CPT International 04/2018

INTERVIEW
since 2017 and the first half of 2018,
they have been feeling a clear upturn.
This was triggered by the growing demand
in the mechanical engineering
sector as a result of a catch-up effect
and a booming phase in all its subsegments,
with the exception of wind
power. Although the current market
situation is very positive, there is a dark
cloud on the horizon. This is due to
the dramatically changing eco-political
environment. Just take the anti-free
trade measures implemented by the US
Administration, the unsolved Brexit or
the increase in sanctions. The reliability
of business relations has definitely
not improved. Let’s hope that the all in
all positive climate will persist beyond
next year’s GIFA.
What will be the main top issue at
next GIFA?
I do not see one single, overwhelming
topic, but several interrelating and interdependent
issues. As well as additive
manufacturing, topics like lightweight
construction in automotive
engineering, Industry 4.0, the digital
transformation, energy and resource
efficiency, and sustainability will play
central roles at next GIFA – not forgetting
e-mobility.
Do you see additive manufacturing
and casting as partners or competitors?
They are two complementary trends.
Generative processes currently represent
one of the most important and
intensive research areas of the global
industry. Products for specific applications,
prototypes and parts for
airplanes are already being produced
by 3-D printing, replacing castings in
these areas. However, for large series
production, casting still is the most
economical process – also according to
statements by major OEMs. With computers
becoming increasingly more efficient
and faster, costs decreasing and
the quality of metal powders improving,
this balance may, however, slightly
shift towards 3-D printing in the future.
There are already examples of application
where 3-D printing and casting
complement each other. These will be
featured in a special show at GIFA.
Is 3D printing also an interesting option
for your company?
We already produce prototype tools
by 3-D printing. This allows us to test
the tools under manufacturing conditions
before kicking off the cost-intensive
production of metal tools in large
series. We know that some pressure die
casting shops use extremely complex
tools which they can produce only by
3-D printing. Additive manufacturing
provides much more design options,
for example, as it can produce parts
with undercuts.
What will be Foseco’s main focus at
GIFA?
Foseco is going to feature the main
R&D areas in foundry technology. Energy
and resource efficiency can be significantly
improved by specific products
and technologies. Visitors may
look forward to our presenting innovations
in gating technology. We will
introduce a new technology allowing
virtually turbulence-free casting of medium-heavy
steel castings. In non-ferrous
metals treatment, we have long
been active in developing products
and processes for optimized melt refining.
At our booth we will showcase
new technologies for our FDU
and MTS equipment in combination
with innovative solutions for the metal
transport. Innovative coating and
binder systems will round out our exhibits.
Do you think there is potential for
the casting process to substitute any
of its competing manufacturing techniques?
Do you expect any new casting
solutions and new markets for
castings to occur?
We are in competition with hybrid
metal/metal and metal/plastics
components, with 3-D printing,
with high-performance machining
techniques, and with our traditional
“competitors” forging and welding.
We don’t see the new technologies
take over significant market
shares from the foundries or vice versa
during the next five years. However,
this does not mean that the new
technologies will not position themselves
in the market as solutions for
certain niche applications or applications
that require a very specific range
of properties. By further sophisticating
the technology of thin-wall casting
not only in pressure die casting
but also in iron and steel casting, the
foundries may open new application
opportunities. Also the development
of new casting materials and the further
development of existing ones
will provide new options. Generally,
due to the advance of e-mobility, we
will see a number of entirely new components
in the market, mainly made
of aluminium.
8 Casting Plant & Technology 4 / 2018