CPT International 02/2019

EDITORIAL
It’s Showtime!
The quadrennial innovation cycle is over at last, so foundrymen
and their suppliers from all over the world will meet again in
Düsseldorf for the world’s largest international foundry trade fair
from 25 - 29 June 2019.
Robert Piterek
e-mail: robert.piterek@bdguss.de
As usual, the interest is enormous:
about 900 exhibitors will be showing
their products at GIFA. And
there will actually be a total of about
2,100 exhibitors at the four simultaneous
trade fairs GIFA, METEC, THERMPROCESS
and NEWCAST. 78,000 visitors are also
expected, more than half of whom are
travelling here from abroad.
If we check out the developments
that have taken place during the last
four years we note that digitalization
and additive manufacture have grown
out of their infancy. This year’s Düsseldorf
trade fairs are paying particular
attention to these two technological
trends, because the increasingly sophisticated
sensor technology in the foundries
is generating more and more data on
production processes. Digitalization thus
simplifies and refines, for example, the
charge make up. And the constant availability
of production data enables realtime
monitoring of all important parameters
– in die-casting foundries and in
core shops (more about this from P. 10),
but also in some iron and steel foundries.
The evaluation of production data with
the help of algorithms will, sooner or
later, also make the identification of
faults conceivable before they even arise.
In short: the reason why digitalization is
a constant subject of discussions in the
sector is plain to see: it offers enormous
potential for improving efficiency, transparency
and quality. And equally affects
all the sectors represented in the quartet
of trade fairs – from the foundry sector,
through the steel industry, to the thermo-process
technology sector.
Additive manufacture, on the other
hand, has already developed into a sensible
expansion of business for some casters,
particularly with low batch numbers.
Molds and patterns are the main
products printed. The extensive use of
3-D printers already pays in invest ment
casting – and considerably accelerates
the production of some components.
GIFA visitors will find out more about
this at the special Additive Manufacturing
exhibition in Hall 3, at the specialist
3-D Metal Printing Conference on 26
June or in this magazine in an article
about 3-D printing and art casting from
P. 68.
When it comes to the outcome of the
trade fairs GIFA President Heinz Nelissen
is optimistic. In an interview with CPT
(from P. 34), he says that he expects a
“veritable explosion of innovations”. In
addition to his assessments, CPT’s GIFA
Special offers an article about recycling
in the foundry sector, a Hall Plan and the
GIFA News which offer a foretaste of the
new developments that will define
foundry operation in the coming years.
Have a good read!
CASTING PLANT & TECHNOLOGY 2/2019 3

CONTENTS
FEATURES
6 INTERVIEW
Creating value for our customers –
with innovative solutions
In an Interview with CPT, Dr. Jens Müller, Global
Head of Innovation at ASK Chemicals, gives a brief
outlook on the upcoming GIFA fair and describes
the importance of innovation for ASK Chemicals.
10 COMPANY
The core shop of the future
It is intended to become a benchmark for the sector
regarding digitalization, efficiency and networking
of plants and machinery: the new high-tech
core shop Inacore in Lower Bavaria.
Robert Piterek
16 COMPONENT DEVELOPMENT
GIFA-SPECIAL
GIFA- and NEWCAST
president Nelissen
expects a „veritable
explosion of innovations.“
COMPANY
In a new joint venture
two engineering
companies evolve
from supplier to
manufacturer.
Aluminum structural castings: integrated
development of component and process
A structural component for the AUDI A8 was awarded
first prize in the Aluminium Die-Casting Competition
at EUROGUSS – the work behind an award.
Klaus Vollrath
20 ENGINEERING OF FOUNDRY PLANTS
Foundry planning undergoing digital change
Companies are required to adopt a sustainable
orien tation of all units – including digitalization –
to create a modern factory.
Axel Edlich, Robin Freitag, Frances Barchmann
24 CLEANING, FETTLING & FINISHING
Fire and flame for metal casting
and processing
An innovative metal foundry in Austria shows how
mass finishing can contribute towards achieving
the customer’s desired surface quality.
Gerhard Franz Roth
COMPONENT
DEVELOPMENT
At DGS Druckguss in
Switzerland the
development of component
and process is
taking place in an
inte grated process.
GIFA Special:
Latest assessments on the
course of the trade show –
Trade fair plan – GIFA News
for product overview.
4

CONTENTS
CLEANING, FETT LING &
FINISHING
Mass finishing at Schösswender
Werke.
28 SIMULATION
Realistic simulation of the combustion
of exothermic feeders
The companies Flow Science and GTP Schäfer have
jointly developed a realistic simulation model of the
combustion of exothermic feeder systems.
Malte Leonhard, Matthias Todte, Jörg Schäfer
33 SPECIAL: GIFA 2019
GIFA 2019 – „A veritable explosion
of innovations!
Interview with GIFA- and NEWCAST president
Heinz Nelissen on the value of the upcoming trade
fairs for exhibitors and visitors.
Tremendous potential – environmental, economic
and social sustainability in foundries
Foundries are one of the best examples of resource
efficiency and sustainability. Because castings implement
the recycling concept almost completely.
Carina Hendricks
Hall plan
GIFA-News
62 COATINGS
Multitasking: Coatings for centrifugal
casting
Innovative coatings formulated for centrifugal casting
help to avoid casting defects, influence mechanical
parameters and even serve as a forming medium.
Klaus Seeger, Ekaterina Potaturina
68 3-D-PRINTING
COATINGS
The range of centrifugal
casting applications
increases – so
does the importance
of coatings.
3-D printing systems evolutionize
traditional art casting
Art foundry Strassacker creates artistic works using
3-D printing systems by voxeljet.
Frederik von Saldern, Peter Mühlhäuser
COLUMNS
3 EDITORIAL
72 FAIRS AND CONGRESSES/AD INDEX
74 PREVIEW/IMPRINT
CASTING PLANT & TECHNOLOGY 2/2019 5

INTERVIEW
6

“Innovations are crucial for success and
growth on both the customer and supplier
side!“
When it comes to innovation Dr. Jens Müller is the suitable
person to talk to at ASK Chemicals. At the fair the
company presents several interesting new developments.
Creating value for our customers
– with innovative solutions
Dr. Jens Müller, Global Head of Innovation at ASK Chemicals, gives in conversation
with CPT a brief outlook on the upcoming GIFA fair in Düsseldorf and describes the
importance of innovation for ASK Chemicals and the role of customers in the
company‘s innovation process.
Photo: ASK Chemicals
GIFA 2019 is just around the corner
and we are all eager to see what the
foundry industry will be presenting at
the industry‘s most important exhibition.
What new solutions can we look
forward to at ASK Chemicals?
A highlight at GIFA 2019 will certainly
be our latest solutions for 3-D sand
printing. Here we will present some
exciting developments both in the field
of organic binders as well as inorganic
binders. We will also present our new
Exactpore 3-D filter technology.
As a leading supplier of environmentally
friendly and employee-friendly
solutions, we will present new products
for this area, such as our latest innovation
– the low-formaldehyde system – a
package solution consisting of binder,
additive and coating that complies with
the stricter formaldehyde limits in
exhaust gas flow that will come into
force at the beginning of 2020. Of
course, that‘s not all. Visitors to our
stand can look forward to further innovative
products that improve technical
and economic performance.
What is innovative for you?
New offers that create high value and
are sustainable are innovative. Knowledge
is translated into values such as
performance, environmental compatibility
or cost savings. Ultimately, customers
and suppliers benefit from this
together. The value for the customer is
that he becomes more competitive,
while the provider of innovative solutions
invests part of the value created
in generating knowledge and developing
further innovation. Innovations are
therefore crucial for success and
growth on both the customer and supplier
side. An innovative product or
business model does not have to be
perfect from the very first minute, but
it has to generate enthusiasm with customers,
surprise them and, at least in
some aspects, offer more than they
expected.
As you say, innovation transforms
knowledge into benefit and ultimately
into value. Can you put this into concrete
terms?
The easiest way to illustrate this is
probably to use examples – such as
cold box binders, which are now standard
in the industry. When Ashland
(then the parent company of ASK
Chemicals) invented this technology, its
knowledge of polyurethane chemistry
converged with the automotive foundries‘
need for fast and reproducible
processes to produce sand cores. Then,
technology push and market pull
forces came together, and our customers
and we at ASK Chemicals benefit
from this innovation until this day.
Another example is the Inotec inorganic
binder system invented by ASK.
The anticipation of stricter environmental
guidelines resulted in a market
pull that our researchers combined
with the possibilities of silicate chemistry.
Without a close cooperation with
our customers‘ innovative thinking and
acting, this development would not
have been possible. Today, both our
customers‘ employees and the environment
benefit from this innovation.
What is the innovation process at ASK
Chemicals like?
Our innovation process consists of
three phases: In the first step, the creative
phase, we develop new
approaches. This is done, for example,
through trend analyses and evaluation
of new topics in discussions with customers,
sales, technical service, R&D,
suppliers and other internal and external
partners. This is primarily about
effectiveness, or “doing the right
thing“. This is a very important step,
because it is basically about “discovering
problems that need to be solved“.
In the second step, idea and project
management, the core assumptions of
the innovation approach, i.e. the technology
and the business model, are
tested. This is then about efficiency, or
CASTING PLANT & TECHNOLOGY 2/2019 7

INTERVIEW
“doing it the right way“. The projects
that also survive this selection process
– and these are usually only a few –
then enter the 3rd phase, the market
launch. At the same time, we aim to
have sufficiently clarified all uncertainties
critical to success at this point in
time in order to be able to convince
our customers of the intrinsic value of
the innovation.
What role does the customer play in
the process described?
ASK Chemicals puts the customer at
the centre. As already mentioned
above, it is about solving a customer‘s
problem or arousing enthusiasm. We
often use the so-called lead-user
method. This means that we try to
involve particularly innovative customers,
with whom we usually have a very
good relationship of trust, in the innovation
process. Our customers not only
contribute to the honing of our ideas
and projects, but are also the essential
litmus test for the value we want to
generate with innovation. In concrete
terms, this can also be seen in the
example of the development of our
low-formaldehyde (LFS) technology.
The customer is confronted with a
problem, namely a tightening of limit
values for formaldehyde in the exhaust
gas flow from 2020 (deadline applies
to old plants), which triggers a process
as described above. Ideas for solving
the problem are generated, initial preliminary
tests carried out and optimised
in an iterative process between
laboratory, test foundry and customer
to such an extent that at the end a
product package was put together
which demonstrably reduces formaldehyde
emissions in the drying oven by
more than 70 %. And this is exactly
what I see as an essential task of innovation,
namely the solution of a customer
problem.
What are the value drivers that ASK
Chemicals has identified for its innovation
activities?
We focus on three core areas that are
particularly important for our customers:
In the “Performance“ area, we
develop products that simplify,
improve or accelerate foundry processes
and thus offer our customers
cost and competitive advantages. In
the “Environment” area, on the other
hand, we have a clear focus on products
that comply with the environmental
regulations and rules to be
expected in the future today without
compromising performance. In this
way, our customers can already now
make their processes and investments
fit for the future.
It has always been part of our philosophy
to work closely with our customers
so that foundries can achieve
optimum results with our products. This
would not be possible without service
as a core element of our business
model. This is why we are also placing a
very clear focus on innovation in the
third area “Services“. In doing so, we
are now increasingly relying on digital
possibilities that enable us to support
our customers even faster and more
competently.
Mr. Müller, thank you for the interview!
8

YXLON – QUALITY ASSURANCE
AND PROCESS OPTIMIZATION
WITH CT IN DIFFERENT FLAVORS
Live at
GIFA 2019
Booth 11F24
YXLON MU60 AE, the universal industrial X-ray and
CT inspection system was designed for a broad
range of applications for foundries in the aerospace
and automotive industries. Compliant with the current
standards such as DICONDE, ASTM, MAI and Nadcap,
and equipped with ADR (automatic defect recognition),
it is the perfect At-Line inspection system for large
castings. The live demonstrations of both 2-dimensional
radioscopy and 3-dimensional computed tomography
will probably impress visitors due to the size of the
cabinet and the parts that can be inspected.
Inline Computed Tomography is the next step toward Industry 4.0, gathering comprehensive data about every
single object in production for reliable product quality and continuous process optimization. Yxlon provides
CT-Inline solutions for individual customer requirements. Equipped with cutting-edge detector technology, mechanics
that keep up with every production cycle, and based on the proven analysis software from Microvista, Yxlon
CT-Inline will raise manufacturing processes to a new level. At the Gifa trade fair, the solution will be introduced to
the public.
YXLON FF35 CT, the high-resolution industrial CT system
for small and medium-sized parts, is presented in its
latest version. The system is designed as laboratory
device to achieve extremely precise inspection results
for a wide range of applications. Available in a single
or dual tube configuration, it is perfect for most diverse
parts inspection in the automotive, aviation, electronics,
and material science industries. Based on the award-winning
software platform Geminy, FF35 CT provides best
inspection results for specialists as well as unexperienced
users. A brand-new detector, additional trajectories and
live filters increase the spectrum of parts and optimize
image quality even more. With the metrology version,
accurate measurements of objects’ inner structures
can reliably be realized.
www.yxlon.com

COMPANY
Photos: Inacore
The new Inacore core shop in Ergoldsbach is intended to set standards and increase the
potentials of core production.
The core shop of the future
It is intended to become a benchmark for the sector regarding digitalization, efficiency
and network ing of plants and machinery: the new Inacore core shop, a joint venture
between Laempe Mössner Sinto and R. Scheuchl GmbH. To manufacture more than
1.5 million core packages for engine production at the BMW light-metal foundry in
Landshut during coming years production began a year ago. Now three-shift operation
has also started in the Lower Bavarian town of Ergoldsbach to further increase capacity.
Robert Piterek, Düsseldorf
At the official opening of the
works in Ergoldsbach in late
September 2018 it was announced
that in future up to two thousand
vehicles with engine blocks produced
using Inacore cores were to roll off
BMW’s assembly line every day. The
BMW light-metal foundry in Landshut
had already been using inorganically
bound cores from Inacore for the casting
molds to produce the 4-cylinder
gasoline engines of the 3 and 5 Series
since early 2018. Construction of the
state-of-the-art core shop, costing double-digit
millions of euros, was financed
by the partners and banks.
Tight time window for construction
of the works
The countdown to start production
began when construction of the works
was initiated in mid-2017 in the industrial
area of Ergoldsbach. The plan was
that the first samples would be ready in
December 2017, and that delivery of
10

the first cores would take place as early
as January 2018.
In logistical terms, the site was well
chosen – it is only 19 kilometers to the
BMW core depot, for whose cores Inacore
is responsible. And Ergoldsbach is a
commuter town with few production
sites of its own. So the new, up to now
only, industrial company there offered
new career prospects, which were
rapidly grasped. Numerous employees
signed their contracts with Inacore
before the core shop had even started
work – more than 30 personnel are now
employed at Inacore. The new company’s
administration and its Research &
Development Department are accommodated
at the joint-venture partners
Scheuchl, Ortenburg, and Laempe Mössner
Sinto, Barleben (both Germany).
Highly automated and networked
production
Six fully automatic high-tech Type
LHL30 core-shooting machines from
Laempe Mössner Sinto are used to
secure BMW’s supply of core packages,
consisting of nine individual cores each.
The Managing Directors and partners Andreas Mössner (left) and Udo Dinglreiter are
also Managing Directors of the family-run companies Laempe Mössner Sinto and
R. Scheuchl GmbH.
The machines are used to shoot cooling
jacket cores, central cores and balance
shaft cores, among other things. Tool
changes can be carried out within a
few minutes. After shooting, industrial
robots from ABB do the deburring,
before employees carry out the final
quality inspection of the cores and
place them in racks equipped with RFID
chips. The racks – and thus the batch
CASTING PLANT & TECHNOLOGY 2/2019 11

COMPANY
production parameters stored in the
RFID chips – form the interface between
production, climatized storage,
and the core depot at the BMW works.
The production cycles and the associated
data can be called up in real time
using a computer or tablet, and can be
compared with old data. This is the
finest side of digitalization, delighting
the Inacore partners and Managing
Directors Udo Dinglreiter and Andreas
Mössner, and spurring them on to
make bold plans: “We are working
with the Chair of Mathematics at the
University of Passau on a multi-parameter
system controlled by artificial intelligence
(AI). We are right at the start
here, our long-term objective, however,
is that the AI learns to derive conclusions
from the data and will ultimately
prevent defects,” ex plains Udo Dinglreiter,
and Andreas Mössner adds:
“Machine and plant constructors have
to take Industry 4.0 into their own
hands.” Other technical possibilities
such as augmented reality (i.e. the computer-supported
expansion of perception)
and virtual reality could one day
be used for maintenance and servicing.
Training of the employees began
after the joint company was founded in
April 2017, parallel to construction of
the works in the industrial area of
Ergoldsbach. Intensive training was
undertaken at BMW because the personnel
had no specific core shop experience
at all. Laempe Mössner Sinto had
already started working on digitalization
in collaboration with the Pragmatic
Industries start-up in January 2017.
In view of the short time window
until production started, the partners
followed the principle of ‘learning by
doing’. The declared aim was to build a
core shop as a sector benchmark, and
thus uncover hidden potentials. The
tools for this were to be the possibilities
of consistent digitalization offering
transparency, networking and traceability.
“It is still uncharted territory,”
admits Andreas Mössner.
But in addition to the technology-driven
aspiration, a great deal of
expertise is necessary. Scheuchl exploited
its many years of experience in the
construction of the works infrastructure,
the air-conditioning and the project
management, while Laempe used
theirs for the machinery – from the
core-shooting plant, through the sand
mixer, to the sand conveyor system. The
partners installed the necessary plants
in two halls, to start with. Hall 1 accommodates
production with the six
Fully automated core production:
industrial robots take over
practically all the work steps
carried out after core shooting.
A finished core leaves the
core-shooting machine, in front
of which a robot is already
waiting.
core-shooting machines and the manipulators.
Hall 2 has the climatized storage
plant and the server, the raw
material depot, and the two sand silos
from the company FAT, in Niederfischbach,
Germany. A third hall is being
planned.
IT security is essential with so much
high-tech, otherwise the system would
face the risk of Trojans, hacking or overloading
attacks initiated by cybercriminals.
The partners invested about
100,000 euros on data security for the
server, and for a doubly protected security
system. Regarding IT security, Udo
Dinglreiter and Andreas Mössner are
confident that the data is not so easy to
interpret.
Sustainable air-conditioning
technology
Climate control is the sticking point in
the production of inorganic cores, and
determines their durability and functional
capability. The two family-run
companies selected a sustainable
approach: they use the waste heat
from the compressors to drive the sorption
rotors that regulate the temperature
in the climatized room. “The cores
harden in the core-shooting machine
and are then put in the climatized
room that is air-conditioned by the
waste heat,” explains Udo Dinglreiter.
In order to ensure transport from the
works to the BMW depot with an air
humidity of a few grams per cubic
meter, Inacore works with a special for-
12

