CPT International 3/2019

EDITORIAL
Converting big data
to smart data!
With interesting new cooperations and numerous future-oriented
innovations, GIFA has come to a successful conclusion. The fair thus
underscored its role as the world‘s leading trade fair for foundry
technology.
Robert Piterek
e-mail: robert.piterek@bdguss.de
Digitalization in the foundry
industry was one of the main
topics at the GIFA in late June.
We discuss it in our trade fair review
from P. 38, which summarizes the trends
and innovations at this year’s trade fair.
Whether molding plant producers, furnace
constructors or die-casting equipment
specialists – all the important
companies had new developments in
their programs for converting big data
to smart data, i.e. enabling visualization
of plant performance in comprehensible
graphics and exploiting optimization
potentials uncovered by comparisons
with old data or other plants.
There were also virtual and augmented
reality applications for servicing, maintenance,
repair and training – showing
that the sector has finally found its way
into the 21st century.
In addition to our GIFA review, we
also offer two digitalization highlights
in this issue: melting furnace producer
Otto Junker used GIFA to present its
optimized Optical Coil Protection System
(OCP), which monitors the service
life of furnace linings and makes maintenance
intervals predictable (more on
this from P. 9). And machine manufacturer
Gustav Eirich GmbH & Co. KG from
Hardheim meets the need for digitalizing
production processes in its sand
preparation plants with the AT1 inline
inspection tester. The system automatically
measures the compactability and
shearing strength of the sand employed,
and was greeted with great interest
by specialist visitors to GIFA (from
P. 18).
The second main trend at the trade
fair was additive manufacturing, which
is increasingly receiving attention from
casters all over the world. Our interview
with ExOne Managing Directors Hartner
and Bader focused on industrialization
of the process and the company’s collaboration
with Siemens in this field, as
well as the increasing importance of the
new technology worldwide (from P. 6).
The rolls made by Gontermann-Peiper
from Siegen using cylindrical centrifugal
casting and gravity die casting are
also found worldwide. The company
casts the world’s heaviest and longest
rolls, and can look back on about 200
years of history and comprehensive
expertise in the casting of rolls (from
P. 28). Gontermann-Peipers also supplied
the world’s most modern steelworks,
Big River Steel, with more than
100 rolls made in Germany. The ‘learning
steelworks’ and its possibilities
were also proudly presented at the GIFA
by plant constructor SMS.
Please note that from now on you find
our Casting Industry Suppliers Guide in
each issue – book your entry now and...
...have a good read!
CASTING PLANT & TECHNOLOGY 3/2019 3

CONTENTS
FEATURES
6 INTERVIEW
„ Siemens is a great industrial partner“
Interview with the ExOne Managing directors
Hartner and Bader about their cooperation with
Siemens on the industrialization of 3-D printing.
Robert Piterek
9 MELTING SHOP
Digitalization in industrial furnace manufacturing
- on the way to Industry 4.0
With examples like the OCP Optical Coil Protection
system industrial furnace manufacturer Otto
Junker presents his innovations on digitalization.
Felix Aßmann, Simon Künne, Kunal Mody, Wilfried
Schmitz and Günther Valder
INTERVIEW
ExOne Managers
Hartner and Bader on
the industrialization
of 3-D-Printing.
COMPANY
Visit to the roller
foundry Gontermann-Peipers
in
Siegen .
18 SAND REGENERATION
Automatic mold material preparation
During sand regeneration at Jürgens Gießerei the
latest technology from machine builder Eirich is in
use. Of particular interest: the AT1 inline tester.
Edith Weiser
22 MOLD AND COREMAKING
Sand core hardening: Digital quality
with new ACS-Technology
Sand core quality plays a decisive role for casting
quality. The ACS solution generates the heat in the
cores and thereby hardens them completely.
Wolfram Bach, Gotthard Wolf
Cover-Photo:
Titelfoto: Bednareck Photography
Gontermann-Peipers GmbH
Hauptstraße 20, 57074 Siegen, Germany
info@gontermann-peipers.de
www.gontermann-peipers.de/en
GIFA SPECIAL
GIFA and NEWCAST
President Nelissen
takes stock after the
completed fair.
Melting shop in the Marienborn plant of Gontermann-Peipers.
The company is one of the world‘s most
important producers of rolls for rolling mills and highperformance
components for machine construction.
4

CONTENTS
MELTING SHOP
Digitalization in
industrial furnace
manufacturing.
24 COATINGS
Waterbased coatings for large-scale castings
The new waterbased coating at the iron foundry
König & Bauer is environmentally friendly and
reduces costs. Ulf Knobloch, Christian Koch
28 COMPANY
Rolls for the world
Gontermann-Peipers casts the world‘s heaviest
rolling mill rolls and has almost 200 years of foundry
expertise. Robert Piterek
35 SPECIAL: GIFA 2019
„ GIFA has underlined its claim to being
the world‘s leading trade fair“
GIFA and NEWCAST President Heinz Nelissen on the
outcome of the fair, Martin Vogt, Robert Piterek
GIFA sets the trends for the future of
the industry
What remains of the Bright World of Metals with
its core, the trade fair GIFA? There was no new
record of visitors, but the fair set clear trends for
the industry‘s future. Robert Piterek, Martin Vogt
44 E-MOBILITY
Powertrain 2030 - driven by diversification
At the specialist conference „Foundry Technology
in Engine Construction“ two automotive engineers
presented a scenario of the future of mobility.
Andreas Pfeifer, Otmar Scharrer
COLUMNS
E-MOBILITY (left)
How will E-Mobility
develop and how will
vehicles be powered
in 2030? A scenario
presented by two
engineers at the
„Foundry Technology
in Engine Construction“
conference in
Magdeburg.
3 EDITORIAL
43 GIFA NEWS
48 NEWS IN BRIEF
55 NEW: THE KEY TO CASTING
INDUSTRY SUPPLIERS
73 FAIRS AND KONGRESSES/AD INDEX
74 PREVIEW/IMPRINT
CASTING PLANT & TECHNOLOGY 3/2019 5

INTERVIEW
“Siemens is a great
industrial partner”
At GIFA, 3-D printer manufacturer ExOne announced a cooperation with Siemens on the
industrialization of 3-D printing. Managing directors John Hartner (USA) and Eric Bader
(Germany) talked with CP+T about the new partnership and the growing importance of
3-D printers in the foundry industry.
Photos: Martin Vogt/BDG
Core and mold makers still use the classic
methods of core shooting and molding
machines. What development has
the branch taken since ExOne and
other companies came up with core
and mold printing?
John Hartner: The conversion of industry
is based on market factors and
things we can do to accelerate those
market factors. One part of this is that
customers come up with more complex
designs and they need to achieve these
designs more rapidly. Thus the complexity
of 3-D printing – and you get it for
free – is one thing driving the 3-D printing
market. The accelerating speed of
the machines is also going to drive the
market. Furthermore, we will continue
to bring down the cost of ownership.
Our new machine is the best example of
that. It has the same price but is up to
30 per cent more productive. I spend a
big part of my business life in the semiconductor
and electronics industry.
Every year we have had to deliver more
for the same price or less. The additive
manufacturing business is going to
become like that.
Eric Bader: I agree. Bringing down the
cost of ownership helps make the technology
affordable and to see it practically
in daily life. Not just for prototyping,
but with these complex structures
it helps start the production of small
series. And it should move to larger
series production.
Do you expect that serial production
with your machines will be possible
one day?
John Hartner: Yes we do, there are
customers that have already started
6

ExOne’s current business
strategy and the
impact of 3-D printing
technology on the
foundry industry were
the topics of discussion
in the interview of the
company’s Managing
Directors Eric Bader
(Germany) and John
Hartner (USA) with CPT
Editor Robert Piterek
(from left).
“The cooperation with
Siemens should help us
with quality control on
the one hand, and digitalization
on the other
hand,” explains John
Hartner.
with it and there are customers whose
plans are much broader. That is very
encouraging for us. The new machine
has not only improved cost of ownership
but it also has the connectivity
required for Industry 4.0 that will allow
people to seamlessly get the automation
to deliver their factory-wide requirements
in volume.
How will the cooperation with Siemens
boost your business?
John Hartner: On the one hand, the
cooperation will help us with quality
control and, on the other hand, the
machine has many new sensors. All that
data is going to improve the process.
And Siemens is a great industrial partner.
They work with the major automotive
companies in Germany; they work
with all major customers around the
world. I think it is a fantastic partnership
and, as Siemens said: our system has
the highest level of integration in
Industry 4.0 applications of all the additive
manufacturing vendors.
So it’s all about industrialization…
Eric Bader: That’s the clear challenge
the industry confronts us with. Not just
having a stand-alone machine – which
we can’t look into, like a black box,
when it comes to quality, result and
operability of the machine – but in
addition to increasing the speed and
reducing the cost of ownership also
increasing reliability and the transparency
of the grinding process. Right
here the collaboration with Siemens is a
big achievement for us.
Your company is still young. How have
revenues developed in recent years?
John Hartner: We were in binder-jetting
for longer than it seems because
we belonged to another company
working with binder-jetting before
ExOne was formed. Our company was
finally established as a sole entity in
2005. That gave us the chance to grow.
In 2014 we became public. Since then
we have grown in the mid-teens, so
14 or 15 per cent per year. We think
we will continue to grow at that pace
or faster.
It is possible to produce complex cores
and molds using 3-D printing. Can you
give us an example of a geometry that
isn’t possible without a printer?
Eric Bader: The classic examples are core
packages where you have 10, 15, 20
parts and you integrate them into a
single core package. Or multiples cores
and the mold are integrated into a
single printed mold package. This is a
big achievement for binder-jetting and
ExOne technology. And other examples
are just coming up, e.g. water-core
jackets for innovative motors for temperature
management. Some of it you
can do traditionally, some you can’t. We
will see many more examples, e.g. in
the pump industry. Where you will also
have a hard time with classically shot
cores is the field of e-mobility. With 3-D
printing you bring more performance
into parts, higher cooling efficiency.
These are really examples where printing
brings a lot of additional benefits
to the end-product and that is what we
aim for – to create additional value and
drive the cost down so that 3-D printing
can be used in more and more applications.
But I don’t really envision that
3-D printing will blow the traditional
market away at a stroke.
CASTING PLANT & TECHNOLOGY 3/2019 7

INTERVIEW
Is operation of the systems becoming
easier?
Eric Bader: With the integration into
Industry 4.0, which we are now implementing
with our new partner, the
fears about the complexity of the technology
should disappear because transparency
has increased. There is a
camera image from the box on which
you can observe the printing process
layer-by-layer. That should lower the
hurdle to enter 3-D printer technology.
How important is Germany as a market
for 3-D printing technology?
Eric Bader: The country is at the top of
the ladder, we have some companies in
here that are pushing the technology to
its limits. There are foundries that have
their own sorting process. Suddenly,
there is space for many other applications
that are possible with the 3-D
printer. Apart from Germany, there are
also other prime examples, such as the
Japanese-American company Kimura,
which has more than ten of our machines.
The company has completely switched
from traditional core and mold
making to 3-D printing. It is important
for companies to become owners of a
machine. It is not enough to be supplied
with 3-D printed products. We
have to use the machines ourselves to
understand the possibilities.
“We print with inorganic binders – this
is a trend that will affect the entire industry,”
Eric Bader predicts.
Who are your customers in the foundry
industry?
Eric Bader: Georg Fischer, Gießerei Grunewald
and many more. Most of the
automotive companies in Europe, the
Americas, India and China are utilizing
3-D printing technology. 70 - 80 percent
are running on our printing equipment.
The pump industry is interesting,
aerospace is very interesting, the building
equipment industry, and parts of
general industry too. These are the
markets that we are in today. We certainly
have a solid backbone in the
automotive industry but the technology
is now spreading out into other
diverse industries.
John Hartner: Many of our customers
have already placed follow-up orders
with us. We also have the largest market
share. Ford is a good example.
Recently, two brand new systems were
deployed at their Advanced Manufacturing
Center in Detroit. The center is one
of our oldest customers.
So business in the US is going well too?
John Hartner: We are just negotiating
with representatives of a construction
equipment company. Yes, business in
the US is going well. But we also have a
very large customer in Japan, for
example, who in turn has customers
who demand high levels of complexity
and who want to automate more
because of the shortage of skilled workers.
How about the environmental friendliness
of your technology?
Eric Bader: The pressure in terms of climate
protection weighs on all companies.
We print with inorganic binders –
this is a trend that will affect the whole
industry. In addition, we also work with
chemical and natural resources companies
to produce binders with low emissions.
We are currently trying to reduce
the emissions of furan resin binder systems.
What is decisive for the ecological
footprint, however, is that 3-D printing
no longer necessarily means that products
need to be shipped, but that the
data can simply be sent to a printer in
another country and printed there. This
gives you the flexibility to produce the
parts where you need them.
We saw some interesting developments
at GIFA: what do you think of the entry
of Laempe Mössner Sinto into the production
of 3-D printers, or the alliance
for 3-D printing involving Loramendi,
voxeljet and ASK Chemicals?
John Hartner: The market is growing,
interest is increasing. However the market
develops, we will be able to handle
it and improve even further!
Eric Bader and John Hartner spoke with
Robert Piterek
8

MELTING SHOP
Photo: Andreas Bednareck
Digitalization in industrial
furnace manufacturing –
on the way to Industry 4.0
OCP system in use. In
contrast to the previous
version, the current one
enables cross-system
communication and standardized
data exchange.
The way to Industry 4.0 is an evolutionary process which offers great potential for
improving and stabilizing production processes and for increasing energy and resource
efficiency by way of digitalization and networking. As a leading supplier to foundries
and semis producers, Otto Junker GmbH (Simmerath/Germany), is determined to meet
this challenge as demonstrated herein on the examples of its OCP Optical Coil Protection
system, predictive maintenance system, and process models (Digital Twins).
by Felix Aßmann, Simon Künne, Kunal Mody, Wilfried Schmitz and Günter Valder
Introduction
While the automation level and hence,
the degree of digitalization of modern
industrial furnace equipment, be it melting
or heat treatment systems, has
kept rising in recent years, these systems
and the associated peripherals
have, in many cases, largely remained
digital islands to this day. Although
extensive digital networking and the
consistent acquisition and, above all,
consolidation of all available data for
the purposes of comprehensive higher-level
analysis within the meaning of
Industry 4.0 is well underway in foundries
and semifinished product manufacturing
plants, there are still many steps
that remain to be taken. Otto Junker
CASTING PLANT & TECHNOLOGY 3/2019 9

MELTING SHOP
Figure 1: Sketch
of a typical furnace
body, with
OCP sensor cable
permanently
embedded in the
furnace‘s permanent
lining (4).
Graphics: Otto Junker
GmbH is making every effort to support
this global process in the best possible
manner. This shall be detailed in the following
sections on the examples of its
OCP Optical Coil Protection system, predictive
maintenance system, and process
models (Digital Twins).
OCP - Optical Coil
Protection system
The OCP Optical Coil Protection system
was first launched on an industrial scale
in 2004 and has since evolved into a
standard in coil and crucible monitoring
technology for induction furnaces.
Addressing the ubiquitous digitalization
process and introduction of Industry 4.0
standards, Otto Junker had set itself the
task of advancing the relevant measuring,
visualization and archiving software
in that direction as well. Before
these efforts are examined in detail, let
us first recapitulate the system‘s basic
functionality.
Functional concept
The materials employed to insulate the
induction coil – e.g., insulating varnish,
resins and, if applicable, insulating
bandages – are commonly heat-resistant
up to around 180 °C. Consequently,
excessive temperatures in this area may
give rise to insulation damage or even
cause insulants to become electrically
conductive, resulting in interturn short
circuiting in the coil, typically in the presence
of moisture [1]. The key fact is
that in terms of temperature resistance,
the coil insulation constitutes the most
sensitive part of the entire coil assembly.
The temperature must never exceed
180 °C permanently in this area,
whether due to erosion or other defects
of the refractory lining or, for instance,
because of problems in the coil‘s cooling
water supply. It appears only logical,
therefore, to devise a temperature measuring
and monitoring system covering
the entire inner side of the coil.
The OCP system is a temperature
measuring and monitoring solution
relying on an optical fibre as a sensor
element, which is particularly suitable
for trouble-free temperature monitoring
in induction melting furnaces due
to its metrological characteristics, i.e.,
the fact that this optical measuring
method is, on principle, not susceptible
to interference by the strong electromagnetic
fields. Figure 1 shows a typical
furnace body structure of a coreless
induction furnace plant with the OCP
sensor cable embedded in the permanent
furnace lining right on the coil (4).
Based on an optical fibre, the system
makes use of the so-called Raman
effect. Laser light of a suitable
wavelength and modulation frequency
is initially fed into the optical fibre. This
laser light then gets scattered as it
impinges on bonding electrons of the
solid state structure over the full fiber
length, and its backscatter spectrum is
detected. This spectrum contains the
Raman lines, the intensity of which is a
function of vibration levels in the solid
state fibre structure, which in turn
depend on temperature. By noting the
laser light‘s time of flight, these lines
can be detected in a position-related
manner and a precise high-resolution
linear temperature profile can thus be
measured online over the length of the
optical fibre.
It can thus be ensured, by an appropriate
arrangement of the sensor cable
on the interior side of the coil, that any
point of particularly high temperature
– e.g., due to infiltration, erosion, formation
of cracks in the crucible, or even
cooling problems – can be accurately
localized and it can be determined
whether the temperature at this point
may become problematic for the coil
insulation.
The core of the OCP sensor cable is,
first of all, a commercially available
high-temperature glass fibre of the type
widely employed in telecommunications.
For mechanical protection, this
fibre is surrounded by a stainless steel
tube having a diameter of 1.2 mm
10

Figure 2:
Arrangement of the
OCP sensor cable on
the coil of a 6-tonne
induction furnace
for steel (4 meander
layers).
Figure 3: Arrangement of the
furnace yokes.
Figure 4: Visualization and operation using mobile terminal devices.
which in turn is coated with an elastic
high-temperature insulant. The overall
diameter of the sensor cable is 5 mm.
The sensor cable is rated for a maximum
continuous operating temperature of
approx. 250 °C which is well above the
maximum temperature resistance of the
coil insulation. The measuring
technique has a range of several kilometers,
and its spatial resolution over
the developed length of the optical
fibre is 27 cm, i.e., a temperature average
is determined over every 27 cm.
This does not interfere with the capturing
of local temperature events
because, on the one hand, the latter
will always have a spatially extended
temperature field; moreover, active
temperature gradient monitoring functions
are in place to detect even small
changes. The relative temperature resolution
of the measuring process is better
than 1K.
In order to provide the fullest possible
crucible sensor coverage in the
close vicinity of the coil, it is desirable to
have a maximum length of sensor cable
in the furnace. To this end, the sensor
cable is arranged in a meandering pattern
on the inside of the coil, taking
into account its minimum bending
radius. Figure 2 exemplifies this method
for the coil of a six-tonne steel melting
furnace. Four meandering fibre layers
were installed in this case. On larger
furnaces, the number of meander layers
is increased accordingly. Once the sensor
cable has been placed in the above-described
manner, a former is placed
in the coil, as is standard practice at
Otto Junker, and a permanent lining of
high thermal conductivity corundum
concrete is cast in which the sensor
cable thus remains permanently embedded.
In the case of new equipment and
coil overhaul projects these operations
can be carried out in the workshop,
while for retrofits or special applications
they can also be performed locally
in the foundry. It is even possible to
replace individual meanders on site if
the fiber has become damaged, e.g.,
due to mechanical impacts.
It is possible to assign alarm
thresholds to every meander, i.e., one
each for an alarm signal and for a furnace
shutdown. On the one hand, the
absolute temperature is an alarm criterion,
but temperature gradients are also
monitored. Especially this gradient
monitoring function is highly valuable
for the early detection of local lining
defects.
It should also be noted here that
one measuring instrument can monitor
up to four furnaces simultaneously. This
capability, plus the fact that the sensor
elements need not be renewed whenever
the furnace is relined (contrary to a
competitor system), makes for an extremely
favourable cost-benefit ratio.
Monitoring furnace yoke temperatures
Nearly every coreless induction furnace
exhibits magnetic yokes radially surrounding
the coil to guide the external
magnetic field and to provide mechanical
support to the coil (Figure 3).
Although these yokes are made of lowloss
transformer sheet laminations,
some heat is produced inside them and
will have to be removed by convection
or, in the case of high-powered furnaces,
via an appropriate water cooling
system. Nevertheless, ageing, corrosion
or local defects may cause inacceptable
local overheating of the yokes, with the
potential effect of damaging the adjoining
coil as well. Monitoring the yoke
temperature is therefore highly recommendable.
This is achieved by inserting
an OCP sensor cable, likewise in meander
form, into the yoke insulation consisting
of micanite sheet between the
yoke and coil. The temperature in this
plane, and hence indirectly the yoke
temperature, is thus captured over the
surface area and visualized. Needless to
say, suitable alarm thresholds can be
defined here as well. It should be
re-emphasized at this point that the
immunity of this measuring process to
electro-magnetic interference is of key
importance.
CASTING PLANT & TECHNOLOGY 3/2019 11

MELTING SHOP
Figure 6: OCP system visualization screen.
Figure 7: Indication of yoke temperatures.
Processing and visualization of OCP
temperature data
Unlike prior OCP software versions, the
present one has data management and
processing features designed fully in
line with the Industry 4.0 concept as
based on the OPC UA standard. This will
permit future cross-system communication
and a standardized data exchange
with higher-level systems.
Figure 5:
Software
architecture
(schematic).
Moreover, in redesigning the visualization
and control interfaces, web-based
solutions were developed so that
the full functionality is also available
with mobile terminal devices (Figure 4).
In a further step, a feature was
implemented whereby OCP temperature
data, together with other furnace
information such as actual furnace
power, charge weight and furnace operating
status, can be stored in a cloud
system in coordination with the plant
owner. This enables Otto Junker, e.g.,
on the one hand, to view and analyze
data so as to assist with the user‘s interpretation
thereof in a given case. On
the other hand, it lays the foundation
for the use of tools such as, e.g., artificial
intelligence to improve the system‘s
predictive capabilities.
Figure 5 illustrates the current software
architecture in simplified form.
Finally, the opportunity was used to
fully redesign the individual input and
visualization screens, with clarity, simplicity
and intuitive control being accorded
high priority. It goes without saying
that alternative (i.e., mouse, keyboard
or touch screen) control methods are
supported.
Let us now look at the relevant
visualization windows by way of
example: The main OCP visualization
screen is depicted in Figure 6. This
window shows a schematic top view of
the furnace, with four meandering
optical fibre layers in this case. On principle,
the temperatures in each of the
four meander layers are initially displayed
in polar form, with the option
to suppress individual layers for the
sake of clarity. The temperature axis
can be scaled at will. As an alternative
to the polar temperature diagram
shown, a corresponding linear rendering
of the temperature profiles in
the meander layers is available. When
an alarm threshold is exceeded, this
will be indicated by appropriate symbols
next to the temperature graphs.
At the same time, the border colour of
the symbolic furnace will change traffic
light style, i.e., from green through yellow
(warning) to red (shutdown), in
the relevant segments. Depending on
the number of furnaces in place, these
can be visualized simultaneously in
separate windows.
By selecting a playback function
and entering a date and time, historic
temperature profiles can be viewed. It
is also possible to show temperature
profile images in a video-like animated
mode, at an adjustable playback speed,
between a previously entered start and
end time. These latter features are particularly
helpful in tracking the
development of a crucible defect in
time and hence, to understand its evolution.
Figure 7 shows the yoke temperature
monitoring screen. Again, the furnace
is shown in a schematic top view
and comprises eight yokes in this case.
12

