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EDITORIAL<br />
Successful casting with<br />
a technological edge!<br />
How do the sector’s top companies position themselves technologically?<br />
What do they invest their money in? One can approach<br />
these questions with examples of best practice – and this issue again<br />
provides insights into the works halls of many successful companies.<br />
Robert Piterek<br />
e-mail: robert.piterek@bdguss.de<br />
Investing money to save money. This is<br />
what happens in the modern foundry<br />
industry of the 21st century. Information<br />
is essential in order to find out<br />
which technologies are worth investing<br />
in – technologies that increase productivity,<br />
efficiency, plant service lives, or the<br />
measurement accuracy of quality inspections,<br />
for example. In this double issue,<br />
CP+T’s editorial staff has again sought<br />
out practical advantages for foundries<br />
worldwide. A double issue because, as<br />
in so many sectors, lockdown and<br />
reduced business activities due to the<br />
coronavirus crisis have not left magazines<br />
such as CP+T and its big sister<br />
GIESSEREI unscathed. This issue covers a<br />
wide range of current examples of best<br />
practice in the most important foundry<br />
functions – such as the melting shop,<br />
mold and core production, as well as<br />
digitalization and simulation – showing<br />
how this old technology, and frequently<br />
its new developments, constantly innovate<br />
and improve, even 5,000 years after<br />
casting was first employed.<br />
In addition to many articles by respected<br />
foundry experts on these and<br />
other topic areas, you will also find a<br />
company report on the Grunewald prototype<br />
foundry in this issue. Grunewald<br />
(located in the west of Germany near<br />
the Dutch border) has experienced a<br />
surprising growth in foundry business<br />
by offering 3-D-printed molds and cores<br />
(more on this from P. 10).<br />
ACS technology (presented at the<br />
Molding Forum in Munich in February,<br />
just before the outbreak of the Covid-<br />
19 pandemic in Germany), with which<br />
the inorganic core can be electrically<br />
hardened, is also very interesting. The<br />
developers of this technology claim that<br />
it is possible to reduce energy costs and<br />
cycle times by 30 percent (from P. 36).<br />
The interview with the head of the<br />
Slovenian Foundry Association, whose<br />
60th <strong>International</strong> Foundry Conference<br />
(IFC) is to take place this year, is an<br />
attempt to wrest back from the pandemic<br />
a moment of personal contact after<br />
the long months without any appointments.<br />
CP+T will also be present. Read<br />
about what can be expected in Portoroz<br />
on Slovenia’s Adriatic coast from P. 6.<br />
Have a good read!<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 3
CONTENTS<br />
FEATURES<br />
6 INTERVIEW<br />
„Our event is an opportunity to meet<br />
in person again!“<br />
Mirjam Jan-Blazic, head of the Slovenian Foundy<br />
Society, hosts the 60. <strong>International</strong> Foundry Congress,<br />
one of few foundry events currently not taking place<br />
online but in real life. Interview by Robert Piterek<br />
10 COMPANY<br />
New perspectives through 3-D printing<br />
At Grunewald in Bocholt, there has been a surprising<br />
growth in foundry business thanks to the new<br />
3-D printer for molds and cores, Robert Piterek<br />
14 FETTLING & FINISHING<br />
Optimizing abrasive precision<br />
Blasting machine maufacturer AGTOS refurbished<br />
an Italian blasting machine at Stadler Stahlguss in<br />
Switzerland, Ulf Kapitza<br />
INTERVIEW<br />
How can a real life<br />
event look like in<br />
corona times? Those<br />
and other questions<br />
were posed in this<br />
issue‘s interview<br />
COMPANY<br />
Automation is a top<br />
priority at Grunewald<br />
in Bocholt. Now a<br />
3-D-Printer was<br />
installed.<br />
18 MELTING SHOP<br />
Upgrading shaft melting furnaces<br />
Shaft melting furnaces are economical and offer<br />
high metal quality in aluminium foundries. Automation,<br />
smart design details and digital innovations<br />
can enhance these furnaces, Rudolf Hillen<br />
New perspectives for steel casting<br />
Low-pressure pouring offers advantages in comparison<br />
with gravity pouring, Markus Hagedorn et al.<br />
MOLD AND<br />
COREMAKING<br />
Elektrical curing of<br />
inorganic sand cores<br />
using the ACS technology.<br />
Cover-Photo:<br />
In the next issue in December, a photo report about the<br />
creation of the cast sculpture „Pendulum“ is published.<br />
It reveals insights into the professional work of the art<br />
casters of Schmees Cast in Pirna. Our current title page<br />
shows them in front of the impressive piece of art.<br />
4
CONTENTS<br />
FETT LING &<br />
FINISHING<br />
Optimizing abrasive<br />
precision.<br />
Reducing downtime with prefabricated<br />
furnace linings<br />
High-quality insulating materials in the lining<br />
process save energy and lower CO 2<br />
emissions<br />
Dirk Schmeisser et al.<br />
30 MOLD AND COREMAKING<br />
Transferring green sand molding‘s<br />
advantages to aluminium casting<br />
“Efficient, high quality and inexpensive: The green<br />
sand process offers these advantages not only<br />
for iron but also for aluminum casting, Per Larsen<br />
Elektrical curing of inorganic sand cores<br />
using the ACS technology<br />
With the newly developed ACS technology inorganic<br />
sand binders heat additionally directly caused by<br />
current flow, Gotthard Wolf et al.<br />
42 DIGITALIZATION<br />
Hybrid Internet of Things service solutions<br />
for the foundry industry<br />
To optimize foundry processes ABP Induction has<br />
launched a promising web-based customer portal.<br />
Moritz Spichartz et al.<br />
46 SAND REGENERATION<br />
Changing mixing tools quick and easy<br />
A new system for changing rotor beaters in mixers<br />
shortens service and standstill times, Philipp Krötz<br />
48 PRESSURE DIE CASTING<br />
Gap monitoring in die casting machines<br />
Machines equipped with inductive sensors enable<br />
manufacturers to reduce costs, Stefan Stelzl<br />
QUALITY<br />
ASSURANCE<br />
Inspections of castings<br />
with Cameras<br />
and Artificial Intelligence<br />
could become<br />
standard in future.<br />
50 QUALITY ASSURANCE<br />
Assuring quality with Cameras and AI<br />
A Berlin-based start-up developed a promising<br />
inspection method, which could become standard<br />
in smart factories, Damian Heimel<br />
COLUMNS<br />
3 EDITORIAL<br />
53 NEWS IN BRIEF<br />
60 SUPPLIERS GUIDE<br />
77 FAIRS AND KONGRESSES/AD INDEX<br />
78 PREVIEW/IMPRINT<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 5
INTERVIEW<br />
6
“In my opinion the conference and foundry<br />
exhibition in Portoroz is one of the bestknown<br />
foundry events in Europe.“<br />
Sculpture in front of one of the conference rooms. Despite<br />
the pandemic, the international foundry conference<br />
(IFC) in Portoroz will take place as planned this year.<br />
“Our event is an opportunity<br />
to meet in person again!”<br />
Mirjam Jan-Blazic, head of the Slovenian Foundry Society, has a Master of Science from the<br />
Faculty of Technology and Metallurgy of the University in Belgrade and long years of professional<br />
experience as laboratory manager of a die-casting foundry. She is almost the only<br />
organizer to host an important foundry event in <strong>2020</strong>: the IFC, which has been going for 60<br />
years, and takes place in Portoroz from 16–18 September <strong>2020</strong>. She spoke to CP+T about<br />
the history of the conference, the upcoming event, as well as Covid-19 and its aftermath.<br />
Photos: Slowenian Foundry Society<br />
Mrs. Jan-Blazic, the <strong>International</strong><br />
Foundry Conference in Slovenia is 60<br />
years old now. How was it originally<br />
launched?<br />
The Slovenian Foundrymen Society,<br />
founded in 1953, together with the<br />
Faculty of Natural Sciences and<br />
Engineering of the University of Ljubljana,<br />
60 years ago started to organize<br />
a foundry conference every year. In<br />
Portoroz the conference was held for<br />
the first time in 1963. The first conferences<br />
were attended mainly by lecturers<br />
from the common state of Yugoslavia<br />
and lecturers from foundry<br />
societies and associations, universities,<br />
and institutes. From the very beginning<br />
participants from abroad attended the<br />
conference. Representatives of the<br />
German Foundry Association (VDG),<br />
Austrian Foundry Institute (ÖGI), and<br />
soon after also experts from Switzerland,<br />
Czechoslovakia and Poland were<br />
among the first.<br />
The conference in Portoroz was also<br />
an opportunity for us to show our<br />
achievements to the world. From its<br />
initiation, the Slovenian Foundrymen’s<br />
Society has provided support regarding<br />
local development, production of our<br />
foundry machines, equipment, auxiliary<br />
foundry materials and raw materials.<br />
This strategy is still successful and<br />
our foundries can obtain a lot of<br />
important high-quality materials and<br />
equipment from Slovenian producers.<br />
60 years is a long time. What have been<br />
the biggest highlights?<br />
The Slovenian Foundrymen’s Society has<br />
always had very ambitious goals, for<br />
example to decrease the technological<br />
gap and to prevent Slovenia from falling<br />
behind developed industrial countries.<br />
So it became apparent that the decision<br />
to organize an annual international<br />
foundry conference was useful not only<br />
for Slovenian foundries, but also for the<br />
other participating foreign countries.<br />
That’s how the foundry conference<br />
grew into a foundry event where we<br />
exchanged scientific and technological<br />
achievements. These possibilities were<br />
enhanced even more after 1970, when<br />
we added the accompanying foundry<br />
exhibition to the Conference.<br />
Our foundry magazine LIVARSKI<br />
VESTNIK, which has been published for<br />
67 years now, plays an important role in<br />
this history. We mainly print scientific<br />
and technical articles from the Conference<br />
in Portoroz. We have been publishing<br />
articles bilingually – in Slovenian<br />
and English – since 2001.<br />
Over the decades, the Conference in<br />
Portoroz has become a traditional meeting<br />
place attended by representatives<br />
from many national foundry societies<br />
and associations as well as from the<br />
World Foundry Organization (WFO), the<br />
European Foundry Association (CAEF),<br />
and the Central European Foundry Initiative<br />
(MEGI).<br />
Entrusting university staff with leadership<br />
of the preparation of the pro-<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 7
INTERVIEW<br />
gram and organization of the Conference<br />
in Portoroz was an important<br />
decision. Then in 2005 it was time for a<br />
change: The University remained responsible<br />
for the program part of the<br />
Conference while a new organizational<br />
symbiosis involving the Society, industry,<br />
and the universities of Ljubljana and<br />
Maribor brought about a new quality<br />
of development of both the Society itself<br />
and the Conference.<br />
How was it possible to hold international<br />
conferences on foundry technology<br />
back in the Cold War era?<br />
This is a question involving world politics,<br />
which I have always been interested<br />
in. I understand the long period of<br />
the Cold War with détente from 1960<br />
to 1980 as a conflict between western<br />
forces led by the USA and eastern forces<br />
headed by the Soviet Union. Because<br />
Yugoslavia, of which Slovenia was a<br />
part, was unaffected by the conflict<br />
because it did not take sides thanks to<br />
decisions made by President J. B. Tito.<br />
Yugoslavia was a very open country at<br />
that time – foreigners could visit and its<br />
citizens could travel abroad. Yugoslavian<br />
passports were the most expensive<br />
on the black market then because they<br />
permitted free access to many countries.<br />
I have not read or heard about any<br />
difficulties organizing the conference in<br />
Portoroz during the Cold War, which<br />
ended with the disintegration of Yugoslavia<br />
and the Soviet Union. The final<br />
foundry conference of the former Yugoslavia<br />
took place in Portoroz in October<br />
1990, two months before the plebiscite<br />
for an independent Slovenia, and the<br />
32nd conference took place in Portoroz<br />
in May 1991, a month before the declaration<br />
of an independent Slovenia.<br />
How significant do you think this event<br />
is for Europe?<br />
In my opinion the conference and<br />
foundry exhibition in Portoroz is one of<br />
The conference center where the <strong>International</strong><br />
Foundry Conference (IFC) will take<br />
place (16-18 September) is in the Slovenian<br />
city of Portoroz at the Adriatic Sea.<br />
the best-known foundry events in<br />
Europe, thanks to its yearly achievements,<br />
scientific contributions and its<br />
current size. And it is certainly the leading<br />
conference in this part of Europe.<br />
That the conference grew to become a<br />
respected international conference of<br />
high quality is demonstrated by the fact<br />
that the World Foundry Organization<br />
entrusted the organization of its WFO<br />
Technical Forum to the Slovenian<br />
Foundrymen’s Society in 2019. It took<br />
place together with the 59th IFC Portoroz<br />
2019. This was the largest foundry<br />
event ever in Portoroz. There were 400<br />
participants and more than 100 speakers<br />
from all around the world. Participation<br />
in the foundry exhibition also<br />
achieved a record high.<br />
Let’s talk about the IFC’s homeland.<br />
What are the cornerstones of the Slovenian<br />
foundry industry?<br />
The foundry sector is an important part<br />
of Slovenia’s industry. Slovenia’s foundry<br />
production in tonnes per resident is<br />
among the world’s highest, based on<br />
statistical information on worldwide<br />
foundry production. We have about 70<br />
foundries with approximately 5,000<br />
employees. Medium and large foundries<br />
produce approximately 90% of all<br />
foundry earnings. Interestingly, all<br />
foundry technologies are represented in<br />
our foundries, which is unusual for<br />
smaller countries. Despite the obvious<br />
signs of a recession during the second<br />
half of last year, the 2019 financial year<br />
was still relatively good for most Slovenian<br />
foundries. The official statistics<br />
show that foundry production in 2019<br />
was 195,609 tonnes of castings, which is<br />
only 1% less than in 2018. Compared to<br />
2018, casting types were as follows:<br />
58,281 tonnes of grey iron (7% less),<br />
43,867 tonnes of ductile iron (the same<br />
as in 2018), 3,200 tonnes of malleable<br />
iron (3% more), 25,099 tonnes of steel,<br />
Fe-granulate (10% less), 54,625 tonnes<br />
of aluminum alloys (5% more), 9,665<br />
tonnes of zinc alloys (14% more) and<br />
872 tonnes of copper alloys (15%<br />
more).<br />
Like everywhere in the world, Slovenia<br />
and its foundry industry has been<br />
affected by the coronavirus pandemic.<br />
How have the foundries in your country<br />
been influenced and what is the<br />
current situation?<br />
The Slovenian government has so far<br />
introduced four packages of measures<br />
to help alleviate the negative effects of<br />
the COVID-19 pandemic on the economy<br />
and population. The first package<br />
of measures from March is aimed at<br />
providing security for the whole population<br />
and especially the economy, with<br />
an emphasis on preserving workplaces.<br />
The second package ensures liquidity<br />
for companies and provides a scheme to<br />
enable new bank loans. The third<br />
package introduced short-time work<br />
and extended the country’s subsidies for<br />
workers who have been temporary laid<br />
off.<br />
We believe that despite the hard<br />
times that COVID-19 brought to our<br />
economy and population, Slovenia has<br />
dealt with it relatively well, taking<br />
many safety measures. Our main goal<br />
was to preserve production and workplaces.<br />
I think that this goal has been<br />
quite well fulfilled.<br />
The conference is planned to take place<br />
from 16 - 18 September <strong>2020</strong>. What can<br />
participants expect?<br />
The regular Conference program includes<br />
34 presentations. Ten plenary lectures<br />
are planned on the first day of the<br />
Conference. 24 lectures will take place<br />
on the second day – 12 each on ferrous<br />
and non-ferrous casting. There will also<br />
be the traditional accompanying<br />
8
foundry exhibition with around 40 exhibitors. With the new conditions<br />
caused by the COVID-19 pandemic we will do everything<br />
necessary to maintain our good reputation as organizers and<br />
good hosts of this traditional foundry event in Portoroz. We will<br />
do our best to ensure appropriate participant safety at the congress<br />
square and hotels. Detailed instructions for a safe stay will<br />
be sent to all participants a week before the official start of the<br />
Conference.<br />
How many participants are expected to take part in the event?<br />
We will certainly have lower participation than in previous years<br />
(around 150 - 200 participants each year) because of the pandemic.<br />
Applications are still coming in and we will be accepting<br />
them until the start of the Conference. A circle of passive participants<br />
will probably decide about coming to Portoroz at the last<br />
minute, depending on conditions in their and other countries,<br />
especially Slovenia. At the moment, citizens from countries that<br />
are on the so-called ‘green list’ can come to Slovenia without<br />
limitations. These are countries that are successfully controlling<br />
the pandemic. Citizens from countries that are on the so-called<br />
“yellow list” can come to Slovenia under certain conditions (with<br />
a negative test for COVID-19 virus).<br />
The number of lectures registered will enable 100 % filling<br />
the usual regular conference program. Based on the number of<br />
participants already registered for the exhibition, it looks like we<br />
will also reach the same number of participants as in the past<br />
years.<br />
Will there be a celebration at the IFC for the 60th jubilee?<br />
For everyone – us, as organizers, and the participants – this meeting<br />
will be a big celebration if we manage to execute it with<br />
the planned conference program and exhibition under these<br />
completely new conditions. It will be a special celebration<br />
because it will provide an opportunity to meet in person again<br />
after one year. After the lockdowns and restrictions that we<br />
have experienced, we all miss our social contacts – absent since<br />
the beginning of the crisis due to the cancellation of most<br />
foundry events.<br />
Our traditional welcome and an ‘acquaintance meeting’ with<br />
the Mayor of the Piran municipality will be organized at the<br />
Georgios Centre’s garden next to the monastery church in Piran.<br />
And the Foundrymen’s Night will take place on the coast across<br />
from the Slovenija congress center with pleasant live music. We<br />
have had to cancel the dinner and the boat ride at the Slovenian<br />
seaside because of the safety measures. But we are sure that we<br />
will also have a great time this year!<br />
MECHANICAL RECLAMATION<br />
USR II<br />
FOR GREEN SAND AND<br />
GREEN SAND-CORE SAND-MIX<br />
YOUR ADVANTAGES:<br />
• High efficiency<br />
• Long service life thanks to ceramic components<br />
• Easy maintenance<br />
• Compact design<br />
• Conservation of resources<br />
Before reclamation<br />
After reclamation<br />
New!<br />
What do you think are the prospects for the foundry industry in<br />
the face of the pandemic – focusing on Slovenian and international<br />
foundries?<br />
In my opinion, foundries here and abroad face a lot of challenges<br />
and difficult changes. One of these is definitely finding a quicker<br />
route to a green future or “green economy” and concern<br />
for sustainable development. In the future, foundries will not<br />
only have to ensure economic growth and profits, but also have<br />
to decrease all emissions for the essential mitigation of climate<br />
change. In this respect, I consider the pandemic to be a warning.<br />
I believe that we need faster restructuring of the automotive<br />
industry, together with their supplier foundries, towards electrical<br />
and hybrid vehicles.<br />
In any case, I am sure foundries will remain an important and<br />
irreplaceable part of industry as a whole and will continue to<br />
secure the survival and development of all other industries.<br />
www.drustvo-livarjev.si<br />
PERFECTION IN EVERY<br />
SINGLE MOULD.<br />
www.sinto.com<br />
HEINRICH WAGNER SINTO<br />
Maschinenfabrik GmbH<br />
SINTOKOGIO GROUP<br />
Bahnhofstr.101 · 57334 Bad Laasphe, Germany<br />
Phone +49 2752 / 907 0 · Fax +49 2752 / 907 280<br />
www.wagner-sinto.de<br />
HWS Anz 85x260 USR-II GB_2019_RZ_neu.indd 1 20.02.<strong>2020</strong> 10:10:38<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 9
New perspectives<br />
through 3-D printing<br />
Michael Klein-Hitpass using a 3-D<br />
printer. The molds and cores are<br />
slotted into the job box like in the<br />
classic computer game Tetris<br />
The prototype foundry Grunewald in Bocholt, Germany, invested in a 3-D sand printer<br />
at the end of 2018. After more than a year, the payoff has been substantial. There is<br />
high demand from customers – and casting has also become the largest sales driver in<br />
the company group.<br />
By Robert Piterek, Düsseldorf<br />
Photos: Andreas Bednareck<br />
Michael Klein-Hitpass is standing<br />
at the screen of an ExOne 3-D<br />
sand printer, Type S-Max Plus,<br />
measuring about two by three meters<br />
in size. He’s currently generating a construction<br />
for four sand molds and a<br />
series of cores. On the screen, it looks a<br />
bit like he’s playing a round of the classic<br />
computer game Tetris. The individual<br />
molds and cores are slotted in above<br />
and next to each other. The only thing<br />
missing to recreate the feel of the game<br />
is for the completed rows to light up<br />
and then disappear with a bit of electronic<br />
music.<br />
Once the box is full, printing begins.<br />
The printer head slides from one side to<br />
the other until the initial contours of<br />
the printed parts start to take shape,<br />
including the openings that risers will<br />
later be fitted into. Right now, molds<br />
are being created for structural elements<br />
as well as cores for an integral<br />
subframe that will be used by a British<br />
automobile manufacturer in a prototype<br />
vehicle.<br />
Utilization significantly higher<br />
than expected<br />
The spacious – about 60 square meters<br />
– and extremely clean room where<br />
everything takes place houses the printer<br />
as well as a table for unpacking<br />
and an optical measuring system.<br />
Though the large viewing window of<br />
the printing room, one can see into<br />
the oven that is used to harden the<br />
molds and cores. Between the hoses<br />
and pipes, there’s also a yellow<br />
movable crane on the ceiling used to<br />
10
COMPANY<br />
Foundry head Harald<br />
Dieckhues (left) and<br />
managing director<br />
Ulrich Grunewald.<br />
The growth thanks<br />
to 3-D sand printing<br />
was a pleasant surprise<br />
for both.<br />
The contours of the<br />
molds and cores are<br />
starting to take shape<br />
in the 3-D printer.<br />
transport the large molds. The cost of<br />
the printer, peripherals, and other systems:<br />
EUR 1.3 million.<br />
Klein-Hitpass is tall and lanky. With<br />
his glasses, it’s easy to believe that he<br />
has a passion for IT-based casting applications.<br />
His career, however, initially led<br />
him to become a classical caster.<br />
An apprenticeship in model building<br />
at Grunewald, a degree in foundry<br />
engineering in Duisburg. Working on<br />
his thesis brought him back to the company<br />
in Bocholt where he had completed<br />
his apprenticeship. “I never would<br />
have thought that the 3-D printer<br />
would be so well utilized,” he says. And<br />
his bosses, Ulrich Grunewald, managing<br />
director of the corporate group, and<br />
foundry head Harald Dieckhues,<br />
couldn’t agree more.<br />
Prototype components for<br />
electric vehicles<br />
After the system was installed at the<br />
end of 2018, the job boxes tended to be<br />
only half-filled. Since spring of last year,<br />
though, the machine has been running<br />
almost around the clock. While uncertainty<br />
in the automobile industry is currently<br />
putting the brakes on business<br />
for suppliers for conventional vehicles,<br />
Grunewald is benefiting from the possibilities<br />
in freedom of design and lightweight<br />
construction offered by<br />
3-D-printed molds and cores. And these<br />
characteristics are in particularly high<br />
demand from electric vehicle manufacturers,<br />
which will account for an<br />
ever-increasing share of vehicles in the<br />
coming years. The team in Bocholt is<br />
currently manufacturing structural components,<br />
drive technology, chassis and<br />
engine parts as well as battery trays for<br />
the automobile manufacturers’ prototype<br />
vehicles – more and more often<br />
with 3-D-printed sand parts, poured off<br />
with aluminum. Grunewald manufactures<br />
parts for vehicles that are still being<br />
Printed molds are hardening. The parts<br />
customers are asking for are getting<br />
bigger and bigger.<br />
tested and will be qualified for market<br />
launch in preproduction tests, for<br />
example in test drives in the harsh Swedish<br />
winter.<br />
3-D sand printing drives<br />
casting production<br />
Over a year after installation, any anxiety<br />
about the risk of the investment has<br />
definitely transitioned to happiness<br />
about the good development. Just how<br />
good the development has been was<br />
evident in the sales at the foundry in<br />
downtown Bocholt that was opened in<br />
2013. While its share of total sales for<br />
the company was at around 50 percent<br />
before the printer was purchased, it is<br />
now at 75 percent, thus offsetting the<br />
decrease in other areas at Grunewald,<br />
such as tool manufacture, which largely<br />
depends on conventional automobile<br />
construction.<br />
Klein-Hitpass demonstrates the ease of<br />
desanding the cores after printing. This is<br />
made possible by the use of phenol cold<br />
resin binder.<br />
The design freedom is one of the<br />
main benefits of 3-D printing. There are<br />
cores and molds that can only be created<br />
through additive manufacturing<br />
due to their complexity. If they can still<br />
be cast, the current technological limits<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 11
COMPANY<br />
The printing room from behind. There’s a refrigerator for chemicals as well as a large sand<br />
silo for automatically filling the ExOne 3-D printer.<br />
of casting technology have been reached.<br />
In addition, there’s the speed of<br />
the printer. “Depending on the part, its<br />
complexity, and the workload, we are<br />
at least four to six weeks faster than<br />
conventional casting manufacturing,”<br />
Ulrich Grunewald states as the main<br />
reason for the acquisition of the hightech<br />
machine. A job box with 1,260<br />
liters of foundry sand (2.14 metric tons)<br />
is completed in 24 hours.<br />
More options for customers<br />
and designers<br />
Time was also an argument for the<br />
customer, for whom the largest “series”<br />
ever at Grunewald will soon be produced:<br />
A total of 1,500 chassis parts,<br />
GRUNEWALD GMBH UND CO. KG<br />
Founded: 1963 as Felix Grunewald Modellbau<br />
Management: Ulrich and Philipp Grunewald (third generation)<br />
Employees: 200 in total. 52 in the foundry, ten in mechanical processing, an<br />
additional 113 in Bocholt and 25 in Irxleben.<br />
Sales: EUR 23 million<br />
Annual production volume: 11,000 cast parts<br />
Materials: aluminum and iron (less than five percent)<br />
Casting processes: gravity and low-pressure sand casting<br />
Lot sizes: from individual construction to small patches (usually 150–300<br />
pieces)<br />
Economic environment: Bocholt was formerly a location for the textile and<br />
dye industry.<br />
Customers: automobile and semiconductor industry, energy and drive technology.<br />
Number of robots: Four in the foundry, one at another location<br />
Mold and core production using:<br />
> Semi-automatic mold system<br />
> Sand mold mill<br />
> 3-D sand printing<br />
Breaking strength of printed molds and cores:<br />
> After hardening: 100 N/cm2<br />
> After firing in the oven at 160°C: 250–600 N/cm 2<br />
Storage period of molds and cores at 10 ° C: six months<br />
Product portfolio: Structural components for automobiles, such as doors, AC<br />
columns, crossbars, struts, chassis parts, drive technology, engine parts, parts<br />
for the electric and IT industry as well as battery trays.<br />
made entirely using printed sand parts.<br />
The customer had the option whether<br />
they wanted to invest in a die casting<br />
mold for the manufacturing or to have<br />
the components manufactured using<br />
printed molds that were manufactured<br />
using sand casting processes in part. The<br />
latter was cheaper and was therefore<br />
chosen. Those who aren’t in such a rush<br />
and don’t need very complex parts can<br />
still order cast parts that are manufactured<br />
using pattern equipment or<br />
sand-milled molds and cores. Any combination<br />
of printed sand parts with<br />
molds and cores manufactured using<br />
pattern equipment is also possible. New<br />
manufacturing options that customers<br />
readily embrace.<br />
The printer thus combines a whole<br />
slew of additional benefits at Grunewald,<br />
which hadn’t even been considered<br />
before the acquisition. “With the<br />
printer, we are now also seen as a technology<br />
company,” Grunewald and<br />
Dieckhues have also observed. The technological<br />
leap thanks to 3-D printers<br />
thus helps the image of modern foundries.<br />
The way of thinking is also changing:<br />
“Our designers are now thinking<br />
completely differently because there is<br />
also the option to print molds and cores<br />
instead of just manufacturing them in<br />
our semiautomatic mold system,” Grunewald<br />
concludes. Then an additional core<br />
might be printed, too, if there’s still<br />
room in the job box – freedoms that one<br />
doesn’t have when printed sand parts<br />
have to be bought in at high prices.<br />
A delicate process that comes<br />
