CPT International 02/2022

www.cpt-international.com
WITH SUPPLIERS GUIDE
June
2022
CASTING
PLANT AND TECHNOLOGY
INTERNATIONAL
2
The great
Freedom
Design freedom, free of emissions.
Inorganic binders for 3D printing sand
molds and cores.

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EDITORIAL
The green foundry is on the
way
Ever-harsher environmental and health & safety at work regulations, greater
demands from original equipment manufacturers (OEMs) regarding sustainability
of the supply chain, and a generally growing awareness of green topics:
the foundry industry faces a turning point. So it is only logical that suppliers
also look into sustainable environmentally friendly products. In this issue you
can read about the latest developments on the path to the green foundry.
Photo: BDG
Jan Kretzmann
Editor-in-chief
e-mail: jan.kretzmann@bdguss.de
Föhl, a German specialist in zinc
die-casting, offers an ecological
alternative to conventional hot
chamber casting with its hot runner technology,
which not only reduces the need
for material and energy, but also enables
the production of entirely new shapes
with zinc. As an energy-intensive production
company, Föhl is particularly aware
of its responsibility and has already been
operating CO2-neutrally since 2020. A
clear incentive for us to take a closer
look at this progressive process.
Sustainability is also the focus of our
second die-casting topic. ExOne from
southern Germany are experts in 3D
printing applications, with an awareness
of environmentally friendly technologies
– inorganic 3D printing promises
considerably lower BTEX, CO2, odor
and noise emissions, as well as improved
working conditions. The system can
be integrated in existing plants, and
enables a step-by-step introduction of
these modern and sustainable processes
for mold and core production.
Our article on new types of furan
resins is also all about environmental
protection. Furan binders – actually ‘old
hat’, having been introduced as long
ago as the late 1950s – could be classified
as the first real NoBake binders due
to their ability to self-harden under acidic
conditions at ambient temperature
(without heat). They are used to produce
all types of metal castings of all
sizes – from small components to large
products, such as the rotor hubs of wind
turbines. In this regard, ASK Chemicals
has now developed a new generation
of environmentally friendly furan resins
with a low content of free furfuryl alcohol
(without the skull-and-crossbones
label), whose performance is comparable
with standard furan resins.
Our article about the cylinder heads
of the current Porsche naturally aspirated
engine may well be a treat for automotive
enthusiasts. Compared to its
predecessor, the 718 Boxster / Cayman
GTS 4.0 liter, Spyder and Cayman GT4
series of engines make greater stress
and weight demands on this fundamental
component. These demands are
countered with a special thin-walled
casting design that is reliably reproducible
with permanent molds using the
Rotacast process. Find out how Porsche
and Nemak have mastered this challenge
to implement the centerpiece of
this powerful high-tech engine.
One Swedish-Thai joint venture is a
project for the complete simulation of
unheated, laser-controlled stopper casting
implemented by pourtech AB (from
Göteborg) and M5 Engineering (based
in Bangkok). In recent months, the two
companies have simulated in detail the
technological basis for unheated casting
with the help of Magma casting simulation
– creating optimization potentials.
Have a good read!
CASTING PLANT & TECHNOLOGY 2/2022 3

CONTENTS
FEATURES
6 DIE CASTING
Gradual Progress to the green foundry
Inorganic 3D printing can be integrated into the
existing environment and enables modern and
sustainable mold and core production.
Andreas Müller
8 DIE CASTING
Hot runner technology enables
casting of filigree geometries
Zinc die-casting specialist Föhl offers an
environmentally friendly alternative to
conventional hot-chamber die-casting.
Nadine Konstanty
12 COREMAKING
The world‘s largest coremaking engine
Laempe Mössner Sinto has assembled the world’s
largest core shooting machine, weighing over 300
tonnes.
Thomas Doriath
PROCESS
Structural components
for automotive
industrie are a key
product for die
casters.
CASTING
Porsche Boxster
models with new
thin-walled cylinder
heads.
14 CASTING
Conserve resources and protect the
environment with Magmasoft
How Brazilian faucet and shower specialist Docol
actively contributes to environmental protection.
Pia Sonntag
www.cpt-international.com
June
WITH SUPPLIERS GUIDE 2022
CASTING
2
PLANT AND TECHNOLOGY
INTERNATIONAL
The great
Freedom
Design freedom, free of emissions.
Inorganic binders for 3D printing sand
molds and cores.
Cover-Photo:
ExOne GmbH
Daimlerstrasse 22, 86368 Gersthofen,
Germany europe@exone.com
www.exone.com
COMPANY
Attention to more
than the mandatory
standards is necessary
when buying the
right protective
clothing.
ExOne is a worldwide leading manufacturer for powerful
3D printers since 1995. The products solve toughest
problems and enable world-changing innovations.
4

CONTENTS
16 CASTING
Complex casting without a melt
Find out about the hybrid gel casting process.
Sebastian Riecker
19 PROCESS
The right release agent for greater
­efficiency and sustainability
Increasing demand from differing sectors involves
new requirements for die-casters regarding component
quality and process optimization. Selecting the
right release agent can help achieve new goals.
John Belyk, Darko Tomazic, Albrecht Vogel
22 PROCESS
Automation trends in material testing
Material tests are increasing being automated.
Find out about new possibilities.
Wolfgang Mörsch
25 PROCESS
High sorting efficiency despite impurities
A new type of complete plant with three
­operating modes filters recycling aluminum
from difficult input material.
Sophie Kesy
28 PROCESS
Consistent and agile exploitation
of business opportunities
Using chances in distribution effectively.
Peter Schreiber
36 CASTING
Eco-friendly furan resigns
A new generation of eco-friendly furan resins with
low furfuryl alcohol and standard performance.
Nicolas A. Riensch, Thomas Krey, Carolin Wallenhorst
40 CASTING
Thin-walled Porsche Boxer cylinder heads
How Porsche and Nemak used the Rotacast process
for a new Boxer engine generation.
Günter Vogelezang, Bernhard Stauder
45 CASTING
PROCESS
In the fully
­automated testing
laboratory, AGVs
transport the samples
between the sample
preparation area and
the testing machines.
Pouring process simulation
How pour-tech AB and M5 engineering simulated
the unheated pouring and created potential for optimization.
Michael Colditz Sävedalen, Loedwilat Thipramongkhon,
Chindanai Challinak
COLUMNS
3 EDITORIAL
49 NEWS IN BRIEF
54 SUPPLIERS GUIDE
62 PREVIEW/IMPRINT
CASTING PLANT & TECHNOLOGY 2/2022 5

plex cores and molds that offer designers
considerably greater freedoms than
conventional processes. It also offers
the direct manufacturing of components
in almost any numbers, from prototypes
to serial production. It is thus
competitive compared to traditional
mold production, and an opportunity to
strengthen a foundry’s competitive
position by expanding its portfolio.
Sustainable chain
Inorganic binders are increasingly being
used for the 3D printing of cores and
molds. Technology leader ExOne uses a
water-based, alkali-silicate binder,
S-Max ® Pro, for the inorganic serial production
of sand cores. The modular system
consists of the S-Max Pro Sand 3D
printer with a Siemens PLC control system,
a microwave station, an automated
de-sanding station, a jobbox and
the appropriate conveyor system. The
expensive ventilation system, essential
for removing toxic emissions when
organic binders are used, is no longer
necessary. Depending on the core’s volume
and geometry, after printing it is
dried and hardened in the microwave
for a period ranging from a few minutes
to about 45 minutes and then
automatically de-sanded in a fraction of
the time otherwise required. The loose
sand is recycled for subsequent printing
processes, ensuring sustainability
throughout the chain. After finishing,
the cores can be stored dry or immediately
inserted in the mold and used for
casting. The technical casting properties
and strength of the cores can be controlled
via the gating system.
Process optimization
by linking up to four
S-Max Pro Sand 3D
printers with one
automatic de-sanding
station.
individual components in the periphery
mean that the plant can grow over time
and adapt to changing throughput. The
microwave and de-sanding stations can
each be combined with up to four
S-Max Pro Sand 3D printers, while core
removal, fine de-sanding and quality
assurance can practically be automated
as desired using robots. The system thus
offers a relatively straightforward entry
to the world of inorganic binders, and
the possibility of gradually migrating to
environmentally friendly processes.
Physical limits are being raised
Organic binders have a considerably
greater market share worldwide than
inorganic binders. This is not solely due
to this process being much younger
than others. Inorganic binders are (still)
not suitable for every application. Heat
behavior above 900°C – generally
uncritical for aluminum castings – is particularly
problematic for processing
steel and sets physical limits. These cannot
be ignored, but are constantly
being raised. Like many institutes and
researchers, ExOne is also working on
preventing vitrification at higher temperatures
by using admixtures, among
other things. At present, however, each
foundry must individually ask itself
whether the process of inorganic binder
jetting matches its particular product
portfolio – yet. Early adopters, companies
with a view of the future of
foundry technology that want to test
whether they can already use the technology,
can try it out in pilot projects
conducted in collaboration with ExOne.
Organic binders also have
green potential
Organic binders, however, have not yet
exhausted their sustainability potentials.
ExOne has already achieved ideal
results in the high-temperature range
with modified furan binders, for example,
that are free from resorcinol and
BPA. Inorganic binders will be available
for all temperature ranges in the
medium and long term. Until then,
foundries should follow a twin-track
approach: if possible, the inorganic
binder and S-Max Pro Sand from ExOne
is to be preferred for light metal casting
at temperatures of up to 900°C. In addition,
the low-classification furan binders
from ExOne provide an organic but
environmentally friendly and safe alternative
to conventional materials.
www.exone.com
System technology that grows as
required
The system solution’s high level of modularity
and the good performance of
Automatic de-sanding and unpacking of complex mold geometries.
CASTING PLANT & TECHNOLOGY 2/2022 7

DIE CASTING
Thomas Herper from Föhl explains hot runner technology using a casting as an example.
Zinc die-casting
Hot runner technology enables
casting of filigree geometries
Föhl, the zinc die-casting specialist based in Baden-Württemberg, offers an environmentally
friendly alternative to conventional hot-chamber die-casting with its hot runner
technology, which not only reduces material and energy consumption, but also enables
completely new shapes with zinc.
By Nadine Konstanty
Photos and Graphics: FOEHL
If desired, the process can be carried
out without a gating system or with
a greatly reduced one, and enables
the casting of geometries with wall
thicknesses of just 0.3 mm and part
weights of below 2 g. Compared to
conventional processes, it is characterized
by greater component quality
due to fewer air inclusions and a high
density of > 650 g/cm3. Finishing
requirements are also considerably
reduced.
Lived sustainability ensures technological
lead
Föhl is well aware of its responsibilities
– particularly as an energy-intensive
production company – and has already
been operating CO2-neutrally since
8

35,00
Quantity CO2 per unit
HOT RUNNER
30,00
25,00
CONVENTIONAL
HOT RUNNER
Reduction of CO 2
emissions by about 80%
Quantity CO2 in g
20,00
15,00
10,00
5,00
0,00
in g
in g
At Föhl
with green electricity so
CO 2
emissions at
ZERO
Quantity CO2 generated in Germany with electricity mix / unit
Quantity CO 2
generated CNG / unit
2020. Environmentally friendly reorganization
measures, renewable energies,
intensive development work, newly
planted forests, and energy scouts all go
hand-in-hand at the family-owned company
in Rudersberg. Sustainable thinking
also has a major influence on development.
So, among other things,
hot-runner processes – developed
in-house – make a contribution towards
reducing the use of energy and materials
in the firm’s core technology of casting.
The proportion of return materials
has been reduced by up to 50%, for
example. Moreover, the lower levels of
sprue means that up to twice as many
parts per shot can be cast given the
same machine size. This results in less
material consumption, more rapid
throughput, and lower energy costs.
“Our aim was to double the number
of parts produced on the same machine.
This has been achieved with new technology,
in that we reduce the runner
and gating to a minimum or do without
any gating at all, and correspondingly
introduce less air into our mold. A positive
side effect of this is that it minimizes
problematic inclusions, which can
cause weak points. Last but not least,
the environment profits because energy
consumption is lower and there is less
return material because of the doubling
of the cavities,” explains Thomas Herper,
responsible for Technical Sales at
Föhl.
Fig. 2: Part of window fitting made with 32-fold hot runner design.
Hot runner nozzle for improved
quality
The development of a new hot runner
nozzle for zinc die-casting, similar to
the hot runner technology familiar from
plastic injection molding, provides the
basis for sprue-free casting. During the
process, the melt is fed directly into the
a
b
Fig. 3a: Motor covers for ventilators produced using hot runner technology.
Fig. 3b: Motor cover for ventilator produced conventionally.
CASTING PLANT & TECHNOLOGY 2/2022 9

DIE CASTING
cavity via the hot runner nozzle. So
parts are zinc die-cast without, or with
far less, sprue formation, which considerably
reduces the air inclusions in the
product due to the lack of gating. Correspondingly,
even with very low wall
thicknesses of from 0.3 mm, parts now
only exhibit minimal porosity – about
2.3%. The use of hot runner nozzles
allows the casting of more complex
shapes that would not be possible with
conventional processes. The use of several
hot runner nozzles also offers the
advantage of multiple mold occupancy.
The use of several nozzles for one component
increases the material quantity
that is introduced into the mold cavity
in the same time. This supports homogeneous
cooling of the cast product
and prevents shrinkage cavities or
stresses.
The positioning of the hot runner
nozzle directly on the component permits
pinpoint feeding-in of the material.
Thus, like with pinpoint gating
during plastic injection molding, the
flow paths into the tool and kept short
and regular. Round castings can now
also be implemented very well because
no flattening is required for any sectioning
of the gating system. The distances
travelled by the material into the
cavity – particularly at the center of the
component – are short. Thus the material
flow into the shaping area is no longer
the diameter of the product to be
manufactured, but the radius. The lack
of a gating system also creates space for
additional cavities on the machine and
reduces follow-up processes.
Serial production for automotive
and industrial applications
Fig. 4a: Conventional process with 8 castings per mold vs. hot runner technology with 16-fold
mold design.
Fig. 4b: Hot runner technology cuts CO2 emissions by about 80% compared to conventional
casting.
The proportion of hot runner products
in serial production at Föhl is steadily
increasing – so high unit numbers have
become established as the norm. Other
projects are taking place during the
design and sample phases. Whereby the
figures compared to conventional production
speak for themselves, as all
aspects yield optimized results. In a case
study on a retaining washer for automotive
construction with dimensions of
ø20 mm x 3.4 mm and a component
weight of 6 g, a saving of 40% in return
a
b
material was achieved using a 16-fold
mold design – doubling the cavities
using the same machine and with density
improved by 1.22% for the 6.5 m.
units currently produced each year.
www.foehl.de/en
10