Arranged around the furnace are the individual yokes in diagram
form, with indication of the temperature profile over
the yoke height plus a numeric display of the given average
temperature. Here again, a „traffic light“ colour change will
mark an overrun of predefined thresholds, with warning and
shutdown functions operating analogously.
Predictive maintenance system
General architecture
As part of Otto Junker GmbH‘s digitalization drive, a maintenance
system for melting furnaces was developed and integrated
into the web-based Junker Furnace Control System
(JOKS).
Designed as a process management tool for Otto Junker
melting equipment, JOKS monitors the entire melting process.
It controls all functions and process sequences automatically.
At the same time, an exchange of data and information
with higher-level process control resources is supported so
that operating data can be logged, analyzed, and made available
via interfaces. Various elements of the process chain
that are subsumed under the functions of automation, monitoring
and documentation are integrated in the JOKS system.
The JOKS automates the furnace charging and melting process
in that it automatically computes the necessary energy
input, the bath temperature and the remaining melting time
on the basis of the captured charge weight. Moreover, its
charge make-up computing and melt composition adjustment
functions provide quantity targets for the addition of additives.
Further, the system monitors the operating states of all
pumps, valves and air coolers. Analogue and digital sensor
readings from the water recooling and switchgear systems
are visualized as well. Continuous monitoring of the mean
refractory thickness and coil-to-ground electrical resistance
provides additional safety. All through the melting process,
production records are generated and analyzed for each heat
and furnace. Moreover, process data such as, e.g., electrical
parameters over time are visualized over a freely selectable
evaluation interval. These JOKS functionalities are now supplemented
by the maintenance system described below.
In operating a furnace system, maintenance has a high priority.
The jobs required in this context must not only be performed
but also documented and archived in an appropriate
manner. A modern system is characterized by its ability to
archive completed steps quickly and easily. Unnecessary
delays in running the furnace can thus be avoided. This rapid
availability and creation of the necessary documentation contents
is also indispensable from the view point of low maintenance
cost. Moreover, the use of a reliable digital system
can reduce the risk of data loss, which may be quite substantial,
e.g., with paper-based systems.
A digitalized maintenance system must include lists of
inspection items, a maintenance schedule and troubleshooting
help functions, which are integrated in the web-based
JOKS. Thus, all functionalities are combined in one system.
During some maintenance steps it may be helpful and
sometimes necessary to access current furnace plant operating
data. Here, too, the system integration will show its
merits as all operating data can be made available by the
JOKS. Another advantage of a web-based system is that in
order to display contents, no additional programs need to be
installed on the given visualization device (e.g., a tablet PC).
In a standard installation the JOKS system can be accessed
via a web browser on an industrial-grade panel PC. The latter
is built into the operating cabinet or console of the furnace
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MELTING SHOP
system. From here, acting through a
secure link, the system accesses a web
server that will provide the relevant
web page contents.
The pages of the maintenance system
display contents from a database
expanded specifically for this purpose.
Accordingly, whenever a step has been
completed, it can be acknowledged in
the visualization system. The web server
will then link up to the database, causing
it to be updated and/or expanded
accordingly. For each of the various
maintenance subjects, individual tables
have been created in the database so as
to cover all inspection, maintenance
and troubleshooting activities. Depending
on the plant configuration, suitable
work instructions will then be read
from the database. Thanks to this
approach, the maintenance system can
be quickly adapted to other furnace
plants as only the link to the database
needs to be updated according to the
plant configuration. The implemented
functionalities can be maintained.
Proper equipment operation means
that those maintenance steps which
Figure 8: Inspection form listing necessary
work on the water circuit; completed
steps can be stored in the database
with operator‘s name and time stamp.
have been completed are documented
afterwards. It can thus be checked
whether necessary measures were carried
out in good time on a given furnace.
The present web-based solution
satisfies these documentation requirements.
Inspections during installation
Inspection activities required during installation
or extensive rebuilding of a
furnace system are itemized in check
lists. These check lists have been implemented
in the system as interactive
forms covering all component assemblies,
e.g., the hydraulic system, switchgear,
water circuit, etc. Figure 8 shows
such a form generated from the database
to document an intervention on
the water circuit. Upon completion of a
task, the relevant row can be checked
off and stored along with the name of
the responsible employee and the current
time. The completed task will then
be updated in the appropriate table
and line of the database and adapted in
the visualization system. For clarity‘s
sake, there exists an additional page listing
all completed inspection steps in
chronologically descending order.
There, a PDF form can be generated
from the displayed database items by
means of a library of functions.
Continuous maintenance
Apart from periodic inspections, a continuous
maintenance of furnace equipment
is important for its trouble-free
and safe operation. The maintenance
schedule comprises all periodically
necessary steps and has likewise been
digitalized; maintenance activities on
the various assemblies as well as the
relevant maintenance intervals are thus
specified by the system. The visualization
once again relies on interactive
forms, but their underlying database
structure functions somewhat differently.
Since the same tasks must be
periodically repeated, every storage
operation initiated via the visualization
14

a
b
c
d e f
Figure 9 a-f: Modelling the temperature distribution in an aluminium rolling ingot during (a-c) and after (d-f) quenching in water
system will generate a new line in the
database instead of updating an existing
one. At the implementation level,
the entire database content is filtered
so that only the most recent entry for a
given step will be displayed. Needless to
say, the entries suppressed by the filter
are not lost; here, too, a page has been
created which presents a summary of all
completed steps.
An additional feature is the listing
of all urgently required jobs that have
not been performed within a defined
period. The omission of maintenance
activities may lead to severe problems,
up to and including – in the worst case
– extended plant downtime. An additional
list of activities that have not been
completed, e.g., over a two-week
period, may avoid such faults which
may have arisen due to high workloads,
etc.
Equipment malfunctions
A malfunction always constitutes a safety
risk for the plant operator, or may
result in plant downtime. It is therefore
important to respond quickly to any arising
fault so that first remedial action
can be taken right away. A list of fault
alarms summarizes all messages the
plant controller is capable of registering.
Using a dedicated function, the
operator can conduct a selective search
of the list maintained in the database
by entering appropriate criteria (fault
number, message text, operating status),
so that relevant messages will be
displayed along with a recommended
first remedial step. Thanks to this search
feature, even inexperienced personnel
can respond appropriately in the event
of an unknown malfunction. For
instance, if a fault message containing
the term „transformer“ is displayed and
the operator also notices that no medium-frequency
voltage is coming from
the converter system, the list can be
CASTING PLANT & TECHNOLOGY 3/2019 15

MELTING SHOP
searched for these terms. From the filtered
entries it may then be concluded
that, in all likelihood, the cooling water
flow rate through the transformer is
too low and the cooling system therefore
needs to be inspected.
Also included in the maintenance
system are instructions intended to
make the troubleshooting process more
well-structured. These instructions
sometimes include service videos which
explain the relevant jobs in detail. By
way of example, the following paragraphs
describe the contents of such a service
video for the job of replacing a
defective thyristor stack.
First of all, the system needs to be
de-energized, locked/tagged out, and
grounded in line with safety regulations.
Next, the water circuit must be
shut off. This step is followed by a presentation
of all tools needed for the
replacement job, and the procedure for
disconnecting the firing-circuit cables is
then shown. It is pointed out how to
mark and disconnect the relevant cooling
water hoses. Ultimately, the procedure
of disassembling and removing the
thyristor stack with its associated power
leads is explained. In a further step, the
operation of installing a new thyristor
stack is demonstrated. The service video
then explains how to re-connect the
power feeders, having cleaned them
beforehand if necessary. A description
of how to connect the water hoses and
firing-circuit cables completes the
demonstration of this part replacement.
Upon resetting of the fault message the
original fault should be removed. The
following QR code/Link gives a path to
the video in question:
https://bit.ly/2YrrCFm
Depending on the fault type, different
components need to be replaced to restore
the proper functionality of all
plant areas. This will normally be done
by drawing on an existing spare parts
stock. All spare parts are listed with full
information regarding quantity, internal
reference numbers, etc. In the maintenance
system this list can be invoked
in a form arranged by component
assemblies. If a part is needed but not
locally in stock, a procurement enquiry
can be started directly out of the maintenance
system by e-mail at this stage.
Key details such as an unequivocal product
code, the item designation and the
necessary quantity are inserted into the
e-mail text automatically. This makes it
easier to contact Otto Junker‘s service
department. The troubleshooting guide
additionally comprises a list of frequently
asked questions on both general
and specific subjects.
Process models (digital twins)
Motivation
Thermoprocessing systems are used to
selectively adjust the properties of a
component by a defined heat treatment.
To this end, the temperature profile within
the material must be controlled in
such a way that the desired metallurgical
processes can take place. The most
important control parameters are the
holding temperature and holding time,
the cooling rate and the ageing temperature,
if applicable. Although the ideal
temperature profile may be known from
laboratory tests, it is usually not possible
in an industrial process to verify whether
it is actually being observed.
With the aid of process modeling,
the full temperature profile inside the
material or component can be determined
by means of a few selected temperature
measurements. Thanks to this
mathematical approach, the data will
be available in a structured form that
facilitates further processing in an
Industry 4.0 environment: Thus, for
every product passing through the system
it is possible to automatically generate
a digital twin that will facilitate
networking with upstream or
downstream process steps.
Modular system for process models
To be able to supply process models as
efficiently as possible for all equipment
in its product range, Otto Junker GmbH
has developed a software library that
enables processes to be mapped as an
FVM simulation using a modular system
of building blocks. The fundamentals
of this system have been explained,
e.g., in [2].
Volume elements can be created
and linked to diverse boundary conditions.
Each volume owns geometrical
dimensions as well as information
about its material properties. The links
represent different heat transfer
mechanisms. It is thus possible to map
effects such as heat conductance, convective
heat transfer with or without
phase change, radiation or enthalpy
flows. The system is then transferred to
a solver capable of providing both
steady and non-steady solutions to systems
of this kind. In doing so, it relies
on various numeric methods such as
the Crank-Nicolson method, MUSCL
schemes or Adams-Moulton methods
in order to be able to handle shocks
and discontinuities in the temperature
profile. These methods can be found in
the standard specialized literature,
e.g., [3], [4] or [5].
Application example of an
ingot quench
In the production of aluminium strip,
ingots with dimensions in the region of
4.5 x 1.2 x 0.5 m are initially heat-treated
in pusher furnaces. Here they are
homogenized at approx. 540 °C. Thereafter,
they must cool down to a uniform
temperature of 400 °C before they can
be hot-rolled. For the ends of the ingot,
a slightly higher temperature is desired
because this is advantageous in the
rolling process. Simply letting the temperature
drop in air by free convection
would take too long; moreover, the
desired temperature profile would not
be achievable in this manner. For this
reason, water quenching with a subsequent
soak phase is employed.
The ingots are fed to the quench
from the various furnaces on a roller
conveyor. In the quench they are subjected
to a selective application of water
before they are transferred to a soak
chamber. There they are held at an
ambient temperature of 400 °C for 20
minutes. After that the ingots are
moved to the hot rolling mill for further
processing.
It is thus a requirement on the water
quench that it should remove no more
energy from the ingot than needs to be
withdrawn to achieve a uniform temperature
decrease from 540 °C to 400 °C.
After all, it is not intended to introduce
any further energy into the soak chamber.
This way, both the energy demand
and, ultimately, process costs will be
minimized.
For the foregoing purposes, the surface
temperature of each ingot is measured
directly upstream of the quench.
Thereafter, its transfer from the furnace
to the quench is simulated using a process
model based on the above-described
modular system. The ingot is assumed
to possess a homogeneous
temperature distribution upon exiting
the furnace, and to lose heat by free
convection during the transfer. If the
surface temperature thus computed
coincides with the measured one, the
simulated temperature distribution will
be used as a basis for the further calculations.
16

An initial recipe is now selected for the quench, and the
entire process is simulated all the way to the end of the soak
cycle. A test is then carried out to ascertain whether or not the
requirements on the ingot temperature are met. If necessary,
the recipe will be adapted to the quench and a new simulation
will be carried out. This process will be repeated until a
setting is found that will cause the ingot to leave the soak
chamber with just the desired temperature profile. This recipe
is then loaded into the quench controller and executed. About
5 to 10 simulation runs are necessary, but these take only a
few seconds to complete. In this manner, every ingot geometry
is treated with a tailor-made recipe so as to make optimum
use of the residual heat.
The results of such a simulation are graphically presented in
(Figures 9 a - f). Figure 9 a shows the temperature distribution
in the ingot at the time when its front end has just exited
the quench. In Figure 9 b, the first half of the ingot is outside
the quench. It is evident that the surface of that portion
has already become distinctly hotter again than it was in the
quench. Its temperature has risen from around 50 °C to
approx. 250 °C due to heat conductance from the interior of
the ingot. Ultimately, the ingot‘s temperature profile upon
leaving the water quench is rendered in Figure 9 c.
Figs. 9d through 9f show the temperature evolution over
the soak phase. It should be noted that the colour scale in this
diagram differs from that used in the previous images. In Fig.
9d we can still detect major temperature differences. As is
evident from Figs. 9e and 9f, these differences decrease over
time. Ultimately, a temperature of around 400 °C is reached
inside the ingot while its ends are slightly hotter to provide
improved rolling properties.
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Conclusion and outlook
The process model presented above generates a digital twin
of every ingot, documenting the temperature profile during
the quenching process. Should any problems arise during hotrolling
of certain ingots, these could thus be correlated to
earlier process steps through data mining methods. This is a
precondition for an extensive interlinking of processes and
equipment (‚networking‘) in the context of Industry 4.0.
In addition, an optimum recipe is generated for every
ingot, thereby increasing process quality. The plant operator
can directly specify the desired temperature the ingot should
have upon exiting the soak chamber. Process parameters such
as the water application density and ingot conveying speed
are defined via an optimization routine that maps the process
with the aid of a process model.
As regards the OCP and predictive maintenance systems, it
remains to be noted that there, too, the Industry 4.0 concept
has been consistently put into practice. Above all, the architecture
of the OCP software, which stores all measurement
data in a cloud together with plant data generated by the
JOKS software, permits a comprehensive analysis of these
data, including, e.g., by means of artificial intelligence. The
foundation has thus been laid for a decisive improvement of
this tool‘s predictive capabilities.
Primary publication in the technical journal „Heat Processing“
Felix Aßmann, Simon Künne, Kunal Mody, Wilfried Schmitz,
and Günter Valder, Otto Junker GmbH, Simmerath
References:
www.cpt-international.com
Honorary sponsors
VDD Verband Deutscher
Druckgießereien, Düsseldorf
CEMAFON, Frankfurt am Main
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NürnbergMesse GmbH
T +49 9 11 86 06-49 16
visitorservice@nuernbergmesse.de

Photos: Eirich
Production Manager Jürgen
Poggemann with
Edith Weiser (Eirich
Foun dry Business Unit).
Background: Visua li zation
of the mold ma te rial
Automatic mold material
preparation process.
preparation – networked
processes – better casting quality
About 25 percent fewer rejects, major progress regarding surface quality (with more
than 50 percent less post-processing work), and considerably more stable processes –
Thomas Poggemann, Production Manager at Jürgens Gießerei GmbH & Co. KG, is more
than just satisfied. Replacement of the old molding material preparation system with a
second-hand plant, a control system and an AT1 inline tester device from the Gustav
Eirich GmbH & Co. KG engineering works is paying off. Molding material preparation
has now been in unmanned operation – using a pattern plates catalog – for two-and-ahalf
years thanks to the SandExpert software solution. A clear advantage given frequent
mold changes on two molding lines and increasingly complex castings.
By Edith Weiser, Hardheim
18

SAND REGENERATION
Perfection is the drive” is the mission
statement of the Jürgens
foundry in Emsdetten, Germany.
This includes production processes that
are optimally coordinated with one
another, that are continuously improved,
and that are adapted to the particular
requirement profile. A good
example of this is the old molding
material preparation plant with its Muller
mixer. After 2012 it no longer met
the demands of a foundry specializing
in gray cast iron and spheroidal graphite
iron.
Eirich mold material preparation
– turning old into new
“We were thinking about expanding silo
capacities when we stumbled across a
two- or three-year-old Eirich molding
sand preparation plant with a Webac
cooler. We were able to purchase the
equipment from the insolvency assets of
a foundry in southern Germany. That
was a stroke of luck”, remembers Thomas
Poggemann, Production Manager at
the Jürgens foundry in Emsdetten. Jürgens
decided to build a new hall, which
was seamless connected to the secondhand
sand preparation plant (in tower
design) with all central system components.
A competent partner was found
– the Gustav Eirich engineering works in
Hardheim, Germany – who carried out
the detailed engineering and assembly
of the machine technology, as well as
the steel construction including the
enclosure. The delivery also included the
complete control system and an AT1
inline tester device for automatically
measuring compactability and shear
strength. The Jürgens foundry inplemented
the conveyor system from VHV Anlagenbau,
Hörstel, Germany. Preventive
molding material control was achieved
using SandExpert software from Eirich
for the continuous registration and analysis
of batch data. The control solution
and quality package together form the
basis for achieving without human intervention
a high quality molding material
preparation despite challenging conditions.
A demanding task in view of the
foundry’s wide range of castings.
Control via pattern catalog database
Jürgens currently produces molding
boxes for about 4,500 different castings
using two HWS molding lines, both operated
with the Seiatsu mold process. The
casting weight of the small molding line
Figure 1: The second-hand Eirich mixer at
the Jürgens foundry uses pre-water.
is between 20 and 140 kg liquid iron,
while that of the large mold line is between
100 and 1,000 kg. The two molding
lines run in parallel. Two completely
different castings are made at the
same time. “The molding material must
be right for both patterns, although the
iron-to-sand ratios are very different,”
according to Thomas Poggemann.
Manually calculating the best molding
material recipe involved much time and
effort considering the frequent changes
of mold. Today, the mold material preparation
is programmed for each specific
mold and processing is fully automated.
This method of operation requires a
lot of advance work – which Thomas
Poggemann and his team have carried
out excellently. Box weight, box size,
liquid iron, required bentonite content,
required compression strength, compactability,
shakeout properties, core decay
– they defined all this meticulously for
each pattern plates,” confirms
Klaus-Dieter Knapp with appreciation.
He is supporting the Jürgens Foundry as
an Eirich service technician and was
already involved in the planning and
design phase
Objective: homogeneous
return sand
The software automatically calculates
the composition of the molding material
when there is a pattern plate
change at the molding line. This takes
into account the values from the pattern
catalog so that the return sand
CASTING PLANT & TECHNOLOGY 3/2019 19

SAND REGENERATION
quality remains identical, regardless of
the castings produced. The return sand
of the new batch is freshened up with
exactly the same amount of bentonite
and additives as will be lost in the subsequent
casting process. Why? Production
Manager Thomas Poggemann puts
it in a nutshell: “It’s very easy: return
sand in order, input materials in order,
casting in order.”
Pre-water for the best molding
material quality
The Eirich control system offers two
options for operating the mixer
(Figure 1): with or without pre-water.
The Jürgens foundry works with
pre-water in order to achieve a preparation
time with water that is as long
as possible while shortening overall
charge times. A high portion of the
total water required for the previous
batch is added to the mixer.
During the mixing time, the probe
in the mixer measures the temperature
and moisture, and automatically
meters the additional water required.
Finally, the correction factor required
for calculating the amount of water
for the next mixture is determined by
measuring compactability with the
Figure 2: The AT1 inline tester device
with an independent local control unit.
Figure 3: Above the molding sand line,
the visualization screen showing the
mold material data can be seen.
AT1. Any possible loss of moisture
during transport is, naturally, taken
into account here.
Preventive molding material control
through networked processes
The AT1 inline tester device
(Figure 2) is mounted on the conveyor
belt immediately behind the mixer, and
equipped with an independent local
control unit. While the mixer is emptying,
the AT1 inline tester device carries
out an analysis of the compactability and
shear strength on two till three samples
from each batch. The measured values
are made available to the plant control
system via an interface, and used for
automatically correcting the next batch.
As a quality assurance measure, Thomas
Poggemann merely takes a molding
material sample once a day and checks
the moisture content, compactability,
shear strength, double shear strength,
splitting strength, compressive strength,
gas permeability and bulk density. He
notes that: “The processes have become
considerably more stable since we started
operating the mold material preparation
system without human intervention
using the pattern catalog.”
Benefits from mold material
preparation
That’s not all: as a result of the improvement
in mold material preparation, the
number of rejects at Jürgens has been
reduced by about 25 percent. Moreover,
there has been an extreme improvement
in the surface quality achieved. The postprocessing
has been drastically reduced
- more than 50 percent less. In Emsdetten,
they have also implemented an operating
mode with break times, which
contributes significantly to saving energy.
During the half-hour breaks when the
molding lines are not producing, the
machinery of the sand preparation system
switches to the break mode. This
takes place in a con trolled manner and
fully automatically. The mixer only switches
itself off after the last batch has
been completely emptied. Then the cooler
follows, also switching off after it is
completely empty.Finally, the conveyor
belts shut down too.
20

Everything in view at all times
All monitors along the process chain
permit the graphic representation of
the actual situation within the molding
material preparation system, as well as
the batch and consumption logs. So
the operating personnel have an
insight into the actual situation and
the quality of the molding material at
each of the screens (Figure 3). When
messages appear, the operator decides
on the next step and can determine
the action necessary. Only the Shift
Manager in the control room and the
Production Manager at his personal
monitor, however, have full access, for
example access to the sand recipe. By
means of the teleservice function,
Eirich is also able to access the visualization
and control system, as well as
the current data, at any time. “If necessary,
someone can always be reached
– that’s helpful,” finds Thomas Poggemann.
He welcomes the fact that
repairs and downtimes are thus kept to
a minimum.
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Investments in the future
“At Juergens, we are digitally focused
and always innovative. We are well
aware that castings will become increasingly
complex and sophisticated in the
future,“ says Thomas Poggemann. As a
railway-certified caster for high-quality
small and medium-sized series for all
sectors except automotive, the Jürgens
foundry considers itself ideally positioned
for mastering the challenges of
the future. “Automated molding material
preparation with the Eirich mixer
and the quality package with the AT1
inline tester device, as well as the Sand-
Expert software for preventive forming
material control, was another step in
the right direction for us,” according to
Production Manager Poggemann. The
next measures he is planning is the
refurbishment of the melting plant as
well as providing the large mold line
with another 40 molding boxes. The
current molding material preparation
system will not interfere with these
plans.
At Gifa 2019 Thomas Poggemann
was invited at the Eirich-Stand to take a
closer look at the possibilities offered
by the new generation of the AT1 inline
tester with web interface and new measuring
options. Perhaps it is still possible
to improve molding material preparation
a little bit more.
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Sand core hardening:
Digital quality with new
ACS-Technology
Corebox for inorganic sand
core test bars adjusted to
ACS technology at DISA core
shooter.
Sand cores are building the back-bone of the foundry business to deliver constantly
improving foundry products. The sand core requirements stretch from high dimensional
accuracy to easy core removal while at the same time demanding the lowest possible
cost. Sand core quality plays an important role as quality defects of sand cores usually
results in defects of final foundry products.
By Wolfram Bach, Sülzetal, and Prof. Gotthard Wolf, Freiberg
Photo: ACS
All these requirements are driven
to ensure the highest possible
quality for the final foundry
product at the lowest price.
All inorganic sand core manufacturing
process offer various parameters to
adjust the sand core quality. The parameters
can be grouped into five main
critical steps during the manufacturing
process:
1. Sand core & core box design
2. Shooting process
3. Curing process
4. Handling & Storage
5. Application
All processes above have a direct impact
on the quality of the sand cores. The
curing process (Step 3.) has the biggest
operational impact on the individual
sand core quality while all other process
parameters are de-signed upfront and
to ensure reliable quality. The main reason
why the curing process is so critical,
is that it requires heat application to
the individual sand core to ensure sufficient
sand core strength.
Heat application processes can be
simulated but are difficult to control in
real time. Especially if heat is generated
externally and conveyed into the core
box for conventional core boxes. The
Tool design.
common heat applications in the core
box use either thermo oil or heating
rod to generate the heat and to heat
up the core box to tar-get temperature.
Additional heat energy is applied to the
22

MOLD AND COREMAKING
Equipment design.
sand core via heated air while removing
humidity.
The key problem remains: The heat
conductivity of sand (cores) is terrible
and hence impacting the efficiency of
the whole core making process. The
negative impact is reduced by operating
the core box with excessive heat even
above 200 °C. This allows to increase
the heat transfer from the core box into
the sand core and to compensate for
the loss in cycle time. This approach has
limitations as the sand binders have a
maximum temperature to avoid damaging
the chemical binder.
The „Advanced Core Solutions“
(ACS) project has patented a new process
that generates the heat directly
inside the sand core. This process uses
the electrical conductivity of all common
inorganic binders and sand core
mixtures. The heat is generated by
applying electrical current to the sand
core and core box based on the principles
of the 1st law of Joule. The patented
innovation allows the adjustment of the
electrical conductivity of the core box
material to match the conductivity of
the sand binder composition.
Thanks to this approach the electrical
resistance is nearly identical at every
single point between the electrodes. As a
consequence the electrical flow through
the core box is very homogeneous and
allows the complete hardening of
sand-cores independent of their shape.
The model of a core box design is
very simple as it mainly contains the
core box, electrodes and isolation layer.
The electrode are applying the electrical
current with the ideal voltage and amperage
level and are measured and adjusted
in milliseconds to increase the optimal
energy introduction into the sand
core. This does allow the reduction of
energy consumption of up to 41 % and
faster cycle times of up to 30%. The
homogeneous current flow through the
sand core also improves the sand core
quality by homogeneous curing.
The bigger benefit is the transformation
of the classic hardening process
into a digital quality process. The flow
of electrical current through the sand
core is at ever millisecond controlled
and documented. This allows to measure
not only the individual energy
consumption over time per individual
sand core. It also enables the first time
to direct comparison of energy
consumption per individual sand core
versus all previous produces sand cores.
Based on Six Sigma concepts it
allows the automatic detection of any
major variation versus previous sand
cores. The ACS-System can then identify
and mark sand cores for additional
inspections or removal.
This decreases quality defects early
in the manufacturing process to reduce
additional losses later in the manufacturing
steps and at the same time increasing
the output capacity.
The same approach can be applied
also for family core boxed with ten or
more cavities or specifically for large
complex sand cores. Furthermore can
the quality data be linked to each sand
core and used for life cycle tracking.
This enables future insights by applying
big data analysis by connecting the
results to final foundry product quality.
Dipl.-Ing. Wolfram Bach, Inventor &
Process Engineer, Advanced Core Solutions(ACS),
Sülzetal, Germany, and Prof.
Dr.-Ing. Gotthard Wolf, Head of
Foundry Institute, Universität Bergakademie
Freiberg, Germany
www.advanced-core-solutions.com
CASTING PLANT & TECHNOLOGY 3/2019 23

COATINGS
Photos and Graphics: ASK Chemicals
Large-scale casting
and water based refractory
coating – does that work?
Solitec HI 703 (water-based coating)
shows the user the current status of
drying by means of a colour change.
With the switch from alcohol to water-based coating, the iron foundry König & Bauer
not only uses an environmentally friendly solution that complies with workplace limit
values with regard to ethanol, but can also reduce costs in the fettling shop, in explosive-protected
areas and in the permanent extraction of the flood basins. With the environmentally
friendly water-based coating from ASK Chemicals the iron foundry Koenig
& Bauer can also realize drying times of less than six hours.
Ulf Knobloch and Christian Koch, Hilden
24

