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CPT International 1/2020

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EDITORIAL<br />

Professional production<br />

in a changing world<br />

Coronavirus, industrial change, technological innovations: our world<br />

is currently surpassing itself with events of relevance to the foundry<br />

sector. But all becomes clear again when one focuses on the main<br />

aspect: what matters is the professional and successful production<br />

of castings – with state-of-the-art equipment.<br />

Robert Piterek<br />

e-mail: robert.piterek@bdguss.de<br />

Despite anxiety about the coronavirus<br />

in many parts of the world,<br />

production in the foundries largely<br />

continues worldwide. And even if<br />

many major events and trade fairs have<br />

been postponed in order to help contain<br />

the spread of the virus, the EURO-<br />

GUSS die-casting trade fair in Nuremberg<br />

in southern Germany at the start<br />

of the year came to a more-than-successful<br />

conclusion. Considerably more<br />

exhibitors were present than two years<br />

ago. At the same time, the proportion<br />

of international exhibitors (who came<br />

from 36 different countries), increased<br />

by more than half (56 percent) – more<br />

about this from P. 10. The foundry<br />

world is in flux – this was also clearly<br />

visible at EUROGUSS. Industry and society<br />

are increasingly feeling the effects<br />

of the trends towards e-mobility and<br />

emission reduction. CP+T spoke with<br />

Huub van der Weiden from the foundry<br />

plant planner Gemco Engineers about<br />

the right strategy for foundries in the<br />

<strong>2020</strong>s and beyond. A conversation with<br />

very interesting insights (more on this<br />

from P. 6)<br />

This issue again examines the<br />

numerous multifaceted processes upon<br />

which the foundry industry relies: from<br />

mold and core production, through the<br />

smelting operation and additive manufacturing,<br />

to digitalization and sand<br />

regeneration. The venues in this issue<br />

include the Hattori Diecast foundry in<br />

Japan, as well as the iron foundry<br />

Frischhut and the investment foundry<br />

Vacucast in Germany. All these companies<br />

have something in common: they<br />

exploit sophisticated technologies to<br />

produce castings with particular efficiency,<br />

productivity or quality – and<br />

thus earn good money. Many of the<br />

technologies presented here are ‘Made<br />

in Germany’, because Germany has<br />

been the unchallenged productivity<br />

world champion for many years – a title<br />

that can only be gained with state-ofthe-art<br />

production resources.<br />

With this in mind – find inspiration…<br />

…and have a good read!<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 3


CONTENTS<br />

FEATURES<br />

6 INTERVIEW<br />

„When you wait, you‘re late!“<br />

„Market and trends, and now?“ was the title of his<br />

presentation at a foundry event recently – Interview<br />

with Huub van der Weiden from Gemco Engineers.<br />

Robert Piterek<br />

10 EUROGUSS FOLLOW-UP<br />

Fantastic atmosphere at EUROGUSS <strong>2020</strong><br />

Four packed halls, enthusiastic visitors and satisfied<br />

exhibitors – this was the story of EUROGUSS.<br />

Kathrin Roedl<br />

12 MOLD AND COREMAKING<br />

Coatings for additively<br />

manufactured molds and cores<br />

HA has developed a special series of coatings for<br />

the 3-D printing process, which are already successfully<br />

being used for actual cast parts.<br />

Ekaterina Potaturina, Klaus Seeger<br />

INTERVIEW<br />

Huub van der Weiden<br />

in conversation with<br />

CP+T reporter<br />

Robert Piterek.<br />

EUROGUSS-<br />

FOLLOW-UP<br />

More exhibitors, more<br />

participants, greater<br />

internationality!<br />

16 MOLD AND COREMAKING<br />

Ecoform – a concept for the hand-molding<br />

of smaller series<br />

The Ecoform concept with molding box geometries<br />

adapted to the casting now offers more economical<br />

hand-molding than ever, Jens Müller Späth<br />

20 MELTING SHOP<br />

New furnace halves energy costs for<br />

Japanese foundry<br />

Hattori Diecast has become the first Japanese company<br />

to order and install a StrikoMelter melting<br />

furnace, Peter Reuther<br />

Cover-Photo:<br />

Martin Vogt, German Foundry Association,<br />

Düsseldorf, Germany<br />

MOLD AND<br />

COREMAKING<br />

HA has developed a<br />

new coating for additively<br />

manufactured<br />

molds and cores..<br />

Is climate neutrality possible in the foundry industry? The<br />

German foundry Lößnitz, manufacturer of molding and<br />

pressing tools for the automotive industry, is committed<br />

to sustainability. More on this in issue 2 of our magazine<br />

in June <strong>2020</strong>.<br />

4


CONTENTS<br />

MOLDMAKING<br />

Molding boxes adapted<br />

to the casting<br />

offer advantages.<br />

24 MELTING SHOP<br />

New foundry technology cuts energy costs<br />

and CO 2<br />

emissions<br />

Light metal foundries will soon be able to cut their<br />

energy costs related to production by as much as<br />

sixty percent and CO 2<br />

emissions by as much as eighty<br />

percent. A new technology will make this possible.<br />

Stefan Scharf, Jörg Tom Felde, Hagen Stein<br />

26 PRESSURE DIE CASTING<br />

Digitalization solutions that improve the<br />

efficiency of die casting foundries<br />

smartfoundry.solutions from Oskar Frech is a solution<br />

for customized digitalization of die casting<br />

foundries, Alexander Marks, Kai Kerber<br />

34 ADDITIVE MANUFACTURING<br />

How the die-casting industry can benefit<br />

from 3-D printing<br />

Additive Manufacturing and automation have the<br />

potential to a more efficient production.<br />

Ralf Frohwerk<br />

37 SAND RECLAMATION<br />

Mixing without vibrations and complete<br />

preparation<br />

The molding sand at iron foundry Frischhut is<br />

prepared with a state-of-the-art mixing system.<br />

Gerhard Krauskopf<br />

40 COMPANY<br />

SAND<br />

RECLAMATION<br />

Left: A new state-ofthe<br />

art mixing system<br />

has been installed at<br />

the iron foundry<br />

Frischhut. It offers<br />

complete preparation.<br />

Investment casting can save lives<br />

Vacucast from Berlin casts implants that are used for<br />

joint replacement in operating theaters worldwide.<br />

Robert Piterek<br />

COLUMNS<br />

3 EDITORIAL<br />

45 NEWS<br />

51 SUPPLIERS GUIDE<br />

69 FAIRS AND KONGRESSES/AD INDEX<br />

70 PREVIEW/IMPRINT<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 5


INTERVIEW<br />

6


“We have transitioned from mass production<br />

to a time of personalized production, via a<br />

period of mass customization.“<br />

Huub van der Weiden is Account Manager<br />

at Gemco Engineers, a full service provider<br />

to the foundry industry.<br />

“When you wait, you’re late!”<br />

Huub van der Weiden is sales engineer at the Dutch foundry consulting and engineering<br />

firm Gemco Engineers. “Market and trends, and now?” – a question that many foundry<br />

men are asking – was the title of a presentation given by the former machine developer at<br />

a significant German foundry event lately. CP+T met van der Weiden at EUROGUSS to talk<br />

about the production site of the future, big data, craftmanship, and new partnerships.<br />

What opportunities do the market<br />

situation and current trends offer<br />

foundries?<br />

Foundries that react flexibly and personalize<br />

their production – adapt to their<br />

customers’ requirements – will have<br />

opportunities. But companies must be<br />

enabled to achieve this, and there is still<br />

a lot to do here because personalization<br />

means that products must be manufactured<br />

in the shortest possible time and<br />

their design may change within a year.<br />

We therefore speak of short product life<br />

times. One of the opportunities this<br />

offers is that the foundry engineer can<br />

already provide his or her knowledge to<br />

the customer during the development<br />

phase, instead of the customer coming to<br />

the foundry and asking whether the<br />

design is possible to cast. The product life<br />

cycle actually already starts then, so time<br />

can be saved. This is valuable, because<br />

there is no ‘start-up time’ involved and<br />

production can begin straight away. A<br />

win-win situation for all involved.<br />

Why is the product life cycle getting<br />

shorter?<br />

Because of market demand. The market<br />

now requires less mass production from<br />

foundries. We have transitioned from<br />

mass production to a time of personalized<br />

production, via a period of mass<br />

customization. The market has<br />

developed from a push to a pull market,<br />

so to speak, in which the foundry<br />

strategically aligns its range upon whatever<br />

the customers’ require – and<br />

on-demand production means that<br />

lead times must get shorter. Everything<br />

CP+T Editor Robert Piterek met van der Weiden at EUROGUSS in Nuremberg in January <strong>2020</strong>.<br />

is changing much quicker now than in<br />

the past. Foundries should be prepared<br />

for products that change during the<br />

course of just one year. The engineering<br />

work must already have taken place at<br />

the customer, and the very first cast<br />

should completely meet the customer’s<br />

requirement in order to optimize use of<br />

the production time, eliminating pilot<br />

series or order for serial production,<br />

because in future customers will mainly<br />

want small series. Numerous aspects at<br />

the foundries, however, will have to<br />

change in order to enable them to provide<br />

this flexible personalized production.<br />

Can foundries actually afford<br />

to do this?<br />

Yes and no. Though there are solutions<br />

for the ‘no’ part! The changes in foundries<br />

which are organizational in nature<br />

require smaller investments that are<br />

rapidly amortized, for example software<br />

systems that optimize operating<br />

times and zero-defect methods. Greater<br />

investment in flexible production and<br />

automation that involves more and<br />

innovative smart engineering, can be<br />

carried out gradually – so these investments<br />

can already be amortized with<br />

smaller production series. ‘Big data’<br />

contributes towards product require-<br />

Photos: Martin Vogt<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 7


INTERVIEW<br />

The Dutch foundry expert is convinced that foundries have to adopt personalized<br />

production to survive in the markets.<br />

ments being met from the very first<br />

component onwards, and the defect<br />

rate being driven down to almost zero.<br />

Specialist knowledge, however, is vital<br />

in addition to big data. Specialization<br />

must still make progress in the foundry<br />

sector in order to develop maximum<br />

expertise in a particular product group.<br />

And how about the costs?<br />

Although it requires investment to<br />

modify foundries, the changes to personalized<br />

production offer a good return<br />

on investment. There are ways to avoid<br />

or minimize costs, particularly when<br />

banks are hesitant to provide credits.<br />

For example by entering into partnerships.<br />

How do you picture that?<br />

Foundries can enter into partnerships,<br />

collaborations. If a foundry does not<br />

have the expertise for a particular product<br />

group they should not give up<br />

their own specialization but join forces<br />

with a foundry that does have that specific<br />

know-how and that foundry should<br />

then handle the production. The task of<br />

the foundry that received the enquiry is<br />

to ensure that the end-customer is supplied<br />

with the right high-quality products.<br />

This could also stretch to machining<br />

work or even some pre-assembly,<br />

depending on what was called for. Each<br />

partner’s investment is reduced when<br />

foundries work together. What we hear<br />

from the sector is that more money is<br />

currently coming from partners than<br />

from banks. For the sector, and for its<br />

future, this means that foundries will<br />

become customers of other foundries or<br />

suppliers to end-customers. But foundry<br />

workforces will also have to acquire<br />

additional specialist knowledge because<br />

this is a totally different business model.<br />

What risks do foundries face?<br />

The biggest risk is that foundries will<br />

wait too long. If you wait, you’re late!<br />

The market is not currently saying what<br />

will happen in future. Carmakers are<br />

being cautious, but life must go on in<br />

the foundries. The foundries must work<br />

on personalization now, on zero defects,<br />

added value, uptime, personnel, traceability,<br />

the reduction of run-times, and<br />

environmental issues. Then the foundries<br />

will already be organizationally set<br />

up when it becomes clear which way the<br />

market is heading.<br />

What do foundry customers expect<br />

from foundries?<br />

Foundries must help their customers by<br />

delivering the right quality and quantity.<br />

Foundry customers will increasingly<br />

expect that they no longer need to concern<br />

themselves with the cast product<br />

itself, but simply use it in their production<br />

lines without any problems. To<br />

achieve this, foundries must be capable<br />

of production that is appropriate and<br />

accurate. Big data analysis will make a<br />

contribution, but only if the experience<br />

of the foundrymen is exploited in the<br />

program. There is, however, a shortage<br />

of specialists in many foundries. During<br />

discussions on expansions, modernizations,<br />

or automations we are always<br />

asked how we can improve working conditions<br />

so that foundries can keep and<br />

attract the right employees. An example:<br />

we built an integrated fettling shop in a<br />

foundry in Hungary. The product clusters<br />

used to come from the foundry and be<br />

machined elsewhere at the works – often<br />

by lesser qualified local workers because<br />

of the type of work and the conditions.<br />

The foundry paid these workers by the<br />

piece. This seemed to be a cheap solution,<br />

but it was ultimately more expensive<br />

because the work was hard, uncomfortable<br />

and unpopular. We have<br />

engineered and installed a fettling line<br />

on which one can personalize every<br />

workplace. Table height, lighting and<br />

ventilation can be adapted to the needs<br />

of each individual worker. Now the<br />

foundry can carry out its fettling work<br />

with its own professionals and without<br />

using temporary workers, reducing costs<br />

in the long term. But what is more<br />

important is that the quality of the product<br />

has improved – and that is what<br />

customers notice.<br />

What else should foundries adjust to?<br />

If possible, foundries should be prepared<br />

to become active abroad. It is not<br />

unusual for producers to ask their suppliers<br />

whether they want to follow<br />

them in moving abroad. If the foundry<br />

does not move with the producer they<br />

will find another foundry that will.<br />

<strong>International</strong>ization also brings about<br />

collaborations, for example joint ventures,<br />

because the foundries start off with<br />

a local partner ship and then expand<br />

production when the orders come in.<br />

We built a foundry in China for Georg<br />

Fischer, initially designed for 35,000<br />

tonnes. We expanded it a few years<br />

later so that 60,000 tonnes can now be<br />

produced there. GF was able to maintain<br />

its customer(s) and subsequently<br />

expand.<br />

What do you think about the direction<br />

of development among carmakers?<br />

That’s very difficult to say. My personal<br />

opinion is that the drive of the future<br />

will be electric, but that all vehicles will<br />

be hybrid. Electricity will be used to<br />

propel the car. The electricity will then<br />

be efficiently managed by a generator<br />

that works in the most efficient rpm<br />

range. In the long term I think that the<br />

e-car will win the race, but this will not<br />

happen overnight.<br />

What solutions does Gemco offer<br />

foundries?<br />

Gemco is a foundry consulting, engineering,<br />

planning, management and realization<br />

service provider. The modern<br />

foundries built by Gemco are clean and<br />

8


offer ergonomic workplaces. A high uptime is assured<br />

because our added value consists in engineering foundries<br />

from the foundrymen‘s point of view. For maintenance work<br />

we make sure that the complete plant offers the required<br />

easy accessibility. All the IT interfaces have already been<br />

planned when we develop a foundry. We build about five<br />

foundries simultaneously each year, so we know how to do it<br />

and can develop new layouts without restricting ourselves.<br />

When we are building an iron foundry we can, for example,<br />

exploit experience gained from building an aluminum<br />

foundry if it makes sense to do so. Automation, machining<br />

and pre-assembly are already found everywhere in aluminum<br />

foundries, but the iron foundries need to catch up.<br />

Regarding big data, these systems still require input from<br />

the foundrymen. We have experts that can assist to implement<br />

big data more quickly than when the foundries use<br />

their own resources. Big data offers many possibilities, but<br />

incorrect input results in incorrect output.<br />

What projects is Gemco currently working on?<br />

The engineering and project management for the new Scania<br />

foundry in Sweden is our largest project at the moment. First<br />

pour is due at the end of this year. The equipment is currently<br />

being installed. Modernizing the foundry for Kamaz in Naberezheney<br />

Chelny in Russia is another large project, which is<br />

also about reducing current scrap rates. We have just commissioned<br />

a green sand foundry in Macedonia, MTI Mexico was a<br />

major project, and early in January production started at an<br />

iron foundry we built in Egypt.<br />

We have new projects in the planning phase in Europe,<br />

and we expect some big investment decisions to be made in<br />

the next few months. We are also involved in several green<br />

sand regeneration projects, and the development of the lost<br />

foam process for iron and aluminum casting. There are smaller<br />

projects as well. Gemco not only engineers and builds<br />

foundries on green-field sites, but also handles every form of<br />

modernization – including digitalization of foundries.<br />

Big data implementation is a comparatively new item for<br />

us but more importantly really, are the analyses and recommendations<br />

that must result from it. We also get more and<br />

more questions from casting buyers about development and<br />

quality assurance. These two topics will become increasingly<br />

intertwined in coming years. Gemco offers the appropriate<br />

services for foundries.<br />

How have your sales developed?<br />

We have achieved annual sales of 15 to 20 million euros in<br />

recent years with the 45 permanent staff we now have. We<br />

want to reach 30 million in the coming five years. More and<br />

more foundries worldwide are becoming aware of us.<br />

And what is your own background?<br />

I am the Account Manager for Europe and China. I used to<br />

develop machines myself, so I have a technical background<br />

which is absolutely vital for this work. I joined Gemco in 1997<br />

and concentrated on lost foam until 2001. I then had a lost<br />

foam foundry of my own for a while, but returned to Gemco<br />

after nine years. I am married, and have four children aged<br />

17 to 22.<br />

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Fantastic atmosphere<br />

at EUROGUSS <strong>2020</strong><br />

Escalator to the 20th Die Casting<br />

Conference, which took place parallel<br />

to EUROGUSS in Nuremberg<br />

with industry-specific lectures.<br />

Kathrin Roedl, Messe Nürnberg, Nuremberg<br />

Photos: Martin Vogt, Messe Düsseldorf<br />

Four packed halls, enthusiastic visitors<br />

and satisfied exhibitors – this<br />

was the story of EUROGUSS <strong>2020</strong>.<br />

A total of 754 exhibitors (641 in 2018)<br />

from 36 countries (33 in 2018) showcased<br />

the latest trends in technology,<br />

innovative processes and new products<br />

for the entire die casting supply chain<br />

to around 15,000 trade visitors (15,354<br />

in 2018). The 20th <strong>International</strong> German<br />

Die Casting Congress that was held concurrently<br />

with the exhibition was also<br />

very well attended.<br />

“We are very satisfied with EURO-<br />

GUSS <strong>2020</strong>. The mood among visitors<br />

and exhibitors alike was excellent and<br />

we received a lot of very positive feedback.<br />

There was particular praise for the<br />

quality of the trade visitors. EUROGUSS<br />

is an event that brings together the<br />

right people with one another,” says<br />

Christopher Boss, Director and <strong>International</strong><br />

Product Manager of EUROGUSS.<br />

“All the major foundries and their<br />

sub-suppliers were represented and<br />

covered the sector’s entire capabilities.<br />

This is further proof that EUROGUSS is<br />

the No. 1 gathering for the die casting<br />

industry.”<br />

The event’s partner associations also<br />

describe EUROGUSS <strong>2020</strong> as a resounding<br />

success. “EUROGUSS has enjoyed<br />

incredibly impressive growth and has<br />

now reached an incredibly high standard,<br />

despite the current uncertainty in<br />

the market. Die casting foundries can<br />

look back on three very successful days<br />

when they were able to share<br />

knowledge, nurture contacts and do<br />

good business. EUROGUSS <strong>2020</strong> once<br />

again brought together the entire ‘die<br />

casting family’,” says Hartmut Fischer,<br />

President of the Association of German<br />

Die Casting Foundries (VDD). Dr Timo<br />

Würz, Secretary General of CEMAFON<br />

(European Foundry Equipment Suppliers<br />

Association) draws a similar conclusion:<br />

“The atmosphere in the exhibition<br />

halls was outstanding. Our<br />

exhibiting member companies were<br />

also very satisfied with their participation<br />

in the fair and particularly applauded<br />

aspects like the excellent quality of<br />

the trade visitors, most of whom were<br />

in decision-making roles. EUROGUSS has<br />

proven its effectiveness as a platform,<br />

despite the difficult market environment<br />

at present.”<br />

Satisfied exhibitors and visitors<br />

Of the 754 exhibitors, 56 percent came<br />

from outside Germany from no less<br />

than 36 different countries. The majority<br />

were from Europe, primarily Italy,<br />

Turkey, Spain, Austria and the Czech<br />

Republic.<br />

Exhibitors were satisfied with their<br />

participation in EUROGUSS <strong>2020</strong>. It is a<br />

fixed date in their calendar, because it<br />

brings together the entire European die<br />

casting community. “EUROGUSS is absolutely<br />

the right platform for us to<br />

showcase our company and reach our<br />

target group. This was our first independent<br />

trade fair appearance as cast-<br />

10


EUROGUSS <strong>2020</strong><br />

Above right: Rear axle supports are no<br />

longer purely mechanical, but – like this<br />

example at the Nemak stand – are<br />

increasingly being electrified.<br />

Below right: Jury chief Franz-Josef<br />

Wöstmann presented awards to the<br />

best young professionals in the sector.<br />

Two came from Germany, one from<br />

Spain and one from Mexico.<br />

Above left: Many exhibits<br />

at the stands<br />

show ed lightweight<br />

parts or functionally<br />

integrated components.<br />

Below left: Dashboard<br />

of the new Land Rover<br />

Defender made of diecast<br />

magnesium (3rd<br />

place at the magnesium<br />

die-casting competition)<br />

by GF Casting<br />

Solutions.<br />

werk. We felt very much at home here<br />

and were well looked after. The calibre<br />

of the visitors was absolutely spot-on<br />

and we had a lot of rewarding discussions.<br />

We are impressed by this trade fair<br />

and will definitely be back for EURO-<br />

GUSS 2022,” explains Michael Schran,<br />

Managing Director of castwerk. Peter<br />

Reuther, Managing Director of Striko-<br />

Westofen, also has positive feedback<br />

about his company’s participation in the<br />

event: “Obviously we also have to consider<br />

which trade fairs are worthwhile for<br />

us, but EUROGUSS is always a firm date<br />

in our calendar. It will always be the<br />

most important die casting exhibition in<br />

Europe for us. The aisles were packed,<br />

our stand was well frequented and we<br />

managed to reach our target group.”<br />

This positive trend is also reflected<br />

in the visitor poll. More than 94 percent<br />

of visitors stated that they were satisfied<br />

with what was on offer at EURO-<br />

GUSS <strong>2020</strong>. The trade visitors came primarily<br />

from the automobile industry,<br />

machinery and equipment manufacturing,<br />

mould making workshops, die casting<br />

foundries, electrical and electronics<br />

segments, the furniture hardware<br />

industry and the energy or medical<br />

technology sectors. The top visitor<br />

countries included Germany, Italy, Austria,<br />

Turkey, the Czech Republic, Spain<br />

and Poland.<br />

Impressive supporting<br />

programme<br />

Alongside the exhibition, the 20th<br />

<strong>International</strong> German Die Casting Congress<br />

took place in NCC Ost and was<br />

extremely well attended again this year.<br />

The topics of the presentations covered<br />

a wide range of issues and were very<br />

well received by the trade visitors to<br />

EUROGUSS.<br />

The rest of the supporting programme,<br />

such as Speakers’ Corner in<br />

Hall 8, was also much appreciated. The<br />

exhibition forum offered numerous presentations<br />

on additive manufacturing,<br />

surface technology, and Industry 4.0.<br />

This is also where the EUROGUSS Talent<br />

Awards were presented. This award is<br />

designed for emerging talent in the die<br />

casting industry and was making its<br />

debut in <strong>2020</strong>.<br />

The next EUROGUSS will take place<br />

from 18 to 20 January 2022 at Exhibition<br />

Centre Nuremberg.<br />

More on the die-casting competition<br />

for aluminium, zinc and magnesium at<br />

EUROGUSS in our news section.<br />

Die casting worldwide<br />

NürnbergMesse is not just the organizer<br />

of EUROGUSS but offers companies<br />

other platforms in the major international<br />

foundry markets through its diverse<br />

network of trade fairs in the core global<br />

die casting markets. The aim is to provide<br />

access to new markets and bring<br />

companies together.<br />

The EUROGUSS family is represented<br />

in China, India, Mexico and Thailand. The<br />

next event is CHINA DIECASTING, China’s<br />

leading die casting exhibition in Shanghai<br />

from 15 to 17 July <strong>2020</strong>. Following its<br />

launch in 2018, EUROGUSS Mexico will<br />

be held in Guadalajara from 10 to 12<br />

November <strong>2020</strong>. Finally ALUCAST, India’s<br />

leading fair for die casting, takes place in<br />

Chennai from 3 to 5 December <strong>2020</strong>.<br />

www.euroguss.de/international<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 11


MOLD AND COREMAKING<br />

Photos and Graphics: Hüttenes Albertus<br />

With Arkopal RP, Hüttenes Albertus<br />

offers a new coating series<br />

especially for additive manufactured<br />

molds and cores.<br />

Coatings for additively<br />

manu factured molds and cores<br />

3-D printing gives designers unprecedented freedom in designing molds and cores. Since<br />

printed cores differ significantly in some important properties from blown cores, there<br />

are specific requirements placed on the coatings. HA has developed a special series of<br />

Arkopal RP (Rapid Prototyping) coatings for the 3-D printing process, which are already<br />

successfully being used for actual cast parts. They provide a smooth surface free of casting<br />

defects in aluminium, iron and steel castings.<br />

Ekaterina Potaturina, Hüttenes-Albertus Düsseldorf, and Klaus Seeger, Hüttenes-Albertus Hannover.<br />

In the foundry industry, additive<br />

manufacturing makes it possible to<br />

produce prototypes and small batches<br />

without incurring high tooling and storage<br />

costs. Molds and cores are preferably<br />

produced 2using the binder jetting<br />

process. Printed sand cores however,<br />

have particular process-induced properties.<br />

This means that products specially<br />

adapted to the process are required.<br />

Printed cores and molds are generally<br />

used in coated form not only in steel<br />

and grey cast iron casting, but also in<br />

aluminium casting.<br />

Both the special surface structure<br />

and the complexity of printed cores<br />

require coatings with distinct application<br />

properties. At the same time, the<br />

coatings themselves must be highly<br />

effective against casting defects such as<br />

penetration or finning (veining).<br />

The axis-dependent strength and<br />

compaction of the sand layers, as well<br />

as the surface structures of the poured<br />

and subsequently resin-bonded molding<br />

materials also play an important role.<br />

The axis-dependent differences in<br />

strength lead, among other things, to<br />

an increased susceptibility to finning.<br />

Using commercially available coatings,<br />

finning can be reduced, but often not<br />

satisfactorily avoided. In order to find<br />

suitable solutions, the coating properties<br />

must be specifically adapted to the<br />

special properties of additive molds and<br />

cores.<br />

The following shows a variety of<br />

examples to demonstrate the effectiveness<br />

of the innovative Arkopal RP coatings<br />

developed by HA to avoiding casting<br />

defects such as finning, when<br />

casting additively manufactured cores.<br />

12


a b c<br />

Figure 1: Left: fin mold, Middle: a printed vertical core (S core); Right: a printed horizontal core (L core).<br />

a b c<br />

Figure 2: Left: rough cast surface formed by an uncoated core surface. Middle: cast surfaces each with the specifically formed finning<br />

direction; Right: smooth surface, free of casting defects achieved with the coating Arkopal RP 200 (layer thickness = 200 µm).<br />

What is additive manufacturing<br />

or 3-D printing?<br />

Various processes are in use in the field<br />

of additive manufacturing. One of<br />

these methods is the binder jetting process.<br />

In this additive manufacturing process,<br />

cores or molds are produced using<br />

a one-component or two-component<br />

binder system and a desired sand.<br />

In the case of the two-component<br />

binder system, the sand is first coated<br />

with the activator in a mixer. The recoater<br />

then applies 4-8 layers of sand to<br />

the bottom of the molding box.<br />

When using a single-component system,<br />

unbound sand is used in this process<br />

step.<br />

The print head then selectively<br />

prints a first layer of binder on the activated<br />

or unbound sand. In the single-component<br />

system, a heating lamp is<br />

additionally used on the recoater to<br />

accelerate the hardening process. The<br />

building platform in the job box is<br />

lowered by one layer and another layer<br />

is applied. After finishing a layer, the<br />

process starts again and is repeated<br />

until the core or mold is completely<br />

printed. Once the printing process is<br />

complete, the unbound sand is removed<br />

from the job box using an industrial<br />

vacuum cleaner, brushes and compressed<br />

air. The core or mold is then removed<br />

from the job box and, if necessary,<br />

post-hardened until the final strength is<br />

reached. De-pending on the binder system<br />

used, the loose sand can be reused.<br />

Arkopal RP (Rapid Prototyping):<br />

Product Development and Studies<br />

HA’s Center of Competence, in the<br />

course of the development of special<br />

coatings for 3-D printing, has thoroughly<br />

examined the role of coatings in<br />

printed cores and how to comply with<br />

the special requirements of the 3-D<br />

printing process.<br />

In the first step, the coatings for<br />

additively manufactured molds and<br />

cores were characterized in benchmark<br />

tests for iron and steel casting. For this<br />

purpose, test molds developed to<br />

demonstrate finning (see Figure 1) were<br />

used in order to be able to better compare<br />

the defect pattern on the cast<br />

parts after casting.<br />

To additionally examine the impacts<br />

of the printing direction, the cores<br />

were each printed in two different<br />

directions: vertical and horizontal (see<br />

Figure 1) [1].<br />

The casting was produced in the first<br />

benchmark test with iron at a casting<br />

temperature of approx-imately 1430 °C.<br />

The sample compression style cores<br />

were manufactured in accordance with<br />

HA specifications (diameter 50 mm).<br />

The average grain size of the sand used<br />

was 0.14 mm (sand GS 14) and the<br />

annealing loss was 1.43 % – using a<br />

phenol-containing binder as a one-component<br />

system. The strength value<br />

achieved in the x-direction was 520 N/<br />

cm2, in the y-direction 430 N/cm 2 and in<br />

the z-direction 190 N/cm 2 . After casting,<br />

the iron parts were sectioned in halves<br />

and cleaned of adhering sand residues<br />

with compressed air. The following pictures<br />

show one of the sectioned halves<br />

with the surfaces on the core side.<br />

Influencing factors: packing<br />

density and printing direction<br />

During the tests, it was found that the<br />

uncoated cores had no casting defects<br />

after casting, such as finning (see<br />

Figure 2, left). In the conventional core<br />

shooting process, the finning is caused<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 13


