundry Machinery

to fully automatic molding

line.

The design of the molding machine

MGM-SM involves an extra strong execution

of the machine frame to avoid

any vibration during the fast shuttle

movement of compaction head. This increases

the stability and life time of the

entire machine. The molds with flask

size 940 x 660 x 280/280 mm are produced

by airflow and multiram squeeze

compaction with a productivity of 120

molds per hour. The molding machine

is based on German components, such

as the Siemens S7 controller.

Molds, produced at the automatic

molding machine, are fully automatic

poured by automatic pouring unit

MGM-PU from a 1 t ladle. During pouring

a new approach to the pouring process

is used. The MGM-PU automatic

pouring unit uses a mathematic calculation

of the pouring curve on basis

of gating system data and metal absorption

capacity of the mold as well

as pouring weight. By this, the pouring

process achieves a very high precision

and the slow down and stop of

pouring on the end of the pouring process

is very smooth. The usual lengthy

set-up when introducing an automatic

pouring is omitted, so that the

start-up period is shortened. The visual

camera control of the metal level in

the pouring cup is used for confirmation

of exact pouring execution and as

safety control during pouring. Inoculation

into the pouring stream occurs

by volume dosing on basis of the pouring

curve.

MGM Muschna Giesserei-Maschinen,

Bad Laasphe, is the Joint venture

partner of Chinese foundry machinery

supplier Suhzu Foundry Machinery,

leading since 50 years in green sand

molding, automatic molding plants,

flasks, core machines and core handling

systems, casting grinding and

other foundry machinery. MGM produces

several types of foundry machinery

at an excellent German machine

building factory. Since GIFA 2015

MGM Muschna Giesserei-Maschinen

extends the supply of Suzhu products

into Europe.

Newly available is the MGM CNC Cut

& Grinder, usable not only for CNC

grinding of castings, but including

the cutting of ricers on the same machine

before grinding of the castings.

The machine is highly productive due

to the ergonomically designed turntable,

on which the castings are set.

www.mgm-foundry.de

54 Casting Plant & Technology 1/2016


ASK CHEMICALS

Sustainable solutions for

Chinese foundries

Under the motto “The future of casting”

ASK Chemicals, Hilden, Germany, will

be showcasing its sustainable solutions

for long-term foundry success at Metal +

Metallurgy China from May 17-20, 2016.

The company will display its portfolio

with a clear focus on its Inotec technology

as well as its water-based coatings

solutions. ASK Chemicals’ feedings system

solutions will round off the company’s

presentation at this year’s Metal +

Metallurgy China trade show.

Visitors can expect to meet a competent

team of foundry experts from both

China and overseas as well as a competent

presentation of innovative foundry

solutions in hall E1 at booth K16.

ASK Chemicals will be highlighting

especially its Inotec inorganic binder

technology, which has already proven

its suitability for series production. The

patented Inotec technology not only

allows emissions to be eliminated but

also has a positive effect on the material

properties of the casting. In addition,

the innovative binder system offers process-related

advantages over conventional

processes. Particularly notable

among these are the significant increases

to productivity in the casting process

and a drastic reduction in the consumption

of resources for maintenance and

servicing work. Inotec technology has

been honored with the BMW Innovation

Award for Sustainability in 2014.

Miratec water-based coatings are

high-performance coatings especially

recommended for automotive applications.

They provide minimum handling

times, which is key to realizing minimum

cycle times and increasing productivity.

The coatings provide an even

coating layer, especially with complex

core packages or challenging core geometries.

Thanks to their engineered formulation

and tailored characteristics

(e.g. gas permeability), Miratec water-based

coatings reduce casting defects

and provide an excellent surface finish.

Frequently, fiber sleeves are used in

steel casting applications. These conventional

sleeves contain, in addition to

With its reduced feeding volume and its exothermic formulation, Exactcast

mini-risers offer interesting savings potential in steel casting applications and

yield improvements (Photo: ASK Chemicals)

the fibers, rice husks that may lead to

casting defects. Moreover, these slurry

sleeves do not utilize their full volume

for counteracting shrinkage defects, so

that the effective yield is only 30 %. The

remaining 70 % of the volume is used to

maintain the heat in the 30 % of the

molten metal needed for feeding.

