CPT International 02/2015
The leading technical journal for the global foundry industry – Das führende Fachmagazin für die weltweite Gießerei-Industrie
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global foundry industry – Das führende Fachmagazin für die
weltweite Gießerei-Industrie
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www.giesserei-verlag.de<br />
10. June<br />
<strong>2015</strong><br />
CASTING<br />
PLANT AND TECHNOLOGY<br />
INTERNATIONAL<br />
GIFA<br />
Special<br />
2<br />
Get ready for the largest<br />
GIFA fair ever!
EDITORIAL K<br />
Welcome to Düsseldorf!<br />
GIFA is not just the world’s largest foundry trade fair. In terms of exhibitor<br />
numbers and reserved exhibition space it will also be larger this year than ever<br />
before!<br />
This issue, naturally the most extensive one for four years, contains some special<br />
highlights that the editorial team of CASTING, PLANT & TECHNOLOGY<br />
has put together for you. The featured technologies are exemplary in their<br />
particular fields. For example, the one on completely linked inorganic core<br />
production for manufacturing cylinder heads at the Volkswagen Foundry in<br />
Hanover (from P. 24), which shows how numerous complex process steps can<br />
be harmonized with one another – from the preparation of the core molding<br />
material and core shooting, through automatic deburring and transport via<br />
robot, to the placement of each two core packages in the double mold on the<br />
casting turned table.<br />
The new material SiWind for wind turbine hubs exemplifies the viability of<br />
the 5,000-year-old production process of casting: foundries have opened up a<br />
new customer group – not just in Germany – and have entered the field of renewable<br />
energies with cast wind turbine hubs. New materials can defy the<br />
harsh marine conditions and be used to optimize the need for greater wind<br />
turbine energy yields (from P. 8).<br />
With its new research and development center in the Dutch city of Enschede,<br />
Foseco also provides an example of best practice: the company has taken a new<br />
path by concentrating the research activities of the foundry supplier group in<br />
one research center (from P. 50).<br />
The use of PET oxygen technology as a reasonably priced alternative to conventional<br />
coke could revolutionize some melting operations. A promising<br />
trial is underway at the Gienandt iron foundry (from P. 32).<br />
Other topics examined in this issue include numerical simulation of the<br />
quenching process for castings (P. 46), an article on progress in inorganic binding<br />
systems and, last but not least, two articles on a trailblazing collaboration<br />
between the German and South African foundry industries involving energy-efficient<br />
technologies (from P. 60).<br />
This GIFA issue of CASTING, PLANT & TECHNOLOGY is rounded out by a<br />
comprehensive GIFA Special that represents a cross-section of the companies<br />
at the trade fair (from P. 73). Are you interested in the technical presentations?<br />
Then check out what the four technical forums have to offer in our Special.<br />
Presentations that are not held in English are simultaneously translated.<br />
Have a good read!<br />
Robert Piterek, e-mail: robert.piterek@bdguss.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 3
K FEATURES<br />
INTERVIEW<br />
Kehrer, Friedrich-Georg<br />
GIFA – the international event where top decision-makers meet 6<br />
MATERIALS<br />
Mikoleizik, Peter; Geier, Georg<br />
SiWind - Development of materials for offshore wind power plants<br />
of the multi megawatt range 8<br />
COREMAKING<br />
Müller, Jens; Deters, Heinz; Oberleiter, Martin; Zupan, Henning;<br />
Lincke, Hannes; Resch, Ronja; Körschgen, Jörg; Kasperowski, Axel<br />
Nothing is impossible – advancements in inorganic binder systems 16<br />
Rösch, Raimund; Dichter, Thomas; Hansen, Ferdinand; Jäger, Günther;<br />
Uhde, Sven<br />
Fully linked inorganic core production at Volkswagen’s cylinder<br />
head foundry 24<br />
MELTING SHOP<br />
Kadelka, Heinz; Dusil, Matthias; Werner, Gerd; Weber, Mike;<br />
Matschkewitz, Ulrich<br />
Gienanth foundry tests PET oxygen technology 32<br />
Cover-Photo:<br />
Impression from GIFA 2011<br />
(Photo: Messe Düsseldorf)<br />
K COLUMNS<br />
Editorial 3<br />
News in brief 68<br />
8<br />
50<br />
The objective of the MEGAWind research project was the<br />
development of a strong material with high ductility which is<br />
suitable for offshore wind power plants (Photo: Siemens)<br />
The new Foseco research and development center in Enschede is<br />
intended to gain a holistic understanding of production and to undertake<br />
forward-looking product redevelopment (Photo: A. Bednareck)
CASTING<br />
2 | <strong>2015</strong><br />
PLANT AND TECHNOLOGY<br />
INTERNATIONAL<br />
CASTING TECHNOLOGY<br />
Schruff, Ingolf<br />
Pressure die cast structural components for lightweight<br />
automotive construction 40<br />
SIMULATION<br />
Schmalhorst, Carsten; Greif, David<br />
Numerical simulation of the quenching process for castings using AVL FIRE 46<br />
RESEARCH & DEVELOPMENT<br />
Piterek, Robert<br />
Exploring tomorrow’s technologies 50<br />
Holub, Pavel<br />
“Critical mass for R&D” 57<br />
INDUSTRIAL COOPERATION<br />
Friedl, Christa<br />
More efficient melting with German foundry technology 60<br />
Bosse, Manuel<br />
BMBF project reduces energy and resource requirements in South African<br />
foundries 64<br />
GIFA SPECIAL 73<br />
Brochures 114<br />
Advertisers´ index 112<br />
Fairs and congresses 116<br />
Preview/Imprint 117<br />
60<br />
The EffSAFound project of Germany's Federal Ministry for Education and Research is intended to help geht South Africa's important<br />
foundry industry off the ground with German efficiency-enhancing technology<br />
(Photo: Palesa Riba)
K INTERVIEW<br />
GIFA – the international event<br />
where top decision-makers meet<br />
“Experience four innovative concepts at the same place and time” – this is the motto for GIFA, the<br />
world’s leading international trade fair for foundry technology, and its offshoots METEC, THERM-<br />
PROCESS and NEWCAST in Düsseldorf, Germany, this year. The four well-established trade fairs<br />
that are devoted to foundries, thermo process technology and metallurgy are focussing in particular<br />
this year on such current trends as 3-D printing, minimization of resource input and energy saving.<br />
Messe Düsseldorf Director Friedrich-Georg Kehrer explains the objectives of the event<br />
What are exhibitors’ main expectations<br />
today when they participate in<br />
GIFA/the Bright World of Metals?<br />
Anyone who intends to be actively involved<br />
in the casting markets of the<br />
future will find that the world’s leading<br />
international trade fair for foundry<br />
technology is the ideal platform. Companies<br />
are also aware, however, that<br />
their business success in the coming<br />
years depends on successful participation<br />
in GIFA. It is a compact forum<br />
lasting five days during which international<br />
contacts can be established<br />
and then need to be followed up afterwards.<br />
The exhibitors in particular<br />
strengthen their market presence by<br />
taking part in GIFA. There is no other<br />
trade fair location where they can meet<br />
such a large number of highly qualified<br />
and capable decisionmakers. A<br />
total of almost 80,000 international<br />
experts came to the Bright World of<br />
Metals (GIFA, METEC, THERMPRO<br />
CESS and NEWCAST) four years ago.<br />
This is of course a major attraction to<br />
exhibitors and they see their participation<br />
as an opportunity to work even<br />
more intensively on establishing a<br />
foothold on the international market.<br />
What are the big advantages of Messe<br />
Düsseldorf to the companies participating?<br />
On the one hand, of course, the outstanding<br />
synergy benefits of holding<br />
four trade fairs at the same time and<br />
place that concentrate on the foundry<br />
technology and metallurgy sectors.<br />
While the Düsseldorf location plays an<br />
important role for GIFA too, on the other<br />
hand. With its position in the heart<br />
of the European market, but combined<br />
at the same time with an excellent international<br />
network of 71 foreign representatives<br />
covering 132 countries,<br />
our trade fair location is ideal for internationally<br />
oriented industries. As<br />
the organiser, we carry out numerous<br />
advertising activities in the most im<br />
6 Casting Plant & Technology 2/<strong>2015</strong>
In <strong>2015</strong> the largest “Bright World of Metals” (GIFA, METEC, NEWCAST and THERMPROCESS) of all time will take place.<br />
2,124 exhibitors will present latest technology and pioneering innovations. At GIFA nearly 900 companies from 46<br />
countries will exhibit (Photos: Messe Düsseldorf)<br />
portant target markets and often hold<br />
local meetings with such opinion leaders<br />
as associations and press representatives,<br />
in order to present the Bright<br />
World of Metals. Our exhibitors benefit<br />
directly from these activities, because<br />
they help to increase the international<br />
spread of the trade visitors.<br />
Has GIFA become more international?<br />
In which regions are the markets developing<br />
particularly well?<br />
In agreement with our partner associations<br />
and board members, we have<br />
increased our efforts to attract exhibitors<br />
and visitors from Asian countries<br />
– particularly India and China – as well<br />
as in Brazil, Mexico and Chile. We anticipate<br />
great interest from the USA<br />
again as well, which is already reflected<br />
in numerous inquiries we have received.<br />
It goes without saying that our<br />
activities also focus to a large extent on<br />
such neighbouring European countries<br />
and producers as the Nether lands,<br />
Austria, Switzerland, Italy, Spain and<br />
Turkey. As far as Russia is concerned,<br />
which has always been a major industrial<br />
trade partner in the past, we will<br />
have to wait and see how the current<br />
general and market situation there develops.<br />
We hope that an upward trend<br />
becomes apparent again in the coming<br />
months.<br />
What news can you give us about the<br />
markets served by the industry? Are<br />
shifts taking place? You will certainly<br />
be hearing what is happening from<br />
the exhibitors.<br />
Apart from Russia, the main regional<br />
outlets for castings have remained<br />
largely unchanged. The trend towards<br />
India and China has, perhaps, continued<br />
to strengthen, so that the potential<br />
number of visitors from there is<br />
even greater now. I see similar developments<br />
in Brazil and South Africa, as<br />
exhibitors have confirmed to us too.<br />
What are the latest developments<br />
and main areas of innovation that<br />
GIFA, METEC, THERMPROCESS and<br />
NEWCAST will be presenting?<br />
3D printing is an issue that will be<br />
playing a central role in the GIFA exhibition<br />
programme. This is a response<br />
to the trend towards computerbased<br />
3D printing processes, with which<br />
sand molds and cores bonded with<br />
synthetic resin can be manufactured<br />
relatively quickly. I am looking forward<br />
to seeing what current developments<br />
the companies will be surprising<br />
us with in this area. We are also<br />
looking forward to the new developments<br />
in the diecasting field, which is<br />
eminently suitable for the use of fully<br />
automatic diecasting cells. GIFA and<br />
NEWCAST will have plenty to present<br />
here, from handling robots to entire<br />
modern “islands” that operate automatically.<br />
www.gifa.com<br />
Casting Plant & Technology 2/<strong>2015</strong> 7
K MATERIALS<br />
Rotor hub for a wind power plant, prior to coating in the shot blasting cabin (Photos: Siempelkamp)<br />
Authors: Dipl.-Ing. Peter Mikoleizik, Dr. mont. Georg Geier, Siempelkamp Giesserei GmbH, Krefeld (today Mahle<br />
König KG, Rheinquell)<br />
SiWind - Development of materials<br />
for offshore wind power plants of<br />
the multi megawatt range<br />
From 2006 until 2012, a circle of companies and institutions collaborated on the MEGAWind<br />
project, a research project launched by the German Federal Ministry for Environment, Nature<br />
Conservation, Building and Nuclear Safety (BMU). The objective of this project was the successful<br />
development of a higher-strength material with sufficiently high ductility to make it a suitable<br />
material for structural members in offshore wind power plants<br />
Status quo in offshore wind<br />
power technology<br />
In the past, the development in wind<br />
power technology has been characterized<br />
by a constant increase in turbine<br />
capacity, a trend which is still continuing<br />
especially in plants intended for offshore<br />
use. Turbines with a nominal capacity<br />
of 5-6 MW currently represent<br />
the top league of turbines installed in<br />
the North Sea. Due to the high costs of<br />
the foundations and the efforts associated<br />
with the connection of offshore<br />
plants, even more powerful turbines are<br />
under development or in the prototype<br />
stage. Building turbines of increasingly<br />
higher capacities holds out the prospect<br />
of higher economic efficiency.<br />
There is a general consensus among<br />
all parties involved that offshore wind<br />
power generation will only have a future<br />
if its costs can compete with other<br />
forms of power generation. This means<br />
that an increase in turbine size for its<br />
own sake is not reasonable. It only<br />
makes sense if considered in the context<br />
of efficiency.<br />
8 Casting Plant & Technology 2/<strong>2015</strong>
K MATERIALS<br />
Development of the te ch nology<br />
The progress in wind power technology<br />
is aimed at condensing the performance<br />
capacity of individual components<br />
rather than scaling the plants up<br />
in proportion to the intended capacity<br />
increase. This would lead to an overproportional<br />
rise in manufacturing<br />
costs due to the increasingly greater<br />
weights and dimensions to be handled<br />
– especially in the case of large components.<br />
For example, precise machining<br />
of the components could become<br />
a problem if the maximum working<br />
load of the machine tools is exceeded.<br />
Also, the growing transport and logistics<br />
effort, for example, for cross-country<br />
transports, would drive up the<br />
costs. Finally, only coastal locations or<br />
locations on inland waters would be<br />
suitable as manufacturing sites. These<br />
would have to be newly built or, if existing,<br />
they would have to be upgraded<br />
with the necessary equipment. Experience<br />
made to date has shown that the<br />
weight and size of the components also<br />
have an effect on the number of available<br />
jack-up vessels, limiting both technological<br />
and financial possibilities. A<br />
higher nacelle weight has also structural<br />
consequences, as more massively designed<br />
towers and stronger foundations<br />
would have to be built. This would require<br />
more material and use up more<br />
resources. The tower height, and in case<br />
of offshore installations also the water<br />
depth, lead to a multiplication of costs.<br />
Limits to component weight<br />
and size<br />
Limiting the weight and size of components<br />
in the nacelle is therefore crucial<br />
to the achievement of higher efficiencies<br />
in wind power generation through<br />
an increase in nominal capacity or<br />
higher-capacity turbines. The resulting<br />
condensation of performance capacity<br />
usually leads to growing loads<br />
acting on the components. These loads<br />
have to be reliably sustained by the respective<br />
material. First of all, higher-strength<br />
materials are more expensive<br />
due their higher contents of<br />
alloying elements. Higher strength<br />
values in metallic materials are generally<br />
accompanied by reduced ductility.<br />
Ductility provides a high degree of<br />
safety against brittle failure of a structural<br />
member. In order to increase the<br />
strength of cast iron alloys, it has been<br />
common practice to add pearlite-stabilizing<br />
alloying elements to achieve<br />
partial or complete pearlitization of<br />
the metallic matrix. This is, however,<br />
accompanied by a distinct decrease in<br />
elongation at break (Table 1). Brittle<br />
materials are prone to spontaneous<br />
failure without prior indication in<br />
the form of a notable plastic deformation.<br />
Therefore, for safety reasons brittle<br />
materials are not allowed to be employed<br />
in the structural members of<br />
wind power plants [1]. In many fields<br />
of technology, it is a widespread belief<br />
that if a component is subjected to excessive<br />
stress, plastic deformation will<br />
lead to energy dissipation, indicating<br />
gradually but visibly an imminent failure<br />
of the component.<br />
Figure1: Weight savings are achieved via reductions in wall thickness. A specimen<br />
geometry was derived from current and anticipated section thicknesses<br />
Figure2: Microsection from the core zone of a 130-mm-thick section: The matrix<br />
is completely ferritic and free from carbides. The majority of the graphite<br />
particles are of form VI, size 5/6<br />
10 Casting Plant & Technology 2/<strong>2015</strong>
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in the market place: higher productivity, greater efficiency, increased flexibility,<br />
and Bühler‘s high quality.<br />
www.buhlergroup.com/GIFA<br />
GIFA <strong>2015</strong>, Düsseldorf / Germany<br />
Hall 11, Booth A42<br />
Innovations for a better world.
K MATERIALS<br />
New materials: Offshore electricity generation calls for systematic<br />
further development of ductile iron grades (Photo: Siemens)<br />
The “MEGAWind” research<br />
project<br />
The objective of the MEGAWind research<br />
project supported by the German<br />
Federal Ministry for Environment,<br />
Nature Conservation, Building and Nuclear<br />
Safety (BMU) (project no. 0327593)<br />
was to develop a higher-strength material<br />
featuring sufficient ductility to make<br />
it a suitable material for structural members<br />
in offshore wind power plants. At<br />
the same time, the aspect of affordability<br />
of renewable energy was to be taken<br />
in due account to ensure resource- and<br />
energy-efficient production and construction<br />
processes. Noteworthy about<br />
this project is the fact that, alongside<br />
the material-related research activities,<br />
a suitable calculation method for the<br />
intended market segment was investigated<br />
and established. The further development<br />
of the material, fracture mechanics<br />
testing and definitions as well as<br />
the resulting fracture mechanics calculation,<br />
all act together to complement<br />
existing component calculation procedures.<br />
All disciplines involved were represented<br />
by renowned and specialist institutes<br />
and companies. The partners to<br />
the project were:<br />
» Siempelkamp Giesserei GmbH,<br />
Krefeld: project management, materials<br />
development and certification,<br />
» Aerodyn Energiesysteme GmbH,<br />
Rendsburg: component calculations<br />
and certification in consideration of<br />
aspects of fracture mechanics,<br />
» Fraunhofer Institute for Structural<br />
Durability and System Reliability<br />
LBF, Darmstadt: determination of fatigue<br />
parameters in consideration of<br />
the surface condition,<br />
» Institute for Materials Technology,<br />
Technical University of Freiberg:<br />
commissioned to determine fracture<br />
mechanics characteristic values,<br />
» DNV GL Renewables Certification:<br />
commissioned to certify materials<br />
and audit the fracture mechanics<br />
verification procedure.<br />
The material SiWind and its<br />
objectives<br />
More than ever, structural materials are<br />
subject to fierce competition. This not<br />
only applies to absolute characteristic<br />
values of the materials but also to aspects<br />
like cost efficiency, availability and<br />
reliability. During the last few decades,<br />
ductile cast iron has increasingly gained<br />
in importance. What makes ductile cast<br />
iron so attractive as a structural material<br />
are its steel-like, static and above all<br />
cyclic strength properties accompanied<br />
by good ductility performance. Another<br />
important aspect, especially in Central<br />
Europe, is the high process security,<br />
which means high reliability and a good<br />
cost-benefit-ratio of the material, all of<br />
which have contributed to its success.<br />
Due to these properties, ductile iron<br />
has become firmly established in the<br />
wind energy sector. It is the predominant<br />
casting material for load-bearing<br />
and large components in the drive train.<br />
Large components such as rotor hubs or<br />
12 Casting Plant & Technology 2/<strong>2015</strong>
machine supports weighing in excess of<br />
60 t are series cast using ductile iron.<br />
Certificationandrulescompliance<br />
In order to facilitate the market acceptance<br />
of the new material and give future<br />
users security, the certification of<br />
the new material was defined as one key<br />
element of the project. DNVGL Renewables<br />
Certification (GL) was selected as<br />
independent certification body. GL not<br />
only boasts a high international reputation<br />
and presence but can also draw on<br />
various rules and guidelines for the design<br />
and calculation of onshore and offshore<br />
wind energy turbines. These rules<br />
and guidelines specify concrete verification<br />
procedures, calculation methods<br />
and requirements to be complied with.<br />
This provided the basis for a plannable<br />
and successful certification process. According<br />
to the GL guideline for offshore<br />
wind power plants, edition 2005 [1], the<br />
employment of cast iron with lamellar<br />
graphite for “load-bearing structural<br />
members” is practically ruled out for<br />
safety reasons, because in the event of<br />
an excessive load acting on the structural<br />
member the failure will be completely of<br />
the brittle type. In contrast, according to<br />
[2], ductile cast iron grades, which do not<br />
belong to the group of higher-strength<br />
grades, have been approved. A material is<br />
commonly defined as ductile if the elongation<br />
at break A is higher than 12.5%<br />
and the impact energy Kv is greater than<br />
10 J at a temperature of -20 °C. Similar<br />
definitions are found in other mechanical<br />
engineering guidelines, for example,<br />
the FKM guideline [3]. Additionally, the<br />
GL guideline stipulates that the ductile<br />
cast iron grades with spheroidal graphite<br />
may not feature more than 10 % pearlite<br />
in the ferritic matrix. The calculated<br />
design verification of a structural member<br />
is based on an analysis of the static<br />
load-carrying capacity at extreme load;<br />
for the lifetime verification, modi fied<br />
Miner’s rule is to be applied. Generally, a<br />
service life of at least 20 years is assumed.<br />
Beside the defined concept of synthetic<br />
S/N curves involving a classification for<br />
component dimensioning, it is also possible<br />
to base the dimensioning on test results.<br />
In the latter case, verification must<br />
be provided by the specific manufacturer<br />
that the measured values are transferrable<br />
to other components and that<br />
the number of specimens is statistically<br />
well founded. Higher-strength cast iron<br />
materials, i.e. according to DIN EN1563<br />
[2] materials featuring a tensile strength<br />
above 400 MPa, cannot be employed unless<br />
specifically approved by the certification<br />
body. In these cases, it is usually<br />
required to provide a verification that<br />
the specific component meets the fracture<br />
mechanics safety requirements. As<br />
an alternative to the additional fracture<br />
mechanics calculations, specifically for<br />
gear box housings the Note on Engineering<br />
Details [4] provides for the consideration<br />
of a Stress Reserve Factor (SRF) of<br />
1.5 in the static and cyclic calculation.<br />
Casting Plant & Technology 2/<strong>2015</strong> 13
K MATERIALS<br />
Characteristic<br />
Material<br />
value<br />
EN-GJS-500-7 EN-GJS-700-2<br />
R m<br />
in MPa 360 420 650<br />
R p0,2<br />
in MPa 220 290 380<br />
A in % 12 5 1<br />
Matrix ferritic ferritic/pearlitic pearlitic<br />
Table1: Decreasing ductility and increasing strength of the ferritic/pearlitic<br />
cast iron grades (characteristic values according to DIN EN 1563:2012 for section<br />
thicknesses ranging from 60 mm to 200 mm); R m<br />
– tensile strength, R p<strong>02</strong><br />
–<br />
yield strength, elongation at break<br />
Projectobjective:higherstrength<br />
In the concrete material development<br />
it was intended to increase the<br />
strength of ductile cast iron by solid-solution<br />
strengthening. This retains<br />
a ferritic matrix. Thanks to this<br />
ferritic matrix, there is only a small<br />
decrease in elongation at break while<br />
tensile and yield strength values are<br />
significantly raised.<br />
Eugen Weil Industrie-Service<br />
Ohmstrasse 1<br />
35315 Homberg/Ohm<br />
Tel.: +49 (0)6633 / 8 26<br />
Fax: +49 (0)6633 / 57 73<br />
info@ewis.eu<br />
www.ewis.eu<br />
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As the characteristic values of casting<br />
materials vary depending on the section<br />
thickness and the focus of the investigation<br />
was specifically on large cast<br />
components for offshore applications,<br />
from the very beginning of the project<br />
the tests were based on representative<br />
section thicknesses. The feasibility<br />
of manufacturing real components<br />
from the higher-strength material and<br />
with an adapted geometry was tested<br />
in a simulation. It<br />
turned out that as<br />
a result of the increased<br />
strength,<br />
weight savings can<br />
be achieved in existing<br />
designs via<br />
reductions in wall<br />
thickness. A representative<br />
specimen<br />
geometry was<br />
derived (Figure1)<br />
from current and<br />
anticipated section<br />
thicknesses.<br />
The result is<br />
a plate weighing<br />
1.2 t with section<br />
thicknesses of 60,<br />
130 and 200 mm.<br />
These section<br />
thicknesses could<br />
be flawlessly cast.<br />
Samples were taken<br />
from the areas<br />
of the various section<br />
thicknesses<br />
and used to determine<br />
the respective<br />
static, cyclic<br />
and fracture mechanics<br />
characteristic<br />
values. Based on the obtained<br />
intermediate results, first the chemical<br />
composition was determined and<br />
optimized in preliminary tests. In subsequent<br />
testing campaigns the casting<br />
method was to be optimized with a view<br />
to the melting process and the treatment<br />
of the melt. Eventually, the final<br />
material modification was reproduced<br />
several times in order to have available<br />
sufficient specimens for the certification<br />
of the material by GL. From the outset,<br />
the sampling and testing was coordinated<br />
with the certification institute. This<br />
involved not only the size and shape of<br />
the samples but especially their location<br />
and orientation as well as comprehensive<br />
documentation and supervision of<br />
all individual steps. With a view to the<br />
critical section thicknesses, the tests to<br />
determine the static characteristic values<br />
were performed on tensile specimens<br />
featuring a testing cross-section<br />
of 14 mm. The cyclic tests were primarily<br />
conducted on round specimens with<br />
testing cross-sections of 15 and 24 mm.<br />
For the fracture mechanics tests SEB20<br />
and CT25 specimens were used.<br />
Fracture mechanics calculations<br />
Besides the development and the testing<br />
of the material, another element of<br />
the certification process consisted in a<br />
model fracture mechanics safety verification.<br />
The tests were performed on the<br />
representative geometry of a rotor hub<br />
assuming real loads and the determined<br />
characteristic material values. Thus a future<br />
user of the material will not only get<br />
a new material with enhanced and certified<br />
properties. He will also be provided<br />
an evaluated and generally accepted<br />
verification and calculation procedure<br />
for any future component approval.<br />
This provides the basis for the universal<br />
use of the material in the wind power<br />
sector, without any limitation to specific<br />
categories of components.<br />
Material characterization<br />
SiWind<br />
The new material has been certified under<br />
the designation SiWind. The standardized<br />
nomenclature according to<br />
[5] is GJSF- SiNi30-5. The characteristic<br />
static values are listed in Table 2<br />
14 Casting Plant & Technology 2/<strong>2015</strong>
versus EN-GJS-400-18-LT, the material<br />
commonly used in the wind power<br />
sector. The characteristic values refer<br />
to cast specimens of type D according<br />
to [2] for a representative section thickness<br />
ranging between 60 and 200 mm.<br />
SiWind is the first higher-strength<br />
casting material certified and approved<br />
for employment in offshore wind power<br />
applications. The characteristic static<br />
values could be increased by up to<br />
50 %. Independent tests have shown<br />
that the ductility under cyclic<br />
stress is higher than expected<br />
and similar to the ductility<br />
of EN-GJS-400-18LT. In fracture<br />
mechanics calculations<br />
for the design of a component<br />
it could be demonstrated that<br />
visible flaws can be endured<br />
over the usual maintenance<br />
intervals. Hence, the currently<br />
usual operational and service<br />
efforts in offshore wind power<br />
plants will not increase as a result<br />
of the enhanced plant performance.<br />
Thanks to the fact<br />
that the new cast iron grade<br />
is a ferritic material, machining,<br />
coating and reworking<br />
costs are comparable to those<br />
of EN-GJS400-18-LT and even<br />
lower than those of currently<br />
known higher-strength ferritic/pearlitic<br />
grades (Figure 2).<br />
Especially a comparison with<br />
the established synthetic S/N<br />
curve calculation method<br />
shows good correspondence<br />
and should foster the confidence<br />
in the new material.<br />
The exemplary calculation<br />
shows that the new material<br />
has a weight-saving potential<br />
of approx. 15 % in the case<br />
of newly designed structures.<br />
Also existing structures can<br />
be optimized by replacing existing<br />
ductile cast iron grades<br />
with the new material. The investigations<br />
performed within<br />
the framework of the MEGAWind<br />
project have partly been<br />
more profound and extensive<br />
than tests performed for the<br />
materials used in the past, especially<br />
the tests relative to the<br />
Table2: Comparison of the static characteristic<br />
values of grades SiWind<br />
and GJS-400-18-LT<br />
behaviour under cyclic stress and to the<br />
fracture mechanics properties.<br />
The “MEGAWind” project , which is the<br />
subject of this report, was conducted under<br />
the sponsorship of the BMU (project no.<br />
0327593). The responsibility for the contents<br />
of this article lies with the authors.<br />
INFUSER<br />
ADVANCED<br />
POLLUTION<br />
CONTROL<br />
Characteristic<br />
Material<br />
value<br />
SiWind GJS-400-18LT<br />
R m in MPa* 410 (459) 360<br />
R p0,2 in MPa* 330 (344) 220<br />
A in %* 10 (17) 12<br />
* Values for section thicknesses between 60 and<br />
200 mm; measured values in brackets.<br />
References:<br />
http://www.cpt-international.com<br />
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Infuser Deutschland GmbH<br />
Phone: +49 177 377 4828<br />
E-Mail: fh@infuser.eu<br />
www.infuser.eu
K COREMAKING<br />
Inorganic core making with industrial robots at ASK Chemicals in Hilden, Germany (Photos + graphics: ASK Chemicals)<br />
Authors: Jens Müller, Heinz Deters, Martin Oberleiter, Henning Zupan, Hannes Lincke, Ronja Resch, Jörg Körschgen<br />
and Axel Kasperowski, ASK Chemicals GmbH, Hilden<br />
Nothing is impossible – advancements<br />
in inorganic binder systems<br />
Odorless core production, odor-reduced casting, significantly less cleaning of machines and<br />
tools, the resulting higher output and productivity, and the advantages in terms of casting, such<br />
as faster solidification due to reduced ingot mold temperatures – these benefits of the Inotec<br />
technology are already well-established. Despite all this, inorganic binder systems will always be<br />
benchmarked against existing technologies such as cold box. This is also the reason why, in the<br />
past, people criticized surface properties for being less smooth than with organic binders and<br />
decomposition after pouring for being worse<br />
16 Casting Plant & Technology 2/<strong>2015</strong>
Figure 1: Factors that can have a major influence on penetrations during the<br />
pouring process<br />
However, recent developments could<br />
prove that inorganic binders have improved<br />
considerably and in some applications<br />
even reveal additional potential<br />
for optimization. With the newly developed<br />
Inotec generation, even areas that<br />
are highly susceptible to penetration,<br />
such as the gate region, can be realized in<br />
a process-consistent manner and without<br />
additional coating of the cores. This<br />
system is 100 % inorganic and leaves absolutely<br />
no condensate deposits in the<br />
casting tools. In addition, there is no formation<br />
of smoke during the casting process.<br />
By contrast, cast pieces that were<br />
produced using conventional methods,<br />
such as the cold box method, exhibited<br />
a significantly inferior surface, which<br />
means that Inotec is much more than<br />
just an alternative here.<br />
In the past, decoring of cast pieces<br />
that were produced using inorganic<br />
binders was often quite a challenge<br />
in the area of water jackets, especially<br />
if the decoring machine had only<br />
a few degrees of freedom. The Inotec<br />
Promoter WJ 4000 has helped to significantly<br />
improve shake-out properties<br />
in particular, with the result that<br />
even complex and filigree water jacket<br />
cores can now be safely removed from<br />
the component after casting.<br />
Further enhancements, such as the<br />
improvement of moisture stability or<br />
the use of inorganic binders beyond<br />
the confines of light metal casting, are<br />
closing the gap on conventional organic<br />
systems. State-of-the-art technical<br />
equipment for the investigation of<br />
system properties and a growing understanding<br />
of the running processes<br />
have led to a more efficient conception<br />
of new binder formulations and<br />
the overcoming of limitations much<br />
faster than before.<br />
Despite all these future challenges<br />
for both inorganic and organic binders,<br />
one thing is beyond doubt: inorganic<br />
binders are more environmentally<br />
friendly than organic systems. This<br />
was confirmed in no uncertain terms<br />
by the German Technical Inspection<br />
Association TÜV Rheinland after carrying<br />
out a comparative life cycle assessment<br />
of cold box and Inotec<br />
You have surely heard it said<br />
before: Nothing is impossible!<br />
This saying effectively typifies the development<br />
of inorganic binder systems<br />
in recent years. However, there are still<br />
some lingering prejudices and doubts<br />
about this technology, and some of<br />
them are hard to break down. Statements<br />
like the following are constantly<br />
being made: Inorganic cores show<br />
a lower dimensional accuracy when<br />
casting, tend to have higher core fracture<br />
and are unstable to moisture and<br />
therefore cannot be coated with water.<br />
The waste sand cannot be regenerated,<br />
the casting surfaces show more sand<br />
accumulations, the cores have worse<br />
shake-out performance and inorganics<br />
are not suitable for iron casting.<br />
Some of these statements are incorrect,<br />
some of them are certainly essentially<br />
correct and others are being<br />
disproved by new developments in inorganic<br />
binders.<br />
In addition, the following statement<br />
is also frequently encountered: “We really<br />
only want an inorganic cold box<br />
system and nothing more!”<br />
However, chemically speaking, they<br />
are worlds apart. By its very nature,<br />
chemistry sets specific limitations here<br />
that are hard to overcome.<br />
Even so – as recent developments in<br />
particular have shown – the new products<br />
are mainly aimed at closing the<br />
gap on traditional methods. Examples<br />
of how this has been achieved in several<br />
sectors, sometimes even exceeding<br />
expectations, are provided below.<br />
Casting surfaces<br />
It is well known that the requirements<br />
for casting surface quality are high.<br />
Foundries spend a great deal of time and<br />
money to meet the growing demands.<br />
In some cases, this also involves investment<br />
in secondary measures in blanks<br />
processing, for instance in blasting sys-<br />
Casting Plant & Technology 2/<strong>2015</strong> 17
K COREMAKING<br />
tems. Of course, the desire to eliminate<br />
many such measures is a factor here, but<br />
there is always something of a discrepancy<br />
between what is technically feasible,<br />
what is asked for and what is viable<br />
in terms of cost. Positive effects on<br />
casting surface quality are attributed to<br />
organic binders for two reasons: firstly<br />
the resulting anthracite layer that forms<br />
a protective barrier between the casting<br />
Figure 2: Sample casting AL 226, 720 °C<br />
Figure 3: Mechanism of action of the new generation of promoters<br />
Figure 4: Optimization of the casting result with the new Inotec TC 4000 promoter<br />
and the core, and secondly the resulting<br />
gas cushion that counters the metallostatic<br />
pressure, thus making it harder<br />
for the metal to penetrate the sand<br />
structure and for penetrations to occur.<br />
Neither can be expected with inorganic<br />
binders, firstly because there are no<br />
combustion products and secondly because<br />
the resulting gas volume (water<br />
+ air) is much lower than with organic<br />
binder systems. It is therefore clear<br />
that another approach must be found<br />
for inorganics in order to counter penetrations<br />
and sand accumulation. But<br />
what factors in the casting process actually<br />
have a positive or negative impact<br />
on penetrations (Figure 1)?<br />
One obvious factor is the casting<br />
temperature or the thermal energy that<br />
acts on the cores in the casting process,<br />
which is clearly indicated by the fact<br />
that more penetrations occur in the<br />
“hot spots” and in the gate region in<br />
particular. The casting pressure also<br />
shows a significant effect. For instance,<br />
in low-pressure permanent mold casting,<br />
a considerable impact on surface<br />
quality is observed if the casting pressure<br />
changes even slightly. There is often<br />
a very fine line between cold laps<br />
and penetration here. To enable new<br />
solutions to be developed for the series<br />
production process in the foundry,<br />
one thing is absolutely crucial: The<br />
problems and questions encountered<br />
in the foundry must be broken down<br />
to laboratory and technology-center<br />
scale in such a way that the casting errors<br />
to be rectified can be reconstructed<br />
or even caused. In the case of optimization<br />
of penetrations, this was carried<br />
out with a gradual increase in the casting<br />
pressure until the casting result in<br />
the technology center matched that<br />
of the foundry. At this point, modification<br />
of the system was started, and the<br />
surface quality was gradually improved<br />
through evaluation of the casting results<br />
and corresponding optimization loops<br />
until the result shown in Figure 2 was<br />
attained. Figure 3 shows how the mechanism<br />
of action that leads to this positive<br />
