CPT International 2-3/2020

EDITORIAL
Successful casting with
a technological edge!
How do the sector’s top companies position themselves technologically?
What do they invest their money in? One can approach
these questions with examples of best practice – and this issue again
provides insights into the works halls of many successful companies.
Robert Piterek
e-mail: robert.piterek@bdguss.de
Investing money to save money. This is
what happens in the modern foundry
industry of the 21st century. Information
is essential in order to find out
which technologies are worth investing
in – technologies that increase productivity,
efficiency, plant service lives, or the
measurement accuracy of quality inspections,
for example. In this double issue,
CP+T’s editorial staff has again sought
out practical advantages for foundries
worldwide. A double issue because, as
in so many sectors, lockdown and
reduced business activities due to the
coronavirus crisis have not left magazines
such as CP+T and its big sister
GIESSEREI unscathed. This issue covers a
wide range of current examples of best
practice in the most important foundry
functions – such as the melting shop,
mold and core production, as well as
digitalization and simulation – showing
how this old technology, and frequently
its new developments, constantly innovate
and improve, even 5,000 years after
casting was first employed.
In addition to many articles by respected
foundry experts on these and
other topic areas, you will also find a
company report on the Grunewald prototype
foundry in this issue. Grunewald
(located in the west of Germany near
the Dutch border) has experienced a
surprising growth in foundry business
by offering 3-D-printed molds and cores
(more on this from P. 10).
ACS technology (presented at the
Molding Forum in Munich in February,
just before the outbreak of the Covid-
19 pandemic in Germany), with which
the inorganic core can be electrically
hardened, is also very interesting. The
developers of this technology claim that
it is possible to reduce energy costs and
cycle times by 30 percent (from P. 36).
The interview with the head of the
Slovenian Foundry Association, whose
60th International Foundry Conference
(IFC) is to take place this year, is an
attempt to wrest back from the pandemic
a moment of personal contact after
the long months without any appointments.
CP+T will also be present. Read
about what can be expected in Portoroz
on Slovenia’s Adriatic coast from P. 6.
Have a good read!
CASTING PLANT & TECHNOLOGY 2–3/2020 3

CONTENTS
FEATURES
6 INTERVIEW
„Our event is an opportunity to meet
in person again!“
Mirjam Jan-Blazic, head of the Slovenian Foundy
Society, hosts the 60. International Foundry Congress,
one of few foundry events currently not taking place
online but in real life. Interview by Robert Piterek
10 COMPANY
New perspectives through 3-D printing
At Grunewald in Bocholt, there has been a surprising
growth in foundry business thanks to the new
3-D printer for molds and cores, Robert Piterek
14 FETTLING & FINISHING
Optimizing abrasive precision
Blasting machine maufacturer AGTOS refurbished
an Italian blasting machine at Stadler Stahlguss in
Switzerland, Ulf Kapitza
INTERVIEW
How can a real life
event look like in
corona times? Those
and other questions
were posed in this
issue‘s interview
COMPANY
Automation is a top
priority at Grunewald
in Bocholt. Now a
3-D-Printer was
installed.
18 MELTING SHOP
Upgrading shaft melting furnaces
Shaft melting furnaces are economical and offer
high metal quality in aluminium foundries. Automation,
smart design details and digital innovations
can enhance these furnaces, Rudolf Hillen
New perspectives for steel casting
Low-pressure pouring offers advantages in comparison
with gravity pouring, Markus Hagedorn et al.
MOLD AND
COREMAKING
Elektrical curing of
inorganic sand cores
using the ACS technology.
Cover-Photo:
In the next issue in December, a photo report about the
creation of the cast sculpture „Pendulum“ is published.
It reveals insights into the professional work of the art
casters of Schmees Cast in Pirna. Our current title page
shows them in front of the impressive piece of art.
4

CONTENTS
FETT LING &
FINISHING
Optimizing abrasive
precision.
Reducing downtime with prefabricated
furnace linings
High-quality insulating materials in the lining
process save energy and lower CO 2
emissions
Dirk Schmeisser et al.
30 MOLD AND COREMAKING
Transferring green sand molding‘s
advantages to aluminium casting
“Efficient, high quality and inexpensive: The green
sand process offers these advantages not only
for iron but also for aluminum casting, Per Larsen
Elektrical curing of inorganic sand cores
using the ACS technology
With the newly developed ACS technology inorganic
sand binders heat additionally directly caused by
current flow, Gotthard Wolf et al.
42 DIGITALIZATION
Hybrid Internet of Things service solutions
for the foundry industry
To optimize foundry processes ABP Induction has
launched a promising web-based customer portal.
Moritz Spichartz et al.
46 SAND REGENERATION
Changing mixing tools quick and easy
A new system for changing rotor beaters in mixers
shortens service and standstill times, Philipp Krötz
48 PRESSURE DIE CASTING
Gap monitoring in die casting machines
Machines equipped with inductive sensors enable
manufacturers to reduce costs, Stefan Stelzl
QUALITY
ASSURANCE
Inspections of castings
with Cameras
and Artificial Intelligence
could become
standard in future.
50 QUALITY ASSURANCE
Assuring quality with Cameras and AI
A Berlin-based start-up developed a promising
inspection method, which could become standard
in smart factories, Damian Heimel
COLUMNS
3 EDITORIAL
53 NEWS IN BRIEF
60 SUPPLIERS GUIDE
77 FAIRS AND KONGRESSES/AD INDEX
78 PREVIEW/IMPRINT
CASTING PLANT & TECHNOLOGY 2–3/2020 5

INTERVIEW
6

“In my opinion the conference and foundry
exhibition in Portoroz is one of the bestknown
foundry events in Europe.“
Sculpture in front of one of the conference rooms. Despite
the pandemic, the international foundry conference
(IFC) in Portoroz will take place as planned this year.
“Our event is an opportunity
to meet in person again!”
Mirjam Jan-Blazic, head of the Slovenian Foundry Society, has a Master of Science from the
Faculty of Technology and Metallurgy of the University in Belgrade and long years of professional
experience as laboratory manager of a die-casting foundry. She is almost the only
organizer to host an important foundry event in 2020: the IFC, which has been going for 60
years, and takes place in Portoroz from 16–18 September 2020. She spoke to CP+T about
the history of the conference, the upcoming event, as well as Covid-19 and its aftermath.
Photos: Slowenian Foundry Society
Mrs. Jan-Blazic, the International
Foundry Conference in Slovenia is 60
years old now. How was it originally
launched?
The Slovenian Foundrymen Society,
founded in 1953, together with the
Faculty of Natural Sciences and
Engineering of the University of Ljubljana,
60 years ago started to organize
a foundry conference every year. In
Portoroz the conference was held for
the first time in 1963. The first conferences
were attended mainly by lecturers
from the common state of Yugoslavia
and lecturers from foundry
societies and associations, universities,
and institutes. From the very beginning
participants from abroad attended the
conference. Representatives of the
German Foundry Association (VDG),
Austrian Foundry Institute (ÖGI), and
soon after also experts from Switzerland,
Czechoslovakia and Poland were
among the first.
The conference in Portoroz was also
an opportunity for us to show our
achievements to the world. From its
initiation, the Slovenian Foundrymen’s
Society has provided support regarding
local development, production of our
foundry machines, equipment, auxiliary
foundry materials and raw materials.
This strategy is still successful and
our foundries can obtain a lot of
important high-quality materials and
equipment from Slovenian producers.
60 years is a long time. What have been
the biggest highlights?
The Slovenian Foundrymen’s Society has
always had very ambitious goals, for
example to decrease the technological
gap and to prevent Slovenia from falling
behind developed industrial countries.
So it became apparent that the decision
to organize an annual international
foundry conference was useful not only
for Slovenian foundries, but also for the
other participating foreign countries.
That’s how the foundry conference
grew into a foundry event where we
exchanged scientific and technological
achievements. These possibilities were
enhanced even more after 1970, when
we added the accompanying foundry
exhibition to the Conference.
Our foundry magazine LIVARSKI
VESTNIK, which has been published for
67 years now, plays an important role in
this history. We mainly print scientific
and technical articles from the Conference
in Portoroz. We have been publishing
articles bilingually – in Slovenian
and English – since 2001.
Over the decades, the Conference in
Portoroz has become a traditional meeting
place attended by representatives
from many national foundry societies
and associations as well as from the
World Foundry Organization (WFO), the
European Foundry Association (CAEF),
and the Central European Foundry Initiative
(MEGI).
Entrusting university staff with leadership
of the preparation of the pro-
CASTING PLANT & TECHNOLOGY 2–3/2020 7

INTERVIEW
gram and organization of the Conference
in Portoroz was an important
decision. Then in 2005 it was time for a
change: The University remained responsible
for the program part of the
Conference while a new organizational
symbiosis involving the Society, industry,
and the universities of Ljubljana and
Maribor brought about a new quality
of development of both the Society itself
and the Conference.
How was it possible to hold international
conferences on foundry technology
back in the Cold War era?
This is a question involving world politics,
which I have always been interested
in. I understand the long period of
the Cold War with détente from 1960
to 1980 as a conflict between western
forces led by the USA and eastern forces
headed by the Soviet Union. Because
Yugoslavia, of which Slovenia was a
part, was unaffected by the conflict
because it did not take sides thanks to
decisions made by President J. B. Tito.
Yugoslavia was a very open country at
that time – foreigners could visit and its
citizens could travel abroad. Yugoslavian
passports were the most expensive
on the black market then because they
permitted free access to many countries.
I have not read or heard about any
difficulties organizing the conference in
Portoroz during the Cold War, which
ended with the disintegration of Yugoslavia
and the Soviet Union. The final
foundry conference of the former Yugoslavia
took place in Portoroz in October
1990, two months before the plebiscite
for an independent Slovenia, and the
32nd conference took place in Portoroz
in May 1991, a month before the declaration
of an independent Slovenia.
How significant do you think this event
is for Europe?
In my opinion the conference and
foundry exhibition in Portoroz is one of
The conference center where the International
Foundry Conference (IFC) will take
place (16-18 September) is in the Slovenian
city of Portoroz at the Adriatic Sea.
the best-known foundry events in
Europe, thanks to its yearly achievements,
scientific contributions and its
current size. And it is certainly the leading
conference in this part of Europe.
That the conference grew to become a
respected international conference of
high quality is demonstrated by the fact
that the World Foundry Organization
entrusted the organization of its WFO
Technical Forum to the Slovenian
Foundrymen’s Society in 2019. It took
place together with the 59th IFC Portoroz
2019. This was the largest foundry
event ever in Portoroz. There were 400
participants and more than 100 speakers
from all around the world. Participation
in the foundry exhibition also
achieved a record high.
Let’s talk about the IFC’s homeland.
What are the cornerstones of the Slovenian
foundry industry?
The foundry sector is an important part
of Slovenia’s industry. Slovenia’s foundry
production in tonnes per resident is
among the world’s highest, based on
statistical information on worldwide
foundry production. We have about 70
foundries with approximately 5,000
employees. Medium and large foundries
produce approximately 90% of all
foundry earnings. Interestingly, all
foundry technologies are represented in
our foundries, which is unusual for
smaller countries. Despite the obvious
signs of a recession during the second
half of last year, the 2019 financial year
was still relatively good for most Slovenian
foundries. The official statistics
show that foundry production in 2019
was 195,609 tonnes of castings, which is
only 1% less than in 2018. Compared to
2018, casting types were as follows:
58,281 tonnes of grey iron (7% less),
43,867 tonnes of ductile iron (the same
as in 2018), 3,200 tonnes of malleable
iron (3% more), 25,099 tonnes of steel,
Fe-granulate (10% less), 54,625 tonnes
of aluminum alloys (5% more), 9,665
tonnes of zinc alloys (14% more) and
872 tonnes of copper alloys (15%
more).
Like everywhere in the world, Slovenia
and its foundry industry has been
affected by the coronavirus pandemic.
How have the foundries in your country
been influenced and what is the
current situation?
The Slovenian government has so far
introduced four packages of measures
to help alleviate the negative effects of
the COVID-19 pandemic on the economy
and population. The first package
of measures from March is aimed at
providing security for the whole population
and especially the economy, with
an emphasis on preserving workplaces.
The second package ensures liquidity
for companies and provides a scheme to
enable new bank loans. The third
package introduced short-time work
and extended the country’s subsidies for
workers who have been temporary laid
off.
We believe that despite the hard
times that COVID-19 brought to our
economy and population, Slovenia has
dealt with it relatively well, taking
many safety measures. Our main goal
was to preserve production and workplaces.
I think that this goal has been
quite well fulfilled.
The conference is planned to take place
from 16 - 18 September 2020. What can
participants expect?
The regular Conference program includes
34 presentations. Ten plenary lectures
are planned on the first day of the
Conference. 24 lectures will take place
on the second day – 12 each on ferrous
and non-ferrous casting. There will also
be the traditional accompanying
8

foundry exhibition with around 40 exhibitors. With the new conditions
caused by the COVID-19 pandemic we will do everything
necessary to maintain our good reputation as organizers and
good hosts of this traditional foundry event in Portoroz. We will
do our best to ensure appropriate participant safety at the congress
square and hotels. Detailed instructions for a safe stay will
be sent to all participants a week before the official start of the
Conference.
How many participants are expected to take part in the event?
We will certainly have lower participation than in previous years
(around 150 - 200 participants each year) because of the pandemic.
Applications are still coming in and we will be accepting
them until the start of the Conference. A circle of passive participants
will probably decide about coming to Portoroz at the last
minute, depending on conditions in their and other countries,
especially Slovenia. At the moment, citizens from countries that
are on the so-called ‘green list’ can come to Slovenia without
limitations. These are countries that are successfully controlling
the pandemic. Citizens from countries that are on the so-called
“yellow list” can come to Slovenia under certain conditions (with
a negative test for COVID-19 virus).
The number of lectures registered will enable 100 % filling
the usual regular conference program. Based on the number of
participants already registered for the exhibition, it looks like we
will also reach the same number of participants as in the past
years.
Will there be a celebration at the IFC for the 60th jubilee?
For everyone – us, as organizers, and the participants – this meeting
will be a big celebration if we manage to execute it with
the planned conference program and exhibition under these
completely new conditions. It will be a special celebration
because it will provide an opportunity to meet in person again
after one year. After the lockdowns and restrictions that we
have experienced, we all miss our social contacts – absent since
the beginning of the crisis due to the cancellation of most
foundry events.
Our traditional welcome and an ‘acquaintance meeting’ with
the Mayor of the Piran municipality will be organized at the
Georgios Centre’s garden next to the monastery church in Piran.
And the Foundrymen’s Night will take place on the coast across
from the Slovenija congress center with pleasant live music. We
have had to cancel the dinner and the boat ride at the Slovenian
seaside because of the safety measures. But we are sure that we
will also have a great time this year!
MECHANICAL RECLAMATION
USR II
FOR GREEN SAND AND
GREEN SAND-CORE SAND-MIX
YOUR ADVANTAGES:
• High efficiency
• Long service life thanks to ceramic components
• Easy maintenance
• Compact design
• Conservation of resources
Before reclamation
After reclamation
New!
What do you think are the prospects for the foundry industry in
the face of the pandemic – focusing on Slovenian and international
foundries?
In my opinion, foundries here and abroad face a lot of challenges
and difficult changes. One of these is definitely finding a quicker
route to a green future or “green economy” and concern
for sustainable development. In the future, foundries will not
only have to ensure economic growth and profits, but also have
to decrease all emissions for the essential mitigation of climate
change. In this respect, I consider the pandemic to be a warning.
I believe that we need faster restructuring of the automotive
industry, together with their supplier foundries, towards electrical
and hybrid vehicles.
In any case, I am sure foundries will remain an important and
irreplaceable part of industry as a whole and will continue to
secure the survival and development of all other industries.
www.drustvo-livarjev.si
PERFECTION IN EVERY
SINGLE MOULD.
www.sinto.com
HEINRICH WAGNER SINTO
Maschinenfabrik GmbH
SINTOKOGIO GROUP
Bahnhofstr.101 · 57334 Bad Laasphe, Germany
Phone +49 2752 / 907 0 · Fax +49 2752 / 907 280
www.wagner-sinto.de
HWS Anz 85x260 USR-II GB_2019_RZ_neu.indd 1 20.02.2020 10:10:38
CASTING PLANT & TECHNOLOGY 2–3/2020 9

New perspectives
through 3-D printing
Michael Klein-Hitpass using a 3-D
printer. The molds and cores are
slotted into the job box like in the
classic computer game Tetris
The prototype foundry Grunewald in Bocholt, Germany, invested in a 3-D sand printer
at the end of 2018. After more than a year, the payoff has been substantial. There is
high demand from customers – and casting has also become the largest sales driver in
the company group.
By Robert Piterek, Düsseldorf
Photos: Andreas Bednareck
Michael Klein-Hitpass is standing
at the screen of an ExOne 3-D
sand printer, Type S-Max Plus,
measuring about two by three meters
in size. He’s currently generating a construction
for four sand molds and a
series of cores. On the screen, it looks a
bit like he’s playing a round of the classic
computer game Tetris. The individual
molds and cores are slotted in above
and next to each other. The only thing
missing to recreate the feel of the game
is for the completed rows to light up
and then disappear with a bit of electronic
music.
Once the box is full, printing begins.
The printer head slides from one side to
the other until the initial contours of
the printed parts start to take shape,
including the openings that risers will
later be fitted into. Right now, molds
are being created for structural elements
as well as cores for an integral
subframe that will be used by a British
automobile manufacturer in a prototype
vehicle.
Utilization significantly higher
than expected
The spacious – about 60 square meters
– and extremely clean room where
everything takes place houses the printer
as well as a table for unpacking
and an optical measuring system.
Though the large viewing window of
the printing room, one can see into
the oven that is used to harden the
molds and cores. Between the hoses
and pipes, there’s also a yellow
movable crane on the ceiling used to
10

COMPANY
Foundry head Harald
Dieckhues (left) and
managing director
Ulrich Grunewald.
The growth thanks
to 3-D sand printing
was a pleasant surprise
for both.
The contours of the
molds and cores are
starting to take shape
in the 3-D printer.
transport the large molds. The cost of
the printer, peripherals, and other systems:
EUR 1.3 million.
Klein-Hitpass is tall and lanky. With
his glasses, it’s easy to believe that he
has a passion for IT-based casting applications.
His career, however, initially led
him to become a classical caster.
An apprenticeship in model building
at Grunewald, a degree in foundry
engineering in Duisburg. Working on
his thesis brought him back to the company
in Bocholt where he had completed
his apprenticeship. “I never would
have thought that the 3-D printer
would be so well utilized,” he says. And
his bosses, Ulrich Grunewald, managing
director of the corporate group, and
foundry head Harald Dieckhues,
couldn’t agree more.
Prototype components for
electric vehicles
After the system was installed at the
end of 2018, the job boxes tended to be
only half-filled. Since spring of last year,
though, the machine has been running
almost around the clock. While uncertainty
in the automobile industry is currently
putting the brakes on business
for suppliers for conventional vehicles,
Grunewald is benefiting from the possibilities
in freedom of design and lightweight
construction offered by
3-D-printed molds and cores. And these
characteristics are in particularly high
demand from electric vehicle manufacturers,
which will account for an
ever-increasing share of vehicles in the
coming years. The team in Bocholt is
currently manufacturing structural components,
drive technology, chassis and
engine parts as well as battery trays for
the automobile manufacturers’ prototype
vehicles – more and more often
with 3-D-printed sand parts, poured off
with aluminum. Grunewald manufactures
parts for vehicles that are still being
Printed molds are hardening. The parts
customers are asking for are getting
bigger and bigger.
tested and will be qualified for market
launch in preproduction tests, for
example in test drives in the harsh Swedish
winter.
3-D sand printing drives
casting production
Over a year after installation, any anxiety
about the risk of the investment has
definitely transitioned to happiness
about the good development. Just how
good the development has been was
evident in the sales at the foundry in
downtown Bocholt that was opened in
2013. While its share of total sales for
the company was at around 50 percent
before the printer was purchased, it is
now at 75 percent, thus offsetting the
decrease in other areas at Grunewald,
such as tool manufacture, which largely
depends on conventional automobile
construction.
Klein-Hitpass demonstrates the ease of
desanding the cores after printing. This is
made possible by the use of phenol cold
resin binder.
The design freedom is one of the
main benefits of 3-D printing. There are
cores and molds that can only be created
through additive manufacturing
due to their complexity. If they can still
be cast, the current technological limits
CASTING PLANT & TECHNOLOGY 2–3/2020 11

COMPANY
The printing room from behind. There’s a refrigerator for chemicals as well as a large sand
silo for automatically filling the ExOne 3-D printer.
of casting technology have been reached.
In addition, there’s the speed of
the printer. “Depending on the part, its
complexity, and the workload, we are
at least four to six weeks faster than
conventional casting manufacturing,”
Ulrich Grunewald states as the main
reason for the acquisition of the hightech
machine. A job box with 1,260
liters of foundry sand (2.14 metric tons)
is completed in 24 hours.
More options for customers
and designers
Time was also an argument for the
customer, for whom the largest “series”
ever at Grunewald will soon be produced:
A total of 1,500 chassis parts,
GRUNEWALD GMBH UND CO. KG
Founded: 1963 as Felix Grunewald Modellbau
Management: Ulrich and Philipp Grunewald (third generation)
Employees: 200 in total. 52 in the foundry, ten in mechanical processing, an
additional 113 in Bocholt and 25 in Irxleben.
Sales: EUR 23 million
Annual production volume: 11,000 cast parts
Materials: aluminum and iron (less than five percent)
Casting processes: gravity and low-pressure sand casting
Lot sizes: from individual construction to small patches (usually 150–300
pieces)
Economic environment: Bocholt was formerly a location for the textile and
dye industry.
Customers: automobile and semiconductor industry, energy and drive technology.
Number of robots: Four in the foundry, one at another location
Mold and core production using:
> Semi-automatic mold system
> Sand mold mill
> 3-D sand printing
Breaking strength of printed molds and cores:
> After hardening: 100 N/cm2
> After firing in the oven at 160°C: 250–600 N/cm 2
Storage period of molds and cores at 10 ° C: six months
Product portfolio: Structural components for automobiles, such as doors, AC
columns, crossbars, struts, chassis parts, drive technology, engine parts, parts
for the electric and IT industry as well as battery trays.
made entirely using printed sand parts.
The customer had the option whether
they wanted to invest in a die casting
mold for the manufacturing or to have
the components manufactured using
printed molds that were manufactured
using sand casting processes in part. The
latter was cheaper and was therefore
chosen. Those who aren’t in such a rush
and don’t need very complex parts can
still order cast parts that are manufactured
using pattern equipment or
sand-milled molds and cores. Any combination
of printed sand parts with
molds and cores manufactured using
pattern equipment is also possible. New
manufacturing options that customers
readily embrace.
The printer thus combines a whole
slew of additional benefits at Grunewald,
which hadn’t even been considered
before the acquisition. “With the
printer, we are now also seen as a technology
company,” Grunewald and
Dieckhues have also observed. The technological
leap thanks to 3-D printers
thus helps the image of modern foundries.
The way of thinking is also changing:
“Our designers are now thinking
completely differently because there is
also the option to print molds and cores
instead of just manufacturing them in
our semiautomatic mold system,” Grunewald
concludes. Then an additional core
might be printed, too, if there’s still
room in the job box – freedoms that one
doesn’t have when printed sand parts
have to be bought in at high prices.
A delicate process that comes
with quirks
In the printer room, the discussion has
now progressed to the costs of 3-D printing.
“Compared to a shot core, a printed
core is still very expensive,”
Dieckhues states. The commonly held
opinion that this is due to the high costs
of electricity is not accurate according to
the foundry head, who completed his
training as a master foundryman at the
Wilhelm-Maybach-Schule in Stuttgart.
Energy comes in third, behind maintenance
and chemistry – meaning binders
and sand. “It’s a delicate process,
not to be compared with the robust
foundry systems that we use otherwise,”
Grunewald describes. Printer heads can
become clogged and replacing them
could cost five-figure sums, which makes
maintenance expensive and tricky as a
result. Benefiting from the advantages
of the system also requires well-trained
workers, as the process is complex and
the list of potential problems is long.
12