This is exactly where the cold-box

bonded Exactcast KMV mini-risers

come in, offering a fiber-free solution for

steel casting. The volume at the riser can

be reduced without sacrifice to the feeding

performance. The exothermic compound

replaces the non-feeding material

and maintains the metal in its molten

state. The KMV mini-risers therefore

present an efficient and reliable alternative

to conventional slurry sleeves.

Exactcast optima risers, available as

water-glass or cold box version, noticeably

increase efficiency in foundries.

These mini-risers are fitted with a loose

metal part in the bottom section (nozzle)

and a rigid pin designed to achieve

an exactly defined breaking point and,

additionally, reduce fettling costs.

A further benefit is the virtually frictionless

sleeve and the integrated riser

cap of the risers, which prevent crumbling

particles from falling into the

mold during the compaction process.

Riser applications with rigid pins usually

destroy the riser during compaction,

and crumbling particles from the riser

can fall into the mold, which needs to

be purged with air afterwards. This can

also happen when using spring pins under

high compaction pressures. Exactcast

optima risers, by contrast, are fitted

with a cover of non-friable material preventing

mold contamination and related

casting defects and thereby raising

the cycle times of the molding systems.

ASK Chemicals will be hosting expert

sessions on Inotec, water-based technology,

and mini-riser solutions:

» “Latest developments in mini-riser

technology for steel castings” by

Huang Hai, Business Line Manager

Feeding Systems

» The future of casting with water-based

coating technology” by Ayin Liu,

Business Line Manager Coatings, Additives

& Auxiliaries

» “Inotec – more than just environmentally

friendly” by Eric You, Business

Line Manager Binders

The presentations will take place every

day at 10:30 am and at 2 pm at the

ASK Chemicals’ booth in hall E1, booth

number K16.

www.ask-chemicals.com

Casting Plant & Technology 1/2016 55


NEWS







First cut of the spade for the new YGG foundry in Taichung Harbor, Taiwan.

The foundry is to set benchmarks with German technology (Photo: Küttner)










KÜTTNER

Groundbreaking ceremony for

wind energy foundry in Taiwan

In November 2015, at Yeong Guan

Energy Technology Group (YGG),

Kuanyin Town, Taiwan, an impressive

groundbreaking ceremony was

celebrated in Taichung Harbor.

At the new location YGG has invested

in a powerful foundry which will

set international standards with German

technology. YGG placed an order

for the planning and delivery of

foundry equipment with the Kaohsiung

based Küttner Asia Ltd., from

which planning and delivery of main

components will be provided by

Küttner, Essen, Germany, while steel

construction and procurement of

standard components is made directly

in Taiwan.

The foundry is designed to produce

small series of large castings weighing

up to 60 t per piece in several qualities

of ductile cast iron.

The foundry will be operated with

Magnesium-treated iron from electric

melting furnaces. The molds will be

produced on vibrating tables which

allows best compactation of the

molding sand. Stationary and mobile

continuous whirl mixers of 100 t/h

capacity will be installed. The flasks

with a weight of up to 450 t and a size

of 9.2 x 7.5 m will be transported by

cranes operating in tandem and will

be emptied on a 90 m 2 large station

consisting of 4 vibrating shake-out

grids. The sand regeneration will be

provided by four conventional mechanical

processing steps. Due to the

tropical climate the reclaimed sand

will be cooled to a suitable processing

temperature by means of chillers. In a

downstream plant the raw castings

will be shot blasted in a centralized

cabin and subsequently treated in a

fettling shop, and finally checked by

non-destructive test.

The Taiwanese new plant is focused

on achieving the high quality demands

for the process, the conservation

of resources by low power consumption,

and ensuring compliance

with the standards of working environment

protection by efficient capture

of harmful pouring gases.

www.kuettner.com

56 Casting Plant & Technology 1/2016


MAUS

Acquisition of Fritz

Hansberg completed

Maus S. r. l., Campodarsego, Italy, one

of the major companies worldwide

in automatic grinding and vertical

turning, completed the acquisition of

Fritz Hansberg S. p. A., Modena, Italy,

long established company leader in

core making equipment and molding

lines. This acquisition enables Maus to

strengthen its position as one of the

global leaders in providing solutions

for foundries: “from casting to finished

part”.

This complementary combination,

besides representing a strategic growth

platform for the two companies involved,

will bring substantial value to

customers. With the advanced core

making and molding line technology

from Fritz Hansberg , Maus in fact completes

its portfolio as a full global solution

provider for foundries.