with quirks<br />
In the printer room, the discussion has<br />
now progressed to the costs of 3-D printing.<br />
“Compared to a shot core, a printed<br />
core is still very expensive,”<br />
Dieckhues states. The commonly held<br />
opinion that this is due to the high costs<br />
of electricity is not accurate according to<br />
the foundry head, who completed his<br />
training as a master foundryman at the<br />
Wilhelm-Maybach-Schule in Stuttgart.<br />
Energy comes in third, behind maintenance<br />
and chemistry – meaning binders<br />
and sand. “It’s a delicate process,<br />
not to be compared with the robust<br />
foundry systems that we use otherwise,”<br />
Grunewald describes. Printer heads can<br />
become clogged and replacing them<br />
could cost five-figure sums, which makes<br />
maintenance expensive and tricky as a<br />
result. Benefiting from the advantages<br />
of the system also requires well-trained<br />
workers, as the process is complex and<br />
the list of potential problems is long.<br />
12
In fact, the Grunewald company has<br />
been experimenting for over 25 years<br />
with the technology that has been<br />
known as rapid prototyping since the<br />
mid-nineties. Sand sintering promised<br />
more than it could deliver back in the<br />
day: the parts were either too soft or<br />
too hard, which meant they couldn’t be<br />
used. Klein-Hitpass was interested in<br />
the technology already back then. Since<br />
then, he has also had a colleague at his<br />
side who originally trained in model<br />
making at Grunewald and also has<br />
many years of experience with 3-D printing.<br />
The knowledge of these two<br />
experts is now really paying off in using<br />
today’s machines.<br />
The binder means less work later<br />
Looking through the printer’s viewing<br />
window, an additional layer is added<br />
about every half a minute and glued<br />
with the sand using phenol cold resin<br />
binder made by ASK Chemicals from<br />
Hilden, Germany. The benefit of this<br />
binder, compared to the commonly<br />
used furan resin, is the reduced need<br />
for subsequent work – the leftover sand<br />
can just be shaken off, whereas with<br />
furan resin it could still stick to the sand<br />
parts. Klein-Hitpass demonstrates this<br />
with one of the cores that is on a pallet<br />
along the wall of the printer room. At<br />
first glance, cleaning the hardened sand<br />
parts is literally child’s play. The parts<br />
are cleaned after printing using a sand<br />
vacuum; next up are the process steps<br />
Ulrich Grunewald in front of a mold for<br />
an aluminum mold tool with integrated<br />
cooling for automobile floor carpets. Tool<br />
manufacture is the second pillar of the<br />
Grunewald corporate group<br />
of<br />
smoothing and casting.<br />
Whether the future of Grunewald<br />
looks like that of the Japanese company<br />
Kimura, where the foundry is filled<br />
around the clock with cores and molds<br />
from about ten 3-D printers and not a<br />
single piece of pattern equipment is in<br />
use, remains to be seen. “At the<br />
moment, we need both – pattern<br />
equipment and the printer,” Grunewald<br />
admits. Instead of the initial problem<br />
that the machine was too productive to<br />
utilize its full capacity, now its capacity<br />
is almost not enough and the 24 hours<br />
of production are too short. “Who<br />
knows how it will be in two years,” Grunewald<br />
said, replying to the question<br />
whether the company is considering the<br />
acquisition of a second printer. Now<br />
that the process is understood, the<br />
foundry is looking to qualify two additional<br />
machine operators in the short or<br />
The semi-automatic mold system with an<br />
automated coating station in front. In the<br />
background on the left is the smelting<br />
operation, with two low-pressure sand<br />
casting ovens with approximately 300<br />
kilograms capacity each.<br />
long term to ease the load on Klein-Hitpass<br />
and his colleague.<br />
Will the 3-D sand printer soon<br />
be indispensable?<br />
How great the potential of 3-D printing<br />
is for the casting industry is evident at<br />
the meeting of the additive manufacturing<br />
work group at the seat of the German<br />
Foundry Association in Düsseldorf<br />
at the end of January: A representative<br />
from BMW had joined, who reported<br />
that 3-D printed cores were already in<br />
use in serial manufacturing in Landshut.<br />
“Increasing the temperatures in the<br />
engine requires cast parts whose complex<br />
geometries are only possible with<br />
printed cores,” Grunewald cites as the<br />
reason the automobile manufacturer is<br />
now embracing the use of 3-D printing.<br />
Time will tell whether this strategic alignment<br />
in core manufacturing will<br />
remain an isolated case or will become<br />
the norm one day.<br />
At Grunewald, it is certainly clear<br />
one year after introducing the 3-D printer<br />
that it has paid off. Strategy for the<br />
future: continue automating to give the<br />
employees the freedom they need to do<br />
their specialist work and also generate<br />
sufficient sales to be covered in tougher<br />
times as well. A plan that suits a medium-sized<br />
company like Grunewald with<br />
its 200 employees well and is aimed at<br />
long-term and sustainable continuance.<br />
www.grunewald.de<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 13
FETTLING & FINISHING<br />
14
„With 30 per cent of the costs of a new<br />
investment, we now have a machine<br />
that satisfies our purposes and delivers<br />
no significant production downtime.“<br />
After modernization, the workpieces are blasted<br />
in less than half the time.<br />
Optimizing abrasive precision<br />
and performance ...<br />
… of an overhead conveyor blasting machine in a Swiss steel foundry.<br />
Ulf Kapitza, Emsdetten<br />
Photos: Agtos<br />
With around 100 employees,<br />
Stadler Stahlguss belongs to<br />
Swiss Stadler Rail, one of the<br />
leading rail vehicle suppliers in Europe.<br />
The foundry, based in Biel, generates<br />
annual sales between 24 and 28 million<br />
Swiss Francs, mainly made up by orders<br />
of the Stadler Group, says Michael<br />
Schmitz, CEO of Stadler Stahlguss.<br />
Other customers come from mechanical<br />
and plant engineering for the plastics<br />
and food industries, from automotive<br />
engineering, energy mechanical<br />
engineering and petrochemicals. The<br />
framework conditions in Switzerland, a<br />
high-wage country, are not easy. Only<br />
two steel foundries are operating in the<br />
country. “We have a unique selling<br />
point in terms of component size and<br />
tonnage,” says Schmitz.<br />
Stadler Stahlguss is internationally<br />
known for high delivery performance,<br />
demanding cast parts and high quality.<br />
All components are treated with blasting<br />
machine. They have unit weights of<br />
3 kg to 10 t.<br />
Blasting machine manufacturer<br />
AGTOS refurbished an Italian blasting<br />
machine lately at Stadler Stahlguss.<br />
AGTOS was founded in 2001 in Emsdetten<br />
and is a 160 employees company<br />
headquartered in Germany with a production<br />
facility in Polish Konin, near<br />
Poznan. In addition to new shot blasting<br />
machines, AGTOS also offers the<br />
View of the overhead conveyor blasting machine modernized by AGTOS.<br />
modernization of existin blasting<br />
machines.<br />
“The surfaces of the castings were<br />
not 100 per cent clean, the scale layers<br />
were too firm. This has resulted in high<br />
costs for manual regrinding,” Stadler<br />
Group CEO Schmitz looks back. In addition,<br />
there were long blasting times:<br />
“30 minutes were standard, up to 60<br />
minutes for exotic parts,” he says. 12<br />
minutes with shiny metallic surfaces are<br />
performed today.<br />
Before modification, AGTOS checked<br />
the blasting machine and discussed<br />
the project with Stadler Stahlguss.<br />
„A first attempt with an AGTOS competitor<br />
did not work at all,“ reports<br />
Schmitz. AGTOS-Turbines deliver the<br />
best results as precision of the abrasive<br />
is optimized through the discharge<br />
angle who defines how the abrasive<br />
hits the workpiece surface. For modification,<br />
AGTOS did not only supplied<br />
new high-performance turbines inclu-<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 15
FETTLING & FINISHING<br />
The new AGTOS high-performance turbines<br />
on the modernized overhead conveyor<br />
blasting machine.<br />
ding an adapter frame. Abrasive feed<br />
and engines were replaced as well. In<br />
total, the modification only took three<br />
days - practically plug and play, whereby<br />
Stadler had already dismantled<br />
the old turbines.<br />
New turbines increases blasting<br />
machine performance<br />
Four turbines type TA 4.6 were installed.<br />
The centrifugal wheel has a diameter<br />
of 420 mm, explains Mario Hintzen,<br />
Technical Manager Service at AGTOS.<br />
“The engine output was constant at<br />
18.5 kW. As a result, we didn‘t have to<br />
change much of the electrical system,<br />
except replacing the live circuit breakers,”<br />
he says. Nevertheless, the performance<br />
was increased by approx. 30 to<br />
35 per cent with the new turbines. A<br />
new guide sleeve with a smaller but<br />
wider window in combination with four<br />
merged turbines creates a hotspot with<br />
significantly higher blasting intensity.<br />
The discharge speed increases due to<br />
the larger centrifugal wheels. Hintzen<br />
noticed that blasting concentration thereby<br />
significantly reduced blasting time.<br />
„The basic substance of the blasting<br />
machine was still well much preserved,<br />
so this modification was justified,“ he<br />
continues. On the one hand due to the<br />
fact that large blasting chambers are<br />
generally not subject to as much wear<br />
as small ones, on the other hand due to<br />
the good maintenance status of the<br />
machine. „We chose AGTOS because<br />
the overall package was right and the<br />
project could be realized in a short time<br />
of six weeks from order to assembly<br />
date. That would not have been possible<br />
with the original manufacturer,”<br />
says Schmitz.<br />
Stadler Stahlguss didn’t buy a new<br />
machine because of a lack of space in<br />
the halls. An interruption of operations<br />
- except at scheduled times - was not<br />
possible. „With 30 per cent of the costs<br />
of a new investment, we now have a<br />
machine that satisfies our purposes and<br />
delivers no significant production<br />
downtime“, he sums up.<br />
Ulf Kapitza, Head of Sales + Marketing,<br />
AGTOS Gesellschaft für technische<br />
Oberflächensysteme mbH, Emsdetten,<br />
Germany<br />
www.agtos.de<br />
16
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MELTING SHOP<br />
Automation, smart design details and new digital innovations enhance the efficiency of a melting furnace type already known for its efficiency.<br />
Upgrading shaft melting furnaces<br />
Options for even more efficient melting<br />
by Rudolf Hillen; Gummersbach<br />
Photos: strikowestofen<br />
A<br />
good melt, efficiently produced,<br />
is the starting point for<br />
any successful die casting process.<br />
In modern aluminium foundries,<br />
shaft melting furnaces set the standard<br />
both in terms of economy and metal<br />
quality. Automation, smart design<br />
details and new digital innovations can<br />
enhance the efficiency of this type of<br />
melting furnace even further. There is<br />
great potential, for example, in improving<br />
efficiency under partial load – an<br />
operating condition just as common in<br />
the reality of everyday foundry life as<br />
permanent full-capacity utilization.<br />
Energy savings of up to 20% are possible.<br />
The shaft furnace principle enables<br />
the energy-saving and resource-efficient<br />
melting of most aluminium alloys.<br />
To fully exploit this efficiency potential,<br />
the furnace design, furnace equipment<br />
and furnace control system must adapt<br />
to the specific conditions of the production<br />
process. Numerous options for<br />
shaft melting furnaces have been<br />
developed for this purpose over the last<br />
few years. The common options, their<br />
fields of application and advantages<br />
will be examined here – using the StrikoMelter<br />
shaft furnace as an example.<br />
The advantages of these options are<br />
available both for new equipment and<br />
for retrofitting existing equipment.<br />
Figure 1: Functional principle of the<br />
shaft furnace.<br />
18
The operating principle of shaft<br />
melting furnaces is simple yet clever.<br />
The core of the system is the shaft,<br />
which is fed with cold material from<br />
above (Figure 1). The melting bridge is<br />
located at the bottom of the shaft. This<br />
preheats the aluminium on its way<br />
down using the heat rising in the shaft,<br />
so that the aluminium only remains in<br />
the high-temperature range for a relatively<br />
short time during melting. The<br />
molten metal flows from the melting<br />
bridge directly into a trough-shaped<br />
holding chamber where it is kept at the<br />
selected holding temperature. Preheating,<br />
heating and melting are combined<br />
in a way that is advantageous in<br />
terms of energy flow – ensuring both<br />
economic efficiency and high metal<br />
quality.<br />
The melting furnace can be equipped<br />
or retrofitted with special components<br />
to increase efficiency even<br />
further. Digital add-ons are also available<br />
for process optimization. Some of<br />
these measures and options will be discussed<br />
below, before looking in detail<br />
at the improvement of part load efficiency<br />
specifically.<br />
Step by step towards the most<br />
efficient melting furnace<br />
Today, there are over 1500 StrikoMelters<br />
in use around the world. Considerable<br />
development work over the years<br />
has gone into continuously improving<br />
the energy efficiency and productivity<br />
of this well-known shaft melting furnace.<br />
This includes optimization of core<br />
components of the furnace, its automation<br />
systems and process control.<br />
First of all, there are design options<br />
for the melt shaft: increasing the shaft<br />
height and using a shaft cover or hot<br />
gas baffle can measurably improve both<br />
energy efficiency and productivity of<br />
the furnace.<br />
A higher shaft almost doubles the<br />
shaft volume in comparison with the<br />
standard version, meaning bulky<br />
returns can be fed in as a whole. More<br />
intensive preheating of the feed material<br />
ensures 10% higher energy efficiency.<br />
A standard shaft cover keeps the<br />
heat in the shaft and prevents cooling.<br />
This reduces energy consumption<br />
during holding, accelerates the start of<br />
the melting process and protects the<br />
refractory lining.<br />
The hot gas baffle is a special cover<br />
plate for the melting shaft. It reduces<br />
energy consumption during both holding<br />
and the free-melting process – by<br />
up to 15% (Figure 2). This means that<br />
the free-melting process can be shortened<br />
by 10 to 20 minutes per shift; the<br />
melting capacity of the furnace is<br />
increased by up to 4 %.<br />
A shaft laser continuously monitors<br />
the fill level in the melting shaft and<br />
automatically triggers the feed process<br />
when there is no further load in the filling<br />
area (Figure 3). This optimized loading<br />
with fill level control reduces<br />
energy consumption by 4% and improves<br />
the melting performance of the furnace.<br />
The shaft laser is a necessary prerequisite<br />
for automated closure of the<br />
shaft cover.<br />
The automation of the feeding process<br />
can be taken even further with a<br />
roller conveyor system. This system<br />
organises full and empty loading containers<br />
so that the loading system can be<br />
loaded with several batches in a single<br />
Figure 2: Using a hot gas baffle can<br />
improve both the energy efficiency and<br />
the productivity of the furnace.<br />
operation. This optimizes the loading<br />
process time. The loading time no longer<br />
depends on the availability of personnel;<br />
delays due to staffing bottlenecks<br />
are eliminated. Loading takes less<br />
time overall.<br />
Another laser, the bath level laser,<br />
measures the fill level of the melt in the<br />
holding bath. This means that the cleaning<br />
door does not have to be opened<br />
to check the fill level, saving both time<br />
and energy.<br />
Data from the bath level laser also<br />
plays an important role in Part Load<br />
Efficiency Control, which can result in<br />
even more savings – in terms of time,<br />
money and energy. More on that<br />
below.<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 19
MELTING SHOP<br />
Figure 3: A shaft laser continuously scans the filling area in the melting shaft.<br />
4 can be used to determine how full the<br />
bath should be at the start of the melting-free<br />
process. The furnace control<br />
system then controls the melting process<br />
according to Feature 1 in such a<br />
way that the bath will have reached<br />
approximately the desired filling level<br />
at the time specified for the melting-free<br />
process. Feature 4 is intended<br />
to ensure that there is always enough<br />
metal available during the melting process.<br />
Taken together, this bundle of features<br />
optimises the melting phases to<br />
minimise energy consumption – no matter<br />
how the shift is going. The lower<br />
the furnace load, the greater the<br />
energy savings compared to operation<br />
without Part Load Efficiency Control. At<br />
the same time, the automation level of<br />
the furnace is increased, which increases<br />
overall work and process efficiency.<br />
Anybody can work at full throttle:<br />
the art of partial load efficiency<br />
At driving school, we learn that ‚anticipatory<br />
driving‘ saves fuel. Why?<br />
Because dynamic adaptation to the current<br />
traffic situation avoids both full<br />
braking and full throttle, so the car can<br />
stay in its most energy-efficient operating<br />
state. Now – thanks to Part Load<br />
Efficiency Control – melting furnaces<br />
too can be operated by ‚anticipatory<br />
driving‘, thereby significantly increasing<br />
their efficiency.<br />
Aluminium melting furnaces, like<br />
most other production facilities, operate<br />
most efficiently at full load. However,<br />
permanent full load quite often<br />
does not correspond to the reality of<br />
everyday foundry operations. Production<br />
plans change or the casting capacities<br />
needed to receive the melt produced<br />
are simply not available.<br />
However, the more irregular the melting<br />
process, the higher the energy<br />
consumption per tonne of melt.<br />
In order to address this shortcoming,<br />
the conventional furnace control system<br />
can now be extended with a new<br />
development that considerably increases<br />
efficiency during partial load operation.<br />
This Part Load Efficiency Control<br />
can achieve energy savings of up to<br />
20%, depending on the frequency of<br />
partial load operation.<br />
What exactly is Part Load Efficiency<br />
Control? It is a software package, implemented<br />
in the furnace control system,<br />
that largely automates the control of<br />
the melting phases during a shift.<br />
The software offers four different<br />
features that can be enabled or disabled<br />
individually on the HMI panel or the<br />
switch cabinet of the StrikoMelter:<br />
> Feature 1 – Control of the melting<br />
process<br />
> Feature 2 – Closure of the shaft<br />
cover in holding mode<br />
> Feature 3 – Automatic starting of<br />
the free-melting process<br />
> Feature 4 – Defined bath level at the<br />
start of melting free<br />
The features are mostly independent of<br />
one other. Selecting all or only some of<br />
the features allows the foundry to optimise<br />
its operation. To benefit fully from<br />
some of these features, the use of a<br />
bath level laser is recommended.<br />
The control of the melting process<br />
(Feature 1) forms the core of Part Load<br />
Efficiency Control and means automatic<br />
control of the furnace „melting“ and<br />
„holding“ operating modes in daily<br />
melting operation. The operating<br />
modes are controlled in a way that<br />
ensures the bath level – the available<br />
melt quantity in the holding chamber<br />
– only ever fluctuates between its maximum<br />
(full bath) and a custom-adjustable<br />
minimum level. Controlling long<br />
periods of melting – and consequently<br />
long periods of holding – increases the<br />
efficiency of the melting process considerably<br />
and reduces specific energy<br />
consumption [kWh/t].<br />
Feature 2 automatically closes the<br />
shaft cover during holding periods. The<br />
prerequisite for this is the presence of a<br />
shaft laser to determine the shaft fill<br />
level. Feature 3 can be used to define<br />
times at which the melting-free process<br />
should be started automatically. Feature<br />
Should you upgrade to Part Load<br />
Efficiency Control?<br />
For new systems, Part Load Efficiency<br />
Control is directly available as an option<br />
and is usually linked to the bath level<br />
laser. However, Part Load Efficiency<br />
Control can also be retrofitted on older<br />
systems, that is, on existing StrikoMelter<br />
furnaces.<br />
Even if no bath level laser is available,<br />
Part Load Efficiency Control can still<br />
be used. The bath level of the Striko-<br />
Melter is simply calculated, for example<br />
by weighing the furnace or using a sensor<br />
system at the point of metal removal;<br />
in tilting furnaces, where the metal<br />
is removed by tilting the furnace, this<br />
sensor system is always present.<br />
Summary: there’s always room<br />
for greater efficiency<br />
The options and features presented for<br />
the StrikoMelter shaft melting furnace<br />
show that furnace technology is constantly<br />
evolving. Even in a melting furnace<br />
known for its impressive efficiency,<br />
there can still be potential for energy<br />
and cost savings. For foundries that<br />
want to continuously reduce their<br />
energy consumption during melting,<br />
retrofittable furnace technology is available<br />
that automates the melting process<br />
and harmonises it with upstream<br />
and downstream processes. The result:<br />
significant savings and better use of<br />
valuable personnel.<br />
Rudolf Hillen, product developer and<br />
StrikoMelter expert at StrikoWestofen,<br />
Gummersbach, Germany<br />
www.strikowestofen.de<br />
20
OCN-25 furnace system from ABP Induction.<br />
New perspectives for steel<br />
by low-pressure pouring<br />
Gravity pouring is still the dominant process for the production of cast steel materials.<br />
The principle is simple and has remained basically unchanged for several centuries.<br />
However: To comply with filigree and complex component geometries as well as increasing<br />
quality demands, the process-related limitations lead to significant challenges for<br />
foundry staff and foundry engineers. Consequently, achieving the target geometry<br />
is only possible by using large quantities of liquid material with, in some cases, simultaneously<br />
high rejection rates. A consequent alternative is low-pressure pouring.<br />
Markus Hagedorn, Marco Rische and Yilmaz Yildir, Dortmund<br />
Photos and Graphics: ABP<br />
Low-pressure pouring of aluminum<br />
components is state-of-the-art,<br />
with a recycling material content of<br />
less than 20 percent of the weight of<br />
the component, compared with 100<br />
percent for gravity pouring [1]. The<br />
capacities saved in the area of melting<br />
result in valuable savings and additional<br />
sales potential for the foundries.<br />
Cast steel as a material in lightweight<br />
mold construction<br />
Given the intensified focus on lightweight<br />
construction in the automotive<br />
sector, it is also interesting to look at<br />
thin-walled cast steel as a material:<br />
Although composite materials such as<br />
CFRP (Carbon fiber reinforced polymer)<br />
and lightweight materials such as aluminum<br />
or magnesium have outstanding<br />
lightweight construction potential, both<br />
materials also have numerous drawbacks<br />
in comparison with steel. For one<br />
thing, the primary material is significantly<br />
more expensive and the joining<br />
technology to adjacent components is<br />
more complex. In the case of construction<br />
material mixes, this requires additi-<br />
22
MELTING SHOP<br />
Figure 1: Stylized illustration of the savings of recycling material for thin-walled components.<br />
Table 1: Comparison of process parameters between gravity and low-pressure pouring.<br />
Points Gravity pouring Low-pressure pour<br />
Output 20 % - 50 % Increased by a factor of 1.5 -2<br />
Share of rejects Up to 25 % depending Reduced by a factor of 5-10 %<br />
(depending on geometry) on geometry through laminar and<br />
reproducible mold filling<br />
Form layout (with several A continuous casting cluster Separated parts<br />
components per mold) → Separation necessary → No separation necessary<br />
Rework Large feeder and gating systems Smaller systems Final dimension sewing<br />
Filter Required Not required<br />
Melting furnace temperature 1700 – 1750 °C approx. 1640 °C<br />
→ higher energy consumption<br />
→ lower energy consumption<br />
→ short durability of the<br />
→ longer durability of<br />
refractory lining<br />
the refractory material<br />
Reproducibility/ repeatability - No controlled flow rate - Controlled low- turbulence pressure curve<br />
- Temperature fluctuations during - Temperature control possible<br />
des Prozesses during the process<br />
Wall thickness Thin wall thicknesses cannot be < 2 mm and
MELTING SHOP<br />
considerable benefits in operation. Besides<br />
the high buffering capacity, the<br />
possibility of depositing residual slag in<br />
the furnace vessel and slag-free pouring<br />
without the risk of freezing have also<br />
proved successful in practical applications.<br />
Furthermore, the crucible inductor<br />
allows the OCN furnace system to be<br />
completely emptied quickly, e.g. for an<br />
alloy change. Last but not least, the furnace<br />
has a modular design so that the<br />
individual elements can be replaced<br />
easily and quickly at the end of their<br />
respective refractory life and the system<br />
is highly available.<br />
Figure 2: Illustration of the modular OCN system for highest system availability.<br />
first time not only to simulate the<br />
technical and economic advantages of<br />
the process.<br />
The environmental factor also plays<br />
a major role: Minimizing of circulation<br />
and scrap material reduce the energy<br />
required per kilogram of good castings<br />
by up to 50 percent. Finally, lower<br />
quantities of liquid material and lower<br />
pouring temperatures mean that less<br />
molding material is required, which is<br />
also a major driver of energy consumption<br />
and costs. „Feedback from our<br />
customers shows that the advantages<br />
mentioned substantially increase the<br />
cost-effectiveness of the process in comparison<br />
to gravity pouring,“ explains Dr.<br />
Marco Rische, CTO at ABP Induction. In<br />
low pressure pouring, the core process<br />
is encapsulated, thus minimizing problems<br />
with sparking, splashing and emissions<br />
for employees during the pouring<br />
process. In terms of environmental and<br />
sustainability aspects, thin-walled production<br />
directly addresses high-strength<br />
lightweight construction, which helps<br />
to reduce fuel and energy consumption<br />
during operation. In terms of production,<br />
the possible wall thickness reduction<br />
in the design process further<br />
reduces energy and material requirements.<br />
In comparison to competitor<br />
processes, this makes it possible to<br />
dispense with mixed construction variants<br />
or composite materials involving<br />
costly recycling processes. As you can<br />
see, it is ultimately also about the interaction<br />
of these operational and<br />
environmental requirements with quality<br />
and cost factors of mass production<br />
as well as design aspects.<br />
The OCN furnace system from<br />
ABP Induction<br />
„The OCN furnace system was developed<br />
on the basis of the established ABP pouring<br />
furnaces in order to enable the<br />
low-pressure pouring process to be used<br />
in cast steel,“ explains ABP CTO Dr.<br />
Marco Rische. This is the only system for<br />
low-pressure pouring of steel castings to<br />
date that has proven itself in industrial<br />
practice after extensive preliminary tests<br />
[5,6]. Depending on the design, it offers<br />
a useful capacity of 1,000 to 10,000 kilograms.<br />
The furnace system with modern<br />
IGBT converter technology is designed<br />
for steel, iron and non-ferrous castings.<br />
The pouring of bronze and copper components<br />
is also possible with the mentioned<br />
benefits.<br />
Components with a thickness of up<br />
to 0.8 millimeters have been realized by<br />
low-pressure pouring. The average in<br />
practice has currently settled at an average<br />
of 1.5 to 2 millimeters, for components<br />
with a length of up to 1.2 meters.<br />
Thanks to the ABP pressure control, corresponding<br />
casting molds can be entirely<br />
filled within a few seconds, without<br />
the risk of imperfections or porosities if<br />
the process is properly controlled.<br />
Low-pressure pouring thus enables<br />
complex and weight-optimized geometries<br />
to an extent similar to that of precision<br />
pouring. In contrast, the significantly<br />
lower manufacturing costs of<br />
low-pressure pouring components and<br />
the possibility of producing thin-walled<br />
components in almost any size.<br />
The OCN low-pressure pouring furnace<br />
is designed according to the<br />
Teapot principle (Figure 2). This offers<br />
From practice: Initial experience<br />
In contrast to gravity pouring, the<br />
low-pressure pouring process is automated<br />
to a high extent. Mold filling is<br />
pressure-controlled and the temperature<br />
can be regulated within a minimum<br />
tolerance range. This process therefore<br />
resolves the challenge posed by<br />
unregulated temperature, because in<br />
the high temperature range there is a<br />
higher risk of gas porosity, sand inclusions,<br />
rough surfaces or even mechanical<br />
adhesion, while in the low temperature<br />
range, there is a risk of crack formation<br />
and inadequate mold filling. In the OCN<br />
system, the metal in the furnace is contained<br />
in a closed container with a protective<br />
gas atmosphere. This means that<br />
the melt absorbs less hydrogen and<br />