In fact, the Grunewald company has
been experimenting for over 25 years
with the technology that has been
known as rapid prototyping since the
mid-nineties. Sand sintering promised
more than it could deliver back in the
day: the parts were either too soft or
too hard, which meant they couldn’t be
used. Klein-Hitpass was interested in
the technology already back then. Since
then, he has also had a colleague at his
side who originally trained in model
making at Grunewald and also has
many years of experience with 3-D printing.
The knowledge of these two
experts is now really paying off in using
today’s machines.
The binder means less work later
Looking through the printer’s viewing
window, an additional layer is added
about every half a minute and glued
with the sand using phenol cold resin
binder made by ASK Chemicals from
Hilden, Germany. The benefit of this
binder, compared to the commonly
used furan resin, is the reduced need
for subsequent work – the leftover sand
can just be shaken off, whereas with
furan resin it could still stick to the sand
parts. Klein-Hitpass demonstrates this
with one of the cores that is on a pallet
along the wall of the printer room. At
first glance, cleaning the hardened sand
parts is literally child’s play. The parts
are cleaned after printing using a sand
vacuum; next up are the process steps
Ulrich Grunewald in front of a mold for
an aluminum mold tool with integrated
cooling for automobile floor carpets. Tool
manufacture is the second pillar of the
Grunewald corporate group
of
smoothing and casting.
Whether the future of Grunewald
looks like that of the Japanese company
Kimura, where the foundry is filled
around the clock with cores and molds
from about ten 3-D printers and not a
single piece of pattern equipment is in
use, remains to be seen. “At the
moment, we need both – pattern
equipment and the printer,” Grunewald
admits. Instead of the initial problem
that the machine was too productive to
utilize its full capacity, now its capacity
is almost not enough and the 24 hours
of production are too short. “Who
knows how it will be in two years,” Grunewald
said, replying to the question
whether the company is considering the
acquisition of a second printer. Now
that the process is understood, the
foundry is looking to qualify two additional
machine operators in the short or
The semi-automatic mold system with an
automated coating station in front. In the
background on the left is the smelting
operation, with two low-pressure sand
casting ovens with approximately 300
kilograms capacity each.
long term to ease the load on Klein-Hitpass
and his colleague.
Will the 3-D sand printer soon
be indispensable?
How great the potential of 3-D printing
is for the casting industry is evident at
the meeting of the additive manufacturing
work group at the seat of the German
Foundry Association in Düsseldorf
at the end of January: A representative
from BMW had joined, who reported
that 3-D printed cores were already in
use in serial manufacturing in Landshut.
“Increasing the temperatures in the
engine requires cast parts whose complex
geometries are only possible with
printed cores,” Grunewald cites as the
reason the automobile manufacturer is
now embracing the use of 3-D printing.
Time will tell whether this strategic alignment
in core manufacturing will
remain an isolated case or will become
the norm one day.
At Grunewald, it is certainly clear
one year after introducing the 3-D printer
that it has paid off. Strategy for the
future: continue automating to give the
employees the freedom they need to do
their specialist work and also generate
sufficient sales to be covered in tougher
times as well. A plan that suits a medium-sized
company like Grunewald with
its 200 employees well and is aimed at
long-term and sustainable continuance.
www.grunewald.de
CASTING PLANT & TECHNOLOGY 2–3/2020 13

FETTLING & FINISHING
14

„With 30 per cent of the costs of a new
investment, we now have a machine
that satisfies our purposes and delivers
no significant production downtime.“
After modernization, the workpieces are blasted
in less than half the time.
Optimizing abrasive precision
and performance ...
… of an overhead conveyor blasting machine in a Swiss steel foundry.
Ulf Kapitza, Emsdetten
Photos: Agtos
With around 100 employees,
Stadler Stahlguss belongs to
Swiss Stadler Rail, one of the
leading rail vehicle suppliers in Europe.
The foundry, based in Biel, generates
annual sales between 24 and 28 million
Swiss Francs, mainly made up by orders
of the Stadler Group, says Michael
Schmitz, CEO of Stadler Stahlguss.
Other customers come from mechanical
and plant engineering for the plastics
and food industries, from automotive
engineering, energy mechanical
engineering and petrochemicals. The
framework conditions in Switzerland, a
high-wage country, are not easy. Only
two steel foundries are operating in the
country. “We have a unique selling
point in terms of component size and
tonnage,” says Schmitz.
Stadler Stahlguss is internationally
known for high delivery performance,
demanding cast parts and high quality.
All components are treated with blasting
machine. They have unit weights of
3 kg to 10 t.
Blasting machine manufacturer
AGTOS refurbished an Italian blasting
machine lately at Stadler Stahlguss.
AGTOS was founded in 2001 in Emsdetten
and is a 160 employees company
headquartered in Germany with a production
facility in Polish Konin, near
Poznan. In addition to new shot blasting
machines, AGTOS also offers the
View of the overhead conveyor blasting machine modernized by AGTOS.
modernization of existin blasting
machines.
“The surfaces of the castings were
not 100 per cent clean, the scale layers
were too firm. This has resulted in high
costs for manual regrinding,” Stadler
Group CEO Schmitz looks back. In addition,
there were long blasting times:
“30 minutes were standard, up to 60
minutes for exotic parts,” he says. 12
minutes with shiny metallic surfaces are
performed today.
Before modification, AGTOS checked
the blasting machine and discussed
the project with Stadler Stahlguss.
„A first attempt with an AGTOS competitor
did not work at all,“ reports
Schmitz. AGTOS-Turbines deliver the
best results as precision of the abrasive
is optimized through the discharge
angle who defines how the abrasive
hits the workpiece surface. For modification,
AGTOS did not only supplied
new high-performance turbines inclu-
CASTING PLANT & TECHNOLOGY 2–3/2020 15

FETTLING & FINISHING
The new AGTOS high-performance turbines
on the modernized overhead conveyor
blasting machine.
ding an adapter frame. Abrasive feed
and engines were replaced as well. In
total, the modification only took three
days - practically plug and play, whereby
Stadler had already dismantled
the old turbines.
New turbines increases blasting
machine performance
Four turbines type TA 4.6 were installed.
The centrifugal wheel has a diameter
of 420 mm, explains Mario Hintzen,
Technical Manager Service at AGTOS.
“The engine output was constant at
18.5 kW. As a result, we didn‘t have to
change much of the electrical system,
except replacing the live circuit breakers,”
he says. Nevertheless, the performance
was increased by approx. 30 to
35 per cent with the new turbines. A
new guide sleeve with a smaller but
wider window in combination with four
merged turbines creates a hotspot with
significantly higher blasting intensity.
The discharge speed increases due to
the larger centrifugal wheels. Hintzen
noticed that blasting concentration thereby
significantly reduced blasting time.
„The basic substance of the blasting
machine was still well much preserved,
so this modification was justified,“ he
continues. On the one hand due to the
fact that large blasting chambers are
generally not subject to as much wear
as small ones, on the other hand due to
the good maintenance status of the
machine. „We chose AGTOS because
the overall package was right and the
project could be realized in a short time
of six weeks from order to assembly
date. That would not have been possible
with the original manufacturer,”
says Schmitz.
Stadler Stahlguss didn’t buy a new
machine because of a lack of space in
the halls. An interruption of operations
- except at scheduled times - was not
possible. „With 30 per cent of the costs
of a new investment, we now have a
machine that satisfies our purposes and
delivers no significant production
downtime“, he sums up.
Ulf Kapitza, Head of Sales + Marketing,
AGTOS Gesellschaft für technische
Oberflächensysteme mbH, Emsdetten,
Germany
www.agtos.de
16

Superior control, speed and efficiency
from a flexible, modular solution.
Based on over 90 years of experience,
Fusion is the next generation, three-platen
die-casting platform, designed to deliver
exceptional OEE. With locking forces from
3,500 to 14,000kN Fusion features a closed
loop control, modular energy frame and
Industry 4.0 automation capability. This
makes it the flexible solution for your
aluminum and magnesium die-casting
process, now and long into the future.
Find out more: buhlergroup.com/en/fusion
Fusion.
Our new die-casting
solution.
Innovations for a better world.

MELTING SHOP
Automation, smart design details and new digital innovations enhance the efficiency of a melting furnace type already known for its efficiency.
Upgrading shaft melting furnaces
Options for even more efficient melting
by Rudolf Hillen; Gummersbach
Photos: strikowestofen
A
good melt, efficiently produced,
is the starting point for
any successful die casting process.
In modern aluminium foundries,
shaft melting furnaces set the standard
both in terms of economy and metal
quality. Automation, smart design
details and new digital innovations can
enhance the efficiency of this type of
melting furnace even further. There is
great potential, for example, in improving
efficiency under partial load – an
operating condition just as common in
the reality of everyday foundry life as
permanent full-capacity utilization.
Energy savings of up to 20% are possible.
The shaft furnace principle enables
the energy-saving and resource-efficient
melting of most aluminium alloys.
To fully exploit this efficiency potential,
the furnace design, furnace equipment
and furnace control system must adapt
to the specific conditions of the production
process. Numerous options for
shaft melting furnaces have been
developed for this purpose over the last
few years. The common options, their
fields of application and advantages
will be examined here – using the StrikoMelter
shaft furnace as an example.
The advantages of these options are
available both for new equipment and
for retrofitting existing equipment.
Figure 1: Functional principle of the
shaft furnace.
18

The operating principle of shaft
melting furnaces is simple yet clever.
The core of the system is the shaft,
which is fed with cold material from
above (Figure 1). The melting bridge is
located at the bottom of the shaft. This
preheats the aluminium on its way
down using the heat rising in the shaft,
so that the aluminium only remains in
the high-temperature range for a relatively
short time during melting. The
molten metal flows from the melting
bridge directly into a trough-shaped
holding chamber where it is kept at the
selected holding temperature. Preheating,
heating and melting are combined
in a way that is advantageous in
terms of energy flow – ensuring both
economic efficiency and high metal
quality.
The melting furnace can be equipped
or retrofitted with special components
to increase efficiency even
further. Digital add-ons are also available
for process optimization. Some of
these measures and options will be discussed
below, before looking in detail
at the improvement of part load efficiency
specifically.
Step by step towards the most
efficient melting furnace
Today, there are over 1500 StrikoMelters
in use around the world. Considerable
development work over the years
has gone into continuously improving
the energy efficiency and productivity
of this well-known shaft melting furnace.
This includes optimization of core
components of the furnace, its automation
systems and process control.
First of all, there are design options
for the melt shaft: increasing the shaft
height and using a shaft cover or hot
gas baffle can measurably improve both
energy efficiency and productivity of
the furnace.
A higher shaft almost doubles the
shaft volume in comparison with the
standard version, meaning bulky
returns can be fed in as a whole. More
intensive preheating of the feed material
ensures 10% higher energy efficiency.
A standard shaft cover keeps the
heat in the shaft and prevents cooling.
This reduces energy consumption
during holding, accelerates the start of
the melting process and protects the
refractory lining.
The hot gas baffle is a special cover
plate for the melting shaft. It reduces
energy consumption during both holding
and the free-melting process – by
up to 15% (Figure 2). This means that
the free-melting process can be shortened
by 10 to 20 minutes per shift; the
melting capacity of the furnace is
increased by up to 4 %.
A shaft laser continuously monitors
the fill level in the melting shaft and
automatically triggers the feed process
when there is no further load in the filling
area (Figure 3). This optimized loading
with fill level control reduces
energy consumption by 4% and improves
the melting performance of the furnace.
The shaft laser is a necessary prerequisite
for automated closure of the
shaft cover.
The automation of the feeding process
can be taken even further with a
roller conveyor system. This system
organises full and empty loading containers
so that the loading system can be
loaded with several batches in a single
Figure 2: Using a hot gas baffle can
improve both the energy efficiency and
the productivity of the furnace.
operation. This optimizes the loading
process time. The loading time no longer
depends on the availability of personnel;
delays due to staffing bottlenecks
are eliminated. Loading takes less
time overall.
Another laser, the bath level laser,
measures the fill level of the melt in the
holding bath. This means that the cleaning
door does not have to be opened
to check the fill level, saving both time
and energy.
Data from the bath level laser also
plays an important role in Part Load
Efficiency Control, which can result in
even more savings – in terms of time,
money and energy. More on that
below.
CASTING PLANT & TECHNOLOGY 2–3/2020 19

MELTING SHOP
Figure 3: A shaft laser continuously scans the filling area in the melting shaft.
4 can be used to determine how full the
bath should be at the start of the melting-free
process. The furnace control
system then controls the melting process
according to Feature 1 in such a
way that the bath will have reached
approximately the desired filling level
at the time specified for the melting-free
process. Feature 4 is intended
to ensure that there is always enough
metal available during the melting process.
Taken together, this bundle of features
optimises the melting phases to
minimise energy consumption – no matter
how the shift is going. The lower
the furnace load, the greater the
energy savings compared to operation
without Part Load Efficiency Control. At
the same time, the automation level of
the furnace is increased, which increases
overall work and process efficiency.
Anybody can work at full throttle:
the art of partial load efficiency
At driving school, we learn that ‚anticipatory
driving‘ saves fuel. Why?
Because dynamic adaptation to the current
traffic situation avoids both full
braking and full throttle, so the car can
stay in its most energy-efficient operating
state. Now – thanks to Part Load
Efficiency Control – melting furnaces
too can be operated by ‚anticipatory
driving‘, thereby significantly increasing
their efficiency.
Aluminium melting furnaces, like
most other production facilities, operate
most efficiently at full load. However,
permanent full load quite often
does not correspond to the reality of
everyday foundry operations. Production
plans change or the casting capacities
needed to receive the melt produced
are simply not available.
However, the more irregular the melting
process, the higher the energy
consumption per tonne of melt.
In order to address this shortcoming,
the conventional furnace control system
can now be extended with a new
development that considerably increases
efficiency during partial load operation.
This Part Load Efficiency Control
can achieve energy savings of up to
20%, depending on the frequency of
partial load operation.
What exactly is Part Load Efficiency
Control? It is a software package, implemented
in the furnace control system,
that largely automates the control of
the melting phases during a shift.
The software offers four different
features that can be enabled or disabled
individually on the HMI panel or the
switch cabinet of the StrikoMelter:
> Feature 1 – Control of the melting
process
> Feature 2 – Closure of the shaft
cover in holding mode
> Feature 3 – Automatic starting of
the free-melting process
> Feature 4 – Defined bath level at the
start of melting free
The features are mostly independent of
one other. Selecting all or only some of
the features allows the foundry to optimise
its operation. To benefit fully from
some of these features, the use of a
bath level laser is recommended.
The control of the melting process
(Feature 1) forms the core of Part Load
Efficiency Control and means automatic
control of the furnace „melting“ and
„holding“ operating modes in daily
melting operation. The operating
modes are controlled in a way that
ensures the bath level – the available
melt quantity in the holding chamber
– only ever fluctuates between its maximum
(full bath) and a custom-adjustable
minimum level. Controlling long
periods of melting – and consequently
long periods of holding – increases the
efficiency of the melting process considerably
and reduces specific energy
consumption [kWh/t].
Feature 2 automatically closes the
shaft cover during holding periods. The
prerequisite for this is the presence of a
shaft laser to determine the shaft fill
level. Feature 3 can be used to define
times at which the melting-free process
should be started automatically. Feature
Should you upgrade to Part Load
Efficiency Control?
For new systems, Part Load Efficiency
Control is directly available as an option
and is usually linked to the bath level
laser. However, Part Load Efficiency
Control can also be retrofitted on older
systems, that is, on existing StrikoMelter
furnaces.
Even if no bath level laser is available,
Part Load Efficiency Control can still
be used. The bath level of the Striko-
Melter is simply calculated, for example
by weighing the furnace or using a sensor
system at the point of metal removal;
in tilting furnaces, where the metal
is removed by tilting the furnace, this
sensor system is always present.
Summary: there’s always room
for greater efficiency
The options and features presented for
the StrikoMelter shaft melting furnace
show that furnace technology is constantly
evolving. Even in a melting furnace
known for its impressive efficiency,
there can still be potential for energy
and cost savings. For foundries that
want to continuously reduce their
energy consumption during melting,
retrofittable furnace technology is available
that automates the melting process
and harmonises it with upstream
and downstream processes. The result:
significant savings and better use of
valuable personnel.
Rudolf Hillen, product developer and
StrikoMelter expert at StrikoWestofen,
Gummersbach, Germany
www.strikowestofen.de
20

OCN-25 furnace system from ABP Induction.
New perspectives for steel
by low-pressure pouring
Gravity pouring is still the dominant process for the production of cast steel materials.
The principle is simple and has remained basically unchanged for several centuries.
However: To comply with filigree and complex component geometries as well as increasing
quality demands, the process-related limitations lead to significant challenges for
foundry staff and foundry engineers. Consequently, achieving the target geometry
is only possible by using large quantities of liquid material with, in some cases, simultaneously
high rejection rates. A consequent alternative is low-pressure pouring.
Markus Hagedorn, Marco Rische and Yilmaz Yildir, Dortmund
Photos and Graphics: ABP
Low-pressure pouring of aluminum
components is state-of-the-art,
with a recycling material content of
less than 20 percent of the weight of
the component, compared with 100
percent for gravity pouring [1]. The
capacities saved in the area of melting
result in valuable savings and additional
sales potential for the foundries.
Cast steel as a material in lightweight
mold construction
Given the intensified focus on lightweight
construction in the automotive
sector, it is also interesting to look at
thin-walled cast steel as a material:
Although composite materials such as
CFRP (Carbon fiber reinforced polymer)
and lightweight materials such as aluminum
or magnesium have outstanding
lightweight construction potential, both
materials also have numerous drawbacks
in comparison with steel. For one
thing, the primary material is significantly
more expensive and the joining
technology to adjacent components is
more complex. In the case of construction
material mixes, this requires additi-
22

MELTING SHOP
Figure 1: Stylized illustration of the savings of recycling material for thin-walled components.
Table 1: Comparison of process parameters between gravity and low-pressure pouring.
Points Gravity pouring Low-pressure pour
Output 20 % - 50 % Increased by a factor of 1.5 -2
Share of rejects Up to 25 % depending Reduced by a factor of 5-10 %
(depending on geometry) on geometry through laminar and
reproducible mold filling
Form layout (with several A continuous casting cluster Separated parts
components per mold) → Separation necessary → No separation necessary
Rework Large feeder and gating systems Smaller systems Final dimension sewing
Filter Required Not required
Melting furnace temperature 1700 – 1750 °C approx. 1640 °C
→ higher energy consumption
→ lower energy consumption
→ short durability of the
→ longer durability of
refractory lining
the refractory material
Reproducibility/ repeatability - No controlled flow rate - Controlled low- turbulence pressure curve
- Temperature fluctuations during - Temperature control possible
des Prozesses during the process
Wall thickness Thin wall thicknesses cannot be < 2 mm and

MELTING SHOP
considerable benefits in operation. Besides
the high buffering capacity, the
possibility of depositing residual slag in
the furnace vessel and slag-free pouring
without the risk of freezing have also
proved successful in practical applications.
Furthermore, the crucible inductor
allows the OCN furnace system to be
completely emptied quickly, e.g. for an
alloy change. Last but not least, the furnace
has a modular design so that the
individual elements can be replaced
easily and quickly at the end of their
respective refractory life and the system
is highly available.
Figure 2: Illustration of the modular OCN system for highest system availability.
first time not only to simulate the
technical and economic advantages of
the process.
The environmental factor also plays
a major role: Minimizing of circulation
and scrap material reduce the energy
required per kilogram of good castings
by up to 50 percent. Finally, lower
quantities of liquid material and lower
pouring temperatures mean that less
molding material is required, which is
also a major driver of energy consumption
and costs. „Feedback from our
customers shows that the advantages
mentioned substantially increase the
cost-effectiveness of the process in comparison
to gravity pouring,“ explains Dr.
Marco Rische, CTO at ABP Induction. In
low pressure pouring, the core process
is encapsulated, thus minimizing problems
with sparking, splashing and emissions
for employees during the pouring
process. In terms of environmental and
sustainability aspects, thin-walled production
directly addresses high-strength
lightweight construction, which helps
to reduce fuel and energy consumption
during operation. In terms of production,
the possible wall thickness reduction
in the design process further
reduces energy and material requirements.
In comparison to competitor
processes, this makes it possible to
dispense with mixed construction variants
or composite materials involving
costly recycling processes. As you can
see, it is ultimately also about the interaction
of these operational and
environmental requirements with quality
and cost factors of mass production
as well as design aspects.
The OCN furnace system from
ABP Induction
„The OCN furnace system was developed
on the basis of the established ABP pouring
furnaces in order to enable the
low-pressure pouring process to be used
in cast steel,“ explains ABP CTO Dr.
Marco Rische. This is the only system for
low-pressure pouring of steel castings to
date that has proven itself in industrial
practice after extensive preliminary tests
[5,6]. Depending on the design, it offers
a useful capacity of 1,000 to 10,000 kilograms.
The furnace system with modern
IGBT converter technology is designed
for steel, iron and non-ferrous castings.
The pouring of bronze and copper components
is also possible with the mentioned
benefits.
Components with a thickness of up
to 0.8 millimeters have been realized by
low-pressure pouring. The average in
practice has currently settled at an average
of 1.5 to 2 millimeters, for components
with a length of up to 1.2 meters.
Thanks to the ABP pressure control, corresponding
casting molds can be entirely
filled within a few seconds, without
the risk of imperfections or porosities if
the process is properly controlled.
Low-pressure pouring thus enables
complex and weight-optimized geometries
to an extent similar to that of precision
pouring. In contrast, the significantly
lower manufacturing costs of
low-pressure pouring components and
the possibility of producing thin-walled
components in almost any size.
The OCN low-pressure pouring furnace
is designed according to the
Teapot principle (Figure 2). This offers
From practice: Initial experience
In contrast to gravity pouring, the
low-pressure pouring process is automated
to a high extent. Mold filling is
pressure-controlled and the temperature
can be regulated within a minimum
tolerance range. This process therefore
resolves the challenge posed by
unregulated temperature, because in
the high temperature range there is a
higher risk of gas porosity, sand inclusions,
rough surfaces or even mechanical
adhesion, while in the low temperature
range, there is a risk of crack formation
and inadequate mold filling. In the OCN
system, the metal in the furnace is contained
in a closed container with a protective
gas atmosphere. This means that
the melt absorbs less hydrogen and
other impurities and the oxide formation
is minimized. This is the basis for
good pouring quality. In addition,
materials can also be cast which could
not be poured in conventional processes
because of their high oxidation tendency,
i.e. including copper alloys with
an affinity for oxygen.
The pressure curve for controlling
the mold filling can be individually
adapted and archived for each casting
mold. The low-pressure control works
with proportional technology and
achieves accuracies of ±1 mbar. „The
support points of the pressure curve can
be adjusted in the range of tenths of a
second“, says Dietmar Mitschulat, software
engineer at ABP Induction responsible
for programming the control of
the OCN system. What he also values:
„With every pouring process, there is an
automatic comparison of target and
actual values.“ Additional production
values (furnace pressure at start, target
pressure, actual pressure, argon
consumption during pouring, mold contact
pressure target and actual, temperature
during pouring) are archived and
can be used for continuous impro-
24

Figure 3: Integration of the OCN system into an existing plant.
vement of the pouring result. „As such,
this makes it possible to sustainably
reduce liquid metal content and it guarantees
minimum process-related scrap
rates. Moreover, the process ensures the
highest possible reproducibility and
automation in line with the principles
of modern Industry 4.0 production“.
Other empirical values from practice
arise with regard to the company organization
and the production process:
> Pouring in short cycle times with low
manpower requirements increases
the productivity of the foundry,
> Relief of staff: Work processes with a
high level of concentration and
repetitive procedures can be automated
and continuously optimized,
> The size of the gating and feeder
system can be reduced, thus reducing
the amount of circulation material,
> When filling the molds, pouring
underfills are avoided, which
reduces the reject rate,
> Turbulence-free entry of the melt
into the gating system,
> Complete mold filling in the shortest
possible time, especially for complex
and thin-walled castings,
> Consistent pouring temperature.
> Possibility of adapting existing production
lines (Figure 3)
Conclusion
When comparing conventional processes
based on the principle of gravity
pouring on the one hand and the
future-oriented low-pressure pouring
process on the other, the benefits for
the latter process are obvious. It shows
that low-pressure pouring can be used
to make steel castings fit for future
requirements, also in automotive
engineering and the related supply
industry. This is especially relevant given
the enormous market and margin pressure
on the remaining components of
the combustion engine. In the practice
of low-pressure pouring, this means
that a wide range of new opportunities
are opening up for the production of
steel castings. On the one hand, this is
the optimization of existing component
series and types for a cost and resource
efficient production using the low-pressure
pouring process. At the same time,
there is also the opportunity to open up
new markets in comparison to alternative
production methods and to maintain
competitive markets.
This makes it possible to produce
lightweight structures made of highstrength
materials, especially for large
series in the automotive industry, as
well as thin-walled castings, which are
an important prerequisite for future
applications based on the changing
requirements of e-mobility. Thin-walled
steel castings offer the most favorable
compromise between design on the one
hand and component and system costs
on the other. This is especially true for
junctions and connecting elements of
the body-in-white [7] as well as other
structurally relevant parts of future
e-mobility vehicles in the passenger car
and commercial vehicle sector.
In terms of the environment and sustainability,
low-pressure pouring not
only saves energy compared to conventional
processes due to the smaller
quantities of input material. As the CO2
emissions from steel production are
about six times lower than those from
the manufacture of comparable aluminum
products, lightweight steel casting
is gaining enormously in importance,
especially in times when resource
and energy efficiency are of the
essence. The time factor is also important:
Those who act now can seize the
opportunity for a unique selling proposition
- and the development of new
castings and markets.
Markus Hagedorn, Product Manager
Low-Pressure Pouring, Dr. Marco Rische,
Chief Technology Officer, Yilmaz Yildir,
Vice President Liquid Metals, ABP Induction
Systems GmbH, Dortmund
www.abpinduction.com
CASTING PLANT & TECHNOLOGY 2–3/2020 25