Mr. Roberto Sammartin, CEO of Maus,

declared: “Recent trends show clearly

An industrial robot is machining a casting (Photo: Maus)

that the foundry equipment industry

is concentrating. The combination

of Maus and Fritz Hansberg supported

by a global presence in key markets

such as Europe, USA and China will

enhance the leadership of Maus and

will position the group to be a reference

point for its customers and play

a leading role in the industry going

forward. Our goal is to maintain this

technological leadership and we will

be willing to invest in the future”.

www.maus.it

www.hansberg.com

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NEWS

VOXELJET

Topology optimization leads

to a prize-winning cast part

A joint project between the Precision

Casting Centre foundry, Portsmouth,

UK, and voxeljet, Friedberg, Germany,

has received the coveted “Component

of the Year” flagship award from the

British Cast Metals Federation (CFM).

The project involved an optimized

aluminum Wheel Upright that is five

times stiffer than before, while maintaining

the same weight. Prior to carrying

out the 3-D print run, voxeljet

and its partners optimized the topology

and ran both a life cycle analysis

and a casting simulation.

The project began with the need to

significantly increase the rigidity of the

Wheel Upright without changing the

weight or materials used. With the help

of cutting-edge simulation tools and

using the full range of structural design

freedom offered by 3-D printing technology,

the partners produced a Wheel

Upright that is up to five times more

rigid than its predecessor. Kevin Smith,

Sales Director with voxeljet UK, describes

the benefits as follows: “The

design freedom of additive manufacturing

processes, combined with simu lation,

allows us to come up with a new

generation of designs that overcome

the earlier conventional design limitations.”

It was voxeljet’s 3-D printing

process that made it possible to implement

cast part geometries with this level

of complexity. “Because of this, the

CMF jurors had a hard time at first believing

that this complex Wheel Upright

was an aluminum investment-cast

part,” Smith adds. This project is an

impressive demonstration of the potential

that exists with regard to boosting

performance and/or reducing weight.

Another reason why the project received

the award was that the component

had been produced particularly

economically by combining voxeljet’s

3-D printing process with traditional

investment casting. In the jury’s view,

the project proved that this manufacturing

process can revolutionize the

production of complex cast parts with

entirely new designs and offers many

Adam Robertson (left) of the Precision Casting Centre and Kevin Smith, Sales

Director of voxeljet UK, with the “Component of the Year“ award presented

by the Cast Metals Federation (Photos: voxeljet)

Bild 1: Comparison between the original Wheel Upright (left) and the optimized

one (right)

benefits for manufacturers and customers

alike.

The Wheel Upright was optimized as

a joint project between Altair, Troy, USA,

Click2Cast, Barcelona, Spain, HBM

nCode, Rotherham, UK, and voxel jet.

The engineers could take full advantage

of component design freedom, thanks

to the 3-D printing technology and the

simulation-driven design. Various software

programs were used for the simulations.

Inspire, which is based on Altair’s

OptiStruct optimization solver,

was used for optimizing the topology.

The component fatigue was simulated

with nCode Designlife, and the Click-

2Cast software was used to simulate the

casting process.

Coinciding with voxeljet’s success at

the CMF Awards, the company has

58 Casting Plant & Technology 1/2016


launched an on-demand service center

for industrial 3-D printing applications

in the UK. The substantial capacities of

three high-speed, large-format printing

systems, each of which has a build

volume of 1,000 x 600 x 500 mm, make

it possible to produce precise investment

casting molds and models in just

a few days. James Reeves, Managing

Director of voxeljet UK, comments:

“Our 3-D printing systems are the biggest

and fastest available today for investment

casting. They enable us to

respond quickly, implement short processing

times and still remain cost-efficient.”

www.voxeljet.de

NADCA SURVEY

Productivity increase in 2015

The North American Die Casting Association

NADCA, which includes mebers

from the USA, Canada and Mexico,

has released the results of the

2015 “Annual Wage and Fringe Benefit

Survey”. This survey is specifically

designed for the die-casting industry

and represents 54 companies in

the industry nationwide with detailed

summaries for direct labor employees.

In addition, the survey includes: wage

rates for 13 key direct labor employees,

analysis of insurance coverage, determining

compensation standards and

selecting fringe benefit plans and insurance.