MOLD AND COREMAKING<br />

Application in aluminium casting<br />

The study included only a small number<br />

of tests with printed cores in aluminium<br />

casting. It was observed that the situation<br />

for the casting of aluminium is significantly<br />

different because of the<br />

lower casting temperatures of 660-<br />

750 °C no finning (veining) occurs.<br />

Generally, conventionally manufactured<br />

cores for aluminium parts are often not<br />

coated at all. Due to the smooth core<br />

surface, acceptable casting surfaces are<br />

achieved here even without a smooth<br />

protective coating layer.<br />

However, cores produced using the<br />

3-D printing process have significantly<br />

rougher surfaces and layer grooves<br />

from the printing process. After casting,<br />

the casting surface is also correspona<br />

b c<br />

Figure 3: Left: casting surface after coating by painting (layer thickness = 200 µm). Middle and Right: casting surface after coating by dipping<br />

(layer thickness middle = 200 µm, right = 300 µm); Conventional water-based zirconium coating.<br />

by a high packing density of the sand<br />

grains, combined with other parameters.<br />

During the casting process, the<br />

phase transition from alpha- to betaquartz<br />

takes place and the sand grains<br />

need space to expand [2].<br />

With printed cores, on the other<br />

hand, the packing density is not as high<br />

as with shot cores as the sand is applied<br />

in layers. The packing density depends<br />

on the printing direction, and the resulting<br />

strengths after the binding process<br />

also depend on the printing direction.<br />

When uncoated cores are used, however,<br />

the cast surfaces are very rough due<br />

to the sand structure (see Figure 2, left).<br />

The study showed that the formation<br />

of finning depends on the one<br />

hand on the core geometry and on the<br />

other hand on the printing direction<br />

(see Figure 2, middle).<br />

Other influencing factors:<br />

Application method and layer<br />

thickness<br />

In further experiments, it was found<br />

that several factors play a major role in<br />

suppressing the tendency of finning:<br />

the printing direction, the core geometry,<br />

the application method, but also<br />

a<br />

b<br />

the composition and the layer thickness<br />

of the coating.<br />

The test results show that the casting<br />

defect is significantly less pronounced<br />

when brush applied compared to<br />

dipping (see Figure 3). One reason for<br />

this is suspected to be the penetration<br />

behaviour of the coating into the core.<br />

In general, it is proven that higher layer<br />

thicknesses provide a better casting surface<br />

with the same application characteristics.<br />

Application in steel casting<br />

In steel casting, the requirements for<br />

the coatings are similar to those in iron<br />

casting, but an even higher temperature<br />

resistance is required. Steel is<br />

usually cast between 1480 and as high<br />

as 1750 °C. The experiments once again<br />

used special test molds developed to<br />

demonstrate finning (see Figure 1, left)<br />

and round compression cores. The sand<br />

mixture contained in this benchmark<br />

test was also GS 14, but a two-component<br />

furan binder system was used.<br />

The test mold was cast at approximately<br />

1480 °C. The results show that in<br />

the case of uncoated cores, there is only<br />

a small finning tendency combined with<br />

Figure 4: Left:<br />

casting surface<br />

(uncoated core).<br />

Right: casting surface<br />

(coated core,<br />

800 µm).<br />

sand adhesion (see Figure 4). The surface<br />

roughness of the uncoated cores<br />

was at an Ra value of approximately 10<br />

µm. In the case of coated cores, the surface<br />

roughness was between 3-5 µm –<br />

depending on the respective coating<br />

composition and the layer thickness<br />

achieved during application.<br />

In view of the test results, it could<br />

also be seen that in steel casting, in parallel<br />

with iron casting, both the direction<br />

of pressure and the layer thickness<br />

play a major role in the occurrence of<br />

casting defects. In tests also carried out<br />

at the HA Center of Competence, more<br />

finning was detected in the vertical<br />

printed cores (S cores) than in the horizontal<br />

printed cores (L cores).<br />

Additionally, the higher layer thicknesses<br />

produced significantly smoother<br />

(Ra value of 3-4 µm) and defect free<br />

surfaces could be achieved with regard<br />

to finning. In principle, the use of a perfectly<br />

matched coating greatly minimizes<br />

both finning and sand adhesions.<br />

14


a b c<br />

Figure 5: Left: casting surface S core (coated, layer thickness = 300 µm). Middle and<br />

Right: casting surface L core (finished, layer thickness middle = 300 µm, right = 800 µm)<br />

conventional water-based coating.<br />

a b c<br />

Figure 6: Left: Cast surface L core, coated with Arkopal RP E (layer thickness = 300 µm).<br />

Middle: Casting surface L core, coated with Arkopal RP G (layer thickness 300 µm). Right:<br />

S core, also coated with Arkopal RP G (layer thickness 300 µm).<br />

dingly rough. In order to achieve a<br />

smooth casting surface, it is therefore<br />

advisable to coat the cores or molds<br />

before casting. Sand adhesion can also<br />

be avoided by applying a coating.<br />

Summary<br />

The use of different coatings for additively<br />

manufactured cores and molds<br />

revealed significant variations in the<br />

casting results. Due to the axis-dependent<br />

strengths, the uncoated cores<br />

achieve positive results with regard to<br />

casting defects such as finning. However,<br />

the use of coatings specially<br />

developed for 3-D printing can prevent<br />

the formation of rough casting surfaces<br />

and sand adhesion.<br />

The study carried out at HA has<br />

shown that several factors in the 3-D<br />

printing process have an influence on<br />

the casting defect characteristics. The<br />

core geometry and the printing direction<br />

play an important role in iron and<br />

steel casting. According to our findings,<br />

the finning is more pronounced in a<br />

vertically printed core compared to a<br />

horizontally printed core. The chemical<br />

composition and processing properties<br />

are important criteria for coating selection<br />

with regard to avoiding casting<br />

defects. The application process and the<br />

resulting layer thickness also play a role.<br />

With the aid of the optimum coating,<br />

casting defects such as finning (veining)<br />

can be avoided and smooth casting surfaces<br />

can be produced.<br />

Due to the lower casting temperatures,<br />

other requirements for the coatings<br />

are important in aluminium casting. The<br />

focus here is on surface quality and the<br />

avoidance of sand adhesion. The surface<br />

quality is strongly influenced by<br />

the printed core. By using special coatings,<br />

sand adhesion can be minimized<br />

and smooth surfaces achieved.<br />

The findings described above have<br />

been incorporated into the development<br />

of Arkopal RP (Rapid Prototyping)<br />

series coatings. Foundries that use 3-D<br />

printing for their molds and cores can<br />

rely on products specifically developed<br />

for the process. The coating experts at<br />

HA will be happy to advise you.<br />

Dr.-Ing. Ekaterina Potaturina, Produkt<br />

Manager Coatings, Hüttenes-Albertus<br />

Chemische Werke GmbH, Düsseldorf<br />

and Dr. Klaus Seeger, Chemist, Hüttenes-Albertus<br />

Chemische Werke GmbH,<br />

Hannover.<br />

Pneumatic conveying<br />

technology<br />

For dry, free-flowing, abrasive and<br />

abrasion-sensitive material<br />

Core sand preparation<br />

technology<br />

For organic and inorganic processes,<br />

turn-key systems including sand,<br />

binder and additive dosing and<br />

core sand distribution<br />

Reclamation technology<br />

Reclamation systems for<br />

no-bake sand and core sand,<br />

CLUSTREG® for inorganically<br />

bonded core sands<br />

Shock wave technology<br />

CERABITE ®<br />

clean castings<br />

The reliable solution for the<br />

removal of residual sand<br />

and coatings of<br />

demanding castings<br />

KLEIN Anlagenbau AG<br />

KLEIN Stoßwellentechnik GmbH<br />

a subsidiary of KLEIN Anlagenbau AG<br />

Obere Hommeswiese 53-57<br />

57258 Freudenberg | Germany<br />

Phone +49 27 34 | 501 301<br />

info@klein-group.eu<br />

www.klein-ag.de<br />

www.stosswellentechnik.de


Ecoform – a concept for the<br />

hand-molding of smaller series<br />

Hand-molded sand casting offers a freedom and variety of design that is found in almost<br />

no other production process. The Ecoform concept with molding box geometries adapted<br />

to the casting – which ensures optimization of the relationship between the molding<br />

material and the casting – now offers more economical hand-molding than ever.<br />

Jens Müller-Späth, GUT Giesserei Umwelt Technik GmbH, Freudenberg<br />

Photos: GUT<br />

16


MOLD AND COREMAKING<br />

The grid network of steel bars in a round Ecoform molding box is positioned close to<br />

the component so that it can also take over the heat transport function.<br />

An Ecoform molding box for pro ducing<br />

a turbine blade.<br />

3-D representation<br />

of a round Ecoform<br />

molding box.<br />

The hand-molding casting process<br />

is utilized for very different geometries,<br />

sizes and materials that<br />

foundries use to create impressive products<br />

for a wide range of industrial sectors.<br />

The weight of the castings ranges<br />

from a few kilograms to well over 100<br />

tonnes. Free-flowing foundry molding<br />

materials are used in the production of<br />

hand-molded castings – mainly based<br />

on quartz sand and generally binding<br />

with synthetic resins. The binders are<br />

added to the molding material in<br />

throughflow rotary mixers. The mixed<br />

molding material is added to the pattern,<br />

limited with molding boxes and, if<br />

necessary, compressed manually or with<br />

mechanical support and – after hardening<br />

of the sand/binder mixture – a<br />

mold or mold half is created that can<br />

then be handled in the hardened state,<br />

e.g. using an overhead crane.<br />

The function of the mold box<br />

and mold material<br />

Foundry molding boxes and the molding<br />

material itself have to fulfil a variety<br />

of functions and tasks. While the<br />

molding boxes offer appropriate transport,<br />

they must also prevent the molding<br />

sand from escaping from the mold<br />

when in its elastic state (boxes are therefore<br />

‘molding material limiters’) as<br />

well as provide stability functions. This<br />

is particularly the case where casting<br />

materials generate additional forces or<br />

pressure on hardening (e.g. using cast<br />

iron with spherical graphite).<br />

The quantity of the molding material<br />

used depends greatly on the size of<br />

the molding box because each casting<br />

requires a particular molding material<br />

layer between the metal and the molding<br />

box that must ‘withstand’ hardening<br />

of the casting in thermal terms.<br />

The molding box is preferably too large<br />

than too small, to ensure that the mold<br />

does not leak. The molding box park of<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 17


MOLD AND COREMAKING<br />

„The Ecoform technology<br />

enables hand molding<br />

with mold geometries<br />

adapted to the casting<br />

geometry. This results in<br />

an optimum ratio of mold<br />

material to metal“<br />

any foundry is finite, and the optimum<br />

box is only rarely available due to the<br />

variety of products and range of casting<br />

materials.<br />

The advantages of modified<br />

molding boxes<br />

The ratio of sand to casting material has<br />

a major effect on the production cost of<br />

a casting. In this regard, one must not<br />

merely consider the cost of the sand<br />

and binder but much more besides. The<br />

necessary cooling time of the metal in<br />

the mold largely defines occupation of<br />

production areas, so shortened cooling<br />

times would create the potential for<br />

increased production. Another aspect<br />

regarding the use of molding material<br />

is its not inconsiderable weight, particularly<br />

for larger components. Taking a<br />

hub for a wind turbine as an example<br />

demonstrates that a very unfavorable<br />

sand/casting material ratio is created<br />

using conventional molding technology<br />

due to the product geometry. 100 tonnes<br />

or more of molding material is<br />

often required for a net casting weight<br />

of 10 tonnes. This can soon load to<br />

capacity – or even overload – a crane, so<br />

weight savings are very welcome in this<br />

context too. The wind turbine hub is an<br />

ideal example of the Ecoform concept<br />

because the casting is often large and<br />

produced in series.<br />

The Ecoform technology described<br />

here is characterized by the use of special<br />

molding boxes that are adapted to<br />

the pattern contour and stabilized by a<br />

grid network of bars. The steel bars are<br />

individually arranged so that they are<br />

positioned close to the component and<br />

can thus also take on the heat transport<br />

function. As a result, it is also no longer<br />

necessary to completely fill molds all<br />

the way to the brim of the molding<br />

box, but instead to fill the molding<br />

material layer like a bowl within the<br />

18


A round Ecoform molding<br />

box by GUT Giesserei Umwelt<br />

Technik GmbH.<br />

grid of bars in the box. A completely<br />

new technical variable is created –<br />

namely, differing molding material<br />

strengths paired with an adapted grid<br />

of bars at different positions of the casting<br />

that permit the technologists to<br />

work without chills, etc. Whereby minimum<br />

distances of 30 mm between the<br />

bars and the pattern have been technically<br />

confirmed. Drill holes in the welded<br />

bars give the hardened molding<br />

material a stable hold.<br />

The Ecoform process not only significantly<br />

reduces the amount of molding<br />

material used – other positive effects<br />

include, for example:<br />

> lower molding material and binder<br />

costs<br />

> elimination of cooling or reinforcing<br />

bars<br />

> shorter cooling times in the mold<br />

> lower internal stress in the casting<br />

> lower mold weight<br />

> elimination of support iron due to<br />

clamped box halves<br />

NEW<br />

Temperature control<br />

multiFlow modular<br />

160 °C<br />

A poured-off molding box. Compared to the<br />

compact mold, a small layer of molding material<br />

is required due to the grid network of bars.<br />

Molds for wind turbine rotor hubs – left the<br />

Ecoform, right a conventional mold.<br />

Summary<br />

The Ecoform technology presented here<br />

enables hand molding with mold geometries<br />

adapted to the geometry of the<br />

casting. This results in an optimum or<br />

minimum ratio of mold material to<br />

metal. This is possible because of the<br />

use of welded molding boxes with a<br />

grid network of bars, in which only a<br />

small molding material layer is inserted<br />

in relation to the compact mold. The<br />

grid of bars provides the necessary mold<br />

stability and accelerates cooling of the<br />

casting. The elimination of cooling bars<br />

or load weights results in shorter mold<br />

production times. The use of special<br />

molding boxes is sensible in the case of<br />

geometrically similar components or for<br />

appropriate batch and series sizes. In<br />

addition to the cold self-hardening molding<br />

materials based on furan or phenol<br />

resins widespread in Germany, the<br />

process can also be used with all<br />

self-hardening molding material systems.<br />

www.gut-gmbh.de<br />

www.eco-form.de<br />

Jens Müller-Späth, GUT Giesserei<br />

Umwelt Technik GmbH, Freudenberg,<br />

Germany<br />

www.regloplas.com


MELTING SHOP<br />

20


StrikoMelter during installation at Hattori Diecast. With<br />

the melting furnace, gas consumption and metal loss<br />

can be significantly reduced compared to older systems.<br />

„The company has benefitted form less<br />

clean ing and its emgineers have been able<br />

to conduct more maintenance in-house.“<br />

New furnace halves energy<br />

costs for Japanese foundry<br />

Hattori Diecast has become the first Japanese company to order and install a<br />

StrikoMelter melting furnace from StrikoWestofen.<br />

Peter Reuther, Striko Westofen, Gummersbach<br />

FOTOS: NORICAN GROUP<br />

Eyeing efficient growth<br />

Established in 1963, Hattori Diecast produces<br />

automotive parts for major<br />

brands including Toyota. The family run<br />

business specialises in aluminium parts<br />

such as computer housings, air-bag sensors,<br />

sump valves, accumulators and<br />

cylinders. Located near to Nagoya, the<br />

company has more than 100 employees.<br />

Unsatisfied with a melting furnace<br />

that had been in operation at its plant<br />

for 15 years, Hattori decided to decommission<br />

it and began looking for a new<br />

furnace that would support its growth<br />

and productivity ambitions and reduce<br />

key monthly melt shop costs, from gas<br />

consumption to maintenance.<br />

The team at Hattori were familiar<br />

with StrikoWestofen through the<br />

Westomat dosing furnace already operating<br />

in the factory, and also thanks to<br />

its wider reputation in Japan where<br />

over 400 dosing furnaces have been<br />

sold.<br />

With an additional understanding of<br />

the local insight and support offered by<br />

Norican Group which has operated in<br />

Japan for over 30 years – and keen to<br />

gain a march on competitors by seizing<br />

the advantages of world class technology,<br />

Hattori invited StrikoWestofen to<br />

tender for the project.<br />

Figure 1: Preparations for lifting the melting unit by crane<br />

A trip to China – seeing<br />

is believing<br />

Hattori was impressed with StrikoMelter’s<br />

technical credentials, in particular<br />

its ability (thanks to clever shaft geometry<br />

and special burner technology) to<br />

combine preheating, heating and melting<br />

processes in one furnace shaft to<br />

maximise efficiency and minimise metal<br />

loss.<br />

Happy with performance on paper,<br />

the team was keen to see their proposed<br />

new furnace – a StrikoMelter 1 MH<br />

II-B 4000/1500, in person. The result? A<br />

trip to China. During the visit, Hattori<br />

could see the furnace’s performance in<br />

live operating conditions and received a<br />

show and tell of its PLC. The results<br />

impressed and the decision was made.<br />

Capitalising on Norican expertise<br />

Before the installation even began,<br />

Hattori experienced the benefit of<br />

working with the wider Norican Group.<br />

For example, a limitation on the transport<br />

of goods exceeding 45 tonnes<br />

with in Japan meant that complex permissions<br />

needed to be obtained. These<br />

were secured thanks to Norican’s<br />

on-the-ground expertise. In fact, Norican’s<br />

detailed knowledge of Japanese<br />

government financial support structures<br />

also reduced the initial cost of Hattori<br />

purchasing the melting furnace.<br />

Norican went on to provide on-theground<br />

knowledge, logistical support,<br />

engineering expertise and<br />

warehousing space for parts for the<br />

duration of the project.<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 21


MELTING SHOP<br />

Figure 2: The installation took place over the roof. Parts of the wall<br />

and roof of the factory hall had to be removed for this.<br />

Figure 3: Fully installed Strikomelter in the die casting foundry.<br />

The installation was completed within a week.<br />

Two weeks to a cleaner,<br />

leaner melting process<br />

Project constraints meant StrikoWestofen<br />

had just over two weeks (16 days)<br />

to complete the installation which<br />

included the removal of the old<br />

machine and sintering. Four engineers<br />

worked together on the project fulltime.<br />

The installation work began with<br />

the removal of the old furnace and the<br />

craning in of the new StrikoMelter.<br />

These tasks required sections of wall<br />

and the factory roof to be taken out<br />

and rebuilt during windy, rainy and<br />

even snowy December conditions.<br />

Impeccable project coordination combined<br />

with the team’s dedication meant<br />

this was all completed within a week<br />

(Figures 1-3).<br />

Another logistical challenge was<br />

the size of the Hattori plant, which at<br />

10,220 m 2 is small for an aluminium<br />

foundry. With parts of the plant remaining<br />

in operation, the installation<br />

team had to work around staff, which<br />

was made difficult by the limited<br />

space. Overcoming all challenges, the<br />

melting furnace installation and refurbishment<br />

works were completed on<br />

time. As soon as equipment was operational,<br />

the team at Hattori received<br />

qualitative training on how to use the<br />

StrikoMelter. To ensure high-performance<br />

is maintained, Norican will visit<br />

Hattori every week for the first 3<br />

months to monitor each status and<br />

optimise performance.<br />

Transforming operations -<br />

and the bottom line<br />

Hattori immediately felt the impact of<br />

its investment. Overall, the StrikoMelter<br />

has halved furnace-related energy costs<br />

thanks to a 43% reduction in gas<br />

consumption and the cutting of metal<br />

loss from 6% to just 2% when compared<br />

with the previous melting furnace.<br />

It isn’t just these headline figures that<br />

are pleasing Hattori. The company has<br />

benefitted from less cleaning and its<br />

engineers have been able to conduct<br />

more maintenance in-house, such as<br />

replacing the air fan filter and checking<br />

the bath temperature.<br />

Mr. Sasaki, Casting Department Subsection<br />

Leader at Hattori Diecast said:<br />

“Remaining a leader means investing<br />

in the very best technology, so when<br />

looking to replace our melting furnace,<br />

we wanted a machine that would keep<br />

us at the forefront of diecasting – globally.<br />

“While the savings unlocked by our<br />

new StrikoMelter speak for themselves,<br />

it is also important to note that the<br />

quality of parts and simple operation of<br />

the machine both exceeded our expectations.<br />

We would like to thank Norican<br />

Group for ensuring a smooth installation<br />

and for helping us to streamline<br />

our business.”<br />

Yoichiro Sakai, OEM sales, Norican<br />

Group, Japan said: “The results that<br />

Hattori is benefitting from will not go<br />

unnoticed by Japanese foundries. The<br />

StrikoMelter offers huge performance<br />

gains that cannot be ignored. We look<br />

forward to helping many more Japanese<br />

operators to seize the benefits of<br />

market leading StrikoMelter technology.”<br />

Peter Reuther, Managing Director<br />

Striko Westofen, Gummersbach<br />

22


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MELTING SHOP<br />

Photo: Leichtmetallgiesserei Bad Langensalza<br />

A lot of energy is required for melting and heating in foundries. Significant savings are possible with a new burner technology.<br />

New foundry technology cuts<br />

energy costs and CO 2<br />

emissions<br />

The metalworking industry and foundries in particular consume extreme amounts<br />

of energy and thus produce large amounts of CO 2<br />

as well. In the future, light metal<br />

foundries will be able to cut their energy costs related to production by as much<br />

as sixty percent and CO 2<br />

emissions by as much as eighty percent. A new technology<br />

developed at the Fraunhofer Institute in Magdeburg together with other partners<br />

will make this possible. This world first was presented for the first time ever at the<br />

Hannover trade fair in 2019.<br />

Stefan Scharf, Fraunhofer-Institut IFF and Otto-von-Guericke-Universität Magdeburg;<br />

Jörg Tom Felde, promeos, Nürnberg; Hagen Stein, Leichtmetallgiesserei Bad Langensalza<br />

Unconventional New Technology<br />

Foundries in general and nonferrous<br />

foundries in particular currently have to<br />

repeatedly transfer and constantly heat<br />

melt charges in a gradual process. In<br />

addition to open-flame gas burners,<br />

electricity is predominantly used to melt<br />

and heat the metal, despite its obvious<br />

economic and environmental drawbacks.<br />

Such conventional methods of<br />

process control and the related transfer<br />

processes detract from casting quality<br />

and necessitate complex actions to<br />

handle the melt. Established processes<br />

typically have correspondingly high<br />

energy and resource requirements.<br />

With their new approach, the researchers<br />

are banking on an unconventional<br />

but highly efficient method instead.<br />

A newly developed burner system<br />

that uses the energy carrier gas for<br />

heating delivers control system performance<br />

and homogeneity previously<br />

only seen in electrically heated units<br />

(Figure 1). The waste heat produced<br />

can be recovered reliably for the first<br />

time ever. The new design based on<br />

24


a<br />

b<br />

Photo: University of Magdeburg<br />

Graphics: Promeos<br />

Figure 1: Burner head consisting of 4 x 5 burner cells (a), burner unit<br />

consisting of 4 burner heads (b).<br />

Figure 2: Mobile ladle with „heat dock“.<br />

this development envisions melting,<br />

transferring and holding the metal in<br />

fully moveable transfer crucibles in the<br />

future. This will make it possible to cut<br />

the multistage process steps necessary<br />

currently necessary down to just one<br />

process step. The movable crucibles are<br />

supplied with the requisite thermal<br />

energy at so-called “heat docks” operated<br />

with the new burner (Figure 2).<br />

This eliminates the drawbacks of current<br />

alternative systems.<br />

An equally new sensor system that<br />

monitors the process continuously and<br />

completely establishes the basis for<br />

connected process control in the<br />

foundry industry, which will be automated<br />

in the future. This ultimately lightens<br />

workers’ workloads especially<br />

during particularly hazardous works<br />

steps and enables companies to transform<br />

manufacturing digitally.<br />

Higher Quality and Lower<br />

Energy Consumption<br />

“This will enable light metal foundries<br />

for which the new system was<br />

developed to cut energy costs by sixty<br />

percent and related CO 2<br />

emissions by as<br />

much as eighty percent. At the same<br />

time, this will increase manufacturing<br />

flexibility and product quality significantly,”<br />

says Dr. Stefan Scharf. “In principle,<br />

the design is transferable to any<br />

foundry and its component solutions<br />

are transferable to other industries as<br />

well.”<br />

According to the German Foundry<br />

Association (BDG), nearly 340 companies<br />

in the light metal foundry sector<br />

(nonferrous metal foundries) produce<br />

around 1.7 million tons of nonferrous<br />

metal casts in Germany. Around one<br />

million tons of CO 2<br />

are produced in the<br />

process. Energy costs presently add up<br />

to roughly twenty-five percent of their<br />

gross value added. Altogether, the<br />

foundry industry with around 80,000<br />

employees in Germany generates<br />

around 13 billion euros a year.<br />

The technology was developed in a<br />

research consortium consisting of the<br />

Fraunhofer IFF, Otto von Guericke University<br />

Magdeburg, promeos GmbH and<br />

Leichtmetallgießerei Bad Langensalza.<br />

The project named ETAL is being funded<br />

by the German Federal Ministry for<br />

Economic Affairs and Energy.<br />

The researchers presented the mass<br />

manufacturable prototypes of the new<br />

transfer crucibles together with the heat<br />

dock for the first time ever at the Fraunhofer-Gesellschaft’s<br />

booth at Hannover<br />

Messe 2019. Right after the trade show,<br />

they were brought to the first implementation<br />

tests at participating companies.<br />

The manufacturable product should<br />

be on the market in the course of <strong>2020</strong>.<br />

Dr.-Ing. Stefan Scharf, Fraunhofer-Institut<br />

für Fabrikbetrieb und -automatisierung<br />

IFF and Otto-von-Guericke-Universität<br />

Magdeburg; Dipl.-Ing. Jörg tom<br />

Felde, promeos GmbH, Nürnberg; Dipl.-<br />

Ing. Hagen Stein, Leichtmetallgiesserei<br />

Bad Langensalza GmbH<br />

www.iff.fraunhofer.de/en.html<br />

https://promeos.com<br />

www.uni-magdeburg.de<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 25


PRESSURE DIE CASTING<br />

For today‘s companies digitalization and networking of production facilities are indispensable to be successful. Smartfoundry.solutions<br />

is a full-service solution that provides die casting foundries the necessary tools and know-how.<br />

Digitalization solutions that<br />

improve the efficiency of die<br />

casting foundries<br />

Photos and graphics: Oskar Frech<br />

In everyday operation, manufacturing companies are constantly confronted with challenges<br />

that have to be solved as quickly and efficiently as possible. Especially for die casting<br />

foundries, which rely on highly demanding and sophisticated production processes,<br />

the achievement of maximum production efficiency is a never-ending task. Consistent<br />

further development of digitalization towards the concept of Industry 4.0 helps die casting<br />

shops to cope more successfully with these challanges and enhance the flexibility of<br />

their production systems. smartfoundry.solutions from Oskar Frech GmbH und Co. KG is<br />

a service and solution portfolio for a customized digitalization of die casting foundries.<br />

Alexander Marks and Kai Kerber, Oskar Frech, Schorndorf<br />

26


100%<br />

Capacity<br />

(unsold)<br />

Stoppages<br />

(unscheduled)<br />

Stoppages<br />

(scheduled)<br />

Figure 1:<br />

OEE and its loss<br />

factors.<br />

Short stoppages<br />

Slow cycles<br />

Out-of-spec<br />

Initial castings<br />

Final inspection<br />

~65-85%<br />

Planned production time<br />

(Shifts on calendar days,<br />

minus weekends, holidays,<br />

annual closing, …)<br />

Availability Speed Quality<br />

OEE<br />

(Zero Defect Production)<br />

At GIFA 2019, Oskar Frech GmbH<br />

and Co. KG unveiled its new<br />

product portfolio smartfoundry.<br />

solutions. The modular software applications,<br />

services and shopfloor-compatible<br />

hardware solutions extend the<br />

product portfolio of a traditional<br />

machinery manufacture with IT products<br />

for die casters made by die casters.<br />

The services for the die casters<br />

include the administration of the systems<br />

components, the maintenance of<br />

hardware and software services, as well<br />

as the IT security management. With<br />

smartfoundry.solutions, die casters<br />

access a modularly structured service<br />

package, enabling them to implement<br />

individually matching digitalization<br />

building blocks into their companies.<br />

OEE<br />

(Zero Defect<br />

Production)<br />

85%<br />

75%<br />

65%<br />

0 to


PRESSURE DIE CASTING<br />

Adaptability<br />

How can autonomous<br />

reactions be achieved?<br />

Predictability<br />

What is going to happen?<br />

Transparency<br />

Why is it happening?<br />

Visibility<br />

What is happening?<br />

Digitalization<br />

and networking<br />

Digitalization Industry 4.0<br />

2018 2019 <strong>2020</strong> 2021<br />

ASSISTANTS<br />

VIRTUAL FOUNDRY<br />

GUARDS<br />

COMMUNITY APPLICATIONS<br />

SERVICES<br />

VISUALS + ENTRY POINTS<br />

EQUIPMENT<br />

INTERFACES<br />

DATA ACQUISITION<br />

Cloud Storage<br />

smartfoundry.platform<br />

Figure 3: Industry 4.0 Maturity Index<br />

and related smartfoundry.solutions<br />

product groups.<br />

Entry Points<br />

Data Connector<br />

Visuals<br />

sive assistance systems) and Assistants<br />

(active assistance systems), together with<br />

digital twin of the die casting plant<br />

(Virtual Foundry), belong to the Adaptability<br />

level, the highest index level of the<br />

Industry 4.0 maturity index.<br />

Encrypted data transfer<br />

The smartfoundry.network builds on the<br />

Ethernet network, which is used for<br />

remote service of production machines,<br />

which already exists in most companies.<br />

As the individual components of the<br />

smartfoundry.network are integrated<br />

into this network, no additional time<br />

and cost-intensive buildup of a specific<br />

Ethernet network is required (Figure 4).<br />

For IT security reasons, the data exchanged<br />

between the individual components<br />

Frech WK DGM<br />

Data Hub<br />

Frech KK DGM<br />

Peripherals<br />

Figure 4: The smartfoundry.solutions components form an integrated digitalization network.<br />