MELTING SHOP
Photo: Foseco/Scheidtmann
Lining with prefabricated Insural components increases system availability
Reducing downtime with
prefabricated furnace linings
By using Insural pre-cast shapes for furnace relining, sintering can be dispensed with
and a constant density index can be achieved. The use of high-quality insulating
materials in the lining process enables significant energy savings and thus a reduction
in CO 2
emissions.
Dirk Schmeisser, Borken
The relining of a dosing furnace in
aluminium foundries is always
labour-intensive and particularly
time-consuming. In the case of a monolithic
lining, the sintering phase in particular
extends the downtime of the furnace.
A market analysis among relevant
customers shows that there is a need
for optimization in the area of furnace
lining and cleaning of dosing furnaces
in connection with corundum formation.
The solution for a dosing furnace in
pressure and low-pressure die casting
foundries: A completely dry lining with
pre-cast components combined with
high-quality insulation materials.
The formation of corundum
There are basically two types of
corundum formation (Figure 1): external
and internal corundum formation.
External corundum formation occurs
on the bath surface by oxidation of
liquid aluminium with oxygen from the
furnace atmosphere. Aluminium is
sucked upwards through pores and oxides
on the metal surface and forms
corundum-lumps. This process is accelerated
by a high proportion of oxygen,
the presence of certain alloying elements
and high temperatures.
In addition, there is internal
corundum formation, also called penetration.
In the contact area of the
refractory lining with the liquid aluminium,
a substitution reaction occurs
due to the higher affinity of oxygen to
the aluminium in the molten melt and
the free oxygen from the SiO 2
in the
refractory lining. This reaction takes
place within the refractory structure
and below the melt surface. A dense
black zone is formed. This is accelerated
by a high bath temperature and an
increase in the pre-baking temperature,
which burns out non-wetting
additives.
In order to solve this problem, extensive
tests were carried out with various Insural
recipes. Suitable compositions were
then determined and new formulations
26

developed. The foundry supplier
Foseco, Borken, Germany, offers a completely
dry lining with Insural pre-shaped
(Figure 2) parts for all common
dosing and low-pressure furnaces,
which is not only economically attractive
but also offers the following
further advantages:
> Direct installation on site possible
> No time-consuming sintering required
> Stable density index after relining is
achieved in a much shorter time
> Corundum formation is reduced to a
minimum
> Easy cleaning, thus alloy change
with little effort possible
> Larger filling volume for some furnace
types due to optimized design
> Energy saving during operation
> Reduction of CO 2
emissions
The installation
The new lining consists of Insural precast
parts, which are assembled according
to a modular principle. The time
required for a furnace installation using
a clean and empty steel shell (Figure 3)
is between two and four days, depending
on the furnace type. In addition to
the pre-cast parts, high-quality insulation
materials (Figure 4) are used. The
insulation materials are mounted between
the Insural parts and the steel
shell. After insulating the bottom area
and the side walls, the main basin
(Figure 5) is inserted. The gap between
the bassin and the insulation is then filled
and the heating and ceiling blocks
are placed on top (Figure 6). The remaining
insulation work is then carried out
and the holes for the thermocouple and
the compressed air supply are drilled.
The last step is closing the furnace with
the lid.
Furnace atmosphere with O 2
~ 700°C
Corundum Al 2
O 3
/Al
Penetration
Aluminium melt Al
Figure 1: Schematic of corundum formation
Roof block - maintanance door end
Blocks
Figure 2: INSURAL precast components
Refractory lining
Roof block - dosing tube end
Liner
Heater
element blocks
Advantages
After complete assembly, the furnace
can be put into operation immediately
and is ready for operation once the
desired furnace chamber temperature
has been reached. A sintering program
as with a conventional installation is
not necessary. As can be seen from
Figure 7, this step saves a great amount
of time.
Depending on the casting process
and quality requirements, the density
index plays an important role in the
availability of the dosing furnace. After
reaching the furnace chamber temperature,
a constantly low density index
value can be measured after only two
days (Figure 8).
Figure 3: Empty steel shell
Figure 4: Insulating materials for floor and
side walls
CASTING PLANT & TECHNOLOGY 2-3/2020 27

MELTING SHOP
Figure 5: Installation of the liner into the steel shell
Figure 8: Density Index
Temperature in °C
Density index in %
800
750
700 700 700
700
600
500
500 500
400
350 350
300
250
250
Traditional lining
200
120 120
INSURAL
100
0
0 6 31 36 48 64 70 98 104 134 140 166
Time in hours
Figure 6: Installation of heating and roof blocks
18
16,2
16
15,9
14
Traditional lining
12,4
12,9
INSURAL
12 12,1
11,2
10
9,3
8
6 6,2
6
4
4,1
3,5
2
0
0 24 48 72 96 120 144 168 169 170
Time in hours
Figure 7: Comparison of preheating curves
The availability of the system by
lining it with Insural pre-cast parts has
clear advantages over conventional
lining. With conventional installations,
the sintering process takes seven days. If
Insural prefabricated parts are used, this
part is completely obsolete. In addition,
a constant density index is achieved
much faster with these linings. As a
result, the furnace can return to the
production process faster due to the
shortened integration time.
The use of prefabricated parts of
this type minimizes corundum formation
and facilitates furnace cleaning.
For this purpose, the method of
corundum formation will be discussed
once again. Parameters that can influence
the formation of corundum are:
> high proportion of O 2
> pores
> SiO 2
ratio in refractory material
> temperature
> wetting properties
Based on these points, the Insural 270
recipe was developed in 2015, which
has a small amount of SiO 2
, low porosity
and good non-wettability with liquid
aluminium. With this recipe, dry lining
with pre-cast parts for dosing furnaces
has been successfully introduced to the
market in recent years and excellent
results have been achieved with a large
number of customers.
28

Insural 270 has a SiO 2
content of
22 %, a porosity of about 17 %, a cold
compressive strength of 50 N/mm² and
excellent non-wetting properties compared
to liquid aluminium. In order to
meet the growing demands of the
market, the Insural 290 recipe formulation
has been developed, which has
expanded the product range since
April 2019. It has a SiO 2
content of less
than 10 % only, a porosity of around
16 % and a higher cold compressive
strength of 100 N/mm². The non-wetting
properties remain excellent
(Figure 9).
Another important point is the temperature
in the furnace, which is a decisive
factor for the formation of
corundum. The compensation of temperature
losses in dosing furnaces is controlled
by the heaters and can be readjusted
depending on the insulation.
Since the heating takes place via radiant
heat, the heating elements become
significantly hotter than the melt bath
temperature. This is a major reason why
the formation of corundum accelerates
and good insulation therefore has a
positive influence on corundum avoidance.
Foseco‘s insulation concept can
counteract corundum formation and
also save energy costs (Figure 10). The
power consumption measurements carried
out in a foundry using a 650 kg
dosing furnace show a lower energy
requirement compared to conventional
lining (Figure 11). The heating power
remains at the lowest level for almost
98 % of the time, which avoids overheating
and effectively prevents
corundum formation. Operation at low
heating output levels also has an influence
on the peak shutdown in the
foundry‘s energy management and
reduces weekly average consumption.
Figure 9: Power consumption
Traditional lining INSURAL
2
30
Conclusion
Furnace linings with Insural pre-cast
parts offer a number of advantages
over conventional linings. On the one
hand, the actual lining process requires
considerably less time, and on the other
hand, time-consuming sintering is no
longer necessary. Furthermore, the dry
lining avoids the absorption of hydrogen
by the melt in the first days after
commissioning. The formation of
corundum is minimized, and furnace
cleaning is simplified. Furnace cleaning
remains important, so a weekly cleaning
interval is recommended. Depending
on the insulation concept selected,
energy and CO 2
output can be significantly
reduced. With a furnace that
saves 48,000 kWh per year, the foundry
achieves a reduction of 24.5 tons of climate-damaging
CO 2
.
Dirk Schmeisser, European Product
Manager Insural & Refractories
Non Ferrous, Borken, Germany
384
0 100 200 300 400 500 600 700 800 900 1000
Time in hours
Measuring in hours Max. level (14,3 KW/h) Min. level (10,7 KW/h)
Figure 10: Condition of furnace after 3.5 years
Figure 11: Furnace surface temperature (left: conventional lining, right: Insural 270)
www.foseco.com
529
905
905
Short video on Insural
dosing furnace linings.
https://bit.ly/2yS2M5G
CASTING PLANT & TECHNOLOGY 2-3/2020 29

MOLD AND COREMAKING
Photo: Disa
Control arm produced in green sand on a Disamatic molding machine.
Transferring green sand
molding’s advantages to
aluminum casting
Green sand molding gives iron foundries an extremely fast, accurate, flexible and
inexpensive process. For the right applications, green sand molding offers the same
advantages for aluminum casting.
Per Larsen, Taastrup
The green sand process is well
known for producing high quality
iron parts efficiently and inexpensively.
Growing global demand for aluminum
castings combined with mounting
pressure to cut costs is leading more
foundries and manufacturers to explore
the green sand process for aluminum
applications as well.
While iron foundries can already profit
from lower costs along with other
benefits like rapid prototyping and
flexibility it is possible to successfully
transfer the benefits of the green sand
process to the production of aluminum
parts.
This article investigates the opportunities
and challenges of efficiently producing
aluminum castings in green
sand. It considers both safety-critical
aluminum components and those with
less stringent demands on mechanical
properties, as well as high and low production
volumes.
Historically, green-sand-cast aluminum
parts have had a reputation for
lower dimensional accuracy and a less
desirable microstructure caused by slow
cooling. Neither of these is now justified,
as will be shown below.
Molding
Green sand molds can be produced
both vertically and horizontally, with
vertical molding delivering the highest
production speeds.
The six operations of the vertical
molding machine are shown in Figure 1.
The best-known vertical molding lines
achieve very high speeds of up to 555
30

molds per hour without cores and up to
485 molds per hour with cores.
However, DISA now supplies vertical
molding lines with lower speeds: 150
molds per hour without cores and 120
molds per hour with manual core insertion.
Their cost is approximately a third
of the price of the high-speed vertical
lines mentioned above. This makes vertical
molding both possible and economical
for smaller production volumes.
Figure 2 shows the Disamatic C3-150
molding machine that produces up to
150 molds per hour with a mold size of
650 x 530 mm.
Producing 120 molds per hour gives a
cycle time of 30 seconds. That allows
plenty of time for pouring and any manual
interventions required; for example,
setting complex cores that are not glued
together. This gives a degree of flexibility
unusual in vertical mold making.
ADVANTAGES OF THE GREEN SAND PROCESS
The green sand process offers several advantages, including:
> Very high productivity;
> A simple and proven core setting process. This makes pouring hollow parts
straightforward, with speeds of up to 470 cored molds per hour;
> When changing tooling to produce a new component, production only
halts for one or two minutes;
> Initial pattern costs are low; depending on size and complexity, pattern
prices start at 5000 euros;
> Pattern plate lifetime is high: one plate can produce hundreds of thousands
of molds;
> Due to the high productivity, normally only one set of pattern plates and
possible one spare set is needed for each part to be manufactured;
> Pattern plate maintenance costs are low due to the long service life and
only having one production set of pattern plates to maintain for each part;
> Lead times from the first 3-D CAD drawing to the first casting prototypes
and the start of series production are short, thanks to simple and inexpensive
tooling. Thereafter, changes to gating and feeding systems are easy,
fast and cheap.
Figure 1: The six steps of the vertical molding process.
Horizontal molding using matchplate
technology is an attractive alternative
to vertical machines, especially
with lower production volumes and
when high flexibility is required. It
demands relatively low investment and
employs the well-known horizontal
principle. Existing pattern plates for
horizontal equipment can usually be
transferred to matchplate molding
machines with little effort.
Molding material composition
Quartz sand mixed with clay and water
remains the molding material. The values
below show the recommended
molding material properties for aluminum
applications using vertical molding.
These are similar to the parameters
Figure 2: Disamatic C3–150.
CASTING PLANT & TECHNOLOGY 2–3/2020 31

MOLD AND COREMAKING
used for cast iron but will have to be
adapted to the specific aluminum application.
The use of coal dust is not necessary
for aluminum.
Recommended sand properties for aluminium
applications (650 x 535 mm
mold)
> Average grain size (washed):
0.14 - 0.16 mm
> Grain size distribution (washed):
4 sieves
> Gas permeability: 100
> Compressibility: 38-40 %
> Moisture content: 3 %
> Green compressive strength:
20.0 N/cm 2
> Green tensile strength: 2.5 N/cm 2
> Spalling strength: 4.0 N/cm 2
Figure 3: Graphic of
a low-pressure filling
system for vertical
green sand
casting.
Figure 4: The nozzle
of the pouring unit
docked onto the
side of the mold.
Pouring the mold
Aluminum forms oxides very quickly;
these harm its mechanical properties.
Because it lets the melt flow relatively
freely, gravity pouring from the top of
the mold generates these unwanted
oxides. To achieve the best possible
mechanical properties, another way of
pouring is needed.
A better alternative is low-pressure
pouring through a sprue positioned low
down on the side of the mold. Filling
from the bottom up gives laminar flow
and full control over the liquid aluminum’s
inflow, minimizing oxide formation.
Mold filling speed is no longer
dependent on gravity and the casting
profile can be easily optimized for each
individual component.
The principle of low pressure casting
of vertically-split molds is shown schematically
in Figure 3. A close-up of the
nozzle of the pouring device in contact
with the green sand mold can be seen
in Figure 4 with the associated first section
of the required gating system
shown in Figure 5.
A simple, small core is placed just
above the inlet channel. After filling
the mold, a pneumatic cylinder pushes
this core into the inlet channel to block
it and prevent any melt from escaping.
This makes it possible to move the pouring
nozzle as soon as mold filling has
finished, allowing production speeds of
up to 300 molds per hour. Actual cycle
times depend on the amount of melt to
be poured.
This variant of low-pressure sand
casting not only helps to improve the
mechanical properties, it also fully automates
the casting process. As can be
seen in Fig. 5, the runner bars can be
very small which improves yield compared
to conventional gravity casting
from above. Smaller runner bars also
mean that more parts per mold can be
accommodated on the pattern plate.
Figure 5:
Standard pouring system inlet
shown on pattern plate.
32

Figure 6: Left: Microstructure of
brake caliper; right: Picture of
brake caliper.
Figure 7: Left: Reference blocks
added to pattern plates; centre:
Reference impressions on the mold;
right: Lasers measuring in real time.
For aluminium parts with less stringent
demands on their mechanical
properties, manual gravity pouring of
green sand molds is a good alternative.
Hand pouring requires little investment
and offers high flexibility, making it
well suited to shorter series.
Metallurgy
Apart from mold filling, handling the
metallurgy correctly is also important
when aiming to achieve the best possible
mechanical properties for aluminum
castings produced in the green
sand casting process.
Compared to the different die-based
processes, casting in green sand molds
gives a lower cooling rate. This makes it
more suited for parts with thinner wall
thicknesses from 3 mm up to approximately
10 mm where cooling power is
less critical. However, thicker walled
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CASTING PLANT & TECHNOLOGY 2–3/2020 33

MOLD AND COREMAKING
Figure 8: Control arm.
Figure 9: Brake caliper
Figure 10: Transmission housing
Figure 11: Intake manifold
parts can still be suitable for the green
sand process, as will be shown with an
example of a brake caliper below.
The modification of the silicon phase
is achieved with strontium, making it
possible to have a continuous production
flow. An example of a microstructure
achieved in green sand after finishing
with 230 ppm strontium can be seen
in Figure 6. The alloy used was
AlSi7Mg0.3 with 0.28 - 0.31 % Mg,
0.1 % Fe and 0.1 % Ti.
Although this brake caliper has a thick
cross section (its typical wall thickness is
22 mm), the obtained mechanical properties
are excellent:
> Elongation in %: 4
> Yield strength in MPa: 233
> Tensile strength in MPa: 270
These mechanical properties were measured
on test bars machined from the
casting with a T6 heat treatment and a
density index of 0.75 %.
Accuracy
Traditionally, sand casting had a reputation
for lower casting accuracy. But the
accuracy of castings produced in green
sand has improved over the years, today
achieving as little as 0.1 mm
machine-related mismatch. Modern systems
for in-line checking of mismatch
and mold gaps just before the molds
are poured give extra protection
against possible dimensional problems.
An example of such a system is the DISA
MAC.
This system is based on reference
blocks added to each corner of the pattern
which leave corresponding impressions
in both mold halves (see Figure 7).
After the mold is closed, a laser measures
the positions of these reference
impressions in the mold halves, making
it possible to calculate mismatch and
other dimensional values. Using sophisticated
software, the system detects and
measures mismatch with an accuracy of
+/- 0.05 mm – well below the average
sand grain size of approximately
0.15 mm.
Operators can directly read the current
values for each mold on the screen
of the molding machine. In the event of
a problem, they automatically receive
warning messages and the casting process
can automatically be stopped, for
example, if mold gaps appear. Receiving
early warnings gives enough time to
react before a real problem arises. Cur-
34

Table 1: Examples of casting aluminium in green sand.
Part Information on part Parts/hour Molding Figure
Control arm Elongation: 6 % obtained, Demand: >3 260 DISAMATIC 8
Yield strength: 245 MPa obtained, Demand: >200
Ultimate strength: 309 MPa obtained, Demand: >250
With T6 heat treatment
Brake calliper Elongation: 4,6 % obtained, Demand: >3 800 DISAMATIC 9
Yield strength: 233 MPa obtained, Demand: >215
Ultimate strength: 270 MPa obtained, Demand: >260
With T6 heat treatment
Transmission housing Weight 4,5 kg 250 DISAMATIC 10
Intake manifold Weight 2,9 kg 280 DISAMATIC 11
Gas valve Weight 2,4 kg 400 DISAMATIC 12
rent data can be accessed via the screen
on the molding machine while historical
data can be viewed and analyzed on a
PC using DISA Monitizer.
With a machine-related mismatch of
less than 0.1 mm and employing the
monitoring system described here, the
dimensional accuracy of aluminum sand
casting is no longer an issue.
Examples of casting aluminum
in green sand
Many different casting types can be
made in green sand, ranging from
safety critical parts to less demanding
components. Some examples are shown
in the Figures 8-12 and Table 1, but
there are many other aluminum castings
that are already produced in green
sand. For example, a large number of
US foundries successfully use the matchplate
process to produce aluminum
castings.
Take full advantage of the
green sand process
Most parts are designed with a production
process in mind. The full
potential of green sand can be
reached by designing castings for the
green sand process. This way, further
weight reduction, productivity gains
and, of course, cost savings can be
achieved.
Examples of valuable design adjustments
that make the most of the
green sand process include: designing
parts with hollow sections for minimum
material consumption; optimising
wall thickness to achieve uniform
stress levels while maintaining wall
thickness at 3 mm or more; adding ribs
to increase stiffness; designs that allow
good filling/feeding during casting;
avoiding pockets that are too deep
and narrow.
Figure 12: Gas valve
Conclusion
Both safety-critical aluminium castings
and castings with less stringent demands
on their mechanical properties can be
feasibly produced in green sand. Systems
available today allow the highest
production speeds of several hundred
molds per hour, but lower throughputs
of less than 100 molds per hour are also
efficiently served by green sand lines.
It does not make sense to produce
every aluminium casting in green sand
and this article
does not claim
this. Instead, the
suitability of each
component and
application should
be judged individually.
The wellknown
benefits of
the green sand process, the fact that certain
castings are inherently well suited
for it and the increased efforts, especially
by automotive manufacturers, to
further reduce costs suggest that aluminium
and the green sand process are an
increasingly attractive combination.
Per Larsen, Product Portfolio and Innovation
Manager, DISA Industries, Taastrup,
Denmark
www.disagroup.com
ConviTec
Vibration machines and conveying technology
Project planning – Manufacturing - Service
www.convitec.net · 069 / 84 84 89 7- 0
2032_Convitec negativ.indd 1 01.02.13 10:02
CASTING PLANT & TECHNOLOGY 2–3/2020 35

MOLD AND COREMAKING
Photo: Benjamin Schultheis, Agentur Bildschön
An employee of a core shop in southern Germany checks an inorganic core for defects. With the ACS technology, such cores can now be cured
electrically and the quality can additionally be controlled digitally.
Electrical curing of inorganic sand
cores using the ACS technology
Inorganic core production is based on the curing of sand cores by dehydration. Dehydrogenation
of the sand core is thereby achieved by heat input. Established processes
are based on heating the core boxes and flushing with hot compressed air to transfer
sufficient heat energy to the sand core in the shortest possible time. With the newly
developed, already patented Advanced Core Solutions (ACS) technology, the inorganic
sand binder mixture heats additionally directly caused by current flow. This enables
energy and cycle time savings of approx. 30 % during the curing of the sand cores as
well as a uniform curing of the sand cores without shell formation.
By Gotthard Wolf und Marco Weider, Freiberg, Wolfram Bach, Welsleben, and Eric Riedel, Magdeburg
Introduction
The curing of sand cores is a decisive
time factor in the production of castings.
Advanced Core Solutions (ACS)
has developed a process that supports
the dehydration electrically. The validation
of the technology on an industrial
scale was carried out on an automated
core shooter at the Foundry Institute of
the TU Freiberg in the German federal
state of Saxony. The test program was
designed with the aim of applying the
ACS process to three possible optimization
scenarios. These are energy
consumption, curing time, and sand
core strength. The results obtained clearly
show the potential of the ACS process
(Figure 1) after the first pilot project
in an industrial environment was
completed. Sand cores with a wall
thickness between 10 and 120 mm are
36

suitable for series production in large
quantities.
Figure 1: Schematic representation of the areas of application of the ACS process for core production
as a function of the planned
Figure 2: Selection of important aspects for project realization.
Figure 3: Sample and contours of the ACS designation in the sand core.
Influence of thermal conductivity
The basic idea of thermal inorganic processes
is the transfer of heat from the
respective heat source to the core box
and to subsequently transfer sufficient
thermal energy to the sand cores. The
good thermal conductivity of aluminium
(236 W/(m × K)) as well as the
thermal conductivity of steel (50 W/(m ×
K)) allow sufficient heat transport to
the sand core. Typical quartz sands have
an unfavourable low thermal conductivity
(< 4 W/(m × K)), which leads to shell
formation when the cores are dried.
This is caused by the fact that the heating
is unevenly distributed within the
sand core, as the incoming thermal
energy in the sand core cannot be efficiently
and quickly transported to the
centre of the sand core. Furthermore,
the efficiency losses of the heat generation
and heat transport to the sand core
influence the energy balance of core
production. The cycle times for curing
the sand core as well as the formation
of the shell are therefore significantly
influenced by the thermal conductivity
of the quartz sand and by the energy
losses. The low thermal conductivity is
one of the reasons why heated core
boxes are operated at temperatures of
180 °C and more, although temperatures
of 100 °C (depending on the pressure)
would already be sufficient to
evaporate the water content. Therefore,
the approach with established
methods is to generate maximum excess
heat in the core box and transfer it to
the sand cores without exceeding the
maximum allowed binder temperature
in the sand core.
The patented process of Advanced-Core-Solutions
(Soplain GmbH)
accelerates the heating of the sand
cores. Instead of external heat sources
and the associated time-consuming
heat transfer, the process uses the electrical
conductivity of all common tested
inorganic binder compositions. The use
of electrically conductive core box
materials specially developed for this
application in combination with the
electrical conductivity of the binders
enables a uniform current flow at any
point of the sand core. Based on the
principle of electrical resistance heating
(Joule heating), the sand core is thus
heated directly and evenly, thus drying
and curing homogeneously from the
inside out. In addition, the core tool
also heats up and provides further thermal
energy, as is the case with established
processes.
Preparation for pilot project
Successful implementation of the pilot
project essentially required coordination
of the following aspects to increase
the overall efficiency of the process,
demonstrated in Figure 2.
> Adaptation between the core shooting
system, the selected geometry of
the sand core, the appropriate sand binder
mix and the material selection of
the tool insert.
> During selection of the project partner,
both the know-how and the availability
of an automated core shooter
were important aspects to enable both
the execution and the competent
evaluation.
PHOTOS AND GRAPHICS: ACS
CASTING PLANT & TECHNOLOGY 2–3/2020 37