This data reflects a sampling of the

information that can be found in the

2015 Wage and Fringe Benefit survey.

This year, the typical participating

company had median annual sales of

47.9 million US-dollar per year; utilized

20 die-casting machines, employed 209

full-time direct labor employees. Eleven

(21 %) were union shops and 16 %

of the total production employees reported

were temporary. Almost 92 % of

the survey participant’s total employees

were hourly production employees.

Three out of every four companies reported

a general wage adjustment in the

last 12 months and a percentage (80 %)

plan to make a general wage adjustment

in the next 12 months. The median value

of adjustment in the last 12 months

was 3 %. The shift in the industry to providing

401(k) type retirement savings

plan is evident by the decrease to 35 % of

the traditional pension plans to 82 % of

the industry offering 401(k) type plans.

Wage and fringe benefit programs

must be competitive in the current

workforce in order to recruit and retain

a top-notch staff in today’s highly

competitive job market.

NADCA’s 2015 Annual Wage and

Fringe Benefit Survey is available as an

instant download or hardcopy publication.

www.diecasting.org

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NEWS

RECYCLING


tonnes of CO 2

are saved, equivalent to the emissions of about 40 000 people

annually (Photo: Billionphotos.com - Fotolia)

Recycling of aluminium packaging

at record level

Together with strong market growth

the quantity of recycled aluminium

packaging reached an all-time high in

2014. According to a current study by

Gesellschaft für Verpackungsmarktforschung

mbH (GVM), Mainz, Germany,

94,900 t of the 106,600 t of aluminium

packaging used in Germany

were recovered as material (2013:

87,300 t). This represents a recycling

rate of 89 %.

“Coupled with greater material efficiency

and perfect product protection,

material recovery from aluminium

packaging makes an important contribution

to conservation of resources,”

was how Hans-Jürgen Schmidt, Managing

Director of Deutsche Aluminium

Verpackung Recycling GmbH (DAVR) in

Grevenbroich, commented on GVM’s

recycling audit. “The contribution to

climate change prevention is considerable:

the quantities of packaging now

being recycled mean annual savings in

greenhouse gases of more than 480,000

tonnes of so-called CO 2

equivalents.”

“Thanks to its material properties, as

a packaging material aluminium

makes a vital contribution to sustainable

and resource-efficient consumption,”

added Christian Wellner, Executive

Director of Gesamtverband der

Aluminiumindustrie (GDA) in Düsseldorf.

“The recycling of aluminium

packaging and the closing of material

loops plays an important role in the

efficient utilization of resources and

environmental protection. Yet another

record result for the recycling of aluminium

packaging will improve the

metal’s sustainability performance

even further.”

GVM determines the quantity of

packaging waste generated and recycled

in Germany every year also on

behalf of the Federal Environmental

Agency in Berlin. It takes into consideration

the quantities of used packaging

recycled via the different Dual Systems

as well as the amounts returned

by other organisations and collection

schemes.

www.aluinfo.de

CAN-ENG

Heat treatment system for the

processing of aluminum automotive

structural castings

CAN-ENG Furnaces International

Limited, Niagara Falls, Canada, has

been contracted by a large Canadian-based

Tier 1 automotive supplier

located in Alabama to design, manufacture

and commission an automated

T-7 Heat Treatment System for the

processing of high integrity aluminum

automotive structural castings.

CAN-ENG is a global expert in the design

of thermal processing solutions

for high pressure die castings (HPDC)

and aluminum automotive structural

components. CAN-ENG’s technology

was chosen for this new light-weighting

project because it offers inherent

part handling features that reduce

floor space requirements and energy

consumption. The technology also

provides predictable mechanical properties

and maintains the dimensional

stability of the casting.

The T-7 cell includes robotic handling,

a solution and age furnace with

CAN-ENG’s precision air quench (PAQ)

technology, and controls integrated

into a Level II SCADA system. CAN-

ENG’s PAQ system offers a unique

combination of recirculating air chambers,

distribution nozzles, dampers

and directional ductwork. Analysis of

CFD modelling by CAN-ENG’s R & D

Center ensures that the PAQ system

delivers controlled quench media to

the casting, leading to repeatable and

uniform mechanical properties and

accurate dimensional results. CAN-

ENG’s T-7 heat treatment system is integrated

with up and down stream

processing operations, reducing W.I.P

inventories. It is scheduled to be commissioned

in the summer of 2016 with

a second phase to follow in 2017.

www.can-eng.com

60 Casting Plant & Technology 1/2016


IMF

Heavy duty tele manipulator

After careful tests the giant manipulator

K20 by IMF (Impianti Macchine

Fonderie), Luino, Italy, was installed at

the VDP foundry, Schio, Italy, in December

2015.