The Koenig & Bauer Foundry
GmbH, Würzburg, Germany, was
divested from the Koenig & Bauer
Group in 2014 and today, as a subsidiary
of Koenig & Bauer AG & Co. KG, serves
well-known customers throughout
Europe. This takes place either directly
with raw parts or in cooperation with
Koenig & Bauer Industrial AG & Co. KG
(the subsidiary responsible for mechanical
processing) with components for
pressure equipment and other parts for
mechanical and plant engineering.
At the Würzburg site, the foundry
looks back on a 200-year company history.
Specialized in the production of
cast iron with lamellar graphite (GJL)
and nodular graphite (GJS), up to
12,000 tons of good castings with individual
weights of 0.1 to 10 tons can be
poured, blasted, fettled and painted
each year via the hand molding process.
In 2011, the foundry with attached
pattern making shop underwent a complete
renovation with an investment
volume of 12 million euros in buildings,
facilities and environmental protection.
Modern requirement profile
The Koenig & Bauer foundry, as many
other foundries in the manual coremaking
and molding sectors, used alcohol
coatings over many years. Alcohol-based
coatings are characterized by
the fact that the cores and molds dry
faster or that the solvent can be burned
off. However, these advantages are contrast
ed by a number of disadvantages,
such as the need for protective measures
and compliance with limit values:
> Clearance areas in the finishing area
(fire and explosion protection)
> Defined work areas for finishing and
flash off
> Two component purchases (coating
and solvents) with special storage in
explosion-protected areas
> Compliance with occupational exposure
limits for ethanol or isopropanol
“As a responsible and modern enterprise,
it was only a matter of time
before we took measures in order to
sustainably comply with occupational
exposure limits and to demonstrate
Figure 1: The mold is coated at the
mobile flood basin.
ecological responsibility,“ states Ulf
Schmidtgen, Segment Manager of
Koenig & Bauer Gießerei GmbH, mentioning
two of the main reasons for the
decision to switch to water-based
refractory coating.
The conversion should be absolutely
cost-neutral, both based on the overall
process and without loss of productivity,
i.e. the core and mold output per day
should at least remain constant. “It was
also important for us not to have to
invest in oven drying,“ adds Stefan
Braun, Production Manager. “On the
one hand, oven drying would have
made our cores and molds more expensive
and, on the other hand, there was
no space for the necessary infrastructure.“
The proviso was therefore to
make the conversion to water-based
coating without the installation of additional
drying ovens.
Water-based refractory coating
for large-scale casting
On the basis of the requirement profile,
the foundry conducted pilot trials
CASTING PLANT & TECHNOLOGY 3/2019 25

COATINGS
Figure 2: Stefan Braun, Production Manager, Ulf Schmidtgen, Segment Manager of Koenig
& Bauer Gießerei GmbH, and Ulf Knobloch, ASK Chemicals GmbH (left to right), measuring
the wet layer thickness.
accompanied by ASK Chemicals, Hilden,
Germany, using Solitec HI 703 coating
over a long period of time.
Solitec HI 703 is a zircon-free brush
and flood coating for cores and molds
manufactured using cold processes.
The high-solid coating is more flexible
in thermal and physical expansion
behaviour than zircon coatings. Graphite
and oxide content also have a separating
effect between sand and the
casting. The state-of-the-art binder
component holds the water on the
coating surface and prevents water
migration into the sand interior. The
flood viscosity is reached with a minimal
addition of water of about 10 %
by weight. The uniformly thick layered
application with a relatively short dripping
time of the coating is a distinguishing
characteristic. In ductile iron,
sulphur absorbent prevents the sulphur
transport from the molding material
into the casting surface and thereby
averts graphite degenerations. In certain
cases, it is also used to combat pinhole
defects. The progress of the drying
progress is easily recognisable to
the user by a colour change.
Custom process setting
The viscosity of the coating for the
cores and molds adapted to dipping
and flooding behaviour was quickly
determined in a few tests. The implementation
of the requirement to
achieve short drying time while maintaining
productivity required some
changes in the production process. For
example, trials with hot spraying were
performed. In this process, the ready-touse
coating is heated to a temperature
of approx. 70-80 °C just upstream from
the spray nozzle. This should lead to
faster flash off of the water and thus
prevent the deep penetration of water
into the mold surface. However, the trials
did not lead to the desired result
due to the geometry of the molds.
Although parallel and slightly sloping
surfaces and contours were well covered
by the coating using the available
nozzles, vertical contours could only
partially be wetted or not at all.
Attempts to heat the top layer of
the mold using infrared radiators also
did not lead to a successful shortening
of the drying time. The specifications
could only be achieved by ensuring constant
circulation of the room air in the
core shop without simultaneously creating
drafts in the working areas. In the
molding shop, the process of „molding
- finishing - form assembling - casting“
was redefined. Here, too, the drying of
the mold halves after coating is assisted
with moving air. Now drying times of
less than six hours could be achieved. To
obtain even more flexibility in the
molding shop, a special construction of
the flood basin has been in use since
the middle of 2018. The mobile flood
basin allows for finishing directly on site
at the respective forming area, the
mold halves now no longer have to be
driven across the entire hall and the
cranes can increasingly be used for
direct production (Figure 1).
In addition to the mentioned advantages,
the chosen Solitec HI 703 coating
also reduced costs in the fettling shop.
26

Likewise, it is now possible to dispense
with the additional application of a precoat
coating to the higher thermally
stressed points of the cores and molds.
The fettling work caused by burn in and
mineralization has been significantly
reduced. The gas bubble defects have
also decreased significantly. Up until
now it was necessary to work with a
special gas-permeable coating for certain
components. Since the conversion
to Solitec HI 703, the majority of these
have been dispensed with. Ultimately,
the surfaces achieved over the entire
product range are significantly better
than with the alcohol coating used
hitherto.
Large-scale casting and waterbased
refractory coating – that
works well!
In 2018, the Koenig & Bauer Foundry
completely converted its core and form
shop sectors from coating with solvent
as a liquid carrier to a water-based
product. ASK Chemicals supported and
accompanied the changeover phase to
the new Solitec HI 703 water-based
coating. Ulf Schmidtgen, Segment
Head of Koenig & Bauer Gießerei
GmbH (Figure 2), is satisfied: “The
result speaks for itself! We use an
en vi ronmentally friendly and
employee-friendly product and have
achieved even more efficiency in the
process. We were able to reduce casting-related
rework and refrain from
additional work steps such as the application
of pre-coat coating. The mobile
flood basin is, of course, a very special
highlight which makes our work processes
easier for our employees and
makes our production processes more
flexible.“ Now the entire surface in the
molding shop provided with overhead
cranes can be used very flexibly,
explains Stefan Braun, because there
are no longer the restrictions due to
the requirement of explosion-proof
areas. Likewise, it is now possible to
pour off in the entire hall, regardless
of restricted areas. Frequent transport
of molds ready for casting is no longer
necessary.
The time spent in the fettling area
for the elimination of mold and corerelated
casting defects has been significantly
reduced. By switching to waterbased
coating and the concurrent
elimination of explosion-proof areas,
maintenance costs in this area were
reduced by about 80%. Furthermore,
there is energy saving, since no permanent
extraction is necessary at all flood
basins. As a result of the conversion, the
occupational exposure limits with
regard to ethanol can now be reliably
adhered to, since there is no longer any
pollution. Again, storage areas in the
production areas are freed up, since day
storage for isopropanol and/or ethanol
is omitted.
This success story shows that the
option of solvent-free coating is also
open to hand-molding. A conversion to
water-based coating can be carried out
without complex drying units and, in
addition to advantages for employees
and the environment, also offers cost
and efficiency advantages for the
foundry. www.ask-chemicals.com
Competence in
Shot Blast Technology
We offer a complete service in surface preparation technology,
not just as machine designers and manufacturers.
Our emphasis is on providing reliable service on:
• Wear and Spare Parts
• Repair and (remote) maintenance
• Inspection and process advice
• Machine upgrades and performance
enhancement
• Upgraded used machines
AGTOS
Gesellschaft für technische Oberflächensysteme mbH
Gutenbergstraße 14 · D-48282 Emsdetten
Tel. +49(0)2572 96026-0 · info@agtos.de
www.agtos.com
157-11/13-4c-GB
CASTING PLANT & TECHNOLOGY 3/2019 27

COMPANY
Rolls for the world
Gontermann-Peipers casts the world’s heaviest rolling mill rolls. With almost 200 years of
foundry expertise, engineering skill and innovative spirit, the Siegen-based company has
become one of the world’s most important producers of rolls for rolling mills and
high-performance components for machine construction.
by Robert Piterek, Düsseldorf
Photos: Andreas Bednareck
It is vibrating in the works hall – from
beneath the cover plate with a diameter
of about five meters. Then a
two-meter-tall casting ladle slowly
descends to the pouring funnel at the
center of the plate. The casting cycle
starts: an employee in heat-protection
gear rapidly, but carefully, tilts the ladle
forward by handwheel. The molten
steel sloshes over the spout. A wide
stream flows, almost silently, into the
underground cylinder about 13 meters
deep where a vertical centrifugal casting
mold is rotating at several hundred
revolutions per minute – operating at
full speed. The centrifugal forces press
the melt to the edge of the mold (like
an enormous salad spinner), ensuring
compact compression of the structure.
Smoke now rises from the funnel and
the gaps in the cover plate, which is
fixed in place with enormous screws. A
work roll, which will one day be used in
the roughing stand of a hot strip or
28

Managing Director Frieder Spannagel explains the layout of the individual depart -ments
on the works grounds. He has been managing the company since 2015, together with
Dr. Hartmut Jacke and Dr. Bernd Hofmann.
Casting on the vertical spin caster.
A mold rotates at several hundred
revolutions per minute below the
round cover plate.
heavy plate mill to roll slabs into sheet,
is being produced here using the vertical
spin casting process. The shell just
cast from extremely wear-resistant steel
will be filled with a ductile core – which
will absorb the forces ultimately exerted
on the roll. The spin caster will still
need some time for the current work
step. After casting, it will take several
days for the raw work roll to cool
enough to permit further processing.
A prime example of an SME
The action is taking place at the Marienborn
works of the Gontermann-Peipers
foundry in the German town of
Siegen which, in addition to other
high-performance components, casts
and finishes about 800 work rolls a year
in a weight class from about eight tonnes.
The company’s two sites, the Hain
works and the Marienborn works,
employ 570 personnel. It achieves sales
of about 100 million euros every year
and is still in family hands. The descendants
of the company founder already
manage the traditional company in the
seventh generation. The foundation
stone was laid in 1825 – in six years the
company will be 200 years old. Gontermann-Peipers
is thus a prime example
of the SME economic power that has
always formed the backbone of German
society.
The company already has more than
a century’s worth of expertise in casting
rolls: the first rolls were cast here in
Three casters in so-called ‘silver man
suits’ – heat protection for work on the
melting plants and during the casting of
components.
1855. No wonder, then, that there are
only a few companies worldwide that
can compete in its market segment.
Gontermann-Peipers set a world record
in 1985 with the casting of a work roll
for the Dillinger Hütte plate mill: it had
a finished weight of 265 tonnes and
was 11.5 meters long. Gontermann-Peipers
collaborated with other regional
foundries and steelworks in order to
put together the 500 to 600 tonnes of
liquid iron necessary to cast a roll of this
magnitude. A mammoth task, at most
only approached by the production of
the largest back-up roll for aluminum
sheet: the world’s longest heavyweight
CASTING PLANT & TECHNOLOGY 3/2019 29

COMPANY
60-tonne electric-arc furnace at the Marienborn
works. Together with the three
other furnaces, the works has a total
melting capacity of 150 tonnes.
The 13-meter-deep casting pit in which two permanent molds are already present.
The larger the rolls at Gontermann-Peipers since the 1970s, the deeper the casting pit.
work roll, weighing 236 tonnes and
13.55 meters long. This was made for
the Arconic works in Davenport, USA,
which produces for aircraft-maker
Boeing among others.
High export rate
The current family representative at
Gontermann-Peipers is Frieder Spannagel
who, together with Dr. Bernd Hofmann
and Dr. Hartmut Jacke, forms
the three member executive team of
the family-run company. In 2015, the
44-year-old took over leadership of
the company from his father Fritz
Spannagel, who now has an advisory
role as Chairman of the Supervisory
Board. Frieder Spannagel studied business
administration and worked for
metallurgical plant supplier SMS
Group for six years before joining the
family company. Spannagel is as unimpressed
by entries in the Guinness
Book of Records as he is by the company’s
recent entry in the ranking of
world market leaders in Wirtschaftswoche,
a German weekly business
news magazine. In his position leading
the company he prefers realistic business
assessments to titles. “In order to
stay at the top of the ladder in worldwide
competition, our products must
be at least as much better as they are
more expensive than those of others,”
he stresses.
For Gontermann-Peipers – with its
export rate of 70 percent for rolls –
worldwide competition is as important
to them as developments on the steel
markets, where its customers (such as
Dillinger Hütte, Dillinger France, Salzgitter
Grobblech, thyssenkrupp, Severstahl
and MMK Magnetogorsk) are
active. The steel sector has been characterized
by enormous overcapacities
since at least 2009, triggered by Chinese
steelworks. The roll business,
however, is now regaining momentum.
The main purchasing countries
are India, Mexico and Russia, as well as
30

those of Latin America. Orders from
China are falling. Demand for the largest
rolls is restricted because there
are only a limited number of plants
that can use them. In addition, of
course, these large rolls have very long
service lives before requiring replacement.
Innovative roll composition
In addition to work rolls, the Marienborn
works also produces back-up rolls
and profile rolls that are also used in
rolling mills. The back-up rolls, which
include the heaviest of rolls, are made
using a composite steel casting process
developed by the company itself in
which, like with the vertical spin casting
process, different materials are combined
in the roll shell and core to create
extremely high-performing rolls.
The materials used for the rolls are
hot-working tool steels, chrome steels
with up to 18 percent chromium, and
HS steels with high vanadium contents.
Recently, unfortunately for the company,
prices for the elements that
increase the toughness (and thus the
resilience) of the steel have increased
massively.
Another prominent product from
Gontermann-Peipers is bodies for nuclear
casks – cast and mechanically processed
thick-walled bodies for the Castor
® casks of GNS (Gesellschaft für
Nuklear Service). Castor ® is a secure container
for the transport and storage of
highly radioactive waste and the spent
fuel of nuclear power stations. The 100-
tonne container bodies, made of spheroidal
graphite iron, are among the
most demanding castings to make. Gontermann-Peipers
is one of a very small
circle of companies capable of casting
and processing Castor ® bodies. The
An employee prepares a casting mold.
Mold elements are available in the most
varied of sizes. So the roll foundry can
flexibly produce different roll sizes.
The rolls are stacked three meters high
on the works grounds – in a variety of
processing stages.
CASTING PLANT & TECHNOLOGY 3/2019 31

company has its own state-accredited
inspection laboratory for these products.
The works in Hain, which uses the
most varied of casting processes, considers
itself a foundry for specialties.
Demanding materials and components
are produced for machine construction
in general. In addition to permanent
mold casting and horizontal spin casting,
production takes place using continuous
casting and hand molding processes.
Typical products include cylinder
liners, cast machine beds, easily
machined continuously cast products,
and composite cast high-performance
wear sections for cement works and
other crushing applications – components
that have sold well in recent
years, according to Spannagel.
A corset made up of
molds and rings
Business with large rolls really got
going at the Marienborn works from
the 1970s onwards. The melting operation
was also expanded then, and now
consists of four electric-arc furnaces
with capacities of 20, 30, 40 and 60 tonnes.
Just now, a large charging basket is
swinging through the hall on an indoor
crane, its cargo clanking as it charges
the furnace. One employee in a bulky
protective suit flushes the melt with
oxygen. Then the clinkering door is
opened; a glance inside revealing three
The roll on this boring machine is tiny
compared to the large rolls. The foundry
casts and processes rolls weighing from
8 to 265 tonnes.
dazzlingly bright graphite electrodes
– the heart of the electric-arc furnace,
at several thousand degrees.
Moving past stacked mold rings and
permanent mold elements – cast in
Hain for use at the sister foundry – we
continue to the 13-meter-deep casting
pit. A back-up roll stands here, wedged
into a corset made up of precisely
these permanent mold elements. It
must have been cast recently because
the structure is still smoking and glowing.
The task of back-up rolls in
rolling mills is to prevent sagging of
the work rolls. “So the back-up rolls
are in effect backing up the work rolls
during forming work,” explains Spannagel.
The back-up rolls thus have a
Ready for further transport – a used roll
from a customer and a heavy permanent
mold produced at the sister works wait
alongside the railway siding at the Marienborn
works. About 75 percent of all
rolls leave the works grounds by train on
their way to Bremen, Bremerhaven or
Rotterdam.
32

COMPANY
For exports – which
account for about
70 percent of the
production – the
journey continues
by ship. Here a huge
236-tonne back-up
roll for Arconic-Davenport,
one of the
world’s largest aluminum
works, crosses
the Mississippi.
central function that is important for
the performance of the entire rolling
mill.
Our path continues to the finishing
area, where one can see that the
demand for rolls is currently high. On
one side, bordering the passage, a red
brick wall with a shingle top and small
tower-shaped structure is unmistakably
from the time of the Kaiser. On the
other side of the passage the hall is filled
with differently sized rolls stacked
three meters high. The rolls still have
rough and spiky surfaces instead of a
gleaming chrome finish.
A hall – about one hundred meters
long and filled from one end to the
other with grinding machines, rough
and fine turning machines, as well as
boring and milling machines – is available
for the finishing work. Rolls of
varying sizes are clamped into these
machines. At the moment, a turning
machine is scraping helical shavings six
centimeters wide from the surface of a
raw roll. The rasping noise – augmented
by short hydraulic impacts and rattling
sounds – fills the hall. Employees stand
at screens monitoring the processes.
Spannagel points out that Gontermann-Peipers
has the world’s largest
roll-turning machine, then he meets
Christian Balling, Works Manager for
mechanical processing, and shakes his
hand. He is responsible for the pre- and
final turning of the rolls, the grinding,
the milling and boring work, and the
packaging. He quotes the annual production
of rolls and the other tasks carried
out by his department, such as contract
processing and repairs. “We have
high capacity utilization here,” he says
assertively, and Spannagel underlines
this by adding that the works’ capacity
utilization is 80 percent. The Marienborn
works currently produces 20,000
tonnes a year; the Hain works 23,000
tonnes. Nothing is left to chance. When
the roll is ready for dispatch it shines
like a Christmas bauble on a tree – in
addition to the ‘internal values’ of the
product, the external impression always
counts.
Keeping up expertise for the third
century of operation
When one sees the great variety of
work steps the question arises: How
will the company’s wide-ranging specialist
expertise survive the transition to
the third century of the family-run
company? The answer is: with increasing
automation and digitalization, and
a well thought-out trainee program –
currently with 30 trainees and about 15
up-and-coming managers with master’s
certification or technician diplomas.
The newly qualified specialists are to
gradually replace the workforce, the
average age of which is currently
around the mid-forties. Gontermann-Peipers’
good reputation in the
region, the varied training at the
works, and the fruitful collaboration
with regional educational institutes
and partner companies help in the
acquisition of a younger generation.
And there is the consistent focus on
innovation – with two full-time R&D
engineers whose task is to continuously
make production more and more efficient,
while taking into account the
opportunities offered by digitalization
(for optimizing process and logistical
systems, for example). The company
obtains young engineers from universities
and colleges in Freiberg, Aachen,
Clausthal, Friedberg, Duisburg and Siegen.
“One of our engineers is just finishing
his PhD at Siegen University,”
Spannagel reports proudly. Regular
investments in the company’s technical
equipment and infrastructure are also
important for the future – amounting
to between six and seven million euros
a year.
This course has been rewarded with
the trust of customers from all over the
world. One prestigious order of recent
years, for example, was for Big River
Steel, a steelworks newly built by the
Düsseldorf-based SMS Group on the
banks of the Mississippi in the US state
of Arkansas. This involved more than
100 rolls with subsequent orders. A
similarly large order has just been received
from Mexico. The large rolls are
usually transported by ship and rail. For
this purpose, the company has its own
rail siding on the works grounds. The
wagons, suitable for transporting the
heaviest of rolls, are a sought-after
commodity for industrial companies
with products of this size. “Though
there are only two wagons of this type
in the whole of Germany,” Spannagel
points out. This occasionally leads to
wrangling with Siemens and other producers
of large components. The rolls
then continue their journey from Bremerhaven
to the destination country,
spreading the good reputation of
‘Made in Germany’ engineering skill
worldwide.
www.gontermann-peipers.de
CASTING PLANT & TECHNOLOGY 3/2019 33

HÜTTENTAG 2019
Steel industry's meeting point
Location: MESSE ESSEN | Messeplatz 1 | 45131 Essen, Germany
FOLLOW
TRADITION,
SHAPE THE
FUTURE!
Professional exchange and networking have a long tradition in the steel industry. The
new HÜTTENTAG is continuing this tradition with a bright new touch in the Foyer East
of Messe Essen. It offers participants and exhibitors a perfect mixture of lectures,
panel discussions, company exhibition and Hüttenabend in one day.
Programme
Thursday, 7 November 2019
9:00 Registration and Start of the Company Exhibition
register now!
9:45 –10:00 Welcome speech by DVS Media GmbH and MESSE ESSEN GmbH
10:00 –10:30 Welcome speech
Rudolf Jelinek, 1st Mayor City of Essen
Conference price for participants
(lecture programme,
visit to the exhibition and
Hüttenabend incl. food and
drinks)
10:30 –11:00
11:00 –11:45
Keynote
Prof. Johannes Schenk, Ferrous Metallurgy, Montanuniversität Leoben, Austria
„The European steel industry on their way to CO2-free steel
production through the use of hydrogen and electrical energy“
Panel
„Current status and outlook for CO2-free Steel Production“
Participants: Prof. Johannes Schenk, Dr. Markus Dorndorf a.o.
Conference price 149.00 €
Booking at:
www.homeofsteel.de/
huettentag/huettentag-en
11:45 –12:15 Coffee break
12:15 –13:00
13:00 –14:00 Lunch break
Panel
„Outlook for Steel and the Challenges of Electromobility“
Participants: Wolfgang Eggert a.o.
14:00 –15:30
Lectures in Room 1 and 2:
Dr. Michael Krenz, Friedrich-Alexander Universität Erlangen
and Klaus Gottwald, VDMA, about Supply Chain Management
in Large-Scale Plant Engineering
Dr. Horst Hill, Deutsche Edelstahlwerke, about Additive Manufacturing
Dr. Andreas Quick, iba AG, about Digital Transformation and Industry 4.0
Further lectures by LOI Thermprocess, Linde AG, Steuler KCH,
Vestas a.o.
15:30 –16:00 Coffee break
Photo: worldsteel / Gregor Schläger
16:00 –17:30
Lectures in Room 1 and 2:
Historical-technical lectures:
Prof. Dr. Manfred Rasch, formerly thyssenkrupp Group Archive:
Germany's first coastal steel mill
Johan van Ikelen, Hoogovens Museum, IJmuiden: Founding history of
IJmuiden
Further lectures by Asinco, Magma, Schuh Anlagentechnik a.o.
18:00 – 23:00
„Hüttenabend“ and Company Exhibition

CASTING
Special
GIFA 2019
Part 3: Opportunities provided by new
technologies
GIFA
Special
Photo: Martin Vogt/BDG

SPECIAL: GIFA 2019/INTERVIEW
“GIFA has underlined its
claim to being the world’s
leading trade fair”
Expectations of the 2019 quartet of trade fairs – made up of GIFA, METEC,
THERM PROCESS and NEWCAST – were ambitious. Heinz Nelissen, President of GIFA
and NEWCAST looks back at the five days in an interview.
Photo: BDG/Vogt
Mr. Nelissen, during our talk before
GIFA you had high expectations but
also mentioned the clouds on the economic
horizon. Was your outlook confirmed?
We did, indeed, have some doubts
about whether the current economic
downturn would impair visitor interest
and lower the quality of the trade fair.
But these misgivings were unfounded.
When did you realize this?
Honestly? 20 minutes after the trade
fair started – when we had the first visitors
at our stand. We registered very
high visitor interest, especially during
the first three days. The visitors – that
was my perception – clearly wanted to
increase their competitiveness. I experienced
this 2019 trade fair as very forward-looking.
What were the main points raised
during customer contacts?
Foseco had a very good supply of
high-quality visitors, i.e. thoroughly
concrete customer contacts, right from
the start of the trade fair. There were
very interesting conversations – for
example about optimizing gating systems.
With the aim of achieving a higher
yield and saving energy. So more
economical production with higher
quality.
So a 2019 trade fair with interesting
and professional customer contacts?
Yes, a trade fair with very positive
customer contacts and interesting
technical discussions which we believe
will also be followed up. During the
conversations, about half of the customers
expressed a wish for us to visit
them. That is a very positive value.
Does this also apply for customers from
the automotive sector? There was a lot
of talk about restraint before the trade
fair.
The resonance here could indeed have
been stronger. As far as I know, the carmakers
didn’t have a chance to visit the
36

trade fair, and there were even travelling
restrictions. We will have to stimulate
follow-ups for customers from the
automotive sector, in particular.
GIFA and NEWCAST are international
trade fairs. What did you think of the
mix among the public?
It is indeed true that we traditionally
have a high percentage of international
visitors. I thought that the Asians were
very strongly represented here, and particularly
visitors to our stand from India.
Though less strongly from the American
side. The talks with German customers
took place on the highest technical
level. Here one had the impression that,
comparatively speaking, the technology
was somewhat lagging behind in the
Asian countries.
Can Germany maintain its lead?
We are maintaining the lead, but Asia is
catching up. We see a real readiness to
make investments there, and a lot of
automation taking place. The quality
level is being cranked up because the
Chinese carmakers have high demands.
The Chinese are catching up, but we
still have the edge.
Is that also true of machine
construction?
German machine constructors are working
on state-of-the-art solutions and
are still in a leading position. But here,
too, it is necessary to defend the lead.
Because in this field the Chinese are
also ambitious – and are catching up.
What were the main areas of interest
that you observed at the trade fair?
I got the clear impression that compared
to the last GIFA a lot has been
achieved regarding digitalization and
automation, in particular. Robots were
in action at a lot of stands. Robot technology
has become more affordable
and easier to program.
What will this mean for works practice?
My forecast is that there will be a big
surge after the trade fair. Many foundries
will think about which departments
could sensibly use additional automation.
And then implement solutions at
their works.
Did you notice any concrete readiness
to invest on the part of the companies?
We had record years in the foundry
industry in 2017 and 2018. Now we are
experiencing a slight dip – whereby
many companies are naturally considering
what the future holds. Actually, I
did get the feeling that there was a readiness
to invest – and the capital costs
for it are still low.
Do you see any focal points for this
surge in automation?
In general, where we now already have
a high level of automation, i.e. at the
die-casters. And this will continue. But
there will also be more automation and
optimization in core and machine mold
technology. And in safety-relevant
areas, where employees are still in
action and are exposed to certain
hazards. There, too, people will be using
robots more.
Were there any other emphases?
I noticed that the printing of cores was
another focus. The printers are becoming
more economical and also quicker
– so that this process can be used to
economically produce an increasingly
wide range of cores.
Was the recruitment of young talent
successful?
I think so. We had several school classes
at our stand every day, as part of the
‘Metals4you’ campaign. We confronted
the schoolkids with technical topics in a
fun way. We have to keep working on
this in collaboration with the German
Foundry Association (BDG) and German
Foundrymen’s Association (VDG)
because during the coming years we
will have a wave of retirements in the
foundry industry – and we have to convince
young people about the benefits
of our sector. We are a small sector and
must draw attention to ourselves.
What stimuli will emanate from GIFA
2019 and what is your final conclusion?
We will have the next GIFA in 2023 – in
my opinion this four-year cycle is
important and very helpful. It ensures
that GIFA remains a leading trade fair
worldwide. Because the 2019 trade fair
very definitely underlined this aspiration.
In four years there will be even
more digitalization and automation to
keep personnel costs under control.
Interview by R. Piterek and M. Vogt
CASTING PLANT & TECHNOLOGY 3/2019 37

