CPT International 01/2018

that compression is not of the same
standard as with a shot core. In order
to achieve the required surface quality,
a coating material is needed to smooth
out the unevenness that occurs during
printing. We are in the process of developing
coatings specifically designed
for 3-D printing, because not every
coating is suitable for this process. This
is a market with a future.
And in iron casting?
Coatings are still necessary in iron and
steel casting, even if inorganic material
is introduced. We have also succeeded
in modifying inorganic systems, which
are generally highly sensitive to water,
and coatings in such a way that they
can be applied without causing damage.
We are continuously working to
ensure that the binder systems and
matching coating materials harmonize
in order to prevent certain casting defects
in the iron and steel casting sector.
So, coatings are an important R&D
topic?
Yes, in fact we have expanded our resources
and increased the number of
researchers working on coatings. These
are scientists who focus exclusively on
developing coatings for the fields of inorganic
and 3-D printing. We are convinced
that coatings will continue to
represent a growing market in the future.
You have touched on additive production.
An engine plant that casts
more than one million engines a year
needs to produce cores economically.
Will 3-D printing ever be able to replace
core shooters?
Certainly not in the short or medium
term. Printing still takes far too long,
although the technology is advancing
in leaps and bounds. Over the last 5
years, speeds have increased fourfold.
And 3-D printing is getting faster all
the time. We already know that 3-D
printing allows maximum geometrical
freedom. In future, cores that cannot
be shot due to their geometry will
be produced using additive manufacturing
technologies, whereas simpler
cores will still be shot at low cost. We
fully expect both methods to be used
in combination. Core-making shops
will not only have 3-D printers or core
shooters – they will use both.
Are these developments being driven
by industry-led demands?
Certainly. In terms of 3-D printing, we
have also built up resources for the development
of new core printing additives.
After all, new processes require
new products. We also recognize the
pressure to innovate from the customer
side. Even today, it is possible
to print complete core packages with
20 cores, whereby it’s not always possible
to clearly distinguish between cores
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Casting Plant & Technology 1 / 2018 9
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