According to IMF it is the biggest manipulator

ever manufactured worldwide,

conceived to perform quick manipulation,

totally safe of heavy and

complicated loads.

It is equipped with three tele cameras

and relevant monitor on board to

control different working areas.

Main technical data:

» Max. handling capacity: 20,000 kg

» Max. extension with horizontal

clamp: 10,600 mm

» Max. extension with vertical clamp:

8,440 mm

» Full load speed: 24 m/min

The whole manipulator with a group of visitors during the open day at IMF

held on Dec. 11, 2015 (Photo: IMF)

» Max. size with open clamp:

2,800 mm

» Boosters diameter: 320 mm

» Working pressure: 280 Bar

» Installed power: 250 kW

» Weight: 180 t

www.imf.it

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NEWS

ASK CHEMICALS

Exactcast technology even


ASK Chemicals, Hilden, Germany, has

significantly improved its Exactcast

riser technology within the last few

years. Recent developments such as

Exactcast Optima mini-risers provide

important benefits to foundries. With

the integration of riser data into the

new MAGMA 5 version, foundrymen

have access to comprehensive validated

data of the Exactcast riser when designing

the riser or gating system.

Both risers and mini-risers are characterized

by specific thermo-physical

properties. They are either exothermic

or isolating and have different feeding

volumes and specific melting properties.

Precise knowledge of this information

is crucial when modelling the appropriate

system. With the latest

MAGMA 5 Release 5.3, foundrymen

Data for Exactcast risers and mini-risers are now available in MAGMA 5

Rel. 5.3 (Photo: ASK Chemicals)

have access to this information and can

apply the new mini-risers even more

efficiently. The

use of simulation

increases

the efficiency of

processes, as it

crucially reveals

where there is

optimization

potential – not

merely with the

casting development

process

specifically, by

reducing “trial

and error”, but

also with existing

processes

generally.

Exactcast Optima

risers represent

a further

solution successfully

rolled out

by ASK Chemicals

to increase

efficiency in

foundries. These

mini-risers are

fitted with a

loose metal part

in the bottom

section (nozzle)

and a rigid pin designed to achieve an

exactly defined breaking point and, additionally,

reduce fettling costs.

A further benefit is the virtually frictionless

sleeve and the integrated riser

cap of the mini-risers, which prevent

crumbling particles from falling into

the mold during the compaction process.

Riser applications with rigid pins

usually destroy the riser during compaction,

and crumbling particles from

the riser can fall into the mold, which

needs to be purged with air afterwards.

This can also happen when using

spring pins under high compaction

pressures. The new risers, by contrast,

are fitted with a cover of non-friable

material preventing mold contamination

and related casting defects and

thereby raising cycle times of the

molding systems.

ASK Chemicals riser solutions are

characterized by their efficiency and

high-quality feeding performance.

They support casting defect prevention

and, with the MAGMA 5 release,

can now also be consulted for modelling

the feeding or gating system. They

are a powerful and effective combination

offering interesting potential for

foundries.

www.ask-chemicals.com

62 Casting Plant & Technology 1/2016


ARTIMPIANTI

Flexible manufacturing

system for cast iron foundries

Delivering products with high quality

standards of different shapes in a short

period as a prompt response to customer

requirement is an important factor for

small and medium-size foundries in order

to grow and sustain.

Developed in a partnership between

Artimpianti Italy S.n.c., Costigliole Saluzzo,

Italy, and the cast iron foundry

Fonderie Palmieri S.p.A., Settimello

Calenzano, Italy, Artdosing is conceived

to fulfill the tasks of a flexible manufacturing

system. This device was first introduced

at GIFA 2015.

The Artdosing system is a solution for

the following barrier faced in foundry

equipment:

» Rigid pouring with intermediate furnace,

which are suitable for mass production

» Pouring manually or by crane with

higher risk of human injuries.

Each empty ladle can be refilled with a

cast iron alloy melt of different chemical

composition with no extra energy

for heating i.e., treatment of cast iron

can be done without pouring the molten

alloy and allowing the operator to

get sample in an easy manner before and

after the metallurgical treatment.

Artdosing is a sophisticated design,

wherein the geometry can be adapted

and configured for custom requirements.