casting situation can be visualized.<br />
Components that reduce the wetting of<br />
the sand core surface by the metal are<br />
incorporated in the binder system. In<br />
addition, compaction of the core is increased<br />
by adding the new ingredients,<br />
thus making it harder for the metal to<br />
penetrate the gaps of the sand core surface.<br />
Together, the two effects lead to a<br />
considerable reduction in visible penetration<br />
on the casting. By taking this<br />
mechanism of action into account, areas<br />
where reworking was previously essential<br />
can now be completed without<br />
processing (Figure 4).<br />
18 Casting Plant & Technology 2/<strong>2015</strong>
Core disintegration – shakeout<br />
In the past, removing the cores of cast<br />
pieces that were produced using inorganic<br />
binders was often quite a challenge<br />
in the area of water jackets, especially<br />
if the core removal system had<br />
only a few degrees of freedom. At the<br />
same time, the requirements for the residual<br />
dirt content of components are<br />
becoming increasingly strict. One development<br />
objective should therefore<br />
be to optimize existing systems with<br />
regard to their disintegration behavior<br />
after casting. Insertion of predetermined<br />
breakage points in the binder<br />
bridges, which are not produced until<br />
the casting process, i.e. when thermal<br />
energy penetrates, significantly improves<br />
the disintegration properties as<br />
Figure 5 clearly shows. With the Inotec<br />
WJ 4000 promoter, complex and<br />
filigree water jacket cores can now be<br />
removed safely from the component<br />
again after casting (Figure 5).<br />
Dimensional accuracy when<br />
casting<br />
To achieve both increased engine output<br />
and low fuel consumption, one essential<br />
requirement is an effective cooling<br />
concept for new cylinder heads and<br />
blocks. The resultant complexity and<br />
low wall thicknesses of the water jackets<br />
necessitate a high degree of thermal<br />
resistance during casting. Otherwise<br />
there is a risk of deformations, which<br />
lead to the scrapping of the component.<br />
For this reason, warm-box and<br />
Croning systems have been used with<br />
organic systems, especially with particularly<br />
critical deformation-prone water<br />
jacket cores as these systems have very<br />
high heat resistance. Inorganic systems<br />
can show plastic behavior without a corresponding<br />
modification in the casting<br />
temperature range of the aluminum and<br />
therefore have a tendency to deform.<br />
A rough description of this behavior<br />
is that the silicate softens like molten<br />
glass, thus becoming deformable under<br />
stress. The difference between a system<br />
that is optimized in terms of thermal resistance<br />
and a system that has not been<br />
modified is shown in the hot-distortion<br />
measurement in Figure 6. Whereas<br />
the non-optimized system has very<br />
fast bending, the heat-stable system<br />
Figure 5: Optimization of shake-out performance after casting with the Inotec<br />
WJ 4000 promoter<br />
Figure 6: Hot-distortion measurement of two inorganic systems (orange: not<br />
optimized, blue: thermal stability increased)<br />
has a much more “stable” characteristic<br />
curve.<br />
If a casting test is performed with<br />
both systems, the picture is also clear.<br />
When the thermally unstable system is<br />
used, clear differences in wall thickness<br />
are apparent, which suggests a massive<br />
amount of deformation during casting.<br />
By contrast, the thermally stable<br />
mixture produces a dimensionally accurate<br />
casting (Figure 7).<br />
Heating microscopy is an extremely<br />
suitable method of examining the resistance<br />
of the binder systems. Here, a rectangular<br />
test specimen of the material is<br />
put into a furnace and the softening and<br />
melting behavior is recorded in real time<br />
with a camera. The differences between<br />
the systems are also clearly apparent<br />
with this measuring method. In the case<br />
of the non-thermally optimized sample,<br />
softening is discernible at 778 °C,<br />
whereas the more thermally stable mixture<br />
only loses its geometric rectangular<br />
shape at 1,310°C (Figure 8). In this way,<br />
systems can be assessed in terms of their<br />
thermal behavior and their effectiveness<br />
at preventing deformations.<br />
Casting Plant & Technology 2/<strong>2015</strong> 19
K COREMAKING<br />
Figure 7: Optimization of dimensional<br />
accuracy as a result of increased<br />
thermal stability<br />
Figure 8: Heating microscope measurements (non-optimized and more thermally<br />
stable system)<br />
New casting-related potential<br />
Many positive influences of inorganic<br />
series core manufacture on the foundry<br />
process have already been described:<br />
Odorless core production, odor-reduced<br />
casting, significantly less cleaning<br />
of machines and tools and the resulting<br />
higher output quantity and<br />
productivity as well as the advantages<br />
in terms of casting, such as faster solidification<br />
enabled by a lowering of ingot<br />
mold temperatures, are well-known advantages<br />
of the inorganic technology.<br />
In particular, the absence of combustion<br />
residue gives component developers<br />
new freedoms that they did not<br />
previously have with organic-based<br />
binding agents. One impressive example<br />
is the new central feed principle,<br />
which is used at BMW’s plant for<br />
crankcases of future engine generations<br />
[1,2] in Landshut, Germany. Inorganic<br />
cores are used as central feeders<br />
here, thus minimizing the risk of sooting<br />
ventilation ducts in the low-pressure<br />
permanent mold. This concept<br />
is not feasible with organic cores. The<br />
DAS distribution of the three concepts<br />
is shown in Figure 9. It is apparent that<br />
the new central feeder concept leads to<br />
DAS advantages in all component areas.<br />
The warmest point (thermal center,<br />
binding of the feeder) and therefore<br />
the point with the highest local DAS is<br />
in the area of the lower dead center of<br />
the piston, a point that is not subject to<br />
excessive thermal or mechanical stress.<br />
The tension rod area also solidifies very<br />
quickly and can be influenced externally<br />
via the permanent mold. The tendency<br />
towards leaking after mechanical<br />
processing falls dramatically, and<br />
the sealing rates are miniscule.<br />
Figure 9: Central feeding concept utilizing inorganic cores in low pressure die casting<br />
20 Casting Plant & Technology 2/<strong>2015</strong>
Figure 10: Test casting of step core, GJL, 1,458 °C (left: Cold Box with additive, right: Inotec)<br />
Iron casting<br />
Use of modern inorganic binders in<br />
iron casting (core hardening with a<br />
hot tool and hot air, not CO 2<br />
) is not yet<br />
widespread. This is probably because –<br />
in contrast with light-alloy permanent<br />
mold casting – the process sequence<br />
and the sand system are regarded as<br />
more complex, the casting temperatures<br />
are around twice as high, and therefore<br />
the requirements for thermal resistance<br />
much higher. In addition, in the case of<br />
inorganic binders, the cold box method<br />
is superior to the largely physical (drying)<br />
process in terms of productivity in<br />
many areas, particularly if the core geometries<br />
become bigger and bulkier.<br />
Even so, inorganics have considerable<br />
potential, particularly in iron casting. In<br />
particular, problematic parts that need<br />
to be worked on with special sands or<br />
additives in combination with a coating<br />
against veining, are predestined for use<br />
of inorganic binders since they show a<br />
much lower tendency towards veining<br />
– or indeed none at all – compared<br />
with organic systems. Figure 10 shows<br />
test castings from step cores in GJL,<br />
1,458 °C. The casting of a cold box system<br />
with an additive and the one with<br />
an inorganic system are shown. One<br />
half of each of the cores was coated. It<br />
is clearly apparent that the coated and<br />
uncoated sides of the inorganic core are<br />
completed better and have fewer penetrations<br />
right through to the final stage,<br />
i.e. the stage with the highest thermal<br />
stress. This figure also reflects initial<br />
experience from foundry operations,<br />
where inorganic cores can be used successfully<br />
in a targeted manner to reduce<br />
veining, penetrations and gas. There is<br />
no doubt that even more positive news<br />
can be expected from this area of application<br />
in future.<br />
Optimization of moisture resistance<br />
and coating resistance of<br />
inorganic cores<br />
Moisture stability has always been the<br />
Achilles’ heel of inorganic cores. This<br />
is because of the nature of the chemistry.<br />
Binding agents are based on<br />
silicates that are dissolved in water,<br />
known as water glass. Water is thus<br />
the solvent in the system. In addition,<br />
the hardening reaction is largely<br />
reversible (balanced reaction). This<br />
means that when large amounts of<br />
energy and water are present (e.g. in<br />
the case of high air humidity and high<br />
temperatures), the back reaction takes<br />
place and the cross-linking of the silicates<br />
is reversed, resulting in the cores<br />
losing their strength and breaking<br />
down. This can be prevented by removing<br />
water from this balance, i.e.<br />
through storage in a dry place. Since<br />
the latter is not always easily possi-<br />
Figure 11: Moisture (green) and strength pattern (numerical values) of watercoated<br />
inorganic cores during furnace drying<br />
Casting Plant & Technology 2/<strong>2015</strong> 21
K COREMAKING<br />
ble in practice, additives (known as<br />
promoters) are used to significantly<br />
delay the back reaction, thereby allowing<br />
the cores to be handled in a<br />
process-consistent manner, even after<br />
“normal” storage. However, inorganic<br />
cores remain hydrophilic. An even<br />
greater challenge is coating the cores<br />
with a water-based coating because<br />
the water acts on the core directly and<br />
in concentrated form. Application of<br />
the water coating on the cold core is<br />
not critical at first but becomes critical<br />
by the time the coating is to be dried<br />
in the oven. Then, the process shown<br />
in Figure 11 takes place. Before coating,<br />
the cold core has a strength level<br />
of 460 N/cm². The core is coated and<br />
starts its “furnace journey.” Because<br />
of the high temperatures (150 °C)<br />
and the water present, the relative air<br />
humidity rises rapidly, which makes<br />
the core increasingly weak and causes<br />
the strength level to fall from 295<br />
to 120 N/cm². When the turnaround<br />
point is reached, i.e. the maximum air<br />
humidity falls again, the drying process<br />
of the coating continues and the<br />
core reaches its minimum strength,<br />
probably the most critical point in the<br />
furnace drying process. It is now determined<br />
whether the core withstands<br />
the stress, deforms or even breaks. If<br />
it gets through this critical phase, at<br />
the end of its furnace journey, the<br />
core will have a highly respectable final<br />
strength of as much as 260 N / cm²<br />
when hot and as much as 360 N/cm²<br />
when cold. The final strength of a<br />
coated core may therefore be quite<br />
high. The main critical factors are the<br />
drying process and the temporarily air<br />
humidity levels in conjunction with<br />
the high temperatures in the furnace.<br />
Consequently, the major chemical<br />
challenge is transferring a water-soluble<br />
system – as this is what inorganic<br />
binders are – to a moisture-resistant<br />
Figure 12: Strength pattern of water-coated cores during furnace drying<br />
(green: standard system, blue: optimized system)<br />
state as much as possible after hardening.<br />
In this respect, Figure 12 shows<br />
the result of the latest research, namely<br />
the moisture level of coated cores in<br />
two binder systems in relation to the<br />
dwell time in the drying furnace. The<br />
standard system shows the strength<br />
pattern portrayed here, with a minimum<br />
strength of approx. 90 N/cm².<br />
Although the second system essentially<br />
has a somewhat lower initial<br />
strength level, it only drops to a figure<br />
of approx. 250 N/cm² during furnace<br />
drying. This means that in relative<br />
terms, the cores produced with<br />
this optimized binder system lose<br />
a maximum of 30 % of their initial<br />
strength, while the standard system<br />
loses approx. 80 % of its strength. It<br />
can also be seen again here that the<br />
final strength rises back to a very acceptable<br />
level in both cases, i.e. after<br />
complete drying and cooling, provided<br />
that the cores come through furnace<br />
drying intact. The optimized<br />
binder system is currently undergoing<br />
testing by the customer and, if the results<br />
are confirmed, this could possibly<br />
broaden the process scope of inorganic<br />
binder systems even further,<br />
either in the use of these binder systems<br />
under non-optimum climatic<br />
conditions or in use with water coatings,<br />
which could particularly benefit<br />
the introduction of inorganic binders<br />
in iron casting.<br />
Summary<br />
Inorganic binders are subject to more<br />
rumors than almost any other area of<br />
foundry work. What can they actually<br />
do, and what can’t they do? The growing<br />
interest and increasing number of<br />
users clearly show that this technology<br />
is now an established part of aluminum<br />
permanent mold casting at least.<br />
The cost savings in terms of maintenance<br />
and cleaning of the systems as<br />
well as the resultant higher productivity<br />
in the casting process are key factors<br />
in this success. At the same time,<br />
new development stages of the binders<br />
are closing the gap on organic systems:<br />
Better casting surfaces, higher<br />
thermal stability and optimization of<br />
disintegration after casting have been<br />
significant optimization steps of the<br />
last generation of inorganic binders.<br />
And there are also signs of progress in<br />
improving the storage stability of the<br />
naturally moisture-sensitive inorganic<br />
cores. At the same time, it is clear<br />
that the use of inorganic cores does<br />
not have to be limited to light-alloy<br />
permanent mold casting as inorganics<br />
offer huge potential in prevention<br />
of classic casting defects (such as veining).<br />
“Nothing is impossible” is therefore<br />
a very fitting phrase for the core<br />
of development in the inorganic sector:<br />
Much of what has been achieved<br />
with inorganic binders to date would<br />
have seemed impossible to many people<br />
in the past. As a result of intensive<br />
research in this field, it can be assumed<br />
that so many hurdles that seem restrictive<br />
at the moment will be cleared in<br />
future.<br />
www.ask-chemicals.com<br />
References:<br />
www.cpt-international.com<br />
22 Casting Plant & Technology 2/<strong>2015</strong>
EXTRUSION + DIECASTING + FOUNDRY + ROLLING + FINISHING + MACHINING + FABRICATING + RECYCLING<br />
21-24 JUNE 2017 VERONA-ITALY<br />
INTERNATIONAL FOUNDRY<br />
EQUIPMENT EXHIBITION<br />
EXPO OF CUSTOMIZED TECHNOLOGY<br />
FOR THE ALUMINIUM & INNOVATIVE METALS INDUSTRY<br />
Organized by<br />
www.metef.com
K COREMAKING<br />
Authors: Dr. Raimund Rösch, Thomas Dichter, Dr. Ferdinand Hansen, Günter Jäger and Sven Uhde, Volkswagen AG,<br />
Hanover Foundry<br />
Fully linked inorganic core production<br />
at Volkswagen’s cylinder head<br />
foundry<br />
Fully linked inorganic core production at Volkswagen (Photos and Graphics: Volkswagen Foundry Hannover)<br />
Inorganic core production is now used in many foundries in Germany, particularly for the automotive<br />
sector. Exploiting the knowledge and experience gained from over ten years of serial production<br />
of intake manifolds and cylinder heads with inorganic cores a fully linked inorganic core<br />
shooting unit was put into operation at Volkswagen foundry in Hanover in 2012. The plant design<br />
is presented here. It reflects the results of a previous planning workshop with all those involved,<br />
including plant operators, the Planning Department and Quality Assurance. The process<br />
consists of core material preparation, core shooting, automatic deburring and transport by robot,<br />
deposition on trays before placement of each two core packages in the double mold on the<br />
casting turned table. The technical and scientific interrelationship of inorganic core technology is<br />
presented. The core properties are illustrated by way of hot and cold bending strengths in the<br />
production process. Finally, the advantages of inorganic core technology are summarized<br />
24 Casting Plant & Technology 2/<strong>2015</strong>
Figure 1: Process of inorganic core production: mixing of sand, binder and additives – shooting of the molding material<br />
into the core box – hardening of the core by the heated tool and heated air – removal of the core<br />
Inorganic core making is now found in<br />
many foundries in Germany, particularly<br />
for the production of castings in<br />
the automotive sector. Industrial-scale<br />
inorganic core making is still a challenge,<br />
particularly with respect to integrated<br />
process chains, robotic and<br />
tray handling, and under extreme climatic<br />
conditions.<br />
Exploiting the knowledge and experience<br />
gained from over ten years of serial<br />
production of intake manifolds and<br />
cylinder heads with inorganic cores a<br />
fully linked inorganic core shooting<br />
unit was put into operation at Volkswagen<br />
foundry in Hanover in 2012.<br />
Inorganic core shooting process<br />
including core hardening<br />
The process of inorganic core production<br />
consists of four steps. It begins<br />
with the mixing of weighed quantities<br />
of silica sand, additives and binders<br />
for the molding material. In a second<br />
step, the molding material is<br />
transported to the core shooter and<br />
shot into the core box. In a third step,<br />
Figure 2: Binder bridges in the core (scanning electron microscope photo)<br />
the core is hardened by means of the<br />
heated core tool and heated purging<br />
or gassing air. Finally, the core box<br />
is opened, the finished core is ejected<br />
and ready for further processing<br />
(Figure 1).<br />
A purely inorganic molding material<br />
system consists of silica sand (SiO 2<br />
),<br />
binder (a modified silicate solution)<br />
and additives (synthetic and natural<br />
minerals). The hardening process is a<br />
condensation process, creating a sol-<br />
Casting Plant & Technology 2/<strong>2015</strong> 25
K COREMAKING<br />
Figure 4: Schematic diagram of the<br />
chemical structure of a binder bridge.<br />
the binder bridge, while the carbon derives<br />
from sample preparation for scanning<br />
electron microscopy (Figure 4).<br />
Figure 3: EDX analysis of a binder bridge.<br />
id silicic acid (silicate). The inorganic<br />
core has sufficient handling strength.<br />
The microscopic structure of the inorganic<br />
core compound has been examined<br />
with the help of scanning electron<br />
microscopy (Figure 2). 30 to 60 % of the<br />
surfaces of the silica sand grains are<br />
coated with the binding agent (binder<br />
with additives). The gaps between sand<br />
grains are filled with the binding agent,<br />
forming binder bridges. A stable binder<br />
bridge can be recognized from its crackfree<br />
structure. The structure of a binder<br />
bridge has been examined using energy<br />
dispersive X-ray spectroscopy (EDX).<br />
The presence of the chemical elements<br />
Al, Si, Na, C and O could be determined<br />
(Figure 3). Si, O and Na are elements of<br />
The core assembly plate and<br />
the casting<br />
The core production process described<br />
here is part of the manufacturing line<br />
1.4 liter TSI for engine power output 90<br />
kW to 110 kW, e.g. in the Golf 7, Passat,<br />
Audi A3 and Seat Leon. The core package<br />
consists of seven cores (Figure 5):<br />
» water jacket core,<br />
» inlet port core,<br />
» outlet port core,<br />
» core for the water-cooled integrated<br />
exhaust manifold,<br />
p core<br />
a<br />
Top core<br />
Insert core<br />
Outlet Insert sidecore<br />
Outlet side<br />
t core<br />
Core for water-cooled<br />
integrated exhaust manifold<br />
Core for water-cooled<br />
integrated exhaust manifold<br />
Water jacket core<br />
Outlet port core<br />
Outlet port core<br />
Integrated exhaust<br />
manifold<br />
Integrated exhaust<br />
manifold<br />
b<br />
Inlet side<br />
Inlet side<br />
ort core<br />
Blow-by core<br />
Inlet port core<br />
Blow-by core<br />
Figure 5: The 1.4 liter TSI cylinder head (EA211): a) outlet side with cores, b) inlet side with cores<br />
26 Casting Plant & Technology 2/<strong>2015</strong>
AlSi10Mg(Cu)<br />
from melting plant<br />
KSM 1<br />
KSM 1 Water<br />
core / watercooled<br />
integrated<br />
exhaust manifold<br />
X2<br />
KSM 3<br />
Top core/insert<br />
core x2<br />
KSM 1<br />
Inlet/outlet/blowby<br />
x2<br />
KSM 4<br />
Top core/insert<br />
core x2<br />
Casting carousel<br />
6 double<br />
casting<br />
machines<br />
Cooling store<br />
Figure 6: Production concept for the 1.4 liter TSI cylinder head (EA211)<br />
» blow-by core,<br />
» insert core,<br />
» top core.<br />
The cores have a total weight of 17 kg.<br />
The casting alloy is AlSi10Mg(Cu). The<br />
as-cast weight is 22 kg; after first-cut<br />
machining the cylinder head weighs<br />
13 kg.<br />
Production concept<br />
The production process of the cylinder<br />
heads is based on a decentralized<br />
concept. Inorganic core shooting and<br />
the preparation of the aluminum alloy<br />
takes place next to the casting<br />
equipment, which consists of a casting<br />
turned table with six double casting<br />
machines. Four core shooting machines<br />
supply cores to the casting<br />
turned table (with a diameter of 12<br />
m). After pouring and solidification,<br />
the cylinder heads are removed from<br />
the molds and placed in the cooling<br />
store (Figure 6).<br />
Figure 7: Transport vehicle (left) after<br />
being filled from the mixing<br />
drum (right)<br />
Production sequence<br />
The basic molding materials – silica<br />
sand, additives and binders – are stored<br />
in silos and containers in the sand<br />
preparation plant. All three basic materials<br />
are automatically weighed according<br />
to a defined recipe, and placed<br />
in a vertical mixer. The mixing process<br />
takes about 2 min. The mixer empties<br />
into a transport vehicle (Figure 7),<br />
which takes the molding material to<br />
the core shooting machine, the vehicle<br />
releases the molding material into the<br />
supply hopper of the core shooting machine<br />
through the opened base flap. After<br />
shooting and hardening of the core<br />
it is removed from the opened core tool<br />
by a robot-operated gripper and placed<br />
upon a conveyor belt (Figure 8). The<br />
two types of water jacket cores are automatically<br />
deburred by robots at a special<br />
workstation on the way to the conveyor<br />
belt (Figure 9).<br />
a<br />
b<br />
Figure 8: Water jacket core (a) and<br />
inlet & outlet port cores (b) made<br />
using inorganic core production<br />
Figure 9: Robots deburr the water jacket cores<br />
Casting Plant & Technology 2/<strong>2015</strong> 27
K COREMAKING<br />
a<br />
a<br />
b<br />
b<br />
Figure 11: Core inspection<br />
Figure 10: Positioning of plant components<br />
for core production: a) 3P<br />
model in the planning workshop, b)<br />
identical real plant design<br />
At the end of the conveyor belts, employees<br />
remove the water jacket and<br />
port cores by hand, inspect them for<br />
any incomplete contours, and place<br />
them by hand directly opposite on<br />
trays at the end of the conveyor belt.<br />
The arrangement and positions of the<br />
four core shooting machines had been<br />
worked out two years before commissioning<br />
in a production/planning/process<br />
workshop (3P) . All workplaces had<br />
been modelled in cardboard and all processes<br />
had been simulated. Even the cycle<br />
time had been determined. The real<br />
plant components were designed based<br />
on these full-scale models, followed by<br />
successful installation and commissioning<br />
(Figure 10a). These 3P workshops<br />
have proved highly successful<br />
and are used for all production facilities<br />
of the Volkswagen group.<br />
A roller conveyor system transports<br />
the trays with the water jacket and port<br />
cores from the two core placement stations<br />
to the casting turned table. On<br />
the way, the trays pass an inspection<br />
camera that checks the completeness<br />
of cores (five pieces) (Figure 11).<br />
Top cores and insert cores are made<br />
on two core shooting machines located<br />
opposite to first mentioned machines,<br />
removed from the opened<br />
core tools by a frame gripper, held still<br />
in the beam path of another illumination<br />
and camera system for inspection<br />
(Figure 12) and, if the core contour is<br />
in order (Figure 13) added to the tray.<br />
Figure 12: Corevision camera and<br />
illumination system: a) removal gripper<br />
with cores, b) system during<br />
illumination (green)<br />
The core package with seven cores<br />
is now complete and has a weight of<br />
17 kg (Figure 14). The cycle time per<br />
core package is 30 seconds.<br />
The manufacturing sequence is<br />
based on a linked production concept<br />
without a core depot. The distance between<br />
core deposition on trays and<br />
placement of the complete core package<br />
in the mold on the casting turned<br />
table is just 12 meters.<br />
A robotic gripping arm picks up two<br />
core packages from the trays on the conveyor<br />
belt (Figure 15), rotates through<br />
Figure 13: Monitor display showing inspection results<br />
for completeness of core contours with ‘in order’ findings<br />
Figure 14: Complete core package. It consists of seven<br />
cores and has a weight of 17 kg. Per core package the<br />
cycle time is 30 seconds<br />
28 Casting Plant & Technology 2/<strong>2015</strong>
Figure 15: Detailed view of gripper<br />
Figure 16: Placement of the core packages in the double<br />
casting machine<br />
180°, and places them into the waiting<br />
double casting machine (Figure 16).<br />
The double casting machine moves to<br />
the next station and the two molds are<br />
simultaneously filled with molten aluminum<br />
alloy from two ladles. The aluminum<br />
solidifies, while the turned table<br />
continues to turn. Then the cylinder<br />
heads are removed.<br />
Smoothly linked core production requires<br />
rapid core hardening. This is provided<br />
by the Cordis binder system from<br />
Hüttenes-Albertus Chemische Werke<br />
GMBH in Düsseldorf, Germany. The<br />
hot and cold bending strengths of all<br />
water jacket and port cores produced<br />
from May to July 2014 are represented<br />
in the graphs shown in Figure 17 and<br />
have a low amount of scatter.<br />
Hot bending strength Water<br />
cores in N/cm²<br />
Cold bending strength Water<br />
cores in N/cm²<br />
205<br />
190<br />
170<br />
465<br />
440<br />
425<br />
Production days from May to July 2014<br />
Summary<br />
The advantages of inorganic core technology<br />
compared to organic systems<br />
can be summarized as follows:<br />
» no emissions, no mold and room extraction<br />
systems required,<br />
» no deposits (condensate) in casting<br />
tool (Figure 18),<br />
» ideal conditions for cooling base<br />
plate,<br />
» low tool wear,<br />
Hot bending strength Port<br />
cores in N/cm²<br />
200<br />
185<br />
170<br />
Production days from May to July 2014<br />
Production days from May to July 2014<br />
Figure 17: Scattering of mechanical<br />
properties of inorganic cores produced<br />
from May to July 2014: hot bending<br />
strength of water jacket cores;<br />
cold bending strength of water jacket<br />
cores; hot bending strength of<br />
port cores; cold bending strength of<br />
port cores (from top to bottom)<br />
Cold bending strength Port<br />
cores in N/cm²<br />
500<br />
460<br />
435<br />
Production days from May to July 2014<br />
Casting Plant & Technology 2/<strong>2015</strong> 29
K COREMAKING<br />
Figure 18: Base plate of a serial mold after 6 hours of operation<br />
The absence of pyrolysis products<br />
in the inorganic process leads to improved<br />
tool and casting product properties,<br />
prevents investments in extraction<br />
systems, and simplifies the<br />
obtaining of operation approval from<br />
factory inspectorate.<br />
Inorganic core technology for cylinder<br />
head production is series-proven.<br />
The cores thus produced are suitable for<br />
handling by robotic grippers as well as<br />
for transport on tray systems.<br />
A specifically selected inorganic<br />
binder system combined with optimally<br />
adjusted core hardening in a heated<br />
core tool with heated purging air is ideal<br />
for cylinder head production in a directly<br />
linked flow.<br />
» longer mold service life (>8 weeks),<br />
» improved dimensional accuracy of<br />
castings,<br />
» ideal for linked production,<br />
» improved prerequisites for approval<br />
of operation by factory inspectorate.<br />
www.volkswagen.com<br />
Setting The Standards For Highest<br />
Efficiency In Thermal Processing<br />
10A19<br />
JASPER<br />
PulsReg® Zentral Regenerator, 12 MW<br />
Gesellschaft für Energiewirtschaft und Kybernetik mbH / Bönninghauser Str. 10 / D-59590 Geseke<br />
Telefon: +49 2942 9747 0 / Fax: +49 2942 9747 47 / www.jasper-gmbh.de / info@jasper-gmbh.de<br />
30 Casting Plant & Technology 2/<strong>2015</strong>
www.sinto.com<br />
16 th - 20 th June <strong>2015</strong><br />
Duesseldorf,<br />
Germany<br />
Hall 17<br />
Stand 17 B 20<br />
• SEIATSU- / ACE-Moulding Machines and Plants<br />
• FBO- / FDNX-Flaskless Moulding Machines and Plants<br />
• VACUUM Moulding Machines and Plants<br />
• POURING UNITS – semi and fully automatic<br />
• SOFTWARE FOR MOULDING AND POURING LINES<br />
HEINRICH WAGNER SINTO Maschinenfabrik GmbH<br />
SINTOKOGIO GROUP<br />
Bahnhofstrasse 101 · 57334 Bad Laasphe, Germany<br />
Phone +49 (0)2752 907-0 · Fax +49 (0)2752 907-280<br />
www.wagner-sinto.de
K MELTING SHOP<br />
Meltshop at Gienanth in Eisenberg (Photos + graphics: Linde AG)<br />
Authors: Heinz Kadelka and Matthias Dusil, Linde Gas Düsseldorf, Gerd Werner, Linde Gas Mainz, Mike Weber, Gienanth<br />
GmbH, Eisenberg, and Ulrich Matschkewitz, Dako coal GmbH, Essen<br />
Gienanth foundry tests PET oxygen<br />
technology<br />
Pulverized petroleum coke (petcoke) is an efficient and cost-saving alternative to conventional<br />
coke as fuel for foundry shaft furnaces. However, in order for the material to be used in the best<br />
possible way, new processes and plants are needed. Linde has developed such a solution: the<br />
TDI-PET technology based on the TDI blowing nozzle injection method. The process has been<br />
tested at Gienanth GmbH, based in Eisenberg, Germany<br />
Over the last few decades, there have<br />
been repeated efforts to use alternative<br />
fuels in shaft furnaces, especially cupola<br />
furnaces. However, ultimately no<br />
field tests were able to prove this to be<br />
viable alternative. The problems posed<br />
by the transport of the material were<br />
too big to overcome. It was impossible<br />
to achieve stable and wear-free feeding.<br />
One key cause of the problem was the<br />
abrasiveness of the various fuels, i. e.<br />
their abrasive effect on surfaces. However,<br />
today we can make use of a material<br />
which features all properties needed<br />
to ensure smooth and wear-free feeding<br />
and an optimal energy exchange,<br />
namely petroleum coke or petcoke.<br />
Pulverized petcoke – origin<br />
and properties<br />
Between 600,000 and 700,000 t of<br />
fuel-grade petcoke are produced every<br />
year at refineries in Germany. Petcoke<br />
is obtained in the last stage of mineral<br />
oil processing. Due to the various<br />
upstream distillation steps aimed<br />
at maximizing the yield of mineral<br />
oil based products, the coke produced<br />
in the delayed coking process<br />
features only very little variations in<br />
combustion properties. Its most outstanding<br />
feature is the extremely low<br />
ash content of less than 1 %, leading<br />
32 Casting Plant & Technology 2/<strong>2015</strong>
Figure 1: Flow diagram of the petcoke feeding plant supplied by Dako GmbH<br />
Figure 2: Manifold at the furnace<br />
to a constantly high carbon content<br />
above 90 %.<br />
In a downstream combined drying<br />
and grinding process, the crude petcoke<br />
is processed into pulverized petcoke.<br />
In order to ensure reliable conveying<br />
of the pulverized material it is<br />
necessary to achieve a residual moisture<br />
content below 1%. Combined<br />
with a low ash content, the pulverized<br />
petcoke supplied by Dako Coal<br />
GmbH, based in Essen, Germany, features<br />
a guaranteed calorific value above<br />
34,000 kJ/kg, making it the commercially<br />
available solid fuel with the<br />
highest calorific value.<br />
Compared to other pulverized fuels,<br />
especially pulverized lignite, pulverized<br />
petcoke is a low-reactivity fuel<br />
(ignition temperature at around<br />
700 °C) due to its low content of volatile<br />
matter (< 10 %). In order to be able<br />
to fulfill the igniting and combustion<br />
requirements for use in industrial furnaces,<br />
the petcoke must be ground in<br />
a sophisticated process down to a fineness<br />
of R 0.09 mm < 6 %.<br />
The soft structure of the crude petcoke<br />
produced in Germany (HGI > 70)<br />
gives the powder properties similar to<br />
graphite. Thanks to these properties, it<br />
is ideally suited for quasi abrasion-free<br />
Runner iron temp. in °C<br />
1510<br />
1505<br />
1500<br />
1495<br />
1485<br />
1480<br />
pneumatic conveying. In spite of its<br />
large surface area, pulverized petcoke<br />
can be considered as non-explosive, in<br />
contrast to other solid fuels in powder<br />
form. When a plant is designed, the<br />
risk assessment generally reveals that<br />
there is no need to implement any constructional<br />
(tertiary) explosion protection<br />
measures. The safety-related plant<br />
engineering requirements are limited<br />
to measures that avoid the occurrence<br />
of ignition sources (primary and secondary<br />
measures).<br />
R-Temp.<br />
PET kg/h<br />
1475<br />
08:38 08:45 08:52 09:00 09:07 09:14 09:21<br />
Time<br />
Figure 3: Effect of petcoke rate on runner iron temperature<br />
260<br />
250<br />
240<br />
230<br />
220<br />
210<br />
190<br />
Petcoke feeding rate in kg/h<br />
Petcoke in a cupola – a longterm<br />
test<br />
Only a long-term test was considered<br />
to be suitable to provide reliable and<br />
conservative information about the<br />
use of petcoke in cupola furnaces.<br />
Linde conducted such a test together<br />
with Dako Coal GmbH. As early as in<br />
2012, at the <strong>International</strong> Cupola Day<br />
in Dresden, Germany, Linde and Dako<br />
presented their first petcoke project: At<br />
the Weilbach plant of Linde Material<br />
Handling GmbH, they tested the fuel<br />
Casting Plant & Technology 2/<strong>2015</strong> 33
K MELTING SHOP<br />
Figure 4: Installed TDI-PET system<br />
Section<br />
Scale<br />
Figure 5: Functional principle of the PET lance in the TDI tube<br />
Figure 6: TDI-PET feeding system inside a water-cooled Cu nozzle<br />
in a long-campaign cold blast cupola<br />
plant. During a period of one year, aspects<br />
of wear, sulfurization and feeding<br />
accuracy could be studied.<br />
Several examinations by the German<br />
Institute of Foundry Technology<br />
(Institut für Gießereitechnik IfG)<br />
and other institutions confirmed that<br />
the use of petcoke as fuel did not have<br />
any negative influence on the off-gas,<br />
slag or metallurgy. Convinced by these<br />
results, the iron foundry Gienanth<br />
GmbH, based in Eisenberg, Germany,<br />
agreed to use Linde’s pet-coke-based<br />
TDI-PET system in production. Dako<br />
adapted the conveying equipment to<br />
the specific conditions of the existing<br />
cupola plant.<br />
The Gienanth foundry<br />
Gienanth GmbH is a foundry with<br />
most state-of-the-art manufacturing<br />
equipment and vast know-how accumulated<br />
during more than 275 years<br />
of company history. Competence and<br />
technological expertise are key elements<br />
of the company’s philosophy.<br />
The 30 t hot blast cupola forms the<br />
centrepiece of the melt shop. In threeshift<br />
operation, the cupola is used to<br />
make both grey cast and ductile iron.<br />
Tasks and objectives of the<br />
pilot plant<br />
Of all contractually specified tasks, safeguarding<br />
maximum security of iron<br />
supply by the cupola had top priority.<br />
To this end, a failure modes and effects<br />
analysis (FMEA) was developed jointly<br />
by all parties involved. The most important<br />
aspects covered by the FMEA were:<br />
» maximum redundancy of the conveying<br />
and feeding systems<br />
» maximum precision of conveying<br />
and distributing between the nozzle<br />
systems<br />
» maximum safety around the conveying<br />
equipment<br />
» economical and ecological benefits<br />
» avoidance of metallurgical problems<br />
» avoidance of problems associated<br />
with sulfurization.<br />
Powder conveying and dosing<br />
plant<br />
When designing and implementing<br />
the powder conveying and dosing sys-<br />
34 Casting Plant & Technology 2/<strong>2015</strong>
tem, the following specifications concerning<br />
the cupola operation had to be<br />
complied with:<br />
» absolute availability<br />
» constant conveying of powder at<br />
a requested rate between 100 and<br />
500 kg/h within the shortest possible<br />
time<br />
» dosing precision<br />
» continuous gravimetric measurement<br />
and verification of the quantities<br />
conveyed<br />
» optimal distribution of the pulverized<br />
fuel to six furnace lines<br />
Due to the positive experience with<br />
the dispensing units used in the Linde<br />
foundry in Weilbach, the basic concept<br />
of this solution was adapted to the<br />
requirements of the Gienanth project.<br />
The dispensing unit was accordingly<br />
adapted and optimized.<br />
Despite the already good flow behaviour<br />
of pulverized petcoke, further<br />
measures were adopted to optimize the<br />
material flow. In addition to modifications<br />
affecting the volume and the geometry,<br />
also mechanical and pneumatic<br />
measures were implemented.<br />
The dispensing unit installed at<br />
Gienanth feeds via three outlets<br />
( Figure 1) which can be coupled with<br />
one another as desired. The current<br />
feeding rate is continuously measured<br />
by gravimetric weighing devices<br />
and checked versus the quantities<br />
required. The conveying accuracy is<br />
higher than 95 %. The target value is<br />
attained in less than three minutes.<br />
The smoothness of the conveying<br />
process allows the use of a manifold<br />
to distribute the pulverized material<br />
into the six furnace lines. Speed flow<br />
meters monitor the even distribution<br />
of the pulverized coke in the feeding<br />
lines (Figure 2).<br />
The entire plant is operated and<br />
controlled via the control room of<br />
the cupola plant. The feeding rate of<br />
pulverized petcoke is set according<br />
to the melting rate, which in turn is<br />
determined by the quantities of added<br />
hot blast and oxygen. Further important<br />
criteria are the CO/CO 2<br />
content<br />
in the top gas, the combustion<br />
chamber temperature and other parameters.<br />
Petcoke rate<br />
ETA in %<br />
C in %<br />
59<br />
58<br />
57<br />
56<br />
55<br />
54<br />
53<br />
3,44<br />
3,42<br />
3,40<br />
3,38<br />
3,36<br />
3,34<br />
3,32<br />
Petcoke rate<br />
Natural gas<br />
Comb. chamber temp.<br />
requirement<br />
( Comb. chamber<br />