After removal, a robot
deburrs the cores with
this tool.
External view of Inacore’s
works grounds:
only six months was
available for construction
and installation of
the equipment.
IT plays a decisive role
at Inacore. Not only in
the quality assurance
taking place here. Production
cycles and the
associated data can be
called up in real time
via computer or tablet
at any time.
Short-wave.
Also interested in really fast, rugged, light,
accurate, customised and inexpensive infrared
thermometers and cameras for non-contact
measurements between −50 °C to +3000 °C?
Visit www.optris.global
There’s no two ways about it:
our short wavelength infrared
cameras enable temperature
measurements of metal surfaces,
graphite or ceramics.
25.–29.06.2019
Visit us in hall 9,
stand A40
from
3150 €
warder who delivers the cores in airtight
trucks.
According to partner Andreas Mössner,
the decision to use sustainable climate
control technology was not taken
following purely economic points-ofview:
“We all have children, so sustainability
is the guard rail for an entrepreneurial
life. Where one can control
things, one does so; if it is also economical
then so much the better.”
2,000 core packages per day are currently
produced in Ergoldsbach, each
weighing 15 kilograms. 30 tonnes of
Innovative Infrared
Technology

COMPANY
sand is required every day – and it has
to be moved by pneumatic vessel conveyor:
from the sand silos to the sand
mixers which, as a result of the hall’s
infrastructure, had to be specially modified
so that they could stand on the
floor. Then the sand flows via more
pneumatic vessel conveyors to the
core-shooting machines in Hall 1. The
filling level of the silos will in future be
networked with the sand suppliers to
secure the sand supply to the silos at all
times. After hardening of the cores in
the core-shooting machines they are
transported to the climatized depot,
where nine different core types are stored
with the help of an ERP system.
Whereby expertise on the storability of
inorganic cores is also used and taken
into account when selecting the storage
spaces. In view of the sensitive climatizing
situation the depot at Inacore is
not only monitored by the company’s
own team – there is also real-time networking
with the BMW depot, resulting
in transparency on both sides, intended
to optimize production reliability and
collaboration.
The partners also consider quality
very important: they have invested
more than 200,000 euros in quality
assurance equipment. This includes a
laboratory core-shooting machine for
determining sand quality, the quality of
the mix, and core breaking strength, as
well as a measurement system by Zeiss,
Oberkochen, Germany, with which,
among other things, measurements are
carried out as proof provided by the
supplier for the customer. The sand
grain size is also determined in the
laboratory. The average grain size at
Inacore is 0.32 micrometers. There is
also a small furnace available for moisture
measurement.
Employee discussions in the production hall. More than 30 personnel are currently
working at Inacore.
Inacore to increase process
understanding
Production could start in Ergoldsbach
shortly before the sampling took place
in early December 2017. 30 core packages
were sent off to BMW punctually –
and they met the carmaker’s requirements.
The gambit had worked, and
machine and plant constructors
R. Scheuchl GmbH and Laempe Mössner
Sinto had become core-makers. The two
partners deliberately exceeded their traditional
business fields in machine and
plant construction in order to gain operator
expertise. “The demands have
increased; process understanding is
required nowadays. How can one plan
plants without understanding the
details?” asks Andreas Mössner, adding:
“We want to understand the daily activities,
and thus also improve the machines.”
Another motivation for the investment
by Laempe and Scheuchl, however,
was undoubtedly to win the order
from BMW. But the new company does
not want to be dependent on a single
OEM so it is currently acquiring more
customers for the high-tech core shop.
All those involved in the new company
are confident about its future
pros pects, as became clear during the
opening ceremony in September 2018.
The founders of R. Scheuchl GmbH
attended, alongside high-ranking guests
from the worlds of politics and commerce.
Finally, the BMW team was also
screened in the production hall. The
men in the BMW waistcoats were showing
solidarity with the Inacore team –
and were thus also celebrating an exemplary
collaboration between supplier
and customer.
www.inacore.de
14

FOUNDRY –
A PASSION FROM
OUR HEART.
DR. CHRISTIAN APPELT, GLOBAL BUSINESS MANAGER INORGANICS
“COURAGE AND
CREATIVITY FOR
INNOVATIVE
SOLUTIONS”
Emission-free binder systems for productive applications.
Meet us at GIFA 2019:
Hall 12, Booth A22
The development and implementation of emission-free binder systems in large-scale production
of metal castings is a key concern of modern foundries. Our product solutions surpass the
ecological and economic requirements of conventional and additive manufacturing processes.
With INOTEC TM and INOTEC TM 3D technology we are driving the most efficient and green
foundry applications today.
www.gifa.ask-chemicals.com
CASTING PLANT & TECHNOLOGY 2/2019 15

COMPONENT DEVELOPMENT
Photo: Audi AG
Die-cast components produced by DGS Druckguss Systeme from St. Gallen.
Aluminum structural castings:
integrated development
of component and process
The work behind a casting award
Klaus Vollrath, Aarwangen, Switzerland
On the occasion of the Euroguss
2018 trade fair in Nuremberg, on
15 January 2018, the German
Association of the Aluminium Industry
awarded first prize in the Aluminium
Die-Casting Competition to a casting
jointly developed by AUDI AG and DGS
Druckguss Systeme AG, St. Gallen, Switzerland.
The large and extremely
thin-walled structural element developed
for the new Audi A8 has a wall thickness
that is mostly only 1.8 - 2 mm, and it
there fore only weighs 3043 grams, despite
dimensions of 797 x 437 x 304 mm.
Just as interesting as the component itself,
however, is the development that lies
behind it, as a conversation with Markus
Heim, Key Account Manager, and Axel
Schmidt, Technology Manager at DGS,
reveals.
“What was special about the development
of the new component for the
Audi A8 was the integrated development
both of the product itself and the production
process, in close collaboration
with our customer Audi,” explains Markus
Heim, Key Account Manager at DGS
Druckguss Systeme. Audi took the decision
to approach this project together
with DGS at the end of 2015, after DGS
made an appropriate offer. The component
is a large but very thin-walled structural
casting that connects the C- and
D-pillars of the new Audi A8 (Model D5).
The structural element also redirects the
safety belt and supports the rear damper
strut via three threaded rings, as well as
accepts the parcel shelf, rear panel and
the hinge of the tailgate. Additional
requirements included as low a weight as
possible compared to the element previously
used, necessitating low wall thicknesses.
The prerequisite for this was the
use of a special high-strength alloy in
combination with a new heat treatment
process. Audi had already begun developing
this new type of alloy (AlSi10MnMgZnZr)
in 2011/2012. In addition to the
material, it was also essential to implement
an evolutionary modification of
the heat treatment process. Trials were
16

Photos: Klaus Vollrath
carried out in close collaboration with
DGS Druckguss Systeme, which invested
in the plant technology necessary for the
heat treatment.
The material, with a yield strength
(R p0.2
) of 180 - 210 MPa at elongation
values of > 7 %, is described in an internal
Group standard. The test program
for qualification of the component was
extremely extensive, ranging from the
die-casting of test panels for the usual
castability and strength experiments to
the production of real components for
test drives and the determination of
their suitability for the most varied of
joining processes – such as welding,
self-piercing riveting, flow-drilling
screws, gluing and MIG welding.
Development of the
casting process
“The process necessary for producing
thin-walled castings was also specially
developed for the new material,” adds
Axel Schmidt, Technology Manager at
DGS. Simulation programs were extensively
employed during development. This
not only involved the complex geometry/
strength testing as well as the design of
the casting system and mold temperature
control, but also the heat treatment
– because the component’s thin walls
make it highly susceptible to warpage.
Audi was able to make a considerable
contribution towards component tolerance
thanks to its pioneering work in
the field of warpage simulation.Where by
important target criteria were the determination
of the optimum course of the
temperature over time and the method
for storing the castings on special heat
treatment racks. In this connection, a
specific Audi test tool was created as a
thin-walled casting tool. The component
cast in the test tool already had dimensions
of 650 x 650 x 300 mm. The production
of smaller serial parts for the Audi
R8 was another preliminary step.
Advantages of the improved
component
“The main advantages of the newly
implemented component are, above all,
a weight reduction of 19 % and a 50 %
increase in strength (R p0.2
) compared to
the component with the same functions
used in the previous model,” explains
Markus Heim. This was achieved by
means of a weight-optimized design
with thinner walls using the new highstrength
and easy-flowing alloy in combination
with a T6 heat treatment. On the
The fully automated die-casting cell
with dosing furnace, extractor robot
and punch.
Each casting is already provided with an individual
data matrix code in the die-casting
cell, enabling access to all the data regarding
its process and quality parameters.
one hand, this requires a complex
stress-optimized wall thickness and rib
distribution and, on the other hand,
complicated optimization of the casting
process and the molding technology
CASTING PLANT & TECHNOLOGY 2/2019 17

COMPONENT DEVELOPMENT
employed. The latter point involves the
use of mold components with cooling
channels that are produced in a 3-D printing
process, and optimization of the
ejectors regarding their number, diameter
and positioning. This permitted a
15 % reduction in the average wall thickness,
which is only between 1.8 mm and
2.0 mm in large areas of the component.
Verified high-tech process chain
“A striking feature of the production
process is the complete traceability of
the entire quality history for each individual
casting,” reveals Axel Schmidt.
This starts as early as the casting cell,
where the component is laser-printed
with an individual data matrix code
after casting and deburring. This allows
allocation of all quality-relevant process
and test parameters throughout the
entire process chain right up to the
packaging and dispatch data. The code
is scanned-in before each process step
and inspected for completeness and
matching of the specifications. The next
processing step is only approved when
the computer confirms that everything
is in order so far. After the stamping
process, the components pass through
the above-mentioned T6 heat treatment
on special racks that prevent any
warpage, and are then polished and
aligned. All further transport processes
also take place in special racks, which
also carry a data matrix code. The code
of each individual casting is scanned
during insertion and allocated to the
rack. This complete traceability concept
was implemented internationally with
Audi – also in the DGS works in the
Czech Republic and China.
Robot processing cells
“Processing takes place in two completely
enclosed robot cells that are mirrored
for reasons of redundancy,” says
Heim. The components are pushed into
the cells on the racks before being individually
removed by the robot. First there
is an inspection, during which the data
matrix code is scanned-in and the correct
heat-treatment state is checked with the
help of a special eddy current process to
determine electrical conductivity. Threaded
inserts are placed in the tap holes
after mechanical processing. Whereby
appropriate inspection processes ensure
that the slugs required for screwing-in
are also reliably removed after the subsequent
breaking off. This prevents any
delay, which could cause difficulties
during subsequent processes. After completion
of the processing, the robot
A view of the fully automatic
cell for processing
the casting, including
insertion of the thread
inserts.
After the casting has
been put down, the
screen delivers all the
data for assessing component
warpage.
18

Left: Fully automatic
plant for heat-treating
the deburred castings.
On the left, the
special racks that are
designed to prevent
warpage.
Right: The castings in
their racks pass
through numerous
pools in the wash and
passivation plant.
Electric driverless
forklifts automatically
transport full and
empty racks for the
castings from station
to station.
replaces the part on the rack – which is
then transported to a fully automatic
wash and passivation line with successive
baths. Some internal transport within the
foundry is carried out by electric driverless
forklifts that drive backwards and
forwards between the stations without
collisions. The final step of the process
chain is the packaging line where employees
manually insert the parts into
Audi-specific transport con tainers. Scanning
of the data matrix code again ensures
that only ‘in order’ parts are
dispatched, and that each part is precisely
allocated to its transport container.
Swiss reliability during
the development and supply
of castings
“This project underlines that we can
ensure a reliable worldwide supply of
high-tech die-cast components for our
partners in the automotive industry,”
sums up Axel Schmidt. In addition to the
jointly implemented component and process
development, DGS also largely designed
and implemented the necessary
plant technology itself. One thus proves
oneself to be a competent partner who
can be trusted with the highly reliable
supply of high-tech components on a
worldwide basis. Naturally, DGS also had
to, and could, take into account the price
expectations of the customer during this
project, otherwise the collaboration
would never have been possible. He is, of
course, particularly pleased that this
development was awarded first prize in
the die-casting competition at Euroguss
trade fair in 2018. This is also an incentive
for proving that European companies
still have plenty of inventive spirit
and technical perfection for successfully
asserting themselves in worldwide competition
on demanding markets.
www.dgs-druckguss.com
CASTING PLANT & TECHNOLOGY 2/2019 19

ENGINEERING OF FOUNDRY PLANTS
Photo: Hörmann Rawema
Foundry planning
undergoing digital change
Digital factory planning is an increasingly
important element for modern
production companies.
The demands made of products, processes and technologies are constantly rising in this
era of digitalization, and require companies to adopt a sustainable orientation of all
units to create a modern factory. The focus is on a general acceleration and parallelization
of processes in planning, implementation and operation.
Axel Edlich, Robin Freitag, Frances Barchmann, Chemnitz
The varied and high demands
made of today’s products and
their industrial production inevitably
necessitate structural changes
with in factories.
Megatrends change the factory
of the future
A few so-called megatrends have
developed regarding how to create the
required conditions in foundry and corporate
planning.
Digitalization along the value stream
Systems such as sensors, robots and
virtual reality can become useful
(Figure 1) as a result of digitalization.
These technical solutions can be combined
and holistically represented in a
model with the help of a digital twin.
The networking of systems in the wake
of digitalization allows, for example,
the constant monitoring of machine
and plant states, and the provision of
warnings before potential breakdowns.
Robots are working increasingly
closely with humans within production
or logistics – increasing quality
and efficiency.
Light construction
Light construction is one of the key
technologies of the future because, in
addition to weighing less, such products
also offer improved properties. In this
connection, the conservation of resources
and material has an important status.
So not only are the materials undergoing
constant further development,
20

ut also the design, joining and production
technologies.
Automation
Production processes and information
technologies interact closely with one
another nowadays. Products, production
plants and operating materials can
be networked with one another due to
their automation – and thus react more
intelligently and faster to improve processes
in real time. This reduces operating
costs and counteracts the shortage
of skilled labor. Lean, flexible and sustainable
production is vital for
safeguard ing future competitiveness.
New business models and market
participants
The digital transformation is subjecting
companies to more rapid change than
has ever been experienced before.
Whereby rigid corporate structures
must be disrupted and transformed.
New business models should be universally
coordinated and aligned upon the
digital changes, while reflecting a company’s
core competences.
In the global information age, information
and knowledge are available
rapidly anywhere and at any time.
There is thus global competition for
Figure 1: The use of a digital twin can
support the work of employees in factories
with, for example, sensors, robots
and virtual reality.
products, processes and services, as well
as resources. Individual customer-specific
products are increasingly forcing
themselves into the spotlight, so it is
important to create innovative products
and services. But factors such as the
alignment of the entire value creation
chain, and the search for cooperating
partners and additional competences,
involve important fundamental decisions
that must be made.
Changes in skills profiles and
personnel requirements
The requirements for personnel and
their skill sets will change a lot in
future. Companies increasingly require
skilled employees with a comprehensive
knowledge of IT, as well as an awareness
of process, production and logistical
structures. Specialists will be needed
with a deep understanding of planning
and the implementation of complex
interactive data-based work processes.
The digital transformation will therefore
not only lead to employees being
supported by machines and robots, but
also to new jobs with new qualification
requirements.
All these megatrends have profound
effects on the development of products
and processes within the factory. The
upcoming changes should be exploited
as opportunities to fundamentally
shape the company of the future and
thus meet new paradigms. From the
factory planner’s point-of-view, the
planning methods will remain the same
– only the content, structures and markets
will be different. Whereby the
objective will be to plan the factory of
the future in such a way that it operates
highly efficiently, its products and processes
are self-monitoring, short delivery
times can be guaranteed, and production
waste and rejects are reduced
to a minimum.
Digitalized processes in the
foundry
Corporate processes are continuously
being permeated by the technologies of
digitalization – so the cycles of production
factories are also changing. New
technologies must be integrated into
the company’s own solutions in order to
cope with this change. Whereby the
existing value creation chain, and all
CASTING PLANT & TECHNOLOGY 2/2019 21

ENGINEERING OF FOUNDRY PLANTS
Figure 2: The simulation model of a
production plant.
the processes within it, must be expanded
and adapted to achieve the goal of
an efficient factory. In this regard, it is
also vital to constantly keep up with all
the new and relevant developments
and, if necessary, implement them. The
following tendencies can be seen in
individual corporate processes:
Sales
The age of digitalization opens up new
possibilities for sales because the focus
is on individual customer requirements.
Central data management plays a major
role in core tasks – such as the registration
of enquiries, costing, and the preparation
of offers – by centrally and
digitally administrating all the important
customer and product data, and
enabling consistency of the information.
It is therefore possible to offer
customers tailor-made solutions whose
details are adapted to their specific
needs. The use of product lifecycle
management systems also provides
further advantages.
Material procurement and storage
The monitoring of warehouse capacities
and stocks, as well as the associated
material planning and procurement,
can change fundamentally and also
affects supplier management. Material
lists can, for example, be generated
using existing 3-D models of the components
and variants. An intelligent and
automated stock monitoring and ordering
system shortens delivery times and
procurement processes. Fully automated
storage systems and automated guided
vehicles are increasingly being
used, saving space and time – and thus
costs.
Production
Digitalization enables the automation
of many production processes, the comprehensive
tracing of products, and the
allocation of certain post-processing
steps. More and more processes will in
future be monitored and evaluated via
sensor or radio-frequency identification
(RFID). Errors and defects can be more
rapidly detected and corrected by
means of monitoring during production,
with the aim of minimizing production
problems and downtimes.
Interdisciplinary processes
In addition to the core processes of molding,
melting, casting and machining,
there are interdisciplinary processes
that are positively influenced by digitalization.
These include, for example,
pattern construction and storage, an
area that is subject to high customer
requirements. Storage and transport
can be supported by automated logistics
and intelligent component tracing
in order to increase process transparency.
The state-oriented maintenance
(condition monitoring) of plant technology
is also being used increasingly in
foundries. It is very important to be
able to predict a breakdown before it
happens – damaging the plant technology
and causing long downtimes – particularly
with automated processes and
interlinked plants.
Work preparation
Pattern designs are created during work
preparation, followed by material
requirements planning and, on this
basis, process planning including
machine utilization. The use of new
technologies such as planning in 3-D,
simulation tools (Figure 2) and virtual
reality allows process and value stream
analyses to be carried out before initial
operation. This enables an examination
of work stations and their safety, as
well as comprehensive planning and
documentation, to be carried out
before implementation.
Figure 3: A three-phase model is
used in factory planning.
22