WK DGM are warm chamber and KK DGM cold chamber die casting machines.<br />

is encrypted. Nowadays it is usually sufficient<br />

to start out a digitalization project<br />

based on the existing network and<br />

expand the network and IT infrastructure<br />

as the project proceeds. But it is up<br />

to foundry to decide whether with a<br />

view to IT security of the data acquisition<br />

and production network a dedicated<br />

network infrastructure should be<br />

implemented right from the beginning.<br />

This would – as a positive side effect –<br />

make the system suitable for handling<br />

the growing volumes of process and<br />

machine data in the future.<br />

Specific, purpose-oriented data<br />

storage using a Data Hub<br />

In data acquisition and analysis, two<br />

basic approaches are commonly<br />

applied. One approach is to initially<br />

store all available machine and process<br />

data without preselecting the data or<br />

bringing them into relation. Any filtering<br />

and correlating of data as well as<br />

bringing the data points into relation<br />

to each other will be performed during<br />

the data analysis phase. The advantage<br />

of this approach is that storage and<br />

visualization of first data can be realized<br />

quickly and with little effort. Additionally<br />

it is possible to add additional<br />

data to an existing data analysis as<br />

required. The drawbacks of this approach<br />

are that data may not be available<br />

in the required format, may not be filtered<br />

in sufficient detail or may not be<br />

stored at sufficiently high sampling<br />

rates. It may also happen unusable or<br />

redundant data is being stored without<br />

notice. However, the most relevant<br />

disadvantage of this approach is that it<br />

may not be possible to generate<br />

important relations between individual<br />

data points, with the consequence that<br />

relevant interdependencies are overlooked.<br />

In the alternative approach data are<br />

acquired that have been preselected<br />

and may even have been specifically<br />

generated for this purpose at machine<br />

level. In most cases, the data is continuously<br />

filtered and stored at a rate<br />

adapted to the purpose of its use.<br />

28


Simultaneously, all necessary relations between the data<br />

points are stored. The advantage of this approach is that<br />

high-quality data and high-density information are available<br />

as soon as the analysis phase begins. A disadvantage is<br />

the extra effort required before and during the data acquisition<br />

process. This prolongs the ramp-up phase of digitalization<br />

projects, i.e. the time during which no “tangible”<br />

results are available. Additionally during the analysis phase<br />

certain data may be missing because during the initial<br />

phase of the project it was not foreseeable that this data<br />

would be useful.<br />

The above described first approach appears to be more<br />

attractive as it quickly delivers first results and provides the<br />

conditions for easy upscaling to accommodate additional<br />

features and the approach does not require much specific<br />

technical knowledge, which otherwise would be needed<br />

to select and generate specific, purpose-oriented data sets.<br />

Nevertheless, in industrial practice this approach is<br />

future-viable only to a certain extent and generates a high<br />

amount of data without a particular use.<br />

Most of today’s production machines and their operating<br />

software are not designed for the acquisition of<br />

machine and process data, but for the achievement of stable<br />

production processes. The data is collected and processed<br />

primarily for process control purposes and, in particular,<br />

to generate a situational display of the machine on the<br />

operating screens. Using the same data for digitalization<br />

and data analytics projects is problematic because much of<br />

the information contained in the data is not sufficiently<br />

structured or categorized, and certain data is often only<br />

available at certain times. In other words, data and relations<br />

that turn out to be important or interesting in retrospect<br />

are simply lost.<br />

As a result of the above described dilemma for the data<br />

acquisition within smart-foundry.solutions a dedicated<br />

modularized database system was developed. This system<br />

enables the recording of different data types at very different<br />

data densities. It is possible to have an extensive range<br />

of underlying relations between the data and the data<br />

sources (machines and their components, tools, production<br />

batches and products, etc.). By making use the know-how<br />

of the Frech Group in die casting technology practice related<br />

data sets were designed, which are preselected and<br />

matched to the different customer orientated use cases.<br />

The database system (Local Storage) runs on an industrial<br />

PC, the so called Data Hub. The Data Hub forms the centre<br />

of the smartfoundry.network. The data acquisition components<br />

and other systems connected via interfaces send<br />

encrypted data continuously to the Data Hub, where they<br />

are temporarily stored in the Local Storage and brought<br />

into relation with one another. At the same time, smartfoundry.network<br />

applications can retrieve static information<br />

from the Data Hub – for example information about<br />

machines and tools or analyses results from the short-term<br />

memory of the system. The Local Storage and the Data Hub<br />

are not designed for long-term storage of the acquired<br />

data. For long-term storage, the data has to be transferred<br />

to the Cloud Storage or to a local storage center provided<br />

by the foundry.<br />

Continuously growing portfolio<br />

of interfaces<br />

For the data exchange between the various components<br />

and production machines interfaces are being used. Wher-<br />

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By contacting, please give us following code: <strong>CPT</strong>_3<strong>2020</strong>.<br />

O.M.LER s.r.l. - Via Don Orione, 198/E, 198/F - 12042 Bra (CN) - ITALY -<br />

Tel. +39-0172-457256 - omler@omlersrl.com - www.omlersrl.com<br />

Industrial Spring in Targi Kielce<br />

23. <strong>International</strong> Fair<br />

of Technologies for Foundry<br />

29.09.-1.10.<strong>2020</strong><br />

Kielce, Poland<br />

STOM<br />

The Fair of Metal<br />

Processing<br />

31.03.-2.04.<strong>2020</strong><br />

Kielce, Poland<br />

metal.targikielce.pl<br />

przemyslowawiosna.pl


PRESSURE DIE CASTING<br />

ever technically feasible, the data transfer<br />

is encrypted in order to rule out the<br />

risk of unauthorized reading or even<br />

manipulation of the data. Frech die casting<br />

machines of the W and DAW, and<br />

the K and DAK series can be integrated<br />

into the smartfoundry.network with<br />

standard interfaces specifically designed<br />

for the data transfer inside of the<br />

smartfoundry.network. Customized<br />

interfaces are currently being<br />

developed for database and software<br />

systems, as well as for other production<br />

equipment of a die casting foundry. The<br />

portfolio of interfaces is being continuously<br />

expanded, both in terms of<br />

diversity and number, and it is today<br />

one of the most important keys to the<br />

success of digitalization projects in a die<br />

casting foundry.<br />

Robust process and machine<br />

data acquisition for three-shift<br />

operation<br />

With interfaces it is possible to collect<br />

primary machine and process data from<br />

production machines and transfer this<br />

data into the smartfoundry.network. In<br />

order to integrate older production<br />

machinery into the data acquisition system,<br />

additional sensors and data acquisition<br />

systems have to be installed. A<br />

detailed monitoring of the machine<br />

components (e.g. for condition monitoring<br />

and predictive maintenance) and<br />

the die casting process requires the installation<br />

of additional sensors into the<br />

the machine or the dies. The data acquisition<br />

task is performed by the Data<br />

Connector, a industrial connectivity and<br />

monitoring system within the smartfoundry.solutions<br />

product portfolio. The<br />

system, which is based on PLC technology<br />

and therefore suitable for three<br />

shift operation in an industrial environment,<br />

captures additional sensor and<br />

Figure 5: Entering<br />

quality data on a<br />

smartfoundry.solutions<br />

panel using<br />

the Quality Panel<br />

application.<br />

machine data and makes raw and aggregated<br />

data available via an OPC-UA<br />

interface. With the Data Connector it is<br />

also possible to identify components<br />

(e.g. with RFID) or to trigger actions<br />

(e.g. with signal lights). The Data<br />

Connector converts measured data into<br />

information, for example, by generating<br />

e.g. a “media temperature” based on a<br />

value measured by a sensor using metadata<br />

and by computing relevant aggregations,<br />

such as the amount of media<br />

required per production cycle. The raw<br />

data of the measurements, the aggregations,<br />

and the metadata are sent to the<br />

data acquisition system using the<br />

OPC-UA interface. The corresponding<br />

data are then assigned by the Data Hub<br />

to specific production machines, production<br />

cycles or batches. In this way, the<br />

additional sensor data captured by the<br />

Data Connector can be smoothly integrated<br />

within the data acquisition logic<br />

of the production process.<br />

Robust sensor systems are available<br />

in packages that cover frequently occurring<br />

application scenarios, such as monitoring<br />

of the die temperature, measurement<br />

of the ambient conditions,<br />

functional monitoring of the machine<br />

cooling system, etc. Sensor packages for<br />

these applications comprise the sensor<br />

equipment proper, installation material,<br />

and the terminals for the Data Connector’s<br />

PLC and software modules. Further<br />

sensor and connectivity packages are<br />

under development (for identification,<br />

actuating, condition monitoring, etc.)<br />

and will contribute to the continuous<br />

broadening of the Data Connector’s<br />

possible applications. Thanks to the<br />

modular design of the system – both<br />

hardware and software –, the measuring<br />

and application scope of the Data<br />

Connector can be expanded, modified<br />

or even reduced at any time as desired.<br />

Role-specific applications<br />

Acquired data and analysis results have<br />

to be made available to the personnel<br />

of a die casting foundry in a way that<br />

enables the employees to make the<br />

best possible use of the data in performing<br />

their tasks. This entails that data<br />

should be displayed and retrievable at<br />

the most suitable place and in a way<br />

optimally adapted to the characteristics<br />

of the employee’s function. Achieving<br />

this for all products, services and<br />

applications, is one of the main goals<br />

of the smartfoundry.solutions development<br />

team. In order to come up to this<br />

requirement, it is essential that data is<br />

displayed and visualized at different<br />

locations within a die casting foundry<br />

and that it is possible to enter additional<br />

data and information as required.<br />

It also has to be taken into account<br />

that the ambient conditions in a die<br />

casting foundry vary dramatically<br />

depending on the location – from the<br />

melt and casting shops, where the conditions<br />

are extremely rough, to the<br />

administration offices. Moreover, data<br />

sets with a varying depth of information<br />

have to be adapted to the various<br />

functions (Roles) within a foundry<br />

(machine operators, setters, process<br />

optimizers, casting shop managers,<br />

etc.).<br />

Meeting this extremely wide range<br />

of requirements with a monolithic soft<br />

and hardware system is almost impossible<br />

and would lead to several disadvantages.<br />

Instead, smartfoundry.solutions’<br />

approach is to use a great<br />

number of smaller applications for different<br />

Roles on visualization terminals<br />

and input devices (Equipment). The<br />

equipment ranges from sturdy PC terminals<br />

for the shopfloor level, various<br />

types of status displays, up to and<br />

including Web-browser-based software<br />

systems for the offices and<br />

mobile devices. In the future, also<br />

wearables like smart glasses or smart<br />

watches may be used in the smartfoundry.network.<br />

The foundry-proof<br />

terminals and input devices as well as<br />

the corresponding applications belong<br />

to the product portfolio of smartfoundry.solutions.<br />

A special service is<br />

that the customers may license individual<br />

applications and lease individual<br />

terminal devices as well for specific<br />

periods of time.<br />

The visualization terminals, input<br />

devices and applications are administered,<br />

monitored, and – in the event of a<br />

failure – quickly replaced by the smartfoundry.solutions<br />

team.<br />

30


Intuitive entry of information<br />

Figure 6: Discussing the machine and order status of a die casting machine in the production<br />

area (Production Transparency Stand).<br />

While much of the machine and process<br />

data is collected and transferred automatically<br />

by production machines, measurement<br />

systems and software systems<br />

into the digitalization infrastructure of<br />

the foundry, other data still need to be<br />

manually recorded and archived by the<br />

operators at numerous locations along<br />

the production process. In many foundries,<br />

this is done with a great number of<br />

isolated software solutions that are not<br />

interlinked. Manual data input and storage<br />

takes place at different places and<br />

using different systems. Inefficient data<br />

entry and processing, unavoidable<br />

errors and inconsistencies between the<br />

systems are commonplace. Often even<br />

manual filing of certain data is still<br />

being daily practice today. Such data<br />

would first have to be digitized before<br />

it can be used within a digital environment.<br />

smartfoundry.solutions contains<br />

Entry Point Applications via which data<br />

can be entered in an intuitive, highly<br />

efficient way. Applications developed<br />

for use at the shopfloor level are e.g.<br />

the Quality Panel, an application with<br />

an intuitive HMI for the entry of quality<br />

data of the cast products (Figure 5)<br />

or the Event Log, an application for<br />

logging events occurring during production.<br />

With the Foundry Information<br />

Manager, a smartfoundry.platform<br />

application, specific production<br />

machine or tooling information can be<br />

centrally stored for future use for<br />

example by Visual Applications. The<br />

task of Entry Point Applications is to<br />

digitize input data only once and as<br />

intuitively as possible, and transmit the<br />

data to the respective components of<br />

the smartfoundry.network.<br />

Competence in<br />

Shot Blast Technology<br />

We offer a complete service in surface preparation technology,<br />

not just as machine designers and manufacturers.<br />

Our emphasis is on providing reliable service on:<br />

• Wear and Spare Parts<br />

• Repair and (remote) maintenance<br />

• Inspection and process advice<br />

• Machine upgrades and performance<br />

enhancement<br />

• Upgraded used machines<br />

AGTOS<br />

Gesellschaft für technische Oberflächensysteme mbH<br />

Gutenbergstraße 14 · D-48282 Emsdetten<br />

Tel. +49(0)2572 96026-0 · info@agtos.de<br />

www.agtos.com<br />

151-11/13-4c-GB<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 31


PRESSURE DIE CASTING<br />

User-friendly visualization<br />

of the data<br />

Today, a great diversity of data of different<br />

information densities and quality<br />

are available in die casting foundries –<br />

however, frequently spread over many<br />

different places. Often highly valuable<br />

data and information exist in the HMI’s<br />

of the production machines and in<br />

other software systems. Just because<br />

they are available at the wrong place,<br />

processed in a way that is unsuitable for<br />

the user and his task, or the relevant<br />

data can simply not be found within the<br />

huge masses of information, data and<br />

information remain unused. This situation<br />

is likely to worsen as digitalization<br />

is expanding and increasingly more<br />

data will be collected and made available.<br />

For the reasons mentioned above,<br />

the data available at the foundries can<br />

in many cases not be used for effective<br />

process optimization. The smartfoundry.<br />

solutions approach is therefore based<br />

on applications, called Visuals, each of<br />

which realizes a single function for a<br />

group of users (Roles).<br />

> Status displays for the shopfloor<br />

level (Production Transparency Boards):<br />

including applications which visualize<br />

the current status of die casting machines<br />

(Foundry Status Board, HPDCM Status<br />

Board) or e.g. the maintenance status<br />

(Maintenance Status Board),<br />

Figure 6.<br />

> smartfoundry.platform: users may<br />

choose from different applications, such<br />

Figure 7: smartfoundry.platform applications<br />

can be used via the Web browser in<br />

the office or on mobile devices.<br />

as the OEE Agent, which analyzes the<br />

OEE’s of the connected machines and<br />

the related performance indicators availability,<br />

speed and quality. For example<br />

the<br />

> Production Intelligence Board: a BI-type<br />

application for the monitoring and analysis<br />

of operating modes, fault and alarm messages,<br />

and different kinds of performance<br />

indicators or<br />

> the Production Transparency Tool:<br />

which can be used by the process<br />

expert, for example, to examine and<br />

analyze machine, process and sensor<br />

data in great detail.<br />

In addition to these applications, the<br />

product portfolio contains various other<br />

Visuals. It is planned to add further<br />

func tions, and the development of new<br />

applications is ongoing. Visuals not only<br />

focus on applications for specific Roles<br />

and on the user-oriented processing<br />

and display of the information, but also<br />

on how to transport the information to<br />

the right place inside a foundry.<br />

High-availability mass<br />

data storage<br />

The acquisition is realized with Data<br />

Hubs connected with production machines,<br />

additional sensor equipment linked<br />

via Data Connectors, and Entry Point<br />

Applications on terminals. It is obvious<br />

that even today, with the system just<br />

having been rolled out, large quantities<br />

of data are collected at very high rates.<br />

For a medium-sized business, like a die<br />

casting foundry, it will be inevitable to<br />

outsource the cloud storage service to a<br />

reliable cloud services provider who as<br />

the necessary capacity and knowledge<br />

to store these enormous quantities of<br />

data today, and even larger quantities<br />

in the near future, assuring that the<br />

data are readily available when needed<br />

and protected by appropriate IT security<br />

systems. For economic reasons alone, it<br />

is not viable for the foundries to set up<br />

and maintain a fail-safe IT infrastructure<br />

at their premises (hard and software,<br />

qualified personnel, at least two<br />

server systems accommodated in separate<br />

rooms, 24/7 operation of high-availability<br />

systems, …).<br />

As the operation of a protected,<br />

high-availability cloud storage requires<br />

high effort and technical knowledge,<br />

smartfoundry.solutions made Cloud<br />

Storage a part of the product portfolio.<br />

For each customer, an individual<br />

Cloud Storage entity is set up, administered<br />

and operated as a service. In<br />

addition to the required cloud infrastructure,<br />

this entity comprises a central<br />

database system for the long-term<br />

storage of the collected machine, process<br />

and sensor data. The link between<br />

the local components of the smartfoundry.network<br />

inside the foundry<br />

32


and the components in the cloud is<br />

established by an encrypted VPN gateway<br />

connection. All the local components<br />

inside of the foundry and the<br />

components in the infrastructure of<br />

the cloud provider are permanently<br />

monitored, assuring maximum IT security,<br />

performance and reliability of the<br />

systems by the smartfoundry.solutions<br />

team.<br />

Data-based decision-making<br />

About one third of the jobs and the<br />

associated Roles within a die casting<br />

foundry are not located on the<br />

shopfloor, Most of these jobs focus production-related<br />

office work. The most<br />

of the information that these employees<br />

need for their work arises at the<br />

shopfloor level. However, it often takes<br />

a long time and involves a great effort<br />

to transmit the information to the<br />

employees – and the foundry management.<br />

The tasks to be performed often<br />

additionally require the retrieval of historical<br />

data from the Cloud Storage. A<br />

interlinking of production and office<br />

networks entails an extreme security<br />

risk. For these reasons, it is highly<br />

recommended to use Web-browser-based<br />

applications in the offices to access<br />

historical data stored in the Cloud Storage.<br />

Web-based applications have the<br />

additional advantage that they also run<br />

on mobile phones and tablets. This<br />

enables managers, or process optimizers,<br />

for example, to have mobile access<br />

to specific data from different workplaces<br />

(Figure 7). The smartfoundry.platform<br />

provides a Web-based application<br />

environment which contains various<br />

Visual and Entry Point Applications. For<br />

each user an individual set of applications<br />

can be licensed for variable license<br />

periods. Smartfoundry.solutions allow<br />

platform applications use a full automated<br />

data acquisition chain which provides<br />

machine, process and sensor data<br />

without the need of manual data processing.<br />

The users are able to access<br />

shopfloor data – virtually in real time<br />

– and use them as valuable input for<br />

their decisions in the office. Historical<br />

data can be retrieved by the users as<br />

well without effort and with the same<br />

performance from the smartfoundry.<br />

platform and the integrated Cloud Storage.<br />

Mastering challenges together<br />

The continuously growing internationalization<br />

and the technological and<br />

structural change in the automotive<br />

industry require die casting foundries to<br />

even further increase the efficiency of<br />

their operations to remain competitive<br />

in the market. For companies wishing to<br />

tackle these and other challenges, digitalization<br />

provides a number of highly<br />

effective tools. Some of the challenges<br />

along the way will take long to overcome<br />

or may even be impossible to be<br />

taken by a single company. For time<br />

and financial reasons, it may be reasonable<br />

to join forces with other companies<br />

and tackle the challenges as a<br />

member of a community of users. Therefore,<br />

the smartfoundry.solutions team<br />

is currently setting up the basis for a<br />

smartfoundry.community as a new<br />

module of its service and product portfolio.<br />

The central idea of this new feature<br />

is the joint acquisition and use of<br />

data by a user community. This service<br />

will generate a refund in the form of a<br />

technology or the possibility to use a<br />

Community-wide application. A core<br />

element of the system are applications<br />

that – when being used – feed individual,<br />

explicitly designated data in a<br />

pseudonymized form into a common<br />

data pool. These data are analyzed and<br />

the result of the analysis will be made<br />

available to the users of the Community<br />

Application as<br />

refund. This can be<br />

easily explained<br />

by way of the<br />

example of a<br />

benchmarking<br />

application: such<br />

an application<br />

could be designed<br />

to<br />

M<br />

benchmark not<br />

only of the production<br />

machines,<br />

toolings or<br />

M<br />

technologies within<br />

the company<br />

R<br />

of the user, but<br />

to include also<br />

the data in the<br />

anonymous data<br />

pool of the<br />

smartfoundry.<br />

community e.g.<br />

to compare selected<br />

key performance<br />

indicators<br />

with other foundry‘s.<br />

Acquiring<br />

operating data of<br />

die casting<br />

machine components<br />

in order to<br />

develop models<br />

odernization<br />

aintenance<br />

etrofit<br />

for the prediction of the remaining<br />

lifetime of these components would be<br />

another – more complex – scenario feasible.<br />

Within the community it would be<br />

possible to develop high-performance<br />

condition monitoring tools for critical<br />

components of the die casting machine,<br />

such as the hydraulic drive and pump<br />

system or the control valves of the shot<br />

end, which otherwise would be extremely<br />

difficult or impossible to accomplish<br />

by a single company. Technological<br />

tasks of this scope, such as the development<br />

of models for enhanced condition<br />

monitoring or for a more comprehensive<br />

understanding of the production<br />

processes involved, can only be accomplished<br />

in a joint effort. Cooperation<br />

must no longer be limited to equipment<br />

manufactures on the one side and the<br />

die casters on the other. Cooperation<br />

amongst die casters has become just as<br />

vital.<br />

https://smartfoundry.solutions<br />

References:<br />

www.cpt-international.com<br />

Dr.-Ing. Alexander Marks, and<br />

Dr.-Ing. Kai Kerber, Oskar Frech GmbH<br />

und Co. KG, Schorndorf, Germany<br />

info@rump.de • www.rump.de • +49 5258 508 0<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 33


ADDITIVE MANUFACTURING<br />

Photo: SLM Solutions<br />

Inorganically bound sand cores with different graphite contents, which influences the<br />

thermal conductivity of the sand binder mixture and thus the hardening times.<br />

How the die-casting industry<br />

can benefit from 3-D printing<br />

The casting industry and its suppliers have been intensively examining the opportunities<br />

and challenges of 3-D printing for many years. Its implementation, and the resultant<br />

further automation of production, has the potential to make a decisive contribution to<br />

more efficient and cost-optimized production.<br />

Ralf Frohwerk, SLM Solutions Group AG, Lübeck<br />

Similar process flows to achieve successful<br />

implementation of selective<br />

laser melting technology are found<br />

in all industries (Figure 1). Companies<br />

such as SLM Solutions not only offer<br />

production machines, but must also<br />

make the SLM process understandable<br />

to the industry and create trust in the<br />

technology. The goal is not to replace<br />

die casting, but instead to make the<br />

industry strong and competitive for the<br />

future by using SLM technology as an<br />

add-on in production.<br />

Where we stand at present<br />

The key question is which production<br />

segments can sensibly use metal-based<br />

3-D printing efficiently. The answer<br />

depends greatly on the die-cast product,<br />

its design and functionality, but<br />

especially on the annual production<br />

requirement. Expert knowledge of the<br />

3-D process, 3-D-compatible design, and<br />

the clear intention and corresponding<br />

budgets of the management are decisive<br />

for the successful implementation<br />

of 3-D technology. What the objectives<br />

are, and what resources should be used<br />

to go down this path, are relevant questions<br />

– particularly for SMEs.<br />

The requirements and opportunities<br />

of additive manufacturing<br />

The entire process chain must be coordinated<br />

in order to be able to offer a<br />

high-quality serially manufactured additive<br />

product. This not only includes<br />

robust and reliable machines. The component<br />

must first be redesigned or<br />

34


developed for the additive manufacturing<br />

process in order to exploit all the<br />

technology’s advantages. By integrating<br />

internal cooling channels, for example,<br />

tool inserts can be manufactured using<br />

the selective laser melting process<br />

which, in the case of die-casting tools,<br />

contributes to shorter cooling times –<br />

and thus to a quicker overall manufacturing<br />

process. Component weight can<br />

be reduced by using internal structures<br />

that also increase stability. After successful<br />

production, the equally important<br />

post-processing of the component<br />

takes place. The part must be detached<br />

from the build plate and the support<br />

structures must be removed.<br />

Figure 1: Laser melting<br />

of metal powder<br />

in the melting<br />

bath in the SLM<br />

Solutions system.<br />

Does additive manufacturing<br />

pay?<br />

Depending on the application, additive<br />

manufacturing can lead to numerous<br />

commercial and technical advantages<br />

that allow companies to strengthen<br />

their competitive position. The die-casting<br />

industry now focuses on additive<br />

manufacturing technology for the production<br />

of prototypes and small<br />

batches, in particular, since the manufacture<br />

of tools is a major cost factor in<br />

this area. The development time can<br />

be massively reduced, and very often<br />

the aluminum alloy intended for serial<br />

production cannot be used for sand<br />

casting molds. Various aluminum<br />

alloys, such as AlSi10Mg, AlSi7Mg and<br />

AlSi9Cu3, are already available in the<br />

powder quality specified for the SLM<br />

process. It should be noted, in particular,<br />

that the material properties of a<br />

3-D-printed component are generally<br />

better than those of a die-cast component,<br />

since a significantly higher density<br />

is produced. In addition, not every<br />

aluminum alloy required for serial production<br />

can also be used in sand casting<br />

molds.<br />

Well-known producers show how<br />

successfully the technology is already<br />

being used in serial production. Bugatti,<br />

for example, uses additive manufacturing<br />

to produce an active heat shield<br />

made of AlSi10Mg with integrated cooling<br />

channels – used in the Bugatti<br />

Chiron since serial production started<br />

(Figure 2). A brake caliper and a spoiler<br />

bracket are under development, to be<br />

manufactured in a topologically optimized<br />

design using the SLM Solutions process.<br />

Selective laser melting technology<br />

enables Bugatti to implement a consistent<br />

lightweight design, enabling the<br />

functionality of the vehicles to be continuously<br />

optimized. The company<br />

Hirschvogel also shows how additive<br />

manufacturing can be used successfully.<br />

In a design study for the manufacture<br />

of a car steering knuckle (Figure 3), SLM<br />

technology reduced the material required<br />

by 40 percent compared to conventional<br />

production.<br />

Cost efficiency thanks<br />

to automation<br />

Metal-based additive manufacturing<br />

offers the possibility of achieving lean<br />

production with high efficiency and a<br />

batch size of one. As in the entire<br />

manufacturing sector, process automation<br />

is important in the additive manufacturing<br />

industry – increasing acceptance<br />

of the technology and creating<br />

cost advantages. With the PSV powder<br />

supply unit, SLM Solutions offers a<br />

material handling system that eliminates<br />

the need for manual powder replenishment.<br />

All powder transport, as well<br />

as the sifting and storage of powder,<br />

takes place in a closed cycle under a<br />

protective gas atmosphere. The contactless<br />

powder handling also achieves a<br />

high degree of work safety.<br />

The SLM800 selective laser melting<br />

system (Figure 4) also stands for automation.<br />

The fully automatic SLM HUB<br />

unpacking station integrates numerous<br />

functions. Several build cylinders are<br />

handled in parallel in a protective gas<br />

atmosphere. The SLM HUB also handles<br />

Figure 2: AlSi10Mg active heat shield<br />

with integrated cooling channels made<br />

for the Bugatti Chiron using additive<br />

manufacturing.<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 35


ADDITIVE MANUFACTURING<br />

pre-heating and controlled cooling of<br />

the build cylinders. The inert removal<br />

of powder takes place with fully automatic<br />

rotation and vibration of the<br />

built substrate plate. All unused powder<br />

is removed and recycled back to<br />

the sieving station so that about 98<br />

percent of the powder that was not<br />

melted can be reused. Up to five<br />

machines can be connected to a single<br />

SLM HUB in modular form. The machines<br />

are automatically supplied from<br />

the central powder station (with its<br />

integrated sieving station) using<br />

vacuum technology. This automation<br />

combined with process engineering<br />

developments support the achievement<br />

of economic goals.<br />

Figure 3: A car steering knuckle from<br />

Hirschvogel requires 40 percent less<br />

material using additive manufacturing<br />

compared with conventional production.<br />

Safety first<br />

One challenge is the certification of<br />

components and integration of 3-D<br />

printing into existing production lines.<br />

SLM Solutions supports its customers<br />

with its profound expertise and intelligent<br />

software solutions. To achieve<br />

certification, all quality-relevant process<br />

parameters are analyzed with the<br />

help of an impact analysis (FMEA),<br />

Figure 4: The SLM800 selective laser<br />

melting system from SLM Solutions.<br />

while the values and their tolerances<br />

are determined for high functionality<br />

in the component. All relevant values<br />

are displayed and controlled by the<br />

quality assurance technology integrated<br />

in SLM machines. Processes in the<br />

melting pool, for example, can be<br />

visualized with the Melt Pool Monitoring<br />

(MPM) system, which determines<br />

the thermal radiation from the melt<br />

throughout the production process.<br />

Laser Power Monitoring (LPM) continuously<br />

logs the target and actual laser<br />

output during the entire production<br />

process. The Layer Control System (LCS)<br />

monitors the powder bed and detects<br />

any irregularities in the coating. These<br />

quality assurance tools ensure low-defect<br />

production of high-quality components.<br />

Prospects<br />

The technology was developed in Germany<br />

by SLM Solutions, among others,<br />

the pioneer of selective laser melting.<br />

For this reason, the technology is well<br />

known in Germany. Since a great<br />

wealth of experience has already been<br />

built up in Europe over the last 15<br />

years, the willingness to use the technology<br />

is relatively great. There is much to<br />

suggest that selective laser melting will<br />

also prevail in the die-casting industry<br />

– solutions and systems using the SLM<br />

Solutions process already exist.<br />

www.slm-solutions.com<br />

Ralf Frohwerk, Global Head of Business<br />

Development, SLM Solutions Group AG,<br />

Lübeck, Germany<br />

36


SAND RECLAMATION<br />

Photo: Robert Piterek<br />

Casting at the two forming plants at Frischhut in Neumarkt-Sankt Veit. Whereas the old<br />

sand processing system could only prepare 60 percent of the required sand, sufficient treated<br />

sand is now available for forming.<br />

Mixing without vibrations<br />

and complete preparation<br />

The synthetic molding sand at Eisengießerei Ludwig Frischhut in the Bavarian<br />

town of Neumarkt-St. Veit is prepared with a state-of-the-art mixing system.<br />