other impurities and the oxide formation<br />
is minimized. This is the basis for<br />
good pouring quality. In addition,<br />
materials can also be cast which could<br />
not be poured in conventional processes<br />
because of their high oxidation tendency,<br />
i.e. including copper alloys with<br />
an affinity for oxygen.<br />
The pressure curve for controlling<br />
the mold filling can be individually<br />
adapted and archived for each casting<br />
mold. The low-pressure control works<br />
with proportional technology and<br />
achieves accuracies of ±1 mbar. „The<br />
support points of the pressure curve can<br />
be adjusted in the range of tenths of a<br />
second“, says Dietmar Mitschulat, software<br />
engineer at ABP Induction responsible<br />
for programming the control of<br />
the OCN system. What he also values:<br />
„With every pouring process, there is an<br />
automatic comparison of target and<br />
actual values.“ Additional production<br />
values (furnace pressure at start, target<br />
pressure, actual pressure, argon<br />
consumption during pouring, mold contact<br />
pressure target and actual, temperature<br />
during pouring) are archived and<br />
can be used for continuous impro-<br />
24
Figure 3: Integration of the OCN system into an existing plant.<br />
vement of the pouring result. „As such,<br />
this makes it possible to sustainably<br />
reduce liquid metal content and it guarantees<br />
minimum process-related scrap<br />
rates. Moreover, the process ensures the<br />
highest possible reproducibility and<br />
automation in line with the principles<br />
of modern Industry 4.0 production“.<br />
Other empirical values from practice<br />
arise with regard to the company organization<br />
and the production process:<br />
> Pouring in short cycle times with low<br />
manpower requirements increases<br />
the productivity of the foundry,<br />
> Relief of staff: Work processes with a<br />
high level of concentration and<br />
repetitive procedures can be automated<br />
and continuously optimized,<br />
> The size of the gating and feeder<br />
system can be reduced, thus reducing<br />
the amount of circulation material,<br />
> When filling the molds, pouring<br />
underfills are avoided, which<br />
reduces the reject rate,<br />
> Turbulence-free entry of the melt<br />
into the gating system,<br />
> Complete mold filling in the shortest<br />
possible time, especially for complex<br />
and thin-walled castings,<br />
> Consistent pouring temperature.<br />
> Possibility of adapting existing production<br />
lines (Figure 3)<br />
Conclusion<br />
When comparing conventional processes<br />
based on the principle of gravity<br />
pouring on the one hand and the<br />
future-oriented low-pressure pouring<br />
process on the other, the benefits for<br />
the latter process are obvious. It shows<br />
that low-pressure pouring can be used<br />
to make steel castings fit for future<br />
requirements, also in automotive<br />
engineering and the related supply<br />
industry. This is especially relevant given<br />
the enormous market and margin pressure<br />
on the remaining components of<br />
the combustion engine. In the practice<br />
of low-pressure pouring, this means<br />
that a wide range of new opportunities<br />
are opening up for the production of<br />
steel castings. On the one hand, this is<br />
the optimization of existing component<br />
series and types for a cost and resource<br />
efficient production using the low-pressure<br />
pouring process. At the same time,<br />
there is also the opportunity to open up<br />
new markets in comparison to alternative<br />
production methods and to maintain<br />
competitive markets.<br />
This makes it possible to produce<br />
lightweight structures made of highstrength<br />
materials, especially for large<br />
series in the automotive industry, as<br />
well as thin-walled castings, which are<br />
an important prerequisite for future<br />
applications based on the changing<br />
requirements of e-mobility. Thin-walled<br />
steel castings offer the most favorable<br />
compromise between design on the one<br />
hand and component and system costs<br />
on the other. This is especially true for<br />
junctions and connecting elements of<br />
the body-in-white [7] as well as other<br />
structurally relevant parts of future<br />
e-mobility vehicles in the passenger car<br />
and commercial vehicle sector.<br />
In terms of the environment and sustainability,<br />
low-pressure pouring not<br />
only saves energy compared to conventional<br />
processes due to the smaller<br />
quantities of input material. As the CO2<br />
emissions from steel production are<br />
about six times lower than those from<br />
the manufacture of comparable aluminum<br />
products, lightweight steel casting<br />
is gaining enormously in importance,<br />
especially in times when resource<br />
and energy efficiency are of the<br />
essence. The time factor is also important:<br />
Those who act now can seize the<br />
opportunity for a unique selling proposition<br />
- and the development of new<br />
castings and markets.<br />
Markus Hagedorn, Product Manager<br />
Low-Pressure Pouring, Dr. Marco Rische,<br />
Chief Technology Officer, Yilmaz Yildir,<br />
Vice President Liquid Metals, ABP Induction<br />
Systems GmbH, Dortmund<br />
www.abpinduction.com<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 25
MELTING SHOP<br />
Photo: Foseco/Scheidtmann<br />
Lining with prefabricated Insural components increases system availability<br />
Reducing downtime with<br />
prefabricated furnace linings<br />
By using Insural pre-cast shapes for furnace relining, sintering can be dispensed with<br />
and a constant density index can be achieved. The use of high-quality insulating<br />
materials in the lining process enables significant energy savings and thus a reduction<br />
in CO 2<br />
emissions.<br />
Dirk Schmeisser, Borken<br />
The relining of a dosing furnace in<br />
aluminium foundries is always<br />
labour-intensive and particularly<br />
time-consuming. In the case of a monolithic<br />
lining, the sintering phase in particular<br />
extends the downtime of the furnace.<br />
A market analysis among relevant<br />
customers shows that there is a need<br />
for optimization in the area of furnace<br />
lining and cleaning of dosing furnaces<br />
in connection with corundum formation.<br />
The solution for a dosing furnace in<br />
pressure and low-pressure die casting<br />
foundries: A completely dry lining with<br />
pre-cast components combined with<br />
high-quality insulation materials.<br />
The formation of corundum<br />
There are basically two types of<br />
corundum formation (Figure 1): external<br />
and internal corundum formation.<br />
External corundum formation occurs<br />
on the bath surface by oxidation of<br />
liquid aluminium with oxygen from the<br />
furnace atmosphere. Aluminium is<br />
sucked upwards through pores and oxides<br />
on the metal surface and forms<br />
corundum-lumps. This process is accelerated<br />
by a high proportion of oxygen,<br />
the presence of certain alloying elements<br />
and high temperatures.<br />
In addition, there is internal<br />
corundum formation, also called penetration.<br />
In the contact area of the<br />
refractory lining with the liquid aluminium,<br />
a substitution reaction occurs<br />
due to the higher affinity of oxygen to<br />
the aluminium in the molten melt and<br />
the free oxygen from the SiO 2<br />
in the<br />
refractory lining. This reaction takes<br />
place within the refractory structure<br />
and below the melt surface. A dense<br />
black zone is formed. This is accelerated<br />
by a high bath temperature and an<br />
increase in the pre-baking temperature,<br />
which burns out non-wetting<br />
additives.<br />
In order to solve this problem, extensive<br />
tests were carried out with various Insural<br />
recipes. Suitable compositions were<br />
then determined and new formulations<br />
26
developed. The foundry supplier<br />
Foseco, Borken, Germany, offers a completely<br />
dry lining with Insural pre-shaped<br />
(Figure 2) parts for all common<br />
dosing and low-pressure furnaces,<br />
which is not only economically attractive<br />
but also offers the following<br />
further advantages:<br />
> Direct installation on site possible<br />
> No time-consuming sintering required<br />
> Stable density index after relining is<br />
achieved in a much shorter time<br />
> Corundum formation is reduced to a<br />
minimum<br />
> Easy cleaning, thus alloy change<br />
with little effort possible<br />
> Larger filling volume for some furnace<br />
types due to optimized design<br />
> Energy saving during operation<br />
> Reduction of CO 2<br />
emissions<br />
The installation<br />
The new lining consists of Insural precast<br />
parts, which are assembled according<br />
to a modular principle. The time<br />
required for a furnace installation using<br />
a clean and empty steel shell (Figure 3)<br />
is between two and four days, depending<br />
on the furnace type. In addition to<br />
the pre-cast parts, high-quality insulation<br />
materials (Figure 4) are used. The<br />
insulation materials are mounted between<br />
the Insural parts and the steel<br />
shell. After insulating the bottom area<br />
and the side walls, the main basin<br />
(Figure 5) is inserted. The gap between<br />
the bassin and the insulation is then filled<br />
and the heating and ceiling blocks<br />
are placed on top (Figure 6). The remaining<br />
insulation work is then carried out<br />
and the holes for the thermocouple and<br />
the compressed air supply are drilled.<br />
The last step is closing the furnace with<br />
the lid.<br />
Furnace atmosphere with O 2<br />
~ 700°C<br />
Corundum Al 2<br />
O 3<br />
/Al<br />
Penetration<br />
Aluminium melt Al<br />
Figure 1: Schematic of corundum formation<br />
Roof block - maintanance door end<br />
Blocks<br />
Figure 2: INSURAL precast components<br />
Refractory lining<br />
Roof block - dosing tube end<br />
Liner<br />
Heater<br />
element blocks<br />
Advantages<br />
After complete assembly, the furnace<br />
can be put into operation immediately<br />
and is ready for operation once the<br />
desired furnace chamber temperature<br />
has been reached. A sintering program<br />
as with a conventional installation is<br />
not necessary. As can be seen from<br />
Figure 7, this step saves a great amount<br />
of time.<br />
Depending on the casting process<br />
and quality requirements, the density<br />
index plays an important role in the<br />
availability of the dosing furnace. After<br />
reaching the furnace chamber temperature,<br />
a constantly low density index<br />
value can be measured after only two<br />
days (Figure 8).<br />
Figure 3: Empty steel shell<br />
Figure 4: Insulating materials for floor and<br />
side walls<br />
CASTING PLANT & TECHNOLOGY 2-3/<strong>2020</strong> 27
MELTING SHOP<br />
Figure 5: Installation of the liner into the steel shell<br />
Figure 8: Density Index<br />
Temperature in °C<br />
Density index in %<br />
800<br />
750<br />
700 700 700<br />
700<br />
600<br />
500<br />
500 500<br />
400<br />
350 350<br />
300<br />
250<br />
250<br />
Traditional lining<br />
200<br />
120 120<br />
INSURAL<br />
100<br />
0<br />
0 6 31 36 48 64 70 98 104 134 140 166<br />
Time in hours<br />
Figure 6: Installation of heating and roof blocks<br />
18<br />
16,2<br />
16<br />
15,9<br />
14<br />
Traditional lining<br />
12,4<br />
12,9<br />
INSURAL<br />
12 12,1<br />
11,2<br />
10<br />
9,3<br />
8<br />
6 6,2<br />
6<br />
4<br />
4,1<br />
3,5<br />
2<br />
0<br />
0 24 48 72 96 120 144 168 169 170<br />
Time in hours<br />
Figure 7: Comparison of preheating curves<br />
The availability of the system by<br />
lining it with Insural pre-cast parts has<br />
clear advantages over conventional<br />
lining. With conventional installations,<br />
the sintering process takes seven days. If<br />
Insural prefabricated parts are used, this<br />
part is completely obsolete. In addition,<br />
a constant density index is achieved<br />
much faster with these linings. As a<br />
result, the furnace can return to the<br />
production process faster due to the<br />
shortened integration time.<br />
The use of prefabricated parts of<br />
this type minimizes corundum formation<br />
and facilitates furnace cleaning.<br />
For this purpose, the method of<br />
corundum formation will be discussed<br />
once again. Parameters that can influence<br />
the formation of corundum are:<br />
> high proportion of O 2<br />
> pores<br />
> SiO 2<br />
ratio in refractory material<br />
> temperature<br />
> wetting properties<br />
Based on these points, the Insural 270<br />
recipe was developed in 2015, which<br />
has a small amount of SiO 2<br />
, low porosity<br />
and good non-wettability with liquid<br />
aluminium. With this recipe, dry lining<br />
with pre-cast parts for dosing furnaces<br />
has been successfully introduced to the<br />
market in recent years and excellent<br />
results have been achieved with a large<br />
number of customers.<br />
28
Insural 270 has a SiO 2<br />
content of<br />
22 %, a porosity of about 17 %, a cold<br />
compressive strength of 50 N/mm² and<br />
excellent non-wetting properties compared<br />
to liquid aluminium. In order to<br />
meet the growing demands of the<br />
market, the Insural 290 recipe formulation<br />
has been developed, which has<br />
expanded the product range since<br />
April 2019. It has a SiO 2<br />
content of less<br />
than 10 % only, a porosity of around<br />
16 % and a higher cold compressive<br />
strength of 100 N/mm². The non-wetting<br />
properties remain excellent<br />
(Figure 9).<br />
Another important point is the temperature<br />
in the furnace, which is a decisive<br />
factor for the formation of<br />
corundum. The compensation of temperature<br />
losses in dosing furnaces is controlled<br />
by the heaters and can be readjusted<br />
depending on the insulation.<br />
Since the heating takes place via radiant<br />
heat, the heating elements become<br />
significantly hotter than the melt bath<br />
temperature. This is a major reason why<br />
the formation of corundum accelerates<br />
and good insulation therefore has a<br />
positive influence on corundum avoidance.<br />
Foseco‘s insulation concept can<br />
counteract corundum formation and<br />
also save energy costs (Figure 10). The<br />
power consumption measurements carried<br />
out in a foundry using a 650 kg<br />
dosing furnace show a lower energy<br />
requirement compared to conventional<br />
lining (Figure 11). The heating power<br />
remains at the lowest level for almost<br />
98 % of the time, which avoids overheating<br />
and effectively prevents<br />
corundum formation. Operation at low<br />
heating output levels also has an influence<br />
on the peak shutdown in the<br />
foundry‘s energy management and<br />
reduces weekly average consumption.<br />
Figure 9: Power consumption<br />
Traditional lining INSURAL<br />
2<br />
30<br />
Conclusion<br />
Furnace linings with Insural pre-cast<br />
parts offer a number of advantages<br />
over conventional linings. On the one<br />
hand, the actual lining process requires<br />
considerably less time, and on the other<br />
hand, time-consuming sintering is no<br />
longer necessary. Furthermore, the dry<br />
lining avoids the absorption of hydrogen<br />
by the melt in the first days after<br />
commissioning. The formation of<br />
corundum is minimized, and furnace<br />
cleaning is simplified. Furnace cleaning<br />
remains important, so a weekly cleaning<br />
interval is recommended. Depending<br />
on the insulation concept selected,<br />
energy and CO 2<br />
output can be significantly<br />
reduced. With a furnace that<br />
saves 48,000 kWh per year, the foundry<br />
achieves a reduction of 24.5 tons of climate-damaging<br />
CO 2<br />
.<br />
Dirk Schmeisser, European Product<br />
Manager Insural & Refractories<br />
Non Ferrous, Borken, Germany<br />
384<br />
0 100 200 300 400 500 600 700 800 900 1000<br />
Time in hours<br />
Measuring in hours Max. level (14,3 KW/h) Min. level (10,7 KW/h)<br />
Figure 10: Condition of furnace after 3.5 years<br />
Figure 11: Furnace surface temperature (left: conventional lining, right: Insural 270)<br />
www.foseco.com<br />
529<br />
905<br />
905<br />
Short video on Insural<br />
dosing furnace linings.<br />
https://bit.ly/2yS2M5G<br />
CASTING PLANT & TECHNOLOGY 2-3/<strong>2020</strong> 29
MOLD AND COREMAKING<br />
Photo: Disa<br />
Control arm produced in green sand on a Disamatic molding machine.<br />
Transferring green sand<br />
molding’s advantages to<br />
aluminum casting<br />
Green sand molding gives iron foundries an extremely fast, accurate, flexible and<br />
inexpensive process. For the right applications, green sand molding offers the same<br />
advantages for aluminum casting.<br />
Per Larsen, Taastrup<br />
The green sand process is well<br />
known for producing high quality<br />
iron parts efficiently and inexpensively.<br />
Growing global demand for aluminum<br />
castings combined with mounting<br />
pressure to cut costs is leading more<br />
foundries and manufacturers to explore<br />
the green sand process for aluminum<br />
applications as well.<br />
While iron foundries can already profit<br />
from lower costs along with other<br />
benefits like rapid prototyping and<br />
flexibility it is possible to successfully<br />
transfer the benefits of the green sand<br />
process to the production of aluminum<br />
parts.<br />
This article investigates the opportunities<br />
and challenges of efficiently producing<br />
aluminum castings in green<br />
sand. It considers both safety-critical<br />
aluminum components and those with<br />
less stringent demands on mechanical<br />
properties, as well as high and low production<br />
volumes.<br />
Historically, green-sand-cast aluminum<br />
parts have had a reputation for<br />
lower dimensional accuracy and a less<br />
desirable microstructure caused by slow<br />
cooling. Neither of these is now justified,<br />
as will be shown below.<br />
Molding<br />
Green sand molds can be produced<br />
both vertically and horizontally, with<br />
vertical molding delivering the highest<br />
production speeds.<br />
The six operations of the vertical<br />
molding machine are shown in Figure 1.<br />
The best-known vertical molding lines<br />
achieve very high speeds of up to 555<br />
30
molds per hour without cores and up to<br />
485 molds per hour with cores.<br />
However, DISA now supplies vertical<br />
molding lines with lower speeds: 150<br />
molds per hour without cores and 120<br />
molds per hour with manual core insertion.<br />
Their cost is approximately a third<br />
of the price of the high-speed vertical<br />
lines mentioned above. This makes vertical<br />
molding both possible and economical<br />
for smaller production volumes.<br />
Figure 2 shows the Disamatic C3-150<br />
molding machine that produces up to<br />
150 molds per hour with a mold size of<br />
650 x 530 mm.<br />
Producing 120 molds per hour gives a<br />
cycle time of 30 seconds. That allows<br />
plenty of time for pouring and any manual<br />
interventions required; for example,<br />
setting complex cores that are not glued<br />
together. This gives a degree of flexibility<br />
unusual in vertical mold making.<br />
ADVANTAGES OF THE GREEN SAND PROCESS<br />
The green sand process offers several advantages, including:<br />
> Very high productivity;<br />
> A simple and proven core setting process. This makes pouring hollow parts<br />
straightforward, with speeds of up to 470 cored molds per hour;<br />
> When changing tooling to produce a new component, production only<br />
halts for one or two minutes;<br />
> Initial pattern costs are low; depending on size and complexity, pattern<br />
prices start at 5000 euros;<br />
> Pattern plate lifetime is high: one plate can produce hundreds of thousands<br />
of molds;<br />
> Due to the high productivity, normally only one set of pattern plates and<br />
possible one spare set is needed for each part to be manufactured;<br />
> Pattern plate maintenance costs are low due to the long service life and<br />
only having one production set of pattern plates to maintain for each part;<br />
> Lead times from the first 3-D CAD drawing to the first casting prototypes<br />
and the start of series production are short, thanks to simple and inexpensive<br />
tooling. Thereafter, changes to gating and feeding systems are easy,<br />
fast and cheap.<br />
Figure 1: The six steps of the vertical molding process.<br />
Horizontal molding using matchplate<br />
technology is an attractive alternative<br />
to vertical machines, especially<br />
with lower production volumes and<br />
when high flexibility is required. It<br />
demands relatively low investment and<br />
employs the well-known horizontal<br />
principle. Existing pattern plates for<br />
horizontal equipment can usually be<br />
transferred to matchplate molding<br />
machines with little effort.<br />
Molding material composition<br />
Quartz sand mixed with clay and water<br />
remains the molding material. The values<br />
below show the recommended<br />
molding material properties for aluminum<br />
applications using vertical molding.<br />
These are similar to the parameters<br />
Figure 2: Disamatic C3–150.<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 31
MOLD AND COREMAKING<br />
used for cast iron but will have to be<br />
adapted to the specific aluminum application.<br />
The use of coal dust is not necessary<br />
for aluminum.<br />
Recommended sand properties for aluminium<br />
applications (650 x 535 mm<br />
mold)<br />
> Average grain size (washed):<br />
0.14 - 0.16 mm<br />
> Grain size distribution (washed):<br />
4 sieves<br />
> Gas permeability: 100<br />
> Compressibility: 38-40 %<br />
> Moisture content: 3 %<br />
> Green compressive strength:<br />
20.0 N/cm 2<br />
> Green tensile strength: 2.5 N/cm 2<br />
> Spalling strength: 4.0 N/cm 2<br />
Figure 3: Graphic of<br />
a low-pressure filling<br />
system for vertical<br />
green sand<br />
casting.<br />
Figure 4: The nozzle<br />
of the pouring unit<br />
docked onto the<br />
side of the mold.<br />
Pouring the mold<br />
Aluminum forms oxides very quickly;<br />
these harm its mechanical properties.<br />
Because it lets the melt flow relatively<br />
freely, gravity pouring from the top of<br />
the mold generates these unwanted<br />
oxides. To achieve the best possible<br />
mechanical properties, another way of<br />
pouring is needed.<br />
A better alternative is low-pressure<br />
pouring through a sprue positioned low<br />
down on the side of the mold. Filling<br />
from the bottom up gives laminar flow<br />
and full control over the liquid aluminum’s<br />
inflow, minimizing oxide formation.<br />
Mold filling speed is no longer<br />
dependent on gravity and the casting<br />
profile can be easily optimized for each<br />
individual component.<br />
The principle of low pressure casting<br />
of vertically-split molds is shown schematically<br />
in Figure 3. A close-up of the<br />
nozzle of the pouring device in contact<br />
with the green sand mold can be seen<br />
in Figure 4 with the associated first section<br />
of the required gating system<br />
shown in Figure 5.<br />
A simple, small core is placed just<br />
above the inlet channel. After filling<br />
the mold, a pneumatic cylinder pushes<br />
this core into the inlet channel to block<br />
it and prevent any melt from escaping.<br />
This makes it possible to move the pouring<br />
nozzle as soon as mold filling has<br />
finished, allowing production speeds of<br />
up to 300 molds per hour. Actual cycle<br />
times depend on the amount of melt to<br />
be poured.<br />
This variant of low-pressure sand<br />
casting not only helps to improve the<br />
mechanical properties, it also fully automates<br />
the casting process. As can be<br />
seen in Fig. 5, the runner bars can be<br />
very small which improves yield compared<br />
to conventional gravity casting<br />
from above. Smaller runner bars also<br />
mean that more parts per mold can be<br />
accommodated on the pattern plate.<br />
Figure 5:<br />
Standard pouring system inlet<br />
shown on pattern plate.<br />
32
Figure 6: Left: Microstructure of<br />
brake caliper; right: Picture of<br />
brake caliper.<br />
Figure 7: Left: Reference blocks<br />
added to pattern plates; centre:<br />
Reference impressions on the mold;<br />
right: Lasers measuring in real time.<br />
For aluminium parts with less stringent<br />
demands on their mechanical<br />
properties, manual gravity pouring of<br />
green sand molds is a good alternative.<br />
Hand pouring requires little investment<br />
and offers high flexibility, making it<br />
well suited to shorter series.<br />
Metallurgy<br />
Apart from mold filling, handling the<br />
metallurgy correctly is also important<br />
when aiming to achieve the best possible<br />
mechanical properties for aluminum<br />
castings produced in the green<br />
sand casting process.<br />
Compared to the different die-based<br />
processes, casting in green sand molds<br />
gives a lower cooling rate. This makes it<br />
more suited for parts with thinner wall<br />
thicknesses from 3 mm up to approximately<br />
10 mm where cooling power is<br />
less critical. However, thicker walled<br />
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CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 33
MOLD AND COREMAKING<br />
Figure 8: Control arm.<br />
Figure 9: Brake caliper<br />
Figure 10: Transmission housing<br />
Figure 11: Intake manifold<br />
parts can still be suitable for the green<br />
sand process, as will be shown with an<br />
example of a brake caliper below.<br />
The modification of the silicon phase<br />
is achieved with strontium, making it<br />
possible to have a continuous production<br />
flow. An example of a microstructure<br />
achieved in green sand after finishing<br />
with 230 ppm strontium can be seen<br />
in Figure 6. The alloy used was<br />
AlSi7Mg0.3 with 0.28 - 0.31 % Mg,<br />
0.1 % Fe and 0.1 % Ti.<br />
Although this brake caliper has a thick<br />
cross section (its typical wall thickness is<br />
22 mm), the obtained mechanical properties<br />
are excellent:<br />
> Elongation in %: 4<br />
> Yield strength in MPa: 233<br />
> Tensile strength in MPa: 270<br />
These mechanical properties were measured<br />
on test bars machined from the<br />
casting with a T6 heat treatment and a<br />
density index of 0.75 %.<br />
Accuracy<br />
Traditionally, sand casting had a reputation<br />
for lower casting accuracy. But the<br />
accuracy of castings produced in green<br />
sand has improved over the years, today<br />
achieving as little as 0.1 mm<br />
machine-related mismatch. Modern systems<br />
for in-line checking of mismatch<br />
and mold gaps just before the molds<br />
are poured give extra protection<br />
against possible dimensional problems.<br />
An example of such a system is the DISA<br />
MAC.<br />
This system is based on reference<br />
blocks added to each corner of the pattern<br />
which leave corresponding impressions<br />
in both mold halves (see Figure 7).<br />
After the mold is closed, a laser measures<br />
the positions of these reference<br />
impressions in the mold halves, making<br />
it possible to calculate mismatch and<br />
other dimensional values. Using sophisticated<br />
software, the system detects and<br />
measures mismatch with an accuracy of<br />
+/- 0.05 mm – well below the average<br />
sand grain size of approximately<br />
0.15 mm.<br />
Operators can directly read the current<br />
values for each mold on the screen<br />
of the molding machine. In the event of<br />
a problem, they automatically receive<br />
warning messages and the casting process<br />
can automatically be stopped, for<br />
example, if mold gaps appear. Receiving<br />
early warnings gives enough time to<br />
react before a real problem arises. Cur-<br />
34
Table 1: Examples of casting aluminium in green sand.<br />
Part Information on part Parts/hour Molding Figure<br />
Control arm Elongation: 6 % obtained, Demand: >3 260 DISAMATIC 8<br />
Yield strength: 245 MPa obtained, Demand: >200<br />
Ultimate strength: 309 MPa obtained, Demand: >250<br />
With T6 heat treatment<br />
Brake calliper Elongation: 4,6 % obtained, Demand: >3 800 DISAMATIC 9<br />
Yield strength: 233 MPa obtained, Demand: >215<br />
Ultimate strength: 270 MPa obtained, Demand: >260<br />
With T6 heat treatment<br />
Transmission housing Weight 4,5 kg 250 DISAMATIC 10<br />
Intake manifold Weight 2,9 kg 280 DISAMATIC 11<br />
Gas valve Weight 2,4 kg 400 DISAMATIC 12<br />
rent data can be accessed via the screen<br />
on the molding machine while historical<br />
data can be viewed and analyzed on a<br />
PC using DISA Monitizer.<br />
With a machine-related mismatch of<br />
less than 0.1 mm and employing the<br />
monitoring system described here, the<br />
dimensional accuracy of aluminum sand<br />
casting is no longer an issue.<br />
Examples of casting aluminum<br />
in green sand<br />
Many different casting types can be<br />
made in green sand, ranging from<br />
safety critical parts to less demanding<br />
components. Some examples are shown<br />
in the Figures 8-12 and Table 1, but<br />
there are many other aluminum castings<br />
that are already produced in green<br />
sand. For example, a large number of<br />
US foundries successfully use the matchplate<br />
process to produce aluminum<br />
castings.<br />
Take full advantage of the<br />
green sand process<br />
Most parts are designed with a production<br />
process in mind. The full<br />
potential of green sand can be<br />
reached by designing castings for the<br />
green sand process. This way, further<br />
weight reduction, productivity gains<br />
and, of course, cost savings can be<br />
achieved.<br />
Examples of valuable design adjustments<br />
that make the most of the<br />
green sand process include: designing<br />
parts with hollow sections for minimum<br />
material consumption; optimising<br />
wall thickness to achieve uniform<br />
stress levels while maintaining wall<br />
thickness at 3 mm or more; adding ribs<br />
to increase stiffness; designs that allow<br />
good filling/feeding during casting;<br />
avoiding pockets that are too deep<br />
and narrow.<br />
Figure 12: Gas valve<br />
Conclusion<br />
Both safety-critical aluminium castings<br />
and castings with less stringent demands<br />
on their mechanical properties can be<br />
feasibly produced in green sand. Systems<br />
available today allow the highest<br />
production speeds of several hundred<br />
molds per hour, but lower throughputs<br />
of less than 100 molds per hour are also<br />
efficiently served by green sand lines.<br />
It does not make sense to produce<br />
every aluminium casting in green sand<br />
and this article<br />
does not claim<br />
this. Instead, the<br />
suitability of each<br />
component and<br />
application should<br />
be judged individually.<br />