GIFA sets the trends for
the future of the industry
The trend towards
e-mobility also played
a major role at the
Bright World of Metals.
What remains of the Bright World of Metals with its core, the leading trade fair GIFA?
There was no new record of visitors, but the fair set clear trends for the future of the
industry.
by Robert Piterek and Martin Vogt
Photos: Martin Vogt, Messe Düsseldorf, Robert Piterek
Trade fairs like to report new
records for their most important
events. The organizers secretly
hoped for 80,000 visitors for the five
days of the Bright World of Metals,
which would have been a slight
increase on 2015. In the end, GIFA,
Metec, Thermprocess and Newcast officially
counted 72,500 visitors from 118
countries. The roughly seven percent
fall in the number of visitors could not
be broken down on a fair-by-fair basis
because the entrance ticket enabled
access to the entire site. One consolation:
quantity is not everything!
Internationality increases again
“GIFA has clearly confirmed its status as
the world’s leading trade fair,” GIFA
President Heinz Nelissen gives his opinion
of the 2019 trade fair. The official
figures also show that the proportion of
international exhibitors rose from 65
percent in 2015 to 70 percent this year,
and foreign visitors from 62 to 66
percent.
Exhibitors stress the quality
of the contacts
Exhibitors particularly emphasized one
aspect of their customer contacts when
talking to the CP+T editors. “We had
fewer walk-in customers – but more
high-quality contacts,” Till Schreiter
(Managing Director of ABP in Dortmund,
Germany) sums up the five days
of the trade fair. “High-quality” was
probably the most often quoted assessment
of the trade fair.
GIFA also kept the promise that Nelissen
had made in advance of it, namely
that there would be “a veritable explosion
of innovations”. We describe the
most concrete trends below with
examples.
38

SPECIAL: GIFA 2019
The die-casting
machine of Oskar Frech
at the stand of the Academy
of the German
Foundrymen’s Association
produced animal
halves – bees and lions
– made of zinc.
The sector needs specialists,
research and
expertise: the Institute’s
show provided a venue
for candidates and companies
to meet.
We had fewer walk-in
customers than in 2015,
but that was offset by
more high-quality contacts.”
Till Schreiter, ABP Induction Systems
The aim of the collaboration that Loramendi,
voxeljet and ASK Chemicals presented
at the trade fair is the automated
serial printing of cores.
Trend: automation
Exhibitors confirm the clear trend
towards automation. Certainly, there
have never been as many robots at a
GIFA as this year – few stands were
without them. Suppliers are seeing continuously
rising demand for industrial
robots. There are reasons for this. In
addition to the predictable argument
regarding increased productivity, another
factor is driving this development
– particularly in the German foundry
industry. “A shortage of specialists and
demographic change are coming
together,” Steffen Günther (Head of
Business Development at Kuka, Friedberg,
Germany) analyzes the situation.
People who retire could in future be
replaced by a machine, particularly for
simple tasks. So-called pre-machining
cells, for example, are doing particularly
well. These are robots that carry out
one processing step on castings before
they go to CNC processing.
Digitalization, by the way, is already
integrated among our sheet metal comrades.
The system notices if one of the
robots suddenly starts using more electricity.
And it is possible to predict wear
and plan maintenance intervals.
In markets with high energy costs, in
particular – so most especially Germany
– development is also increasingly focusing
on electricity consumption. Kuka is
specifically marketing its SKT 22 press
with up to 40 percent less electricity
consumption. Electric motors regulated
on a needs-oriented basis replace the
hydraulic system in the press, used for
deburring die-cast components. The
new technology is not only more economical,
but also faster.
The increasing use of the OPC-UA
standardized digital interface is particularly
noticeable here, and among many
other machine constructors – so digitalization
now has a promising future in
modern foundry technology.
Trend: additive manufacturing
For the first time in the history of the
Bright World of Metals this subject had
its own specialist conference, at which
many aspects of direct and indirect 3-D
printing were examined on the second
day of the trade fair. Representatives
from companies such as MAN Energy
Solutions, SLM Solutions, EMEA Voxeljet,
Trumpf, Protiq, EDAG Engineering
and the Fraunhofer Institute for Manufacturing
Technology and Advanced
Materials (IFAM) reported on the applications
of additive manufacturing,
including tool, mold and core production;
metal 3-D printing; and laser
deposition welding. In his presentation,
Ralf Frohwerk from SLM Solutions quoted
concrete figures on the profitability
of the metal 3-D printing process which
has recently become increasingly relevant
in production: he revealed that
from series of up to 3,000 units, metal
3-D printing of components for medical
technology, shipbuilding, aviation, small
automotive series or spare parts for oldtimers
already paid off.
The indirect 3-D printing of molds
and cores has meanwhile taken over a
considerably broader range of uses in
the foundry industry. Printing is now
also taking place with phenolic and
inorganic binders. The molds and cores
(sometimes printed in one piece) can be
used in combination with conventional
CASTING PLANT & TECHNOLOGY 3/2019 39

SPECIAL: GIFA 2019
metal casting for the production of
components – and are high quality,
environmentally friendly and quick, as
Matthias Steinbusch from EMEA Voxeljet
AG showed in his presentation.
The trade fair offered an impressive
number of innovations in indirect additive
manufacturing. And cooperations
on the industrialization of the process
were announced at the trade fair. Thus
Loramendi (a specialist in mold and
core production), voxeljet (one of the
leading players in the production of
3-D printers), and ASK Chemicals (who
produce, among other things, inorganic
binding agents for cores and
molds), presented a plant for the automated
serial printing of cores. ASK
Chemicals has developed its own inorganic
binder, Inotec 3D (consisting of a
printing fluid and a promotor), which
can be used for hot-hardening additive
manufacturing processes. The aim of
this collaboration is to introduce 3-D
printing technology for medium and
large serial production. The partners
spent four years working on the construction
of the automated core printing
plant – whose presentation attracted a
large crowd.
ExOne, a competitor of voxeljet, was
also able to score points in the sector
and among visitors for its indirect 3-D
printing: the company presented a collaboration
with Siemens. The cooperation
between the technology group and
the producer of 3-D printers also involves
the industrialization of 3-D printing.
In an interview with CP+T (page XXX),
John Hartner (ExOne’s Managing Director
USA) said that the two companies
are working together closely on both
quality assurance and digitalization.
The latest product at the stand of the
Gersthofen-based producer was the
new S-Max Pro 3D printer which, for
the same purchase price, offers 25 - 30
percent higher productivity than conventional
printers, according to Eric
Bader (ExOne’s Managing Director Germany).
The technology, which also uses
environmentally friendly inorganic binding
agent, can be employed to make
innovative water jacket cores for the
temperature management of engines,
the pump industry and e-mobility, for
example.
The triumphant advance of indirect
3-D printing in the sector was finally
crowned with the announcement that
Laempe Mössner Sinto (which produces
conventional core-shooting plants,
among other things), is also entering
the 3-D printer market. In a strictly
A sand core from Laempe Mössner
Sinto made using additive
manufacturing. Selected visitors
to the trade fair were able to
see the machine constructor’s
first 3-D printer.
This so-called Pre-Machining Cell
at the Kuka stand was the subject
of enormous interest.
Foundries often cannot find any
employees for finishing work.
screened area, the Schopfheim-based
machine constructor presented its first
3-D printer, developed during the last
three years. It is more productive and
faster than the competition because the
printing head, which constructs the core
contour layer-by-layer, prints in both
directions, according to Managing
Director Andreas Mössner. The accuracy
of the printing and production is monitored
by a measurement device from
the recently acquired subsidiary inspectomation
systems. The plant is likely to
be tested in the state-of-the-art Inacore
core shop (see also corporate report on
the company in CP+T Issue 1-2019 from
page 10) and presented to the public
during the last quarter of the year.
Laempe Mössner Sinto is one of the
partners in Inacore, which produces
inorganic cores for BMW’s light-metal
foundry in the southern German town
of Landshut.
Other interesting topics covered
during the conference on additive production
included 3-D printing in tool
and mold construction, and the opportunities
offered by near-contour cooling
in die-casting, presented by Christoph
Dörr from machine constructor Trumpf.
Thus 3-D printing can be used to make
molds for die-casting machines with
cooling channels designed to precisely
dissipate the heat where necessary to
produce a perfect die-cast component.
The advantages are improved cycle
times, more stable casting processes
with lower solidification porosity, lon-
40

At its stand, ABP showed how
customers can take courses in
making up a charge, inoculation, or
safety in virtual training rooms
with virtual reality (VR) glasses.
ger mold service lives, and an improved
energy and resource balance. In addition,
according to Dörr, this technology
allows the amount of spray fluid to be
reduced – with benefits for the workplace
and for surface quality. Other presentations
covered the processing of
The presence of Chinese
foundries, in particular,
could not be
overlooked. Overall,
GIFA has become even
more international.
Sustainability was also
a topic at GIFA. Magma
had decorated an entire
wall with green foliage
– a thoroughly original
stand design.
zinc die-casting materials in selective
laser-melting processes, and hybrid production
chains in which a combination
of light-metal die-casting and laser-melting
bring together the advantages of
die-casting with those of additive
manufacturing.
Trend: digitalization
Industry 4.0, the Internet of Things,
digitalization. The field which can selectively
be described with these words –
even if not entirely congruent terminologically
– exhibited a real boom at the
trade fair. There were promising solutions
for, say, predicting faults and thus
for reducing the number of rejects. And
from Denmark’s Norican Group, which
presented its four brands (DISA, Wheelabrator,
StrikoWestofen and Italpresse-Gauss)
for the first time. With DISA,
for example, every casting is assigned
an ID number with which the link can
be made between the casting and its
process parameters in a so-called ‘trace
and guidance’ (TAG) concept. TAG tracking
also paves the way for advanced
analysis of the cause of any rejects.
The Refill Monitor from StrikoWestofen
is interesting, supporting workers
operating fork-lift trucks loaded
with ladles. They can see the filling level
of the various furnaces at any time on
screens. The result is that the furnaces
are always filled in time, increasing
availability for customers. At the same
time, data on all the modern plants in
the Group are collected in a cloud, from
where they can be called up at any time
and analyzed. As Peter Holm Larsen
(COO and President of the Group) said
in an interview with CP+T, the Group’s
purchases in recent years have been
intended to expand its presence in aluminum
and thus meet demand in the
automotive sector – among other
things, StrikoWestofen constructs shaft
melting furnaces for non-ferrous metal
foundries, while Italpresse-Gauss makes
die-casting equipment.
The innovations at the stand of
machine constructor Eirich (known for
its sand mixers, among other things)
were also the subject of great interest.
The focus here was on the Qualimaster
AT1, in particular. A plant that when
installed downstream of the mixer measures
gas permeability, spring-back and
the malleability of the sand for each
individual charge. The continuously collected
data, connected via the OPC-UA
international interface standard, considerably
improves sand quality as well as
CASTING PLANT & TECHNOLOGY 3/2019 41

SPECIAL: GIFA 2019
mold and casting precision. This helps
meet the tighter tolerances demanded
by customers and considerably reduces
corrective work. The sand loop can also
be included in the digitally monitored
process chain, improving the traceability
of the castings, among other things.
“Many visitors would like to replace
their current plant with a modern one
with the Qualimaster AT1,” observed
Edith Weiser, Foundry Sector Manager
at Eirich. The company came to Düsseldorf
with low expectations but
returned to its home in Hardheim very
satisfied indeed.
Trend: digital services
A clear tendency towards becoming service
providers can be seen among some
foundry suppliers – mostly exploiting
the new possibilities offered by digitalization.
This does not mean that they
will give up their main business, just
that the service aspect is expanding
considerably alongside it. This group
includes the internationally positioned
melting furnace manufacturer ABP
from Dortmund. It presented an open
platform for maintenance and training
for thermoprocessing equipment. It is
not necessary to own a plant from ABP
to exploit this service, and no technicians
are flown in. The new service and
training environment at ABP is entirely
based upon the technical possibilities
offered by augmented and virtual reality.
The stand had a headset containing
a camera that transmitted the video picture
directly onto a small screen. During
maintenance, a service technician can
thus observe every movement of the
on-site technician and, if necessary, provide
circuit diagrams, for example, and
give instructions. “We make a virtual
visit to customers,” explains Till Schreiter
(CEO of ABP). The aim is to increase
productivity and availability for customers,
who can also practice mixing a
charge or undergo complete safety training
for emergencies in virtual training
rooms using virtual reality (VR) glasses.
Schreiter also looks back at the trade
fair with great satisfaction: 380 potential
customers were introduced to the
technology – the interest was enormous.
In past GIFA years, the stand of
Oskar Frech was largely characterized
by the Schorndorf-based manufacturer’s
die-casting equipment. It was different
this year – an enormous hemisphere
took up most of the stand
space. Groups of visitors flowed in at
regular intervals to find out about the
European machine construction (here at
Bühler) is the world leader. And in
future? GIFA witnessed Asians who were
scrutinizing every technical detail very,
very carefully.
company’s new Smart Foundry solution.
The control systems for production
shown at the stand were impressive.
The possibilities offered by the
new software were clearly demonstrated
by means of a digital game where
the aim was to increase the level of
digitalization by networking a die-casting
foundry: modules such as the
Foundry Information Manager, Reporting
Services, Data Safe and Overall
Equipment Effectiveness cover all networked
departments of the digital
die-casting foundry, offer comparisons
with old data and other machines, and
visualize the data understandably in
bar or curve form. The prediction of
faults and planning of maintenance
intervals will be added in future. Frech
accepts that the company’s focus will
shift more towards services, because
the company itself will be taking responsibility
for the data security of its
Smart Foundry solutions. And the concept
could be successful. After all, 80
percent of die-casting foundries are
SMEs and would therefore probably be
grateful to place data security and
digitalization in the hands of this innovative
producer of die-casting equipment.
Smart Foundry can be installed
from September. The competition,
however, is far from asleep: the Swiss
die-casting equipment producer Bühler
showed its ‘Digital Cells’ at the trade
fair and campaigned with “0 percent
defects, 40 percent lower cycle times
and 100 percent availability”.
42

SPECIAL: GIFA 2019
FOSECO
Flow control for iron and steel foundries
Hot and cold start steel ladle systems
At GIFA 2019 Foseco
Foundry Division from
Borken, Germany, highlighted
the latest technologies
available for
controlling the metal
flow in steel ladles and autopour iron
applications. On show were alternative
steel ladle lining and flow control systems
for both cold start and hot start
ladle systems.
Foseco showed the Kaltek board
system for bottom pour ladles, a
unique lining system that requires no
pre-heating. The Kaltek board system
is suitable for ladles up to 25 tonnes
capacity and more for specific projects.
A new generation of Kaltek board
multi-life system has been introduced
to the market to combine the properties
(no pre-heating, metal cleanliness,
insulation) with a set that can be used
up to 5 times and allow thermal cycles
and nozzle exchange.
Foseco’s new, VISO isopressed
zoned nozzle offers the steel foundry a
multi-life nozzle for improved productivity.
The zoned nozzle uses a combination
of different refractory systems
to enhance strength and performance,
thereby enabling repeated use of the
nozzle in a steel foundry ladle.
In addition Foseco presented the
latest flow control technology for grey
and ductile iron, especially for
unheated pouring boxes, consisting of
a range of design and refractory combinations
to meet the requirements of
a variety of autopour applications.
www.foseco.com
Photo: Foseco
FOSECO
Refractory linings for iron and steel foundries
At GIFA, Foseco
Foundry Devision, Borken,
Germany, launched
the Triad Z no
cement castable range
for iron and steel
foundry applications.
No cement castables have been available
for many years and are attractive
for minimizing furnace downtime
during the relining process. The recent
development of the Triad Z range
brings added advantages in terms of
superior slag resistance and enhanced
hot properties of the castable system.
Triad Z can be cast, pumped and
shotcreted and is now available for
most iron and steel foundry applications
such as long campaign cupola melting,
channel holding and pouring furnaces
as well as iron and steel ladle
applications.
On the stand Foseco presented a
complete package of lining and purging
refractories designed for long life
and improved metal cleanliness in
Photo: Foseco
Triad Z no cement
castable range for
iron and steel
foundry applications
coreless induction furnaces melting
steel grades. The portfolio consists of
high quality Kellundite lining systems
suitable for melting a wide range of
steel alloys and purge plugs utilizing
integral earth protection and precise
gas flow control systems to ensure safe
and optimal operation. Foseco also
showed a complete package of longlife
linings for long campaign cupolas
melting iron grades. The cupola portfolio
consists of high quality Ramwell
ramming mixes and Hydra-Max low
cement castable lining systems enriched
with silicon carbide and graphite
aggregates to improve slag resistance.
www.foseco.com
CASTING PLANT & TECHNOLOGY 3/2019 43

Powertrain 2030 –
driven by diversification
At the specialist conference “Foundry Technology
in Engine Construction” two automotive
engineers presented a scenario of the future of
mobility and tried to find an answer on the
question how E-Mobility will develop.
How will vehicles be powered in 2030? Will only a minority of newly registered vehicles
still have a combustion engine under the hood? Will battery electric vehicles (BEVs) have
replaced their conventional predecessor? The scenario as forecast by Mahle follows. This
article reflects the keynote speech given by Andreas Pfeifer at the ‘Foundry Technology
in Engine Construction’ conference which took place in January 2019 in Magdeburg,
Germany.
By Andreas Pfeifer and Otmar Scharrer, Stuttgart
Photo: Privat
Increasing global temperatures and
CO 2
emissions, as well as continuing
population growth, are increasingly
changing the conditions of life for the
world’s inhabitants. The agreement ratified
at the UN Climate Conference in
Paris on 12.12.2015 is intended to limit
global warming to considerably less
than 2°C compared to pre-industrial
values. What is certain is that most of
the continuous rise in average annual
temperatures seen since at least the
1960s is of anthropogenic origin. Studies
suggest that the two-degree objective
– intended to prevent irreversible
feedback effects that would push the
earth’s climate into a warm age with
enormous consequences – is already
unachievable (Figure 1).
Against this background, all CO 2
emitters are equally called upon to significantly
and rapidly reduce their absolute
emissions in order to prevent us
overshooting the 2 °C level of global
warming – requiring a far more costly
realignment from above to achieve the
long-term global warming objective of
considerably below 2 °C (Figure 2).
For the traffic sector, and thus for
the automotive industry, this can only
mean simultaneously doing absolutely
everything technically possible to
reduce CO 2
emissions. As anthropogenic
CO 2
does not cause any purely regional
emission problem that could be countered
by purely regional measures, only a
44

E-MOBILITY
cradle-to-grave consideration with realistic
emission evaluation can provide a
clear stimulus for applying significant
measures to reduce a vehicle’s total CO 2
footprint over its entire lifetime. It is
not just the direct CO 2
emissions of
vehicles in a tank-to-wheel consideration
that matter for the world’s climate,
but also the emissions resulting from
fuel production and electricity generation
plus their supply chains, as well as
from the production and subsequent
disposal of the vehicles themselves. If
the expenditure required to achieve
negative CO 2
emissions by the end of
the century – for example, using Carbon
Capture and Storage (CCS) – is to be
kept within an affordable range, and if
one considers the risks of irreversible
climate change (a warm age), it is obvious
that now is the time to act and, in
view of the service life of existing
vehicles, solely focusing on providing
new vehicles with battery electric powertrains
as rapidly as possible is simply
not enough.
If we take an aggressive global
‘Green Planet’ scenario in which, from
now on, the share of pure battery electric
vehicles gradually rises to 50 % and
that of hybrid vehicles by another 25 %
of all new vehicles in 2030 (Figure 3),
then by 2030 only 14 % of the entire
vehicle fleet will have an alternative
drive, namely 210 million of the total of
1.5 billion cars and light commercial
vehicles (Figure 4). A CO 2
saving of
about 520 million tonnes is possible
with these 210 million vehicles with
alternative drives if electricity from
purely renewable sources is used. A
similar effect can be achieved by substituting
19 % of fossil fuel use with fuel
produced from renewable sources (i.e.
CO 2
-neutrally) in an existing stock of
about 1.1 billion vehicles with combustion
engines (Figure 5).
But where should the renewably
produced fuel come from? It could
come from the excess power produced
from renewable sources. Even if renewable
electricity represents, on average,
about 30 % of all electricity produced in
Germany, the availability of renewable
energies is subject to major fluctuations
of up to 400 % due, above all, to
weather phenomena. The electrical storage
of excess energy is seriously limited,
as Figure 6 shows. Germany’s pumped-storage
power plants, as a typical
solution, only have a capacity of about
50 GWh. This would only be enough to
cover an average electrical energy
requirement of about 60 GW for one
Figure 1: The average annual temperature has been rising continuously since the
1960s.
Figure 2: Historical and future CO 2
emissions.
Figure 3: MAHLE base and Green Planet scenarios: proportion of vehicles with battery
electric and hybrid drives by 2030.
CASTING PLANT & TECHNOLOGY 3/2019 45

E-MOBILITY
Figure 4: Only an estimated 14 % of cars will have an alternative drive by 2030 –
even in the Green Planet scenario.
Figure 5: Mahle’s Green Planet scenario, CO 2
reduction potential.
hour. If all cars were electrified, requiring
a total capacity of 600 GWh (assuming
45 million battery electric vehicles
[BEV] at 50 kWh and 50 % state-ofcharge
[SOC], of which 50 % are on the
electric grid at any one time) it would
be possible to guarantee security of
supply in Germany for about ten hours.
Thus a BEV fleet could make a significant
contribution to offsetting shortterm
fluctuations in energy production.
But we need other solutions for the
long-term storage of energy because
renewable electricity production is not
only subject to brief fluctuations but
also to serious seasonal fluctuations. In
the distant future, one solution could
be renewables-driven gas power stations
which, using existing natural gas
reservoirs, could be operated for more
than 2,000 hours (equivalent to roughly
three months). On the way to this situation,
the sector-coupling of regenerative
gaseous or liquid hydrocarbons
could make an important contribution
towards further decarbonizing the traffic
sector. The study on e-fuels [1] presented
by the German Energy Agency
(dena) shows that comparable fuel costs
could be achieved using pure renewable
electricity and renewable hydrocarbons
for combustion engines.
The CO 2
emissions of the existing
fleet of vehicles could also be reduced
by using gaseous or liquid hydrocarbons
renewably produced from renewable
excess electricity. Focusing the use of
Figure 6: The electrical storage of excess energy is seriously limited.
46

Figure 7: The monovalent
gas engine can
be operated with
highly efficient
stoichio metric engine
characteristics – and
thus low CO 2
emissions.
Figure 8: CO 2
emissions are highly dependent on the vehicle type.
renewably produced hydrocarbons
purely on aviation and shipping seems
inappropriate, given the global challenge.
The necessary investments must
be made now in order to be able to
continue to run existing vehicles with
combustion engines CO 2
-neutrally,
reduce exploitation of the corresponding
resources. There are many
examples of the efficient use of renewably
produced hydrocarbons in combustion
engines – ranging from monovalent
gas engines with highly efficient
stoichiometric engine characteristics
and thus low-CO 2
operation (Figure 7),
to mixtures of dimethyl carbonate with
gasoline and oxy-methyl ester as a diesel-drop-in
fuel.
In the long term, renewably produced
hydrogen will in future drive
vehicles CO 2
-neutrally – principally by
means of fuel cells, but in special cases
(like mobile work machines) with combustion
engines. It is foreseeable that
the construction of the necessary infrastructure
will require considerably more
than two decades. In the meantime, in
addition to converting the fleet with an
increasing share of battery electric
vehicles and the introduction of renewably
produced fuels for existing
vehicles, there must also be a massive
rethinking process among vehicle buyers
and users. The type of vehicle with the
lowest CO 2
footprint should be selected,
depending on the usage profile.
Figure 8 shows a striking comparison
of vehicle type-dependent CO 2
emissions.
Assuming that each tree takes up
about 12.5 kg CO 2
/year, compensating
for a purely fossil-powered SUV driven
15,000 km annually would require a
stock of about 260 trees per SUV. For a
compact car, on the other hand, only
160 trees would be necessary [2].
The emission and efficiency problems
of cars with combustion engines
are particularly evident in urban use,
and are largely due to the customers’
misuse of modern efficiency-optimized
combustion engines. From an energy
(and thus CO 2
reduction) point of view
the most frequent causes of misuse are
the high proportion of cold starts, the
low efficiency of inner-city journeys,
and the use of vehicles that are far too
heavy for their transport task. A transition
to pure e-vehicles would be sensible
here. In future, the combustion
engine will remain the drive system of
first choice for longer journeys with
high levels of utilization. When vehicles
are used both within cities and for
long-distance journeys, hybrid vehicles
will continue to establish themselves
despite the greater mass of the powertrain
(and thus the entire vehicle). In
addition to the possibility of zero emissions
locally, hybrid concepts also offer
the potential of phlegmatization of the
combustion engine and use at the most
efficient operation points for optimum
consumption, whereby CO 2
potentials
that already exist can be exploited.
Until there is widespread conversion
to a pure hydrogen economy there will
be further differentiation of vehicle
powertrains in order to enable the
lowest CO 2
footprint for the particular
vehicle concept, taking into account the
customer’s wishes regarding user-friendliness,
the availability of drive energy,
driving performance, and range.
Dr. Andreas Pfeifer, Manager Product
Development Engine Systems & Components,
and Dr. Otmar Scharrer, Vice President
Corporate Research & Advanced
Engineering, Mahle GmbH, Stuttgart
References:
www.cpt-international.com
CASTING PLANT & TECHNOLOGY 3/2019 47