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COREMAKING
Photos: Laempe Mössner Sinto GmbH
Laempe LHL200-1700
Laempe employees pose with the new flagship, the
LHL200-1700. The picture gives an impression of the
facility’s enormous size.
The world’s largest core shooter
Laempe Mössner Sinto has assembled the world’s largest core shooting machine
at a works in Magdeburg (Saxony-Anhalt). The customer is a leading Chinese engine
manufacturer.
By Thomas Doriath
Laempe constructed this automated
core shooter – which exceeds all
previous dimensions – for a large
Chinese engine producer. The Laempe
machine will be used in Weifang, China,
to produce cores for casting ships’
engines. The LHL200-1700, as the
machine is officially called, has been put
into operation with the customer,
shipped out and is currently being set
up at destination.
The LHL200-1700 will be installed
and operated in China. The heavyweight
among core shooters is an
impressive giant – eleven meters tall, 16
meters long and 30 meters wide, with a
weight of 300 tonnes. The dimensions
of the core box are the same as those of
a standard Laempe core shooter. The
shooting volume of the LHL200-1700 is
1,700 liters with core box dimensions of
3 x 3 meters and a tool weight of up to
30 tonnes – also a new record in the
foundry industry. Consequently, the
cores also set new standards: they can
weigh up to 2.5 tonnes, and the customer
will use them in their foundry as
parts of a mold for ships’ engines.
The core shooter was designed in
Schopfheim, Baden, by the research and
development department of Laempe
Mössner Sinto GmbH, and produced in
Meitzendorf and, since the machine
12

dimensions would have exceeded the
possibilities of Laempe’s own production
hall, the record LHL was assembled
at SKET GmbH (Schwermaschinenkombinat
Ernst Thälmann) in Magdeburg.
“The LHL200-1700 is a milestone for
us because it shows that we are the perfect
partner for foundries when it
comes to the construction of customized
machines. This major project was
implemented with excellent collaboration
between all the departments at
our three locations in Meitzendorf,
Schopfheim and Mannheim. This
impressively demonstrates how
cross-departmental and cross-site cooperation
can lead to top performance in
the interests of our customers,” says
Rudolf Wintgens, Managing Director of
Laempe Mössner Sinto GmbH. Laempe
employs around 240 people at its headquarters
in Meitzendorf, about 90
employees in Schopfheim and eleven in
Mannheim.
Delivery of the LHL200-1700 is the
largest component of the customer’s
order. The company from the Shandong
province produces engines, among
other things, and employs more than
50,000 people.
www.laempe.com
On target.
IR Cameras. Pyrometers. Accessories.
Software. We measure temperature
non-contact from –50 °C to +3000 °C.
Visit: www.optris.global
Our affordable and fixed installed
longwave and shortwave IR cameras
with analog/digital outputs are ideal
for industrial and R&D applications.
Rudolf Wintgens, Managing Director of Laempe Mössner Sinto, standing next to a
produced core.
when temperature matters

CASTING DIE CASTING
Numerical simulation
Conserve resources and protect
the environment with Magmasoft
For Brazilian faucet and shower specialist Docol, sustainability is an integral part of their
corporate policy. To actively contribute to environmental protection in this area, the
company decided to use numerical simulation with Magmasoft.
By Pia Sonntag, Aachen
Photos: Magmasoft
The following example shows how
virtual simulation enabled Docol
to reduce the scrap rate in the
production of a single-lever mixer.
Figure 1a shows the „Lift“ mixer, whose
body is cast from a copper-zinc alloy in
a low-pressure casting process. The cast
part systematically showed hot tears in
the rear area, which affected the surface
of the part, (Fig. 1c). Hot tears
occur at the end of solidification,
usually run along grain boundaries, and
the fracture surface is intercrystallin.
This formation mechanism can often be
recognized from the shape of the crack,
which is „jagged“ in the finished part,
(Fig. 1d).
In order to find a solution as quickly
as possible, Docol contacted Magma
with the question: What is the optimal
way to detect the factors influencing
the tendency for hot tears? The objective
was to reduce scrap by 50% and
thus reduce material consumption. At
the same time, the lead time in production
should be shortened systematically.
Fig. 2 shows the initial situation:
There is still partially solidified melt in
the rear area of the component, while
the material outside is already comple-
14

Fig. 1: „Lift“-single-lever
mixer (a),
Magmasoft-model
(b) and occuring casting
defect (c) as
well as location of
heat tear (d).
tely solidified. This means that here
even slight stresses are sufficient to
form ductile deformations or cracks.
The entire height of the single-lever
mixer shows increased strain rates in
areas that have not yet solidified ((Fig.
2a) (Fig. 2b). This causes a high hot tear
tendency (Fig. 2c).
Shrinkage porosity remains stable
Based on this results analysis, Docol set
up a virtual test plan with Magmasoft to
investigate the influence of geometry
variations on the tendency for hot tears.
The geometry was parameterized at the
gate (thickness and radius) and within
the casting (wall thickness). However, it
was important to ensure that the
change in casting and process parameters
did not lead to an increased shrinkage
porosity in the critical area. The
evaluation of the 25 different designs
calculated by Magmasoft showed that,
with regard to hot tears, design 20 is the
optimal variant: lower strain rates
(represented by the result ‚Max Principal
Strain Rate‘) as well as reduced fraction
liquid (‚Fraction Liquid‘) in the investigated
area. Figure 3 compares the results
of the original and the optimized version
of the project. The hot tear tendency
decreases significantly and the
shrinkage porosity remains stable at a
low level. Mission accomplished.
The change of geometry reduced
scrap by 70% and weight by 8%. In
addition to the robust production as
well as the desired quality requirements,
there were further advantages
with regard to sustainability: the
consumption and the disposal of sand
and resins were minimized. In addition,
the consumption of water, electrical
energy, abrasives and liquid gas was
reduced. As it turns out, protecting
nature and being environmentally conscious
can be so easy when you have the
right tools.
www.magmasoft.de/en/
Fig. 2: result analysis of the initial situation: (a) fraction liquid ‚Fraction Liquid‘, (b) strain rates
‚Max. Principal Strain Rate‘, (c) Hot Tear Tendency ‚Hot Tear‘.
Fig. 3: Comparison of the initial and the optimized version: The optimized version shows a lower fraction liquid ((a) vs. (c)) as well as lower
strain rates ((b) vs. (d)).
CASTING PLANT & TECHNOLOGY 2/2022 15

CASTING
Photos and graphics: FRAUNHOFER IFAM
Gel casting
From the suspension to a dense metal component
in just a few steps.
Producing complex castings
without a melt
It is impossible to burn one’s fingers here. No metal is melted for subsequent casting
when the hybrid gel casting process is used. This is a suspension casting technique that
permits the production of complex metal components with internal channels and thus
achieves the structural freedom of additive processes. The process chain is equally suitable
for the production of components made of metals or ceramics.
By Sebastian Riecker, Dresden
The gel casting hybrid suspension
process runs at moderate temperatures
and makes very low
demands of the molds. The newly
developed metal powder suspension –
which mainly consists of water, powdered
metal (generally greater than 55
percent of volume), and a variety of
organic additives – is at the heart of this
innovative process presented by the
researchers of the Fraunhofer Institute
for Manufacturing Technology and
Advanced Materials (IFAM) in Dresden.
The suspension is liquid when heated to
about 40 - 70°C, and hardens into a
flexible but solid gel when cooled to
room temperature.
The process
The following process steps are necessary
to produce metallic components
using the gel casting technique (Fig. 1):
FRAUNHOFER IFAM, DRESDEN
Mold production
As with classic metal casting, molds are
required. But, because of the low thermal
and mechanical stresses in suspension
casting, these can be made of plastic,
wax, metal, or even other materials
such as wood. A simple approach is the
production of plastic molds from a 3D
The Fraunhofer Institute for Manufacturing Technology and Advanced Materials
(IFAM) in Dresden is one of the world’s leading research institutions in the field
of powder metallurgical technologies, as well as sinter and composite materials
for functional applications. It carries out fundamental applied research to
develop solution-oriented materials and technologies. Its activities range from
the industrial implementation of research results to the production of prototype
components and their transfer to industrial use. Developments take place along
the entire process chain. In the field of additive manufacturing, powder-based
selective electron beam melting (SEBM) and five sinter-based processes are currently
being further developed. In addition to the gel casting process described
above, the sinter-based AM processes include 3D screen printing, fused filament
fabrication (FFF), lithography-based metal manufacturing (LMM) and the MoldJet
process. All technological expertise in this area is consolidated in the ICAM (Innovation
Center Additive Manufacturing) of the Fraunhofer IFAM in Dresden.
16

Polymer
Mold Production
Casting Process
Demolding
1
Heat Treatment
Fig. 1: The individual process steps in gel casting based on an example: a) mold production, b) filling with suspension, c) removal of the
hardened component from the mold, d) heat treatment.
printer via the so-called fused filament
fabrication (FFF) process.
Suspension casting
After heating to 40 - 70°C, the suspension
has a viscosity similar to that of varnish
and can be inserted into the mold.
This can be carried out without pressure
in open or closed molds, or supported
by pressure with vacuum or positive
pressure.
Removal from the mold
Depending on the complexity of the
component, the castings can be directly
removed from the mold after cooling
and meshing of the binder (Fig. 2) or
the mold can be completely dissolved in
a solvent bath. Complex undercut structures
and internal channels can be
achieved by using a lost-mold technique
and dissolution in a solvent bath.
Heat treatment
The demolded component still consists
of metal powder and binder (adhesive)
in the form of a so-called green part.
After pre-drying, the organic components
are now burnt out in a furnace
process (thermal de-binding) and the
still-porous green part transformed into
a dense metal component at high temperatures
(sintering).
FeSi6.5, FeCo50 or nickel-based alloys
such as Inconel 718 (2.4668) and Inconel
625 (2.4856); light metal alloys such as
Ti-6Al-4V (3.7164); or even pure copper
and copper alloys, refractory metals and
alloys, as well as hard metals and composite
materials. Up to now the process
has been successfully tested on tool
steel M2, stainless steel 316L, hard
metal (tungsten carbide), copper-diamond
and Ti-6Al-4V.
The components exhibit typical sinter
structures and are somewhat finely
grained. The structure naturally
depends on the material and the heat
treatment, and can be precisely
adjusted via the furnace process, if
required. As a result of the high sintering
temperatures of about 80% of the
melting temperature, the components
come out of the furnace stress-free and
have a very finely distributed residual
porosity of typically 0.1 - 4%. If the
demands made of the material are particularly
high, the components can be
completely re-pressed with hot isostatic
pressing. Whereby the component
properties are comparable to those of
components produced using metal
powder injection molding. For stainless
steel, for example, a tensile strength of
514 MPa and a uniform elongation of
41% was achieved. The material specification
for 1.4404 is a tensile strength of
500 - 700 MPa and a breaking elongation
of 30 - 40% [1].
Geometries
The components that can be manufactured
mainly depend on the geometries
that can be produced as a mold, and
whether these can be filled without
faults. The suspension remains liquid for
several minutes so that a too-rapid
hardening is generally no problem
during pouring. Moreover, there is no
loss of volume during hardening (meshing),
so that the shrinkage cavities
caused by thermal shrinkage are also
not relevant here. In contrast to this,
plastic molds are not permeable to air,
so the prevention of gas pores in the
corners of the molds requires a suitable
casting process or air vents.
When one takes these aspects into
account, wall thicknesses of about 0.3
mm to > 40 mm can be achieved in a
component. Fine structures or a particularly
smooth mold surface are thereby
reflected in great detail. For example,
printed molds can be smoothed using
solvent before the casting process to
avoid subsequent complicated finishing
of the metal component (Fig. 3). The
Materials and properties
The process route via the green part
made of metal powder and the sintering
step in the furnace is already familiar
from other processes such as ‘press &
sinter’, metal injection molding (MIM),
or sinter-based additive manufacturing
(AM). So a wide range of materials is
already available that are, in principle,
also suitable for processing via the gel
casting process. Typical examples of
these include various iron-based alloys
such as the stainless steels 316L (1.4404)
and 17-4PH (1.4542); working steels
such as M2 (1.3343), D2 (1.2379) or H13
(1.2344); magnetic alloys such as
Fig. 2: Direct
removal of the
so-called green part
from a divided,
3D-printed plastic
mold (component
from input picture).
CASTING PLANT & TECHNOLOGY 2/2022 17

CASTING
Fig. 3: Complex
mathematical
‘gyroid’ structure
made of stainless
steel 316L, produced
using a plastic
3D-printed mold
smoothed in a solvent
bath.
sintered parts have a correspondingly
high surface quality when milled molds
are used. In addition, internal channels
and strong undercuts can be implemented
by using lost molds. Fig. 4 shows
part of a calibration tool for plastic
extrusion. The component was made of
M2, weighs about 800 g, and contains
both vacuum and cooling channels.
The weight of sintered components
is typically below 500 g, though in
exceptional cases – and depending on
the material and geometry – weights of
up to 5 kg are also possible. Users of the
gel casting process have many possibilities
for individually adapting the process
because both mold production and
the casting process can be very specifically
fashioned. Individual single parts
can be produced using a mold made via
additive manufacturing, while small
and medium-sized series can be implemented
with reusable permanent
molds. Depending on the component
geometry, mass production is conceivable
with filling on a conveyor belt.
If certain component features cannot
be generated directly via the casting
process, there is still the possibility
of mechanically processing the green
part, which consists of powder and
binder, before sintering. Whereby the
strength of the green part is similar to
that of plaster, and the cutting forces
during processing are very low – so
work can take place without coolant.
Whereby very fine details can be
achieved with good surface quality. In a
trial geometry (Fig. 5), pins with a
length of 2 mm and a diameter of 0.4
mm could be carved out with multiple
reproducibility and fault-free. The
milled structure could then be converted
to a dense component without
deformation. Whether a part can be
produced depends on many factors that
must be individually assessed. The limits
of what is technically possible are constantly
expanding because the process is
continuously developing.
Summary
The gel casting process is a suspension
casting technique that was developed
for the production of complex metal
parts. It requires no liquid metal and
can be implemented with many different
alloys, pure metals or composite
materials. The use of watery suspensions
at low temperatures, and the
great freedom permitted during production
of the mold and during the
casting process, make gel casting very
flexible and individually adaptable.
www.ifam.fraunhofer.de/gelcasting
Further information:
The Fraunhofer Institute for Manufacturing
Technology and Advanced
Materials (IFAM)
Dr.-Ing. Sebastian Riecker
Winterbergstrasse 28
D-01277 Dresden
Germany
Tel.: +49 (0)351 2537-429
e-mail: Sebastian.riecker@ifam-dd.
fraunhofer.de
Literature:
[1] Wegst, Claus W, & Wegst, Micah,
Stahlschlüssel-Taschenbuch, 22. Aufl.
2010, Verlag Stahlschlüssel Wegst
GmbH, Marbach.
Fig. 4: Part of a calibration tool with internal
vacuum and cooling channels: a) CAD sectional
view and b) sintered component made of
working steel M2. The mold was 3D-printed,
the component could subsequently be
removed from the mold in an acetone bath.
Fig. 5: Test component with fine pins (D = 0.4 mm, H = 2 mm) milled and sintered from
the green body (consisting of powder and binder).
18

PROCESS
Process optimization
The right release agent for greater
efficiency and sustainability
Increasing demand from differing sectors always involves new requirements for die-casters
regarding component quality and process optimization. As a result, options that
really can be implemented and that are sustainable are required to optimize production
processes to meet rising competitive and costs pressures. Selected releasing agents – proven
to meet the rigorous and demanding requirements in practice – are available to help
reach these goals.
By John Belyk, Darko Tomazic, Albrecht Vogel, Maisach near Munich
Photos and graphics: Chem-Trend
Innovations in die-casting are obvious:
innovative technologies, for example,
promise to increase efficiency during
the production process. New materials,
tools and processes are regularly presented,
and digitalization and the use
of robots promise further improvements
in production. The result: continuous
optimization and increasing component
quality.
Die-casting on the rise
These developments coincide with
changing, though constantly growing,
demand. Whereby the changes in automotive
construction – the key industry
for die-casting, for which a major proportion
of production is destined – are
of particular significance (Fig. 1). No
change in this trend is discernible, even
with the upcoming development
towards alternative drives. On the contrary:
although the drives of e-vehicles
require far fewer cast components that
was the case for combustion engines, a
considerably higher proportion of light
components are required – and carmakers
rely on dependable partners in the
foundry industry for their production.
Whereby die-casting also profits from
positive economic development in
CASTING PLANT & TECHNOLOGY 2/2022 19