temp. )<br />
Figure 7: The petcoke rate indirectly controls the C content of the iron and<br />
the consumption of natural gas<br />
Specifications of the conveying<br />
equipment<br />
When the new process was implemented,<br />
the specifications concerning the<br />
Time<br />
ETA V<br />
C %<br />
08:38 08:45 08:52 09:00 09:07 09:14 09:21<br />
Figure 8: Effect of ETA V on carburization<br />
Comb. chamber<br />
temp.<br />
C % without HIGHJET TDI PET<br />
3,40<br />
3,35<br />
3,30<br />
3,25<br />
C % with HIGHJET TDI PET<br />
08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00<br />
Time<br />
Figure 9: Carbon analyses with and without TDI-PET<br />
C-Content<br />
C-Content<br />
Natural gas<br />
requirement<br />
Carbon content in %<br />
accuracy of the conveying equipment<br />
were redefined. This was necessary because<br />
even very small variations would<br />
affect the metallurgy of the melt and<br />
Casting Plant & Technology 2/<strong>2015</strong> 35
K MELTING SHOP<br />
the furnace operation. The conveying<br />
system, developed by Dako, today operates<br />
with an accuracy of < 5 % petcoke.<br />
There is a direct relationship between<br />
the Boudouard reaction and the<br />
amount of petcoke added (Figure 3).<br />
The basis: TDI-PET technology<br />
Figure 4 shows the TDI-PET installation<br />
at the penstock above the water<br />
seal trough and below the hot blast<br />
duct and the expansion joint. Directly<br />
above the inspection flap, a steel<br />
pipe feeds the petcoke to the oxygen<br />
system. The TDI blowing nozzle injection<br />
system has been arranged to the<br />
right of the penstock.<br />
Runner iron temp. in °C<br />
1515<br />
1510<br />
1505<br />
1500<br />
1495<br />
Runner iron-temp. with HIGHJET TDI PET<br />
As shown in Figure 5, this design allows<br />
the fuel – in this case, pulverized petcoke<br />
– to be guided to the respective TDI-PET<br />
burner lances and carried along by the<br />
HighJet stream. This stream is characterized<br />
by a high impulse and a high<br />
oxygen content. Consequently, a mixture<br />
of pulverized petcoke, pneumatic<br />
air and oxygen can be injected into the<br />
cupola by a high impulse, facilitating<br />
a very deep penetration into the shaft<br />
furnace, whilst optimally exploiting the<br />
energy contained in the fuel.<br />
Thus, the energy required to melt<br />
the charge is not only provided by the<br />
foundry coke but also by the solids injected<br />
by the TDI-PET burner lances.<br />
This allows the furnace operation to<br />
be optimized and the coke rate further<br />
reduced. It is deemed realistic that up<br />
to 22 % of foundry coke can be saved,<br />
depending on the amount of initially<br />
charged coke. Of course, each furnace<br />
must be considered separately.<br />
Figure 6 shows the arrangement<br />
of the TDI-PET lance inside the water-cooled<br />
cooper nozzle. An advantage<br />
is that the injection speed of the<br />
PET 1.25 %<br />
1490<br />
Runner iron-temp. without HIGHJET TDI PET<br />
1485<br />
08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00<br />
Time<br />
Figure 10: Effect on the runner iron temperature (idealized time line)<br />
CO in %<br />
12<br />
11<br />
10<br />
9<br />
8<br />
Burner on<br />
Burner on<br />
CO % with HIGHJET TDI PET<br />
Burner on Burner on Burner on<br />
CO % without HIGHJET TDI PET<br />
08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00<br />
time<br />
Figure 11: Effect on CO content in the top gas (idealized time line)<br />
pulverized petcoke is much higher<br />
than the hot blast speed in the copper<br />
nozzle. At the relining intervals, no<br />
significant wear was observed at the<br />
injection system.<br />
Figure 7 illustrates and describes the<br />
principle of using pulverized petcoke<br />
as fuel.<br />
Results of the TDI-PET technology<br />
– sulfur analysis<br />
Due to the fact that pulverized petcoke<br />
contains up to 2.5 % of sulfur, special<br />
attention was placed on the sulfur<br />
analysis. It turned out that the sulfur<br />
has no effect whatsoever.<br />
During the long-time operation of<br />
the furnace, it could be proved without<br />
doubt that the higher sulfur contents<br />
posed no problem. During five months<br />
of grey cast iron production, an increase<br />
by not more than 0.0063 % was<br />
determined. In case of ductile iron, the<br />
value was 0.005 over the same period.<br />
Any variations are the result of variations<br />
in the coke quality. Obviously, a<br />
slightly higher part of the metallurgical<br />
sulfur is discharged via the slag and the<br />
top gas. However, the quantities are below<br />
the respective limits of detection.<br />
Petcoke – effect on efficiency<br />
and carburization<br />
A key factor for the proper application of<br />
the petcoke technology is to understand<br />
the furnace-specific processes going on<br />
when petcoke is charged, especially in<br />
cases where the furnaces are operated<br />
with reduced rates of foundry coke.<br />
Continuous measurements of the<br />
CO and CO 2<br />
concentrations in the top<br />
gas between the below-charge take-off<br />
and the combustion chamber helped<br />
to optimize the furnace operation and<br />
made any negative influences immediately<br />
obvious. While Figure 7 illustrates<br />
how petcoke can influence the<br />
iron chemistry, Figure 8 shows that the<br />
operation with petcoke does actually<br />
have a decisive effect.<br />
Analyses of the runner iron typically<br />
reveal fluctuating carbon contents,<br />
which cannot be avoided due to<br />
the specifics of the furnace operation.<br />
However, by the objective use of petcoke,<br />
these analysis fluctuations can be<br />
kept within closer tolerances ( Figure 9).<br />
36 Casting Plant & Technology 2/<strong>2015</strong>
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40549 Düsseldorf<br />
Germany<br />
Phone +49 211 5858 0<br />
casting@refra.com<br />
www.refra.com
MADE IN<br />
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Complete product range<br />
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Effect of petcoke on the runner<br />
iron temperature<br />
In the case of reducing the coke charge<br />
by approximately 18 % and adding<br />
< 12.5 % of petcoke, it had to be made<br />
sure that it would be possible to raise<br />
temperature-related problems during<br />
restarting could be significantly eased.<br />
The long-term analysis showed that the<br />
mean temperature of the runner iron in<br />
the case of grey iron was 7 °C higher as<br />
a result of the petcoke. The described<br />
Design, Manufacturing,<br />
Commissioning, Overhaul,<br />
Maintenance, Spare Parts.<br />
Combustion chamber temp. in °C<br />
905<br />
895<br />
885<br />
875<br />
865<br />
855<br />
Comb. chamber temp. with HIGHJET TDI PET<br />
Comb. chamber temp. without<br />
HIGHJET TDI PET<br />
08:24 09:36 10:48 12:00 13:12 14:24 15:36 16:48 18:00<br />
Time<br />
Figure 12: Effect on the combustion chamber temperature<br />
Economic basis<br />
• Coke reduction: 18.5 % of charge coke<br />
• Petcoke feeding*: 12.5 % of charge coke<br />
• Substitution rate: < 70 %<br />
• Beneficial effects on CO 2<br />
emissions and improved combustion to be proved under<br />
production conditions<br />
Metallurgical basis<br />
• No changes to furnace campaigns (as of April 2014)<br />
• Stable runner iron temperature of > 1,505° C<br />
Metallurgical basis<br />
• CO in crude gas: up to approx. 1 % increase (despite coke substitution)<br />
• Reduced external energy input in the combustion chamber<br />
• Improved Si combustion<br />
• Improved temperature control<br />
• Fast attainment of suitable “metallurgical” condition during restarts after furnace stops<br />
(grey iron)<br />
* Petcoke is available on the market at much lower costs than foundry coke.<br />
Table 1: Oberview of the plants parameters<br />
WOKO Magnet- und<br />
Anlagenbau GmbH<br />
Theodor-Heuss-Strasse 57<br />
47167 Duisburg<br />
Germany<br />
Phone +49 203 48275.0<br />
Fax +49 203 48275.25<br />
woko@woko.de<br />
www.woko.de<br />
the runner iron temperature to a higher<br />
level, because in the specific case the<br />
cupola operation was interrupted several<br />
times during the day. Operation<br />
had to be restarted with a lower coke<br />
charge potential, hence a lower energy<br />
potential. The petcoke proved to be<br />
a reliable tool here. Compared to the<br />
original situation, it was possible to<br />
reach a higher energy level after the offtimes<br />
much quicker (Figure 10). The<br />
reactions may vary depending on the<br />
quality of the foundry coke.<br />
Influence of the petcoke on the<br />
combustion chamber temperature<br />
and the CO content<br />
Generally, a reduced coke charge raises<br />
the requirement of an external energy<br />
input. For environmental reasons, it is<br />
necessary in most cases to have combustion<br />
chamber temperatures of more<br />
Woko.indd 1 15.08.13 10:03<br />
38 Casting Plant & Technology 2/<strong>2015</strong>
X:\00-Küttner-Image\00_CDR-Dateien\2012-Giesserei-85 x260.cdr<br />
Freitag, 15. Mai <strong>2015</strong> 15:53:21<br />
Farbprofil: Deaktiviert<br />
Composite Standardbildschirm<br />
than 890 °C to reliably keep the residual CO content in 95 the<br />
clean gas at the stack at >150 mg/m 3 .<br />
75<br />
A falling combustion chamber temperature leads to a<br />
significant increase in external energy input. Also after a<br />
furnace stop, it takes some time to bring the combustion<br />
chamber back to the required temperature and achieve 25<br />
high hot blast temperatures. Figure 11 shows that especially<br />
after furnace stops and the consequently low energy<br />
5<br />
content of the top gas it was necessary to add the required<br />
0<br />
energy by activating the main burner.<br />
By injecting petcoke during the furnace start, the energy<br />
content of the top gas can be raised faster, minimizing the<br />
power-on time of the main burner. The result is an overall<br />
higher temperature level. ( Figure 12)<br />
Approaches to automation<br />
When petcoke injection was introduced in long-time operation,<br />
it could be proved that it was never possible to guarantee<br />
that the foundry coke was properly metered and charged<br />
depending on the weight of the metal charge. This may result<br />
in energy fluctuations of up to 10%, as was revealed by<br />
tracking the energy contents of the charges or batches all<br />
the way down to the melting zone. These variations in energy<br />
efficiency result in different energy contents in the top<br />
gas (CO, CO 2<br />
) and different combustion behaviour of the<br />
charged materials, especially silicon. As a rule, during these<br />
phases there is no reacting with the furnace blast or oxygen.<br />
The companies Gienanth and Linde have been working successfully<br />
on the development of solutions.<br />
Summary<br />
The TDI-PET technology developed by Linde facilitates<br />
the use of petcoke as a cost-efficient fuel for foundry shaft<br />
furnaces through the employment of innovative burner<br />
lances and the specific conveying technology provided<br />
by the company Dako. The above presented intermediate<br />
results (as of March 2014) obtained during a one-year<br />
industrial-scale field test under production conditions in<br />
three-shift operation at the iron foundry Gienanth prove<br />
the potentials of this process. One result is the positive<br />
influence on the runner iron temperature. The tests also<br />
proved that any negative effects of the sulfur content in<br />
the petcoke could be reliably precluded.<br />
Operation of the furnace with a reduced coke rate here<br />
100<br />
still means that the coke rate includes a “safety buffer”,<br />
which in the event of a plant failure guarantees that until 95<br />
conventional furnace operation with a high coke rate has<br />
75<br />
been resumed the “situation” in the furnace is such that<br />
there will be no harmful effects on the furnace and the<br />
quality of the iron. Such situation was produced on purpose.<br />
The resulting repercussions on the iron chemistry 25<br />
were manageable. However, this problem could be completely<br />
eliminated by providing a backup petcoke supply<br />
5<br />
system for emergency situations.<br />
www.linde-gas.de<br />
100<br />
0<br />
Good reasons for good castings!<br />
Meet our experts on<br />
METEC / GIFA Dusseldorf<br />
June 16th to 20th, <strong>2015</strong><br />
stand 4C28<br />
Küttner GmbH & Co. KG, Essen info@kuettner.com<br />
Phone +49 (0)201 7293 0 www.kuettner.com<br />
stand 16G26<br />
CHARGE MAKE-UP<br />
AND BURDENING<br />
Batching of scrap and alloys<br />
Fully-automatic charging<br />
cranes<br />
Large charging cars for<br />
induction furnaces<br />
Bucket transportation<br />
systems<br />
CUPOLA MELT SHOPS<br />
Cold-blast cupolas<br />
Hot-blast cupolas for<br />
long-campaign operation<br />
Atmospheric or pressurized<br />
syphon design<br />
Oxygen injection systems<br />
Carbon injection systems<br />
Desulphurization<br />
CASTINGS / SAND TREATMENT<br />
Shake-out conveyor<br />
Castings cooling equipment<br />
Green sand preparation with<br />
Fluid-bed coolers<br />
Continuous mixers for<br />
No bake systems<br />
Shake-out stations<br />
Sand reclamation<br />
CENTRIFUGAL CASTING<br />
Pouring units<br />
Casting machines of hot<br />
mould / de Lavaud-type for:<br />
drain / pressure water pipe<br />
cylinder liners<br />
liners & pipes in<br />
special alloys<br />
Electric control with HMI<br />
Auxiliary systems<br />
ALUMINIUM MELTING<br />
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Casting Plant & Technology 2/<strong>2015</strong> 39
Detail view of a pressure die cast<br />
structural component (Photos +<br />
Graphics: Kind & Co Edelstahlwerk)<br />
Author: Ingolf Schruff, Kind & Co., Edelstahlwerk, GmbH & Co. KG, Wiehl<br />
Pressure die cast structural components<br />
for lightweight automotive<br />
construction<br />
The European Union’s commitment to carbon reduction requires the automotive industry to<br />
bring down CO 2<br />
emissions from new passenger cars down to 95 g/km by the year 2<strong>02</strong>0. The<br />
consistent implementation of lightweight design in automotive engineering has a direct positive<br />
impact on CO 2<br />
emissions. This was motivation during the last few years to strongly promote the<br />
use of pressure die cast structural components made of light metal<br />
Pressure die casting competes with<br />
alternative techniques, such as tailored<br />
blanks – i.e. parts made by joining<br />
steel sheets of special properties<br />
to meet specific requirements of use –<br />
or press-hardened high-strength steel<br />
sheets. Pressure die cast structural components<br />
can only succeed in this competitive<br />
environment if high-capacity,<br />
reliable dies are available. The key advantage<br />
of pressure die cast structural<br />
components over alternative solutions<br />
is that they are made to high precision<br />
and are virtually ready for installation.<br />
Compared to tailored blanks, many<br />
manufacturing steps can be dispensed<br />
with.<br />
Pressure die cast structural<br />
components<br />
Today, a wide range of automotive<br />
structural components are pressure<br />
die cast, for example, pillars, various<br />
beams, strut mounts and even complete<br />
frames for side and rear doors.<br />
While this type of pressure die cast<br />
components initially used to be installed<br />
primarily in premium-class vehicles,<br />
today they are also employed in<br />
many middle-class cars.<br />
The high complexity of these parts is<br />
an extremely challenging task for die<br />
casters, die makers and steel producers.<br />
Ribbings in the castings are prone<br />
to cause localized stress peaks. Side and<br />
rear doors are frame-type constructions.<br />
During casting only relatively<br />
small volumes of the die are in contact<br />
with the casting alloy, making it very<br />
40 Casting Plant & Technology 2/<strong>2015</strong>
Steel grade<br />
Alloying contents in % by mass<br />
Mat. no. Brand Short name C Si Mn P S Cr Mo V Nb<br />
1.2343 USN X37CrMoV5-1 0.38 1.00 0.40 < 0.<strong>02</strong>0
K CASTING TECHNOLOGY<br />
Mat. no Brand<br />
Thermal conductivity in W/m x K<br />
20 °C 200 °C 400 °C<br />
1.2343 USN 26.8 27.8 27.3<br />
1.2367 USD 29.9 32.1 32.4<br />
--- TQ 1 29.5 30.5 30.5<br />
--- HP 1 29.8 31.0 31.4<br />
Table 2: Thermal conductivity of hot working steels for pressure die casting<br />
dies. All steels hardened and tempered to 45 HRC<br />
a<br />
Figure 2: Thermal shock resistance of<br />
steels 1.2343 (top), TQ 1/ HP 1 (middle)<br />
and HTR (bottom). Crack formation<br />
due to thermal shock and mean<br />
crack length in mm. Testing conditions:<br />
all steels hardened and tempered<br />
to 45 HRC; testing temperature:<br />
600 °C/water, 4,000 cycles<br />
b<br />
Figure 3: CCT diagrams for steels TQ 1 (top) and HP 1 (bottom)<br />
(Figure 1c) because the die inserts are<br />
subjected to high sudden mechanical<br />
loads at each shot. Steel 1.2343 features<br />
the highest impact strength of the<br />
three standard alloys. Based on specimens<br />
of identical hardness, the impact<br />
strength of the three alloys decreases<br />
in the sequence: 1.2343 => 1.2344 =><br />
1.2367. The impact strength values of<br />
two special hot working steels TQ 1 and<br />
HP 1 are both at the same level, about<br />
25 % higher than the corresponding<br />
value for alloy 1.2343. This comparison<br />
of the key mechanical properties<br />
illustrates the exceptional blend<br />
of properties found in the steels TQ 1<br />
and HP 1.<br />
Especially for the casting of exposed<br />
parts, thermal shock resistance is a<br />
crucial property of the hot working<br />
steels used to make the casting dies.<br />
The images in Figure 2 show thermal<br />
shock-induced cracks in specimens of<br />
the described steel grades. The mean<br />
length of each crack is indicated in<br />
the blue bar. Hot working steel 1.2343<br />
is used as a reference. The significantly<br />
better thermal shock resistance of TQ 1<br />
and HP 1 is obvious. Steel HTR, which<br />
is also shown in this comparison, has<br />
been developed for applications with<br />
extremely exacting requirements on<br />
hot working strength and thermal conductivity.<br />
However, for inserts in dies<br />
for casting structural components this<br />
steel is of less importance.<br />
In pressure die casting dies, thermal<br />
conductivity plays a key role for various<br />
reasons. Firstly, it is responsible for<br />
the heat transfer from the alloy into<br />
the cooling channels and, secondly,<br />
it contributes to the alleviation of local<br />
temperature peaks and a decrease<br />
in temperature-induced stresses in the<br />
dies. The thermal conductivity values<br />
of the here discussed steels are compiled<br />
in Table 2.<br />
42 Casting Plant & Technology 2/<strong>2015</strong>
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K CASTING TECHNOLOGY<br />
The comparison reveals that TQ 1<br />
and HP 1 feature property blends far<br />
superior to those of the three standard<br />
hot working steels 1.2343, 1.2344 and<br />
1.2367. Between TQ 1 and HP 1, the differences<br />
in the described properties are<br />
only minor. This raises the question of<br />
selection criteria between the two steels.<br />
Due to their special blend of properties,<br />
both steels are extremely well<br />
suited for making pressure die casting<br />
dies for structural components. A distinction<br />
between the two steels can be<br />
made based on the thickness of the<br />
die inserts. To clarify this distinction,<br />
in Figure 3 we have plotted the continuous<br />
cooling diagrams (CCT curves) of<br />
the two steel grades.<br />
In both cases, the CCT curves are typical<br />
curves of martenisitic hot working<br />
steels. However, the difference between<br />
the two is that the bainitic transformation<br />
starts at different points in time.<br />
While in the case of TQ 1, the bainitic<br />
phase is likely to form after about 2,500<br />
s, in the case of HP 1, this is likely to occur<br />
as early as after 800 s. This time difference<br />
of 28 min is crucial especially<br />
to the solidification of thick-walled inserts<br />
because, in order to achieve high<br />
toughness of the material, everything<br />
possible should be done to ensure that<br />
during solidification the steel microstructure<br />
transforms completely to the<br />
martensitic phase. Bainite transformation<br />
starting at a later stage, facilitates<br />
the desired transformation to the martensitic<br />
phase especially in the core<br />
area of thick-walled die parts. From<br />
this, the following recommendations<br />
Figure 4: Modern vacuum hardening furnace at Kind & Co. for pressure die<br />
casting dies weighing up to 6,000 kg (Photo: Georg Fischer AG)<br />
Mat. no Short name Brand Hardening temperature<br />
in °C<br />
Holding time<br />
in min<br />
1.2343 X37CrMoV5-1 USN 1000 45<br />
1.2344 X40CrMoV5-1 USD 1<strong>02</strong>0 45<br />
1.2367 X38CrMoV5-3 RPU 1030 45<br />
--- --- TQ 1 1010 60<br />
--- --- HP 1 1<strong>02</strong>0 60<br />
--- --- HTR 1060 60<br />
Table 3: Recommended parameters for vacuum hardening pressure die casting<br />
dies<br />
can be derived: Use HP 1 preferably for<br />
die inserts up to approx. 200 mm thick;<br />
beyond that thickness use TQ 1.<br />
TQ 1 should also be used for smaller<br />
die inserts with extremely filigree engraved<br />
structures that require a maximum<br />
of toughness.<br />
To summarize the recommendations:<br />
HP 1 is suitable for die inserts of<br />
up to 200 mm thickness for structur-<br />
44 Casting Plant & Technology 2/<strong>2015</strong>
al components which have to comply<br />
with exacting requirements in terms<br />
of toughness and surface quality. TQ1<br />
is recommended to be used for dies<br />
which have to comply with extremely<br />
exacting requirements in terms of<br />
toughness and surface quality, and<br />
particularly for die inserts of greater<br />
thickness. TQ 1 has also proved to be<br />
more appropriate for die inserts with<br />
pronounced height offsets or a jagged<br />
surface structure.<br />
These steels feature a useful<br />
hardness typically ranging between<br />
44 and 46 HRC. In order<br />
to cater to specific properties,<br />
the values can be lower or<br />
higher. The choice should always<br />
be based on a joint decision<br />
by the steel producer, die<br />
maker, hardening shop and<br />
foundry.<br />
The die inserts can exhibit<br />
the desired properties only<br />
after an appropriate heat<br />
treatment. For the vacuum<br />
hardening treatment of pressure<br />
die casting dies, special<br />
steelmaker Kind & Co.<br />
recommends the temperatures<br />
and holding times compiled<br />
in Table 3. The company’s<br />
modern, high-capacity<br />
vacuum hardening shop can<br />
heat treat pressure die casting<br />
dies weighing up to 6,000 kg<br />
(Figure 4).<br />
Summary<br />
Extremely exacting demands<br />
are placed on dies used for<br />
the production of pressure<br />
die cast structural components<br />
due to their size and<br />
their often highly sophisticated<br />
design. Common standard<br />
hot working steels cannot<br />
guarantee compliance<br />
with these demands. In contrast,<br />
the special hot working<br />
steels TQ 1 and HP 1 offer a<br />
significantly improved combination<br />
of properties, such<br />
as increased toughness, higher<br />
hot working strength, better<br />
thermal shock resistance<br />
and improved thermal conductivity.<br />
The choice between these<br />
two steel grades basically depends on<br />
the thickness of the die inserts to be<br />
produced.<br />
Provided that they have been properly<br />
heat treated, die inserts made of<br />
these steels make a major contribution<br />
to the cost-efficient production<br />
Our value<br />
adding solutions<br />
for your process<br />
of pressure die cast structural components<br />
made of light metals.<br />
www.kind-co.de/en<br />
References:<br />
www.cpt-international.com<br />
Meet us at GIFA in Dusseldorf<br />
Germany: June 16 – 20, <strong>2015</strong><br />
Hall 12 / Booth A22<br />
Our services provide you with real added value.<br />
ASK Chemicals experts look forward to hearing from you:<br />
Phone: +49 211 71103-0<br />
E-Mail: addedvalue@ask-chemicals.com<br />
www.ask-chemicals.com<br />
Casting Plant & Technology 2/<strong>2015</strong> 45
K SIMULATION<br />
Authors: Dr. Carsten Schmalhorst, AVL Deutschland GmbH, Munich, Dr. David Greif, AVLAST d.o.o., Maribor, Slovenia<br />
Numerical simulation of the<br />
quench ing process for castings<br />
using AVL FIRE<br />
Motor downsizing and weight-reduction measures have increasingly led to material failures. Automotive<br />
producers have therefore sought ways to optimize their heat treatment processes. AVL<br />
List GmbH, based in Graz in Austria, has developed an innovative solution to meet this need and<br />
integrated it in their AVL FIRE 3-D CFD software<br />
With this software solution a precise<br />
advance calculation of the transient<br />
cooling process of the quenched component<br />
can be made through accurate<br />
modelling of the various boiling<br />
phases that occur during quenching.<br />
Methods of computational fluid dynamics<br />
(CFD) have been used during<br />
the development of a wide range of<br />
vehicle components for decades. This<br />
new type of process, developed at AVL<br />
to simulate the quenching of metal<br />
parts, contributes towards reducing<br />
residual stress in complex components<br />
such as cylinder heads.<br />
Downsizing and weight-reduction<br />
measures have hitherto repeatedly led<br />
to material failures in the critical areas<br />
of highly stressed components – failures<br />
that cannot be traced back to the<br />
operational loads alone. Thus, for example,<br />
valve bridges require special attention<br />
because residual stresses could<br />
potentially superimpose the operational<br />
loads as a result of the heat treatment<br />
of the casting. The software precisely<br />
calculates the cooling history of the<br />
Well-known OEMs and suppliers such as Volkswagen, Ford, HMC and Nemak already successfully use AVL FIRE for optimizing<br />
quenching processes (Photos: AVL LIST)<br />
46 Casting Plant & Technology 2/<strong>2015</strong>
quenched component in advance, providing<br />
the necessary prerequisites for<br />
analyzing thermal loads and deformations<br />
that occur during heat treatment.<br />
The quenching of castings is a highly<br />
dynamic process: immediately after<br />
immersion into the liquid the solid<br />
body is covered by a film of steam that<br />
acts as an insulator, preventing rapid<br />
heat dissipation. The vapor blanket<br />
breaks down after a while and there is<br />
a transition to so-called nucleate boiling.<br />
This results in improved contact<br />
with the cooling medium – typically<br />
water or oil – and the amount of heat<br />
dissipation increases greatly. Now rising<br />
bubbles of vapor can hinder the<br />
flow of coolant to the higher-lying regions<br />
of the component, further slowing<br />
down the cooling process. All these<br />
effects lead to local temperature differences<br />
in the component and thus to<br />
uneven local expansion of the material.<br />
These variations in expansion lead<br />
to plastic deformations which, in turn,<br />
cause the residual stresses (Figure 1).<br />
AVL FIRE ensures the precise calculation<br />
of the various regimes of the complex<br />
boiling process, the spread of vapor<br />
bubbles and the simultaneous<br />
cooling processes taking place in the<br />
component. The temperature distribution<br />
in the component provided by<br />
this flow simulation now serves as an<br />
input value for simulating stress-strain<br />
states. Whereby a non-linear material<br />
law determines the plastic deformations.<br />
For this purpose, AVL has developed<br />
strain-rate-dependent material<br />
laws that can represent the material<br />
properties based on the rate of change<br />
of strain. This simulation step is carried<br />
out separately from the flow simulation<br />
with suitable commercial finite-element<br />
method codes (Figure 2).<br />
The stress calculation can only reflect<br />
the pure quenching process or addi-<br />
Figure 1: View of the simulated steam on the hot component surface<br />
Figure 2: One cylinder head, two submerging<br />
directions, two stress states:<br />
immersed in a water bath via the oil<br />
gallery (left), or via the inlet port side<br />
(right)<br />
GIFA · Hall 10 · Booth A 49<br />
THERMPROCESS · Hall 9 · Booth A 32<br />
Non-contact and wear-free<br />
temperature measurement<br />
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• Portable and stationary pyrometers<br />
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• Sighting options: through-the-lens or<br />
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SEE MORE<br />
CellaCast<br />
info@keller-msr.de · www.keller-msr.com<br />
FEEL BETTER<br />
Casting Plant & Technology 2/<strong>2015</strong> 47
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www.giesserei-verlag.de<br />
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Die Zeitschrift für Technik, Innovation und Management<br />
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tional downstream heat treatment and<br />
processing steps, depending on the application<br />
case. Completion of the simulation<br />
chain provides an overview of<br />
residual deformation as illustrated in<br />
Figure 2 (here inflated 50-fold), and<br />
the local stresses as shown in Figure 3.<br />
These residual stresses can be superimposed<br />
on the component loads so that<br />
the total load of the workpiece becomes<br />
visible. Ideally, pressure-related residual<br />
stresses are, for example, superimposed<br />
on tensile loads here, providing<br />
overall relief for operation of the component.<br />
This effect is known as autofrettage<br />
from pipeline construction, for example.<br />
The long-term aim is to be able<br />
to arrange processes on the basis of additional<br />
analysis methods so that the<br />
residual stress generated works against<br />
operational loads. In this way less material<br />
could be used and the reliability of<br />
the component is increased (Figure 3).<br />
Figure 3: von Mises comparative stresses after completion of the quenching<br />
process: immersed via the oil gallery (left), or via the intake port side (right)<br />
Simulation of the quenching process<br />
permits the analysis of residual stresses<br />
and enables the evaluation of counter-measures,<br />
such as definition of the<br />
optimum submerging direction, cooling<br />
agent temperature and a modulated<br />
flow of coolant. It is also possible to<br />
examine questions of whether component<br />
geometry changes – perhaps<br />
through additional ribs – can prevent<br />
flows during quenching and thus influence<br />
the residual stresses. This could<br />
both reduce the extent of the residual<br />
stresses and positively influence their<br />
nature.<br />
Simulation of immersion quenching<br />
can be obtained from AVL as a service,<br />
or AVL FIRE can be licensed for use.<br />
www.avl.com<br />
Innovative solutions for the foundry and forge<br />
industry from the world´s leader!<br />
We are going to<br />
present in Hall 16<br />
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CastingPlant_Ausgabe<strong>02</strong>.indd 1 12.05.<strong>2015</strong> 15:00:33<br />
Casting Plant & Technology 2/<strong>2015</strong> 49
The aluminum melt at 700 °C is decanted from the furnace (from Støtek in Vojens, Denmark) into a small ladle. The<br />
melt was previously degassed using an impeller (Photos: Andreas Bednareck)<br />
Authors: Robert Piterek, German Foundry Association, Düsseldorf<br />
Exploring tomorrow’s technologies<br />
The foundry supplier Foseco has a new research and development center in the Dutch town of<br />
Enschede. The facility is intended to gain a holistic understanding of customers’ production processes<br />
and undertake a forward-looking redevelopment of products<br />
Almost no other foundry supplier has<br />
as large a portfolio of products as<br />
Foseco, the Foundry Division of Britain’s<br />
Vesuvius Group. It ranges from<br />
binding agents and coatings; through<br />
feeding and filtration systems, and melt<br />
treatment technology; to melting crucibles,<br />
ladle linings and measuring equipment<br />
of all sorts. Foseco is the market<br />
leader in many of these product areas,<br />
and a serious competitor in the others.<br />
With its 3,500 employees worldwide<br />
and the support of its ‘big brother’ Vesuvius<br />
(with a worldwide workforce of<br />
11,000), Foseco is an important player<br />
on the market – and intends to remain<br />
so during coming decades.<br />
Appropriate location with optimum<br />
conditions<br />
Continuous further development of the<br />
company and its products will no longer<br />
be enough if Foseco and Vesuvius want<br />
to maintain and expand their technological<br />
lead. The company’s Global R&D<br />
Director, Pavel Holub, is convinced of<br />
this. “The aim must be to change the<br />
viewpoint and direct our attention to<br />
tomorrow’s technologies and the socalled<br />
game-changers, i.e. technologies<br />
and developments with wide-ranging<br />
potentials for change.” The company<br />
has meanwhile reacted by opening a<br />
new five-million-euro research and development<br />
center in the Dutch town<br />
of Enschede, a few kilometers from the<br />
German border. It is a modern building<br />
constructed on grounds totaling<br />
about 4,500 m², with offices, laboratories<br />
and a test foundry. The building<br />
was originally used by another company<br />
as its headquarters, for its chemical<br />
industry pilot plants and for constructing<br />
machinery. Now only the façade<br />
reflects the building’s former history –<br />
the interior has been completely redeveloped.<br />
The campus of the University<br />
of Twente is nearby, a prestigious university<br />
that is also active in the fields of<br />
inorganic chemistry and nanotechnology<br />
– areas of fundamental interest for<br />
Foseco. The R&D center has been built<br />
50 Casting Plant & Technology 2/<strong>2015</strong>
ight next to the football stadium of<br />
FC Twente, a club in the Dutch Honorary<br />
Division, which first became Netherlands’<br />
champion in the 2009/2010<br />
season. The new research center is just<br />
10 kilometers from Hengelo, Foseco’s<br />
Dutch production site for coatings and<br />
binders, and 45 minutes from the company’s<br />
German headquarters in Borken<br />
in Münsterland. An excellent location<br />
therefore, with optimum conditions for<br />
researching tomorrow’s technologies.<br />
Concentrated research and expertise<br />
In order to create the prerequisites for<br />
a modern R&D institute with a holistic<br />
research approach, the fundamental research<br />
on binders and coatings moved<br />
from Hengelo to Enschede and experts<br />
in the important area of research on filters<br />
and feeders in Borken were recruited<br />
for the center. “Research and expertise<br />
have now been consolidated in one<br />
location,” polymer chemist Holub emphasizes<br />
proudly. “In order to better understand<br />
our customers’ processes we<br />
also use comparable equipment.” The<br />
Czech Holub is not the only researcher<br />
in Enschede with a foreign background:<br />
the 26 top-flight scientists so<br />
far recruited for the research team come<br />
from eight different countries, including<br />
France, Poland, the Netherlands, the<br />
UK, Nigeria and Germany. They speak<br />
English with one another. Enschede offers<br />
another locational advantage for international<br />
teams like this one: an international<br />
school. Four more technicians<br />
are currently being sought.<br />
Exterior view of the building: the grounds total 4,500 m², the casting hall and<br />
laboratories take up 700 m² and the offices 800 m²<br />
The creative impulse for the technologies of tomorrow should originate in this<br />
room: CP+T Editor Robert Piterek, Project Manager Dr. Fabian Sander, Managing<br />
Director Heinz Nelissen and Head of Research Pavel Holub (from left to right)<br />
visit the brainstorming room in Foseco’s new research and development center<br />
Giving free rein to creativity<br />
Dr. Fabian Sander, Development Scientist<br />
and Project Manager in the areas of<br />
feeders and processes, guides through<br />
the new building. The first stop is the<br />
so-called brainstorming room, in which<br />
the researchers come up with creative<br />
solutions for future challenges in foundries<br />
and steelworks. “Between 10 and<br />
20 % of their working time is available<br />
for brainstorming,” explains Dr. Sander,<br />
who commutes from the German border<br />
town of Gronau to Enschede for his<br />
new task. Green floor, orange walls, blue<br />
sky and a big whiteboard – the winner of<br />
an interior design competition (specially<br />
organized by Foseco) came up with<br />
the color scheme and spatial designs of<br />
the brainstorming room, as well as all<br />
the other interior areas of the research<br />
center. Dr. Sander describes how the creative<br />
process is approached here: “The<br />
brain is basically relatively lazy. When<br />
someone starts to tackle a new problem<br />
they first exploit their wealth of experience.<br />
There are, however, techniques<br />
that help empty the brain first. This<br />
takes about one hour – then we are ready<br />
for new paths to problem-solving!” In<br />
practice, this frequently means that<br />
the researchers write loads of Post-it<br />
notes during the idea-finding stage and<br />
then sift out the unrealistic approaches,<br />
gradually separating the wheat from<br />
the chaff. “Rooms like this one are still<br />
rather unusual in this sector, but VW<br />
and BMW – upon whom we orient ourselves<br />
– also have them,” emphasizes<br />
Martin Scheidtmann, Foseco’s Head of<br />
Communications.<br />
Foseco not only exploits the latest<br />
knowledge on creativity, but also the<br />
most modern techniques regarding<br />
communication: regular link-ups with<br />
Casting Plant & Technology 2/<strong>2015</strong> 51
K RESEARCH & DEVELOPMENT<br />
In the lobby of the R&D Center there are cozy sitting areas as well as exhibits<br />
from Foseco’s product range<br />
There are four melting furnaces in the casting hall. The Initek converter is in<br />
the foreground<br />
other research institutes, Foseco sites<br />
and customers take place in the neighboring<br />
video conference room. This permits<br />
the center to access a wide-ranging<br />
network of contacts. Foseco alone employs<br />
about 130 to 150 personnel in research<br />
– mostly in the Netherlands,<br />
France, England, and in the US town<br />
of Pittsburgh, where research focuses<br />
on crucibles and refractory products.<br />
There are another 34 Foseco sites worldwide.<br />
Diagrams can be hand-drawn on<br />
the enormous, almost futuristic, touchscreen<br />
monitor in the conference room<br />
so conference participants can work<br />
with one another from anywhere and<br />
access the drawings or PowerPoint presentations<br />
worldwide.<br />
Research with test castings<br />
At the heart of research activities in Enschede,<br />
however, is the test foundry<br />
with its four furnaces for iron, steel and<br />
aluminum. The hall is about twelve meters<br />
from top to bottom. From the gallery<br />
on the first floor, Foundry Foreman<br />
Niek Bruinewoud looks somewhat<br />
lost amongst the four furnaces lined<br />
up next to one another and the caster<br />
clad in silver protective equipment.<br />
A hall crane with a load capacity of 2<br />
x 10 t is mounted on the ceiling. “We<br />
run a 500 kg induction furnace here, a<br />
250 kg furnace for iron and steel, as well<br />
as one 500 kg and one 50 kg aluminum<br />
furnace,” Dr. Sander counts them off.<br />
“These furnace sizes are the right compromise<br />
because otherwise we would<br />
have too much material,” adds Holub.<br />
Tests under serial conditions must still,<br />
however, be carried out at customers’<br />