MOLD AND COREMAKING
> The tool material was selected in
such a way that an adjustment of the
electrical conductivity to that of the
sand binder composition could be ensured.
The procedure was based on the
underlying patent. The selection was
made according to internally defined
standards and test methods for determining
the electrical properties of the
sand binder mixture and fell on a silicon
carbide ceramic with additives to adjust
the electrical conductivity.
Leading companies from the industry
could be won for the pilot project. The
overall design and installation on the
core shooting machine were finally carried
out by one of the leading toolmakers
in Germany and proceeded very
satisfactorily. The installation of the
complete plant including final acceptance
was carried out in less than three
days.
Figure 4: Cavity before and after performing the test series.
Figure 5: Temperature distribution recorded by thermal imaging camera in the heated tool
without external heat supply.
> The selection of a sand core geometry
was based on a general test specimen,
in which essential aspects such as
different wall thicknesses, curves and
filigree contours could be investigated
(Figure 3).
> An H 32 sand was used for the sand
selection due to its wide distribution in
the industry and the extensive comparative
data.
> For the binder compositions, a commercial
binder from one of the wellknown
suppliers was used. The selection
criterion for this was compatibility with
binders used in industry and the available
comparative data.
Control & security concepts
The implementation of the process on
an automated system required the
development and adaptation of the
control technology to the selected core
shooting system. A modular approach
was chosen which allows the plant to
be operated with both the ACS process
and the cold box process originally designed
for the plant. The mode can be
changed at the push of a button, thus
allowing flexible use of the plant.
A special focus during project preparation
and implementation was on the
consideration and implementation of
all safety regulations and machine guidelines
for the development of the
necessary hardware. To ensure maximum
safety of the plant, a multi-stage
safety concept was implemented in the
control system and the associated sensor
technology. The possible sources of
error were determined by means of a
Failure Mode and Effects Analysis
(FMEA) before the start of the construction
and updated during the project.
Table 1: Selected test series for optimizing of curing time.
Test series* Initial tool Final tool Required heating
temperature in °C temperature in °C time in s
Simulation 200 150 54
ACSS06 36 110 180
ACSS17 95 100 68
ACSS31 103 113 55
ACSS32 105 113 51
ACSS92 115 120 52
ACSS96 114 120 49
* Selected test series. Complete test series are available on request.
38

Table 2: Selected test series for optimizing of curing time.
Test series* Energy consumption Curing Initial tool
in kWh time in s temperature in °C
ACSS91 0.0338 59 113
ACSS92 0.0300 52 115
ACSS93 0.0297 53 115
ACSS95 0.0280 49 116
ACSS96 0.0296 49 114
* Selected test series. Complete test series are available on request.
Figure 6: Illustration of the cycle times and the quality of the sand cores for selected test series.
The ACS control system was also equipped
with a two-way safety signal exchange
and linked to the existing control
system of the core shooting plant.
Before commissioning, an external safety
check of the plant was successfully
carried out. Subsequently, all employees
participated in a safety training course
on handling and operation of the new
plant.
Experiment execution
Test preparation and execution was
based on a concept for the optimization
of test series with stepwise modification
of individual process parameters. This
made it possible to reduce the various
test series from over 200 to less than 40,
the most important parameters being
the power supply, molf temperature,
power consumption, flushing time, and
flushing temperature. Due to the new
experiences with the tool material,
these test series were additionally prioritized,
with the aim of carrying out the
test series with lower loads first. This
was intended as a precautionary measure
in order to obtain as many meaningful
results as possible; also in the
event that the tool inserts should suffer
unexpected damage during the test.
Figure 4 shows the silicon carbide
ceramic used after the test series has
been carried out. The surface coloration
was caused by minimal residues of process
aids in the production of the
high-performance ceramic. The tests
were carried out after completion of
the installation qualification. During
the installation phase, the properties,
e.g. the temperature, of the plant and
the ceramics were recorded (Figure 5)
and made available to the PLC control
system to optimize the control logic.
The various test series were then processed
accordingly, and the most
important process parameters were
meticulously documented both within
the PLC and manually to be able to
make reliable statements afterwards. A
quick-change system made it possible to
replace the cavity within 3 minutes.
Results
The evaluations described below focus
mainly on the cycle times for curing,
energy consumption and bending
strength.
Cycle time for curing
The cycle time for curing was defined as
the time between the completion of
the shooting process and the start of
the tool flushing. The upstream and
downstream process steps such as core
shooting, purging, ejection and lifting
movements are not affected by the ACS
process. Only the phases for molf heating
and cooling are influenced by the
molf material and the molf design
(insulation). Even with a throttled operation
mode the molf was heated
homogeneously by more than 100 °C in
less than 180 seconds. This means that
warm-up times of < 120 seconds can be
expected in regular operation at full
power.
Reference times. Two approaches were
used to determine comparison times for
established inorganic processes. On the
one hand, a simulation was performed
for the test specimen. On the other
hand, the heat transfer of the core box
to the sand core was also simulated
with the ceramic („baking“) since the
thermal conductivity of silicon carbide
(about 140 W/(m × K)) is much higher
than the thermal conductivity of standard
tool steel (about 35 W/(m × K)). A
curing time with shell formation of
approx. 54 seconds was determined for
the test specimen in the ACS “baking”
mode.
Determined measured values. The measured
values in Table 1 show selected
test series in which sand cores of particularly
good quality could be produced.
CASTING PLANT & TECHNOLOGY 2–3/2020 39

MOLD AND COREMAKING
Figure 7: Comparison of current course and temperature curves for a selected test specimen.
Figure 8: Energy input per sand core over time.
When the cycle times for curing are
plotted in correlation with energy
consumption, a clear trend towards
reduced consumption can be seen
(Figure 6). It is not surprising that the
higher energy consumption of the core
also leads to faster curing, but this clearly
shows the potential of the ACS process.
The more energy that can be
applied per time unit, the faster the
sand core cures. The maximum possible
power input Pmax was only tested at
50 % in this experiment. This results in a
further potential for cycle time savings.
The continuous power supply increases
the temperature in the molf accordingly
(Figure 7). The ACS control system automatically
optimizes the current intensity
based on the desired process parameters.
In addition, the PLC control system
ensures that the current is regulated
according to the resistance curve to prevent
unintentional overheating.
Conclusion. With the ACS process, the
duration for curing can be controlled
directly by the power input of the electrical
current. In less than 10 days, the
automatic core shooter not only
demonstrated the effectiveness of the
process, but also achieved significant
improvements. The limiting factor here
is the maximum power input without
permanent damage to the molf material.
This power consumption will be
further optimized in future investigations.
Energy consumption
In addition to the reduction of curing
time, it is also possible for foundries to
optimize the process of core production
in an energy-efficient manner. The calculated
energy consumption refers to the
thermal energy required for curing the
inorganic sand cores. The difficulty arose
from the determination of the thermal
energy used per single sand core. In established
processes, the corresponding
tools are kept at an almost constant
temperature by means of heating elements
or thermal oil, so that an individual
energy requirement per sand core
cannot be determined directly. Therefore,
an approximate comparative
energy consumption was determined
under the assumption of continuous
operation and the average number of
cores shot per hour. This shows a further
significant advantage of the ACS process:
The individual power consumption
per manufactured sand core can be
recorded and evaluated at any time and
thus allows conclusions to be drawn
about its quality and approaches to
energy optimization (Table 2, Figure 8).
Conclusion
The initial temperature of the tool
influences the sand core energy required
for curing the cores. It could be
shown, that with the ACS process sand
cores can already be cured at temperatures
between 100 °C and 130 °C. Compared
to conventional temperature
levels this temperature difference alone
allows for significant energy savings.
Bending strength
A sufficiently high bending strength is
required to ensure adequate strength
40

Figure 9: Illustration of the ceramic core boxes for the production of bending bars with the ACS process and the corresponding bending bars
with strengths >350N/cm².
of the sand core during the casting process.
Typical reference values are
strengths between 200 N/cm² and 400
N/cm². The bending strengths were
determined both after 2.5 h and after
24 h (Table 3) and show that the cores
produced by the ACS process readily
meet the requirements for sufficient
strength required for the casting process.
With measured bending strengths
of up to approx. 400 N/cm², the cores
manufactured by the ACS process meet
the standard industrial requirements.
The optimization of the strengths is one
of the tasks for the upcoming test
series.
Advantages of the new process
In a direct comparison with conventional
processes, the new ACS process
shows significant overall cost savings.
The savings are mainly due to two reasons.
On the one hand, the direct use
of electrical current, which does not
have to be converted into heat with
losses before the process, enables
energy savings of up to 30 % compared
to conventional processes. On the
other hand, cycle time savings of up to
30 % are expected, which means that
despite the possibly higher tool costs
(depending on the material used) the
annual operating costs can be massively
reduced.
Another so far not mentioned
aspect is the possibility for digitalization
of the core drying process. Recording
the relevant electrical process parameters,
the ACS technology allows a realtime
monitoring of the drying process
itself for the first time. Thus, enables an
Table 3: Measured bending strength.
Test series* Weight in g Bending strength in N/cm²
ACSS55M 141.5 202.1
ACSS411 146.0 269.7
ACSS102H 147.5 292.7
ACSS113H 148.0 347.9
* Selected test series. Complete test series are available on request.
increase in the quality of both the
manufactured sand cores and the core
drying process.
Outlook
With the successful realization of the
first pilot project on an automated
industrial core shooter, the functionality
and advantages of the ACS process has
been demonstrated. The next step is to
optimize the control system and process
parameters using the bending bars
(Figure 9). At the same time, interested
foundries will be supported in the conversion
and implementation of the new
process into series production. For this
purpose, the possibilities for further
development of the plant for sand core
thicknesses > 100 mm are being considered,
so that these can also be produced
efficiently and in an energy-saving
manner.
Further research activities also focus
on alternative materials for the electrically
conductive core boxes and on process
simulation. In the first case, an electrically
conductive epoxy resin as an
alternative material for large-scale production
is being worked on at an
advanced stage, as is a new type of
high-performance plastic, which should
also make small series and prototyping
economically feasible. The use of temperature-resistant
PEEK materials will
make it possible to produce prototypes
from design to the finished sand core in
a series environment within days. In the
second case a comprehensive process
simulation of the ACS process is being
worked on, using software that is well
established in the foundry industry, in
order to cover another important
aspect for industrial use of the ACS
technology.
https://advanced-core-solutions.com
Prof. Dr. Wolf und Dr. Weider, TU Bergakademie
Freiberg, Freiberg, Dipl. Ing.
Wolfram Bach, Advanced-Core-Solution,
Soplain GmbH, Welsleben, Dr. Eric Riedel,
Otto-von-Guericke-Universität Magdeburg,
Magdeburg
CASTING PLANT & TECHNOLOGY 2–3/2020 41

DIGITALIZATION
Photos: ABP
The ABP service is directly available as „Expert on Demand“ online without any need for traveling (Figures: ABP).
Hybrid Internet of Things service
solutions for the foundry industry
The changing global economic environment and the change in social values with the
desire for sustainability are forcing energy-intensive industries in particular to further
optimize their processes. The new technical possibilities by digitalization allow to
move the boundaries of lean principles further. For this purpose, ABP Induction offers
a web-based customer portal that provides innovative hybrid service solutions.
This brings ABP closer to the plant operators and supports them in their daily work
and maintenance, and in training their staff.
By Moritz Spichartz, Marco Rische and Markus Fournell, Dortmund
Increasing productivity and quality
while simultaneously reducing
environmental impact and production
costs are challenges that foundries are
confronted with every day. Over the
past few years, a large number of companies
have addressed this challenge in
the spirit of lean and agility and
developed suitable concepts for the
economical and time-efficient use of
the most important production factors
within the framework of all corporate
activities like equipment, personnel,
materials, planning and organization.
The fourth industrial revolution (Internet
of Things, abbr. IoT) with its machine-oriented
data evaluation by machine
learning and network-based interaction
between production plants, but also the
consolidation of the machine manufacturers’
know how with that of the operators,
will advance the processes of
self-optimization. Finally, it will lead to
Lean 4.0 [1,2].
A high degree of transparency of
the machine data from production is
crucial in this context [3-8]: The product
quality is documented seamlessly from
scrap selection to the final product.
Fault information and condition monitoring
systems are available throughout
the company, enabling faster reaction
to production interruptions and accelerating
the resumption of production
[3-6]. In addition, predictive and preventive
maintenance concepts based on
42

the analysis of real-time data enable
proactive maintenance and repair [7].
Operators benefit from additional
information and recommended actions
[8]. The machine manufacturer obtains
direct feedback on the operation of
their products that can be used directly
for further development. New service
concepts enable the manufacturer to
get closer to the operators and support
them with his expertise [9].
As a leading manufacturer of induction
systems for ferrous and non-ferrous
applications [10-12] (Figure 1), ABP
Induction offers a high number of
assets in the production value chain of a
foundry with its crucible, channel and
pouring furnaces. The company sees itself
as a competent partner which
develops in cooperation with the
foundry operators the most suitable
individual solutions, both with existing
high-end products in furnace and converter
technology and with novel digital
products. The optimization of the
melting and pouring processes as well
as the support of the foundries in terms
of maintenance and training using
web-based technologies in combination
with the ABP domain knowledge are
the drivers of the digital service solutions.
Motivation
The digitalization level is still very different
in the foundries. All foundry
owners are aware that they must invest
in digital solutions to stay competitive
in the future, but most of them hesitate
to start. That is the result of the discussions
in the working team “Foundry
4.0” (German: Gießerei 4.0) of the
Federation of the German Foundry
Industry (German: Bundesverband der
Deutschen Gießerei-Industrie, abbr.
BDG). The working group published a
guideline to help foundries to analyze
their digitalization level and to give
them approaches for development. Ten
topics are outlined in this guideline [8]:
> Data acquisition in production,
> Data processing in production,
> Machine to machine communication
(M2M),
> Process automation by using robots,
> Flexible production, flexible resources,
> CAx (computer-aided) technology,
> Product development,
> Process development,
> Information and communication
structure,
> Employees, management and organization.
It is becoming obvious that digitalization
is not limited to machine-oriented
technology improvements. Ultimately,
change processes must be implemented
by employees and managers who
perceive these changes as an opportunity
and are committed to new technologies
and information and learning
methods [8] (Figure 2). In line with the
lean philosophy the human must be in
foreground when implementing new
digital solution. That is why the BDG
recommends that the focus should not
be exclusively on technical improvements
but rather on all subject areas
and that they should be brought to the
same maturity level [8]. Summarized,
every company needs a digital strategy.
ABP Induction committed itself early
on supporting foundries in this process
and also recognized its own opportunity
to get closer to the operators in
order to be able to offer customer-oriented
service solutions and expedite its
own developments in the field of furnace
and converter technology. This
Figure 1: ABP is a technology leader in
furnace and converter technology with
the most powerful induction furnaces in
the world (65t, 42MW).
results in hybrid IoT service solutions
that complement ABP‘s existing service
strategy. The starting points were the
machine-to-machine communication in
conjunction with mapping the digital
twin and the improvements in information
and communication structure
regarding new maintenance concepts
and training for machine operators. All
solutions provide added value to
foundry operators directly.
Hybrid IoT service solutions
„What if your furnace had a smartphone?“
asks Till Schreiter, CEO and
President of the ABP Induction Group,
and answers his question immediately:
„It would completely change the relationship
with your plant. It would allow
your furnace to notify you when needed,
to look for ways to improve per-
CASTING PLANT & TECHNOLOGY 2–3/2020 43

DIGITALIZATION
Figure 2: The BDG guideline (BDG Kompass) enables analyzing one‘s own degree of digitalization
and it supports the digital transformation process. Each of the ten topics are divided into
five degrees of maturity [8].
formance, and even to plan the best
production cycle. And that is exactly
what we want to achieve. Service apps
use the connection to device sensors
and make all information available to
the right people at exactly the right
time“.
Technology giants such as Amazon,
Facebook, Google and Apple have
already revolutionized the way everyone
behaves in their private lives,
enabling new ways to make information
available everywhere. The way we
communicate and interact with our
environment has changed fundamentally
in recent years. However, this has
only been reflected to a limited extent
in the day-to-day work of the foundries.
Although there have been improvements
in plant technology and process
automation, nothing can compare
with the progress which is already
being made in private life. Service is the
interface between ABP and its customers
in the foundries. ABP has fully
revised its service solutions in recent
years. Operational excellence has been
improved continuously, products and
processes have been digitalized and
optimized, and service solutions have
been completely redesigned and established
successfully [9] (Figure 3): The
myABP platform is the logical digital
extension of our service offering and
the introduction to the new digital
world. The platform works transparently,
in a location and time independent
manner. It is designed for all processes
and machines involved in a
foundry, regardless of whether it is a
melting shop, sand preparation or molding
plant. Any upstream and
downstream processes can be connected
easily to the platform. All system-related
documents are available in the
platform, from product descriptions and
drawings to maintenance manuals and
service reports. MyABP acts as a personal
information and maintenance
assistant for melting and heating
plants, also those of different manufacturers.
It is the central collection point
for insights and advice, and it consolidates
all relevant knowledge about the
plant. Operators can make use of it to
manage their services, parts lists, documentation,
offers and orders, to request
support and to establish connections to
the various systems that are used in pro-
Figure 3: The digital products marked in blue complete ABP’s service concept C3 (Complete Customer Care). For further information please
refer to https://c3.abpinduction.com.
44

Figure 4: The virtual training scenarios on operation, maintenance
and safety aspects received great attention at GIFA 2019. The training
sessions can be used with VR glasses or PC.
duction [9]. The ABP service department can be accessed
directly via the worldwide web as an „Expert on Demand“
using data glasses, tablet or smartphone. ABP helps maintenance
personnel in troubleshooting by enabling ABP
experts to look through the eyes of the maintenance team
via the digital devices. This saves travel costs, reduces production
downtimes and protects the environment [9,13].
Every employee in the foundry can be trained in virtual
training scenarios on a digital twin of their own plant, either
on a PC or with VR glasses (Figure 4). Virtual classrooms allow
to interact with the experts from ABP without travelling to
training sessions. The participants in the training courses
receive suggestions which training courses are required to
carry out upcoming maintenance work, to increase productivity
and to ensure a high level of safety in the operation of
the plants [9,13]. „A revolution is not something that is done
just by one person or company. Therefore we rely on the
assistance of our customers, suppliers and other machine and
plant manufacturers, and on partnerships with other companies
and universities to enable us to develop the platform
continuously,“ says Mr. Schreiter, looking optimistically into
the future.
Summary
The digital transformation of foundries can be understood as
a continuation of business optimization based on the lean
philosophy, with the aim of further increase of productivity
and quality while reducing environmental impact and costs,
and thus remaining competitive. This is a true change in culture
that must be addressed jointly by foundry operators and
machine manufacturers. ABP‘s hybrid IoT service solutions
bridge the gap between traditional services and a new level
of connectivity between plant manufacturers and foundries.
The hybrid concept of these innovative service tools is to
connect people, machines and processes across manufacturer
boundaries by the new myABP platform and to lead them
through the ongoing digital revolution with ever new service
apps.
Moritz Spichartz, Marco Rische, Markus Fournell,
ABP Induction Systems GmbH, Dortmund.
References: www.cpt-international.com

SAND REGENERATION
Photos and graphics: Eirich
Simple and fast mixing tool replacement
Changing mixing tools
quick and easy
Changing mixing tools is something every operator of a mixer is familiar with. This maintenance
work is absolutely essential in order to ensure that consistent throughput is
achieved with consistently high processing quality. The mixing tool is exposed to increased
wear as a result of constantly coming into contact with the product. A new system
for changing rotor beaters in production mixers significantly shortens service and standstill
times and saves additional material costs.
By Philipp Krötz, Hardheim
Time-intensive maintenance work
The maintenance work required to
replace wearing parts is often performed
later than it should be. The work
that needs to be performed is very
time-intensive and is generally associated
with extended production shutdowns.
The first step that is often taken
when the quality of molding materials
starts to deteriorate is to extend mixing
times in order to counter the deterioration
in quality. The result is often
increased molding material temperatures,
which leads to increasing sand
inclusion in the casting. This type of
quality-relevant work is often not scheduled
until it becomes absolutely essential
due to a reduction in throughput or
a deterioration in casting quality.
In the past, a great deal of time –
typically several hours – was required to
change the beaters attached to the
rotor. First all the tension needed to be
released on all of the beaters, and only
then was it possible to replace individual
parts that displayed signs of wear
– a process requiring large levers and
lots of muscle power.
Easy and quick rotor
beater change
Eirich has developed a quick-change system
for rotor beaters, which can now
be replaced individually in a simple procedure
that only takes a few minutes.
One particularly useful feature of
this new system is that the easy process
for replacing the beaters makes it possible
to swap out beaters with increased
wear in high-wearing zones against less
worn ones from other areas to optimize
use of the material. Users who have
switched to the new system have confir-
46

Figure 1: Layout of the optimized mixing tool.
med a significant reduction in downtime
and maintenance costs.
Migrating to the new SmartFix
quick-change system is easy because
there is no need to replace the existing
rotor shaft or purchase a new one. Only
the tool support disks need to be changed.
Suited for retrofitting
Particularly cost-effective: Existing spare
parts can still be used, making this system
well suited for retrofitting. The new
system, which is called SmartFix and for
which a patent application is pending, is
available as a retrofit or conversion
package for all Eirich production mixers,
i.e. mixers with a capacity of 75 liters or
more. With this, the company helps to
make their production setup more cost
effective – while at the same time
keeping up high quality. SmartFix is not
only well suited for brand new mixers –
it can also be used as a retrofit solution
for existing Eirich mixers.
Hidden Champion with core
expertise in the preparation
of free-flowing materials
The Eirich Group is a supplier of industrial
mixing, granulating/pelletizing,
drying and fine grinding machinery, systems,
and services. The Group has its
main strategic base at the corporate
headquarters in Hardheim, Germany.
The company has core expertise in processes
and techniques used for the preparation
of free-flowing materials,
slurry, and sludge. The main fields of
application for such technologies include
e.g. ceramic and refractory materials,
foundries, building materials such as
concrete and plaster, battery pastes, fertilizers,
glass, and the processing of ores.
Close co-operation between the company’s
test centers around the world and
collaboration with the research and academic
community enables the „hidden
champion“ to provide solutions for innovative,
cost-efficient products and processes.
The family-managed company
was founded in 1863 and operates from
twelve locations on five continents. The
Group has approximately 1,500 employees,
more than half of whom work at
the headquarters site in Hardheim.
Group turnover is in the region of 200
million euros.
Philipp Krötz, Head of Service-Sales,
Maschinenfabrik Gustav Eirich GmbH &
Co KG, Hardheim, Germany
www.eirich.de
Pneumatic conveying
technology
For dry, free-flowing, abrasive and
abrasion-sensitive material
Core sand preparation
technology
For organic and inorganic processes,
turn-key systems including sand,
binder and additive dosing and
core sand distribution
Reclamation technology
Reclamation systems for
no-bake sand and core sand,
CLUSTREG® for inorganically
bonded core sands
Shock wave technology
CERABITE ®
clean castings
The reliable solution for the
removal of residual sand
and coatings of
demanding castings
KLEIN Anlagenbau AG
KLEIN Stoßwellentechnik GmbH
a subsidiary of KLEIN Anlagenbau AG
Obere Hommeswiese 53-57
57258 Freudenberg | Germany
Phone +49 27 34 | 501 301
info@klein-group.eu
www.klein-ag.de
www.stosswellentechnik.de
CASTING PLANT & TECHNOLOGY 2–3/2020 47