PROCESS
Release agents have a key role in the
production process, providing the
die-casting industry with decisive leverage
for positioning itself as future-oriented
and sustainable. Because the
quality properties of advanced release
agents are still underestimated.
Whereby they have a considerable
effect on the quality features of the finished
components – and an intensive
effect on a variety of areas such as process
technology, component function
and, consequently, not least on environmental
impact (Fig. 3). The length of
the service lives of foundry tools is also
dependent on this – apart from the
question of how much mold release
agent is actually required.
Fig. 1: Structural components for vehicle production are a key product for die-casters.
other important segments that are also
significant purchasers of components:
medical technology, for example, or
home electronics, the e-bike segment
and 5G mobile phone technology are
booming.
High competitive pressure and
a poor environmental balance
But even if it sounds paradoxical, the
costs and competitive pressures facing
die-casting companies are increasing
given the constant high demand – particularly
because a large number of
machines are in operation. The benefits
brought about by new technologies
often have an insufficient effect from
an economic point-of-view, because
unexpected situations frequently arise
in the production process and cannot
be handled with the advertised technological
improvements alone. Consider
premature mold wear, high consumption
of compressed air, and rising
energy requirements. These considerable
‘frictional losses’ are caused by the
casting process itself which, in turn, is
characterized by factors such as temperature,
pressure, and the growing
size and complexity of the castings
(Fig. 2). Furthermore, there is a high
consumption of resources in many
cases. Water, for example, is required to
dilute the release agents used. The
more waste water, the higher the costs.
Another challenge facing the sector
is gaining in importance given the topicality
of climate and environmental protection:
the compromises made regarding
sustainability. Not for nothing is the
foundry industry still considered traditional,
energy-intensive and, at least to
some extent, not very environmentally
aware. Though there are already many
companies that show that one can do
better – for example by reducing CO 2
emissions and waste, the need for fresh
water to dilute release agents, or even
the use of release agents in the production
process itself.
Mold release agents with
a key function
Fig. 2: The complexity
of structural
components, in this
case a side member
made of aluminum,
affects the cost-effectiveness
of the
casting process.
Selecting the right release agent
The current generation of release
agents is, by and large, extremely effective,
but there are still very few sustainable
solutions that really offer maximum
process efficiency and
effectiveness. Applications with minimal
quantity requirements are particularly
recommended because a minimum
amount of release agent to protect the
mold is sufficient for optimum results,
applied to the location that is of most
importance for component demolding.
The following criteria are relevant for
deciding on the specific suitable solution:
> A highly efficient release agent concentrate
considerably reduces release
agent consumption because the smallest
of quantities is sufficient to ensure
high demolding performance.
> The application of only a very low
volume of release agent leads to a completely
new type of process and production
technology – for which a variety of
terms already exist on the market, for
example micro-sprays and minimum
quantity sprays.
> A certain expertise is required to
exploit all the advantages. For example,
the use of a special release agent is
required that meets both the demands
of the process (new application technology,
increased mold temperatures) and
the requirements of the component
(OEM delivery specifications).
20

Fig. 3: Advanced release agents have a major
influence on process technology and
environmental impacts.
> The application of minimum
amounts of release agent reduces the
gradients between the tensile stresses
and compressive stresses in the casting
tool, leading to increased tool service
lives.
the costs associated with the die-casting
process. Chem-Trend suggested the
Hera micro-spray to help the company
take a major step forward – regarding
both the technology and the processes.
For this purpose, the customer’s casting
process was analyzed, new paths taken
together, and a future-oriented casting
concept established.
The customer was able to continuously
improve their original results with
the help of a Hera solution presented
ten years ago, in combination with
modern technology for applying the
release agent and optimized mold temperature
control. In particular, Chem-
Trend was able to provide the customer
with fundamental process optimization
support.
The benefits of Hera were immediately
apparent: the cycle time was reduced by
10.5%, leading to a considerable
increase in productivity. Other shortand
long-term benefits included:
> Overall optimization of the production
process.
> Longer mold service lives due to
reduced thermal shock.
> Efficient and reliable spray application
– both for static and mobile spraying.
> Considerably reduced consumption
of compressed air, and much lower use
of fresh water – and almost no waste
water.
> Improved sustainability.
https://chemtrend.com
Watch a video at:
https://bit.ly/3rlNlLO
John Belyk, Global Business Development
Director for Die-Casting, Darko
Tomazic, Sales Manager Die-Casting
Northern Europe, Albrecht Vogel, Sales
and Application Engineer, Chem-Trend
Users can already take advantage of
extremely positive effects by applying
very low amounts of release agent:
> The enormously reduced spraying
volume lessens the otherwise induced
temperature shock, leading to increased
mold lifetimes.
> The lack of diluting water improves
the cast structure because less residual
water and steam is trapped (porosity).
The volume of waste water – which
would otherwise have to be recycled or
expensively disposed of – is also
reduced.
> The lower spraying time correspondingly
reduces the total cycle time. This
increases yields.
> The consumption of compressed air
is considerably reduced because dry
blowing is no longer required after
spraying.
> Less heat energy (and thus electricity)
is required because thermal regulation
of the mold changes from heating
to cooling, leading to a more positive
carbon footprint.
M
M
R
odernization
aintenance
etrofit
Application example from
the automotive sector
A company in the automotive industry
was looking for possibilities for optimizing
its casting processes and reducing
info@rump.de • www.rump.de • +49 5258 508 0
CASTING PLANT & TECHNOLOGY 2/2022 21

PROCESS
Photos: ZwickRoell
In the fully automated testing laboratory, AGVs transport the samples between the sample preparation area and the testing machines.
Industry 4.0
Automation trends in
material testing
Material tests are increasing being automated because even the slightest disruptions can
change the measurement results. Time-consuming or monotonous work is also increasingly
being left to robots. ZwickRoell offers comprehensive possibilities for automating
material tests. The testing systems range from the efficient automation of small series
tests by means of collaborative robots in a testing laboratory to fully automated testing
laboratories that work around the clock.
By Wolfgang Mörsch, Ulm
Classic robotic testing systems, for
example based on industrial
robots, have been used successfully
for years. They are able to move
even heavy specimens because of their
high load capacity. The wide range of
specimen magazines makes them ideal
for long test series – hundreds, and
even thousands, of specimens are
autonomously processed magazine-by-magazine.
For example, using
various roboTest testing systems from
ZwickRoell. In connection with the corresponding
testing machine, they are
not only the perfect solution for standard
tensile tests on metals or plastics
under normal conditions – flexure tests;
temperature-controlled tensile, notch
impact and puncture tests; as well as
measurements of ball indentation hardness
can also be automated.
Complete systems
Not only can the actual test be performed
without employee intervention,
but ZwickRoell also builds fully autono-
22

mous testing laboratories using AGVs
(automated guided vehicles) and additional
handling robots that are coordinated
with ZwickRoell’s autoEdition 3,
just like the robots used for the testing
process. When necessary, they run 24
hours a day and autonomously assume
materials testing, from placement of
the specimens onto a transport belt to
disposal of the destroyed specimen.
All that’s left for workers to do are
specimen production and preparation.
A fully automated testing lab is especially
worthwhile for quality assurance
in ongoing production with high material
throughput. After removing the
specimens or materials from the manufacturing
process, they are formed into
the required shape and size. Every specimen
is given a bar code or 2D code and
can then be automatically and clearly
identified in the system.
The only thing left is transfer of the
specimens to the robot testing lab: the
specimens are placed on a belt conveyor
and sent risk-free within reach of the
robot, they are recognized by their
code, assigned to the correct test and
testing machine, and sorted onto the
proper tray.
Driverless transport
Fig. 2: An AGV delivering samples to a roboTest testing system.
Further transport is carried out by the
AGVs, which bring the trays to the particular
testing machine. They use the
integrated laser navigation system to
create a map of their surroundings and
autonomously find the ideal route to
their destination. Their autonomous
navigation makes them superior to classic
solutions which, for example, have
to follow a wire embedded in the driving
lane or a contrast line glued to it.
Their only way to react to obstacles is to
stop and wait until the path is free or to
inform an operator. If the path is not
freed up, the delivery remains stationary
– in the worst case, until the material
runs out at the destination station
and an employee searches for the
cause. The solution used by ZwickRoell,
on the other hand, can drive around
obstacles and thus ensure stability of
the transport chain.
When the AGV has arrived at the
intended testing machine, it loads its
tray – and thus the fresh samples – into
the magazine of the testing system.
One of the recognized robot testing systems
from ZwickRoell, such as the robo-
Test L, takes over processing of the samples
delivered. Filling of the testing
machine, the testing process, transfer of
the data to the customer’s software system
and, of course, removal of the
destroyed samples all takes place completely
automatically. Here, too, the
identification numbers of the test
pieces are read out by cameras to correctly
link the test data with the particular
sample.
An AGV picks up the empty trays
again and transports them back for
sample preparation, where they are
CASTING PLANT & TECHNOLOGY 2/2022 23

PROCESS
Test N can work alongside persons without
the need for additional safety measures
– locked off work areas are
unnecessary.
Fig. 3: Automation of hardness tests with the roboTest N.
refilled and the next cycle starts from
the beginning.
Automating small series tests
Until now, the work carried out successfully
on a large scale – saving a lot of
time – has not been economical on a
small scale. The installation of stationary
robotic testing systems is costly and
requires time, as well as specialists who
are familiar with their programming. In
addition, depending on the system, a
wide range of safety measures are necessary
to avoid injuries and accidents:
the powerful industrial robots are not
intended for use in direct collaboration
with humans. They do not have the
option of reacting to their environment
with an emergency stop, for example, if
a person moves within their working
range. In most cases a safety barrier is
required, eliminating direct interactions
between the robot and humans. So up
until now small series tests have been
carried out by humans. Even if a task is
extremely monotonous, it was much
quicker to entrust an employee with 20
tensile tests or 50 Charpy impact tests,
than to install a large robotic testing
system.
For the first time, with roboTest N,
ZwickRoell is able to offer automation
of series testing with a small number of
specimens and a lower specimen
weight. Based on a smart robot, the system
is fully integrated in ZwickRoell’s
autoEdition 3 and testXpert III. So no
robot operator terminal or special robot
programming and operating knowledge
are necessary. Instead the roboTest
N is literally taken ‘by the hand’ and
taught the necessary point of reference.
In regards to software, parameters are
set in a familiar software environment.
Not only is the setup of the smart robot
easy and uncomplicated, its work speed
and force are similar to human proportions.
Sensors detect external influences
and stop the system if something gets
in its way. Therefore, once cleared with
laboratory safety personnel, the robo-
Diverse application options
The lightweight robot is fastened to a
movable table specifically intended for
it. This mobile base widely expands
application options. The smart robot
can be moved to the appropriate testing
machine and connected to the system.
This not only enables uncomplicated
processing of alternating small
series, but also the automated performance
of a variety of tests. Tensile and
compression tests can be processed
autonomously, as can three-point flexure
tests, Charpy impact tests or hardness
tests.
The movable base also provides
space for customized magazines – produced,
for example, in a 3D printer –
from which the roboTest N can automatically
take additional specimens. If
started just before the end of a shift,
the robot can thus extend the workday
by the contents of a magazine, and the
results are available at the start of the
next day.
Automation of monotonous standard
tests allows qualified employees to
focus on more complex test applications
that require greater attention. The
independence from the operator that is
achieved with the use of a robot is also
a benefit. The uniform movement
sequences in feeding the testing
machine, and the subsequent consistent
positioning of the specimens, eliminate
user errors or inaccuracies – and
increase the reliability of test results.
Summary
Robotic testing systems provide the user
with a number of benefits in series testing,
from time savings all the way to
improvement of the informative value
of the test results. ZwickRoell covers the
full range of testing automation with a
various of roboTest testing systems –
from short-term support for continually
changing small series in the lab, all the
way up to fully automated testing laboratories
without human intervention.
www.zwickroell.com
24

PROCESS
Fig. 1: Shredding and sorting of aluminum scrap: the first step is to feed the raw material into the ‘ripper’, where it is shredded.
Aluminum preparation
High sorting efficiency despite
impurities
A new type of complete plant with three operating modes filters recycling aluminum
from difficult input material. The gentle temperature-reduced preparation process is
intended to prevent ignition and explosions of the dusts, and alloys with magnesium
content, during the shredding operation.
By Sophie Kesy
Photos: Erdwich GmbH
Metals are currently among the
most sought-after raw materials
worldwide: the aluminum
price alone has risen from about 1620
USD/t to more than 2550 USD/t since
early July 2020. The advantage of aluminum
is that the metal can be melted
and processed to make a variety of products
almost any number of times. And
the recycling of aluminum scrap only
requires five percent of the energy compared
to producing primary aluminum.
But the recycling companies must supply
material that is as pure as possible
– which can be melted and reprocessed
without delays – for processing companies
(such as carmakers or the producers
of electronic articles or packaging materials)
to purchase the raw material at
the prices demanded.
High purity demands require new
plant concept
Until a few years ago, an Austrian company
used a conventional two-shaft
shredder for its shredding. But the plant
regularly suffered mechanical breakdowns
and blockages, which had a considerable
negative impact on operations.
So the company started looking
for a replacement shredding plant in
CASTING PLANT & TECHNOLOGY 2/2022 25

PROCESS
Zerkleinerungs-Systeme GmbH. “Then
there was the fact that some of the
input material was made up of undefined
constituents, such as non-metallic
intrusive materials or even solid bits of
iron, that made sorting more difficult.
So it was necessary to implement several
processes and appropriate equipment
for separating the various materials
and alloys.”
Fig. 2: A gripper helps pre-sort the raw material.
2017. After comprehensive consultations
with Erdwich, the management
decided to install the RM1350 ripper.
Compared to the previous shredder, the
main advantage of this two-shaft ripper
developed by Erdwich is that the blades
do not simply shred the input material
but literally tear it apart thanks to their
special shape. As a result, the plant can
grip the aluminum scrap much better
and there are rarely blockages or
damage to the machine.
As the metal processing firms, however,
increasingly demanded unmixed
recycling materials, in 2019 the management
decided to optimize the entire
plant concept regarding preparation of
the aluminum scrap. Due to its good
experience with the two-shaft ripper,
the company again turned to the shredding
system experts at Erdwich. But this
time, a single machine would not
resolve the situation: in order to be able
to react as flexibly as possible to differing
input materials, the Iglingen-based
company planned and implemented a
complete plant concept which integrated
the existing two-shaft ripper. The
shredder plant was supplemented with
a hammer mill, also developed by Erdwich.
Whereby the aim was to solve
several challenges at the same time.
“For one thing, the space available for
the plant was limited to a very narrow
half-open hall which necessitated very
accurate dimensioning and forward-looking
planning,” explains Harald Erdwich,
Managing Director of Erdwich
Three different operating modes
for differing input materials
While ultra-fine materials, such as sand
or dirt particles, are extracted using a
vibrating screen, a magnetic drum
separator ensures that pieces of iron
are removed from the shredded aluminum
scrap via the magnet. A zig-zag
air separator also separates out foils or
wood chips from the metallic components,
while an eddy current separator
is responsible for filtering out pieces of
plastic. There is also a four-fold sorting
device for impure alloys, which works
using X-ray detection, among other
things. This enables particularly fine
separation of the materials and thus a
high level of grade purity.
But the input fractions are not
always composed in the same way. In
order to be able to react more flexibly,
Erdwich therefore implemented a
hitherto unique concept: three different
modes can be set for the efficient
processing of the material. “In mode A,
the aluminum scrap is fed directly into
the RM1350 pre-shredder by means of
a gripper or stacker, and then re-shredded
using our HA800 hammer mill,”
Erdwich reports. “The mixed fractions
are separated using various sorting
techniques and then discharged into
containers provided by the customer.”
Mode B enables the faster processing
of pure aluminum scrap. After shredding
in the twin-shaft shredder, a separation
of FE and V2A material is carried
out by means of a double magnetic
stage; the discharge into the existing
containers is carried out using swiveling
stockpile belt.
Double feeding enables parallel
processing of input fractions
Mode C is a special feature: this mode
ensures double feeding in order to be
able to process input material with different
compositions at the same time.
This makes it possible to process both
pure aluminum scrap, as in mode B, and
aluminum/copper cast material in parallel.
The latter is fed into the vibrating
feeder via the mobile conveyor belt,
26