Gerhard Krauskopf, Krauskopf Maschinentechnik, Buchen im Odenwald<br />

The preparation of molding sand in<br />

foundries mostly takes place in<br />

mixers that have vertically mounted<br />

mixer tools with agitators. This is<br />

also the case at the Gießerei Ludwig<br />

Frischhut foundry (part of the TALIS<br />

Group since 2010) located in Neumarkt-St.<br />

Veit, Germany, where a Tune-<br />

Mixx mixing tool system is used to treat<br />

and mix the sand components. This system<br />

not only ensures quieter mixing, a<br />

higher level of treatment, and lower<br />

electricity consumption, but also a significant<br />

increase in throughput.<br />

The Frischhut foundry prepares its<br />

synthetic molding sand in a tilted intensive<br />

mixer. Over a long period the extreme<br />

vibrations of the foundry’s old star<br />

agitator led to cracks in the mixer<br />

frame. The Maintenance Management<br />

Initiative, in collaboration with the executive,<br />

decided to exploit a market<br />

innovation to reduce the vibrations<br />

caus ed by imbalances, and selected the<br />

TuneMixx mixing tool system from<br />

Krauskopf Maschinentechnik in Buchen<br />

(Figure 1). Frischhut produces molded<br />

parts made of cast iron with spheroidal<br />

and lamellar graphite for water supply<br />

and sewerage systems. The castings are<br />

processed in the same plant in Pfarrkirchen<br />

and are given an epoxy powder<br />

coating using environmentally friendly<br />

vortex sintering or spray processes. On<br />

commission, castings are also processed<br />

(using modern CNC machining centers)<br />

and coated according to customer<br />

orders before being tested with up to<br />

25 bar internal pressure.<br />

Two molding plants are used to<br />

mold the castings: one from Künkel-Wagner<br />

(in Alfeld, Germany) with<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 37


SAND RECLAMATION<br />

Photos: Krauskopf<br />

Figure 1: New TuneMixx mixing tool system<br />

in the mixer plant at Eisengießerei Frischhut.<br />

molding box dimensions of 620 x 520 x<br />

200/220 mm³ and the other from Heinrich<br />

Wagner Sinto (Bad Laasphe, Germany)<br />

with molding box dimensions of<br />

1250 x 900 x 400/400 mm³, with a nominal<br />

sand requirement of 28.5 tonnes per<br />

hour. The sand preparation system,<br />

however, only supplied about 60<br />

percent of the necessary sand quantity<br />

until 2015. Just replacing the conventional<br />

agitator with the patented Tune-<br />

Mixx system brought a reduction in preparation<br />

times of almost 40 percent and<br />

a subsequent increase in throughput of<br />

the same magnitude. The molding plant<br />

has been supplied with sufficient molding<br />

sand since then. “An absolutely<br />

worthwhile investment that has exceeded<br />

our expectations many times over,”<br />

according to the then Maintenance<br />

Manager, Alois Spiegl.<br />

The TuneMixx system was initially<br />

purchased because of its precise rotation,<br />

eliminating mixer vibration and<br />

the resultant damage. This requirement<br />

has been fulfilled in every way, which<br />

managers could see for themselves<br />

when they visited the mixer platform.<br />

Encouraged by the successful elimination<br />

of vibrations and the resultant<br />

increase in throughput, the molding<br />

sand properties were examined by an<br />

independent testing laboratory. The<br />

results brought further positive aspects<br />

to light. The TuneMixx system succeeded<br />

in increasing the preparation level<br />

to 100 percent and reducing sand<br />

agglomeration to almost zero.<br />

The Continuous Improvement Process<br />

for energy savings – standard at<br />

Frischhut – even placed the mixer with<br />

the TuneMixx in second place after one<br />

year, because the savings resulting from<br />

the new mixing tool reduced electricity<br />

consumption by about 45 percent compared<br />

to the conventional agitator previously<br />

used.<br />

What has not yet been mentioned is<br />

the fact that all parts subject to wear<br />

due to contact with the product, such as<br />

the mixing blades, base wear protection<br />

plate, etc. can be exchanged or turned<br />

around in seconds thanks to the<br />

hydraulic clamping system of the Tune-<br />

Mixx (Figure 2). The foundry was thus<br />

able to shorten its production downtimes<br />

from several hours to a few minutes.<br />

Krauskopf, whose original aim was<br />

to enable maintenance work to be carried<br />

out rapidly and easily on a vertically<br />

driven mixing tool, can look back<br />

on sales of more than 30 TuneMixx<br />

units after a fruitful market introduction.<br />

The system is not only successfully<br />

used for preparing sand in foundries,<br />

but also in the refractory industry, the<br />

glass sector, the building materials and<br />

carbon industries, and in metallurgy.<br />

The variations and combinations<br />

offered by the mixing blade design are<br />

another advantage. The profile, the<br />

cross-section, the length, and the<br />

wear-resistant materials can be individually<br />

adapted to the mixed material<br />

and flexibly tested with the rapid-change<br />

system – because such changes no<br />

longer involve time- and personnel-intensive<br />

downtimes (Figure 3). Frischhut<br />

started out with a wear-resistant mixing<br />

blade made of hard-cast chrome. Initial<br />

results showed that wear is greatest in<br />

the lower area and high-quality wear<br />

protection is entirely appropriate. From<br />

then on the mixing blades were used<br />

with globular tungsten carbide armoring,<br />

which still proves economical in<br />

the cost-benefit calculation. The axially<br />

symmetrical construction of the mixing<br />

Figure 2:<br />

Exploded view of<br />

the TuneMixx mixing<br />

tool system.<br />

38


Figure 3: Changing a<br />

mixing blade on a<br />

conventional agitator<br />

tool often takes<br />

several hours. This<br />

can be achieved in<br />

minutes with the<br />

TuneMixx.<br />

Figure 4: Reconditioned<br />

furan resin<br />

mixer shaft with<br />

special wear-resistant<br />

armoring at<br />

Ludwig Frischhut.<br />

blades also contributes towards cost<br />

savings and resource conservation: both<br />

sides of the blades can be utilized – so<br />

they can be used twice.<br />

In addition to its quick-change system,<br />

Frischhut and other companies<br />

have long appreciated improved process-related<br />

parameters resulting from<br />

sand preparation with a TuneMixx system.<br />

The quality of the mixed material,<br />

the throughput rate, and the reduced<br />

need for heating due to shorter mixing<br />

times are major reasons for many plant<br />

operators to employ the mixing tool.<br />

At its site in Buchen im Odenwald,<br />

the ten employees of the machine construction<br />

company Krauskopf Maschinentechnik<br />

GmbH & Co. KG (founded in<br />

2013) develop, produce and market<br />

mixing tool systems, replacement parts<br />

and parts subject to wear, as well as<br />

individual wear-protection solutions for<br />

a variety of mixer producers and sectors<br />

(Figure 4). The company’s tasks also<br />

include measurements, service and installation<br />

work, as well as on-site process-related<br />

consultations.<br />

www.krauskopf-maschinentechnik.de<br />

Gerhard Krauskopf, Krauskopf Maschinentechnik,<br />

Buchen (Odenwald), Germany<br />

your Partner<br />

for turnKey Projects<br />

in no-bake moulding shops for:<br />

• moulding lines<br />

• continuous mixers<br />

• mechanical and thermal reclamations<br />

• chromite separations<br />

Smooth pneumatic conveying system for:<br />

• sand • bentonite • carbon • filter dust<br />

QuAliTY<br />

maDe In germany<br />

FAT Förder- und Anlagentechnik GmbH · D-57572 Niederfischbach · Tel. +49 (0) 27 34/5 09-0 · fat.info@f-a-t.de · www.f-a-t.de


Investment casting<br />

can save lives<br />

Berlin-based company Vacucast, a business of LINK Holding GmbH, casts implants that<br />

are used for joint replacement in operating theaters worldwide. Managing Director<br />

Tonguc Sahin guides a group of doctors through his investment foundry and shows<br />

them the manufacturing process of these sophisticated products - which can sometimes<br />

even save lives.<br />

Robert Piterek, German Foundry Association, Düsseldorf<br />

Photo: Fotolia, Clemens Schöll<br />

Doctor‘s round at Vacucast in Berlin:<br />

Managing Director Tonguc<br />

Sahin is welcoming a group of<br />

doctors today, all of whom are specialists<br />

in the use of so-called endoprostheses<br />

and would like to learn more about<br />

the production process during a tour of<br />

the company. The attending physicians<br />

come from all parts of Germany and<br />

regularly use the prostheses in the operating<br />

theater to replace damaged<br />

joints either partially or completely.<br />

Today, it is an established, continuously<br />

growing business area, with global sales<br />

of 43.1 billion US dollars in 2012. Knee<br />

and hip endoprostheses, which are also<br />

predominantly manufactured by<br />

Vacucast, account for more than 40<br />

percent of sales.<br />

The critical eyes of the doctors are<br />

now focused on Sahin, who is passing<br />

around a palm-sized bent metal part<br />

– an artificial skullcap made of titanium.<br />

A counterpart of this implant was used<br />

to help a seriously injured motorcyclist.<br />

The surgery saved his life.<br />

A Passion for Titanium<br />

Tonguc Sahin, a materials science<br />

engineer from the Turkish Mediterranean<br />

city of Anamur and living in Germany<br />

since 1995, starts his remarks with<br />

the beginnings of titanium casting at<br />

Vacucast. The material inspired the<br />

founders of the company, which was<br />

launched in 1974, from the very beginning,<br />

even though their intention to<br />

cast the material instead of forging was<br />

initially met with skepticism. „Everybody<br />

wanted to work with this mate-<br />

40


COMPANY<br />

Cast blanks: Vacucast‘s<br />

managing director<br />

Tonguc Sahin in front<br />

of already cooled<br />

down cast alloys with<br />

hip stems made of a<br />

cobalt-chrome-molybdenum<br />

alloy.<br />

Patterns: Like on a<br />

cable car, these wax<br />

pattern clusters float<br />

slowly through the<br />

factory.<br />

Immersion process: A robot then covers<br />

the clusters with one or more layers of<br />

ceramic.<br />

rial, which was first used in the military<br />

and later in civil aviation,“ says Sahin.<br />

Pros: Light weight combined with excellent<br />

strength. „Today we also use the<br />

material to produce dynamically resilient<br />

artificial hip shafts on our cold-wall<br />

vacuum casting machine, which you will<br />

see in a moment,“ he announces. The<br />

guests nod their approval. But first<br />

Sahin leads the group of doctors down<br />

to the production hall to show them<br />

the investment casting process right<br />

from the start.<br />

Precise wax patterns<br />

Three wax injection molding machines<br />

are located in a room measuring about<br />

70 square meters. In the preceding<br />

room, several people work on wax patterns,<br />

giving them the finishing touches<br />

or combining them to clusters. An<br />

employee uses a lamp to check whether<br />

the clusters are properly joined. The<br />

doctors spread out in the room and<br />

look over the workers‘ shoulders. Some<br />

reach for their reading glasses to take a<br />

close look at the negatives of the castings.<br />

Then, Sahin takes the floor again<br />

and familiarizes the group of doctors<br />

with the manufacturing process used<br />

here – the lost wax process. He explains<br />

that the 3-D data sets are used to produce<br />

the patterns in the wax injection<br />

molding machines and that Vacucast<br />

collaborates with an external mold<br />

maker for the production of the injection<br />

molds. The company regularly<br />

receives the data sets for pattern production<br />

from the headquarters of<br />

Vacucast‘s parent company LINK in<br />

Hamburg, where 45 development<br />

engineers are employed. The family-run<br />

medical technology company took over<br />

Vacucast from its founder in 1997. The<br />

company, which has around 1000<br />

employees, manufactures endoprostheses<br />

from cast, forged and now also printed<br />

blanks.<br />

Forging or Casting?<br />

„The tolerances of our components are<br />

very tight,“ continues Sahin, looking<br />

from doctor to doctor. „They have to be<br />

true to size and close to the final contour,<br />

because the precise final dimensions<br />

have to be as close as possible to<br />

the blank.“ Another general nodding<br />

and approving murmur go through the<br />

ranks of the assembled doctors. A physician<br />

in a coarse brown wool jacket asks<br />

an interposed question: What materials<br />

are used and what other medical<br />

devices are produced here. Sahin counts<br />

the product range on his fingers - from<br />

thigh prostheses from the pelvis to the<br />

knee, artificial hip shafts and knee<br />

joints to so-called modular revision<br />

shafts consisting of up to three parts<br />

and artificial ankle joints. He adds that<br />

Vacucast offers hip stems in various<br />

lengths and thicknesses and does not<br />

forget to mention that intervertebral<br />

prostheses also used to be part of the<br />

product portfolio.<br />

To compare the materials, Sahin passes<br />

around two hip shafts made of different<br />

materials. One is cast from a<br />

cobalt-chrome-molybdenum alloy, the<br />

other from titanium. „The titanium<br />

shaft has a slightly roughened middle<br />

section. This enlarges the surface so<br />

that the bone cells can attach themselves<br />

more easily to the prosthesis,“ he<br />

explains, stroking the rough surface of<br />

the casting. This is followed by another<br />

question from a doctor with an unmistakable<br />

North German accent. He asks<br />

whether forged hip shafts are not better<br />

than cast ones. „There is a prevailing<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 41


COMPANY<br />

Melting and casting:<br />

A worker prepares<br />

the melt for casting in<br />

ceramic molds.<br />

Burning: The wax is<br />

melted out at high<br />

temperatures and the<br />

mold is burned.<br />

Titanium casting: The display in the control room shows the melting<br />

process of titanium. In a moment, the worker will prepare a<br />

ceramic mold for casting in an airtight chamber.<br />

belief that forged parts are more<br />

durable,“ says Sahin, „but with anatomical,<br />

complex shapes, casting is actually<br />

easier than forging. This is because<br />

the various post-treatments, such as<br />

hipping, often allow values far above<br />

the required standards to be achieved.<br />

Cable Car for Pattern Clusters<br />

A further essential step in the lost wax<br />

process is the application of a ceramic<br />

layer to the wax pattern. The huge<br />

room that the doctors now walk<br />

through with Sahin is dominated by a<br />

facility that at first glance looks like a<br />

cable car for pattern clusters. As if<br />

strung together like a string of pearls,<br />

the blue wax arrangements float slowly<br />

through the room on a flexible frame.<br />

Their destination is the manipulator<br />

covered with a protective foil in the<br />

middle of the room. A protective fence<br />

blocks the way to a pool of white tough<br />

liquid and the working robot. This is<br />

where the group comes to a stop. „The<br />

manipulator is one of two that we use<br />

in our 75-man operation here in Berlin-Reinickendorf,“<br />

Sahin points out.<br />

Behind him, the robot is maneuvering a<br />

cluster of wax patterns to the basin filled<br />

with ceramic slurry in front of it and<br />

gently dips them in. Sahin adds that<br />

depending on the application, the cluster<br />

is dipped several times. After each<br />

dipping, sanding and drying follows<br />

before the cluster is dipped again. This<br />

is a lengthy process, which is owed to<br />

the high quality of Vacucast and also<br />

means that some castings can cost several<br />

hundred euros. „For us, quality is<br />

more important than quantity,“ Sahin<br />

explains the production requirements.<br />

„How important is automation for<br />

you?“ asks a young man with glasses.<br />

„It is indispensable in our ceramic coating<br />

process,“ emphasizes Sahin, while<br />

the robot is doing its job reliably behind<br />

him. „The process runs in three shifts<br />

and I can only staff two shifts. The<br />

robot covers the third one.“ However,<br />

given the complexity of some parts, it is<br />

not always so easy to automate this<br />

process. Vacucast also operates a<br />

semi-automatic machine for the wax<br />

spraying process, for example.<br />

Despite limited possibilities for automation,<br />

the company has made a considerable<br />

leap in productivity in recent<br />

years: „Today, we have slightly fewer<br />

production employees than before, but<br />

we produce twice as many castings,“<br />

says Shahin proudly. On a production<br />

area of 5000 square meters, the company<br />

currently produces around 200 to<br />

220,000 castings a year. The batch sizes<br />

of the approximately 400 permanently<br />

produced articles range from two to<br />

144 pieces. To optimize processes, nine<br />

million euros have been invested over<br />

the past ten years.<br />

Hot Passion<br />

Then the doctors and Tonguc Sahin<br />

reach the inner sanctum of the investment<br />

foundry – the casting hall. The<br />

doctors are visibly thrilled by the<br />

encounter with the fire at the<br />

autoclave, where the wax in the dried<br />

ceramic molds is melted, and the casting<br />

area, where knee joints and hip<br />

shafts are poured with cobalt-chrome<br />

melt in the burned molds. However,<br />

they respectfully keep their distance<br />

without Sahin having to ask them to<br />

keep the safety distance. „Each mold is<br />

cast individually to ensure traceability<br />

and quality,“ emphasizes the Managing<br />

Director when the group finally settles<br />

down after some technical discussions<br />

among themselves. The quality of the<br />

Vacucast prostheses must also meet the<br />

highest standards beyond Germany‘s<br />

borders.<br />

42


The LINK Group has subsidiaries and agencies around<br />

the world, so Vacucast prostheses are also sold in China,<br />

EU countries such as Sweden, Spain and Italy, and South<br />

America - the export share is 85 percent. Sahin is one of<br />

four managing directors at LINK and is thus also responsible<br />

for the good reputation of the products around the<br />

world. „Our products are Made in Germany and Made in<br />

Berlin and can compete on the world market,“ he tells<br />

the assembled medical professionals.<br />

Sophisticated Titanium Casting Process<br />

Then the group finally arrives at the cold-wall vacuum<br />

casting machine for titanium, which Sahin had announced<br />

at the beginning. The white-painted plant is housed<br />

on two levels. A seemingly complex construction of boilers,<br />

control cabinets, coiled cables and wiring. On the<br />

second level a display in a control room shows a titanium<br />

block in a copper crucible inside the melting chamber. A<br />

young doctor demonstrates her knowledge of materials<br />

technology and is surprised at the use of the copper crucible<br />

in the titanium melting process. „You‘re right,“ confirms<br />

Sahin. „The melting point of titanium is 1605 to<br />

1650, that of copper is only 1084 degrees. So, the crucible<br />

wouldn‘t stand a chance. But, as the name of the plant<br />

suggests, it is cooled extremely effectively. This creates a<br />

so-called ‚skull‘ at the bottom of the container, which<br />

forms a barrier between the titanium melt and the copper<br />

crucible.<br />

A foundryman at the machine is just placing a red-hot<br />

ceramic mold in an airtight chamber and then carefully<br />

closes the door. „Titanium is a highly reactive metal. It<br />

must not come into contact with oxygen, nitrogen or<br />

hydrogen – remelting must therefore take place under a<br />

vacuum,“ says Sahin, describing the technically sophisticated<br />

process. „I don‘t need to tell you that titanium prostheses<br />

are indispensable for allergy patients. In addition,<br />

we have to prepare for more and more younger patients.<br />

Arthrosis is already being treated in younger people,“ he<br />

says, sparking a lively exchange among doctors on the<br />

way to the next production station.<br />

Master of all Processes<br />

The quality cycle does not end with the casting and<br />

removal of the ceramic mold but receives a decisive boost<br />

at the end of the production process during hot isostatic<br />

pressing. Vacucast has been carrying out this process,<br />

known as hipping, since 1985. “It is also known as gas<br />

forging because the process takes place in an argon gas<br />

atmosphere,“ explains Sahin. At over 1000 bar pressure<br />

and high temperatures, cavities that may have formed<br />

during solidification close. This additional refinement of<br />

the prostheses is carried out by a truck-sized plant located<br />

at the periphery of the production hall. Sahin: „99<br />

percent of our processes are in-house, so we are in control<br />

of the processes from pattern to blank.“<br />

Before the implants are sent to the LINK headquarters<br />

in Hamburg for completion by grinding, polishing, sterilization<br />

and packaging, they are subjected to heat treatment<br />

and extensive quality control measurements by<br />

emission spectrometer, fluorescent penetrant crack detection<br />

and X-ray testing. The life cycle simulation, which<br />

completes the extensive documentation effort for all components<br />

manufactured here, also attracts the attention of<br />

interested doctors. Clattering noisily in a quality control<br />

MECHANICAL RECLAMATION<br />

USR II<br />

FOR GREEN SAND AND<br />

GREEN SAND-CORE SAND-MIX<br />

YOUR ADVANTAGES:<br />

• High efficiency<br />

• Long service life thanks to ceramic components<br />

• Easy maintenance<br />

• Compact design<br />

• Conservation of resources<br />

Before reclamation<br />

After reclamation<br />

New!<br />

PERFECTION IN EVERY<br />

SINGLE MOULD.<br />

www.sinto.com<br />

HEINRICH WAGNER SINTO<br />

Maschinenfabrik GmbH<br />

SINTOKOGIO GROUP<br />

Bahnhofstr.101 · 57334 Bad Laasphe, Germany<br />

Phone +49 2752 / 907 0 · Fax +49 2752 / 907 280<br />

www.wagner-sinto.de<br />

HWS Anz 85x260 USR-II GB_2019_RZ_neu.indd 1 20.02.<strong>2020</strong> 10:10:38


COMPANY<br />

A look at Vacucast from the outside: The red brick building has a production area of 5000 square meters. Currently, around 200 to 220,000<br />

castings are produced here each year.<br />

room, the load bearing capacity of a<br />

prosthesis is tested in a dynamic simulator.<br />

Vacucast‘s prostheses are really<br />

good, as the test according to the Swedish<br />

knee arthroplasty register proves.<br />

There, the SP II Lubinus hip endoprosthesis<br />

from LINK was rated the safest of<br />

all available implants with a survival<br />

rate of 94.7 percent after 16 years. „In<br />

Sweden, the model is the most frequently<br />

used implant for the cemented<br />

hip joint replacement,“ says Sahin.<br />

E-mobility Drives Up Cobalt Prices<br />

At the end of the tour, the managing<br />

director addresses final questions. The<br />

young doctor who already proved her<br />

knowledge of materials – as it turns<br />

out, an expert in endoprosthetics from<br />

a specialist clinic in the German federal<br />

state of Saarland – raises her hand.<br />

„How is it with you?“ she asks. „How<br />

did you get to your current position“?<br />

Sahin laughs and then reports on his<br />

studies to become a mining engineer in<br />

Izmir, Turkey, followed by a university<br />

education in Germany and his career<br />

start as a working student at Vacucast,<br />

where he worked his way up from quality<br />

manager to foundry manager to<br />

managing director. In his private life he<br />

is married and has two daughters.<br />

A medical doctor wants to know:<br />

„Isn‘t cobalt also needed on a large scale<br />

for batteries in electric cars?” „At the<br />

This employee<br />

checks the dimensional<br />

accuracy of<br />

medical technology<br />

components.<br />

moment, cobalt is used extensively in the<br />

manufacture of batteries for e-mobility,<br />

among other things. I actually wonder<br />

whether the increasing demand for<br />

e-cars might one day lead to hospitals no<br />

longer being supplied with inexpensive<br />

implants,“ says the managing director,<br />

looking to the future. The price per kilogram<br />

has temporarily risen from 30 to<br />

up to 90 US dollars.<br />

Resilient Industry<br />

Vacucast offers top quality Made in Germany<br />

thanks to sophisticated system<br />

technology and high process reliability.<br />

Tonguc Sahin demonstrated this to the<br />

doctors during their visit – a visit that<br />

did not take place, but which could<br />

have looked like this. Sahin regularly<br />

guides doctors through the plant but<br />

has organized this tour exclusively for<br />

us. His company is in an excellent position<br />

and is well placed to expand its<br />

product range in the coming years - for<br />

example, to include parts for the<br />

mechanical engineering and aviation<br />

industries.<br />

But qualified know-how carriers are<br />

also essential. Such specialists are<br />

sometimes rare – even in the cosmopolitan<br />

city of Berlin. Currently, a production<br />

manager, engineers and other specialists<br />

are needed: „The demand for<br />

our products will not decrease“, Sahin is<br />

convinced, „because the focus is on helping<br />

people!” www.vacucast.de<br />

44


NEWS<br />

EUROGUSS DIE CASTING AWARD<br />

Innovative Products in three material categories<br />

1st prize aluminium competition: Oil-coolant<br />

module of the alloy AISi9Cu3 (Fe) by Hengst<br />

SE from Nordwalde, Germany.<br />

1st Prize magnesium competition: Magnesium chainsaw piston made by Stihl, Prüm, Germany.<br />

The part weighs only 69 grams and consists of the alloy MRI (Mg-Al-Mn-Ca-RE), which is<br />

known for good high-temperature properties, good creep behavior and good castability.<br />

Traditionally, a die-casting competition<br />

for aluminum, zinc and magnesium<br />

components is held at EUROGUSS.<br />

The <strong>2020</strong> winners for aluminum<br />

were:<br />

1st prize: Hengst SE, Nordwalde,<br />

oil-coolant module, alloy: AISi9Cu3 (Fe),<br />

2nd prize: Druckguss Westfalen GmbH<br />

& Co. KG, Geseke, housing HV Booster,<br />

alloy: EN AC-AISi10MnMg, weight: 2785<br />

g, dimensions: L 344 mm x W 365 mm x<br />

H 176 mm,<br />

3rd prize: Alupress AG, Brixen, upper<br />

housing section for 2-channel EBS, alloy:<br />

EN AC-47100, weight: 780 g, dimensions:<br />

L 193 mm x W 98 mm x H 98 mm,<br />

3rd prize: Nemak Slovakia s.r.o., Žiar nad<br />

Hronom, battery housing, alloy: AlSi9Mn<br />

(naturally hard without heat treatment),<br />

weight: 15,900 g; Cast with base plate<br />

extrusion 38 000 g, dimensions: L 1045<br />

mm x W 753 mm x H 218 mm.<br />

The <strong>2020</strong> winners for magnesium<br />

were:<br />

1st prize: Andreas Stihl AG & Co KG, piston<br />

for professional chain saw with<br />

two-stroke engine, component weight:<br />

0.06 kg, alloy: MRI,<br />

One of the winners of zinc competition: This casting by Georg Frank GmbH, Heilbronn,<br />