NEWS
SILBITZ GROUP
Foundry Group joins Meuselwitz Guss
Silbitz Group Beteiligungs GmbH has
acquired a stake in Meuselwitz Guss
Eisengiesserei GmbH. The Silbitz Group,
headquartered in Silbitz, in the German
federal state of Thuringia, has three
foundries in Silbitz, Zeitz and in Košice,
Slovakia, as well as a mechanical processor
in Stassfurt. The Silbitz Group, a
company from the portfolio of Deutsche
Beteiligungs AG (DBAG), is joining
Meuselwitz Guss with immediate effect.
„We are very pleased to be able to
give the company a long-term perspective
as a new co-shareholder of Meuselwitz
Guss Eisengiesserei GmbH. We are
convinced of the performance of the
company and its employees,“ said Dr.
Torsten Tiefel, Managing Director of Silbitz
Group GmbH.
The group entered the Meuselwitz
Guss Eisengiesserei GmbH by acquiring
the shares of the former executive
director, Mr. Herbert Werner. His merit
is to have decisively developed and
advanced the foundry: „After 48 years
with Meuselwitz Guss and my many
years as managing director and consultant
in the company, the foundry is very
important to me. The technical equipment
of Meuselwitz Guss Eisengiesserei
GmbH offers an excellent starting point
for the further development of the
company, so that I have decided to sell
my company shares to Silbitz Group
Beteiligungs GmbH „, explained Werner
the reasons for the sale of his shares.
And further: „I am sure that with the
Silbitz Group, my life‘s work can continue
not only in my own interests, but
also in the interests of the motivated
Casting in the iron foundry in Silbitz: The Thuringian foundry group has acquired a stake
in the DIHAG foundry Meuselwitz Guss
workforce and can be developed
further on,“ said the former Managing
Director of Meuselwitz Guss Eisengiesserei
GmbH.
„As the Silbitz Group, we are aware
of the long-standing commitment of
Mr. Werner and we will be responsible
for shaping the technically well-aligned
company in his spirit,“ commented Dr.
Tiefel the transition of the shares.
The Silbitz Group is one of the leading
foundry groups in Europe. It
employs 1,230 people and 67 apprentices
at four company locations. For the
current year, a turnover of 192 million
euros is planned. The foundry group
has a casting capacity of more than
75,000 tonnes per year and is a reliable
partner for casting in precision in nine
business areas, including wind power,
engine technology, mechanical engineering,
drive technology, mining and utility
and rail engineering.
Meuselwitz Guss Eisengiesserei
GmbH, which belongs to the DIHAG
Group, generates annual sales of 65
million euros and has a production
volume of 30,000 tons. Meuselwitz
employs around 320 people and 27
apprentices. With the help of modern
manual and large forming plants, large
parts up to 80 tons of piece weight,
high reproducibility of the workpiece
quality and inductive melting operation
in the material quality up to „solid
solution hardened nodular cast iron“
are the specialty for the machine tools,
injection molding, measuring plates,
press construction and wind energy
sectors.
www.silbitz-group.com/en
www.meuselwitz-guss.de/home/?L=1
Photo: Silbitz Guss
ASK CHEMICALS
Foundry chemistry group to acquire industrial
resin business
ASK Chemicals, Hilden, Germany, one of
the world’s leading suppliers of foundry
chemicals, has entered into a definitive
agreement to purchase the industrial
resin business from SI Group (New York,
USA). With this acquisition, ASK Chemicals
is reinforcing its position in the
foundry market and at the same time
strengthening its non-foundry business.
ASK Chemicals and SI Group have
agreed on the purchase of SI Group’s
industrial resins business and associated
manufacturing sites in Rio Claro (Brazil),
Ranjangaon (India), Johannesburg and
Durban (South Africa), as well as licensed
technology and multiple tolling
agreements globally. The transaction is
expected to close later this year.
SI Group’s industrial resin business
serves a wide range of markets and
applications such as foundry, friction,
abrasives, refractory, paper impregnation,
insulation and composites. “This
acquisition is an important step in our
growth strategy. It substantially reinforces
our position in the foundry business
and helps us to accelerate our
penetration in certain growth countries.”
states Frank Coenen, Chief Executive
Officer of ASK Chemicals. “At
the same time, it allows us to take a
first step in building a phenolic industrial
resins business, an attractive market
with promising growth opportunities.”
www.ask-chemicals.com
48

FRAUNHOFER IFAM
Low-cost powders developed for the additive
manufacturing of steels
Photo: Fraunhofer IFAM
Demonstrator component made of iron powder,
produced by selective electron beam
melting
At the Fraunhofer Institute for Manufacturing
Technology and Advanced
Materials IFAM in Dresden, Germany, a
new type of iron powder has been successfully
processed and tested, which
answers one of the cost questions in
additive manufacturing and opens up
new possibilities.
Up to now, only spherical powders
produced by inert gas atomization have
been used for additive manufacturing
in the powder bed-based processes
Selective Electron Beam Melting (SEBM)
and Selective Laser Melting (SLM). As a
result, the prices are very high.
With the newly tested production
method, prices for iron powder can be
achieved which are only around 10 %
of current costs. There are also inexpensive
alternatives for other materials,
such as HDH titanium powder.
Fraunhofer IFAM in Dresden has
now shown with a feasibility study for
processing by SEBM that dimensionally
stable components can be produced
with this iron powder. Despite the more
irregular particle shape and the expected
poorer flowability compared to gas
atomized powders, this iron powder is a
real low-cost alternative. Furthermore,
it has been repeatedly proven that the
SEBM process is a very robust technology
with regard to variations in the flowability
of the powder.
The addition of various powder mixtures
and, thus, the processing of a
wide variety of alloys have also been
successfully tested. Detailed investigations
into the respective alloy behavior
are currently underway.
Thus, Fraunhofer IFAM Dresden has
not only created an inexpensive alternative
for the additive manufacturing of
steels, which is also conceivable for
other materials. Material flexibility also
increases and a larger range of materials
becomes economically feasible.
The institute offers partners from
industry and research a wide range of
development services from powder to
component, e.g. in the form of feasibility
studies, the evaluation of powders
for additive manufacturing and the
qualification of new materials. Furthermore,
component development, starting
with powder and continuing
through design (e.g. topology optimization
for weight reduction and/or component
integration) to production and
post-processing, is part of the offer.
In the Innovation Center Additive
Manufacturing (ICAM), the institute has
bundled its additive manufacturing
technologies in one location and can
thus offer tailor-made solutions for a
wide variety of problems from a single
source. Customers can choose from the
following processes at the site: Selective
Electron Beam Melting, 3-D Screen Printing,
Fused Filament Fabrication,
three-dimensional stencil printing and
dispense printing.
www.ifam.fraunhofer.de/en.html
VELCO
Injection Systems for Foundries
Cost efficiency is one of the most
important factors today. The injection
systems developed and manufactured
by Velco, Velbert, Germany, offer economic
advantages
> when injecting carbon into cupola
furnaces instead of using costly
batch coke
> when FeSi and other additives are
dosed added
> when foundry residues like filter
dust, grinding- and fettling dusts are
injected, whereby valuable residues
are added to the melt without charging
the environment and high disposal
costs are avoided
Within the framework of a research
project of the German Government
Velco injected Zn-containing filter dusts
into the metal melt. Here high-concentrated
zinc oxide is produced.
A similar installation is used in an
iron foundry for the injection of carbon
fines into the melt for their carburization
process.
Also for non-iron melting plant the
recycling of production residues fines is
Photo: Velco
Fines injection in a
German foundry.
a practicable method. Depending on
the grain sizes and the melt volumes
the fines are blown into or onto the
melt. Hence, valuable raw materials are
recovered from residues.
www.velco.de/en
CASTING PLANT & TECHNOLOGY 3/2019 49

NEWS
Photo: ABP
ABP INDUCTION SYSTEMS
MHI and Primetals Technologies
to acquire melting furnace manufacturer
IFM 7 Twin Power from ABP, capacity
13.4 tons, rated power 6 MW.
Mitsubishi Heavy Industries (MHI) and
Primetals Technologies will acquire ABP
Induction Systems (ABP), Dortmund,
Germany, a global manufacturer and
servicer of induction furnaces and heating
systems from CM Acquisitions, a
Chicago based private equity firm. ABP
offers a variety of best-in-class products
and comprehensive services to blue-chip
customers, including leading automotive
OEMs and suppliers, industrial
manufacturers, independent foundries
as well as steel plant manufacturers and
steel producers. MHI and Primetals
Technologies will jointly take ABP’s shares.
Future business activities will be
conducted in close cooperation with
and under the leadership of Primetals
Technologies.
ABP provides state-of-the-art equipment
for ferrous and non-ferrous metal
casting, forging and steel making. Its
main products are induction melting,
holding and pouring furnaces as well as
induction heaters. ABP’s business is built
upon a large and global customer base
with more than 1,600 active units worldwide.
ABP also has a core competence
in the service business and provides
comprehensive aftermarket solutions to
customers though the entire product
lifecycle. Service centers are strategically
located close to the major industrial
areas in Germany, the United States,
China, India, Mexico, Russia, South
Africa, Sweden and Thailand.
ABP also exclusively provides special
induction heaters to Primetals Technologies
for endless strip production,
which helps provide a competitive
edge. “ABP’s induction heaters are one
of the most crucial elements for endless
strip production, a flagship process for
Primetals Technologies. With ABP becoming
one of MHI’s group companies
and the further close ties that will
bring, we can develop and provide
customers with even more advanced
technologies. Also, with the acquisition
of ABP, we combine its competence in
induction heating and related activities
with our know-how as a worldwide
engineering, plant-building, lifecycle
services and digitalization partner for
the metals industry,” said Satoru Iijima,
Chairman of the Board and CEO of Primetals
Technologies. “ABP´s well-experienced
portfolio and its know-how will
certainly complement our wide range
of customer plants, namely mini mills
and long rolling plants, especially in
emerging markets, as well as in endless
strip production.” Till Schreiter, CEO of
ABP, added: “ABP’s state-of-art induction
products and technology-driven
culture will fit well with both shareholders.
Through a closer tie-up with MHI
and Primetals Technologies, ABP can
pursue further growth potentials, which
will also lead to a contribution to
them”. With MHI and Primetals Technologies,
ABP has access to their resources
worldwide, which will improve ABP´s
global market presence, provide opportunities
to develop new business sectors,
and drive digitalization. “This will
assure long-term stability for our facilities,
employees and customers”. ABP
will be a group company of MHI under
the ownership of Mitsubishi Heavy
Industries America, Inc., headquartered
in Houston, Texas, and Primetals Technologies
USA LLC, Alpharetta, Georgia.
www.abpinduction.com
50

OSKAR FRECH GROUP
Huge investments in Europe and Asia
Die casting machine manufacturer
Oskar Frech, Schorndorf, Germany, is
massively expanding at the Weiler site
near Stuttgart for a figure well into the
double-digit millions. It is about
15,000 m 2 for a logistics center and two
assembly halls for hot and cold chamber
die casting machines. Furthermore a
new plant in China for several million
euros is planned in the next two years.
This increases the production and
business space in Schorndorf-Weiler from
30,000 to around 50,000 m 2 . Part of the
production at the Plüderhausen site will
in future be relocated to the expanded
Schorndorf-Weiler site. “Beside the large
machines we haves new ideas for our
works in Plüderhausen”, Frech-CEO
Dr.-Ing. Ioannis Ioannidis told CASTING,
Plant & Technology. The production
capacity in China will be increased with a
new plant over the course of two years
for several million euros. Frech already
operates a production site in Fengxiang,
China, near Shanghai.
The Oskar Frech Group is the only
group-independent family-owned company
with the brand “Made in Germany”
which competes on international
markets.
www.frech.com
Production of large machines which can
be used for the production of structural
components and gearbox housings at the
Frech production site in Plüderhausen.
Photo: Robert Piterek/BDG
ALUMINIUM 2000
Great success for foundry congress
With 35 nations represented, participation
at the congress in the Italian city of
Treviso was about 9 % higher than in
Verona 2017. During the three intense
conference days in April 2019, about 80
papers were presented by technicians
and industry experts, researchers and
managers, coming from the most
famous companies and universities all
over the world.
The three conference days were divided
in three parallel sessions and
during these days, 25 sponsors presented
their products in the exhibition
area. It was a meeting point for all participants.
More sections were represented by
markets and strategies, extrusion, surface
treatments, rolling, and coil technologies,
casting and melting, transport
industry, recycling & environmental
issues. Experts came from Europe,
China, the Far East, as well as North and
South America.
On Friday, a huge number of participants
took part to the technical visits
to the following companies: Volpato
Participation at Aluminium 2000 congress in Treviso was significantly higher than at the
last congress in Verona in 2017.
Industrie and Eureka, two excellences
in the world of processing and anodizing
for the furniture sector, and Hydro
Extrusion Italy (which is part of the
Norwegian Global Player Hydro) for
the extrusion sector. The next conference
is planned in 2021, location and
date will be announced.
www.aluminium2000.com
Photo: Aluminium2000
CASTING PLANT & TECHNOLOGY 3/2019 51

NEWS
BÜRKERT
Gas control for casting and thermal
processing technology
Photos: Bürkert Fluid Control Systems
Figure 1: Tailored automation concepts for gas control: delivering the optimum communication
solution at all times (Photos: Bürkert Fluid Control Systems).
Bürkert from Ingelfingen in Germany is
presenting gas controls customized for
a variety of casting plants. The mass
flow controllers are suitable for solutions
fitted with analogue interfaces all
the way up to complete Industry 4.0 systems.
Industrial plants for producing steel,
for casting or for thermal processing
technology place different requirements
on their gas supply and rely on
different automation concepts. Therefore,
communication between components
must always be tailored to the
specific needs of the plant. Bürkert
Fluid Control Systems is presenting a
range of automation concepts for gas
control (Figure 1) based on its proven
mass flow controllers (MFC). Possibilities
range from data exchange through to
“conventional” analogue standardized
interfaces and digital networking using
all common fieldbus protocols all the
way to plug-and-play MFC assemblies,
not to mention complete control cabinets
including all components for gas
control (Figure 2).
For smaller or simpler plants where
only small amounts of data need to be
transferred, the conventional analogue
interface is the ideal choice. Start-up
and maintenance are straightforward,
and signals can be checked with the
help of simple aids. These vendor-neutral
devices operate independently of
the controller and are extremely easy to
replace.
If diagnostic data, device state etc.
are to be transmitted in addition to setpoint
and actual values, the mass flow
controllers can communicate via digital
interfaces, e.g. Profinet, EtherNet/IP,
Profibus DP, Modbus TCP, EtherCAT,
CANopen or RS485. Gateways and Bürkert’s
proprietary büS network also
allow the integration of other protocols
– for gas-control functions that are fully
compatible with Industry 4.0.
Plug-and-play complete solutions,
which can easily be connected to the
higher-level controller for precise
dosing and logging of gas volumes, can
be realized with digital as well as analogue
interfaces. The MFC assemblies and
complete control cabinets are tailored
to the application requirements. The
entire fluid control layout is factory-tested,
ensuring that installation and
start-up can be completed easily and
quickly on site.
In all automated gas-control solutions,
the “Communicator” software
simplifies the configuration, parameterization
and diagnostics tasks. This
practical EDIP tool (Efficient Device Integration
Platform) is suitable for analogue
and digital devices. It gives the user
a complete overview of all cyclical process
values as well as all acyclic diagnostic
data. Device configurations can be
backed up and restored and the integrated,
graphical programming environment
makes it possible to create control
functions for decentralized sub-systems.
Connections to a PC can also be established
on the fly using a USB-CAN adapter.
www.burkert.com/en
Figure 2: Plug-and-play complete
solutions can easily be
connected to the higher-level
controller for precise dosing
and logging of gas volumes.
52

SPEKTRO
Analyzer for Process Control and Research
Metal Analysis
Spectro Analytical Instruments, Kleve,
Germany, the arc/spark innovation leader,
introduces the Spectrolab S
high-performance arc/spark optical
emission spectrometry (OES) analyzer
for the analysis of metal in process control
and research applications. The analyzer
represents a real revolution in highend
OES metal analysis – featuring
Spectro’s proprietary CMOS+T technology
and delivering the fastest measurements,
lowest limits of detection, longest
uptime, and most future-proof
flexibility in its class.
Many users of high-end stationary
metal analyzers are tasked with identifying
and measuring – with exceptionally
high accuracy and precision – all
the elements and compounds in their
incoming, in-production, and outgoing
materials. This may also include research
on new materials. The new Spectro LAB
S is designed to be the best-performing
spectrometer available for primary metal
producers – as well as an equally excellent
solution for secondary metal producers;
automotive and aerospace
manufacturers; and makers of finished
and semi-finished goods, electronics,
semiconductors, and other end products.
In terms of sample throughput, Spectrolab
S meets the metal market’s need
for ultra-high-speed measurement.
Example: when analyzing low alloy
steel, it can deliver highly accurate measurements
in less than 20 seconds. The
analyzer has the world’s first CMOS-based
detector system that’s perfected for
high-end metal analysis – thanks to
Spectro’s proprietary CMOS+T technology.
From trace elements to multi-matrix
applications, it provides high-speed,
highly accurate analysis plus the lowest
limits of detection in its class – limits
previously attainable only with PMT
detectors. On some key elements, Spectrolab
S CMOS+T technology surpasses
PMT performance. Uptime is outstanding.
Spectrolab’s regular maintenance
intervention requirements (spark stand
cleaning) have been reduced by a factor
of eight. Calibration is easy and cost-efficient,
needing only a single-sample,
5-minute standardization. In most cases,
unique iCAL 2.0 diagnostics ensure stable
performance from then on —
regardless of most shifts in ambient
temperature or pressure. Most users
Spectrolab S analyzer with user.
save at least 30 minutes a day. The analyzer’s
flexibility ensures that it is future
proof. New elements or matrices can be
added via a simple software update —
eliminating the need for substantial
hardware modifications. The intuitive
user interface ensures effortless ease-ofuse
— even for
less experienced
personnel. Instead
of multiple dialog
boxes, a simplified
operator view
presents clear
choices via dedicated
toolbar buttons.
Tailored
application profiles
eliminate complicated
method
development.
Furthermore the
analyzer provides
both short-term
and long-term
stability. Unlike
conventional analyzers,
its sealed,
no-purge optical
system maximizes
light transmission
stability, even in
the far UV. Its
software utilizes
sophisticated
measures such as
online drift correction
and iCAL
2.0 temperature
compensation for
reproducible readings, even over successive
shifts or maintenance intervals. To
fit packed laboratory spaces, the SPECT-
ROLAB S features a 27 % decrease in
footprint over previous models.
https://www.spectro.com/lab-s
DECORING HAMMERS FOR GRAVITY, LOW
PRESSURE AND LOST WAX PROCESS
- DIFFERENT MODELS
- EASILY CARRIED
- HIGH PERFORMANCES
- WORLDWIDE PRESENCE
- CUSTOMER CARE
NEW MONITORING SYSTEM THOR V4.0 TO CHECK
THE HAMMER’S PERFORMANCES
JUST CONTACT US TO KNOW MORE ABOUT OUR PRODUCTS!
O.M.LER SRL, Via Don Orione, 198/E -198/F 12042 Bandito-BRA (CN), ITALY
Tel. +39 0172/457256 omlersrl@gmail.com www.omlersrl.com
Photo: Spectro
CASTING PLANT & TECHNOLOGY 3/2019 53

NEWS
Photo: Robert Piterek/BDG
VDMA METALLURGY
On the way to intelligent machinemachine
communication
Stand of VDMA Metallurgy at GIFA,
where OPC UA was presented. The standard
is an important step for die casters
in the direction of Industry 4.0.
The die casting sector is preparing for
Industry 4.0; more than 30 European
companies are developing jointly a
standardized open communication
interface under the umbrella of VDMA
(German Mechanical Engineering Industry
Association) Metallurgy and CEMA-
FON, the European Association of
foundry equipment suppliers.
The die casting sector is a strong
part of the foundry business in Europe,
which is characterized by extensive
experience but also by very different
organizational and technological levels.
With Industry 4.0, the age of the intelligent
machine to machine communication
has also started in this area.
Fast commissioning, detailed process
monitoring, optimal productivity,
reproducible product quality or complete
storage of setting and process
data – the market requirements on a
die casting cell are constantly increasing.
All these demands require an efficient
exchange of information across
manufacturers. A boundary condition
that has only been met to a limited
extent up to now. The available fieldbus
technologies are only partially
standardized; communication with higher-level
MES systems requires manufacturer-specific
solutions. This means
that the die-caster must implement
various communication technologies
and protocols in his system for this task
alone; a bottleneck in data communication
and high project costs.
In order to meet the requirements
of Industry 4.0 with intelligent communication
in and to a die casting cell, the
representatives of the European die casting
industry are jointly developing a
standardised open communication
interface. The open interface standard
„Open Platform Communications Unified
Architecture (OPC UA)“ will be
used. This provides security functions, is
freely accessible and provides meta-information
about the data that can be
viewed by anyone.
Under the umbrella of VDMA Metallurgy
and CEMAFON, over 60 experts
from over 30 European companies are
developing manufacturer-independent
information models (Companion Specifications),
the interface between components,
machines and systems. These
describe device and capability information
so that a machine can be easily
integrated into a plant network by all
manufacturers and can, for example, be
connected to a software system for
planning and controlling production.
Among other things, the description
of the manufacturer‘s name, the device
type and the process data, such as temperatures
or pressure as well as organizational
information such as information
on productivity and quality, are standardized.
The first release candidate is
planned for the beginning of 2020.
https://metallurgy.vdma.org
54

SUPPLIERS GUIDE
CASTING
PLANT AND TECHNOLOGY
INTERNATIONAL
© DVS Media GmbH
Contact person: Vanessa Wollstein
Aachener Straße 172 Phone: +49 211 1591-152
40223 Düsseldorf Fax: +49 211 1591-150
E-Mail: vanessa.wollstein@dvs-media.info
1 Foundry Plants and Equipment
17 Surface Treatment and Drying
2
Melting Plants and Equipment for Iron and
Steel Castings and for Malleable Cast Iron
18
Plant, Transport, Stock, and Handling
Engineering
3 Melting Plants and Equipment for NFM
4 Refractories Technology
19 Pattern- and Diemaking
20 Control Systems and Automation
5
6
7
8
Non-metal Raw Materials and Auxiliaries for
Melting Shop
Metallic Charge Materials for Iron and Steel
Castings and for Malleable Cast Iron
Metallic Charge and Treatment Materials for
Light and Heavy Metal Castings
Plants and Machines for Moulding and
Coremaking Processes
21 Testing of Materials
22 Analysis Technique and Laboratory
23 Air Technique and Equipment
24 Environmental Protection and Disposal
9 Moulding Sands
10 Sand Conditioning and Reclamation
11 Moulding Auxiliaries
12 Gating and Feeding
13 Casting Machines and Equipment
25 Accident Prevention and Ergonomics
26 Other Products for Casting Industry
27 Consulting and Service
28 Castings
29 By-Products
14
Discharging, Cleaning, Finishing of Raw
Castings
30 Data Processing Technology
15 Surface Treatment
16 Welding and Cutting
31 Foundries
32 Additive manufacturing / 3-D printing
CASTING PLANT & TECHNOLOGY 3/2019 55