Fig. 3: The material is re-shredded in the hammer mill and then sorted.
Fig. 4: The end-product: the output fractions
are only about 70 mm in size after shredding
with the hammer mill.
crushed by a hammer mill, separated by
means of X-ray sorting, and then transported
into containers. The different
modes can be selected on the operator
panel by means of a softkey before the
system is started. A throughput of up to
2500 kg/h can be achieved, depending
on the composition of the material and
the mode.
Gentle shredding and sensors prevent
ignitable dust concentrations
“However, the shredding process for
aluminum scrap, in particular, must be
constantly monitored,” explains Erdwich.
“Because as soon as aluminum is
shredded to less than 4 mm, or the
input material contains aluminium
alloys with magnesium components, it
can ignite and trigger an explosion.” In
the case of aluminum dust, for example,
a concentration of 50 g/m³ is sufficient
to reach an ignitable air concentration.
If there are magnesium admixtures, the
material reacts even more sensitively:
here, the mere frictional energy can
trigger spontaneous combustion. “To
avoid accidents, the cutting mechanism
geometry of the ripper is therefore designed
in such a way that the material is
shredded as gently as possible under
temperature-reduced conditions,” explains
Erdwich. “Sensors also ensure that
no excessive dust concentration can
occur inside the hammer mill if, for
example, there is a filter defect or other
failure of the extraction/filter system.”
After crushing with the hammer mill,
the output fractions are only about 70
mm in size, so the material can easily be
transported and subsequently remelted.
Changes in the composition of the input
material do not pose a problem because
the three different operating modes
and the innovative sorting techniques
mean that other types of scrap can also
be processed gently. There is no need to
worry about clogging or machine breakages.
With the plant completely
planned and implemented by Erdwich,
the company is optimally equipped for
the future and can easily and quickly
adapt to new developments in scrap
processing without having to put up
with lengthy repairs and downtimes.
www.erdwich.com
www.agtos.com
375-01/22-4c-GB
CASTING PLANT & TECHNOLOGY 2/2022 27

COMPANY
Photo: sommai – stock.adobe.com
Corporate management
Consistent and agile exploitation
of business opportunities
Sales personnel at companies are often unclear about what they should do to achieve
their sales targets during the coming months. This is because there is often a gaping
planning gap between the sales strategy and the everyday work of sales staff. A selling
plan would close this gap.
By Peter Schreiber, Ilsfeld
The same procedure every year.
The Executive Board or company
management announces the
goals for the coming fiscal year to the
sales managers. For example: “Sales
should increase by 15% with returns
rising by three percent. We also want
to achieve 20 percent of our sales with
services, and 20 percent with new
customers.”
The sales managers sit down with
their staff and tell them: “Next year,
you must... This is, admittedly, a demanding
target – but it is achievable.” But
the sales personnel groan: “We were
only able to reach the sales target this
year with great difficulty. How are we
going to pile on another 15 percent
again, especially given the current
Covid-related situation in which nobody
knows what’s going to happen?”
Strategic goals are soon forgotten
Those responsible for key accounts are
meanwhile going through their regular
customers in their heads: “I’ve almost
certainly got 100,000 euros of sales at
Customer A and 60,000 euros at Customer
B. Then there’s Customer C with…
That means that 60 percent of the sales
are already almost taken care of. So I still
need to find orders for 250,000 euros
and then I’ve reached the sales target.”
In an instant, however, the sales personnel
have forgotten strategic sales
goals such as:
> acquire new customers, or
> sell more services, or
> aim for higher profit margins, or
> find reference customers for new
product lines
28

deriving goals for their everyday
work from their defined targets, and
> planning the measures necessary to
achieve them.
So most companies have sales plans that
list the sales planned with individual
customers or customer groups, but they
do not have selling plans – i.e. the planning
of measures that define the activities
that the sales personnel want to use
to achieve their targets (Fig. 1).
Photos: Peter Schreiber
Fig. 1: Selling plans list the measures with which sales personnel want to achieve their targets.
(Graphic: Peter Schreiber)
– because experience has shown them
that: “Ultimately, my bosses focus on
the sales near the end of a quarter or
the year. And I’ll get my commission if
they are OK.” So they carry on working
as usual without re-planning their work
to take the new goals into account.
have derived their definition of (strategic)
goals. They also have no access to
the sales data that they require to
enable them to plan measures, such as
the profit margins aimed for with customers.
And almost all companies lack a
tool that supports the sales staff in:
B2B: successful sales require planning
The creation of such selling plans is
indispensable for the planning and controlling
of sales success in B2B sales
because:
> How should sales personnel adequately
react to market opportunities
and risks if they have not analyzed
the situation regarding the market
and the competition?
> How should they discover untapped
market potentials if they do not
know the needs of their (not yet)
customers in their sales region?
> How should they work effectively if
they do not know which (not yet)
customers offer major opportunities
for landing additional orders in response
to their company providing
The market drives sales – not the
other way round
One often registers such attitudes in
companies due to the following strategic
planning gap in sales departments: individual
targets are generally formulated
in addition to the departmental goals –
but without planning any sales measures
derived from the strategic goals, referencing
individual customers or customer
groups and oriented upon the potentials
of target customers and the opportunities
for achieving the desired outcome.
And what if sales managers want such
planning of measures from their staff?
Then they often hear excuses such as “I
can’t plan so far ahead; I have to be flexible.”
The sales personnel thus consider
their lack of planning to be proof of
their agility. In reality, however, such statements
are generally an indication that
the market drives sales and not that sales
drive the market.
Many companies, however, do not
meet the prerequisites for professionally
planning measures for their
employees. Personnel are, for example,
often insufficiently informed about the
assumptions from which their superiors
Fig. 2: Sales staff receive a ‘planning letter’ from the management every year describing the
corporate goals and sales strategy. (Graphic: Peter Schreiber)
CASTING PLANT & TECHNOLOGY 2/2022 29

COMPANY
some added value that they also do
not know about?
The analysis and planning processes
must themselves meet certain prerequisites
in order to ensure that sales personnel
are open to such market analysis
and planning of measures. For example:
The order of the planning steps
must be inherently logical and their
benefits comprehensible for the staff.
The necessary data must be easily
accessible or provided in prepared form.
And the planning effort, and thus
the time required, must be manageable.
In addition, the planning should be
in a dynamic form. The employees must
therefore be able to change and update
the plans at any time.
A practical example: creating a
selling plan
The example of a production company
that introduced such a sales planning
and controlling instrument and designed
an appropriate computer program
for their sales staff with support from
Peter Schreiber & Partner illustrates
how to create selling plans.
In the company, the management
writes a ‘planning letter’ to its almost
100 sales personnel every year after the
(sales) goals have been formulated for
the coming year (Fig. 2). The letter first
explains what the future sales targets are
on the basis of the corporate goals and
the sales strategy, and which planning
data and market estimations they were
based on. The employees are also informed
about the derived operative targets
this involves for them. With this preliminary
information, the employees can
start working out individual selling plans
for themselves and their sales region.
This process is divided into four phases:
1. Analysis of the business environment,
the market, and the company’s
own situation.
2. Formulation of forecasts and
assumptions.
3. Consideration of the defined aims,
and derivation of their own goals.
4. The development and planning of
measures that conform to the strategy
and goals.
Market analysis
During the analysis phase the sales personnel
first identify the external factors
that will probably influence their work
currently or in the future. This may
involve overall economic, political,
legal, technological and sector-related
aspects; as well as those that only affect
their sales region. Then they estimate
whether this offers opportunities or
poses risks for their work (Fig. 3).
After this, the sales personnel are
asked to name the five strongest rivals
in their region together with their estimated
market share. They should also
input potential new competitors in the
computer program. In addition, they
should estimate whether the competition
will become harsher – differentiated
into factors such as price, quality
and service.
After the sales personnel have
gained such an overview of their market,
they focus on which two companies
they consider to be their toughest competitors.
They then name the strengths
and weaknesses of these rivals in
technical, process/organizational, social/
communicative and commercial/economic
terms. The aim here is that the sales
staff should be aware of the factors
upon which the current market position
of the competitor is based. Because
then they can use this information to
work out where they can apply leverage
to win over these customers or this
market share. The opportunities and
risks identified by the sales staff flow
into an automatically generated graphic
and finally into a SWOT analysis.
Analyzing one’s own situation
But before this, the sales personnel analyze
their own situation. They start by
inputting into the computer program
the sales and profit margins achieved in
the past in the individual market or product
segments so that their development
is clear to see. Controlling provides
the necessary data. When the
employees see the development of their
sales and profit margins they should
name the factors leading to success in
their sector. They should also estimate
how strongly these factors are present
in their company or sales department
compared with the competitors.
After this analytical step, the sales
personnel list the ten customers that
currently purchase most – with their
names as well as the sales achieved with
them – and assign them to pre-defined
customer groups, e.g. OEMs, plant constructors,
users. The sales to the individual
customers or customer groups are
automatically graphically visualized as a
proportion of total sales so that imbalances
in the customer structure and
dependencies on major customers can
be seen because they are to be taken
into account in the planning of goals
and measures.
Photo: Ngampol – stock.adobe.com
Fig. 3: During the analysis phase, the sales personnel identify the factors that influence their
work.
Formulating forecasts and defining
goals
After the analysis phase comes the formulation
of forecasts and assumptions.
Now the sales staff should formulate
customer- and region-related assumptions,
for example about how their
customers’ behavior will change as a
result of the coronavirus pandemic or
due to changed procurement rules. Or
how newly launched products or major
upcoming projects will affect customer
relationships. Now the sales staff should
think about what special aspects and
developments in their region, and at
30

their customers, should be taken into
account in the planning of goals and
measures.
Thus prepared, in Phase 3 they formulate
the targets for their own work
– differentiated into financial, market
and process goals, as well as personal
goals. In a first step, the employees
should identify ten target customers in
their sales region, where:
> there is great potential for growth,
and
> there is a good opportunity to
achieve growth in sales due to the
added value that the employee’s
company can offer them.
For these ten target customers they
should break down in detail:
> the sales potentials in the individual
product segments,
> the sales they were already able to
achieve there the year before, and
> what sales they want to achieve
there in the coming year.
The sales personnel therefore now
define for themselves where and with
what they want to achieve the desired
sales. The planned sales are added up
again and graphically prepared in such
a way that the sales employee immediately
sees what sales they will achieve in
the individual product groups as well as
in total, if everything goes as planned.
– for example due to the planned attack
on a competitor.
During the year, the sales employees
can also always input into the computer
program the extent to which they have
already fulfilled particular tasks, and
achieved the corresponding goals, so
that they can always see:
> Am I on the right path for achieving
my annual target? And:
> Where do I need to do something
more to achieve this target?
This overview is simplified by a traffic
light function. A green light appears
when a goal has been achieved. The
traffic light is amber if divergences
appear, and something therefore needs
to be done in response. And red lights
up if there is a risk that a sales employee
is losing sight of the objective.
Less gut feeling, more brain
The company deliberately decided
against using the data the sales staff
put into the ‘selling plan’ program and
determined the measures centrally –
among other things, to prevent the
program being considered as an instrument
of control and not a planning and
controlling instrument. It is, however,
common practice for the employees
and their superiors to start the computer
program for their employee appraisal
interviews, and to discuss whether
the planned measures comply with the
strategy and can be used to achieve the
objectives. The employee’s planning is
also used to determine what (operative)
support they need.
Among other reasons, this way of
using the system has resulted in a high
level of acceptance of the ‘selling plan’
instrument among sales staff. The company
also learned that employee
appraisals are much more effective
because there is a systematic basis for
discussions. Furthermore, the sales
employees work their market with
much greater structure than before.
And, on the basis of their market overview
and structured planning, they can
react to market changes with greater
agility. Because they rely less on a diffuse
gut feeling in their work and more
on strategic considerations. This is also
reflected in the sales figures.
www.schreiber-training.de
Peter Schreiber is the owner of the B2B
sales and management consultancy
Peter Schreiber & Partner in Ilsfeld, near
Heilbronn.
Defining customer- and region-related
measures
Planning of the measures in compliance
with the strategy and customers takes
place after the sales staff have defined
the target customers and what they
want to sell them. Now the employees
formulate the individual measures for
achieving the desired sales for each of
the ten target customers. All measures
have deadlines.
The individual customers are not the
focus of the second part of the measures
planning process. Now it is instead
about opening up the entire sales
region. The defined operational objectives
for the sales staff are listed in the
computer mask provided for this purpose
– like in a balance scorecard. For
each objective, the sales employees
should formulate five measures that
they will use to achieve the objective.
These are also given deadlines. In the
third part of the measures planning, the
measures brought about in response to
particular sales objectives are defined
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CASTING PLANT AND TECHNOLOGY INTERNATIONAL
Issue # 3|2022
Core Production
Molding Material
Die-Casting
Foundry Plants
Sand Preparation &
Regeneration
Advertising Deadline:
August 12, 2022
Issue # 4|2022
including
FOOTBALL WORLD CUP 2022
Match Schedule
METAL – International Fair for Foundry
Technology in Kielce (Poland) 20.-22.09.2022
FOND-EX – International foundry trade fair
in Brünn (Czech Republic) 03.-07.10.2022
TURKCAST in Istanbul (Turkey)
06.-08.10.2022
74th World Foundry Congress in Busan (Korea)
16.-20.10.2022
ALUMINIUM INDIA in Bhubaneswar (India)
February 2023
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Die-Casting Process
3-D-Printing & Digitalization
Environment & Energy
Advertising Deadline:
November 18, 2022
including
YEARLY CALENDAR 2023
INTERMOLD – International Die, Mould & Related
Equipment Exhibition Goyang in Seoul (Korea)
March 2023