Germany, is a connection component in a fan. It is insulated for use as a conductive<br />

connection by overmolding with plastic.<br />

2nd prize: Stolfig Leichtbau Kompetenzzentrum<br />

GmbH, “High-Voltage”<br />

inverter housing (e-mobility), component<br />

weight: 0.2 kg, alloy: AZ91,<br />

3rd prize: GF Casting Solutions, cockpit<br />

cross member with visible surfaces, LR<br />

Defender <strong>2020</strong>, component weight:<br />

1.0kg + 1.1kg, alloy: AM60,<br />

3rd prize: DGH Heidenau GmbH & Co.<br />

KG, cylinder head cover (BMW R1250),<br />

component weight: 0.555 kg, alloy:<br />

AZ91.<br />

The <strong>2020</strong> winners for zinc were:<br />

Automotive category: Druckguss Westfalen<br />

Behringer GmbH & Co. KG, Velbert,<br />

Sanitary engineering category: HDO<br />

Druckguß und Oberflächentechnik<br />

GmbH, Paderborn,<br />

Lifestyle category: Heiligenstädter Reißverschluß<br />

GmbH & Co. KG, Heilbad Heiligenstadt,<br />

Category electrical engineering &<br />

mechanical engineering: Georg Frank<br />

GmbH, Heilbronn,<br />

Medical technology category: Dipl.-Ing.<br />

Siegfried Müller Druckguss GmbH & Co.<br />

KG, Velbert,<br />

Security & Locking Technology category:<br />

Groß Druckguss GmbH, Heilbad<br />

Heiligenstadt.<br />

www.euroguss.com<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 45


NEWS<br />

NORICAN GLOBAL<br />

Shoulder to shoulder for artificial intelligence<br />

in the foundry industry<br />

Norican Global A/S, a leading Danish<br />

metallic parts enhancement company,<br />

has entered an industry-exclusive partnership<br />

with DataProphet from South<br />

Africa, a global leader in artificial intelligence<br />

(AI) for manufacturing. Goal is<br />

to bring meaningful AI applications into<br />

real-life foundry environments.<br />

The partnership follows a number of<br />

joint innovation projects carried out<br />

over the past 12 months with the Norican<br />

brand DISA, one of the leading suppliers<br />

of green sand foundry technology.<br />

The results of these projects are<br />

already maturing into products and the<br />

first commercial AI application<br />

developed under the collaboration is<br />

scheduled to go live in a customer production<br />

in a few months.<br />

Anders Wilhjelm, CEO of Norican<br />

Group, says: “We know foundries and<br />

how they work, DataProphet really<br />

knows AI. Together, we can bring<br />

practical AI applications into foundries<br />

faster – applications that will have a<br />

tangible impact for our customers now,<br />

not in a distant future.” Frans Cronje,<br />

CEO and co-founder of DataProphet,<br />

Reduction of rejects via artificial intelligence? The Norican Group is now getting serious<br />

about the future project with partner DataProphet.<br />

adds: “Working closely with an equipment<br />

manufacturer of DISA’s deep<br />

expertise allows us to make a genuine<br />

difference in foundries.”<br />

The new AI applications developed<br />

as part of the partnership are equipment-agnostic,<br />

meaning they will be<br />

available not only on solutions from<br />

the other Norican brands (Italpresse<br />

Gauss for die casting, StrikoWestofen<br />

for high-end furnace technology and<br />

Wheelabrator for surface preparation),<br />

but will also work with non-Norican<br />

equipment. www.noricangroup.com<br />

Photo: Fotolia<br />

RHEINMETALL AUTOMOTIVE<br />

Innovation Award for Hydrogen<br />

Recirculation Blower<br />

This new hydrogen recirculation blower by<br />

the Rheinmetall Automotive subsidiary Pierburg<br />

from Neuss, Germany, received an<br />

award in Shanghai in December of last year.<br />

Rheinmetall Automotive received an<br />

award for its new hydrogen recirculation<br />

blower at the 12th <strong>International</strong><br />

Automotive Congress 2019 on the 4th<br />

of December in Shanghai. With the<br />

Automotive Technology Innovation<br />

Award for a fuel-cell driveline component<br />

developed by Rheinmetall Automotive<br />

subsidiary Pierburg the jury<br />

honored innovative developments in<br />

the field of future drivelines.<br />

Fuel cell systems have a recirculation<br />

system for unused hydrogen on the<br />

anode side. An active blower is often<br />

used for this purpose, which must function<br />

safely and efficiently even at high<br />

concentrations of hydrogen. To ensure<br />

this, Pierburg has developed a hydrogen<br />

recirculation blower (HRB) based<br />

on a side-channel blower and without<br />

dynamic sealing elements to ensure ultimate<br />

hydrogen tightness over lifetime.<br />

The hydrogen recirculation blower is<br />

available in both high- and low-voltage<br />

variants. The blower can start from cold<br />

and has excellent NVH (Noice Vibration<br />

Harshness) characteristics. It has a rating<br />

of 0.7 to 2 kilowatts or up to 400 watts<br />

in the low-voltage version. It is driven by<br />

a brushless motor with sensorless control;<br />

LIN / CAN bus communication and<br />

diagnostic functions are also available.<br />

The Chinese congress is a technology<br />

forum focusing on trends in the automotive<br />

industry such as New Energy<br />

Vehicles (NEV), Future Mobility and<br />

lightweight engineering. It is organized<br />

by the Institut für Kraftfahrzeuge (ika)<br />

of RWTH Aachen University and the<br />

Vogel Automotive Media Group. The<br />

congress, which has been held in Shanghai<br />

since 2008, has become an important<br />

meeting-point for experts in automotive<br />

technology and is of growing<br />

significance.<br />

www.rheinmetall-automotive.com<br />

Photo: Rheinmetall Automotive<br />

46


CASTFORGE <strong>2020</strong><br />

On course for success<br />

The second anniversary of CastForge,<br />

which will be taking place from 16 to<br />

18 June <strong>2020</strong> at the Messe Stuttgart, is<br />

already nearly fully booked. More<br />

than 250 international exhibitors will<br />

be participating in the Trade Fair for<br />

Castings and Forgings with Processing.<br />

This corresponds to an increase of 66<br />

percent on the première in 2018, and<br />

double the number of spaces occupied<br />

in the hall. Amongst the exhibitors<br />

from across Europe are well-known<br />

names such as Bosch Rexroth, GF Casting<br />

Solutions and Fonderie Schlumberger.<br />

„We are so pleased with the great<br />

encouragement that CastForge has<br />

received,“ says Gunnar Mey, Department<br />

Director of Industrial Solutions at<br />

Messe Stuttgart. He announces that,<br />

„despite being in a challenging time<br />

economically, we sense great enthusiasm<br />

from the trade fair exhibitors.<br />

Together with the castings and forgings<br />

CastForge <strong>2020</strong> is almost fully booked. Here,<br />

visitors can get a comprehensive idea of the<br />

market and keep an eye on current developments.<br />

sector, we are optimistic about getting<br />

one of the biggest purchasing events<br />

for castings and forgings on its feet.“<br />

The high level of specialization offered<br />

by this trade fair, with its focus on<br />

castings and forgings with processing, is<br />

one of the key reasons why so many<br />

companies want to exhibit at CastForge<br />

<strong>2020</strong>.<br />

Specialist visitors of CastForge <strong>2020</strong><br />

can also look forward to a varied<br />

accompanying programme of high professional<br />

quality. Gunnar Mey gives us a<br />

glimpse, explaining that „the Project<br />

Team is currently developing a suitable<br />

three-day accompanying programme,<br />

together with various associations and<br />

institutions. This will include a stage for<br />

specialist talks in the trade fair hall. In<br />

addition, workshops, seminars and conferences<br />

will be taking place at the ICS<br />

<strong>International</strong> Congress Center Stuttgart,<br />

making CastForge an even more attractive<br />

event for visitors who are interested<br />

in castings and forgings with processing.<br />

This includes the “cast iron<br />

forum”, organized by the Academy of<br />

the Association of German Foundrymen<br />

(VDG), which will be taking place<br />

alongside CastForge.“<br />

www.castforge.de<br />

Photo: Messe Stuttgart<br />

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FOR AUTOMOBILE INDUSTRY & AEROSPACE INDUSTRY.<br />

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CONTINUOUS TYPE ALUMINUM ALLOY SOLUTION<br />

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TEL: 886-4-2337-4938 / 2336-2553 FAX: 886-4-2338-2380 / 2336-2218<br />

E-mail: lucky.winsun@msa.hinet.net Web: http://www.dainipponent.com/<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 47


NEWS<br />

SPECTRO<br />

New quick and efficient spark spectrometer<br />

Spectro Analytical Instruments, Kleve,<br />

Germany, has introduced the eighth<br />

generation of its Spectromaxx with iCAL<br />

2.0 arc/spark OES Analyzer - improved<br />

with new capabilities and advancements<br />

in performance to achieve fast,<br />

accurate elemental analysis precisely<br />

tuned for material control and foundry<br />

applications.<br />

The newest generation instrument<br />

features high speed, quick and simple<br />

standardization, reliable and accurate<br />

results, low gas consumption, and a low<br />

cost of ownership for a better elemental<br />

analysis of incoming source materials,<br />

for in-process testing and traceability,<br />

and for final quality inspection. The<br />

new Spectromaxx analyzer’s even faster<br />

measurement times and low consumables<br />

consumption provide high productivity,<br />

analytical performance, ease of<br />

use, and cost-effectiveness.<br />

According to Spectro the Spectromaxx<br />

achieves a 12 percent reduction in<br />

measurement times with optimized<br />

spark parameters. (Example: low-alloy<br />

steel takes 3 seconds less than with previous<br />

models.) This enables users to<br />

quickly react to changing process conditions<br />

for savings in both time and<br />

energy costs.<br />

Quick, Simple Standardization: The<br />

new analyzer features Spectro’s proprietary<br />

iCAL 2.0 calibration logic, which<br />

needs 5 minutes and a single sample per<br />

The new Spectromaxx<br />

achieves a<br />

fast, accurate elemental<br />

analysis precisely<br />

tuned for<br />

material control and<br />

foundry applications.<br />

day. Spectromaxx with iCAL 2.0 compensates<br />

for most changes in environmental<br />

temperature or pressure without requiring<br />

reruns, unlike conventional instruments.<br />

Moreover, Spectro’s Spark Analyzer<br />

Pro software features a simplified<br />

operator view and programmable application<br />

profiles to ensure ease of use for<br />

less experienced personnel. The result:<br />

unparalleled stability, productivity, and<br />

savings. Spectromaxx also minimizes the<br />

use of costly argon gas without sacrificing<br />

analytical performance. The analyzer’s<br />

low maintenance requirements<br />

deliver higher availability, while advanced<br />

diagnostics with critical status indicators<br />

make maintenance easier and<br />

prevent downtime. Amecare services<br />

help promote uninterrupted performance<br />

and maximize return on investment<br />

with machine-to-machine support<br />

that allows proactive alerts, backed up<br />

by an on-request PC connection with a<br />

remote Spectro service expert.<br />

Furthermore advanced OES technology<br />

enables the spark spectrometer to<br />

precisely detect and analyze samples<br />

containing free graphite, with results<br />

comparable to those achieved by combustion<br />

analysis. The analyzer can monitor<br />

carbon during the pre-spark phase<br />

to detect free graphite and minimize its<br />

effects by selecting analytical conditions.<br />

This approach also uses a statistical<br />

method to detect bad samples automatically.<br />

www.spectro.com/maxx<br />

Photo: Spectro<br />

OTTO JUNKER<br />

Increasing flexibility with Medium-frequency<br />

induction melting plant<br />

48<br />

Eisenwerke Erzgebirge, Schönheide,<br />

Germany, an iron foundry that produces<br />

high-grade castings for the automotive<br />

industry, has a new medium-frequency<br />

coreless induction furnace system. Furnace<br />

constructor is Otto Junker from<br />

Simmerath, Germany.<br />

With its new coreless furnaces the<br />

company aims to safeguard its viability<br />

in tomorrow‘s markets and intends to<br />

establish itself as a supplier of grey cast<br />

iron and spheroidal graphite iron (SGI)<br />

products. Its stated goal is to become a<br />

flexible contract foundry producing<br />

small lot sizes of castings in whiteheart<br />

and blackheart malleable iron, grey cast<br />

iron and SGI.<br />

The new melting furnace system<br />

consists of two 6,000 kg furnaces operated<br />

in tandem off a 4,800 kW converter.<br />

The Duomelt set-up allows for an infinitely<br />

variable power split between the<br />

two furnaces. The converter employed<br />

features modern IGBT modules, enabling<br />

the plant to run with a constantly<br />

high power factor (cos phi = 1.0 at the<br />

converter input). Multi-Frequency technology<br />

(250 Hz /125 Hz) provides a melt<br />

stirring capability for carburizing and<br />

alloying work.<br />

Automatic process management is<br />

provided on the basis of a JOKS touch<br />

control system in this application. The<br />

bidirectionally tiltable extractor hood<br />

collects the fumes released in the melting<br />

process. An OCP (Optical Coil Protection)<br />

system is fitted for continuous<br />

monitoring of the temperature on the<br />

inside of the coil. This ensures an early<br />

detection of crucible defects and prevents<br />

coil damage and melt breakthrough.<br />

The furnaces are mechanically<br />

filled with the necessary raw materials<br />

by means of the charging machines.<br />

This solution improves operator safety<br />

on the one hand while also facilitating<br />

an optimum utilization of the furnace‘s<br />

melting capacity due to adjustability of<br />

the charging speed.<br />

The pouring process is fully automated<br />

thanks to the use of the 1.2 tonne<br />

stoppered ladle that was part of Otto<br />

Junker‘s scope of supply. The system distinguishes<br />

itself by high ease of maintenance<br />

and hence, high equipment<br />

availability.<br />

www.otto-junker.de


FOSECO<br />

New foundry coating<br />

improves inner cleanliness<br />

Today the influence of a coating applied at a thickness of<br />

about three human hairs goes way beyond the actual cast<br />

component; it can beneficially improve the surface roughness<br />

resulting in an improvement of the performance of the<br />

engine and extend the service interval frequency of modern<br />

combustion engines.<br />

Photo: Foseco<br />

The new coatings result in very clean surfaces, even in critical areas.<br />

The choice of the right refractory coating during casting production<br />

can influence engine performance to a degree that<br />

longer service intervals can be applied as well as the replacement<br />

of cooling and lubrication fluids reduced. These improvements<br />

can contribute directly to environmental requirements<br />

laid down by Euro 6 and future Euro 7 regulations.<br />

The new range of “Inner Cleanliness” coatings from Foseco is<br />

meant for automotive foundries and addresses the increasing<br />

quality demands specified for the next generations of emission-reduced<br />

and performance-enhanced internal combustion<br />

engines.<br />

Major Benefits:<br />

> Reduction of remaining dirt in inaccessible parts of the<br />

engine (head and block)<br />

> Reduction of rework and cleaning costs<br />

> Improvement of engine performance<br />

> Extension of service intervals<br />

> CO 2<br />

-emission reduction<br />

> Reduced impurities in the cooling circulation system<br />

www.vesuvius.com/en/our-solutions/international.html<br />

Do you want your press information<br />

to be published in our News<br />

section?<br />

Then please send your reports to:<br />

redaktion@bdguss.de


NEWS<br />

The Carl Loper Symposium<br />

in Bilbao<br />

brought together<br />

around 160 participants<br />

from 21 countries.<br />

Photo: Azterlan<br />

2ND CARL LOPER SYMPOSIUM BILBAO<br />

The future of cast iron<br />

At the 2nd Carl Loper Symposium in the<br />

Spanish coastal city of Bilbao more than<br />

160 participants from 21 countries<br />

gathered from 30 September to 1 October<br />

2019 to share the most advanced<br />

technological innovations and applications<br />

of cast iron.<br />

Organized by the IK4-Azterlan<br />

Metallurgy Research Center, along with<br />

the American Foundry Society (AFS), the<br />

World Foundry Organization (WFO) and<br />

the Tabira Foundry Institute, the event<br />

has reviewed the metallurgy fundamentals<br />

of cast iron by sharing some of the<br />

latest research and technological<br />

developments for the industry. More<br />

than 85 companies, organizations and<br />

technology centers from 21 countries<br />

have been represented in the event.<br />

The results of the symposium were as<br />

follows:<br />

The undeniable effort to promote the<br />

electric vehicle and the need to reduce<br />

CO 2<br />

emissions have led the European<br />

automotive sector to put in practice<br />

diverse initiatives to lighten the weight<br />

of automobiles. However, strategies like<br />

the substitution of diesel engine for the<br />

gasoline one, the development of new<br />

metallic alloys or the redesign and substitution<br />

of specific components seem to<br />

affect specially the projections of the<br />

same industry: cast iron.<br />

This material, that not long ago was<br />

a collective bet of the industry, due to<br />

the provided mechanical characteristics,<br />

as well as for its capacity to shape complex<br />

geometries or its low manufacturing<br />

cost, now seems to be losing the<br />

battle, at least, in Europe.<br />

In fact, the Symposium offered the<br />

opportunity to know the stance of the<br />

OEM companies like Renault. Representing<br />

this French automobile manufacturer,<br />

Mr. Loïc Vaissierre and Mr. Eric<br />

Albertalli, experts in casting processes<br />

innovation, predicted that “until 2035,<br />

a yearly reduction of 1.85 percent will<br />

happen in the presence of cast iron<br />

parts within the automobile”. The numbers<br />

presented by the engineers talked<br />

by themselves: some years ago, an average<br />

of 175 kg of casted parts could be<br />

found by car, nowadays this number has<br />

descended to 138 kg by car and in the<br />

mentioned date only a total of 50 kg<br />

will be found. The Renault representatives<br />

also pointed out some potential<br />

substitutes for iron casting: aluminium<br />

(forged and cast) and steel (forged, cast<br />

and stamped).<br />

But, is the iron foundry destined to<br />

be a minority material within the passenger<br />

vehicles? Is this a global tendency?<br />

This same meeting also had the<br />

presentation of Dr. Steve Dawson, CEO<br />

of the Sintercast company who, in<br />

opposition to the previous point of<br />

view, was able to foretell a more positive<br />

future for cast iron. Dr. Dawson<br />

highlighted how the strategy to push<br />

the electric vehicle is a “mainly European<br />

and Chinese” trend, but that it<br />

does not correspond to other markets,<br />

like American one, “where bigger and<br />

heavier cars are being manufactured”.<br />

He predicted a steady increase in the<br />

application of cast iron parts within the<br />

passenger vehicle and, in his words, it<br />

will necessarily keep occupying a key<br />

role in the automotive industry.<br />

In front of this discussion, the R&D<br />

director of the Azterlan Metallurgy<br />

Research Centre, Ramón Suárez, assured<br />

that, for iron foundry to keep occupying<br />

a relevant place, it must be able to<br />

showcase new opportunities and<br />

advance towards new attractive frontiers<br />

for the industry.<br />

“With no doubt, the passenger<br />

vehicle industry will keep innovating to<br />

achieve lighter and more secure cars,<br />

promoting lower fuel consumption and<br />

a greater efficiency in the use of raw<br />

materials”. In this field, in the words of<br />

Suárez, the symposium has allowed to<br />

prove that, “even though this is a<br />

mature technology, iron casting has still<br />

a lot to offer to the automotive sector<br />

and it is open to innovation”. That way,<br />

only if we keep researching and “taking<br />

the materials to new limits” will it be<br />

able to show all of its potential to components<br />

designers and users”.<br />

“Obviously, this requires the industry<br />

to make a significant effort”. Developing<br />

new and more efficient processes,<br />

data mining and “why not, linking<br />

these data to the information generated<br />

by the components through their<br />

service life”, can offer the foundry the<br />

clues to define its innovation lines, as<br />

well as the arguments it needs to maintain<br />

an outstanding place within this<br />

highly demanding industry.<br />

Interview with<br />

Dr. Steve Dawson,<br />

SinterCast, at the<br />

symposium<br />

50


SUPPLIERS GUIDE<br />

CASTING<br />

PLANT AND TECHNOLOGY<br />

INTERNATIONAL<br />

© DVS Media GmbH<br />

Contact person: Vanessa Wollstein<br />

Aachener Straße 172 Phone: +49 211 1591-152<br />

40223 Düsseldorf Fax: +49 211 1591-150<br />

E-Mail: vanessa.wollstein@dvs-media.info<br />

1 Foundry Plants and Equipment<br />

17 Surface Treatment and Drying<br />

2<br />

Melting Plants and Equipment for Iron and<br />

Steel Castings and for Malleable Cast Iron<br />

18<br />

Plant, Transport, Stock, and Handling<br />

Engineering<br />

3 Melting Plants and Equipment for NFM<br />

4 Refractories Technology<br />

19 Pattern- and Diemaking<br />

20 Control Systems and Automation<br />

5<br />

6<br />

7<br />

8<br />

Non-metal Raw Materials and Auxiliaries for<br />

Melting Shop<br />

Metallic Charge Materials for Iron and Steel<br />

Castings and for Malleable Cast Iron<br />

Metallic Charge and Treatment Materials for<br />

Light and Heavy Metal Castings<br />

Plants and Machines for Moulding and<br />

Coremaking Processes<br />

21 Testing of Materials<br />

22 Analysis Technique and Laboratory<br />

23 Air Technique and Equipment<br />

24 Environmental Protection and Disposal<br />

9 Moulding Sands<br />

10 Sand Conditioning and Reclamation<br />

11 Moulding Auxiliaries<br />

12 Gating and Feeding<br />

13 Casting Machines and Equipment<br />

25 Accident Prevention and Ergonomics<br />

26 Other Products for Casting Industry<br />

27 Consulting and Service<br />

28 Castings<br />

29 By-Products<br />

14<br />

Discharging, Cleaning, Finishing of Raw<br />

Castings<br />

30 Data Processing Technology<br />

15 Surface Treatment<br />

16 Welding and Cutting<br />

31 Foundries<br />

32 Additive manufacturing / 3-D printing<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 51


SUPPLIERS GUIDE<br />

01 Foundry Plants and Equipment<br />

▼ Remelting Furnaces 700<br />

▼ Foundry Equipment and Facilities, in general 20<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Second Hand Foundry Plants and Equipment 45<br />

TCT TESIC GmbH<br />

Foundry Marketing & Services<br />

58640 Iserlohn, Germany<br />

( +49 2371 77260<br />

Innernent:<br />

www.ncn-nesic.com<br />

02 Melting Plants and Equipment for Iron and<br />

Steel Castings and for Malleable Cast Iron<br />

02.06 Maintenance and Repairing<br />

▼ Repairing of Induction Furnaces 584<br />

TCT TESIC GmbH<br />

Foundry Marketing & Services<br />

58640 Iserlohn, Germany<br />

( +49 2371 77260<br />

Innernent:<br />

www.ncn-nesic.com<br />

03 Melting Plants and Equipment for NFM<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

04 Refractories Technology<br />

04.01 Plants, Equipment and Tools for Lining in Melting<br />

and Casting<br />

▼ Mixers and Chargers for Refractory Mixes 930<br />

UELZENER Maschinen GmbH<br />

Snahlsnr. 26-28, 65428 Rüsselsheim, Germany<br />

( +49 6142 177 68 0<br />

E--ailt:<br />

connacn@uelzener-ums.de<br />

Innernent:<br />

www.uelzener-ums.de<br />

▼ Gunning for Relining of Cupolas 950<br />

UELZENER Maschinen GmbH<br />

Snahlsnr. 26-28, 65428 Rüsselsheim, Germany<br />

( +49 6142 177 68 0<br />

E--ailt:<br />

connacn@uelzener-ums.de<br />

Innernent:<br />

www.uelzener-ums.de<br />

▼ Wear Indicators for Refractory Lining 980<br />

Saveway GmbH & Co. KG<br />

Wümbacher Landsnraße 8, 98693 Ilmenau, Germany<br />

( +49 3677 8060-0 7 +49 3677 8060-99<br />

Innernent:<br />

www.saveway-germany.de<br />

▼ Wear Measuring and Monitoring for Refractory Lining 982<br />

Refratechnik Steel GmbH<br />

Refratechnik Casting GmbH<br />

Schiess-Snr. 58, 40549 Düsseldorf, Germany<br />

( +49 211 5858-0<br />

E--ailt:<br />

sneel@refra.com<br />

Innernent:<br />

www.refra.com<br />

▼ Insulating Refractoy Bricks 1050<br />

Division Etex Industry<br />

Raningen/Germany<br />

E--ailt:<br />

www.proman-indusnry.com<br />

▼ Insulating Products 1130<br />

Division Etex Industry<br />

Raningen/Germany<br />

E--ailt:<br />

www.proman-indusnry.com<br />

EIKA, S.COOP<br />

Urresolo 47, 48277 Enxebarria, Spain<br />

( +34 946 16 77 32<br />

E--ailt:<br />

jorniz@isoleika.es<br />

Innernent:<br />

www.isoleika.es<br />

▼ Ceramic Fibre Mats, Papers, Plates, and Felts 1155<br />

Division Etex Industry<br />

Raningen/Germany<br />

E--ailt:<br />

www.proman-indusnry.com<br />

▼ Micro Porous Insulating Materials 1220<br />

Division Etex Industry<br />

Raningen/Germany<br />

E--ailt:<br />

www.proman-indusnry.com<br />

03.02 Melting and Holding Furnaces, Electrically<br />

Heated<br />

▼ Aluminium Melting Furnaces 630<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Induction Furnaces (Mains, Medium,<br />

and High Frequency) 660<br />

INDUGA GmbH & Co. KG<br />

52152 Simmeranh, Germany<br />

E--ailt:<br />

info@induga.de<br />

Innernent:<br />

www.induga.com<br />

Saveway GmbH & Co. KG<br />

Wümbacher Landsnraße 8, 98693 Ilmenau, Germany<br />

( +49 3677 8060-0 7 +49 3677 8060-99<br />

Innernent:<br />

www.saveway-germany.de<br />

▼ State Diagnosis of Refractory Lines 985<br />

Saveway GmbH & Co. KG<br />

Wümbacher Landsnraße 8, 98693 Ilmenau, Germany<br />

( +49 3677 8060-0 7 +49 3677 8060-99<br />

Innernent:<br />

www.saveway-germany.de<br />

04.02 Refractory Materials (Shaped and Non Shaped)<br />

▼ Refractories, in general 1040<br />

EIKA, S.COOP<br />

Urresolo 47, 48277 Enxebarria, Spain<br />

( +34 946 16 77 32<br />

E--ailt:<br />

jorniz@isoleika.es<br />

Innernent:<br />

www.isoleika.es<br />

▼ Ladle Refractory Mixes 1240<br />

UELZENER Maschinen GmbH<br />

Snahlsnr. 26-28, 65428 Rüsselsheim, Germany<br />

( +49 6142 177 68 0<br />

E--ailt:<br />

connacn@uelzener-ums.de<br />

Innernent:<br />

www.uelzener-ums.de<br />

04.04 Refractory Building<br />

▼ Maintenance of Refractory Linings 1462<br />

UELZENER Maschinen GmbH<br />

Snahlsnr. 26-28, 65428 Rüsselsheim, Germany<br />

( +49 6142 177 68 0<br />

E--ailt:<br />

connacn@uelzener-ums.de<br />

Innernent:<br />

www.uelzener-ums.de<br />

EIKA, S.COOP<br />

Urresolo 47, 48277 Enxebarria, Spain<br />

( +34 946 16 77 32<br />

E--ailt:<br />

jorniz@isoleika.es<br />

Innernent:<br />

www.isoleika.es<br />

L. & F. PETERS GmbH<br />

E--ailt:<br />

www.peners-feuerfesn.de<br />

52


05 Non-metal Raw Materials and Auxiliaries for<br />

Melting Shop<br />

▼ Vacuum Moulding Machines and Processes 3280<br />

10 Sand Conditioning and Reclamation<br />

05.04 Carburization Agents<br />

▼ Coke Breeze, Coke-Dust 1680<br />

ARISTON Formstaub-Werke GmbH & Co. KG<br />

Worringersnr. 255, 45289 Essen, Germany<br />

( +49 201 57761 7 +49 201 570648<br />

Innernent:<br />

www.arisnon-essen.de<br />

08 Plants and Machines for Moulding and<br />

Coremaking Processes<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

08.03 Additives and Accessories<br />

▼ Core Handling 3450<br />

▼ Sand Reclamation System 4448<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

08.01 Moulding Plants<br />

▼ Moulding Machines, Fully and Partially Automatic 3070<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

08.02 Moulding and Coremaking Machines<br />

▼ Multi-Stage Vacuum Process 3223<br />

Pfeiffer Vacuum GmbH<br />

35614 Asslar, Germany<br />

( +49 6441 802-1190 7 +49 6441 802-1199<br />

E--ailt:<br />

andreas.wuerz@pfeiffer-vacuum.de<br />

Innernent:<br />

www.pfeiffer-vacuum.de<br />

▼ Automatic Moulding Machines 3100<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Moulding Machines, Boxless 3150<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Air-flow Squeeze Moulding Machines and Plants 3190<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

09 Moulding Sands<br />

09.01 Basic Moulding Sands<br />

▼ Chromite Sands 3630<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Ceramic Sands/Chamotte Sands 3645<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Silica Sands 3720<br />

STROBEL QUARZSAND GmbH<br />

Freihungsand, 92271 Freihung, Germany<br />

( +49 9646 9201-0 7 +49 9646 9201-1257<br />

E--ailt:<br />

info@snrobel-quarzsand.de<br />

Innernent:<br />

www.snrobel-quarzsand.de<br />

09.04 Mould and Core Coating<br />

▼ Blackings, in general 4270<br />

ARISTON Formstaub-Werke GmbH & Co. KG<br />

Worringersnr. 255, 45289 Essen, Germany<br />

( +49 201 57761 7 +49 201 570648<br />

Innernent:<br />

www.arisnon-essen.de<br />

09.06 Moulding Sands Testing<br />

▼ Moisture Testing Equipment for Moulding Sand 4410<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Moulding Sand Testing Equipment, in general 4420<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

10.01 Moulding Sand Conditioning<br />

▼ Aerators for Moulding Sand Ready-to-Use 4470<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Sand Preparation Plants and Machines 4480<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Mixers 4520<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Sand Mixers 4550<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Aerators 4560<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Scales and Weighing Control 4590<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

10.04 Sand Reconditioning<br />

▼ Sand Coolers 4720<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

12 Gating and Feeding<br />

▼ Covering Agents 5320<br />

Refratechnik Steel GmbH<br />

Refratechnik Casting GmbH<br />

Schiess-Snr. 58, 40549 Düsseldorf, Germany<br />

( +49 211 5858-0<br />

E--ailt:<br />

sneel@refra.com<br />

Innernent:<br />

www.refra.com<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 53


SUPPLIERS GUIDE<br />

▼ Breaker Cores 5340<br />

▼ Multi-Stage Vacuum Process 5876<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Exothermic Products 5360<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Insulating Sleeves 5375<br />

INDUGA GmbH & Co. KG<br />

52152 Simmeranh, Germany<br />

E--ailt:<br />

info@induga.de<br />

Innernent:<br />

www.induga.com<br />

13.02 Die Casting and Accessories<br />

▼ Diecasting Lubricants 5670<br />

Pfeiffer Vacuum GmbH<br />

35614 Asslar, Germany<br />

( +49 6441 802-1190 7 +49 6441 802-1199<br />

E--ailt:<br />

andreas.wuerz@pfeiffer-vacuum.de<br />

Innernent:<br />

www.pfeiffer-vacuum.de<br />

13.03 Gravity Die Casting<br />

▼ Gravity Diecasting Machines 5940<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Exothermic Mini-Feeders 5400<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Exothermic Feeder Sleeves 5420<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