Potential solutions in foundry
planning
Different demands are made along the
value creation chain at all the above-mentioned
areas. When these are
implemented, a linear unstructured production
flow can be transformed into a
circular networked production site. This
makes new demands of factory and
production planning, to which factory
planners such as Hörmann Rawema
Engineering & Consulting GmbH react
by using a variety of tools and methods
(Figure 3). 3D laser scanning, material
flow simulation and virtual commissioning
are used here, for example. As a
result, a variety of planning variants can
be examined in a short time, significantly
increasing planning security. For
customers this means a considerably
lower level of risk in implementation,
and the prevention of potential follow-up
costs. In addition, the visualization
and dynamic representation of processes
increase the comprehensibility
and transparency of the planning solution.
The methodical, structured and
holistic approach towards planning is
intended to ensure the provision of
solutions that are as sustainable and
efficient as possible, and that meet the
aspirations of future factories in the
context of global competition.
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CLEANING; FETTLING & FINISHING
Photo: Thomas Topf
Successful technological partnership: Leopold Haubenberger,
Sales and Project Manager at Rösler (left) with
Martin Gaugusch, Project Coordinator Vibratory Finishing
at Schösswender, beside the pilot plant for vibratory
finishing.
Fire and flame for
metal casting and processing
An innovative metal foundry in Austria’s northernmost town shows how mass finishing
can contribute towards achieving the customer’s desired surface quality in the 21st century
– with a lot of initiative and a committed technology partner.
Gerhard Franz Roth, Vienna, Austria
The Litschau town council in the
Gmünd district is famous for
being the northernmost town in
Austria and a forest health resort. The
path between tottering rocks, thick
forest and idyllic hills leads directly to
S. Schösswender Werke. The company
has proved that one can make the transition
from down-to-earth metal casters
to internationally renowned cast-iron
technicians for aluminum and copper
alloys. Founded in 1959 – specializing in
metal door fittings, locking plates and
door handles – the company and its 68
employees has developed into a specialist
for industrial castings and cast components
for the rail vehicle industry
worldwide. This is demonstrated by its
well-known customers and its orders
from the USA, Asia and Europe.
From small quantities to serial
production
Schösswender expanded gradually:
after concentrating on small quantities,
the first CNC machine was purchased
twenty years ago. Today the
24

foundry is busy working with eight
CNC machines and ten melting furnaces.
Mass finishing technology is used
to deburr castings, initially with two
plants from Tauss that have been successfully
doing their job for fifty years
– and are still doing it. “We commissioned
Rösler Oberflächentechnik to
modernise the plants,” Martin Gaugusch,
Project Coordinator Mass
Finishing at Schösswender, recalls his
first contact with the subsequent technology
partner. “And then we gave
Rösler an order to build us a completely
new mass finishing plant for aluminum
alloy castings.” And this resulted
in a very innovative, but also
personal, business relationship between
Martin Gaugusch and Leopold
Haubenberger, his Sales and Project
Manager at the Rösler branch in
Vienna. The specialists in surface technology
are headquartered in Bad Staffelstein
in Franconia, Germany.
It’s simply better when it’s
personal
How did the cooperation come about?
Leopold Haubenberger puts it down to
competence: “We are the number one
worldwide for mass finishing plants.”
Robert Halke, Team Leader for Marketing
at Rösler, adds: “Customers are sold
a process, not the machine.” And
Schösswender was looking for just such
a partner for the new mass finishing
plant, stresses Gaugusch: “At Rösler
everything comes from a single source,
they buil d whatever the customer
needs.” In addition to examining the
existing plants, Rösler set up a complete
pilot plant for Schösswender that met
its customer’s personal wishes. “The
results of the trial clinched the sale,”
Halke sums up the strong argument in
favor of cooperation. “One always has
to test vibratory finishing in reality, not
just on paper.” They also offer a wide
range of grinding bodies, the be all and
end all of vibratory finishing. “We have
a portfolio that includes 8,000 grinding
bodies,” says Haubenberger, not
without pride, “and we find what fits
economically and technologically.” Even
the peripheral equipment and conveyor
belts come from Rösler. They have been
developing grinding bodies for more
Greater than the sum of its parts
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CLEANING; FETTLING & FINISHING
than 60 years, with geometries that
now range from 0.5 to 60 mm.
From the trial to the purchase
The new R425/4600DA continuous-flow
vibratory grinding plant from Rösler has
been in successful operation at Schösswender
since January 2018 in a completely
enclosed sound-insulating cabin,
with care and maintenance constantly
available from the producer. “The two
companies have been working together
for twelve years now,” Gaugusch praises
S. SCHÖSSWENDER WERKE
As one of Austria’s leading metal casting
and processing companies,
Schösswender sets worldwide standards
for high-quality cast-iron
developments and solutions – from
batch size one to mass production;
through design consulting, casting
simulation, the hardening of aluminum,
and X-ray inspection; to prototype
construction and surface treatment.
The company, based in
Litschau, focuses on the rail sector,
responsible for more than half of the
company’s sales.
www.schoesswender-metallguss.at
the partner company. “Leopold Haubenberger
comes round within a few days of
receiving a message.” Further development
of the consumables, as well as the
water supply and output, are the main
topics that are discussed again and
again. “The plant must be well set up in
process terms – then it covers the costs,”
adds Robert Halke from a marketing
point-of-view. “The topic of waste water
is also important, both ecologically and
economically.” In continuous flow systems,
after CNC machining vibratory
finishing frees the cast aluminum components
of burrs and structures that are
not part of the component. “The plant is
currently running in one-shift operation
but we could use two-shift operation,”
Gaugusch stresses the capacity reserves.
“Due to intensive automation, one
employee is sufficient to operate the
plant.” Only slots and the insides of
threads are still manually deburred, but
all the exterior burrs are removed
mechanically with the grinding bodies.
Worldwide focus on railway
vehicles
The R425/4600DA is fully automatic: the
parts are inserted and, depending on
the casting material, vibratory finishing
takes place using plastic grinding
Including regular support from the producer:
the new continuous flow vibratory
grinding plant has been in successful
operation in a completely enclosed
sound-insulating cabin at Schösswender
since January 2018.
Even the peripheral equipment and conveyor
belts come from Rösler. They have been
developing grinding bodies for more than 60
years, with geometries that now range from
0.5 to 60 mm.
bodies, water is added containing a
chemical treatment agent (so-called
‘compound’), and the finished parts are
transported out again dry and deburred.
“In the sound-absorbing enclosure,
26

the mass finishing system can deburr
components of all shapes with sizes of
up to 20 x 20 x 20 cm³, mainly made of
aluminum alloys for railway vehicles,”
Leopold Haubenberger emphasizes the
flexibility benefits of the plant from
Rösler. Above all mountings and bearing
blocks for doors, but also parts for
brakes and emergency actuation on
trains and trams, are deburred here.
“For instance for subway trains in many
major cities worldwide,” Martin Gaugusch
provides an example. The optimum
process adjustment can be seen
from the consumption of grinding
bodies: “We only need 75 kg of grinding
bodies per month now,” calculates
Patrick Eggenberger, responsible for the
vibratory finishing machine. “The parameters
are individually set for each
deburring process, for example bearing
components on train doors.” Whereby
the throughput time and input cycle of
the parts are determined, i.e. how long
the machine should run for. The throughput
time varies between 10 and 20
minutes, depending on the part. “For
small parts, for example, input can also
take place every few seconds,” Martin
Gaugusch knows from experience.
“Parts that are still visible after installation
need a longer throughput time
because they require more accurate
deburring – for aesthetic reasons and a
nice feel.”
www.rosler.com
After vibratory finishing of the aluminum
components, the grinding bodies are
transported upwards again via a conveyor
channel and returned to the circulatory
system.
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SIMULATION
Photo: GTP Schäfer/Flow Science Deutschland
Course of the burning process in exothermic feeder sleeves. Comparison between reality and the simulation.
Realistic simulation of the combustion
of exothermic feeders
Exothermic feeder sleeves are increasingly being used in iron casting and are now the
most commonly used type of feeder system. Simulations have hitherto only described
exothermic feeders using simple analogous models that use the release of a defined
energy over the entire volume. The companies Flow Science and GTP Schäfer have jointly
developed a model that enables realistic simulation of the combustion of exothermic
feeder systems. With the help of casting trials it has been possible to show that the deviations
of the simulation results from the test results lie within the range of measurement
accuracy.
Malte Leonhard, Matthias Todte, Rottenburg, and Jörg Schäfer, Grevenbroich
The use of feeders is generally unavoidable
in gravity casting, but
often represents a conflict for
designers: the dimensions and number
of feeders should be large enough to
reliably prevent shrinkage cavities, but
the feeder weight should be minimized
to reduce energy and processing costs,
as well as recycled material, as far as
possible. The rising complexity of castings
further increases development
demands. Highly exothermic feeder systems
have become increasingly important
because they are more space-saving
and efficient than traditional natural
sand feeders.
Feeder systems can be divided into
two types: with insulating or exothermic
feeder materials. In the case of insulation
feeders, the solidification time of
the melt in the feeder is lengthened by
means of a feeder body whose thermal
conductivity is considerably lower than
that of the mold material. The melt thus
remains liquid for longer and is available
to the junction to compensate for
shrinkage. Reduction of the size of the
feeder can be achieved by using an exothermic
cap material. As a result, there
is an exothermic reaction of the cap
material when the ignition temperature
has been exceeded. The melt is warmed
by the heat that is released and thus
remains liquid for longer [1]. Exothermic
feeder systems are therefore very efficient,
and can supply the casting with
liquid melt for longer with less volume.
Whereas the simple formulae of geometric
modulus calculations were used
in the past, casters can now exploit casting
simulations that can predict the
thermic module and solidification mor-
28

State of the art
Exothermic feeder materials contain,
among other things, aluminum and iron
oxide. These react strongly exothermically
because the aluminum has a higher
affinity to oxygen than iron does.
Aluminum oxide and iron are produced
when iron oxide and aluminum react,
generating a lot of heat (aluminothermy,
or the Goldschmidt Process).
Fe 2
O 3
+ 2Al → Al 2
O 3
+ 2Fe (1)
Figure 1: Test setup to examine the burning behavior of exothermic feeder materials.
Photo: GTP Schäfer/Flow Science Deutschland
phology, among other things, and are
thus helpful for feeder design. Simulations
are an effective tool for finding
efficient solutions, particularly regarding
the selection and dimensioning of
appropriate feeders. The growing
demands made of digital design and the
use of casting simulations have been
addressed again and again, and the
methods have meanwhile become a
fixed component of most development
processes in foundries. The numerical
description of natural and insulating
feeder systems is accurate, and
dependable results can be achieved. The
models for using exothermic feeder systems,
however, have so far been unable
to predict processes accurately enough,
leading to over-dimensioning of the
feeder in practice – and thus to uneconomical
solutions. The motivation to
depict the burning behavior of exothermic
feeder materials as accurately as
possible in simulation programs is high
because exothermic feeders are now the
most commonly used feeder variant in
iron casting. The model developed
jointly by GTP Schäfer, Grevenbroich,
and Flow Science, Rottenburg (both
Germany) now makes it possible, for the
first time, to accurately describe the burning
behavior of the feeder cap, i.e. the
chronological and spatial course of the
release of energy in the cap.
This reaction only gets going above a
particular ignition temperature – which
the feeder material reaches as a result
of the melt filling the mold. In most
feeder systems the exothermic material
burns radially outwards from within the
feeder. The burning time depends on
the feeder sleeve geometry and the
specific combustion speed of the material.
There is constant development of
further variants and combinations of
feeders, for example hybrid feeders like
the Eco series from GTP Schäfer, consisting
of a combination of insulating and
exothermic materials.
Exothermic feeder systems have up
to now only been simply depicted in
simulation programs, with the entire
sleeve volume being assigned an energy
content that is constantly released
during a defined burning time. It is
already difficult enough for users to
determine the energy content, but it is
even more difficult to define a burning
time because, as previously explained,
this depends on the feeder geometry.
This simplified form of modelling can
potentially lead to major deviations of
the simulation results from reality – and
consequently to over-dimensioning of
the feeder. The fact that the material
properties also vary in the unburnt and
burnt states has hitherto not been
taken into account in foundry simulations.
Photos: Flow Science Deutschland
Figure 2: Simulation of the burning behavior of exothermic test bodies.
CASTING PLANT & TECHNOLOGY 2/2019 29

SIMULATION
Figure 3: Positions of the thermocouples in the real casting trials.
Temperature [°C]
1200
1000
800
600
400
200
Standard deviaon TE1
Standard deviaon TE2
Standard deviaon TE3
Standard deviaon TE4
Standard deviaon TE5
Simulaon TE1
Simulaon TE2
Simulaon TE3
Simulaon TE4
Simulaon TE5
0
350 550 750 950 1150 1350 1550 1750 1950 2150
Time, s
Figure 4: Comparison of measured temperature curves with the simulation results.
Figure 5: Representation of the burning behavior of exothermic feeder sleeves: Left: Start of
the exothermic reaction, Middle: Combustion of the exothermic feeder, Right: ‘Afterglow’ of
the feeder material.
Experimental investigations
GTP Schäfer started by carrying out
measurements of the thermo-physical
properties in order to obtain data on
exothermic feeder materials. Whereby a
sample with a defined energy per time
unit was heated and the material properties
continuously determined. One
difficulty during these measurements
was the high level of dynamism caused
by the exothermic reaction. As soon as
the ignition temperature is reached, the
material burns up autonomously – and
no longer follows the temperature of
the measurement system. So it was only
possible to reliably determine the material
properties in the unburnt state
during these experiments. Therefore
the combustion behavior and material
properties during and after burning
were initially inaccurate or unknown.
So it was necessary to examine the
burning behavior with more precision.
For this purpose, an experimental setup
similar to that in the German Foundrymen’s
Association (VDG) Specification
P81 on the testing of exothermic materials
[2] was selected (Figure 1). Two test
pieces (D = 50 mm, H = 50 mm) were
made for the experiment using exothermic
material, and one was placed on
top of the other. The lower test piece
was ignited and the burning behavior
of the two samples investigated. This
setup allowed good observation and
understanding of the progress of the
combustion process. Then the chronological
and spatial course of the burning
behavior was compared with the simulation
model (Figure 2).
Real casting trials in furan sand
molds were then carried out after the
investigation of the burning behavior
of the test bodies. The effort required
for these experiments turned out to be
considerably greater than anticipated.
But it was shown that the burning
behavior of feeders within sand molds
differs substantially from that in ambient
air. This difference can be explained
by the fact that only a limited amount
of oxygen is available for the exothermic
material within a sand mold. During
the casting experiments, exothermic
feeder sleeve in a furan sand mold were
filled with melt and the temperature
curves were determined. For this purpose,
separate thermocouples were
positioned in the exothermic material,
the molding sand, and the melt in order
to determine the temperature changes.
One thermocouple was placed within
the melt in the feeder. Two more were
located in the sleeve, and two in the
30

Figure 6: GTP Schäfer feeder database within the Flow 3D Cast software.
molding sand (Figure 3). The sleeve was
filled with molten GJS 400 iron for the
measurements.
The measurements were carried out
repeatedly to provide high reproducibility
and temperature curves that would
be as conclusive as possible. The tests
were repeated with three different cap
sizes with a thermal module of 0.95 cm,
GIFA 2019
Hall 16
Booth F11
- NEW MONITORING SYSTEM
THOR V4.0
CASTING PLANT & TECHNOLOGY 2/2019 31

SIMULATION
Figure 7: Casting clusters with different feeder sleeves: left: Insulating feeder material,
right: Exothermic feeder material.
1.5 cm and 2.7 cm. They were intended
to include as many different factors as
possible (e.g. differing measurement
positions, materials or densities) and the
simulation model was examined with a
large geometric bandwidth. Standard
deviations were calculated from the
recorded temperature curves and compared
with the measurement values of
the simulation results (Figure 4).
It was possible to show that the
temperature curves of the simulation
results mostly lay within the calculated
standard deviations. It could therefore
be derived that the deviations of the
temperature curves between the simulation
and the experimental results
were within the measurement accuracies
and, furthermore, that the implemented
model of exothermic feeder
sleeve behavior was accurately represented.
The new model
The Flow 3D Cast model is intended to
reflect reality as precisely as possible.
Therefore the feeder is not treated as a
complete exothermic volume that
behaves identically everywhere, but
instead each cell of the computational
grid is treated separately. The exothermic
reaction is triggered as soon as a
grid cell of the feeder reaches the ignition
temperature, and heat is released
according to a calculated function. The
temperature of the cells increases and
heats the neighboring cells as in a
chain reaction, so that they also reach
their ignition temperature. In this way
a realistic combustion behavior is
shown within the feeder sleeve. After
the exothermic reaction has taken
place, the properties of the feeder
material change and there is then an
insulating effect. The material properties
of the feeder sleeves for each cell
were also adapted to the level of combustion
in the simulation. Thus the
thermo-physical properties of the
unburnt and burnt material vary,
having a further effect on temperature
distribution during the combustion of
the exothermic material. The different
stages of the combustion process are
shown in Figure 5. The feeder insert
starts the exothermic reaction when
the melt has raised the material to
above the ignition temperature. Then
the material burns autonomously and
releases heat that warms the melt.
After the exothermic reaction has finished,
there is an ‘afterglow’ as a result
of the insulating properties. The high
temperature of the exothermic reaction
can therefore be retained, and the
feeder can supply liquid melt to the
casting for a long time.
A major added value compared to
previous definitions is that a material,
all of whose parameters are known, can
be laid down in the database with
general validity. Unknown values, such
as the burning time of the entire sleeve,
come up autonomously during simulation.
A feeder database from GTP Schäfer
has been implemented in the Flow 3D
Cast software (Figure 6). The database
contains feeder data on exothermic and
insulating feeder sleeves. It is possible
to select and position a suitable feeder
with just a few mouse-clicks. The correct
feeder for a casting can therefore be
selected rapidly and efficiently on the
basis of a modulus calculation, and its
effect examined.
Validation
A case study in which an insulating feeder
is used is shown in Figure 7. A
porosity analysis shows that the feeder
can only just compensate for the shrinkage
of the component. As a result of
the high solidification time, insulating
feeders cannot maintain the melt at a
high temperature sufficiently long, and
a critical secondary cavity forms in the
gate area. Although the defect is located
within the feeder it is nevertheless
very unstable, as fluctuations in the
process parameters (such as the chemical
composition of the casting material,
or the casting temperature) lead to
shifts in the porosities in the component
and thus to rejection. There are
therefore some defective components
despite the process parameters being
within the tolerances. Exothermic feeders
were selected and dimensioned
using the new simulation model in
order to find a robust and efficient
solution. It can clearly be seen that
there is now no formation of
secondary cavities, i.e. there is sufficient
liquid melt available to compactly
fill the component before solidification
is complete. As a result of the more
efficient mode of action a smaller feeder
body – with 30 % less melt volume
– can be selected, preventing unnecessary
recycling material. It was possible
to achieve a robust solution with the
feeders used as they do not behave
sensitively to process-related fluctuations,
and reliably prevent imperfections
within the component.
Summary
Simulations always merely approach
reality. The models used for the simulation
should, however, be capable of sufficiently
accurately describing the physical
effects of importance to the
objectives of the simulation so that the
correct conclusions for practical use can
be drawn from the simulation results.
This is now the case, for the first time,
for the design of exothermic feeders
thanks to the new model that has been
implemented in Flow 3D Cast. The new
approach of comparing temperature
measurement values from casting trials
with simulation results ensures a high
level of accuracy for the use of exothermic
feeders. www.gtp-schaefer.com
www.flow3d.de
Malte Leonhard & Dr. Matthias Todte,
Flow Science Deutschland GmbH, Rottenburg,
and Jörg Schäfer, GTP Schäfer
GmbH, Grevenbroich.
Literature:
www.cpt-international.com
32