COMPANY
The safety offered by PPE not only depends on its protection class, but also its maintenance and a good fit.
Purchasing protective clothing
Caution about common PPE
misconceptions
Attention to more than the mandatory standards is necessary when buying the right
protective clothing. The wearers’ safety should always be the top priority. This article dispels
common misconceptions and provides six useful tips that should be followed when
selecting PPE.
By Teodora Guncheva, Dreieich
Photos: CWS
1. Light or heavy PPE?
In the past, the weight of the PPE was
considered an important indicator of
quality and durability. During recent
years, however, many producers have
decided to make their protective clothing
lighter to improve wearing comfort.
The convenience and appearance
of PPE are now also focused on – ultimately,
employees should feel good
while working. So the clothing should
be safe, fashionable, and comfortable
to wear. A lower weight of the fabric
works well for certain requirements and
can offer good protection in these
cases. Where the demands are greater,
however, thinner fabrics may be worn
out after a few uses. So it is impossible
to make sweeping statements about the
weight of PPE. The area of use and level
of wear are ultimately decisive when
deciding which protective clothing is
right.
2. Have the needs and risk analyses
been taken into account?
In a first step, every company must
make an internal risk analysis that
determines and evaluates all the risks
faced by employees. Work clothes can
34

contribute towards minimizing them.
The precise protective clothing should
be carefully selected. Whereby it is
necessary to compare the various PPE
and obtain detailed advice. An accurate
needs analysis takes into account requirements
and personal preferences to
determine the suitable clothing. Whereby,
above all, the specified standards
must be observed. The total number of
standards covering particular PPE need
not always be a quality feature. More is
not always more.
3. Do more standards mean more
protection?
Multifunctional protection or multi-standard
clothing is protective clothing
that offers numerous protective
properties. These generally range from
heat/flame protection and welding protection,
through arc fault protection, to
chemical protection and supplementary
high-visibility functionality (Fig. 1).
Demand for this type of PPE has also
risen recently because it is often assumed
that the more protective functions,
the safer the clothing is overall.
For someone who does welding
work every day it ultimately makes
sense to select welding protection in at
least Class 2. Because it does not help
the wearers if the clothing also offers
additional chemical protection but does
not have the required level of welding
protection. So classic welding protection
clothing is the right choice in this case.
A detailed consultation accompanied by
a needs analysis – as also offered by service
provider CWS Workwear – should
therefore always take place in advance.
4. Have the employees
tested the PPE?
Employees should be involved in the
process before any final decision is
made. They can wear and test the clothing
during everyday work in advance.
In some industries, such as foundries,
so-called shower tests can be carried
out, whereby the resistance of the
material to molten metal splashes is
tested. The drip-off behavior of molten
metal and the flammability of the fabric,
in particular, are observed. In other
areas, the visibility of employees or
weatherproofing is of decisive importance.
CWS Workwear also offers companies
a wearability test so that they
can be completely confident about the
suitability of the PPE. Companies
should always demand an opportunity
to conduct their own test of the PPE in
practice. This can considerably simplify
the decision, especially when there are
several suppliers or collections in the
running.
5. Do the work clothes fit?
The fit of the clothing is a decisive criterion,
not just for optimum wearing
comfort but also for safety reasons.
Whereby not only is the right size
important, but also the overall fit. Each
article of clothing is different. If the size
does not fit an employee the procurement
process should permit exchange
for a different size. The same applies for
trouser or arm lengths. The employer
should ensure that adjustments are carried
out if these are too long or too
short.
When the work clothes fit and sit
properly it not only looks professional
and increases worker satisfaction – it
also enables safe work. Thus, for
example, high-visibility clothing whose
legs and arms are too long become
creased – covering the reflective stripes
and making the wearer less visible. This
is why regulations stipulate that high-visibility
clothing must have five centimeters
between the reflector and the end
of the trouser leg. During welding or in
foundries, for example, if the trouser
legs are too short metal splashes can
enter the shoe and cause injuries. Every
change to clothing is subject to strict
safety regulations – and cannot be carried
out by amateurs.
6.Has maintenance been
organized?
As with all other work clothes, the care
and maintenance of PPE should be precisely
regulated. Service providers like
CWS offer a comprehensive service here
which, in addition to washing, also
includes repair of the clothing. The
major advantage: protective clothing
has a considerably longer service life
when it has long-term professional
maintenance. Repair of the clothing
also requires professional treatment.
Thus, for example, use of original materials
for repairs is stipulated. Any repair
of PPE must be carried out with great
care because the fabric can break, causing
gaps in the protective function for
the wearer.
Temperatures that are too high
during washing or drying can damage
the intelligent functional fabric and
make it ineffective – thus, for example,
the brightness of reflectors may be lost.
Specialized washing programs are used
in professional industrial laundries,
determined by the particular type of
clothing and its level of contamination.
The handling of protective clothing,
from changes through care to maintenance,
should therefore only be
undertaken by specialist personnel.
www.cws.com
Teodora Guncheva, PPE Expert, CWS
Workwear
Fig. 1: When it comes to the protection classes of PPE what matters is selecting the right ones
and not as many as possible.
CASTING PLANT & TECHNOLOGY 2/2022 35

CASTING
Binders
New generation of environmentally
friendly furan resins
Photo: stepper.yull /Shutterstock.com
The modern foundry sector is characterized by strict quality requirements and demanding
environmental regulations to observe emission limit values. The costs pressure is
currently further intensified due to strongly rising raw material prices. At the same time,
sustainability aspects and the awareness of health aspects are increasingly gaining in
importance. In this regard, ASK Chemicals has developed a new generation of environmentally
friendly furan resins with a low content of free furfuryl alcohol and performance
that compares with standard furan resins.
By Nicolas A. Riensch, Thomas Krey and Carolin Wallenhorst
36

The development of new binders
for ColdBox, NoBake or inorganic
core and mold production processes
is subject to constantly increasing
demands regarding productivity with
unchanged high casting qualities (prevention
of casting faults due to nitrogen,
sulfur or related elements). At the
same time, the binders developed must
comply with strict emission and environmental
regulations (regarding, for
example, BTX and total emissions), as
well as health and safety at work limit
values. As in other industries, the
importance of sustainability is growing,
leading to ever-greater pressures. The
constantly rising demand for efficient
and economical foundry chemistry solutions
is above all due to the high costs
pressure – mainly driven by wage costs
and raw material prices.
ASK Chemicals has been carrying out
research in NoBake technology since the
invention of PEP-SET binder technology
in the 1970s. The producer has been
offering customer-specific furan NoBake
binders (FNBs) for several decades, e.g.
based on its core product Askuran.
Unlike phenol-urethane or ester-hardened
phenol systems that are based on
petrochemical components, furan binders
are based on furfuryl alcohol, an
easily available raw material obtained
from agricultural waste such as maize or
rice husks. This is therefore a renewable
raw material [1]. Interest in furfuryl
alcohol has increased greatly, mainly
due to declining stocks of petrochemical
compounds.
Furan binders were introduced in the
late 1950s and could be classified as the
first real NoBake binders due to their
self-hardening capability under acidic
conditions at ambient temperature
(without heat) [2]. In general, FNB systems
exhibit a high level of thermal stability
and hot strength, as well as excellent
disintegration properties. They can
be used to produce all types of metal
castings of all sizes, from small to large,
e.g. the rotor hubs of wind turbines.
The basic chemical structure
Aryl sulfonic acids have generally been
used as hardening catalysts. Addition of
the catalyst starts the polymerization
reaction, which involves chain propagation
and meshing. In the case of FNB
resins, the starting point of the polymerization
reaction between two furfuryl
alcohol (FA) monomers is the construction
of a methylene bridge with the formation
of water. This leads to Condensation
Product 1, which still has one
Fig. 1: Top: FA-FA Condensation Product 1 and proposed structure of an FNB Polymer 2. Bottom:
Proposed phenol resin synthesis via condensation of phenol P and formaldehyde F and
further condensation.
Fig. 2: Data obtained for an FNB and a PFNB system (ASK Chemicals): a) Evaluation of storage
stability through monitoring of rise in viscosity during storage at ambient temperature over
time; b+c) Data (ASK Chemicals) obtained under the following conditions: 100% new sand, 1%
resin, 0.4% hardener; b) Reactivity of FNB and PFNB on the basis of the processing and stripping
times; c) Sand analysis and observation of strength development after 2 h, 4 h and 24 h.
Photo: ASK Chemicals Photo: ASK Chemicals
CASTING PLANT & TECHNOLOGY 2/2022 37

CASTING
reactive methylol group (Fig. 1, top,
orange box). Further completed condensation
reactions result in the proposed
FNB Polymer 2.
Compared to this, phenol-novolak
resin synthesis takes place via the condensation
of phenol P with formaldehyde
F to obtain proposed Condensation
Product 3 and proposed Polymer 4
(Fig. 1, bottom).
In the case of FNB resins, no addition
of formaldehyde is necessary to start
the reaction because a methylol group
is present in both the FA monomer and
the condensation product (Fig. 1, top,
orange box) [3].
Environmental requirements and
casting performance
In general, FNB binders based exclusively
on furfuryl alcohol are very
environmentally compatible. On the
other hand, the sand cores and molds
produced tend to crack and break
during casting and general handling
due to lack of flexibility [2]. Typically,
polymers based on urea and formaldehyde
are added to improve tensile
strength and flexibility. During recent
years, this technology has been called
‘new furan technology’ (NFT) [2b]. The
modified resins have a similar hardening
speed to phenol-urethane systems
but exhibit the environmental
and casting quality properties of
furans. These systems also have better
reactivity and thorough hardening.
Under the brand name Askuran, ASK
Chemicals has developed and optimized
its portfolio of FNBs in collaboration
with customers to enable the company
to offer customized solutions for
all types of castings. The Askuran portfolio
also includes mixed resins, including
furan-phenol systems such as
Fig. 3: Hazard labelling of standard furan resins (free FA: 50 - 95%) and MAGNASET resins
(free FA:

ange of resins offering specific features
that are suitable for all types of castings
and customer requirements, with good
mold properties and excellent casting
surfaces. Magnaset 5912 LFA is a phenol-free
resin with a very low content
of free formaldehyde (

CASTING
Photo: PORSCHE AG
Maximum engine performance in the models Spyder and GT4.
Engine technology
Thin-walled cylinder heads for
engines in Porsche Boxer
Compared to its predecessors, the 718 Boxster / Cayman GTS 4.0 Liter, Spyder and Cayman
GT4 series of engines make greater load and weight demands of cylinder heads. In
addition to a special design, these demands are being met with thin-walled castings –
reliably made using permanent mold casting with the Rotacast process.
By Günter Vogelezang, Weissach and Bernhard Stauder, Linz
The performance-optimized Porsche
Boxer’s B6S engine was derived
from the basic 4.0-liter engine
within the existing Porsche 9A2 modular
system and designed specifically to
meet the requirements of a high-revving
naturally aspirated engine.
The Porsche Boxer 4.0-liter engine
The main components of the 9A2
modular system are:
> two borehole variants: 91 mm and
102 mm,
> two stroke variants: 76.4 mm and
81.5 mm,
> closed-deck AlSi7 crankcase with
iron (Fe) track coating,
> four-valve technology with inlet/outlet
camshaft adjustment,
> centrally positioned direct gasoline
injection,
> integrated dry sump with fully variable
oil pump,
> thermal management with switchable
water pump and map-controlled
thermostat,
> compliant with EU6 AP emission
standard.
The valve train, cylinder head with
cross-flow cooling, the suction unit and
the exhaust system were basically com-
40

pletely newly developed for use as a
naturally aspirated engine. Proven systems
– such as the integrated dry sump
with plastic oil sump, the timing and
belt drives as well as the thermal
management with switchable water
pump – were adopted by the 9A2evo
turbo engine with minor adaptations.
As in the predecessor model, the engine
is installed in the vehicle as a mid-mounted
engine with three-point mounting
(Fig. 1).
Demands made of the cylinder
heads
In order to take the increased performance
demand into account, it was
necessary to increase cylinder filling by
improving the flow rate coefficient of
the inlet ducts with longer timing
cross-sections by means of demanding
valve lift curves. The greater heat input
due to the increased performance
requires an optimized water jacket so
that the alloy AlSi7Cu0.5Mg-T6 with air
quenching can still be used. To ensure
the return feeding of the oil from the
cylinder heads in highly dynamic drive
mode it was necessary to further
develop the design of the oil cores and
reduce oil throughput. Weight reduction
is desirable both for high-revving
operation (regarding high longitudinal
and cross-dynamism) and for sustainability.
Adaptation of the technical design
The very different requirements compared
to turbo engines necessitated a
redesign of the cylinder heads. For the
benefit of large inlet valves, compact
spark plugs with M10 threads (proven in
the 918 Spyder) were used instead of
the 14 mm of the predecessor. The Piezo/A
nozzle adopted from the turbo
engines was arranged on the outlet side
to rule out any wetting of the inlet
valve during the injection process (Fig.
2). The spark plugs are thus centrally
positioned. In addition, the ground
electrodes of the spark plugs are installed
with a tight angular tolerance in the
direction of the outlet to deliberately
reduce spark plug temperature and
ensure a long component service life.
On the basis of the new layout – with a
twisted injector position compared to
the turbo engines – the inlet channels,
inlet valves and area close to the valves
in the combustion chamber were numerically
optimized with a proven CAD
model. To achieve good filling, the flow
may not be broken at the transition of
the channel to the seating ring on the
Fig. 1: 4.0-liter Boxer’s
naturally aspirated B6S
engine (internal designation:
9A2evo).
bottom, even at full stroke. For maximum
filling, however, it is not sufficient
to consider just the channel and seat
region, but also discharge in the cylinders.
In addition, the flow proportion at
the perimeter of the seating ring was
evaluated in a polar diagram and optimally
homogenized via adjustment of
the valve diameter, the distances of the
inlet valves from one another, and the
distance of the valves from the cylinder
wall (Fig. 3). The simulation found the
optimum at an inlet valve diameter of
42.3 mm. As the geometry in front of,
within, and behind the valve gap exhibits
an optimum that changes with the
valve lift, the challenge here was to
determine the best possible integral
geometry. Following processing of the
seating ring, the cast surface of the inlet
channel’s internal contour is now processed
in three paths, so that the tolerances
and variance of the flow in the
decisive area of the channel can be
minimized in serial production (Fig. 4).
Compared to the predecessor engine, it
was thus possible to achieve a considerable
increase in the inlet valve flow rate
cooefficients. In combination with the
inlet valve stroke (which was also enlarged),
this provides clear filling benefits
for the new naturally aspirated engine.
The following diagram shows further
increasing potential for extension levels
compared to the predecessor beyond
the valve stroke of 12 mm (Fig. 5).
Fig. 2: Arrangement of the components and parameters of numerical inlet channel optimization.
Graphic: PORSCHE AG Photo: PORSCHE AG
CASTING PLANT & TECHNOLOGY 2/2022 41