The wellknown<br />
benefits of<br />
the green sand process, the fact that certain<br />
castings are inherently well suited<br />
for it and the increased efforts, especially<br />
by automotive manufacturers, to<br />
further reduce costs suggest that aluminium<br />
and the green sand process are an<br />
increasingly attractive combination.<br />
Per Larsen, Product Portfolio and Innovation<br />
Manager, DISA Industries, Taastrup,<br />
Denmark<br />
<br />
www.disagroup.com<br />
ConviTec<br />
Vibration machines and conveying technology<br />
Project planning – Manufacturing - Service<br />
www.convitec.net · 069 / 84 84 89 7- 0<br />
2032_Convitec negativ.indd 1 01.02.13 10:02<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 35
MOLD AND COREMAKING<br />
Photo: Benjamin Schultheis, Agentur Bildschön<br />
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<br />
electrically and the quality can additionally be controlled digitally.<br />
Electrical curing of inorganic sand<br />
cores using the ACS technology<br />
Inorganic core production is based on the curing of sand cores by dehydration. Dehydrogenation<br />
of the sand core is thereby achieved by heat input. Established processes<br />
are based on heating the core boxes and flushing with hot compressed air to transfer<br />
sufficient heat energy to the sand core in the shortest possible time. With the newly<br />
developed, already patented Advanced Core Solutions (ACS) technology, the inorganic<br />
sand binder mixture heats additionally directly caused by current flow. This enables<br />
energy and cycle time savings of approx. 30 % during the curing of the sand cores as<br />
well as a uniform curing of the sand cores without shell formation.<br />
By Gotthard Wolf und Marco Weider, Freiberg, Wolfram Bach, Welsleben, and Eric Riedel, Magdeburg<br />
Introduction<br />
The curing of sand cores is a decisive<br />
time factor in the production of castings.<br />
Advanced Core Solutions (ACS)<br />
has developed a process that supports<br />
the dehydration electrically. The validation<br />
of the technology on an industrial<br />
scale was carried out on an automated<br />
core shooter at the Foundry Institute of<br />
the TU Freiberg in the German federal<br />
state of Saxony. The test program was<br />
designed with the aim of applying the<br />
ACS process to three possible optimization<br />
scenarios. These are energy<br />
consumption, curing time, and sand<br />
core strength. The results obtained clearly<br />
show the potential of the ACS process<br />
(Figure 1) after the first pilot project<br />
in an industrial environment was<br />
completed. Sand cores with a wall<br />
thickness between 10 and 120 mm are<br />
36
suitable for series production in large<br />
quantities.<br />
Figure 1: Schematic representation of the areas of application of the ACS process for core production<br />
as a function of the planned<br />
Figure 2: Selection of important aspects for project realization.<br />
Figure 3: Sample and contours of the ACS designation in the sand core.<br />
Influence of thermal conductivity<br />
The basic idea of thermal inorganic processes<br />
is the transfer of heat from the<br />
respective heat source to the core box<br />
and to subsequently transfer sufficient<br />
thermal energy to the sand cores. The<br />
good thermal conductivity of aluminium<br />
(236 W/(m × K)) as well as the<br />
thermal conductivity of steel (50 W/(m ×<br />
K)) allow sufficient heat transport to<br />
the sand core. Typical quartz sands have<br />
an unfavourable low thermal conductivity<br />
(< 4 W/(m × K)), which leads to shell<br />
formation when the cores are dried.<br />
This is caused by the fact that the heating<br />
is unevenly distributed within the<br />
sand core, as the incoming thermal<br />
energy in the sand core cannot be efficiently<br />
and quickly transported to the<br />
centre of the sand core. Furthermore,<br />
the efficiency losses of the heat generation<br />
and heat transport to the sand core<br />
influence the energy balance of core<br />
production. The cycle times for curing<br />
the sand core as well as the formation<br />
of the shell are therefore significantly<br />
influenced by the thermal conductivity<br />
of the quartz sand and by the energy<br />
losses. The low thermal conductivity is<br />
one of the reasons why heated core<br />
boxes are operated at temperatures of<br />
180 °C and more, although temperatures<br />
of 100 °C (depending on the pressure)<br />
would already be sufficient to<br />
evaporate the water content. Therefore,<br />
the approach with established<br />
methods is to generate maximum excess<br />
heat in the core box and transfer it to<br />
the sand cores without exceeding the<br />
maximum allowed binder temperature<br />
in the sand core.<br />
The patented process of Advanced-Core-Solutions<br />
(Soplain GmbH)<br />
accelerates the heating of the sand<br />
cores. Instead of external heat sources<br />
and the associated time-consuming<br />
heat transfer, the process uses the electrical<br />
conductivity of all common tested<br />
inorganic binder compositions. The use<br />
of electrically conductive core box<br />
materials specially developed for this<br />
application in combination with the<br />
electrical conductivity of the binders<br />
enables a uniform current flow at any<br />
point of the sand core. Based on the<br />
principle of electrical resistance heating<br />
(Joule heating), the sand core is thus<br />
heated directly and evenly, thus drying<br />
and curing homogeneously from the<br />
inside out. In addition, the core tool<br />
also heats up and provides further thermal<br />
energy, as is the case with established<br />
processes.<br />
Preparation for pilot project<br />
Successful implementation of the pilot<br />
project essentially required coordination<br />
of the following aspects to increase<br />
the overall efficiency of the process,<br />
demonstrated in Figure 2.<br />
> Adaptation between the core shooting<br />
system, the selected geometry of<br />
the sand core, the appropriate sand binder<br />
mix and the material selection of<br />
the tool insert.<br />
> During selection of the project partner,<br />
both the know-how and the availability<br />
of an automated core shooter<br />
were important aspects to enable both<br />
the execution and the competent<br />
evaluation.<br />
PHOTOS AND GRAPHICS: ACS<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 37
MOLD AND COREMAKING<br />
> The tool material was selected in<br />
such a way that an adjustment of the<br />
electrical conductivity to that of the<br />
sand binder composition could be ensured.<br />
The procedure was based on the<br />
underlying patent. The selection was<br />
made according to internally defined<br />
standards and test methods for determining<br />
the electrical properties of the<br />
sand binder mixture and fell on a silicon<br />
carbide ceramic with additives to adjust<br />
the electrical conductivity.<br />
Leading companies from the industry<br />
could be won for the pilot project. The<br />
overall design and installation on the<br />
core shooting machine were finally carried<br />
out by one of the leading toolmakers<br />
in Germany and proceeded very<br />
satisfactorily. The installation of the<br />
complete plant including final acceptance<br />
was carried out in less than three<br />
days.<br />
Figure 4: Cavity before and after performing the test series.<br />
Figure 5: Temperature distribution recorded by thermal imaging camera in the heated tool<br />
without external heat supply.<br />
> The selection of a sand core geometry<br />
was based on a general test specimen,<br />
in which essential aspects such as<br />
different wall thicknesses, curves and<br />
filigree contours could be investigated<br />
(Figure 3).<br />
> An H 32 sand was used for the sand<br />
selection due to its wide distribution in<br />
the industry and the extensive comparative<br />
data.<br />
> For the binder compositions, a commercial<br />
binder from one of the wellknown<br />
suppliers was used. The selection<br />
criterion for this was compatibility with<br />
binders used in industry and the available<br />
comparative data.<br />
Control & security concepts<br />
The implementation of the process on<br />
an automated system required the<br />
development and adaptation of the<br />
control technology to the selected core<br />
shooting system. A modular approach<br />
was chosen which allows the plant to<br />
be operated with both the ACS process<br />
and the cold box process originally designed<br />
for the plant. The mode can be<br />
changed at the push of a button, thus<br />
allowing flexible use of the plant.<br />
A special focus during project preparation<br />
and implementation was on the<br />
consideration and implementation of<br />
all safety regulations and machine guidelines<br />
for the development of the<br />
necessary hardware. To ensure maximum<br />
safety of the plant, a multi-stage<br />
safety concept was implemented in the<br />
control system and the associated sensor<br />
technology. The possible sources of<br />
error were determined by means of a<br />
Failure Mode and Effects Analysis<br />
(FMEA) before the start of the construction<br />
and updated during the project.<br />
Table 1: Selected test series for optimizing of curing time.<br />
Test series* Initial tool Final tool Required heating<br />
temperature in °C temperature in °C time in s<br />
Simulation 200 150 54<br />
ACSS06 36 110 180<br />
ACSS17 95 100 68<br />
ACSS31 103 113 55<br />
ACSS32 105 113 51<br />
ACSS92 115 120 52<br />
ACSS96 114 120 49<br />
* Selected test series. Complete test series are available on request.<br />
38
Table 2: Selected test series for optimizing of curing time.<br />
Test series* Energy consumption Curing Initial tool<br />
in kWh time in s temperature in °C<br />
ACSS91 0.0338 59 113<br />
ACSS92 0.0300 52 115<br />
ACSS93 0.0297 53 115<br />
ACSS95 0.0280 49 116<br />
ACSS96 0.0296 49 114<br />
* Selected test series. Complete test series are available on request.<br />
Figure 6: Illustration of the cycle times and the quality of the sand cores for selected test series.<br />
The ACS control system was also equipped<br />
with a two-way safety signal exchange<br />
and linked to the existing control<br />
system of the core shooting plant.<br />
Before commissioning, an external safety<br />
check of the plant was successfully<br />
carried out. Subsequently, all employees<br />
participated in a safety training course<br />
on handling and operation of the new<br />
plant.<br />
Experiment execution<br />
Test preparation and execution was<br />
based on a concept for the optimization<br />
of test series with stepwise modification<br />
of individual process parameters. This<br />
made it possible to reduce the various<br />
test series from over 200 to less than 40,<br />
the most important parameters being<br />
the power supply, molf temperature,<br />
power consumption, flushing time, and<br />
flushing temperature. Due to the new<br />
experiences with the tool material,<br />
these test series were additionally prioritized,<br />
with the aim of carrying out the<br />
test series with lower loads first. This<br />
was intended as a precautionary measure<br />
in order to obtain as many meaningful<br />
results as possible; also in the<br />
event that the tool inserts should suffer<br />
unexpected damage during the test.<br />
Figure 4 shows the silicon carbide<br />
ceramic used after the test series has<br />
been carried out. The surface coloration<br />
was caused by minimal residues of process<br />
aids in the production of the<br />
high-performance ceramic. The tests<br />
were carried out after completion of<br />
the installation qualification. During<br />
the installation phase, the properties,<br />
e.g. the temperature, of the plant and<br />
the ceramics were recorded (Figure 5)<br />
and made available to the PLC control<br />
system to optimize the control logic.<br />
The various test series were then processed<br />
accordingly, and the most<br />
important process parameters were<br />
meticulously documented both within<br />
the PLC and manually to be able to<br />
make reliable statements afterwards. A<br />
quick-change system made it possible to<br />
replace the cavity within 3 minutes.<br />
Results<br />
The evaluations described below focus<br />
mainly on the cycle times for curing,<br />
energy consumption and bending<br />
strength.<br />
Cycle time for curing<br />
The cycle time for curing was defined as<br />
the time between the completion of<br />
the shooting process and the start of<br />
the tool flushing. The upstream and<br />
downstream process steps such as core<br />
shooting, purging, ejection and lifting<br />
movements are not affected by the ACS<br />
process. Only the phases for molf heating<br />
and cooling are influenced by the<br />
molf material and the molf design<br />
(insulation). Even with a throttled operation<br />
mode the molf was heated<br />
homogeneously by more than 100 °C in<br />
less than 180 seconds. This means that<br />
warm-up times of < 120 seconds can be<br />
expected in regular operation at full<br />
power.<br />
Reference times. Two approaches were<br />
used to determine comparison times for<br />
established inorganic processes. On the<br />
one hand, a simulation was performed<br />
for the test specimen. On the other<br />
hand, the heat transfer of the core box<br />
to the sand core was also simulated<br />
with the ceramic („baking“) since the<br />
thermal conductivity of silicon carbide<br />
(about 140 W/(m × K)) is much higher<br />
than the thermal conductivity of standard<br />
tool steel (about 35 W/(m × K)). A<br />
curing time with shell formation of<br />
approx. 54 seconds was determined for<br />
the test specimen in the ACS “baking”<br />
mode.<br />
Determined measured values. The measured<br />
values in Table 1 show selected<br />
test series in which sand cores of particularly<br />
good quality could be produced.<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 39
MOLD AND COREMAKING<br />
Figure 7: Comparison of current course and temperature curves for a selected test specimen.<br />
Figure 8: Energy input per sand core over time.<br />
When the cycle times for curing are<br />
plotted in correlation with energy<br />
consumption, a clear trend towards<br />
reduced consumption can be seen<br />
(Figure 6). It is not surprising that the<br />
higher energy consumption of the core<br />
also leads to faster curing, but this clearly<br />
shows the potential of the ACS process.<br />
The more energy that can be<br />
applied per time unit, the faster the<br />
sand core cures. The maximum possible<br />
power input Pmax was only tested at<br />
50 % in this experiment. This results in a<br />
further potential for cycle time savings.<br />
The continuous power supply increases<br />
the temperature in the molf accordingly<br />
(Figure 7). The ACS control system automatically<br />
optimizes the current intensity<br />
based on the desired process parameters.<br />
In addition, the PLC control system<br />
ensures that the current is regulated<br />
according to the resistance curve to prevent<br />
unintentional overheating.<br />
Conclusion. With the ACS process, the<br />
duration for curing can be controlled<br />
directly by the power input of the electrical<br />
current. In less than 10 days, the<br />
automatic core shooter not only<br />
demonstrated the effectiveness of the<br />
process, but also achieved significant<br />
improvements. The limiting factor here<br />
is the maximum power input without<br />
permanent damage to the molf material.<br />
This power consumption will be<br />
further optimized in future investigations.<br />
Energy consumption<br />
In addition to the reduction of curing<br />
time, it is also possible for foundries to<br />
optimize the process of core production<br />
in an energy-efficient manner. The calculated<br />
energy consumption refers to the<br />
thermal energy required for curing the<br />
inorganic sand cores. The difficulty arose<br />
from the determination of the thermal<br />
energy used per single sand core. In established<br />
processes, the corresponding<br />
tools are kept at an almost constant<br />
temperature by means of heating elements<br />
or thermal oil, so that an individual<br />
energy requirement per sand core<br />
cannot be determined directly. Therefore,<br />
an approximate comparative<br />
energy consumption was determined<br />
under the assumption of continuous<br />
operation and the average number of<br />
cores shot per hour. This shows a further<br />
significant advantage of the ACS process:<br />
The individual power consumption<br />
per manufactured sand core can be<br />
recorded and evaluated at any time and<br />
thus allows conclusions to be drawn<br />
about its quality and approaches to<br />
energy optimization (Table 2, Figure 8).<br />
Conclusion<br />
The initial temperature of the tool<br />
influences the sand core energy required<br />
for curing the cores. It could be<br />
shown, that with the ACS process sand<br />
cores can already be cured at temperatures<br />
between 100 °C and 130 °C. Compared<br />
to conventional temperature<br />
levels this temperature difference alone<br />
allows for significant energy savings.<br />
Bending strength<br />
A sufficiently high bending strength is<br />
required to ensure adequate strength<br />
40
Figure 9: Illustration of the ceramic core boxes for the production of bending bars with the ACS process and the corresponding bending bars<br />
with strengths >350N/cm².<br />
of the sand core during the casting process.<br />
Typical reference values are<br />
strengths between 200 N/cm² and 400<br />
N/cm². The bending strengths were<br />
determined both after 2.5 h and after<br />
24 h (Table 3) and show that the cores<br />
produced by the ACS process readily<br />
meet the requirements for sufficient<br />
strength required for the casting process.<br />
With measured bending strengths<br />
of up to approx. 400 N/cm², the cores<br />
manufactured by the ACS process meet<br />
the standard industrial requirements.<br />
The optimization of the strengths is one<br />
of the tasks for the upcoming test<br />
series.<br />
Advantages of the new process<br />
In a direct comparison with conventional<br />
processes, the new ACS process<br />
shows significant overall cost savings.<br />
The savings are mainly due to two reasons.<br />
On the one hand, the direct use<br />
of electrical current, which does not<br />
have to be converted into heat with<br />
losses before the process, enables<br />
energy savings of up to 30 % compared<br />
to conventional processes. On the<br />
other hand, cycle time savings of up to<br />
30 % are expected, which means that<br />
despite the possibly higher tool costs<br />
(depending on the material used) the<br />
annual operating costs can be massively<br />
reduced.<br />
Another so far not mentioned<br />
aspect is the possibility for digitalization<br />
of the core drying process. Recording<br />
the relevant electrical process parameters,<br />
the ACS technology allows a realtime<br />
monitoring of the drying process<br />
itself for the first time. Thus, enables an<br />
Table 3: Measured bending strength.<br />
Test series* Weight in g Bending strength in N/cm²<br />
ACSS55M 141.5 202.1<br />
ACSS411 146.0 269.7<br />
ACSS102H 147.5 292.7<br />
ACSS113H 148.0 347.9<br />
* Selected test series. Complete test series are available on request.<br />
increase in the quality of both the<br />
manufactured sand cores and the core<br />
drying process.<br />
Outlook<br />
With the successful realization of the<br />
first pilot project on an automated<br />
industrial core shooter, the functionality<br />
and advantages of the ACS process has<br />
been demonstrated. The next step is to<br />
optimize the control system and process<br />
parameters using the bending bars<br />
(Figure 9). At the same time, interested<br />
foundries will be supported in the conversion<br />
and implementation of the new<br />
process into series production. For this<br />
purpose, the possibilities for further<br />
development of the plant for sand core<br />
thicknesses > 100 mm are being considered,<br />
so that these can also be produced<br />
efficiently and in an energy-saving<br />
manner.<br />
Further research activities also focus<br />
on alternative materials for the electrically<br />
conductive core boxes and on process<br />
simulation. In the first case, an electrically<br />
conductive epoxy resin as an<br />
alternative material for large-scale production<br />
is being worked on at an<br />
advanced stage, as is a new type of<br />
high-performance plastic, which should<br />
also make small series and prototyping<br />
economically feasible. The use of temperature-resistant<br />
PEEK materials will<br />
make it possible to produce prototypes<br />
from design to the finished sand core in<br />
a series environment within days. In the<br />
second case a comprehensive process<br />
simulation of the ACS process is being<br />
worked on, using software that is well<br />
established in the foundry industry, in<br />
order to cover another important<br />
aspect for industrial use of the ACS<br />
technology.<br />
https://advanced-core-solutions.com<br />
Prof. Dr. Wolf und Dr. Weider, TU Bergakademie<br />
Freiberg, Freiberg, Dipl. Ing.<br />
Wolfram Bach, Advanced-Core-Solution,<br />
Soplain GmbH, Welsleben, Dr. Eric Riedel,<br />
Otto-von-Guericke-Universität Magdeburg,<br />
Magdeburg<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 41
DIGITALIZATION<br />
Photos: ABP<br />
The ABP service is directly available as „Expert on Demand“ online without any need for traveling (Figures: ABP).<br />
Hybrid Internet of Things service<br />
solutions for the foundry industry<br />
The changing global economic environment and the change in social values with the<br />
desire for sustainability are forcing energy-intensive industries in particular to further<br />
optimize their processes. The new technical possibilities by digitalization allow to<br />
move the boundaries of lean principles further. For this purpose, ABP Induction offers<br />
a web-based customer portal that provides innovative hybrid service solutions.<br />
This brings ABP closer to the plant operators and supports them in their daily work<br />
and maintenance, and in training their staff.<br />
By Moritz Spichartz, Marco Rische and Markus Fournell, Dortmund<br />
Increasing productivity and quality<br />
while simultaneously reducing<br />
environmental impact and production<br />
costs are challenges that foundries are<br />
confronted with every day. Over the<br />
past few years, a large number of companies<br />
have addressed this challenge in<br />
the spirit of lean and agility and<br />
developed suitable concepts for the<br />
economical and time-efficient use of<br />
the most important production factors<br />
within the framework of all corporate<br />
activities like equipment, personnel,<br />
materials, planning and organization.<br />
The fourth industrial revolution (Internet<br />
of Things, abbr. IoT) with its machine-oriented<br />
data evaluation by machine<br />
learning and network-based interaction<br />
between production plants, but also the<br />
consolidation of the machine manufacturers’<br />
know how with that of the operators,<br />
will advance the processes of<br />
self-optimization. Finally, it will lead to<br />
Lean 4.0 [1,2].<br />
A high degree of transparency of<br />
the machine data from production is<br />
crucial in this context [3-8]: The product<br />
quality is documented seamlessly from<br />
scrap selection to the final product.<br />
Fault information and condition monitoring<br />
systems are available throughout<br />
the company, enabling faster reaction<br />
to production interruptions and accelerating<br />
the resumption of production<br />
[3-6]. In addition, predictive and preventive<br />
maintenance concepts based on<br />
42
the analysis of real-time data enable<br />
proactive maintenance and repair [7].<br />
Operators benefit from additional<br />
information and recommended actions<br />
[8]. The machine manufacturer obtains<br />
direct feedback on the operation of<br />
their products that can be used directly<br />
for further development. New service<br />
concepts enable the manufacturer to<br />
get closer to the operators and support<br />
them with his expertise [9].<br />
As a leading manufacturer of induction<br />
systems for ferrous and non-ferrous<br />
applications [10-12] (Figure 1), ABP<br />
Induction offers a high number of<br />
assets in the production value chain of a<br />
foundry with its crucible, channel and<br />
pouring furnaces. The company sees itself<br />
as a competent partner which<br />
develops in cooperation with the<br />
foundry operators the most suitable<br />
individual solutions, both with existing<br />
high-end products in furnace and converter<br />
technology and with novel digital<br />
products. The optimization of the<br />
melting and pouring processes as well<br />
as the support of the foundries in terms<br />
of maintenance and training using<br />
web-based technologies in combination<br />
with the ABP domain knowledge are<br />
the drivers of the digital service solutions.<br />
Motivation<br />
The digitalization level is still very different<br />
in the foundries. All foundry<br />
owners are aware that they must invest<br />
in digital solutions to stay competitive<br />
in the future, but most of them hesitate<br />
to start. That is the result of the discussions<br />
in the working team “Foundry<br />
4.0” (German: Gießerei 4.0) of the<br />
Federation of the German Foundry<br />
Industry (German: Bundesverband der<br />
Deutschen Gießerei-Industrie, abbr.<br />
BDG). The working group published a<br />
guideline to help foundries to analyze<br />
their digitalization level and to give<br />
them approaches for development. Ten<br />
topics are outlined in this guideline [8]:<br />
> Data acquisition in production,<br />
> Data processing in production,<br />
> Machine to machine communication<br />
(M2M),<br />
> Process automation by using robots,<br />
> Flexible production, flexible resources,<br />
> CAx (computer-aided) technology,<br />
> Product development,<br />
> Process development,<br />
> Information and communication<br />
structure,<br />
> Employees, management and organization.<br />
It is becoming obvious that digitalization<br />
is not limited to machine-oriented<br />
technology improvements. Ultimately,<br />
change processes must be implemented<br />
by employees and managers who<br />
perceive these changes as an opportunity<br />
and are committed to new technologies<br />
and information and learning<br />
methods [8] (Figure 2). In line with the<br />
lean philosophy the human must be in<br />
foreground when implementing new<br />
digital solution. That is why the BDG<br />
recommends that the focus should not<br />
be exclusively on technical improvements<br />
but rather on all subject areas<br />
and that they should be brought to the<br />
same maturity level [8]. Summarized,<br />
every company needs a digital strategy.<br />
ABP Induction committed itself early<br />
on supporting foundries in this process<br />
and also recognized its own opportunity<br />
to get closer to the operators in<br />
order to be able to offer customer-oriented<br />
service solutions and expedite its<br />
own developments in the field of furnace<br />
and converter technology. This<br />
Figure 1: ABP is a technology leader in<br />
furnace and converter technology with<br />
the most powerful induction furnaces in<br />
the world (65t, 42MW).<br />
results in hybrid IoT service solutions<br />
that complement ABP‘s existing service<br />
strategy. The starting points were the<br />
machine-to-machine communication in<br />
conjunction with mapping the digital<br />
twin and the improvements in information<br />
and communication structure<br />
regarding new maintenance concepts<br />
and training for machine operators. All<br />
solutions provide added value to<br />
foundry operators directly.<br />
Hybrid IoT service solutions<br />
„What if your furnace had a smartphone?“<br />
asks Till Schreiter, CEO and<br />
President of the ABP Induction Group,<br />
and answers his question immediately:<br />
„It would completely change the relationship<br />
with your plant. It would allow<br />
your furnace to notify you when needed,<br />
to look for ways to improve per-<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 43
DIGITALIZATION<br />
Figure 2: The BDG guideline (BDG Kompass) enables analyzing one‘s own degree of digitalization<br />
and it supports the digital transformation process. Each of the ten topics are divided into<br />
five degrees of maturity [8].<br />
formance, and even to plan the best<br />
production cycle. And that is exactly<br />
what we want to achieve. Service apps<br />
use the connection to device sensors<br />
and make all information available to<br />
the right people at exactly the right<br />
time“.<br />
Technology giants such as Amazon,<br />
Facebook, Google and Apple have<br />
already revolutionized the way everyone<br />
behaves in their private lives,<br />
enabling new ways to make information<br />
available everywhere. The way we<br />
communicate and interact with our<br />
environment has changed fundamentally<br />
in recent years. However, this has<br />
only been reflected to a limited extent<br />
in the day-to-day work of the foundries.<br />
Although there have been improvements<br />
in plant technology and process<br />
automation, nothing can compare<br />
with the progress which is already<br />
being made in private life. Service is the<br />
interface between ABP and its customers<br />
in the foundries. ABP has fully<br />
revised its service solutions in recent<br />
years. Operational excellence has been<br />
improved continuously, products and<br />
processes have been digitalized and<br />
optimized, and service solutions have<br />
been completely redesigned and established<br />
successfully [9] (Figure 3): The<br />
myABP platform is the logical digital<br />
extension of our service offering and<br />
the introduction to the new digital<br />
world. The platform works transparently,<br />
in a location and time independent<br />
manner. It is designed for all processes<br />
and machines involved in a<br />
foundry, regardless of whether it is a<br />
melting shop, sand preparation or molding<br />
plant. Any upstream and<br />
downstream processes can be connected<br />
easily to the platform. All system-related<br />
documents are available in the<br />
platform, from product descriptions and<br />
drawings to maintenance manuals and<br />
service reports. MyABP acts as a personal<br />
information and maintenance<br />
assistant for melting and heating<br />
plants, also those of different manufacturers.<br />
It is the central collection point<br />
for insights and advice, and it consolidates<br />
all relevant knowledge about the<br />