CASTING
Special
GIFA 2019
Part 2: Opportunities provided by new
technologies
GIFA
Special
Photo: Fotolia

SPECIAL: GIFA 2019/INTERVIEW
34

“Germany is a trade fair country with a high
level of quality. GIFA is high quality because
all foundry decision-makers attend!“
It‘s always about products: GIFA-President
Heinz Nelissen, Managing Director of
Vesuvius, in the local company in Borken
“A veritable explosion
of innovations”
Heinz Nelissen is expecting a “veritable explosion of innovations” at the trade-fair
quartet of GIFA, METEC, THERMPROCESS and NEWCAST (GMTN, also known as the
Bright World of Metals). The President of GIFA and NEWCAST explains in an interview
what makes the trade fair so enormously valuable for exhibitors and visitors, and how
the sector can attract new talent.
Photo: BDG/Vogt
Let’s start with what is, in effect, a
never-ending topical subject: what is
your view about Brexit?
One has to say that the elemental anxiety
that economic life as we know it
will collapse completely is long past.
This will evidently not happen. How
Brexit is developing, however, is
annoying because it is simply unnerving.
One would have wished to have
had a concrete and dependable date.
The twenty-ninth of March has passed
– and now? I hope for a reasonable
settlement and the prevention of
customs duties.
Big plans: Heinz Nelissen (middle) shows CPT editors Robert Piterek (left) and Martin Vogt,
what is planned for the trade fair quartet.
At least GIFA has a concrete date at
the end of June. What can you tell us
about it?
GIFA and NEWCAST seamlessly pick up
from their successful predecessors in
2015. Both trade fairs are superbly
booked up; the world market leaders
are represented, as are the SMEs. Overall,
at all four trade fairs of the quartet,
the Bright World of Metals will
again break the threshold of 2,000
exhibitors: more than 2,100 companies
are expected from all over the world.
The international range of visitors is
correspondingly large: we expect – not
least thanks to our extensive marketing
measures – about 78,000 visitors
from Europe and overseas.
The economy is deteriorating. Could it
affect this year’s GIFA?
The exhibitors have largely completed
their planning for the trade fair, the
stands have been firmly booked, and
the innovations intended for GIFA have
been developed and made suitable for
trade fair presentation in collaboration
with the customers. We come from two
years of excellent production figures,
from a clear boom phase. We had several
thriving years in the non-ferrous
and iron foundries. Now we face a
Photos: Martin Scheidtmann, BDG/Vogt
CASTING PLANT & TECHNOLOGY 2/2019 35

SPECIAL: GIFA 2019/INTERVIEW
sharp dip in the economy. This will not
blow us casters away. Particularly now
it is important to ask oneself the question:
how do I, as a businessman,
handle the coming years? And GIFA is
coming at just the right time.
In what way?
There is a lot going on regarding digitalization.
The high tempo of digitalization
opens up new possibilities for
automating production. Plant constructors
are exploiting this and will be presenting
innovative solutions. So GIFA is
focusing on this, among other things.
The trade fair offers a wide-ranging
framework program of specialist conferences.
How important are they?
The specialist framework program,
with its range of international congresses,
symposia, forums and special
events, really is extremely important
and, indeed, is unique worldwide.
Whether additive manufacturing,
metallurgical topics, trends in the steel
sector, current aspects in thermo-processing
technology, or innovations in
energy and resource efficiency – the
entire spectrum of foundry technology,
cast products, metallurgy and thermo-processing
technology is covered.
Some specialist events are having their
premieres, for example the two-day
expert forum on thermal energy storage,
the specialist conference on 3-D
printing with metals, and the special
events on additive manufacturing or
digitalization & climate protection.
Digitalization is quite advanced and
will lead to innovative solutions that
will be presented at the trade fair.
Numerous congresses and presentations
help build up networks and shed
light on innovative topics.
Is the impression misleading, or has
the automotive sector – with its e-vehicles
– really made the most progress
since our conversation last autumn?
That is my perception too. There really
has been some movement in the field
of e-mobility in recent months. One
has to differentiate between commercial
vehicles and cars. Regarding commercial
vehicles, particularly for overland
transport, work is still continuing
with conventional fuel-powered drives,
while package services in the cities,
inner city traffic, and buses are increasingly
electrically powered.
What you describe is a market that is
becoming even more differentiated.
What does this mean for the sector?
I think it is good that cast products will
continue to be used for all types of drives
and vehicles. Both conventional
vehicles and e-vehicles need cast products,
but very different ones of
course. And the casters have to position
themselves appropriately for this.
And so parts are being constructed,
particularly in the non-ferrous field –
battery housings and structural elements,
for example.
And what can a caster of classic engine
components do now?
They will have to think about what to
do, because the machine park may not
be suitable for e-mobility components.
Then one could either concentrate
more on the commercial vehicle seg-
36

ment – which will continue to produce trucks with combustion
engines – or look for new sectors. Specialization will be
decisive.
Back to GIFA. The Bright World of Metals, as well as the
German Foundry Association (BDG) and the German Foundrymen’s
Association (VDG), have announced a youth program
like that at the last trade fair. The ‘Gießzeit’ (Casting
Time) competition is about casting a clock face. Many youth
groups are again expected to attend the trade fair. What’s
your take on this?
We know how much the future of foundry work depends on
finding new personnel –one of the priorities in the BDG’s
Mission Statement – and the Association has already organized
a lot of events. The VDG has even defined finding new
personnel as a statutory task. So a significant proportion of
the trade fair presence of both the BDG and VDG is dedicated
to this topic. Numerous groups of schoolkids will get to
know about careers in foundries during their visit to the
trade fair, and especially at the school foundry in Hall 13.
Castings will also be produced here. This is a strong argument
for the career, because the casting produced gives a
tangible meaning to the whole thing. Groups of schoolchildren
can mold and cast the clock face of a classroom clock this
year. The best ones will receive prizes. Such a youth program
is indispensable for demonstrating the profession’s fascination.
And the competition spurs the young people on. I can
only encourage the foundries to participate in the excursions
to the trade fair in Düsseldorf organized by the
Metals4You Initiative. After all, we are expecting more than
500 potential new foundrymen and -women every day!
What youth recruitment activities of your own can we
expect at the trade fair?
We are using part of our stand as a Career Corner this year.
It will be run by our personnel department and trainees,
outlining to some extent the aim of the stand concept. The
personnel department will provide relevant information on
the site and the company, while the trainees will present
interesting projects from their training. We are also inviting
our partner school and participating in Metals4You. The
concept is designed to win over young people for technical
professions before they take their final decisions on their
career orientation.
What do you think GIFA contributes to the sector?
The entire range of casting products will be presented at
NEWCAST. METEC and THERMPROZESS are the leading international
trade fairs for metallurgy and thermo-processing
technology. GIFA takes place in its proven 4-year cycle. So
the world’s best will be presented there. The major suppliers
have coordinated their development programs to this trade
fair rhythm, so we can expect a veritable explosion of innovations.
SEIATSU
FlASk MOUldING MACHINES
ANd MOUldING lINES
The requirements placed on cast parts, in particular dimen sional
accuracy, repeatability, surface quality and the constantly high
demands on the mouldability of the most complex models
requires the maximum in mould quality, which is facilitated by
the different HWS moulding processes. The following methods
are available:
• SEIATSU airflow squeeze moulding process
• SEIATSU.plus (model-side pressing)
• SEIATSU aeration technology ACE
Available moulding machines that utilise the aforementioned
processes include not only fully-automatic high performance
moulding machines, but also simple series moulding machines
for manual and semi-manual operation.
25.-29.06.2019
Visit us!
Hall 17, Booth B20/d20
What is your closing message for the sector?
Germany is a trade fair country – and with an extremely
high level of quality in worldwide comparisons. GIFA is also
high-quality, because all the decision-makers in the global
foundry sector are at GIFA. This is an excellent opportunity
for networking, also internationally. The proportion of international
visitors is nowhere near as high at comparable specialist
trade fairs as it is in Düsseldorf. Make sure you don’t
miss this opportunity!
www.gifa.com
HEINRICH WAGNER SINTO
Maschinenfabrik GmbH
SINTOKOGIO GROUP
www.sinto.com
Bahnhofstr.101 · 57334 Bad Laasphe, Germany
Phone +49 2752 / 907 0 · Fax +49 2752 / 907 280
CASTING PLANT & TECHNOLOGY 2/2019
www.wagner-sinto.de
37

SPECIAL: GIFA 2019
Photo: Andreas Bednareck
Foundries use scrap as a raw material for production
Tremendous potential – environmental,
economic and social
sustainability in foundries
Foundries are one of the best examples of resource efficiency and sustainability.
Because castings implement the recycling concept almost completely.
Carina Hendricks, Kleve
Sustainability and resource
efficiency
This energy-intensive industry has, in
addition, always had a strong commitment
to the objectives of sustainability
and resource efficiency. Innovations in
the product and process simulation field
make it possible nowadays to manufacture
cast components that satisfy the
requirements of economically and
environmentally sound lightweight
structure production. Cesare Troglio,
Technology and Innovation Division
Manager at the German Foundry Association
(BDG), thinks that there are
numerous significant ways to take
account of the demands for sustainability
and resource minimization in product
development, in production and
during product life: “Cast components
embody the basic idea behind the eco-
Metals label outstandingly well.”
With the latter, the four Düsseldorf
metallurgy trade fairs GIFA, METEC,
THERMPROCESS and NEWCAST emphasize
the importance of resource and
energy efficiency, climate protection
and innovative processes and products.
Exhibitors who present products, solutions
or process operations relating to at
least one of these areas will once again
be highlighted particularly strongly
in Düsseldorf in June 2019 (25th to
29th of June). “The USP of the four
trade fairs GIFA, METEC, THERMPRO-
CESS and NEWCAST is their coverage of
almost the entire market – so sustainability
is an issue that cannot be left
out”, explains Friedrich Kehrer, Global
Portfolio Director Metals and Flow
Technology at Messe Düsseldorf GmbH.
Visitors to the event can inform them-
38

selves about what the exhibitors are
presenting at ecoMetals via a special
brochure about this subject as well as
online. There will also be guided tours
– known as ecoTrails – specifically for all
visitors who are interested.
A number of exhibitors are allowed
to display the ecoMetals label in this
context. Because many foundries are
investing in manufacturing processes,
are increasing vertical integration and
are reducing resource consumption on
an ongoing basis. One major feature of
this process – and the driving force
behind it – is the digitization of production.
This is creating enormous opportunities
not only to improve one’s competitive
position but also to implement
sustainable strategies.
Saving time and money
Simulation and, to an increasing extent,
3-D printing are making it possible not
merely to produce highly complex parts
but also to replace the energy-/resource-intensive
and time-consuming trial
and error method. The Leipzig team
from GF Casting Solutions came to this
conclusion too. Series production of sand
cores by 3-D printing started here in the
summer of 2018. “The foundations for
With the 3-D printer, the Leipzig location has become an innovation center.
this were laid as long as two years ago”,
reports Matthias Heinrich, Director of GF
Casting Solutions Leipzig GmbH.
As part of the corporate strategy for
2020, the Leipzig location succeeded in
persuading the division management to
invest in a 3-D series printer for sand
cores by presenting a convincing concept.
As a result, the location now acts
not just as an innovation centre and
supplier of prototypes to all the other
foundries in the GF Division; it also
manufactures in series. Heinrich explains:
“The cold-curing phenolic 3-D
printer in Leipzig is the second of its
kind in Germany and the first one in the
Photo: GF Casting Solutions
RUDOLF UHLEN GmbH
Face protection for every application
Rudolf Uhlen GmbH is a manufacturer of personal protective
equipment (PPE) for face protection. Especially for the steel
and foundry industry we provide special solutions in the field
of IR-protection. We produce:
Ÿ Visor Carriers
Ÿ Gold-coated visors
Ÿ Mesh visors
Ÿ PC-visors
Ÿ Bochumer Brillen
Ÿ Flip-up goggles
PRODUCTIVITY IN 3D
3D- PRINTED CAST SOLUTIONS
Düsseldorf 2019
Hall 10 - C18
RUDOLF UHLEN GmbH Telefon: (02129) 1444
Am Höfgen 13 - 42781 Haan Telefax: (02129) 59980
www.aschua-uhlen.de info@aschua-uhlen.de
CREATE COMPLEX COMPONENTS
Innovative 3D printing solutions for sand &
investment casting using common casting
materials, where all light and heavy metals that
are castable and of series-production quality
can be processed. Complex geometric shapes
can be created with speed and precision.
voxeljet AG
Paul-Lenz-Straße 1a 86316 Friedberg Germany
info@ voxeljet.com
CASTING PLANT & TECHNOLOGY 2/2019 39

FILTECH
October 22 – 24, 2019
Cologne – Germany
The Filtration Event
www.Filtech.de
SPECIAL: GIFA 2019
ASK Chemicals uses
its own technical
center to increase
the effectiveness of
the products, thus
providing users with
added value such as:
lower resource consumption.
Photo: ASK Chemicals
Platform
for your
success
Targeted
Solutions
for the
Casting
Industry
Your Contact: Suzanne Abetz
E-mail: info@filtech.de
40
Phone: +49 (0)2132 93 57 60
country that is being used in series production”.
The advantages for customers: considerable
time and money is saved in the
production of prototypes and spare
parts. In addition to this, process reliability
is increased by the elimination of
core assembly, while designers are enthusiastic
about the unlimited design
potential. There are many different
application areas for the castings, which
weigh between 100 and 1,000 kg. Heinrich
lists them: “They are used in lorries,
construction equipment, agriculture and
forestry management, solar farms and
wind turbines, rolling stock, machine
manufacturing in general and hydraulics,
our new product segment”. BDG
executive Troglio summarizes: “Such
technologies can help to save a great
deal of time and energy when tooling is
being built, particularly where prototypes
and short series are concerned”.
Products with greater impact
The progress that has been made with
organic bonding agents and the use of
inorganic bonding agents of the kind
developed by, for example, foundry
supplier ASK Chemicals, Hilden, Germany,
also improves environmental performance.
Dr. Jens Müller, Research and
Development Manager at ASK Chemicals,
explains: “We are focusing primarily
on increasing the impact of our products
and on generating added value
for our customers, as – for example –
material input can be decreased and
the total potential emissions can be
reduced as a consequence.”
The company has succeeded in
developing the first unmarked phenolic
resin in the world for the cold box process
in iron casting. A hazardous product
is therefore not needed in this process.
Müller adds: “There are other
advantages apart from the environmental
benefits: The particularly high reactivity
of this new system makes it possible
to reduce bonding agent and catalyst
volumes in many cases.”
Inorganic bonding systems are becoming
increasingly important in aluminium
casting. ASK Chemicals is also
noticing greater awareness of sustainable
products. Müller thinks that “this is
certainly driven by the fact that the
general conditions in Europe particularly
have become more demanding
due to the implementation of relevant
regulations” and is therefore delighted
that product developments for protection
of the environment are successful
above and beyond this too: “Initially,
no-one really believed that the technology
of inorganic bonding systems
would replace conventional processes.
This may be attributable to the fact that
there are technological and economic
benefits in addition to the original
environmental aspect. Now it is an established
feature in lightweight metal
permanent casting.“
Environmental, economic, social Sustainability
cannot, after all, always be
considered solely at the environmental
level. Elke Radtke, who is responsible
for environmental protection as well as
occupational health and safety at BDG,
also thinks that “sustainability involves
economic and social action too. As an
association, we provide information
about the regulations that affect the
foundry industry. Our observation is
that legal regulations designed to protect
the environment often fail in particular
to take social and economic factors
into sufficient account. Wherever
appropriate, small and medium-sized
companies especially also need to be
able to adapt processes and take advantage
of new technologies. Because operations
that are not economic lead in
the long run to failure, which in turn
jeopardizes jobs. That is not sustainable
at the social level.”