CASTING
Photo: PORSCHE AG Graphic: PORSCHE AG Photo and Graphic: PORSCHE AG
Fig. 3: Simulated speed in the inlet channel and in valve gap.
Fig. 5: Comparison of throughflow quality in the inlet channel between the 9A2evo 4.0 liter
and the 9A1 3.8 liter.
Fig. 6: Valve drive of
the 718 4.0-liter
naturally aspirated
engine.
Fig. 4: Processing of the inlet channel.
The outlet channels and valves were
also optimized in a transient simulation
of the outlet process. The change from
inlet-side switching tappets and outlet-side
3-CF tappets to roller cam followers
enabled a reduction in friction and
an increase in valve speed. In order to
open up the full potential of the roller
cam followers, a precision-cast lever was
developed for lower mass and greater
rigidity. This configuration of the valve
drive, with the relatively short timings
with large strokes due to high accelerations,
ultimately made switchability
unnecessary. Thanks to adjustment of
hydraulic valve clearance, the valve
drive is maintenance-free despite
high-revving operation (Fig. 6). The
doubling of the bearing forces – resulting
from the design of the valve drive
to more than 8,000 rpm and valve strokes
of up to 14 mm – made a particularly
stiff mounting of the camshafts
inevitable, achieved via a so-called
guide frame structure. The oil circulation
system in the cylinder heads had to
be improved regarding both oil throughput
and dead volumes. The oil throughflow
of a cylinder head arises from the
number of users and their oil throughflow.
The main measures are:
> changing from switching tappets to
roller cam followers.
> moving the oil feed point to the
area of a local low bearing clearance
from below, just in front of the
hydrodynamic pressure peak in the
camshaft bearings, taking into
account the rotational directions
and displacement paths.
Determining the optimum location of
the oil feed point in the camshaft bearings
is calculated by means of simulation
for all four camshafts. The oil
42

consumption could thus be reduced to a
sixth of the output value per bearing
(Fig. 7). The design of the oil cores was
focused on the oil flowing back reliably
and rapidly to the suction points – even
under 1.4 g lateral acceleration. For this
purpose, great value was placed on a
smooth design with walls as vertical as
possible in the installation position. The
volume of the pressure-free oil chamber
could be reduced by 0.7 and 0.8 l per
cylinder head by means of additional
cores between the cylinders. These
areas are oil-free and are vented with a
small borehole on the outlet side (Fig.
8). The familiar cross-flow cooling could
be improved to the extent that even at
extension levels the maximum temperatures
in the combustion chamber
remained below 250°C regarding the
heat transfer coefficients – without any
notable increase in pressure loss.
Adaptation of the casting technology
The requirement of combining large
gas channels with the central spark
plug and injector positions dictated the
use of thin-walled casting as the production
process. Like the GT3 cylinder
heads, the 718 sand-cast prototype
cylinder heads were designed with a
general wall thickness of 3 mm. Casting
trials by the company Nemak during
the awarding of the contract demonstrated
the feasibility of thin-walled casting
in a mold using the Rotacast process
without any major additional
effort. Controlled rotation and the
consistently high melt temperature at
the casting front enable complete filling
of the mold, and the high temperature
gradient due to intensive combustion
chamber cooling supports the
feed very well. The AlSi7Cu0.5Mg alloy,
proven in two generations of engines
since 2008, could be used without problems
and – with T64 air quenching –
led to very good static and dynamic
coefficients with high thermal stability,
low density and good corrosion
resistance. The stresses could be
reduced and the rigidity increased by
exploiting the experience gained from
the design of the 9A2 cylinder heads
and the supplementary displacing
cores. The weight of the two cylinder
heads fell by a total of 3.2 kg compared
to the predecessor while, at the same
time, the combustion pressure to be
borne rose by 24%. In addition to the
evident advantages in driving dynamism,
this weight reduction also takes
into account sustainability aspects due
Fig. 7: Oil feed point in 9A2evo and 718 4.0-liter lead frames.
Fig. 8: Oil return in pressure-free oil chamber.
to the reduction in the material required
and thus lower energy use.
Managing casting changes
The first feasibility assessment of the
data in the enquiry for the B6S
(9A2evo) cylinder head took place on
the basis of the many years of experience
gained in this product segment
and were very positive. The main new
requirement involved the component
areas designed with a nominal wall
thickness of 3 mm – around the gascarrying
channels to the water chamber,
the oil chamber with displacement
areas, and the cast-on chain box. This
would be a further 25% reduction compared
to previous demanding nominal
wall thicknesses of 4 - 4.5 mm made
using permanent mold casting. Additional
investigations were therefore required,
as well as measures regarding tool
design, process control and inspection
processes, to ensure producibility. The
company’s quality orientation and
openness for process improvement
across all departments was important
for the subsequent success. Based on
these considerations, it was necessary to
analyze the local specifications for the
present component design, starting
with adaptation of the casting simulation.
A cell number increased by a factor
of 4 had to be used for the casting
simulation shown in Fig. 9 to sufficiently
resolve the wall thickness, increasing
computing time by a factor of ten. The
thin-walled nature of the component
needed to be represented sufficiently
accurately – particularly in the areas of
high ribs, the oil chamber walls, and the
chain box (Fig. 10). This refinement was
important, especially during the
development phase, for identifying
neuralgic component areas and planning
the necessary measures for the
tool concept.
The tool concept
The tool concept involves, in particular,
the casting mold, core box occupancy
and shrinkage determinations, as well
Graphic: PORSCHE AG Graphic: PORSCHE AG
CASTING PLANT & TECHNOLOGY 2/2022 43

CASTING
Graphic: NEMAK
a
b
Fig. 9: Casting simulation and casting: a) Casting simulation using the chain box as an
example, illustrating moistening at the 3-mm-thick cross-section, b) Final component, chain
box view.
important cores to be minimized and an
absolute minimum wall thickness of 2.3
mm guaranteed. The challenge of
delineating the completely thin-walled
chain box without deformation required
several measures, both in mold
technology and in the design, as well as
introducing additional geometries in
the processing areas. In combination
with the heat treatment and air quenching,
the chain box thus remained within
the necessary tolerance (Fig. 12).
Graphic: PORSCHE AG
Fig. 10: Sectional view of the component.
as the very important tolerances in this
project for the core prints and fixing of
the cores. The molds were appropriately
designed for the process requirements
determined earlier, with active temperature
regulation via cooling and heating
processes, with additional ventilation
measures through inserts and surface
ribbing (Fig. 11). These aspects were
further refined after the initial casting
batches. The cooling effect of the combustion
chamber inserts led to DAS
values of below 20 µm throughout the
entire combustion chamber area. Regarding
their dimensional accuracy, these
inserts are finely adjustable within a
range of 50 µm. In addition, the channel
cores are fixed in the mold using a
special clamping concept without play.
The shrinkage factors of the warm-box
and cold-box cores used were defined in
advance on the basis of similar product
families. Great care was taken to ensure
dimensional accuracy in the water
jacket and flow channel areas, in particular,
suppressing a variety of multi-dimensional
shrinkage factors. In combination
with dimensionally optimized
core prints, this allows the relative positional
tolerance of these functionally
Process design
Design of the process for this thin-walled
component required special attention
to potential filling and cold-running
problems. It was also necessary to
minimize porosity risks at node points
(e.g. bolt slugs) in isolated positions
completely surrounded by thin-walled
areas. To achieve continuous production,
the manufacture of the heads for
cylinder banks 1-3 and 4-6 is carried
out on a Rotacast tandem casting plant
with two molds simultaneously. The
resultant flexible choice of mold filling
speed ensures continuous filling of the
thin-walled areas. As expected, the
mold slider temperatures required restriction
of the temperature range to 50
- 80% of an otherwise usual range for
casting. In the wake of component-related
experimental casting batches,
reliable serial parameters were defined
during the development process (Fig.
13). The logging of a mold side-element
temperature and a comparative
measurement point in Fig. 13a shows
how sensitive casting quality is to the
temperature. So a stable thermal state
is necessary for successful serial production,
as well as an absolute minimum
mold temperature in general (see
Fig. 13b). This causes multidimensional
consequences that led to the use of
automated data analysis tools to identify
quality risks to enable their avoidance.
Photo and Graphic: NEMAK
a
b
Fig. 11: Mold construction: a) Mold with individually cooled combustion chamber inserts,
with front sides with mold inserts behind to form a rib structure, b) Casting mold with inserted
water jacket and channel cores as well as chain box core.
Quality concept / serial capability
As for other products, a quality
assurance concept was implemented for
cylinder head production and for the
methods used. During sampling, the use
of CT for imaging the 3D volume of the
water chamber is particularly noteworthy.
In combination with GOM contour
scans, it provided almost complete
3D measurement of the component.
Wall thickness sections verify the precise
core orientation achieved through the
tool concept. The water cooling channels
in the highly thermally-mechani-
44

cally stressed spandrel area had a 3 mm
wall thickness to the channel (Fig. 14).
A high awareness of production
quality and a consistent lived culture of
improvement is required in practical
manufacturing. This results in the need
to carry out production processes with
maximum attention and a high level of
continuity. In order to monitor the
serial quality of these components, the
pervasiveness of the water chamber was
quickly and automatically checked using
an At-Line CT testing unit, after no
alternative inspection methods proved
applicable for the existing water jacket
geometry. This examination is already
carried out on the blank before heat
treatment to enable rapid feedback for
the production team. The volume dataset
generally offers the possibility of
testing the integrity of a component,
for example any displacement of cores.
During the course of the further process
chain there is then heat treatment with
hardening inspections, CNC processing
with checks, a tightness test, and packaging
for dispatch after positive proof of
all test features has been provided on
the basis of the NORIS process data logging
system. This concept allows the
usual quality indicators to be maintained
both on the customer side and
internally.
Conclusions and prospects
The first prototypes have shown that
thin-walled casting is also a challenge
when sand casting is used. Extensive
thin-walled areas of the cylinder heads
are often only possible to cast completely
using sand casting with gravity filling
if additional measures – such as
fluting in the cores and higher casting
temperatures – are taken. The rotating
mold-filling of the Rotacast process significantly
reduces the tendency to
cold-running, even with permanent
mold casting. In other areas, the thin
wall thicknesses can be very well provided
with a normal casting process.
Cold-running is only a risk with longer
stand times, particularly for the external
ribs. Their casting-oriented design
(regarding thickness, shape, position
and their venting) is critical for reliable
mold filling. The chain box – with its
large and thin areas – also makes great
demands of a stable casting process.
In permanent mold casting of
thin-walled components it is more
about controlling the hardening
through active mold temperature control
(heating and cooling) to disperse
shrinkage deficits at isolated node
Fig. 12: Deformation optimization for the chain box: location of typical chain box deformation
a) In starting state and b) The stabilization achieved after application of the measures.
points. The shrinkage factors for the
sand cores are to be designed with even
more differentiation regarding all the
axes, and positioning of the core in the
mold must be robust regarding locational
tolerance. On the basis of the robust
Rotacast casting process with the use of
intensive combustion chamber cooling,
high mechanical values were again confirmed
with the alloy AlSi7Cu0.5Mg,
and with heat treatment with air quenching.
As a result of the good structure
and reliable process, the cast thin-walled
718 4.0-liter cylinder heads form the
basis for the coming cylinder heads in
higher unit numbers. To increase the
process reliability of future cylinder
heads, they should be designed as
externally smooth as possible and provided
with stiffening ribs pointing
a
a
inwards in the sand cores. Minor
wall-thickness adaptations or special
flow assistance is only required in the
area of the extensive chain boxes for
process stabilization. Cooling to master
the maximum temperatures, thermal
stresses and for reliability will have to
be further developed with a view to
more increases in performance and
more demanding (also supercharged)
combustion processes to implement the
combination of thin-walled casting and
turbo engines.
www.porsche.de, www.nemak.com
Dr. F. Günther Vogelezang, Manager
Base Engine Design Boxer Engines, Porsche
AG, Weissach.
Dr. Bernhard Stauder, Nemak Europe,
Linz.
Fig. 13: Process control: a) Process development regarding temperature control, b) Serial process
temperatures at the mold elements above a casting shaft.
a
Fig. 14: Quality assurance: a) Inspection of core adhesive, b) CT inspection of water jacket integrity.
b
b
b
GRAPHIC: NEMAK
GRAPHIC: NEMAK
GRAPHIC: NEMAK
CASTING PLANT & TECHNOLOGY 2/2022 45

CASTING
Photos: POUR-TECH / M5 ENGINEERING
Interchangeable stopper pouring vessel with open hydraulic charging flap.
Case Study
Simulation of the pouring process
Swedish-Thai joint venture: In the past few months, the companies pour-tech AB from
Gothenburg and the Bangkok company M5 Engineering have simulated the technological
basis for unheated pouring in detail and created potential for optimization.
By Michael Colditz Sävedalen, Göteborg, Sweden
Loedwilat Thipramongkhon,
Chindanai Challinak, Bangkok, Thailand
Energy costs and their reduction in
the foundry process have been the
dominant issues in our industry for
years. Around 80% of this energy is
used in the area of melting and holding
the temperature of molten metal. More
and more efficient melting technologies
have been used in the melting shops in
recent years, so that nowadays marginal
reductions are expected.
With the project of the wholistic simulation
of the unheated, laser-controlled
bottom stopper pouring, further potential
for energy savings should be discovered.
The term ‘wholistic’ considers the
process from the targeted refilling of the
molten metal in the pouring vessel to the
filling of the mold via the pouring cup
into the down sprue of the gating system.
On the trail of the secret
Another important issue in the project
was the actual secret of the foundries to
produce high-quality castings with the
lowest scrap rate: the constant process
conditions. Only those who produce continuously
under constant process conditions
can also expect high-quality products.
Two casting processes were
known on green sand mold lines:
> Discontinuous ladle pouring with
the necessary large pouring cups, residual
amounts of iron remaining in the
ladle at the end of the pouring cycle
and ladle changing times that are missing
for production.
> Stopper pouring in channel induction
furnaces, which are heated 24
hours a day and metal grade changes
consume a lot of time because of the
large sump.
46

To find a way around the complications
and increase flexibility, pour-tech AB
has created a pouring technology that
combines the best of both: the unheated
stopper pouring device with
instream temperature measurement,
inoculation and an artificial intelligence-controlled
pouring process.
Efficiency is key
The process is ideal for continuous pouring
with a uniform bath level in the
pouring cup of up to 600 molds per
hour on vertical parted mold lines, as
well as more complex pouring parameters
on large, slower running horizontal
parted mold lines. With regular recharging
according to pour-tech AB guidelines
for the pouring vessel, the temperature
losses can be kept constant at
under 2K loss per minute. In the past
eleven years, the pouring process has
been continuously developed by pourtech
AB and is becoming more and
more popular worldwide. One of the
reasons for the success are greatly
reduced carbon footprint, reduced manpower,
higher yield, the avoidance of
holding energy and reduced repairs to
the refractory lining.
The system itself has robust steel
construction and hydraulics, stable
laser technology and comprehensible
control technology. Now it was time to
take this leading technology to a new
level through further development.
The basics about the unheated pouring
process were worked out together with
the specialists from M5 Engineering
(Thailand) Co. Ltd. Their expertise in
process optimization has now contributed
to the optimization of the process
through extensive simulations. The
temperature distribution and turbulence
during pouring of the molds and
the recharging of melt into the pouring
vessel, but also for laminar pouring via
stopper and nozzle, were explained
and improved.
Based on intensive preliminary discussions
between pour-tech AB and M5
Engineering (Thailand) Co. Ltd. on
technical questions, the first simulations
were carried out. They showed the optimization
potential for various topics
that had not been thought of, which
were also tackled immediately. This
included the optimization of the refractory
lining of the pouring vessel in the
inlet for low-turbulence recharging and
thus the reduction of the air entrapment
of the melt in the otherwise closed
pouring device. As a result, the
angle at which the molten metal hits
Figure 1: Laser-controlled stopper pouring on a vertical parted mold line.
Figure 2: Summery of basic devices to create a production operated by artificial intelligence.
Figure 3: Air entrapment in pouring vessel and flow tracer through pouring nozzle down to
mold.
CASTING PLANT & TECHNOLOGY 2/2022 47

CASTING
alloy change can be carried out by
over-treatment of the fresh molt in
many cases without first emptying the
vessel.
Ultimately, a design was found that
increases flexibility for foundries while
reducing production costs. At the same
time, the laminar exit of the molten
metal from the pouring nozzle during
mold filling could be verified. For
foundries, there is sometimes an ROI of
just six months using this pouring
device.
Figure 4: Reduced air entrapment at refilling from initial value in the process optimization.
Figure 5: Different shapes of the slag weir before simulation of the flow behaviour / correlation
matrix.
the lining was optimized and the air
entrapment was reduced to below 10%
of the initial value. An automatic skip
system to empty transfer ladles was
designed for this, which ensures a
defined and constant refilling process.
The first of these systems are already in
operation.
which also gave valuable information
for future developments. In this way,
the heal in the vessel could be reduced
by more than 25%. About six seconds
after the start of recharging, the fresh
molten metal has reached the area of ​
the stopper and nozzle. The mixing
takes place very quickly. As a result, an
Summary
With more than 30 years of experience
and over 500 installed systems for pouring
iron-based alloys, pour-tech AB has
become the leading supplier of automatic
pouring equipment. Through
intensive cooperation with M5/MAG-
MASOFT the basic knowledge of the
process could be deepened and new
conclusions from simulations could be
summarized. In this way, constructive
detail changes could be made, which
reduce possible sources of error. A casting
defect always arises from the sum
of a large number of parameters that
lie outside the respective process
window. The changes made will thus
reduce the bundle of these possible
sources and casting failures and facilitate
troubleshooting in the operational
process.
www.pour-tech.com
www.m5engineering.co.th
Alloy change as a part of the
simulation
Another major topic was the design of
the slag weir to prevent process slag in
the area around the stopper. This slag
weir extends the service life of the stopper
and nozzle, but ensures at the same
time no slag particles are poured. As
important as this slag weir is to keep
clean melt and stopper and nozzle,
when changing alloys, it increases the
time for fresh molten metal of the new
alloy and the previous alloy to mix in
the heal of the vessel.
In order to optimize all requirements
in relation to each other, several designs
of a new slag weir were drawn and the
process was simulated with these new
variants. These comparisons also
brought new and unexpected results,
Figure 6: Automatic, unheated pouring system.
48