▼ Exothermic Feeding Compounds 5430<br />

GTP Schäfer GmbH<br />

41515 Grevenbroich, Germany<br />

( +49 2181 23394-0 7 +49 2181 23394-55<br />

E--ailt:<br />

info@gnp-schaefer.de<br />

Innernent:<br />

www.gnp-schaefer.com<br />

13 Casting Machines and Equipment<br />

▼ Pouring Machines and Equipment 5436<br />

Chem-Trend (Deutschland) GmbH<br />

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany<br />

( +49 40 52955-0 7 +49 40 52955-2111<br />

E--ailt:<br />

service@chemnrend.de<br />

Innernent:<br />

www.chemnrend.com<br />

▼ Diecasting Parting Agents 5680<br />

Chem-Trend (Deutschland) GmbH<br />

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany<br />

( +49 40 52955-0 7 +49 40 52955-2111<br />

E--ailt:<br />

service@chemnrend.de<br />

Innernent:<br />

www.chemnrend.com<br />

▼ Hydraulic Cylinders 5750<br />

HYDROPNEU GmbH<br />

Sudenensnr. , 73760 Osnfildern, Germany<br />

( +49 711 342999-0 7 +49 711 342999-1<br />

E--ailt:<br />

info@hydropneu.de<br />

Innernent:<br />

www.hydropneu.de<br />

▼ Piston Lubricants 5790<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Low Pressure Diecasting Machines 5980<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

14 Discharging, Cleaning, Finishing of Raw<br />

Castings<br />

14.05 Additional Cleaning Plants and Devices<br />

▼ Pneumatic Hammers 6940<br />

MD Drucklufttechnik GmbH & Co. KG<br />

Weissacher Snr. 1, 70499 Snunngarn, Germany<br />

( +49 711 88718-0 7 +49 711 88718-100<br />

Innernent:<br />

www.mannesmann-demag.com<br />

INDUGA GmbH & Co. KG<br />

52152 Simmeranh, Germany<br />

E--ailt:<br />

info@induga.de<br />

Innernent:<br />

www.induga.com<br />

Chem-Trend (Deutschland) GmbH<br />

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany<br />

( +49 40 52955-0 7 +49 40 52955-2111<br />

E--ailt:<br />

service@chemnrend.de<br />

Innernent:<br />

www.chemnrend.com<br />

▼ Parting Agents for Dies 5850<br />

17 Surface Treatment and Drying<br />

▼ Heat Treatment and Drying 7398<br />

13.01 Pouring Furnaces and their Equipment<br />

▼ Pouring Equipment 5450<br />

INDUGA GmbH & Co. KG<br />

52152 Simmeranh, Germany<br />

E--ailt:<br />

info@induga.de<br />

Innernent:<br />

www.induga.com<br />

▼ Pouring Equipment for Molding Plants, Railborn or<br />

Crane-operated 5470<br />

Chem-Trend (Deutschland) GmbH<br />

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany<br />

( +49 40 52955-0 7 +49 40 52955-2111<br />

E--ailt:<br />

service@chemnrend.de<br />

Innernent:<br />

www.chemnrend.com<br />

▼ Dry Lubricants (Beads) 5865<br />

Gebr. Löcher Glüherei GmbH<br />

-ühlenseifen 2, 57271 Hilchenbach, Germany<br />

( +49 2733 8968-0 7 +49 2733 8968-10<br />

Innernent:<br />

www.loecher-glueherei.de<br />

17.01 Plants and Furnaces<br />

▼ Tempering Furnaces 7400<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

Chem-Trend (Deutschland) GmbH<br />

Robern-Koch-Snr. 27, 22851 Nordersnedn, Germany<br />

( +49 40 52955-0 7 +49 40 52955-2111<br />

E--ailt:<br />

service@chemnrend.de<br />

Innernent:<br />

www.chemnrend.com<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

54


▼ Ageing Furnaces 7401<br />

▼ Hearth Bogie Type Furnaces 7525<br />

▼ Software for Production Planning and Control 9042<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Annealing and Hardening Furnaces 7430<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

18 Plant, Transport, Stock, and Handling<br />

Engineering<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Control Systems and Automation, in general 9090<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Solution Annealing Furnaces 7455<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Annealing Furnaces 7490<br />

18.01 Continuous Conveyors and Accessories<br />

▼ Flexible Tubes with Ceramic Wear Protection 7676<br />

STEIN INJECTION TECHNOLOGY GmbH<br />

Hagener Snr. 20-24, 58285 Gevelsberg, Germany<br />

( +49 2332 75742-0 7 +49 2332 75742-40<br />

E--ailt:<br />

snein@sin-gmbh.nen<br />

Innernent:<br />

www.sin-gmbh.nen<br />

▼ Vibratory Motors 7980<br />

FRIEDRICH Schwingtechnik GmbH<br />

Am Höfgen 24, 42781 Haan, Germany<br />

( +49 2129 3790-0 7 +49 2129 3790-37<br />

E--ailt:<br />

info@friedrich-schwingnechnik.de<br />

Innernent:<br />

www.friedrich-schwingnechnik.de<br />

19 Pattern- and Diemaking<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

20.02 Measuring and Control Instruments<br />

▼ Immersion Thermo Couples 9230<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

▼ Laser Measurement Techniques 9310<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Quenching and Tempering Furnaces 7510<br />

19.04 Rapid Prototyping<br />

▼ Pattern and Prototype Making 9025<br />

POLYTEC GmbH<br />

76337 Waldbronn, Germany<br />

( +49 7243 604-0 7 +49 7243 69944<br />

E--ailt:<br />

Lm@polynec.de<br />

Innernent:<br />

www.polynec.de<br />

▼ Positioning Control 9345<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

▼ Heat Treating Furnaces 7520<br />

Georg Herrmann Metallgießerei GmbH<br />

-uldenhünnen 22, 09599 Freiberg, Germany<br />

( +49 3731 3969 0 7 +49 3731 3969 3<br />

E--ailt:<br />

mail@ghm-aluguss.de<br />

Innernent:<br />

www.ghm-aluguss.de<br />

20 Control Systems and Automation<br />

20.01 Control and Adjustment Systems<br />

▼ Automation and Control for Sand Preparation 9030<br />

POLYTEC GmbH<br />

76337 Waldbronn, Germany<br />

( +49 7243 604-0 7 +49 7243 69944<br />

E--ailt:<br />

Lm@polynec.de<br />

Innernent:<br />

www.polynec.de<br />

▼ Temperature Measurement 9380<br />

LOI Thermoprocess GmbH<br />

45141 Essen/Germany<br />

( +49 201 1891-1<br />

E--ailt:<br />

loi@nenova.com<br />

Innernent:<br />

www.loi.nenova.com<br />

Maschinenfabrik Gustav Eirich<br />

GmbH & Co KG<br />

Walldürner Snr. 50, 74736 Hardheim, Germany<br />

▼ Automation 9040<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 55


SUPPLIERS GUIDE<br />

▼ Thermal Analysis Equipment 9400<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

▼ Thermo Couples 9410<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

20.03 Data Acquisition and Processing<br />

▼ Data Logging and Communication 9440<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Machine Data Logging 9480<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Numerical Solidification Analysis<br />

and Process Simulation 9500<br />

MAGMA Giessereitechnologie GmbH<br />

Kackernsnr. 11, 52072 Aachen, Germany<br />

( +49 241 88901-0 7 +49 241 88901-60<br />

E--ailt:<br />

info@magmasofn.de<br />

Innernent:<br />

www.magmasofn.com<br />

▼ Numerical Solidification Simulation<br />

and Process Optimization 9502<br />

MAGMA Giessereitechnologie GmbH<br />

Kackernsnr. 11, 52072 Aachen, Germany<br />

( +49 241 88901-0 7 +49 241 88901-60<br />

E--ailt:<br />

info@magmasofn.de<br />

Innernent:<br />

www.magmasofn.com<br />

▼ Computer Programmes and Software for Foundries 9520<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Simulation Software 9522<br />

MAGMA Giessereitechnologie GmbH<br />

Kackernsnr. 11, 52072 Aachen, Germany<br />

( +49 241 88901-0 7 +49 241 88901-60<br />

E--ailt:<br />

info@magmasofn.de<br />

Innernent:<br />

www.magmasofn.com<br />

▼ Software for Foundries 9523<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

▼ Fault Indicating Systems, Registration<br />

and Documentation 9540<br />

HEINRICH WAGNER SINTO<br />

57334 Bad Laasphe, Germany<br />

( +49 2752 907-0 7 +49 2752 907-280<br />

Innernent:<br />

www.wagner-sinno.de<br />

21 Testing of Materials<br />

21.01 Testing of Materials and Workpieces<br />

▼ Dye Penetrants 9600<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

▼ Instruments for Non-destructive Testing 9610<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

▼ Magnetic Crack Detection Equipment 9680<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

▼ Ultrasonic Testing Equipment 9750<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

▼ UV-Lamps 9758<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

▼ Devices for Testing of Materials,<br />

non-destructive, in general 9836<br />

KARL DEUTSCH<br />

Prüf- und Messgerätebau GmbH + Co. KG<br />

Onno-Hausmann-Ring 101, 42115 Wuppernal, Germany<br />

( +49 202 71 92-0 7 +49 202 71 49 32<br />

E--ailt:<br />

info@karldeunsch.de<br />

Innernent:<br />

www.karldeunsch.de<br />

22 Analysis Technique and Laboratory Equipment<br />

▼ Sampling Systems 9970<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

26 Other Products for Casting Industry<br />

26.02 Industrial Commodities<br />

▼ Joints, Asbestos-free 11120<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

▼ Sealing and Insulating Products up to 1260 øC 11125<br />

MINKON GmbH<br />

Heinrich-Hernz-Snr. 30-32, 40699 Erkranh, Germany<br />

( +49 211 209908-0 7 +49 211 209908-90<br />

E--ailt:<br />

info@minkon.de<br />

Innernent:<br />

www.minkon.de<br />

27 Consulting and Service<br />

▼ Machining 11292<br />

Behringer GmbH<br />

Maschinenfabrik und Eisengiesserei<br />

Posnfacht:<br />

1153, 74910 Kirchardn, Germany<br />

( +49 7266 207-0 7 +49 7266 207-500<br />

Innernent:<br />

www.behringer.nen<br />

▼ Simulation Services 11310<br />

MAGMA Giessereitechnologie GmbH<br />

Kackernsnr. 11, 52072 Aachen, Germany<br />

( +49 241 88901-0 7 +49 241 88901-60<br />

E--ailt:<br />

info@magmasofn.de<br />

Innernent:<br />

www.magmasofn.com<br />

56


▼ Heat Treatment 11345<br />

Gebr. Löcher Glüherei GmbH<br />

-ühlenseifen 2, 57271 Hilchenbach, Germany<br />

( +49 2733 8968-0 7 +49 2733 8968-10<br />

Innernent:<br />

www.loecher-glueherei.de<br />

28 Castings<br />

▼ Aluminium Pressure Diecasting 11390<br />

▼ Spheroidal Iron 11540<br />

Behringer GmbH<br />

Maschinenfabrik und Eisengiesserei<br />

Posnfacht:<br />

1153, 74910 Kirchardn, Germany<br />

( +49 7266 207-0 7 +49 7266 207-500<br />

Innernent:<br />

www.behringer.nen<br />

▼ Steel Castings 11550<br />

KS Gleitlager GmbH, Werk Papenburg<br />

Friesensnr. 2, 26871 Papenburg, Germany<br />

( +49 4961 986-150 7 +49 4961 986-166<br />

E--ailt:<br />

sales-cc@de.rheinmenall.com<br />

Innernent:<br />

www.rheinmenall-aunomonive.com<br />

30 Data Processing Technology<br />

31 Foundries<br />

31.01 Iron, Steel, and Malleable-Iron Foundries<br />

▼ Iron Foudries 11855<br />

Behringer GmbH<br />

Maschinenfabrik und Eisengiesserei<br />

Posnfacht:<br />

1153, 74910 Kirchardn, Germany<br />

( +49 7266 207-0 7 +49 7266 207-500<br />

Innernent:<br />

www.behringer.nen<br />

31.02 NFM Foundries<br />

▼ Light Metal Casting Plants 11862<br />

Schött Druckguß GmbH<br />

Aluminium Die Casting<br />

Posnfacht:<br />

27 66, 58687 -enden, Germany<br />

( +49 2373 1608-0 7 +49 2373 1608-110<br />

E--ailt:<br />

vernrieb@schoenn-druckguss.de<br />

Innernent:<br />

www.schoenn-druckguss.de<br />

▼ Rolled Wire 11489<br />

Behringer GmbH<br />

Maschinenfabrik und Eisengiesserei<br />

Posnfacht:<br />

1153, 74910 Kirchardn, Germany<br />

( +49 7266 207-0 7 +49 7266 207-500<br />

Innernent:<br />

www.behringer.nen<br />

▼ Mold Filling and Solidification Simulation 11700<br />

MAGMA Giessereitechnologie GmbH<br />

Kackernsnr. 11, 52072 Aachen, Germany<br />

( +49 241 88901-0 7 +49 241 88901-60<br />

E--ailt:<br />

info@magmasofn.de<br />

Innernent:<br />

www.magmasofn.com<br />

Georg Herrmann Metallgießerei GmbH<br />

-uldenhünnen 22, 09599 Freiberg, Germany<br />

( +49 3731 3969 0 7 +49 3731 3969 3<br />

E--ailt:<br />

mail@ghm-aluguss.de<br />

Innernent:<br />

www.ghm-aluguss.de<br />

Index to Companies<br />

Company Product Company Product<br />

ARISTON Formsnaub-Werke GmbH & Co. KG 1680, 4270<br />

BEHRINGER GmbH 11292, 11489, 11540, 11855<br />

-aschinenfabrik&Eisengießerei<br />

Chem Trend (Deunschland) GmbH 5670, 5680, 5790, 5850, 5865<br />

-aschinenfabrik 4410, 4420, 4470, 4480, 4520,<br />

Gusnav Eirich GmbH & Co KG 4550, 4560, 4590, 4720, 9030<br />

Enex Building Performance GmbH 1050, 1130, 1155, 1220<br />

Friedrich Schwingnechnik GmbH 7980<br />

GTP Schäfer 3630, 3645, 5340, 5360, 5375,<br />

Giessnechnische Produkne GmbH 5400, 5420, 5430<br />

Heinrich Wagner Sinno -aschinenfabrik GmbH 20, 3070, 3100, 3150, 3190,<br />

3280, 3450, 4448, 5470, 5940,<br />

5980, 9040, 9042, 9090, 9440,<br />

9480, 9520, 9523, 9540<br />

HYDROPNEU GmbH 5750<br />

INDUGA GmbH & Co. KG 660, 5436, 5450, 5470<br />

Isoleika S. Coop 1040, 1130, 1220<br />

KARL DEUTSCH Prüf- und 9600, 9610, 9680, 9750, 9758,<br />

-essgeränebau GmbH + Co KG 9836<br />

KS Gleinlager GmbH Werk Papenburg 11550<br />

Gebr. Löcher Glüherei GmbH 7398, 11345<br />

LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430,<br />

7455, 7490, 7510, 7520, 7525<br />

-AG-A Gießereinechnologie GmbH 9500, 9502, 9522, 11310, 11700<br />

-D Drucklufnnechnik GmbH & Co. KG 6940<br />

Georg Herrmann -enallgießerei GmbH 9025, 11862<br />

-INKON GmbH 9230, 9380, 9400, 9410, 9970,<br />

11120, 11125<br />

L. & F. PETERS GmbH 1040<br />

Pfeiffer Vacuum GmbH 3223, 5876<br />

Polynec GmbH 9310, 9345<br />

Refranechnik Sneel GmbH 1040, 5320<br />

Saveway GmbH & Co. KG 980, 982, 985<br />

Schönn-Druckguß GmbH 11390<br />

Snein Injecnion Technology GmbH 7676<br />

Snrobel Quarzsand GmbH 3720<br />

TCT TESIC GmbH 45, 584<br />

Uelzener -aschinen GmbH 930, 950, 1240, 1462<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 57