It has a floating fulcrum point

on the ladle located close to spout so

that it optimizes a laminar and concentrated

pouring stream in the die sand.

Load Cells are provided for continuous

monitoring of electronic weight

display of the material in the ladle. The

Ladle carrying capacity ranges from

300 kg through 1800 kg. The operator

is sitting in a enclosed cabin protected

from drops/splashes during pouring.

The advantage of Artdosing-model is

summarized as follows:

» Artdosing allows customer to use

the equipment with minimal or no

changes to the melting and forming

upstream process;

» The system can be used for small

quantity of alloy according to the

model that is present in molding;

» Artdosing is very flexible and can

move/ reach every area of the plant

without rigid items such as cranes or

having additional furnaces which will

boost energy savings;

» Casting quality will improve as pouring

will be a continuous and laminar

flow;

» Ladle carrying capacity 300 through

1800 kg;

» Weight control is continuous ;

» Low maintenance and investment

cost.

www.artimpianti.it

ArtDosing – the new


Device

http://bit.ly/1pbCVLB

PERFORM

YOUR OWN WAY!

The independent welding system

High Performance Electrodes

High Performance Power Source

High Performance Welding Results

UTPperform is a unique welding system that allows

you to weld independently of any stationary power

supply – anytime and everywhere. A machine

designed for the demands of independent people

who go for individual welding performance.

Welding filler metals designed for the special welding

requirements even under toughest conditions.

Check out your live independent welding demo at:

www.utp-maintenance.com/perform

voestalpine Böhler Welding

www.voestalpine.com/welding


BROCHURES

Molding sand management

4 pages, English, German

A concise brochure outlining the solutions and systems offered by Datec Dosier- und

Automationstechnik for the modernization of electronic equipment for mold sand

conditioning. For example, Datec offers a sand testing system which automatically

tests sand compactibility and green compression strength.

www.datec.org

Hose technology

4 pages, English, German

A product brochure detailing the features of the non-conductive cooling water

hose ProtectorTM offered by Lippmann. The hose has been designed for use in

induction, electric arc, ladle and ESR furnaces. The brochure describes the hose ma-


www.lippmann-gmbh.com


16 pages, English


Junker. The plant and equipment range includes induction furnaces for melting,

holding, pouring and vacuum treatment, melting furnaces for aluminium, and thermoprocessing

plants, e.g. for homogenizing, quenching and tempering, annealing

and heating.

www.otto-junker.de

Bulk material technology

28 pages, English


bulk materials technology, control systems as well as mechanical and plant engineering.

Equipment supplied by Emde includes trough and tubular screw conveyors,

dosing units, trough chain conveyors, bucket elevators, pneumatic and vacuum

equipment, etc.

www.emde.de

64 Casting Plant & Technology 1/2016


Eye and face protection

48 pages, English

A catalogue of head and face protection products offered by Rudolf Uhlen. The

wide range of products includes hard hats, hard hat brackets, headgears, face



provided.

www.aschua-uhlen.de

Vibrator motors

10 pages, English, French, German

Friedrich Schwingtechnik manufactures vibrating motors and unbalance exciters

for vibration tasks. The brochure provides detailed technical information about

the range of vibrator motors (2- to 10-pole) offered, in text and table form, and as

technical drawings.

www.friedrich-schwingtechnik.de

Impregnation products and services

12 pages, English

A brochure featuring the Loctite high-performance impregnation products offered

by Henkel. The process, suitable for metal parts such as engine blocks, cylinder


the products with lifetime sealant, which will withstand oils, grease, virtually all


www.loctiteimpregnation.com

Vacuum die casting

8 pages, English



features Cosma’s High-Q-Cast high-pressure aluminium casting process for body and

chassis applications.