HÜTTENTAG 2019
Get-Together of the steel industry
Thursday, 7 November 2019
Motto: STEEL — Traditional material and hightech
product
FOLLOW
TRADITION,
SHAPE THE
FUTURE!
09:00 — 17:30
Lecture programme with company exhibition
starting 18:00 "Hüttenabend"
Get-Together and Networking
Venue: Messe Essen
Messeplatz 1 | 45131 Essen, Germany
Information at:
www.homeofsteel.de/huettentag
Organizer:
SAVE THE DATE
7 NOVEMBER 2019
Photo: worldsteel / Gregor Schläger

Halls
10–13
15–17
Halls
3 + 4 + 5
Halls
9 + 10
Halls
13 + 14
P1
P2
Entrance North
MERKUR
SPIEL-ARENA
5
9
3
4
17
CCD Süd
CCD Ost/CCD Süd
Congresses
Entrance South II/
GIFA MAIN TOPICS
Grafik: messe-duesseldorf
42
Entrance South
Hall 13
Additive manufacturing
Hall 12
Gating and feeding
Hall 15-17
Moulding, pattern and core ma

The Bright World of Metals
With the international claim "The Bright World of Metals"
Messe Düsseldorf summarizes the technology fair quartet of
GIFA, METEC, THERMPROCESS and NEWCAST. Thanks to
the largest number of exhibitors and hall space, GIFA will be
the focal point of the fair. GIFA and NEWCAST meet in Hall 13.
Visit us in Hall 13, Stand C30!
CASTING
PLANT AND TECHNOLOGY
INTERNATIONAL
10
18
11
12
13
16
15
14
CCD Ost
Hall 17
P4
Entrance East
king
Hall 12
Chemical materials for foundries
Hall 11
Die casting and peripheral equipment
Hall 15-17
Foundry machines and foundry plants
CASTING PLANT & TECHNOLOGY 2/2019 43

SPECIAL: GIFA 2019
MAGMA
“The Digital Foundry Process”
At GIFA 2019, MAGMA
GmbH presents a new
generation of trendsetting
solutions for virtual
casting, tooling
and process optimization.
In Hall 12 at Booth A19/20, the
company will demonstrate how Autonomous
Engineering is replacing conventional
casting process simulation. Magmasoft
autonomous engineering
supports casting design, robust process
layout and optimized casting evaluation
even before the first part is produced.
By making use of the fully integrated
capabilities of virtual Design of Experiments
and genetic optimization, Magmasoft
easily and reliably finds the best
solutions – from the first casting design
to improvement of a running production
layout. As a world premiere, visitors
will experience Autonomous Engineering
live in 4-D in a captivating
Holo-Theater performance.
MAGMA has been developing powerful
solutions for digitizing foundry
processes for over 30 years. With the
“Virtual Core Shooting Machine”, the
company showcases an innovative
Industry 4.0 application together with
leading industry partners. A direct coupling
between process simulation, core
box design, molding material and core
shooting machine enables the real-time
optimization of the complete core
shooting system for the first time.
With the “Virtual Die Casting Die”,
MAGMA demonstrates how to simultaneously
realize and reliably evaluate a
robust tooling design and an optimized
production window simultaneously within
the shortest possible time for high
pressure die casting processes. Moreover,
the company introduces numerous
new capabilities for virtual optimization
of all casting processes and alloys, heat
treatment and the complete core production
process. In cooperation with
leading partners from the supplying
industry, new developments for digitizing
molding materials and for quantitative
prediction of core distortion,
degradation behavior of binder systems
and core gas related defects during the
casting process will be presented.
Through new solutions, accessing databases
for feeding system components in
Magmasoft has become even easier.
MAGMAinteract, the new and innovative
visualization program for
Foundrymen’s Playground 2.0 – playfully learn how to optimize casting designs with the
MAGMAacademy
Magma soft results, supports communication
internally within a company as
well as a fast exchange of information
with both customers and suppliers.
Using real castings as examples,
MAGMA will interactively show how
easy it is to use information from
Magma soft with MAGMAinteract. The
MAGMAacademy will present its offering
of comprehensive opportunities
for further education for foundrymen,
casting designers and casting consumers.
The “Foundrymen’s Playground
2.0” will playfully show how easy it is
to virtually optimize casting designs
today. Here, visitors can interactively
run their own simulations in a virtual
test field, while simultaneously pursuing
different quality and cost-related
objectives. As part of a competition
against Magmasoft autonomous
engineering, visitors will lay out their
own casting on an electronic drawing
board in just a few minutes.
MAGMA will also be presenting its
innovative solutions for process optimization
in continuous and ingot casting
at its own booth at METEC (Hall 4,
Stand E 29). Here, too, the company will
showcase state-of-the-art solutions for
the virtual optimization of conflicting
objectives regarding productivity and
quality, as well as for establishing
robust process windows.
With its Student Camp, MAGMA
once more shows its commitment to
recruiting young professionals for the
foundry industry. The young visitors will
be shown in a fun and playful manner
how interesting and innovative the
foundry world is.
Be inspired by the fascinating world of
“Magmasoft - The Digital Foundry Process”!
Hall 12, Stand A19/20
www.magmasoft.de/en
Photo: Magma
44

FOSECO
Non ferrous melt shop
Insural multi-part and
highly insulating
dosing furnace linings
for aluminium foundries
combine energy
savings with long-service
life and resistance to oxide
build-up.
The use of energy efficient dosing
furnaces in aluminium foundries is seen
by many as the best available technology
today. Foseco is now able to supply
a new multi-part and highly insulating
lining made of Insural which is delivered
ready to install. Installation can
be achieved in 3 days with no ongoing
hydrogen issues and due to a totally dry
installation process no sintering of the
lining is necessary. Energy saving can be
as high as 17 %.
Hall 12 – Stand A1 + A2
www.foseco.com
Insural dosing furance lining for aluminium foundries
FOTOS AND GRAPHICS: FOSECO
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
Please see us at GIFA,
Düsseldorf, June 25-29,
hall 16, stand A39
AGTOS
Gesellschaft für technische Oberflächensysteme mbH
Gutenbergstraße 14 · D-48282 Emsdetten
Tel. +49(0)2572 96026-0 · info@agtos.de
www.agtos.com
157-01/19-4c-GB
CASTING PLANT & TECHNOLOGY 2/2019 45

SPECIAL: GIFA 2019
Graphics: ASK Chemicals
ASK CHEMICALS, MAGMA
Material database for predicting binder
decomposition and core gases
Prediction of the time dependent
penetration of core
gases into the melt for different
mold materials (left) and
visualized defect risk within
the casting
MAGMA GmbH,
Aachen, Germany ,specialist
in virtual optimization
of casting processes,
and ASK
Chemicals GmbH,
Hilden (both Germany) one of the
world‘s leading suppliers of foundry
chemicals and consumables, are involved
in a joint development project on binder
decomposition in sand cores and associated
gas formation. The aim is to provide
the Magmasoft users with validated
data on quantitative prediction of process-relevant
effects for ASK products.
With a new database, joint customers
should be even better supported in the
interpretation of the venting behavior
of sand cores and the prediction of core
gas-related casting defects.
During the casting process, gases
form and expand in cores and molds
amongst others due to the decomposition
of binder components and other
volatile components. This is closely
related to the basic sand binder mixture
used and its compaction as well as its
specific gas permeability. Different volumes
of gas are produced at different
times depending on the type and quantity
of the volatile components, the
thermal exposure and the respective
decomposition behavior. Relatively high
gas pressures at the interface to the
melt can result in gas inclusions in the
casting. In the cases of complex cores or
even core packages, it is difficult in
practice to determine if core gases are
the cause of defects due to the numerous
and diverse influencing factors.
Newly developed simulation models
in Magmasoft virtually depict gas formation,
gas flow, and venting through core
prints or the penetration into the melt.
This functionality enables accurate prediction
of the risk of defects due to gases
from cores and molds. The availability of
practical quantitative data already
during simulation-based design of castings
and cores therefore contributes significantly
to the prevention of defects.
ASK Chemicals and MAGMA have
agreed on a collaboration as part of a
development project to quantify the
decomposition behavior and gas formation
of different ASK binder systems. To
this end, ASK Chemicals will carry out
extensive research in their laboratories
and Technical Center. Respective laws of
decomposition behavior and resulting
gas formation will be quantitatively
determined for different binder systems
and heating characteristics. Product-dependent
kinetic models will be derived
from these data that will make the formation
of gas volumes and the resulting
effects in Magmasoft quantitatively
predictable.
“For MAGMA, this project is an
important step in the direction of
‚robust process design for casting technology‘.
The possibility of systematically
avoiding core gas-related casting
defects through quantitative consideration
of different ASK binder systems
already at the project planning stage
represents a significant benefit for our
customers,“ confirms Dr.-Ing. Jörg C.
Sturm, Managing Director of MAGMA
GmbH. “We are pleased to have gained
a competent development partner with
ASK Chemicals, who are interested in
quantifying the behavior of their binder
systems during casting.“
“With the possibility to predict the
behavior of our products with any core
geometries during casting, we can support
our customers in a more targeted
manner. Comprehensive customer service
therefore already has the highest
priority for us in the planning stage of
production processes,“ confirms Jörg
Brotzki, Executive Vice President Europe
at ASK Chemicals. „The user-friendly
integration of our data in Magmasoft is
thus decisive for the quality of planning.“
Both partners will present the first
results of the joint development project
at the GIFA trade fair. The collaboration
is designed for the long-term.
Hall 12 Stand A19/20, Hall 4, Stand
E29 and Hall 12, Stand A22
www.ask-chemicals.com
ww.magmasoft.de/en
46

IMERYS
Kersand and Durandal –
the right alternative
to chromite sands
Two sands by Imerys, Paris, France, Kersand
(AFS 60) & Durandal 60 (AFS 50) now used
by sand casting foundries, appear to fulfill
requirements in terms of refractoriness
and thermal expansion, as well as in terms
of supplying, and price condition stability.
Those two products are similar, made with natural minerals
with intrinsic high refractoriness and low thermal expansion.
In addition, they are respirable crystalline silica free,
and this over the several sand loops. The two sands are
performing in all steel alloys, cast iron & copper alloy
foundries and are compatible with all type of binding systems
(organic & Inorganic), and furthermore, generate no
low melting temperature point when mixed with silica
sand.
In a two years time period, chromite price FOB South
Africa more than doubled from initial price. This clearly
shows the high volatility of the chromite market price. This
is not surprising, considering that all South African producers
are primarily in the ferrochrome business producing
metallurgical grade, with non-metallurgical grades being
produced as a by-product.
Special sand, even if used in lower volume compared to
silica sand (for instance 10 %), can represent roughly 50 %
of the expenses when it is compared to silica sand, resin
and coating cost.
New types of special sands were developed over the
past 10 years, in order to improve the performance and
compensate the high price volatility associated with the
traditional chromite sand. Durandal D60 and Kersand are
two natural mineral products which have been designed
specifically to reduce casting defects and are respectively
produced in South Africa & France. European sourcing is an
important advantage considering logistic delivery delays as
well as geopolitics stability situation.
Chromite is heavy and will need 40 % more in weight
to fill the same volume of cores compared to Kersand and
Durandal 60. This is a key point regarding sand consumption.
Indeed, loose bulk density is around 1,6 for Kersand
and Durandal 60 whereas chromite sand lies at 2,7. This difference
leads to immediate savings of 40 % of sand
consumption for a constant volume of core produced.
Both, Kersand and Durandal 60 show linear and low
expansion with temperature compared to silica which exhibits
the well know transition quartz a to b at about 573 °C.
Anti-veining properties have been proven in numbers of
foundries, in tough casting conditions for Kersand and
Durandal 60 products. Iron casting has been performed
with chromite, silica sand, Durandal 60, and a mix of
Durandal 60 and silica sand cores with alkaline phenolic
resin. Results show sand fusion defect when silica is used,
and clean casting for chromite and Durandal 60. Furthermore,
under those casting conditions it is demonstrated
that a mix 50 %/50 % Durandal 60 and silica still leads to
clean casting. Hall 12, Stand C 34
www.imerys.com
A CENTURY
OF FOUNDRY
EXPERIENCE
GIFA 2019
Hall 17 Booth 18A
We have tailored solutions for your
casting application – worldwide.
Individual machines or complete systems.
100 years of experience in vibrating technology.

SPECIAL: GIFA 2019
Fotos and Graphics: Foseco
Schematic setting of Foseco’s automated treatment technology Smartt.
FOSECO
Non ferrous metal treatment
In recent years, a number
of new features
and technologies have
been added to the
Foseco FDU and MTS
equipment range – the
state of the art in technology for the
automated treatment of an aluminium
melt. Smartt software offers various
programs for rotary degassing and the
operator simply defines a melt quality
after treatment. Smartt predicts the
best treatment practice based on ambient
conditions, melt temperature,
rotor design and alloy composition.
The treatment parameters are automatically
transferred into the FDU
MTS.
In conjunction with innovative rotor
designs Foseco guarantees a constant
quality level and reliable results. Smartt
not only controls degassing but
together with forming gas any defined
hydrogen level can be reached. A customised
report system records all parameters.
The chemical grain refiner in granulated
form can be added through the
automated Metal Treatment Station.
This grain refiner offers many advantages
such as improved melt fluidity
during casting, reduced inclusion level
and better mechanical properties. The
dross remaining after the treatment is
low in metal which additionally saves
costs. The dosing equipment uses a gravimetric
load cell to ensure highest
dosing precision for best metallurgical
results as well as repeatability and traceability.
Shaft and rotor design are continuously
improved to offer high efficiency
in degassing at long service life.
Hall 12, Stand A1 + A2
www.foseco.com
ASK CHEMICALS
New binder-additive-coating system for compliance
with formaldehyde limits
German foundries are
faced with the challenge
of reducing
formaldehyde emissions
in the exhaust
gas flow of their existing
plants from 20 mg/m 3 (mass concentration)
to 5 mg/m 3 by February
2020 at the latest. At GIFA 2019, ASK
Chemicals, Hilden, Germany, will present
a specially designed binderadditive-coat
ing package that allows
foundries to comply with this new
limit value without investing in additional
secondary measures.
ASK Chemicals has developed a new
concept to provide foundries with a
solution that greatly reduces the formaldehyde
emissions by more than 70 %
and does not require investment in
washers or RTO (i.e. regenerative thermal
oxidation).
Analyses have shown that, in particular,
the exhaust gas flow from coating
drying furnaces plays a special role in
the reduction of formaldehyde emissions.
Cores produced in the cold box
process have residual amounts of formaldehyde
per se, but can, in conjunction
with an additive and coating, emit additional
formaldehyde, especially at temperatures
around 150 °C, so that the
limit of 5 mg/m 3 is easily exceeded.
The newly developed low-formaldehyde
system (LFS) from ASK Chemicals is
a specially designed package of binder,
additive and coating that, due to its
design, develops only a very low basicload
and thus a greatly reduced formal-
48

dehyde potential. Furthermore, the
new system absorbs released formaldehyde,
so that the first users of this technology
have the ability to undercut the
5 mg/m 3 limit.
“I am convinced that we offer users
real added value with this new system.
With the application of the Ecocure
BLUE LFS binder, Miratec LFS coating
and VEINO LFS additive tailored to the
specific requirements, the LF system
meets the legal formaldehyde limits
with pinpoint accuracy. This is a clear
advantage for foundries that do not
want to invest in secondary equipment
at this time“, says Frank Lenzen, Technical
Product Manager at ASK Chemicals,
summarizing the benefits of the new
system.
Hall 12, Stand A22
www.ask-chemicals.com
Low formaldehyde system
Photo: ASK Chemicals
WALTHER TROWAL
Compact continuous feed shot blast machine
for small, delicate castings
At the GIFA 2019 exhibition
Walther Trowal,
Haan, Germany, introduces
the compact
troughed belt continuous
shot blast system
THM 300/1 to the public. This machine
was especially developed for processing
high volumes of small, delicate work
pieces. The new design combines the
small footprint of batch machines with
the advantages of continuous feed
operation and, thus, helps streamline
and speed up the blast cleaning processes
for small castings.
Walther Trowal developed the THM
300/1 specifically for small, delicate or
thin-walled cast work pieces like, for
example, aluminum or zinc die-castings
with diagonal dimensions of between
20 and 150 mm (about 0.8 to 6.0”).
Work pieces can range from components
for toys (model cars and trains),
furniture parts, components for the
computer industry and even small automotive
parts.
For the first time a shot blast
machine for processing small work
pieces is available with the footprint of
a batch tumble belt machine that permits,
however, continuous feed operation.
Compared to the smallest THM
machines supplied to date by Walther
Trowal, the THM 300/1 design is considerably
more compact: It requires an
area of only 1,4 × 2,7 m (5 x 9 feet) and
can, therefore, be easily integrated into
existing production lines.
With this new machine concept Walther
Trowal meets the demands of customers
in the foundry industry, who
want to integrate their blast cleaning
operations seamlessly into already existing
manufacturing lines.
The troughed belt work piece transport
system Walther Trowal is utilizing
for its continuous shot blast machines is
gently moving the work pieces through
the machine in a spiral motion. This
ensures that all work piece surface
areas are equally exposed to the blast
media stream.
Meik Seidler, sales manager at Walther
Trowal, recognizes a significant
trend towards continuous shot blasting:
“The THM continuous feed machines
with their unique troughed belt work
piece transport system are more and
more displacing the conventional batch
tumble belt machines. Our customers
integrate the THM systems into linked
manufacturing processes allowing them
to significantly simplify the work piece
handling. The work pieces are continuously
fed into the machine at preset
cycle times determined by the actual
production volume. Intermediate transport
operations from one process stage
to the next, as well as intermediate
storage, are completely eliminated.”
For the new blast system Walther
Trowal is using the newly developed
Photo: Walther Trowal
The compact troughed belt continuous shot
blast system THM 300/1 combines the small
footprint of batch machines with the advantages
of continuous feed operation
WTY turbines with curved throwing
blades. Compared to conventional blast
turbines they generate a substantially
higher throwing speed. This increases
the impact energy of the blast media on
the work pieces, which in turn helps
reduce the processing times.
A communication processor allows
integrating the shot blasting operation
into higher-level process controls.
Explosion protected dust collectors
ensure safe operation in line with prevailing
explosion prevention standards.
Hall 15, Stand D 15
www.walther-trowal.de
CASTING PLANT & TECHNOLOGY 2/2019 49

SPECIAL: GIFA 2019
Graphics: Elkem
ELKEM
New foundry products takes casting
iron to the next level
Elkem’s stand at GIFA 2019.
From 25 until 29 June
foundry products by
Elkem, Oslo, Norway,
will be present at GIFA,
the world’s leading
trade fair for casting
technology, in Düsseldorf, Germany.
There, Elkem will highlight its all-round
competence to improve the metallurgical
iron foundry process.
GIFA is the international exhibition
for foundry, foundry products and
foundry technology and one of the
world‘s largest and most comprehensive
fairs of this kind. The focus of
GIFA is on foundry equipment, raw
materials and supplies, die-casting
technology, foundry chemicals, suppliers
and processing technology. This
exhibition provides an excellent stage
for Elkem Foundry Products to highlight
its capabilities and most current
innovations.
Elkem Foundry Products has evolved
to being an all-round solution provider
for the metallurgy of iron foundries,
supporting its customers globally with
highly specialized alloys and excellent
advice, which results in premium castings.
Elkem innovates constantly and
supports its customers with new, digital
and automated solutions for analysis
and alloy dosing.
One of these solutions is the new
Dynamic Dosing System, which enables
foundries to precisely and automatically
calculate, dose and position the treatment
alloys into a dedicated pocket in
the treatment ladle, for high quality
ductile iron production.
This customized equipment calculates
the alloy addition rates based on the
chemical analysis of the iron and other
important parameters before and after
each treatment. This self-learning
equipment stabilizes and documents
the treatment process, reduces cycle
time, improves the iron quality and
avoids human error.
Another example of Elkem’s improvements
is Elkem’s EPIC, an important
process control tool based on thermal
analysis of cast irons. The EPIC system
provides real-time information on the
condition of cast iron that can be used
at any point in the liquid state production
process. EPIC enables the foundry
to acquire, record and evaluate a considerable
amount of relevant data, which
helps to improve the castings.
Increased efficiency in alloy treatment
not only results in increased process
stability for Elkem’s customers, but
it also leads to less consumption and
emissions, supporting Elkem’s focus on
sustainability.
Hall 13, Stand C 50
www.elkem.com
50