List of Products<br />

01 Foundry Plants and Equipment<br />

10 Foundry Plants, Planning and<br />

Construction<br />

20 Foundry Equipment and Facilities,<br />

in general<br />

30 Foundry Plants, fully and<br />

partially automatic<br />

40 Maintenance and Repairing of<br />

Foundry Plants<br />

44 Swing-Technique Machines for<br />

Handling, Dosing, and Classing<br />

45 Second Hand Foundry Plants and<br />

Equipment<br />

47 Spray Deposition Plants<br />

01.01. Components<br />

47 Spray Deposition Plants<br />

50 Charging Systems, in general<br />

52 Cored Wire Treatment Stations<br />

53 Plug Connections, Heat Resisting<br />

02 Melting Plants and Equipment for Iron and<br />

Steel Castings and for Malleable Cast Iron<br />

02.01. Cupolas<br />

55 Cupolas<br />

60 Hot-Blast Cupolas<br />

70 Cold-Blast Cupolas<br />

80 Circulating Gas Cupolas<br />

90 Gas Fired Cupolas<br />

100 Cupolas, cokeless<br />

110 Cupolas with Oxygen-Enrichment<br />

120 Cupolas with Secondary Blast<br />

Operation<br />

02.02. Cupola Accessories and<br />

Auxiliaries<br />

130 Lighter<br />

140 Cupola Charging Equipment<br />

150 Tuyères<br />

160 Burners for Cupolas<br />

180 Blowing-In Equipment for Carbo Fer<br />

190 Blowing-In Equipment for Filter<br />

Dusts into Cupolas<br />

210 Blowing-In Equipment for Carbon<br />

211 Blowing-In Equipment for Metallurgical<br />

Processes<br />

220 Dedusting, Cupolas<br />

225 Gas Cleaning<br />

230 Charging Plants, fully and partially<br />

automatic<br />

240 Blowers, Cupolas<br />

270 Recuperators<br />

280 Oxygen Injection for Cupolas<br />

290 Shaking Ladles, Plants<br />

295 Dust Briquetting<br />

300 Monitoring Plants, Cupola<br />

310 Forehearths, Cupola<br />

320 Blast Heater<br />

02.03. Melting and Holding<br />

Furnaces, Electrically Heated<br />

330 Electric melting Furnaces, in general<br />

340 Induction Channel Furnaces<br />

350 Crucible Induction Furnaces, medium<br />

Frequency<br />

360 Crucible Induction Furnaces,<br />

Mains Frequency<br />

370 Short-Coil Induction Furnaces<br />

390 Filters, in general<br />

399 Tower Melter<br />

400 Holding Furnaces<br />

02.04. Accessories and Auxiliaries<br />

for Electric Furnaces<br />

410 Charging Units<br />

420 Blowing-In Equipment for Carbo Fer<br />

430 Blowing-In Equipment for Filter Dusts<br />

440 Blowing-In Equipment for Carbon<br />

445 Inert Gas Systems for EAF and EIF<br />

450 Inert Gas Systems for EAF and EIF<br />

460 Electro-magnetic Conveyor Chutes<br />

470 Dust Separation Plant<br />

480 Charging Equipment<br />

500 Graphite Electrodes<br />

510 Lime Dosing Device<br />

520 Condensors<br />

540 Cooling Equipment<br />

550 Scrap preheating Plants<br />

560 Secondary Metallurgical Plants<br />

565 Control Installations<br />

570 Equipment for induction stirring<br />

02.05. Rotary Furnaces<br />

580 Rotary Furnaces<br />

02.06. Maintenance and Repairing<br />

584 Repairing of Induction Furnaces<br />

586 Maintenance of Complete<br />

Induction Furnace Plants<br />

03 Melting Plants and Equipment for NFM<br />

03.01. Melting Furnaces, Fuel Fired<br />

590 Hearth-Type (Melting) Furnaces<br />

599 Tower Furnaces<br />

600 Bale-Out Furnaces<br />

610 Crucible Furnaces<br />

620 Drum-Type Melting Furnaces<br />

03.02. Melting and Holding<br />

Furnaces, Electrically Heated<br />

630 Aluminium Melting Furnaces<br />

640 Dosing Furnace<br />

655 Heating Elements for Resistance<br />

Furnaces<br />

660 Induction Furnaces (Mains,<br />

Medium, and High Frequency)<br />

665 Magnesium Melting Plants and<br />

Dosing Devices<br />

670 Melting Furnacs, in general<br />

680 Bale-Out Furnaces<br />

690 Crucible Furnaces<br />

700 Remelting Furnaces<br />

710 Holding Furnaces<br />

720 Electric Resistance Furnaces<br />

902 Vacuum Melting and Casting<br />

Furnaces<br />

03.03. Accessories and Auxiliaries<br />

730 Exhausting Plants<br />

740 Molten Metal Refining by Argon<br />

742 Gassing Systems for Aluminium<br />

Melting<br />

750 Gassing Systems for Magnesium<br />

Melting<br />

760 Charging Plants<br />

770 Blowing-in Equipment for Alloying<br />

and Inoculating Agents<br />

774 Blowing-in Equipment for<br />

Inoculating Agents<br />

778 Degassing Equipment<br />

780 Dedusting Equipment<br />

785 Crucibles, Ready-To-Use<br />

790 Charging Equipment<br />

800 Graphite Melting Pots<br />

825 Emergency Iron Collecting<br />

Reservoirs<br />

847 Cleaning Devices for Cleaning<br />

Dross in Induction Furnaces<br />

848 Cleaning Device and Gripper for<br />

Deslagging - Induction Furnaces<br />

850 Crucibles<br />

860 Inert Gas Systems<br />

870 Silicon Carbide Pots<br />

875 Special Vibrating Grippers for<br />

the Removal of Loose Dross and<br />

Caking<br />

880 Gas Flushing Installations<br />

890 Crucibles, Pots<br />

895 Power Supply, Plasma Generators<br />

900 Vacuum Degassing Equipment<br />

04 Refractories Technology<br />

04.01. Plants, Equipment and Tools for<br />

Lining in Melting and Casting<br />

910 Spraying Tools for Furnace Lining<br />

920 Breakage Equipment for Cupolas,<br />

Crucibles, Pots, Torpedo Ladles<br />

and Ladles<br />

923 Lost Formers<br />

930 Mixers and Chargers for<br />

Refractory Mixes<br />

940 Charging Units for Furnaces<br />

950 Gunning for Relining of Cupolas<br />

954 Ramming Mix Formers<br />

956 Ramming Templates<br />

980 Wear Indicators for Refractory Lining<br />

982 Wear Measuring and Monitoring<br />

for Refractory Lining<br />

985 State Diagnosis of Refractory Lines<br />

64 58


04.02. Refractory Materials<br />

(Shaped and Non Shaped)<br />

1000 Boron-Nitride Isolation<br />

1005 Sand Gaskets, Isolation<br />

Materials (up to 1260 °C)<br />

1009 Running and Feeding<br />

Systems (Gating Systems)<br />

1010 Running and Feeding Systems<br />

(Runner Bricks, Centre Bricks,<br />

Sprue Cups)<br />

1020 Fibrous Mould Parts<br />

1021 Fibrous Mould Parts up to 1750 °C<br />

1030 Refractory Castables<br />

1040 Refractories, in general<br />

1050 Insulating Refractoy Bricks<br />

1060 Refractoy Cements<br />

1070 Refractories for Aluminium Melting<br />

Furnaces<br />

1080 Refractory Materials for Anode<br />

Kilns<br />

1090 Refractory Materials for Melting<br />

Furnaces, in general<br />

1100 Refractory Materials for Holding<br />

Furnaces<br />

1103 Ceramic Fibre Mould Parts and<br />

Modules<br />

1104 Mold Sections and Modules made<br />

of HTW (High Temperature Wool)<br />

1109 Precasts<br />

1110 Pouring Lip Bricks<br />

1113 Fibreglass Mats<br />

1114 Slip Foils for Glowing Materials<br />

1117 High Temperature Mats, Papers,<br />

Plates, and Felts<br />

1120 Induction Furnace Compounds<br />

1123 Insulating and Sealing Panels up<br />

to 1200 °C<br />

1125 Insulating Fabrics up to 1260 °C<br />

1128 Insulating Felts and Mats up to<br />

1260 °C<br />

1130 Insulating Products<br />

1140 Insulating Products (such as<br />

Fibres, Micanites)<br />

1150 Insulating Bricks<br />

1155 Ceramic Fibre Mats, Papers,<br />

Plates, and Felts<br />

1160 Ceramic Fibre Modules<br />

1169 Ceramic Fibre Substitutes<br />

1170 Ceramic Fibre Products<br />

1180 Loamy Sands<br />

1190 Carbon Bricks<br />

1200 Cupola and Siphon Mixes<br />

1210 Cupola Bricks<br />

1220 Micro Porous Insulating Materials<br />

1222 Nano Porous Insulating Materials<br />

1225 Furnace Door Sealings, Cords, and<br />

Packings<br />

1230 Furnace Linings<br />

1240 Ladle Refractory Mixes<br />

1250 Ladle Bricks<br />

1260 Plates, free from Ceramic Fibres<br />

1261 Plates made of Ground Alkali<br />

Silicate Wool<br />

1270 Acid and Silica Mixes<br />

1280 Fire-Clay Mixes and Cements<br />

1290 Fire-Clay Bricks<br />

1310 Porous Plugs<br />

1312 Stirring Cones for Steel, Grey Cast<br />

Iron and Aluminium<br />

1320 Moulding Mixtures for Steel Casting<br />

1330 Ramming, Relining, Casting,<br />

Gunning, and Vibration Bulks<br />

1333 Ramming, Casting, Gunning, and<br />

Repairing Compounds<br />

1340 Plugs and Nozzles<br />

1345 Textile Fabrics up to 1260 °C<br />

988 Substitutes of Aluminium Silicate<br />

Wool<br />

990 Coating and Filling Materials,<br />

Protective Coatings<br />

04.03. Refractory Raw Materials<br />

1350 Glass Powder<br />

1360 Loamy Sands<br />

1370 Magnesite, Chrom-Magnesite,<br />

Forsterite<br />

1390 Chamotte, Ground Chamotte<br />

1400 Clays, Clay Powders<br />

04.04. Refractory Building<br />

1410 Bricking-Up of Furnaces<br />

1420 Refractory Building/Installation<br />

1430 Fire and Heat Protection<br />

1435 Furnace Door Joints<br />

1440 Furnace Reconstruction<br />

1450 Repairing of Furnaces and Refractories<br />

1460 Heat Insulation<br />

1462 Maintenance of Refractory Linings<br />

05 Non-metal Raw Materials and Auxiliaries for<br />

Melting Shop<br />

05.01. Coke<br />

1480 Lignite Coke<br />

1490 Foundry Coke<br />

1510 Petroleum Coke<br />

05.02. Additives<br />

1520 Desulphurization Compounds<br />

1530 Felspar<br />

1540 Fluorspar<br />

1550 Casting Carbide<br />

1560 Glass Granulate<br />

1570 Lime, Limestones<br />

1575 Briquets for Cupolas<br />

1580 Slag Forming Addition<br />

05.03. Gases<br />

1590 Argon<br />

1600 Oxygen<br />

1610 Inert Gases<br />

1620 Nitrogen<br />

1622 Hydrogen<br />

05.04. Carburization Agents<br />

1630 Carburization Agents, in general<br />

1640 Lignite Coke<br />

1650 Electrode Butts<br />

1660 Electrode Graphite<br />

1665 Desulfurizer<br />

1670 Graphite<br />

1680 Coke Breeze, Coke-Dust<br />

1700 Petroleum Coke<br />

1710 Silicon Carbide<br />

3261 Automatic Powder Feeding<br />

05.05. Melting Fluxes for NF-Metals<br />

1720 Aluminium Covering Fluxes<br />

1730 Desoxidants, in general<br />

1740 Degassing Fluxes<br />

1750 Desulphurisers<br />

1760 Charcoal<br />

1770 Refiners<br />

1780 Fluxing Agents<br />

1785 Melt Treatment Agents<br />

1790 Fluxing Agents<br />

06 Metallic Charge Materials for Iron and Steel<br />

Castings and for Malleable Cast Iron<br />

06.01. Scrap Materials<br />

1810 Cast Scrap<br />

1811 Cast Turnings<br />

1813 Cuttings/Stampings<br />

1817 Steel Scrap<br />

06.02. Pig Iron<br />

1820 Hematite Pig Iron<br />

1830 Foundry Pig Iron<br />

1838 DK Pig Iron<br />

1840 DK-Perlit Special Pig Iron<br />

1880 DK Pig Iron for Malleable Cast Iron<br />

1898 DK Pig Iron, low-carbon, Quality<br />

DKC<br />

1900 DK-Perlit Special Pig Iron, Low<br />

Carbon, DKC Quality<br />

1936 DK Phosphorus Alloy Pig Iron<br />

1940 DK-Perlit Special Pig Iron, Type<br />

Siegerlaender<br />

1950 Spiegel Eisen<br />

1970 Blast Furnace Ferro Silicon<br />

06.03. Specials (Pig Iron)<br />

1990 Foundry Pig Iron<br />

2000 Hematite Pig Iron<br />

2010 Sorel Metal<br />

<strong>2020</strong> Special Pig Iron for s. g. Cast Iron<br />

Production<br />

2030 Special Pig Iron for s.g. Cast Iron<br />

2040 Steelmaking Pig Iron<br />

06.04. Ferro Alloys<br />

2050 Ferro-Boron<br />

2060 Ferro-Chromium<br />

2070 Ferroalloys, in general<br />

2080 Ferro-Manganese<br />

2090 Ferro-Molybdenum<br />

2100 Ferro-Nickel<br />

2110 Ferro-Niobium<br />

2120 Ferro-Phosphorus<br />

2130 Ferro-Selenium<br />

2140 Ferro-Silicon<br />

2150 Ferro-Silicon-Magnesium<br />

2160 Ferro-Titanium<br />

2170 Ferro-Vanadium<br />

2180 Ferro-Tungsten<br />

2190 Silicon-Manganese<br />

06.05. Other Alloy Metals and Master<br />

Alloys<br />

2200 Aluminium Granulates<br />

2210 Aluminium, Aluminium Alloys<br />

2220 Aluminium Powder<br />

2230 Aluminium Master Alloys<br />

2250 Calcium Carbide<br />

2260 Calcium-Silicon<br />

2265 Cerium Mischmetal<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 59


2280 Chromium Metals<br />

2290 Cobalt<br />

2300 Chromium Metal, Aluminothermic<br />

2310 Deoxidation Alloys<br />

2318 High-grade Steel<br />

2320 Iron Powder<br />

2350 Copper<br />

2360 Cupola Briquets<br />

2370 Alloying Metals, in general<br />

2380 Alloying Additives<br />

2390 Magnesium, Magnesium Alloys<br />

2410 Manganese Metal<br />

2420 Manganese Metal, Electrolytic<br />

2430 Molybdenum<br />

2440 Molybdenum Alloys<br />

2450 Molybdenum Oxide<br />

2460 Nickel, Nickel Alloys<br />

2470 Nickel-Magnesium<br />

2490 Furnace Additives<br />

2500 Ladle Additives<br />

2510 High-Purity Iron, Low-Carbon<br />

2520 Sulphuric Iron<br />

2530 Silicon Carbide<br />

2540 Silicon Metal<br />

2545 Silicon Metal Granules<br />

2550 Special Alloys<br />

2570 Titanium Sponge<br />

2575 Master Alloys for Precious Metals<br />

2580 Bismuth<br />

2590 Tungsten<br />

2600 Tin<br />

2610 Alloying Metals, Master Alloys<br />

06.06. Nodularizing Additives and<br />

Auxiliaries<br />

2620 Magnesium Treatment Alloys for<br />

s. g. Cast Iron<br />

2630 Mischmetal<br />

06.07. Inoculants and Auxiliary<br />

Appliances<br />

2640 Cored-Wire Injectors<br />

2645 Injection Appliances for Cored Wire<br />

2650 Cored Wires for Secondary and<br />

Ladle Metallurgy<br />

2653 Cored Wires for Magnesium Treatment<br />

2656 Cored Wires for Inoculation of Cast<br />

Iron Melts<br />

2658 Stream Inoculants<br />

2660 Automatic IDA-Type Inoculation<br />

Dosing Devices<br />

2670 Injection Appliances<br />

2680 Inoculants and Inoculation Alloys,<br />

in general<br />

2690 Inoculants for Cast Iron<br />

2692 MSI Pouring Stream Inoculation<br />

Devices<br />

2694 Ladle Inoculants<br />

07 Metallic Charge and Treatment Materials for<br />

Light and Heavy Metal Castings<br />

07.01. Scrap<br />

2730 Metal Residues<br />

07.02. Ingot Metal<br />

2740 Standard Aluminium Alloys<br />

2750 Brass Ingots<br />

2770 High-Grade Zinc Alloys<br />

2790 Copper<br />

2800 Copper Alloys<br />

2810 Magnesium, Magnesium Alloys<br />

2830 Tin<br />

07.03. Alloying Addition for Treatment<br />

2838 Aluminium-Beryllium Master Alloys<br />

2840 Aluminium-Copper<br />

2852 Aluminium Master Alloys<br />

2870 Arsenic Copper<br />

2875 Beryllium-Copper<br />

2890 Calcium<br />

2891 Calcium Carbide, Desulphurisers<br />

2893 Chromium-Copper<br />

2900 Ferro-Copper<br />

2910 Grain Refiner<br />

2920 Granulated Copper<br />

2924 Copper Magnesium<br />

2925 Copper Salts<br />

2927 Copper Master Alloys<br />

2930 Alloy Metals, in general<br />

2935 Alloy Biscuits<br />

2936 Lithium<br />

2938 Manganese Chloride (anhydrate)<br />

2940 Manganese Copper<br />

2950 Metal Powder<br />

2960 Niobium<br />

2970 Phosphor-Copper<br />

2980 Phosphor-Tin<br />

2990 Silicon-Copper<br />

3000 Silicon Metal<br />

3010 Strontium, Strontium Alloys<br />

3020 Tantalum<br />

3025 Titanium, powdery<br />

3030 Refining Agents for Aluminium<br />

3033 Zirconium-Copper<br />

08 Plants and Machines for Moulding and<br />

Coremaking Processes<br />

08.01. Moulding Plants<br />

3050 Moulding Plants, in general<br />

3058 Moulding Machines, Boxless<br />

3060 Moulding Machines, Fully Automatic<br />

3070 Moulding Machines, Fully and<br />

Partially Automatic<br />

08.02. Moulding and Coremaking<br />

Machines<br />

3080 Lifting Moulding Machine<br />

3090 Pneumatic Moulding Machines<br />

3100 Automatic Moulding Machines<br />

3110 High-Pressure Squeeze Moulding<br />

Machines<br />

3130 Impact Moulding Machines<br />

3140 Moulding Plants and Machines for<br />

Cold-Setting Processes<br />

3150 Moulding Machines, Boxless<br />

3160 Core Blowers<br />

3170 Coremaking Machines<br />

3180 Core Shooters<br />

3190 Air-flow Squeeze Moulding Machines<br />

and Plants<br />

3200 Shell Moulding Machines<br />

3210 Shell Moulding Machines<br />

3220 Shell Moulding Machines and<br />

Hollow Core Blowers<br />

3225 Multi-Stage Vacuum Process<br />

3230 Multi-Stage Vacuum Processes for<br />

Pressure Die Casting Processes<br />

3235 Rapid Prototyping<br />

3240 Jolt Squeeze Moulding Machines<br />

3250 Suction Squeeze Moulding Machines<br />

and Plants<br />

3260 Pinlift Moulding Machines<br />

3270 Rollover Moulding Machines<br />

3280 Vacuum Moulding Machines and<br />

Processes<br />

3290 Multi-Piston Squeeze Moulding<br />

Machines<br />

3300 Turnover Moulding Machines<br />

08.03. Additives and Accessories<br />

3310 Exhaust Air Cleaning Plants for<br />

Moulding Machines<br />

3320 Gassing Units for Moulds and<br />

Cores<br />

3325 Seal Bonnets for Immersion Nozzles<br />

3330 Metering Dosing Devices for<br />

Binders and Additives<br />

3340 Electrical Equipment for Moulding<br />

Machines and Accessories<br />

3350 Electrical and Electronic Controlling<br />

Devices for Moulding<br />

Machines<br />

3355 Mould Dryer<br />

3360 Vents<br />

3370 Screen-Vents<br />

3380 Spare Parts for Moulding Machines<br />

3390 Flow Coating Plants<br />

3400 Pattern Plates<br />

3420 Manipulators<br />

3430 Core Setting Equipment<br />

3440 Core Removal Handling<br />

3450 Core Handling<br />

3460 Coremaking Manipulators<br />

3462 Core Transport Racks<br />

3470 Shell Mould Sealing Equipment<br />

and Presses<br />

3480 Mixers for Blackings and Coatings<br />

3500 Plastic Blowing and Gassing Plates<br />

3510 Coating Equipment<br />

3512 Coating Dryers<br />

3520 Equipment for Alcohol-based<br />

Coatings<br />

3525 Coating Stores and<br />

Preparation Equipment<br />

3530 Coating Mixers, Coating Preparation<br />

Equipment<br />

3540 Screen Vents, front Armoured<br />

3560 Swing Conveyors<br />

3570 Screening Machines<br />

3580 Plug Connections, Heat-Resisting<br />

08.04. Mould Boxes and Accessories<br />

3590 Moulding Boxes<br />

3610 Moulding Box Round-hole and<br />

Long-hole Guides<br />

09 Moulding Sands<br />

09.01. Basic Moulding Sands<br />

3630 Chromite Sands<br />

3640 Moulding Sands<br />

3645 Ceramic Sands/Chamotte Sands<br />

3650 Core Sands<br />

60


3660 Molochite<br />

3670 Mullite Chamotte<br />

3690 Olivine Sands<br />

3700 Fused Silica<br />

3705 Lost Foam Backing Sands<br />

3710 Silica Flour<br />

3720 Silica Sands<br />

3730 Zircon Powder<br />

3740 Zircon Sands<br />

09.02. Binders<br />

3750 Alkyd Resins<br />

3755 Inorganic Binders<br />

3760 Asphalt Binders<br />

3770 Bentonite<br />

3790 Binders for Investment Casting<br />

3800 Cold-Box Binders<br />

3803 Resins for the Shell Moulding<br />

Process<br />

3820 Ethyl Silicate<br />

3830 Moulding Sand Binders, in general<br />

3833 Binders, Inorganic<br />

3840 Resins<br />

3860 Oil Binders<br />

3870 Core Sand Binders, in general<br />

3875 Silica Sol<br />

3880 Synthetic Resin Binders, in general<br />

3890 Synthetic Resin Binders for<br />

Refractories<br />

3900 Synthetic Resin Binder for Gas<br />

Curing Processes<br />

3910 Synthetic Resin Binder for Hot<br />

Curing Processes<br />

3920 Synthetic Resin Binder for Cold<br />

Setting Processes<br />

3930 Facing Sand Binders<br />

3940 Binders for the Methyl-Formate<br />

Process<br />

3950 Phenolic Resins<br />

3960 Phenolic Resins (alkaline)<br />

3970 Polyurethane Binders and Resins<br />

3980 Swelling Binders<br />

3990 Swelling Clays<br />

4000 Quick-Setting Binders<br />

4010 Silicate Binders<br />

4020 Silica Sol<br />

4030 Binders for the SO2 Process<br />

4040 Cereal Binders<br />

4050 Warm-Box Binders<br />

4060 Water-Glass Binders (CO2-Process)<br />

09.03. Moulding Sand Additives<br />

4066 Addition Agents<br />

4070 Iron Oxide<br />

4080 Red Iron Oxide<br />

4090 Lustrous Carbon Former<br />

4100 Pelleted Pitch<br />

4110 Coal Dust<br />

4120 Coal Dust Substitute (Liquid or<br />

Solid Carbon Carrier)<br />

4130 Coal Dust (Synthetic)<br />

09.04. Mould and Core Coating<br />

4140 Inflammable Coating<br />

4150 Alcohol-Based Coatings<br />

4160 Alcohol-based Granulated Coatings<br />

4170 Boron-Nitride Coatings<br />

4180 Coatings, Ready-to-Use<br />

4190 Mould Varnish<br />

4200 Mould Coating<br />

4210 Black Washes<br />

4220 Graphite Blackings<br />

4224 Lost-Foam Coatings<br />

4225 Ceramic Coatings<br />

4230 Core Coatings<br />

4240 Core Blackings<br />

4260 Paste Coatings<br />

4266 Coatings (with metallurgical effects)<br />

4270 Blackings, in general<br />

4280 Steel Mould Coatings<br />

4290 Talc<br />

4298 Coatings for Full Mould Casting<br />

4300 Water-based Coatings<br />

4310 Granulated Water-based Coatings<br />

4320 Zircon Coatings<br />

4321 Zircon-free Coatings<br />

09.05. Moulding Sands<br />

Ready-to-Use<br />

4340 Sands for Shell Moulding, Readyto-use<br />

4350 Sands Ready-to-Use, Oil-Bonded<br />

(Water-free)<br />

4360 Precoated Quartz Sands, Zircon<br />

Sands, Chromite Sands, Ceramic<br />

Sands<br />

4370 Moulding Sands for Precision<br />

Casting<br />

4380 Steel Moulding Sands<br />

4390 Synthetic Moulding and Core Sand<br />

09.06. Moulding Sands Testing<br />

4400 Strength Testing Equipment for<br />

Moulding Sand<br />

4410 Moisture Testing Equipment for<br />

Moulding Sand<br />

4420 Moulding Sand Testing Equipment,<br />

in general<br />

4426 Core Gas Meters for Al + Fe<br />

4440 Sand Testing<br />

10 Sand Conditioning and Reclamation<br />

4446 Sand Preparation and<br />

Reclamation<br />

4448 Sand Reclamation System<br />

10.01. Moulding Sand Conditioning<br />

4450 Nozzles for Moistening<br />

4459 Continuous Mixers<br />

4460 Continuous Mixers for Cold-Setting<br />

Sands<br />

4470 Aerators for Moulding Sand<br />

Ready-to-Use<br />

4480 Sand Preparation Plants and<br />

Machines<br />

4490 Sand Mullers<br />

4500 Measuring Instruments for Compactibility,<br />

Shear Strength, and<br />

Deformability<br />

4510 Measuring Instruments for<br />

Mouldability Testing (Moisture,<br />

Density, Temperature)<br />

4520 Mixers<br />

4550 Sand Mixers<br />

4560 Aerators<br />

4567 Vibration Sand Lump Crusher<br />

4568 Vibratory Screens<br />

4570 Sand Precoating Plants<br />

4590 Scales and Weighing Control<br />

10.03. Conditioning of Cold, Warm,<br />

and Hot Coated Sands<br />

4650 Preparation Plants for Resin<br />

Coated Sand<br />

10.04. Sand Reconditioning<br />

4660 Used Sand Preparation Plants<br />

4662 Batch Coolers for Used Sand<br />

4664 Flow Coolers for Used Sand<br />

4670 Magnetic Separators<br />

4690 Core Sand Lump Preparation<br />

Plants<br />

4700 Reclamation Plants for Core Sands<br />

4710 Ball Mills<br />

4720 Sand Coolers<br />

4730 Sand Reclamation Plants<br />

4740 Sand Screens<br />

4760 Separation of Chromite/Silica Sand<br />

10.05. Reclamation of Used Sand<br />

4780 Reclamation Plants, in general<br />

4785 Reclamation Plants,<br />

Chemical-Combined<br />

4790 Reclamation Plants,<br />

Mechanical<br />

4800 Reclamation Plants,<br />

Mechanical/Pneumatic<br />

4810 Reclamation Plants,<br />

Mechanical-Thermal<br />

4820 Reclamation Plants, Mechanical/<br />

Thermal/Mechanical<br />

4830 Reclamation Plants, wet<br />

4840 Reclamation Plants, Thermal<br />

4850 Reclamation Plants,<br />

Thermal-Mechanical<br />

11 Moulding Auxiliaries<br />

4880 Mould Dryers<br />

4890 Foundry Nails, Moulding Pins<br />

4910 Moulders‘ Tools<br />

4920 Mould Hardener<br />

4950 Guide Pins and Bushes<br />

4965 High Temperature Textile Fabrics<br />

up to 1260 °C<br />

4970 Ceramic Pouring Filters<br />

4980 Ceramic Auxiliaries for Investment<br />

Foundries<br />

4990 Ceramic Cores for Investment<br />

Casting - Gunned, Pressed, Drawn<br />

4998 Cope Seals<br />

5000 Core Benches<br />

5007 Core Putty Fillers<br />

5010 Core Wires<br />

5020 Cores (Cold-Box)<br />

5030 Cores (Shell)<br />

5040 Core Boxes<br />

5050 Core Box Dowels<br />

5070 Core Adhesives<br />

5080 Core Loosening Powder<br />

5090 Core Nails<br />

5100 Core Powders<br />

5110 Chaplets<br />

5130 Tubes for Core and Mould Venting<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 61


5140 Core Glueing<br />

5150 Core Glueing Machines<br />

5155 Cleaners<br />

5160 Adhesive Pastes<br />

5170 Carbon Dioxide<br />

(CO2 Process)<br />

5180 Carbon Dioxide Dosing<br />

Devices<br />

5210 Coal Dust and Small Coal<br />

5220 Chill Nails<br />

5230 Chill Coils<br />

5240 Antipiping Compounds<br />

5260 Shell Mould Sealers<br />

5270 Mould Dryers, Micro-Wave<br />

5280 Screening Machines<br />

5290 Glass Fabric Filters<br />

5300 Strainer Cores<br />

5310 Release Agents<br />

11.01. Moulding Bay Equipment<br />

5312 Glass Fabric Filters<br />

5314 Strainer Cores<br />

12 Gating and Feeding<br />

5320 Covering Agents<br />

5330 Heating-up Agents<br />

5340 Breaker Cores<br />

5350 Strainer Cores<br />

5360 Exothermic Products<br />

5365 Glass Fabric Filters<br />

5370 Insulating Products and Fibres<br />

5375 Insulating Sleeves<br />

5380 Ceramic Filters<br />

5390 Ceramic Breaker Cores<br />

5400 Exothermic Mini-Feeders<br />

5405 Non-Ceramic Foam Filters<br />

5410 Ceramic Dross Filters<br />

5416 Riser (exothermic)<br />

5418 Riser (insulating)<br />

5420 Exothermic Feeder Sleeves<br />

5430 Exothermic Feeding Compounds<br />

13 Casting Machines and Equipment<br />

5436 Pouring Machines and<br />

Equipment<br />

5437 Casting Machine,<br />

without Heating<br />

13.01. Pouring Furnaces and their<br />

Equipment<br />

5440 Aluminium Dosing Furnaces<br />

5450 Pouring Equipment<br />

5460 Pouring Ladles<br />

5461 Pouring Ladles, Insulating<br />

5468 Pig and Ingot Casting<br />

Machines<br />

5470 Pouring Equipment for Moulding<br />

Plants, Railborn or Crane-operated<br />

5480 Pouring Ladles<br />

5485 Pouring Ladles, Electrically Heated<br />

5490 Drum-Type Ladles<br />

5500 Ingot Casting Machines<br />

5510 Low Pressure Casting<br />

Machine<br />

13.02. Die Casting and<br />

Accessories<br />

5530 Trimming Presses for<br />

Diecastings<br />

5540 Trimming Tools for Diecastings<br />

(Standard Elements)<br />

5545 Exhausting and Filtering Plants for<br />

Diecastings<br />

5550 Ejectors for Diecasting Dies<br />

5560 Ejectors for Diecasting Dies (Manganese<br />

Phosphate Coated)<br />

5570 Feeding, Extraction, Spraying, and<br />

Automatic Trimming for Diecasting<br />

Machines<br />

5580 Trimming Tools<br />

5600 Dosing Devices for<br />

Diecasting Machines<br />

5610 Dosing Furnaces for<br />

Diecasting Machines<br />

5620 Diecasting Dies<br />

5630 Heating and Cooling Devices for<br />

Diecasting Dies<br />

5640 Diecasting Machines<br />

5641 Diecasting Machines and Plants<br />

5644 Diecasting Machines for Rotors<br />

5650 Diecasting Machine Monitoring<br />

and Documentation Systems<br />

5660 Diecasting Coatings<br />

5670 Diecasting Lubricants<br />

5675 Lost Diecasting Cores<br />

5680 Diecasting Parting Agents<br />

5689 Venting Blocks for HPDC Dies<br />

5690 Extraction Robots for<br />

Diecasting Machines<br />

5695 Frames and Holders for<br />

Diecasting Dies<br />

5700 Spraying Equipment for Diecasting<br />

Machines<br />

5710 Goosenecks and Shot Sleeves<br />

5720 Hand Spraying Devices<br />

5730 Heating Cartridges<br />

5740 High-duty Heating Cartridges<br />

5750 Hydraulic Cylinders<br />

5760 Core Pins<br />

5770 Cold Chamber Diecasting Machines<br />

5780 Pistons for Diecasting Machines<br />

5790 Piston Lubricants<br />

5800 Piston Spraying Devices<br />

5810 Mixing Pumps for Parting Agents<br />

5815 Electric Nozzle Heatings<br />

5817 Oil Filters<br />

5820 Melting and Molten Metal Feeding<br />

in Zinc Die Casting Plants<br />

5830 Steel Molds for Diecasting Machines<br />

5838 Heating and Cooling of Dies<br />

5840 Temperature Control Equipment for<br />

Diecasting Dies<br />

5850 Parting Agents for Dies<br />

5860 Parting Agent Spraying Devices for<br />

Diecasting Machines<br />

5865 Dry Lubricants (Beads)<br />

5870 Vacural-Type Plants<br />

5876 Multi-Stage Vacuum Process<br />

5880 Multi-Stage Vacuum Process<br />

5890 Vacuum Die Casting Plants<br />

5900 Hot Working Steel for<br />

Diecasting Dies<br />

5910 Hot Working Steel for Diecasting<br />

Tools<br />

5912 Hot Chamber Diecasting Machines<br />

13.03. Gravity Die Casting<br />

5914 Dosing Devices for Gravity Diecasting<br />

Stations<br />

5920 Permanent Molds<br />

5930 Automatic Permanent Moulding<br />

Machines<br />

5940 Gravity Diecasting Machines<br />

5941 Gravity and High Pressure Diecasting<br />

Automation<br />

5945 Cement and Fillers for Permanent<br />

Moulds up to 1600 °C<br />

5950 Cleaning Devices for Permanent<br />

Molds<br />

5960 Coatings for Permanent Molds<br />

5970 Colloidal Graphite<br />

5975 Chills<br />

5980 Low Pressure Diecasting Machines<br />

13.04. Centrifugal Casting<br />

5990 Centrifugal Casting Machines<br />

13.05. Continuous Casting<br />

6000 Anode Rotary Casting Machines<br />

6001 Length and Speed Measuring,<br />

non-contact, for Continuous<br />

Casting Plants<br />

6002 Thickness and Width Measurement<br />

for Continuous Casting<br />

Plants, non-contact<br />

6006 Casting and Shear Plants for<br />

Copper Anodes<br />

6007 Casting and Rolling Plants for<br />

Copper Wire<br />

6008 Casting and Rolling Plants for<br />

Copper Narrow Strips<br />

6010 Continuous Casting Plant, horizontal,<br />

for Tube Blanks with integrated<br />

Planetary Cross Rolling Mill for the<br />

Production of Tubes<br />

6020 Continuous Casting Moulds<br />

6030 Continuous Casting<br />

Machines and Plants<br />

6032 Continuous Casting, Accessories<br />

6033 Continuous Casting Machines and<br />

Plants (non-ferrous)<br />

13.06. Investment and Precision<br />

Casting<br />

6040 Burning Kilns for Investment<br />

Moulds<br />

6045 Investment Casting Waxes<br />

6050 Embedding Machines for Investment<br />

Casting Moulding Materials<br />

6060 Investment Casting Plants<br />

6062 Centrifugal Investment<br />

Casting Machines<br />

13.07. Full Mould Process Plants<br />

6070 Lost-Foam Pouring Plants<br />

13.08. Auxiliaries, Accessories, and<br />

Consumables<br />

6080 Pouring Manipulators<br />

6090 Slag Machines<br />

6093 Copper Templates<br />

6100 Nozzles, Cooling<br />

62


6110 Electrical and Electronic Control<br />

for Casting Machines<br />

6120 Extraction Devices<br />

6130 Pouring Consumables, in general<br />

6140 Rotary Casting Machines<br />

6150 Pouring Ladle Heaters<br />

6160 Ladle Bails<br />

6170 Stream Inoculation Devices<br />

6175 Graphite Chills<br />

6176 Marking and Identification<br />

6177 Bone Ash (TriCalcium Phosphate)<br />

6190 Long-term Pouring Ladle Coatings<br />

6200 Long-term Lubricants<br />

6210 Manipulators<br />

6220 Ladle Covering Compounds<br />

6240 Robots<br />

6245 Protective Jacket for Robots, Heat<br />

and Dust Resistant<br />

6250 Dosing Devices for Slag Formers<br />

Addition<br />

6270 Silicon Carbide Chills<br />

6280 Silicon Carbide Cooling Compounds<br />

6290 Crucible Coatings<br />

6300 Heat Transfer Fluids<br />

14 Discharging, Cleaning, Finishing of Raw<br />

Castings<br />

6305 Casting Cooling Plants<br />

14.01. Discharging<br />

6330 Knock-out Drums<br />

6340 Vibratory Shake-out Tables<br />

6345 Knock-out Vibratory Conveyors<br />

6346 Shake-out Grids<br />

6347 Shake-out Separation Runners<br />

6350 Decoring Equipment<br />

6352 Discharging of Metal Chips<br />

6360 Hooking<br />

6370 Manipulators<br />

6373 Manipulators for Knock-out Floors<br />

6380 Robots<br />

6390 Vibratory Grids, Hangers, and<br />

Chutes<br />

6400 Vibratory Tables<br />

14.02. Blast Cleaning Plants and<br />

Accessories<br />

6410 Turntable Blasting Fans<br />

6420 Pneumatic Blasting Plants<br />