sites. Foundry Foreman Bruinewoud<br />
and his colleagues Marvin and Bertus,<br />
who were still working in Hengelo until<br />
late November last year, are preparing<br />
an aluminum casting with which<br />
the effectiveness of Foseco melt degassing<br />
is to be tested. In the case of this degassing,<br />
an impeller, hydrogen among<br />
others, is used during removal of the<br />
aluminum melt, significantly improv-<br />
Foseco Germany Managing Director<br />
Heinz Nelissen (left) and the Foundry<br />
Foreman Niek Bruinewoud just<br />
before a test casting<br />
52 Casting Plant & Technology 2/<strong>2015</strong>
ing the quality of the melt. One area<br />
of sales could be the automotive industry,<br />
where weight-optimized aluminum<br />
castings are produced using this treated<br />
melt. Another innovation is in the<br />
middle of the hall: an Initek converter<br />
for treating iron melts. “This converter<br />
produces spheroidal graphite cast iron.<br />
The design allows magnesium treatment<br />
with a high yield. The searingly<br />
bright reaction of the magnesium with<br />
the iron takes place within the converter,”<br />
Heinz Nelissen, Foseco’s Managing<br />
Director Germany, describes the exhibit<br />
– which will be shown at GIFA this summer.<br />
The Initek converter is not entirely<br />
new – it was already one of the company’s<br />
highlights at the world’s most<br />
important foundry sector trade fair<br />
in 2011. “But we have been able to reduce<br />
process temperatures and further<br />
optimize the safety aspects,” Nelissen<br />
explains the advantages of the roughly<br />
two-meter tall steel monster. Apropos<br />
GIFA – the international foundry<br />
fair is of particular importance for the<br />
universal foundry supplier Foseco: the<br />
foundry and steel experts from Vesuvius<br />
will have four stands for the trade fair<br />
quartet in Düsseldorf in June – at GIFA,<br />
METEC, THERMPROCESS and at the<br />
Schools Program. According to Holub,<br />
“exciting new developments” are to be<br />
expected in the area of inorganic binders.<br />
State-of-the-art apparatus<br />
In terms of dimensions and volume, the<br />
core shooting machine in the neighboring<br />
room is the same size as a plant in<br />
an aluminum or iron foundry. It masters<br />
all common processes, such as cold- and<br />
hot-box processes, and can handle tools<br />
of up to 12 liters. Small batches of cores<br />
are made here with new binder recipes.<br />
All the necessary examinations of the<br />
cores can then be undertaken straight<br />
away. Dr. Sander: “After coating, we can<br />
do the casting and carry out tests in our<br />
center’s own laboratories. The dip test,<br />
for example, with which we find out<br />
how the metal sticks to the core and<br />
whether metal penetrates the core.”<br />
State-of-the-art apparatus can also<br />
be found in the numerous laboratories<br />
in which cores are examined, for<br />
example, for their storability in oth-<br />
The casters in Enschede carefully fill the molds with aluminum melt<br />
Satisfied faces after the casting: Heinz Nelissen (left), Process Control<br />
Manager Torben Hanson (center), and Pavel Holub<br />
Casting Plant & Technology 2/<strong>2015</strong> 53
K RESEARCH & DEVELOPMENT<br />
Manuel Le Borgne from France<br />
(right) and Ugo Nwaogu from<br />
Nigeria examine a sample<br />
er climatic zones. Comprehensive examinations<br />
of coatings are also carried<br />
out here, e.g. the sedimentation test<br />
to measure the stability of coating dispersions<br />
over time, which chemist Michael<br />
Smola from Poland is currently<br />
doing on a bright white laboratory<br />
bench. Smola was in China for Foseco<br />
for one year and then worked at the<br />
Hengelo site. At another workbench<br />
Marloes Goorhuis is determining the<br />
optimum contact angle between liquid<br />
and solid with a wettability test – an experiment<br />
that will provide information<br />
on the best possible spraying angle for<br />
coatings. Goorhuis was glad to swap her<br />
workplace in Hengelo for a job at Foseco’s<br />
new site in Enschede – she studied<br />
here and likes the town.<br />
Holistic understanding of production<br />
processes<br />
Ugo Nwaogu from Nigeria is preparing<br />
samples for examination in the metallurgy<br />
laboratory. “Until recently Ugo<br />
was working in Denmark,” Scheidtmann<br />
reveals. The mechanical properties<br />
of binders and coatings are determined<br />
here and the dilatometer, for<br />
example, provides values on heat resistance:<br />
the device heats the samples<br />
and then tests their deformability.<br />
A special highlight awaits visitors<br />
completing their tour – the analytical<br />
laboratory with some of the world’s<br />
most modern electron microscopes, e.g.<br />
the scanning electron microscope from<br />
Zeiss with its energy dispersive X-ray<br />
spectroscopy sensor (EDX). The device<br />
has the largest sensor area currently<br />
commercially available, and efficiently<br />
and rapidly determines the elemental<br />
composition of metallic samples. Or<br />
an electron microscope for statistically<br />
analyzing melt quality, at which the<br />
Dutchman Dr. Emiel Speets is carrying<br />
out a statistical analysis of aluminum<br />
samples that have just been cast: “We<br />
can use statistical analyses to prove the<br />
long-term quality of our degassed aluminum<br />
melt,” says Dr. Speets.<br />
Foseco’s new research and development<br />
center in Enschede permits the<br />
company to make progress towards a<br />
holistic understanding of customers’<br />
production processes. This also helps<br />
fulfil Holub’s professional goal: “I want<br />
to surprise our customers with the developments<br />
from Enschede. When<br />
they look at our solutions they should<br />
think, “Oh, I never thought of that!”<br />
www.foseco.com<br />
Pavel Holub, Robert Piterek, René Tamboer and Dr. Fabian Sander (from left to right) at the Zeiss electron microscope<br />
54 Casting Plant & Technology 2/<strong>2015</strong>
Visit us on GIFA in Düsseldorf / Germany<br />
June 16 - 20, <strong>2015</strong><br />
Hall 16 · Stand 16C04
“Critical mass for R&D”<br />
Interview with Pavel Holub, Global Head of Research of Foseco<br />
The Managing Director of Vesuvius<br />
in Borken, Mr. Nelissen, has said that<br />
the research institute is a milestone<br />
for maintaining the company’s technological<br />
leadership. How do you,<br />
Mr. Holub, see this as Global Head<br />
of Research?<br />
A challenging question. Within Vesuvius,<br />
we reviewed the leading position<br />
on the market. Given our fragmented<br />
R&D we concluded that we are much<br />
more focused on incremental development.<br />
There was thus a need to change<br />
the scope and change the view and<br />
look more towards the technologies of<br />
tomorrow and for the game changers<br />
in industry. As a result, we developed<br />
the whole R&D strategy of Vesuvius<br />
including Foundry, and therefore Foseco.<br />
One of the conclusions was the<br />
need to create a global R&D and examine<br />
the global problems of our customers,<br />
creating a critical mass in one<br />
location and putting all the technologies<br />
in one place. Once we decided to<br />
create a team and build an R&D center<br />
the next step was to determine where<br />
that would be. The first decision was<br />
to do it in Europe, close to our major<br />
customers. Our most innovative major<br />
customers are in Germany. But we<br />
were also considering an international<br />
team. Then the choice was the Netherlands.<br />
It’s much easier to bring the<br />
people here and let them settle, with<br />
international schools, universities,<br />
etc. We’re very happy to be here.<br />
I am curious about the new services<br />
announced for the foundry industry,<br />
of which you spoke at the opening<br />
of the institute. What is that about?<br />
That’s really looking at our business<br />
from a different point-of-view – that<br />
we do not supply just products. We<br />
want to have in-depth understanding.<br />
That’s why we have a lot of people<br />
in the field with the customers, to<br />
understand their processes and then<br />
transform them into new product<br />
designs, delivering the whole package<br />
to our customers or even helping<br />
them to improve or develop their processes.<br />
That’s what we call service. But<br />
we maintain our teams in the different<br />
countries. They will continue to<br />
look at raw material substitution.<br />
What exactly is improving in terms<br />
of research at Foseco?<br />
The first part is really the changing of<br />
focus. We try to combine all the technologies<br />
that we have in one center.<br />
We also concentrated on open offices<br />
in order to create a different working<br />
situation and stimulate people to<br />
talk about the products and improvements.<br />
What really improved is the<br />
creation of a critical mass and putting<br />
people together to understand<br />
the whole process.<br />
How has Foseco conducted research<br />
projects in the past?<br />
In the past there was a decision to<br />
decentralize R&D. Our labs and our<br />
R&D were close to our customers but<br />
we didn’t have the critical mass. Our<br />
Casting Plant & Technology 2/<strong>2015</strong> 57
K RESEARCH & DEVELOPMENT<br />
change of view is not looking at simply<br />
coatings, binders, filters or feeding<br />
systems. What we do is to look at<br />
our customers and find out what kind<br />
of castings they manufacture. “How<br />
can we solve their problem?” is the<br />
question we want to answer!<br />
Employees are currently being hired<br />
for the Institute. How many employees<br />
will work in Enschede and how<br />
many are already there?<br />
The first part of strategy was based on<br />
mapping our capabilities and we targeted<br />
30 people to start with. However,<br />
the building was designed for 50<br />
people. So the space is there if there<br />
is a need in the future.<br />
Do you have more plans in mind?<br />
There are always opportunities! They<br />
come with the service model, with<br />
which we want to understand more<br />
and more what the trends are. 3-D<br />
printing might be another trend. We<br />
cannot avoid looking at that. Maybe<br />
an adjacent market, either new technologies<br />
inside or outside the foundry<br />
business.<br />
What experts are you looking for?<br />
In general we have a need for chemists,<br />
material engineers, metallurgists.<br />
It’s a bit difficult to find the right people<br />
these days. You have many people<br />
doing economics and law and there<br />
are fewer and fewer people available.<br />
Here in Holland you have quite a<br />
lot of metallurgists but they are employed<br />
in powder metallurgy – which<br />
is a big industry here in the Netherlands.<br />
More important for us is how<br />
the people fit in the team!<br />
How important is the university environment?<br />
It is an important part for us. The University<br />
of Enschede has a very good<br />
background. But we also cooperate<br />
with universities in Germany, in<br />
France, in the US, in Japan. The direct<br />
university environment will also<br />
be a source of new employees in the<br />
future. Enschede has a department<br />
of inorganic chemistry and a strong<br />
faculty of nanotechnology. This is interesting<br />
for us in the future when it<br />
comes to questions about how to manipulate<br />
microstructures or improve<br />
the castings and the processes.<br />
Another research and development<br />
center for crucible and refractory<br />
products is located in Pittsburgh in<br />
the United States. Will the two research<br />
institutes cooperate?<br />
The Pittsburgh R&D center focusses<br />
on advanced refractories. It is a Division<br />
of Vesuvius. We have 10 people<br />
over there and work together closely.<br />
On top of that we have quite some cooperation<br />
across those teams.<br />
The competition in many business<br />
areas of Foseco (e.g. feeders, binder<br />
systems and coatings) is large. Nowadays<br />
one always has to keep one<br />
step ahead of the competitors. What<br />
research projects have this kind of<br />
potential?<br />
It is always good to have competition<br />
because it reflects where you are. You<br />
need to be ahead and that is the reason<br />
why we built this center. There<br />
are many interesting projects about<br />
which I cannot disclose too much information.<br />
There are many more players<br />
in the field of inorganic binders<br />
and Vesuvius/Foseco is not the market<br />
leader there. Nonetheless, it is a<br />
very important business for us and we<br />
have exciting new outputs in this field<br />
which we will present at the GIFA.<br />
At the opening ceremony it was said<br />
that the “technologies of tomorrow”<br />
will come from Enschede. What exciting<br />
new technologies are meant<br />
here?<br />
One of the ideal cases will be binder<br />
systems and there is the huge market<br />
of cold box polyurethanes. However,<br />
we are now talking about emissions<br />
and the environmental aspects and<br />
you have some nasty chemicals and<br />
we burn them with the molten metal.<br />
The question is whether we replace<br />
that. The regulations will change and<br />
we must be ready for that. This is one<br />
of the holy grails, can we replace that<br />
system? Ideally with inorganic binders,<br />
but cost-effectively.<br />
How important is 3-D printing for<br />
you?<br />
It is a nice idea, but how can you translate<br />
that into the final product? You<br />
can do direct printing of the metal,<br />
but then how do you center it, how<br />
do you melt it and keep it in shape.<br />
You have the machines for manufacturing<br />
the cores, but then there are<br />
questions regarding the type of resin,<br />
etc. So there are a lot of issues we<br />
have to look at. And maybe there is<br />
even something different from 3-D<br />
printing. For the next 10 to 20 years<br />
this will not be competitive. But we<br />
want to be ready. On the whole, I see<br />
a greater need to address the environmental<br />
issues.<br />
And which of the planned projects<br />
here in Enschede fascinate you the<br />
most?<br />
I am a polymer chemist. I come from<br />
a different business, so I am very interested<br />
in the development of inorganic<br />
binders.<br />
You are Global Head of Research at<br />
Foseco and will pursue your activities<br />
from Enschede. Why from here<br />
and not from Pittsburgh or London?<br />
This is the center of excellence for<br />
foundry-related research and this is<br />
where I want to be.<br />
What do you want the research institute<br />
to accomplish for your company?<br />
I want to surprise customers with the<br />
developments from Enschede. I want<br />
them to look at the new solutions and<br />
think: “Oh, I never thought of that.”<br />
That’s my goal!<br />
What significance has the institute<br />
on an international scale?<br />
Within the foundry industry it is<br />
quite significant to put people together<br />
in one place. Within the current<br />
situation there are not many companies<br />
building new R&D centers. What<br />
attracted me was the commitment of<br />
Foseco and Vesuvius to R&D. And<br />
there is a continuing engagement.<br />
There are plans to build R&D centers<br />
in the USA and in India.<br />
58 Casting Plant & Technology 2/<strong>2015</strong>
METEC DÜSSELDORF / GERMANY<br />
16-20 JUNE <strong>2015</strong><br />
Visit us hall 04, booth no. B35
K INDUSTRIAL COOPERATION<br />
Author: Christa Friedl, Johannesburg<br />
More efficient melting with<br />
German foundry technology<br />
EffSAFound, Part 1: Emerging economies have a key role in climate protection and resource conservation.<br />
The EffSAFound project of Germany’s Federal Ministry for Education and Research<br />
(BMBF) is intended to help get South Africa’s important foundry industry off the ground with<br />
German efficiency-enhancing technology<br />
Leaden clouds hang low on this November<br />
morning. The harsh wind blows<br />
through the streets of Johannesburg<br />
and forces the cold rain onto the car’s<br />
windscreen. German autumn weather<br />
in South Africa? In summer? “It’s not<br />
so bad!” Palesa Riba laughs. Like all her<br />
compatriots, the black African woman<br />
from Johannesburg University is philosophical<br />
about the weather: it is as it<br />
is. The young chemical engineer and<br />
foundry expert stops her BMW in front<br />
of a large barrier at the Banoni industrial<br />
estate, 20 km from the city centre.<br />
A brief exchange with the security officer,<br />
incomprehensible for Europeans,<br />
and the bar rises. A German visitor is<br />
nothing new for the man at the gate.<br />
The Guestro foundry, located behind<br />
the barrier, is one of nine companies<br />
that have been taking part in a research<br />
project since 2013, bringing South African<br />
and German casters and experts<br />
together for the first time.<br />
According to business studies graduate<br />
Manuel Bosse, who initiated the<br />
project as an employee of the Düsseldorf-based<br />
IfG-Service GmbH, the central<br />
question for the EffSAFound project<br />
is “How, and via which routes, can<br />
efficient foundry technology be transferred<br />
to South Africa in order to promote<br />
climate protection and the conservation<br />
of resources?”. EffSAFound<br />
is financed with about 700,000 Euro<br />
from the German Federal Ministry of<br />
Education and Research, with a further<br />
400,000 Euro from the German<br />
companies involved and 100,000 Euro<br />
The workers at Guestro insert freshly produced cores into the 35-year-old molding plant (Photos: Palesa Riba)<br />
60 Casting Plant & Technology 2/<strong>2015</strong>
from South Africa’s Ministry of Industry.<br />
In South Africa, 178 foundries with<br />
about 15,000 employees currently produce<br />
approximately 400,000 t of good<br />
castings, of which 60 % are made from<br />
ferrous materials and 40 % non-ferrous.<br />
The nine foundries in the project<br />
principally produce castings made<br />
of high-chrome white cast iron for the<br />
automotive, mining and power station<br />
industries, and together represent over<br />
half the iron castings market. Almost<br />
all the foundries in South Africa were<br />
politically and economically isolated<br />
for decades, and little has improved<br />
since the end of apartheid 20 years ago.<br />
This becomes apparent at a glance<br />
in the production halls of Guestro,<br />
one of the country’s leading foundries<br />
which mainly produces vehicle parts.<br />
The dust hanging in the large foundry<br />
hall is thick and impenetrable. There<br />
are no filters or extraction systems.<br />
The few, exclusively black, workers do<br />
Many work steps are carried out by semi-skilled employees in South African<br />
foundries – jobs are more important than productivity<br />
Euromac - PP_<strong>CPT</strong> GIFA - 210x145mm - fiera_Layout 1 29/04/15 08:53 Pagina 1<br />
©<strong>2015</strong>_www.imagination.it<br />
• Core making machines<br />
(shell process, croning, cold and hot box;<br />
inorganic processes)<br />
• Automatic green sand moulding lines<br />
• Core sand preparation, mixing and<br />
distribution plant<br />
• Pouring, Treatment and automatic metal<br />
Transfer plant<br />
Hall 16<br />
Stand H22-5<br />
Euromac srl _ 36035 Marano Vic. (VI) Italy _ Via dell’Industria, 62 _ Tel +39 0445 637629 _ Fax +39 0445 639057 _ info@euromac-srl.it _ www.euromac-srl.it
K INDUSTRIAL COOPERATION<br />
» Optimization of the work processes:<br />
HegerPro GmbH from Enkenbach<br />
offers PC-supported tools with<br />
which even those with low qualifications<br />
can understand processes<br />
and correctly operate plants. The<br />
software also serves to train employees<br />
with the help of pictures, animations,<br />
videos and short texts.<br />
» Material-efficient foundry sand management:<br />
the Freudenberg-based<br />
company GUT, together with IfG<br />
Service GmbH and the Metal Casting<br />
Technology Station (MCTS) of<br />
Johannesburg University will construct<br />
a sand regeneration plant to<br />
prepare and recycle used sand.<br />
Open-heart surgery: melting furnaces are also used without lids (here at<br />
Guestro). No-one has yet worked out how much energy is lost in this way<br />
not wear any protective clothing. Protective<br />
glasses or gloves are only rarely<br />
seen. Three of the six high-frequency<br />
furnaces are operating today. One<br />
of them is missing its lid and the mechanical<br />
transport arm has been broken<br />
for some time. Repairs have been<br />
ordered, says the responsible ‘Melting<br />
Manager’, Marius Djankou. He cannot<br />
say, however, when this assistance will<br />
arrive. Outside, the rain is splashing on<br />
large heaps of unsorted scrap, covered<br />
in a thick layer of rust and dirt.<br />
High energy and resource consumption<br />
due to old plants<br />
The main problems that are typical of<br />
South African foundries rapidly become<br />
clear: the melting furnaces, converters<br />
and molding plants are at least 35 years<br />
old – energy consumption and wasted<br />
energy are correspondingly high. Many<br />
companies produce 100 or even 200 different<br />
products, making any automation<br />
difficult and forcing up production<br />
costs. Only low-quality castings are produced<br />
and the reject rates are over 15 %<br />
because there is no modern process or<br />
material flow management, and unwashed<br />
scrap is mainly used.<br />
But it is not just energy that is wasted,<br />
but also expensive material: metal consumption<br />
is high and few companies<br />
recycle their molding sand – it usually<br />
ends up in landfill after one cycle. In addition,<br />
20 to 30 % of the employees are<br />
illiterate, only a few understand English,<br />
and about three-quarters of them are<br />
considered unqualified or low-skilled.<br />
EffSAFound is intended to help solve<br />
three of these problems by October <strong>2015</strong>:<br />
» Improvement of casting quality:<br />
the Aachen-based company Magma<br />
GmbH has installed simulation software<br />
in three of the foundries. It simulates<br />
the casting, hardening and<br />
cooling processes, and can considerably<br />
improve the quality of a casting<br />
by predicting structures and mechanical<br />
properties. Thinner walls, smaller<br />
feeders and a compact casting system<br />
also decrease metal consumption.<br />
New jobs are as important as<br />
new technology<br />
“EffSAFound is a great opportunity for<br />
our industry and our country,” says<br />
Palesa Riba, who is coordinating the<br />
project at the MCTS on the South African<br />
side. She hopes that when the<br />
foundry industry in the country at<br />
the Cape gets back on its feet it will be<br />
able to create new jobs whilst retaining<br />
the old ones – an important argument<br />
in a nation with 25 % unemployment.<br />
“If the foundries are doing well,<br />
all the downstream sectors (such as the<br />
metal-processing industry) will profit<br />
from it and then they will also create<br />
new jobs,” agrees John Davies, Head of<br />
the South Africa Institute of Foundrymen.<br />
German expertise for South African<br />
foundries is a good concept, but<br />
also an enormous challenge. This has<br />
been demonstrated in recent months.<br />
South Africans do not make rapid decisions,<br />
responsibilities change often,<br />
and the long journeys need to be well<br />
planned. Important questions thus still<br />
remain unresolved after the one-anda-half<br />
years during which the project<br />
has been running. “There is often no<br />
contact person on site,” Kai Molitor, IT<br />
Manager at HegerPro, has found out. So<br />
it remains unclear who will collect the<br />
necessary process data in the works, or<br />
who is responsible for installing and<br />
operating the new technology. In addition,<br />
the mostly highly indebted companies<br />
have difficulty finding the funds<br />
to pay for a sand regeneration plant or<br />
62 Casting Plant & Technology 2/<strong>2015</strong>
finance the license fees for German software. Communication<br />
is, and will remain, a major obstacle – black South<br />
Africans use eleven different languages.<br />
“While we place great hope in German technology, it<br />
must be proven, simple and economical,” Geoffrey Harding,<br />
who has long been active as the General Manager of<br />
Guestro, sums up South African expectations. It is therefore<br />
of decisive important for the success of EffSAFound<br />
to clarify the advantages of more efficient technology in<br />
concrete terms.<br />
This is why a trial plant is to be constructed at MTCS,<br />
to reclaim samples of the various sands used by several<br />
foundries and provide it again for use by the companies.<br />
The company GUT has delivered the planning and engineering<br />
for this plant. MCTS has also recently acquired<br />
a license for Magma simulation software. This can then<br />
be used to demonstrate to interested foundries the major<br />
process- and quality-related progress that can be achieved<br />
with modern simulation. Similarly, the demo software<br />
from Heger has also been installed, with whose help processes<br />
can be controlled efficiently and economically, and<br />
workforce qualification improved.<br />
Time is pressing. Electricity prices in South Africa have<br />
more than doubled during the last six years, and are now<br />
almost at European levels. Consumption in the country<br />
exceeds what the state-owned energy group Eskom can<br />
produce in its old coal-driven power stations: 2014 was<br />
far and away the year with the most frequent power cuts.<br />
Many foundries are also suffering from costs of up to 100<br />
Euro per tonne for landfilling molding sand – particularly<br />
in the highly industrialized region of Gauteng near<br />
Johannesburg, where many foundries are located. And<br />
last but not least, Chinese companies are forcing their<br />
way onto the South African market with cheap castings.<br />
“Many companies face bankruptcy unless they can very<br />
soon change how they operate,” says Bosse.<br />
It has, meanwhile, stopped raining in the Benoni industrial<br />
estate. The first rays of sunshine are timidly peeping<br />
through the opaque grey and making the blossoming<br />
jacaranda trees flicker in violet. There is light on the<br />
horizon again. As if to match this, those responsible at<br />
Guestro have insisted on optimism. Despite poor sales figures<br />
and a mountain of debt, General Manager Harding<br />
is convinced that “We will be able to get back on our feet<br />
within two years.”<br />
The company wants to install a new medium-frequency<br />
tandem melting furnace, modernize its molding plant<br />
and construct a sand regeneration system. For these investments<br />
it has applied for funding from the state. If everything<br />
works out, Bosse believes, Guestro will become a<br />
success story that can also convince other companies to<br />
take similar steps. And if not? “Then at least we will have<br />
increased awareness about efficiency and resource conservation<br />
in this important sector,” says GUT Managing Director<br />
Jens Müller-Späth. Because one thing is certain: the<br />
Germans cannot supply personal initiative and the readiness<br />
to try something new.<br />
Casting Plant & Technology 2/<strong>2015</strong> 63
K INDUSTRIAL COOPERATION<br />
Author: Manuel Bosse, IfG Service GmbH, Düsseldorf<br />
BMBF project reduces energy and<br />
resource requirements in South African<br />
foundries<br />
EffSAFound, Part 2: The German and South African foundry industries have been collaborating<br />
since 2013 to jointly stabilize iron and steel foundries in South Africa and drive forward European<br />
standards. The interim conclusion of the EffSAFound research project shows that efficiency<br />
considerations still receive little attention, though the potentials are enormous<br />
Holding the reins of the research project: Manuel Bosse from IfG Service GmbH and the South African Project Manager<br />
Palesa Riba (Photo: Palesa Riba)<br />
IfG-Service GmbH in Düsseldorf,<br />
the Metal Casting Technology Station<br />
(MCTS) at Johannesburg University<br />
and three German partner companies<br />
have initiated a joint research<br />
project called EffSAFound in order to<br />
lead South Africa’s foundries onto the<br />
world market and jointly work out improvement<br />
measures for iron and steel<br />
foundries in both countries. There have<br />
already been close exchanges between<br />
the research institutes on a specialist<br />
level for years. In addition, the fact<br />
that foundry technology ‘Made in Germany’<br />
has a high status in South Africa<br />
simplified setting up the joint project.<br />
The other South African partners<br />
in the project are:<br />
» The South African Institute of Foundrymen<br />
(SAIF): an association of South<br />
African foundries and the training<br />
partner in the research project.<br />
» The National Foundry Technology<br />
Network (NFTN): as part of the Department<br />
of Trade and Industry (dti)<br />
the NFTN is committed to making<br />
targeted improvements in the glo-<br />
64 Casting Plant & Technology 2/<strong>2015</strong>
al competitiveness of South Africa’s<br />
foundry industry.<br />
» Eskom: South Africa’s state energy<br />
supply company has been brought<br />
in as a transfer partner for intermediate<br />
project results.<br />
Figure 1: Natural gas is not available in many South African foundries. Paraffin<br />
or diesel is used in preheating processes instead (Photos: Manuel Bosse)<br />
Energy efficiency has hitherto<br />
received little attention<br />
Nine South African foundries are participating<br />
in EffSAFound. The country’s<br />
largest foundry, Atlantis Foundries in<br />
Cape Town, is a subsidiary of Mercedes<br />
Benz Trucks following the example of<br />
the iron foundry in Mannheim, and is<br />
responsible for about 15 % of good castings<br />
in South Africa. Two iron and steel<br />
foundries in the research project are located<br />
in Durban and five are in the greater<br />
Johannesburg area, mainly producing<br />
highly wear-resistant castings for the domestic<br />
mining and mechanical engineering<br />
industries. One brass foundry<br />
for fittings is rather exotic in this field.<br />
It quickly became clear that the<br />
data situation in South Africa is rather<br />
meagre because there are no aggregated<br />
data for the entire foundry industry<br />
due to the many small foundries involved.<br />
Personnel costs make up about<br />
34 % of the total costs of iron and steel<br />
foundries, according to a recent survey<br />
carried out by SAIF. The proportion of<br />
total costs spent on raw materials, additives<br />
and operating supplies is 28 %,<br />
while energy costs have risen to 16 % in<br />
recent years. The automation pressure<br />
is considerably lower than in Germany<br />
as a result of the generally low personnel<br />
costs and high level of unemployment<br />
in South Africa. For this reason<br />
South African foundries should actually<br />
achieve a lower energy requirement<br />
Figure 2: Rusted and unsorted cast iron scrap reduces the casting quality and increases the energy consumption per<br />
ton of molten metal significantly<br />
Casting Plant & Technology 2/<strong>2015</strong> 65
K INDUSTRIAL COOPERATION<br />
power requirements by 10 %. Moreover,<br />
electricity prices rose by an average<br />
of 25 % a year between 2008 and<br />
2011. The state energy supplier Eskom<br />
can only increase prices by 8 % a year<br />
between 2013 and 2017. EffSAFound<br />
has ensured that the foundries and Eskom<br />
finally sit at a table together and<br />
jointly try to find solutions. One alternative<br />
would be to invest in fuel-fired<br />
melting plants. There are only a few cupola<br />
furnaces in South Africa, however,<br />
and almost no foundries have access<br />
to natural gas, or only at great cost, so<br />
production largely operates with electricity<br />
while others use paraffin or diesel<br />
instead of natural gas.<br />
Figure 3: Magnesium treatment: Cast iron is also produced with spheroidal<br />
graphite in South African foundries – magnesium is added to the converters<br />
for this purpose (Photo: Palesa Riba)<br />
per tonne of good castings compared to<br />
German foundries – but the opposite<br />
is the case: existing melting facilities<br />
and foundry plants are outdated and<br />
the topic of energy efficiency received<br />
little attention when investment decisions<br />
were being made in the past.<br />
Fluctuating power supply<br />
The South African foundry industry<br />
faces major challenges. These include<br />
the energy supply. The relationship between<br />
the electricity supplier Eskom<br />
and the foundries is strained. Nominally,<br />
South Africa has a power plant output<br />
of about 46,000 megawatts (MW),<br />
of which about 85 % is generated using<br />
coal. The old power plants, combined<br />
with poor maintenance in some cases,<br />
lead to the actual output being considerably<br />
below 40,000 MW. The Medupi<br />
and Kusile power stations (each<br />
with six 800-MW turbines) which are<br />
supposed to be gradually synchronized<br />
with the grid are still not available after<br />
a seven-year building phase. On peak<br />
days, however, more than 44,000 MW<br />
is called up, leading to power outages.<br />
In addition, rainfall in the north of the<br />
country has soaked the coal reserves<br />
and, in early November 2014, a large<br />
coal silo at a power station collapsed<br />
– leading to further nationwide power<br />
cuts. Eskom is thus relying on so-called<br />
‘load shedding’: electricity is cut off for<br />
up to 5 h a day in previously announced<br />
parts of the towns. While German consumers<br />
suffer average periods of interrupted<br />
power supply of about 16 minutes<br />
a year, this figure is 42 h per year<br />
in South Africa.<br />
This is a nightmare for production<br />
planners in the foundries. For South African<br />
companies, energy efficiency currently<br />
means that at times of high electricity<br />
demand they have to cut their<br />
Limited training – great competition<br />
Another problem is that large quantities<br />
of ‘simple’ castings from China<br />
have displaced domestic foundry capacities.<br />
Furthermore, high-quality<br />
core-intensive castings are imported<br />
from Europe and North America.<br />
The number of foundries in South Africa<br />
fell by 40 % – and production from<br />
650,000 to 400,000 t of good castings –<br />
between 2003 and 2013 alone. In addition<br />
to harsh competition there are also<br />
country-specific problems. Almost twothirds<br />
of foundry employees have no<br />
training or have only learnt briefly ‘onthe-job’,<br />
although the training efforts<br />
of the MCTS have resulted in the first<br />
positive results: in many larger foundries<br />
university graduates now hold key<br />
positions, e.g. in the melting plants, the<br />
molding shops or the core shops. And,<br />
last but not least, South Africa increasingly<br />
suffers from escalating strikes.<br />
Many were injured during strikes at<br />
a chromate mine in 2013. More than<br />
100,000 platinum miners went on<br />
strike for almost six months in 2014. No<br />
work was carried out in South Africa’s<br />
foundries in June and July 2014 when<br />
more than 220,000 metalworkers went<br />
on strike. The strike only ended after a<br />
three-year agreement was reached providing<br />
an annual 10 % increase in pay.<br />
Project content<br />
Three main topic areas for the<br />
EffSAFound project were extrapolated<br />
from these challenges:<br />
66 Casting Plant & Technology 2/<strong>2015</strong>
» In collaboration with its South African<br />
partner Ametex, Magma GmbH<br />
(based in Aachen), is developing a<br />
module within its Magmasoft simulation<br />
software especially for highchrome<br />
white cast iron in order to<br />
prevent rejections even before the<br />
first casting. The thermo-physical<br />
properties of the casting materials<br />
were determined for three of the<br />
nine participating foundries and test<br />
rods have been cast for a comprehensive<br />
series of measurements to ascertain<br />
the thermo-mechanical data<br />
(hot tensile and creep experiments).<br />
The data obtained has been validated<br />
on the basis of selected components<br />
produced by the participating<br />
foundries, so that it is possible for<br />
the foundries to achieve energy-efficient<br />
production with the help of<br />
the software.<br />
» With the help of detailed energy efficiency<br />
analyses in the foundries,<br />
and in collaboration with the company<br />
HegerPro (based in Enkenbach-<br />
Alsenborn), English-language<br />
software is being prepared for the<br />
qualification and awareness-raising<br />
of employees regarding energy efficiency.<br />
The German software has already<br />
been translated into English,<br />
and the next step will involve its<br />
modification for the topic of energy<br />
efficiency.<br />
» GUT Gießerei Umwelt Technik GmbH<br />
(based in Freudenberg) will collaborate<br />
in investigating the sand circuit<br />
regarding material and energy efficiency,<br />
working out optimization potentials<br />
and carrying out some regeneration<br />
trials. Although the foundries<br />
have been able to deposit their waste<br />
sand without regeneration in the<br />
past, the legal requirements here<br />
have been tightened up in recent<br />
years. Thus re-use of the waste sand,<br />
e.g. for roadbuilding, is currently illegal<br />
because this is considered dangerous.<br />
In addition, the costs for disposing<br />
of waste foundry sand have risen<br />
from about 7 to 31 Euro within seven<br />
years, and some foundries are already<br />
paying 100 Euro per tonne.<br />
The MCTS has carried out intensive<br />
work on this and examined the new<br />
sand, as well as the waste foundry<br />
sand, in all foundries. Moreover, one<br />
tonne of waste sand from each of two<br />
South African foundries has been regenerated<br />
and analyzed to prove that<br />
this can be re-used in the works. The<br />
construction of regeneration plants<br />
is being considered with the help of<br />
GUT. In addition, European data is being<br />
used to help achieve an assessment<br />
of waste foundry sand as ‘safe’ and thus<br />
enable recycling.<br />
Precise coordination required<br />
There is enormous potential for increasing<br />
the efficiency of South African<br />
foundries, and the most important<br />
improvement potentials have been<br />
identified within the framework of<br />
EffSAFound. The South African Project<br />
Manager Palesa Riba, the Managing<br />
Director of the MCTS Farouk Varachia,<br />
and Project Manager Bosse are in<br />
daily contact to drive the pro ject forward.<br />
But it is not just technical and structural<br />
questions. Precise coordination<br />
is required, particularly before project<br />
trips and concrete work in situ in<br />
the companies, because otherwise important<br />
contacts are simply not available.<br />
Intercultural competence is also<br />
called for when the German virtues<br />
of to-the-minute punctuality and<br />
dependability come up against socalled<br />
‘African time’. The first thing<br />
that one learns as a German in Johannesburg<br />
is that stress, hectic and<br />
feverish time definitions make little<br />
sense. One of the South African partners<br />
smilingly put it in a nutshell at<br />
one of the first meetings: “Europeans<br />
have the clock, we have the time!” Despite<br />
all the challenges, the research<br />
project achieved the three intermediate<br />
objectives in August 2014 after 16<br />
months and will thus be continued,<br />
as planned, until the end of October<br />
<strong>2015</strong>.<br />
The research project is financed<br />
on the German side by the Federal<br />
Ministry for Education and Research<br />
(BMBF) and on the South African<br />
side by the Department of Trade<br />
and Industry (dti) and the National<br />
Foundry Technology Network<br />
(NFTN).