PRESSURE DIE CASTING
Photos: Micro-Epsilon
By applying machines equipped with inductive sensors from Micro-Epsilon, manufacturers of aluminum die-cast parts reduce their costs. These
eddy-current based sensors monitor the mold deformation with high accuracy.
Efficient gap monitoring
in die casting machines
Machines equipped with inductive sensors enable manufacturers of aluminum diecast
parts to reduce their costs significantly. These eddy-current based sensors monitor
the mold deformation, i. e., the so called mold breathing, with high accuracy. This
narrow gap that occurs between the tool halves when the material is injected under
pressure is a crucial factor that affects the quality in the die-casting processes.
By Stefan Stelzl, Ortenburg
Monitoring based on inductive
sensors enables the early recognition
of tool wear and false
process parameters. This reduces
lengthy and expensive rework of the
component, while keeping tool wear
to a minimum and the tool’s service life
clearly increases.
Aluminum die-cast parts combine
robustness with low weight. In addition,
they offer extremely high electrical
conductivity and corrosion
resistance.
When processing this versatile type
of material, precision is required – particularly
when it comes to monitoring
the mold deformation in aluminum
die-casting processes.
Challenges in aluminum
die-casting
Manufacturing aluminum die-cast parts
requires high pressure of approx. 600 to
1000 bar in order to press the liquid hot
48

form a solid unit. This integrated system
design increases robustness and
resistance to external factors, protecting
the system in harsh industrial
environments with high temperatures
up to 100 °C, dust, dirt, vibration and
pressure, and delivers accurate measurements
regardless of the environment.
Their compact design enables these systems
to be easily integrated in existing
plants.
Figure 1: When monitoring the mold deformation, three to four eddy current systems are
used to determine the expansion and the gap opening of the tool to micrometer accuracy.
Here, one measuring system consists of a compact and robust controller, which together
with the cable and sensor form a solid unit.
material with a temperature of 700 to
900 °C into a pre-heated steel mold. The
shot time is only 50 to 100 milliseconds.
The mold that receives the aluminum
consists of two mold halves, which are
pressed together under significant force
of more than 1000 tons. This high pressure
applied during the injection process
causes a narrow gap between the mold
halves. This is also called mold breathing.
If this gap becomes too large,
this would negatively affect the manufacturing
process, as the component
would fray into splinters. Manufacturers
place high quality requirements on the
production process, which is why splinters
would cause extensive reworks.
Consequently, this results in loss of time
and higher costs. Another negative
aspect are aluminum residuals on the
tool. They cause increased wear and
therefore reduce the tool’s service life.
Figure 2: Due to
their design and
technology, eddy
current-based sensors
from Micro-Epsilon
can be easily
adapted to the high
requirements of the
manufacturing process
for aluminum
die-cast parts.
Precise measurement of
mold deformation
Easy, quick and reliable monitoring of
tool deformation can be achieved using
inductive sensors based on eddy currents.
Robust design and compactness
make the eddyNCDT 3005 sensors well
suited to these types of application.
Sensor manufacturer Micro-Epsilon
headquartered in Germany is reknown
for its expertise in this field. Based on
state-of-the-art sensor technology, the
sensors ensure continuous and high precision
gap monitoring, while increasing
manufacturing efficiencies. When monitoring
mold deformation, three to four
eddy current systems are used to determine
the expansion and the gap
opening of the tool to micrometer
accuracies. Here, one system consists of
a compact and robust controller, which
together with the cable and sensor,
Conclusion
Due to their design and technology,
eddy current-based sensors from
Micro-Epsilon are easily adapted to the
high requirements of the manufacturing
process for aluminum die-cast
parts. In contrast to conventional inductive
sensors, they stand out due to their
high accuracy, high frequency response
and temperature stability. Depending
on the model, the systems are insensitive
to temperatures up to 200 °C. The
active temperature compensation feature
enables the systems to provide
highly accurate measurement results
even with fluctuating temperatures. In
addition, movements are rapidly detected
using measurement frequencies up
to 5 kHz. Their ease of use is another
positive feature that makes these sensors
well suited to OEM and serial applications.
With higher quantities, it is possible
to adapt the sensors to the
customer’s specific application.
Inductive sensors based
on eddy currents
The eddy current principle occupies a
unique position amongst inductive
measuring methods. Measuring via
eddy current is based on the extraction
of energy from an oscillating circuit.
This energy is needed for the induction
of eddy currents in electrically-conductive
materials. Here, a coil is supplied
with an alternating current, causing a
magnetic field to form around the coil.
If an electrically conducting object is
placed in this magnetic field, eddy currents
are induced which form a field
according to Faraday‘s induction law.
This field acts against the field of the
coil, which also causes a change in the
impedance of the coil. This impedance
can be calculated by the controller by
looking at the change in the amplitude
and phase position of the sensor coil.
Dipl.-Ing. Stefan Stelzl, Product Manager,
Micro-Epsilon Messtechnik GmbH &
Co. KG, Ortenburg, Germany
www.micro-epsilon.com
CASTING PLANT & TECHNOLOGY 2–3/2020 49

QUALITY ASSURANCE
Photos: Deevio
Special cameras and AI should also automate inspection processes in foundries
Cameras and AI: foundries
automate quality assurance
Many processes in the foundry sector are still carried out manually in 2020, despite the
advance of factory automation. This is particularly the case for quality assurance. deevio,
a Berlin-based start-up, has stepped up to change this. It uses special cameras and
artificial intelligence to automate the most varied of inspection processes. This promising
solution could soon become the new standard in smart factories.
By Damian Heimel, Berlin
Quality assurance as an integral
component of automation
Rising production costs, a shortage of
specialists, digitalization: all sectors
have to cope with these trends, and
foundries are no exception. The range
of components produced is also rising,
while demands for precision and quality
are increasing. None of these requirements
can be readily met using manual
processes. This applies for production
just as much as for quality assurance,
where there is the additional problem
that foundries are finding it increasingly
difficult to find suitable employees.
Fewer and fewer people, particularly
in structurally weak regions, are
prepared to take on this relatively
monotonous task.
Manual quality assurance also
suffers from specific weaknesses
It is extremely time-consuming: a single
inspection process generally takes several
seconds (Figure 1). Moreover, the
accuracy of the inspections naturally
depends on an employee’s level of qualification
and their performance on the
day. Performance efficiency at any particular
time is influenced by factors such
50

as motivation, tiredness and lighting
conditions.
These facts make it clear that the
automation of quality inspections
brings a wide variety of advantages.
Apart from this, it is an indispensable
component of the smart factory, characterized
in its final form by completely
automated processes.
Traditional processes are
not enough
The idea of automating quality
assurance is not particularly new. For
some time foundries have already been
using cameras and image processing
software, for example, to inspect their
products. The technology, called
machine vision, is thoroughly practicable
in particular scenarios (Figure 2),
though its limits are rapidly reached
when there is a high variability of
defects. This is the case, for example,
when surface cracks or inclusions take
on different colors and shapes, or can
occur at different locations on a casting.
Variances of these types cannot be
fully uncovered using classic machine
vision approaches because they use
rule-based algorithms. So it is necessary
to define in advance where a scratch,
for example, could be located. In addition,
particularly for surface defects, it
has been observed that machine vision
systems have a high rate of false negatives,
i.e. non-genuine defects. They are
thus ‘over-precisely’ adjusted and
wrongly detect intact products as defec-
Figure 1: Manual quality inspection is
time-consuming and depends on the
employees’ level of qualification.
Figure 2: Image processing software
is already being used for quality
assurance.
CASTING PLANT & TECHNOLOGY 2–3/2020 51

QUALITY ASSURANCE
tive, increasing both the number of
rejects and production follow-up costs.
Despite major investments in corresponding
systems, they ultimately fail to
achieve the desired effect – or even
make the situation worse.
Machine learning as a problem-solver
The Berlin-based start-up deevio has
developed a solution for quality
assurance that overcomes the weaknesses
of classic machine vision systems.
The approach is fundamentally founded
on two components: industrial cameras,
and software based on machine learning
– an advanced form of artificial
intelligence.
First of all, deevio needs pictures.
The team either uses existing pictures
from an image processing system or,
together with its partners, installs
industrial cameras in the foundry
works. These high-resolution cameras
with professional illumination are used
to take pictures of intact and faulty
products in all the potential defect
categories, for example with cavities or
impact marks. The data scientists at
deevio then use this material as the
basis for training an individual machine
learning model optimized for the specific
case (Figure 3).
The advantage compared to traditional
processes lies in the solution’s high
level of flexibility. It can detect, for
example, scratches with a variety of
individual structures at the surface or
elsewhere. The AI model learns continuously,
enabling it to handle defect
variability increasingly well.
deevio does not simply supply intelligent
software for quality assurance –
the young company considers itself to
be a complete service provider. Its various
partners handle camera installation,
organize the necessary illumination,
install the machine control system, and
automate the processes.
Numerous advantages
for companies
The deevio solution provides several
advantages for foundries: firstly, the
system provides quality improvements
because – unlike human inspections – it
ensures a constant level of performance
and accuracy. Processes are also accelerated:
an inspection process only takes
one second, on average. Costs savings
can also be achieved because fewer personnel
are tied up for quality assurance.
Resources that have been freed up are
then available for other value-creating
activities.
Furthermore, deevio stores the photos
it takes in a database – together
with the particular analysis results. Over
time, a valuable source of information
builds up, permitting accurate conclusions
to be made about the production
process. Among other things, it becomes
clear which defects occur particularly
often – and where there is a need
for improvement.
Figure 3: deevio creates an individually
optimized machine learning model with
the help of pictures of actual intact and
defective products.
Machine learning as a key
technology in future quality
assurance
Machine learning is a relatively young
technology. It only became attractive
for image processing in 2012. The breakthrough,
however, did not come then
because, among other things, the algorithms
had still not reached the level of
accuracy necessary for industrial quality
assurance. So the software, which could
only assess product quality with 95%
accuracy, was simply not practical in the
foundry sector.
Recently, however, both the machine
learning algorithms and computers’
performance and graphic cards have
become considerably more powerful.
The application opportunities have thus
increased significantly.
At present, the deevio solution still
focuses on inspections at the end of
production lines. In the future, however,
it is conceivable that machine learning
technologies could be used in various
upstream processes. The potential is
enormous, particularly for the early
detection of defects. Imperfect parts
could thus be diverted out early on,
without passing through the entire process
unnoticed.
Summary: considerable improvements
are possible in quality
assurance processes
deevio provides a solution that is greatly
superior to either human quality
assurance or classic machine vision
approaches, particularly when there is
high defect variance. The purchasing of
new cameras or image processing systems
is not always a prerequisite for
introducing deevio’s software – existing
inspection systems that have so far provided
unsatisfactory results can be
retrofitted with the machine learning
solution and thus optimized.
deevio’s system is also attractive for
foundries with no experience of automated
quality assurance using visual
processes. A major advantage is that
the Berlin-based service provider can
offer complete solutions – thanks to its
partners in machine construction, image
processing and factory automation.
www.deevio.ai
Damian Heimel, COO, deevio GmbH,
Berlin
52

NEWS
RUSAL
New foundry complex at BoAZ
Rusal, a leading global aluminium producer,
announces the commissioning of
a new foundry complex at the central
Russian Boguchansky aluminium smelter
(BoAZ) with a capacity of 120 thousand
tonnes of alloys per year.
The new foundry by the Italian company
Properzi will produce a qualitatively
new product – high silicon aluminium
alloy with increased strength,
which is commonly used in the automotive
industry for the manufacture of
wheels, engine units and various spare
parts. Demand for this product is strong
in markets such as Japan, Indonesia,
Turkey, South Korea, Germany, and the
United States.
The new complex is fully automated,
producing ingots through continuous
casting technology which eliminates the
formation of any slag inclusions and
other defects inherent in traditional
casting methods.
Rusal has invested over 600 million
rubles (around 6,9 million euros) in the
project. „The new foundry complex at
the Boguchansky aluminium smelter,
Ingot casting facility at the Boguchansky aluminium smelter
(…) will significantly expand the VAP
line. The new foundry will produce high
quality alloys for the automotive industry,
which are used in the manufacture
of key automotive parts and units. As
foreign markets recover, the demand
for these products will continue to
grow,“ said Rusal’s CEO Evgenii Nikitin.
https://boaz-zavod.ru/en
Photo: Rusal
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RUDOLF UHLEN GmbH
Face protection for every application
Rudolf Uhlen GmbH is a manufacturer of personal protective
equipment (PPE) for face protection. Especially for the steel
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of IR-protection. We produce:
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www.aschua-uhlen.de info@aschua-uhlen.de
CASTING PLANT & TECHNOLOGY 2–3/2020 53

NEWS
FOSECO
Die-coatings increase operating life
Foseco from Borken in Germany reports
that its latest range of Dycote Safeguard
die-coatings increase die operating
life by up to 3 times compared to conventional
coatings. This new range of
die coatings has been developed specifically
to maximize the service life and
maintain surface quality for critical aluminium
components such as aluminium
wheels and cylinder heads.
Poor die coating service life leads to
reduced productivity and increases the
risk of rejects due to poor casting surface
quality. Foseco’s Dycote Safeguard
products are nano-ceramic coatings
designed to be applied on top of existing
insulating Dycote base coatings.
Best results are achieved when applied
using the Foseco Dycote Spraygun
which ensures a very consistent and uniform
coating layer application.
The extended life achieved with the
coatings reduces the frequency of coating
touch-up operations and also complete
mold cleaning and re-coating operations,
thereby reducing die downtime
and maximizing productivity. Improved
casting surface finish consistency has
also been noted.
www.foseco.com
Dycote Safeguard die-coatings are
e. g. recommended for the production
of aluminum wheels
Photo: Foseco
YXLON
Time for a new inspection experience
Red carpet roll-out and premiere: Yxlon
International from Hamburg, Germany,
has launched its completely new operating
concept with the innovative universal
x-ray and CT system Yxlon UX20.
Specialized x-ray knowledge is no longer
mandatory. Now, even untrained
personnel can easily achieve optimal
inspection results. This is made possible
by the award winning Yxlon Geminy
software platform, which combines all
the programs involved. With intuitive
menu navigation, numerous pre-settings
and the ability to switch seamlessly
between radioscopy and computed
tomography quickly performed
testing processes are easy.
With its compact footprint, the
UX20 is specially designed for use in
harsh environments like foundries in
the automotive and aviation industries.
The system components such as the
generator, cooler and high-voltage
cable are economically integrated into
the cabin for protected and extended
use while still easily accessible for
maintenance work. UX20 is ideally suited
for the inspection of castings,
Yxlon cast part inspection system Yxlon UX20
welds, plastic and ceramic components
and special alloys. Thanks to the
advanced CT functions, parts of sizes
up to 800 mm in diameter and 1100
mm in height can reliably be inspected.
The height-adjustable operator work
Photo: Yxlon
area is directly attached to the system.
When opening the door, the parts
manipulator automatically moves to
the edge of the cabin offering ease of
loading.
www.yxlon.com
54

TESLA
Giga structural die casting for Model Y
IDRA OL CS die casting cells like this are
to be used in Tesla plants in the USA
China and probably also in Germany to
produce XXL-structural castings.
Tesla is to produced one million Model Y
vehicles per year. Elon Musk has now
announced that the entire rear underbody
structure will be represented by a
one-piece aluminum die-cast part.
The electric car manufacturer Tesla is
following construction plans for its new
Model Y that gives casting a previously
unimagined new meaning. With the
world‘s largest aluminum die-casting
machine, IDRA‘s OL6200 CS HPDC, the
car manufacturer wants to cast the
entire rear underbody of the 231 kph
electric car in one piece.
Implementation of the construction
concept is planned for this year. The
one-piece cast part is to replace around
70 stamped, cast and profile components
that make up the same assembly
in Tesla Model 3, the construction basis
for Model Y.
Tesla boss Elon Musk spoke in a
podcast in April 2020 for the first time
about the new one-piece rear cast
part, which will also integrate the rear
crash rails. US automotive experts
described the cast part as the largest
cast application to date in automotive
engineering. The huge castings are to
be produced in series in the Tesla
plants in Fremont, California, and in
Shanghai, China, on the giant die casting
machines of the Italian mechanical
engineering company IDRA, which
Musk calls Gigapresses. They are also
likely to be manufactured in the new
Tesla plant in Grünheide near Berlin in
Germany. The German Gigafactory,
which is currently under construction,
will employ 10,000 people and is
expected to produce up to 500,000
Models 3 and Y vehicles per year. The
works also has a die casting foundry.
Various news channels are already speculating
that the Giga presses will also
be used there to produce the cast rear
body. Because of such state-of-the-art
production technology, experts expect
that the German Tesla-Gigafactory
could become the most profitable factory
to date
The machine behind the new cast
construction does not skimp on superlatives.
There is talk of Gigapresses or
Goliath machines. Meanwhile, there is
confusion about which IDRA die casting
machine will actually be used to
manufacture the one-piece rear casting.
Tesla spoke of the OL 6100 CS
model, but the system does not officially
exist. Probably the OL 6200 CS
HPDC is meant, which actually has considerable
dimensions and performance
parameters: with a weight of 430 tons,
5500 tons of clamping force and a
maximum shot weight of 104.6 kilograms,
the 19.5 meter long and 5.3
meter high die casting machine is
huge, with the dimensions of a small
house.
Musk‘s pioneering commitment to
automotive engineering and cast part
design sends out a significant signal to
the German automotive and foundry
industries. Although the momentum is
currently being slowed in part by the
Corona pandemic, a reaction by German
carmakers to Musk‘s advance in
electromobility in Germany will sooner
or later be inevitable.
Photos: Private
Photo: IDRA
An IDRA video shows
how the Tesla XXL
parts are cast
https://bit.ly/2CiQWTI
CASTING PLANT & TECHNOLOGY 2–3/2020 55

NEWS
VOXELJET
Largest industrial 3-D printing system goes to India
The 3-printing specialist voxeljet AG
further expands its presence in India.
The supplier of industrial 3-D printing
solutions based in Friedberg, Germany,
is selling a VX 4000 system, one of the
world’s largest and most productive 3-D
printers with a build volume of eight
cubic meters, to the Indian steel casting
expert Peekay Steel Castings (P) Ltd.
Peekay is present in the Indian cities of
Calicut, Coimbatore and Hindupur. The
VX4000 will be set up in a brand new
location at Bangalore in the Airport
City. The machine has a Job Box size of
4000 x 2000 x 1000 mm. Peekay Steel
has chosen the VX4000 system to
quickly and economically realize technically
demanding projects and to expand
into new business areas.
Peekay Steel specializes in the production
of high-quality steel castings,
predominantly for the Oil & Gas sector,
starting from 1 kg to 20 tons per casting.
For most of these products they
require less than four castings. As a
result, the time and cost towards
development of patterns can outweigh
total project costs. For some complicated
castings, that require non-traditional
gating, the VX4000 was most
suitable.
“When it comes to castings weighing
several tons, the requirements for
dimensional stability and accuracy are
particularly high. With our 20 years of
experience in the field of industrial 3-D
printing and the VX4000, we can offer
both a wealth of experience and the
right tool,” says Rudolf Franz, COO &
CFO of voxeljet AG. “We want to offer
our customers an end-to-end solution
The VX4000 is voxeljet’s largest 3-D printer and has a building volume of 4000 x 2000 x
1000 mm or 8 cubic meters (Photo: voxeljet).
and position ourselves as a supplier of
high-quality, ready-to-install components
in record times. With the
VX4000, we are able to increase the
flexibility of our production in order to
be able to react quickly, even to complex
projects. A specialized Design Center
aligned to the VX4000 will help add
value for our customers,” adds K.E.
Shanavaz, Jt. Managing Director,
Peekay Steel Castings (P) Ltd.
Additionally, one of the drivers was
the impending uncertainty in these trying
times. With the size, speed and
flexibility of the VX4000 Peekay Steel
can cater to new projects from their
existing customers at record times
while also looking for different business
areas to venture into.
Peekay Steel has a multi-pronged
approach to their VX4000. They not
only want to support the foundry
industry in India by providing services
from their large system, but also plan
to set up a high-tech Knowledge Center
around their VX4000. This will
include a training facility to support
educational institutes and the industry
alike. An open access of this kind is a
means to attract more and more people
towards the foundry industry – a
much needed paradigm shift.
www.voxeljet.com
Photo: Private
TARGI KIELCE
Metal trade fair invites to Poland
For years, the International Fair of Technologies
for Foundry Metal in Kielce has
been the meeting arena for top-class
companies and professionals from all
corners of the world. Save the date for
14-16 October 2020 as the trade fair is
taking place as planned.
The Metal expo is held in the everyother-year
cycle as a part of the exhibitions
cluster composed of Aluminium &
Nonfermet, Recycling and Control-Tech.
The exhibitions have advanced to
become Central and Eastern Europe‘s
most important foundry and casting
business-sector‘s events cluster. The
Metal exhibitors have always included a
wide range of companies which professionally
deal with metals heat treatment
and heating devices.
All industry insiders consider the
expo a part of the whole business-sector‘s
tradition. This year‘s event
abounds with the latest technologies,
machines and equipment designed for
everyday use in foundries and casting
houses. The „Industrial Autumn“ has
been the meetings platform for various
industries‘ representatives, and among
them foundry and casting, machine and
electromechanical, railways, shipbuilding,
armaments, robotics and automation,
automotive and aviation and
many related industries. Exhibitors
come from all parts of the world including
France, Switzerland, Germany,
Hungary, Great Britain, the United Sta-
56

tes, Turkey, India, China and Japan.
Furthermore, Targi Kielce has enjoyed
the support of prominent, foreign
foundry organizations for years like the
Italian Foundry Suppliers‘ Association
Amafond, the China Foundry Association
(CFA) and the Polish Stop - Technical
Association of Polish Foundrymen.
Until now, containers with disinfecting
liquid have been made available
in Targi Kielce exhibition facilities.
Every person who wants to enter the
facility has had to undergo mandatory
temperature screening. Regular disinfection
of frequently touched infrastructure
elements, i.e. door handles,
handrails, balustrades, counter-tops,
tables and other sanitary measures
have also been intensified. The autumn
events‘ participants will be offered
extra points of sale operating in front
of the terminals - face-covering masks,
gloves and anti-virus fluids will be distributed
there. The fairgrounds will
also be equipped with decontamination
gates, information boards, traffic
directions designed to ensure social
distancing. Medical service units and
personal protective equipment points
of sales will come at the top of the priority
list.
www.targikielce.pl
Trade fair activity in Kielce. Despite the
pandemic, the Metal trade fair will again
take place this year from October 14-16,
2020
Photo: Targi Kielce
PNEUMATIC DECORING HAMMERS FOR GRAVITY,
LOW PRESSURE AND LOST WAX PROCESS
Different models
Easily carried
High performances
Worldwide presence
Customer care
Repair service
Monitoring system Thor V4.0 to check the
hammers performances during operation
O.M.LER designs and manufactures decoring benches in
accordance to the specific needs of every customer.
Example of a decoring bench
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omler@omlersrl.com - www.omlersrl.com
CASTING PLANT & TECHNOLOGY 2–3/2020 57

NEWS
O.M.LER
Decoring solutions from Italy
The mechanical engineering company
O.M.LER srl, established in 1974 in
northwest Italy, designs, manufactures
and sells pneumatic decoring hammers
for foundries worlwide. Current decoring
solution of the company are the
two pneumatic decoring hammers
RVC70 and AF1470. Decoring hammers
are usually adopted to remove the sand
core from cast iron, aluminium and
steel foundry castings, such as for
example cylinder heads, engine blocks,
structural parts, motorbikes’, and snowmobiles’
engines. Pneumatic decoring
hammers can also be adopted by foundries
who use the investment casting
process to break or remove the ceramic
shell. This is possible because O.M.LERs
decoring hammers can work at different
air pressures and with different
set-ups, avoiding damages to the castings
and removing sand or ceramic also
from castings with complicated structure
and/or thin walls.
Decoring hammers like the AF1470 are usually used to remove sand cores from castings.
To decore a casting the hammers
have to be fastened in a decoring unit,
such as a decoring bench. The decoring
bench is is also offered by O.M.LER. The
company designers create every decoring
bench in accordance to the specific
needs of every customer and the specialized
technical staff manufacture it in
the production department.
In every decoring bench the decoring
hammers are fastened to the
machine structure and they have a fixed
position, both vertical or horizontal,
depending on the kind of casting to
decore. The hammers‘ positionning has
to be defined during the design stage.
Normally every decoring bench has
from 1 up to 4 hammers.
The castings to be decored are loaded
and unloaded by a robot outside
the machine. The casting is always positioned
in the same preset housing.
www.omlersrl.com
Photo: O.M.LER
FLOW-3D
New process workspaces and state-of-the-art
solidification model
Flow Science, Inc., Santa Fe, USA, has
announced a major release of their
metal casting simulation software
Flow-3D Cast v5.1, a modeling platform
that combines extraordinary accuracy
with versatility, ease of use, and high
performance cloud computing.
Flow-3D Cast v5.1 features new process
workspaces for investment casting,
sand core making, centrifugal casting,
and continuous casting, as well as a
chemistry-based alloy solidification
model capable of predicting the
strength of the part at the end of the
process, an expansive exothermic riser
database, and improved interactive
geometry creation. Flow-3D Cast now
has 11 process workspaces that cover
the spectrum of casting applications,
which can be purchased individually or
as bundles.
“Offering Flow-3D Cast by process
workspace gives foundries and tool &
die shops the flexibility to balance their
needs with cost, in order to address the
increased challenges and demands of
the manufacturing sector,” said Dr.
Amir Isfahani, CEO of Flow Science.
FLOW-3D CAST‘s new chemistry-based solidification model accurately predicts secondary
dendrite arm spacing (SDAS) in a gravity sand casting of an Al-Si alloy
Flow-3D Cast T v5.1’s brand new
solidification model gives users the ability
to predict the strength and mechanical
properties of cast parts while
reducing scrap and still meeting product
safety and performance requirements.
By accessing a database of chemical
compositions of alloys, users can
predict ultimate tensile strength,
elongation, and thermal conductivity
to better understand both mechanical
properties and microstructure of the
part. Databases for heat transfer coefficients,
air vents, HPDC machines, and
GTP Schäfer risers provide information
at users’ fingertips. The new Exothermic
Riser Database along with the Solidification
Hotspot Identification tool
helps users with the precise placement
of exothermic risers to prevent predicted
shrinkage.
www.flow3d.com
Graphics: Flow Science
58