NEWS
SURFACE FINISHING
The largest multivib vibratory finishing machine
Photo: Walther Trowal
The blisks are finished in the processing bowl (red). A conveyor belt returns the processing
media into a storage hopper above the processing bowl.
Walther Trowal introduces the MV 50
multivib vibratory finishing machine for
the fully automatic surface finishing of
large components for aircraft turbines
like blisks, but also for forging dies.
With an internal diameter of 1,650 mm
the MV 50 is the largest machine of its
kind ever built by the company.
The first of this new generation of mass
finishing machines will be used for finishing
blisks (“blade integrated disks”)
for aircraft turbines. To a considerable
extent the quality of the surface finish
on these components determines, how
well they are performing under operational
loads. A good surface finish
allows the turbulence-free airflow
through the integrated blades. This
helps decrease the fuel consumption
and noise emissions and optimizes the
overall efficiency.
The company who purchased the
first MV 50 finishing machine chose the
mass finishing technology, because
blisks require an extremely smooth surface,
but with the sharp edges of the
blade segments remaining intact.
With a usable diameter of 1,300 mm
the MV 50 can also handle planetary
gears for wind turbines, where the finishing
of internal surface areas is especially
critical. Likewise, it can also be
used for large forging dies, which, to
date, could not be treated in a mass finishing
machine.
The new finishing system was
designed for fully automatic operation.
Once the work piece has been mounted
into the bottom of the processing bowl,
no additional manual operations are
required. Compared to previous finishing
methods this improves the process
consistency and stability. Moreover, the
new finishing system saves time,
because on average the finishing process
requires cycle times of less than
three hours.
Christoph Cruse, sales director at Walther
Trowal, is focusing on the special
quality requirements of the aerospace
industry: „Especially in the production of
components for aircraft turbines any
manual manufacturing operations can
be detrimental because they can be
highly inconsistent. With the new automated
machine we are eliminating the
risk for human error. Moreover, the finishing
time per blisk is reduced from several
days to a few hours.”
For finishing the surface of blisks
Walther Trowal is using the processing
media AF. This media generates
extremely low surface roughness readings
on the materials typically used for
the manufacture of blisks. The first MV
50 machine will be delivered to an aerospace
customer by September 2022.
www.walther-trowal.com/en/
PALLETIZING
Increased efficiency with robot-based palletizers
German company Keller IMS from
Ibbenbüren-Laggenbeck has convinced
an aluminium foundry operator: By
replacing a failure-prone ingot stacking
system with an industrial robot palletizing
system, downtimes could be
reduced and the speed of palletizing
400°C hot aluminium ingots increased.
Ingot stacking racks, which are placed
on a roller conveyor, serve as means of
transport. A fixed stopper is installed
at the end of the conveyor. In this way,
the frames which are adjusted on one
side are made available to the robot.
The frames and ingots are handled by a
layer gripper with an offset system
(Photo 1). The ingots are transferred
from an existing mould belt to the
existing conveyor system. Afterwards,
they move against a hinged stop and
are aligned transversely to the direction
of transport. Alignment is
achieved programme-controlled by
means of a rotating device. The foot
ingot layers are transferred to a second
chain conveyor and are then spaced by
stoppers as desired. The industrial
robot moves a rack, removes a layer of
ingots and positions it on the rack. At
the same time, the first ingot layer is
formed. After a defined number of
ingots have been lined up, a lifting
device removes the layer from the conveyor
(Photo 2). The next layer is
already lined up in parallel and can
then be palletized.
The robot-based palletizing process is
characterised in particular by the following
features:
> Individual pick-up and transfer from
an ingot mould belt to a conveyor
system
> Product-dependent positioning by
optional turning device
CASTING PLANT & TECHNOLOGY 2/2022 49

NEWS
Photos: Keller IMS
Photo 1: Exact palletizing with height compensation system.
Photo 2: Performance optimization through retractable lifting device.
> Positioning of foot ingots by means
of a flexible stopper built into the
conveyor system, which can be
adjusted mechanically or automatically
as desired.
> Individual gripping technology for
handling a wide variety of geometries
> Optional lifting device to increase
production
> Optional functional extension of the
robot by transferring transport
frames
> Optional device to protect plant
components against radiant heat
Components of the system
Industrial robot - With the very flexible
industrial robot, the working area is
optimally utilized. Software modules
can be used to virtually limit the working
area of the robot so that the operator
and the machine are completely
protected.
Unit load gripper - The material
take-up and the payload are designed
product-specifically.
Lifting device - The lifting device is
used to lift out the individual ingot layers
in order to achieve continuous transport
of the aluminium ingots through
the chain conveyor while the palletizer
carries out other work such as moving
transport racks.
Integrated stoppers are used to
ensure exact positioning of the aluminium
ingots. Depending on the product,
a wide variety of palletizing options are
possible through manual or automatic
adjustment.
Solutions from Keller IMS can be easily
and individually integrated into
existing production lines. By means of
continuously improved technology, a
robot-supported system was developed
in which the scope of the components
used was reduced to the most necessary.
At the same time, it was possible to
achieve high availability with minimal
susceptibility to faults.
With the creation of complex 3D
process simulations, the process could
be made visible to the customer already
in the project phase and before the
start of production, and spatial particularities
could be taken into account in
the conceptual design of the plant.
www.keller.de/en/
GLASS-FREE FOR HOT PROCESSES
First fully nanoceramic wheel casting coating
According to Ceranovis, the company
has succeeded in developing a nano-ceramic,
functional basic coating that can
be applied to metal surfaces with a temperature
of up to 500 °C. A full nanoceramic
system is thus available that does
not require a water glass binder.
Top coatings are offered for aluminum
gravity die casting that protect the
underlying functional coating and thus
generally triple the service life of the
overall system. The early sintering
nano-ceramic generates an inert, robust
shell providing this protection. The
functional base coating, on the other
hand, is based on a glass-binder system,
as are all such coatings. Especially in
very hot processes such as wheel casting
or other processes in low-pressure die
casting, the glassy binder systems are
the weak point.
The nano-ceramic becomes more
robust as the mold temperature
increases and develops its full potential
in these very hot processes. The zirconia-based
nanobinder sinters at temperatures
of 400°C and above. However,
applying a nanoceramic in the production
process at these or higher mold
temperatures had been considered difficult
to date.
For some years now, Ceranovis has
been able to offer a nano-ceramic top
coating for wheel casting, which can be
applied to an existing base coating at
temperatures above 400°C. The resulting
“RIM” system is considered one of
the best on the market in terms of quality
and performance. The nano-ceramic
top coating can also be combined with
some competitor products to form a
high-performance system.
It has now been possible to develop
a nano-ceramic, functional base coating
that can be applied to metal surfaces at
temperatures of up to 500°C. This
makes it possible to produce a fully
nanoceramic top coating. Thus, a fully
nano-ceramic system can be offered
that does not require a water glass
binder. This 1-layer coating has so far
been used mainly in the bottom mold in
wheel casting, where it delivers impressive
results. The roughness meets the
high demands on appearance and coating
technology. With impressively fine
50

Photo: Ceranovis
The coating is particularly suitable for molds used in low-pressure casting of wheels and
engine parts.
and stable surface quality, the service
life in practice reaches an unprecedented
level. Frequent touchup does
not result in any loss of product quality.
Production batches of over 2,000 pieces
are possible without tool replacement.
This is the result of field tests in wheel
casting of AlSi11 and AlSi7Mg grades.
The product offered as “RIMBOP”
should be used primarily in molds that
reach high temperatures in the manufacturing
process. Preheating of the
molds in the furnace to process temperature
is recommended. This also
improves productivity, as heating up the
mold in the production unit is avoided.
The nanoceramics are thus sintered
directly. However, it also sintered in situ
with the first melt contact if sufficient
preheating cannot be guaranteed. Best
results can be expected in the low-pressure
casting of wheels and engine parts.
Transferring this young innovation to
other manufacturing areas is currently
being tested with high expectations.
www.ceranovis.com
INTERNATIONAL CONGRESS
Join “InCeight Casting C8” 2022
The International Congress of the
Foundry Industry for intelligent Combining
of Design, Casting, Computer Simulation,
Checking and Cyclic Behavior for
efficient Cast Components „InCeight
Casting C8“ offers the opportunity to
share experiences and knowledge of all
the disciplines involved in the product
life cycle of cast components.
The congress targets people from
research & development, construction
& design, production & quality assurance
from mechanical and plant engineering,
foundries and material processing,
vehicle construction and power
generation, and provides a view going
beyond companies’ own products and
services, allowing consideration of
other casting materials, new methods
of component testing and dimensioning,
and reliable designs optimized for
lightweight construction.
www.inceight-casting.com
The aim is to develop a common understanding
of the various requirements
for high-performance and efficient cast
products. Now the proceedings of the
1st congress are available at Fraunhofer
Bookshop (online-Version). From 6 to 8
March 2023, the second congress
„InCeight Casting C8“will take place in
Darmstadt, Germany.
The disciplines design and product
development, structural durability,
non-destructive component testing,
foundry technology and simulation are
on the agenda. Papers focus on linking
methods and competencies from the
various disciplines, with the aim of
obtaining efficient, optimized cast components.
Foundries, designers, users of
cast components and experts in simulation,
structural durability and non-destructive
testing will benefit from this.
The 2021 congress: Dr. Christoph Bleicher (Fraunhofer Institute for Structural Durability and
System Reliability LBF) with presenter Thomas Ranft.
Photo: Fraunhofer LBF
CASTING PLANT & TECHNOLOGY 2/2022 51

NEWS
EIRICH GROUP
Site extension in India
Photo: Eirich Group
A new milestone for the globally active
Eirich Group: a new plant in India will
produce state-of-the-art machinery and
equipment in the future.
The Eirich Group, with Maschinenfabrik
Gustav Eirich as its strategic center in
Hardheim, Germany, has been a global
leader in mixing and processing technology
for almost 160 years. With a new
building in India, Eirich is continuing its
strategy of global expansion. The
groundbreaking ceremony for the construction
of the new plant site of the
subsidiary of Eirich India took place in
the Chakan industrial area in Pune,
India. It is planned to start production
of Eirich machinery and equipment as
early as mid-2023.
Stephan Eirich is the fifth generation
to head the family business and sees the
expansion of the Indian site as an important
strategic step for the Eirich Group:
“India has a lot of technical talent and a
good infrastructure, which is also ideally
suited to producing more of our products
locally. Proximity to our customers in the
world’s major markets is always a guiding
principle for us. The second plant in India
is in line with the country’s “Made in
India” philosophy, but also reflects our
confidence to serve markets outside India
once the ramp-up curve is successfully
mastered,” says Eirich.
Located on a three-acre site in Pune’s
Chakan Industrial Area, this new manufacturing
facility will produce intensive
mixers and plant technology. Eirich
enjoys a strong market position worldwide
for its unique mixing and processing
technology in various industry segments
such as metallurgy, refractories,
ceramics, agrochemicals, foundry, battery,
carbon products and many more.
With the commissioning of the Chakan
plant, Eirich India will significantly
increase its capacity. The current site in
Mumbai, established in 1998, is too
small today and will be relocated once
the new plant is completed.
“India is a focus market for Eirich.
The Chakan plant, with its expanded
capacity, will meet the growing demand
for our products in all customer industries.
And especially the on-site support
of our Indian customers with fast service,
spare parts “Made in India” and
good process consultancy is key for us.
The space limitations in Mumbai became
a critical bottleneck for us and we are all
the more looking forward to the new
plant. Even more so because from 2025
onwards, Eirich India will then also be
able to supply overseas markets with
parts and complete machines through a
strong network of Eirich Group companies
in 12 countries,” said Mr. Sourav
Sen, MD, Eirich India.
www.eirich.com/en/
DIE CASTING
Intelligent solutions by Quaker Houghton
Industrial process fluids producer
Quaker Houghton is showing its portfolio
of die casting solutions at EURO-
GUSS 2022. Taking place in Nuremberg,
Germany, from 8-10 June, the
international trade show brings
together experts from the die casting
industry.
Visitors to Quaker Houghton’s stand,
Booth 628 in Hall 7, will have the opportunity
to discover Quaker Houghton’s
smarter solution for die casting, DieCast
iQ, combining process and lubrication
solutions together to drive manufacturing
change in high pressure aluminium
die casting from start to finish.
Quaker Houghton’s complete solution
includes die and plunger lubricants
and application systems, process fluids,
fire resistant hydraulics, high performance
metalworking fluids and
post-casting porosity sealing from its
subsidiary business, Ultraseal International.
Technical experts from the busi-
52

ness will be on hand to guide visitors
through Quaker Houghton’s range of
equipment, lubricant, and service solutions,
including the unique Lubrolene
electrostatic die lubricant solutions
which will be on display.
Dr Mark Cross, Global Business
Development Director - Die Casting at
Quaker Houghton, said, “Automotive
production processes are changing rapidly
with engineers pushing boundaries
in design, and as a result, die cast components
are becoming larger and
increasingly complex. As the industry
looks to produce more complex structural
parts, die casting needs to become
more intelligent.
“We are leading this revolution.
With a comprehensive product range,
unrivalled process expertise, industry
knowledge and customised support,
Quaker Houghton provides the end-toend
solution for intelligent die casting.
We’re eager to show this at EUROGUSS
2022 and talk to customers about how
they can drive efficiency, maximise performance
and achieve lightweighting
targets, all through one single source.”
Quaker Houghton will be situated at
stand 7-628 at EUROGUSS 2022.
www.diecastiq.quakerhoughton.com
Photo: Quaker Houghton
Media Kit 2022
Give your marketing
the significant boost!
+49 211 1591 142
CASTING PLANT & TECHNOLOGY 2/2022 53

© DVS Media GmbH
Contact person: Vanessa Wollstein
Aachener Straße 172 : +49 211 1591-152
40223 Düsseldorf : +49 211 1591-150
: vanessa.wollstein@dvs-media.info
: www.keytocasting.com
1 Foundry Plants and Equipment
17 Surface Treatment and Drying
2
Melting Plants and Equipment for Iron and
Steel Castings and for Malleable Cast Iron
18
Plant, Transport, Stock, and Handling
Engineering
3 Melting Plants and Equipment for NFM
4 Refractories Technology
19 Pattern- and Diemaking
20 Control Systems and Automation
5
6
7
8
Non-metal Raw Materials and Auxiliaries for
Melting Shop
Metallic Charge Materials for Iron and Steel
Castings and for Malleable Cast Iron
Metallic Charge and Treatment Materials for
Light and Heavy Metal Castings
Plants and Machines for Moulding and
Coremaking Processes
21 Testing of Materials
22 Analysis Technique and Laboratory
23 Air Technique and Equipment
24 Environmental Protection and Disposal
9 Moulding Sands
10 Sand Conditioning and Reclamation
11 Moulding Auxiliaries
12 Gating and Feeding
13 Casting Machines and Equipment
25 Accident Prevention and Ergonomics
26 Other Products for Casting Industry
27 Consulting and Service
28 Castings
29 By-Products
14
Discharging, Cleaning, Finishing of Raw
Castings
30 Data Processing Technology
15 Surface Treatment
16 Welding and Cutting
31 Foundries
32 Additive manufacturing / 3-D printing
54