K NEWS<br />
The premises of the Kurtz Ersa foundry in Hasloch, Germany<br />
KURTZ ERSA<br />
Molding a sustainable future<br />
With a ceremony held directly in the<br />
production hall, the Kurtz Ersa Corporation<br />
opened its new Smart Foundry on 6<br />
March in Hasloch, Germany. A year and<br />
a month had passed since the turning<br />
of the first sod – the starting shot for an<br />
ambitious project which has now been<br />
brought to a successful conclusion and<br />
officially handed over for its intended<br />
purpose. 150 invited guests, customers,<br />
project partners, representatives of important<br />
associations and staff were in attendance<br />
as the ribbon was cut.<br />
With the decision for the Smart<br />
Foundry, Kurtz Ersa pursued a strategic<br />
reorientation intended to secure the<br />
long-term continuity of the iron foundry<br />
and the over 100 jobs at the Hasloch<br />
site. This resulted in investments<br />
amounting to 12 million Euro for what<br />
is probably the world’s most modern<br />
hand mold foundry – a further significant<br />
milestone in the over 235-year history<br />
of the company which has included<br />
iron casting in its core competences<br />
since 1852. Today the broadly-based<br />
product range encompasses, among<br />
other things, planetary carriers, machine<br />
beds and pump housings for wellknown<br />
customers from such branches<br />
as mechanical engineering, drive engineering,<br />
power engineering, vehicle<br />
construction, vacuum engineering and<br />
wind energy. A study commissioned in<br />
advance attests to the necessary potential<br />
for the Kurtz product range to utilise<br />
the full capacity of the iron foundry<br />
with the production of high-quality cast<br />
iron parts for German industry in the<br />
future as well.<br />
From this, the parties involved in the<br />
project have developed a creative solution<br />
which illustrates the trend to “Industrie<br />
4.0” and leads to a doubling of<br />
productivity with increased efficiency.<br />
The concept: Exploiting as many existing<br />
buildings as possible, Smart Foundry<br />
focuses on a completely new material<br />
flow and continuous clocked hand<br />
molding production in keeping with<br />
the Toyota production system. An<br />
SAP-controlled production concept,<br />
parcelled production areas and an unmanned,<br />
universally mobile transport<br />
system result in a flexible process chain<br />
in which manual production phases<br />
and an automated logistics system can<br />
be ideally combined. 1,700 m 2 of<br />
ground-up renovations and 2,580 m 2<br />
of newly-constructed buildings are two<br />
of the major figures in the project, but<br />
say little about the very short construction<br />
period. Just one example: The<br />
construction of the hall alone required<br />
extensive foundation work with over<br />
2,000 m of bored pile rammed in far<br />
below the water table. Numerous partners<br />
contributed to the successful outcome<br />
of the Smart Foundry project –<br />
from the architects, Menig & Partner<br />
to the developer Riedel Bau und Bauer,<br />
the plant supplier F.A.T. Förder- and<br />
Anlagentechnik, Nederman Filtration,<br />
Demag Krane and WFT Fertigungstechnik.<br />
Max Schumacher, Managing Director<br />
of the German Foundry Association<br />
(BDG), accepted the invitation to<br />
speak and used the opportunity to<br />
prove that the German iron foundry<br />
industry continues to be an engine of<br />
innovation and a technological leader.<br />
It was worth investing in iron<br />
foundries in Germany, he claimed,<br />
68 Casting Plant & Technology 2/<strong>2015</strong>
The Smart Foundry is particularly high-capacity with unit weights from 1 to 10 tonnes, which can be manufactured<br />
from all currently common iron casting materials<br />
even if the volume growth is now taking<br />
place in Asia. “I walked around<br />
here today and I can assure you that<br />
Kurtz Ersa has set the bar very high<br />
indeed with its Smart Foundry – even<br />
in global terms: customer-oriented,<br />
productive, innovative, efficient, active<br />
– these are what allow progress to<br />
be moulded”, said the BDG man<br />
Schumacher. Only those who permanently<br />
adapt to changing circumstances<br />
have the chance to enjoy permanent<br />
success.<br />
Shortly before the traditional ribbon-cutting<br />
ceremony, Rainer Kurtz<br />
told the assembled guests: “With the<br />
Smart Foundry, I am pleased and proud<br />
to be able to present you with an Industrie<br />
4.0 foundry with a length of 320 m<br />
and with 23,000 m 2 of production<br />
area. We have spared no effort to set<br />
standards in terms of the SAP-controlled<br />
production concept, including<br />
continuous clocking in accordance<br />
with the Toyota principle, workplace<br />
quality, environmental protection and<br />
energy recovery. For we are firmly rooted<br />
in this location; this is where it all<br />
began - and this is where we want to<br />
Everything in view: All the work processes are centrally monitored at the<br />
Kurtz Ersa Smart Foundry control centre<br />
stay. With our new iron foundry, we<br />
are completely hardwired to growth!”<br />
www.kurtzersa.com<br />
PDF-File: Brochure Smart Foundry<br />
– the Industry 4.0 Foundry<br />
http://1drv.ms/1FCNgVV<br />
Casting Plant & Technology 2/<strong>2015</strong> 69
K NEWS<br />
Award ceremony with managers of<br />
ABB and Georg Fischer in Zurich,<br />
Switzerland (Photo: GF)<br />
GEORG FISCHER<br />
Global ABB Supplier Sustainability<br />
Award<br />
Georg Fischer (GF), Schaffhausen,<br />
Switzerland, is honoured with the<br />
first Global ABB Supplier Sustainability<br />
Award. The award, which recognizes<br />
sustainability leaders in its supply<br />
chains, was handed over on 25 March<br />
at ABB in Zurich.<br />
The GF foundry in Leipzig, Germany,<br />
with its 260 employees produces<br />
housings for ABB Turbocharging. “I am<br />
pleased that we reward the Global ABB<br />
Supplier Sustainability Award to GF in<br />
Leipzig,” says Daniel Helmig, ABB’s<br />
Head of Supply Chain Management.<br />
“The company is an example of an ABB<br />
supplier that is in line with our high<br />
standards on sustainability and top<br />
quality – a real benchmark in our supply<br />
base.”<br />
GF Leipzig has adopted robust and effective<br />
sustainability practices. The location<br />
uses new fuels that help limit carbon-dioxide<br />
emissions, recycles its raw<br />
materials and provides training to reduce<br />
accidents and to improve health<br />
and safety for its employees. “This award<br />
is a symbol for the excellent and trustworthy<br />
collaboration of both companies<br />
and honored our sustainability efforts<br />
over the last years” states Matthias Heinrich,<br />
Managing Director of GF Leipzig.<br />
The GF foundry sets a high benchmark<br />
in the ABB supply chain with its<br />
state-of-the-art operations. This is particularly<br />
important for suppliers with<br />
inherently hazardous and energy-intensive<br />
manufacturing processes such<br />
as smelting and casting. “I am happy<br />
to see the continuous investments in<br />
technologies to reduce energy consumption,<br />
emissions and waste volumes”,<br />
says Adam Roscoe, ABBs Head<br />
of Sustainability Affairs.<br />
“We are greatly honored to receive this<br />
Award from ABB. It is a stimulus to resolutely<br />
pursue our sustainability efforts,“<br />
stated Manfred Leyrer, GF Corporate<br />
Sustainability Officer.<br />
www.gfau.com<br />
Klumpf_Technische_Chemie_en 21.11.2007 17:59 Uhr Seite 1<br />
RUDOLF UHLEN GmbH<br />
Face protection for every application<br />
Rudolf Uhlen GmbH is a manufacturer of personal protective<br />
equipment (PPE) for face protection. Especially for the<br />
steel and foundry industry we provide special solutions in<br />
the field of IR-protection. We produce:<br />
Visor carriers<br />
Gold-coated visors<br />
Mesh visors<br />
PC-visors<br />
Head Gears<br />
Electric arc protection<br />
PARTICLE<br />
RUDOLF UHLEN GmbH Telefon: (<strong>02</strong>129) 1444<br />
Am Höfgen 13 - 42781 Haan Telefax: (<strong>02</strong>129) 59980<br />
www.aschua-uhlen.de info@aschua-uhlen.de<br />
70 Casting Plant & Technology 2/<strong>2015</strong><br />
Visit us at<br />
GIFA <strong>2015</strong><br />
in Düsseldorf!<br />
Hall 10 - D14<br />
D - 45699 HERTEN • Industriestr. 15<br />
www.diffu-therm.de<br />
please visit us: GIFA <strong>2015</strong> hall 11 stand 11H16<br />
Klumpf_Messehinweis.indd 1 26.11.14 08:<strong>02</strong>
METSEARCH<br />
New sector portal for the<br />
metal-working industries<br />
With immediate effect, the new sector<br />
portal Metsearch is offering a comprehensive<br />
and complete product and<br />
company database in English and German<br />
across the various metal-working<br />
sectors at www.metsearch.net.<br />
Sector and company news along<br />
with background information on the<br />
industrial sectors of the national and<br />
international trade fairs covering the<br />
areas of foundry technology, metallurgy,<br />
cast products, thermal process<br />
technology, industrial fittings, pipes/<br />
tubes along with wire and cable<br />
round off the range of services. Always<br />
up-to-date, Metsearch is an international<br />
sector portal which covers<br />
the complete metal-working<br />
industry market.<br />
By using the navigation bar the user<br />
accesses a comprehensive database<br />
containing products, companies, sector<br />
and company news. It is also possible<br />
to search for trade fairs where specific<br />
companies are exhibiting or<br />
presenting special products. In this<br />
connection the GIFA, METEC, THERM-<br />
PROCESS, NEWCAST, wire, Tube and<br />
Valve World Expo trade fairs have been<br />
taken into account.<br />
Quite irrespective of whether the<br />
search is specifically for exhibitors,<br />
countries or products, the structure of<br />
the database enables the user to conduct<br />
a quick search and navigate directly<br />
to concentrated information.<br />
Changing monthly highlights with<br />
different key themes round off the portal’s<br />
diversity for every industrial sector.<br />
www.metsearch.net<br />
Please see us at GIFA,<br />
Düsseldorf, June 16-20,<br />
hall 16, stand A39<br />
Competence in<br />
Shot Blast Technology<br />
We offer a complete service in surface preparation technology,<br />
not just as machine designers and manufacturers.<br />
Our emphasis is on providing reliable service on:<br />
• Wear and Spare Parts<br />
• Repair and (remote) maintenance<br />
• Inspection and process advice<br />
• Machine upgrades and performance<br />
enhancement<br />
• Upgraded used machines<br />
AGTOS<br />
Gesellschaft für technische Oberflächensysteme mbH<br />
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Tel. +49(0)2572 96<strong>02</strong>6-0 · info@agtos.de<br />
www.agtos.com<br />
194-01/15-4c-GB<br />
Casting Plant & Technology 2/<strong>2015</strong> 71
30.09.2008 8:08:15 Uhr<br />
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ISBN 978-3-514-00751-2 79.00 €<br />
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A special chapter is dedicated to the great variety of Oriental dasmascus<br />
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Casting<br />
Special<br />
GIFA <strong>2015</strong><br />
GIFA<br />
Special
Approximately 50 % of cast products produced in Germany are used in the automotive industry (Photo: BDG/<br />
Soschinski)<br />
Author: Tanja Vellen, Messe Düsseldorf<br />
Foundry machines: high-tech solutions<br />
from a traditional industry<br />
Global production of castings exceeds 100 million tonnes<br />
Casting processes are the only way to<br />
manufacture many functional metal<br />
parts economically – or at all. The<br />
foundry industry is a major supplier to<br />
other sectors of industry, is responsible<br />
for much of the technical progress that<br />
is made and is therefore important to<br />
many national economies. To remain<br />
competitive, it requires production resources<br />
with which operating costs can<br />
be reduced and individual strengths can<br />
be improved. The <strong>International</strong> Foundry<br />
Trade Fair GIFA <strong>2015</strong>, which is taking<br />
place in Düsseldorf from 16. to 20.<br />
June <strong>2015</strong>, will be providing an insight<br />
into the latest state of the art in foundry<br />
machine technology and all areas of<br />
manu facturing technology.<br />
More than 100 million tonnes of castings,<br />
parts made from cast standard/<br />
malleable iron and steel (EST castings)<br />
or non-ferrous metals are manufactured<br />
in total all over the world every year.<br />
According to the most recent global statistics,<br />
the total volume in 2013 was<br />
103.2 million tonnes, with the following<br />
breakdown: EST castings 84.8 million<br />
tonnes, aluminium 15.4 million<br />
tonnes and other non-ferrous metals<br />
3 million tonnes.<br />
Apart from political developments<br />
and their consequences, the foundry<br />
industry depends heavily on the development<br />
of the automotive industry,<br />
machine manufacturing, the construction<br />
industry and the energy market.<br />
According to figures calculated by the<br />
German Foundry Association (BDG),<br />
Düsseldorf, a good 50 % of the castings<br />
manufactured in Germany are, for example,<br />
supplied to the automotive industry,<br />
while just under 25 % are used<br />
in machine manufacturing.<br />
Market development<br />
At the <strong>International</strong> Foundry Forum<br />
(IFF) that was held in Venice in September<br />
2014, the President of the European<br />
Foundry Association (CAEF),<br />
Luis Filipe Villas-Boas, drew attention<br />
to uncertain geopolitical circumstances,<br />
which were reducing willingness to<br />
invest in many areas of the industry, although<br />
the non-ferrous sector was de-<br />
74 Casting Plant & Technology 2/<strong>2015</strong>
veloping better than the ferrous sector.<br />
Dr Ioannis Ioannidis, Vice-President<br />
of the European Foundry Equipment<br />
Suppliers Association and Chairman of<br />
the Board of the VDMA Foundry Machine<br />
Association, shares this view,<br />
emphasising in December 2014: “Business<br />
is slower at steel and iron foundries,<br />
whereas it is developing more<br />
positively at die and permanent mold<br />
casting foundries.”<br />
Markets<br />
The automotive industry has always had<br />
a major influence on the geographic and<br />
technical development of the foundry<br />
sector. Dr Heinz Büchner from IKB Industriebank<br />
expects demand for castings<br />
from the automotive industry to increase<br />
in general over the next decade.<br />
Rising prosperity in the emerging markets<br />
is likely to drive growth on the car<br />
market, while stricter legal regulations<br />
about energy efficiency and emissions<br />
should lead to higher sales on the European<br />
market. From 2018 onwards, there<br />
is also likely to be substitution of EST<br />
castings by lightweight metal castings<br />
for certain parts when a switch is made<br />
to new car models. According to Dr Ioannidis,<br />
smaller and smaller engines are<br />
being developed, which need to be able<br />
to cope with increasingly high-performance<br />
operation. Foundries and their<br />
suppliers are expected to develop important<br />
components here. More materials<br />
will be combined with each other<br />
in future too. The objective is to manufacture<br />
parts with better properties<br />
but lower production costs. The foundry<br />
industry can expect high growth in<br />
the machine manufacturing, chemical,<br />
food and energy generation industries<br />
as well. Resource and energy efficiency<br />
will in general become a considerably<br />
more important issue.<br />
The IKB market survey reveals that the<br />
markets for the European foundry industry<br />
will be shifting to a larger extent<br />
towards Eastern Europe and East Asia.<br />
China has become a more significant<br />
sales market for foundry machines<br />
again, which is associated with the anticipated<br />
expansion of casting capacities.<br />
In view of the political and economic<br />
sanctions and their impact on<br />
project funding, the situation in Russia<br />
Structural parts made of cast aluminum are becoming ever more important in<br />
the automotive industry<br />
In the design and manufacture of motor vehicles parts are increasingly replaced<br />
by castings<br />
is likely to become substantially more<br />
difficult. At the IFF, Andrew Dibrov,<br />
Vice-President of the Russian Association<br />
of Foundrymen, pointed out that<br />
Russian foundries needed modern<br />
equipment for such areas as casting and<br />
medium-frequency furnaces, but he<br />
also drew attention to the fact that the<br />
current political sanctions would have<br />
the effect that the business community<br />
in the country will be turning to the east<br />
to an increased extent. When Russian<br />
banks provide support to companies,<br />
Asian suppliers would then be preferred,<br />
although European manufacturers<br />
would also be commissioned when they<br />
had manufacturing facilities in Russia or<br />
Asia.<br />
Casting Plant & Technology 2/<strong>2015</strong> 75
The situation in the NAFTA area, which<br />
is being reindustrialised thanks to favourable<br />
energy costs, can, in general,<br />
be considered good. A large proportion<br />
of the growth is taking place in Mexico.<br />
This development is leading to higher<br />
demand for casting production capacities<br />
and the relevant manufacturing<br />
equipment.<br />
Recommendations<br />
CAEF President Villas-Boas thinks that<br />
the foundry industry has strengths in<br />
the design potential it has, with which<br />
the demands made by the automotive<br />
industry for lightweight structures can<br />
be met. At the IFF, he also encouraged<br />
companies to form electronic networks<br />
that have the potential to make corporate<br />
operations even more successful<br />
and profitable. Dr Büchner recommends<br />
that manufacturers of foundry<br />
machines continue to invest in research,<br />
development and qualified staff,<br />
make ongoing reviews of the technical<br />
lead they hold, develop appropriate<br />
strategies and, in this context, e xpand<br />
such arrangements as sales co-operation<br />
agreements. He also thinks that it is very<br />
important to participate in trade fairs.<br />
Not only in the foundry machine industry<br />
are leading manufacturers working<br />
on supplying machines with technology<br />
that is customised as precisely as possible<br />
to satisfy the requirements of the<br />
users and their markets.<br />
The GIFA <strong>2015</strong> trade fair<br />
Foundries need innovative machines,<br />
equipment and software systems in order<br />
to be able to operate efficiently. The<br />
<strong>International</strong> Foundry Trade Fair GIFA,<br />
which is taking place at the same time<br />
as the trade fairs METEC, THERMPRO-<br />
CESS and NEWCAST that focus on associated<br />
fields and all share the same motto<br />
(“The Bright World of Metals“), will<br />
be providing information about this<br />
and the innovative developments that<br />
are being made. The exhibition programme<br />
consists of foundry plants and<br />
equipment, melting plants and equipment,<br />
refractories technology, moulding<br />
and core making plants and equipment,<br />
moulding sands and moulding<br />
auxiliaries, sand preparation and reclamation,<br />
gating and feeding, casting machines<br />
and pouring equipment, knockout,<br />
fettling and finishing, pattern and<br />
die making, process control technology<br />
and automation, environmental protection<br />
and waste removal as well as information<br />
technology.<br />
Technical forums at the trade fair<br />
GIFA-Forum<br />
Tuesday, 16.06.<strong>2015</strong><br />
*Speaker<br />
10:45 Opening: Dr.-Ing. C. Wilhelm, German Foundry Association,<br />
Düsseldorf/Germany<br />
11:00 Energy Efficient Use of Medium Frequency Induction<br />
Furnaces with Constant Power Range by Use of Power<br />
Optimized Charging; Dr.-Ing. M. Rische*, Dr. E. Dötsch, Y.<br />
Yildir, R. Ibach, ABP Induction Systems, Dortmund/Germany<br />
11:30 A New Generation of Ceramic Foam Filters Providing<br />
Real Opportunities for Cleaner Steel Castings; N. Child,<br />
Foseco <strong>International</strong> Limited, Tamworth/UK<br />
12:00 New Trends in Feeder Technology; G. Brieger, Chemex<br />
GmbH, Delligsen/Germany<br />
12:30 High Value Added Cast Parts - Advanced Feeding<br />
Systems and Metallurgical Improvements; J. Prat*, ASK<br />
Chemicals España, Castro Urdiales/Spain; I. Julián, A.<br />
Garikoitz, IK4-Azterlan, Durango/Spain<br />
13:00 Break<br />
13:15 Inorganic Core Sand: Decoring of Castings and Sand<br />
Reclamation; Dr. U. Dinglreiter, R. Scheuchl GmbH, Ortenburg/Germany<br />
13:45 New possibilities of surface finishing for the die-casting<br />
industry; I. Löken, Spaleck Oberflächentechnik GmbH &<br />
Co. KG, Bocholt/Germany<br />
14:15 Methods for Describing the Flow Behavior of Inorganic<br />
Core Sand Material for the Production of Complex<br />
Cast Components; Dr.-Ing. A. Schrey*, Foseco Europe<br />
Marketing & Technology, Borken/Germany; Dr. V.<br />
Haanappel, Foseco Nederland, Enschede/Netherlands<br />
14:45 Minimizing Air Entrainment in High Pressure Die<br />
Casting Shot Sleeves; M. Stefano*, XC Engineering,<br />
Cantù/Italy; Dr. M. Barkhudarov, Flow Science, Santa Fe/<br />
USA<br />
15:15 Innovative coating to prevent white film defects<br />
C. Joachim*, C. Fourberg, Hüttenes-Albertus Chemische<br />
Werke GmbH, Düsseldorf/Germany; M. Vorrath, Dr. K.<br />
Seeger, Hüttenes-Albertus Chemische Werke GmbH,<br />
Hannover/Germany<br />
15:45 Equipment Availability and Energy Efficiency – a Contradiction?<br />
Dr. P. Reichen*, U. Jordi, Bühler AG, Uzwil/Switzerland;<br />
F. Hoffmann, Bühler GmbH, Mannheim/Germany<br />
16:15 Performance of Long Thin Printed Sand Cores in<br />
Aluminium Castings; T. Mueller, Voxeljet of America,<br />
Canton/USA<br />
16:45 Advancements in Die Lubricant Technology for the<br />
Evolving Die Cast Process; D. Tomazic*, Chem-Trend<br />
Deutschland GmbH, Gernlinden/Germany; J. Belyk, Chem-<br />
Trend, Howell/USA<br />
17:15 Development of Intelligent Green Sand Preparation<br />
System; T. Sakai*, S. Katsuhito, O. Yuichi, SINTOKOGIO,<br />
Toyokawa/Japan<br />
17:45 End<br />
76 Casting Plant & Technology 2/<strong>2015</strong>
All presentations at the technical forums at GIFA are either held in English or are simultaneously translated<br />
Venue<br />
Messe Düsseldorf GmbH, Hall 13, Stand C 38<br />
Registration<br />
Not required<br />
Participants<br />
Open to all<br />
Participation fee<br />
Free of charge<br />
Lectures<br />
The proceedings with the abstracts of the<br />
lectures will be available at the counter<br />
Language<br />
German – English (Simultaneous interpretation)<br />
NEWCAST-Forum<br />
Wednesday, 17.06.<strong>2015</strong><br />
10:30 Competiveness by Leadership – Ensure the Competitiveness<br />
of Foundries in High Wage Countries by Using a<br />
Clear Leadership Model; H. Doppler, Managementberatung<br />
Doppler, Freiberg am Neckar/Germany<br />
11:00 TENSAL ® - Development of a High Strength Aluminum<br />
Casting Alloy for the Production of Highly Loaded<br />
Chassis Components; Dr. rer. nat. K. Greven*, M. Loganathan,<br />
O. Grimm, KSM Castings, Hildesheim/Germany<br />
11:30 Productivity and Ecology Considerations of High<br />
Production CB Processes; J. Archibald*, M. Hartman, J.<br />
Benavente, ASK-Chemicals, Dublin Ohio /USA<br />
12:00 Cast product design driven by front-loading through<br />
virtual experimentation and optimization – baseline<br />
technology for efficient CAE-Development Processes;<br />
Dr.-Ing. H. Bramann*, Dr.-Ing. J. C. Sturm, H. Rockmann,<br />
H. J. Gaspers, MAGMA Gießereitechnologie, Aachen/Germany<br />
12:30 <strong>International</strong> Foundry Challenge - Suitable Production<br />
of Thin Walled Aluminum Prototype and Small<br />
Series Castings for Body in White Applications;<br />
Dr. J. Gundlach*, Dr. J. Detering, Grunewald, Bocholt/Germany<br />
13:00 Methodical, Automatic Optimization of the Casting<br />
Process in Terms of Economy, Resource Efficiency<br />
and Quality; P. Kohlmeyer, G. A. Röders, Soltau/ Germany<br />
13:30 Development of a Novel AlCu-Cast Alloy for Thermally<br />
High Loaded Cylinder Heads; Dr.-Ing. F. J. Feikus*, Dr.<br />
L. Kniewallner, Nemak Europe, Frankfurt/Germany; M.<br />
Rafetzeder, Dr. M. Djurdjevic, B. Stauder, Nemak Linz<br />
GmbH, Linz/Austria<br />
14:00 Lightweighting the Right Material at the Right Place<br />
- A Comparison of Iron, Aluminum, Magnesium and<br />
Carbon Fiber; K. Decking*, M. Holtkötter, Georg Fischer<br />
Automotive, Schaffhausen/Switzerland<br />
14:30 Energy Balance and CO 2<br />
Emissions Study for the<br />
Total Life Cycle of Engine Blocks from Aluminum<br />
and Cast Iron; Dr.-Ing. A. Sobota*, W. Görtz, Eisenwerk<br />
Brühl GmbH, Brühl/Germany<br />
15:00 End<br />
16:30 NEWCAST-Award<br />
Casting Plant & Technology 2/<strong>2015</strong> 77
WFO-Technical-Forum<br />
Thursday, 18.06.<strong>2015</strong><br />
12:55 Up-date on use of blended Bentonite & Coonerdite; B.<br />
Officer, P. Verdot, Amcol Metalcasting<br />
13:20 Environmental Inorganic binder systems; A. Tagg, John<br />
Winter, Geopola<br />
13:45 Innovative approach to training - A challenge for our<br />
industry; Dr. Pam Murrell FICME, Cast Metals Federation<br />
Birmingham/UK<br />
10:45 Opening Address by Vinod Kapur, WFO-President<br />
11:00 Keynote: The foundry of the future-advanced managing<br />
and manufacturing concepts for a global competitive<br />
cast iron plant; Jorge Fesch, Sakthi Portugal Group<br />
11:45 Comparing the USA and Europe Casting Industries<br />
D. Trinowski, Hüttenes-Albertus Chemische Werke<br />
12:15 RFI in No Bake Foundries; C. Wilding, Omega Foundry<br />
Machinery, Peterborough/UK<br />
14:10 Novel No bake binders with reduced fume; S. Trikha,<br />
Hüttenes Albertus<br />
14:35 Rapid development of new castings using simulation<br />
techniques; Tappan Roy, Texmaco Rail. Kolkata/ India<br />
15:00 Improving casting quality through lustrous carbon<br />
N. Richardson S & B/UK<br />
15:25 End<br />
16:00-17:30 World Foundry Organization General Assembly<br />
12:40 Break<br />
VDI-Technical-Forum<br />
Friday, 19.06.<strong>2015</strong><br />
10:30 Proven Odor and VOC Abatement in Foundries; C. Mülleder*,<br />
M. Klimisch, Dr. M. Krenn, CTP, Graz/Austria<br />
11:00 Determination and Assessment of Volume Defects in<br />
Aluminum Castings by Means of Computed Tomography<br />
Dr. B. Oberdorfer*, D. Habe, Dr. E. Kaschnitz, G. Schindelbacher,<br />
Österreichisches Gießerei-Institut (ÖGI), Leoben/Austria<br />
11:30 Simulation-Aided Optimization of Gating and Feeding<br />
Systems for Aluminum Sand Castings; Dr.-Ing. G. W. Dieckhues*,<br />
H. Rockmann, Ohm & Häner, Olpe/Germany<br />
12:00 Simulation in the Support of the Development of<br />
Innovative Processes in the Casting Industry; Dr.-Ing. M.<br />
Todte*, Flow Science Deutschland, Rottenburg/Germany;<br />
Dr. A Fent, H. Lang, BMW, Landshut/Germany<br />
12:30 Economic and Energy-Related Aspects of Batch Planning<br />
and the Optimization of Melt Operations; Dr. H. Ortloff*, K.<br />
Bembenek, K. Herzog, S. Recktor, RGU, Dortmund/Germany<br />
13:00 Break<br />
13:15 High Effective Linked Production of Cylinder Heads<br />
and Cylinder Blocks in Double Casting Machines at<br />
Volkswagen; Dr.-Ing. F. Hansen*, Dr.-Ing. R. Rösch, S. Uhde,<br />
K. Wagner, Volkswagen, Leichtmetallgießerei Hannover,<br />
Hannover/Germany<br />
13:45 Graded Sands: Impact of Grain Size Distribution on<br />
Molding Materials; Dr. H. Görke*, Dr. J. U. Zilles, M. Demary,<br />
Quarzwerke, Frechen/Germany<br />
14:15 Increase Your Casting Output, with 30 % Higher Productivity<br />
on DISA Vertical Machines; B. W. Haugbølle, DISA<br />
Industries, Taastrup/Denmark<br />
14:45 A Novel Emission Control System for the Reduction<br />
Air Pollutants in Flue Gases from Foundries<br />
Prof. Dr. P. Wiesen*, Bergische Universität Wuppertal,<br />
Wuppertal/Germany, Prof. M. S. Johnson, University of<br />
Copenhagen/Denmark; F. Hartung, M. Gallus, Infuser<br />
Deutschland, Mannheim/Germany<br />
15:15 Influence of Silicon Content, Strain Rate and Temperature<br />
on Toughness of High Si Ferritic Ductile Cast Iron; T. Ikeda*,<br />
Dr. Eng. U. Takuo, Dr. Eng. O. Keisaku, K. Nobuhiro, HI-<br />
NODE, Tokio/Japan<br />
15:45 Automated Quality Control for Tools, Patterns and Cast<br />
Metal Parts with Optical 3D Metrology Systems; S. Adolf,<br />
GOM Gesellschaft für Optische Messtechnik mbH, Braunschweig/Germany<br />
16:15 Defective Castings Detection in Large Ductile Iron Production<br />
Using a Machine Learning Approach; Dr.-Ing. G.<br />
Bertuzzi, SACMI Imola, Imola/Italy<br />
16:45 Thread New Paths in Automated Defect Recognition<br />
(ADR) for Castings; H. Schulenburg, VisiConsult, Stockelsdorf/Germany<br />
17:15 End<br />
78 Casting Plant & Technology 2/<strong>2015</strong>
Elemental Analyzers<br />
for C, H, N, O, S<br />
VELCO<br />
ELEMENTRAC ®<br />
ONH-p<br />
The ideal analyzer<br />
for the simultaneous<br />
determination of<br />
oxygen, nitrogen<br />
and hydrogen in<br />
solid samples such<br />
as cast iron.<br />
n Freely selectable<br />
configuration of<br />
O, N, H<br />
n Closed gas<br />
management<br />
n PC-controlled,<br />
segmented leakage<br />
test<br />
n Optimized catalyst<br />
for CO oxidation<br />
Reliable partner for more than 40 years<br />
Velco, Velbert, Germany, is known to foundries all over<br />
the world, as manufacturer of gunning machines and injections<br />
installations especially for this line of industry.<br />
Based on the continuous demand for environmental<br />
protection and reduction of costs Velco developed in<br />
close cooperation with the foundry industry installations<br />
for the re-use of foundry materials (filter dust,<br />
grinding dust, cold resin dust) and the introduction of<br />
alloys and carbon fines to reduce the batch coke by injection<br />
through separate nozzle which is placed near to the<br />
cupola tuyere.<br />
The injection is mainly done in the melting area as<br />
there are the highest temperatures so that the injected<br />
products can be quickly converted. Velco’s system with<br />
separate nozzles enables the user of cupola furnaces to<br />
inject bigger amounts without any problems in the furnace<br />
process.<br />
Velco offers for this purpose competent consulting service<br />
at site, test facilities, visit of reference plants, planning,<br />
manufacturing and installation of tailor-made<br />
equipment.<br />
Hall 5, Stand D 26<br />
www.velco.de<br />
Injection installation for a cupola furnace (Photo:<br />
Velco)<br />
www.eltra.com
Optical<br />
Particle Analyzers<br />
ELECTRONICS GMBH<br />
Experience pays<br />
For more than 35 years the name Electronics, Neuhausen,<br />
Germany, has been a guarantee for performance,<br />
precision, reliability and quality in the development of<br />
measuring systems for the casting industry with specialization<br />
in die-casting, low pressure casting and gravity<br />
die-casting. The customers include automotive suppliers<br />
and well-known European car manufacturers.<br />
As a leading manufacturer of process data measuring<br />
systems for casting machines the company provides customers<br />
with day-to-day support in optimizing their production<br />
processes. A reliable process flow and dependable<br />
documentation are just as important for success as<br />
the reduction of rejects and optimal reproducibility of<br />
cast parts – goals that are easy to regulate, control and<br />
measure.<br />
Decades of experience, sound expertise and an understanding<br />
of the parameters that are decisive for the casting<br />
process make the company a sought-after system<br />
partner - worldwide.<br />
Tough international competition, increased customer<br />
demands and legal requirements – for example concerning<br />
product liability – constantly increase the demands<br />
made on modern casting and the respective quality management<br />
system. A company can only be successful on<br />
the market if a high quality of cast parts is guaranteed.<br />
Electroniccs offer its customers the right solutions to<br />
meet these high demands: Electronics process data measuring<br />
systems<br />
Hall 11, Stand C 12<br />
www.electronics-gmbh.de<br />
The CAMSIZER P4 is the<br />
new generation of the<br />
well-proven CAMSIZER<br />
system with patented<br />
Dual Camera Technology.<br />
The new analyzer offers<br />
improved performance<br />
and extended functionalities.<br />
n Extended measuring<br />
range from 20 μm<br />
to 30 mm<br />
n Faster hard- and software<br />
record more<br />
particles per second<br />
n Particle library and 3D<br />
cloud software<br />
Overview of products and services (Photo: Electronics)<br />
www.retsch-technology.com
ASK CHEMICALS<br />
Decoring test: The Inotec promoter TC 5000 achieves a considerable<br />
improvement in shakeout<br />
Casting advantages of the<br />
new Inotec generation<br />
ASK Chemicals, Hilden, Germany, has<br />
succeeded in further enhancing its inorganic<br />
Inotec technology through<br />
its new Inotec TC 5000 and Inotec HS<br />
3000 products. The new developments<br />
lead in particular to improved shakeout<br />
and higher moisture stability of<br />
the cores.<br />
The mounting advantages of using<br />
Inotec technology for the foundry industry<br />
are not only odorless core production<br />
and odor-reduced casting, but<br />
also the significantly lower cleaning<br />
required for machines and tools, leading<br />
to productivity increases for foundries.<br />
Inorganic binder systems also offer<br />
casting advantages that result in<br />
stronger components.<br />
The newly developed promoter Inotec<br />
TC 5000 complements the positive<br />
qualities of the previous generation in<br />
regard to penetration-free and sand-adhesion-free<br />
casting surfaces, and in<br />
terms of improved collapsibility properties<br />
in light metal casting, improved<br />
immediate strength levels, as well as<br />
increased storage life of the cores. Previously,<br />
the decoring of cast parts manufactured<br />
with inorganic binders presented<br />
a challenge in relation to water<br />
jackets, especially if the gutting machine<br />
had limited degrees of freedom.<br />
Inotec TC 5000 now enables even complex<br />
and delicate water jacket cores to<br />
be safely shaken out after casting. The<br />
system is 100 % inorganic and leaves<br />
no residual condensate deposits in the<br />
tooling, nor causes any smoke to form<br />
during the casting process.<br />
Likewise, the storage life of cores<br />
manufactured using inorganic binders<br />
previously posed a challenge, especially<br />
on hot summer days with high humidity<br />
and a high ambient temperature.<br />
Now, the new binder Inotec<br />
HS 3000 significantly improves the<br />
moisture stability of the inorganically<br />
bound cores. This in turn makes it possible<br />
to manufacture stable cores coated<br />
with a water-based coating, which<br />
also makes the Inotec binder system<br />
interesting for iron casting.<br />
Hall 12, Stand A22.<br />
www.ask-chemicals.com<br />
SMS HOLDING GmbH<br />
Plant and machinery for industrial<br />
metalworking applications<br />
The SMS group, Hilchenbach, Germany,<br />
ranks among the global leaders in<br />
plant construction and mechanical<br />
engineering for the entire metallurgical<br />
process chain.<br />
The company works in partnership<br />
with the steel and aluminum industry<br />
in building and upgrading plants or<br />
erecting complete turnkey plant complexes.<br />
The planning, engineering and<br />
financing are all closely interlinked<br />
here. The SMS group supplies plants for<br />
reduction metallurgy, steelmaking, secondary<br />
metallurgy and continuous casting<br />
technology for flat and long products.<br />
Alongside CSP technology, hot<br />
and cold rolling mills, strip processing<br />
plants and furnace technology, our<br />
range also includes tube plants, long<br />
product plants, forging plants, NF metal<br />
plants and heat treatment technology.<br />
A huge task SMS faces is reconciling<br />
ecology and economy. The company<br />
has solutions that focus equally on<br />
both areas. It has a name for product<br />
innovations that offer customers special<br />
economic and ecological advantages:<br />
Ecoplants.<br />
The customers also benefit from a<br />
needs-based service - ranging from selected<br />
services right up to a full service<br />
package. This means high plant availability<br />
with low maintenance costs.<br />
SMS has built up a global service network<br />
that provides the best possible<br />
support to plant owners using short<br />
routes as well as the local language.<br />
The company looks after the plant and<br />
machinery from commissioning right<br />
through its entire life cycle.<br />
Hall 5, Stand F 16,<br />
Hall 10, Stand H 41<br />
www.sms-group.com<br />
82 Casting Plant & Technology 2/<strong>2015</strong>
WALTHER-PRÄZISION<br />
Flexibility and safety in core<br />
making facilities<br />
Working in core making facilities for<br />
casting molds is often extremely hazardous<br />
to health and environment,<br />
since harmful and toxic chemicals<br />
like “ethyldimethylamine“ are commonly<br />
added to the core sand. This<br />
fluids speed up the curing process of<br />
the cores and will be added to the core<br />
sand out of larger containers.<br />
While replacing empty containers,<br />
screwed connections have to be unlocked<br />
in many cases. Remaining<br />
quantities of the hazardous fluid may<br />
escape freely forcing the user to wear<br />
cumbersome protective clothing.<br />
Walther-Präzision, Haan, Germany,<br />
provides a safe, environmentally<br />
friendly and clean solution: clean<br />
break couplings of the BF series. The<br />
couplings of these series meet highest<br />
demands on operating safety, residual<br />
leakage and reliability. The proven<br />
adaptor design and the ball face front<br />
surfaces on the coupling halves ensure<br />
an easy connection and seal the coupling<br />
before the valves open. Additionally,<br />
the special valve design creates a<br />
perfect clean break effect: “dead space<br />