BÜRKERT
Modular platform for heating and cooling
in metal processing
Exact temperature control
is a critical factor
in many industrial
metal and plastic processing
sequences. In
these scenarios, the
requirements regarding temperature
control can vary substantially depending
on the production conditions.
However, what is always required are
solutions that guarantee one-hundredpercent
repeatability wherever possible
to ensure high product quality.
They must also be simple to integrate
and capable of being extended or converted
as required.
The modular temperature control
platform developed by Bürkert Fluid
Control Systems, Ingelfingen, Germany,
which permits seamless adjustment to
suit the most varied processes, was designed
precisely with these requirements
in mind. It is based on a broad range of
electromotive and pneumatic valves as
well as various measurement principles,
e.g. for coolant flows (ultrasound and
paddle wheel), air quantities (thermal
sensor) as well as pressure and temperature.
Supplied as a custom assembled
complete system, the temperature control
can then easily be integrated into
the most diverse applications.
Thanks to the modular design, individual
valve clusters can easily be realized,
as can multi-channel media distribution
systems or complete media
cabinets – always adapted to meet individual
requirements. The user avoids
the need to install piping between individual
valves and dead spaces are
reduced thanks to the compact design.
In contrast to discrete assembly solutions,
this allows the valve block to be
placed close to the tool. Since the very
compact design also reduces the
heat-radiating surfaces, energy efficiency
improves accordingly. The service-friendly
structure also makes it
easier to replace individual components.
Orbital welding seams and
high-temperature graphite seals that
can also withstand extreme temperature
differences guarantee leak-free
operation.
The Bürkert EDIP (Efficient Device
Integration Platform) can be used to
connect the temperature control to all
standard bus systems; the wiring complexity
is reduced, start-up and parameterization
are simple. Depending on the
tool and process, temperatures can be
specified, the flow control set automatically,
or a constant pressure maintained.
Once parameters have been stored,
they can be restored at any time. All
things considered, the temperature control
processes are reliably repeatable
which boosts product quality and eliminates
waste.
Hall 10, Stand A74
www.buerkert.de
CASTING PLANT & TECHNOLOGY 2/2019 51

SPECIAL: GIFA 2019
Photo: Gemco
GEMCO
Since 1978, complete foundry solutions
Turnkey greenfield foundry realization in Mexico.
GEMCO, Eindhoven,
The Netherlands, a
family owned business
for more than 40 years
with worldwide experience
in the foundry
industry offers foundry solutions for
iron, steel, aluminum and all other castable
metals.
Topics as Industry 4.0, IOT, 3-D Printing,
Automation, Sustainable development
and Environmental impact are
increasingly important. Quality equipment
is important but only part of the
solution. The added value that GEMCO
provides is related to how this equipment
is incorporated into the complete
production facility, making sure no bottlenecks
will occur, making sure that
supporting systems are adequately designed;
making sure that equipment
maintenance can be carried out with
easy access and in right conditions. And
making sure the design is appreciated
by the workers with regard to
movement, lighting, noise and dust.
Since last GIFA, GEMCO has completed
turnkey foundry projects for among
other, Linde (DE), Brembo (PL, MX),
MFA (FR) and Rassini (MX). Projects concerned
modernization and/or capacity
expansion or new greenfield foundry
realizations. Projects currently in course
or close to completion include new
foundries and modernization projects in
North America, Europe, Russia and
China.
The company’s track record includes the
realization of over 100 Greenfield and
Brownfield foundries worldwide. An
extensive global network of foundry
experts covers all foundry disciplines
and provides a complete range of services
that encompass:
> Design and Feasibilities of Greenfield
& Brownfield Projects (for justification
and development of investment)
> Realization (turnkey), ranging from
customized engineering projects to
large multimillion investments
> Strategic Information (Market information,
Technical Due Diligence,
M&A, Competitor Analysis)
> Process Know-how (based in
expert-network)
Gemco is an independent company and
makes use of the latest technology and
engineering tools such as 3-D design
and Foundry Logistics Simulation,
emphasizing on Efficiency, Energy and
Environment. Clients can be found
among international key-players in the
automotive and truck industry, mining,
dredging, oil & gas, rail, heavy machinery,
wind energy and many other business
sectors. GEMCO operates from
offices in The Netherlands, Germany,
China, Mexico and Russia.
Hall 16, Stand C12
www.gemco.nl
52

Photo: Foseco
Foseco’s new, patented Feedex VAK feeding technology
will be presented with best in class application examples.
FOSECO
Feeding systems for iron
and steel foundries
The application of feeder sleeves is a major
factor in reducing metal remelt and fettling
costs in foundry customers. By working in
close partnership with foundries, Foseco
continues to deliver tailored solutions for
specific applications and develop new process
technologies. In this year’s exhibition, we will showcase
several new developments that advance the capabilities of
the foundryman in optimising casting yield, minimising
defects and reducing production costs.
The new range of Feedek VAK spot feeders will be presented
through a variety of ductile iron castings. This patented
development provides an improved feeder neck pass-through
on the most critical feeding applications.
The development of Feedex SCK (Sleeve Construction Kit)
feeders opens up the application of spot feeding to the jobbing
iron and steel sector where the modular product range
enables our customers to optimise both casting yield and fettling
costs on large steel and iron castings.
All relevant exhibits will feature simulations using the
most recent version of the Foseco Pro Module for Magmasoft.
www.foseco.com
Hall 12 – Stand A1 + A2
CLARIANT
Catch LE+ Technology’s
foundry successes
LE+ Technology for green sand casting makes a big difference
to operations. Why? Because it ticks the boxes for enhancing
eco-credentials, lowering total cost of ownership and ensuring
high precision casting. And it’s proving its value where it
matters – in foundries. Latest updates on how Clariant’s Low
Emission+ Technology is delivering on its promises will will be
presented at the media “Meet & Greet” on June 27th at
8 a.m. at the Clariant booth.
Hall 12, Stand C 13
www.clariant.com
QualiMaster AT1
Step by Step to the Ideal
Molding Material Quality
Molding material always exactly as required
Individual solutions
Preventive molding material controlling
Choose your own individual solution. This new generation of the quality system has a modular structure.
Compaction, shear strength, deformability, springback, gas permeability – you decide which values you consider important
for improved casting quality and stable automated processes. QualiMaster AT1 Eco, Profi or ProfiPlus provide
a reporting tool for stand-alone operation and a web interface for mobile viewing.
Find out more about our new inline tester. Visit us at GIFA 2019 in Hall 17/ A38.
www.eirich.com

SPECIAL: GIFA 2019
ASK CHEMICALS
Optimizing Environmental Protection and Occupational
Health and Safety, Increasing Productivity
Protecting the environment
and employees
from emissions: This is
one of the biggest challenges
currently in the
foundry industry. ASK
Chemicals, Hilden, Germany, uses its
innovative product portfolio to help
customers produce sustainably – with
additional advantages for economic
efficiency and quality. Foundries can
therefore meet stringent regulatory
requirements, without having to make
big investments in additional filter and
exhaust systems.
ASK Chemicals helps to improve
environmental protection and occupational
health and safety and optimized
economic efficiency by developing
more powerful and environmentally-friendly
solutions. Innovative technology
platforms, such as Ecocure Blue
and Inotec, as well as product packages,
such as the Low Formaldehyde
System (LFS), offer answers to typical
challenges of the foundry industry
regarding emissions.
ASK’s sustainability approach is to
reduce the emissions of phenol, formaldehyde,
VOC and aromatic hydrocarbons
(BTX) and to increase the effect of
its products. “Innovative and more sustainable
products ensure the competitiveness
of a company in the long
term,” emphasizes Dr. Jens Müller,
Global Head of Research & Development
at ASK. “Countries in East Asia,
especially China, are also increasingly
investing in innovative processes and
sustainable products.”
The patented inorganic binder technology
is currently the optimum in
terms of environmental protection. The
Inotec procedure for aluminum casting
developed by the Hilden company is
characterized by an impressive environmental
balance and increased productivity
in production processes. It is completely
free of emissions. No additional
measures are required to filter or treat
the exhaust air.
Together with the development
partners from the automotive industry,
ASK Chemicals is working on making it
possible to use inorganic binders as a
forward-looking technology in the
future for iron and steel casting on an
industrial scale.
Innovations for greater sustainability in the foundry industry.
Increased regulatory requirements
– such as the amendment to the TA Luft
(Clean Air Guidelines) – concern, for
example, formaldehyde emissions in the
exhaust air of foundries. In Germany,
these must be reduced to a quarter by
no later than February 2020.
ASK Chemicals is supporting its customers
here with the Low Formaldehyde
System (LFS). This is a package of
Ecocure Blue LFS binder, Miratec LFS
coating and Veino LFS additive specially
tailored to the respective requirements.
Users can therefore precisely comply
with the new emissions limits and
improve occupational health and safety
without having to invest in secondary
measures, such as scrubbers or RTOs.
The new Ecocure Blue, which combines
efficiency with a significant reduction
in emissions, stands for the holistic
approach of product innovations at ASK
Chemicals. With the phenolic resin Ecocure
Blue, ASK Chemicals has introduced
the first label-free, Cold Box part
1 component in the history of binder
chemistry. It saves up to 66 % of BTX
emissions and reduces the required
amount of binder by up to 22 %.
Given this success, ASK Chemicals
has expanded the Ecocure Blue families:
Ecocure Blue is now called Ecocure Blue
Pure, and there is also Ecocure Blue
Ultra, which contains even less formaldehyde
than Ecocure Blue Pure. The
product family is complemented by Ecocure
Blue Ice, which can withstand storage
at temperatures as low as -18 °C.
Modern foundries are increasingly
relying on the Pep Set process due to
the processing properties, the better
casting results and higher productivity.
ASK Chemicals has recognized this
trend and is now presenting a new solution
at GIFA for reducing phenol emissions
in the PU No-Bake process: The
new generation of the self-curing Pep
Set binder system on a polyurethane
basis – Pep Set Silver.
This is characterized by a particularly
low proportion of environmentally-friendly
monomers, especially phenol.
In practical applications, it is shown that
the phenol concentrations in the regenerate
are significantly reduced with the
help of Pep Set Silver. In addition to
advantages for the environment, this
also means a clear plus for economic
efficiency, because the landfill costs are
also reduced. In addition, employees as
well as residents in adjacent residential
areas will appreciate the use of the new
technology due to the reduced smoke
pollution.
Hall 12, Stand A22
www.ask-chemicals.com
Photo: ASK Chemicals
54

IDECO
Hydrogen Analysis in
Aluminum Melt
The company IDECO GmbH, situated in
Bocholt, Germany, is the exclusive distributor
for the HYCAL series in Central Europe, India
and China.
The HYCAL series is a
brand of devices for
measuring the hydrogen
content of liquid
aluminum and aluminum
alloy melts.
Even at very low concentrations, it is
possible to analyze and adjust the
hydrogen content quickly and precisely
during both the melting and casting
processes to meet the highest possible
material requirements. The company
IDECO GmbH, situated in Bocholt, Germany,
is the exclusive distributor for
the HYCAL series in Central Europe,
India and China.
IDECO is expanding their product
range by adding a second measuring
device for hydrogen analysis in aluminum
melts. In addition to the classical
procedure of “first bubble” measurement
and the Density Index systems
for determining the overall potential
pore behavior (H2 and oxides) of a
melt, the devices from the company
EMC Ltd. offer the possibility of analyzing
the hydrogen content directly in
the liquid melt. A sensor based on a
new ceramic material (CaZrO3-In) can
be introduced directly into the melt at
any point during the entire melting
and casting process. It produces a
potentiality measurement of the H2
ion concentration as compared to a
standard concentration contained within
the probe.
The aviation and automotive industries
set high standards of material
requirements for the aluminum industry.
HYCAL devices eliminate the subjective
judgment factor from the classification
of pore behavior and, with
their great precision, make it possible
to maintain a pre-defined range of
hydrogen concentration, even as low
as 0,05 ml/100 g, for example. The continuous
online monitoring allows for
the feasibility of finding a variable
optimum end point for the melting
process. By continuing measurement
during the casting process, one can
further assure that no external factors
have changed the hydrogen concentration,
which results in reduced quality.
For overall quality control, all measurements
during the entire process
are digitally saved and made available
to a databank network.
Particularly for the casting process
with its high standards of material
quality, the use of the HYCAL series for
hydrogen analysis has proven to be
especially economical. The HYCAL Mini
is comparable in cost to classical measuring
devices. The variable additional
investment for the insertion probe
with a capacity of 20 hours of accumulated
data may be compensated by a
commensurate rise in the material
quality of the product.
“HYCAL 1000” is the panel mounted
hydrogen analysis unit featuring
great flexibility for different control
processes. A portable analysis unit with
the identical internal components may
be fitted variably to different production
conditions. It has an internal gas
tank, a storage battery, along with
extensive software. Both devices are
suited for foundries producing large
quantities of top quality cast aluminum
products.
“HYCAL Mini” is a small portable
system for the direct analysis of hydrogen
concentration. It includes the analysis
unit, the HYCAL measurement
probe with adapter, a connection cable
and PC based software for processing
and storage of the measurement data.
Hall 11, Stand C56
www.ideco-gmbh.de
Photo: Ideco
NEW
multiPuls
160 °C
Hall 11H73

SPECIAL: GIFA 2019
DISA
Premieres of game-changing foundry innovations
for Zero Defect Manufacturing
At GIFA 2019, DISA,
Taastrup, Denmark,
will reveal three radical
new digitally-driven
innovations that move
foundries closer to
Zero Defect Manufacturing (ZDM). Inspired
by DISA’s unmatched experience
in helping customers continuously
improve casting quality, these cutting-edge
ZDM solutions – the novel
Trace and Guidance (TAG) concept, the
patent-pending Mold Accuracy Controller
(MAC) and the upgraded Monitizer
– open the door to a new era of
scrap elimination.
Visitors to the DISA section of the
Norican Group stand will have hands-on
access to both hardware and digital
models so they can see for themselves
how process data, real-time analysis and
forensic quality control combine to help
trace and eliminate scrap. “Finding the
root cause of scrap can be extremely
difficult,” says Per Larsen, Portfolio and
Innovation Manager at DISA. “The total
quality-related costs across foundries
and casting users can represent up to
10 % of the casting price.”
For the first time ever, foundries can
gain full traceability with DISA’s ingenious
new Trace and Guidance (TAG)
concept. TAG adds a unique ID number
to each casting to provide the missing
link between individual scrapped castings
and their process parameters like
sand compressibility, shot pressure and
pouring temperature. TAG tracking
also paves the way for advanced
machine-learning-based analysis of
scrap causes.
“TAG tracking promises to be a
major game changer for our industry,
helping drive down quality-related costs
to previously unseen levels,” says Larsen.
“GIFA visitors will be able to
explore the patent-pending TAG design
for themselves in the demonstration
area on our stand and sign up for exclusive
news as this exciting concept is
developed further.”
The trailblazing Mold Accuracy Controller
(MAC) forms the second plank of
DISA’s ZDM strategy. The MAC alerts
operators to mold mismatches and gaps
– causing scrap, rework and damaging
melt run-through – before the mold is
DISA CIM (Computer Integrated Modules), featuring a completely new suite of data analysis
and alerting tools
poured. At GIFA 2019, visitors to the
DISA stand can test drive the MAC using
a Disamatic Digital Twin (a digital simulation
of a molding machine). They can
change the virtual machine’s settings
via a Disamatic D3 control panel and
immediately see how those changes
affect mold quality.
“Delegates can inspect a full-size
MAC on the stand, then use the Digital
Twin to virtually test how the MAC
monitors the molding machine’s output
and helps spot any developing problems,”
explains Larsen. “They will get a
real feel for how operators are kept
fully informed and can react to quality
issues seconds after they first appear
and, most importantly, before pouring
the molds.”
The MAC will be released at GIFA as
a retrofit option for Disamatic machines
with Automatic Mold Conveyors, helping
more customers wave goodbye to
scrap.
GIFA also sees the release of Monitizer
| CIM, DISA’s third ZDM solution.
This is the next generation of DISA CIM
(Computer Integrated Modules), featuring
a completely new suite of data
analysis and alerting tools.
As the digital platform which collects
and shares data between your
foundry equipment, Monitizer keeps
processes synchronized and delivers a
full digital view of real-time and historic
foundry data. Monitizer | CLOUD from
Norican Group extends the platform,
using IIoT technology to collect, monitor,
and analyse complete foundry data
from one or multiple global foundry
sites.
“With the Disamatic Digital Twin,
MAC, TAG, and Monitizer, visitors can
see how DISA’s disruptive digital innovations
make it possible to “dive into the
data” to troubleshoot problems, optimize
critical foundry processes and take
major steps towards zero scrap,” states
Larsen.
During on-stand sessions and within
the official GIFA lecture programme,
DISA experts will discuss how its ZDM
solutions enable the data-driven
foundry and help improve productivity,
quality and resource utilization.
Hall 11, stand A74-A78
www.disagroup.com
Photo: Disa
56

FOSECO
Filtration for iron and steel foundries
The demand for improved
casting integrity
and performance continues,
often associated
with the need to
reduce casting weight.
The benefits provided by molten metal
filters are increasingly valuable to casting
producers and their customers in
achieving these goals.
In addition to enhancements to the
range of Sedex and Stelex filters that
offer foundries enhanced choice and
performance characteristics in filter
application, Foseco will be launching a
new filter technology for large, high
value steel castings.
The Hollotex shroud filtration
system combines the
known benefits of Stelex filters
with a fused silica shroud.
This innovative technology
provides a method of protecting
the molten steel as it is
poured from a bottom pour
ladle into the mould and casting
cavity. Aspiration of air is
eliminated reducing re-oxidation
inclusions and enhancing
the performance of the integral
filters. An application case
study will detail the major
improvements that this process
can facilitate in the production
and quality of highly
specified castings.
Recent developments in
the Sedex and Stelex product
portfolios offer foundries
increasing choice in filter products.
The attributes of these
products will be compared so
the user can understand the
associated benefits and select
the correct filter type for
their casting needs.
Foseco will be showing
many case studies demonstrating
the benefits provided by
applying Sedex and Stelex filters
to a variety of iron and
steel castings. These will be
complemented by Magmasoft
simulations which model the
molten metal flow control and
turbulence reduction that are
vital to achieving high finished
casting quality.
Hall 12 – Stand A1 + A2
www.foseco.com
Photo: Foseco
Hollotex shrould
application for large
steel castings will be
highlighted at the
Foseco stand at GIFA
2019
CASTING PLANT & TECHNOLOGY 2/2019 57

