CPT International 3/2019

cptinternational

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

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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

CASTING PLANT & TECHNOLOGY 3/2019 69


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.

Die richtige Lösung von Anfang an.

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

INTERNATIONAL

Order form

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For further keywords please use a separate sheet.

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Discontinuation will be accepted at the end of a subscribtion year considering 6 weeks notice. Deadline is the 15th of each month.

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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:

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Deputy Editor in Chief:

Robert Piterek, M.A.

P.O. Box 10 51 44

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ISSN 0935-7262

74

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