03 Melting Plants and Equipment for NFM
03.02 Melting and Holding Furnaces, Electrically
Heated
▼ Aluminium Melting Furnaces 630
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Am Seestern 5, 40547 Düsseldorf, Germany
+49 211 5858-0
E-Mail:
steel@refra.com
Internet:
www.refra.com
▼ Insulating Products 1130
08 Plants and Machines for Moulding and
Coremaking Processes
08.02 Moulding and Coremaking Machines
▼ Multi-Stage Vacuum Process 3223
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Remelting Furnaces 700
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
+34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
▼ Micro Porous Insulating Materials 1220
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
+49 6441 802-1190 7 +49 6441 802-1199
E-Mail:
andreas.wuerz@pfeiffer-vacuum.de
Internet:
www.pfeiffer-vacuum.de
09 Moulding Sands
09.01 Basic Moulding Sands
▼ Chromite Sands 3630
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
04 Refractories Technology
04.01 Plants, Equipment and Tools for Lining in Melting
and Casting
▼ Mixers and Chargers for Refractory Mixes 930
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
+34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
▼ Ladle Refractory Mixes 1240
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Ceramic Sands/Chamotte Sands 3645
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
+49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
▼ Gunning for Relining of Cupolas 950
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
+49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
04.04 Refractory Building
▼ Maintenance of Refractory Linings 1462
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Silica Sands 3720
STROBEL QUARZSAND GmbH
Freihungsand, 92271 Freihung, Germany
+49 9646 9201-0 7 +49 9646 9201-701
E-Mail:
info@strobel-quarzsand.de
Internet:
www.strobel-quarzsand.de
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
+49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
04.02 Refractory Materials (Shaped and Non Shaped)
▼ Refractories, in general 1040
UELZENER Maschinen GmbH
Stahlstr. 26-28, 65428 Rüsselsheim, Germany
+49 6142 177 68 0
E-Mail:
contact@uelzener-ums.de
Internet:
www.uelzener-ums.de
05 Non-metal Raw Materials and Auxiliaries for
Melting Shop
05.04 Carburization Agents
▼ Coke Breeze, Coke-Dust 1680
09.04 Mould and Core Coating
▼ Blackings, in general 4270
ARISTON Formstaub-Werke GmbH & Co. KG
Worringerstr. 255, 45289 Essen, Germany
+49 201 57761 7 +49 201 570648
Internet:
www.ariston-essen.de
EIKA, S.COOP
Urresolo 47, 48277 Etxebarria
+34 946 16 77 32
Internet:
Spain
E-Mail:
aagirregomezkorta@isoleika.es
Internet:
www.isoleika.es
ARISTON Formstaub-Werke GmbH & Co. KG
Worringerstr. 255, 45289 Essen, Germany
+49 201 57761 7 +49 201 570648
Internet:
www.ariston-essen.de
CASTING PLANT & TECHNOLOGY 2/2022 55

SUPPLIERS GUIDE
09.06 Moulding Sands Testing
▼ Moisture Testing Equipment for Moulding Sand 4410
▼ Scales and Weighing Control 4590
▼ Exothermic Feeder Sleeves 5420
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
▼ Moulding Sand Testing Equipment, in general 4420
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
10.04 Sand Reconditioning
▼ Sand Coolers 4720
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Feeding Compounds 5430
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
10 Sand Conditioning and Reclamation
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
12 Gating and Feeding
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
13 Casting Machines and Equipment
10.01 Moulding Sand Conditioning
▼ Aerators for Moulding Sand Ready-to-Use 4470
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
▼ Sand Preparation Plants and Machines 4480
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
▼ Mixers 4520
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
▼ Sand Mixers 4550
▼ Covering Agents 5320
Refratechnik Steel GmbH
Refratechnik Casting GmbH
Am Seestern 5, 40547 Düsseldorf, Germany
+49 211 5858-0
E-Mail:
steel@refra.com
Internet:
www.refra.com
▼ Breaker Cores 5340
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Products 5360
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Insulating Sleeves 5375
13.02 Die Casting and Accessories
▼ Diecasting Lubricants 5670
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
+49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Diecasting Parting Agents 5680
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
+49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Hydraulic Cylinders 5750
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
▼ Aerators 4560
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
▼ Exothermic Mini-Feeders 5400
HYDROPNEU GmbH
Sudetenstr. , 73760 Ostfildern, Germany
+49 711 342999-0 7 +49 711 342999-1
E-Mail:
info@hydropneu.de
Internet:
www.hydropneu.de
▼ Piston Lubricants 5790
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
GTP Schäfer GmbH
41515 Grevenbroich, Germany
+49 2181 23394-0 7 +49 2181 23394-55
E-Mail:
info@gtp-schaefer.de
Internet:
www.gtp-schaefer.com
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
+49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
56

▼ Parting Agents for Dies 5850
▼ Annealing and Hardening Furnaces 7430
18 Plant, Transport, Stock, and Handling
Engineering
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
+49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Dry Lubricants (Beads) 5865
Chem-Trend (Deutschland) GmbH
Robert-Koch-Str. 27, 22851 Norderstedt, Germany
+49 40 52955-0 7 +49 40 52955-2111
E-Mail:
service@chemtrend.de
Internet:
www.chemtrend.com
▼ Multi-Stage Vacuum Process 5876
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Solution Annealing Furnaces 7455
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Annealing Furnaces 7490
18.01 Continuous Conveyors and Accessories
▼ Vibratory Motors 7980
FRIEDRICH Schwingtechnik GmbH
Am Höfgen 24, 42781 Haan, Germany
+49 2129 3790-0 7 +49 2129 3790-37
E-Mail:
info@friedrich-schwingtechnik.de
Internet:
www.friedrich-schwingtechnik.de
20 Control Systems and Automation
20.01 Control and Adjustment Systems
▼ Automation and Control for Sand Preparation 9030
Pfeiffer Vacuum GmbH
35614 Asslar, Germany
+49 6441 802-1190 7 +49 6441 802-1199
E-Mail:
andreas.wuerz@pfeiffer-vacuum.de
Internet:
www.pfeiffer-vacuum.de
17 Surface Treatment and Drying
▼ Heat Treatment and Drying 7398
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Quenching and Tempering Furnaces 7510
Maschinenfabrik Gustav Eirich GmbH & Co KG
Walldürner Str. 50, 74736 Hardheim, Germany
Internet:
www.eirich.de
20.02 Measuring and Control Instruments
▼ Immersion Thermo Couples 9230
Gebr. Löcher Glüherei GmbH
Mühlenseifen 2, 57271 Hilchenbach, Germany
+49 2733 8968-0 7 +49 2733 8968-10
Internet:
www.loecher-glueherei.de
17.01 Plants and Furnaces
▼ Tempering Furnaces 7400
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Ageing Furnaces 7401
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Heat Treating Furnaces 7520
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
▼ Hearth Bogie Type Furnaces 7525
LOI Thermoprocess GmbH
45141 Essen/Germany
+49 201 1891-1
E-Mail:
service-loi@tenova.com
Internet:
www.loi.tenova.com
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Laser Measurement Techniques 9310
POLYTEC GmbH
76337 Waldbronn, Germany
+49 7243 604-0 7 +49 7243 69944
E-Mail:
Lm@polytec.de
Internet:
www.polytec.de
▼ Positioning Control 9345
POLYTEC GmbH
76337 Waldbronn, Germany
+49 7243 604-0 7 +49 7243 69944
E-Mail:
Lm@polytec.de
Internet:
www.polytec.de
CASTING PLANT & TECHNOLOGY 2/2022 57

SUPPLIERS GUIDE
▼ Temperature Measurement 9380
22 Analysis Technique and Laboratory Equipment
▼ Simulation Services 11310
▼ Sampling Systems 9970
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Thermal Analysis Equipment 9400
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
+49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
▼ Heat Treatment 11345
24 Environmental Protection and Disposal
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Thermo Couples 9410
▼ Waste Disposal, Repreparation, and Utilization 24.03
Remondis Production GmbH - LEGRAN
Brunnenstraße 138 , 44536 Lünen
+49 2306 106 8831
Internet:
Germany
E-Mail:
yannik.droste@remondis.de
Internet:
www.legran.de
Gebr. Löcher Glüherei GmbH
Mühlenseifen 2, 57271 Hilchenbach, Germany
+49 2733 8968-0 7 +49 2733 8968-10
Internet:
www.loecher-glueherei.de
28 Castings
▼ Aluminium Pressure Diecasting 11390
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
20.03 Data Acquisition and Processing
▼ Numerical Solidification Analysis
and Process Simulation 9500
26 Other Products for Casting Industry
26.02 Industrial Commodities
▼ Joints, Asbestos-free 11120
Schött Druckguß GmbH
Aluminium Die Casting
Postfach:
27 66, 58687 Menden, Germany
+49 2373 1608-0 7 +49 2373 1608-110
E-Mail:
vertrieb@schoett-druckguss.de
Internet:
www.schoett-druckguss.de
▼ Rolled Wire 11489
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
+49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
▼ Numerical Solidification Simulation
and Process Optimization 9502
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
▼ Sealing and Insulating Products up to 1260 øC 11125
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
+49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
▼ Spheroidal Iron 11540
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
+49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
▼ Simulation Software 9522
MINKON GmbH
Heinrich-Hertz-Str. 30-32, 40699 Erkrath, Germany
+49 211 209908-0 7 +49 211 209908-90
E-Mail:
info@minkon.de
Internet:
www.minkon.de
27 Consulting and Service
▼ Machining 11292
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
+49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
30 Data Processing Technology
▼ Mold Filling and Solidification Simulation 11700
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
+49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
+49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
MAGMA Giessereitechnologie GmbH
Kackertstr. 11, 52072 Aachen, Germany
+49 241 88901-0 7 +49 241 88901-60
E-Mail:
info@magmasoft.de
Internet:
www.magmasoft.com
58

31 Foundries
31.01 Iron, Steel, and Malleable-Iron Foundries
▼ Iron Foudries 11855
Behringer GmbH
Maschinenfabrik und Eisengiesserei
Postfach:
1153, 74910 Kirchardt, Germany
+49 7266 207-0 7 +49 7266 207-500
Internet:
www.behringer.net
Index to Companies
Company Product Company Product
ARISTON Formstaub-Werke
GmbH & Co. KG 1680, 4270
BEHRINGER GmbH 11292, 11489, 11540, 11855
Maschinenfabrik&Eisengießerei
Chem Trend (Deutschland) GmbH 5670, 5680, 5790, 5850, 5865
Maschinenfabrik 4410, 4420, 4470, 4480, 4520,
Gustav Eirich GmbH u. Co KG 4550, 4560, 4590, 4720, 9030
Friedrich Schwingtechnik GmbH 7980
GTP Schäfer 3630, 3645, 5340, 5360, 5375,
Giesstechnische Produkte GmbH 5400, 5420, 5430
HYDROPNEU GmbH 5750
EIKA, S.COOP 1040, 1130, 1220
REMONDIS Production GmbH 24.03
Gebr. Löcher Glüherei 7398, 11345
GmbH
LOI Thermprocess GmbH 630, 700, 7400, 7401, 7430,
7455, 7490, 7510, 7520, 7525
MAGMA Gießereitechnologie GmbH 9500, 9502, 9522, 11310, 11700
MINKON GmbH 9230, 9380, 9400, 9410, 9970,
Geschäftsleitung 11120, 11125
Pfeiffer Vacuum GmbH 3223, 5876
Polytec GmbH 9310, 9345
Refratechnik Steel GmbH 1040, 5320
Schött-Druckguß GmbH 11390
Strobel Quarzsand GmbH 3720
Uelzener Maschinen GmbH 930, 950, 1240, 1462
Click here for the product list:
CASTING PLANT & TECHNOLOGY 2/2022 59

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60

INTERNATIONAL FAIRS AND CONGRESSES
Fairs and Congresses
Euroguss 2022
June, 8-10, 2022, Nuremberg, Germany
www.euroguss.de/en
6. Conference „Steels in Cars and Trucks”
June, 19-23, 2022, Milan, Italy
www.sct-2022.com
CastForge
June, 21-23, 2022, Stuttgart, Germany
www.messe-stuttgart.de/castforge/en
Zinc Die Casting Conference – Europe
October, 5-7, 2022, Koblenz, Germany
www.zinc.org/2020-zinc-die-casting-conference-europe
GIFA Southeast Asia 2022
October, 5-7, 2022, Bangkok, Thailand
www.gifa-southeastasia.com/
Advertisers‘ Index
AGTOS Gesellschaft für technische Oberflächensysteme
mbH, Emsdetten /Germany 27
ExOne GmbH, Gersthofen/Germany
GLAMA Maschinenbau GmbH,
Gladbeck
Title
Back Cover
Optris GmbH, Berlin/Germany 13
Rump Strahlanlagen GmbH & Co.,
Salzkotten/Germany21
Simpson Technologies Corporation,
Aurora/USA39
Targi Kielce S.A., Kielce/Poland 31
CASTING PLANT & TECHNOLOGY 2/2022 61

PREVIEW/IMPRINT
The Euroguss, which takes place
every two years, is the biggest
trade fair of its kind, focuses on
innovative solutions for die casting
processes like aluminium die casting,
magnesium die casting or zinc
die casting.
Preview of the next issue
Selection of topics:
Euroguss, CastForge, specialist congresses
Due to the postponement caused by the pandemic, important trade fairs in Germany are clustered in June: Euroguss in Nuremberg
is the performance show for the die casting industry at the beginning of June. Shortly afterwards, at the end of June,
there is CastForge in Stuttgart, the trade fair for cast and forged parts with processing. Both trade fairs are flanked by specialist
congresses – Die Casting Day and Iron Casting Forum – with a program of lectures. In edition 3 we report in detail on both
trade fairs.
Company report
Germany wants to become climate neutral by 2045. On the one hand, Germany’s foundry industry will benefit from this,
because many components have to be replaced, but on the other hand, foundries themselves also have to modernize. Our
company report uses the foundry Harzguss Zorge from the south-eastern Harz region, Germany, to explain the challenges that
have to be mastered on the way to decarbonization.
Hybrid casting - 3D printing for investment casting models in machining
In search of optimization potential in the investment casting process, BLANK has developed a hybrid process in which the wax
parts are now additively manufactured and then fed into the regular investment casting process. This shortens the production
time and geometries can be realized that were previously hardly possible in investment casting.
Imprint
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ISSN 0935-7262
62

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always
the durable
solution
Cost effective heavy duty
mobile equipment
for aluminium industries . . .
GLAMA Maschinenbau GmbH
Headquarters:
Hornstraße 19
D-45964 Gladbeck / Germany
Fon: +49 (0) 2043 9738 0
Fax: +49 (0) 2043 9738 50
email: info@glama.de
GLAMA USA Inc.
ALUMINIUM CHINA
6-8 July 2022
Visit us at Stand No 1E23
Shanghai New International Expo Centre
NEW ADDRESS:
60 Helwig St., Berea, Ohio 44017
Fon: +1 877 452 6266
Email: sales@glama-us.com
glama.de