SPECIAL: GIFA 2019
MAGMA
Prediction of hot distortion of sand cores
MAGMA GmbH,
Aachen, specialist for
the virtual optimization
of foundry processes,
and HA, Düsseldorf
(both Germany), as a
supplier of foundry chemicals, have
joined forces in a long-term cooperation
to quantitatively describe the hot
distortion of sand cores. Together, they
intend to develop and provide digital
core data for foundries. Visitors at GIFA
2019 have the chance to see the concrete
steps being taken at the stands of
the two cooperation partners.
Increasing demands on the dimensional
tolerances of castings are especially
critical for thin-walled sections,
where even small deformations of sand
cores can be critical for maintaining the
required wall thicknesses and component
geometry. The deformation of a
sand core is dependent on its thermal
expansion and the position of the corresponding
core marks. For long thinwalled
cores, buoyancy forces of the
metal on the core play an additional
important role. In the case of organic
binders, even low buoyancy forces can
lead to time-dependent deformation of
the core due to creep effects in the
binder resin.
In order minimize the deformation
of sand cores, their thermal and
mechanical behavior during casting
must be understood. With this knowledge,
simulation programs can be used
to predict how the core sand will
behave during the casting process, particularly
at high temperatures.
MAGMA has implemented a numerical
model in Magmasoft in which the
core sand is treated as a porous medium,
and both the pressure and temperature
dependence of the core strength is considered.
Time-dependent core deformation
due to binder softening and decomposition
are additionally taken into
account through creep models. The
effects on the core of e.g. buoyancy
Core distortion during casting is a complex interaction between thermal, mechanical and
time-dependent influencing factors
forces during casting are also calculated.
The cooperation between HA and
MAGMA is aimed at quantifying the
thermo-mechanical behavior of different
molding materials during casting
for the primary HA binder systems.
MAGMA has developed a methodology
to characterize the material
behavior of cores using standard samples.
HA is using this systematic
approach in carrying out extensive
investigations at its Center of Competence
for both organic and inorganic
HA binder systems and different sand
types. These data will be used to generate
product-dependent data sets, to
make both the time and temperature
dependent behavior of core distortion
quantitatively predictable in Magmasoft.
The results are being validated
through in-situ measurements at the
HA technical center in Baddeckenstedt,
Germany, using optical measurement
methods to quantify the deformation
of sand cores as a function of
time during solidification.
“The aim of our cooperation is to
provide users of Magmasoft with validated
data for the quantitative prediction
of core distortion for HA products,“
confirms Dr.-Ing. Jörg C. Sturm,
a Managing Director of MAGMA. “With
this new database, our joint customers
will be supported even better in the layout
of their core and casting designs.“
“We have a great interest in quantifying
the behavior of our binder systems
during casting,“ says Amine Serghini,
member of HA‘s Executive Board
responsible for Sales and Marketing.
“The cooperation with MAGMA in this
area will enable us to offer our customers
another important added benefit.”
At GIFA, both partners will present
the first results of the joint development
project, which is planned as a
long-term cooperation.
HA at GIFA: Hall 12, Stand C50
MAGMA at GIFA: Hall 12, Stand A19/20
www.magmasoft.de/en
www.huettenes-albertus.com/en/
Photo: MAGMA
58

WHEELABRATOR
A new wheel, advanced
simulation technology and
equipment evolutions
Surface preparation
specialist Wheelabrator,
a Norican technology,
will be showcasing
a suite of new
blast machines and
solutions at GIFA 2019, evolved and
improved to meet emerging customer
requirements and industry trends.
A host of updates and extensions
to existing equipment ranges has
been developed particularly with aluminium
applications in mind – fitting
in with the brand’s new stand location
in the aluminium hall (Hall 11) at
GIFA, as part of the Norican Group
presence.
The Wheelabrator line-up for GIFA
includes:
> a new heavy-duty Universal blast
wheel
> a deep dive into the very latest
blast simulation technology
> numerous machine innovations
Visitors to the Norican stand will also
be able to learn about the latest digital
developments, for Wheelabrator
equipment and beyond, with experts
from Norican Digital on hand to share
the latest thinking.
Wheelabrator’s new blast wheel
for foundry applications will be unveiled
at GIFA. Representing the latest
innovations and proven technologies
from across the company’s global
blast wheel range, the new Universal
wheel has been refined in rigorous
testing over the past 12 months. It
will offer a new level of performance
and productivity for foundry blast
operations.
Simulation of blast processes can
speed up development of new machines
and even inform the design process
of the produced part – by testing
buildability early on.
Working with leading manufacturers,
namely in Automotive, as well as
simulation specialists, Wheelabrator
has been advancing blast simulation
technology to enable the design of
ever more complex parts and associated
processes, particularly those with
intricate internal surface areas.
At GIFA, Wheelabrator will show
what is possible in blast simulation,
including how advanced simulation
techniques save time and money
during part and process design – a key
advantage in today’s ever faster product
development cycles.
Also on show will be the latest
machine developments soft-launched
in recent months. They include extensions
to and variations on existing
ranges, which have been adapted to
anticipate evolving customer requirements.
They are:
> The SPH-2-3/8, a new compact
blast machine designed specifically
for aluminium applications. Based
on Wheelabrator’s trusted batchtype
spinner-hanger wheel blast
concept, the new machine excels
at descaling, deburring/deflashing
and cleaning of a variety of aluminium
parts. Optimising the
machine for this application enabled
the design team to also reduce
its price significantly.
> The LBS 1000, a lighter version of
the LBS mesh belt shot blast
machine range. The mesh belt concept
allows the efficient blasting
of parts from all sides within a
relatively compact space and
without tumbling. It offers pitless
installation and a more ergonomic
loading height. Like the new SPH,
it is suited particularly to the processing
of aluminium parts.
> A new range of wire mesh belt
shot blast machines for medium-duty
applications. The new
CMS machine sits between Wheelabrator’s
light LBS for nonfoundry
and the high capacity
CMC range for heavy duty foundry
applications. The CMS wire mesh
belt machine completes Wheelabrator’s
mesh belt machine offering.
Mesh belt machines are perfect for
applications where parts are too
big or too delicate for the tumblast
processes.
Hall 11, Stand A74-A78
www.noricangroup.com/gifa
FONDAREX
MODULAR
GIFA 11 / D41
new

SPECIAL: GIFA 2019
ZPF GMBH
New furnace plant enables simultaneous melting
of aluminium chips and ingots
Due to the different
shapes of ingots, return
material and aluminium
chips, different furnace
types were previously
required for
melting the respective material. However,
separate plants for the different
types of material do not pay off for die
casting foundries with too low volumes
of aluminium chips or return material,
so that only ingots are molten down.
ZPF GmbH, Siegelsbach, Germany, have
now developed a melting furnace
which is qualified for melting down aluminium
chips as well as recycling material
and ingots – a sustainable utilization
of the system is thus always
ensured. The plant is equipped with an
automatic charging system and is able
to melt up to 500 kg raw material per
hour, for example 250 kg aluminium
chips and 250 kg ingots. The new melting
furnace technology will be presented
for the very first time at this
year‘s GIFA with an exhibit.
Production by-products such as scrap
material and runner systems or even
aluminium chips are usually collected
and recycled externally in most foundries,
as they cannot be returned directly
to the melting process for economic
reasons. This results in high costs for
storage and transport, and the logistical
effort should not be underestimated.
“Until now, our aluminium melting furnaces
were only designed for charging
with unmixed material; a material mix
of ingots and recirculation aluminium
parts was previously only possible to a
limited extent due to the desired
boundary parameters such as melting
loss and melting rate“, reports Sven-
Olaf Sauke, head of R & D at ZPF GmbH.
“For some foundries, a pure chip furnace
is uneconomic, since the metal-cutting
share in the cast product is often
too low.“ ZPF has taken this market
need as an opportunity to develop a
new technology for melting furnaces
enabling the simultaneous melting of
chips, ingots or return material while still
keeping the melting loss values at an
extremely low level. This offers companies
greater flexibility in the recycling
process and new opportunities to optimize
the melting process.
For an optimal constructive design
“Since there are two different shapes in the case of chips and ingots, we first had to
choose the main variant“, reports Sven-Olaf Sauke, head of R & D at ZPF GmbH. “For our
prototype, we opted for chips as the main material and designed the furnace as a heel
melter (Graphics: ZPF GmbH).
of the new furnace, simulations were
used in the course of development to
be able to assess the basic system
behaviour. In addition, power and
exhaust gas measurements were carried
out under foundry conditions which
were used to determine the functional
parameters. “The decisive factor for us
was the optimum melting of the metal
and the required temperature control
in the furnace,“ explains Sauke. “In
addition to energy consumption,
numerous other factors that strongly
influence the melting result play a role
here in a modern furnace system - for
example the quality of the raw material
and the melting loss. For practical
implementation, ZPF analysed the data
collected and determined the parameters
required for simultaneous melting
of chips and other aluminium materials.
Based on these results, a prototype with
the new technology was implemented.
The melting furnace has dimensions
of 575 cm x 380 cm x 445 cm (L x W x H)
at an empty weight of approximately
28 tons. It is dimensioned for a maximum
throughput of 500 kg/h in total.
The furnace system is extended by an
automatic charging unit. This modular
unit is designed in such a way that different
types of material can be loaded
according to customer requirements.
“For the simultaneous melting of different
material forms in one furnace,
the first step is to determine the leading
material variant,“ Sauke says. “For our
prototype, we opted for aluminium
chips as the main material and therefore
designed the furnace as a heel melter.
As a result, the chips can be molten
down in combination with return material,
return wheels or ingots“. Which
variant is added to the chips can be
selected by the operator. The only
important thing is to pay attention to
the optimum quantity ratio between
chips and secondary material in order to
achieve optimum melting performance.
The new system will be presented at
this year‘s GIFA in Düsseldorf. “We will
be demonstrating the new system technology
using a furnace at our trade fair
stand. This gives us the opportunity to
present the innovations to interested
users in a detailed and practical manner,“
explains Sauke. Hall 10, Stand F59
www.zpf-gmbh.de
60

GIFA 2019
hall 16 / C11
Torque motors – here on an Eirich Intensive
Mixer R28 – are an energy saving alternative to
asynchronous motors.
EIRICH
Molding Material as
an Opportunity
As a specialist in the
processing of clay-bonded
molding materials,
Eirich, Hardheim, Germany,
enables foundries
to meet ever-increasing
demands. The molding
material holds opportunities for improving
the casting quality. A preparation
system from Eirich achieves higher
energy efficiency. Optimized and automated
processes enable the autonomous
preparation of molding material.
They are the basis for the Industrial
Internet of Things (IIoT). At GIFA 2019,
visitors can gather information about
groundbreaking EIRICH technology,
from which every founder can benefit.
The highlights and exhibits presented
at the fair include a QualiMaster AT1
of the new generation and an Intensive
Mixer R28 with torque motors.
The QualiMaster AT1 system is well
known and proven as the heart of quality
assurance in molding material preparation.
The new generation of modular
design is available as Eco, Profi or
ProfiPlus version. In the Eco version, the
inline tester is equipped with a compactability
measuring unit. A reporting tool
facilitates using it as a stand-alone unit.
The Profi version additionally measures
compactability and shear strength with
deformability. Completely new possibilities
are now available with the Quali-
Master AT1 ProfiPlus: For the first time,
the inline tester also measures springback
and gas permeability. Due to its
modular design, the AT1 Eco can be
upgraded to the AT1 Profi or AT1 ProfiPlus
at any time Eirich mixers equipped
with torque motors as direct drives
achieve a new level of energy efficiency.
Energy savings of up to 25 % are a realistic
prospect. These motors also have
the advantages of lower maintenance
requirements and reduced noise emissions.
Torque motors are not just a good
option for new Eirich mixers; they can
also be retrofitted to Eirich mixers in
operation without any problems. Another
highlight expected at the fair is the
prototype of an Evactherm mixer in a
new small size.
Hall 17, Stand A 38
www.eirich.de
Pneumatic conveying
technology
For dry, free-flowing, abrasive and
abrasion-sensitive material
Core sand preparation
technology
For organic and inorganic processes,
turn-key systems including sand,
binder and additive dosing and
core sand distribution
Reclamation technology
Reclamation systems for
no-bake sand and core sand,
CLUSTREG® for inorganically
bonded core sands
Shockwave Technology
CERABITE ®
Clean Castings
for the efficient removal
of residual sand and coatings
out of complex castings
KLEIN Anlagenbau AG
KLEIN Stoßwellentechnik GmbH
a subsidiary of KLEIN Anlagenbau AG
Obere Hommeswiese 53-57
57258 Freudenberg | Germany
Phone +49 27 34 | 501 301
info@klein-group.eu
www.klein-ag.de
www.stosswellentechnik.de
CASTING PLANT & TECHNOLOGY 2/2019 61

COATINGS
Multitasking: Coatings for
centrifugal casting
As the range of centrifugal casting applications increases, so does the importance of
coatings. In the past, coatings were mainly used as a separating layer between the mold
and the casting part, whereas today they are designed to meet very specific requirements:
Innovative coatings formulated for centrifugal casting help to avoid casting
defects, influence mechanical parameters and even serve as a forming medium to allow
the creation of special surface structures.
Klaus Seeger, Ekaterina Potaturina, Düsseldorf
The centrifugal casting process
Centrifugal casting was first used in the
middle of the 19th century by the British
engineer and inventor Sir Henry
Bessemer to produce rotationally symmetrical
parts. In centrifugal casting,
the melt is poured into a metal mold
which rotates around its central axis at
high speed. The centrifugal forces
acting on it press the melt against the
mold wall and produce a very pure and
highly densified composite. The metal
solidifies as the mold rotates – with the
advantage that a cavity-free casting in
the form of a cylindrical (hollow) body
is produced without the use of feeders.
The inner geometry of the mold determines
the outer contour of the casting,
62

act the casting and extends the life of
the mold.
Avoiding casting defects
Casting defects such as inclusions, gas or
reaction defects, which cannot be completely
eliminated simply by changing
the process parameters, are a significant
problem in the centrifugal casting process.
As the metallic permanent mold is
impermeable to gas during centrifugal
casting, the mold coating plays an
important “gas management” role. In
order to avoid gas defects such as pinholes,
the coating must have a certain
porosity and be able to absorb the
decomposition gases produced.
By targeted optimisation of the
composition and structure of the coating,
casting defects can be effectively
avoided. If, for example, organic components
are replaced with inorganic
ones, or calcined raw materials are
used, the loss on ignition and thus the
risk of gas defects is reduced. Selecting
raw materials with low reactivity also
helps reduce the risk of reaction errors
(Figure 3).
In centrifugal casting castings can be
manufactured without voids, where you
can dispense with the use of feeders.
Photo: ??
Figure 1: The mold is coated using a spray
lance.
coatings for centrifugal casting make it
possible to achieve clearly defined properties
and advantages. The various
functions that a centrifugal casting coating
can perform are described below
and illustrated using practical application
examples (Figure 2).
Coatings as separating agents
The coating can be applied by
sprinkling a dry powder into the rotating
mold. An alternative frequently
used process involves applying the coating
by spraying a coating dispersion
into the mold.. The coating’s primary
task is to achieve a separating effect
between mold and melt. Powder coatings
can, for example, consist of a mixture
of ferrosilicon, graphite, quartz
dust, bentonite or diatomaceous earth .
The addition of water and a dispersion
agent makes it possible to paint or
spray the coating. The uniform coating
of the mold wall makes it easier to ext-
Insulating effect
The insulating effect of the coating is
an important factor in the composition
formation and the hardness profile. It
regulates the heat transfer from the
molten metal to the mold, thus contributing
to the control of solidification
and the casting structure.
The insulating properties depend on
the one hand on the composition of the
coating, and on the other hand, on the
layer thickness on the mold. Both para-
the quantity of metal supplied determines
the wall thickness.
In horizontal casting, the melt is
poured into a lying mold. In the case of
particularly long castings or during continuous
centrifugal casting, the runner
can be moved during the casting process
(Figure 1). In vertical casting, the
casting takes place in a mold with a vertically
rotating axis. Vertical casting can
be used to produce conical or spherical
outer contours. The rotational speed is
often significantly slower than with
horizontal casting.
In centrifugal casting, the mold is
usually lined with a ceramic protective
layer, the so-called coating. Since the
development of the centrifugal casting
process, the demands placed on the casting
parts and, at the same time, the
functions to be met by the coating have
continuously increased. Today, modern
Figure 2: Several molds can be arranged in a casting carousel to produce large numbers of
castings.
CASTING PLANT & TECHNOLOGY 2/2019 63