6430 Automatic Continuous Shot-blasting<br />

plants<br />

6440 Descaling Plants<br />

6445 Spare Parts for Blasting Plants<br />

6450 Hose Blasting Plants, Fans<br />

6460 Hose Blasting Chambers<br />

6470 Monorail Fettling Booths<br />

6475 Efficiency Tuning for Blasting<br />

Plants<br />

6480 Manipulator Shotblast Plants<br />

6485 Tumbling Belt Blasting Plants,<br />

Compressed Air Driven<br />

6490 Wet and Dry Shotblast Plants<br />

6500 Fettling Machines<br />

6530 Airless Blast Cleaning Machines<br />

6540 Blasting Plants Efficiency Tuning<br />

6550 Shot Transport, Pneumatic<br />

6560 Shot-Blasting Plants<br />

6569 Shot Blasting Machines<br />

6570 Shot Blasting Machines, with/<br />

without Compressed Air Operating<br />

6572 Dry Ice Blasting<br />

6574 Dry Ice Production<br />

14.03. Blasts<br />

6580 Aluminium Shots<br />

6590 Wire-Shot<br />

6600 High-Grade Steel Shots<br />

6610 Granulated Chilled Iron, Chilled<br />

Iron Shots<br />

6630 Cast Steel Shots<br />

6640 Stainless Steel Shot<br />

6650 Shot-Blast Glass<br />

6660 Shot-Blast Glass Beads<br />

6670 Blasts<br />

6671 Stainless Steel Abrasives<br />

14.04. Grinding Machines and Accessories<br />

6675 Stainless Steel Grit<br />

6680 Belt Grinders<br />

6685 chamfering machines<br />

6690 Flexible Shafts<br />

6695 Diamond Cutting Wheels for<br />

Castings<br />

6700 Compressed Air Grinders<br />

6710 Fibre discs<br />

6714 Centrifugal Grinders<br />

6720 Vibratory Cleaning Machines and<br />

Plants<br />

6730 Rough Grinding Machines<br />

6735 Abrasive Wheels, visual, with<br />

Flakes/Lamellas<br />

6740 Numerical Controlled Grinders<br />

6750 Swing Grinders<br />

6760 Polishing Machines<br />

6770 Polishing Tools<br />

6773 Precision Cutting Wheels, 0,8 mm<br />

6780 Tumbling Drums<br />

6790 Pipe Grinders<br />

6800 Floor Type Grinders<br />

6810 Grinding Textiles<br />

6820 Emery Paper<br />

6830 Grinding Wheel Dresser<br />

6850 Grinding Wheels and Rough<br />

Grinding Wheels<br />

6855 Grinding Pins<br />

6860 Grinding Fleece<br />

6870 Grinding Tools<br />

6874 Drag Grinding Plants<br />

6880 Rough Grinding Machines<br />

6885 Cutting Wheels<br />

6890 Abrasive Cut-off Machines<br />

6900 Vibratory Cleaning Machines<br />

6910 Angle Grinders<br />

14.05. Additional Cleaning Plants<br />

and Devices<br />

6920 Gate Break-off Wedges<br />

6925 Plants for Casting Finishing<br />

6930 Automation<br />

6940 Pneumatic Hammers<br />

6950 Deflashing Machines<br />

6954 Deburring Machines,<br />

robot-supported<br />

6955 Robot Deburring Systems<br />

6960 Fettling Cabins<br />

6970 Fettling Manipulators<br />

6980 Fettling Benches<br />

6990 Core Deflashing Machines<br />

7000 Chipping Hammers<br />

7010 Dedusting of Fettling Shops<br />

7020 Fettling Hammers<br />

7030 Fettling Shops, Cabins, Cubicles<br />

7035 Refining Plants<br />

7040 Robot Fettling Cubicles<br />

7041 Robot Deflashing Units for Casting<br />

7050 Feeder Break-off Machines<br />

7052 Stamping Deflashing<br />

Equipment (tools, presses)<br />

7055 Break-off Wedges<br />

7056 Cutting and Sawing Plants<br />

7058 Band Saw Blades<br />

7059 Cut-off Saws<br />

7060 Cut-off Saws for Risers and Gates<br />

14.06. Jig Appliances<br />

7066 Magnetic Clamping Devices for<br />

Casting Dies<br />

7068 Core-Slides and Clamping<br />

Elements for Casting Dies<br />

7070 Clamping Devices<br />

14.07. Tribology<br />

7073 Lubricants for High Temperatures<br />

7074 Chain Lubricating Appliances<br />

7075 Cooling Lubricants<br />

7077 Central Lubricating Systems<br />

15 Surface Treatment<br />

7083 Anodizing of Aluminium<br />

7100 Pickling of High Quality Steel<br />

7105 CNC Machining<br />

7110 Paint Spraying Plants<br />

7115 Yellow/Green Chromating<br />

7130 Priming Paints<br />

7140 Casting Sealing<br />

7150 Casting Impregnation<br />

7166 Hard Anodic Coating of Aluminium<br />

7180 High Wear-Resistant Surface<br />

Coating<br />

7190 Impregnation<br />

7198 Impregnation Plants<br />

7200 Impregnating Devices and Accessories<br />

for Porous Castings<br />

7210 Anticorrosion Agents<br />

7220 Corrosion and Wearing Protection<br />

7230 Shot Peening<br />

7232 Wet Varnishing<br />

7234 Surface Treatment<br />

7235 Surface Coatings<br />

7240 Polishing Pastes<br />

7245 Powder Coatings<br />

7250 Repair Metals<br />

7260 Slide Grinding, free of Residues<br />

7290 Quick Repair Spaddle<br />

7292 Special Coatings<br />

7295 Special Adhesives up to 1200 °C<br />

7296 Shot-Blasting<br />

7297 Power Supply, Plasma Generators<br />

7300 Galvanizing Equipment<br />

7302 Zinc Phosphating<br />

7310 Scaling Protection<br />

7312 Subcontracting<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 63


16 Welding and Cutting<br />

16.01. Welding Machines and<br />

Devices<br />

7330 Welding Consumables, Electrodes<br />

16.02. Cutting Machines and Torches<br />

7350 Gougers<br />

7352 Special Machines for Machining<br />

7360 Coal/Graphite Electrodes<br />

7365 Water Jet Cutting<br />

7370 Oxygen Core Lances<br />

16.03. Accessories<br />

7394 Protective Blankets, Mats, and<br />

Curtains, made of Fabric, up to<br />

1250 °C<br />

7397 Protective Welding Paste, up to<br />

1400 °C<br />

17 Surface Treatment and Drying<br />

7398 Heat Treatment and Drying<br />

17.01. Plants and Furnaces<br />

7400 Tempering Furnaces<br />

7401 Ageing Furnaces<br />

7402 Combustion Chambers<br />

7404 Baking Ovens for Ceramic Industries<br />

7420 Mould Drying Stoves<br />

7430 Annealing and Hardening Furnaces<br />

7440 Induction Hardening and Heating<br />

Equipment<br />

7450 Core Drying Stoves<br />

7452 Microwave Drying Stoves and<br />

Chambers<br />

7455 Solution Annealing Furnaces<br />

7460 Ladle Dryers<br />

7470 Sand Dryers<br />

7480 Inert Gas Plants<br />

7490 Annealing Furnaces<br />

7500 Drying Stoves and Chambers<br />

7510 Quenching and Tempering Furnaces<br />

7520 Heat Treating Furnaces<br />

7525 Hearth Bogie Type Furnaces<br />

17.02. Components, Accessories,<br />

Operating Materials<br />

7550 Multi-purpose Gas Burners<br />

7560 Heating Equipment, in general<br />

7564 Special Torches<br />

7580 Firing Plants<br />

7590 Gas Torches<br />

7600 Gas Heatings<br />

7610 Capacitors<br />

7616 Furnace Optimization<br />

7620 Oil Burners<br />

7630 Recuperative Burners<br />

7640 Oxygen Burners<br />

7650 Heat Recovery Plants<br />

18 Plant, Transport, Stock, and Handling<br />

Engineering<br />

7654 Lifting Trucks<br />

7656 Transport, Stock, and<br />

Handling Technology<br />

18.01. Continuous Conveyors and<br />

Accessories<br />

7660 Belt Conveyors<br />

7670 Bucket Elevators<br />

7676 Flexible Tubes with Ceramic Wear<br />

Protection<br />

7680 Conveyors, in general<br />

7690 Conveyors, Fully Automatic<br />

7710 Conveyor Belts<br />

7720 Conveyor Belt Ploughss<br />

7730 Conveyor Belt Idlers<br />

7740 Conveyor Chutes<br />

7750 Conveying Tubes<br />

7760 Belt Guides<br />

7780 Overhead Rails<br />

7790 Hot Material Conveyors<br />

7810 Chain Conveyors<br />

7820 Chain Adjusters<br />

7850 Conveyors, Pneumatic<br />

7860 Roller Beds, Roller Conveyor<br />

Tables, Roller Tables<br />

7870 Sand Conveyors<br />

7890 Bulk Material Conveyors<br />

7900 Swing Conveyor Chutes<br />

7910 Elevators<br />

7920 Chip Dryers<br />

7950 Idlers and Guide Rollers<br />

7960 Transport Equipment, in general<br />

7970 Conveyor Screws<br />

7980 Vibratory Motors<br />

7981 Vibration Conveyors<br />

18.02. Cranes, Hoists, and<br />

Accessories<br />

8000 Grippers<br />

8010 Lifting Tables and Platforms<br />

8020 Jacks and Tilters<br />

8030 Operating Platforms, Hydraulic<br />

8032 Hydraulic and Electric Lifting<br />

Trucks<br />

8040 Cranes, in general<br />

8050 Lifting Magnets<br />

8060 Lifting Magnet Equipment<br />

18.03. Vehicles and Transport Containers<br />

8080 Container Parking Systems<br />

8090 Fork Lift Trucks, in general<br />

8100 Fork Lift Trucks for Fluid Transports<br />

8110 Equipment for Melt Transport<br />

18.04. Bunkers, Siloes and<br />

Accessories<br />

8140 Linings<br />

8145 Big-bag Removal Systems<br />

8150 Hopper Discharger and<br />

Discharge Chutes<br />

8160 Hoppers<br />

8170 Conveyor Hoses<br />

8190 Silos<br />

8200 Silo Discharge Equipment<br />

8210 Silo Over-charging Safety Devices<br />

8218 Wearing Protection<br />

8220 Vibrators<br />

18.05. Weighing Systems and Installations<br />

8230 Charging and Charge<br />

Make-up Scales<br />

8240 Metering Scales<br />

8250 Monorail Scales<br />

8260 Crane Weighers<br />

8280 Computerized Prescuption Plants<br />

8290 Scales, in general<br />

18.07. Handling Technology<br />

8320 Manipulators<br />

8340 Industrial Robots<br />

8350 Industrial Robots, Resistant to Rough<br />

8364 Chipping Plants with Robots<br />

18.08. Fluid Mechanics<br />

8365 Pumps<br />

8367 Compressors<br />

18.09. Storage Systems, Marshalling<br />

8368 Marking and Identification<br />

18.10. Components<br />

8374 Marking and Identification<br />

19 Pattern- and Diemaking<br />

19.01. Engines for Patternmaking<br />

and Permanent Mold<br />

8380 Band Sawing Machines for<br />

Patternmaking<br />

8400 CAD/CAM/CAE Systems<br />

8410 CAD Constructions<br />

8420 CAD Standard Element Software<br />

8423 CNC Milling Machines<br />

8425 Automatic CNC Post-Treatment<br />

Milling Machines<br />

8430 CNC Programming Systems<br />

8440 CNC, Copying, Portal and Gantry<br />

Milling Machines<br />

8470 Dosing Equipment and Suction<br />

Casting Machines for the Manufacture<br />

of Prototypes<br />

8480 Electrochemical Discharge Plants<br />

8490 Spark Erosion Plants<br />

8500 Spark Erosion Requirements<br />

8510 Development and Production of<br />

Lost-Foam Machines<br />

8520 Milling Machines for Lost-Foam<br />

Patterns<br />

8522 Hard Metal Alloy Milling Pins<br />

8525 Lost-Foam Glueing Equipment<br />

8527 Patternmaking Machines<br />

8576 Rapid Prototyping<br />

8610 Wax Injection Machines<br />

19.02. Materials, Standard Elements<br />

and Tools for Pattern- and<br />

Diemaking<br />

8630 Thermosetting Plastics for Patternmaking<br />

8650 Toolmaking Accessories<br />

8660 Milling Cutters for Lost-Foam<br />

Patterns<br />

8670 Free-hand Milling Pins made of<br />

Hard Metal Alloys and High-speed<br />

Steels<br />

8675 Hard Metal Alloy Milling Pins<br />

8680 Adhesives for Fabrication<br />

64


8690 Synthetic Resins for Patternmaking<br />

8700 Plastic Plates Foundry and Patternmaking<br />

8705 Lost-Foam Tools and<br />

Patterns<br />

8710 Patternmaking Requirements, in<br />

general<br />

8720 Patternmaking Materials, in general<br />

8730 Pattern Letters, Signs, Type Faces<br />

8740 Pattern Dowels (metallic)<br />

8750 Pattern Resins<br />

8760 Pattern Resin Fillers<br />

8770 Pattern Plaster<br />

8780 Pattern Gillet<br />

8790 Lumber for Patterns<br />

8800 Pattern Varnish<br />

8810 Pattern-Plate Pins<br />

8820 Pattern Spaddles<br />

8830 Standard Elements for Tools and<br />

Dies<br />

8840 Precision-shaping Silicone<br />

8846 Rapid Tooling<br />

19.03. Pattern Appliances<br />

8880 CNC Polystyrol<br />

Patternmaking<br />

8890 Development and Manufacture of<br />

Lost-Foam Patterns<br />

8900 Moulding Equipment<br />

8910 Wood Patterns<br />

8930 Core Box Equipment for Series<br />

Production<br />

8940 Resin Patterns<br />

8960 Metal Patterns<br />

8970 Pattern Equipment, in general<br />

8980 Pattern Plates<br />

8985 Pattern Shop for Lost-Foam<br />

Processes<br />

9000 Stereolithography Patterns<br />

9010 Evaporative Patterns for the Lost-<br />

Foam Process<br />

19.04. Rapid Prototyping<br />

9021 Design<br />

9022 Engineering<br />

9023 Hardware and Software<br />

9024 Complete Investment Casting<br />

Equipment for Rapid<br />

Prototyping<br />

9025 Pattern and Prototype<br />

Making<br />

9026 Rapid Prototyping for the Manufacture<br />

of Investment Casting<br />

Patterns<br />

9027 Integrable Prototypes<br />

9028 Tools<br />

9029 Tooling Machines<br />

20 Control Systems and Automation<br />

20.01. Control and Adjustment Systems<br />

9030 Automation and Control for Sand<br />

Preparation<br />

9040 Automation<br />

9042 Software for Production Planning<br />

and Control<br />

9050 Electric and Electronic Control<br />

9080 Equipment for the Inspection of<br />

Mass Production<br />

9090 Load Check Systems for Recording<br />

and Monitoring Energy Costs<br />

9120 Control Systems and<br />

Automation, in general<br />

9130 Control Systems, in general<br />

9160 Switch and Control Systems<br />

20.02. Measuring and Control<br />

Instruments<br />

9165 Automatic Pouring<br />

9166 Compensation Leads<br />

9185 Contactless Temperature Measurement,<br />

Heat Image Cameras<br />

9190 Leakage Testing and Volume<br />

Measuring Instruments<br />

9210 Flow Meters<br />

9220 Flow control Instruments<br />

9230 Immersion Thermo Couples<br />

9240 Moisture Controller<br />

9250 Level Indicator<br />

9280 Bar Strein Gauge<br />

9301 In-Stream Inoculation Checkers<br />

9302 In-Stream Inoculant Feeder<br />

9306 Calibration and Repair Services<br />

9310 Laser Measurement Techniques<br />

9320 Multi-coordinate Measuring<br />

Machine<br />

9330 Measuring and Controlling Appliances,<br />

in general<br />

9335 Measuring and Controlling Appliances<br />

for Fully Automatic Pouring<br />

9345 Positioning Control<br />

9350 Pyrometers<br />

9370 Radiation Pyrometers<br />

9375 Measuring Systems for Nuclear<br />

Radiation (receiving inspection)<br />

9376 Measuring Systems for Radioactivity,<br />

Incoming Goods‘ Inspection<br />

9380 Temperature Measurement<br />

9382 Temperature Control Units<br />

9385 Molten Metal Level Control<br />

9390 Temperature Measuring and<br />

Control Devices<br />

9391 Thermoregulator<br />

9395 Molten Metal Level Control<br />

9400 Thermal Analysis Equipment<br />

9410 Thermo Couples<br />

9420 Protection Tubes for Thermocouples<br />

9425 In-stream Inoculant Checkers<br />

9430 Heat Measuring Devices<br />

9433 Resistance Thermometers<br />

20.03. Data Acquisition and<br />

Processing<br />

9438 Automation of Production- and<br />

Warehouse-Systems<br />

9440 Data Logging and Communication<br />

9445 Business Intelligence<br />

9450 Data Processing/Software Development<br />

9456 ERP/PPS - Software for Foundries<br />

9470 EDP/IP Information and Data<br />

Processing<br />

9480 Machine Data Logging<br />

9484 Machine Identification<br />

9490 Data Logging Systems<br />

9500 Numerical Solidification Analysis<br />

and Process Simulation<br />

9502 Numerical Solidification Simulation<br />

and Process Optimization<br />

9504 ERP - Software for Foundries<br />

9506 Process Optimization with EDP, Information<br />

Processing for Foundries<br />

9510 Computer Programmes for Foundries<br />

9520 Computer Programmes and Software<br />

for Foundries<br />

9522 Simulation Software<br />

9523 Software for Foundries<br />

9525 Software for Coordinate<br />

Measuring Techniques<br />

9527 Software for Spectographic Analyses<br />

9530 Statistical Process Control<br />

9540 Fault Indicating Systems,<br />

Registration and Documentation<br />

20.04. Process Monitoring<br />

9541 High Speed Video<br />

21 Testing of Materials<br />

21.01. Testing of Materials and<br />

Workpieces<br />

9548 Calibration of Material Testing<br />

Machines<br />

9550 Aluminium Melt Testing<br />

Instruments<br />

9554 Acoustic Materials Testing<br />

9555 Acoustic Construction<br />

Element Testing<br />

9560 CAQ Computer-Aided Quality<br />

Assurance<br />

9564 Image Documentation<br />

9580 Chemical Analyses<br />

9585 Computerized Tomography, CT<br />

9586 Core Gas - System for Measurement<br />

and Condensation<br />

9587 Die Cast Control<br />

9589 Natural Frequency Measuring<br />

9590 Endoscopes<br />

9600 Dye Penetrants<br />

9610 Instruments for<br />

Non-destructive Testing<br />

9620 Hardness Testers<br />

9630 Inside Pressure Testing Facilities<br />

for Pipes and Fittings<br />

9645 Calibration of Material Testing<br />

Machines<br />

9650 Low-temperature Source of<br />

Lighting Current<br />

9670 Arc-baffler<br />

9678 Magna Flux Test Agents<br />

9680 Magnetic Crack Detection Equipment<br />

9690 Material Testing Machines and<br />

Devices<br />

9695 Metallographic and Chemical<br />

Analysis<br />

9696 Microscopic Image Analysis<br />

9697 Surface Analysis<br />

9700 Surface Testing Devices<br />

9710 Testing Institutes<br />

9719 X-ray Film Viewing Equipment and<br />

Densitometers<br />

9720 X-Ray Films<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 65


9730 X-Ray Testing Equipment<br />

9740 Spectroscopy<br />

9750 Ultrasonic Testing Equipment<br />

9755 Vacuum Density Testing Equipment<br />

9758 UV-Lamps<br />

9759 UV Shiners<br />

9760 Ultraviolet Crack Detection Plants<br />

9765 Hydrogen Determination Equipment<br />

9770 Material Testing Equipment, in<br />

general<br />

9780 Testing of Materials<br />

9800 Inside Pressure Measuring for<br />

Tools<br />

9836 Devices for Testing of Materials,<br />

non-destructive, in general<br />

9838 NDT Non-destructive Testing of<br />

Materials<br />

9840 NDT X-ray Non-destructive Testing<br />

of Materials<br />

9850 Tensile Testing Machines<br />

22 Analysis Technique and Laboratory Equipment<br />

10000 Sample Preparation Machines<br />

10010 Quantometers<br />

10018 X-Ray Analysis Devices<br />

10020 Spectographic Analysis Devices<br />

10022 Certified Reference Materials for<br />

Spectrochemical and -scopic<br />

Analysis<br />

10040 Cut-off Machines for Metallography<br />

9860 Analyses<br />

9865 Image Analysis<br />

9880 Gas Analysis Appliances<br />

9890 Carbon and Sulphur<br />

Determination Equipment<br />

9900 Laboratory Automation<br />

9910 Laboratory Equipment, Devices,<br />

and Requirements, in general<br />

9920 Laboratory Kilns<br />

9930 Metallographic Laboratory<br />

Equipment<br />

9940 Microscopes<br />

9948 Optical Emission Spectrometers<br />

9950 Microscopic<br />

Low-temperature Illumination<br />

9955 Continuous Hydrogen Measurement<br />

9960 Polishing Machines for Metallography<br />

9970 Sampling Systems<br />

9980 Sample Transport<br />

23 Air Technique and Equipment<br />

23.01. Compressed Air Technique<br />

10050 Compressed Air Plants<br />

10060 Compressed Air Fittings<br />

10070 Compressed Air Tools<br />

10080 Compressors<br />

10100 Compressor Oils<br />

23.02. Fans and Blowers<br />

10120 Fans, in general<br />

23.03. Ventilators<br />

10150 Axial Ventilators<br />

10160 Hot-gas Circulating Ventilators<br />

10170 Radial Ventilators<br />

10180 Ventilators, in general<br />

23.04. Other Air Technique<br />

Equipments<br />

10188 Waste Gas Cleaning<br />

10190 Exhausting Plants<br />

10192 Exhaust Air Cleaning for Cold-Box<br />

Core Shooters<br />

10220 Air-engineering Plants, in general<br />

24 Environmental Protection and Disposal<br />

10230 Environmental Protection and<br />

Disposal<br />

10231 Measures to Optimize Energy<br />

10232 Fume Desulphurization for Boiler<br />

and Sintering Plants<br />

10235 Radiation Protection Equipment<br />

24.01. Dust Cleaning Plants<br />

10240 Extraction Hoods<br />

10258 Pneumatic Industrial Vacuum<br />

Cleaners<br />

10260 Pneumatic Vacuum Cleaners<br />

10270 Equipment for Air Pollution Control<br />

10280 Dust Cleaning Plants, in general<br />

10290 Gas Cleaning Plants<br />

10300 Hot-gas Dry Dust Removal<br />

10309 Industrial Vacuum Cleaners<br />

10310 Industrial Vacuum Cleaners<br />

10320 Leakage Indication Systems for<br />

Filter Plants<br />

10340 Multicyclone Plants<br />

10350 Wet Separators<br />

10360 Wet Dust Removal Plants<br />

10370 Wet Cleaners<br />

10380 Cartridge Filters<br />

10400 Pneumatic Filter Dust Conveyors<br />

by Pressure Vessels<br />

10410 Punctiform Exhausting Plants<br />

10420 Dust Separators<br />

10430 Vacuum Cleaning Plants<br />

10440 Dry Dust Removal Plants<br />

10450 Multi-Cell Separators<br />

10458 Central Vacuum Cleaning Plants<br />

10460 Cyclones<br />

24.02. Filters<br />

10470 Compressed Air Filters<br />

10490 Dedusting Filters<br />

10500 Filters, in general<br />

10510 Filter Gravel<br />

10520 Filter Materials<br />

10530 Filter Bags/Hoses<br />

10550 Fabric Filters<br />

10560 Air Filters<br />

10570 Cartridge Filters<br />

10580 Hose Filters<br />

10585 Electro-Filters<br />

10590 Air Filters<br />

10610 Fabric Filters<br />

24.03. Waste Disposal,<br />

Repreparation, and Utilization<br />

10618 Waste Air Cleaning<br />

10620 Waste Water Analyzers<br />

10630 Waste Water Cleaning and -Plants<br />

10640 Clean-up of Contaminated Site<br />

10646 Used Sands, Analysing of Soils<br />

10650 Waste Sand Reutilization and<br />

Reconditioning<br />

10655 Amine Recycling<br />

10660 Foundry Debris-conditioning Plants<br />

10680 Soil Clean-up<br />

10690 Briquetting Presses<br />

10695 Briquetting of Foundry<br />

Wastes/Filter Dusts<br />

10700 Disposal of Foundry Wastes<br />

10702 Hazardous Waste Disposal<br />

10705 Bleeding Plants<br />

10710 Reconditioning of Foundry Wastes<br />

10720 Ground Water Cleaning<br />

10740 Dross Recovery Plants<br />

10760 Cooling Towers<br />

10770 Cooling Water Processing Plants<br />

10780 Cooling Water Treatment<br />

10810 Post-combustion Plants<br />

10830 Recooling Systems<br />

10840 Recycling of Investment Casting<br />

Waxes<br />

10850 Slag Reconditioning<br />

10870 Waste Water Cooling Towers<br />

10880 Scrap Preparation<br />

10890 Transport and Logistic for Industrial<br />

Wastes<br />

10900 Rentilization of Foundry Wastes<br />

10910 Rentilization of Furnace Dusts and<br />

Sludges<br />

10920 Roll Scale De-oilers<br />

10940 Rentilization of Slide Grinding<br />

Sludges<br />

25 Accident Prevention and Ergonomics<br />

10960 Health and Safety Protection<br />

Products<br />

10970 Asbestos Replacements<br />

10990 Ventilators<br />

10993 Fire Protection Blankets and<br />

Curtains made of Fabrics<br />

10996 Fire-extinguishing Blankets and<br />

Containers<br />

11020 Heat Protection<br />

11025 Heat-Protection Clothes and Gloves<br />

11030 Climatic Measurement Equipment<br />

for Workplace Valuation<br />

11040 Protection against Noise<br />

11050 Light Barriers<br />

11060 Sound-protected Cabins<br />

11070 Sound-protected Equipment and<br />

Parting Walls<br />

11080 Vibration Protection<br />

26 Other Products for Casting Industry<br />

26.01. Plants, Components, and<br />

Materials<br />

11100 Concreting Plants<br />

11102 Devellopping and Optimizing of<br />

Casting Components<br />

11118 Vibration Technology<br />

26.02. Industrial Commodities<br />

11120 Joints, Asbestos-free<br />

66


11125 Sealing and Insulating<br />

Products up to 1260 °C<br />

11130 Dowels<br />

11150 Foundry Materials, in general<br />

11155 Heat-protecting and Insulating<br />

Fabrics up to 1260 °C<br />

11160 Hydraulic Oil, Flame-resistant<br />

11165 Marking and Identification<br />

11170 Signs for Machines<br />

11175 Fire-proof Protection Blankets,<br />

-mats, and -curtains<br />

11180 Screen and Filter Fabrics<br />

26.04. Job Coremaking<br />

11182 Inorganic Processes<br />

11183 Hot Processes<br />

11184 Cold Processes<br />

27 Consulting and Service<br />

11186 Ordered Research<br />

11190 CAD Services<br />

11200 Interpreters<br />

11202 Diecasting, Optimization of Mould<br />

Temperature Control<br />

11205 EDP Consulting<br />

11208 Wage Models<br />

11210 Emission, Immission, and Workplace<br />

Measurements<br />

11211 E-Business<br />

11212 eProcurement<br />

11213 Technical Literature<br />

11215 Investment Casting Engineering<br />

11220 Foundry Consulting<br />

11230 Foundry Legal Advice<br />

11240 Lean Foundry Organization<br />

11250 Foundry Planning<br />

11252 Greenfield Planning<br />

11253 Casting, Construction and Consulting,<br />

Optimizing of Mould Core<br />

Production and Casting Techniques<br />

11260 Nuclear Engineering Consulting<br />

11278 Customer Service for Temperature<br />

Control Units and Systems<br />

11280 Customer Service for<br />

Diecasting Machines<br />

11283 Jobbing Foundry<br />

11286 Efficiency of Material<br />

(Consulting)<br />

11290 Management of Approval<br />

Procedures<br />

11291 Management Consulting<br />

11292 Machining<br />

11293 Metallurgical Consulting<br />

11294 Patinating<br />

11295 Human Resources Services<br />

11296 Personnel Consulting<br />

11298 Process Optimization<br />

11299 Testing Status and Safety Labels<br />

11300 Rationalization<br />

11301 M&A Consulting<br />

11303 Recruitment<br />

11305 Centrifugal Casting Engineering<br />

11310 Simulation Services<br />

11320 Castings Machining<br />

11325 Steel Melting Consulting<br />

11330 Technical Translation and Documentation<br />

11336 Environmental Protection Management<br />

Systems (Environmental<br />

Audits)<br />

11339 Restructuring<br />

11340 Environmental Consulting<br />

11342 Business Consultancy<br />

11343 Leasing of Industrial Vacuum<br />

Cleaners<br />

11345 Heat Treatment<br />

11346 Associations<br />

11360 Material Consulting<br />

11370 Material Advices<br />

11380 Time Studies<br />

11382 Carving<br />

28 Castings<br />

11387 Aluminium Casting<br />

11389 ADI<br />

11390 Aluminium Pressure Diecasting<br />

11400 Aluminium Permanent Moulding<br />

(Gravity Diecasting)<br />

11410 Aluminium Sand Casting<br />

11420 Billet Casting<br />

11430 Cast Carbon Steel, Alloy and<br />

High-alloy Cast Steel<br />

11440 Non-ferrous Metal Gravity Diecasting<br />

11450 Pressure Diecasting<br />

11460 High-grade Investment Cast Steel<br />

11462 High-grade Steel Casting<br />

11470 High-grade Steel Castings<br />

11472 High-grade Centrifugal Cast Steel<br />

11480 Ingot Casting<br />

11485 Castings<br />

11489 Rolled Wire<br />

11490 Grey Cast Iron<br />

11492 Large-size Grey Iron Castings<br />

11496 Direct Chill Casting<br />

11498 Art Casting<br />

11499 Light Metal Casting<br />

11501 Magnesium Pressure<br />

Diecasting<br />

11510 Brass Pressure Diecasting<br />

11520 Non-ferrous Metal Sand Casting<br />

11525 Prototype Casting<br />

11530 Sand Casting SAND CASTING<br />

11539 Centrifugal Casting<br />

11540 Spheroidal Iron<br />

11547 Spheroidal Graphite Cast Iron<br />

11550 Steel Castings<br />

11552 Continuously Cast Material<br />

11553 Thixoforming<br />

11555 Full Mold (lost-foam) Casting<br />

11558 Rolls<br />

11560 Zinc Pressure Diecasting<br />

11570 Cylinder Pipes and Cylinder Liners<br />

29 By-Products<br />

11580 Sporting Field Sands<br />

30 Data Processing Technology<br />

11700 Mold Filling and Solidification<br />

Simulation<br />

11800 Simulation Programmes for<br />

Foundry Processes<br />

11820 Software for Foundries<br />

31 Foundries<br />

11850 Foundries, in general<br />

31.01. Iron, Steel, and Malleable-Iron<br />

Foundries<br />

11855 Iron Foudries<br />

11856 Steel Foundries<br />

11857 Malleable-Iron Foundries<br />

31.02. NFM Foundries<br />

11860 Heavy Metals Foundries<br />

11861 Die Casting Plants<br />

11862 Light Metal Casting Plants<br />

11863 Permanent Mold Foundry<br />

31 Additive manufacturing / 3-D printing<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 67


CASTING<br />

PLANT AND TECHNOLOGY<br />

INTERNATIONAL<br />

Order form<br />

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In addition and at no extra charge: Your entry on the<br />

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68


INTERNATIONAL FAIRS AND CONGRESSES<br />

Fairs and Congresses<br />

64th Austrian Foundry Conference<br />

April, 2-3, <strong>2020</strong>, Schladming, Austria<br />

www.ogi.at<br />

Metalcasting Congress <strong>2020</strong><br />

April, 21-23, <strong>2020</strong>, Cleveland, USA<br />

www.afsinc.org<br />

German Foundry Day<br />

April, 23-24, <strong>2020</strong>, Aachen, Germany<br />

www.bdguss.de<br />

Metal + Metallurgy China<br />

May, 13-16, <strong>2020</strong>, Shanghai, China<br />

www.mm-china.com/en<br />

19th <strong>International</strong> Foundrymen Conference<br />

May, 13-15, <strong>2020</strong>, Split, Croatia<br />

www.simet.hr/~foundry<br />

WFO World Foundry Summit<br />

May, 18-19, <strong>2020</strong>, New York, USA<br />

www.thewfo.com/world-foundry-summit<br />

Litmash Russia <strong>2020</strong><br />

June, 9-11, <strong>2020</strong>, Moscow, Russia<br />

www.litmash-russia.com<br />

CastForge <strong>2020</strong><br />

June, 16-18, <strong>2020</strong>, Stuttgart, Germany<br />

www.messe-stuttgart.de/castforge/en<br />

Advertisers‘ Index<br />

AGTOS Gesellschaft für technische Oberflächensysteme<br />

mbH, Emsdetten/Germany 31<br />

ASTI - Gießereigeräte GmbH,<br />

Sinsheim/Germany25<br />

automatic Klein GmbH, Essen/Germany 15<br />

ExOne GmbH, Gersthofen/Germany 9<br />

Förder- und Anlagentechnik GmbH,<br />

Niederfischbach/Germany 39<br />

Heinrich Wagner Sinto Maschinenfabrik GmbH,<br />

Bad Laasphe/Germany 43<br />

Hüttenes-Albertus Chemische Werke GmbH,<br />

Düsseldorf/GermanyBC<br />

JASPER Germany Gesellschaft für Energiewirtschaft<br />

und Kybernetik mbH, Geseke/Germany<br />

IFC<br />

Lucky -Winsun Enterprise Ltd.,<br />

Taichung/Taiwan47<br />

Maschinenfabrik Gustav Eirich GmbH & Co KG,<br />

Hardheim/Germany49<br />

O.M.LER Srl Bra, (CN)/Italy 29<br />

Regloplas AG, St. Gallen/Switzerland 19<br />

RUMP Strahlanlagen GmbH & Co. KG,<br />

Salzkotten/Germany33<br />

Targi Kielce Sp.u.o.o., Kielce/Poland 29<br />

CASTING PLANT & TECHNOLOGY 1/<strong>2020</strong> 69


PREVIEW/IMPRINT<br />

The new de-dusting system –<br />

recognizable by the pipes and the<br />

exhaust air chimney – ensures ‘a<br />

good atmosphere’ between residents<br />

and the Lößnitz foundry.<br />

Photo: Martin Vogt<br />

Preview of the next issue<br />

Selection of topics:<br />

M. Vogt: From the Ore Mountains to the world<br />

The Lößnitz foundry near Aue in the Ore Mountains in Germany, a classic iron foundry making molding and pressing tools for<br />

the automotive industry, is committed to sustainability. This is being driven forward by Max Jankowsky, Managing Director of<br />

the family business since the beginning of the year.<br />

T. Evert, K. Köppen: Blasting and degreasing in one operation<br />

In the PantaTec process, blasting is expanded by adding a powdery cleaning additive to the blasting agent. This means that,<br />

despite contamination, most metal surfaces can be blasted without wet chemical pre-cleaning.<br />

G. Zwick: Hot-work steel sets new standards<br />

Uddeholm Dievar is a premium steel for demanding die-casting applications. It is suitable for use in large die-casting molds and<br />

complies with the new specification of at least 25 joule impact energy according to the rules of the strict NADCA delivery<br />

guidelines.<br />

Imprint<br />

Publisher:<br />

German Foundry Association<br />

Editor in Chief:<br />

Martin Vogt, Dipl.-Journalist<br />

Deputy Editor in Chief:<br />

Robert Piterek, M.A.<br />

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40042 Düsseldorf, Germany<br />

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