volumes” or enclosed air volumes<br />
while coupling can be disregarded.<br />
Ball face clean break coupling BF series (Photo: Walther Präzision)<br />
In many field tests at well-known<br />
manufacturers Walther-Präzision<br />
demonstrated the advantages of these<br />
couplings. In the meantime, all of their<br />
core making facilities have been reequipped<br />
with couplings of the BF series.<br />
The replacement of chemical containers<br />
has thus become a clean job.<br />
Benefits of the BF series for core making<br />
at a glance:<br />
» quick replacement of tanks<br />
» leakage-free connection/no escape<br />
of fluids<br />
» no health hazard<br />
» no environmental pollution<br />
» easy cleaning thanks to smooth surfaces<br />
» one-hand operation<br />
» reliable and long-lasting due to modified<br />
sealing materials<br />
» no protective clothing required<br />
Thanks to this development, damages<br />
to health or environment are finally<br />
things of the past!<br />
Hall 11, Stand D 46<br />
www.walther-praezision.de<br />
CALDERYS<br />
Silica Mix – often copied but<br />
never matched<br />
Within the fundry industry, silica based<br />
refractories have been well known as<br />
the first choice lining for coreless induction<br />
furnaces for melting and holding<br />
of ferrous and copper based metals.<br />
Calderys, Issy-Les-Moulineaux,<br />
France, has been a leader for over<br />
50 years in this segment by providing<br />
the market with the world famous<br />
Swedish microcrystalline quartzite.<br />
Branded as Silica Mix this range is the<br />
benchmark reference in a competitive<br />
market.<br />
The technical advantages of Silica<br />
Mix linings brings the following and<br />
in some-ways considered unique advantages:<br />
» Naturally mineralized unique micro-crystalline<br />
Swedish quartzite<br />
-Slow crystal transformations<br />
-High thermal stability & refractoriness<br />
-Minimal growth and crack formation<br />
-Metal & slag compatibility<br />
» Reliable and predictable performance<br />
» High corrosion & erosion resistance<br />
together with mechanical strengths<br />
» Ease and speed of use<br />
» Good value in use economics<br />
Today, this becomes more relevant as<br />
foundries upgrade to modern, high<br />
density power rated, batch melting<br />
units.<br />
Calderys enjoys the major advantage<br />
of totally owned and fully in-house<br />
controlled production process available<br />
to the valued customers as needed.<br />
Calderys feels proud that its R&D and<br />
extended resources permit the availability<br />
of these special products and<br />
concepts to over 60 countries and future<br />
generations.<br />
Hall 10, Stand A 18<br />
www.calderys.com<br />
Casting Plant & Technology 2/<strong>2015</strong> 83
GTP SCHÄFER<br />
Foundry 4.0: Digitalisation as a<br />
key indicator for sustainable<br />
business success<br />
In the same way as the invention of<br />
the steam engine and the production<br />
line a few hundred years ago, digitalisation<br />
is fundamentally turning production<br />
processes as well our internally<br />
and externally-oriented methods<br />
upside down nowadays. Industrial<br />
success and, as a result, the success of<br />
the foundry industry will significantly<br />
depend upon the success of improvements<br />
in efficiency in terms of data<br />
exchange and intercompany communication<br />
in forthcoming years. Considerable<br />
investments are required in<br />
order to exploit the potential. As a consequence,<br />
the topic is assuming a leading<br />
position on the agenda of the highest<br />
levels of management in German<br />
industrial companies.<br />
“Foundry Industry 4.0”: Redefining<br />
and possibly revolutionizing the digitalization<br />
and the data exchange of product<br />
services and service offerings from<br />
industrial companies in order to identify<br />
customer requirements more quickly<br />
and to fulfil them in a better way. Companies<br />
are networking with customers<br />
and partners. In doing so, the special<br />
quality of the digital revolution is the<br />
rapid acceleration of processes and the<br />
amazing speed in terms of adjustment<br />
and change. At this point, the greatest<br />
changes will surely be faced by the socalled<br />
“old economy” companies, i.e.<br />
traditional producing companies such<br />
as foundries.<br />
With regard to the foundry industry,<br />
this means that the aforementioned<br />
improvement in efficiency and acceleration<br />
of the processes are already being<br />
increasingly practiced and re-quired by<br />
the end customers (cast purchasers).<br />
This starts with the provision and processing<br />
of construction and production<br />
data on shared virtual drives and<br />
through to connected goods management<br />
systems that update the needs of<br />
the customers in the foundry system<br />
each day. Within the framework of the<br />
trend towards digitalization and process<br />
acceleration, foundries have so far<br />
experienced significant stipulations<br />
from the customers. The objective of<br />
these stipulations is to simplify inhouse<br />
processes but not to necessarily<br />
simplify those of the foundries.<br />
Today, the suppliers to the foundry<br />
industry are faced with the task of improving<br />
the data exchange, communication<br />
and support of the customer or<br />
to adapt it to the new speed level. The<br />
requirement in terms of response speed<br />
in the event of technical problems or<br />
issues with the supplier has dramatically<br />
increased. Furthermore, the provision<br />
of data such as drawings, 3-D data<br />
sets, product and data sheets, etc. must<br />
be automated and efficiently designed.<br />
In addition to the aforementioned efficient<br />
design of the data exchange, digitalization<br />
can, above all, structure the<br />
interaction between the foundry and<br />
the supplier in a more efficient manner<br />
and create new added<br />
values. If a technical<br />
problem occurs,<br />
the founder<br />
must be able to contact<br />
the supplier<br />
immediately, they<br />
must be able to simply<br />
collect images,<br />
details and information<br />
regarding<br />
the problem at<br />
hand and they<br />
must be able to internally<br />
and externally<br />
distribute<br />
them. Establishing<br />
a working group that is then necessary<br />
and that consists of foundry employees<br />
and supplier application technicians<br />
must take place smoothly and in an automated<br />
manner. The solution to the<br />
problem must take place promptly and<br />
in a way that is transparent for all participants<br />
of the working group. A loss of<br />
information of individual participants<br />
or a temporal delay caused by incomplete<br />
mailing lists and full diaries is no<br />
longer acceptable today.<br />
Due to the aforementioned developments<br />
and requirements of the market,<br />
GTP Schäfer, Grevenbroich, Germany,<br />
has designed an App solution for its customers.<br />
The objective of this innovative<br />
system is to structure the provision of<br />
data and the exchange of information<br />
with customers in a more efficient and<br />
transparent manner. It is a network information<br />
system that, via smartphones,<br />
tablets and desktops, provides<br />
required information in a targeted manner,<br />
supports the collection and distribution<br />
of “on the go” data and promptly<br />
enables a problem-free integration of<br />
internal and external persons into individual<br />
working groups concerning various<br />
topics. Within this framework, a<br />
further aim is to provide the founder<br />
with additional “tools” in order to support<br />
their work in various modules. GTP<br />
Schäfer will present Version 1.0 of the<br />
“GTP Toolbox” within the context of<br />
GIFA <strong>2015</strong>.<br />
“Many industrial companies misjudge<br />
the transformational force of digital<br />
network”, says Andreas Diehl who,<br />
with his company firstangel.co, is specialized<br />
in the field of digital business<br />
modelling and products. Mr Diehl says<br />
that there is often a shortage in terms of<br />
the required willingness to innovate<br />
and invest. “Digital products define our<br />
everyday lives. GTP Schäfer has recognized<br />
the potential for their own business<br />
model and the advantages for its<br />
customers and have implemented it in<br />
a very resolute manner”, said a delighted<br />
Andreas Diehl at the launch of the<br />
GTP ToolBox. Interested parties can register<br />
for further information today at<br />
www.gtp-toolbox.com.<br />
Hall 12, Stand E 22 + E 29<br />
www.gtp-schaefer.de<br />
84 Casting Plant & Technology 2/<strong>2015</strong>
FOSECO<br />
New Inorganic Binder System of Foseco (Photo: Foseco)<br />
Binders for iron, steel and aluminum<br />
foundries<br />
At the show, Foseco, Borken, Germany,<br />
is highlighting a diverse range of binders<br />
that fulfil the needs of all foundry<br />
production processes. This will be<br />
achieved through the presentation of<br />
individual binder solutions for the production<br />
of automotive, marine engineering<br />
and steel castings. Intelligent,<br />
customized solutions help customers<br />
to save resources and increase the efficiency<br />
of their casting production, and<br />
examples of this will be demonstrated<br />
through specific case studies.<br />
Specific focus will be given to environmentally<br />
compliant solutions and<br />
the launch of a newly developed, fully<br />
inorganic binder system which is suitable<br />
for the manufacture of highly<br />
complex automotive castings such as<br />
cylinder heads or motor blocks. In contrast<br />
to conventional organic systems<br />
the new inorganic binder system does<br />
not release any harmful emissions and<br />
contributes both to the well-being of<br />
the foundry employees and the protection<br />
of the local environment.<br />
Hall 12, Stand A 1 + A 2<br />
www,foseco.com<br />
Videos about<br />
Foseco products<br />
http://foseco-at-gifa.com/en/highlights-<strong>2015</strong><br />
COLD JET<br />
New pelletizer provides best output to smallest footprint ratio in dry ice<br />
production (Photo: Cold Jet)<br />
E160 Pelletizer<br />
Cold Jet, Loveland, USA, – the world<br />
leader in developing innovative, environmentally<br />
responsible dry ice cleaning<br />
solutions and production equipment<br />
– announces the launch of the<br />
E160 Pelletizer, a highly efficient dry<br />
ice extruder that has minimal space requirements<br />
and is designed to manufacture<br />
3 mm-16 mm dry ice pellets and<br />
nuggets on demand. The E160 Pelletizer<br />
provides the best output to footprint<br />
ratio in dry ice production and has the<br />
lowest maintenance cost and lowest energy<br />
consumption.<br />
“The E160 Pelletizer is easy to operate,<br />
can go to full production in less than<br />
three minutes and requires only half of<br />
the normal space needed by similar dry<br />
ice production equipment on the market<br />
today,” said Wim Eeckelaers, Senior<br />
Vice President, Global Dry Ice Manufacturing,<br />
Cold Jet.<br />
In addition to its compact footprint,<br />
the fully automatic E160 Pelletizer produces<br />
up to 160 kg per hour of consistent,<br />
high density dry ice pellets or nuggets<br />
on demand; has the highest liquid<br />
to solid conversion rate; is simple to<br />
operate – either as a standalone machine<br />
or when integrated into an automated<br />
dry ice cleaning or surface preparation<br />
system; has a closed, stainless<br />
steel frame; can be operated from cylinders,<br />
dewars or storage tanks of liquid<br />
CO 2<br />
; and has multiple industrial voltage<br />
ports, enabling global installations.<br />
Cold Jet once again sets a new industry<br />
standard for dry ice production with<br />
the E160 Pelletizer.<br />
Cold Jet’s dry ice production equipment<br />
produces consistent, high density<br />
dry ice for transportation and blasting<br />
and has been engineered to extrude the<br />
highest density dry ice available. Due to<br />
our proprietary knowledge of dry ice,<br />
Cold Jet’s process creates a longer shelf<br />
life, better transportability and offers<br />
better blasting performance. Cold Jet<br />
pelletizers are also fully automated with<br />
one-button operation and are made to<br />
UL, USDA, FDA and CE standards.<br />
Hall 16, Stand A 24<br />
www.coldjet.com<br />
Casting Plant & Technology 2/<strong>2015</strong> 85
FOSECO<br />
Centrifugally cast iron cylinder<br />
liners for iron and aluminium<br />
foundries<br />
Globally the accepted emission levels<br />
for new vehicles is being driven ever<br />
lower, with car manufacturers focusing<br />
on lightweight design and energy efficiency<br />
to meet the legislative requirements.<br />
One area of specific focus is the<br />
downsizing of engines whilst retaining<br />
power output, in many cases utilising<br />
low weight aluminium blocks with grey<br />
iron cylinder liners.<br />
Foseco, Borken, Germany, will be displaying<br />
a technology package for the<br />
process of manufacturing grey cast iron<br />
cylinder liners. The liners exhibit a special<br />
surface structure which enables the<br />
casting to be directly cast into the aluminium<br />
block by gravity die casting as<br />
well as pressure die casting.<br />
Hall 12, Stand A1 + A2<br />
www.foseco.com<br />
Videos about Foseco products<br />
http://foseco-at-gifa.com/en/highlights-<strong>2015</strong><br />
Foseco’s technology package for iron cylinder liners<br />
(Photo: Foseco)<br />
CONVITEC<br />
Shake-out feeders CAV and<br />
CAH<br />
Vario shake-out feeders (CAV) are particularly<br />
suitable for shaking out sensitive<br />
castings and for different casting<br />
programs with small and big castings<br />
per order. These shake-out feeders<br />
work in the rotational speed range<br />
from 1,000 to 1,500 rpm respectively<br />
frequency 16-25 hertz, at an earth acceleration<br />
of 4.5 to 5.0 g. Depending<br />
on the casting program, the feeders are<br />
equipped with longitudinal or transversal<br />
slot grids and/or perforated metal<br />
sheets. A typical case of application<br />
exists where the casted molds require<br />
different shakeout behaviours and adaptation<br />
is necessary while production<br />
is running. The shakeout behaviour<br />
can be pre-selected individually and/<br />
or model-related at the moulding<br />
plant or via PC of the Vario shake-out<br />
feeder. For this, the drives (directed exciters)<br />
of the Vario shake-out feeder are<br />
electronically synchronized. It is possible<br />
to adjust the desired impact angle<br />
and thus the conveying speed by<br />
changing the phase position as well as<br />
the intensity of shaking out by changing<br />
the rpm to meet the requirements.<br />
CAH type shake-out feeders are used<br />
for the continuous separation of casting<br />
and sand after automatically operating<br />
flask or flask less molding plants.<br />
They are suitable for a wide range of<br />
castings including castings of different<br />
sensitivity. These shake-out feeders<br />
work in the rotational speed range<br />
from 1,000 to 1,500 rpm at an earth<br />
acceleration of 4.5 to 5.0 g. Depending<br />
on the casting program, the feeders are<br />
equipped with longitudinal or transversal<br />
slot grids and/or perforated metal<br />
sheets. The drive is usually provided<br />
by means of directed exciters, which<br />
can be located in the middle, above or<br />
underneath the machine. Due to the<br />
afore-mentioned arrangement of the<br />
exciters, it is possible to carry out<br />
maintenance works even from above.<br />
Shake-out feeders are designed according<br />
to the mold body dimensions and<br />
the conveying capacity of the molding<br />
plant. The width varies from 800 to<br />
3,000 mm and the length from 4,500<br />
(+500) to 7,500 (+500) mm.<br />
However, in case of very different<br />
casting programs and/or frequent<br />
model changes the Vario shake-out<br />
feeders, type CAV, are used.<br />
Hall 15, Stand F 23<br />
www.convitec.net<br />
86 Casting Plant & Technology 2/<strong>2015</strong>
Energy-Efficient<br />
Exhaust Air Filters<br />
JÖST<br />
Vibrating machines and<br />
systems<br />
Jöst, Dülmen, Germany, is globally<br />
known for innovation and constant developments<br />
of vibrating machines and<br />
systems for the foundry industry which<br />
are important to meet the changing requirements<br />
of modern foundries.<br />
As leading manufacturer of vibrating<br />
machines and system solutions for the<br />
foundry industry, Jöst GmbH + Co. KG<br />
VELCO<br />
presents an interesting products overview<br />
for primary and secondary metallurgy.<br />
Our scope of supply refers to the<br />
conveying of raw materials, screening,<br />
storage and dosing of different products<br />
up to the different furnace melting processes<br />
like EAF, RH, VD or LF.<br />
Hall 3, Stand F 33<br />
Hall 17, Stand D 47<br />
www.joest.com<br />
Process for concentration of<br />
Zn-dust<br />
In the framework of a research project<br />
by the German ministry of education<br />
and Research with Velco GmbH, Velbert,<br />
VDEh-Betriebsforschungsinstitut<br />
GmbH (BFI), Düsseldorf, and DK Recycling<br />
und Roheisen GmbH, Duisburg,<br />
(all Germany) as project partner, Velco<br />
installed at DK Recycling and Roheisen<br />
GmbH an installation for the injection<br />
of zinc-bearing filter dusts.<br />
The zinc-bearing furnace gas dust is<br />
injected into the induction furnace via a<br />
refractory dipping lance into the pig iron<br />
melt, whereby the zinc at first is converted<br />
into metallic form, vaporized and finally<br />
changing over to zinc-oxide that is<br />
separated in the filter of the dedusting<br />
plant. This zinc-oxide contains up to<br />
64 % Zn (about 80 % ZnO).<br />
The dust is stored in transport bins and<br />
brought to the injection installation<br />
with fork lifters. The injection installation<br />
consists of a support frame for receipt<br />
of the transport bins, a sieving installation<br />
for separation of overgrain and<br />
foreign particles, a pneumatic conveying<br />
installation and a manipulator allowing<br />
to dip the lance deep into the melt. The<br />
installation is running with conveying<br />
rates up to 60 kg/min. About 2 t of dust<br />
can be processed within one hour.<br />
Hall 5 / Stand D 26<br />
www.velco.de/englisch/englisch.php3<br />
Clean the air in your<br />
foundry and save<br />
energy!<br />
KMA has the right solution for<br />
each exhaust air problem:<br />
Centralized filter in an exhaust<br />
air mode and with integrated<br />
heat recovery<br />
Or: Recirculating air mode<br />
without heat loss <br />
High energy savings:<br />
up to 80 %<br />
Combinable with extraction<br />
hoods and room ventilation<br />
systems<br />
High air quality by high<br />
filtration efficiency<br />
Reducing heatig costs &<br />
CO2 emissions<br />
Low maintenance by automatic<br />
filter cleaning system<br />
Filter replacement is not<br />
necessary<br />
Visit us at<br />
GIFA<br />
in Dusseldorf/Germany!<br />
Hall 11, Booth H73<br />
Centralized exhaust air filter for an exhaust air capacity<br />
of 30,000 m³/h.<br />
With integrated heat exchanger and<br />
automatic cleaning system.<br />
Velco-Injection plant at DK Recycling und Roheisen GmbH in Duisburg, Germany<br />
(Photo: Velco)<br />
KMA Umwelttechnik GmbH<br />
Eduard-Rhein-Str. 2<br />
53639 Koenigswinter<br />
Germany<br />
www.kma-filter.de<br />
info@kma-filter.de<br />
Phone: +49 2244 - 9248 0
MEDENUS<br />
New cellular gas filter series<br />
DF100<br />
Medenus Gasdruckregeltechnik GmbH,<br />
Olpe, Germany, will present the new<br />
cellular gas filter series DF100 at THER-<br />
MPROCESS <strong>2015</strong>. This completes the<br />
existing product range of gas pressure<br />
regulators, safety shut off valves and<br />
safety relief valves. These cellular filters<br />
are available in size DN 25 – DN 200,<br />
with DIN flanges PN16 or ANSI150RF.<br />
The standard efficiency rate of dust<br />
of the filter cartridge is about 99,9 %<br />
> 2µm and they are suitable to all kinds<br />
of dry gases according to G 260/262<br />
(others upon request). If necessary it<br />
is possible to add a differential pressure<br />
gauge with or without remote indication<br />
and ball valves as well.<br />
Hall 9, Stand A34<br />
www.medenus.de<br />
New cellular gas filter DF100 – size<br />
DN50 (Photo: Medenus)<br />
LGC STANDARDS<br />
Industrial standards from LGC<br />
LGC, Teddington, UK, is a global leading<br />
manufacturer and supplier for:<br />
» Metals: pure metals as well as all<br />
type of alloys, which are available<br />
as CRM, RM or SUS. The established<br />
IARM standards are produced by<br />
LGC Standards in USA according<br />
ISO Guide 34<br />
» Powders: cement, slags and ashes,<br />
ferro alloys and ores, geological materials,<br />
plants, coke and coal<br />
» Water and oil-based reference materials<br />
which are produced by VHG<br />
labs under ISO Guide 34, ISO Guide<br />
35 and ISO Guide 17<strong>02</strong>5.<br />
The company also offers equipment and<br />
consumable for sample preparation:<br />
» Grinding, polishing and milling machines<br />
for metals<br />
» Own-brand autofluxer<br />
» Plastic films and cups for XRF.<br />
LGC also has the expertise to supply<br />
your physical testing materials requirements.<br />
To underline LGC Standards’<br />
position as a single-source-supplier<br />
in the industrial sector, it<br />
continually seeks to expand its portfolio<br />
to ensure it has the best fit for its<br />
customers’ needs. This includes sourcing<br />
materials from across the world including<br />
unique suppliers in Asia, USA<br />
and Europe.<br />
Hall 11, Stand H 10<br />
www.lgcstandards.com<br />
88 Casting Plant & Technology 2/<strong>2015</strong>
SCHLAGER INDUSTRIEOFENBAU<br />
Industrial furnace construction<br />
At Thermoprozess Wärmebehandlungen<br />
Austria GmbH an existing boogie<br />
hearth furnace with measurements l =<br />
13,000 x w = 6,500 x h = 7,000 mm for<br />
charging weights up to 250 t was modernized<br />
by Schlager Industrieofenbau<br />
from Hagen, Germany, with new gas<br />
heating including control system with<br />
Siemens Simatic S7 PLC.<br />
Following main improvements have<br />
been achieved:<br />
» About 30 % energy savings through<br />
optimized gas-air control with pulse<br />
control of the burners and installation<br />
of an automatic electric motor<br />
driven furnace pressure control valve<br />
» Improved exhaust emissions according<br />
requirements from local environmental<br />
authorities – 50 mg/ Nm³ CO<br />
from 300 °C operating temperature;<br />
200 mg/Nm³ NOx up to 750 °C operating<br />
temperature (values based on<br />
5 % residual oxygen in the exhaust<br />
gas)<br />
There were 10 burners installed, each<br />
with 360 kW power, including standard-compliant<br />
valve technology. By<br />
the new offset arrangement of the burners<br />
in the side walls with high flame<br />
speed and flame alignment under the<br />
charge very good temperature uniformity<br />
is achieved.<br />
The conversion was carried out rapidly<br />
within 2 weeks before Christmas.<br />
Regarding the high energy savings,<br />
the investment will pay for itself within<br />
short time.<br />
Thermoprozess Wärmebehandlungen<br />
Austria GmbH offers heat treatments in<br />
stationary furnaces in Linz and the following<br />
other services:<br />
Heat treatments at external customer<br />
workshops or construction sites<br />
» in temporary modular heat treatment<br />
furnaces<br />
» On-Situ heat treatment operations<br />
performed with methods of<br />
-resistance heating,<br />
-induction heating<br />
» Production and supply of mobile heat<br />
treatment equipment with<br />
-resistance heating,<br />
-induction heating<br />
» drying-out of refractory linings<br />
Its customers include renowned national<br />
and international companies in the<br />
areas of:<br />
» Energy and environmental<br />
» Power generation<br />
» Plant, container and equipment manufacturing<br />
(Photo: Schlager)<br />
» Mechanical and piping manufacturing<br />
» Chemical/petrochemical<br />
Schlager Industrieofenbau provides new<br />
industrial furnaces and offers modernizations<br />
and refractory repairs to existing<br />
furnaces. The company has its own<br />
manufacturing as well as electrical and<br />
automation department with cabinet<br />
construction.<br />
Hall 9, Stand E 39<br />
www.schlager-gmbh.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 89
ELTRA<br />
Precise carbon and sulfur<br />
analysis in inorganic samples<br />
The CS-800 by Eltra, Haan, Germany,<br />
is a flexible and robust combustion<br />
analyzer for the determination of carbon<br />
and sulfur in inorganic sample<br />
materials such as steel, cast iron or cement.<br />
Organic samples like soil, graphite<br />
or chemicals can also be analyzed<br />
with the CS-800. It is equipped with<br />
a 2,500 °C induction furnace to examine<br />
the element concentrations in<br />
solids without time-consuming sample<br />
preparation. The typical analysis<br />
time is approximately 45 to 60 s.<br />
Whereas spectrometric methods require<br />
a homogeneous and plane sample<br />
surface for C/ S analysis, the CS-800<br />
also accepts samples in the form of<br />
powders, grains, drillings or broken<br />
Carbon/Sulfur Analyzer CS-800 (Photo:<br />
Eltra)<br />
pieces. Thanks to the high sample<br />
weight of up to 1 g even inhomogeneous<br />
samples can be reliably characterized.<br />
The CS-800 features up to four independent<br />
infrared measuring cells allowing<br />
for accurate analysis of low as<br />
well as high carbon and sulfur concentrations<br />
simultaneously in one measurement.<br />
The sensitivity of the IR cells<br />
can be individually configured to ensure<br />
optimum adaptation to application<br />
requirements. If the analysis involves<br />
aggressive reactive gases (for<br />
example from acidulous soil samples)<br />
the use of robust and durable gold cuvettes<br />
is an option.<br />
Benefits:<br />
» Simultaneous analysis of carbon<br />
and sulfur in a 2,500 °C induction<br />
furnace<br />
» Up to four independent infrared cells<br />
with flexible measuring ranges<br />
» Very short measurement times<br />
» High sample weights from a few milligrams<br />
to 1 gram<br />
» Flexible sample geometry<br />
» Gold IR cells (option)<br />
» Automated sample feeding (option)<br />
Hall 11, Stand H 29<br />
www.eltra.com<br />
Dross<br />
Momometer Ad_186_128.indd 1 07.05.15 08:26<br />
90 Casting Plant & Technology 2/<strong>2015</strong>
ELEMENTAR ANALYSENSYSTEME<br />
Elemental analysis of metals and inorganic<br />
materials<br />
As the leader in elemental analysis of organic substances,<br />
Elementar Analysensysteme, Hanau, Germany,<br />
uses its leading technology for the development<br />
of a completely new instrument concept for the analysis<br />
of the elements C, S, O, N, H in metals and other<br />
inorganic materials.<br />
The new Inductar instrument line with the worldwide<br />
first “5-elements-analyser” for metals and<br />
inorganic materials (Photo: Elementar)<br />
Packed with innovative solutions and most modern<br />
technology the induction based instrument line Inductar<br />
sets new standards like:<br />
» solid-state technology for the high frequency induction<br />
furnace guarantees an almost unlimited<br />
lifetime<br />
» due to its design, no annoying cleaning procedures<br />
are necessary to remove dust or particulate residues<br />
» sample feeding with semi- or fully automated 90 positions<br />
sampler<br />
» new detection technology for precise hydrogen determination<br />
» optimized for safe and unattended 24/7 use<br />
» extremely compact design based on the well-known<br />
„cube“ platform of Elementar.<br />
As top performer of the new Inductar instrument<br />
line, Elementar introduces the worldwide first “5-elements-analyser”<br />
for metals and inorganic materials.<br />
It combines the analysis of CS and ONH in one<br />
instrument. The modular concept of the instrument<br />
line allows an upgrade of the CS and ONH analysers<br />
to a 5-element-design, at any time or to any other element<br />
combination for special applications.<br />
Hall 11, Stand D 9<br />
www.elementar.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 91
KÜTTNER<br />
High quality and low priced<br />
iron from cupola plant<br />
The cupola furnace with hot blast generation<br />
has been established over many<br />
years as the practice for the production<br />
of gray and ductile iron for serial castings.<br />
Küttner, Essen, Germany, has built<br />
over 300 cupolas in capacities ranging<br />
from 7 to 100 t/h and offers the appropriate<br />
design for specific process requirements.<br />
For the cupola furnaces, Küttner has<br />
developed a sophisticated design with<br />
long-life insulation and a proven furnace<br />
hearth geometry for the special<br />
metallurgical tasks. In addition, injection<br />
systems for oxygen to improve the<br />
thermal efficiency and injection for<br />
coke fines for flexible carburization are<br />
recommended. For the treatment of the<br />
iron different methods for desulphurization<br />
and magnesium treatment are<br />
available.<br />
Küttner has designed the dry gas<br />
cleaning system so that internationally<br />
required limits for dust, CO and SOx can<br />
be reliably achieved. This is ensured by<br />
special process technology with complete<br />
combustion, cooling and particle<br />
separation in a cloth filter system.<br />
By using a hot blast process approximately<br />
30 % of the energy of the off-gas<br />
of the cupola is used. It is increasingly<br />
important to use the remaining energy<br />
and a variety of solutions based on thermal<br />
oil and steam systems are available.<br />
Solutions for the heating of furnaces for<br />
core drying and painting but also for<br />
vaporisation of curing chambers are implemented<br />
at site. Blast drying systems<br />
are efficient in humid tropical regions.<br />
Examples of multi-site intergrated solutions<br />
have been implemented between<br />
neighbors from the paper industry,<br />
laundries and food manufacturers having<br />
a need for process heat. The environmental<br />
benefits as well.<br />
10 t/h Long-campaign cupola furnace with pressurized siphon and holding<br />
furnace (Photo: Küttner)<br />
Hall 16, Stand 26<br />
www.kuettner.com<br />
Visit our booth in Hall 16 / A34<br />
Working moment<br />
to 12,300 kgcm<br />
Working<br />
moment<br />
to<br />
6,500 kgcm<br />
FRIEDRICH Schwingtechnik GmbH<br />
P.O. Box 10 16 44 · 42760 Haan · Germany<br />
Phone +49 (0) 2129- 37 90-0<br />
Fax +49 (0) 2129- 37 90-37<br />
www.friedrich-schwingtechnik.de<br />
info@friedrich-schwingtechnik.de<br />
Unbalance Exciters<br />
>> Extended product range for driving motors<br />
with 750, 900, 1,000, 1,200 and 1,500 min -1<br />
>> Centrifugal force from 29 to 482 kN<br />
>> Working moment from 300 to 12,300 kgcm<br />
Vibrator Motors<br />
>> Maintenance free – bearings greased for lifetime<br />
>> Centrifugal force from 0.5 to 216 kN<br />
>> Working moment from 1.2 to 6,500 kgcm
EIRICH<br />
Molding sand preparation for foundries of all sizes<br />
Evactherm process: For many years, eco-friendly technology developed by<br />
Eirich, Hardheim, Germany, has been the best option available to foundries<br />
that are looking for top quality molding sand at an affordable cost. The mixing,<br />
cooling and bentonite activation steps all take place in a single machine. Preparation<br />
under vacuum prevents ambient climatic conditions from having any effect<br />
on the molding sand. The sand has uniform quality and the temperature of<br />
the prepared sand remains constant. More than 60 “vacuum mixers” have been<br />
installed worldwide. Depending on size, the systems have a throughput rate of<br />
6 - 300 m³/h. The mixing, cooling and activation process takes 70 s. The residual<br />
moisture of the return sand is less than 0.5 % and the sand is cooled under<br />
precision control to 40 °C. Besides the best possible bentonite activation without<br />
prior ageing, there are other advantages as well. Consumption of bentonite<br />
and auxiliary materials can be reduced. Elimination of the sand cooler and<br />
other subsystems cuts dust extraction air volumes nearly in half. Fines remain<br />
in the molding sand and do not have to be captured and disposed of as filter<br />
dust at considerable expense. Entrained fines are deposited in a condenser and<br />
the condensate is cycled back to the preparation process via the water scale.<br />
Modular tower system design with integrated façade: The entire sand preparation<br />
system is factory mounted on individual platforms. Modular design significantly<br />
reduces installation and commissioning time. The advantages are<br />
immense, particularly on modernization of existing sand preparation systems<br />
including projects that are carried out while normal operations continue. Furthermore<br />
Eirich has developed a comprehensive set of modular control solutions<br />
designed to safeguard quality and increase productivity. The spectrum<br />
ranges from entry-level versions to preventive molding sand management featuring<br />
a model catalogue, formulation calculation and additive calculation<br />
functions which work from a set of model-based parameters. Eirich control<br />
systems offer proactive management and control of molding sand properties,<br />
particularly in combination with the QualiMaster AT1 online sand tester (used<br />
to determine the compactability and shear strength control parameters), Sand-<br />
Report software (continuous acquisition, analysis and archiving of production<br />
data) and SandExpert (additional calculation of all model-based formulations<br />
using production plans). Teleservice (remote monitoring), Condition Monitoring<br />
(online diagnostics) and IMD (Intelligent Material Distribution) modules<br />
are also available. All production and system data can be transferred to higher-level<br />
production data acquisition systems for further processing.<br />
Molding sand aerator – also as a retrofit: The sand aerator improves the flowability<br />
of the molding sand in the molding box and increases compactability<br />
at the molding machine. Casting quality is better and post-processing costs are<br />
lower. The aerator consists of an aerator tool and a sand collection unit. It is<br />
installed along with a belt conveyor on the prepared sand line downstream from<br />
a mixer. In addition to on-conveyor installation, between-conveyor or head-on<br />
configurations are also possible. It is designed for all standard conveyor sizes,<br />
takes up little space and can easily be adapted to existing conveyors.<br />
Eirich sand preparation systems installed as complete or partial solutions are<br />
highly versatile and can be adapted to different molding technologies and sand<br />
parameters. They supply sand to molding lines made by all manufacturers. The<br />
portfolio includes material handling, pre-treatment, return sand storage, sand<br />
preparation and transfer to the molding line. Eirich can supply individual machines<br />
or turn-key sand preparation solutions.<br />
Hall 17, Stand A 38<br />
www.eirich.com
A selection of innovative Chemex<br />
feeders (Photo: Chemex)<br />
CHEMEX<br />
Telefeeder technology for Aluminium<br />
sand casting<br />
A newly developed feeder material by<br />
Chemex, Delligsen, Germany, makes<br />
it possible: The approved and patented<br />
telefeeder technology can now also<br />
be used for aluminium sand casting.<br />
This innovation allows for a significant<br />
reduction of the melting, fettling<br />
and parting costs, which means that<br />
castings can be manufactured more<br />
cost-effectively.<br />
Up until 2014 technological and economic<br />
circumstances made it impossible<br />
to apply the innovative, modern<br />
feeder technology in this sector. The<br />
new feeder material from Chemex –<br />
specially developed to meet the requirements<br />
for aluminum casting – enables<br />
this sector to benefit from the<br />
advantages provided by the telefeeder<br />
technology, from which the iron and<br />
steel casting sector has benefited for<br />
the past approx. 20 years.<br />
Apart from the common open cylindrical<br />
feeders, Chemex now also supplies<br />
the entire range of telefeeders to<br />
the aluminium casting sector in modules<br />
starting from 0,8-8,5 cm. In so doing,<br />
Chemex makes an important contribution<br />
to the competitiveness of the<br />
foundry industry.<br />
Hall 12 - Stand C 50<br />
www.chemex.de<br />
TREATY<br />
SALE<br />
DUFERCO CARSID,<br />
2 MILLION<br />
TPA IRON<br />
& STEEL<br />
MAKING<br />
AND SLAB<br />
CASTING PLANT<br />
FEATURING:<br />
• Blast Furnace - Capacity<br />
2 Million Tonnes Per<br />
Annum- Refurbished 2007<br />
• Pulverised Coal<br />
Injection Plant -<br />
CMI / Paul Wurth<br />
• Basic Oxygen Steel<br />
Making Plant -<br />
170 Tonnes Converters<br />
• Continuous Caster -<br />
Voest Alpine Twin Strand<br />
LOCATION:<br />
Charleroi,Belgium<br />
• Continuous Caster - Demag Single Strand<br />
• Electric Ladle Furnace - 160 Tonnes Capacity<br />
• Sinter Plant - Delattre / Levivier<br />
• Torpedo Cars and Locomotives<br />
• Vibratory Screens – Skako<br />
FOR SALE AS A WHOLE OR IN<br />
LOTS - EARLY INSPECTION<br />
RECOMMENDED<br />
To view and bid on the lots, please visit:<br />
http://www.go-dove.com/en/events?cmd=details&event=561<strong>02</strong>1<br />
For further details on technical specification or to arrange an inspection contact:<br />
STEVE TRIBE Tel.: + 44 (0) 7836 688453 steve.tribe@liquidityservices.com<br />
In association with<br />
94 Casting Plant & Technology 2/<strong>2015</strong>
LAEMPE<br />
World market leader for core<br />
shop equipment<br />
Laempe & Mössner GmbH, Barleben,<br />
is a German based international supplier<br />
of core shooters and solutions<br />
for core shops in the foundry industry.<br />
Present in all relevant branches,<br />
e.g. automotive, truck or railway industry,<br />
Laempe & Mössner covers all<br />
areas of core making. State-of-the-art<br />
production equipment and technologies<br />
assure the quality of the systems<br />
of the company, whilst high flexibility<br />
characterizes production and logistics.<br />