Photo: Italpresse Gauss
ITALPRESSE GAUSS
Tailor-made die casting cells for Siemens
Siemens AG received two die casting machines from
Italpresse Gauss, types IP 750 SC and IP 550, with
a clamping force of 750 and 550 tonnes respectively
It all began with a rethink of how space
is used at a Siemens AG location in Germany.
The die casting operations at the
company’s Bad Neustadt facility was
going to have to “move house”. The
project team was given a new building
to redesign the die casting of components
for Siemens electric motors from
scratch.
Two new, fully automated die casting
cells were to become the heart of
the new facility. The existing tools
quickly narrowed down the choice to a
three-platen cold-chamber machine.
Beyond this machine type, the team
had a raft of specific requirements for
the new cells.
For the team at Siemens, the
engineering and integration of such a
cell, and defining all its interfaces, was
a task for experts: focus during the
purchasing process was very much on
ensuring any potential partner had the
ability to deliver a complete solution.
One that works, seamlessly, even when
integrating special requests and specifications.
Volker Ress continues: “Ultimately,
we want a solution that is ready to
go and a folder that tells us everything
we need to know to run it. The team at
Italpresse Gauss has realised and integrated
all our special requirements
without any problems.”
The ability to connect to Mind-
Sphere was particularly important to
Siemens. Machine controls have to be
primed for new demands in terms of
data collection – by offering sufficient
internal memory, for example – and
have to be open for local IIoT integration.
Volker Ress explains: “Openness,
both technical and organisational, is
key. The equipment manufacturer has
to be happy for us to plug an ethernet
cable into the machine and grab data
straight from the PLC. I need a system
that gives me data relevant to the die
casting process. Italpresse Gauss’ HMe
machine control does just that.”
Marco Giegold from Italpresse
Gauss summarises the project: “Flexibility
in the specification of die casting
cells is becoming more and more
important. Aluminium foundries have
their individual, specific requirements
and are increasingly asked to integrate
these cells into sophisticated production
systems. In this context, Industry
4.0 is only one aspect – albeit an
important one. For us, all of this is simply
an exciting challenge. The more
open we are to unusual customer
requests, the more technologies and
components we get to see and know. It
allows us to constantly expand our
knowledge and find the best solutions
for our customers faster.”
www.italpressegauss.com/en-gb
CASTING PLANT & TECHNOLOGY 2–3/2020 59

SUPPLIERS GUIDE
CASTING
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1 Foundry Plants and Equipment
17 Surface Treatment and Drying
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Melting Plants and Equipment for Iron and
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18
Plant, Transport, Stock, and Handling
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3 Melting Plants and Equipment for NFM
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Non-metal Raw Materials and Auxiliaries for
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29 By-Products
14
Discharging, Cleaning, Finishing of Raw
Castings
30 Data Processing Technology
15 Surface Treatment
16 Welding and Cutting
31 Foundries
32 Additive manufacturing / 3-D printing
60

SUPPLIERS GUIDE
03 Melting Plants and Equipment for NFM
03.02 Melting and Holding Furnaces, Electrically
Heated
▼ Aluminium Melting Furnaces 630
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Am Seestern 5, 40547 Düsseldorf, Germany
( +49 211 5858-0
E-Mail:
steel@refra.com
Internet:
www.refra.com
▼ Insulating Products 1130
08 Plants and Machines for Moulding and
Coremaking Processes
08.02 Moulding and Coremaking Machines
▼ Multi-Stage Vacuum Process 3223
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Remelting Furnaces 700
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
( +34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
▼ Micro Porous Insulating Materials 1220
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
( +49 6441 802-1190 7 +49 6441 802-1199
E-Mail:
andreas.wuerz@pfeiffer-vacuum.de
Internet:
www.pfeiffer-vacuum.de
09 Moulding Sands
09.01 Basic Moulding Sands
▼ Chromite Sands 3630
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
04 Refractories Technology
04.01 Plants, Equipment and Tools for Lining in Melting
and Casting
▼ Mixers and Chargers for Refractory Mixes 930
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
( +34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
▼ Ladle Refractory Mixes 1240
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Ceramic Sands/Chamotte Sands 3645
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
▼ Gunning for Relining of Cupolas 950
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
04.04 Refractory Building
▼ Maintenance of Refractory Linings 1462
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Silica Sands 3720
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
04.02 Refractory Materials (Shaped and Non Shaped)
▼ Refractories, in general 1040
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
( +49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
05 Non-metal Raw Materials and Auxiliaries for
Melting Shop
05.04 Carburization Agents
▼ Coke Breeze, Coke-Dust 1680
STROBEL QUARZSAND GmbH
Freihungsand, 92271 Freihung, Germany
( +49 9646 9201-0 7 +49 9646 9201-701
E-Mail:
info@strobel-quarzsand.de
Internet:
www.strobel-quarzsand.de
09.04 Mould and Core Coating
▼ Blackings, in general 4270
ARISTON Formstaub-Werke GmbH & Co. KG
Worringerstr. 255, 45289 Essen, Germany
( +49 201 57761 7 +49 201 570648
Internet:
www.ariston-essen.de
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
( +34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
ARISTON Formstaub-Werke GmbH & Co. KG
Worringerstr. 255, 45289 Essen, Germany
( +49 201 57761 7 +49 201 570648
Internet:
www.ariston-essen.de
CASTING PLANT & TECHNOLOGY 2–3/2020 61

09.06 Moulding Sands Testing
▼ Moisture Testing Equipment for Moulding Sand 4410
▼ Aerators 4560
▼ Insulating Sleeves 5375
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
▼ Moulding Sand Testing Equipment, in general 4420
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
▼ Scales and Weighing Control 4590
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Mini-Feeders 5400
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
10 Sand Conditioning and Reclamation
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
10.04 Sand Reconditioning
▼ Sand Coolers 4720
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Feeder Sleeves 5420
10.01 Moulding Sand Conditioning
▼ Aerators for Moulding Sand Ready-to-Use 4470
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
▼ Sand Preparation Plants and Machines 4480
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
▼ Mixers 4520
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
12 Gating and Feeding
▼ Covering Agents 5320
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Am Seestern 5, 40547 Düsseldorf, Germany
( +49 211 5858-0
E-Mail:
steel@refra.com
Internet:
www.refra.com
▼ Breaker Cores 5340
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Feeding Compounds 5430
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
13 Casting Machines and Equipment
13.02 Die Casting and Accessories
▼ Diecasting Lubricants 5670
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
▼ Sand Mixers 4550
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Products 5360
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Diecasting Parting Agents 5680
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50,
74736 Hardheim, Germany
Internet: www.eirich.de
GTP Schäfer GmbH
41515 Grevenbroich, Germany
( +49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
62

SUPPLIERS GUIDE
▼ Hydraulic Cylinders 5750
17.01 Plants and Furnaces
▼ Tempering Furnaces 7400
▼ Heat Treating Furnaces 7520
HYDROPNEU GmbH
Sudetenstr. , 73760 Ostfildern, Germany
( +49 711 342999-0 7 +49 711 342999-1
E-Mail:
info@hydropneu.de
Internet:
www.hydropneu.de
▼ Piston Lubricants 5790
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Ageing Furnaces 7401
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Hearth Bogie Type Furnaces 7525
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Parting Agents for Dies 5850
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Annealing and Hardening Furnaces 7430
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
18 Plant, Transport, Stock, and Handling
Engineering
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Dry Lubricants (Beads) 5865
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Solution Annealing Furnaces 7455
18.01 Continuous Conveyors and Accessories
▼ Vibratory Motors 7980
FRIEDRICH Schwingtechnik GmbH
Am Höfgen 24, 42781 Haan, Germany
( +49 2129 3790-0 7 +49 2129 3790-37
E-Mail:
info@friedrich-schwingtechnik.de
Internet:
www.friedrich-schwingtechnik.de
20 Control Systems and Automation
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
( +49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Multi-Stage Vacuum Process 5876
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
( +49 6441 802-1190 7 +49 6441 802-1199
E-Mail:
andreas.wuerz@pfeiffer-vacuum.de
Internet:
www.pfeiffer-vacuum.de
17 Surface Treatment and Drying
▼ Heat Treatment and Drying 7398
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Annealing Furnaces 7490
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Quenching and Tempering Furnaces 7510
20.01 Control and Adjustment Systems
▼ Automation and Control for Sand Preparation 9030
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
20.02 Measuring and Control Instruments
▼ Immersion Thermo Couples 9230
Gebr. Löcher Glüherei GmbH
Mühlenseifen 2, 57271 Hilchenbach, Germany
( +49 2733 8968-0 7 +49 2733 8968-10
Internet:
www.loecher-glueherei.de
LOI Thermoprocess GmbH
45141 Essen/Germany
( +49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
CASTING PLANT & TECHNOLOGY 2–3/2020 63

▼ Laser Measurement Techniques 9310
▼ Numerical Solidification Simulation and Process Optimization
9502
27 Consulting and Service
▼ Machining 11292
POLYTEC GmbH
76337 Waldbronn, Germany
( +49 7243 604-0 7 +49 7243 69944
E-Mail:
Lm@polytec.de
Internet:
www.polytec.de
▼ Positioning Control 9345
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
▼ Simulation Software 9522
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
( +49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
▼ Simulation Services 11310
POLYTEC GmbH
76337 Waldbronn, Germany
( +49 7243 604-0 7 +49 7243 69944
E-Mail:
Lm@polytec.de
Internet:
www.polytec.de
▼ Temperature Measurement 9380
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
22 Analysis Technique and Laboratory Equipment
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
▼ Heat Treatment 11345
▼ Sampling Systems 9970
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Thermal Analysis Equipment 9400
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
Gebr. Löcher Glüherei GmbH
Mühlenseifen 2, 57271 Hilchenbach, Germany
( +49 2733 8968-0 7 +49 2733 8968-10
Internet:
www.loecher-glueherei.de
28 Castings
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Thermo Couples 9410
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
20.03 Data Acquisition and Processing
▼ Numerical Solidification Analysis and Process Simulation
9500
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
26 Other Products for Casting Industry
26.02 Industrial Commodities
▼ Joints, Asbestos-free 11120
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Sealing and Insulating Products up to 1260 øC 11125
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
( +49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Aluminium Pressure Diecasting 11390
Schött Druckguß GmbH
Aluminium Die Casting
Postfach:
27 66, 58687 Menden, Germany
( +49 2373 1608-0 7 +49 2373 1608-110
E-Mail:
vertrieb@schoett-druckguss.de
Internet:
www.schoett-druckguss.de
▼ Rolled Wire 11489
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
( +49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
▼ Spheroidal Iron 11540
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
( +49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
64

SUPPLIERS GUIDE
30 Data Processing Technology
▼ Mold Filling and Solidification Simulation 11700
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
( +49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
31 Foundries
31.01 Iron, Steel, and Malleable-Iron Foundries
▼ Iron Foudries 11855
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
( +49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
Internet:
Index to Companies
Company Product Company Product
ARISTON Formstaub-Werke 1680, 4270
GmbH & Co. KG
BEHRINGER GmbH 11292, 11489, 11540, 11855
Maschinenfabrik&Eisengießerei
Chem Trend (Deutschland) GmbH 5670, 5680, 5790, 5850, 5865
Maschinenfabrik 4410, 4420, 4470, 4480, 4520,
Gustav Eirich GmbH u. Co KG 4550, 4560, 4590, 4720, 9030
Friedrich Schwingtechnik GmbH 7980
GTP Schäfer 3630, 3645, 5340, 5360, 5375,
Giesstechnische Produkte GmbH 5400, 5420, 5430
HYDROPNEU GmbH 5750
EIKA, S.COOP 1040, 1130, 1220
Gebr. Löcher Glüherei 7398, 11345
GmbH
LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430,
7455, 7490, 7510, 7520, 7525
MAGMA Gießereitechnologie GmbH 9500, 9502, 9522, 11310, 11700
MINKON GmbH 9230, 9380, 9400, 9410, 9970,
Geschäftsleitung 11120, 11125
Pfeiffer Vacuum GmbH 3223, 5876
Polytec GmbH 9310, 9345
Refratechnik Steel GmbH 1040, 5320
Schött-Druckguß GmbH 11390
Strobel Quarzsand GmbH 3720
Uelzener Maschinen GmbH 930, 950, 1240, 1462
CASTING PLANT & TECHNOLOGY 2–3/2020 65

List of Products
01 Foundry Plants and Equipment
10 Foundry Plants, Planning and
Construction
20 Foundry Equipment and Facilities,
in general
30 Foundry Plants, fully and
partially automatic
40 Maintenance and Repairing of
Foundry Plants
44 Swing-Technique Machines for
Handling, Dosing, and Classing
45 Second Hand Foundry Plants and
Equipment
47 Spray Deposition Plants
01.01. Components
47 Spray Deposition Plants
50 Charging Systems, in general
52 Cored Wire Treatment Stations
53 Plug Connections, Heat Resisting
02 Melting Plants and Equipment for Iron and
Steel Castings and for Malleable Cast Iron
02.01. Cupolas
55 Cupolas
60 Hot-Blast Cupolas
70 Cold-Blast Cupolas
80 Circulating Gas Cupolas
90 Gas Fired Cupolas
100 Cupolas, cokeless
110 Cupolas with Oxygen-Enrichment
120 Cupolas with Secondary Blast
Operation
02.02. Cupola Accessories and
Auxiliaries
130 Lighter
140 Cupola Charging Equipment
150 Tuyères
160 Burners for Cupolas
180 Blowing-In Equipment for Carbo Fer
190 Blowing-In Equipment for Filter
Dusts into Cupolas
210 Blowing-In Equipment for Carbon
211 Blowing-In Equipment for Metallurgical
Processes
220 Dedusting, Cupolas
225 Gas Cleaning
230 Charging Plants, fully and partially
automatic
240 Blowers, Cupolas
270 Recuperators
280 Oxygen Injection for Cupolas
290 Shaking Ladles, Plants
295 Dust Briquetting
300 Monitoring Plants, Cupola
310 Forehearths, Cupola
320 Blast Heater
02.03. Melting and Holding
Furnaces, Electrically Heated
330 Electric melting Furnaces, in general
340 Induction Channel Furnaces
350 Crucible Induction Furnaces, medium
Frequency
360 Crucible Induction Furnaces,
Mains Frequency
370 Short-Coil Induction Furnaces
390 Filters, in general
399 Tower Melter
400 Holding Furnaces
02.04. Accessories and Auxiliaries
for Electric Furnaces
410 Charging Units
420 Blowing-In Equipment for Carbo Fer
430 Blowing-In Equipment for Filter Dusts
440 Blowing-In Equipment for Carbon
445 Inert Gas Systems for EAF and EIF
450 Inert Gas Systems for EAF and EIF
460 Electro-magnetic Conveyor Chutes
470 Dust Separation Plant
480 Charging Equipment
500 Graphite Electrodes
510 Lime Dosing Device
520 Condensors
540 Cooling Equipment
550 Scrap preheating Plants
560 Secondary Metallurgical Plants
565 Control Installations
570 Equipment for induction stirring
02.05. Rotary Furnaces
580 Rotary Furnaces
02.06. Maintenance and Repairing
584 Repairing of Induction Furnaces
586 Maintenance of Complete
Induction Furnace Plants
03 Melting Plants and Equipment for NFM
03.01. Melting Furnaces, Fuel Fired
590 Hearth-Type (Melting) Furnaces
599 Tower Furnaces
600 Bale-Out Furnaces
610 Crucible Furnaces
620 Drum-Type Melting Furnaces
03.02. Melting and Holding
Furnaces, Electrically Heated
630 Aluminium Melting Furnaces
640 Dosing Furnace
655 Heating Elements for Resistance
Furnaces
660 Induction Furnaces (Mains,
Medium, and High Frequency)
665 Magnesium Melting Plants and
Dosing Devices
670 Melting Furnacs, in general
680 Bale-Out Furnaces
690 Crucible Furnaces
700 Remelting Furnaces
710 Holding Furnaces
720 Electric Resistance Furnaces
902 Vacuum Melting and Casting
Furnaces
03.03. Accessories and Auxiliaries
730 Exhausting Plants
740 Molten Metal Refining by Argon
742 Gassing Systems for Aluminium
Melting
750 Gassing Systems for Magnesium
Melting
760 Charging Plants
770 Blowing-in Equipment for Alloying
and Inoculating Agents
774 Blowing-in Equipment for
Inoculating Agents
778 Degassing Equipment
780 Dedusting Equipment
785 Crucibles, Ready-To-Use
790 Charging Equipment
800 Graphite Melting Pots
825 Emergency Iron Collecting
Reservoirs
847 Cleaning Devices for Cleaning
Dross in Induction Furnaces
848 Cleaning Device and Gripper for
Deslagging - Induction Furnaces
850 Crucibles
860 Inert Gas Systems
870 Silicon Carbide Pots
875 Special Vibrating Grippers for
the Removal of Loose Dross and
Caking
880 Gas Flushing Installations
890 Crucibles, Pots
895 Power Supply, Plasma Generators
900 Vacuum Degassing Equipment
04 Refractories Technology
04.01. Plants, Equipment and Tools for
Lining in Melting and Casting
910 Spraying Tools for Furnace Lining
920 Breakage Equipment for Cupolas,
Crucibles, Pots, Torpedo Ladles
and Ladles
923 Lost Formers
930 Mixers and Chargers for
Refractory Mixes
940 Charging Units for Furnaces
950 Gunning for Relining of Cupolas
954 Ramming Mix Formers
956 Ramming Templates
980 Wear Indicators for Refractory Lining
982 Wear Measuring and Monitoring
for Refractory Lining
985 State Diagnosis of Refractory Lines
66

04.02. Refractory Materials
(Shaped and Non Shaped)
1000 Boron-Nitride Isolation
1005 Sand Gaskets, Isolation
Materials (up to 1260 °C)
1009 Running and Feeding
Systems (Gating Systems)
1010 Running and Feeding Systems
(Runner Bricks, Centre Bricks,
Sprue Cups)
1020 Fibrous Mould Parts
1021 Fibrous Mould Parts up to 1750 °C
1030 Refractory Castables
1040 Refractories, in general
1050 Insulating Refractoy Bricks
1060 Refractoy Cements
1070 Refractories for Aluminium Melting
Furnaces
1080 Refractory Materials for Anode
Kilns
1090 Refractory Materials for Melting
Furnaces, in general
1100 Refractory Materials for Holding
Furnaces
1103 Ceramic Fibre Mould Parts and
Modules
1104 Mold Sections and Modules made
of HTW (High Temperature Wool)
1109 Precasts
1110 Pouring Lip Bricks
1113 Fibreglass Mats
1114 Slip Foils for Glowing Materials
1117 High Temperature Mats, Papers,
Plates, and Felts
1120 Induction Furnace Compounds
1123 Insulating and Sealing Panels up
to 1200 °C
1125 Insulating Fabrics up to 1260 °C
1128 Insulating Felts and Mats up to
1260 °C
1130 Insulating Products
1140 Insulating Products (such as
Fibres, Micanites)
1150 Insulating Bricks
1155 Ceramic Fibre Mats, Papers,
Plates, and Felts
1160 Ceramic Fibre Modules
1169 Ceramic Fibre Substitutes
1170 Ceramic Fibre Products
1180 Loamy Sands
1190 Carbon Bricks
1200 Cupola and Siphon Mixes
1210 Cupola Bricks
1220 Micro Porous Insulating Materials
1222 Nano Porous Insulating Materials
1225 Furnace Door Sealings, Cords, and
Packings
1230 Furnace Linings
1240 Ladle Refractory Mixes
1250 Ladle Bricks
1260 Plates, free from Ceramic Fibres
1261 Plates made of Ground Alkali
Silicate Wool
1270 Acid and Silica Mixes
1280 Fire-Clay Mixes and Cements
1290 Fire-Clay Bricks
1310 Porous Plugs
1312 Stirring Cones for Steel, Grey Cast
Iron and Aluminium
1320 Moulding Mixtures for Steel Casting
1330 Ramming, Relining, Casting,
Gunning, and Vibration Bulks
1333 Ramming, Casting, Gunning, and
Repairing Compounds
1340 Plugs and Nozzles
1345 Textile Fabrics up to 1260 °C
988 Substitutes of Aluminium Silicate
Wool
990 Coating and Filling Materials,
Protective Coatings
04.03. Refractory Raw Materials
1350 Glass Powder
1360 Loamy Sands
1370 Magnesite, Chrom-Magnesite,
Forsterite
1390 Chamotte, Ground Chamotte
1400 Clays, Clay Powders
04.04. Refractory Building
1410 Bricking-Up of Furnaces
1420 Refractory Building/Installation
1430 Fire and Heat Protection
1435 Furnace Door Joints
1440 Furnace Reconstruction
1450 Repairing of Furnaces and Refractories
1460 Heat Insulation
1462 Maintenance of Refractory Linings
05 Non-metal Raw Materials and Auxiliaries for
Melting Shop
05.01. Coke
1480 Lignite Coke
1490 Foundry Coke
1510 Petroleum Coke
05.02. Additives
1520 Desulphurization Compounds
1530 Felspar
1540 Fluorspar
1550 Casting Carbide
1560 Glass Granulate
1570 Lime, Limestones
1575 Briquets for Cupolas
1580 Slag Forming Addition
05.03. Gases
1590 Argon
1600 Oxygen
1610 Inert Gases
1620 Nitrogen
1622 Hydrogen
05.04. Carburization Agents
1630 Carburization Agents, in general
1640 Lignite Coke
1650 Electrode Butts
1660 Electrode Graphite
1665 Desulfurizer
1670 Graphite
1680 Coke Breeze, Coke-Dust
1700 Petroleum Coke
1710 Silicon Carbide
3261 Automatic Powder Feeding
05.05. Melting Fluxes for NF-Metals
1720 Aluminium Covering Fluxes
1730 Desoxidants, in general
1740 Degassing Fluxes
1750 Desulphurisers
1760 Charcoal
1770 Refiners
1780 Fluxing Agents
1785 Melt Treatment Agents
1790 Fluxing Agents
06 Metallic Charge Materials for Iron and Steel
Castings and for Malleable Cast Iron
06.01. Scrap Materials
1810 Cast Scrap
1811 Cast Turnings
1813 Cuttings/Stampings
1817 Steel Scrap
06.02. Pig Iron
1820 Hematite Pig Iron
1830 Foundry Pig Iron
1838 DK Pig Iron
1840 DK-Perlit Special Pig Iron
1880 DK Pig Iron for Malleable Cast Iron
1898 DK Pig Iron, low-carbon, Quality
DKC
1900 DK-Perlit Special Pig Iron, Low
Carbon, DKC Quality
1936 DK Phosphorus Alloy Pig Iron
1940 DK-Perlit Special Pig Iron, Type
Siegerlaender
1950 Spiegel Eisen
1970 Blast Furnace Ferro Silicon
06.03. Specials (Pig Iron)
1990 Foundry Pig Iron
2000 Hematite Pig Iron
2010 Sorel Metal
2020 Special Pig Iron for s. g. Cast Iron
Production
2030 Special Pig Iron for s.g. Cast Iron
2040 Steelmaking Pig Iron
06.04. Ferro Alloys
2050 Ferro-Boron
2060 Ferro-Chromium
2070 Ferroalloys, in general
2080 Ferro-Manganese
2090 Ferro-Molybdenum
2100 Ferro-Nickel
2110 Ferro-Niobium
2120 Ferro-Phosphorus
2130 Ferro-Selenium
2140 Ferro-Silicon
2150 Ferro-Silicon-Magnesium
2160 Ferro-Titanium
2170 Ferro-Vanadium
2180 Ferro-Tungsten
2190 Silicon-Manganese
06.05. Other Alloy Metals and Master
Alloys
2200 Aluminium Granulates
2210 Aluminium, Aluminium Alloys
2220 Aluminium Powder
2230 Aluminium Master Alloys
2250 Calcium Carbide
2260 Calcium-Silicon
2265 Cerium Mischmetal
CASTING PLANT & TECHNOLOGY 2–3/2020 67