SUPPLIERS GUIDE
01 Foundry Plants and Equipment
▼ Foundry Equipment and Facilities, in general 20
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Second Hand Foundry Plants and Equipment 45
TCT TESIC GmbH
Foundry Marketing & Services
58640 Iserlohn, Germany
( +49 2371 77260
Innernent:
www.ncn-nesic.com
02 Melting Plants and Equipment for Iron and
Steel Castings and for Malleable Cast Iron
02.06 Maintenance and Repairing
▼ Repairing of Induction Furnaces 584
▼ Remelting Furnaces 700
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
04 Refractories Technology
04.01 Plants, Equipment and Tools for Lining in Melting
and Casting
▼ Mixers and Chargers for Refractory Mixes 930
UELZENER Maschinen GmbH
Snahlsnr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E--ailt:
connacn@uelzener-ums.de
Innernent:
www.uelzener-ums.de
▼ Gunning for Relining of Cupolas 950
UELZENER Maschinen GmbH
Snahlsnr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E--ailt:
connacn@uelzener-ums.de
Innernent:
www.uelzener-ums.de
▼ Wear Indicators for Refractory Lining 980
▼ Insulating Refractoy Bricks 1050
Etex Building Performance GmbH
Division Etex Industry
Raningen/Germany
E--ailt:
www.proman-indusnry.com
▼ Insulating Products 1130
Etex Building Performance GmbH
Division Etex Industry
Raningen/Germany
E--ailt:
www.proman-indusnry.com
▼ Ceramic Fibre Mats, Papers, Plates, and Felts 1155
Etex Building Performance GmbH
Division Etex Industry
Raningen/Germany
E--ailt:
www.proman-indusnry.com
▼ Micro Porous Insulating Materials 1220
Etex Building Performance GmbH
Division Etex Industry
Raningen/Germany
E--ailt:
www.proman-indusnry.com
▼ Ladle Refractory Mixes 1240
UELZENER Maschinen GmbH
Snahlsnr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E--ailt:
connacn@uelzener-ums.de
Innernent:
www.uelzener-ums.de
04.04 Refractory Building
▼ Maintenance of Refractory Linings 1462
TCT TESIC GmbH
Foundry Marketing & Services
58640 Iserlohn, Germany
( +49 2371 77260
Innernent:
www.ncn-nesic.com
03 Melting Plants and Equipment for NFM
Saveway GmbH & Co. KG
Wümbacher Landsnraße 8, 98693 Ilmenau, Germany
( +49 3677 8060-0 7 +49 3677 8060-99
Innernent:
www.saveway-germany.de
▼ Wear Measuring and Monitoring for Refractory Lining 982
UELZENER Maschinen GmbH
Snahlsnr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E--ailt:
connacn@uelzener-ums.de
Innernent:
www.uelzener-ums.de
05 Non-metal Raw Materials and Auxiliaries for
Melting Shop
03.02 Melting and Holding Furnaces, Electrically
Heated
▼ Aluminium Melting Furnaces 630
Saveway GmbH & Co. KG
Wümbacher Landsnraße 8, 98693 Ilmenau, Germany
( +49 3677 8060-0 7 +49 3677 8060-99
Innernent:
www.saveway-germany.de
▼ State Diagnosis of Refractory Lines 985
05.04 Carburization Agents
▼ Coke Breeze, Coke-Dust 1680
ARISTON Formstaub-Werke GmbH & Co. KG
Worringersnr. 255, 45289 Essen, Germany
( +49 201 57761 7 +49 201 570648
Innernent:
www.arisnon-essen.de
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Induction Furnaces (Mains, Medium,
and High Frequency) 660
Saveway GmbH & Co. KG
Wümbacher Landsnraße 8, 98693 Ilmenau, Germany
( +49 3677 8060-0 7 +49 3677 8060-99
Innernent:
www.saveway-germany.de
04.02 Refractory Materials (Shaped and Non Shaped)
▼ Refractories, in general 1040
08 Plants and Machines for Molding and
Coremaking Processes
08.01 Moulding Plants
▼ Moulding Machines, Fully and Partially Automatic 3070
INDUGA GmbH & Co. KG
52152 Simmeranh, Germany
E--ailt:
info@induga.de
Innernent:
www.induga.com
L. & F. PETERS GmbH
E--ailt:
www.peners-feuerfesn.de
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Schiess-Snr. 58, 40549 Düsseldorf, Germany
( +49 211 5858-0
E--ailt:
sneel@refra.com
Innernent:
www.refra.com
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
56

08.02 Moulding and Coremaking Machines
▼ Automatic Moulding Machines 3100
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Moulding Machines, Boxless 3150
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Air-flow Squeeze Moulding Machines and Plants 3190
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Multi-Stage Vacuum Process 3223
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
( +49 6441 802-1190 7 +49 6441 802-1199
E--ailt:
andreas.wuerz@pfeiffer-vacuum.de
Innernent:
www.pfeiffer-vacuum.de
Innernent:
▼ Vacuum Moulding Machines and Processes 3280
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
08.03 Additives and Accessories
▼ Core Handling 3450
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
09 Molding Sands
09.01 Basic Moulding Sands
▼ Chromite Sands 3630
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Ceramic Sands/Chamotte Sands 3645
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Silica Sands 3720
STROBEL QUARZSAND GmbH
Freihungsand, 92271 Freihung, Germany
( +49 9646 9201-0 7 +49 9646 9201-1257
E--ailt:
info@snrobel-quarzsand.de
Innernent:
www.snrobel-quarzsand.de
09.04 Mould and Core Coating
▼ Blackings, in general 4270
ARISTON Formstaub-Werke GmbH & Co. KG
Worringersnr. 255, 45289 Essen, Germany
( +49 201 57761 7 +49 201 570648
Innernent:
www.arisnon-essen.de
09.06 Moulding Sands Testing
▼ Moisture Testing Equipment for Moulding Sand 4410
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Moulding Sand Testing Equipment, in general 4420
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
10 Sand Conditioning and Reclamation
▼ Sand Reclamation System 4448
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
10.01 Moulding Sand Conditioning
▼ Aerators for Moulding Sand Ready-to-Use 4470
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Sand Preparation Plants and Machines 4480
▼ Mixers 4520
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Sand Mixers 4550
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Aerators 4560
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Scales and Weighing Control 4590
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
10.04 Sand Reconditioning
▼ Sand Coolers 4720
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
12 Gating and Feeding
▼ Covering Agents 5320
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Schiess-Snr. 58, 40549 Düsseldorf, Germany
( +49 211 5858-0
E--ailt:
sneel@refra.com
Innernent:
www.refra.com
▼ Breaker Cores 5340
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Exothermic Products 5360
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Insulating Sleeves 5375
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Exothermic Mini-Feeders 5400
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
▼ Exothermic Feeder Sleeves 5420
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
CASTING PLANT & TECHNOLOGY 3/2019 57

SUPPLIERS GUIDE
▼ Exothermic Feeding Compounds 5430
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E--ailt:
info@gnp-schaefer.de
Innernent:
www.gnp-schaefer.com
13 Casting Machines and Equipment
▼ Pouring Machines and Equipment 5436
INDUGA GmbH & Co. KG
52152 Simmeranh, Germany
E--ailt:
info@induga.de
Innernent:
www.induga.com
▼ Hydraulic Cylinders 5750
HYDROPNEU GmbH
Sudenensnr. , 73760 Osnfildern, Germany
( +49 711 342999-0 7 +49 711 342999-1
E--ailt:
info@hydropneu.de
Innernent:
www.hydropneu.de
▼ Piston Lubricants 5790
Chem-Trend (Deutschland) GmbH
Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E--ailt:
service@chemnrend.de
Innernent:
www.chemnrend.com
▼ Parting Agents for Dies 5850
14 Discharging, Cleaning, Finishing of Raw
Castings
14.05 Additional Cleaning Plants and Devices
▼ Pneumatic Hammers 6940
MD Drucklufttechnik GmbH & Co. KG
Weissacher Snr. 1, 70499 Snunngarn, Germany
( +49 711 88718-0 7 +49 711 88718-100
Innernent:
www.mannesmann-demag.com
17 Surface Treatment and Drying
▼ Heat Treatment and Drying 7398
13.01 Pouring Furnaces and their Equipment
▼ Pouring Equipment 5450
INDUGA GmbH & Co. KG
52152 Simmeranh, Germany
E--ailt:
info@induga.de
Innernent:
www.induga.com
▼ Pouring Equipment for Molding Plants,
Railborn or Crane-operated 5470
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
INDUGA GmbH & Co. KG
52152 Simmeranh, Germany
E--ailt:
info@induga.de
Innernent:
www.induga.com
13.02 Die Casting and Accessories
▼ Diecasting Lubricants 5670
Chem-Trend (Deutschland) GmbH
Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E--ailt:
service@chemnrend.de
Innernent:
www.chemnrend.com
▼ Dry Lubricants (Beads) 5865
Chem-Trend (Deutschland) GmbH
Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E--ailt:
service@chemnrend.de
Innernent:
www.chemnrend.com
▼ Multi-Stage Vacuum Process 5876
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
( +49 6441 802-1190 7 +49 6441 802-1199
E--ailt:
andreas.wuerz@pfeiffer-vacuum.de
Innernent:
www.pfeiffer-vacuum.de
13.03 Gravity Die Casting
▼ Gravity Diecasting Machines 5940
Gebr. Löcher Glüherei GmbH
-ühlenseifen 2, 57271 Hilchenbach, Germany
( +49 2733 8968-0 7 +49 2733 8968-10
Innernent:
www.loecher-glueherei.de
17.01 Plants and Furnaces
▼ Tempering Furnaces 7400
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Ageing Furnaces 7401
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Annealing and Hardening Furnaces 7430
Chem-Trend (Deutschland) GmbH
Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E--ailt:
service@chemnrend.de
Innernent:
www.chemnrend.com
▼ Diecasting Parting Agents 5680
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Low Pressure Diecasting Machines 5980
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Solution Annealing Furnaces 7455
Chem-Trend (Deutschland) GmbH
Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E--ailt:
service@chemnrend.de
Innernent:
www.chemnrend.com
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
58

▼ Annealing Furnaces 7490
19 Pattern- and Diemaking
▼ Laser Measurement Techniques 9310
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Quenching and Tempering Furnaces 7510
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Heat Treating Furnaces 7520
19.04 Rapid Prototyping
▼ Pattern and Prototype Making 9025
Georg Herrmann Metallgießerei GmbH
-uldenhünnen 22, 09599 Freiberg, Germany
( +49 3731 3969 0 7 +49 3731 3969 3
E--ailt:
mail@ghm-aluguss.de
Innernent:
www.ghm-aluguss.de
20 Control Systems and Automation
20.01 Control and Adjustment Systems
▼ Automation and Control for Sand Preparation 9030
POLYTEC GmbH
76337 Waldbronn, Germany
( +49 7243 604-0 7 +49 7243 69944
E--ailt:
Lm@polynec.de
Innernent:
www.polynec.de
▼ Positioning Control 9345
POLYTEC GmbH
76337 Waldbronn, Germany
( +49 7243 604-0 7 +49 7243 69944
E--ailt:
Lm@polynec.de
Innernent:
www.polynec.de
▼ Temperature Measurement 9380
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
▼ Hearth Bogie Type Furnaces 7525
Maschinenfabrik Gustav Eirich
GmbH & Co KG
Walldürner Snr. 50, 74736 Hardheim, Germany
▼ Automation 9040
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
▼ Thermal Analysis Equipment 9400
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E--ailt:
loi@nenova.com
Innernent:
www.loi.nenova.com
18 Plant, Transport, Stock, and Handling
Engineering
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Software for Production Planning and Control 9042
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
▼ Thermo Couples 9410
18.01 Continuous Conveyors and Accessories
▼ Flexible Tubes with Ceramic Wear Protection 7676
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Control Systems and Automation, in general 9090
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
STEIN INJECTION TECHNOLOGY GmbH
Hagener Snr. 20-24, 58285 Gevelsberg, Germany
( +49 2332 75742-0 7 +49 2332 75742-40
E--ailt:
snein@sin-gmbh.nen
Innernent:
www.sin-gmbh.nen
▼ Vibratory Motors 7980
FRIEDRICH Schwingtechnik GmbH
Am Höfgen 24, 42781 Haan, Germany
( +49 2129 3790-0 7 +49 2129 3790-37
E--ailt:
info@friedrich-schwingnechnik.de
Innernent:
www.friedrich-schwingnechnik.de
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
20.02 Measuring and Control Instruments
▼ Immersion Thermo Couples 9230
20.03 Data Acquisition and Processing
▼ Data Logging and Communication 9440
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Machine Data Logging 9480
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
CASTING PLANT & TECHNOLOGY 3/2019 59

SUPPLIERS GUIDE
▼ Numerical Solidification Analysis
and Process Simulation 9500
MAGMA Giessereitechnologie GmbH
Kackernsnr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E--ailt:
info@magmasofn.de
Innernent:
www.magmasofn.com
▼ Numerical Solidification Simulation
and Process Optimization 9502
MAGMA Giessereitechnologie GmbH
Kackernsnr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E--ailt:
info@magmasofn.de
Innernent:
www.magmasofn.com
▼ Computer Programmes and Software for Foundries 9520
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Simulation Software 9522
MAGMA Giessereitechnologie GmbH
Kackernsnr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E--ailt:
info@magmasofn.de
Innernent:
www.magmasofn.com
▼ Software for Foundries 9523
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
▼ Fault Indicating Systems, Registration
and Documentation 9540
HEINRICH WAGNER SINTO
57334 Bad Laasphe, Germany
( +49 2752 907-0 7 +49 2752 907-280
Innernent:
www.wagner-sinno.de
21 Testing of Materials
21.01 Testing of Materials and Workpieces
▼ Dye Penetrants 9600
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
▼ Instruments for Non-destructive Testing 9610
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
▼ Magnetic Crack Detection Equipment 9680
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
▼ Ultrasonic Testing Equipment 9750
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
▼ UV-Lamps 9758
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
▼ Devices for Testing of Materials,
non-destructive, in general 9836
KARL DEUTSCH
Prüf- und Messgerätebau GmbH + Co. KG
Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany
( +49 202 71 92-0 7 +49 202 71 49 32
E--ailt:
info@karldeunsch.de
Innernent:
www.karldeunsch.de
22 Analysis Technique and Laboratory Equipment
▼ Sampling Systems 9970
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
26 Other Products for Casting Industry
26.02 Industrial Commodities
▼ Joints, Asbestos-free 11120
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
▼ Sealing and Insulating Products up to 1260 øC 11125
MINKON GmbH
Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany
( +49 211 209908-0 7 +49 211 209908-90
E--ailt:
info@minkon.de
Innernent:
www.minkon.de
27 Consulting and Service
▼ Machining 11292
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Posnfacht:
1153, 74910 Kirchardn, Germany
( +49 7266 207-0 7 +49 7266 207-500
Innernent:
www.behringer.nen
▼ Simulation Services 11310
MAGMA Giessereitechnologie GmbH
Kackernsnr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E--ailt:
info@magmasofn.de
Innernent:
www.magmasofn.com
▼ Heat Treatment 11345
Gebr. Löcher Glüherei GmbH
-ühlenseifen 2, 57271 Hilchenbach, Germany
( +49 2733 8968-0 7 +49 2733 8968-10
Innernent:
www.loecher-glueherei.de
28 Castings
▼ Aluminium Pressure Diecasting 11390
Schött Druckguß GmbH
Aluminium Die Casting
Posnfacht:
27 66, 58687 -enden, Germany
( +49 2373 1608-0 7 +49 2373 1608-110
E--ailt:
vernrieb@schoenn-druckguss.de
Innernent:
www.schoenn-druckguss.de
▼ Rolled Wire 11489
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Posnfacht:
1153, 74910 Kirchardn, Germany
( +49 7266 207-0 7 +49 7266 207-500
Innernent:
www.behringer.nen
▼ Spheroidal Iron 11540
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Posnfacht:
1153, 74910 Kirchardn, Germany
( +49 7266 207-0 7 +49 7266 207-500
Innernent:
www.behringer.nen
▼ Steel Castings 11550
KS Gleitlager GmbH, Werk Papenburg
Friesensnr. 2, 26871 Papenburg, Germany
( +49 4961 986-150 7 +49 4961 986-166
E--ailt:
sales-cc@de.rheinmenall.com
Innernent:
www.rheinmenall-aunomonive.com
60

30 Data Processing Technology
31.02 NFM Foundries
▼ Light Metal Casting Plants 11862
▼ Mold Filling and Solidification Simulation 11700
MAGMA Giessereitechnologie GmbH
Kackernsnr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E--ailt:
info@magmasofn.de
Innernent:
www.magmasofn.com
31 Foundries
Georg Herrmann Metallgießerei GmbH
-uldenhünnen 22, 09599 Freiberg, Germany
( +49 3731 3969 0 7 +49 3731 3969 3
E--ailt:
mail@ghm-aluguss.de
Innernent:
www.ghm-aluguss.de
31.01 Iron, Steel, and Malleable-Iron Foundries
▼ Iron Foudries 11855
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Posnfacht:
1153, 74910 Kirchardn, Germany
( +49 7266 207-0 7 +49 7266 207-500
Innernent:
www.behringer.nen
Index to Companies
Company Product Company Product
ARISTON Formsnaub-Werke GmbH & Co. KG 1680, 4270
BEHRINGER GmbH 11292, 11489, 11540, 11855
-aschinenfabrik & Eisengießerei
Chem Trend (Deunschland) GmbH 5670, 5680, 5790, 5850, 5865
-aschinenfabrik Gusnav Eirich GmbH & Co KG 4410, 4420, 4470, 4480, 4520,
4550, 4560, 4590, 4720, 9030
Enex Building Performance GmbH 1050, 1130, 1155, 1220
Friedrich Schwingnechnik GmbH 7980
GTP Schäfer Giessnechnische Produkne GmbH 3630, 3645, 5340, 5360, 5375,
5400, 5420, 5430
Heinrich Wagner Sinno -aschinenfabrik GmbH 20, 3070, 3100, 3150, 3190,
3280, 3450, 4448, 5470, 5940,
5980, 9040, 9042, 9090, 9440,
9480, 9520, 9523, 9540
HYDROPNEU GmbH 5750
INDUGA GmbH & Co. KG 660, 5436, 5450, 5470
KARL DEUTSCH Prüf- und 9600, 9610, 9680, 9750, 9758,
-essgeränebau GmbH + Co KG 9836
KS Gleinlager GmbH 11550
Gebr. Löcher Glüherei GmbH 7398, 11345
LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430,
7455, 7490, 7510, 7520, 7525
-AG-A Gießereinechnologie GmbH 9500, 9502, 9522, 11310, 11700
-D Drucklufnnechnik GmbH & Co. KG 6940
Georg Herrmann -enallgießerei GmbH 9025, 11862
-INKON GmbH 9230, 9380, 9400, 9410, 9970,
11120, 11125
L. & F. PETERS GmbH 1040
Pfeiffer Vacuum GmbH 3223, 5876
Polynec GmbH 9310, 9345
Refranechnik Sneel GmbH 1040, 5320
Saveway GmbH & Co. KG 980, 982, 985
Schönn-Druckguß GmbH 11390
Snein Injecnion Technology GmbH 7676
Snrobel Quarzsand GmbH 3720
TCT TESIC GmbH 45, 584
Uelzener -aschinen GmbH 930, 950, 1240, 1462
CASTING PLANT & TECHNOLOGY 3/2019 61

List of Products
01 Foundry Plants and Equipment
10 Foundry Plants, Planning and
Construction
20 Foundry Equipment and Facilities,
in general
30 Foundry Plants, fully and
partially automatic
40 Maintenance and Repairing of
Foundry Plants
44 Swing-Technique Machines for
Handling, Dosing, and Classing
45 Second Hand Foundry Plants and
Equipment
47 Spray Deposition Plants
01.01. Components
47 Spray Deposition Plants
50 Charging Systems, in general
52 Cored Wire Treatment Stations
53 Plug Connections, Heat Resisting
02 Melting Plants and Equipment for Iron and
Steel Castings and for Malleable Cast Iron
02.01. Cupolas
55 Cupolas
60 Hot-Blast Cupolas
70 Cold-Blast Cupolas
80 Circulating Gas Cupolas
90 Gas Fired Cupolas
100 Cupolas, cokeless
110 Cupolas with Oxygen-Enrichment
120 Cupolas with Secondary Blast
Operation
02.02. Cupola Accessories and
Auxiliaries
130 Lighter
140 Cupola Charging Equipment
150 Tuyères
160 Burners for Cupolas
180 Blowing-In Equipment for Carbo Fer
190 Blowing-In Equipment for Filter
Dusts into Cupolas
210 Blowing-In Equipment for Carbon
211 Blowing-In Equipment for Metallurgical
Processes
220 Dedusting, Cupolas
225 Gas Cleaning
230 Charging Plants, fully and partially
automatic
240 Blowers, Cupolas
270 Recuperators
280 Oxygen Injection for Cupolas
290 Shaking Ladles, Plants
295 Dust Briquetting
300 Monitoring Plants, Cupola
310 Forehearths, Cupola
320 Blast Heater
02.03. Melting and Holding
Furnaces, Electrically Heated
330 Electric melting Furnaces, in general
340 Induction Channel Furnaces
350 Crucible Induction Furnaces, medium
Frequency
360 Crucible Induction Furnaces,
Mains Frequency
370 Short-Coil Induction Furnaces
390 Filters, in general
399 Tower Melter
400 Holding Furnaces
02.04. Accessories and Auxiliaries
for Electric Furnaces
410 Charging Units
420 Blowing-In Equipment for Carbo Fer
430 Blowing-In Equipment for Filter Dusts
440 Blowing-In Equipment for Carbon
445 Inert Gas Systems for EAF and EIF
450 Inert Gas Systems for EAF and EIF
460 Electro-magnetic Conveyor Chutes
470 Dust Separation Plant
480 Charging Equipment
500 Graphite Electrodes
510 Lime Dosing Device
520 Condensors
540 Cooling Equipment
550 Scrap preheating Plants
560 Secondary Metallurgical Plants
565 Control Installations
570 Equipment for induction stirring
02.05. Rotary Furnaces
580 Rotary Furnaces
02.06. Maintenance and Repairing
584 Repairing of Induction Furnaces
586 Maintenance of Complete
Induction Furnace Plants
03 Melting Plants and Equipment for NFM
03.01. Melting Furnaces, Fuel Fired
590 Hearth-Type (Melting) Furnaces
599 Tower Furnaces
600 Bale-Out Furnaces
610 Crucible Furnaces
620 Drum-Type Melting Furnaces
03.02. Melting and Holding
Furnaces, Electrically Heated
630 Aluminium Melting Furnaces
640 Dosing Furnace
655 Heating Elements for Resistance
Furnaces
660 Induction Furnaces (Mains,
Medium, and High Frequency)
665 Magnesium Melting Plants and
Dosing Devices
670 Melting Furnacs, in general
680 Bale-Out Furnaces
690 Crucible Furnaces
700 Remelting Furnaces
710 Holding Furnaces
720 Electric Resistance Furnaces
902 Vacuum Melting and Casting
Furnaces
03.03. Accessories and Auxiliaries
730 Exhausting Plants
740 Molten Metal Refining by Argon
742 Gassing Systems for Aluminium
Melting
750 Gassing Systems for Magnesium
Melting
760 Charging Plants
770 Blowing-in Equipment for Alloying
and Inoculating Agents
774 Blowing-in Equipment for
Inoculating Agents
778 Degassing Equipment
780 Dedusting Equipment
785 Crucibles, Ready-To-Use
790 Charging Equipment
800 Graphite Melting Pots
825 Emergency Iron Collecting
Reservoirs
847 Cleaning Devices for Cleaning
Dross in Induction Furnaces
848 Cleaning Device and Gripper for
Deslagging - Induction Furnaces
850 Crucibles
860 Inert Gas Systems
870 Silicon Carbide Pots
875 Special Vibrating Grippers for
the Removal of Loose Dross and
Caking
880 Gas Flushing Installations
890 Crucibles, Pots
895 Power Supply, Plasma Generators
900 Vacuum Degassing Equipment
04 Refractories Technology
04.01. Plants, Equipment and Tools for
Lining in Melting and Casting
910 Spraying Tools for Furnace Lining
920 Breakage Equipment for Cupolas,
Crucibles, Pots, Torpedo Ladles
and Ladles
923 Lost Formers
930 Mixers and Chargers for
Refractory Mixes
940 Charging Units for Furnaces
950 Gunning for Relining of Cupolas
954 Ramming Mix Formers
956 Ramming Templates
980 Wear Indicators for Refractory Lining
982 Wear Measuring and Monitoring
for Refractory Lining
985 State Diagnosis of Refractory Lines
62

04.02. Refractory Materials
(Shaped and Non Shaped)
1000 Boron-Nitride Isolation
1005 Sand Gaskets, Isolation
Materials (up to 1260 °C)
1009 Running and Feeding
Systems (Gating Systems)
1010 Running and Feeding Systems
(Runner Bricks, Centre Bricks,
Sprue Cups)
1020 Fibrous Mould Parts
1021 Fibrous Mould Parts up to 1750 °C
1030 Refractory Castables
1040 Refractories, in general
1050 Insulating Refractoy Bricks
1060 Refractoy Cements
1070 Refractories for Aluminium Melting
Furnaces
1080 Refractory Materials for Anode
Kilns
1090 Refractory Materials for Melting
Furnaces, in general
1100 Refractory Materials for Holding
Furnaces
1103 Ceramic Fibre Mould Parts and
Modules
1104 Mold Sections and Modules made
of HTW (High Temperature Wool)
1109 Precasts
1110 Pouring Lip Bricks
1113 Fibreglass Mats
1114 Slip Foils for Glowing Materials
1117 High Temperature Mats, Papers,
Plates, and Felts
1120 Induction Furnace Compounds
1123 Insulating and Sealing Panels up
to 1200 °C
1125 Insulating Fabrics up to 1260 °C
1128 Insulating Felts and Mats up to
1260 °C
1130 Insulating Products
1140 Insulating Products (such as
Fibres, Micanites)
1150 Insulating Bricks
1155 Ceramic Fibre Mats, Papers,
Plates, and Felts
1160 Ceramic Fibre Modules
1169 Ceramic Fibre Substitutes
1170 Ceramic Fibre Products
1180 Loamy Sands
1190 Carbon Bricks
1200 Cupola and Siphon Mixes
1210 Cupola Bricks
1220 Micro Porous Insulating Materials
1222 Nano Porous Insulating Materials
1225 Furnace Door Sealings, Cords, and
Packings
1230 Furnace Linings
1240 Ladle Refractory Mixes
1250 Ladle Bricks
1260 Plates, free from Ceramic Fibres
1261 Plates made of Ground Alkali
Silicate Wool
1270 Acid and Silica Mixes
1280 Fire-Clay Mixes and Cements
1290 Fire-Clay Bricks
1310 Porous Plugs
1312 Stirring Cones for Steel, Grey Cast
Iron and Aluminium
1320 Moulding Mixtures for Steel Casting
1330 Ramming, Relining, Casting,
Gunning, and Vibration Bulks
1333 Ramming, Casting, Gunning, and
Repairing Compounds
1340 Plugs and Nozzles
1345 Textile Fabrics up to 1260 °C
988 Substitutes of Aluminium Silicate
Wool
990 Coating and Filling Materials,
Protective Coatings
04.03. Refractory Raw Materials
1350 Glass Powder
1360 Loamy Sands
1370 Magnesite, Chrom-Magnesite,
Forsterite
1390 Chamotte, Ground Chamotte
1400 Clays, Clay Powders
04.04. Refractory Building
1410 Bricking-Up of Furnaces
1420 Refractory Building/Installation
1430 Fire and Heat Protection
1435 Furnace Door Joints
1440 Furnace Reconstruction
1450 Repairing of Furnaces and Refractories
1460 Heat Insulation
1462 Maintenance of Refractory Linings
05 Non-metal Raw Materials and Auxiliaries for
Melting Shop
05.01. Coke
1480 Lignite Coke
1490 Foundry Coke
1510 Petroleum Coke
05.02. Additives
1520 Desulphurization Compounds
1530 Felspar
1540 Fluorspar
1550 Casting Carbide
1560 Glass Granulate
1570 Lime, Limestones
1575 Briquets for Cupolas
1580 Slag Forming Addition
05.03. Gases
1590 Argon
1600 Oxygen
1610 Inert Gases
1620 Nitrogen
1622 Hydrogen
05.04. Carburization Agents
1630 Carburization Agents, in general
1640 Lignite Coke
1650 Electrode Butts
1660 Electrode Graphite
1665 Desulfurizer
1670 Graphite
1680 Coke Breeze, Coke-Dust
1700 Petroleum Coke
1710 Silicon Carbide
3261 Automatic Powder Feeding
05.05. Melting Fluxes for NF-Metals
1720 Aluminium Covering Fluxes
1730 Desoxidants, in general
1740 Degassing Fluxes
1750 Desulphurisers
1760 Charcoal
1770 Refiners
1780 Fluxing Agents
1785 Melt Treatment Agents
1790 Fluxing Agents
06 Metallic Charge Materials for Iron and Steel
Castings and for Malleable Cast Iron
06.01. Scrap Materials
1810 Cast Scrap
1811 Cast Turnings
1813 Cuttings/Stampings
1817 Steel Scrap
06.02. Pig Iron
1820 Hematite Pig Iron
1830 Foundry Pig Iron
1838 DK Pig Iron
1840 DK-Perlit Special Pig Iron
1880 DK Pig Iron for Malleable Cast Iron
1898 DK Pig Iron, low-carbon, Quality
DKC
1900 DK-Perlit Special Pig Iron, Low
Carbon, DKC Quality
1936 DK Phosphorus Alloy Pig Iron
1940 DK-Perlit Special Pig Iron, Type
Siegerlaender
1950 Spiegel Eisen
1970 Blast Furnace Ferro Silicon
06.03. Specials (Pig Iron)
1990 Foundry Pig Iron
2000 Hematite Pig Iron
2010 Sorel Metal
2020 Special Pig Iron for s. g. Cast Iron
Production
2030 Special Pig Iron for s.g. Cast Iron
2040 Steelmaking Pig Iron
06.04. Ferro Alloys
2050 Ferro-Boron
2060 Ferro-Chromium
2070 Ferroalloys, in general
2080 Ferro-Manganese
2090 Ferro-Molybdenum
2100 Ferro-Nickel
2110 Ferro-Niobium
2120 Ferro-Phosphorus
2130 Ferro-Selenium
2140 Ferro-Silicon
2150 Ferro-Silicon-Magnesium
2160 Ferro-Titanium
2170 Ferro-Vanadium
2180 Ferro-Tungsten
2190 Silicon-Manganese
06.05. Other Alloy Metals and Master
Alloys
2200 Aluminium Granulates
2210 Aluminium, Aluminium Alloys
2220 Aluminium Powder
2230 Aluminium Master Alloys
2250 Calcium Carbide
2260 Calcium-Silicon
2265 Cerium Mischmetal
CASTING PLANT & TECHNOLOGY 3/2019 63