Fundamental for the success are<br />
the qualified and motivated employees.<br />
Laempe & Mössner has about 300<br />
employees worldwide at two German<br />
locations in Barleben (headquarters)<br />
and Schopfheim. With over 25 representatives<br />
worldwide as well as direct<br />
distribution Laempe & Mössner generates<br />
an annual turnover of 65 million<br />
Euros (2013).<br />
At GIFA <strong>2015</strong> Laempe & Mössner focuses<br />
all its interests on resource-efficient<br />
production. Among other exhibits,<br />
the company will present a product<br />
range from lab machines to high-performance<br />
core shooting machines. The<br />
machines will show innovations that<br />
do not only meet the increasing demands<br />
on tool weight and precision in<br />
tool guidance but also provide easier<br />
operation and optimized control technology.<br />
Hall 15, Stand F 2<br />
www.laempe.com<br />
Top of the Range: Extremely fast<br />
cycle time thanks to solid design –<br />
the LHL-series (here: LHL50) automatic<br />
core shooters can cope with<br />
the most challenging tasks (Photo:<br />
Laempe)<br />
MONITORING-SYSTEM<br />
THOR V3.0<br />
- 5.7” T S D<br />
- R S<br />
- D L<br />
NEW HAMMER AF1470<br />
- S , <br />
- N M<br />
- G P<br />
- I W O<br />
O.M.LER 2000 H<br />
- L ( E )<br />
DÜSSELDORF, DEUTSCHLAND<br />
16.-20. JUNI <strong>2015</strong>
INSULCON GROUP<br />
High temperature resistant<br />
products<br />
During the last 35 years, the Insulcon<br />
Group (Insulcon and Kermab) has<br />
grown into the leading supplier of high<br />
temperature resistant products with<br />
thermal shock-, chemical and wear resistance<br />
and/or high thermal insulation<br />
properties for industrial energy<br />
savings.<br />
Insulcon was founded in 1980 and<br />
with the experience since then of over<br />
160 dedicated, specialized professionals<br />
in heat management, the company is<br />
confident to be the matching partner:<br />
as manufacturer, adviser and as trouble<br />
shooter. Innovative tailor-made solutions<br />
are available for almost any application.<br />
During THERMPROCESS <strong>2015</strong><br />
the Insulcon Group will show:<br />
» HT Composite; a thin but strong,<br />
> 1,350 °C, extreme thermal shock<br />
resistant composite, composed out<br />
of high temperature resistant ceramic<br />
endless fibers and matrices, based<br />
on metal oxides like AL 2<br />
O 3<br />
, mullite<br />
or SiO 2<br />
. Available in each required<br />
thickness starting from 0,5 mm.<br />
» Insulvax 1600 P shapes (1,600 °C)<br />
manufactured by vacuum forming<br />
high performance refractory fibres,<br />
blended with specially selected organic<br />
and inorganic refractory binders.<br />
» Refrex heat shields, zone dividers,<br />
mono en multi tube bellows and dust<br />
free LTM hot face finish (REL system)<br />
up to 1,400 °C.<br />
» Wearflex tube seals and expansion<br />
joints; flexible connections in air, flue<br />
gas pipes and duct systems found in<br />
all kind of industries<br />
» Wearflex insulation covers; tailor-made<br />
prefabricated insulation<br />
mattresses of all kind of shapes and<br />
in all kinds of dimensions.<br />
» High temperature resistant textile,<br />
manufactured in our Temse (B) industrial<br />
high temperature textile plant<br />
(Keramab N.V.)<br />
» Hot spot repair and hot endoscopy<br />
inspection services. Repair and/or inspection<br />
of damaged refractory (LTM)<br />
linings during full operation!<br />
Keramab N.V. (part of the Insulcon<br />
Group) is one of the leading manufacturers<br />
of high temperature resistant<br />
(textile) products up to 1,260 °C.<br />
In our state of the art textile plant in<br />
Temse, Belgium, a wide range of insulation<br />
and sealing end products are being<br />
custom made, such as twisted ropes, fibre<br />
ropes, braided and knitted packings,<br />
woven and knitted tapes, sleeves and<br />
cloths. All Keramab products are available<br />
in a wide range of dimensions and<br />
various raw materials.<br />
Whether made from E-Glass, HT-<br />
Glass, ceramic fibres, body soluble fibres<br />
or silica, with or without a special coating,<br />
Keramab’s high temperature textiles<br />
are always high quality and the best<br />
solution to all gaskets and sealing applications<br />
within the industry.<br />
Hall 9, Stand D2<br />
www.insulcon.com<br />
www.keramab.com<br />
Head office of the Insulcon Group in Steenbergen, The Netherlands: Warehouse,<br />
production facilities and offices (Photo: Insulcon)<br />
please visit us:<br />
METEC <strong>2015</strong> hall 5 booth D 26
DRACHE UMWELTTECHNIK<br />
Transport crucibles for aluminium<br />
foundries<br />
Transport crucibles for liquid aluminium<br />
in foundries can have an essential<br />
impact on the quality of the liquid metal.<br />
Hydrogen pick-up and abrasion of refractory<br />
material must be prevented to<br />
avoid contamination of the melt.<br />
Drache Umwelttechnik, Diez, Germany,<br />
offers transport crucibles which<br />
match even the highest quality demands.<br />
The precast crucibles are manufactured<br />
from Drache’s genuine refractory<br />
material Drache fused silica, which<br />
is characterized by its excellent non-wetting<br />
properties, erosion resistance, thermal<br />
shock resistance as well as resistance<br />
again aluminium foundry alloys, combined<br />
with a relatively low thermal conductivity.<br />
Transport crucibles made by Drache<br />
are always precast, fully dried and fired.<br />
They are shipped as a ready-to-use,<br />
moisture free part, which can be installed<br />
immediately with no need for<br />
further thermal treatment.<br />
All crucibles are fully customized to<br />
match the individual needs of the<br />
foundry. In addition to the crucibles<br />
themselves, Drache offers the full package<br />
of installation services, including<br />
the installation of a highly efficient insulation<br />
as well the precast Drache fused<br />
silica liner into existing steel housings.<br />
Furthermore, beyond the crucibles<br />
and installation services, Drache can<br />
offer preheating stations as well as<br />
highly efficient holding stations with<br />
very low power consumption, keeping<br />
the Aluminium liquid inside the crucibles<br />
between two casts.<br />
Hall 12, Stand C 22<br />
www.drache-gmbh.de<br />
Precast Drache fused silica transport<br />
crucible for aluminium foundries<br />
(Photo: Drache)<br />
3<br />
By order of Alcoa Australia & Alcoa Inc.<br />
SALES<br />
ALUMINUM ROLLING<br />
& STRIP MILLS, CASTING<br />
LINES AND PROCESSING<br />
EQUIPMENTIMMEDIATELY AVAILABLE<br />
LOCATIONS: Point Henry, VIC; & Yennora, NSW; Australia<br />
and Various Locations in USA & Canada<br />
Australia Equipment<br />
ALUMINUM ROLLING<br />
MILL, INGOT SCALPERS,<br />
ALUMINUM<br />
PROCESSING EQUIP.<br />
To view and bid on the lots, visit: http://tiny.cc/go-dove_<strong>CPT</strong>I<br />
USA Equipment<br />
ALUMINUM<br />
CASTING LINES<br />
To view and bid on the lots, visit: http://tiny.cc/084cyx<br />
USA & Canada Equipment<br />
ALUMINUM STRIP MILL,<br />
GLASS LINE, BILLET<br />
SAW & TRIM PRESSES<br />
To view and bid on the lots, visit: http://tiny.cc/ra5cyx<br />
For further information, please contact:<br />
BILL GUINANE<br />
Telephone: +61 (0) 404 800 397<br />
bill.guinane@liquidityservices.com<br />
Punkt-Sp_Federdorn_85x128_sw_eng.indd 1 18.03.15 10:01<br />
Casting Plant & Technology 2/<strong>2015</strong> 97
SUYASH SOLUTIONS<br />
Analysis of molten white iron<br />
before pouring<br />
Suyash Solutions Pvt. Ltd., Pune, India,<br />
specializes in manufacturing carbon<br />
cups, thermocouple tips, oxy<br />
probes, samplers, carbon silicon analysers<br />
(CSA) & temperature measuring<br />
instruments for molten grey cast iron<br />
& steel.<br />
The patented super cup (carbon cup)<br />
is the most economical way for instantaneous<br />
and dependable analysis of<br />
molten grey cast, ductil iron or white<br />
iron before pouring. CSA detects CE, C<br />
& Si in 45 s with unmatched accuracy.<br />
CSA has got facility to measure molten<br />
metal temperature also.<br />
Hall 11, Stand 9<br />
www.suyashsolutions.com<br />
Modern bright annealing furnace (Photo: FK Industrieofen + Schutzgastechnik)<br />
FK INDUSTRIEOFENBAU<br />
Bright annealing furnace for<br />
tubular heating elements<br />
FK Industrieofen + Schutzgastechnik<br />
GmbH, Hagen, Germany, will attend<br />
again the THERMPROCESS fair<br />
during the time from 16. – 20. June<br />
<strong>2015</strong>. The company will show its innovative<br />
concepts which are the<br />
guideline of the company for more<br />
than 40 years.<br />
“The whole spectrum of the heat<br />
treatment technology out of one<br />
hand” – following this guideline, you<br />
get information about the most modern<br />
heat treatment technologies, special<br />
inert gas generators for DRI (direct<br />
reduced iron) technologies, as well as<br />
modern technologies for generating<br />
inert gas.<br />
This time the company will exhibit<br />
a modern bright annealing furnace for<br />
tubular heating elements. The tubular<br />
heating elements will be transported<br />
through heat resistant tubes made of<br />
special heat resistant steel. The annealing<br />
temperature will be approximately<br />
1,150 °C. The tubes are filled with inert<br />
gas (N 2<br />
and/or H 2<br />
). The inert gas remains<br />
in the tubes during the annealing<br />
process, because inlet and outlet of<br />
the tubes are closed with special elastic<br />
gaskets. The extreme low inert gas consumption<br />
of max. 0,1 Nm³/h guarantees<br />
excellent annealing results under<br />
economic top conditions.<br />
Modern pneumatic tensioning devices,<br />
installed on the automatic feeding<br />
device, guarantee a fast loading<br />
and even feeding and transport of the<br />
tubular heating elements into the furnace.<br />
The feeding speed is adjustable<br />
by use of a frequency converter. The<br />
standard annealing furnaces are designed<br />
with 2 up to 30 annealing channels<br />
in accordance with customer´s<br />
needs. The standard furnaces have a<br />
throughput from 5 kg/h up to<br />
300 kg/h. An additional cooling of the<br />
tubular heating elements by means of<br />
cooling water is not necessary. The<br />
cooling tubes dispend the radiant heat<br />
directly to the atmosphere. Due to the<br />
number of tubes it is possible to reach<br />
a large heat dissipation which makes<br />
an additional cooling with water unnecessary.<br />
The amortization time of the annealing<br />
furnace is very short due to energy<br />
savings and savings in inert gas and<br />
water.<br />
Halle 9 B 29<br />
www.industrieofen-schutzgas.de<br />
98 Casting Plant & Technology 2/<strong>2015</strong>
Installed thermal reclamation plant (Photo: FAT)<br />
FAT<br />
Thermal reclamation of<br />
no-bake sand<br />
Since 1973 the company FAT, Niederfischbach,<br />
Germany, supports the<br />
foundry industry with equipment. FAT<br />
is able to provide the complete product<br />
range for mold production and sand<br />
reclamation in the no-bake sector.<br />
Environmental protection, economic<br />
use of resources and higher getting<br />
demands on casting quality makes a<br />
continuous development in processes<br />
necessary for foundries. Economical<br />
and sustainable recycling is becoming<br />
more and more important.<br />
By using a thermal reclamation the<br />
organic binder, which is still on the<br />
sand (LOI), gets burned. The system<br />
ensures compliance with the German<br />
“air quality regulations”. It has a thin<br />
sand hight in the oven, therby every<br />
sand grain has contact with the flame<br />
and fine sands can be regenerated. The<br />
reclaim sand has a loss of ignition<br />
(LOI) of up to 0,1 %.<br />
A decision for a thermal reclamation<br />
offers following possibilities:<br />
in bypass, generating new sand from<br />
reclaimed sand. This generated new<br />
sand can be added flexibly to the reclaimed<br />
sand, which means a reduction<br />
of LOI or treating reclaimed sand,<br />
which should be removed to dump.<br />
This thermal re-claimed sand can be<br />
used as new sand.<br />
A thermal reclamation is a chance to<br />
minimize the costs for new sand as well<br />
as the quantity and costs of used sand<br />
which must be disposed. The acquisition<br />
costs for new sand and the disposal<br />
costs can be reduced by up to 95 %.<br />
With costs of<br />
» 40 € per t new sand and<br />
» 40 € per t waste sand<br />
a thermal reclamation produces potential<br />
saving, of<br />
» about 100,000 Euro/year in case of 8<br />
t new sand per day<br />
» about 240,000 Euro/year in case of<br />
16 t new sand per day<br />
» about 680,000 Euro/year in case of<br />
42 t new sand per day<br />
The maintenance-friendly system<br />
does not need foundations and can be<br />
integrated in existing plants respectively<br />
processes.<br />
Hall 15, Stand H 14<br />
www.f-a-t.de<br />
GLOBAL ONE STOP SOLUTIONS FOR CASTING & ROLLING UNDER WORLD LEADING BRANDS<br />
&<br />
www.alpinemetaltech.com VISIT US AT METEC | HALL 04, BOOTH 4E18
Titel Key_Casting 2014.fh11 23.05.2013 12:35 Uhr Seite 1<br />
Probedruck<br />
C M Y CM MY CY CMY K<br />
Titel_Key Casting <strong>2015</strong>.indd 3 29.04.15 09:16<br />
EUROMAC<br />
(Photo: Euromac)<br />
Foundry plants and core making<br />
equipment<br />
Euromac S.r.l., Marano Vicentino, Italy,<br />
has served the foundry industry for<br />
more than 50 years, originally under<br />
the company name “CPF”.<br />
Its speciality is the manufacture of<br />
green sand molding lines, core making<br />
machines and associated sand plant,<br />
metal handling and treatment equipment.<br />
The technical office, supported by<br />
3-D model software, designs the entire<br />
lines & machineries, takes care of every<br />
detail thanks to the cooperation with<br />
customer’s technicians and with the<br />
purpose to find solutions suitable for<br />
the foundry production requirements.<br />
In the factory in Marano Vicentino,<br />
Euromac takes care of all the production<br />
phases. The facility is completed<br />
with high specs CNC machines & high<br />
performance workstations.<br />
Its sales network covers most of the<br />
states all over the world, in particular<br />
Europe, Mexico, Brazil, North Africa,<br />
Russia and India.<br />
Furthermore Euromac is focused on<br />
the South American market where a<br />
branch facility has been built in Brazil.<br />
Euromac America Latina carries out the<br />
manufacturing and the assembl ing of<br />
the same equipment produced in Italy.<br />
Euromac’s philosophy is to pay special<br />
attention to details and the individual<br />
needs of the customers.<br />
Manufacturing Program:<br />
» Core making machines and robot<br />
production cells (shell process, croning,<br />
cold and hot box; inorganic processes)<br />
» Automatic green sand molding lines<br />
» Core sand preparation, mixing and<br />
distribution plant<br />
» Shell molding machines, complete<br />
of automatic gluing systems<br />
» Gas generators for isocure (Amine),<br />
CO 2<br />
SO 2<br />
and betaset<br />
» Amine scrubber towers<br />
» Hydraulic molding machines<br />
» Pouring, treatment and automatic<br />
metal transfer and handling plant<br />
for ladles<br />
» Metal treatment plant with ferroalloys<br />
dosing or cored wired inoculation<br />
for nodular cast iron.<br />
» Decore machines<br />
Halle 16, Stand H 22-05<br />
www.euromac-srl.it<br />
The KEY to Casting Industry and Suppliers 2014<br />
The KEY<br />
to Casting Industry<br />
and Suppliers THE KEY<br />
TO CASTING INDUSTRY SUPPLIERS<br />
<strong>2015</strong><br />
<strong>2015</strong>. 14,8 x 21,0 cm, 68 pages<br />
ISBN 978-3-87260-180-3<br />
Order your free sample copy!<br />
2014<br />
The Key to Casting<br />
Industry <strong>2015</strong><br />
The KEY to Casting Industry <strong>2015</strong> is a comprehensive English-language reference work,<br />
a navigation aid through the international supply markets for the foundry industry.<br />
<strong>International</strong>ly active suppliers and equipment manufacturers<br />
present themselves in a clearlystructured form.<br />
GIESSEREI-VERLAG GMBH Postfach 10 25 32 · D-40016 Düsseldorf<br />
Tel. +49 211 69936-264 · E-Mail: annette.engels@stahleisen.de · www.giesserei-verlag.de<br />
The_Key_Casting_1_3_Q_D.indd 1 01.06.15 14:01<br />
100 Casting Plant & Technology 2/<strong>2015</strong>
KMA UMWELTTECHNIK<br />
Energetic air purification<br />
through innovative heat<br />
pump technology<br />
Die casting processes generate huge<br />
amounts of gases and vapors, which<br />
consist of aerosols and fine smoke particles.<br />
Due to the occupational safety<br />
and environmental protection, these<br />
must be removed from the work area.<br />
For some foundry this is not an easy<br />
task, because each foundry is designed<br />
differently and standardized solutions<br />
do not always provide the optimum<br />
solution for individual plants.<br />
KMA Umwelttechnik GmbH, Königswinter,<br />
Germany, is specialized since<br />
more than 25 years on the development<br />
of energy-saving and environmentally<br />
friendly methods of exhaust<br />
air purification in foundries. KMA offers<br />
to each exhaust air problem the<br />
best solution. Today´s most energy efficient<br />
method of exhaust air treatment<br />
is the recirculating air mode. Due to the<br />
high filtration efficiency of the KMA<br />
electrostatic precipitators the purified<br />
air often gets discharged back to the<br />
workplace. Thus, the air circulates in<br />
the hall and compared to the exhaust<br />
air mode excessive heat loss can be<br />
avoided during the heating period. Accordingly,<br />
this method offers the greatest<br />
potential for energy savings. However,<br />
certain production processes or<br />
the company´s corporate philosophy<br />
in general does not always enable a recirculating<br />
air mode. In addition, peripheral<br />
devices – such as sprayers, furnaces<br />
and presses – sometimes limit the<br />
space around the die casting machine.<br />
Therefore, installing extraction devices<br />
such as hoods sometimes become impossible.<br />
But even in such cases an energy-efficient<br />
air purification solution<br />
needs to be placed.<br />
This view is what KMA Umwelttechnik<br />
is standing for and that’s the reason<br />
why they developed for such applications<br />
an energy-efficient air filtration<br />
system, which operates in an exhaust<br />
air mode. The new system with a highly<br />
efficient heat recovery system enables<br />
by the use of 1 kW of energy (electricity)<br />
to achieve more than 20 kW of<br />
heat output due to utilizing the waste<br />
heat. The high efficiency is based on an<br />
innovative heat pump technology,<br />
which will be introduced at the GIFA<br />
exhibition <strong>2015</strong>.<br />
Hall 11, Stand H 73<br />
www.kma-filter.de<br />
RWP GmbH, Bundesstraße 77, 52159 Roetgen, Germany<br />
Tel. +49(0)2471 1230-0<br />
www.rwp-simtec.de
WEBAC<br />
Customer success in mind<br />
For many years Webac Gesellschaft für<br />
Maschinenbau mbH, Euskirchen, Germany,<br />
has been a reliable partner for<br />
its customers, satisfying needs and requirements,<br />
delivering quick and safe<br />
solutions and providing the very best<br />
quality.<br />
In addition, the company offers innovations<br />
from all the divisions of its<br />
product range.<br />
The product range of Webac:<br />
» molding sand preparation plants<br />
» core sand preparation plants<br />
» sand regeneration plants (mechanical<br />
and thermal)<br />
» sand coating plants (also with proppants)<br />
» No-bake molding systems<br />
» High performance continous mixers<br />
Webac Sandmixer WSM for molding sand preparation plants (Photo: Webac)<br />
Hall 17, Stand A 41<br />
www.webac-gmbh.de<br />
A. CESANA<br />
New Dosing-Flux<br />
A. Cesana company from Pero in Italy<br />
will launch, at Gifa <strong>2015</strong>, a new dosing<br />
system called “Dosing-Flux” to perform<br />
automatic addition of powdered<br />
or granulated fluxes during transfer of<br />
molten aluminium alloys.<br />
The system is automatic and can be<br />
placed either on a fixed or on a moving<br />
station. Ideal as a retrofit on rotor degassing<br />
machines or as a flux feeder for<br />
transfer launders.<br />
The dosing system eliminates the<br />
manual addition problems.<br />
Benefits include:<br />
» Flux usage reduction.<br />
» Improved and reproducible aluminium<br />
quality thanks to the controlled<br />
flux dosage.<br />
» Reduced manual labour and improved<br />
safety by keeping operators<br />
out of the hazardous areas.<br />
The “Dosing-Flux” system performs automatic addition of powdered or granulated<br />
fluxes during transfer of molten aluminium alloys (Photo: A. Cesana)<br />
The system is easily accessed for refilling<br />
and maintenance. For the control of<br />
nearly empty level in the hopper, Dosing-Flux<br />
is equipped with a capacitative<br />
sensor control. Ideal for all foundries,<br />
casthouses and recycling plants.<br />
Hall 12, Stand A 33<br />
www.acesana.com<br />
1<strong>02</strong> Casting Plant & Technology 2/<strong>2015</strong>
FAGUS-GRECON<br />
Fire protection in the casting<br />
industry<br />
Gases and fumes occur in many areas<br />
in the metalworking industry. These<br />
have to be removed by suction from<br />
the workplace. Gases and fumes pose<br />
a risk in exhaust pipes and filters.<br />
Deposits in the exhaust pipe are extremely<br />
dangerous. In addition to metal<br />
parts, grease or wax can also condense<br />
in the pipe. The process of<br />
gravity casting contains additionally<br />
proportions of the binder and the<br />
blackening. When casting with lost<br />
form polystyrene enters the air and<br />
condenses in the pipe. The resulting<br />
fire loads in the pipes are often underestimated.<br />
The deposits can be ignited<br />
by sparks or hot particles. This results<br />
in glow nests or a fire in the exhaust<br />
pipe. The fire extends in the conveying<br />
direction. This process can last over a<br />
long period of time.<br />
Besides deposits in the exhaust pipes<br />
a filter fire holds another risk. The exhaust<br />
air can consist of many different<br />
components. A very complex material<br />
mixture can accumulate in the filter.<br />
Depending on material, the accumulated<br />
dusts can be flammable.<br />
A fire in pipes or filters usually leads<br />
to a shutdown for several days. Next<br />
to the actual damage a delay in delivery<br />
or even the loss of clients is imminent.<br />
An individually tailored concept based<br />
on a spark extinguishing system creates<br />
remedy. The spark extinguishing<br />
system detects and extinguishes sparks<br />
before an actual fire starts.<br />
The goal of a spark extinguishing<br />
system is to detect the fire in its earliest<br />
development. The selected extinguishing<br />
medium is based on the material.<br />
If the material is extinguishable with<br />
water, a water extinguishment is the<br />
cheapest option. For metals which<br />
cannot be extinguished with water<br />
(aluminum, magnesium and zinc) an<br />
Filter with burn marks (Photo: Fagus-Grecon)<br />
Argon-extinguishing system is an option.<br />
Halle 15, Stand D 37<br />
www.grecon.com<br />
DÜSSELDORF, GERMANY<br />
16. - 20. JUNE <strong>2015</strong><br />
Please visit us at:<br />
Hall 15 / F23<br />
T<br />
ConviTec GmbH<br />
vibration machines and conveying technology<br />
Project planning<br />
Manufacturing<br />
Service<br />
YOUR COMPETENT PARTNER IN THE FIELDS VIBRATION MASCHINES – MATERIALS HANDLING – PLANT CONSTRUCTION<br />
ConviTec GmbH - Mühlheimer Straße 231 - D-63075 Offenbach - Germany - +49 (0) 69 / 84 84 897-0<br />
www.convitec.net<br />
Convitec_210_148.indd 1 22.05.15 08:52<br />
Casting Plant & Technology 2/<strong>2015</strong> 103
KLEIN ANLAGENBAU<br />
Competent partner of the<br />
foundry industry<br />
Almost five decades of experience in<br />
international plant engineering make<br />
Klein Anlagenbau AG, Niederfischbach,<br />
Germany, the competent partner<br />
in the area of pneumatic conveying<br />
systems, core sand preparation, sand<br />
reclamation and peripheral foundry<br />
equipment. The business activities of<br />
Klein range from consultation to project<br />
planning and execution; engineering<br />
services, manufacture, installation<br />
and start-up as well as training of operating<br />
staff and after-sales services complement<br />
this profile.<br />
For modern core production the company<br />
offers complete systems with the<br />
main component, the unique core sand<br />
mixer Statormix. Thanks to the special<br />
design of this mixer with its horizontal<br />
shaft and the two-chamber mixing<br />
principle, most homogeneous core sand<br />
mixtures are achieved in short mixing<br />
times. This does in particular apply to<br />
the preparation of inorganic sand-binder<br />
mixtures, consisting of liquid and<br />
powdery components. The preparation<br />
of inorganic mixtures in a Statormix has<br />
proven that considerably less binder is<br />
consumed to achieve bending strengthes<br />
comparable to those achieved with<br />
conventional mixers.<br />
Remarkable features are the tightness<br />
of the mixer closure and very<br />
short mixing cycles, contributing to<br />
avoid moisture loss of the mixed batch.<br />
The core sand mixer is equipped with<br />
an integrated cleaning system by<br />
means of which the mixer interior can<br />
be kept clean very well. With three different<br />
mixer sizes capacity demands of<br />
up to 9 t/h can be met. More than 400<br />
core sand preparation systems with<br />
Statormix are operated worldwide.<br />
During GIFA <strong>2015</strong> Klein will present<br />
a complete core sand preparation plant<br />
for inorganic binders, including a sand<br />
conditioner for cooling/heating and<br />
dedusting the sand, additive tanks<br />
with disaggregation unit and dosing<br />
screw, a pneumatic conveyor for additives,<br />
a weighing system for the recipe<br />
ingredients, a binder dosing system<br />
and a core sand distribution system.<br />
The energy-saving pneumatic conveyor<br />
SP-HL was especially conceived<br />
for the transport of granular bulk material<br />
such as foundry sands. Visitors of<br />
the companys booth in hall 16 will see<br />
a tandem conveyor SP-HL in action,<br />
where two conveyors feed sand into<br />
one conveying pipe. With tandem installations<br />
like that conveying capacities<br />
of more than 20 t/h can be<br />
achieved. More than 1000 SP-HL conveyors<br />
are operated worldwide. Remarkable<br />
features of the SP-HL are its<br />
high performance with energy savings<br />
of about 40 % compared to conventional<br />
conveyors, its gentle transport<br />
that saves the grain structure of the<br />
sand as well as the minimal wear of the<br />
conveying pipes and last but not least<br />
its small space requirements.<br />
In addition to the exhibited conveying<br />
system for foundry sand, Klein also<br />
supplies pneumatic conveyors for all<br />
other materials handled in a foundry<br />
such as bentonite, carbon dust, filter<br />
dust, different additives etc.<br />
Hall 16, Stand C11<br />
www.klein-ag.de<br />
Klein Anlagenbau AG develops and manufactures pneumatic conveying systems, core sand preparation systems and<br />
used sand reclamation systems as well as peripheral foundry equipment (Photos: Klein)<br />
104 Casting Plant & Technology 2/<strong>2015</strong>
OPTRIS<br />
Infrared camera for temperatures<br />
of up to 1,800 °C<br />
The optris PI 1M thermal imaging camera<br />
is the latest innovation in the camera<br />
range of Optris GmbH, Berlin, Germany.<br />
In addition to the well-known<br />
advantages of Optris infrared cameras,<br />
such as their compact size, USB interface<br />
and license-free software, the new<br />
PI 1M is the only model on the market<br />
that features a continuous temperature<br />
measurement range of 450 °C to<br />
1,800°C, a frame rate of up to 1 kHz<br />
and a choice of optical resolution/<br />
frame rate modes. “The camera is designed<br />
for measuring the temperature<br />
of metal surfaces, graphite or ceramic,”<br />
explains Torsten Czech, Product Marketing<br />
Manager at Optris GmbH.<br />
The optris PI 1M has an extensive<br />
temperature measurement range of<br />
450 °C to 1,800 °C. Unlike those of<br />
other thermal imaging cameras in<br />
this class, this range is continuous,<br />
i.e. it can be used without subdivisions.<br />
That means it no longer needs<br />
to be switched for many applications,<br />
making the camera much more versatile.<br />
The highly dynamic CMOS detector<br />
allows a maximum optical resolution<br />
of 764 x 480 pixels at a frame rate<br />
of 32 Hz. The ultra-compact infrared<br />
camera can be switched to 382 x 288<br />
pixels at 80 Hz or 27 Hz and 72 x 56<br />
pixels at 1,000 Hz for fast processes.<br />
“That way the camera can be operated<br />
as a fast pyrometer,” adds Czech. “The<br />
middle pixel can be displayed via a<br />
0-10 V analog output with an adjustment<br />
time of 1 ms in real time, which<br />
Optris infrared cameras have frame<br />
rates of up to 1,000 Hz for fast processes<br />
(Photo: Optris)<br />
puts it on a par with our high-performance<br />
thermometers.”<br />
Halle 9, Stand B49<br />
www.optris.de<br />
CONTINUOUS MESH<br />
BELT ATMOSPHERE<br />
FURNACE SYSTEMS<br />
PLATE HEAT<br />
TREATING SYSTEMS<br />
BASKETLESS HEAT<br />
TREATING SYSTEMS (BHTS®)<br />
ALUMINUM STRUCTURAL<br />
COMPONENTS HEAT<br />
TREATING SYSTEMS<br />
CONTINUOUS BAR PRODUCT<br />
HEAT TREATING SYSTEMS<br />
FLEXIBLE BATCH CAR<br />
BOTTOM HEAT<br />
TREATING SYSTEMS<br />
ROTARY HEARTH<br />
HEAT TREATING SYSTEMS<br />
PRECISION AIR QUENCH<br />
(PAQ)SYSTEMS FOR<br />
ALUMINUM<br />
CAN-ENG FURNACES<br />
ENGINEERING SOLUTIONS TO LAST<br />
CAN-ENG Furnaces <strong>International</strong> Limited is a leading designer and manufacturer of thermal<br />
processing solutions. With 50 years of experience and installations worldwide, CAN-ENG<br />
understands your business and its unique demands.<br />
To learn more about CAN-ENG Furnaces <strong>International</strong> Limited’s Engineering, Design & Manufacturing<br />
capabilities please visit us at GIFA in Düsseldorf, Germany, June 16 - 20, <strong>2015</strong> stand10G41,<br />
www.can-eng.com or email furnaces@can-eng.com<br />
P.O. Box 235, Niagara Falls, New York 143<strong>02</strong>-<strong>02</strong>35 www.can-eng.com | T. 905.356.1327 | F. 905.356.1817<br />
Casting Plant & Technology 2/<strong>2015</strong> 105
StrikoWestofen engineers regularly evaluate the dosing system data recorded<br />
and provided to them by the customers to take the needs of the companies<br />
into account when developing the new series of dosing furnaces (Photo:<br />
StrikoWestofen)<br />
STRIKOWESTOFEN<br />
Dosing technology redesigned<br />
Still under wraps: the StrikoWestofen<br />
Group, Gummersbach, Germany, will<br />
be surprising everyone at the GIFA<br />
<strong>2015</strong> in Düsseldorf with a completely<br />
redesigned series of dosing furnaces.<br />
According to the globally active<br />
manu facturer of thermal process<br />
technology, this marks the company’s<br />
entry into the next stage of development<br />
in dosing technology –<br />
with numerous advantages for light<br />
metal foundries. The new dosing furnaces<br />
are to set new standards in the<br />
fields of design, heating, efficiency,<br />
controllability and operational safety<br />
in particular.<br />
How to reduce costs, save resources<br />
and make work easier: aluminium<br />
foundries are very experienced in the<br />
constant optimization of their process<br />
procedures and technologies. The StrikoWestofen<br />
Group is no exception<br />
here. For years now, the worldwide<br />
manufacturer of thermal process technology<br />
for light metal casting has been<br />
well-known as an expert and a pioneer<br />
for energy-efficient dosing and melting<br />
solutions. In order to fulfil this<br />
commitment in the future too, StrikoWestofen<br />
is presenting the results of<br />
its recent development work at the international<br />
trade fair for the foundry<br />
sector GIFA <strong>2015</strong> in Düsseldorf: a completely<br />
redesigned series of dosing furnaces.<br />
StrikoWestofen is also presenting<br />
new options for the ProDos 3 control<br />
to the specialist audience at the fair.<br />
“We are proud to be a German company<br />
at the forefront of development<br />
whose innovations set new standards<br />
for dosing furnaces in light metal casting.<br />
Especially so considering that the<br />
requirements – for the casting of structural<br />
components for example – have<br />
been steadily rising,” explains StrikoWestofen<br />
General Manager Rudi<br />
Riedel. “After years of development,<br />
the GIFA is always precisely the right<br />
context for presenting our innovations<br />
to experts worldwide.” The focus<br />
at StrikoWestofen was on offering a<br />
new technology for aluminium foundries<br />
with further improvements in<br />
terms of availability, energy efficiency,<br />
operation, operational safety, space<br />
requirements and sustainability. This<br />
is because even higher dosing precision<br />
and easy controllability contribute<br />
to saving resources and making life<br />
easier for the personnel in foundry<br />
companies.<br />
The performance and availability of<br />
dosing furnaces and the maintenance<br />
effort they require can only be realistically<br />
demonstrated by values measured<br />
in practical operation. “5,000<br />
Westomat sold mean 5,000 opportunities<br />
to build on the experience of<br />
our customers, which was valuable<br />
and inspiring for our product development.<br />
This is why good cooperation<br />
with customers and manufacturers<br />
of foundry machines is so<br />
important for successful development”,<br />
Riedel explains. For this reason,<br />
the engineers from StrikoWestofen<br />
regularly evaluate the<br />
data coming from dosing systems.<br />
These are recorded while the foundry<br />
systems are in operation and are provided<br />
to us by our customers. As these<br />
values are based on the experience<br />
gained with various in-situ parameters,<br />
they give us information on the<br />
optimum conditions in combination<br />
with the foundry system used as well<br />
as data showing the requirements of<br />
a foundry company. “Among other<br />
things, our new series profits from an<br />
innovative type of heating, improved<br />
insulations and an excellent, even<br />
more functional design. Happily, we<br />
were able to gain the services of an<br />
internationally well-known machine<br />
designer for the development of the<br />
design” – that’s how much Peter<br />
Reuther is prepared to reveal in advance.<br />
In addition, our new developments<br />
allow companies to make another<br />
step towards doing more<br />
sustainable business.”<br />
Hall 11, Stand D 38<br />
www.strikowestofen.com<br />
106 Casting Plant & Technology 2/<strong>2015</strong>
CLARIANT<br />
Eco-friendly Geko LE and Ecosil LE green sand molding<br />
additives<br />
Clariant, Muttenz/Basel, Switzerland, a world leader in specialty<br />
chemicals, is gearing up to reveal its support for a greener foundry<br />
industry at GIFA <strong>2015</strong>. Visitors at the booth of the company can<br />
look forward to a showcase of Clariant’s unique sustainable emission-reducing<br />
casting additives<br />
Geko LE and Ecosil<br />
LE, already enabling more<br />
eco-friendly production of<br />
steel and iron castings by<br />
We look after every<br />
grain of sand<br />
Pneumatic conveying<br />
technology<br />
For dry, free flowing, abrasive<br />
and abrasion-sensitive material<br />
several major European automotive manufacturers.<br />
Over 50 % of green sand castings produced in Europe in 2013 were<br />
used in road vehicle production. The technology is used for molding<br />
a vast array of vehicle components, including engine blocks, gearboxes,<br />
drive shafts, suspension arms, and brake discs. It is characterized<br />
by its flexibility, low cost as molds do not have to be pre-treated, short<br />
cycle times and lower weight castings.<br />
Ecosil LE and Geko LE significantly reduce emissions generated in<br />
green sand mold casting. They build on the unrivaled precision,<br />
smooth processability and surface finish, and easy shake out associated<br />
with Clariant’s Ecosil lustrous carbon former ranges and Geko bentonite<br />
boosters for green sand castings. Used together or individually,<br />
Ecosil and Geko play an important role in mold production and<br />
during the subsequent separation of casting and mold material.<br />
Adding to the ranges’ sustainability value, customers choosing<br />
those products have the assurance of Clariant’s responsible mining<br />
approach, and long-term supply continuity guaranteed by Clariant’s<br />
investment in its own bentonite mines and production facilities located<br />
close to customers worldwide.<br />
“Ecosil LE and Geko LE reinforce the market-leading position of<br />
Clariant’s customizable Ecosil and Geko ranges, valued by the global<br />
foundry industry for more than 25 years. As the only low emission<br />
solution, they can help foundries comply with highly demanding<br />
environmental regulations and standards. Customers also report a<br />
significant reduction in additive quantity requirements.<br />
The result is a one-of-a-kind efficient molding sand system that<br />
supports manufacturers’ investment in becoming greener without<br />
any compromise on mold quality or the surface finish of castings,”<br />
comments Lorenzo Sechi, Head of Sales Foundry Additives Europe &<br />
Middle East at Clariant.<br />
Hall 12, Stand C 13<br />
www.clariant.com<br />
Ecosil LE and Geko LE<br />
drastically reduce emissions<br />
and help foundries<br />
comply with highly demanding<br />
environmental<br />
regulations and standards<br />
(Photo: Clariant)<br />
Core sand preparation<br />
technology<br />
Turn-key systems including sand<br />
and binder dosing and<br />
core sand distribution<br />
Reclamation technology<br />
Reclamation systems for<br />
no-bake sand and core sand<br />
GIFA <strong>2015</strong><br />
Hall 16 / C11<br />
Konrad-Adenauer-Straße 200 · D-57572 Niederfischbach<br />