www.cosma.com

Casting Plant & Technology 1/2016 65


INTERNATIONAL FAIRS AND CONGRESSES

Fairs and Congresses

Cast-Expo & Metalcasting Congress 2016

April, 16-19, 2016, Minneapolis/USA

http://bit.ly/1QwPDxF

73rd World Magnesium Conference

May, 15-17, Rome/Italy

http://www.intlmag.org

14th World Conference in Investment Casting

April, 17-20, 2016, Paris/France

http://www.eicf.org/events.php

Metal + Metallurgy China 2016

May, 17-20, Beijing/China

http://www.foundry-china.com/Index.aspx

Hannover Messe 2016

April, 25-29, Hannover/Germany

http://www.hannovermesse.de/en

The 72nd World Foundry Congress

May, 21-25, Nagoya/Japan

http://wfc2016.jp/?page_id=95

Metal & Steel Saudi Arabia 2016

May, 1-4, Riyadh/Saudi Arabia

http://www.metalsteelsa.com

Metallurgy 2016

June, 6-9, Moscow/Russia

http://www.metallurgy-tube-russia.com

15th International Foundrymen Conference

May, 11-13, Opatija/Croatia

http://www.simet.hr/~foundry

World Congress Aluminium Two Thousand - ICEB

June, 20-24, Verona/Italy

www.aluminium2000.com

Advertisers‘ Index

ABP Induction Systems GmbH 2

AGTOS Ges. für technische Oberflächensysteme mbH 68

Hannover-Messe ANKIROS FUARCILIK A. S. 35

voestalpine Böhler Welding GmbH 57, 59, 61, 63

Chesapeake Speciality Products, Inc. 11

CIEC Exhibition Company Ltd. 53

Gustav Eirich GmbH & Co. KG 23

ExOne GmbH 47

FAT Förder- und Anlagentechnik GmbH 19

FSG Frank Stapelmann Gießereimaschinen GmbH 13

Giesserei-Verlag GmbH 12

GTP Schäfer GmbH 13

GUT Gießerei Umwelt Technik GmbH 51

Inspectomation GmbH 37

Jasper Ges. für Energiewirtschaft & Kybernetik mbH 29

KELLER H.C.W. GmbH 39

Klein Anlagenbau AG 52

Helmut Klumpf Technische Chemie KG 57

Küttner GmbH & Co. KG 44

Friedrich Ley GmbH 61

MEISSNER AG 49

O.M.LER 2000 S.R.L. 62

Regloplas AG 21

RUMP STRAHLANLAGEN GmbH & Co.KG 63

Rudolf Uhlen GmbH 59

WOKO Magnet- und Anlagenbau GmbH 56

66 Casting Plant & Technology 1/2016


PREVIEW / IMPRINT

Preview of the next issue

Publication date: June 2016

Albert Handtmann with an aluminum casting produced at the die-casting foundry in Biberach. He has shaped the history of the Handtmann

Group since the end of the Second World War (Photo: Klaus Bolz)

Selection of topics:

K. Hardtke: The Handtmann Group – a family company with a future

Albert Handtmann Metallgusswerk GmbH & Co. KG in Biberach (Baden-Württemberg) is the heavyweight of the Handtmann

pany

whose technical solutions are in demand in a variety of markets worldwide.

C. Nowaczyk: Core shooting simulation – to the economic and environmental advantage

of the foundry

ASK Chemicals, Hilden, intensively focuses on simulating foundry processes. This involves using almost all well-known software

solutions, such as Magma, Flow-3D, Arena-Flow and Novacast. The article provides an overview of the potential that core shooting

simulation offers

A. Kleine : The alloy Trimal-37 in modern car body construction

A weight-optimized self-supporting frame structure can be realized in the vehicle body with the help of cast nodes made of the

die-cast aluminum alloy Trimal-37.

Imprint

Pub lish er:

Ger man Foundry As so ci a tion

Ed i tor in Chief :

Michael Franken M.A.

Ed i tor:

Robert Piterek M.A.

Ed i to ri al As sist ant:

Ruth Fran gen berg-Wol ter

P.O. Box 10 51 44

D-40042 Düsseldorf

Tele phone: (+49-2 11) 6871-358

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Gies se rei-Ver lag GmbH

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E-Mail: cpt@stah lei sen.de

Man ag ing Di rec tors:

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Publishing Di rec tor:

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Ad ver tis ing Man ag er:

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Cir cu la tion:

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Pro duc tion Man ag er:

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Layout:

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ISSN 0935-7262

Casting Plant & Technology 1/2016 67


Competence in

Shot Blast Technology

We offer a complete service in surface

preparation technology, not just as machine

designers and manufacturers.

Our emphasis is on providing reliable

service on:

• Wear and Spare Parts

• Repair and (remote) maintenance

• Inspection and process advice

• Machine upgrades and performance

enhancement

• Upgraded used machines

AGTOS

Gesellschaft für technische Oberflächensysteme mbH

Gutenbergstraße 14 · D-48282 Emsdetten

Tel. +49(0)2572 96026-0 · info@agtos.de

www.agtos.com

214-12/15-2c

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