2280 Chromium Metals
2290 Cobalt
2300 Chromium Metal, Aluminothermic
2310 Deoxidation Alloys
2318 High-grade Steel
2320 Iron Powder
2350 Copper
2360 Cupola Briquets
2370 Alloying Metals, in general
2380 Alloying Additives
2390 Magnesium, Magnesium Alloys
2410 Manganese Metal
2420 Manganese Metal, Electrolytic
2430 Molybdenum
2440 Molybdenum Alloys
2450 Molybdenum Oxide
2460 Nickel, Nickel Alloys
2470 Nickel-Magnesium
2490 Furnace Additives
2500 Ladle Additives
2510 High-Purity Iron, Low-Carbon
2520 Sulphuric Iron
2530 Silicon Carbide
2540 Silicon Metal
2545 Silicon Metal Granules
2550 Special Alloys
2570 Titanium Sponge
2575 Master Alloys for Precious Metals
2580 Bismuth
2590 Tungsten
2600 Tin
2610 Alloying Metals, Master Alloys
06.06. Nodularizing Additives and
Auxiliaries
2620 Magnesium Treatment Alloys for
s. g. Cast Iron
2630 Mischmetal
06.07. Inoculants and Auxiliary
Appliances
2640 Cored-Wire Injectors
2645 Injection Appliances for Cored Wire
2650 Cored Wires for Secondary and
Ladle Metallurgy
2653 Cored Wires for Magnesium Treatment
2656 Cored Wires for Inoculation of Cast
Iron Melts
2658 Stream Inoculants
2660 Automatic IDA-Type Inoculation
Dosing Devices
2670 Injection Appliances
2680 Inoculants and Inoculation Alloys,
in general
2690 Inoculants for Cast Iron
2692 MSI Pouring Stream Inoculation
Devices
2694 Ladle Inoculants
07 Metallic Charge and Treatment Materials for
Light and Heavy Metal Castings
07.01. Scrap
2730 Metal Residues
07.02. Ingot Metal
2740 Standard Aluminium Alloys
2750 Brass Ingots
2770 High-Grade Zinc Alloys
2790 Copper
2800 Copper Alloys
2810 Magnesium, Magnesium Alloys
2830 Tin
07.03. Alloying Addition for Treatment
2838 Aluminium-Beryllium Master Alloys
2840 Aluminium-Copper
2852 Aluminium Master Alloys
2870 Arsenic Copper
2875 Beryllium-Copper
2890 Calcium
2891 Calcium Carbide, Desulphurisers
2893 Chromium-Copper
2900 Ferro-Copper
2910 Grain Refiner
2920 Granulated Copper
2924 Copper Magnesium
2925 Copper Salts
2927 Copper Master Alloys
2930 Alloy Metals, in general
2935 Alloy Biscuits
2936 Lithium
2938 Manganese Chloride (anhydrate)
2940 Manganese Copper
2950 Metal Powder
2960 Niobium
2970 Phosphor-Copper
2980 Phosphor-Tin
2990 Silicon-Copper
3000 Silicon Metal
3010 Strontium, Strontium Alloys
3020 Tantalum
3025 Titanium, powdery
3030 Refining Agents for Aluminium
3033 Zirconium-Copper
08 Plants and Machines for Moulding and
Coremaking Processes
08.01. Moulding Plants
3050 Moulding Plants, in general
3058 Moulding Machines, Boxless
3060 Moulding Machines, Fully Automatic
3070 Moulding Machines, Fully and
Partially Automatic
08.02. Moulding and Coremaking
Machines
3080 Lifting Moulding Machine
3090 Pneumatic Moulding Machines
3100 Automatic Moulding Machines
3110 High-Pressure Squeeze Moulding
Machines
3130 Impact Moulding Machines
3140 Moulding Plants and Machines for
Cold-Setting Processes
3150 Moulding Machines, Boxless
3160 Core Blowers
3170 Coremaking Machines
3180 Core Shooters
3190 Air-flow Squeeze Moulding Machines
and Plants
3200 Shell Moulding Machines
3210 Shell Moulding Machines
3220 Shell Moulding Machines and
Hollow Core Blowers
3225 Multi-Stage Vacuum Process
3230 Multi-Stage Vacuum Processes for
Pressure Die Casting Processes
3235 Rapid Prototyping
3240 Jolt Squeeze Moulding Machines
3250 Suction Squeeze Moulding Machines
and Plants
3260 Pinlift Moulding Machines
3270 Rollover Moulding Machines
3280 Vacuum Moulding Machines and
Processes
3290 Multi-Piston Squeeze Moulding
Machines
3300 Turnover Moulding Machines
08.03. Additives and Accessories
3310 Exhaust Air Cleaning Plants for
Moulding Machines
3320 Gassing Units for Moulds and
Cores
3325 Seal Bonnets for Immersion Nozzles
3330 Metering Dosing Devices for
Binders and Additives
3340 Electrical Equipment for Moulding
Machines and Accessories
3350 Electrical and Electronic Controlling
Devices for Moulding
Machines
3355 Mould Dryer
3360 Vents
3370 Screen-Vents
3380 Spare Parts for Moulding Machines
3390 Flow Coating Plants
3400 Pattern Plates
3420 Manipulators
3430 Core Setting Equipment
3440 Core Removal Handling
3450 Core Handling
3460 Coremaking Manipulators
3462 Core Transport Racks
3470 Shell Mould Sealing Equipment
and Presses
3480 Mixers for Blackings and Coatings
3500 Plastic Blowing and Gassing Plates
3510 Coating Equipment
3512 Coating Dryers
3520 Equipment for Alcohol-based
Coatings
3525 Coating Stores and
Preparation Equipment
3530 Coating Mixers, Coating Preparation
Equipment
3540 Screen Vents, front Armoured
3560 Swing Conveyors
3570 Screening Machines
3580 Plug Connections, Heat-Resisting
08.04. Mould Boxes and Accessories
3590 Moulding Boxes
3610 Moulding Box Round-hole and
Long-hole Guides
09 Moulding Sands
09.01. Basic Moulding Sands
3630 Chromite Sands
3640 Moulding Sands
3645 Ceramic Sands/Chamotte Sands
3650 Core Sands
68

3660 Molochite
3670 Mullite Chamotte
3690 Olivine Sands
3700 Fused Silica
3705 Lost Foam Backing Sands
3710 Silica Flour
3720 Silica Sands
3730 Zircon Powder
3740 Zircon Sands
09.02. Binders
3750 Alkyd Resins
3755 Inorganic Binders
3760 Asphalt Binders
3770 Bentonite
3790 Binders for Investment Casting
3800 Cold-Box Binders
3803 Resins for the Shell Moulding
Process
3820 Ethyl Silicate
3830 Moulding Sand Binders, in general
3833 Binders, Inorganic
3840 Resins
3860 Oil Binders
3870 Core Sand Binders, in general
3875 Silica Sol
3880 Synthetic Resin Binders, in general
3890 Synthetic Resin Binders for
Refractories
3900 Synthetic Resin Binder for Gas
Curing Processes
3910 Synthetic Resin Binder for Hot
Curing Processes
3920 Synthetic Resin Binder for Cold
Setting Processes
3930 Facing Sand Binders
3940 Binders for the Methyl-Formate
Process
3950 Phenolic Resins
3960 Phenolic Resins (alkaline)
3970 Polyurethane Binders and Resins
3980 Swelling Binders
3990 Swelling Clays
4000 Quick-Setting Binders
4010 Silicate Binders
4020 Silica Sol
4030 Binders for the SO2 Process
4040 Cereal Binders
4050 Warm-Box Binders
4060 Water-Glass Binders (CO2-Process)
09.03. Moulding Sand Additives
4066 Addition Agents
4070 Iron Oxide
4080 Red Iron Oxide
4090 Lustrous Carbon Former
4100 Pelleted Pitch
4110 Coal Dust
4120 Coal Dust Substitute (Liquid or
Solid Carbon Carrier)
4130 Coal Dust (Synthetic)
09.04. Mould and Core Coating
4140 Inflammable Coating
4150 Alcohol-Based Coatings
4160 Alcohol-based Granulated Coatings
4170 Boron-Nitride Coatings
4180 Coatings, Ready-to-Use
4190 Mould Varnish
4200 Mould Coating
4210 Black Washes
4220 Graphite Blackings
4224 Lost-Foam Coatings
4225 Ceramic Coatings
4230 Core Coatings
4240 Core Blackings
4260 Paste Coatings
4266 Coatings (with metallurgical effects)
4270 Blackings, in general
4280 Steel Mould Coatings
4290 Talc
4298 Coatings for Full Mould Casting
4300 Water-based Coatings
4310 Granulated Water-based Coatings
4320 Zircon Coatings
4321 Zircon-free Coatings
09.05. Moulding Sands
Ready-to-Use
4340 Sands for Shell Moulding, Readyto-use
4350 Sands Ready-to-Use, Oil-Bonded
(Water-free)
4360 Precoated Quartz Sands, Zircon
Sands, Chromite Sands, Ceramic
Sands
4370 Moulding Sands for Precision
Casting
4380 Steel Moulding Sands
4390 Synthetic Moulding and Core Sand
09.06. Moulding Sands Testing
4400 Strength Testing Equipment for
Moulding Sand
4410 Moisture Testing Equipment for
Moulding Sand
4420 Moulding Sand Testing Equipment,
in general
4426 Core Gas Meters for Al + Fe
4440 Sand Testing
10 Sand Conditioning and Reclamation
4446 Sand Preparation and
Reclamation
4448 Sand Reclamation System
10.01. Moulding Sand Conditioning
4450 Nozzles for Moistening
4459 Continuous Mixers
4460 Continuous Mixers for Cold-Setting
Sands
4470 Aerators for Moulding Sand
Ready-to-Use
4480 Sand Preparation Plants and
Machines
4490 Sand Mullers
4500 Measuring Instruments for Compactibility,
Shear Strength, and
Deformability
4510 Measuring Instruments for
Mouldability Testing (Moisture,
Density, Temperature)
4520 Mixers
4550 Sand Mixers
4560 Aerators
4567 Vibration Sand Lump Crusher
4568 Vibratory Screens
4570 Sand Precoating Plants
4590 Scales and Weighing Control
10.03. Conditioning of Cold, Warm,
and Hot Coated Sands
4650 Preparation Plants for Resin
Coated Sand
10.04. Sand Reconditioning
4660 Used Sand Preparation Plants
4662 Batch Coolers for Used Sand
4664 Flow Coolers for Used Sand
4670 Magnetic Separators
4690 Core Sand Lump Preparation
Plants
4700 Reclamation Plants for Core Sands
4710 Ball Mills
4720 Sand Coolers
4730 Sand Reclamation Plants
4740 Sand Screens
4760 Separation of Chromite/Silica Sand
10.05. Reclamation of Used Sand
4780 Reclamation Plants, in general
4785 Reclamation Plants,
Chemical-Combined
4790 Reclamation Plants,
Mechanical
4800 Reclamation Plants,
Mechanical/Pneumatic
4810 Reclamation Plants,
Mechanical-Thermal
4820 Reclamation Plants, Mechanical/
Thermal/Mechanical
4830 Reclamation Plants, wet
4840 Reclamation Plants, Thermal
4850 Reclamation Plants,
Thermal-Mechanical
11 Moulding Auxiliaries
4880 Mould Dryers
4890 Foundry Nails, Moulding Pins
4910 Moulders‘ Tools
4920 Mould Hardener
4950 Guide Pins and Bushes
4965 High Temperature Textile Fabrics
up to 1260 °C
4970 Ceramic Pouring Filters
4980 Ceramic Auxiliaries for Investment
Foundries
4990 Ceramic Cores for Investment
Casting - Gunned, Pressed, Drawn
4998 Cope Seals
5000 Core Benches
5007 Core Putty Fillers
5010 Core Wires
5020 Cores (Cold-Box)
5030 Cores (Shell)
5040 Core Boxes
5050 Core Box Dowels
5070 Core Adhesives
5080 Core Loosening Powder
5090 Core Nails
5100 Core Powders
5110 Chaplets
5130 Tubes for Core and Mould Venting
CASTING PLANT & TECHNOLOGY 2–3/2020 69

5140 Core Glueing
5150 Core Glueing Machines
5155 Cleaners
5160 Adhesive Pastes
5170 Carbon Dioxide
(CO2 Process)
5180 Carbon Dioxide Dosing
Devices
5210 Coal Dust and Small Coal
5220 Chill Nails
5230 Chill Coils
5240 Antipiping Compounds
5260 Shell Mould Sealers
5270 Mould Dryers, Micro-Wave
5280 Screening Machines
5290 Glass Fabric Filters
5300 Strainer Cores
5310 Release Agents
11.01. Moulding Bay Equipment
5312 Glass Fabric Filters
5314 Strainer Cores
12 Gating and Feeding
5320 Covering Agents
5330 Heating-up Agents
5340 Breaker Cores
5350 Strainer Cores
5360 Exothermic Products
5365 Glass Fabric Filters
5370 Insulating Products and Fibres
5375 Insulating Sleeves
5380 Ceramic Filters
5390 Ceramic Breaker Cores
5400 Exothermic Mini-Feeders
5405 Non-Ceramic Foam Filters
5410 Ceramic Dross Filters
5416 Riser (exothermic)
5418 Riser (insulating)
5420 Exothermic Feeder Sleeves
5430 Exothermic Feeding Compounds
13 Casting Machines and Equipment
5436 Pouring Machines and
Equipment
5437 Casting Machine,
without Heating
13.01. Pouring Furnaces and their
Equipment
5440 Aluminium Dosing Furnaces
5450 Pouring Equipment
5460 Pouring Ladles
5461 Pouring Ladles, Insulating
5468 Pig and Ingot Casting
Machines
5470 Pouring Equipment for Moulding
Plants, Railborn or Crane-operated
5480 Pouring Ladles
5485 Pouring Ladles, Electrically Heated
5490 Drum-Type Ladles
5500 Ingot Casting Machines
5510 Low Pressure Casting
Machine
13.02. Die Casting and
Accessories
5530 Trimming Presses for
Diecastings
5540 Trimming Tools for Diecastings
(Standard Elements)
5545 Exhausting and Filtering Plants for
Diecastings
5550 Ejectors for Diecasting Dies
5560 Ejectors for Diecasting Dies (Manganese
Phosphate Coated)
5570 Feeding, Extraction, Spraying, and
Automatic Trimming for Diecasting
Machines
5580 Trimming Tools
5600 Dosing Devices for
Diecasting Machines
5610 Dosing Furnaces for
Diecasting Machines
5620 Diecasting Dies
5630 Heating and Cooling Devices for
Diecasting Dies
5640 Diecasting Machines
5641 Diecasting Machines and Plants
5644 Diecasting Machines for Rotors
5650 Diecasting Machine Monitoring
and Documentation Systems
5660 Diecasting Coatings
5670 Diecasting Lubricants
5675 Lost Diecasting Cores
5680 Diecasting Parting Agents
5689 Venting Blocks for HPDC Dies
5690 Extraction Robots for
Diecasting Machines
5695 Frames and Holders for
Diecasting Dies
5700 Spraying Equipment for Diecasting
Machines
5710 Goosenecks and Shot Sleeves
5720 Hand Spraying Devices
5730 Heating Cartridges
5740 High-duty Heating Cartridges
5750 Hydraulic Cylinders
5760 Core Pins
5770 Cold Chamber Diecasting Machines
5780 Pistons for Diecasting Machines
5790 Piston Lubricants
5800 Piston Spraying Devices
5810 Mixing Pumps for Parting Agents
5815 Electric Nozzle Heatings
5817 Oil Filters
5820 Melting and Molten Metal Feeding
in Zinc Die Casting Plants
5830 Steel Molds for Diecasting Machines
5838 Heating and Cooling of Dies
5840 Temperature Control Equipment for
Diecasting Dies
5850 Parting Agents for Dies
5860 Parting Agent Spraying Devices for
Diecasting Machines
5865 Dry Lubricants (Beads)
5870 Vacural-Type Plants
5876 Multi-Stage Vacuum Process
5880 Multi-Stage Vacuum Process
5890 Vacuum Die Casting Plants
5900 Hot Working Steel for
Diecasting Dies
5910 Hot Working Steel for Diecasting
Tools
5912 Hot Chamber Diecasting Machines
13.03. Gravity Die Casting
5914 Dosing Devices for Gravity Diecasting
Stations
5920 Permanent Molds
5930 Automatic Permanent Moulding
Machines
5940 Gravity Diecasting Machines
5941 Gravity and High Pressure Diecasting
Automation
5945 Cement and Fillers for Permanent
Moulds up to 1600 °C
5950 Cleaning Devices for Permanent
Molds
5960 Coatings for Permanent Molds
5970 Colloidal Graphite
5975 Chills
5980 Low Pressure Diecasting Machines
13.04. Centrifugal Casting
5990 Centrifugal Casting Machines
13.05. Continuous Casting
6000 Anode Rotary Casting Machines
6001 Length and Speed Measuring,
non-contact, for Continuous
Casting Plants
6002 Thickness and Width Measurement
for Continuous Casting
Plants, non-contact
6006 Casting and Shear Plants for
Copper Anodes
6007 Casting and Rolling Plants for
Copper Wire
6008 Casting and Rolling Plants for
Copper Narrow Strips
6010 Continuous Casting Plant, horizontal,
for Tube Blanks with integrated
Planetary Cross Rolling Mill for the
Production of Tubes
6020 Continuous Casting Moulds
6030 Continuous Casting
Machines and Plants
6032 Continuous Casting, Accessories
6033 Continuous Casting Machines and
Plants (non-ferrous)
13.06. Investment and Precision
Casting
6040 Burning Kilns for Investment
Moulds
6045 Investment Casting Waxes
6050 Embedding Machines for Investment
Casting Moulding Materials
6060 Investment Casting Plants
6062 Centrifugal Investment
Casting Machines
13.07. Full Mould Process Plants
6070 Lost-Foam Pouring Plants
13.08. Auxiliaries, Accessories, and
Consumables
6080 Pouring Manipulators
6090 Slag Machines
6093 Copper Templates
6100 Nozzles, Cooling
70

6110 Electrical and Electronic Control
for Casting Machines
6120 Extraction Devices
6130 Pouring Consumables, in general
6140 Rotary Casting Machines
6150 Pouring Ladle Heaters
6160 Ladle Bails
6170 Stream Inoculation Devices
6175 Graphite Chills
6176 Marking and Identification
6177 Bone Ash (TriCalcium Phosphate)
6190 Long-term Pouring Ladle Coatings
6200 Long-term Lubricants
6210 Manipulators
6220 Ladle Covering Compounds
6240 Robots
6245 Protective Jacket for Robots, Heat
and Dust Resistant
6250 Dosing Devices for Slag Formers
Addition
6270 Silicon Carbide Chills
6280 Silicon Carbide Cooling Compounds
6290 Crucible Coatings
6300 Heat Transfer Fluids
14 Discharging, Cleaning, Finishing of Raw
Castings
6305 Casting Cooling Plants
14.01. Discharging
6330 Knock-out Drums
6340 Vibratory Shake-out Tables
6345 Knock-out Vibratory Conveyors
6346 Shake-out Grids
6347 Shake-out Separation Runners
6350 Decoring Equipment
6352 Discharging of Metal Chips
6360 Hooking
6370 Manipulators
6373 Manipulators for Knock-out Floors
6380 Robots
6390 Vibratory Grids, Hangers, and
Chutes
6400 Vibratory Tables
14.02. Blast Cleaning Plants and
Accessories
6410 Turntable Blasting Fans
6420 Pneumatic Blasting Plants
6430 Automatic Continuous Shot-blasting
plants
6440 Descaling Plants
6445 Spare Parts for Blasting Plants
6450 Hose Blasting Plants, Fans
6460 Hose Blasting Chambers
6470 Monorail Fettling Booths
6475 Efficiency Tuning for Blasting
Plants
6480 Manipulator Shotblast Plants
6485 Tumbling Belt Blasting Plants,
Compressed Air Driven
6490 Wet and Dry Shotblast Plants
6500 Fettling Machines
6530 Airless Blast Cleaning Machines
6540 Blasting Plants Efficiency Tuning
6550 Shot Transport, Pneumatic
6560 Shot-Blasting Plants
6569 Shot Blasting Machines
6570 Shot Blasting Machines, with/
without Compressed Air Operating
6572 Dry Ice Blasting
6574 Dry Ice Production
14.03. Blasts
6580 Aluminium Shots
6590 Wire-Shot
6600 High-Grade Steel Shots
6610 Granulated Chilled Iron, Chilled
Iron Shots
6630 Cast Steel Shots
6640 Stainless Steel Shot
6650 Shot-Blast Glass
6660 Shot-Blast Glass Beads
6670 Blasts
6671 Stainless Steel Abrasives
14.04. Grinding Machines and Accessories
6675 Stainless Steel Grit
6680 Belt Grinders
6685 chamfering machines
6690 Flexible Shafts
6695 Diamond Cutting Wheels for
Castings
6700 Compressed Air Grinders
6710 Fibre discs
6714 Centrifugal Grinders
6720 Vibratory Cleaning Machines and
Plants
6730 Rough Grinding Machines
6735 Abrasive Wheels, visual, with
Flakes/Lamellas
6740 Numerical Controlled Grinders
6750 Swing Grinders
6760 Polishing Machines
6770 Polishing Tools
6773 Precision Cutting Wheels, 0,8 mm
6780 Tumbling Drums
6790 Pipe Grinders
6800 Floor Type Grinders
6810 Grinding Textiles
6820 Emery Paper
6830 Grinding Wheel Dresser
6850 Grinding Wheels and Rough
Grinding Wheels
6855 Grinding Pins
6860 Grinding Fleece
6870 Grinding Tools
6874 Drag Grinding Plants
6880 Rough Grinding Machines
6885 Cutting Wheels
6890 Abrasive Cut-off Machines
6900 Vibratory Cleaning Machines
6910 Angle Grinders
14.05. Additional Cleaning Plants
and Devices
6920 Gate Break-off Wedges
6925 Plants for Casting Finishing
6930 Automation
6940 Pneumatic Hammers
6950 Deflashing Machines
6954 Deburring Machines,
robot-supported
6955 Robot Deburring Systems
6960 Fettling Cabins
6970 Fettling Manipulators
6980 Fettling Benches
6990 Core Deflashing Machines
7000 Chipping Hammers
7010 Dedusting of Fettling Shops
7020 Fettling Hammers
7030 Fettling Shops, Cabins, Cubicles
7035 Refining Plants
7040 Robot Fettling Cubicles
7041 Robot Deflashing Units for Casting
7050 Feeder Break-off Machines
7052 Stamping Deflashing
Equipment (tools, presses)
7055 Break-off Wedges
7056 Cutting and Sawing Plants
7058 Band Saw Blades
7059 Cut-off Saws
7060 Cut-off Saws for Risers and Gates
14.06. Jig Appliances
7066 Magnetic Clamping Devices for
Casting Dies
7068 Core-Slides and Clamping
Elements for Casting Dies
7070 Clamping Devices
14.07. Tribology
7073 Lubricants for High Temperatures
7074 Chain Lubricating Appliances
7075 Cooling Lubricants
7077 Central Lubricating Systems
15 Surface Treatment
7083 Anodizing of Aluminium
7100 Pickling of High Quality Steel
7105 CNC Machining
7110 Paint Spraying Plants
7115 Yellow/Green Chromating
7130 Priming Paints
7140 Casting Sealing
7150 Casting Impregnation
7166 Hard Anodic Coating of Aluminium
7180 High Wear-Resistant Surface
Coating
7190 Impregnation
7198 Impregnation Plants
7200 Impregnating Devices and Accessories
for Porous Castings
7210 Anticorrosion Agents
7220 Corrosion and Wearing Protection
7230 Shot Peening
7232 Wet Varnishing
7234 Surface Treatment
7235 Surface Coatings
7240 Polishing Pastes
7245 Powder Coatings
7250 Repair Metals
7260 Slide Grinding, free of Residues
7290 Quick Repair Spaddle
7292 Special Coatings
7295 Special Adhesives up to 1200 °C
7296 Shot-Blasting
7297 Power Supply, Plasma Generators
7300 Galvanizing Equipment
7302 Zinc Phosphating
7310 Scaling Protection
7312 Subcontracting
CASTING PLANT & TECHNOLOGY 2–3/2020 71