plant. Operators can make use of it to<br />
manage their services, parts lists, documentation,<br />
offers and orders, to request<br />
support and to establish connections to<br />
the various systems that are used in pro-<br />
Figure 3: The digital products marked in blue complete ABP’s service concept C3 (Complete Customer Care). For further information please<br />
refer to https://c3.abpinduction.com.<br />
44
Figure 4: The virtual training scenarios on operation, maintenance<br />
and safety aspects received great attention at GIFA 2019. The training<br />
sessions can be used with VR glasses or PC.<br />
duction [9]. The ABP service department can be accessed<br />
directly via the worldwide web as an „Expert on Demand“<br />
using data glasses, tablet or smartphone. ABP helps maintenance<br />
personnel in troubleshooting by enabling ABP<br />
experts to look through the eyes of the maintenance team<br />
via the digital devices. This saves travel costs, reduces production<br />
downtimes and protects the environment [9,13].<br />
Every employee in the foundry can be trained in virtual<br />
training scenarios on a digital twin of their own plant, either<br />
on a PC or with VR glasses (Figure 4). Virtual classrooms allow<br />
to interact with the experts from ABP without travelling to<br />
training sessions. The participants in the training courses<br />
receive suggestions which training courses are required to<br />
carry out upcoming maintenance work, to increase productivity<br />
and to ensure a high level of safety in the operation of<br />
the plants [9,13]. „A revolution is not something that is done<br />
just by one person or company. Therefore we rely on the<br />
assistance of our customers, suppliers and other machine and<br />
plant manufacturers, and on partnerships with other companies<br />
and universities to enable us to develop the platform<br />
continuously,“ says Mr. Schreiter, looking optimistically into<br />
the future.<br />
Summary<br />
The digital transformation of foundries can be understood as<br />
a continuation of business optimization based on the lean<br />
philosophy, with the aim of further increase of productivity<br />
and quality while reducing environmental impact and costs,<br />
and thus remaining competitive. This is a true change in culture<br />
that must be addressed jointly by foundry operators and<br />
machine manufacturers. ABP‘s hybrid IoT service solutions<br />
bridge the gap between traditional services and a new level<br />
of connectivity between plant manufacturers and foundries.<br />
The hybrid concept of these innovative service tools is to<br />
connect people, machines and processes across manufacturer<br />
boundaries by the new myABP platform and to lead them<br />
through the ongoing digital revolution with ever new service<br />
apps.<br />
Moritz Spichartz, Marco Rische, Markus Fournell,<br />
ABP Induction Systems GmbH, Dortmund.<br />
References: www.cpt-international.com
SAND REGENERATION<br />
Photos and graphics: Eirich<br />
Simple and fast mixing tool replacement<br />
Changing mixing tools<br />
quick and easy<br />
Changing mixing tools is something every operator of a mixer is familiar with. This maintenance<br />
work is absolutely essential in order to ensure that consistent throughput is<br />
achieved with consistently high processing quality. The mixing tool is exposed to increased<br />
wear as a result of constantly coming into contact with the product. A new system<br />
for changing rotor beaters in production mixers significantly shortens service and standstill<br />
times and saves additional material costs.<br />
By Philipp Krötz, Hardheim<br />
Time-intensive maintenance work<br />
The maintenance work required to<br />
replace wearing parts is often performed<br />
later than it should be. The work<br />
that needs to be performed is very<br />
time-intensive and is generally associated<br />
with extended production shutdowns.<br />
The first step that is often taken<br />
when the quality of molding materials<br />
starts to deteriorate is to extend mixing<br />
times in order to counter the deterioration<br />
in quality. The result is often<br />
increased molding material temperatures,<br />
which leads to increasing sand<br />
inclusion in the casting. This type of<br />
quality-relevant work is often not scheduled<br />
until it becomes absolutely essential<br />
due to a reduction in throughput or<br />
a deterioration in casting quality.<br />
In the past, a great deal of time –<br />
typically several hours – was required to<br />
change the beaters attached to the<br />
rotor. First all the tension needed to be<br />
released on all of the beaters, and only<br />
then was it possible to replace individual<br />
parts that displayed signs of wear<br />
– a process requiring large levers and<br />
lots of muscle power.<br />
Easy and quick rotor<br />
beater change<br />
Eirich has developed a quick-change system<br />
for rotor beaters, which can now<br />
be replaced individually in a simple procedure<br />
that only takes a few minutes.<br />
One particularly useful feature of<br />
this new system is that the easy process<br />
for replacing the beaters makes it possible<br />
to swap out beaters with increased<br />
wear in high-wearing zones against less<br />
worn ones from other areas to optimize<br />
use of the material. Users who have<br />
switched to the new system have confir-<br />
46
Figure 1: Layout of the optimized mixing tool.<br />
med a significant reduction in downtime<br />
and maintenance costs.<br />
Migrating to the new SmartFix<br />
quick-change system is easy because<br />
there is no need to replace the existing<br />
rotor shaft or purchase a new one. Only<br />
the tool support disks need to be changed.<br />
Suited for retrofitting<br />
Particularly cost-effective: Existing spare<br />
parts can still be used, making this system<br />
well suited for retrofitting. The new<br />
system, which is called SmartFix and for<br />
which a patent application is pending, is<br />
available as a retrofit or conversion<br />
package for all Eirich production mixers,<br />
i.e. mixers with a capacity of 75 liters or<br />
more. With this, the company helps to<br />
make their production setup more cost<br />
effective – while at the same time<br />
keeping up high quality. SmartFix is not<br />
only well suited for brand new mixers –<br />
it can also be used as a retrofit solution<br />
for existing Eirich mixers.<br />
Hidden Champion with core<br />
expertise in the preparation<br />
of free-flowing materials<br />
The Eirich Group is a supplier of industrial<br />
mixing, granulating/pelletizing,<br />
drying and fine grinding machinery, systems,<br />
and services. The Group has its<br />
main strategic base at the corporate<br />
headquarters in Hardheim, Germany.<br />
The company has core expertise in processes<br />
and techniques used for the preparation<br />
of free-flowing materials,<br />
slurry, and sludge. The main fields of<br />
application for such technologies include<br />
e.g. ceramic and refractory materials,<br />
foundries, building materials such as<br />
concrete and plaster, battery pastes, fertilizers,<br />
glass, and the processing of ores.<br />
Close co-operation between the company’s<br />
test centers around the world and<br />
collaboration with the research and academic<br />
community enables the „hidden<br />
champion“ to provide solutions for innovative,<br />
cost-efficient products and processes.<br />
The family-managed company<br />
was founded in 1863 and operates from<br />
twelve locations on five continents. The<br />
Group has approximately 1,500 employees,<br />
more than half of whom work at<br />
the headquarters site in Hardheim.<br />
Group turnover is in the region of 200<br />
million euros.<br />
Philipp Krötz, Head of Service-Sales,<br />
Maschinenfabrik Gustav Eirich GmbH &<br />
Co KG, Hardheim, Germany<br />
www.eirich.de<br />
Pneumatic conveying<br />
technology<br />
For dry, free-flowing, abrasive and<br />
abrasion-sensitive material<br />
Core sand preparation<br />
technology<br />
For organic and inorganic processes,<br />
turn-key systems including sand,<br />
binder and additive dosing and<br />
core sand distribution<br />
Reclamation technology<br />
Reclamation systems for<br />
no-bake sand and core sand,<br />
CLUSTREG® for inorganically<br />
bonded core sands<br />
Shock wave technology<br />
CERABITE ®<br />
clean castings<br />
The reliable solution for the<br />
removal of residual sand<br />
and coatings of<br />
demanding castings<br />
KLEIN Anlagenbau AG<br />
KLEIN Stoßwellentechnik GmbH<br />
a subsidiary of KLEIN Anlagenbau AG<br />
Obere Hommeswiese 53-57<br />
57258 Freudenberg | Germany<br />
Phone +49 27 34 | 501 301<br />
info@klein-group.eu<br />
www.klein-ag.de<br />
www.stosswellentechnik.de<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 47
PRESSURE DIE CASTING<br />
Photos: Micro-Epsilon<br />
By applying machines equipped with inductive sensors from Micro-Epsilon, manufacturers of aluminum die-cast parts reduce their costs. These<br />
eddy-current based sensors monitor the mold deformation with high accuracy.<br />
Efficient gap monitoring<br />
in die casting machines<br />
Machines equipped with inductive sensors enable manufacturers of aluminum diecast<br />
parts to reduce their costs significantly. These eddy-current based sensors monitor<br />
the mold deformation, i. e., the so called mold breathing, with high accuracy. This<br />
narrow gap that occurs between the tool halves when the material is injected under<br />
pressure is a crucial factor that affects the quality in the die-casting processes.<br />
By Stefan Stelzl, Ortenburg<br />
Monitoring based on inductive<br />
sensors enables the early recognition<br />
of tool wear and false<br />
process parameters. This reduces<br />
lengthy and expensive rework of the<br />
component, while keeping tool wear<br />
to a minimum and the tool’s service life<br />
clearly increases.<br />
Aluminum die-cast parts combine<br />
robustness with low weight. In addition,<br />
they offer extremely high electrical<br />
conductivity and corrosion<br />
resistance.<br />
When processing this versatile type<br />
of material, precision is required – particularly<br />
when it comes to monitoring<br />
the mold deformation in aluminum<br />
die-casting processes.<br />
Challenges in aluminum<br />
die-casting<br />
Manufacturing aluminum die-cast parts<br />
requires high pressure of approx. 600 to<br />
1000 bar in order to press the liquid hot<br />
48
form a solid unit. This integrated system<br />
design increases robustness and<br />
resistance to external factors, protecting<br />
the system in harsh industrial<br />
environments with high temperatures<br />
up to 100 °C, dust, dirt, vibration and<br />
pressure, and delivers accurate measurements<br />
regardless of the environment.<br />
Their compact design enables these systems<br />
to be easily integrated in existing<br />
plants.<br />
Figure 1: When monitoring the mold deformation, three to four eddy current systems are<br />
used to determine the expansion and the gap opening of the tool to micrometer accuracy.<br />
Here, one measuring system consists of a compact and robust controller, which together<br />
with the cable and sensor form a solid unit.<br />
material with a temperature of 700 to<br />
900 °C into a pre-heated steel mold. The<br />
shot time is only 50 to 100 milliseconds.<br />
The mold that receives the aluminum<br />
consists of two mold halves, which are<br />
pressed together under significant force<br />
of more than 1000 tons. This high pressure<br />
applied during the injection process<br />
causes a narrow gap between the mold<br />
halves. This is also called mold breathing.<br />
If this gap becomes too large,<br />
this would negatively affect the manufacturing<br />
process, as the component<br />
would fray into splinters. Manufacturers<br />
place high quality requirements on the<br />
production process, which is why splinters<br />
would cause extensive reworks.<br />
Consequently, this results in loss of time<br />
and higher costs. Another negative<br />
aspect are aluminum residuals on the<br />
tool. They cause increased wear and<br />
therefore reduce the tool’s service life.<br />
Figure 2: Due to<br />
their design and<br />
technology, eddy<br />
current-based sensors<br />
from Micro-Epsilon<br />
can be easily<br />
adapted to the high<br />
requirements of the<br />
manufacturing process<br />
for aluminum<br />
die-cast parts.<br />
Precise measurement of<br />
mold deformation<br />
Easy, quick and reliable monitoring of<br />
tool deformation can be achieved using<br />
inductive sensors based on eddy currents.<br />
Robust design and compactness<br />
make the eddyNCDT 3005 sensors well<br />
suited to these types of application.<br />
Sensor manufacturer Micro-Epsilon<br />
headquartered in Germany is reknown<br />
for its expertise in this field. Based on<br />
state-of-the-art sensor technology, the<br />
sensors ensure continuous and high precision<br />
gap monitoring, while increasing<br />
manufacturing efficiencies. When monitoring<br />
mold deformation, three to four<br />
eddy current systems are used to determine<br />
the expansion and the gap<br />
opening of the tool to micrometer<br />
accuracies. Here, one system consists of<br />
a compact and robust controller, which<br />
together with the cable and sensor,<br />
Conclusion<br />
Due to their design and technology,<br />
eddy current-based sensors from<br />
Micro-Epsilon are easily adapted to the<br />
high requirements of the manufacturing<br />
process for aluminum die-cast<br />
parts. In contrast to conventional inductive<br />
sensors, they stand out due to their<br />
high accuracy, high frequency response<br />
and temperature stability. Depending<br />
on the model, the systems are insensitive<br />
to temperatures up to 200 °C. The<br />
active temperature compensation feature<br />
enables the systems to provide<br />
highly accurate measurement results<br />
even with fluctuating temperatures. In<br />
addition, movements are rapidly detected<br />
using measurement frequencies up<br />
to 5 kHz. Their ease of use is another<br />
positive feature that makes these sensors<br />
well suited to OEM and serial applications.<br />
With higher quantities, it is possible<br />
to adapt the sensors to the<br />
customer’s specific application.<br />
Inductive sensors based<br />
on eddy currents<br />
The eddy current principle occupies a<br />
unique position amongst inductive<br />
measuring methods. Measuring via<br />
eddy current is based on the extraction<br />
of energy from an oscillating circuit.<br />
This energy is needed for the induction<br />
of eddy currents in electrically-conductive<br />
materials. Here, a coil is supplied<br />
with an alternating current, causing a<br />
magnetic field to form around the coil.<br />
If an electrically conducting object is<br />
placed in this magnetic field, eddy currents<br />
are induced which form a field<br />
according to Faraday‘s induction law.<br />
This field acts against the field of the<br />
coil, which also causes a change in the<br />
impedance of the coil. This impedance<br />
can be calculated by the controller by<br />
looking at the change in the amplitude<br />
and phase position of the sensor coil.<br />
Dipl.-Ing. Stefan Stelzl, Product Manager,<br />
Micro-Epsilon Messtechnik GmbH &<br />
Co. KG, Ortenburg, Germany<br />
www.micro-epsilon.com<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 49
QUALITY ASSURANCE<br />
Photos: Deevio<br />
Special cameras and AI should also automate inspection processes in foundries<br />
Cameras and AI: foundries<br />
automate quality assurance<br />
Many processes in the foundry sector are still carried out manually in <strong>2020</strong>, despite the<br />
advance of factory automation. This is particularly the case for quality assurance. deevio,<br />
a Berlin-based start-up, has stepped up to change this. It uses special cameras and<br />
artificial intelligence to automate the most varied of inspection processes. This promising<br />
solution could soon become the new standard in smart factories.<br />
By Damian Heimel, Berlin<br />
Quality assurance as an integral<br />
component of automation<br />
Rising production costs, a shortage of<br />
specialists, digitalization: all sectors<br />
have to cope with these trends, and<br />
foundries are no exception. The range<br />
of components produced is also rising,<br />
while demands for precision and quality<br />
are increasing. None of these requirements<br />
can be readily met using manual<br />
processes. This applies for production<br />
just as much as for quality assurance,<br />
where there is the additional problem<br />
that foundries are finding it increasingly<br />
difficult to find suitable employees.<br />
Fewer and fewer people, particularly<br />
in structurally weak regions, are<br />
prepared to take on this relatively<br />
monotonous task.<br />
Manual quality assurance also<br />
suffers from specific weaknesses<br />
It is extremely time-consuming: a single<br />
inspection process generally takes several<br />
seconds (Figure 1). Moreover, the<br />
accuracy of the inspections naturally<br />
depends on an employee’s level of qualification<br />
and their performance on the<br />
day. Performance efficiency at any particular<br />
time is influenced by factors such<br />
50
as motivation, tiredness and lighting<br />
conditions.<br />
These facts make it clear that the<br />
automation of quality inspections<br />
brings a wide variety of advantages.<br />
Apart from this, it is an indispensable<br />
component of the smart factory, characterized<br />
in its final form by completely<br />
automated processes.<br />
Traditional processes are<br />
not enough<br />
The idea of automating quality<br />
assurance is not particularly new. For<br />
some time foundries have already been<br />
using cameras and image processing<br />
software, for example, to inspect their<br />
products. The technology, called<br />
machine vision, is thoroughly practicable<br />
in particular scenarios (Figure 2),<br />
though its limits are rapidly reached<br />
when there is a high variability of<br />
defects. This is the case, for example,<br />
when surface cracks or inclusions take<br />
on different colors and shapes, or can<br />
occur at different locations on a casting.<br />
Variances of these types cannot be<br />
fully uncovered using classic machine<br />
vision approaches because they use<br />
rule-based algorithms. So it is necessary<br />
to define in advance where a scratch,<br />
for example, could be located. In addition,<br />
particularly for surface defects, it<br />
has been observed that machine vision<br />
systems have a high rate of false negatives,<br />
i.e. non-genuine defects. They are<br />
thus ‘over-precisely’ adjusted and<br />
wrongly detect intact products as defec-<br />
Figure 1: Manual quality inspection is<br />
time-consuming and depends on the<br />
employees’ level of qualification.<br />
Figure 2: Image processing software<br />
is already being used for quality<br />
assurance.<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 51
QUALITY ASSURANCE<br />
tive, increasing both the number of<br />
rejects and production follow-up costs.<br />
Despite major investments in corresponding<br />
systems, they ultimately fail to<br />
achieve the desired effect – or even<br />
make the situation worse.<br />
Machine learning as a problem-solver<br />
The Berlin-based start-up deevio has<br />
developed a solution for quality<br />
assurance that overcomes the weaknesses<br />
of classic machine vision systems.<br />
The approach is fundamentally founded<br />
on two components: industrial cameras,<br />
and software based on machine learning<br />
– an advanced form of artificial<br />
intelligence.<br />
First of all, deevio needs pictures.<br />
The team either uses existing pictures<br />
from an image processing system or,<br />
together with its partners, installs<br />
industrial cameras in the foundry<br />
works. These high-resolution cameras<br />
with professional illumination are used<br />
to take pictures of intact and faulty<br />
products in all the potential defect<br />
categories, for example with cavities or<br />
impact marks. The data scientists at<br />
deevio then use this material as the<br />
basis for training an individual machine<br />
learning model optimized for the specific<br />
case (Figure 3).<br />
The advantage compared to traditional<br />
processes lies in the solution’s high<br />
level of flexibility. It can detect, for<br />
example, scratches with a variety of<br />
individual structures at the surface or<br />
elsewhere. The AI model learns continuously,<br />
enabling it to handle defect<br />
variability increasingly well.<br />
deevio does not simply supply intelligent<br />
software for quality assurance –<br />
the young company considers itself to<br />
be a complete service provider. Its various<br />
partners handle camera installation,<br />
organize the necessary illumination,<br />
install the machine control system, and<br />
automate the processes.<br />
Numerous advantages<br />
for companies<br />
The deevio solution provides several<br />
advantages for foundries: firstly, the<br />
system provides quality improvements<br />
because – unlike human inspections – it<br />
ensures a constant level of performance<br />
and accuracy. Processes are also accelerated:<br />
an inspection process only takes<br />
one second, on average. Costs savings<br />
can also be achieved because fewer personnel<br />
are tied up for quality assurance.<br />
Resources that have been freed up are<br />
then available for other value-creating<br />
activities.<br />
Furthermore, deevio stores the photos<br />
it takes in a database – together<br />
with the particular analysis results. Over<br />
time, a valuable source of information<br />
builds up, permitting accurate conclusions<br />
to be made about the production<br />
process. Among other things, it becomes<br />
clear which defects occur particularly<br />
often – and where there is a need<br />
for improvement.<br />
Figure 3: deevio creates an individually<br />
optimized machine learning model with<br />
the help of pictures of actual intact and<br />
defective products.<br />
Machine learning as a key<br />
technology in future quality<br />
assurance<br />
Machine learning is a relatively young<br />
technology. It only became attractive<br />
for image processing in 2012. The breakthrough,<br />
however, did not come then<br />
because, among other things, the algorithms<br />
had still not reached the level of<br />
accuracy necessary for industrial quality<br />
assurance. So the software, which could<br />
only assess product quality with 95%<br />
accuracy, was simply not practical in the<br />
foundry sector.<br />
Recently, however, both the machine<br />
learning algorithms and computers’<br />
performance and graphic cards have<br />
become considerably more powerful.<br />
The application opportunities have thus<br />
increased significantly.<br />
At present, the deevio solution still<br />
focuses on inspections at the end of<br />
production lines. In the future, however,<br />
it is conceivable that machine learning<br />
technologies could be used in various<br />
upstream processes. The potential is<br />
enormous, particularly for the early<br />
detection of defects. Imperfect parts<br />
could thus be diverted out early on,<br />
without passing through the entire process<br />
unnoticed.<br />
Summary: considerable improvements<br />
are possible in quality<br />
assurance processes<br />
deevio provides a solution that is greatly<br />
superior to either human quality<br />
assurance or classic machine vision<br />
approaches, particularly when there is<br />
high defect variance. The purchasing of<br />
new cameras or image processing systems<br />
is not always a prerequisite for<br />
introducing deevio’s software – existing<br />
inspection systems that have so far provided<br />
unsatisfactory results can be<br />
retrofitted with the machine learning<br />
solution and thus optimized.<br />
deevio’s system is also attractive for<br />
foundries with no experience of automated<br />
quality assurance using visual<br />
processes. A major advantage is that<br />
the Berlin-based service provider can<br />
offer complete solutions – thanks to its<br />
partners in machine construction, image<br />
processing and factory automation.<br />
www.deevio.ai<br />
Damian Heimel, COO, deevio GmbH,<br />
Berlin<br />
52
NEWS<br />
RUSAL<br />
New foundry complex at BoAZ<br />
Rusal, a leading global aluminium producer,<br />
announces the commissioning of<br />
a new foundry complex at the central<br />
Russian Boguchansky aluminium smelter<br />
(BoAZ) with a capacity of 120 thousand<br />
tonnes of alloys per year.<br />
The new foundry by the Italian company<br />
Properzi will produce a qualitatively<br />
new product – high silicon aluminium<br />
alloy with increased strength,<br />
which is commonly used in the automotive<br />
industry for the manufacture of<br />
wheels, engine units and various spare<br />
parts. Demand for this product is strong<br />
in markets such as Japan, Indonesia,<br />
Turkey, South Korea, Germany, and the<br />
United States.<br />
The new complex is fully automated,<br />
producing ingots through continuous<br />
casting technology which eliminates the<br />
formation of any slag inclusions and<br />
other defects inherent in traditional<br />
casting methods.<br />
Rusal has invested over 600 million<br />
rubles (around 6,9 million euros) in the<br />
project. „The new foundry complex at<br />
the Boguchansky aluminium smelter,<br />
Ingot casting facility at the Boguchansky aluminium smelter<br />
(…) will significantly expand the VAP<br />
line. The new foundry will produce high<br />
quality alloys for the automotive industry,<br />
which are used in the manufacture<br />
of key automotive parts and units. As<br />
foreign markets recover, the demand<br />
for these products will continue to<br />
grow,“ said Rusal’s CEO Evgenii Nikitin.<br />
https://boaz-zavod.ru/en<br />
Photo: Rusal<br />
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RUDOLF UHLEN GmbH<br />
Face protection for every application<br />
Rudolf Uhlen GmbH is a manufacturer of personal protective<br />
equipment (PPE) for face protection. Especially for the steel<br />
and foundry industry we provide special solutions in the field<br />
of IR-protection. We produce:<br />
Ÿ Visor Carriers<br />
Ÿ Gold-coated visors<br />
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CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 53
NEWS<br />
FOSECO<br />
Die-coatings increase operating life<br />
Foseco from Borken in Germany reports<br />
that its latest range of Dycote Safeguard<br />
die-coatings increase die operating<br />
life by up to 3 times compared to conventional<br />
coatings. This new range of<br />
die coatings has been developed specifically<br />
to maximize the service life and<br />
maintain surface quality for critical aluminium<br />
components such as aluminium<br />
wheels and cylinder heads.<br />
Poor die coating service life leads to<br />
reduced productivity and increases the<br />
risk of rejects due to poor casting surface<br />
quality. Foseco’s Dycote Safeguard<br />
products are nano-ceramic coatings<br />
designed to be applied on top of existing<br />
insulating Dycote base coatings.<br />
Best results are achieved when applied<br />
using the Foseco Dycote Spraygun<br />
which ensures a very consistent and uniform<br />
coating layer application.<br />
The extended life achieved with the<br />
coatings reduces the frequency of coating<br />
touch-up operations and also complete<br />
mold cleaning and re-coating operations,<br />
thereby reducing die downtime<br />
and maximizing productivity. Improved<br />
casting surface finish consistency has<br />
also been noted.<br />
www.foseco.com<br />
Dycote Safeguard die-coatings are<br />
e. g. recommended for the production<br />
of aluminum wheels<br />
Photo: Foseco<br />
YXLON<br />
Time for a new inspection experience<br />
Red carpet roll-out and premiere: Yxlon<br />
<strong>International</strong> from Hamburg, Germany,<br />
has launched its completely new operating<br />
concept with the innovative universal<br />
x-ray and CT system Yxlon UX20.<br />
Specialized x-ray knowledge is no longer<br />
mandatory. Now, even untrained<br />
personnel can easily achieve optimal<br />
inspection results. This is made possible<br />
by the award winning Yxlon Geminy<br />
software platform, which combines all<br />
the programs involved. With intuitive<br />
menu navigation, numerous pre-settings<br />
and the ability to switch seamlessly<br />
between radioscopy and computed<br />
tomography quickly performed<br />
testing processes are easy.<br />
With its compact footprint, the<br />
UX20 is specially designed for use in<br />
harsh environments like foundries in<br />
the automotive and aviation industries.<br />
The system components such as the<br />
generator, cooler and high-voltage<br />
cable are economically integrated into<br />
the cabin for protected and extended<br />
use while still easily accessible for<br />
maintenance work. UX20 is ideally suited<br />
for the inspection of castings,<br />
Yxlon cast part inspection system Yxlon UX20<br />
welds, plastic and ceramic components<br />
and special alloys. Thanks to the<br />
advanced CT functions, parts of sizes<br />
up to 800 mm in diameter and 1100<br />
mm in height can reliably be inspected.<br />
The height-adjustable operator work<br />
Photo: Yxlon<br />
area is directly attached to the system.<br />
When opening the door, the parts<br />
manipulator automatically moves to<br />
the edge of the cabin offering ease of<br />
loading.<br />
www.yxlon.com<br />
54
TESLA<br />
Giga structural die casting for Model Y<br />
IDRA OL CS die casting cells like this are<br />
to be used in Tesla plants in the USA<br />
China and probably also in Germany to<br />
produce XXL-structural castings.<br />
Tesla is to produced one million Model Y<br />
vehicles per year. Elon Musk has now<br />
announced that the entire rear underbody<br />
structure will be represented by a<br />
one-piece aluminum die-cast part.<br />
The electric car manufacturer Tesla is<br />
following construction plans for its new<br />
Model Y that gives casting a previously<br />
unimagined new meaning. With the<br />
world‘s largest aluminum die-casting<br />
machine, IDRA‘s OL6200 CS HPDC, the<br />
car manufacturer wants to cast the<br />
entire rear underbody of the 231 kph<br />
electric car in one piece.<br />
Implementation of the construction<br />
concept is planned for this year. The<br />
one-piece cast part is to replace around<br />
70 stamped, cast and profile components<br />
that make up the same assembly<br />
in Tesla Model 3, the construction basis<br />
for Model Y.<br />
Tesla boss Elon Musk spoke in a<br />
podcast in April <strong>2020</strong> for the first time<br />
about the new one-piece rear cast<br />
part, which will also integrate the rear<br />