COATINGS
Figure 3: A coating with good
gas permeability helps to
avoid gas-related casting
defects such as “dents” (left)
or “pinholes” (right)
Figure 4: High-quality
centrifugal casting products
after finishing.
Figure 5: Castings
before further processing.
meters have a significant impact on the
cooling rate of the melt and consequently
the mechanical properties of
the casting. These, in turn, are a crucial
component of customer requirements.
Particularly with thin-walled pipes, insulating
properties need to be specifically
adjusted in order to achieve maximum
workability.
The selection of suitable raw materials
has an impact on thermal conductivity,
but also on factors such as chemical
reactivity, fire resistance, hardness and
application properties of the coating.
The grain size distribution is also
important: a fine grain size has many
grain boundaries and thus slows down
heat transfer. A large grain size, on the
other hand, creates more cavities between
the individual grains, which also
leads to an insulating effect.
Solids content, viscosity and rheological
properties must be balanced in
such a way that, on the one hand, the
desired layer thickness is achieved
while, at the same time, the coating is
easy to spray on and allows an even
application. Since the coating is a dispersion
that may sediment out during
storage, appropriate preparation is
required before application. Before use,
the coating is adjusted to the desired
processing viscosity by determining the
density or efflux time.
Controlling surface textures
Since most castings are machined after
production, there are no special requirements
regarding the roughness of the
casting surface for many applications.
For certain applications, the shape and
height of any roughness are clearly
defined. This applies, for example, to
grey cast iron wastewater pipes: during
their manufacture, the aim is to achieve
smooth cast surfaces. Although this
requirement has no direct influence on
the functionality of the casting, some
foundries regard it as an externally
visible quality criterion with which they
want to score points with their customers.
There are, however, also customer
specifications that require the production
of rough surface textures: For cylinder
liners, a rough surface with a precisely
defined surface structure is
expressly desired (Figures 4 and 5).
Cylinder liners can be pressed into
engine blocks. It is also possible to cast
the liners into the engine block after
machining. With the further development
of casting processes and coatings,
it is now possible to produce defined
surface structures that enable the liners
to be cast directly into the engine block.
The molten metal flows around the
structured surface, filling in recesses
and undercuts so that the engine block
and liner materials form an extremely
strong and resilient bond.
The aim of this process is to obtain a
rough surface structure during casting
so that the outside of the cylinder liner
does not require any further processing.
The depth and shape of the structure
can be determined according to customer
specifications. Hedgehog or mushroom-shaped
elevations are possible,
as are structures with undercuts. The
structure depths vary between 0.3 and
1.1 mm, depending on customer requirements.
The structures with undercuts
can only be processed in pressure die
casting, while the liners with hedgehog
or mushroom structure can be processed
in conventional gravity die casting.
In addition to the special configuration
of certain machine parameters, the
coating plays a decisive role in achieving
these surface structures. It can therefore
be said that the coating acts as a
forming factor (molding material).
A modern coating for the production
of structured cylinder liners is composed
of special refractory materials
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COATINGS
Figure 6: Schematic illustration of the Leidenfrost effect.
Figure 7: The formation of different structures is controlled, among other things, by the
coating.
Figure 8: When drawing the tubes, the coating should adhere to the cast part and be completely
removed.
with defined grain sizes and shapes,
water, binder, dispersion agent and surfactants
to control surface tension.
Figure 6 shows the various processes
that occur when an aqueous coating is
sprayed onto the hot centrifugal casting
mold. If drops of the coating hit the
mold, the coating is accelerated by the
rotary motion of the mold and pressed
against the hot mold as a result of the
centrifugal forces. The water in the coating
immediately begins to boil. Leidenfrost
effects cause gas layers or gas bubbles
to form. As the coating dries,
channels form in the coating. Figure 7
illustrates the concept of forming different
structures from the gas bubbles.
Depending on the coating composition,
the centrifugal forces and the mold
temperature, different channels are formed,
which in turn lead to different
surface structures during casting.
Additional coating requirements
In addition to the functions of coating
for centrifugal casting described above,
there are a number of additional, application-specific
requirements: A key characteristic
with regard to the process
steps is, for example, extraction behaviour:
When the tube is extracted from
the mold after solidification, the coating
should adhere to the casting and,
ideally, be completely removed from
the mold with the casting (Figure 8).
In terms of cleanliness in the workplace,
it is also desirable that a contiguous
layer of the coating remains on
the casting, and that it is as dust-free as
possible (Figure 9). If the next process
step involves blasting, the coating
should be easy to remove – in case of a
textured surface it may also need to be
removed from the undercuts. For health
and safety reasons, the coating must
not contain crystalline quartz.
Consistent quality is crucial
In order to gain a competitive advantage,
many foundries strive to increase
the productivity of their processes and/
or improve the quality of their castings.
This leads to ever narrower process
windows, with the risk that even the
smallest defects can cause major disruption.
Coatings must also meet these
more demanding requirements. It is
therefore becoming increasingly
important to use stable coating products
of uniform quality. Foundries
need products with consistent properties
in terms of composition, viscosity
and application behaviour. However,
natural raw materials are typically used
66

Figure 9: A continuous layer of coating remains on the casting, which minimizes dust.
Figure 10: The uniformity of the defined surface
structure is checked during the quality
inspection.
in the production of coatings, and these
can vary in their quality. Comprehensive
quality testing of the raw materials
enables deviations from specified properties
to be detected at an early stage.
In addition, regular process checks
should be carried out using suitable
measuring methods. In structural casting,
the uniformity of the surface structure
desired by the customer is also an
integral component of the quality
assurance process (Figure 10).
Innovation potential for foundries
and coating suppliers
From the automotive to the chemical
and paper industries; from pipes to
rolls to cylinder liners: when it comes
to the production of rotationally symmetrical
components, centrifugal casting
is a proven, technically sophisticated
casting process with enormous
application and innovation potential.
For foundries, it is well worth consulting
an experienced coating supplier at
an early stage in the development process
of any new centrifugal casting
applications. The foundry specialists
and chemists at Hüttenes-Albertus are
always happy to take on new challenges.
Since there is often no “off-theshelf”
product for special applications,
we develop and test solutions step by
step together with our customers –
from initial testing all the way through
to series production readiness.
www.huettenes-albertus.com
Dr. Klaus Seeger, Head of Research and
Development Coatings, Dr. Ekaterina
Potaturina, Product Manager Coatings,
Hüttenes-Albertus Chemische Werke
GmbH
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CASTING PLANT & TECHNOLOGY 2/2019 67
FAT Förder- und Anlagentechnik GmbH · D-57572 Niederfischbach · Tel. +49 (0) 27 34/5 09-0 · fat.info@f-a-t.de · www.f-a-t.de

3-D-PRINTING
68

The Kinetic Assembly Structure reflects the materialization
of a train of thought. The lines form an infinite
loop. voxeljet printed the models of the complex
sculpture in several parts.
The stool „Infiniala“ by designer
Sergej Ehret: Future of Sculpture.
With voxeljet 3-D printing systems,
even the most complex
sculptures that would have been
impossible using traditional molding
techniques can be realized.
3-D printing systems evolutionize
traditional art casting
Art foundry Strassacker creates artistic works using 3-D printing systems by voxeljet
Frederik von Saldern, Friedberg; Peter Mühlhäuser, Süßen
Photos: Voxeljet
Strassacker, one of the oldest and
largest art foundries in Europe, is
modernizing art casting with 3-D
printing from voxeljet, Friedberg, Germany.
The printing technology is used
to create investment casting patterns
and increases the artists’ freedom of
design. Artworks which previously could
not be produced using traditional molding
techniques can now be printed
directly in the form of a casting pattern.
Have you heard of The Bambi
Award? The German Media and Television
Prize, which is awarded annually to
people with visions and for outstanding
achievements? The award winners
include world stars such as Christoph
Waltz, Samuel L. Jackson and Kate
Winslet. But far less known is the company
that produces the coveted bronze
deer: the family owned company Strassacker
from Süßen near Stuttgart. Since
it was founded in 1919, the company
has evolved from the manufacture of
pasta machines and everyday objects to
the production of numerous precious
artworks. The company has made a
name for itself especially in the art
industry and is now a well-known
player. Their customers include world
renowned contemporary artists, who
rely on the Strassackers’ specialist expertise.
Digital model creation at Strassacker
While traditional production
methods have characterized the creation
of works of art to date, today there
The Strassacker foundry can offer customers both manual and digital manufacturing
processes. If necessary, even both can be combined. Like here at a part of the sculpture
KAS by Simon Mühlhäußer.
are new possibilities for the design of
art. One that clearly pushes the
boundaries of what is possible is 3-D
printing. Industrial 3-D printing systems
can be used to print models made from
acrylic glass (PMMA) or casting molds
made from silica sand. These are then
handled by casters in the same way as
traditional wax patterns or sand casting
molds. Strassacker recognized the
potential of 3-D printing early on. For
more than 15 years, the company has
been working with printed patterns –
including printed plastic patterns from
voxeljet. During this time, the family
business has been able to build up a
wealth of experience that it is sharing
with its customers.
This means that customers can either
send in their completed CAD data sets
to Strassacker, where they will be processed
in the company’s in-house digital
workshop, or customers can approach
Strassacker with their project plans and
allow the specialists in the 3-D modelling
department to advise them. „There
CASTING PLANT & TECHNOLOGY 2/2019 69

3-D-PRINTING
are hardly any limits to the ideas, but
you still need to develop them yourself,“
says Peter Mühlhäußer, product
line manager at Strassacker. “The same
way you have to know where the application
of technology makes sense and
where it doesn’t. Our technicians, designers
and 3-D modelling experts are the
right people to talk to, in order to
define the right technological execution.”
Strassacker can offer its customers
both manual and digital manufacturing
processes. If required, they can even
combine the two together in a hybrid
approach.
Examples
“Wachsende Steine” (“Growing Stones”)
by Timm Ulrichs. A stone, in its
natural form, was used as the initial
model. At Strassacker it was 3-D
scanned, digitized, scaled to the desired
size and then printed in several parts by
voxeljet. The larger stones, made from
several individually printed PMMA
parts, were manually assembled and
then prepared for casting by hand. The
PMMA models were cast like conventional
wax models and then individually
patinated by hand. Finally, the bronze
casts were airbrushed to look like the
natural model and painted by hand.
Another project are the bronze
reconstructions of the “Boxer at Rest”
and the “Hellenistic Prince” sculptures
by Prof. Dr. Vinzenz Brinkmann, which
were originally handmade between the
4th and 1st centuries BC and rediscovered
on the Quirinal in Rome in 1885.
The original sculptures were
3-D-scanned, digitized and printed as
PMMA patterns by voxeljet in their service
center in Friedberg, Bavaria. Finally,
the patterns were cast by Strassacker,
chiselled by hand, partially restored and
patinated. The finishing touches were
made by experts at the Liebieghaus
sculpture museum in Frankfurt.
Unpacking of the PMMA part,
which is then dipped into ceramic
and burnt out.
Printed and wax-infiltrated
PMMA part “KAS”.
Two other more current examples of
the collaboration between Strassacker
and voxeljet can be seen in the sculpture
“KAS”, an in-house project by
artist Peter Simon Mühlhäußer, and the
sculpture “Infiniala” by designer Sergej
Ehret.
“KAS” stands for “Kinetic Assembly
Structure” and reflects the materialization
of a digital thought process. This
also served as inspiration for the seat
„Infiniala“. A closer look at the numerous
contours of the seat reveals that
the lines always form an endless loop.
„KAS“ and „Infiniala“ show the
unique possibilities in the realization of
3-D printing gives
artists the opportunity
to make
fantastic changes.
For this reason,
3-D printing is
already firmly
established in the
repertoire of
sculptural artists
and will gain
further market
share.
ABOUT STRASSACKER
Ernst Strassacker GmbH & Co. KG was founded in Süßen, Germany, in 1919,
and today is one of the world’s leading manufacturers in artistic casting.
Since 2001, Edith Strassacker has been at the head of the family business in
its fourth generation. Their workshop creates ambitions sculptures, modern
architectural elements, sacred art and large-scale sculptures for public spaces.
Various processes are used, including the lost wax process and ceramic, fire
clay, vacuum and sand casting. The main focus is on preserving and encouraging
craftwork skills. Their customer base includes renowned artists, designers
and architects from all over the world. The company employs around 300
people at the headquarters in Süßen and their French branch in Heimsbrunn.
They also have sales offices in the USA and Saudi Arabia.
highly complex, digitally created works
of art.
The complex nested geometries can
only be realized by the use of additive
processes, such as binder jetting from
voxeljet. It would be impossible to produce
these casting models using conventional
molding processes.
70

Production of a 3-D pattern and
its advantages
Strassacker uses voxeljet‘s 3-D printing
service to produce, among other things,
positive and tooling less patterns for
bronze casting. In order to achieve this,
they send the 3-D data set of an artwork
to the voxeljet service center in
Friedberg near Augsburg. Here, the
CAD data is checked and further uploaded
into the VX1000 3-D printing system.
In the subsequent Binder-Jetting
process, the recoater moves over the
1,000 x 600 x 500 millimetre building
platform and spreads a 150 micrometre
thin layer of the plastic polymethyl methacrylate
(PMMA). Then, the print head
bonds the PMMA with a binder through
polymerisation wherever the artwork is
to be created. After each of these two
steps, the building platform is lowered
by one layer thickness and the recoater
and print head process the next layer.
This process produces the CAD data
layer by layer with a resolution of up to
600 dpi.
Once the print is finished, voxeljet
employees remove the model from the
The elaborate interlaced geometries
can only be realized
through the use of additive
processes, such as the voxeljet
binder jetting. Making a cast
blank with conventional
molding techniques would
be impossible.
The production of complex
model geometries is now
easily possible. Even the
gating system can be printed.
job box, remove unbound plastic powder
which can be reused 100 %,
infiltrate the components with wax to
further smoothen the surface and send
the positive pattern to Strassacker. 3 to
5 days after the placed order the pattern
is on-site at Strassacker and ready
for further processing.
The casting process at Strassacker
can then take its regular course. With a
significant advantage: no silicone negative
mold has to be created. The supplied
PMMA pattern can then be
immersed directly in ceramic to build a
shell and burnt out in the furnace at
700 °C. The PMMA material burns out
without leaving any residue, leaving
just the ceramic mold, into which the
liquid metal can then be poured.
In combination with 3-D printing,
the investment casting process opens up
completely new design possibilities.
Complex geometries that would have
been unthinkable in the past are now
possible in the near future. Added to
that, the gating system can also be printed
directly. This saves time and delivers
consistent casting results.
Chiselling and patination
Once the casting process has been completed,
the chiselling and patinating
work begins. A service that Strassacker
customers particularly appreciate. In
intensive cooperation with the artist, the
final appearance of an artwork is created
mutually. With custom-made tools,
the chisellers precisely carve out intricate
shapes and structures. Multi-piece cast
parts are joined by a specially developed
welding process without any visible
welds on the finished work of art. The
Bambi also gets its highly polished surface
here. Last but not least, the patinater
gives the work its colour by anticipating
the natural oxidation process using
chemical reactions. A high level of craftsmanship
and expertise is required to create
the subtlest of nuances in colour.
The future of sculpting
Nobody can exactly say, what the future
holds for the art of sculpting. But
change is clearly audible. There are
already a significant number of
open-minded artists using new, digital
technologies. This change will be of particular
benefit when it comes to conceptualizing
new artistic works. It allows
drafts to be drawn up and developed
using a computer in cases where manual
shaping techniques would be insufficient.
Innovative artists are constantly
striving to shift boundaries and develop
something new. The path they take to
achieve their vision is not the priority.
Decisive is the transformation into reality.
3-D printing gives artists the opportunity
to truly innovate. This is why 3-D
printing has already become firmly established
in sculptors’ repertoires and will
continue to gain market share.
It could also be conceivable that in
the distant future the model pre-acceptance
could take place using Virtual Reality
glasses. This would allow customers
to view the finished artwork in size,
colour and shape in three-dimensional
space before it actually is fabricated.
Peter Mühlhäußer is certain: “This would
be a practical relief that could solve
many problems in advance. It continues
expanding the dynamic creative dialogue
between artist and craftsman.”
Until then, it remains to be seen
what new, unique, 3-D-printed projects
will emerge at Strassacker in the near
future with the help of Binder Jetting
from voxeljet. One thing is for sure:
next time you get to see another Bambi
Award celebration, you’ll certainly
know, where the Bambi originated.
www.voxeljet.com
CASTING PLANT & TECHNOLOGY 2/2019 71

INTERNATIONAL FAIRS AND CONGRESSES
Fairs and Congresses
20th International Die Casting, Foundry & Industrial
Furnace Exhibition
June, 13-15, 2019, Pazhou, Guangzhou, China
www.julang.com.cn/english/yazhu/index.asp
GIFA, METEC, THERMPROCESS, NEWCAST
June, 25-29, 2019, Düsseldorf, Germany
www.gifa.com
China Diecasting 2019
July, 17-19, 2019, Shanghai, China
www.diecastexpo.cn/en
11th International Exhibition of Steel, Metallurgy, Foundry,
Machinery and related Industries
September, 1-4, 2019, Isfahan, Iran
https://bit.ly/2MrZT1P
FENAF 2019 – Latin American Foundry Fair
September, 17-20, 2019, São Paulo, Brazil
https://bit.ly/2MrZT1P
WFO Technical Forum and 59th IFC
September, 18-20, 2019, Portoroz, Slovenia
www.drusto-livarjev.si
International Conference of Metals, Ceramics and Composites
September, 25-27, 2019, Varna, Bulgaria
https://mcc.foundry-conference.com
International Foundry Congress & Exhibition (IFCE-2020)
November (3rd Week), 2019, Lahore, Pakistan
www.pfa.org.pk/info/8th-IFCE/587/0
72
Advertisers‘ Index
Admar Group, Ocala FL/USA 23
AGTOS Gesellschaft für technische
Oberflächensysteme mbH, Emsdetten/Germany 41
ASK Chemicals GmbH, Hilden/Germany 15
ASTI - Gießereigeräte GmbH, Sinsheim/Germany 19
DISA Industries A/S, Taastrup/Denmark 25
DVS Media GmbH, Düsseldorf/Germany Inside Front
Cover, Inside Back Cover, 40
Euromac srl, Marano Vicentino (VI)/Italy 47
ExOne GmbH, Gersthofen/Germany Front Cover
FAT Förder- und Anlagentechnik GmbH,
Niederfischbach/Germany 63
Filtech Exhibitions Germany GmbH & Co. KG,
Meerbusch/Germany 40
FONDAREX SA, St. Légier/Switzerland 55
Hitachi High-Tech Analytical Science GmbH,
Uedem/Germany 61
Hüttenes-Albertus Chemische Werke GmbH,
Düsseldorf/Germany
Back Cover
Jasper Gesellschaft für Energiewirtschaft und
Kybernetik mbH, Geseke/Germany 8
JÖST GmbH & Co. KG, Dülmen/Germany 43
KLEIN Anlagenbau AG, Freudenberg/Germany 57
KÜNKEL WAGNER Germany GmbH,
Alfeld/Germany 53
Luoyang Hongfeng Abrasives Co., Ltd.,
Luoyang/PR China 14
Maschinenfabrik Gustav Eirich GmbH & Co KG,
Hardheim/Germany 49
O.M.LER S.r.l. Bra, (CN)/Italy 31
Optris GmbH, Berlin/Germany 13
regloplas AG, St. Gallen/Switzerland 51
RUMP Strahlanlagen GmbH & Co. KG,
Salzkotten/Germany 31
Rudolf Uhlen GmbH, Haan/Germany 39
Heinrich Wagner Sinto Maschinenfabrik GmbH,
Bad Laasphe/Germany 37
voxeljet AG, Friedberg/Germany 39
YXLON International GmbH, Hamburg/Germany 9

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PREVIEW/IMPRINT
A group of foundymen is waiting
for the end of the tapping on the
cupola of Gießerei Stolle in Bonn-
Beuel. Deliveries and services for
worldwide investment projects
make up a considerable part of
sales.
Photo: Andreas Bednareck
Preview of the next issue
Selection of topics:
R. Piterek: The foundry as project partner
The iron foundry Gießerei Stolle is successfully involved in the casting of special machines – the range of services not only
includes the casting and machining, but the complete project planning.
D. Sauerwald: Recycling – certainly safely!
The GreCon spark extinguishing system sees to a safe production at Siegfried Jacob Metal Works, which has been specializing
in metal recycling for more than six decades.
B. Pinto et al.: Thermally-efficient crucibles: Fundamentals, modelling and applications for energy savings
Since melting and holding metal in crucibles accounts for a large portion of energy demand in foundries, recent advancements
in crucible technologies resulting from these studies could significantly impact cost-efficiency and carbon footprint.
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