16 Welding and Cutting
16.01. Welding Machines and
Devices
7330 Welding Consumables, Electrodes
16.02. Cutting Machines and Torches
7350 Gougers
7352 Special Machines for Machining
7360 Coal/Graphite Electrodes
7365 Water Jet Cutting
7370 Oxygen Core Lances
16.03. Accessories
7394 Protective Blankets, Mats, and
Curtains, made of Fabric, up to
1250 °C
7397 Protective Welding Paste, up to
1400 °C
17 Surface Treatment and Drying
7398 Heat Treatment and Drying
17.01. Plants and Furnaces
7400 Tempering Furnaces
7401 Ageing Furnaces
7402 Combustion Chambers
7404 Baking Ovens for Ceramic Industries
7420 Mould Drying Stoves
7430 Annealing and Hardening Furnaces
7440 Induction Hardening and Heating
Equipment
7450 Core Drying Stoves
7452 Microwave Drying Stoves and
Chambers
7455 Solution Annealing Furnaces
7460 Ladle Dryers
7470 Sand Dryers
7480 Inert Gas Plants
7490 Annealing Furnaces
7500 Drying Stoves and Chambers
7510 Quenching and Tempering Furnaces
7520 Heat Treating Furnaces
7525 Hearth Bogie Type Furnaces
17.02. Components, Accessories,
Operating Materials
7550 Multi-purpose Gas Burners
7560 Heating Equipment, in general
7564 Special Torches
7580 Firing Plants
7590 Gas Torches
7600 Gas Heatings
7610 Capacitors
7616 Furnace Optimization
7620 Oil Burners
7630 Recuperative Burners
7640 Oxygen Burners
7650 Heat Recovery Plants
18 Plant, Transport, Stock, and Handling
Engineering
7654 Lifting Trucks
7656 Transport, Stock, and
Handling Technology
18.01. Continuous Conveyors and
Accessories
7660 Belt Conveyors
7670 Bucket Elevators
7676 Flexible Tubes with Ceramic Wear
Protection
7680 Conveyors, in general
7690 Conveyors, Fully Automatic
7710 Conveyor Belts
7720 Conveyor Belt Ploughss
7730 Conveyor Belt Idlers
7740 Conveyor Chutes
7750 Conveying Tubes
7760 Belt Guides
7780 Overhead Rails
7790 Hot Material Conveyors
7810 Chain Conveyors
7820 Chain Adjusters
7850 Conveyors, Pneumatic
7860 Roller Beds, Roller Conveyor
Tables, Roller Tables
7870 Sand Conveyors
7890 Bulk Material Conveyors
7900 Swing Conveyor Chutes
7910 Elevators
7920 Chip Dryers
7950 Idlers and Guide Rollers
7960 Transport Equipment, in general
7970 Conveyor Screws
7980 Vibratory Motors
7981 Vibration Conveyors
18.02. Cranes, Hoists, and
Accessories
8000 Grippers
8010 Lifting Tables and Platforms
8020 Jacks and Tilters
8030 Operating Platforms, Hydraulic
8032 Hydraulic and Electric Lifting
Trucks
8040 Cranes, in general
8050 Lifting Magnets
8060 Lifting Magnet Equipment
18.03. Vehicles and Transport Containers
8080 Container Parking Systems
8090 Fork Lift Trucks, in general
8100 Fork Lift Trucks for Fluid Transports
8110 Equipment for Melt Transport
18.04. Bunkers, Siloes and
Accessories
8140 Linings
8145 Big-bag Removal Systems
8150 Hopper Discharger and
Discharge Chutes
8160 Hoppers
8170 Conveyor Hoses
8190 Silos
8200 Silo Discharge Equipment
8210 Silo Over-charging Safety Devices
8218 Wearing Protection
8220 Vibrators
18.05. Weighing Systems and Installations
8230 Charging and Charge
Make-up Scales
8240 Metering Scales
8250 Monorail Scales
8260 Crane Weighers
8280 Computerized Prescuption Plants
8290 Scales, in general
18.07. Handling Technology
8320 Manipulators
8340 Industrial Robots
8350 Industrial Robots, Resistant to Rough
8364 Chipping Plants with Robots
18.08. Fluid Mechanics
8365 Pumps
8367 Compressors
18.09. Storage Systems, Marshalling
8368 Marking and Identification
18.10. Components
8374 Marking and Identification
19 Pattern- and Diemaking
19.01. Engines for Patternmaking
and Permanent Mold
8380 Band Sawing Machines for
Patternmaking
8400 CAD/CAM/CAE Systems
8410 CAD Constructions
8420 CAD Standard Element Software
8423 CNC Milling Machines
8425 Automatic CNC Post-Treatment
Milling Machines
8430 CNC Programming Systems
8440 CNC, Copying, Portal and Gantry
Milling Machines
8470 Dosing Equipment and Suction
Casting Machines for the Manufacture
of Prototypes
8480 Electrochemical Discharge Plants
8490 Spark Erosion Plants
8500 Spark Erosion Requirements
8510 Development and Production of
Lost-Foam Machines
8520 Milling Machines for Lost-Foam
Patterns
8522 Hard Metal Alloy Milling Pins
8525 Lost-Foam Glueing Equipment
8527 Patternmaking Machines
8576 Rapid Prototyping
8610 Wax Injection Machines
19.02. Materials, Standard Elements
and Tools for Pattern- and
Diemaking
8630 Thermosetting Plastics for Patternmaking
8650 Toolmaking Accessories
8660 Milling Cutters for Lost-Foam
Patterns
8670 Free-hand Milling Pins made of
Hard Metal Alloys and High-speed
Steels
8675 Hard Metal Alloy Milling Pins
8680 Adhesives for Fabrication
72

8690 Synthetic Resins for Patternmaking
8700 Plastic Plates Foundry and Patternmaking
8705 Lost-Foam Tools and
Patterns
8710 Patternmaking Requirements, in
general
8720 Patternmaking Materials, in general
8730 Pattern Letters, Signs, Type Faces
8740 Pattern Dowels (metallic)
8750 Pattern Resins
8760 Pattern Resin Fillers
8770 Pattern Plaster
8780 Pattern Gillet
8790 Lumber for Patterns
8800 Pattern Varnish
8810 Pattern-Plate Pins
8820 Pattern Spaddles
8830 Standard Elements for Tools and
Dies
8840 Precision-shaping Silicone
8846 Rapid Tooling
19.03. Pattern Appliances
8880 CNC Polystyrol
Patternmaking
8890 Development and Manufacture of
Lost-Foam Patterns
8900 Moulding Equipment
8910 Wood Patterns
8930 Core Box Equipment for Series
Production
8940 Resin Patterns
8960 Metal Patterns
8970 Pattern Equipment, in general
8980 Pattern Plates
8985 Pattern Shop for Lost-Foam
Processes
9000 Stereolithography Patterns
9010 Evaporative Patterns for the Lost-
Foam Process
19.04. Rapid Prototyping
9021 Design
9022 Engineering
9023 Hardware and Software
9024 Complete Investment Casting
Equipment for Rapid
Prototyping
9025 Pattern and Prototype
Making
9026 Rapid Prototyping for the Manufacture
of Investment Casting
Patterns
9027 Integrable Prototypes
9028 Tools
9029 Tooling Machines
20 Control Systems and Automation
20.01. Control and Adjustment Systems
9030 Automation and Control for Sand
Preparation
9040 Automation
9042 Software for Production Planning
and Control
9050 Electric and Electronic Control
9080 Equipment for the Inspection of
Mass Production
9090 Load Check Systems for Recording
and Monitoring Energy Costs
9120 Control Systems and
Automation, in general
9130 Control Systems, in general
9160 Switch and Control Systems
20.02. Measuring and Control
Instruments
9165 Automatic Pouring
9166 Compensation Leads
9185 Contactless Temperature Measurement,
Heat Image Cameras
9190 Leakage Testing and Volume
Measuring Instruments
9210 Flow Meters
9220 Flow control Instruments
9230 Immersion Thermo Couples
9240 Moisture Controller
9250 Level Indicator
9280 Bar Strein Gauge
9301 In-Stream Inoculation Checkers
9302 In-Stream Inoculant Feeder
9306 Calibration and Repair Services
9310 Laser Measurement Techniques
9320 Multi-coordinate Measuring
Machine
9330 Measuring and Controlling Appliances,
in general
9335 Measuring and Controlling Appliances
for Fully Automatic Pouring
9345 Positioning Control
9350 Pyrometers
9370 Radiation Pyrometers
9375 Measuring Systems for Nuclear
Radiation (receiving inspection)
9376 Measuring Systems for Radioactivity,
Incoming Goods‘ Inspection
9380 Temperature Measurement
9382 Temperature Control Units
9385 Molten Metal Level Control
9390 Temperature Measuring and
Control Devices
9391 Thermoregulator
9395 Molten Metal Level Control
9400 Thermal Analysis Equipment
9410 Thermo Couples
9420 Protection Tubes for Thermocouples
9425 In-stream Inoculant Checkers
9430 Heat Measuring Devices
9433 Resistance Thermometers
20.03. Data Acquisition and
Processing
9438 Automation of Production- and
Warehouse-Systems
9440 Data Logging and Communication
9445 Business Intelligence
9450 Data Processing/Software Development
9456 ERP/PPS - Software for Foundries
9470 EDP/IP Information and Data
Processing
9480 Machine Data Logging
9484 Machine Identification
9490 Data Logging Systems
9500 Numerical Solidification Analysis
and Process Simulation
9502 Numerical Solidification Simulation
and Process Optimization
9504 ERP - Software for Foundries
9506 Process Optimization with EDP, Information
Processing for Foundries
9510 Computer Programmes for Foundries
9520 Computer Programmes and Software
for Foundries
9522 Simulation Software
9523 Software for Foundries
9525 Software for Coordinate
Measuring Techniques
9527 Software for Spectographic Analyses
9530 Statistical Process Control
9540 Fault Indicating Systems,
Registration and Documentation
20.04. Process Monitoring
9541 High Speed Video
21 Testing of Materials
21.01. Testing of Materials and
Workpieces
9548 Calibration of Material Testing
Machines
9550 Aluminium Melt Testing
Instruments
9554 Acoustic Materials Testing
9555 Acoustic Construction
Element Testing
9560 CAQ Computer-Aided Quality
Assurance
9564 Image Documentation
9580 Chemical Analyses
9585 Computerized Tomography, CT
9586 Core Gas - System for Measurement
and Condensation
9587 Die Cast Control
9589 Natural Frequency Measuring
9590 Endoscopes
9600 Dye Penetrants
9610 Instruments for
Non-destructive Testing
9620 Hardness Testers
9630 Inside Pressure Testing Facilities
for Pipes and Fittings
9645 Calibration of Material Testing
Machines
9650 Low-temperature Source of
Lighting Current
9670 Arc-baffler
9678 Magna Flux Test Agents
9680 Magnetic Crack Detection Equipment
9690 Material Testing Machines and
Devices
9695 Metallographic and Chemical
Analysis
9696 Microscopic Image Analysis
9697 Surface Analysis
9700 Surface Testing Devices
9710 Testing Institutes
9719 X-ray Film Viewing Equipment and
Densitometers
9720 X-Ray Films
CASTING PLANT & TECHNOLOGY 2–3/2020 73

9730 X-Ray Testing Equipment
9740 Spectroscopy
9750 Ultrasonic Testing Equipment
9755 Vacuum Density Testing Equipment
9758 UV-Lamps
9759 UV Shiners
9760 Ultraviolet Crack Detection Plants
9765 Hydrogen Determination Equipment
9770 Material Testing Equipment, in
general
9780 Testing of Materials
9800 Inside Pressure Measuring for
Tools
9836 Devices for Testing of Materials,
non-destructive, in general
9838 NDT Non-destructive Testing of
Materials
9840 NDT X-ray Non-destructive Testing
of Materials
9850 Tensile Testing Machines
22 Analysis Technique and Laboratory Equipment
10000 Sample Preparation Machines
10010 Quantometers
10018 X-Ray Analysis Devices
10020 Spectographic Analysis Devices
10022 Certified Reference Materials for
Spectrochemical and -scopic
Analysis
10040 Cut-off Machines for Metallography
9860 Analyses
9865 Image Analysis
9880 Gas Analysis Appliances
9890 Carbon and Sulphur
Determination Equipment
9900 Laboratory Automation
9910 Laboratory Equipment, Devices,
and Requirements, in general
9920 Laboratory Kilns
9930 Metallographic Laboratory
Equipment
9940 Microscopes
9948 Optical Emission Spectrometers
9950 Microscopic
Low-temperature Illumination
9955 Continuous Hydrogen Measurement
9960 Polishing Machines for Metallography
9970 Sampling Systems
9980 Sample Transport
23 Air Technique and Equipment
23.01. Compressed Air Technique
10050 Compressed Air Plants
10060 Compressed Air Fittings
10070 Compressed Air Tools
10080 Compressors
10100 Compressor Oils
23.02. Fans and Blowers
10120 Fans, in general
23.03. Ventilators
10150 Axial Ventilators
10160 Hot-gas Circulating Ventilators
10170 Radial Ventilators
10180 Ventilators, in general
23.04. Other Air Technique
Equipments
10188 Waste Gas Cleaning
10190 Exhausting Plants
10192 Exhaust Air Cleaning for Cold-Box
Core Shooters
10220 Air-engineering Plants, in general
24 Environmental Protection and Disposal
10230 Environmental Protection and
Disposal
10231 Measures to Optimize Energy
10232 Fume Desulphurization for Boiler
and Sintering Plants
10235 Radiation Protection Equipment
24.01. Dust Cleaning Plants
10240 Extraction Hoods
10258 Pneumatic Industrial Vacuum
Cleaners
10260 Pneumatic Vacuum Cleaners
10270 Equipment for Air Pollution Control
10280 Dust Cleaning Plants, in general
10290 Gas Cleaning Plants
10300 Hot-gas Dry Dust Removal
10309 Industrial Vacuum Cleaners
10310 Industrial Vacuum Cleaners
10320 Leakage Indication Systems for
Filter Plants
10340 Multicyclone Plants
10350 Wet Separators
10360 Wet Dust Removal Plants
10370 Wet Cleaners
10380 Cartridge Filters
10400 Pneumatic Filter Dust Conveyors
by Pressure Vessels
10410 Punctiform Exhausting Plants
10420 Dust Separators
10430 Vacuum Cleaning Plants
10440 Dry Dust Removal Plants
10450 Multi-Cell Separators
10458 Central Vacuum Cleaning Plants
10460 Cyclones
24.02. Filters
10470 Compressed Air Filters
10490 Dedusting Filters
10500 Filters, in general
10510 Filter Gravel
10520 Filter Materials
10530 Filter Bags/Hoses
10550 Fabric Filters
10560 Air Filters
10570 Cartridge Filters
10580 Hose Filters
10585 Electro-Filters
10590 Air Filters
10610 Fabric Filters
24.03. Waste Disposal,
Repreparation, and Utilization
10618 Waste Air Cleaning
10620 Waste Water Analyzers
10630 Waste Water Cleaning and -Plants
10640 Clean-up of Contaminated Site
10646 Used Sands, Analysing of Soils
10650 Waste Sand Reutilization and
Reconditioning
10655 Amine Recycling
10660 Foundry Debris-conditioning Plants
10680 Soil Clean-up
10690 Briquetting Presses
10695 Briquetting of Foundry
Wastes/Filter Dusts
10700 Disposal of Foundry Wastes
10702 Hazardous Waste Disposal
10705 Bleeding Plants
10710 Reconditioning of Foundry Wastes
10720 Ground Water Cleaning
10740 Dross Recovery Plants
10760 Cooling Towers
10770 Cooling Water Processing Plants
10780 Cooling Water Treatment
10810 Post-combustion Plants
10830 Recooling Systems
10840 Recycling of Investment Casting
Waxes
10850 Slag Reconditioning
10870 Waste Water Cooling Towers
10880 Scrap Preparation
10890 Transport and Logistic for Industrial
Wastes
10900 Rentilization of Foundry Wastes
10910 Rentilization of Furnace Dusts and
Sludges
10920 Roll Scale De-oilers
10940 Rentilization of Slide Grinding
Sludges
25 Accident Prevention and Ergonomics
10960 Health and Safety Protection
Products
10970 Asbestos Replacements
10990 Ventilators
10993 Fire Protection Blankets and
Curtains made of Fabrics
10996 Fire-extinguishing Blankets and
Containers
11020 Heat Protection
11025 Heat-Protection Clothes and Gloves
11030 Climatic Measurement Equipment
for Workplace Valuation
11040 Protection against Noise
11050 Light Barriers
11060 Sound-protected Cabins
11070 Sound-protected Equipment and
Parting Walls
11080 Vibration Protection
26 Other Products for Casting Industry
26.01. Plants, Components, and
Materials
11100 Concreting Plants
11102 Devellopping and Optimizing of
Casting Components
11118 Vibration Technology
26.02. Industrial Commodities
11120 Joints, Asbestos-free
74

11125 Sealing and Insulating
Products up to 1260 °C
11130 Dowels
11150 Foundry Materials, in general
11155 Heat-protecting and Insulating
Fabrics up to 1260 °C
11160 Hydraulic Oil, Flame-resistant
11165 Marking and Identification
11170 Signs for Machines
11175 Fire-proof Protection Blankets,
-mats, and -curtains
11180 Screen and Filter Fabrics
26.04. Job Coremaking
11182 Inorganic Processes
11183 Hot Processes
11184 Cold Processes
27 Consulting and Service
11186 Ordered Research
11190 CAD Services
11200 Interpreters
11202 Diecasting, Optimization of Mould
Temperature Control
11205 EDP Consulting
11208 Wage Models
11210 Emission, Immission, and Workplace
Measurements
11211 E-Business
11212 eProcurement
11213 Technical Literature
11215 Investment Casting Engineering
11220 Foundry Consulting
11230 Foundry Legal Advice
11240 Lean Foundry Organization
11250 Foundry Planning
11252 Greenfield Planning
11253 Casting, Construction and Consulting,
Optimizing of Mould Core
Production and Casting Techniques
11260 Nuclear Engineering Consulting
11278 Customer Service for Temperature
Control Units and Systems
11280 Customer Service for
Diecasting Machines
11283 Jobbing Foundry
11286 Efficiency of Material
(Consulting)
11290 Management of Approval
Procedures
11291 Management Consulting
11292 Machining
11293 Metallurgical Consulting
11294 Patinating
11295 Human Resources Services
11296 Personnel Consulting
11298 Process Optimization
11299 Testing Status and Safety Labels
11300 Rationalization
11301 M&A Consulting
11303 Recruitment
11305 Centrifugal Casting Engineering
11310 Simulation Services
11320 Castings Machining
11325 Steel Melting Consulting
11330 Technical Translation and Documentation
11336 Environmental Protection Management
Systems (Environmental
Audits)
11339 Restructuring
11340 Environmental Consulting
11342 Business Consultancy
11343 Leasing of Industrial Vacuum
Cleaners
11345 Heat Treatment
11346 Associations
11360 Material Consulting
11370 Material Advices
11380 Time Studies
11382 Carving
28 Castings
11387 Aluminium Casting
11389 ADI
11390 Aluminium Pressure Diecasting
11400 Aluminium Permanent Moulding
(Gravity Diecasting)
11410 Aluminium Sand Casting
11420 Billet Casting
11430 Cast Carbon Steel, Alloy and
High-alloy Cast Steel
11440 Non-ferrous Metal Gravity Diecasting
11450 Pressure Diecasting
11460 High-grade Investment Cast Steel
11462 High-grade Steel Casting
11470 High-grade Steel Castings
11472 High-grade Centrifugal Cast Steel
11480 Ingot Casting
11485 Castings
11489 Rolled Wire
11490 Grey Cast Iron
11492 Large-size Grey Iron Castings
11496 Direct Chill Casting
11498 Art Casting
11499 Light Metal Casting
11501 Magnesium Pressure
Diecasting
11510 Brass Pressure Diecasting
11520 Non-ferrous Metal Sand Casting
11525 Prototype Casting
11530 Sand Casting SAND CASTING
11539 Centrifugal Casting
11540 Spheroidal Iron
11547 Spheroidal Graphite Cast Iron
11550 Steel Castings
11552 Continuously Cast Material
11553 Thixoforming
11555 Full Mold (lost-foam) Casting
11558 Rolls
11560 Zinc Pressure Diecasting
11570 Cylinder Pipes and Cylinder Liners
29 By-Products
11580 Sporting Field Sands
30 Data Processing Technology
11700 Mold Filling and Solidification
Simulation
11800 Simulation Programmes for
Foundry Processes
11820 Software for Foundries
31 Foundries
11850 Foundries, in general
31.01. Iron, Steel, and Malleable-Iron
Foundries
11855 Iron Foudries
11856 Steel Foundries
11857 Malleable-Iron Foundries
31.02. NFM Foundries
11860 Heavy Metals Foundries
11861 Die Casting Plants
11862 Light Metal Casting Plants
11863 Permanent Mold Foundry
31 Additive manufacturing / 3-D printing
CASTING PLANT & TECHNOLOGY 2–3/2020 75

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76

INTERNATIONAL FAIRS AND CONGRESSES
Fairs and Congresses
64th IFC Portoroz 2020
September, 16-18, 2020, Portoroz, Slovenia
www.drustvo-livarjev.si
Thermprocess China
September, 23-26, 2020, Shanghai, China
www.tubechina.net/en/exhibition/tpchina
Metal Expo 2020
October, 14-16, 2020, Kielce, Poland
www.targikielce.pl/en/metal
Formnext 2020 (Additive Manufacturing)
November, 10-13, 2020, Frankfurt/Main, Germany
https://formnext.mesago.com/frankfurt/en.html
Ankiros 2020
November, 12-14, 2020, Istanbul, Turkey
www.ankiros.com/home-en
Alucast 2020
December, 3-5, 2020, Chennai, India
www.alucastexpo.com/home
Advertisers‘ Index
AGTOS Gesellschaft für technische Oberflächensysteme
mbH, Emsdetten/Germany 53
Bühler AG, Uzwil/Switzerland 17
ConviTec GmbH, Offenbach/Germany 35
Hannover Messe Ankiros Fuarcilik A.S.,
Ankara, Cankaya/Turkey 21
Heinrich Wagner Sinto Maschinenfabrik GmbH,
Bad Laasphe/Germany 9
Hüttenes-Albertus Chemische Werke GmbH,
Düsseldorf/GermanyBC
KLEIN Anlagenbau AG,
Freudenberg/Germany47
Lucky -Winsun Enterprise Ltd.,
Taichung/Taiwan33
Maschinenfabrik Gustav Eirich GmbH & Co KG
Hardheim/Germany45
O.M.LER Srl, Bra (CN)/Italy 57
Rudolf Uhlen GmbH, Haan/Germany 53
YXLON International GmbH,
Hamburg/GermanyIFC
CASTING PLANT & TECHNOLOGY 2–3/2020 77

PREVIEW/IMPRINT
Modern design: extensive IT solutions
and simulations of the
casting process are used in prototype
construction in particular.
Photo: ACTech
Preview of the next issue
Selection of topics:
M. Vogt: The start-up has grown up
What is business success? For example, when a start-up celebrates its 25th birthday. The medium-sized company ACTech from
Freiberg in Saxony celebrated this occasion in early summer. The secret of success: “Rapid prototyping”, based on additive
manu facturing processes. A company history.
C. Schmees: Pendulum - the creation of a work of art.
The cast sculpture “Pendulum”, made by the stainless steel foundry Schmees in Pirna, has been inviting art enthusiasts to linger
in front of the European Medicines Agency in Amsterdam since March 2020. The casters of Schmees in Pirna have set themselves
a monument with the sculpture. A photo report.
I. Meling et al.: Standard AlSi7Mg foundry alloys with reduced Mg content
The new European standard for aluminium alloys includes an alloy variant with only 0.10-0.25 wt% Mg. Lowering Mg contents
could be industrially beneficial for high ductility alloy parts, as strength requirements are met more easily. A research investigation.
Imprint
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78