crash rails. US automotive experts<br />
described the cast part as the largest<br />
cast application to date in automotive<br />
engineering. The huge castings are to<br />
be produced in series in the Tesla<br />
plants in Fremont, California, and in<br />
Shanghai, China, on the giant die casting<br />
machines of the Italian mechanical<br />
engineering company IDRA, which<br />
Musk calls Gigapresses. They are also<br />
likely to be manufactured in the new<br />
Tesla plant in Grünheide near Berlin in<br />
Germany. The German Gigafactory,<br />
which is currently under construction,<br />
will employ 10,000 people and is<br />
expected to produce up to 500,000<br />
Models 3 and Y vehicles per year. The<br />
works also has a die casting foundry.<br />
Various news channels are already speculating<br />
that the Giga presses will also<br />
be used there to produce the cast rear<br />
body. Because of such state-of-the-art<br />
production technology, experts expect<br />
that the German Tesla-Gigafactory<br />
could become the most profitable factory<br />
to date<br />
The machine behind the new cast<br />
construction does not skimp on superlatives.<br />
There is talk of Gigapresses or<br />
Goliath machines. Meanwhile, there is<br />
confusion about which IDRA die casting<br />
machine will actually be used to<br />
manufacture the one-piece rear casting.<br />
Tesla spoke of the OL 6100 CS<br />
model, but the system does not officially<br />
exist. Probably the OL 6200 CS<br />
HPDC is meant, which actually has considerable<br />
dimensions and performance<br />
parameters: with a weight of 430 tons,<br />
5500 tons of clamping force and a<br />
maximum shot weight of 104.6 kilograms,<br />
the 19.5 meter long and 5.3<br />
meter high die casting machine is<br />
huge, with the dimensions of a small<br />
house.<br />
Musk‘s pioneering commitment to<br />
automotive engineering and cast part<br />
design sends out a significant signal to<br />
the German automotive and foundry<br />
industries. Although the momentum is<br />
currently being slowed in part by the<br />
Corona pandemic, a reaction by German<br />
carmakers to Musk‘s advance in<br />
electromobility in Germany will sooner<br />
or later be inevitable.<br />
Photos: Private<br />
Photo: IDRA<br />
An IDRA video shows<br />
how the Tesla XXL<br />
parts are cast<br />
https://bit.ly/2CiQWTI<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 55
NEWS<br />
VOXELJET<br />
Largest industrial 3-D printing system goes to India<br />
The 3-printing specialist voxeljet AG<br />
further expands its presence in India.<br />
The supplier of industrial 3-D printing<br />
solutions based in Friedberg, Germany,<br />
is selling a VX 4000 system, one of the<br />
world’s largest and most productive 3-D<br />
printers with a build volume of eight<br />
cubic meters, to the Indian steel casting<br />
expert Peekay Steel Castings (P) Ltd.<br />
Peekay is present in the Indian cities of<br />
Calicut, Coimbatore and Hindupur. The<br />
VX4000 will be set up in a brand new<br />
location at Bangalore in the Airport<br />
City. The machine has a Job Box size of<br />
4000 x 2000 x 1000 mm. Peekay Steel<br />
has chosen the VX4000 system to<br />
quickly and economically realize technically<br />
demanding projects and to expand<br />
into new business areas.<br />
Peekay Steel specializes in the production<br />
of high-quality steel castings,<br />
predominantly for the Oil & Gas sector,<br />
starting from 1 kg to 20 tons per casting.<br />
For most of these products they<br />
require less than four castings. As a<br />
result, the time and cost towards<br />
development of patterns can outweigh<br />
total project costs. For some complicated<br />
castings, that require non-traditional<br />
gating, the VX4000 was most<br />
suitable.<br />
“When it comes to castings weighing<br />
several tons, the requirements for<br />
dimensional stability and accuracy are<br />
particularly high. With our 20 years of<br />
experience in the field of industrial 3-D<br />
printing and the VX4000, we can offer<br />
both a wealth of experience and the<br />
right tool,” says Rudolf Franz, COO &<br />
CFO of voxeljet AG. “We want to offer<br />
our customers an end-to-end solution<br />
The VX4000 is voxeljet’s largest 3-D printer and has a building volume of 4000 x 2000 x<br />
1000 mm or 8 cubic meters (Photo: voxeljet).<br />
and position ourselves as a supplier of<br />
high-quality, ready-to-install components<br />
in record times. With the<br />
VX4000, we are able to increase the<br />
flexibility of our production in order to<br />
be able to react quickly, even to complex<br />
projects. A specialized Design Center<br />
aligned to the VX4000 will help add<br />
value for our customers,” adds K.E.<br />
Shanavaz, Jt. Managing Director,<br />
Peekay Steel Castings (P) Ltd.<br />
Additionally, one of the drivers was<br />
the impending uncertainty in these trying<br />
times. With the size, speed and<br />
flexibility of the VX4000 Peekay Steel<br />
can cater to new projects from their<br />
existing customers at record times<br />
while also looking for different business<br />
areas to venture into.<br />
Peekay Steel has a multi-pronged<br />
approach to their VX4000. They not<br />
only want to support the foundry<br />
industry in India by providing services<br />
from their large system, but also plan<br />
to set up a high-tech Knowledge Center<br />
around their VX4000. This will<br />
include a training facility to support<br />
educational institutes and the industry<br />
alike. An open access of this kind is a<br />
means to attract more and more people<br />
towards the foundry industry – a<br />
much needed paradigm shift.<br />
www.voxeljet.com<br />
Photo: Private<br />
TARGI KIELCE<br />
Metal trade fair invites to Poland<br />
For years, the <strong>International</strong> Fair of Technologies<br />
for Foundry Metal in Kielce has<br />
been the meeting arena for top-class<br />
companies and professionals from all<br />
corners of the world. Save the date for<br />
14-16 October <strong>2020</strong> as the trade fair is<br />
taking place as planned.<br />
The Metal expo is held in the everyother-year<br />
cycle as a part of the exhibitions<br />
cluster composed of Aluminium &<br />
Nonfermet, Recycling and Control-Tech.<br />
The exhibitions have advanced to<br />
become Central and Eastern Europe‘s<br />
most important foundry and casting<br />
business-sector‘s events cluster. The<br />
Metal exhibitors have always included a<br />
wide range of companies which professionally<br />
deal with metals heat treatment<br />
and heating devices.<br />
All industry insiders consider the<br />
expo a part of the whole business-sector‘s<br />
tradition. This year‘s event<br />
abounds with the latest technologies,<br />
machines and equipment designed for<br />
everyday use in foundries and casting<br />
houses. The „Industrial Autumn“ has<br />
been the meetings platform for various<br />
industries‘ representatives, and among<br />
them foundry and casting, machine and<br />
electromechanical, railways, shipbuilding,<br />
armaments, robotics and automation,<br />
automotive and aviation and<br />
many related industries. Exhibitors<br />
come from all parts of the world including<br />
France, Switzerland, Germany,<br />
Hungary, Great Britain, the United Sta-<br />
56
tes, Turkey, India, China and Japan.<br />
Furthermore, Targi Kielce has enjoyed<br />
the support of prominent, foreign<br />
foundry organizations for years like the<br />
Italian Foundry Suppliers‘ Association<br />
Amafond, the China Foundry Association<br />
(CFA) and the Polish Stop - Technical<br />
Association of Polish Foundrymen.<br />
Until now, containers with disinfecting<br />
liquid have been made available<br />
in Targi Kielce exhibition facilities.<br />
Every person who wants to enter the<br />
facility has had to undergo mandatory<br />
temperature screening. Regular disinfection<br />
of frequently touched infrastructure<br />
elements, i.e. door handles,<br />
handrails, balustrades, counter-tops,<br />
tables and other sanitary measures<br />
have also been intensified. The autumn<br />
events‘ participants will be offered<br />
extra points of sale operating in front<br />
of the terminals - face-covering masks,<br />
gloves and anti-virus fluids will be distributed<br />
there. The fairgrounds will<br />
also be equipped with decontamination<br />
gates, information boards, traffic<br />
directions designed to ensure social<br />
distancing. Medical service units and<br />
personal protective equipment points<br />
of sales will come at the top of the priority<br />
list.<br />
www.targikielce.pl<br />
Trade fair activity in Kielce. Despite the<br />
pandemic, the Metal trade fair will again<br />
take place this year from October 14-16,<br />
<strong>2020</strong><br />
Photo: Targi Kielce<br />
PNEUMATIC DECORING HAMMERS FOR GRAVITY,<br />
LOW PRESSURE AND LOST WAX PROCESS<br />
Different models<br />
Easily carried<br />
High performances<br />
Worldwide presence<br />
Customer care<br />
Repair service<br />
Monitoring system Thor V4.0 to check the<br />
hammers performances during operation<br />
O.M.LER designs and manufactures decoring benches in<br />
accordance to the specific needs of every customer.<br />
Example of a decoring bench<br />
JUST CONTACT US TO KNOW MORE ABOUT OUR PRODUCTS! By contacting, please<br />
give us following code: <strong>CPT</strong>_4<strong>2020</strong><br />
O.M.LER SRL - Via Don Orione , 198/E, 198/F – 12042 Bra (CN) – Italy – Tel. +39 0172 457256 -<br />
omler@omlersrl.com - www.omlersrl.com<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 57
NEWS<br />
O.M.LER<br />
Decoring solutions from Italy<br />
The mechanical engineering company<br />
O.M.LER srl, established in 1974 in<br />
northwest Italy, designs, manufactures<br />
and sells pneumatic decoring hammers<br />
for foundries worlwide. Current decoring<br />
solution of the company are the<br />
two pneumatic decoring hammers<br />
RVC70 and AF1470. Decoring hammers<br />
are usually adopted to remove the sand<br />
core from cast iron, aluminium and<br />
steel foundry castings, such as for<br />
example cylinder heads, engine blocks,<br />
structural parts, motorbikes’, and snowmobiles’<br />
engines. Pneumatic decoring<br />
hammers can also be adopted by foundries<br />
who use the investment casting<br />
process to break or remove the ceramic<br />
shell. This is possible because O.M.LERs<br />
decoring hammers can work at different<br />
air pressures and with different<br />
set-ups, avoiding damages to the castings<br />
and removing sand or ceramic also<br />
from castings with complicated structure<br />
and/or thin walls.<br />
Decoring hammers like the AF1470 are usually used to remove sand cores from castings.<br />
To decore a casting the hammers<br />
have to be fastened in a decoring unit,<br />
such as a decoring bench. The decoring<br />
bench is is also offered by O.M.LER. The<br />
company designers create every decoring<br />
bench in accordance to the specific<br />
needs of every customer and the specialized<br />
technical staff manufacture it in<br />
the production department.<br />
In every decoring bench the decoring<br />
hammers are fastened to the<br />
machine structure and they have a fixed<br />
position, both vertical or horizontal,<br />
depending on the kind of casting to<br />
decore. The hammers‘ positionning has<br />
to be defined during the design stage.<br />
Normally every decoring bench has<br />
from 1 up to 4 hammers.<br />
The castings to be decored are loaded<br />
and unloaded by a robot outside<br />
the machine. The casting is always positioned<br />
in the same preset housing.<br />
<br />
www.omlersrl.com<br />
Photo: O.M.LER<br />
FLOW-3D<br />
New process workspaces and state-of-the-art<br />
solidification model<br />
Flow Science, Inc., Santa Fe, USA, has<br />
announced a major release of their<br />
metal casting simulation software<br />
Flow-3D Cast v5.1, a modeling platform<br />
that combines extraordinary accuracy<br />
with versatility, ease of use, and high<br />
performance cloud computing.<br />
Flow-3D Cast v5.1 features new process<br />
workspaces for investment casting,<br />
sand core making, centrifugal casting,<br />
and continuous casting, as well as a<br />
chemistry-based alloy solidification<br />
model capable of predicting the<br />
strength of the part at the end of the<br />
process, an expansive exothermic riser<br />
database, and improved interactive<br />
geometry creation. Flow-3D Cast now<br />
has 11 process workspaces that cover<br />
the spectrum of casting applications,<br />
which can be purchased individually or<br />
as bundles.<br />
“Offering Flow-3D Cast by process<br />
workspace gives foundries and tool &<br />
die shops the flexibility to balance their<br />
needs with cost, in order to address the<br />
increased challenges and demands of<br />
the manufacturing sector,” said Dr.<br />
Amir Isfahani, CEO of Flow Science.<br />
FLOW-3D CAST‘s new chemistry-based solidification model accurately predicts secondary<br />
dendrite arm spacing (SDAS) in a gravity sand casting of an Al-Si alloy<br />
Flow-3D Cast T v5.1’s brand new<br />
solidification model gives users the ability<br />
to predict the strength and mechanical<br />
properties of cast parts while<br />
reducing scrap and still meeting product<br />
safety and performance requirements.<br />
By accessing a database of chemical<br />
compositions of alloys, users can<br />
predict ultimate tensile strength,<br />
elongation, and thermal conductivity<br />
to better understand both mechanical<br />
properties and microstructure of the<br />
part. Databases for heat transfer coefficients,<br />
air vents, HPDC machines, and<br />
GTP Schäfer risers provide information<br />
at users’ fingertips. The new Exothermic<br />
Riser Database along with the Solidification<br />
Hotspot Identification tool<br />
helps users with the precise placement<br />
of exothermic risers to prevent predicted<br />
shrinkage.<br />
www.flow3d.com<br />
Graphics: Flow Science<br />
58
Photo: Italpresse Gauss<br />
ITALPRESSE GAUSS<br />
Tailor-made die casting cells for Siemens<br />
Siemens AG received two die casting machines from<br />
Italpresse Gauss, types IP 750 SC and IP 550, with<br />
a clamping force of 750 and 550 tonnes respectively<br />
It all began with a rethink of how space<br />
is used at a Siemens AG location in Germany.<br />
The die casting operations at the<br />
company’s Bad Neustadt facility was<br />
going to have to “move house”. The<br />
project team was given a new building<br />
to redesign the die casting of components<br />
for Siemens electric motors from<br />
scratch.<br />
Two new, fully automated die casting<br />
cells were to become the heart of<br />
the new facility. The existing tools<br />
quickly narrowed down the choice to a<br />
three-platen cold-chamber machine.<br />
Beyond this machine type, the team<br />
had a raft of specific requirements for<br />
the new cells.<br />
For the team at Siemens, the<br />
engineering and integration of such a<br />
cell, and defining all its interfaces, was<br />
a task for experts: focus during the<br />
purchasing process was very much on<br />
ensuring any potential partner had the<br />
ability to deliver a complete solution.<br />
One that works, seamlessly, even when<br />
integrating special requests and specifications.<br />
Volker Ress continues: “Ultimately,<br />
we want a solution that is ready to<br />
go and a folder that tells us everything<br />
we need to know to run it. The team at<br />
Italpresse Gauss has realised and integrated<br />
all our special requirements<br />
without any problems.”<br />
The ability to connect to Mind-<br />
Sphere was particularly important to<br />
Siemens. Machine controls have to be<br />
primed for new demands in terms of<br />
data collection – by offering sufficient<br />
internal memory, for example – and<br />
have to be open for local IIoT integration.<br />
Volker Ress explains: “Openness,<br />
both technical and organisational, is<br />
key. The equipment manufacturer has<br />
to be happy for us to plug an ethernet<br />
cable into the machine and grab data<br />
straight from the PLC. I need a system<br />
that gives me data relevant to the die<br />
casting process. Italpresse Gauss’ HMe<br />
machine control does just that.”<br />
Marco Giegold from Italpresse<br />
Gauss summarises the project: “Flexibility<br />
in the specification of die casting<br />
cells is becoming more and more<br />
important. Aluminium foundries have<br />
their individual, specific requirements<br />
and are increasingly asked to integrate<br />
these cells into sophisticated production<br />
systems. In this context, Industry<br />
4.0 is only one aspect – albeit an<br />
important one. For us, all of this is simply<br />
an exciting challenge. The more<br />
open we are to unusual customer<br />
requests, the more technologies and<br />
components we get to see and know. It<br />
allows us to constantly expand our<br />
knowledge and find the best solutions<br />
for our customers faster.”<br />
www.italpressegauss.com/en-gb<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 59
SUPPLIERS GUIDE<br />
CASTING<br />
PLANT AND TECHNOLOGY<br />
INTERNATIONAL<br />
© DVS Media GmbH<br />
Contact person: Vanessa Wollstein<br />
Aachener Straße 172 Phone: +49 211 1591-152<br />
40223 Düsseldorf Fax: +49 211 1591-150<br />
E-Mail: vanessa.wollstein@dvs-media.info<br />
1 Foundry Plants and Equipment<br />
17 Surface Treatment and Drying<br />
2<br />
Melting Plants and Equipment for Iron and<br />
Steel Castings and for Malleable Cast Iron<br />
18<br />
Plant, Transport, Stock, and Handling<br />
Engineering<br />
3 Melting Plants and Equipment for NFM<br />
4 Refractories Technology<br />
19 Pattern- and Diemaking<br />
20 Control Systems and Automation<br />
5<br />
6<br />
7<br />
8<br />
Non-metal Raw Materials and Auxiliaries for<br />
Melting Shop<br />
Metallic Charge Materials for Iron and Steel<br />
Castings and for Malleable Cast Iron<br />
Metallic Charge and Treatment Materials for<br />
Light and Heavy Metal Castings<br />
Plants and Machines for Moulding and<br />
Coremaking Processes<br />
21 Testing of Materials<br />
22 Analysis Technique and Laboratory<br />
23 Air Technique and Equipment<br />
24 Environmental Protection and Disposal<br />
9 Moulding Sands<br />
10 Sand Conditioning and Reclamation<br />
11 Moulding Auxiliaries<br />
12 Gating and Feeding<br />
13 Casting Machines and Equipment<br />
25 Accident Prevention and Ergonomics<br />
26 Other Products for Casting Industry<br />
27 Consulting and Service<br />
28 Castings<br />
29 By-Products<br />
14<br />
Discharging, Cleaning, Finishing of Raw<br />
Castings<br />
30 Data Processing Technology<br />
15 Surface Treatment<br />
16 Welding and Cutting<br />
31 Foundries<br />
32 Additive manufacturing / 3-D printing<br />
60
SUPPLIERS GUIDE<br />
03 Melting Plants and Equipment for NFM<br />
03.02 Melting and Holding Furnaces, Electrically<br />
Heated<br />
▼ Aluminium Melting Furnaces 630<br />
Refratechnik Steel GmbH<br />
Refratechnik Casting GmbH<br />
Am Seestern 5, 40547 Düsseldorf, Germany<br />
( +49 211 5858-0<br />
E-Mail:<br />
steel@refra.com<br />
Internet:<br />
www.refra.com<br />
▼ Insulating Products 1130<br />
08 Plants and Machines for Moulding and<br />
Coremaking Processes<br />
08.02 Moulding and Coremaking Machines<br />
▼ Multi-Stage Vacuum Process 3223<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Remelting Furnaces 700<br />
EIKA, S.COOP<br />
Urresolo 47, 48277 Etxebarria<br />
( +34 946 16 77 32<br />
Internet:<br />
Spain<br />
E-Mail:<br />
aagirregomezkorta@isoleika.es<br />
Internet:<br />
www.isoleika.es<br />
▼ Micro Porous Insulating Materials 1220<br />
Pfeiffer Vacuum GmbH<br />
35614 Asslar, Germany<br />
( +49 6441 802-1190 7 +49 6441 802-1199<br />
E-Mail:<br />
andreas.wuerz@pfeiffer-vacuum.de<br />
Internet:<br />
www.pfeiffer-vacuum.de<br />
09 Moulding Sands<br />
09.01 Basic Moulding Sands<br />
▼ Chromite Sands 3630<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
04 Refractories Technology<br />
04.01 Plants, Equipment and Tools for Lining in Melting<br />
and Casting<br />
▼ Mixers and Chargers for Refractory Mixes 930<br />
EIKA, S.COOP<br />
Urresolo 47, 48277 Etxebarria<br />
( +34 946 16 77 32<br />
Internet:<br />
Spain<br />
E-Mail:<br />
aagirregomezkorta@isoleika.es<br />
Internet:<br />
www.isoleika.es<br />
▼ Ladle Refractory Mixes 1240<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Ceramic Sands/Chamotte Sands 3645<br />
UELZENER Maschinen GmbH<br />
Stahlstr. 26-28, 65428 Rüsselsheim, Germany<br />
( +49 6142 177 68 0<br />
E-Mail:<br />
contact@uelzener-ums.de<br />
Internet:<br />
www.uelzener-ums.de<br />
▼ Gunning for Relining of Cupolas 950<br />
UELZENER Maschinen GmbH<br />
Stahlstr. 26-28, 65428 Rüsselsheim, Germany<br />
( +49 6142 177 68 0<br />
E-Mail:<br />
contact@uelzener-ums.de<br />
Internet:<br />
www.uelzener-ums.de<br />
04.04 Refractory Building<br />
▼ Maintenance of Refractory Linings 1462<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Silica Sands 3720<br />
UELZENER Maschinen GmbH<br />
Stahlstr. 26-28, 65428 Rüsselsheim, Germany<br />
( +49 6142 177 68 0<br />
E-Mail:<br />
contact@uelzener-ums.de<br />
Internet:<br />
www.uelzener-ums.de<br />
04.02 Refractory Materials (Shaped and Non Shaped)<br />
▼ Refractories, in general 1040<br />
UELZENER Maschinen GmbH<br />
Stahlstr. 26-28, 65428 Rüsselsheim, Germany<br />
( +49 6142 177 68 0<br />
E-Mail:<br />
contact@uelzener-ums.de<br />
Internet:<br />
www.uelzener-ums.de<br />
05 Non-metal Raw Materials and Auxiliaries for<br />
Melting Shop<br />
05.04 Carburization Agents<br />
▼ Coke Breeze, Coke-Dust 1680<br />
STROBEL QUARZSAND GmbH<br />
Freihungsand, 92271 Freihung, Germany<br />
( +49 9646 9201-0 7 +49 9646 9201-701<br />
E-Mail:<br />
info@strobel-quarzsand.de<br />
Internet:<br />
www.strobel-quarzsand.de<br />
09.04 Mould and Core Coating<br />
▼ Blackings, in general 4270<br />
ARISTON Formstaub-Werke GmbH & Co. KG<br />
Worringerstr. 255, 45289 Essen, Germany<br />
( +49 201 57761 7 +49 201 570648<br />
Internet:<br />
www.ariston-essen.de<br />
EIKA, S.COOP<br />
Urresolo 47, 48277 Etxebarria<br />
( +34 946 16 77 32<br />
Internet:<br />
Spain<br />
E-Mail:<br />
aagirregomezkorta@isoleika.es<br />
Internet:<br />
www.isoleika.es<br />
ARISTON Formstaub-Werke GmbH & Co. KG<br />
Worringerstr. 255, 45289 Essen, Germany<br />
( +49 201 57761 7 +49 201 570648<br />
Internet:<br />
www.ariston-essen.de<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 61
09.06 Moulding Sands Testing<br />
▼ Moisture Testing Equipment for Moulding Sand 4410<br />
▼ Aerators 4560<br />
▼ Insulating Sleeves 5375<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
▼ Moulding Sand Testing Equipment, in general 4420<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
▼ Scales and Weighing Control 4590<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Exothermic Mini-Feeders 5400<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
10 Sand Conditioning and Reclamation<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
10.04 Sand Reconditioning<br />
▼ Sand Coolers 4720<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Exothermic Feeder Sleeves 5420<br />
10.01 Moulding Sand Conditioning<br />
▼ Aerators for Moulding Sand Ready-to-Use 4470<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
▼ Sand Preparation Plants and Machines 4480<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
▼ Mixers 4520<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
12 Gating and Feeding<br />
▼ Covering Agents 5320<br />
Refratechnik Steel GmbH<br />
Refratechnik Casting GmbH<br />
Am Seestern 5, 40547 Düsseldorf, Germany<br />
( +49 211 5858-0<br />
E-Mail:<br />
steel@refra.com<br />
Internet:<br />
www.refra.com<br />
▼ Breaker Cores 5340<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Exothermic Feeding Compounds 5430<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
13 Casting Machines and Equipment<br />
13.02 Die Casting and Accessories<br />
▼ Diecasting Lubricants 5670<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
▼ Sand Mixers 4550<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
▼ Exothermic Products 5360<br />
Chem-Trend (Deutschland) GmbH<br />
Robert-Koch-Str. 27, 22851 Norderstedt, Germany<br />
( +49 40 52955-0 7 +49 40 52955-2111<br />
E-Mail:<br />
service@chemtrend.de<br />
Internet:<br />
www.chemtrend.com<br />
▼ Diecasting Parting Agents 5680<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50,<br />
74736 Hardheim, Germany<br />
Internet: www.eirich.de<br />
GTP Schäfer GmbH<br />
41515 Grevenbroich, Germany<br />
( +49 2181 23394-0 7 +49 2181 23394-55<br />
E-Mail:<br />
info@gtp-schaefer.de<br />
Internet:<br />
www.gtp-schaefer.com<br />
Chem-Trend (Deutschland) GmbH<br />
Robert-Koch-Str. 27, 22851 Norderstedt, Germany<br />
( +49 40 52955-0 7 +49 40 52955-2111<br />
E-Mail:<br />
service@chemtrend.de<br />
Internet:<br />
www.chemtrend.com<br />
62
SUPPLIERS GUIDE<br />
▼ Hydraulic Cylinders 5750<br />
17.01 Plants and Furnaces<br />
▼ Tempering Furnaces 7400<br />
▼ Heat Treating Furnaces 7520<br />
HYDROPNEU GmbH<br />
Sudetenstr. , 73760 Ostfildern, Germany<br />
( +49 711 342999-0 7 +49 711 342999-1<br />
E-Mail:<br />
info@hydropneu.de<br />
Internet:<br />
www.hydropneu.de<br />
▼ Piston Lubricants 5790<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Ageing Furnaces 7401<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Hearth Bogie Type Furnaces 7525<br />
Chem-Trend (Deutschland) GmbH<br />
Robert-Koch-Str. 27, 22851 Norderstedt, Germany<br />
( +49 40 52955-0 7 +49 40 52955-2111<br />
E-Mail:<br />
service@chemtrend.de<br />
Internet:<br />
www.chemtrend.com<br />
▼ Parting Agents for Dies 5850<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Annealing and Hardening Furnaces 7430<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
18 Plant, Transport, Stock, and Handling<br />
Engineering<br />
Chem-Trend (Deutschland) GmbH<br />
Robert-Koch-Str. 27, 22851 Norderstedt, Germany<br />
( +49 40 52955-0 7 +49 40 52955-2111<br />
E-Mail:<br />
service@chemtrend.de<br />
Internet:<br />
www.chemtrend.com<br />
▼ Dry Lubricants (Beads) 5865<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Solution Annealing Furnaces 7455<br />
18.01 Continuous Conveyors and Accessories<br />
▼ Vibratory Motors 7980<br />
FRIEDRICH Schwingtechnik GmbH<br />
Am Höfgen 24, 42781 Haan, Germany<br />
( +49 2129 3790-0 7 +49 2129 3790-37<br />
E-Mail:<br />
info@friedrich-schwingtechnik.de<br />
Internet:<br />
www.friedrich-schwingtechnik.de<br />
20 Control Systems and Automation<br />
Chem-Trend (Deutschland) GmbH<br />
Robert-Koch-Str. 27, 22851 Norderstedt, Germany<br />
( +49 40 52955-0 7 +49 40 52955-2111<br />
E-Mail:<br />
service@chemtrend.de<br />
Internet:<br />
www.chemtrend.com<br />
▼ Multi-Stage Vacuum Process 5876<br />
Pfeiffer Vacuum GmbH<br />
35614 Asslar, Germany<br />
( +49 6441 802-1190 7 +49 6441 802-1199<br />
E-Mail:<br />
andreas.wuerz@pfeiffer-vacuum.de<br />
Internet:<br />
www.pfeiffer-vacuum.de<br />
17 Surface Treatment and Drying<br />
▼ Heat Treatment and Drying 7398<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Annealing Furnaces 7490<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
▼ Quenching and Tempering Furnaces 7510<br />
20.01 Control and Adjustment Systems<br />
▼ Automation and Control for Sand Preparation 9030<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Walldürner Str. 50, 74736 Hardheim, Germany<br />
20.02 Measuring and Control Instruments<br />
▼ Immersion Thermo Couples 9230<br />
Gebr. Löcher Glüherei GmbH<br />
Mühlenseifen 2, 57271 Hilchenbach, Germany<br />
( +49 2733 8968-0 7 +49 2733 8968-10<br />
Internet:<br />
www.loecher-glueherei.de<br />
LOI Thermoprocess GmbH<br />
45141 Essen/Germany<br />
( +49 201 1891-1<br />
E-Mail:<br />
service-loi@tenova.com<br />
Internet:<br />
www.loi.tenova.com<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 63
▼ Laser Measurement Techniques 9310<br />
▼ Numerical Solidification Simulation and Process Optimization<br />
9502<br />
27 Consulting and Service<br />
▼ Machining 11292<br />
POLYTEC GmbH<br />
76337 Waldbronn, Germany<br />
( +49 7243 604-0 7 +49 7243 69944<br />
E-Mail:<br />
Lm@polytec.de<br />
Internet:<br />
www.polytec.de<br />
▼ Positioning Control 9345<br />
MAGMA Giessereitechnologie GmbH<br />
Kackertstr. 11, 52072 Aachen, Germany<br />
( +49 241 88901-0 7 +49 241 88901-60<br />
E-Mail:<br />
info@magmasoft.de<br />
Internet:<br />
www.magmasoft.com<br />
▼ Simulation Software 9522<br />
Behringer GmbH<br />
Maschinenfabrik und Eisengiesserei<br />
Postfach:<br />
1153, 74910 Kirchardt, Germany<br />
( +49 7266 207-0 7 +49 7266 207-500<br />
Internet:<br />
www.behringer.net<br />
▼ Simulation Services 11310<br />
POLYTEC GmbH<br />
76337 Waldbronn, Germany<br />
( +49 7243 604-0 7 +49 7243 69944<br />
E-Mail:<br />
Lm@polytec.de<br />
Internet:<br />
www.polytec.de<br />
▼ Temperature Measurement 9380<br />
MAGMA Giessereitechnologie GmbH<br />
Kackertstr. 11, 52072 Aachen, Germany<br />
( +49 241 88901-0 7 +49 241 88901-60<br />
E-Mail:<br />
info@magmasoft.de<br />
Internet:<br />
www.magmasoft.com<br />
22 Analysis Technique and Laboratory Equipment<br />
MAGMA Giessereitechnologie GmbH<br />
Kackertstr. 11, 52072 Aachen, Germany<br />
( +49 241 88901-0 7 +49 241 88901-60<br />
E-Mail:<br />
info@magmasoft.de<br />
Internet:<br />
www.magmasoft.com<br />
▼ Heat Treatment 11345<br />
▼ Sampling Systems 9970<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
▼ Thermal Analysis Equipment 9400<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
Gebr. Löcher Glüherei GmbH<br />
Mühlenseifen 2, 57271 Hilchenbach, Germany<br />
( +49 2733 8968-0 7 +49 2733 8968-10<br />
Internet:<br />
www.loecher-glueherei.de<br />
28 Castings<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
▼ Thermo Couples 9410<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
20.03 Data Acquisition and Processing<br />
▼ Numerical Solidification Analysis and Process Simulation<br />
9500<br />
MAGMA Giessereitechnologie GmbH<br />
Kackertstr. 11, 52072 Aachen, Germany<br />
( +49 241 88901-0 7 +49 241 88901-60<br />
E-Mail:<br />
info@magmasoft.de<br />
Internet:<br />
www.magmasoft.com<br />
26 Other Products for Casting Industry<br />
26.02 Industrial Commodities<br />
▼ Joints, Asbestos-free 11120<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
▼ Sealing and Insulating Products up to 1260 øC 11125<br />
MINKON GmbH<br />
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany<br />
( +49 211 209908-0 7 +49 211 209908-90<br />
E-Mail:<br />
info@minkon.de<br />
Internet:<br />
www.minkon.de<br />
▼ Aluminium Pressure Diecasting 11390<br />
Schött Druckguß GmbH<br />
Aluminium Die Casting<br />
Postfach:<br />
27 66, 58687 Menden, Germany<br />
( +49 2373 1608-0 7 +49 2373 1608-110<br />
E-Mail:<br />
vertrieb@schoett-druckguss.de<br />
Internet:<br />
www.schoett-druckguss.de<br />
▼ Rolled Wire 11489<br />
Behringer GmbH<br />
Maschinenfabrik und Eisengiesserei<br />
Postfach:<br />
1153, 74910 Kirchardt, Germany<br />