Phone ++49 27 34 / 5 01-3 01 · Telefax ++49 27 34 / 5 01-3 27<br />
e-mail: info@klein-ag.de · http://www.klein-ag.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 107
MAGMA<br />
Quality<br />
Yield<br />
Virtual experimentation using Magma 5 establishes the best compromise<br />
between required quality and costs (Photo: Magma)<br />
Fully optimize<br />
At GIFA <strong>2015</strong>, Magma GmbH, Aachen,<br />
Germany, will present the next generation<br />
of simulation software for process<br />
optimization of all casting applications.<br />
On its stand in Hall 12, the<br />
company will demonstrate how casting<br />
process simulation with Magma 5<br />
contributes to foundry profitability<br />
through optimization at all stages of<br />
casting manufacturing.<br />
In Düsseldorf, Magma will show the<br />
new software version Magma 5.3 with<br />
fully integrated capabilities for virtual<br />
design of experiments and optimization,<br />
and including extended capabilities<br />
for all casting processes. For the<br />
first time, Magma 5 5.3 makes virtual<br />
experimentation and automatic optimization<br />
on-screen possible. Robust<br />
process conditions and optimized<br />
solutions for casting layouts and part<br />
production can be determined before<br />
the first casting is produced. The software<br />
is designed to find the best possible<br />
conditions for runner dimensions,<br />
gate positions and also for both the<br />
position and optimum size of feeders<br />
and chills. Foundrymen can use simulations<br />
in a virtual proving ground to<br />
pursue different quality and cost objectives<br />
simultaneously.<br />
The company will present new options<br />
for the simulation of all casting<br />
processes and cast alloys, the optimization<br />
of heat treatment processes, and<br />
the optimization of the entire core production<br />
process. Moreover, Magma<br />
will provide insights into future developments<br />
for high pressure die casting<br />
and continuous casting. The use of<br />
Magma results for a fast and easy exchange<br />
of information, within a company<br />
and for intensive communication<br />
with customers, will be presented<br />
interactively based on real examples.<br />
A key focus of Magma’s GIFA presence<br />
is on opportunities for further education<br />
in the MagmaAcademy for foundrymen,<br />
casting designers and casting<br />
consumers.<br />
Hall 12, Stand A 20<br />
www.magmasoft.de/en<br />
JUNG INSTRUMENTS<br />
Universal sand testing machine<br />
and high volume sampler<br />
for dust measurement<br />
The innovative, computer-controlled<br />
universal testing machine for molding<br />
sands by Jung Instruments, Viersen,<br />
Germany, enables the reproducible determination<br />
of a large variety of mechanical-technological<br />
parameters<br />
– independent of the operator. The<br />
robust, time- and space-saving unit is<br />
designed and manufactured acc. to the<br />
guidelines of the Association of German<br />
Foundrymen (VDG) and bundles<br />
many functions of a sand test lab. State<br />
of the art technology combined with<br />
ease of use and user-friendly operation<br />
allows for a reliable quality control<br />
of molding materials and helps<br />
you avoid unnecessary costs of defective<br />
products.<br />
The new dust collection device Gravikon<br />
VC 25 II is designed for stationary<br />
sampling of dust at work places with a<br />
controlled flow rate of 22.5 m 3 /h. The<br />
sampler combines new technologies in<br />
operation and flow control with proven<br />
and recognized dust collection. With<br />
the original interchangeable sampling<br />
heads of the former VC 25, type<br />
Ströhlein, the collection of the inhalable<br />
and respirable dust fraction acc. to<br />
EN 481 is guaranteed. The filter cassettes<br />
for filter diam. 150 mm enable<br />
easy handling and safe transport and<br />
shipment to the lab for subsequent<br />
gravimetric and analytical evaluation.<br />
Hall 13, Stand B 30<br />
www.jung-instruments.com<br />
108 Casting Plant & Technology 2/<strong>2015</strong>
COLD JET<br />
Aero foundry edition - recommended<br />
cleaning technology<br />
A major issue for the foundry and forging<br />
industries is the downtime caused<br />
when cleaning permanent aluminum<br />
molds, core boxes and vents, die<br />
cast machines and tooling, shell core<br />
molds, semi-solid castings and conveyors.<br />
Cold Jet, Loveland, USA, has<br />
developed an all new foundry edition<br />
– a comprehensive application solution<br />
that addresses all the needs for<br />
the foundry industry.<br />
The foundry edition systems are full<br />
pressure dry ice cleaning systems packaged<br />
with accessories that will provide<br />
the best clean for the foundry environment.<br />
They are performance class machines<br />
utilizing the advanced sureFlow<br />
pellet technology, featuring an isolated,<br />
insulated hopper with advanced<br />
agitation, internal pressure regulator,<br />
full pressure dosing system, stainless<br />
steel rotor and are equipped with<br />
foundry-friendly accessories. They<br />
guarantee the best pellet integrity,<br />
maximum cleaning aggression and the<br />
most reliable blast stream on the market.<br />
Additional features and accessories<br />
include an upgraded stainless steel rotor<br />
for improved durability; a high performance<br />
applicator with sealed electrical<br />
switches, tough outer shell, designed<br />
water release channels and dual triggers<br />
to protect against moisture, grit and<br />
drop damage; a urebrade blast hose<br />
with fire sleeve to protect from high<br />
temperatures and ensure continued<br />
blast flow; Sureflow quick disconnect<br />
fittings that are ultra-light and aerodynamic<br />
to ensure full particle flow and<br />
maximum performance; a low noise<br />
foundry nozzle that is axisymmetric to<br />
allow you to clean at a distance from the<br />
contaminant without sacrificing pellet<br />
integrity; and a protective machine cover<br />
to provide a barrier around the machine<br />
to shield the feeder system from<br />
foreign contaminants and further protect<br />
the investment.<br />
Dry ice cleaning with the Cold Jet<br />
aero foundry series offers significant<br />
improvement in cleaning times (up to<br />
60 %) as well as reduction of damage to<br />
equipment and resulting scrap product.<br />
Cold Jet aero foundry series offers<br />
significant improvement in cleaning<br />
times (up to 60 %) as well as reduction<br />
of damage to equipment and<br />
resulting scrap (Photo: Cold Jet)<br />
Hall 16, Stand A 24<br />
www.coldjet.com<br />
KNIGHT WENDLING<br />
Part of the solution<br />
Knight Wendling, Düsseldorf, Germany,<br />
is a leading consulting firm in the<br />
cast metals industry. Over 40 years of<br />
experience, an extensive worldwide<br />
network and in-depth market expertise<br />
enable the company to provide<br />
a comprehensive range of consulting<br />
and engineering services<br />
Strategic consulting comprises mergers<br />
& acquisitions, due diligence and<br />
joint-venture projects. In the field of<br />
“merger & acquisition /due diligence<br />
– strategic partnership” the firm has,<br />
in the last 10 years, been involved in<br />
about 80 of such projects for financial<br />
and industrial interested parties working<br />
either on buyer or seller side. This<br />
represents approximately 20 % of all<br />
closed deals in the casting industry.<br />
Operational consulting offers creative,<br />
practical yet sustainable solutions to<br />
technical as well as operational issues<br />
in the complete range of foundry processes.<br />
Knight Wendling performs Interim-<br />
and Turn-around Management<br />
as part of their range of services. Within<br />
the scope of the increasingly important<br />
market globalisation, the firm<br />
also provides for international/global<br />
casting competence analysis. <strong>International</strong><br />
investment groups have consulted<br />
Knight Wendling’s extensive<br />
operational and strategic expertise<br />
for operational audit & evaluation of<br />
business potential, turnaround management<br />
as well as for benchmarking<br />
analysis and in-depth products’, technology<br />
and market studies.<br />
Together with sister company Gemco<br />
Engineers the company is dedicated to<br />
build long-term relationships with the<br />
mission to make customers successful.<br />
Clients can be found among international<br />
key-players in the automotive<br />
Benchmarking KPI (Image: Knight<br />
Wendling)<br />
industry, heavy machinery, railway,<br />
wind energy, and many other business<br />
sectors.<br />
Hall 16, Stand C12<br />
www.knightwendling.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 109
FTL FOUNDRY EQUIPMENT<br />
Foundry Plant & Equipment<br />
For 50 years, FTL Foundry Equipment<br />
Ltd, Willenhall, UK, has been<br />
designing and supplying technically<br />
advanced molding and material<br />
handling systems in a cost-effective<br />
way. Visitors to GIFA will again get a<br />
chance to witness some of FTL’s latest<br />
innovative technology for no bake and<br />
green sand molding plants, reclamation<br />
and material handling systems.<br />
At GIFA, FTL will be highlighting its<br />
know-how and expertise in offering<br />
complete turnkey projects, providing<br />
plant design, consultancy, through<br />
to project management. On display<br />
will be a range of its No Bake Equipment<br />
with FTL’s full range of foundry<br />
material handling equipment to give<br />
increased productivity and improved<br />
casting quality.<br />
FTL has designed and installed<br />
equipment in many notable foundries<br />
in the UK and is building a well-earned,<br />
respected reputation in foundries all<br />
around the world in particular repeat<br />
orders from Turkey Russia, Scandinavia,<br />
Europe and the Middle East having<br />
commissioned and installed a variety<br />
of plant and equipment in those regions<br />
over the years. As UK foundries<br />
consolidate their position, overseas<br />
customers are investing in new production<br />
capacity or converting from older<br />
greensand production to chemically<br />
bonded molding. FTL has an extensive<br />
range of chemically bonded sand mixing,<br />
molding and reclamation equipment<br />
for them to choose from. From<br />
simple manual handling, semi auto or<br />
fully automatic molding plants with<br />
30tph mixer & linear molding plant<br />
with rollover strip (Photo: FTL)<br />
versatile mold shuttle, loop or carousel<br />
molding and auto rollover strip machines<br />
to the latest design.<br />
Hall 15 Stand H15<br />
www.ftl-foundry.co.uk<br />
KÜTTNER<br />
One stop cast iron pipe production<br />
In 2014, Küttner Centrifugal Casting<br />
GmbH, a joint venture with Düker<br />
(both Karlstadt, Germany) has been<br />
completely integrated at Küttner, Essen,<br />
Germany. In the production of<br />
ductile iron pressure pipes Küttner<br />
is able to offer the melting operation<br />
up to centrifugal casting, everything<br />
from a single source, as well as the engineering<br />
for the complete pressure<br />
pipe manufacturing plant including<br />
the fitting foundry.<br />
Ductile iron pressure pipes in nominal<br />
sizes 80-1200 mm are produced in<br />
Delavaud-centrifugal process in which<br />
the molds are spinning in a water bath.<br />
This process enables the production of<br />
up to 80 pipes per hour for smaller diameters.<br />
Highest process accuracy and<br />
optimum material logistics or liquid<br />
iron logistics are basic requirements for<br />
a consistent quality and a continuous<br />
production.<br />
The Delavaud centrifugal casting<br />
machines are equipped with an automatic<br />
pouring system, which allows a<br />
flying exchange of ladles during the<br />
solidification cycle. A precise dosage of<br />
liquid iron allows the production of<br />
very small wall thicknesses of class C40<br />
with the best possible material efficiency.<br />
The liquid iron is introduced via<br />
runners into the mold. Two runners<br />
are alternately in use, allowing cleaning<br />
and maintenance of the standby<br />
runner during the operation. The runners<br />
remain fixed, while the machine<br />
carriage moves with the mold. Into the<br />
mold a sand core is inserted, which<br />
models the pipe sleeve. An optical sensor<br />
on the bell end of the mold detects<br />
the incoming liquid metal and triggers<br />
the traveling motion of the machine<br />
DeLavaud centrifugal casting machine<br />
(Photo: Küttner)<br />
carriage. In the end position, the pipe<br />
is automatically extracted from the<br />
mold and the casting cycle starts again.<br />
The Delavaud centrifugal casting machines<br />
are just one component of a fully<br />
automated production line: from<br />
casting, heat treatment, mechanical<br />
processing, coating inside and outside,<br />
etc. Küttner integrates the centrifugal<br />
casting machines into existing production<br />
lines or provides the engineering<br />
and supply of completely new plants.<br />
Hall 16, Stand G 26<br />
Hall 4, Stand C 28<br />
www.kuettner.com<br />
110 Casting Plant & Technology 2/<strong>2015</strong>
RÖSLER<br />
Gamma 400 G – improved blast performance,<br />
higher uptimes and easier maintenance<br />
Shot blasting for surface cleaning and surface preparation<br />
represents an indispensable manufacturing<br />
phase in many metal-processing industries. Generally,<br />
blast turbines are the most expensive component<br />
of many shot blasting system, requiring significant<br />
upkeep in terms of maintenance and wear parts.<br />
By simply turning the Y-shaped throwing blades<br />
in the new Gamma 400 G turbines around, both<br />
blade sides can be utilized resulting in a doubling<br />
of the uptime compared to conventional blast<br />
turbines (Photo: Rösler)<br />
At the GIFA exhibition in Düsseldorf, Rösler,<br />
Untermerz bach, Germany, will present its newly developed<br />
and extremely versatile Gamma 400 G blast<br />
turbine which will be setting new standards in cost<br />
efficiency. For example, compared to conventional<br />
turbines the Gamma 400 G offers a 100 % higher<br />
uptime and a significantly improved blast performance<br />
together with drastically reduced maintenance<br />
costs.<br />
Rösler GmbH is international market leader in the<br />
production of surface finishing, shot blasting machines,<br />
painting systems and preservation lines as<br />
well as process technology for the rational surface<br />
finishing (deburring, descaling, sand removal, polishing,<br />
grinding…) of metals and other components.<br />
Besides the German plants in Untermerzbach and<br />
Bad Staffelstein, the Rösler Group has branches in<br />
Great Britain, France, Italy, The Netherlands, Belgium,<br />
Austria, Switzerland, Spain, Romania, Russia,<br />
China, India, Brazil, South Africa and USA.<br />
Hall 16 Stand G 40<br />
www.rosler.com<br />
Casting Plant & Technology 2/<strong>2015</strong> 111<br />
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Gemco realized the expansion of the iron foundry of Georg Fischer in Kunshan, China (Photo: Gemco)<br />
GEMCO ENGINEERS<br />
Complete foundry solutions<br />
Gemco Engineers, Eindhoven, The<br />
Netherlands, counts for more than 35<br />
years of worldwide experience in the<br />
foundry industry and offers dedicated<br />
foundry solutions for iron, steel, aluminum<br />
and all other castable metals. The<br />
company’s track record includes the<br />
realization of over 100 Greenfield and<br />
Brownfield foundries worldwide. Gemco<br />
operates from offices in The Netherlands,<br />
Germany, China, Mexico and<br />
Russia. An extensive global network of<br />
foundry experts cover all foundry disciplines<br />
and provides a full range of services<br />
from process- and feasibility studies,<br />
(concept-) engineering, design, and<br />
planning and project management of<br />
smaller as well as bigger projects up to<br />
overall contracting and turnkey realization<br />
of foundry projects. Further services<br />
encompass, among other:<br />
Engineering and Management of<br />
Foundry Projects:<br />
» Master-planning capital investments<br />
(greenfield / brownfield / modernizations)<br />
» Operational and financial feasibility<br />
analysis<br />
» Energy and logistic simulations/process<br />
integration and interface engineering<br />
» Risk management and project control<br />
» Contracting and turnkey deliveries<br />
Dedicated Installations:<br />
» For improvement of ergonomics<br />
» For improvement of safety and environment<br />
» For efficiency improvements<br />
Gemco Engineers is an independent<br />
company and makes use of the latest<br />
technology and engineering tools<br />
such as 3-D design and Foundry Logistics<br />
Simulation, emphasizing on<br />
Efficiency, Energy and Environment.<br />
Clients can be found among international<br />
key-players in the automotive<br />
and truck industry, mining, dredging,<br />
oil & gas, rail, heavy machinery, wind<br />
energy and many other business sectors.<br />
Recent and current projects include<br />
foundry modernizations in Europe<br />
and the USA and new foundries<br />
in Mexico and China.<br />
Hall 16, Stand C 12<br />
www.gemco.nl<br />
Advertisers‘ Index<br />
ABP Induction Systems GmbH 43<br />
AGTOS Ges. für technische Oberflächensysteme mbH 71<br />
Alpine Metal Tech Holding GmbH 99<br />
Hannover-Messe ANKIROS FUARCILIK A. S. 79<br />
ASK Chemicals GmbH 45<br />
Bühler AG 11<br />
Büro für angewandte Mineralogie 44<br />
CAN-ENG Furnaces 105<br />
ConviTec GmbH 103<br />
Gustav Eirich GmbH & Co. KG 2<br />
Eltra GmbH 80<br />
Euromac spa 61<br />
FRIEDRICH Schwingtechnik GmbH 92<br />
Giesserei Verlag GmbH 48, 72, 100<br />
112 Casting Plant & Technology 2/<strong>2015</strong>
HÜTTENES ALBERTUS<br />
The HA Group – innovative<br />
and multifaceted<br />
Casting has been for centuries and<br />
will remain in the future one thing<br />
above all else: an innovative process.<br />
The Hüttenes-Albertus Group, Düsseldorf,<br />
Germany, has set itself the goal to<br />
be a reliable and inventive partner to<br />
all foundries – worldwide and with all<br />
products and services that are required<br />
for advanced and efficient casting processes.<br />
At GIFA <strong>2015</strong> Hüttenes-Albertus will<br />
be represented by its very own GIFA<br />
foundryman. He will guide the visitors<br />
over the HA Group stand in hall 12 and<br />
will show them the way to various exhibits,<br />
presentations and demonstrations.<br />
The world’s leading foundry fair is<br />
the ideal platform to present the latest<br />
developments and trends relating to<br />
foundry chemistry. Visitors can expect<br />
numerous exhibits – from very small<br />
and filigree parts to huge castings.<br />
Based on these displays the results of<br />
intensive research and technological<br />
progress can be discussed in detail.<br />
More than 30 subsidiaries and trading<br />
partners of the HA Group will be represented<br />
by technical and sales experts at<br />
the GIFA stand, to answer all questions<br />
and provide comprehensive advice.<br />
The major challenge in our time is<br />
the compatibility of high productivity<br />
with environmentally friendly raw materials<br />
and „green“ casting processes.<br />
The Hüttenes-Albertus Group accepted<br />
the challenge and will present various<br />
innovations and developments regarding<br />
organic and inorganic binder systems<br />
and foundry auxiliary materials.<br />
When developing environmentally<br />
friendly and economical products<br />
Hüttenes-Albertus did not only focus<br />
its efforts on inorganic binder systems<br />
– even if this will surely be a major topic<br />
of interest at GIFA. Further progress<br />
was also made in the field of established<br />
organic processes. Cold-Box systems<br />
with reduced emissions and carbon<br />
are important keywords.<br />
In the product category coatings specific<br />
emphasis is laid upon the new impregnation<br />
coating against the casting<br />
defect “white film”, which can occur<br />
on casting surfaces. Interested visitors<br />
can certainly find out more about this<br />
innovation at the HA stand but they are<br />
also welcome to attend the lecture at<br />
the Technical Forum. A further presentation<br />
will be held about the latest innovations<br />
in feeder technology, where<br />
HA’s GIFA<br />
foundryman<br />
(Image: HA)<br />
great advancements<br />
have been<br />
made regarding<br />
aluminium sand<br />
casting.<br />
The HA Group<br />
is known to lay<br />
value on the education<br />
of new<br />
young talents and<br />
therefore gladly<br />
supports the initiative<br />
„metals4you“.<br />
Interesting experiments and<br />
demonstrations will be carried out on a<br />
separate stand. The aim is to familiarize<br />
the young groups of visitors with the<br />
exciting world of foundry chemistry.<br />
The team of experienced chemists and<br />
analysts was overwhelmed by the participation<br />
in past years and expect even<br />
more young visitors this year.<br />
Overall GIFA visitors can expect much<br />
action at Hüttenes-Albertus‘ stand – be<br />
it the machines, animations or exhibits.<br />
Hall 12, Stand C 50<br />
www.huettenes-albertus.com<br />
GLAMA Maschinenbau GmbH 59<br />
GoIndustry (UK) Limited 94<br />
GTP Schäfer GmbH 97<br />
HOMA Hochstromtechnik GmbH & Co. KG 67<br />
Hüttenes-Albertus Chemische Werke GmbH 118<br />
ICE<br />
Insert<br />
INFUSER DEUTSCHLAND GmbH 15<br />
Jasper Ges. für Energiewirtschaft & Kybernetik mbH 30<br />
JÖST GmbH + Co. KG 111<br />
KELLER H.C.W. GmbH 47<br />
Targi Kielce S.A. 94<br />
Klein Anlagenbau AG 107<br />
Helmut Klumpf Technische Chemie KG 70<br />
KMA Umwelttechnik GmbH 87<br />
Küttner GmbH & Co. KG 39<br />
Liquidity Services Global Solutions Pty Ltd 97<br />
Metef Srl 23<br />
Monometer Holdings Ltd 90<br />
O.M.LER 2000 S.R.L. 95<br />
Refratechnik Casting GmbH 37<br />
Regloplas AG 93<br />
Retsch Technology GmbH 81<br />
RÖSLER Oberflächentechnik GmbH 49<br />
Konrad Rump Oberflächen technik GmbH & Co. KG 91<br />
RWP GmbH 101<br />
S&B Industrial Minerals GmbH 9<br />
Space Srl 63<br />
Rudolf Uhlen GmbH 70<br />
VELCO GmbH 96<br />
VETTER Krantechnik GmbH 55, 56<br />
VHV Anlagenbau GmbH 89<br />
Heinrich Wagner Sinto Maschinenfabrik GmbH 31<br />
WEBAC Gesellschaft für Maschinenbau mbH 88<br />
Eugen Weil 14<br />
WOKO Magnet- und Anlagenbau GmbH 38<br />
Casting Plant & Technology 2/<strong>2015</strong> 113
K BROCHURES<br />
Heat treatment solutions<br />
6 pages, English<br />
This brochure sets out the range of materials and complementary products developed<br />
by Mersen for thermal applications, for example, resistors, insulating elements,<br />
walls and channels. The materials used include graphite, carbon and carbon<br />
composites, rigid carbon and carbon foam insulation materials, etc.<br />
Information: www.mersen.com<br />
Laser welding<br />
8 pages, English<br />
A product catalogue presenting laser welding systems offered by joke Technology.<br />
Product photos and descriptions, technical data, fields of application as well as descriptions<br />
of additional features of the products are provided. Also accessories such<br />
as work positioners or magnetic clamping balls are covered by the brochure.<br />
Information: www.joke.de<br />
Two-platen die casting machine<br />
8 pages, English, Italian, German, Spanish<br />
A brochure setting out the range of two-platen die casting machines offered by<br />
Italpresse-Gauss. It lists the key advantages of the toggle-free casting machine<br />
design and contains a table of technical data for all machine types as well as various<br />
photos and drawings illustrating the components and the outstanding features of<br />
these machines.<br />
Information: www.italpresse.it; www.gaussautomazione.it<br />
Rotary bed regenerator<br />
4 pages, English, German<br />
A product brochure detailing the functioning principle and the advantages of the<br />
EcoReg® rotary bed regenerator developed by Jasper. Photographs and drawings<br />
illustrate the process flow and explain the key components of this regenerator design,<br />
which is custom-built for gas, oil and coal dust furnace systems.<br />
Information: www.jasper-gmbh.de<br />
114 Casting Plant & Technology 2/<strong>2015</strong>
Vibrating and conveying solutions<br />
24 pages, English, German, French<br />
A brochure summarizing the range of vibrating and conveying solutions offered by<br />
ConviTec. This includes equipment like shake-out systems, casting coolers, picking<br />
conveyors, sand regeneration systems, polygonal screens, conveyor belts, vibrating<br />
machines as well as the associated drive, control and visualization systems.<br />
Information: www.convitec.net<br />
Mobile metals analyzer<br />
6 pages, English<br />
A brochure describing the performance features and innovative aspects of the analyzer<br />
system Q4 Mobile offered by Bruker. The mobile optical emission spectrometer<br />
is designed for all fields of application in metal sorting and analysis, such as incoming<br />
goods inspection and mix-up tests.<br />
Information: www.bruker.com/oes<br />
Universal sand testing machine<br />
4 pages, English<br />
A brochure presenting a new sand testing instrument developed by Jung Instruments.<br />
Due to its comprehensive functionalities and wide-ranging analysis options,<br />
the instrument may replace an entire sand test lab. The brochure provides an overview<br />
of the technical parameters, benefits and specifications of the instrument.<br />
Information: www.jung-instruments.com<br />
Cast, forged and welded parts and constructions<br />
16 pages, English, German<br />
A comprehensive brochure outlining the range of activities and services provided by<br />
Cast-Con Engineering, a company specialized in the construction, optimization and<br />
supply of castings, welded constructions and forgings for plant engineering applications<br />
as well as melting plants.<br />
Information: www.cast-con.de<br />
Casting Plant & Technology 2/<strong>2015</strong> 115
K INTERNATIONAL FAIRS AND CONGRESSES<br />
Fairs and Congresses<br />
Metallurgy/Tube/Aluminium <strong>2015</strong><br />
June, 8-11, <strong>2015</strong>, Moskow/Russia<br />
www.metallurgy-tube-russia.com<br />
GIFA, METEC, THERMPROCESS, NEWCAST<br />
June, 16-20, <strong>2015</strong>, Düsseldorf/Germany<br />
www.gifa.com<br />
Aluminium China<br />
July, 8-10, <strong>2015</strong>, Shanghai/China<br />
www.aluminiumchina.com/en<br />
China Diecasting <strong>2015</strong><br />
July, 8-10, <strong>2015</strong>, Shanghai/China<br />
www.diecastexpo.cn/en<br />
Foundry China <strong>2015</strong><br />
September, 8-10, Beijing/China<br />
http://bit.ly/1KnYvBj<br />
55th <strong>International</strong> Foundry Conference<br />
September, 16-18, <strong>2015</strong>, Portorož/Slovenia<br />
www.drustvo-livarjev.si<br />
Next Metef scheduled<br />
for 2017<br />
Metef, expo of customized technology<br />
for the aluminium and innovative<br />
metals industry, and its siding shows<br />
Foundeq, Metalriciclo and Alumotive<br />
move to odd-numbered years.<br />
This choice was announced by<br />
Giovanni Mantovani, General Manager<br />
of trade fair organiser Veronafiere, and<br />
aims at meeting the needs of the adhering<br />
companies by showcasing the specialization<br />
of the Italian and European<br />
firms in the aluminium and innovative<br />
metals industry in a single event scheduled<br />
for June 21-24, 2017.<br />
In force of this process, Metef will invest<br />
on a communication plan that involves<br />
a further development of Metef’s<br />
project, approaching new markets and<br />
offering real business opportunities to<br />
the companies that invest on the expo.<br />
This is why from <strong>2015</strong> Metef is organizing<br />
a series of Road Shows and B2B<br />
meetings in different reference markets<br />
to boost promotion by the potential<br />
visitors of the show’s next edition, that<br />
is international specialized operators,<br />
technicians and purchasing managers<br />
as well as foreign institutional de le -<br />
gations in order to side the e xhibiting<br />
companies in an uninterrupted<br />
relationship path in view of the expo.<br />
The fair cooperates with Amafond – Italian<br />
association of companies which produce<br />
machinery, plants, furnaces products<br />
and services for the foundry<br />
industry.<br />
Visitors watch a multi-piston squeeze<br />
molding machine at Metef 2014<br />
(Photo: Veronafiere)<br />
“It’s a crucial decision having a major<br />
evolution value for Metef in the light of<br />
the economic context of the Italian and<br />
European manufacturing industry. This<br />
change will make us focus even more on<br />
promoting the event abroad with ad<br />
hoc projects and in dedicated markets<br />
aimed at bringing international operators<br />
to our show” – says Giovanni Mantovani.<br />
Veronafiere along with Amafond,<br />
Assomet – Italian Association of<br />
Non-Ferrous Metals Industries, Assofond<br />
– Italian Foundries’ Association,<br />
Anfia– Italian Association of the Automotive<br />
Industry, Assofermet - National<br />
Association for the distribution of Iron<br />
& Steel products and ferrous and non<br />
ferrous scrap collection, and AIB – Industrial<br />
Association of Brescia, which<br />
represent some of the business sectors<br />
present at the exhibition, will work together<br />
to consolidate the expo 10-edition<br />
experience thus offering real business<br />
opportunities to the exhibiting<br />
companies.<br />
“We have satisfied the needs of our<br />
exhibitors and of the international<br />
technical and scientific communities<br />
who asked for the show to be in a different<br />
period from that of other sector<br />
events thus allowing potential foreign<br />
operators to visit the exhibition and<br />
come to know the Italian sector excellence<br />
products, which have showed the<br />
international players their capability to<br />
offer innovative and customized solutions<br />
in quick time”, explains Giovanni<br />
Mantovani.<br />
Metef has gone through the structural<br />
changes of the global economic system<br />
and the aluminium global production<br />
chain and has adjusted its contents<br />
and communication strategies to the<br />
new evolving situations. In this respect,<br />
the expo has magnified its efforts and<br />
commitment to represent and protect<br />
the interests of the small and medium<br />
converting enterprises upstream the aluminium<br />
and innovative metals production<br />
chain. These sectors are the real<br />
propellers of the downstream application<br />
development and account for the<br />
largest share of the entire sector’s workforce<br />
in Italy and Europe.<br />
www.metef.com<br />
116 Casting Plant & Technology 2/<strong>2015</strong>
PREVIEW / IMPRINT K<br />
Preview of the next issue<br />
Publication date: 4 September <strong>2015</strong><br />
Selection of topics:<br />
Strong bath movement is possible<br />
with the new furnaces in the Frischhut<br />
foundry allowing rapid material corrections,<br />
e. g. a subsequent carburizing<br />
increasing the flexibility of foundries<br />
with a large product range (Photo:<br />
BDG/R. Piterek)<br />
R. Piterek: Towards smaller batch sizes with product flexibility<br />
The fittings foundry Frischhut in Neumarkt-Sankt Veit, Bavaria, Germany, has invested three million Euros in more flexible and energy-saving<br />
production. The company is thus well equipped for the future. Maintenance Manager Max Altmannshofer played an important part in the<br />
modernization process – a caster with a penchant for extreme sports<br />
S. Borgs; W. Stets: Porosity in ductile cast iron and its influence on mechanical properties<br />
The most common defects in ductile cast iron are porosities or microscopic shrink holes as a result of shrinkage. As part of a research project<br />
funded by AiF, a German Research Network for SMEs, the negative impact of increasing porosity on the mechanical properties of samples<br />
made of ductile cast iron was quantified<br />
Interview: Designing optimal production processes<br />
Complex casting concepts require accomplished foundry expertise, the necessary technical equipment, extensive experience, and a high<br />
degree of interdisciplinary competence. How suppliers face this challenge was the issue of an interview with Jörg Brotzki, a member of the<br />
senior leadership at ASK Chemicals, Hilden, Germany, a manufacturer of foundry chemicals and auxiliaries<br />
Imprint<br />
Pub lish er:<br />
Ger man Foundry As so ci a tion<br />
Ed i tor in Chief :<br />
Michael Franken M.A.<br />
Ed i tor:<br />
Robert Piterek M.A.<br />
Ed i to ri al As sist ant:<br />
Ruth Fran gen berg-Wol ter<br />
P.O. Box 10 51 44<br />
D-40042 Düsseldorf<br />
Tele phone: (+49-2 11) 68 71-358<br />
Tele fax: (+49-2 11) 68 71-365<br />
E-mail: re dak tion@bdguss.de<br />
Pub lished by:<br />
Gies se rei-Ver lag GmbH<br />
P.O. Box 10 25 32<br />
D-40016 Düsseldorf, Ger ma ny<br />
Tele phone: (+49-2 11) 69936-200<br />
Tele fax: (+49-2 11) 69936-225<br />
E-Mail: cpt@stah lei sen.de<br />
Man ag ing Di rec tor:<br />
Jürgen Beckers, Arnt Hannewald<br />
Ad ver tis ing Man ag er:<br />
Sig rid Klinge<br />
Cir cu la tion:<br />
Ga briele Wald<br />
Pro duc tion Man ag er:<br />
Burk hard Star kul la<br />
Layout:<br />
Peter Büchele<br />
Ad ver tis ing rate card No. 26 from 1.1.<strong>2015</strong><br />
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Print ed by:<br />
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into for eign lan guag es and stor age in data<br />
banks, re served.<br />
Pho to me chan i cal re pro duc tion (pho to copy,<br />
mi cro copy) of this tech ni cal pub li ca tion or<br />
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mis sion.<br />
The re pro duc tion in this jour nal of reg is -<br />
tered trademarks does not war rant the as -<br />
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that such names are to be con sid ered<br />
free under the trade-mark law and may be<br />
used by any one.<br />
Cer tifi ca tion of cir cu la tion by the<br />
Ger man Aud it Bu reau of Cir cu la tion<br />
ISSN 0935-7262<br />
Casting Plant & Technology 2/<strong>2015</strong> 117
PREVIEW / IMPRINT K<br />
Preview of the next issue<br />
Publication date: 4 September <strong>2015</strong><br />
Selection of topics:<br />
Strong bath movement is possible<br />
with the new furnaces in the Frischhut<br />
foundry allowing rapid material corrections,<br />
e. g. a subsequent carburizing<br />
increasing the flexibility of foundries<br />
with a large product range (Photo:<br />
BDG/R. Piterek)<br />
R. Piterek: Towards smaller batch sizes with product flexibility<br />
The fittings foundry Frischhut in Neumarkt-Sankt Veit, Bavaria, Germany, has invested three million Euros in more flexible and energy-saving<br />
production. The company is thus well equipped for the future. Maintenance Manager Max Altmannshofer played an important part in the<br />
modernization process – a caster with a penchant for extreme sports<br />
S. Borgs; W. Stets: Porosity in ductile cast iron and its influence on mechanical properties<br />
The most common defects in ductile cast iron are porosities or microscopic shrink holes as a result of shrinkage. As part of a research project<br />
funded by AiF, a German Research Network for SMEs, the negative impact of increasing porosity on the mechanical properties of samples<br />
made of ductile cast iron was quantified<br />
Interview: Designing optimal production processes<br />
Complex casting concepts require accomplished foundry expertise, the necessary technical equipment, extensive experience, and a high<br />
degree of interdisciplinary competence. How suppliers face this challenge was the issue of an interview with Jörg Brotzki, a member of the<br />
senior leadership at ASK Chemicals, Hilden, Germany, a manufacturer of foundry chemicals and auxiliaries<br />
Imprint<br />
Pub lish er:<br />
Ger man Foundry As so ci a tion<br />
Ed i tor in Chief :<br />
Michael Franken M.A.<br />
Ed i tor:<br />
Robert Piterek M.A.<br />
Ed i to ri al As sist ant:<br />
Ruth Fran gen berg-Wol ter<br />
P.O. Box 10 51 44<br />
D-40042 Düsseldorf<br />
Tele phone: (+49-2 11) 68 71-358<br />
Tele fax: (+49-2 11) 68 71-365<br />
E-mail: re dak tion@bdguss.de<br />
Pub lished by:<br />
Gies se rei-Ver lag GmbH<br />
P.O. Box 10 25 32<br />
D-40016 Düsseldorf, Ger ma ny<br />
Tele phone: (+49-2 11) 69936-200<br />
Tele fax: (+49-2 11) 69936-225<br />
E-Mail: cpt@stah lei sen.de<br />
Man ag ing Di rec tor:<br />
Jürgen Beckers, Arnt Hannewald<br />
Ad ver tis ing Man ag er:<br />
Sig rid Klinge<br />
Cir cu la tion:<br />
Ga briele Wald<br />
Pro duc tion Man ag er:<br />
Burk hard Star kul la<br />
Layout:<br />
Peter Büchele<br />
Ad ver tis ing rate card No. 26 from 1.1.<strong>2015</strong><br />
Pub li ca tion: Quar ter ly<br />
An nu al sub scrip tion rate (incl. post age)<br />
Home: 110,– incl. 7 % VAT; Mem ber States<br />
in the EC: Sub scrib ers with VAT-No. and<br />
Third Coun tries: 110,–; Sub scrib ers without<br />
VAT-No.: 110,– plus 7 % VAT; Sin gle<br />
copy 33,–.<br />
Min i mum sub scrip tion pe ri od 12 months.<br />
Ter mi na tion of sub scrip tions can only be<br />
made from 31st De cem ber and no tice of ter -<br />
mi na tion must be re ceived by the Pub lish ers<br />
by 15th No vem ber.<br />
Oth er wise, the sub scrip tion is au to mat i cal ly<br />
re newed and pay able for a fur ther 12<br />
months.<br />
© <strong>2015</strong> Gies se rei-Ver lag GmbH. Düsseldorf<br />
Print ed by:<br />
Kraft Druck GmbH<br />
Industriestr. 5-9<br />
76275 Ettlingen, Ger ma ny<br />
Printed on paper bleached totally chlorine-free<br />
All rights, in clud ing those of trans la tion<br />
into for eign lan guag es and stor age in data<br />
banks, re served.<br />
Pho to me chan i cal re pro duc tion (pho to copy,<br />
mi cro copy) of this tech ni cal pub li ca tion or<br />
parts of it is not al lowed with out spe cial per -<br />
mis sion.<br />
The re pro duc tion in this jour nal of reg is -<br />
tered trademarks does not war rant the as -<br />
sump tion, even with out any spe cial marking,<br />
that such names are to be con sid ered<br />
free under the trade-mark law and may be<br />
used by any one.<br />
Cer tifi ca tion of cir cu la tion by the<br />
Ger man Aud it Bu reau of Cir cu la tion<br />
ISSN 0935-7262<br />
Casting Plant & Technology 2/<strong>2015</strong> 117