SUPPLIERS GUIDE
2280 Chromium Metals
2290 Cobalt
2300 Chromium Metal, Aluminothermic
2310 Deoxidation Alloys
2318 High-grade Steel
2320 Iron Powder
2350 Copper
2360 Cupola Briquets
2370 Alloying Metals, in general
2380 Alloying Additives
2390 Magnesium, Magnesium Alloys
2410 Manganese Metal
2420 Manganese Metal, Electrolytic
2430 Molybdenum
2440 Molybdenum Alloys
2450 Molybdenum Oxide
2460 Nickel, Nickel Alloys
2470 Nickel-Magnesium
2490 Furnace Additives
2500 Ladle Additives
2510 High-Purity Iron, Low-Carbon
2520 Sulphuric Iron
2530 Silicon Carbide
2540 Silicon Metal
2545 Silicon Metal Granules
2550 Special Alloys
2570 Titanium Sponge
2575 Master Alloys for Precious Metals
2580 Bismuth
2590 Tungsten
2600 Tin
2610 Alloying Metals, Master Alloys
06.06. Nodularizing Additives and
Auxiliaries
2620 Magnesium Treatment Alloys for
s. g. Cast Iron
2630 Mischmetal
06.07. Inoculants and Auxiliary
Appliances
2640 Cored-Wire Injectors
2645 Injection Appliances for Cored Wire
2650 Cored Wires for Secondary and
Ladle Metallurgy
2653 Cored Wires for Magnesium Treatment
2656 Cored Wires for Inoculation of Cast
Iron Melts
2658 Stream Inoculants
2660 Automatic IDA-Type Inoculation
Dosing Devices
2670 Injection Appliances
2680 Inoculants and Inoculation Alloys,
in general
2690 Inoculants for Cast Iron
2692 MSI Pouring Stream Inoculation
Devices
2694 Ladle Inoculants
07 Metallic Charge and Treatment Materials for
Light and Heavy Metal Castings
07.01. Scrap
2730 Metal Residues
07.02. Ingot Metal
2740 Standard Aluminium Alloys
2750 Brass Ingots
2770 High-Grade Zinc Alloys
2790 Copper
2800 Copper Alloys
2810 Magnesium, Magnesium Alloys
2830 Tin
07.03. Alloying Addition for Treatment
2838 Aluminium-Beryllium Master Alloys
2840 Aluminium-Copper
2852 Aluminium Master Alloys
2870 Arsenic Copper
2875 Beryllium-Copper
2890 Calcium
2891 Calcium Carbide, Desulphurisers
2893 Chromium-Copper
2900 Ferro-Copper
2910 Grain Refiner
2920 Granulated Copper
2924 Copper Magnesium
2925 Copper Salts
2927 Copper Master Alloys
2930 Alloy Metals, in general
2935 Alloy Biscuits
2936 Lithium
2938 Manganese Chloride (anhydrate)
2940 Manganese Copper
2950 Metal Powder
2960 Niobium
2970 Phosphor-Copper
2980 Phosphor-Tin
2990 Silicon-Copper
3000 Silicon Metal
3010 Strontium, Strontium Alloys
3020 Tantalum
3025 Titanium, powdery
3030 Refining Agents for Aluminium
3033 Zirconium-Copper
08 Plants and Machines for Moulding and
Coremaking Processes
08.01. Moulding Plants
3050 Moulding Plants, in general
3058 Moulding Machines, Boxless
3060 Moulding Machines, Fully Automatic
3070 Moulding Machines, Fully and
Partially Automatic
08.02. Moulding and Coremaking
Machines
3080 Lifting Moulding Machine
3090 Pneumatic Moulding Machines
3100 Automatic Moulding Machines
3110 High-Pressure Squeeze Moulding
Machines
3130 Impact Moulding Machines
3140 Moulding Plants and Machines for
Cold-Setting Processes
3150 Moulding Machines, Boxless
3160 Core Blowers
3170 Coremaking Machines
3180 Core Shooters
3190 Air-flow Squeeze Moulding Machines
and Plants
3200 Shell Moulding Machines
3210 Shell Moulding Machines
3220 Shell Moulding Machines and
Hollow Core Blowers
3225 Multi-Stage Vacuum Process
3230 Multi-Stage Vacuum Processes for
Pressure Die Casting Processes
3235 Rapid Prototyping
3240 Jolt Squeeze Moulding Machines
3250 Suction Squeeze Moulding Machines
and Plants
3260 Pinlift Moulding Machines
3270 Rollover Moulding Machines
3280 Vacuum Moulding Machines and
Processes
3290 Multi-Piston Squeeze Moulding
Machines
3300 Turnover Moulding Machines
08.03. Additives and Accessories
3310 Exhaust Air Cleaning Plants for
Moulding Machines
3320 Gassing Units for Moulds and
Cores
3325 Seal Bonnets for Immersion Nozzles
3330 Metering Dosing Devices for
Binders and Additives
3340 Electrical Equipment for Moulding
Machines and Accessories
3350 Electrical and Electronic Controlling
Devices for Moulding
Machines
3355 Mould Dryer
3360 Vents
3370 Screen-Vents
3380 Spare Parts for Moulding Machines
3390 Flow Coating Plants
3400 Pattern Plates
3420 Manipulators
3430 Core Setting Equipment
3440 Core Removal Handling
3450 Core Handling
3460 Coremaking Manipulators
3462 Core Transport Racks
3470 Shell Mould Sealing Equipment
and Presses
3480 Mixers for Blackings and Coatings
3500 Plastic Blowing and Gassing Plates
3510 Coating Equipment
3512 Coating Dryers
3520 Equipment for Alcohol-based
Coatings
3525 Coating Stores and
Preparation Equipment
3530 Coating Mixers, Coating Preparation
Equipment
3540 Screen Vents, front Armoured
3560 Swing Conveyors
3570 Screening Machines
3580 Plug Connections, Heat-Resisting
08.04. Mould Boxes and Accessories
3590 Moulding Boxes
3610 Moulding Box Round-hole and
Long-hole Guides
09 Moulding Sands
09.01. Basic Moulding Sands
3630 Chromite Sands
3640 Moulding Sands
3645 Ceramic Sands/Chamotte Sands
3650 Core Sands
64

3660 Molochite
3670 Mullite Chamotte
3690 Olivine Sands
3700 Fused Silica
3705 Lost Foam Backing Sands
3710 Silica Flour
3720 Silica Sands
3730 Zircon Powder
3740 Zircon Sands
09.02. Binders
3750 Alkyd Resins
3755 Inorganic Binders
3760 Asphalt Binders
3770 Bentonite
3790 Binders for Investment Casting
3800 Cold-Box Binders
3803 Resins for the Shell Moulding
Process
3820 Ethyl Silicate
3830 Moulding Sand Binders, in general
3833 Binders, Inorganic
3840 Resins
3860 Oil Binders
3870 Core Sand Binders, in general
3875 Silica Sol
3880 Synthetic Resin Binders, in general
3890 Synthetic Resin Binders for
Refractories
3900 Synthetic Resin Binder for Gas
Curing Processes
3910 Synthetic Resin Binder for Hot
Curing Processes
3920 Synthetic Resin Binder for Cold
Setting Processes
3930 Facing Sand Binders
3940 Binders for the Methyl-Formate
Process
3950 Phenolic Resins
3960 Phenolic Resins (alkaline)
3970 Polyurethane Binders and Resins
3980 Swelling Binders
3990 Swelling Clays
4000 Quick-Setting Binders
4010 Silicate Binders
4020 Silica Sol
4030 Binders for the SO2 Process
4040 Cereal Binders
4050 Warm-Box Binders
4060 Water-Glass Binders (CO2-Process)
09.03. Moulding Sand Additives
4066 Addition Agents
4070 Iron Oxide
4080 Red Iron Oxide
4090 Lustrous Carbon Former
4100 Pelleted Pitch
4110 Coal Dust
4120 Coal Dust Substitute (Liquid or
Solid Carbon Carrier)
4130 Coal Dust (Synthetic)
09.04. Mould and Core Coating
4140 Inflammable Coating
4150 Alcohol-Based Coatings
4160 Alcohol-based Granulated Coatings
4170 Boron-Nitride Coatings
4180 Coatings, Ready-to-Use
4190 Mould Varnish
4200 Mould Coating
4210 Black Washes
4220 Graphite Blackings
4224 Lost-Foam Coatings
4225 Ceramic Coatings
4230 Core Coatings
4240 Core Blackings
4260 Paste Coatings
4266 Coatings (with metallurgical effects)
4270 Blackings, in general
4280 Steel Mould Coatings
4290 Talc
4298 Coatings for Full Mould Casting
4300 Water-based Coatings
4310 Granulated Water-based Coatings
4320 Zircon Coatings
4321 Zircon-free Coatings
09.05. Moulding Sands
Ready-to-Use
4340 Sands for Shell Moulding, Readyto-use
4350 Sands Ready-to-Use, Oil-Bonded
(Water-free)
4360 Precoated Quartz Sands, Zircon
Sands, Chromite Sands, Ceramic
Sands
4370 Moulding Sands for Precision
Casting
4380 Steel Moulding Sands
4390 Synthetic Moulding and Core Sand
09.06. Moulding Sands Testing
4400 Strength Testing Equipment for
Moulding Sand
4410 Moisture Testing Equipment for
Moulding Sand
4420 Moulding Sand Testing Equipment,
in general
4426 Core Gas Meters for Al + Fe
4440 Sand Testing
10 Sand Conditioning and Reclamation
4446 Sand Preparation and
Reclamation
4448 Sand Reclamation System
10.01. Moulding Sand Conditioning
4450 Nozzles for Moistening
4459 Continuous Mixers
4460 Continuous Mixers for Cold-Setting
Sands
4470 Aerators for Moulding Sand
Ready-to-Use
4480 Sand Preparation Plants and
Machines
4490 Sand Mullers
4500 Measuring Instruments for Compactibility,
Shear Strength, and
Deformability
4510 Measuring Instruments for
Mouldability Testing (Moisture,
Density, Temperature)
4520 Mixers
4550 Sand Mixers
4560 Aerators
4567 Vibration Sand Lump Crusher
4568 Vibratory Screens
4570 Sand Precoating Plants
4590 Scales and Weighing Control
10.03. Conditioning of Cold, Warm,
and Hot Coated Sands
4650 Preparation Plants for Resin
Coated Sand
10.04. Sand Reconditioning
4660 Used Sand Preparation Plants
4662 Batch Coolers for Used Sand
4664 Flow Coolers for Used Sand
4670 Magnetic Separators
4690 Core Sand Lump Preparation
Plants
4700 Reclamation Plants for Core Sands
4710 Ball Mills
4720 Sand Coolers
4730 Sand Reclamation Plants
4740 Sand Screens
4760 Separation of Chromite/Silica Sand
10.05. Reclamation of Used Sand
4780 Reclamation Plants, in general
4785 Reclamation Plants,
Chemical-Combined
4790 Reclamation Plants,
Mechanical
4800 Reclamation Plants,
Mechanical/Pneumatic
4810 Reclamation Plants,
Mechanical-Thermal
4820 Reclamation Plants, Mechanical/
Thermal/Mechanical
4830 Reclamation Plants, wet
4840 Reclamation Plants, Thermal
4850 Reclamation Plants,
Thermal-Mechanical
11 Moulding Auxiliaries
4880 Mould Dryers
4890 Foundry Nails, Moulding Pins
4910 Moulders‘ Tools
4920 Mould Hardener
4950 Guide Pins and Bushes
4965 High Temperature Textile Fabrics
up to 1260 °C
4970 Ceramic Pouring Filters
4980 Ceramic Auxiliaries for Investment
Foundries
4990 Ceramic Cores for Investment
Casting - Gunned, Pressed, Drawn
4998 Cope Seals
5000 Core Benches
5007 Core Putty Fillers
5010 Core Wires
5020 Cores (Cold-Box)
5030 Cores (Shell)
5040 Core Boxes
5050 Core Box Dowels
5070 Core Adhesives
5080 Core Loosening Powder
5090 Core Nails
5100 Core Powders
5110 Chaplets
5130 Tubes for Core and Mould Venting
CASTING PLANT & TECHNOLOGY 3/2019 65

SUPPLIERS GUIDE
5140 Core Glueing
5150 Core Glueing Machines
5155 Cleaners
5160 Adhesive Pastes
5170 Carbon Dioxide
(CO2 Process)
5180 Carbon Dioxide Dosing
Devices
5210 Coal Dust and Small Coal
5220 Chill Nails
5230 Chill Coils
5240 Antipiping Compounds
5260 Shell Mould Sealers
5270 Mould Dryers, Micro-Wave
5280 Screening Machines
5290 Glass Fabric Filters
5300 Strainer Cores
5310 Release Agents
11.01. Moulding Bay Equipment
5312 Glass Fabric Filters
5314 Strainer Cores
12 Gating and Feeding
5320 Covering Agents
5330 Heating-up Agents
5340 Breaker Cores
5350 Strainer Cores
5360 Exothermic Products
5365 Glass Fabric Filters
5370 Insulating Products and Fibres
5375 Insulating Sleeves
5380 Ceramic Filters
5390 Ceramic Breaker Cores
5400 Exothermic Mini-Feeders
5405 Non-Ceramic Foam Filters
5410 Ceramic Dross Filters
5416 Riser (exothermic)
5418 Riser (insulating)
5420 Exothermic Feeder Sleeves
5430 Exothermic Feeding Compounds
13 Casting Machines and Equipment
5436 Pouring Machines and
Equipment
5437 Casting Machine,
without Heating
13.01. Pouring Furnaces and their
Equipment
5440 Aluminium Dosing Furnaces
5450 Pouring Equipment
5460 Pouring Ladles
5461 Pouring Ladles, Insulating
5468 Pig and Ingot Casting
Machines
5470 Pouring Equipment for Moulding
Plants, Railborn or Crane-operated
5480 Pouring Ladles
5485 Pouring Ladles, Electrically Heated
5490 Drum-Type Ladles
5500 Ingot Casting Machines
5510 Low Pressure Casting
Machine
13.02. Die Casting and
Accessories
5530 Trimming Presses for
Diecastings
5540 Trimming Tools for Diecastings
(Standard Elements)
5545 Exhausting and Filtering Plants for
Diecastings
5550 Ejectors for Diecasting Dies
5560 Ejectors for Diecasting Dies (Manganese
Phosphate Coated)
5570 Feeding, Extraction, Spraying, and
Automatic Trimming for Diecasting
Machines
5580 Trimming Tools
5600 Dosing Devices for
Diecasting Machines
5610 Dosing Furnaces for
Diecasting Machines
5620 Diecasting Dies
5630 Heating and Cooling Devices for
Diecasting Dies
5640 Diecasting Machines
5641 Diecasting Machines and Plants
5644 Diecasting Machines for Rotors
5650 Diecasting Machine Monitoring
and Documentation Systems
5660 Diecasting Coatings
5670 Diecasting Lubricants
5675 Lost Diecasting Cores
5680 Diecasting Parting Agents
5689 Venting Blocks for HPDC Dies
5690 Extraction Robots for
Diecasting Machines
5695 Frames and Holders for
Diecasting Dies
5700 Spraying Equipment for Diecasting
Machines
5710 Goosenecks and Shot Sleeves
5720 Hand Spraying Devices
5730 Heating Cartridges
5740 High-duty Heating Cartridges
5750 Hydraulic Cylinders
5760 Core Pins
5770 Cold Chamber Diecasting Machines
5780 Pistons for Diecasting Machines
5790 Piston Lubricants
5800 Piston Spraying Devices
5810 Mixing Pumps for Parting Agents
5815 Electric Nozzle Heatings
5817 Oil Filters
5820 Melting and Molten Metal Feeding
in Zinc Die Casting Plants
5830 Steel Molds for Diecasting Machines
5838 Heating and Cooling of Dies
5840 Temperature Control Equipment for
Diecasting Dies
5850 Parting Agents for Dies
5860 Parting Agent Spraying Devices for
Diecasting Machines
5865 Dry Lubricants (Beads)
5870 Vacural-Type Plants
5876 Multi-Stage Vacuum Process
5880 Multi-Stage Vacuum Process
5890 Vacuum Die Casting Plants
5900 Hot Working Steel for
Diecasting Dies
5910 Hot Working Steel for Diecasting
Tools
5912 Hot Chamber Diecasting Machines
13.03. Gravity Die Casting
5914 Dosing Devices for Gravity Diecasting
Stations
5920 Permanent Molds
5930 Automatic Permanent Moulding
Machines
5940 Gravity Diecasting Machines
5941 Gravity and High Pressure Diecasting
Automation
5945 Cement and Fillers for Permanent
Moulds up to 1600 °C
5950 Cleaning Devices for Permanent
Molds
5960 Coatings for Permanent Molds
5970 Colloidal Graphite
5975 Chills
5980 Low Pressure Diecasting Machines
13.04. Centrifugal Casting
5990 Centrifugal Casting Machines
13.05. Continuous Casting
6000 Anode Rotary Casting Machines
6001 Length and Speed Measuring,
non-contact, for Continuous
Casting Plants
6002 Thickness and Width Measurement
for Continuous Casting
Plants, non-contact
6006 Casting and Shear Plants for
Copper Anodes
6007 Casting and Rolling Plants for
Copper Wire
6008 Casting and Rolling Plants for
Copper Narrow Strips
6010 Continuous Casting Plant, horizontal,
for Tube Blanks with integrated
Planetary Cross Rolling Mill for the
Production of Tubes
6020 Continuous Casting Moulds
6030 Continuous Casting
Machines and Plants
6032 Continuous Casting, Accessories
6033 Continuous Casting Machines and
Plants (non-ferrous)
13.06. Investment and Precision
Casting
6040 Burning Kilns for Investment
Moulds
6045 Investment Casting Waxes
6050 Embedding Machines for Investment
Casting Moulding Materials
6060 Investment Casting Plants
6062 Centrifugal Investment
Casting Machines
13.07. Full Mould Process Plants
6070 Lost-Foam Pouring Plants
13.08. Auxiliaries, Accessories, and
Consumables
6080 Pouring Manipulators
6090 Slag Machines
6093 Copper Templates
6100 Nozzles, Cooling
66

6110 Electrical and Electronic Control
for Casting Machines
6120 Extraction Devices
6130 Pouring Consumables, in general
6140 Rotary Casting Machines
6150 Pouring Ladle Heaters
6160 Ladle Bails
6170 Stream Inoculation Devices
6175 Graphite Chills
6176 Marking and Identification
6177 Bone Ash (TriCalcium Phosphate)
6190 Long-term Pouring Ladle Coatings
6200 Long-term Lubricants
6210 Manipulators
6220 Ladle Covering Compounds
6240 Robots
6245 Protective Jacket for Robots, Heat
and Dust Resistant
6250 Dosing Devices for Slag Formers
Addition
6270 Silicon Carbide Chills
6280 Silicon Carbide Cooling Compounds
6290 Crucible Coatings
6300 Heat Transfer Fluids
14 Discharging, Cleaning, Finishing of Raw
Castings
6305 Casting Cooling Plants
14.01. Discharging
6330 Knock-out Drums
6340 Vibratory Shake-out Tables
6345 Knock-out Vibratory Conveyors
6346 Shake-out Grids
6347 Shake-out Separation Runners
6350 Decoring Equipment
6352 Discharging of Metal Chips
6360 Hooking
6370 Manipulators
6373 Manipulators for Knock-out Floors
6380 Robots
6390 Vibratory Grids, Hangers, and
Chutes
6400 Vibratory Tables
14.02. Blast Cleaning Plants and
Accessories
6410 Turntable Blasting Fans
6420 Pneumatic Blasting Plants
6430 Automatic Continuous Shot-blasting
plants
6440 Descaling Plants
6445 Spare Parts for Blasting Plants
6450 Hose Blasting Plants, Fans
6460 Hose Blasting Chambers
6470 Monorail Fettling Booths
6475 Efficiency Tuning for Blasting
Plants
6480 Manipulator Shotblast Plants
6485 Tumbling Belt Blasting Plants,
Compressed Air Driven
6490 Wet and Dry Shotblast Plants
6500 Fettling Machines
6530 Airless Blast Cleaning Machines
6540 Blasting Plants Efficiency Tuning
6550 Shot Transport, Pneumatic
6560 Shot-Blasting Plants
6569 Shot Blasting Machines
6570 Shot Blasting Machines, with/
without Compressed Air Operating
6572 Dry Ice Blasting
6574 Dry Ice Production
14.03. Blasts
6580 Aluminium Shots
6590 Wire-Shot
6600 High-Grade Steel Shots
6610 Granulated Chilled Iron, Chilled
Iron Shots
6630 Cast Steel Shots
6640 Stainless Steel Shot
6650 Shot-Blast Glass
6660 Shot-Blast Glass Beads
6670 Blasts
6671 Stainless Steel Abrasives
14.04. Grinding Machines and Accessories
6675 Stainless Steel Grit
6680 Belt Grinders
6685 chamfering machines
6690 Flexible Shafts
6695 Diamond Cutting Wheels for
Castings
6700 Compressed Air Grinders
6710 Fibre discs
6714 Centrifugal Grinders
6720 Vibratory Cleaning Machines and
Plants
6730 Rough Grinding Machines
6735 Abrasive Wheels, visual, with
Flakes/Lamellas
6740 Numerical Controlled Grinders
6750 Swing Grinders
6760 Polishing Machines
6770 Polishing Tools
6773 Precision Cutting Wheels, 0,8 mm
6780 Tumbling Drums
6790 Pipe Grinders
6800 Floor Type Grinders
6810 Grinding Textiles
6820 Emery Paper
6830 Grinding Wheel Dresser
6850 Grinding Wheels and Rough
Grinding Wheels
6855 Grinding Pins
6860 Grinding Fleece
6870 Grinding Tools
6874 Drag Grinding Plants
6880 Rough Grinding Machines
6885 Cutting Wheels
6890 Abrasive Cut-off Machines
6900 Vibratory Cleaning Machines
6910 Angle Grinders
14.05. Additional Cleaning Plants
and Devices
6920 Gate Break-off Wedges
6925 Plants for Casting Finishing
6930 Automation
6940 Pneumatic Hammers
6950 Deflashing Machines
6954 Deburring Machines,
robot-supported
6955 Robot Deburring Systems
6960 Fettling Cabins
6970 Fettling Manipulators
6980 Fettling Benches
6990 Core Deflashing Machines
7000 Chipping Hammers
7010 Dedusting of Fettling Shops
7020 Fettling Hammers
7030 Fettling Shops, Cabins, Cubicles
7035 Refining Plants
7040 Robot Fettling Cubicles
7041 Robot Deflashing Units for Casting
7050 Feeder Break-off Machines
7052 Stamping Deflashing
Equipment (tools, presses)
7055 Break-off Wedges
7056 Cutting and Sawing Plants
7058 Band Saw Blades
7059 Cut-off Saws
7060 Cut-off Saws for Risers and Gates
14.06. Jig Appliances
7066 Magnetic Clamping Devices for
Casting Dies
7068 Core-Slides and Clamping
Elements for Casting Dies
7070 Clamping Devices
14.07. Tribology
7073 Lubricants for High Temperatures
7074 Chain Lubricating Appliances
7075 Cooling Lubricants
7077 Central Lubricating Systems
15 Surface Treatment
7083 Anodizing of Aluminium
7100 Pickling of High Quality Steel
7105 CNC Machining
7110 Paint Spraying Plants
7115 Yellow/Green Chromating
7130 Priming Paints
7140 Casting Sealing
7150 Casting Impregnation
7166 Hard Anodic Coating of Aluminium
7180 High Wear-Resistant Surface
Coating
7190 Impregnation
7198 Impregnation Plants
7200 Impregnating Devices and Accessories
for Porous Castings
7210 Anticorrosion Agents
7220 Corrosion and Wearing Protection
7230 Shot Peening
7232 Wet Varnishing
7234 Surface Treatment
7235 Surface Coatings
7240 Polishing Pastes
7245 Powder Coatings
7250 Repair Metals
7260 Slide Grinding, free of Residues
7290 Quick Repair Spaddle
7292 Special Coatings
7295 Special Adhesives up to 1200 °C
7296 Shot-Blasting
7297 Power Supply, Plasma Generators
7300 Galvanizing Equipment
7302 Zinc Phosphating
7310 Scaling Protection
7312 Subcontracting
CASTING PLANT & TECHNOLOGY 3/2019 67