( +49 7266 207-0 7 +49 7266 207-500<br />
Internet:<br />
www.behringer.net<br />
▼ Spheroidal Iron 11540<br />
Behringer GmbH<br />
Maschinenfabrik und Eisengiesserei<br />
Postfach:<br />
1153, 74910 Kirchardt, Germany<br />
( +49 7266 207-0 7 +49 7266 207-500<br />
Internet:<br />
www.behringer.net<br />
64
SUPPLIERS GUIDE<br />
30 Data Processing Technology<br />
▼ Mold Filling and Solidification Simulation 11700<br />
MAGMA Giessereitechnologie GmbH<br />
Kackertstr. 11, 52072 Aachen, Germany<br />
( +49 241 88901-0 7 +49 241 88901-60<br />
E-Mail:<br />
info@magmasoft.de<br />
Internet:<br />
www.magmasoft.com<br />
31 Foundries<br />
31.01 Iron, Steel, and Malleable-Iron Foundries<br />
▼ Iron Foudries 11855<br />
Behringer GmbH<br />
Maschinenfabrik und Eisengiesserei<br />
Postfach:<br />
1153, 74910 Kirchardt, Germany<br />
( +49 7266 207-0 7 +49 7266 207-500<br />
Internet:<br />
www.behringer.net<br />
Internet:<br />
Index to Companies<br />
Company Product Company Product<br />
ARISTON Formstaub-Werke 1680, 4270<br />
GmbH & Co. KG<br />
BEHRINGER GmbH 11292, 11489, 11540, 11855<br />
Maschinenfabrik&Eisengießerei<br />
Chem Trend (Deutschland) GmbH 5670, 5680, 5790, 5850, 5865<br />
Maschinenfabrik 4410, 4420, 4470, 4480, 4520,<br />
Gustav Eirich GmbH u. Co KG 4550, 4560, 4590, 4720, 9030<br />
Friedrich Schwingtechnik GmbH 7980<br />
GTP Schäfer 3630, 3645, 5340, 5360, 5375,<br />
Giesstechnische Produkte GmbH 5400, 5420, 5430<br />
HYDROPNEU GmbH 5750<br />
EIKA, S.COOP 1040, 1130, 1220<br />
Gebr. Löcher Glüherei 7398, 11345<br />
GmbH<br />
LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430,<br />
7455, 7490, 7510, 7520, 7525<br />
MAGMA Gießereitechnologie GmbH 9500, 9502, 9522, 11310, 11700<br />
MINKON GmbH 9230, 9380, 9400, 9410, 9970,<br />
Geschäftsleitung 11120, 11125<br />
Pfeiffer Vacuum GmbH 3223, 5876<br />
Polytec GmbH 9310, 9345<br />
Refratechnik Steel GmbH 1040, 5320<br />
Schött-Druckguß GmbH 11390<br />
Strobel Quarzsand GmbH 3720<br />
Uelzener Maschinen GmbH 930, 950, 1240, 1462<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 65
List of Products<br />
01 Foundry Plants and Equipment<br />
10 Foundry Plants, Planning and<br />
Construction<br />
20 Foundry Equipment and Facilities,<br />
in general<br />
30 Foundry Plants, fully and<br />
partially automatic<br />
40 Maintenance and Repairing of<br />
Foundry Plants<br />
44 Swing-Technique Machines for<br />
Handling, Dosing, and Classing<br />
45 Second Hand Foundry Plants and<br />
Equipment<br />
47 Spray Deposition Plants<br />
01.01. Components<br />
47 Spray Deposition Plants<br />
50 Charging Systems, in general<br />
52 Cored Wire Treatment Stations<br />
53 Plug Connections, Heat Resisting<br />
02 Melting Plants and Equipment for Iron and<br />
Steel Castings and for Malleable Cast Iron<br />
02.01. Cupolas<br />
55 Cupolas<br />
60 Hot-Blast Cupolas<br />
70 Cold-Blast Cupolas<br />
80 Circulating Gas Cupolas<br />
90 Gas Fired Cupolas<br />
100 Cupolas, cokeless<br />
110 Cupolas with Oxygen-Enrichment<br />
120 Cupolas with Secondary Blast<br />
Operation<br />
02.02. Cupola Accessories and<br />
Auxiliaries<br />
130 Lighter<br />
140 Cupola Charging Equipment<br />
150 Tuyères<br />
160 Burners for Cupolas<br />
180 Blowing-In Equipment for Carbo Fer<br />
190 Blowing-In Equipment for Filter<br />
Dusts into Cupolas<br />
210 Blowing-In Equipment for Carbon<br />
211 Blowing-In Equipment for Metallurgical<br />
Processes<br />
220 Dedusting, Cupolas<br />
225 Gas Cleaning<br />
230 Charging Plants, fully and partially<br />
automatic<br />
240 Blowers, Cupolas<br />
270 Recuperators<br />
280 Oxygen Injection for Cupolas<br />
290 Shaking Ladles, Plants<br />
295 Dust Briquetting<br />
300 Monitoring Plants, Cupola<br />
310 Forehearths, Cupola<br />
320 Blast Heater<br />
02.03. Melting and Holding<br />
Furnaces, Electrically Heated<br />
330 Electric melting Furnaces, in general<br />
340 Induction Channel Furnaces<br />
350 Crucible Induction Furnaces, medium<br />
Frequency<br />
360 Crucible Induction Furnaces,<br />
Mains Frequency<br />
370 Short-Coil Induction Furnaces<br />
390 Filters, in general<br />
399 Tower Melter<br />
400 Holding Furnaces<br />
02.04. Accessories and Auxiliaries<br />
for Electric Furnaces<br />
410 Charging Units<br />
420 Blowing-In Equipment for Carbo Fer<br />
430 Blowing-In Equipment for Filter Dusts<br />
440 Blowing-In Equipment for Carbon<br />
445 Inert Gas Systems for EAF and EIF<br />
450 Inert Gas Systems for EAF and EIF<br />
460 Electro-magnetic Conveyor Chutes<br />
470 Dust Separation Plant<br />
480 Charging Equipment<br />
500 Graphite Electrodes<br />
510 Lime Dosing Device<br />
520 Condensors<br />
540 Cooling Equipment<br />
550 Scrap preheating Plants<br />
560 Secondary Metallurgical Plants<br />
565 Control Installations<br />
570 Equipment for induction stirring<br />
02.05. Rotary Furnaces<br />
580 Rotary Furnaces<br />
02.06. Maintenance and Repairing<br />
584 Repairing of Induction Furnaces<br />
586 Maintenance of Complete<br />
Induction Furnace Plants<br />
03 Melting Plants and Equipment for NFM<br />
03.01. Melting Furnaces, Fuel Fired<br />
590 Hearth-Type (Melting) Furnaces<br />
599 Tower Furnaces<br />
600 Bale-Out Furnaces<br />
610 Crucible Furnaces<br />
620 Drum-Type Melting Furnaces<br />
03.02. Melting and Holding<br />
Furnaces, Electrically Heated<br />
630 Aluminium Melting Furnaces<br />
640 Dosing Furnace<br />
655 Heating Elements for Resistance<br />
Furnaces<br />
660 Induction Furnaces (Mains,<br />
Medium, and High Frequency)<br />
665 Magnesium Melting Plants and<br />
Dosing Devices<br />
670 Melting Furnacs, in general<br />
680 Bale-Out Furnaces<br />
690 Crucible Furnaces<br />
700 Remelting Furnaces<br />
710 Holding Furnaces<br />
720 Electric Resistance Furnaces<br />
902 Vacuum Melting and Casting<br />
Furnaces<br />
03.03. Accessories and Auxiliaries<br />
730 Exhausting Plants<br />
740 Molten Metal Refining by Argon<br />
742 Gassing Systems for Aluminium<br />
Melting<br />
750 Gassing Systems for Magnesium<br />
Melting<br />
760 Charging Plants<br />
770 Blowing-in Equipment for Alloying<br />
and Inoculating Agents<br />
774 Blowing-in Equipment for<br />
Inoculating Agents<br />
778 Degassing Equipment<br />
780 Dedusting Equipment<br />
785 Crucibles, Ready-To-Use<br />
790 Charging Equipment<br />
800 Graphite Melting Pots<br />
825 Emergency Iron Collecting<br />
Reservoirs<br />
847 Cleaning Devices for Cleaning<br />
Dross in Induction Furnaces<br />
848 Cleaning Device and Gripper for<br />
Deslagging - Induction Furnaces<br />
850 Crucibles<br />
860 Inert Gas Systems<br />
870 Silicon Carbide Pots<br />
875 Special Vibrating Grippers for<br />
the Removal of Loose Dross and<br />
Caking<br />
880 Gas Flushing Installations<br />
890 Crucibles, Pots<br />
895 Power Supply, Plasma Generators<br />
900 Vacuum Degassing Equipment<br />
04 Refractories Technology<br />
04.01. Plants, Equipment and Tools for<br />
Lining in Melting and Casting<br />
910 Spraying Tools for Furnace Lining<br />
920 Breakage Equipment for Cupolas,<br />
Crucibles, Pots, Torpedo Ladles<br />
and Ladles<br />
923 Lost Formers<br />
930 Mixers and Chargers for<br />
Refractory Mixes<br />
940 Charging Units for Furnaces<br />
950 Gunning for Relining of Cupolas<br />
954 Ramming Mix Formers<br />
956 Ramming Templates<br />
980 Wear Indicators for Refractory Lining<br />
982 Wear Measuring and Monitoring<br />
for Refractory Lining<br />
985 State Diagnosis of Refractory Lines<br />
66
04.02. Refractory Materials<br />
(Shaped and Non Shaped)<br />
1000 Boron-Nitride Isolation<br />
1005 Sand Gaskets, Isolation<br />
Materials (up to 1260 °C)<br />
1009 Running and Feeding<br />
Systems (Gating Systems)<br />
1010 Running and Feeding Systems<br />
(Runner Bricks, Centre Bricks,<br />
Sprue Cups)<br />
1020 Fibrous Mould Parts<br />
1021 Fibrous Mould Parts up to 1750 °C<br />
1030 Refractory Castables<br />
1040 Refractories, in general<br />
1050 Insulating Refractoy Bricks<br />
1060 Refractoy Cements<br />
1070 Refractories for Aluminium Melting<br />
Furnaces<br />
1080 Refractory Materials for Anode<br />
Kilns<br />
1090 Refractory Materials for Melting<br />
Furnaces, in general<br />
1100 Refractory Materials for Holding<br />
Furnaces<br />
1103 Ceramic Fibre Mould Parts and<br />
Modules<br />
1104 Mold Sections and Modules made<br />
of HTW (High Temperature Wool)<br />
1109 Precasts<br />
1110 Pouring Lip Bricks<br />
1113 Fibreglass Mats<br />
1114 Slip Foils for Glowing Materials<br />
1117 High Temperature Mats, Papers,<br />
Plates, and Felts<br />
1120 Induction Furnace Compounds<br />
1123 Insulating and Sealing Panels up<br />
to 1200 °C<br />
1125 Insulating Fabrics up to 1260 °C<br />
1128 Insulating Felts and Mats up to<br />
1260 °C<br />
1130 Insulating Products<br />
1140 Insulating Products (such as<br />
Fibres, Micanites)<br />
1150 Insulating Bricks<br />
1155 Ceramic Fibre Mats, Papers,<br />
Plates, and Felts<br />
1160 Ceramic Fibre Modules<br />
1169 Ceramic Fibre Substitutes<br />
1170 Ceramic Fibre Products<br />
1180 Loamy Sands<br />
1190 Carbon Bricks<br />
1200 Cupola and Siphon Mixes<br />
1210 Cupola Bricks<br />
1220 Micro Porous Insulating Materials<br />
1222 Nano Porous Insulating Materials<br />
1225 Furnace Door Sealings, Cords, and<br />
Packings<br />
1230 Furnace Linings<br />
1240 Ladle Refractory Mixes<br />
1250 Ladle Bricks<br />
1260 Plates, free from Ceramic Fibres<br />
1261 Plates made of Ground Alkali<br />
Silicate Wool<br />
1270 Acid and Silica Mixes<br />
1280 Fire-Clay Mixes and Cements<br />
1290 Fire-Clay Bricks<br />
1310 Porous Plugs<br />
1312 Stirring Cones for Steel, Grey Cast<br />
Iron and Aluminium<br />
1320 Moulding Mixtures for Steel Casting<br />
1330 Ramming, Relining, Casting,<br />
Gunning, and Vibration Bulks<br />
1333 Ramming, Casting, Gunning, and<br />
Repairing Compounds<br />
1340 Plugs and Nozzles<br />
1345 Textile Fabrics up to 1260 °C<br />
988 Substitutes of Aluminium Silicate<br />
Wool<br />
990 Coating and Filling Materials,<br />
Protective Coatings<br />
04.03. Refractory Raw Materials<br />
1350 Glass Powder<br />
1360 Loamy Sands<br />
1370 Magnesite, Chrom-Magnesite,<br />
Forsterite<br />
1390 Chamotte, Ground Chamotte<br />
1400 Clays, Clay Powders<br />
04.04. Refractory Building<br />
1410 Bricking-Up of Furnaces<br />
1420 Refractory Building/Installation<br />
1430 Fire and Heat Protection<br />
1435 Furnace Door Joints<br />
1440 Furnace Reconstruction<br />
1450 Repairing of Furnaces and Refractories<br />
1460 Heat Insulation<br />
1462 Maintenance of Refractory Linings<br />
05 Non-metal Raw Materials and Auxiliaries for<br />
Melting Shop<br />
05.01. Coke<br />
1480 Lignite Coke<br />
1490 Foundry Coke<br />
1510 Petroleum Coke<br />
05.02. Additives<br />
1520 Desulphurization Compounds<br />
1530 Felspar<br />
1540 Fluorspar<br />
1550 Casting Carbide<br />
1560 Glass Granulate<br />
1570 Lime, Limestones<br />
1575 Briquets for Cupolas<br />
1580 Slag Forming Addition<br />
05.03. Gases<br />
1590 Argon<br />
1600 Oxygen<br />
1610 Inert Gases<br />
1620 Nitrogen<br />
1622 Hydrogen<br />
05.04. Carburization Agents<br />
1630 Carburization Agents, in general<br />
1640 Lignite Coke<br />
1650 Electrode Butts<br />
1660 Electrode Graphite<br />
1665 Desulfurizer<br />
1670 Graphite<br />
1680 Coke Breeze, Coke-Dust<br />
1700 Petroleum Coke<br />
1710 Silicon Carbide<br />
3261 Automatic Powder Feeding<br />
05.05. Melting Fluxes for NF-Metals<br />
1720 Aluminium Covering Fluxes<br />
1730 Desoxidants, in general<br />
1740 Degassing Fluxes<br />
1750 Desulphurisers<br />
1760 Charcoal<br />
1770 Refiners<br />
1780 Fluxing Agents<br />
1785 Melt Treatment Agents<br />
1790 Fluxing Agents<br />
06 Metallic Charge Materials for Iron and Steel<br />
Castings and for Malleable Cast Iron<br />
06.01. Scrap Materials<br />
1810 Cast Scrap<br />
1811 Cast Turnings<br />
1813 Cuttings/Stampings<br />
1817 Steel Scrap<br />
06.02. Pig Iron<br />
1820 Hematite Pig Iron<br />
1830 Foundry Pig Iron<br />
1838 DK Pig Iron<br />
1840 DK-Perlit Special Pig Iron<br />
1880 DK Pig Iron for Malleable Cast Iron<br />
1898 DK Pig Iron, low-carbon, Quality<br />
DKC<br />
1900 DK-Perlit Special Pig Iron, Low<br />
Carbon, DKC Quality<br />
1936 DK Phosphorus Alloy Pig Iron<br />
1940 DK-Perlit Special Pig Iron, Type<br />
Siegerlaender<br />
1950 Spiegel Eisen<br />
1970 Blast Furnace Ferro Silicon<br />
06.03. Specials (Pig Iron)<br />
1990 Foundry Pig Iron<br />
2000 Hematite Pig Iron<br />
2010 Sorel Metal<br />
<strong>2020</strong> Special Pig Iron for s. g. Cast Iron<br />
Production<br />
2030 Special Pig Iron for s.g. Cast Iron<br />
2040 Steelmaking Pig Iron<br />
06.04. Ferro Alloys<br />
2050 Ferro-Boron<br />
2060 Ferro-Chromium<br />
2070 Ferroalloys, in general<br />
2080 Ferro-Manganese<br />
2090 Ferro-Molybdenum<br />
2100 Ferro-Nickel<br />
2110 Ferro-Niobium<br />
2120 Ferro-Phosphorus<br />
2130 Ferro-Selenium<br />
2140 Ferro-Silicon<br />
2150 Ferro-Silicon-Magnesium<br />
2160 Ferro-Titanium<br />
2170 Ferro-Vanadium<br />
2180 Ferro-Tungsten<br />
2190 Silicon-Manganese<br />
06.05. Other Alloy Metals and Master<br />
Alloys<br />
2200 Aluminium Granulates<br />
2210 Aluminium, Aluminium Alloys<br />
2220 Aluminium Powder<br />
2230 Aluminium Master Alloys<br />
2250 Calcium Carbide<br />
2260 Calcium-Silicon<br />
2265 Cerium Mischmetal<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 67
2280 Chromium Metals<br />
2290 Cobalt<br />
2300 Chromium Metal, Aluminothermic<br />
2310 Deoxidation Alloys<br />
2318 High-grade Steel<br />
2320 Iron Powder<br />
2350 Copper<br />
2360 Cupola Briquets<br />
2370 Alloying Metals, in general<br />
2380 Alloying Additives<br />
2390 Magnesium, Magnesium Alloys<br />
2410 Manganese Metal<br />
2420 Manganese Metal, Electrolytic<br />
2430 Molybdenum<br />
2440 Molybdenum Alloys<br />
2450 Molybdenum Oxide<br />
2460 Nickel, Nickel Alloys<br />
2470 Nickel-Magnesium<br />
2490 Furnace Additives<br />
2500 Ladle Additives<br />
2510 High-Purity Iron, Low-Carbon<br />
2520 Sulphuric Iron<br />
2530 Silicon Carbide<br />
2540 Silicon Metal<br />
2545 Silicon Metal Granules<br />
2550 Special Alloys<br />
2570 Titanium Sponge<br />
2575 Master Alloys for Precious Metals<br />
2580 Bismuth<br />
2590 Tungsten<br />
2600 Tin<br />
2610 Alloying Metals, Master Alloys<br />
06.06. Nodularizing Additives and<br />
Auxiliaries<br />
2620 Magnesium Treatment Alloys for<br />
s. g. Cast Iron<br />
2630 Mischmetal<br />
06.07. Inoculants and Auxiliary<br />
Appliances<br />
2640 Cored-Wire Injectors<br />
2645 Injection Appliances for Cored Wire<br />
2650 Cored Wires for Secondary and<br />
Ladle Metallurgy<br />
2653 Cored Wires for Magnesium Treatment<br />
2656 Cored Wires for Inoculation of Cast<br />
Iron Melts<br />
2658 Stream Inoculants<br />
2660 Automatic IDA-Type Inoculation<br />
Dosing Devices<br />
2670 Injection Appliances<br />
2680 Inoculants and Inoculation Alloys,<br />
in general<br />
2690 Inoculants for Cast Iron<br />
2692 MSI Pouring Stream Inoculation<br />
Devices<br />
2694 Ladle Inoculants<br />
07 Metallic Charge and Treatment Materials for<br />
Light and Heavy Metal Castings<br />
07.01. Scrap<br />
2730 Metal Residues<br />
07.02. Ingot Metal<br />
2740 Standard Aluminium Alloys<br />
2750 Brass Ingots<br />
2770 High-Grade Zinc Alloys<br />
2790 Copper<br />
2800 Copper Alloys<br />
2810 Magnesium, Magnesium Alloys<br />
2830 Tin<br />
07.03. Alloying Addition for Treatment<br />
2838 Aluminium-Beryllium Master Alloys<br />
2840 Aluminium-Copper<br />
2852 Aluminium Master Alloys<br />
2870 Arsenic Copper<br />
2875 Beryllium-Copper<br />
2890 Calcium<br />
2891 Calcium Carbide, Desulphurisers<br />
2893 Chromium-Copper<br />
2900 Ferro-Copper<br />
2910 Grain Refiner<br />
2920 Granulated Copper<br />
2924 Copper Magnesium<br />
2925 Copper Salts<br />
2927 Copper Master Alloys<br />
2930 Alloy Metals, in general<br />
2935 Alloy Biscuits<br />
2936 Lithium<br />
2938 Manganese Chloride (anhydrate)<br />
2940 Manganese Copper<br />
2950 Metal Powder<br />
2960 Niobium<br />
2970 Phosphor-Copper<br />
2980 Phosphor-Tin<br />
2990 Silicon-Copper<br />
3000 Silicon Metal<br />
3010 Strontium, Strontium Alloys<br />
3020 Tantalum<br />
3025 Titanium, powdery<br />
3030 Refining Agents for Aluminium<br />
3033 Zirconium-Copper<br />
08 Plants and Machines for Moulding and<br />
Coremaking Processes<br />
08.01. Moulding Plants<br />
3050 Moulding Plants, in general<br />
3058 Moulding Machines, Boxless<br />
3060 Moulding Machines, Fully Automatic<br />
3070 Moulding Machines, Fully and<br />
Partially Automatic<br />
08.02. Moulding and Coremaking<br />
Machines<br />
3080 Lifting Moulding Machine<br />
3090 Pneumatic Moulding Machines<br />
3100 Automatic Moulding Machines<br />
3110 High-Pressure Squeeze Moulding<br />
Machines<br />
3130 Impact Moulding Machines<br />
3140 Moulding Plants and Machines for<br />
Cold-Setting Processes<br />
3150 Moulding Machines, Boxless<br />
3160 Core Blowers<br />
3170 Coremaking Machines<br />
3180 Core Shooters<br />
3190 Air-flow Squeeze Moulding Machines<br />
and Plants<br />
3200 Shell Moulding Machines<br />
3210 Shell Moulding Machines<br />
3220 Shell Moulding Machines and<br />
Hollow Core Blowers<br />
3225 Multi-Stage Vacuum Process<br />
3230 Multi-Stage Vacuum Processes for<br />
Pressure Die Casting Processes<br />
3235 Rapid Prototyping<br />
3240 Jolt Squeeze Moulding Machines<br />
3250 Suction Squeeze Moulding Machines<br />
and Plants<br />
3260 Pinlift Moulding Machines<br />
3270 Rollover Moulding Machines<br />
3280 Vacuum Moulding Machines and<br />
Processes<br />
3290 Multi-Piston Squeeze Moulding<br />
Machines<br />
3300 Turnover Moulding Machines<br />
08.03. Additives and Accessories<br />
3310 Exhaust Air Cleaning Plants for<br />
Moulding Machines<br />
3320 Gassing Units for Moulds and<br />
Cores<br />
3325 Seal Bonnets for Immersion Nozzles<br />
3330 Metering Dosing Devices for<br />
Binders and Additives<br />
3340 Electrical Equipment for Moulding<br />
Machines and Accessories<br />
3350 Electrical and Electronic Controlling<br />
Devices for Moulding<br />
Machines<br />
3355 Mould Dryer<br />
3360 Vents<br />
3370 Screen-Vents<br />
3380 Spare Parts for Moulding Machines<br />
3390 Flow Coating Plants<br />
3400 Pattern Plates<br />
3420 Manipulators<br />
3430 Core Setting Equipment<br />
3440 Core Removal Handling<br />
3450 Core Handling<br />
3460 Coremaking Manipulators<br />
3462 Core Transport Racks<br />
3470 Shell Mould Sealing Equipment<br />
and Presses<br />
3480 Mixers for Blackings and Coatings<br />
3500 Plastic Blowing and Gassing Plates<br />
3510 Coating Equipment<br />
3512 Coating Dryers<br />
3520 Equipment for Alcohol-based<br />
Coatings<br />
3525 Coating Stores and<br />
Preparation Equipment<br />
3530 Coating Mixers, Coating Preparation<br />
Equipment<br />
3540 Screen Vents, front Armoured<br />
3560 Swing Conveyors<br />
3570 Screening Machines<br />
3580 Plug Connections, Heat-Resisting<br />
08.04. Mould Boxes and Accessories<br />
3590 Moulding Boxes<br />
3610 Moulding Box Round-hole and<br />
Long-hole Guides<br />
09 Moulding Sands<br />
09.01. Basic Moulding Sands<br />
3630 Chromite Sands<br />
3640 Moulding Sands<br />
3645 Ceramic Sands/Chamotte Sands<br />
3650 Core Sands<br />
68
3660 Molochite<br />
3670 Mullite Chamotte<br />
3690 Olivine Sands<br />
3700 Fused Silica<br />
3705 Lost Foam Backing Sands<br />
3710 Silica Flour<br />
3720 Silica Sands<br />
3730 Zircon Powder<br />
3740 Zircon Sands<br />
09.02. Binders<br />
3750 Alkyd Resins<br />
3755 Inorganic Binders<br />
3760 Asphalt Binders<br />
3770 Bentonite<br />
3790 Binders for Investment Casting<br />
3800 Cold-Box Binders<br />
3803 Resins for the Shell Moulding<br />
Process<br />
3820 Ethyl Silicate<br />
3830 Moulding Sand Binders, in general<br />
3833 Binders, Inorganic<br />
3840 Resins<br />
3860 Oil Binders<br />
3870 Core Sand Binders, in general<br />
3875 Silica Sol<br />
3880 Synthetic Resin Binders, in general<br />
3890 Synthetic Resin Binders for<br />
Refractories<br />
3900 Synthetic Resin Binder for Gas<br />
Curing Processes<br />
3910 Synthetic Resin Binder for Hot<br />
Curing Processes<br />
3920 Synthetic Resin Binder for Cold<br />
Setting Processes<br />
3930 Facing Sand Binders<br />
3940 Binders for the Methyl-Formate<br />
Process<br />
3950 Phenolic Resins<br />
3960 Phenolic Resins (alkaline)<br />
3970 Polyurethane Binders and Resins<br />
3980 Swelling Binders<br />
3990 Swelling Clays<br />
4000 Quick-Setting Binders<br />
4010 Silicate Binders<br />
4020 Silica Sol<br />
4030 Binders for the SO2 Process<br />
4040 Cereal Binders<br />
4050 Warm-Box Binders<br />
4060 Water-Glass Binders (CO2-Process)<br />
09.03. Moulding Sand Additives<br />
4066 Addition Agents<br />
4070 Iron Oxide<br />
4080 Red Iron Oxide<br />
4090 Lustrous Carbon Former<br />
4100 Pelleted Pitch<br />
4110 Coal Dust<br />
4120 Coal Dust Substitute (Liquid or<br />
Solid Carbon Carrier)<br />
4130 Coal Dust (Synthetic)<br />
09.04. Mould and Core Coating<br />
4140 Inflammable Coating<br />
4150 Alcohol-Based Coatings<br />
4160 Alcohol-based Granulated Coatings<br />
4170 Boron-Nitride Coatings<br />
4180 Coatings, Ready-to-Use<br />
4190 Mould Varnish<br />
4200 Mould Coating<br />
4210 Black Washes<br />
4220 Graphite Blackings<br />
4224 Lost-Foam Coatings<br />
4225 Ceramic Coatings<br />
4230 Core Coatings<br />
4240 Core Blackings<br />
4260 Paste Coatings<br />
4266 Coatings (with metallurgical effects)<br />
4270 Blackings, in general<br />
4280 Steel Mould Coatings<br />
4290 Talc<br />
4298 Coatings for Full Mould Casting<br />
4300 Water-based Coatings<br />
4310 Granulated Water-based Coatings<br />
4320 Zircon Coatings<br />
4321 Zircon-free Coatings<br />
09.05. Moulding Sands<br />
Ready-to-Use<br />
4340 Sands for Shell Moulding, Readyto-use<br />
4350 Sands Ready-to-Use, Oil-Bonded<br />
(Water-free)<br />
4360 Precoated Quartz Sands, Zircon<br />
Sands, Chromite Sands, Ceramic<br />
Sands<br />
4370 Moulding Sands for Precision<br />
Casting<br />
4380 Steel Moulding Sands<br />
4390 Synthetic Moulding and Core Sand<br />
09.06. Moulding Sands Testing<br />
4400 Strength Testing Equipment for<br />
Moulding Sand<br />
4410 Moisture Testing Equipment for<br />
Moulding Sand<br />
4420 Moulding Sand Testing Equipment,<br />
in general<br />
4426 Core Gas Meters for Al + Fe<br />
4440 Sand Testing<br />
10 Sand Conditioning and Reclamation<br />
4446 Sand Preparation and<br />
Reclamation<br />
4448 Sand Reclamation System<br />
10.01. Moulding Sand Conditioning<br />
4450 Nozzles for Moistening<br />
4459 Continuous Mixers<br />
4460 Continuous Mixers for Cold-Setting<br />
Sands<br />
4470 Aerators for Moulding Sand<br />
Ready-to-Use<br />
4480 Sand Preparation Plants and<br />
Machines<br />
4490 Sand Mullers<br />
4500 Measuring Instruments for Compactibility,<br />
Shear Strength, and<br />
Deformability<br />
4510 Measuring Instruments for<br />
Mouldability Testing (Moisture,<br />
Density, Temperature)<br />
4520 Mixers<br />
4550 Sand Mixers<br />
4560 Aerators<br />
4567 Vibration Sand Lump Crusher<br />
4568 Vibratory Screens<br />
4570 Sand Precoating Plants<br />
4590 Scales and Weighing Control<br />
10.03. Conditioning of Cold, Warm,<br />
and Hot Coated Sands<br />
4650 Preparation Plants for Resin<br />
Coated Sand<br />
10.04. Sand Reconditioning<br />
4660 Used Sand Preparation Plants<br />
4662 Batch Coolers for Used Sand<br />
4664 Flow Coolers for Used Sand<br />
4670 Magnetic Separators<br />
4690 Core Sand Lump Preparation<br />
Plants<br />
4700 Reclamation Plants for Core Sands<br />
4710 Ball Mills<br />
4720 Sand Coolers<br />
4730 Sand Reclamation Plants<br />
4740 Sand Screens<br />
4760 Separation of Chromite/Silica Sand<br />
10.05. Reclamation of Used Sand<br />
4780 Reclamation Plants, in general<br />
4785 Reclamation Plants,<br />
Chemical-Combined<br />
4790 Reclamation Plants,<br />
Mechanical<br />
4800 Reclamation Plants,<br />
Mechanical/Pneumatic<br />
4810 Reclamation Plants,<br />
Mechanical-Thermal<br />
4820 Reclamation Plants, Mechanical/<br />
Thermal/Mechanical<br />
4830 Reclamation Plants, wet<br />
4840 Reclamation Plants, Thermal<br />
4850 Reclamation Plants,<br />
Thermal-Mechanical<br />
11 Moulding Auxiliaries<br />
4880 Mould Dryers<br />
4890 Foundry Nails, Moulding Pins<br />
4910 Moulders‘ Tools<br />
4920 Mould Hardener<br />
4950 Guide Pins and Bushes<br />
4965 High Temperature Textile Fabrics<br />
up to 1260 °C<br />
4970 Ceramic Pouring Filters<br />
4980 Ceramic Auxiliaries for Investment<br />
Foundries<br />
4990 Ceramic Cores for Investment<br />
Casting - Gunned, Pressed, Drawn<br />
4998 Cope Seals<br />
5000 Core Benches<br />
5007 Core Putty Fillers<br />
5010 Core Wires<br />
5020 Cores (Cold-Box)<br />
5030 Cores (Shell)<br />
5040 Core Boxes<br />
5050 Core Box Dowels<br />
5070 Core Adhesives<br />
5080 Core Loosening Powder<br />
5090 Core Nails<br />
5100 Core Powders<br />
5110 Chaplets<br />
5130 Tubes for Core and Mould Venting<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 69
5140 Core Glueing<br />
5150 Core Glueing Machines<br />
5155 Cleaners<br />
5160 Adhesive Pastes<br />
5170 Carbon Dioxide<br />
(CO2 Process)<br />
5180 Carbon Dioxide Dosing<br />
Devices<br />
5210 Coal Dust and Small Coal<br />
5220 Chill Nails<br />
5230 Chill Coils<br />
5240 Antipiping Compounds<br />
5260 Shell Mould Sealers<br />
5270 Mould Dryers, Micro-Wave<br />
5280 Screening Machines<br />
5290 Glass Fabric Filters<br />
5300 Strainer Cores<br />
5310 Release Agents<br />
11.01. Moulding Bay Equipment<br />
5312 Glass Fabric Filters<br />
5314 Strainer Cores<br />
12 Gating and Feeding<br />
5320 Covering Agents<br />
5330 Heating-up Agents<br />
5340 Breaker Cores<br />
5350 Strainer Cores<br />
5360 Exothermic Products<br />
5365 Glass Fabric Filters<br />
5370 Insulating Products and Fibres<br />
5375 Insulating Sleeves<br />
5380 Ceramic Filters<br />
5390 Ceramic Breaker Cores<br />
5400 Exothermic Mini-Feeders<br />
5405 Non-Ceramic Foam Filters<br />
5410 Ceramic Dross Filters<br />
5416 Riser (exothermic)<br />
5418 Riser (insulating)<br />
5420 Exothermic Feeder Sleeves<br />
5430 Exothermic Feeding Compounds<br />
13 Casting Machines and Equipment<br />
5436 Pouring Machines and<br />
Equipment<br />
5437 Casting Machine,<br />
without Heating<br />
13.01. Pouring Furnaces and their<br />
Equipment<br />
5440 Aluminium Dosing Furnaces<br />
5450 Pouring Equipment<br />
5460 Pouring Ladles<br />
5461 Pouring Ladles, Insulating<br />
5468 Pig and Ingot Casting<br />
Machines<br />
5470 Pouring Equipment for Moulding<br />
Plants, Railborn or Crane-operated<br />
5480 Pouring Ladles<br />
5485 Pouring Ladles, Electrically Heated<br />
5490 Drum-Type Ladles<br />
5500 Ingot Casting Machines<br />
5510 Low Pressure Casting<br />
Machine<br />
13.02. Die Casting and<br />
Accessories<br />
5530 Trimming Presses for<br />
Diecastings<br />
5540 Trimming Tools for Diecastings<br />
(Standard Elements)<br />
5545 Exhausting and Filtering Plants for<br />
Diecastings<br />
5550 Ejectors for Diecasting Dies<br />
5560 Ejectors for Diecasting Dies (Manganese<br />
Phosphate Coated)<br />
5570 Feeding, Extraction, Spraying, and<br />
Automatic Trimming for Diecasting<br />
Machines<br />
5580 Trimming Tools<br />
5600 Dosing Devices for<br />
Diecasting Machines<br />
5610 Dosing Furnaces for<br />
Diecasting Machines<br />
5620 Diecasting Dies<br />
5630 Heating and Cooling Devices for<br />
Diecasting Dies<br />
5640 Diecasting Machines<br />
5641 Diecasting Machines and Plants<br />
5644 Diecasting Machines for Rotors<br />
5650 Diecasting Machine Monitoring<br />
and Documentation Systems<br />
5660 Diecasting Coatings<br />
5670 Diecasting Lubricants<br />
5675 Lost Diecasting Cores<br />
5680 Diecasting Parting Agents<br />
5689 Venting Blocks for HPDC Dies<br />
5690 Extraction Robots for<br />
Diecasting Machines<br />
5695 Frames and Holders for<br />
Diecasting Dies<br />
5700 Spraying Equipment for Diecasting<br />
Machines<br />
5710 Goosenecks and Shot Sleeves<br />
5720 Hand Spraying Devices<br />
5730 Heating Cartridges<br />
5740 High-duty Heating Cartridges<br />
5750 Hydraulic Cylinders<br />
5760 Core Pins<br />
5770 Cold Chamber Diecasting Machines<br />
5780 Pistons for Diecasting Machines<br />
5790 Piston Lubricants<br />
5800 Piston Spraying Devices<br />
5810 Mixing Pumps for Parting Agents<br />
5815 Electric Nozzle Heatings<br />
5817 Oil Filters<br />
5820 Melting and Molten Metal Feeding<br />
in Zinc Die Casting Plants<br />
5830 Steel Molds for Diecasting Machines<br />
5838 Heating and Cooling of Dies<br />
5840 Temperature Control Equipment for<br />
Diecasting Dies<br />
5850 Parting Agents for Dies<br />
5860 Parting Agent Spraying Devices for<br />
Diecasting Machines<br />
5865 Dry Lubricants (Beads)<br />
5870 Vacural-Type Plants<br />
5876 Multi-Stage Vacuum Process<br />
5880 Multi-Stage Vacuum Process<br />
5890 Vacuum Die Casting Plants<br />
5900 Hot Working Steel for<br />
Diecasting Dies<br />
5910 Hot Working Steel for Diecasting<br />
Tools<br />
5912 Hot Chamber Diecasting Machines<br />
13.03. Gravity Die Casting<br />
5914 Dosing Devices for Gravity Diecasting<br />
Stations<br />
5920 Permanent Molds<br />
5930 Automatic Permanent Moulding<br />
Machines<br />
5940 Gravity Diecasting Machines<br />
5941 Gravity and High Pressure Diecasting<br />
Automation<br />
5945 Cement and Fillers for Permanent<br />
Moulds up to 1600 °C<br />
5950 Cleaning Devices for Permanent<br />
Molds<br />
5960 Coatings for Permanent Molds<br />
5970 Colloidal Graphite<br />
5975 Chills<br />
5980 Low Pressure Diecasting Machines<br />
13.04. Centrifugal Casting<br />
5990 Centrifugal Casting Machines<br />
13.05. Continuous Casting<br />
6000 Anode Rotary Casting Machines<br />
6001 Length and Speed Measuring,<br />
non-contact, for Continuous<br />
Casting Plants<br />
6002 Thickness and Width Measurement<br />
for Continuous Casting<br />
Plants, non-contact<br />
6006 Casting and Shear Plants for<br />
Copper Anodes<br />
6007 Casting and Rolling Plants for<br />
Copper Wire<br />
6008 Casting and Rolling Plants for<br />
Copper Narrow Strips<br />
6010 Continuous Casting Plant, horizontal,<br />
for Tube Blanks with integrated<br />
Planetary Cross Rolling Mill for the<br />
Production of Tubes<br />
6020 Continuous Casting Moulds<br />
6030 Continuous Casting<br />
Machines and Plants<br />
6032 Continuous Casting, Accessories<br />
6033 Continuous Casting Machines and<br />
Plants (non-ferrous)<br />
13.06. Investment and Precision<br />
Casting<br />
6040 Burning Kilns for Investment<br />
Moulds<br />
6045 Investment Casting Waxes<br />
6050 Embedding Machines for Investment<br />
Casting Moulding Materials<br />
6060 Investment Casting Plants<br />
6062 Centrifugal Investment<br />
Casting Machines<br />
13.07. Full Mould Process Plants<br />
6070 Lost-Foam Pouring Plants<br />
13.08. Auxiliaries, Accessories, and<br />
Consumables<br />
6080 Pouring Manipulators<br />
6090 Slag Machines<br />
6093 Copper Templates<br />
6100 Nozzles, Cooling<br />
70
6110 Electrical and Electronic Control<br />
for Casting Machines<br />
6120 Extraction Devices<br />
6130 Pouring Consumables, in general<br />