SUPPLIERS GUIDE
16 Welding and Cutting
16.01. Welding Machines and
Devices
7330 Welding Consumables, Electrodes
16.02. Cutting Machines and Torches
7350 Gougers
7352 Special Machines for Machining
7360 Coal/Graphite Electrodes
7365 Water Jet Cutting
7370 Oxygen Core Lances
16.03. Accessories
7394 Protective Blankets, Mats, and
Curtains, made of Fabric, up to
1250 °C
7397 Protective Welding Paste, up to
1400 °C
17 Surface Treatment and Drying
7398 Heat Treatment and Drying
17.01. Plants and Furnaces
7400 Tempering Furnaces
7401 Ageing Furnaces
7402 Combustion Chambers
7404 Baking Ovens for Ceramic Industries
7420 Mould Drying Stoves
7430 Annealing and Hardening Furnaces
7440 Induction Hardening and Heating
Equipment
7450 Core Drying Stoves
7452 Microwave Drying Stoves and
Chambers
7455 Solution Annealing Furnaces
7460 Ladle Dryers
7470 Sand Dryers
7480 Inert Gas Plants
7490 Annealing Furnaces
7500 Drying Stoves and Chambers
7510 Quenching and Tempering Furnaces
7520 Heat Treating Furnaces
7525 Hearth Bogie Type Furnaces
17.02. Components, Accessories,
Operating Materials
7550 Multi-purpose Gas Burners
7560 Heating Equipment, in general
7564 Special Torches
7580 Firing Plants
7590 Gas Torches
7600 Gas Heatings
7610 Capacitors
7616 Furnace Optimization
7620 Oil Burners
7630 Recuperative Burners
7640 Oxygen Burners
7650 Heat Recovery Plants
18 Plant, Transport, Stock, and Handling
Engineering
7654 Lifting Trucks
7656 Transport, Stock, and
Handling Technology
18.01. Continuous Conveyors and
Accessories
7660 Belt Conveyors
7670 Bucket Elevators
7676 Flexible Tubes with Ceramic Wear
Protection
7680 Conveyors, in general
7690 Conveyors, Fully Automatic
7710 Conveyor Belts
7720 Conveyor Belt Ploughss
7730 Conveyor Belt Idlers
7740 Conveyor Chutes
7750 Conveying Tubes
7760 Belt Guides
7780 Overhead Rails
7790 Hot Material Conveyors
7810 Chain Conveyors
7820 Chain Adjusters
7850 Conveyors, Pneumatic
7860 Roller Beds, Roller Conveyor
Tables, Roller Tables
7870 Sand Conveyors
7890 Bulk Material Conveyors
7900 Swing Conveyor Chutes
7910 Elevators
7920 Chip Dryers
7950 Idlers and Guide Rollers
7960 Transport Equipment, in general
7970 Conveyor Screws
7980 Vibratory Motors
7981 Vibration Conveyors
18.02. Cranes, Hoists, and
Accessories
8000 Grippers
8010 Lifting Tables and Platforms
8020 Jacks and Tilters
8030 Operating Platforms, Hydraulic
8032 Hydraulic and Electric Lifting
Trucks
8040 Cranes, in general
8050 Lifting Magnets
8060 Lifting Magnet Equipment
18.03. Vehicles and Transport Containers
8080 Container Parking Systems
8090 Fork Lift Trucks, in general
8100 Fork Lift Trucks for Fluid Transports
8110 Equipment for Melt Transport
18.04. Bunkers, Siloes and
Accessories
8140 Linings
8145 Big-bag Removal Systems
8150 Hopper Discharger and
Discharge Chutes
8160 Hoppers
8170 Conveyor Hoses
8190 Silos
8200 Silo Discharge Equipment
8210 Silo Over-charging Safety Devices
8218 Wearing Protection
8220 Vibrators
18.05. Weighing Systems and Installations
8230 Charging and Charge
Make-up Scales
8240 Metering Scales
8250 Monorail Scales
8260 Crane Weighers
8280 Computerized Prescuption Plants
8290 Scales, in general
18.07. Handling Technology
8320 Manipulators
8340 Industrial Robots
8350 Industrial Robots, Resistant to Rough
8364 Chipping Plants with Robots
18.08. Fluid Mechanics
8365 Pumps
8367 Compressors
18.09. Storage Systems, Marshalling
8368 Marking and Identification
18.10. Components
8374 Marking and Identification
19 Pattern- and Diemaking
19.01. Engines for Patternmaking
and Permanent Mold
8380 Band Sawing Machines for
Patternmaking
8400 CAD/CAM/CAE Systems
8410 CAD Constructions
8420 CAD Standard Element Software
8423 CNC Milling Machines
8425 Automatic CNC Post-Treatment
Milling Machines
8430 CNC Programming Systems
8440 CNC, Copying, Portal and Gantry
Milling Machines
8470 Dosing Equipment and Suction
Casting Machines for the Manufacture
of Prototypes
8480 Electrochemical Discharge Plants
8490 Spark Erosion Plants
8500 Spark Erosion Requirements
8510 Development and Production of
Lost-Foam Machines
8520 Milling Machines for Lost-Foam
Patterns
8522 Hard Metal Alloy Milling Pins
8525 Lost-Foam Glueing Equipment
8527 Patternmaking Machines
8576 Rapid Prototyping
8610 Wax Injection Machines
19.02. Materials, Standard Elements
and Tools for Pattern- and
Diemaking
8630 Thermosetting Plastics for Patternmaking
8650 Toolmaking Accessories
8660 Milling Cutters for Lost-Foam
Patterns
8670 Free-hand Milling Pins made of
Hard Metal Alloys and High-speed
Steels
8675 Hard Metal Alloy Milling Pins
8680 Adhesives for Fabrication
68

8690 Synthetic Resins for Patternmaking
8700 Plastic Plates Foundry and Patternmaking
8705 Lost-Foam Tools and
Patterns
8710 Patternmaking Requirements, in
general
8720 Patternmaking Materials, in general
8730 Pattern Letters, Signs, Type Faces
8740 Pattern Dowels (metallic)
8750 Pattern Resins
8760 Pattern Resin Fillers
8770 Pattern Plaster
8780 Pattern Gillet
8790 Lumber for Patterns
8800 Pattern Varnish
8810 Pattern-Plate Pins
8820 Pattern Spaddles
8830 Standard Elements for Tools and
Dies
8840 Precision-shaping Silicone
8846 Rapid Tooling
19.03. Pattern Appliances
8880 CNC Polystyrol
Patternmaking
8890 Development and Manufacture of
Lost-Foam Patterns
8900 Moulding Equipment
8910 Wood Patterns
8930 Core Box Equipment for Series
Production
8940 Resin Patterns
8960 Metal Patterns
8970 Pattern Equipment, in general
8980 Pattern Plates
8985 Pattern Shop for Lost-Foam
Processes
9000 Stereolithography Patterns
9010 Evaporative Patterns for the Lost-
Foam Process
19.04. Rapid Prototyping
9021 Design
9022 Engineering
9023 Hardware and Software
9024 Complete Investment Casting
Equipment for Rapid
Prototyping
9025 Pattern and Prototype
Making
9026 Rapid Prototyping for the Manufacture
of Investment Casting
Patterns
9027 Integrable Prototypes
9028 Tools
9029 Tooling Machines
20 Control Systems and Automation
20.01. Control and Adjustment Systems
9030 Automation and Control for Sand
Preparation
9040 Automation
9042 Software for Production Planning
and Control
9050 Electric and Electronic Control
9080 Equipment for the Inspection of
Mass Production
9090 Load Check Systems for Recording
and Monitoring Energy Costs
9120 Control Systems and
Automation, in general
9130 Control Systems, in general
9160 Switch and Control Systems
20.02. Measuring and Control
Instruments
9165 Automatic Pouring
9166 Compensation Leads
9185 Contactless Temperature Measurement,
Heat Image Cameras
9190 Leakage Testing and Volume
Measuring Instruments
9210 Flow Meters
9220 Flow control Instruments
9230 Immersion Thermo Couples
9240 Moisture Controller
9250 Level Indicator
9280 Bar Strein Gauge
9301 In-Stream Inoculation Checkers
9302 In-Stream Inoculant Feeder
9306 Calibration and Repair Services
9310 Laser Measurement Techniques
9320 Multi-coordinate Measuring
Machine
9330 Measuring and Controlling Appliances,
in general
9335 Measuring and Controlling Appliances
for Fully Automatic Pouring
9345 Positioning Control
9350 Pyrometers
9370 Radiation Pyrometers
9375 Measuring Systems for Nuclear
Radiation (receiving inspection)
9376 Measuring Systems for Radioactivity,
Incoming Goods‘ Inspection
9380 Temperature Measurement
9382 Temperature Control Units
9385 Molten Metal Level Control
9390 Temperature Measuring and
Control Devices
9391 Thermoregulator
9395 Molten Metal Level Control
9400 Thermal Analysis Equipment
9410 Thermo Couples
9420 Protection Tubes for Thermocouples
9425 In-stream Inoculant Checkers
9430 Heat Measuring Devices
9433 Resistance Thermometers
20.03. Data Acquisition and
Processing
9438 Automation of Production- and
Warehouse-Systems
9440 Data Logging and Communication
9445 Business Intelligence
9450 Data Processing/Software Development
9456 ERP/PPS - Software for Foundries
9470 EDP/IP Information and Data
Processing
9480 Machine Data Logging
9484 Machine Identification
9490 Data Logging Systems
9500 Numerical Solidification Analysis
and Process Simulation
9502 Numerical Solidification Simulation
and Process Optimization
9504 ERP - Software for Foundries
9506 Process Optimization with EDP, Information
Processing for Foundries
9510 Computer Programmes for Foundries
9520 Computer Programmes and Software
for Foundries
9522 Simulation Software
9523 Software for Foundries
9525 Software for Coordinate
Measuring Techniques
9527 Software for Spectographic Analyses
9530 Statistical Process Control
9540 Fault Indicating Systems,
Registration and Documentation
20.04. Process Monitoring
9541 High Speed Video
21 Testing of Materials
21.01. Testing of Materials and
Workpieces
9548 Calibration of Material Testing
Machines
9550 Aluminium Melt Testing
Instruments
9554 Acoustic Materials Testing
9555 Acoustic Construction
Element Testing
9560 CAQ Computer-Aided Quality
Assurance
9564 Image Documentation
9580 Chemical Analyses
9585 Computerized Tomography, CT
9586 Core Gas - System for Measurement
and Condensation
9587 Die Cast Control
9589 Natural Frequency Measuring
9590 Endoscopes
9600 Dye Penetrants
9610 Instruments for
Non-destructive Testing
9620 Hardness Testers
9630 Inside Pressure Testing Facilities
for Pipes and Fittings
9645 Calibration of Material Testing
Machines
9650 Low-temperature Source of
Lighting Current
9670 Arc-baffler
9678 Magna Flux Test Agents
9680 Magnetic Crack Detection Equipment
9690 Material Testing Machines and
Devices
9695 Metallographic and Chemical
Analysis
9696 Microscopic Image Analysis
9697 Surface Analysis
9700 Surface Testing Devices
9710 Testing Institutes
9719 X-ray Film Viewing Equipment and
Densitometers
9720 X-Ray Films
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SUPPLIERS GUIDE
9730 X-Ray Testing Equipment
9740 Spectroscopy
9750 Ultrasonic Testing Equipment
9755 Vacuum Density Testing Equipment
9758 UV-Lamps
9759 UV Shiners
9760 Ultraviolet Crack Detection Plants
9765 Hydrogen Determination Equipment
9770 Material Testing Equipment, in
general
9780 Testing of Materials
9800 Inside Pressure Measuring for
Tools
9836 Devices for Testing of Materials,
non-destructive, in general
9838 NDT Non-destructive Testing of
Materials
9840 NDT X-ray Non-destructive Testing
of Materials
9850 Tensile Testing Machines
22 Analysis Technique and Laboratory Equipment
10000 Sample Preparation Machines
10010 Quantometers
10018 X-Ray Analysis Devices
10020 Spectographic Analysis Devices
10022 Certified Reference Materials for
Spectrochemical and -scopic
Analysis
10040 Cut-off Machines for Metallography
9860 Analyses
9865 Image Analysis
9880 Gas Analysis Appliances
9890 Carbon and Sulphur
Determination Equipment
9900 Laboratory Automation
9910 Laboratory Equipment, Devices,
and Requirements, in general
9920 Laboratory Kilns
9930 Metallographic Laboratory
Equipment
9940 Microscopes
9948 Optical Emission Spectrometers
9950 Microscopic
Low-temperature Illumination
9955 Continuous Hydrogen Measurement
9960 Polishing Machines for Metallography
9970 Sampling Systems
9980 Sample Transport
23 Air Technique and Equipment
23.01. Compressed Air Technique
10050 Compressed Air Plants
10060 Compressed Air Fittings
10070 Compressed Air Tools
10080 Compressors
10100 Compressor Oils
23.02. Fans and Blowers
10120 Fans, in general
23.03. Ventilators
10150 Axial Ventilators
10160 Hot-gas Circulating Ventilators
10170 Radial Ventilators
10180 Ventilators, in general
23.04. Other Air Technique
Equipments
10188 Waste Gas Cleaning
10190 Exhausting Plants
10192 Exhaust Air Cleaning for Cold-Box
Core Shooters
10220 Air-engineering Plants, in general
24 Environmental Protection and Disposal
10230 Environmental Protection and
Disposal
10231 Measures to Optimize Energy
10232 Fume Desulphurization for Boiler
and Sintering Plants
10235 Radiation Protection Equipment
24.01. Dust Cleaning Plants
10240 Extraction Hoods
10258 Pneumatic Industrial Vacuum
Cleaners
10260 Pneumatic Vacuum Cleaners
10270 Equipment for Air Pollution Control
10280 Dust Cleaning Plants, in general
10290 Gas Cleaning Plants
10300 Hot-gas Dry Dust Removal
10309 Industrial Vacuum Cleaners
10310 Industrial Vacuum Cleaners
10320 Leakage Indication Systems for
Filter Plants
10340 Multicyclone Plants
10350 Wet Separators
10360 Wet Dust Removal Plants
10370 Wet Cleaners
10380 Cartridge Filters
10400 Pneumatic Filter Dust Conveyors
by Pressure Vessels
10410 Punctiform Exhausting Plants
10420 Dust Separators
10430 Vacuum Cleaning Plants
10440 Dry Dust Removal Plants
10450 Multi-Cell Separators
10458 Central Vacuum Cleaning Plants
10460 Cyclones
24.02. Filters
10470 Compressed Air Filters
10490 Dedusting Filters
10500 Filters, in general
10510 Filter Gravel
10520 Filter Materials
10530 Filter Bags/Hoses
10550 Fabric Filters
10560 Air Filters
10570 Cartridge Filters
10580 Hose Filters
10585 Electro-Filters
10590 Air Filters
10610 Fabric Filters
24.03. Waste Disposal,
Repreparation, and Utilization
10618 Waste Air Cleaning
10620 Waste Water Analyzers
10630 Waste Water Cleaning and -Plants
10640 Clean-up of Contaminated Site
10646 Used Sands, Analysing of Soils
10650 Waste Sand Reutilization and
Reconditioning
10655 Amine Recycling
10660 Foundry Debris-conditioning Plants
10680 Soil Clean-up
10690 Briquetting Presses
10695 Briquetting of Foundry
Wastes/Filter Dusts
10700 Disposal of Foundry Wastes
10702 Hazardous Waste Disposal
10705 Bleeding Plants
10710 Reconditioning of Foundry Wastes
10720 Ground Water Cleaning
10740 Dross Recovery Plants
10760 Cooling Towers
10770 Cooling Water Processing Plants
10780 Cooling Water Treatment
10810 Post-combustion Plants
10830 Recooling Systems
10840 Recycling of Investment Casting
Waxes
10850 Slag Reconditioning
10870 Waste Water Cooling Towers
10880 Scrap Preparation
10890 Transport and Logistic for Industrial
Wastes
10900 Rentilization of Foundry Wastes
10910 Rentilization of Furnace Dusts and
Sludges
10920 Roll Scale De-oilers
10940 Rentilization of Slide Grinding
Sludges
25 Accident Prevention and Ergonomics
10960 Health and Safety Protection
Products
10970 Asbestos Replacements
10990 Ventilators
10993 Fire Protection Blankets and
Curtains made of Fabrics
10996 Fire-extinguishing Blankets and
Containers
11020 Heat Protection
11025 Heat-Protection Clothes and Gloves
11030 Climatic Measurement Equipment
for Workplace Valuation
11040 Protection against Noise
11050 Light Barriers
11060 Sound-protected Cabins
11070 Sound-protected Equipment and
Parting Walls
11080 Vibration Protection
26 Other Products for Casting Industry
26.01. Plants, Components, and
Materials
11100 Concreting Plants
11102 Devellopping and Optimizing of
Casting Components
11118 Vibration Technology
26.02. Industrial Commodities
11120 Joints, Asbestos-free
70

11125 Sealing and Insulating
Products up to 1260 °C
11130 Dowels
11150 Foundry Materials, in general
11155 Heat-protecting and Insulating
Fabrics up to 1260 °C
11160 Hydraulic Oil, Flame-resistant
11165 Marking and Identification
11170 Signs for Machines
11175 Fire-proof Protection Blankets,
-mats, and -curtains
11180 Screen and Filter Fabrics
26.04. Job Coremaking
11182 Inorganic Processes
11183 Hot Processes
11184 Cold Processes
27 Consulting and Service
11186 Ordered Research
11190 CAD Services
11200 Interpreters
11202 Diecasting, Optimization of Mould
Temperature Control
11205 EDP Consulting
11208 Wage Models
11210 Emission, Immission, and Workplace
Measurements
11211 E-Business
11212 eProcurement
11213 Technical Literature
11215 Investment Casting Engineering
11220 Foundry Consulting
11230 Foundry Legal Advice
11240 Lean Foundry Organization
11250 Foundry Planning
11252 Greenfield Planning
11253 Casting, Construction and Consulting,
Optimizing of Mould Core
Production and Casting Techniques
11260 Nuclear Engineering Consulting
11278 Customer Service for Temperature
Control Units and Systems
11280 Customer Service for
Diecasting Machines
11283 Jobbing Foundry
11286 Efficiency of Material
(Consulting)
11290 Management of Approval
Procedures
11291 Management Consulting
11292 Machining
11293 Metallurgical Consulting
11294 Patinating
11295 Human Resources Services
11296 Personnel Consulting
11298 Process Optimization
11299 Testing Status and Safety Labels
11300 Rationalization
11301 M&A Consulting
11303 Recruitment
11305 Centrifugal Casting Engineering
11310 Simulation Services
11320 Castings Machining
11325 Steel Melting Consulting
11330 Technical Translation and Documentation
11336 Environmental Protection Management
Systems (Environmental
Audits)
11339 Restructuring
11340 Environmental Consulting
11342 Business Consultancy
11343 Leasing of Industrial Vacuum
Cleaners
11345 Heat Treatment
11346 Associations
11360 Material Consulting
11370 Material Advices
11380 Time Studies
11382 Carving
28 Castings
11387 Aluminium Casting
11389 ADI
11390 Aluminium Pressure Diecasting
11400 Aluminium Permanent Moulding
(Gravity Diecasting)
11410 Aluminium Sand Casting
11420 Billet Casting
11430 Cast Carbon Steel, Alloy and
High-alloy Cast Steel
11440 Non-ferrous Metal Gravity Diecasting
11450 Pressure Diecasting
11460 High-grade Investment Cast Steel
11462 High-grade Steel Casting
11470 High-grade Steel Castings
11472 High-grade Centrifugal Cast Steel
11480 Ingot Casting
11485 Castings
11489 Rolled Wire
11490 Grey Cast Iron
11492 Large-size Grey Iron Castings
11496 Direct Chill Casting
11498 Art Casting
11499 Light Metal Casting
11501 Magnesium Pressure
Diecasting
11510 Brass Pressure Diecasting
11520 Non-ferrous Metal Sand Casting
11525 Prototype Casting
11530 Sand Casting SAND CASTING
11539 Centrifugal Casting
11540 Spheroidal Iron
11547 Spheroidal Graphite Cast Iron
11550 Steel Castings
11552 Continuously Cast Material
11553 Thixoforming
11555 Full Mold (lost-foam) Casting
11558 Rolls
11560 Zinc Pressure Diecasting
11570 Cylinder Pipes and Cylinder Liners
29 By-Products
11580 Sporting Field Sands
30 Data Processing Technology
11700 Mold Filling and Solidification
Simulation
11800 Simulation Programmes for
Foundry Processes
11820 Software for Foundries
31 Foundries
11850 Foundries, in general
31.01. Iron, Steel, and Malleable-Iron
Foundries
11855 Iron Foudries
11856 Steel Foundries
11857 Malleable-Iron Foundries
31.02. NFM Foundries
11860 Heavy Metals Foundries
11861 Die Casting Plants
11862 Light Metal Casting Plants
11863 Permanent Mold Foundry
31 Additive manufacturing / 3-D printing
CASTING PLANT & TECHNOLOGY 3/2019 71

CPT Titelfond
rund 1
Sicher zum SOP.
Autonomous Engineering mit MAGMA bedeutet
Planungssicherheit für Konstrukteur und Gießer.
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made by
Committed to casting excellence. www.magmasoft.de
Titelanzeige_GIFA_final.indd 1 18.12.2018 17:03:16
March
2019
25.- 29. Juni 2019
Düsseldorf
Halle 12 / Stand A20
cpt titel druckformular.indd 2 20.02.2019 11:57:12
CASTING
PLANT AND TECHNOLOGY
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72

INTERNATIONAL FAIRS AND CONGRESSES
Fairs and Congresses
Fenaf 2019 - Latin American Foundry Fair
September, 17-20, 2019, Sao Paulo, Brazil
www.abifa.org.br
The WFO Technical Forum and 59th IFC
September, 18-20, 2019, Portoroz, Slovenia
www.drustvo-livarjev.si
Metal+Metallurgy Thailand
September, 18-20, 2019, Bangkok, Thailand
www.expochina.cn
Die Casting Expo 2019
October, 8-9, 2019, Queretaro, Mexico
http://diecastingexpo.mx
Aluexpo 2019
October, 10-12, 2019, Istanbul, Turkey
https://aluexpo.com/Home-En
Foundry on Wheels Congress 2019
October, 17-18, 2019, Aguenda, Portugal
www.citnm.pt
Advertisers‘ Index
Admar Group, Ocala, FL/USA 21
AGTOS Gesellschaft für technische Oberflächensysteme
mbH, Emsdetten/Germany 27
ExOne GmbH, Gersthofen/Germany 13
Hüttenes-Albertus Chemische Werke GmbH
Düsseldorf/Germany
Back Cover
Kjellberg Vertrieb GmbH,
Finsterwalde/Germany23
Lucky-Winsun Enterprise Ltd.,
Taichung/Taiwan
Inside Front Cover
Luoyang Hongfeng Abrasives Co., Ltd.,
Luoyang/PR China 15
NürnbergMesse GmbH,
Nürnberg/Germany17
O.M.LER S.r.l.,
Bra (CN)/Italy 53
2nd International Conference of Casting and
Materials Engineering
November, 8, 2019, Krakow, Poland
www.iccme.foundry-conference.com
CASTING PLANT & TECHNOLOGY 3/2019 73

PREVIEW/IMPRINT
Production of die-casting machines
at Oskar Frech in Plüderhausen
near Stuttgart. Each year around
150 machines are manufactured
here.
Photo: Robert Piterek/BDG
Preview of the next issue
Selection of topics:
R. Piterek: 70 years are not enough
The German Oskar Frech Group will be 70 years old this year. The family-owned company represents the brand “Made in Germany”
with ingenuity and entrepreneurial courage and keeps up in competition with companies with a corporate background.
R. Riedel: Foundry Group pioneers data-driven productivity project
What if analysis of casting could be replaced by real-time process awareness and gives transparency, how multiple global sites are
performing in relation to each other? Questions the German MAT Foundry Group was asking. The Norican Group found a solution.
B. Böndel: The digital cell is a step change for the die-casting industry
The SmartCMS (Smart Cell Management System) by Bühler Die Casting, Uzwil, Switzerland, which is the core of its new digital
cell improves process performance and makes it possible to significantly increase OEE (Overall Equipment Effectiveness).
Imprint
Publisher:
German Foundry Association
Editor in Chief:
Martin Vogt, Dipl.-Journalist
Deputy Editor in Chief:
Robert Piterek, M.A.
P.O. Box 10 51 44
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Telephone: +49 211 6871-358
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74