6140 Rotary Casting Machines<br />
6150 Pouring Ladle Heaters<br />
6160 Ladle Bails<br />
6170 Stream Inoculation Devices<br />
6175 Graphite Chills<br />
6176 Marking and Identification<br />
6177 Bone Ash (TriCalcium Phosphate)<br />
6190 Long-term Pouring Ladle Coatings<br />
6200 Long-term Lubricants<br />
6210 Manipulators<br />
6220 Ladle Covering Compounds<br />
6240 Robots<br />
6245 Protective Jacket for Robots, Heat<br />
and Dust Resistant<br />
6250 Dosing Devices for Slag Formers<br />
Addition<br />
6270 Silicon Carbide Chills<br />
6280 Silicon Carbide Cooling Compounds<br />
6290 Crucible Coatings<br />
6300 Heat Transfer Fluids<br />
14 Discharging, Cleaning, Finishing of Raw<br />
Castings<br />
6305 Casting Cooling Plants<br />
14.01. Discharging<br />
6330 Knock-out Drums<br />
6340 Vibratory Shake-out Tables<br />
6345 Knock-out Vibratory Conveyors<br />
6346 Shake-out Grids<br />
6347 Shake-out Separation Runners<br />
6350 Decoring Equipment<br />
6352 Discharging of Metal Chips<br />
6360 Hooking<br />
6370 Manipulators<br />
6373 Manipulators for Knock-out Floors<br />
6380 Robots<br />
6390 Vibratory Grids, Hangers, and<br />
Chutes<br />
6400 Vibratory Tables<br />
14.02. Blast Cleaning Plants and<br />
Accessories<br />
6410 Turntable Blasting Fans<br />
6420 Pneumatic Blasting Plants<br />
6430 Automatic Continuous Shot-blasting<br />
plants<br />
6440 Descaling Plants<br />
6445 Spare Parts for Blasting Plants<br />
6450 Hose Blasting Plants, Fans<br />
6460 Hose Blasting Chambers<br />
6470 Monorail Fettling Booths<br />
6475 Efficiency Tuning for Blasting<br />
Plants<br />
6480 Manipulator Shotblast Plants<br />
6485 Tumbling Belt Blasting Plants,<br />
Compressed Air Driven<br />
6490 Wet and Dry Shotblast Plants<br />
6500 Fettling Machines<br />
6530 Airless Blast Cleaning Machines<br />
6540 Blasting Plants Efficiency Tuning<br />
6550 Shot Transport, Pneumatic<br />
6560 Shot-Blasting Plants<br />
6569 Shot Blasting Machines<br />
6570 Shot Blasting Machines, with/<br />
without Compressed Air Operating<br />
6572 Dry Ice Blasting<br />
6574 Dry Ice Production<br />
14.03. Blasts<br />
6580 Aluminium Shots<br />
6590 Wire-Shot<br />
6600 High-Grade Steel Shots<br />
6610 Granulated Chilled Iron, Chilled<br />
Iron Shots<br />
6630 Cast Steel Shots<br />
6640 Stainless Steel Shot<br />
6650 Shot-Blast Glass<br />
6660 Shot-Blast Glass Beads<br />
6670 Blasts<br />
6671 Stainless Steel Abrasives<br />
14.04. Grinding Machines and Accessories<br />
6675 Stainless Steel Grit<br />
6680 Belt Grinders<br />
6685 chamfering machines<br />
6690 Flexible Shafts<br />
6695 Diamond Cutting Wheels for<br />
Castings<br />
6700 Compressed Air Grinders<br />
6710 Fibre discs<br />
6714 Centrifugal Grinders<br />
6720 Vibratory Cleaning Machines and<br />
Plants<br />
6730 Rough Grinding Machines<br />
6735 Abrasive Wheels, visual, with<br />
Flakes/Lamellas<br />
6740 Numerical Controlled Grinders<br />
6750 Swing Grinders<br />
6760 Polishing Machines<br />
6770 Polishing Tools<br />
6773 Precision Cutting Wheels, 0,8 mm<br />
6780 Tumbling Drums<br />
6790 Pipe Grinders<br />
6800 Floor Type Grinders<br />
6810 Grinding Textiles<br />
6820 Emery Paper<br />
6830 Grinding Wheel Dresser<br />
6850 Grinding Wheels and Rough<br />
Grinding Wheels<br />
6855 Grinding Pins<br />
6860 Grinding Fleece<br />
6870 Grinding Tools<br />
6874 Drag Grinding Plants<br />
6880 Rough Grinding Machines<br />
6885 Cutting Wheels<br />
6890 Abrasive Cut-off Machines<br />
6900 Vibratory Cleaning Machines<br />
6910 Angle Grinders<br />
14.05. Additional Cleaning Plants<br />
and Devices<br />
6920 Gate Break-off Wedges<br />
6925 Plants for Casting Finishing<br />
6930 Automation<br />
6940 Pneumatic Hammers<br />
6950 Deflashing Machines<br />
6954 Deburring Machines,<br />
robot-supported<br />
6955 Robot Deburring Systems<br />
6960 Fettling Cabins<br />
6970 Fettling Manipulators<br />
6980 Fettling Benches<br />
6990 Core Deflashing Machines<br />
7000 Chipping Hammers<br />
7010 Dedusting of Fettling Shops<br />
7020 Fettling Hammers<br />
7030 Fettling Shops, Cabins, Cubicles<br />
7035 Refining Plants<br />
7040 Robot Fettling Cubicles<br />
7041 Robot Deflashing Units for Casting<br />
7050 Feeder Break-off Machines<br />
7052 Stamping Deflashing<br />
Equipment (tools, presses)<br />
7055 Break-off Wedges<br />
7056 Cutting and Sawing Plants<br />
7058 Band Saw Blades<br />
7059 Cut-off Saws<br />
7060 Cut-off Saws for Risers and Gates<br />
14.06. Jig Appliances<br />
7066 Magnetic Clamping Devices for<br />
Casting Dies<br />
7068 Core-Slides and Clamping<br />
Elements for Casting Dies<br />
7070 Clamping Devices<br />
14.07. Tribology<br />
7073 Lubricants for High Temperatures<br />
7074 Chain Lubricating Appliances<br />
7075 Cooling Lubricants<br />
7077 Central Lubricating Systems<br />
15 Surface Treatment<br />
7083 Anodizing of Aluminium<br />
7100 Pickling of High Quality Steel<br />
7105 CNC Machining<br />
7110 Paint Spraying Plants<br />
7115 Yellow/Green Chromating<br />
7130 Priming Paints<br />
7140 Casting Sealing<br />
7150 Casting Impregnation<br />
7166 Hard Anodic Coating of Aluminium<br />
7180 High Wear-Resistant Surface<br />
Coating<br />
7190 Impregnation<br />
7198 Impregnation Plants<br />
7200 Impregnating Devices and Accessories<br />
for Porous Castings<br />
7210 Anticorrosion Agents<br />
7220 Corrosion and Wearing Protection<br />
7230 Shot Peening<br />
7232 Wet Varnishing<br />
7234 Surface Treatment<br />
7235 Surface Coatings<br />
7240 Polishing Pastes<br />
7245 Powder Coatings<br />
7250 Repair Metals<br />
7260 Slide Grinding, free of Residues<br />
7290 Quick Repair Spaddle<br />
7292 Special Coatings<br />
7295 Special Adhesives up to 1200 °C<br />
7296 Shot-Blasting<br />
7297 Power Supply, Plasma Generators<br />
7300 Galvanizing Equipment<br />
7302 Zinc Phosphating<br />
7310 Scaling Protection<br />
7312 Subcontracting<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 71
16 Welding and Cutting<br />
16.01. Welding Machines and<br />
Devices<br />
7330 Welding Consumables, Electrodes<br />
16.02. Cutting Machines and Torches<br />
7350 Gougers<br />
7352 Special Machines for Machining<br />
7360 Coal/Graphite Electrodes<br />
7365 Water Jet Cutting<br />
7370 Oxygen Core Lances<br />
16.03. Accessories<br />
7394 Protective Blankets, Mats, and<br />
Curtains, made of Fabric, up to<br />
1250 °C<br />
7397 Protective Welding Paste, up to<br />
1400 °C<br />
17 Surface Treatment and Drying<br />
7398 Heat Treatment and Drying<br />
17.01. Plants and Furnaces<br />
7400 Tempering Furnaces<br />
7401 Ageing Furnaces<br />
7402 Combustion Chambers<br />
7404 Baking Ovens for Ceramic Industries<br />
7420 Mould Drying Stoves<br />
7430 Annealing and Hardening Furnaces<br />
7440 Induction Hardening and Heating<br />
Equipment<br />
7450 Core Drying Stoves<br />
7452 Microwave Drying Stoves and<br />
Chambers<br />
7455 Solution Annealing Furnaces<br />
7460 Ladle Dryers<br />
7470 Sand Dryers<br />
7480 Inert Gas Plants<br />
7490 Annealing Furnaces<br />
7500 Drying Stoves and Chambers<br />
7510 Quenching and Tempering Furnaces<br />
7520 Heat Treating Furnaces<br />
7525 Hearth Bogie Type Furnaces<br />
17.02. Components, Accessories,<br />
Operating Materials<br />
7550 Multi-purpose Gas Burners<br />
7560 Heating Equipment, in general<br />
7564 Special Torches<br />
7580 Firing Plants<br />
7590 Gas Torches<br />
7600 Gas Heatings<br />
7610 Capacitors<br />
7616 Furnace Optimization<br />
7620 Oil Burners<br />
7630 Recuperative Burners<br />
7640 Oxygen Burners<br />
7650 Heat Recovery Plants<br />
18 Plant, Transport, Stock, and Handling<br />
Engineering<br />
7654 Lifting Trucks<br />
7656 Transport, Stock, and<br />
Handling Technology<br />
18.01. Continuous Conveyors and<br />
Accessories<br />
7660 Belt Conveyors<br />
7670 Bucket Elevators<br />
7676 Flexible Tubes with Ceramic Wear<br />
Protection<br />
7680 Conveyors, in general<br />
7690 Conveyors, Fully Automatic<br />
7710 Conveyor Belts<br />
7720 Conveyor Belt Ploughss<br />
7730 Conveyor Belt Idlers<br />
7740 Conveyor Chutes<br />
7750 Conveying Tubes<br />
7760 Belt Guides<br />
7780 Overhead Rails<br />
7790 Hot Material Conveyors<br />
7810 Chain Conveyors<br />
7820 Chain Adjusters<br />
7850 Conveyors, Pneumatic<br />
7860 Roller Beds, Roller Conveyor<br />
Tables, Roller Tables<br />
7870 Sand Conveyors<br />
7890 Bulk Material Conveyors<br />
7900 Swing Conveyor Chutes<br />
7910 Elevators<br />
7920 Chip Dryers<br />
7950 Idlers and Guide Rollers<br />
7960 Transport Equipment, in general<br />
7970 Conveyor Screws<br />
7980 Vibratory Motors<br />
7981 Vibration Conveyors<br />
18.02. Cranes, Hoists, and<br />
Accessories<br />
8000 Grippers<br />
8010 Lifting Tables and Platforms<br />
8020 Jacks and Tilters<br />
8030 Operating Platforms, Hydraulic<br />
8032 Hydraulic and Electric Lifting<br />
Trucks<br />
8040 Cranes, in general<br />
8050 Lifting Magnets<br />
8060 Lifting Magnet Equipment<br />
18.03. Vehicles and Transport Containers<br />
8080 Container Parking Systems<br />
8090 Fork Lift Trucks, in general<br />
8100 Fork Lift Trucks for Fluid Transports<br />
8110 Equipment for Melt Transport<br />
18.04. Bunkers, Siloes and<br />
Accessories<br />
8140 Linings<br />
8145 Big-bag Removal Systems<br />
8150 Hopper Discharger and<br />
Discharge Chutes<br />
8160 Hoppers<br />
8170 Conveyor Hoses<br />
8190 Silos<br />
8200 Silo Discharge Equipment<br />
8210 Silo Over-charging Safety Devices<br />
8218 Wearing Protection<br />
8220 Vibrators<br />
18.05. Weighing Systems and Installations<br />
8230 Charging and Charge<br />
Make-up Scales<br />
8240 Metering Scales<br />
8250 Monorail Scales<br />
8260 Crane Weighers<br />
8280 Computerized Prescuption Plants<br />
8290 Scales, in general<br />
18.07. Handling Technology<br />
8320 Manipulators<br />
8340 Industrial Robots<br />
8350 Industrial Robots, Resistant to Rough<br />
8364 Chipping Plants with Robots<br />
18.08. Fluid Mechanics<br />
8365 Pumps<br />
8367 Compressors<br />
18.09. Storage Systems, Marshalling<br />
8368 Marking and Identification<br />
18.10. Components<br />
8374 Marking and Identification<br />
19 Pattern- and Diemaking<br />
19.01. Engines for Patternmaking<br />
and Permanent Mold<br />
8380 Band Sawing Machines for<br />
Patternmaking<br />
8400 CAD/CAM/CAE Systems<br />
8410 CAD Constructions<br />
8420 CAD Standard Element Software<br />
8423 CNC Milling Machines<br />
8425 Automatic CNC Post-Treatment<br />
Milling Machines<br />
8430 CNC Programming Systems<br />
8440 CNC, Copying, Portal and Gantry<br />
Milling Machines<br />
8470 Dosing Equipment and Suction<br />
Casting Machines for the Manufacture<br />
of Prototypes<br />
8480 Electrochemical Discharge Plants<br />
8490 Spark Erosion Plants<br />
8500 Spark Erosion Requirements<br />
8510 Development and Production of<br />
Lost-Foam Machines<br />
8520 Milling Machines for Lost-Foam<br />
Patterns<br />
8522 Hard Metal Alloy Milling Pins<br />
8525 Lost-Foam Glueing Equipment<br />
8527 Patternmaking Machines<br />
8576 Rapid Prototyping<br />
8610 Wax Injection Machines<br />
19.02. Materials, Standard Elements<br />
and Tools for Pattern- and<br />
Diemaking<br />
8630 Thermosetting Plastics for Patternmaking<br />
8650 Toolmaking Accessories<br />
8660 Milling Cutters for Lost-Foam<br />
Patterns<br />
8670 Free-hand Milling Pins made of<br />
Hard Metal Alloys and High-speed<br />
Steels<br />
8675 Hard Metal Alloy Milling Pins<br />
8680 Adhesives for Fabrication<br />
72
8690 Synthetic Resins for Patternmaking<br />
8700 Plastic Plates Foundry and Patternmaking<br />
8705 Lost-Foam Tools and<br />
Patterns<br />
8710 Patternmaking Requirements, in<br />
general<br />
8720 Patternmaking Materials, in general<br />
8730 Pattern Letters, Signs, Type Faces<br />
8740 Pattern Dowels (metallic)<br />
8750 Pattern Resins<br />
8760 Pattern Resin Fillers<br />
8770 Pattern Plaster<br />
8780 Pattern Gillet<br />
8790 Lumber for Patterns<br />
8800 Pattern Varnish<br />
8810 Pattern-Plate Pins<br />
8820 Pattern Spaddles<br />
8830 Standard Elements for Tools and<br />
Dies<br />
8840 Precision-shaping Silicone<br />
8846 Rapid Tooling<br />
19.03. Pattern Appliances<br />
8880 CNC Polystyrol<br />
Patternmaking<br />
8890 Development and Manufacture of<br />
Lost-Foam Patterns<br />
8900 Moulding Equipment<br />
8910 Wood Patterns<br />
8930 Core Box Equipment for Series<br />
Production<br />
8940 Resin Patterns<br />
8960 Metal Patterns<br />
8970 Pattern Equipment, in general<br />
8980 Pattern Plates<br />
8985 Pattern Shop for Lost-Foam<br />
Processes<br />
9000 Stereolithography Patterns<br />
9010 Evaporative Patterns for the Lost-<br />
Foam Process<br />
19.04. Rapid Prototyping<br />
9021 Design<br />
9022 Engineering<br />
9023 Hardware and Software<br />
9024 Complete Investment Casting<br />
Equipment for Rapid<br />
Prototyping<br />
9025 Pattern and Prototype<br />
Making<br />
9026 Rapid Prototyping for the Manufacture<br />
of Investment Casting<br />
Patterns<br />
9027 Integrable Prototypes<br />
9028 Tools<br />
9029 Tooling Machines<br />
20 Control Systems and Automation<br />
20.01. Control and Adjustment Systems<br />
9030 Automation and Control for Sand<br />
Preparation<br />
9040 Automation<br />
9042 Software for Production Planning<br />
and Control<br />
9050 Electric and Electronic Control<br />
9080 Equipment for the Inspection of<br />
Mass Production<br />
9090 Load Check Systems for Recording<br />
and Monitoring Energy Costs<br />
9120 Control Systems and<br />
Automation, in general<br />
9130 Control Systems, in general<br />
9160 Switch and Control Systems<br />
20.02. Measuring and Control<br />
Instruments<br />
9165 Automatic Pouring<br />
9166 Compensation Leads<br />
9185 Contactless Temperature Measurement,<br />
Heat Image Cameras<br />
9190 Leakage Testing and Volume<br />
Measuring Instruments<br />
9210 Flow Meters<br />
9220 Flow control Instruments<br />
9230 Immersion Thermo Couples<br />
9240 Moisture Controller<br />
9250 Level Indicator<br />
9280 Bar Strein Gauge<br />
9301 In-Stream Inoculation Checkers<br />
9302 In-Stream Inoculant Feeder<br />
9306 Calibration and Repair Services<br />
9310 Laser Measurement Techniques<br />
9320 Multi-coordinate Measuring<br />
Machine<br />
9330 Measuring and Controlling Appliances,<br />
in general<br />
9335 Measuring and Controlling Appliances<br />
for Fully Automatic Pouring<br />
9345 Positioning Control<br />
9350 Pyrometers<br />
9370 Radiation Pyrometers<br />
9375 Measuring Systems for Nuclear<br />
Radiation (receiving inspection)<br />
9376 Measuring Systems for Radioactivity,<br />
Incoming Goods‘ Inspection<br />
9380 Temperature Measurement<br />
9382 Temperature Control Units<br />
9385 Molten Metal Level Control<br />
9390 Temperature Measuring and<br />
Control Devices<br />
9391 Thermoregulator<br />
9395 Molten Metal Level Control<br />
9400 Thermal Analysis Equipment<br />
9410 Thermo Couples<br />
9420 Protection Tubes for Thermocouples<br />
9425 In-stream Inoculant Checkers<br />
9430 Heat Measuring Devices<br />
9433 Resistance Thermometers<br />
20.03. Data Acquisition and<br />
Processing<br />
9438 Automation of Production- and<br />
Warehouse-Systems<br />
9440 Data Logging and Communication<br />
9445 Business Intelligence<br />
9450 Data Processing/Software Development<br />
9456 ERP/PPS - Software for Foundries<br />
9470 EDP/IP Information and Data<br />
Processing<br />
9480 Machine Data Logging<br />
9484 Machine Identification<br />
9490 Data Logging Systems<br />
9500 Numerical Solidification Analysis<br />
and Process Simulation<br />
9502 Numerical Solidification Simulation<br />
and Process Optimization<br />
9504 ERP - Software for Foundries<br />
9506 Process Optimization with EDP, Information<br />
Processing for Foundries<br />
9510 Computer Programmes for Foundries<br />
9520 Computer Programmes and Software<br />
for Foundries<br />
9522 Simulation Software<br />
9523 Software for Foundries<br />
9525 Software for Coordinate<br />
Measuring Techniques<br />
9527 Software for Spectographic Analyses<br />
9530 Statistical Process Control<br />
9540 Fault Indicating Systems,<br />
Registration and Documentation<br />
20.04. Process Monitoring<br />
9541 High Speed Video<br />
21 Testing of Materials<br />
21.01. Testing of Materials and<br />
Workpieces<br />
9548 Calibration of Material Testing<br />
Machines<br />
9550 Aluminium Melt Testing<br />
Instruments<br />
9554 Acoustic Materials Testing<br />
9555 Acoustic Construction<br />
Element Testing<br />
9560 CAQ Computer-Aided Quality<br />
Assurance<br />
9564 Image Documentation<br />
9580 Chemical Analyses<br />
9585 Computerized Tomography, CT<br />
9586 Core Gas - System for Measurement<br />
and Condensation<br />
9587 Die Cast Control<br />
9589 Natural Frequency Measuring<br />
9590 Endoscopes<br />
9600 Dye Penetrants<br />
9610 Instruments for<br />
Non-destructive Testing<br />
9620 Hardness Testers<br />
9630 Inside Pressure Testing Facilities<br />
for Pipes and Fittings<br />
9645 Calibration of Material Testing<br />
Machines<br />
9650 Low-temperature Source of<br />
Lighting Current<br />
9670 Arc-baffler<br />
9678 Magna Flux Test Agents<br />
9680 Magnetic Crack Detection Equipment<br />
9690 Material Testing Machines and<br />
Devices<br />
9695 Metallographic and Chemical<br />
Analysis<br />
9696 Microscopic Image Analysis<br />
9697 Surface Analysis<br />
9700 Surface Testing Devices<br />
9710 Testing Institutes<br />
9719 X-ray Film Viewing Equipment and<br />
Densitometers<br />
9720 X-Ray Films<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 73
9730 X-Ray Testing Equipment<br />
9740 Spectroscopy<br />
9750 Ultrasonic Testing Equipment<br />
9755 Vacuum Density Testing Equipment<br />
9758 UV-Lamps<br />
9759 UV Shiners<br />
9760 Ultraviolet Crack Detection Plants<br />
9765 Hydrogen Determination Equipment<br />
9770 Material Testing Equipment, in<br />
general<br />
9780 Testing of Materials<br />
9800 Inside Pressure Measuring for<br />
Tools<br />
9836 Devices for Testing of Materials,<br />
non-destructive, in general<br />
9838 NDT Non-destructive Testing of<br />
Materials<br />
9840 NDT X-ray Non-destructive Testing<br />
of Materials<br />
9850 Tensile Testing Machines<br />
22 Analysis Technique and Laboratory Equipment<br />
10000 Sample Preparation Machines<br />
10010 Quantometers<br />
10018 X-Ray Analysis Devices<br />
10020 Spectographic Analysis Devices<br />
10022 Certified Reference Materials for<br />
Spectrochemical and -scopic<br />
Analysis<br />
10040 Cut-off Machines for Metallography<br />
9860 Analyses<br />
9865 Image Analysis<br />
9880 Gas Analysis Appliances<br />
9890 Carbon and Sulphur<br />
Determination Equipment<br />
9900 Laboratory Automation<br />
9910 Laboratory Equipment, Devices,<br />
and Requirements, in general<br />
9920 Laboratory Kilns<br />
9930 Metallographic Laboratory<br />
Equipment<br />
9940 Microscopes<br />
9948 Optical Emission Spectrometers<br />
9950 Microscopic<br />
Low-temperature Illumination<br />
9955 Continuous Hydrogen Measurement<br />
9960 Polishing Machines for Metallography<br />
9970 Sampling Systems<br />
9980 Sample Transport<br />
23 Air Technique and Equipment<br />
23.01. Compressed Air Technique<br />
10050 Compressed Air Plants<br />
10060 Compressed Air Fittings<br />
10070 Compressed Air Tools<br />
10080 Compressors<br />
10100 Compressor Oils<br />
23.02. Fans and Blowers<br />
10120 Fans, in general<br />
23.03. Ventilators<br />
10150 Axial Ventilators<br />
10160 Hot-gas Circulating Ventilators<br />
10170 Radial Ventilators<br />
10180 Ventilators, in general<br />
23.04. Other Air Technique<br />
Equipments<br />
10188 Waste Gas Cleaning<br />
10190 Exhausting Plants<br />
10192 Exhaust Air Cleaning for Cold-Box<br />
Core Shooters<br />
10220 Air-engineering Plants, in general<br />
24 Environmental Protection and Disposal<br />
10230 Environmental Protection and<br />
Disposal<br />
10231 Measures to Optimize Energy<br />
10232 Fume Desulphurization for Boiler<br />
and Sintering Plants<br />
10235 Radiation Protection Equipment<br />
24.01. Dust Cleaning Plants<br />
10240 Extraction Hoods<br />
10258 Pneumatic Industrial Vacuum<br />
Cleaners<br />
10260 Pneumatic Vacuum Cleaners<br />
10270 Equipment for Air Pollution Control<br />
10280 Dust Cleaning Plants, in general<br />
10290 Gas Cleaning Plants<br />
10300 Hot-gas Dry Dust Removal<br />
10309 Industrial Vacuum Cleaners<br />
10310 Industrial Vacuum Cleaners<br />
10320 Leakage Indication Systems for<br />
Filter Plants<br />
10340 Multicyclone Plants<br />
10350 Wet Separators<br />
10360 Wet Dust Removal Plants<br />
10370 Wet Cleaners<br />
10380 Cartridge Filters<br />
10400 Pneumatic Filter Dust Conveyors<br />
by Pressure Vessels<br />
10410 Punctiform Exhausting Plants<br />
10420 Dust Separators<br />
10430 Vacuum Cleaning Plants<br />
10440 Dry Dust Removal Plants<br />
10450 Multi-Cell Separators<br />
10458 Central Vacuum Cleaning Plants<br />
10460 Cyclones<br />
24.02. Filters<br />
10470 Compressed Air Filters<br />
10490 Dedusting Filters<br />
10500 Filters, in general<br />
10510 Filter Gravel<br />
10520 Filter Materials<br />
10530 Filter Bags/Hoses<br />
10550 Fabric Filters<br />
10560 Air Filters<br />
10570 Cartridge Filters<br />
10580 Hose Filters<br />
10585 Electro-Filters<br />
10590 Air Filters<br />
10610 Fabric Filters<br />
24.03. Waste Disposal,<br />
Repreparation, and Utilization<br />
10618 Waste Air Cleaning<br />
10620 Waste Water Analyzers<br />
10630 Waste Water Cleaning and -Plants<br />
10640 Clean-up of Contaminated Site<br />
10646 Used Sands, Analysing of Soils<br />
10650 Waste Sand Reutilization and<br />
Reconditioning<br />
10655 Amine Recycling<br />
10660 Foundry Debris-conditioning Plants<br />
10680 Soil Clean-up<br />
10690 Briquetting Presses<br />
10695 Briquetting of Foundry<br />
Wastes/Filter Dusts<br />
10700 Disposal of Foundry Wastes<br />
10702 Hazardous Waste Disposal<br />
10705 Bleeding Plants<br />
10710 Reconditioning of Foundry Wastes<br />
10720 Ground Water Cleaning<br />
10740 Dross Recovery Plants<br />
10760 Cooling Towers<br />
10770 Cooling Water Processing Plants<br />
10780 Cooling Water Treatment<br />
10810 Post-combustion Plants<br />
10830 Recooling Systems<br />
10840 Recycling of Investment Casting<br />
Waxes<br />
10850 Slag Reconditioning<br />
10870 Waste Water Cooling Towers<br />
10880 Scrap Preparation<br />
10890 Transport and Logistic for Industrial<br />
Wastes<br />
10900 Rentilization of Foundry Wastes<br />
10910 Rentilization of Furnace Dusts and<br />
Sludges<br />
10920 Roll Scale De-oilers<br />
10940 Rentilization of Slide Grinding<br />
Sludges<br />
25 Accident Prevention and Ergonomics<br />
10960 Health and Safety Protection<br />
Products<br />
10970 Asbestos Replacements<br />
10990 Ventilators<br />
10993 Fire Protection Blankets and<br />
Curtains made of Fabrics<br />
10996 Fire-extinguishing Blankets and<br />
Containers<br />
11020 Heat Protection<br />
11025 Heat-Protection Clothes and Gloves<br />
11030 Climatic Measurement Equipment<br />
for Workplace Valuation<br />
11040 Protection against Noise<br />
11050 Light Barriers<br />
11060 Sound-protected Cabins<br />
11070 Sound-protected Equipment and<br />
Parting Walls<br />
11080 Vibration Protection<br />
26 Other Products for Casting Industry<br />
26.01. Plants, Components, and<br />
Materials<br />
11100 Concreting Plants<br />
11102 Devellopping and Optimizing of<br />
Casting Components<br />
11118 Vibration Technology<br />
26.02. Industrial Commodities<br />
11120 Joints, Asbestos-free<br />
74
11125 Sealing and Insulating<br />
Products up to 1260 °C<br />
11130 Dowels<br />
11150 Foundry Materials, in general<br />
11155 Heat-protecting and Insulating<br />
Fabrics up to 1260 °C<br />
11160 Hydraulic Oil, Flame-resistant<br />
11165 Marking and Identification<br />
11170 Signs for Machines<br />
11175 Fire-proof Protection Blankets,<br />
-mats, and -curtains<br />
11180 Screen and Filter Fabrics<br />
26.04. Job Coremaking<br />
11182 Inorganic Processes<br />
11183 Hot Processes<br />
11184 Cold Processes<br />
27 Consulting and Service<br />
11186 Ordered Research<br />
11190 CAD Services<br />
11200 Interpreters<br />
11202 Diecasting, Optimization of Mould<br />
Temperature Control<br />
11205 EDP Consulting<br />
11208 Wage Models<br />
11210 Emission, Immission, and Workplace<br />
Measurements<br />
11211 E-Business<br />
11212 eProcurement<br />
11213 Technical Literature<br />
11215 Investment Casting Engineering<br />
11220 Foundry Consulting<br />
11230 Foundry Legal Advice<br />
11240 Lean Foundry Organization<br />
11250 Foundry Planning<br />
11252 Greenfield Planning<br />
11253 Casting, Construction and Consulting,<br />
Optimizing of Mould Core<br />
Production and Casting Techniques<br />
11260 Nuclear Engineering Consulting<br />
11278 Customer Service for Temperature<br />
Control Units and Systems<br />
11280 Customer Service for<br />
Diecasting Machines<br />
11283 Jobbing Foundry<br />
11286 Efficiency of Material<br />
(Consulting)<br />
11290 Management of Approval<br />
Procedures<br />
11291 Management Consulting<br />
11292 Machining<br />
11293 Metallurgical Consulting<br />
11294 Patinating<br />
11295 Human Resources Services<br />
11296 Personnel Consulting<br />
11298 Process Optimization<br />
11299 Testing Status and Safety Labels<br />
11300 Rationalization<br />
11301 M&A Consulting<br />
11303 Recruitment<br />
11305 Centrifugal Casting Engineering<br />
11310 Simulation Services<br />
11320 Castings Machining<br />
11325 Steel Melting Consulting<br />
11330 Technical Translation and Documentation<br />
11336 Environmental Protection Management<br />
Systems (Environmental<br />
Audits)<br />
11339 Restructuring<br />
11340 Environmental Consulting<br />
11342 Business Consultancy<br />
11343 Leasing of Industrial Vacuum<br />
Cleaners<br />
11345 Heat Treatment<br />
11346 Associations<br />
11360 Material Consulting<br />
11370 Material Advices<br />
11380 Time Studies<br />
11382 Carving<br />
28 Castings<br />
11387 Aluminium Casting<br />
11389 ADI<br />
11390 Aluminium Pressure Diecasting<br />
11400 Aluminium Permanent Moulding<br />
(Gravity Diecasting)<br />
11410 Aluminium Sand Casting<br />
11420 Billet Casting<br />
11430 Cast Carbon Steel, Alloy and<br />
High-alloy Cast Steel<br />
11440 Non-ferrous Metal Gravity Diecasting<br />
11450 Pressure Diecasting<br />
11460 High-grade Investment Cast Steel<br />
11462 High-grade Steel Casting<br />
11470 High-grade Steel Castings<br />
11472 High-grade Centrifugal Cast Steel<br />
11480 Ingot Casting<br />
11485 Castings<br />
11489 Rolled Wire<br />
11490 Grey Cast Iron<br />
11492 Large-size Grey Iron Castings<br />
11496 Direct Chill Casting<br />
11498 Art Casting<br />
11499 Light Metal Casting<br />
11501 Magnesium Pressure<br />
Diecasting<br />
11510 Brass Pressure Diecasting<br />
11520 Non-ferrous Metal Sand Casting<br />
11525 Prototype Casting<br />
11530 Sand Casting SAND CASTING<br />
11539 Centrifugal Casting<br />
11540 Spheroidal Iron<br />
11547 Spheroidal Graphite Cast Iron<br />
11550 Steel Castings<br />
11552 Continuously Cast Material<br />
11553 Thixoforming<br />
11555 Full Mold (lost-foam) Casting<br />
11558 Rolls<br />
11560 Zinc Pressure Diecasting<br />
11570 Cylinder Pipes and Cylinder Liners<br />
29 By-Products<br />
11580 Sporting Field Sands<br />
30 Data Processing Technology<br />
11700 Mold Filling and Solidification<br />
Simulation<br />
11800 Simulation Programmes for<br />
Foundry Processes<br />
11820 Software for Foundries<br />
31 Foundries<br />
11850 Foundries, in general<br />
31.01. Iron, Steel, and Malleable-Iron<br />
Foundries<br />
11855 Iron Foudries<br />
11856 Steel Foundries<br />
11857 Malleable-Iron Foundries<br />
31.02. NFM Foundries<br />
11860 Heavy Metals Foundries<br />
11861 Die Casting Plants<br />
11862 Light Metal Casting Plants<br />
11863 Permanent Mold Foundry<br />
31 Additive manufacturing / 3-D printing<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 75
CASTING<br />
PLANT AND TECHNOLOGY<br />
INTERNATIONAL<br />
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76
INTERNATIONAL FAIRS AND CONGRESSES<br />
Fairs and Congresses<br />
64th IFC Portoroz <strong>2020</strong><br />
September, 16-18, <strong>2020</strong>, Portoroz, Slovenia<br />
www.drustvo-livarjev.si<br />
Thermprocess China<br />
September, 23-26, <strong>2020</strong>, Shanghai, China<br />
www.tubechina.net/en/exhibition/tpchina<br />
Metal Expo <strong>2020</strong><br />
October, 14-16, <strong>2020</strong>, Kielce, Poland<br />
www.targikielce.pl/en/metal<br />
Formnext <strong>2020</strong> (Additive Manufacturing)<br />
November, 10-13, <strong>2020</strong>, Frankfurt/Main, Germany<br />
https://formnext.mesago.com/frankfurt/en.html<br />
Ankiros <strong>2020</strong><br />
November, 12-14, <strong>2020</strong>, Istanbul, Turkey<br />
www.ankiros.com/home-en<br />
Alucast <strong>2020</strong><br />
December, 3-5, <strong>2020</strong>, Chennai, India<br />
www.alucastexpo.com/home<br />
Advertisers‘ Index<br />
AGTOS Gesellschaft für technische Oberflächensysteme<br />
mbH, Emsdetten/Germany 53<br />
Bühler AG, Uzwil/Switzerland 17<br />
ConviTec GmbH, Offenbach/Germany 35<br />
Hannover Messe Ankiros Fuarcilik A.S.,<br />
Ankara, Cankaya/Turkey 21<br />
Heinrich Wagner Sinto Maschinenfabrik GmbH,<br />
Bad Laasphe/Germany 9<br />
Hüttenes-Albertus Chemische Werke GmbH,<br />
Düsseldorf/GermanyBC<br />
KLEIN Anlagenbau AG,<br />
Freudenberg/Germany47<br />
Lucky -Winsun Enterprise Ltd.,<br />
Taichung/Taiwan33<br />
Maschinenfabrik Gustav Eirich GmbH & Co KG<br />
Hardheim/Germany45<br />
O.M.LER Srl, Bra (CN)/Italy 57<br />
Rudolf Uhlen GmbH, Haan/Germany 53<br />
YXLON <strong>International</strong> GmbH,<br />
Hamburg/GermanyIFC<br />
CASTING PLANT & TECHNOLOGY 2–3/<strong>2020</strong> 77
PREVIEW/IMPRINT<br />
Modern design: extensive IT solutions<br />
and simulations of the<br />
casting process are used in prototype<br />
construction in particular.<br />
Photo: ACTech<br />
Preview of the next issue<br />
Selection of topics:<br />
M. Vogt: The start-up has grown up<br />
What is business success? For example, when a start-up celebrates its 25th birthday. The medium-sized company ACTech from<br />
Freiberg in Saxony celebrated this occasion in early summer. The secret of success: “Rapid prototyping”, based on additive<br />
manu facturing processes. A company history.<br />
C. Schmees: Pendulum - the creation of a work of art.<br />
The cast sculpture “Pendulum”, made by the stainless steel foundry Schmees in Pirna, has been inviting art enthusiasts to linger<br />
in front of the European Medicines Agency in Amsterdam since March <strong>2020</strong>. The casters of Schmees in Pirna have set themselves<br />
a monument with the sculpture. A photo report.<br />
I. Meling et al.: Standard AlSi7Mg foundry alloys with reduced Mg content<br />
The new European standard for aluminium alloys includes an alloy variant with only 0.10-0.25 wt% Mg. Lowering Mg contents<br />
could be industrially beneficial for high ductility alloy parts, as strength requirements are met more easily. A research investigation.<br />
Imprint<br />
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